KOIKE ARONSON, INC

RANSOME

Automatic Welding Systems

AGW Girth Welder for Horizontal Welds

VUP Vertical-Up Single Pass Welding Systems
VUP Portable Track-Guided Vertical-Up Systems
VUP Manipulator Supported Vertical-Up Systems
Ransome Automatic Welding Systems
Save You Welding Time In-Field & In-Plant.
Ransomes’ 30 years of experience and technology in automatic RANSOME PORTABLE VUP TRACK-GUIDED
welding systems provides you with true time-saving methods for SYSTEMS SPEED YOUR IN-PLANT
field construction of storage tanks and in-plant fabrication of butt
FABRICATIONS.
welds requiring out of position vertical seam welding.
Ransome VUP Track-Guided
Our AGW, for example, welds horizontal tank seams 20 times
single pass system for inplant
faster than standard manual techniques. And, our VUP system
fabrication is easy to handle, simple
can complete 10 to 12 vertical joints on 8 foot (2.4m) plates in
to operate and capable of vertical
each workshift....with just one operator and only one machine.
welds up to 6’(1 .8m). Additional
track available.
RANSOME AGW AUTOMATIC GIRTH WELDER Volt-Amp and wire speed-meters
CUTS HORIZONTAL WELDING TIME UP TO 40%. can be preset to monitor welding
The Ransome AGW Automatic Girth Welder is an automatic parameters. Lift motor and welding
system that speeds up construction of field-erected storage controls are electronically integrated
tanks. It straddles the shell plates riding on adjustable flanged to provide continuous and automatic
wheels at operator controlled speeds of 4 IPM to 105 IPM (.10- adjustments and maintain optimum
2.67m/min). copper shoe to weld puddle
It can handle plates as thick relationship.
as ¾” (44.5mm) and tank
diameters as small as 30’
(9.1m). Available as dual or
single side machines. Each is X-RAY QUALITY WELDS.
equipped with welding heads,
controls, flux support belts Ransome Automatic Welding
and flux recovery units so Systems provide x-ray quality
that 3 and 9 o’clock welds welds, free from undercut and slag
can be made simultaneously. inclusion.
The Lincoln NA-3 solid state
control and welding head
fitted with nozzles, wire feed
rolls, straighteners and 50 lb.
(22.7kg) wire reels for either
single or Twin-arc wire are COST EFFICIENT
standard. Submerged arc flux
belt mechanism ensures Ransome Systems speed your in-
retention of the flux at the field construction and in-plant
joint...and efficient recycling fabrication operations up to 20
of the flux. times faster than other available
techniques. Assures quicker return
RANSOME WELDS TWICE AS FAST AS OTHER on investment.
AUTOMATIC VERTICAL
SYSTEMS.
The Ransome VUP Single Pass Automatic
Vertical-Up welding system provides x-ray RELIABLE LINCOLN EQUIPMENT.
quality welds at twice the speed of other
automatic systems. The VUP can weld The AGW and the VUP systems
use the efficient Lincoln NA-3 solid
vertical shell plate seams 20 times faster state submerged arc system.
than manual electrodes. The Lincoln NR-431 Inner-shield
It consists of a sturdy main frame column Process provides the VUP Single
mounted on a carriage that rides the top of Pass unit high deposition rate
the tank ring. A gear reducer with variable capability.
speed ¾ hp motor can raise the weldhead Lincoln power sources are also
assembly at speeds from 1 IPM to 40 IPM provided for all Ransome automatic
(.02-1.0m/min). The lift motor is systems. They do not require special power service, use
electronically integrated with the welding competitively priced consumables and are easy to install and
control which automatically adjusts speed simple to operate.
to maintain the optimum copper shoe to
weld puddle relationship.
Lincoln NR-431 Innershield Process offers
tremendous savings, good mechanical
properties, impact and x-ray quality welds
on steels normally used in storage tank construction. And...it
provides deposition rates of 65 lbs./hr. (29.5kg/hr.) ...up to 20
times faster than vertical stick welding.
Ransome VUP Single Pass
Vertical Up Welding System
RANSOME VUP SINGLE PASS VERTICAL UP COMPLETES 10 TO 12 VERTICAL JOINTS ON
WELDING SYSTEM FOR FIELD CONSTRUCTION. EACH WORK SHIFTEWITH JUST ONE MACHINE
RANSOME VUP VERTICAL UP WELDING AND A SINGLE OPERATOR.
SYSTEM WELDS 20 TIMES FASTER THAN
CONVENTIONAL STICK ELECTRODES.

LIFT SYSTEM
Self Locking gear reducer and ¾ hp
variable speed motor raises and
lowers the saddle using a triple RC-
60 (12 Ton capacity) roller chain.

RANSOME SADDLE
SAFETY LOCK COLUMN SUPPORTS
Main column is supported by top
Automatically locks the head mount
roller assembly, two adjustable
and saddle assembly to the main
wheels that grip the back of the
support column in the event of
plate and by two wheels at the
chain failure.
bottom of the column.

WELDING HEAD AND OPERATOR

CONTROLS CONTROLS
Lincoln NA-3 head and control is
Lift controls include up/down
supplied with two K-176 nozzles for
switch, low/high speed
welding with 3/32” or .120” (2.4 and
potentiometers and rapid speed
3.0 mm) diameter NR-431 Inner-
selector.
shield wire.

MECHANICAL SEAM WELDING CONTROLS

Include current, voltage, wire
GUIDANCE speed, start/stop weld, manual
Welding head mounted on free cross-seam adjustment, in/out
moving slide allows lateral adjustment of electrode and
movement. Air-operated bracket cylinder switch.
supports articulated copper shoe
and cross-slide assembly.
OPTIONAL
SKID-MOUNTED EQUIPMENT
Powered lateral travel unit.
POWER SUPPLY Back sliding shoe attachment.
Lincoln DC-1000 skid-mounted Water recirculating system.
power supply. Oscillator (for plate thickness up to
Lincoln NA-3 control and water flow 2” [5Omm]).
panel is provided. Water Voltages (other than standard or 50
recirculation system is optional. RANSOME MODEL VUPNA3-ST Cycle).
Cable (longer than standard 200’
[61m]).
Ransome VUP Manipulator
Vertical-Up Welding Systems
RANSOME VUP MANIPULATOR SUPPORTED PROVIDES X-RAY QUALITY WELDS AT TWICE
SINGLE PASS WELDING SYSTEMS FOR IN- THE SPEED OF OTHER AUTOMATICS.
PLANT FABRICATION. INTEGRATED LIFT SYSTEM MAINTAINS
AVAILABLE IN UNITS FOR VERTICAL WELDS OPTIMUM COPPER SHOE-TO-WELD
FROM 6’ UP TO 50’ (1.8-15m). RELATIONSHIP.
FEATURES LINCOLN NR-431 INNERSHIELD
PROCESS.

VOLT-AMP AND WIRE SPEED

METERS.
Can be preset to monitor welding
parameters.

EASY ACCESS OPERATOR

CONTROLS.

LINCOLN NR-431 INNERSHIELD

PROCESS.
For all applications where out of
position vertical butt welds are
required.

CHOICE OF FIXTURE
MOUNTS.

RANSOME MODEL VUPNA-3 MNP

Ransome AGW
Automatic Girth Welder
AUTOMATIC GIRTH WELDING SYSTEM FOR
FIELD ERECTED STORAGE TANKS SELF-
PROPELLED-CAN TRAVEL AT OPERATOR-
CONTROLLED SPEEDS FROM 4 IPM TO 105 IPM
(.10- 2.67m/min).
CUTS WELDING TIME UP TO 40% AND MORE.
ADJUSTS TO HANDLE PLATES 6’ TO 10’ (1.8-
3.05m) HIGH AND AS THICK AS 1 ¾” (44.5mm).
WELDS TANKS FROM THE LARGEST
DIAMETER TO AS SMALL AS 30’ (9.1m).

STURDY “A” FRAME ADJUSTABLE DRIVE

Balanced tubular “A” Frame WHEELS
straddles shell plates Serrated flanged drive wheels
providing a solid and sturdy ride the tank ring. Enables
welding platform for long in- operation on tanks as small
service life. as 30’ (9.lm).

ADJUSTABLE FRAME DUAL OPERATOR

Tubular frame telescopes CONTROLS
manually for efficient welding Travel speed from 4 IPM to
of various heights. 105 IPM (.10-2.67m/min) and
all welding operations can be
controlled —from either side
GUARD RAIL of the AGW platform.
PLATFORM FOR
OPERATOR SAFETY
Hand rail platform includes LINCOLN NA-3
weather curtains for operator EQUIPMENT
safety and comfort. Access Standard equipment includes
ladder to primary separator the Lincoln NA-3 solid state
tank allows operator control and welding head
movement from either side. fitted with nozzle, wire feed
rolls, straightener and 50 lb.
(22.7kg) wire reels for either
QUICK POSITIONING single or Twinarc wire are
Guide wheels simplify standard.
loading and offloading. Helps
speed up positioning for
welding alignment. COST EFFICIENT
FLUX RECOVERY
SYSTEM
Submerged Arc flux belt
mechanism included in the
RANSOME MODEL AGW-II welding head assembly
retains the flux at the joint.
Recovers and recirculates the
flux to the primary separator
tank.
Ransome Automatic Welding Systems
RANSOME AGW AUTOMATIC RANSOME VUP NA3-ST
GIRTH WELDER SINGLE PASS VERTICAL-UP
WELDER
APPLICATION: APPLICATION:
Automatic self-propelled horizontal welding Vertical joint welding on field storage tanks,
machine for field construction of storage 3/8“ to 2” (10-100mm) thick plate 6’ to 10’
tanks from the largest diameter to as small high (1.8-3.05m).
as 30’ (9.1m). MAIN COLUMN AND LIFT-
MACHINE FRAME: SYSTEM:
Dual or single manually adjustable “A” Features vertical column with self-locking
frame telescopes to handle 6’ to 10’ (1.8- gear reducer and 3/4 hp variable speed lift
3.05m) high steel plate. Unit straddles shell motor and dynamic brake. Motor raises and
plates riding on adjustable steel wheels. lowers welding assembly at speeds from 1
Each operator platform is equipped with IPM to 40 IPM (.02-1.0 m/min).
welding heads, controls, flux support belts Motor control is integrated with welding
and recovery unit. Welds can be made control to optimize copper shoe to weld
simultaneously from both sides. puddle relationship. Main column is
WELDING POWER SUPPLY: supported by two wheels at the top of the
Current supplied by Lincoln DC-600 Amp tank, two adjustable wheels that grip the
unit on each side. Available for back of the tank plates and by two wheels
230/460/60Hz service. Line requirement: 40 at the bottom of the column.
KVA per side. Voltage is stepped down to HEAD MOUNT ASSEMBLY:
115V AC required at the welding machine. Lincoln NA-3 welding head is mounted on
Standard skid mount. free moving slide. Allows lateral movement
STANDARD EQUIPMENT: and mechanical seam guidance.
Pre-heat torch Articulating copper shoe and head/nozzle
IPM travel meter assembly on cross-slide system easily
Operator Communications System positions and maintains proper relationship
(AGW-ll) to the joint.
OPERATOR CONTROLS:
SOLID STATE ELECTRONIC Include current; voltage; wire speed;
UNIT ON MASTER SIDE start/stop weld; manual cross-seam
adjustment/in-out electrode adjustment; and
INCLUDES:
air cylinder switch. Lift controls include
Speed control potentiometer; direction
up/down switch; low/high speed
switch; and rapid travel control.
potentiometers; and rapid set speed
selector. Auxiliary control pendant is
located at column base.
WELDING POWER SUPPLY:
Lincoln DC-1000 with Lincoln NA-3 control
and plumbing service box is standard.
Fabricator should supply 460/3/60 power of
at least 105 KVA. Fused disconnect switch
provided. Space for optional water
recirculating system provided. 10’ (3.05m)
double 4/0 ground cable; multi-conductor
control cable; water hose and air hose with
quick disconnect joints standard.
OPTIONAL EQUIPMENT:
Back sliding shoe attachment.
Water recirculating system and hoses.
Oscillator for plates up to 2” (50mm).
RANSOME VUP VERTICAL UP Voltages other than standard or 50 cycle.
SHIPBUILDING MODEL Cable assemblies in excess of standard
200’ (61m).
Powered lateral travel.
Eastern Regional Office Southern Regional Office
Division Headquarters 1285 North Post Oak
635 West Main Street Suite 150
Arcade, NY 14009 Houston, TX 77055
Tel: (585)-492-2400 Tel: (713) 682-9645
Fax: (585)-457-3517 Fax: (713) 957-4852
Visit us on the web @ www.koike.com
Specifications subject to change without notice.
RANSOME PORTABLE TRACK
GUIDED VUP VERTICAL-UP
WELDING SYSTEM
APPLICATION:
For gapped square butt and single “Vee”
vertical welds up to 6’ (1.8m) and plate from
3/8“ to 4” (10-100mm) thick.
CARRIAGE ASSEMBLY:
Consists of vertical track; powered carriage
with special Lincoln nozzle, oscillator for
plate 1¼” (32mm) or thicker, water cooled
copper dam nozzle cross seam / in-out
adjustment.
WIRE FEED AND CONTROL
SYSTEM:
Lincoln LN9V solid-state control and wire
feeder with 50 lb. (22.7kg) reel are wheel
mounted for mobility. Wire is fed through
15’ (4.6m) conduit for either 3/32” or .120”
(2.4 or 3.0mm) diameter wire. Ammeter,
voltmeter and wire speed meters can be
preset to monitor parameters. copper dam
is automatically maintained in fixed relation
to weld puddle. Flow regulator and switch in
water cooling circuit protects against no or
low water flow Water recirculator cooler
optional.
WELDING EQUIPMENT:
Power is provided by Lincoln DC-1000
Standard: 25’ (7.6m) of double 4/0 cable
and 25’ (7.6m) of double 4/0 ground cable.
Multi-conductor cables supply control
functions. Assembly includes water hoses.
Wire feeder pressure rolls and inlet/outlet
guides for either 3/32 or .120” (2.4 or
3.0mm) diameter wire is standard.
OPTIONAL EQUIPMENT
Water recirculator cooler system.
Service skid for power supply and water
recirculator.
Wiring for other than standard or for 50 Hz.
Additional track for welds longer than 6’
(1.8m).
Latino America Office
Manquehue Sur 520
Las Condes, Santiago, Chile
Tel: (562) 211-1081
Fax: (562) 246-7387
 KOIKE ARONSON, INC
RANSOME
Automatic
Girth Welders

Automatic Girth Welder (AGW)

Speeds construction 20 times faster
than standard manual techniques
for field erected storage tanks.

Effectively cuts welding time

40% The AGW travels at operator
controlled speeds of 4 IPM to 105
IPM and can handle plate as thick
as 2” and tank diameters from the
largest to as small as 15’. It is
available as a single or dual mobile
welding station completely
equipped with welding heads, all
controls, flux support belts and flux
Ransome AGW Cuts In- recovery units.
field Storage Tank Equipment
Welding Time Up To Neatly arranged ergonomically for
40% convenience, accessibility and
efficiency. Includes the Lincoln NA-
3 solid state control and welding
Self Propelled At
Operator Controlled
Speeds From 4 IPM to
105 IPM
Adjustable “A” Frame
It straddles the tank shell plates
Handles Plates 6’ To 10’ riding on serrated steel drive
wheels that can be adjusted for
As Thick As 2” your tank diameter. The frame
telescopes manually to handle 6’ to head fitted with nozzles, wire feed
10’ high steel plate. rolls, straighteners and 50 lb wire
Welds Tanks From The reels for either single or twin-arc
Largest To As Small As Stable Platform wire. The submerged arc flux belt
Operator platform is a sturdy and mechanism ensures retention of the
15’ In Diameter solid workstation with guard rails flux at the joint for efficient
and all-weather curtains for recycling.
operator safety and comfort.
Ransome’s Double Platform is fully Power
equipped with its own direction and Lincoln DC-600 Amp power source
speed controls. Access ladder supplied with DC-1000 optional.
allows movement to the primary
flux separator tank and to the other Ransome’s 40 years of
side of the dual unit. experience and technology in
automated welding systems
provides you with a true time
saving method that improves
your productivity.
Ransome
Single Pass
VUP Welders
Ransome VUP Can
Weld 10 to 12 Vertical
Tank Plate Seams In
One Workshift
Ransome’s VUP Single Pass
Automatic Welding System
can complete 10 to 12
vertical seams on field
erected storage tank 8’ high,
1” thick steel plate in each
workshift…with x-ray quality
welds.., just one operator
and only one machine.
Sturdy Mainframe consists
—
of a vertical column mounted
on a carriage and roller
assembly that rides on the
top of the tank plates as
shown above. The VUP can
handle vertical joint welding
on plates 3/8” to 2” thick 6’ to
10’ high.
Self-locking gear reducer —
with variable speed 3/4 hp
motor is electronically
integrated with the welding
control which automatically
adjusts speed to maintain the
optimum copper-shoe-to-
weld puddle relationship.
Lift Controls include
-
up/down switch, low/high
speed potentiometers and
rapid speed selector.
Eastern Regional Office
Division Headquarters
635 West Main Street
Arcade, NY 14009
Tel: (585)-492-2400
Fax: (585)-457-3517
Specifications subject to change without notice.
Power Supply skid mounted
—
Lincoln DC-1000 with NA-3
Portable Track Guided
VUP Welding System
The Ransome Track-Guided VUP
is a versatile, easy-to-use and
easy-to-setup system for in-plant
vertical up applications. Ideal for
accurate seam welding of gapped
square butt and single “Vee” welds
on plates from 3/8” to 4” up to 6’
high. Additional track available in
6’ height.
The VUP consists of a vertical
track, a powered carriage with
special Lincoln nozzle, oscillator
for plate 1-1/4” to 4” thick, water-
cooled copper dam, nozzle and
cross seam and in-out adjustment.
Features the Lincoln LN9V or NA-
5 solid state control and wire
feeder with 50 lb reel. Wheel
mounted for in-plant mobility.
All parameters can be preset to
monitor ammeter, voltmeter and
wire speed meters. Copper dam is
automatically maintained in a fixed
relation to the weld puddle. Flow
regulator and switch in water
cooling circuit protects against no
or low flow.
Southern Regional Office
1285 North Post Oak
Suite 150
Houston, TX 77055
Tel: (713) 682-9645
Fax: (713) 957-4852
Visit us on the web @ www.koike.com
control and water flow panel.
Standard Lincoln NR-431/NR-
432 Innershield Processes offer
tremendous savings, good
mechanical properties and x-ray
quality welds providing
deposition rates of 48 lbs/hr.
Options water recirculating
-
system, lateral power travel
unit, back sliding shoe
attachment, oscillator for
plate thickness to 2” (50mm),
voltages other than standard
or 50 cycle and cable longer
than 200’ (61m.). Other
applications include
shipbuilding, and manipulator
mounted butt welding of 6’ to
50’ vertical plate.
Power – Lincoln DC-1000.
Multiconductor cables to supply
control functions and 25’ of double
4/0 ground cable are standard.
Assembly includes water hoses,
wire feeder pressure rolls and inlet
/ outlet guides for either 3/32” or
.120” diameter wire fed through 15’
conduit.
Options – water recirculator cooler
system, skid for power supply and
water recirculator, wiring for other
than standard or for 50 Hz,
additional track for welds taller
than 6’.
Latino America Office
Manquehue Sur 520
Las Condes, Santiago, Chile
Tel: (562) 211-1081
Fax: (562) 246-7387
Ransome VUP Single Pass
Vertical Up Welding System
RANSOME VUP SINGLE PASS VERTICAL UP COMPLETES 10 TO 12 VERTICAL JOINTS ON
WELDING SYSTEM FOR FIELD CONSTRUCTION. EACH WORK SHIFTEWITH JUST ONE MACHINE
RANSOME VUP VERTICAL UP WELDING AND A SINGLE OPERATOR.
SYSTEM WELDS 20 TIMES FASTER THAN
CONVENTIONAL STICK ELECTRODES.

LIFT SYSTEM
Self Locking gear reducer and ¾ hp
variable speed motor raises and
lowers the saddle using a triple RC-
60 (12 Ton capacity) roller chain.

RANSOME SADDLE
SAFETY LOCK COLUMN SUPPORTS
Main column is supported by top
Automatically locks the head mount
roller assembly, two adjustable
and saddle assembly to the main
wheels that grip the back of the
support column in the event of
plate and by two wheels at the
chain failure.
bottom of the column.

WELDING HEAD AND OPERATOR

CONTROLS CONTROLS
Lincoln NA-3 head and control is
Lift controls include up/down
supplied with two K-176 nozzles for
switch, low/high speed
welding with 3/32” or .120” (2.4 and
potentiometers and rapid speed
3.0 mm) diameter NR-431 Inner-
selector.
shield wire.

MECHANICAL SEAM WELDING CONTROLS

Include current, voltage, wire
GUIDANCE speed, start/stop weld, manual
Welding head mounted on free cross-seam adjustment, in/out
moving slide allows lateral adjustment of electrode and
movement. Air-operated bracket cylinder switch.
supports articulated copper shoe
and cross-slide assembly.
OPTIONAL
SKID-MOUNTED EQUIPMENT
Powered lateral travel unit.
POWER SUPPLY Back sliding shoe attachment.
Lincoln DC-1000 skid-mounted Water recirculating system.
power supply. Oscillator (for plate thickness up to
Lincoln NA-3 control and water flow 2” [50mm]).
panel is provided. Water Voltages (other than standard or 50
recirculation system is optional. RANSOME MODEL VUPNA3-ST Cycle).
Cable (longer than standard 200’
[61m]).
 Koike Aronson, Inc. / Ransome
VUP (Vertical Up Single Pass) Welding System

The Vertical Up Single Pass Welding System is an automated system to provide x-

ray quality welds at TWICE the speed of any other automated system and
TWENTY times faster than the manual electrode method.

Advantages of VUP process:

• High deposition rates of 40 to 65 pounds per hour
• Fast vertical speeds, 9IPM on 3/8 plate; 6 IPM on 1” plate; 4IPM on 4” plates
• X-Ray quality with impacts better than 20 ft-lbs at 0° F
• Weld joints of either square edge or single bevel
• Square butt reduces plate preparation time
• Operates with either two movable shoes or one moving shoe with a fixed backing
bar (comes standard with rear sliding shoe)
• Self-shielding means no additional gas or flux is required
• Standard unit works on plates from 3/8” up to 2” thick and 10’ high

The “VUP” was mainly developed for the construction of Field Storage Tanks, other
models using the same proven technology are available for ship-building, blast furnace
repair, structure supports and in-plant fabrication. The VUP welding process was
developed by Lincoln Electric and uses their Innershield “NR-431 and NR-432” wires.

The Lincoln Wire specifications:

NR-431, 3/32 and .120 NR-432, 3/32 and .120
AWS Classification AWS Classification
AWS: EG72T per A5.26 AWS: EG82T-G per A5.26
Agency Approval Agency Approval
ABS: Grade 3YA ABS: 3A-3YA
Lloyds: 3Y
DNV: IIIY

Wire description:
NR-431 is an Innershield, self-shielded, flux cored wire designed specifically for the single
pass vertical-up process.
Mechanical Properties- Yield Strength, 76,000 PSI; Tensile Strength, 92,000 PSI;
Elongation, 28%; Charpy V-Notch ft-lbs @-20° F, 33.

NR-432 is an Innershield, self-shielded, flux cored wire designed specifically for the single
pass vertical-up process for structural steels, including columbium-bearing steels and where
excellent impact properties are desired.
Mechanical Properties- Yield Strength, 70,000 PSI; Tensile Strength, 90,000 PSI;
Elongation, 29%; Charpy V-Notch ft-lbs @-20° F, 50.
Plate size range for Storage Tank Model VUP
Thickness: 3/8” to 2”
Plate heights of up to 10 feet

Process:
Moving Rear Copper Shoe
Fixed Rear Backing Bar

Joint Design:
Square Butt
Single Beveled

Typical welding parameters for 1” Plate using .120 NR-431 wire

Plate gap-3/4”, Wire feed speed-350 IPM, Amps-645 to 685, Volts-40 to 42, travel
speed-4.1 IPM and deposition rate-45 lbs / hr.

EQUIPMENT

VUPNA-3ST will consist of:

Vertical Support Column with Lifting Bale
Front and Rear Sliding Shoe
Lateral Travel Attachment to manually move from joint to joint
Main Control Panel
Lincoln modified NA-3 Control
Lincoln NA-3 Wire Feeder
Lincoln DC-1000 Power Source
Lincoln K-176 Nozzle
Lincoln Wire Reel and Support
Mounting Slides
Power Source Skid
Water Recirculator
Input Power Disconnect
200 Feet of Control Cables and hoses
25 feet of ground cables
Wired for 220/380/440V - 3PH - 50/60HZ
Tropicalized Controls
Tool Kit

All that is required to begin welding is to hang the unit on the tank, add the correct NR-
431 or NR-432 Wire and provide electrical power and air.

Optional components
Powered lateral travel-powered to move from joint to joint
Oscillator –required for all plates 1-1/4 or thicker.
 Information required to provide a quotation
VUP (Vertical Up Single Pass) Welding System

Project information
• Location of project ______________________________________
• Equipment required date __________________________________
• Project completion date __________________________________
• Size of project __________________________________________
Tank Size
• Diameter (provide below)
• Course Height (provide below)
• Number of Courses (provide below)
• Plate thickness for each course (provide below)
• Joint design (square butt or single bevel) (provide below)
Equipment
• Electrical power (provide below)
• Rear Shoe or Backing Bar (provide below)
• Oscillator (required for 1-1/4 plate or larger) (provide below)
• Lateral travel (powered or manual) (provide below)
Welding Wire
• Will NR-431 or NR-432 wire meet construction codes for tank project?

Number of Tanks
Diameter of Tank
Height of Tank
Plate Height
Number of Courses
Joint Design Square Butt Beveled
Plate Thickness-list for each course

Will Construction codes allow to be used Yes No I do not know

NR-431
NR-432
Plate Material
Electrical Power Available
Lateral Travel (from Joint to Joint) Manual Powered
Rear Dam Sliding Fixed Backing Bar
Shoe(standard)
 Koike Aronson Inc, / Ransome
1285 North Post Oak
Suite 150
Houston, Texas 77055
Phone-713-682-9645 Fax-713-957-4852

SPECIFICATIONS

RANSOME MODEL VUPNA-3ST HEAVY DUTY, SINGLE PASS FULLY

AUTOMATIC VERTICAL UP WELDING SYSTEM for Automatic Welding vertical
joints on field erected Storage Tanks, with all accessories needed for operation.

OPERATION
The Ransome Model VUPNA-3ST Machine is designed to weld 5/16” to 2” thick, 6 to 10
ft. high vertical joints erected storage tanks at speeds considerably faster than any other
means. The Lincoln Innershield (NR-431 or 432) process is employed.
The machine consists of a vertical column supported by a carriage that rides the top of the
tank ring. Lincoln Welding Equipment is attached to a saddle, which in turn travels up the
column during welding. Seam guidance and vertical travel speed are automatically
controlled during welding. The machine is manually propelled to a succeeding joint after
completion of each weld. A power skid, usually located in the center of the storage tank,
contains the welding power supply and other service equipment.

MAIN COLUMN AND LIFT SYSTEM

A Lincoln NA-3N Innershield head mount assembly, including a 50-pound wire reel, is
fastened to a saddle which in turn is supported by a main column assembly. The lift system,
located at the top of the column, employs a self-locking gear reducer and 3/4 HP variable
speed motor with dynamic brake. The lift drive raises and lowers the saddle along the
column by means of a triple RC-60 (25,000 lb. capacity) roller chain at infinitely variable
speeds from 1 to 40 IPM.
The VUP machine employs the same lift system as employed on standard Manipulator and
features our proven saddle safety lock which locks the head mount and saddle assembly to
the column in the event of chain failure.
The lift motor control is electrically integrated with the welding control to provide the
continuous and automatic speed changes necessary to maintain a constant copper shoe-to-
weld puddle relationship during welding. This is achieved by having the welding head
assembly alternately travel vertically at a speed slightly lower than and then slightly higher
than the weld puddle rise rate. At weld start, carriage travel is zero. As the puddle rises in
the shoe it reduces the electrode stickout; the welding current increases and trips a relay
which starts the up travel. The welding puddle is maintained between the front and rear slide
shoe assemblies.

The shoes then moves up faster than the weld puddle. This increases the electrode stickout
and causes a reduction in current, which signals the travel to switch to a speed slower than
weld progression rate. The cycle repeats as necessary to maintain constant wire stickout and
automatically maintains the arc in fixed relation to the copper shoe even with variations in
joint gap. A flow regulator and switch in the water system regulates the flow and protects
the shoes against no or low water flow.

HEAD MOUNT ASSEMBLY

The NA-3 welding head is mounted on a free moving slide, which allows lateral movement
of the head assembly and automatic seam guidance. This assembly is also controlled by an
air operated bracket which supports an articulating copper shoe, and cross-slide with the
NA-3 head and special nozzle assembly. With this arrangement the copper shoes and weld
nozzle can be easily positioned and maintained with respect to the joint. A swivel mount
provides easy alignment for inside or outside application and torch relationship to joint.

COLUMN SUPPORTS
The main column is supported at the top by two wheels riding on the top edge of the plates
to be welded, by two adjustable wheels which grip the back of the plates at the top, and by
two wheels at the bottom of the column. The assembly can be pushed or pulled along the
tank shell plate to the next vertical joint. A friction lock is provided to clamp the column to
the plate in the desired location. An electro magnet is furnished at the bottom of the column
to stabilize the location of the column in relation to the plate.

OPERATOR'S CONTROLS
The operator's control consists of the following:

Welding Controls - Current, voltage, wire speed, start weld, stop weld, manual cross seam
adjustment, manual in-out adjustment of electrode. Air Cylinder Switch. (Cylinder may
operate from compressed air or CO2.)

Lift Controls - Up and down switch, low speed and high-speed potentiometers, rapid - set
speed selector. Operator's control is fastened to the saddle of the vertical travel mechanism.
An auxiliary pendant is located at base of column.

Power Skid - The fabricator must supply a source of power of at least 100 amp. capacity for
operation of the VUP machine. A fused disconnect switch to receive the power service is
mounted on the skid with a Lincoln DC-1000 power supply, Water Recirculator, and
plumbing service box is provided and mounted.

The machine is provided with 10 feet of double 4/0 ground cable which is generally fastened
to the tank floor. A 200 ft. long cable assembly consisting of double 4/0 welding cable,
multi-conductor control cable, water hose and air hose conveys all the services from the
power skid to the tank mounted welding machine. All of the cable and hoses have quick
disconnect joints at the machine proper to facilitate separation of the two basis units for
transportation. The skid is provided with a canvas cover that may be opened for ventilation
when the machine is operating. The fabricator must supply a source of air or bottled
nitrogen of 100 to 200 PSI to the skid for operating the pneumatic copper shoe mechanism.

WELDING HEAD AND CONTROLS

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

TOP ROLLER ASSEMBLY

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

BACK SLIDING SHOE ATTACHMENT

This attachment is required for the standard square butt joint process. The attachment is
removable for a “V” groove joint preparation, which uses a front moveable dam (sliding
shoe), and fixed copper back up bar. The fixed copper back-up bars can be supplied by
Ransome but are of simple design and readily fabricated by user.

WATER RECIRCULATING SYSTEM

A forced air water recirculator is provided with 200’ of hose to provide cooling for the
shoes. The water flows through a flow switch that will shut the weld off if water is not
flowing to prevent damage to shoes or nozzle. The water recirculator and plumping box are
located on the power skid.

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

OPTIONS:
Powered Oscillator to weld with oscillation on plate thickness from (1-3/8" to 2")
Powered Lateral Travel for power positioning from joint to joint.

VUPNA-3ST VERTICAL WELDING SYSTEM, includes:

1. Welding Equipment Lincoln NA3 Wire Feeder and Control, and DC-1000 Power
Source.
2. Vertical Support Column.
3. Front and Rear Sliding Shoe.
4. Water Recirculator.
5. Power Skid.
6. Lifting Bale.
7. Input Power Disconnect
8. 200 Feet of Control Cable.
9. Wired for 220/380/440V - 3PH - 50/60HZ.
10. Tropicalized Controls.
11. Lateral Travel

Shipping dimension and weights

VUPNA3-ST.178cm high X 193cm wide X 468cm long. Weight 2223kg
SKID......175cm high X 132cm wide X 178cm long. Weight 1792kg

TRAINING & START UP

Customer is encouraged to send their Operators and/or Supervisors to Houston for
inspection and training, during Ransome's final tests of the equipment. This usually requires
2-3 days, and there is no cost for this service, except for travel and living expenses. If start
up supervision is required at customer's jobsite, the charge for this service is $960.00 per day
plus travel and living expenses.

* Payment Terms: Confirmed Irrevocable Letter of Credit on a U.S. Bank payable in full at
sight upon presentation of shipping documents. All banking charges are for the account of
the buyer.
 1 2 3

Process 1 NR-431 2 Electroslag 3 Tandem Sub 4 Single Sub 5 Stick

Number of
1 1 2 2 4
Passes
300/350 (60˚) 950/1050
Amps 765 700/900 135/275/275/400
600 (45˚) 700/800
35/36
Volts 48 44 35/36
40/41
Weld Met. Req’d 1.73 (60˚)
2.06 .67 .76 1.08
(LBS./FT) 1.71 (45˚)
Dep. Rate 10.3 (60˚)
65 57 20 12
(LBS./HR) 51 (45˚) flux cored
ARC SPEED 6 (60˚)
37.5 85 26 10.6
(FT/HR) 30 (45˚)

4 5
 1 2 3

Process 1 NR-431 2 Electroslag 3 Tandem Sub 4 Single Sub 5 Stick

Number of
1 1 2 3 9
Passes
300/350 (60˚)
Amps 710/790 1000/800 850/950 400
600 (45˚)
Volts 49/51 42 36/43 35/36
Weld Met. Req’d 3.14 (60˚)
2.86 1.02 1.30 2.19
(LBS./FT) 2.56 (45˚)
Dep. Rate
60 15-17 52 32 14
(LBS./HR)
ARC SPEED
21 5.5 (60˚) 45 18 4.6
(FT/HR)

5
4
 1 2

3 4

Process 1 NR-431 2 Electroslag 3 Tandem Sub 4 Single Sub

Number of
1 1 9 6
Passes
Amps 840 475/525 600/900 850/950
Volts 51 48 32/40 35/36
Weld Met. Req’d
5.54 7.97 3.25 3.25
(LBS./FT)
Dep. Rate
74.8 24 51 32
(LBS./HR)
ARC SPEED
13.5 3 16.7 10
(FT/HR)
 NP-MD
June 18, 1998

MOVABLE DAM PROCEDURES BULLETIN

FOR MECHANICAL VERTICAL-UP WELDING

WITH 1/16”, 3/32”, and .120”
NR-431 and NR-432 ELECTRODES
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

APPLICATIONS FEATURES
Vertical up butt welds - single pass Single bevel joints
3/8” thru 4” thick plate Square edge joints
Tank construction Moving copper shoe travels along seam
Shipbuilding Moving or fixed copper backup
Fixed steel or ceramic backup
Welds of virtually any length
Single pass - low distortion
- no interpass cleaning or grinding

MOVABLE DAM

The Movable Dam Verti-Shield process was developed to vertically weld 3/8” to 4”
thick steel, 4 ft. and longer in one pass.

The Movable Dam process consists of feeding an electrode through a contact nozzle
positioned just above a movable copper dam. When the weld puddle reaches a
specific point, the nozzle and dam must move vertically up the plate. Therefore, a
fixture is required to move the contact nozzle, copper dam, and wire feeder, but may
also be designed to carry the wire reel and the operator. The joint must remain open
on at least one side to allow the fixture to move. The contact nozzle is not
consumed.

Retainer dams of water-cooled copper, steel, or ceramic may be used on the

opposite side of the open joint to contain and form the weld metal. For steels
approximately 1-1/4” and thicker, or on some special applications, a horizontal
oscillator for the nozzle is required. The only restriction on the maximum length of
weld is the size of the fixture.
 NP-MD
June 18, 1998

Index
Safety Precautions ....................................... .............................................................4
Electrode Operating Data ............................. .............................................................6
Special Notes .......................................... .............................................................6
Set-Up Procedures ....................................... .............................................................7
Welder ..................................................... .............................................................7
Joint Preparation and Design .................. .............................................................7
Electrode Oscillation................................ .............................................................7
Starting .................................................... .............................................................8
Sumps ..................................................... .............................................................8
Risers ...................................................... .............................................................9
Grounding................................................ .............................................................9
Moving Copper Shoes ............................. .............................................................9
Stationary Copper Dams ......................... ...........................................................10
Steel Backups.......................................... ...........................................................10
Ceramic Backups .................................... ...........................................................10
Welding Procedure with Ceramic ............Backups..............................................11
Tip Height ................................................ ...........................................................11
Electrical Stickout .................................... ...........................................................11
Drag Angle............................................... ...........................................................12
Electrode Location................................... ...........................................................12
Current Setting Adjustments.................... ...........................................................13
Travel Speed ........................................... ...........................................................13
General Welding Procedures
Preheat.................................................... ...........................................................14
Starting Procedure................................... ...........................................................14
Restarting ................................................ ...........................................................15
Starting Without Sump............................. ...........................................................15
Finish Procedure ..................................... ...........................................................16
General Welding Problems
Distortion ................................................. ...........................................................16
Weld Bead Condition............................... ...........................................................16
Cracking and Porosity ............................. ...........................................................16

2
Suggested Procedures ...................................................................................... 17-20
For 1/16” Electrodes Using Copper Dams ........................................................ 17
For 3/32” Electrodes Using Copper Dams ........................................................ 18
For .120” Electrodes Using Copper Dams ........................................................ 20
For .120” Electrodes With Oscillated Electrode................................................. 21

Equipment .............................................................................................................. 22

Troubleshooting Guide ...................................................................................... 22-28

3
ARC WELDING SAFETY PRECAUTIONS
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND
BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER
EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION.
1. HAVE ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR WORK performed 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 “hot” 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.
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.
4
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 cover
plates to protect your eyes from sparks and the
rays of the arc when welding or observing open
arc welding. Headshield and filter lens should
conform to ANSI Z87.I. standards.
b. Use suitable clothing made from durable, flame-
resistant material to protect your skin and that of
your helpers from the arc rays.
c. Protect other nearby personnel with suitable
nonflammable screening and/or warn them not
to watch the arc nor expose themselves to the
arc rays or to hot spatter or metal.
5. FIRE OR EXPLOSION can cause death or
property damage.
a. Remove fire hazards well away from the area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember
that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas. Have a fire
extinguisher readily available.
b. Where compressed gases are to be used at the
job site, special precautions should be used to
prevent hazardous situations. Refer to “Safety
in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment
being used.
c. When not welding, make certain no part of the
electrode circuit is touching the work or ground.
Accidental contact can cause overheating and
create a fire hazard.
 d. Do not heat, cut or weld tanks, drums or
containers until the proper steps have been taken
to insure that such procedures will not cause
flammable or toxic vapors from substances
inside. They can cause an explosion even though
they have been “cleaned”. For information
purchase “Recommended Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held
Hazardous Substances”, AWS F4.1-80 from the
American Welding Society (see address below).
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.
5
f. Valve protection caps should always be in place
and hand tight 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.
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 strongly
recommended that you purchase a copy of “Safety in
Welding & Cutting - ANSI Standard Z49.1” from the
American Welding Society, P. 0. Box 351040 Miami,
Florida 33135.
 NP-MD
June 18, 1998

ELECTRODE OPERATING DATA

Wire Feed Approx. Arc Deposition

NR-431 Speed Current Voltage Rate
(DC+) (in/min) (amps), DC+ (volts) (lbs/hr)
1/16” 300 260—270 32—34 11.3
1” ESO 350 275—285 35—37 13.0
. 71 lbs. per 400 285—295 37—39 14.7
1000” of electrode 450 300—310 39—41 16.4
3/32” 250 390—430 33—35 20.0
1—1/2” ESO 300 435—465 35—37 24.3
1.58 lbs. per 350 480—520 36—38 28.6
1000” off electrode 400 530—570 38—40 33.0
450 570—610 39—41 37.4
.120” 200 500—540 37—39 23.3
2—1/2” ESO 300 595—635 41—43 36.0
2.4 lbs. per 400 695—735 44—4& 48.8
1000” of electrode 500 790—830 48—50 61.8

Wire Feed Approx. Arc Deposition

NR-432 Speed Current Voltage Rate
(DC+) (in/min) (amps), DC+ (volts) (lbs/hr)
1/16”
300 260—270 32—34 11.7
1” ESO 350 285—295 35—37 13.2
. 74lbs. Per 400 305—315 37—39 14.6
1000” of electrode 450 330—350 39—41 16.1

3/32” 250 430—470 33—35 23.7

1—1/2” ~ 300 475—515 35—37 28.0
1.71lbs. per 350 520—560 36—38 32.3
1000” of electrode 400 560—600 38—40 36.6
450 610—650 39—41 41.0
.120” 200 520—560 37—39 26.0
2—1/2” ESO 300 615—655 41—43 40.0
2.52 lbs. per 400 715—755 44—46 53.8
1000” off electrode 500 810—850 48—50 68.0

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).

6
 NP-MD
June 18, 1998

Plate fixtures must be adequate to hold plates securely and to prevent changes in joint
and joint volume. This could affect weld quality, mechanical properties and operation
of equipment.

These procedures represent tested starting points for setting up individual field
applications. Variations other than those used to set the procedures, such as plate
chemistry, plate surface condition (oil, scale), plate thickness, joint fit-up and
equipment, may produce results different than those expected. Some adjustments to
the procedure may be necessary to compensate for the unique individual conditions.
Test all procedures duplicating actual field conditions. Some joints may require special
dam designs. For these applications or other questions, consult the Welding and
Cutting Technology Center at The Lincoln Electric Company in Cleveland, Ohio at
(216) 481-8100.

SET-UP PROCEDURES

Welder

For optimum bead wetting, the welder should be set in the Constant Voltage
Innershield (CVI) mode. Both NR-431 and NR-432 are welded DC(+), (electrode
positive).

Joint Preparation and Design

The joints welded with this process are normally square-edge or beveled butt welds.
Plates should be free from grease, oil, excessive scale, etc. Sizeable nicks and dents
in the edges being welded can be tolerated provided fold-overs and laminations did
not occur. The plates should be fit-up so that the dams prevent slag spillage between
the dams and plates.

Electrode Oscillation

On 1-1/4 thru 4” plate, the electrode oscillates between the locations shown and along
the centerline of the gap. The oscillation locations, dwell times, and travel times are
given in the Procedures sheets (Page 20).

The electrode should dwell at each location for the dwell time given in the procedure
table. The electrode should travel between the locations with the oscillation travel time
given in the table.

7
 NP-MD
June 18, 1998

Starting

In order to minimize start porosity and obtain good wetting, use of a start circuit and
procedure is recommended. This circuit provides for a reduced wire feed speed and
reduced voltage for a given number of seconds. The starting time is decreased as the
plate thickness decreases. This reduces the possibility of the weld paddle spilling over
the top of the shoe(s) on thinner plates due to the reduced joint volume being filled
quicker.

Sumps

Starting sumps permit striking the arc below the actual joint so any starting porosity
can be easily removed. The sump must be long enough to allow time for the switch
from starting to welding procedures and for the arc and travel to stabilize before the
puddle rises into the joint being welded. The sump is cut off after welding.

The sump plate thickness and gap

configuration must be the same as the
plates being welded. Attach the sump
to the plates as shown. Be sure the
top of the sump where it fits against
the bottom of the plates is clean and
dry. Use continuous seal welds and
grind them flush where the dams fit.
Insufficient seal weld strength or
thickness of material under the sump
can result in weld metal leakage which
may prevent the travel from starting.

The depth of the sump should be 2”

minimum. The use of 880M flux will
help produce good starts with
shallower sumps. A steel sump is cut
off after the weld is completed.

If a copper sump is used, it should be large enough so that it does not become fused
to the weld. It should also have a tapered hole or be split for easy removal. A small
piece of steel should be placed in the bottom of a copper sump to avoid arcing the
copper. A small piece of fiberglass tape may be placed on the sump below the gap to
prevent weld spilling upon initiating the weld.

8
 NP-MD
June 18, 1998

Risers

Risers (or run-off tabs) are recommended because the solidification of the large
puddle at the end of the weld creates a shrinkage crater that has a tendency to trap
slag or gas. Typical risers are shown in the previous figure. Weld should continue into
the riser until weld puddle is approximately 1” to 2” above the top of the work.

Grounding (Weld Toward Ground)

Ground leads should be connected to the top of each plate. Connect the ground leads
securely approximately 1 foot away from the seam. If arc blow problems exist, adjust
grounding to reduce the problem.

Moving Copper Shoes

Whenever a moving shoe is employed, it must be water-cooled. The size of the

copper shoe and degree of water-cooling are very important factors since they have a
strong effect on the quench rate of the weld puddle. Quench rate controls bead
appearance, wetting, porosity, cracking and mechanical properties of the weld bead.
The location of the water passage in the copper shoe relative to the groove in the
shoe, size of the passage, and length of the total flow pattern are also very important.
For these reasons, it is very important to use copper shoes that meet the
specifications given in the procedure sheets. In addition, the water flow should be
controlled as prescribed. The groove dimensions are very important in the copper
shoe since they control bead contour, reinforcement, and proper tie-in on the corners.
A narrow groove will cause poor tie-in. A wide groove will cause square edges on the
weld bead. Always try to maintain perfect alignment of the shoe(s). Obviously, any
projections on the face of the plates should be removed or the copper shoe(s) may be
pushed away from the plate surface and the weld puddle will spill out. The top chamfer
must be maintained as specified for proper electrode clearance. Water should not be
turned on until welding starts or moisture will condense on the shoes and joint in
warm, humid weather.

Copper shoes are grooved to provide proper bead contour on front of weld. Shoes
have a V cut out at the top to permit excess slag to drain out. The weld puddle should
be just below the apex of the V. Enough water flow must be used to prevent
overheating of the shoe and vapor lock of the water flow (approximately 1-1/2 - 2
gal/mm). Water flow must not be interrupted while welding. lf the water lines vibrate
while welding, it means that water flow is insufficient and some of the water in the
copper shoe is boiling. The formation of steam results in high pressures in the water
lines. If a water line fails due to steam formation, it could cause injury to nearby
personnel. Do not use the same water supply for the copper shoe and the backup
dams. The travel mechanism should be adjusted to give the smoothest travel possible.
Large jerks indicate travel speed set too high or slight arcing to the copper shoe. If
slag builds up on the shoe (or nozzle), it may be knocked off with a piece of wood or
other non-conductive material.

9
 NP-MD
June 18, 1998

Stationary Copper Dams

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

Dams should be wedged or clamped tightly against the plates to prevent leakage of
the molten slag on the weld puddle. Dams must be replaced or repaired if they
become damaged enough so that they no longer fit properly against the plate.

When more than two dam sections are employed, each section must be water-cooled.
Enough water flow must be used to prevent overheating of dam and vapor lock of the
water flow (approximately 1 - 1-1/2 gals/mm in each side of each section). Exit water
should be warm to the touch (not hot). Water-cooling passages are located at the top
of the dams. The copper dams should extend a few inches beyond the top of the weld
to reduce heat buildup and help produce sound craters. Water flow should be left on
for several minutes after the weld is completed to cool the dams. Water flow must not
be interrupted while welding. If the water lines vibrate while welding, it means that
water flow is insufficient and some of the water in the copper dams is boiling. The
formation of steam results in high pressures in the water lines. If a water line fails due
to steam formation, it could cause injury to nearby personnel.

If the humidity is high, do not leave the water flow on when not welding or moisture will
condense on the outside of the dams.

Steel Backups

When a stationary steel backup is used, all rust, scale, oil, or other foreign material
should be ground off the mating faces. Otherwise, porosity will occur along the plate
edges where the steel backup is positioned. Steel backups should be mild steel or the
same material as the steel being welded.

Ceramic Backups

1/16” electrode may be used with certain ceramic backing material. The ceramic
should be high melting point type.

A metal retainer is recommended to hold the ceramic tight against the base plate. The
retainer should be clamped or welded to the base plate. It will act as a heat sink and
prevent melted ceramic, slag and molten weld metal from flowing away from the weld.

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June 18, 1998

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.

Tip Height

Tip height above the top of the copper cutout should be 7/8” to 1-3/4”. The puddle
height must be 1/4” below the top of the copper cutout. This will allow excess slag, if
any, to drain out. There may be some draining on heavier plate; little or none on
thinner plate.

While welding, do not allow the puddle to rise up too high in the shoe (stick-out too
short) or molten weld metal will run out. This will stop the vertical travel and interrupt
the weld. Do not let the puddle go too far down in the shoe (stick-out too long) or the
resulting weld will be “cold” and have poorly wet edges.

Electrical Stickout

Electrical stick-out of the electrode beyond the contact tip determines current and the
welding characteristics of the electrode. Incorrect stick-out can cause porosity, low
impact strength and improper location of the electrode during welding. Improper
electrode location can result in poorly wet bead edges and arcing to the copper shoe
or dam. Set the stick-out before bringing the electrode into the joint. Do not change the
stick-out when making other adjustments.

When welding with the extension guide (.120” diameter electrode), the electrical stick-
out is 1” longer than the visible stick-out.

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Drag angle

Drag angle determines direction of arc force and affects heat flow. A large drag
angle will direct more heat to the back, possibly causing missed edges on the
front. A large drag angle also causes relatively larger changes in electrode
location with variations in stick-out. Copper backup dams or front shoes may be
arced if this angle is improperly set. Drag angle is measured from the vertical to
the line of the electrode as it exists from the tip (or from the extension guide) as
shown below. Drag angle should be 6°-10°, depending on application.

Electrode Iocation

Electrode location is measured from the front face of the plate to the near side of
the electrode end after establishing correct stickout. Location must be set
carefully and monitored during welding. If location is too close to front, the
electrode may arc to the copper shoe and/or the back bead face may be poorly
wet. If location is too far back, the front bead face may be poorly wet and/or the
electrode may arc to the back dam. Set the electrode location according to the
recommended procedures on Pages 17-20 and defined in the diagrams below:

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June 18, 1998

The electrode location changes as the nozzle contact tip wears. Replace the
contact tip when it becomes worn or the end is fused or deformed.

Electrode location can also change due to wire straightness and flip. Wire
straightens and guides should be used to reduce this problem.

Current Setting Adjustments

Current setting adjustments on the current meter relay are made only to control
stick-out and puddle height. Puddle height is defined as the distance between the
molten slag puddle and the copper cutout on the shoe. If the puddle height is too
great (stick-out too long), increase the current setting on meter relay. If the puddle
height is too low (stick-out too short), decrease the current setting. A 25-amp
change in current setting on .120” wire will change stick-out and puddle level by
1/4” to 1/2”. Stickout and puddle level must be held closely to maintain proper
electrode location and slag control.

Travel Speed

The operator has no direct control over weld travel speed. The electrode
diameter, wire feed speed, and joint volume will determine the actual weld travel
speed. The movement of the fixture is automatically controlled.

For a given electrode diameter, wire feed speed and electrical stick-out, there is a
resultant welding current. A change in any of these variables will cause a change
in the welding current. Since the electrode diameter and wire feed speed are
constant, only the electrical stick-out can change and influence the welding
current. This change in current is the basis for controlling the travel of the fixture.
As the stick-out gets longer, the current decreases; as the stick-out gets shorter,
the current increases. The change in current is the important factor and not the
actual current that may vary from setup to setup.

All Verti-Shield fixture manufacturers use this change in current to control the
fixture travel. The Ransome fixture uses a set point ammeter, the needle indicator
sets the point at which the travel starts and stops. This is not a travel speed
control but determines the level of the weld puddle in relation to the moving shoe.
A rule of thumb is “the higher the set point, the higher the puddle - the lower the
set point, the lower the puddle”.

Once the wire feed speed and stick-out are set, the ammeter set point controls
the position of the puddle in the moving shoe. The travel speed of the fixture,
when activated by the ammeter, is set by a different speed control. This speed
control sets the speed that the fixture moves when the control signals it to move.

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On equipment with on and off travel control, carriage travel speed should be set at
125% to 150% of arc travel speed. The arc travel speed range is determined by
the joint gap for a given wire feed speed.

GENERAL WELDING PROCEDURES

Preheat

Preheating is recommended, particularly at the start area. Preheating minimizes

any tendency for starting cracks and starting porosity, and will improve the edge
wetting of the weld bead at the start of the weld.

The following minimum preheat temperatures are recommended as starting

points. Higher or lower temperatures may be used as required by job conditions
and/or prevailing codes. If cracking occurs at the start, higher preheat
temperature may be required. Cracking, if it occurs, will be internal. Test welds of
length equal to the job should be welded and tested along their entire length for
internal cracking. Higher or lower preheat temperatures may be used as required
by job conditions and/or prevailing codes.

3/8” 1/2 — 1” 1—2” 3—4”

Plate Plate Plate Plate
Thickness Thickness Thickness Thickness
Recommended
Minimum Preheat START AREA 200°F 250°F 300°F 350°F
Temperatures

Starting Procedure

Wire Diameter (in) 1/16 3/32 .120

Wire Feed Speed (in/mm) Same as weld 150 250
Voltage (volts) procedure 29 37
Electrical Stickout (in) 1 1—1/2 2—1/2 to 3
Visible Stickout (in) 1 1—1/2 1-1/2 to 2

After starting time has elapsed, the weld procedure stick-out should be maintained.

Starting Porosity: Some starting porosity may occur. To improve starting and reduce
porosity, preheat starts and/or add 880M flux.

Use approximately 1-1/4 teaspoons of 880M flux for each inch of plate thickness.

The 880M flux is poured into the gap when starting the arc. Half of the
recommended amount of flux may be added before striking the arc as long as the
electrode is in contact with the striking surface. Add the remaining flux gradually so
as not to quench the arc. Add the flux with a non-metallic instrument to avoid arcing.

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Restarting

If a weld is interrupted before completion:

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 the affected area. Reference “Starting without sump”
section of this Guideline.

4. Cut electrode and reset proper stick-out.

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 start procedure.

Starting Without Sump

Sometimes the weld must be started without a starting sump. For example, the start
of vertical welds in tank erection is on the top of the previous course. Where such
starts or restarts are made on good plate, some repairs in the starting area are
sometimes necessary, particularly on the heavier plate thickness. The size and
accessibility of these repair areas can be controlled by preheating to about 400°F
min. One method of preparing the plate for a fast, preheated start using an arc
gouged start area is shown below. For plates requiring oscillation, it is best to simply
remove the slag from the crater and preheat to 600°F to 700°F.

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1. Arc gouge starting sump.

2. Preheat starting area 400°F.

3. Make weld.

4. Repair should be in starting area

on front side.

Finish Procedure

Just before pressing the “Off” button, “cap” the weld by adding enough 880M flux to
completely cover the weld. This flux addition will help reduce shrinkage cavity and
crater porosity. This procedure should be done when the crater is in the run-off tab
area.

GENERAL WELDING PROBLEMS

Distortion

If the joint tends to close during welding, the weld quality will be affected. On
beveled joints, the back bead may be lost. The plates must be held rigidly or allow a
1/8” greater gap at the top of the plates regardless of seam length.

Weld Bead Condition

Higher wire feed speeds and voltage are used on thicker plates or wider face
openings to get good wet-in on the faces. Square bead edges can result from a
“cold arc”. Increasing wire feed speed and arc volts will usually correct this
condition. The current meter relay should be increased to maintain proper stick-out.
Remember to check for a narrow gap that will make the puddle colder or mis-
location of the electrode due to improper tracking, improper electrical stick-out
(check meter relay setting), or improper setup location.

On oscillated welds, bad back beads can occur if the electrode moves too close to
the front of the joint and arcs off the sidewalls. Too short a dwell or too slow an
oscillation will cause square edges. Misalignment of the shoes on the joint will cause
under-wash on one edge with or without oscillation.

Cracking and Porosity

The most critical problems with automatic vertical up welding are cracking and
porosity.

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June 18, 1998

Since the Moving Dam Process is an open arc process, the electrical stickout,
current, voltage and depth of the weld puddle below the top of the copper shoe(s)
control porosity. Decreased current for the same voltage, increased voltage for the
same current, or decreased stick-out for the same current and voltage will all
increase the tendency for porosity.

The starting circuit parameters are very important since poor starts can result in
completely porous welds for a considerable length of the joint.

The most important parameter that controls’ cracking is the wire feed speed.
Decreasing the wire feed speed by 15% and the voltage by 2-3 volts makes a
significant decrease in cracking tendency. Increasing the gap is sometimes
beneficial in decreasing cracking but may cause incomplete sidewall fusion.
Increasing the voltage will decrease cracking but must be done with caution since
the porosity tendency will increase. As with other processes, decreasing the quench
rate decreases the cracking tendency. With this process, lower wire feed rates
(lower current), for the same ESO actually result in slower quench rates due to
slower travel speeds. Oscillation is also very effective in decreasing cracking.
Welding on very cold days may produce cracking unless preheating is used.

SUGGESTED PROCEDURES

For 1/16” Electrodes Using Copper Dams

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

Joint Angle (degrees) 60 60 40 40
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
Stationary Copper Dam (see below) A A or B B B
Wire Feed Speed (in/mm) 300 300 350 400
Current (Amps) (Approx.) NR-431 260-270 260-270 275-285 285-295
NR-432 260-270 260-270 285-295 305-315
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
NR-432 11.7 11.7 13.2 14.6

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June 18, 1998

For 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) 1x3x5-3/32 1x3x5-3/32 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-431 435-465 470-510 510-550 510-550
NR-432 475-515 510-550 545-585 545-585
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-431 24.3 27.8 31.2 31.2
MR-432 28.0 31.4 35.0 35.0

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June 18, 1998

19
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June 18, 1998

For .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-431 645-685 645-685
NR-432 665-705 665-705
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 45.0 45.0
NR-432 50.0 50.0

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June 18, 1998
For 120” Electrodes Using Copper Dams on 1-1/4 4” Plate With Oscillated Electrode
-

Plate Thickness (in) (T) 1-1/4 to 1-1/2 2 3 4

Joint Angle (degrees) 90 90 90 90
Gap (in) 7/8 - 1 1 - 1-1/8 1 - 1-1/8 1 - 1-1/8
Front Moving Shoe (in) 1.5” Groove 2” Groove 2” Groove 2” Groove
1x4x6- .120 1x4x6- .120 1x4x6- .120 1x4x6- .120
Stationary Copper Dam K412 K412 K412 K412
Wire Feed Speed (in/min) 350 350 350 300
Current (Amps) (Approx.) NR-431 645-685 645-685 645-685 595-635
NR-432 665-705 665-705 665-705 615-655
Voltage (volts) 40-42 4345 4345 41-43
Electrical Stickout (in) (± 1/8”) 2-1/2 - 3 2-1/2 - 3 2-1/2 - 3 2-1/2 - 3
Visible Stickout (in) 1-1/2 1-1/2 1-1/2 1-1/2 - 2
Electrode Drag Angle (degrees) 8-10 8-10 8-10 8 10
Electrode Location from Front (in) 1/4 - 3/8 1/4 - 3/8 1/4 - 3/8 1/4 - 3/8
Electrode Location from Back (in) 3/8 - 1/2 3/8 - 1/2 3/8 - 1/2 3/8 - 1/2
Oscillation Period (sec) 5 6 8 10
Dwell Time (sec) 2 Front; 2 Back
Travel Time (sec) 1/2 1 2 3
Puddle Height (in) 1/4 1/4 1/4 1/4
Start Procedure Time (sec) 10 15 20 30
Travel Speed (in/min - approx.) 1.8 1.4 1.0 .6
Deposition Rates (lbs/hr) NR-431 450 45.0 45.0 39.5
NR-432 50.0 50.0 50.0 42.6

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

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June 18, 1998

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

EQUIPMENT

Wire Diameter 1/16” 3/32” .120”

Power Source DC—400, DC—600 DC—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 Welding Carriage ** ** **
Copper Dam K561—1 K562—1 K412
1”x3”x4”—1/16 or
Copper Shoe 1”x3”x5”—3/32 1”x4”x8”—. 120
1”x3”x5”—3/32

* Not standard Lincoln part numbers.

* * Koike Aronson Inc. / Ransome is the recommended supplier of Movable Dam

welding equipment. For specific information, contact Koike Aronson Inc. or
Ransome in Houston, Texas, or the local Lincoln Electric Technical
Representative.

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

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June 18, 1998

TROUBLESHOOTING GUIDE
STARTING PROBLEMS

PROBLEM CAUSE CORRECTION

POROSITY 1. Dirt, oil, water, rust in joint.
2. Cold plates.
3. High starting voltage.
4. Short starting stick-out.
5. Excessive slag drainage.
6. Incorrect start procedure or
start time.
7. Not enough arc protection.
8. Incorrect power source.
CRACKING 1. Poor weldability steel.
1. Remove contaminants.
2. Preheat.
3. Lower start voltage.
4. Increase stick-out.
5. Use 880M flux at start.
Improve fit up.
6. Use correct start procedure
and time.
7. Add 880M flux.
8. Use correct power source.
1. Use better steel.

2. Cold plates. 2. Preheat.

3. Wire feed speed too high. 3. Lower wire feed speed.

4. High restraint. 4. Preheat and use lower wire

feed speed.
LACK OF FUSION 1. Cold plates. 1. Increase preheat.
AT START OF
2. Too much flux added 2. Use less flux.
WELD
(quenching arc).

3. Flux added too fast (quenching 3. Add flux more slowly.

arc).
4. Electrode located too far away
4. Correct electrode location.
from one plate.
5. Gap too tight at start - plates
5. Use correct gap.
not cut square.
6. Start time too long.
6. Use shorter start time.

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

23
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June 18, 1998

TROUBLESHOOTING GUIDE
WELD PROBLEMS

PROBLEM CAUSE CORRECTION

1. Excessive slag drainage. 1. See corrections for excessive
slag drainage.
2. Voltage too high. 2. Lower voltage.
3. Bad start carried up through 3. Use 880M flux at start and
weld. recommended starting
procedure.
4. Stickout too short. 4. Decrease current setting to
increase stickout. Check
fixturing.
5. Low wire feed speed for 5. Raise wire feed speed.
voltage.
6. Dirty, rusty, oily, or wet plates. 6. Remove contaminants.
POROSITY IN 7. Arc blow. 7. Change ground location.
WELD
8. Gap too small causing too fast 8. Use correct gap or improve
travel speed. fixturing to prevent gap from
changing.
9. Poor fit between shoe and 9. Improve fitup and/or clamping
plates or backup and plates devices.
allowing slag cover or weld
puddle to leak out side.

10.lncorrect power source. 10.Use correct power source

(such as DC-600 or DC-
1000).
1. Poor weldability steel. 1. Use better steel.
2. Cold plates. 2. Preheat.
3. Wire feed speed too high. 3. Lower wire feed speed.
CRACKING 4. High restraint. 4. Preheat and use lower wire
feed speed.
5. Copper pick up due to arcing 5. See corrections for arcing or
or melting dam. melting copper dam.

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

24
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June 18, 1998
TROUBLESHOOTING GUIDE
WELD PROBLEMS (continued)
Problem CAUSE CORRECTION
1. Narrow gap causing too fast 1. Increase gap.
travel speed.

2. Edges of groove in copper 2. Line up dam properly.

dam too close to edge of
gap.

3. Groove in dam too small. 3. Use correctly grooved dam.

4. High wire feed speed 4. Lower wire feed speed.

LACK OF FUSION causing too fast travel
speed.
ALONG LENGTH
OF WELD
5. Voltage too low. 5. Raise voltage.

6. Electrode located too far 6. Correct electrode location.

away from edge.
7. Gap much too wide causing 7. Reduce gap.
electrode to be too far from
edges.
8. Too little slag drainage. 8. See corrections for “choked
sounding arc”.
9. Copper shoe not tracking 9. Line up fixture so shoe tracks
along seam properly. properly.
1. Shoe not staying tight 1. Check mounting of shoe and
SQUARE EDGES - against plate - riding out and fixture. Shoe should be able to
WIDE BEAD, allowing puddle to flow remain in contact with plates.
LUMPY BEAD beyond groove in copper. Or Reduce hi-low.
bad hi-low.
1. Electrode location too far 1. Move location toward front.
back.
2. Excessive slag drainage. 2. See corrections for excessive
COLD LOOKING slag drainage.
FRONT 3. Too much electrode angle. 3. Decrease electrode angle.
IRREGULAR OR
MISSED EDGES - 4. Stick-out too long - puddle 4. Adjust nozzle, shoe, current
POORLY WET running too low. sensing mechanism to give
EDGES correct stick-out and puddle
height.
5. Wire feed speed too low or 5. Use correct wire feed (see
too high. procedure).

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

25
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June 18, 1998

TROUBLESHOOTING GUIDE
WELD PROBLEMS (continued)

COLD LOOKING 6. Travel speed too fast due to 6. Lower carriage travel speed.
FRONT - carriage travel speed set too Use wider gap.
IRREGULAR OR high or narrow gap.
MISSED EDGES - 7. Incorrect power source. 7. Use correct power source.
POORLY WET
EDGES (continued)
1. Shoe not tracking properly - 1. Center gap in groove.
joint gap off center with
respect to groove in copper.

2. Too much heat - arc too close
to front or setting too hot
UNDERWASHED causing bead width to extend
EDGES beyond copper groove. Face
opening too large.
2. Move arc away from front.
Reduce heat. Reduce face
opening.

3. Voltage too high. 3. Decrease voltage.

4. Groove in shoe or dam to 4. Increase groove width.

narrow.

TROUBLESHOOTING GUIDE
CRATER PROBLEMS

PROBLEM CAUSE CORRECTION

1. Large crater shrink or
porosity.
2. Excessive slag drainage.
BAD CRATER 3. Excessive heat buildup.
4. Stopping weld at very top of
plate and dams which do not
extend beyond plate.
1. Cap with 880M flux to
protect molten puddle.
See corrections for
2.
excessive slag drainage.
3. Reduce wire feed speed
feed and voltage at top of
weld.
4. Use risers and dams which
extend beyond top of plates.
Cap with 880M flux.

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

26
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June 18, 1998
DAM/SHOE PROBLEMS

PROBLEM CAUSE CORRECTION

METAL SPILLAGE 1. No glass tape plugs in copper 1. Use glass tape plugs.
AT START OF dam or shoe grooves at start.
WELD
1. Puddle too high (stick-out too 1. Decrease current setting to
short). lengthen stickout and lower
puddle.
SHOE STOPS
2. Electrode location too close 2. Move location away from shoe.
TRAVELING AND
to front - arcs shoe and fuses
WELD PUDDLE
it to weld. 3. Remove irregularities.
SPILLS OVER VEE
3. Irregularities, spatter on
surface interfere with shoe
travel.
1. Arc too close to shoe. 1. Move arc away from shoe.
2. Wire feed speed or voltage 2. Use correct procedure.
too high.

ARCING FRONT 3. Puddle riding too high - metal 3. Adjust parameters so that
SHOE spilling over top of shoe. puddle rides approximately
1/4” below cut out on shoe.
4. Too little electrode angle 4. Use correct electrode angle.
(electrode too much straight
up and down).
1. Electrode location too close 1. Move location away from dam
to dam or shoe. or shoe.
2 Excessive slag drainage (on 2. See corrections for excessive
thin plate). slag drainage.
3. Dams or shoe overheating. 3. Use water-cooled dams or
shoe; increase water flow.

No water-cooling. Use water-cooled dams.

Vapor lock due to not enough Increase water flow.

ARCING OR
water flow.
MELTING COPPER
DAM; COPPER
Ends of dams do not extend Use longer dams.
DAMS
beyond end of weld.
OVERHEATING,
TURNING RED
Dams too small in cross Use larger dams.
section.
4. Voltage too high. 4. Reduce voltage.
5. Arc blow due to improper 5. Ground at top of each plate or
grounding. change ground.
6. Wrong composition of copper 6. Use 99.9% pure copper such
dams. as alloy #110.
7. Too long dwell time. 7. Reduce dwell time.
8. Too much electrode angle. 8. Adjust nozzle so that electrode
is more straight up and down.

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

27
 NP-MD
June 18, 1998

TROUBLESHOOTING GUIDE
MISCELLANEOUS PROBLEMS

PROBLEM CAUSE CORRECTION

1. Voltage too high. 1. Lower voltage.

2. Low wire feed speed for 2. Raise wire feed speed.

voltage.
SMOOTH 3. See corrections for excessive
SOUNDING ARC 3. Excessive slag drainage. slag drainage.

4. Decrease current setting to

4. Stickout too short. increase stick-out. Check
fixtures.
1. Voltage too low. 1. Raise voltage.
CHOKED
SOUNDING 2. Wire feed speed too high. 2. Lower wire feed speed.
ARC - NOT
ENOUGH 3. Puddle too low in shoe. 3. Increase current setting to
SLAG DRAINAGE. shorten stick-out and raise
puddle height.
1. Loose fit between dam and 1. Tighter fit between dam and
plates. plates.

2. Puddle too high in shoe. 2. Decrease current setting to

EXCESSIVE SLAG lengthen stick-out and raise
DRAINING puddle.

3. Irregular surface doesn’t allow 3. Remove irregularities.

shoe to stay tight against
plate.
EXCESSIVE SMOKE 1. Welding in confined area. 1. Use smoke removal equipment.

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

28
 IDEALARC ® DC-1000

The DC-1000 is a multiprocess DC arc
welding power source for semiauto-
matic and automatic welding
applications. It produces outstanding
arc characteristics on both constant
voltage and constant current
processes. This provides great weld-
ing versatility in a single power source.
The DC-1000 is designed for
submerged arc welding, and FCAW
processes within the capacity of the
machine, plus the capability of air
carbon arc gouging up to 5/8” (16mm)
diameter carbons. It produces
outstanding welding performance with
a single range full output control
potentiometer.
The precise output of the DC-1000
enhances productivity and quality
control when used with Lincoln LN-7,
LN-8 and LN-9 semiautomatic wire
feeders, NA-3, NA-5, and NA-5R
automatic wire feeders, and the LT-56
and LT-7 tractors.
• Mode switch used to select the
desired output characteristics for
the process being used.
• Line voltage compensation for
maintaining weld consistency, even
with line voltage changes of ±10%.
• Low profile case allows installation
of the DC-1000 under a workbench
and for stacking up to 2 machines
to conserve floor space.
• Removable side panels for easy
access to internal parts.
• Fan cooled with electronic and
thermostatic protection from current
overload and excessive temperatures.
• Windings and rectifiers protected
against moisture and corrosive
environments.
• Recessed front panel protects
operating controls.
• Terminal strip and output studs for
remote connections and cable.
• 500 amp output connections
provide enhanced arc characteris-
tics for submerged arc and MIG
welding procedures.
• Fuse protected 115V wire feeder
auxiliary power with 1000 volt-amp
capacity.
• Power start/stop push button (NVR)
switches with pilot light.
• 3 year warranty on parts and labor.
• Manufactured under a quality
system certified to ISO 9002
requirements.

Factory installed ammeter and

voltmeter is standard. Order
appropriate model and product
number.

ADVANTAGE
LINCOLN
• Solid state circuitry provides extra
long life for repetitive welding
applications. R

• Full range output voltage control for

easy operation and precise output
control.
TECHNICAL
SPECIFICATIONS

Rated DC Output(1) Additional Rating Output Range Weight Dimensions

Product Name Amps/Volts/Duty Cycle(2) Amps/Volts/Duty Cycle(2) (continuous) (net) HxWxD

VOLTS
Idealarc DC-1000 1000A / 44V / 100% 1000A / 50V / 100% 16-46 821 lbs 30.7* x 22.5 x 39.0 in.
(372 kg) (781 x 572 x 991mm)
AMPS *includes lift
150-1300 bail

(1)
NEMA Class I Rated Output.
(2)
Based on a 10 minute period.

ORDERING
INFORMATION

Input Current at Rated Product Number

Standard Voltage
DC Output DC-1000 with Meters

230/460/3/60 193A / 96.5A K1386-3

220/380/440/3/50/60 193A / 112A / 96.5A K1387-3
380/500/3/50/60 112A / 85A K1387-4
415/3/50/60 102A K1387-6

OPTIONS
AVAILABLE
Remote Output Control Paralleling Kit 115V/42V Transformer Kit
For remote adjustment of output. Permits paralleling of two DC-1000’s Provides a way to use the LN-10 or
Consists of a control box with 28 ft. for welding currents of up to 2000 DH-10 wire feeder on a DC-1000 that
(8.5m) of four conductor cable for ter- amps, 100% duty cycle. has a 115V AC available on the
minal strip connection. Order K775. Order S20428. terminal strip. Order K1520-1.

Customer Assistance Policy

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs
of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our
customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect
to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information
or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does
the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of
the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

DISTRIBUTED BY:

THE
LINCOLN ELECTRIC
COMPANY
Local Sales and Service through Global
Subsidiaries and Distributors
Cleveland, Ohio 44117-1199 U.S.A .
TEL (216) 481-8100
FAX (216) 486-1751
WEB SITE: www.lincolnelectric.com

CC/CV Welders
E5.50 6/00
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Vertical Seams - 66M (216.48ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 32 0.75 0.941 92.61 29.12 21 611.55
2 NR431-.120 28 0.75 0.824 81.04 25.48 21 535.10
3 NR431-.120 28 0.75 0.824 81.04 25.48 21 535.10
4 NR431-.120 22 0.75 0.647 63.67 20.02 21 420.44
5 NR431-.120 18 0.75 0.529 52.09 16.38 21 343.99
6 NR431-3/32 14 0.56 0.309 30.39 9.56 21 200.66
7 NR431-3/32 10 0.5 0.196 19.29 6.07 21 127.41
8 NR431-3/32 10 0.5 0.196 19.29 6.07 21 127.41
Dimension of plates 2.5 x 10M Total Pounds required per tank 2901.66

Vertical Seams - 92M (301.76ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 42 0.75 1.235 121.55 38.22 29 1108.43
2 NR431-.120 41 0.75 1.206 118.66 37.31 29 1082.04
3 NR431-.120 33 0.75 0.971 95.51 30.03 29 870.91
4 NR431-.120 33 0.75 0.971 95.51 30.03 29 870.91
5 NR431-.120 24 0.75 0.706 69.46 21.84 29 633.39
6 NR431-3/32 18 0.75 0.529 52.09 16.38 29 475.04
7 NR431-3/32 12 0.5 0.235 23.15 7.28 29 211.13
8 NR431-3/32 10 0.5 0.196 19.29 6.07 29 175.94
Dimension of plates 2.5 x 10M Total Pounds required per tank 5427.78
12/26/96
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Vertical Seams - 51M (167.28ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 30 0.75 0.882 86.82 27.30 17 464.12
2 NR431-.120 26 0.75 0.765 75.25 23.66 17 402.24
3 NR431-.120 22 0.75 0.647 63.67 20.02 17 340.35
4 NR431-.120 20 0.75 0.588 57.88 18.20 17 309.41
5 NR431-3/32 16 0.625 0.392 38.59 12.13 17 206.28
6 NR431-3/32 12 0.56 0.265 26.05 8.19 17 139.24
7 Manual 8 0.5 0.157 15.44 4.85 17 82.51
8 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

Girth Seams - 55M (180.4ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 31 0.75 0.912 89.72 28.21 18 507.80
2 NR431-.120 28 0.75 0.824 81.04 25.48 18 458.66
3 NR431-.120 24 0.75 0.706 69.46 21.84 18 393.14
4 NR431-.120 20 0.75 0.588 57.88 18.20 18 327.61
5 NR431-3/32 16 0.56 0.353 34.73 10.92 18 196.57
6 NR431-3/32 12 0.56 0.265 26.05 8.19 18 147.43
7 Manual 8 0.5 0.157 15.44 4.85 18 87.36
8 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 2205.94

Vertical Seams - 57M (186.96ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 34 0.75 1.000 98.40 30.94 18 556.94
2 NR431-.120 30 0.75 0.882 86.82 27.30 18 491.42
3 NR431-.120 25 0.75 0.735 72.35 22.75 18 409.52
4 NR431-.120 18 0.75 0.529 52.09 16.38 18 294.85
5 NR431-.120 14 0.75 0.412 40.52 12.74 18 229.33
6 NR431-3/32 10 0.56 0.221 21.71 6.83 18 122.86
7 Manual 8 0.5 0.157 15.44 4.85 18 87.36
8 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
12/26/96
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Vertical Seams - 51M (167.28ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 30 0.75 0.882 86.82 27.30 17 464.12
2 NR431-.120 26 0.75 0.765 75.25 23.66 17 402.24
3 NR431-.120 22 0.75 0.647 63.67 20.02 17 340.35
4 NR431-.120 20 0.75 0.588 57.88 18.20 17 309.41
5 NR431-3/32 16 0.625 0.392 38.59 12.13 17 206.28
6 NR431-3/32 12 0.56 0.265 26.05 8.19 17 139.24
7 Manual 8 0.5 0.157 15.44 4.85 17 82.51
8 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

Girth Seams - 55M (180.4ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 31 0.75 0.912 89.72 28.21 18 507.80
2 NR431-.120 28 0.75 0.824 81.04 25.48 18 458.66
3 NR431-.120 24 0.75 0.706 69.46 21.84 18 393.14
4 NR431-.120 20 0.75 0.588 57.88 18.20 18 327.61
5 NR431-3/32 16 0.56 0.353 34.73 10.92 18 196.57
6 NR431-3/32 12 0.56 0.265 26.05 8.19 18 147.43
7 Manual 8 0.5 0.157 15.44 4.85 18 87.36
8 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 2205.94

Vertical Seams - 57M (186.96ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 34 0.75 1.000 98.40 30.94 18 556.94
2 NR431-.120 30 0.75 0.882 86.82 27.30 18 491.42
3 NR431-.120 25 0.75 0.735 72.35 22.75 18 409.52
4 NR431-.120 18 0.75 0.529 52.09 16.38 18 294.85
5 NR431-.120 14 0.75 0.412 40.52 12.74 18 229.33
6 NR431-3/32 10 0.56 0.221 21.71 6.83 18 122.86
7 Manual 8 0.5 0.157 15.44 4.85 18 87.36
8 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
12/26/96
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Vertical Seams - 30M (98.4.4ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 22 0.75 0.647 63.67 20.02 10 200.21
2 NR431-3/32 16 0.625 0.392 38.59 12.13 10 121.34
3 NR431-3/32 14 0.625 0.343 33.76 10.62 10 106.17
4 NR431-3/32 12 0.625 0.294 28.94 9.10 10 91.00
5 NR431-3/32 11 0.50 0.216 21.22 6.67 10 66.74
6 NR431-3/32 10 0.50 0.196 19.29 6.07 10 60.67
7 Manual 7 0.5 0.137 13.51 4.25 10 42.47
8 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 TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 22 0.75 0.647 63.67 20.02 12 240.25
2 NR431-.120 20 0.75 0.588 57.88 18.20 12 218.41
3 NR431-3/32 16 0.625 0.392 38.59 12.13 12 145.61
4 NR431-3/32 14 0.625 0.343 33.76 10.62 12 127.41
5 NR431-3/32 11 0.50 0.216 21.22 6.67 12 80.08
6 NR431-3/32 10 0.50 0.196 19.29 6.07 12 72.80
7 Manual 8 0.5 0.157 15.44 4.85 12 58.24
8 Manual 7 0.5 0.137 13.51 4.25 12 50.96
Dimension of plates 2.5 x 10M Total Pounds required per tank 993.76

Vertical Seams - 48M (157.44.4ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-.120 28 0.75 0.824 81.04 25.48 16 407.70
2 NR431-.120 24 0.75 0.706 69.46 21.84 16 349.46
3 NR431-.120 22 0.75 0.647 63.67 20.02 16 320.33
4 NR431-3/32 18 0.75 0.529 52.09 16.38 16 262.09
5 NR431-3/32 14 0.56 0.309 30.39 9.56 16 152.89
6 NR431-3/32 11 0.56 0.243 23.88 7.51 16 120.13
7 NR431-3/32 10 0.5 0.196 19.29 6.07 16 97.07
8 Manual 8 0.5 0.157 15.44 4.85 16 77.66
Dimension of plates 2.5 x 10M Total Pounds required per tank 1787.32
12/26/96
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Vertical Seams - 17.5M (57.4ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-3/32 14 0.625 0.343 33.76 10.62 6 63.70
2 NR431-3/32 12 0.625 0.294 28.94 9.10 6 54.60
3 NR431-3/32 10 0.625 0.245 24.12 7.58 6 45.50
4 NR431-3/32 10 0.625 0.245 24.12 7.58 6 45.50
5 Manual 8 0.50 0.157 15.44 4.85 6 29.12
6 Manual 7 0.50 0.137 13.51 4.25 6 25.48
7 Manual 7 0.5 0.137 13.51 4.25 6 25.48
8 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 (73.8ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-3/32 12 0.625 0.294 28.94 9.10 7 63.70
2 NR431-3/32 10 0.625 0.245 24.12 7.58 7 53.09
3 NR431-3/32 10 0.625 0.245 24.12 7.58 7 53.09
4 Manual 8 0.50 0.157 15.44 4.85 7 33.97
5 Manual 7 0.50 0.137 13.51 4.25 7 29.73
6 Manual 7 0.50 0.137 13.51 4.25 7 29.73
7 Manual 7 0.5 0.137 13.51 4.25 7 29.73
8 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

Vertical Seams - 22.5M (73.8ft) - METER DIAMETER TANK

Weld Wire Plate Joint Joint Area Volume of joint Lbs. Number Total
Consumable Size mm Gap inches2 cubic inches Required of Verts Weight
1 NR431-3/32 12 0.625 0.294 28.94 9.10 8 72.80
2 NR431-3/32 11 0.625 0.270 26.53 8.34 8 66.74
3 NR431-3/32 10 0.625 0.245 24.12 7.58 8 60.67
4 Manual 8 0.50 0.157 15.44 4.85 8 38.83
5 Manual 8 0.50 0.157 15.44 4.85 8 38.83
6 Manual 8 0.50 0.157 15.44 4.85 8 38.83
7 Manual 7 0.5 0.137 13.51 4.25 8 33.97
8 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
12/26/96
Ransome VUPNA3ST Single Pass Welding System for Vertical Seams on Field Erected Storage Tanks.
Lincoln NA3S Head & Controls. DC1500 Power Supply – Innershield Process NR431 Electrode.

Koike Aronson, Inc. / Ransome

Houston Sales Center
1285 North Post Oak, Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400
Ransome VUP System for Field Erected Storage Tanks – Lincoln NR431 – Vertical Up Single Pass
Innershield process. USS Fabrication – Division of United States Steel Corp.

Koike Aronson, Inc. / Ransome

Houston Sales Center
1285 North Post Oak, Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400
 KOIKE ARONSON INC. / RANSOME TRACK GUIDED VUPLN-9TG
VERTICAL-UP WELDING SYSTEM.

Light Duty Portable

This machine is designed to make gapped square butt and single "V" vertical welds in steel
plates ranging from 3/8 to 4 inches thick. It utilizes the proven Lincoln Innershield process
with Special NR-431 or NR-432 wire developed for vertical welding. Constructed of
aluminum, the welding unit is easily transported and set up by one operator. Typical
welding applications include: bridge girder flanges and webs, building column splices, and a
myriad of other in-plant fabrications requiring welds up to about 6 feet long. Longer welds
are possible with extra length track.

Carriage Assembly

The welding unit consists of a 7 ft. long track that is fastened to the weldment, parallel to the
weld joint, my means of the clamps provided; weld studs, or other suitable means. The
track receives a powered carriage on which are mounted a special welding nozzle and a
nozzle oscillator for use when welding plate 1-1/4" and thicker. Means are provided for
maintaining a front water-cooled copper dam in contact with and in alignment to the weld
seam.

Running adjustments of the electrode nozzle in-out and cross seam is standard. Vertical
nozzle height and initial angular adjustment are preset fixed settings as required by the
process. The articulated shoe mounting provides cross seam and vertical angular tracking
while maintaining vertical alignment. A fixed copper bar running the full length of the weld
is required and is held in contact with the weldment by means of strong backs and wedges.
The backing bar is not supplied with the equipment but is of simple design and readily
fabricated by the user to the design shown in the Lincoln welding procedure.

Wire Feed and Control System

The welding system consists of a Lincoln LN-9 solid-state control and wire feeder with 50
lb. wire reel in a dust resistant enclosure. These units are mounted on a four-wheel
undercarriage for mobility throughout the shop. Welding wire is fed to the nozzle assembly
on the welding unit through a 15 ft. long conduit suitable for either 3/32 or .120-inch
diameter wire. Ammeter, voltmeter, and wire speed meters are included to present and
monitor the welding parameters. During welding, the copper dam is automatically
maintained in fixed relation to the weld puddle by controlling carriage travel as a function of
change in electrode extension. A flow regulator and switch in the water-cooling circuit
protects the copper shoe against no or low water flow. A water recirculator cooler is
available as an option.

Welding Equipment

A Lincoln DC-600 Power Source provides welding power. Twenty-five feet control cables
run from the Power Source to the Control Unit along with 25 feet of ground cables. Also
provided are 15 feet of control cable, wire conduit and water hoses running from the Control
Unit to the Welding Carriage. The cable assembly going to the Welding Carriage is tie
wrapped together.

Wire Feeder

A Lincoln LN-9 Wire Feeder is provided with feed and pressure rolls, along with inlet-outlet
guides for either 3/32 or .120 inch diameter wire and a cored wire, wire straightener.

Nozzle Assembly

For welding plate 3/4 to 4 inch thick, the .120-inch diameter wire size is recommended. For
plate from 5/8 inch thick and under, 3/32-inch wire is used. One nozzle assembly for
welding with .120-inch diameter wire is supplied. A nozzle assembly for 3/32-inch wire is
optional.

The machine is complete; ready for welding up to 6 foot long welds. Additional track in 6 ft.
increments is available for making longer welds. However, when making welds higher than
10 ft. from the floor, means must be provided by the user to raise the tractor unit above the
floor because of the limited length of cable and wire conduit between the control unit and
welding unit. Machine is wired for 460 volt, 3 phase, 60 hertz operation.

Water Recirculator Cooler System

Furnish and install water cooler recirculating system. Recommended for service where
clean water is at a premium or not available and is required where available water pressure
is below 80 P.S.I. Two 25 ft. long hoses are supplied with the water recirculator.

Service Skid

Basically a steel channel base on which is mounted the power supply and water recirculator
The base has lifting lugs for a single pick when moving around the shop.

Machine Weight - 7 ft. track and carriage assembly- 80 Lbs

Tractor unit with cables- 300 Lbs

Dimension and Shipping weights

1- Crate 100” X 50” X 51” ......Weight 1,000 Pounds
1- Crate 74” X 43” X 45” .......Weight 900 Pounds
Shipping class 70
Ransome VUP-LN-9 Single Pass Welding System for Vertical Seams on Blast Furnace Relining Application.
Lincoln NA3S Head & Controls. DC1000 Power Supply – Innershield Process – NR431 Electrode.

Koike Aronson, Inc. / Ransome

Houston Sales Center
1285 North Post Oak, Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400
Ransome AGW
Automatic Girth Welder
AUTOMATIC GIRTH WELDING SYSTEM FOR
FIELD ERECTED STORAGE TANKS SELF-
PROPELLED-CAN TRAVEL AT OPERATOR-
CONTROLLED SPEEDS FROM 4 IPM TO 105 IPM
(.10- 2.67m/min).
CUTS WELDING TIME UP TO 40% AND MORE.
ADJUSTS TO HANDLE PLATES 6’ TO 10’ (1.8-
3.05m) HIGH AND AS THICK AS 1 ¾” (44.5mm).
WELDS TANKS FROM THE LARGEST
DIAMETER TO AS SMALL AS 30’ (9.1m).

STURDY “A” FRAME ADJUSTABLE DRIVE

Balanced tubular “A” Frame WHEELS
straddles shell plates Serrated flanged drive wheels
providing a solid and sturdy ride the tank ring. Enables
welding platform for long in- operation on tanks as small
service life. as 30’ (9.lm).

ADJUSTABLE FRAME DUAL OPERATOR

Tubular frame telescopes CONTROLS
manually for efficient welding Travel speed from 4 IPM to
of various heights. 105 IPM (.10-2.67m/min) and
all welding operations can be
controlled —from either side
GUARD RAIL of the AGW platform.
PLATFORM FOR
OPERATOR SAFETY
Hand rail platform includes LINCOLN NA-3
weather curtains for operator EQUIPMENT
safety and comfort. Access Standard equipment includes
ladder to primary separator the Lincoln NA-3 solid state
tank allows operator control and welding head
movement from either side. fitted with nozzle, wire feed
rolls, straightener and 50 lb.
(22.7kg) wire reels for either
QUICK POSITIONING single or Twinarc wire are
Guide wheels simplify standard.
loading and offloading. Helps
speed up positioning for
welding alignment. COST EFFICIENT
FLUX RECOVERY
SYSTEM
Submerged Arc flux belt
mechanism included in the
RANSOME MODEL AGW-II welding head assembly
retains the flux at the joint.
Recovers and recirculates the
flux to the primary separator
tank.
 Koike Aronson, Inc. / Ransome
AGW (Automatic Girth Seam) Welding System

The Automatic Girth Seam Welding System (AGW) is a self-propelled

system that will allow for single sided (3 o’clock) or double-sided
(9 o’clock) welds on field erected storage tanks.

Advantages of AGW process:

• Construction speeds up to 20 times faster than manual
• Self propelled unit for controlled quality
• Travel speeds from 4 IPM to 105 IPM based on procedures
• Plates sizes up to 10’ tall and up to 1-3/4 inches thick
• Operate on tanks 30’ in diameter or larger
• Can use any combination of wire and flux based on procedure
• Comes complete, just add wire, flux and operator.
• Can welds from one side or both sides of tank
• Can weld with single wire or tiny twin wire; sub arc or open arc process

Average weld procedure called for a welding travel speed of around 30 IPM, 400 Amps,
28-30 Volts and a wire feed speed of 90 IPM. Single torch deposition rate is
approximately 11 lbs/hr.

The AGW system is available as a single sided (AGW-I) or double-sided unit (AGW-II).

The single sided unit, AGW-I, is the most commonly used unit due to a lighter weight
allowing it to operator on lighter plates. The AGW also requires only one operator and
will not be restricted due to slave side operations.

The double-sided unit, AGW-II, allows for welding on both sides of the plate at once. On
thicker plates (1/2 inch or thicker), this will provide a higher deposition rate.

On the AGW-II, two operators are required, one will have the main travel controls and
the slave operator will just have the welding controls for the slave side. A communication
system is provided to talk to one another.

The AGW systems will operator on standard plate sizes of 6’, 8’ and 10’. Pin adjustments
will set the unit up for the 6, 8 and 10 ft. plate sizes. For in between sizes, the equipment
mounting brackets will need to be adjusted.

Special units have been designed for larger height plates up to 13 ft. and thickness up to
2-1/2 inches. Units have also been provided to work on double walled tanks.
The Koike Aronson, Inc. / Ransome AGW Systems are provided complete, all that is
required is the hang unit on tank, add wire, flux and an operator and begin welding.

Equipment provided on the AGW’s are:

MODEL AGW-I SINGLE SIDED SYSTEM to include:

Operator's Platform with seat
Lincoln NA-3 Wire Feeder and Control
K-231 and K-129 Nozzles
Lincoln DC-600 Power Source.
Horizontal Adjuster
Flux Belt Assembly
Flux Recirculating System
Pre-Heat Torch
Service Skid with Disconnect
Weather Curtains.
200 Feet of Control Cable Assembly
220/380/440V - 3PH - 50/60HZ
Loading Safety Wheels.

MODEL AGW-II DOUBLE SIDED SYSTEM to include:

Operator’s Platform with Seat (2)
Lincoln NA-3 Wire Feeder and Controls (2)
K-231 and K-129 Nozzles
Lincoln DC-600 Power Sources (2)
Vertical Adjusters. (2)
Horizontal Adjusters (2)
Flux Belt Assemblies (2)
Flux Recirculating Systems (2)
Pre-Heat Torches (2)
Service Skid with Disconnects (2)
Weather Curtains (2)
200 Feet of Control Cable Assemblies (2)
220/380/440V - 3PH - 50/60HZ
Loading Safety Wheels
Operator Communication System

Options:

Replace DC-600 Power Source with DC-1000

 Koike Aronson Inc, / Ransome
1285 North Post Oak
Suite 150
Houston, Texas 77055
Phone-713-682-9645 Fax-713-957-4852

SPECIFICATIONS

AUTOMATIC GIRTH WELDING SYSTEM, Single and Double Sided Units

The Ransome AGW System, using Lincoln's NA3 heads and controls, deposits welds in the
3 O’clock position (AGW-I) or 3 O’clock and 9 O' clock positions (AGW-II) on the tank.
The equipment is suitable for single wire subarc, twinarc subarc, or innershield; on both
sides.
Our technology on these systems dates back about 25 years, when we began building
Chicago Bridge & Iron Co's 3 O’clock Welders. We have been the primary builder of
AGW’s ever since, and have built upward of 400 systems.
We have shipped these systems throughout the world; and they truly represent the
benchmark of design, construction, and performance for high production and reliability.
Each system is designed, built, and sold; with every anticipated tool, accessory and
convenience; so you need nothing but power, wire, flux and an operator, to make continuous
horizontal automatic welds on tanks.
All replacement parts, like PC board, nozzles, tips, flux belts; etc., are readily available from
Ransome and/or Lincoln, and are the same components used in other standard
Ransome/Lincoln products.
The systems are in use by Pittsburgh Des Moines Steel Co., American Bridge Div., of U.S.
Steel Co., Graver Tank, CB&I, Rothschild Boiler Co., Shiloh Tank Co., General Dynamics
Corp., Babcock & Wilcox Co., General Electric Co., etc.
We also have systems operating in Indonesia, Philippines, Kenya, Iran, Columbia, Canada,
Kuwait, Romania, Brazil, Mexico, Venezuela, China, Thailand, Korea, etc.
These systems are truly the most modern high technology processes available for automatic
welding storage tank construction, and are designed to anticipate the rugged conditions of
field construction.

RANSOME AUTOMATIC GIRTH WELDER (A.G.W.) SYSTEM for Automatic

Welding Horizontal Joints on Field Erected Storage Tanks.

GENERAL
The Ransome Girth Welder is an automatic self-propelled welding machine used for the
construction of field storage tanks having 6', 8’ and 10' (1.8, 2.4 and 3.04 M) high plate
courses. The unit is basically an "A" frame that straddles and is supported by the shell plates
to be welded. Each side of the machine has its own welding head, control, flux support belt
apparatus and flux recovery unit so that 3 O’clock welds can be made simultaneously from
both sides of the shell. The standard welding process supplied is the Lincoln Electric
Company's submerged arc system, using a Lincoln NA-3S solid state control. The system is
also designed for Lincoln Twinarc process, and Innershield process; where the client
approves such procedures.

MACHINE FRAME
"A" frame constructed of structural steel and tubular steel members. One side, referred to as
the master, is an entity and can be used by itself for one side welding. The second side
(slave) is pivotally fastened to the top of the master frame and is used when welding two
sides. The tubular legs of the frame telescope and are manually adjusted by removing pins
and lowering the platform. This machine can weld shell plate ranging from 6’,8’ and 10 Ft.
high (1.8,2.4 and 3.04 M.) The customer can drill additional holes for positions within the
above range. You can also make find adjustments of +/- 3 inches of the coarse adjustments.
The master frame contains two serrated hardened steel flanged drive wheels which are
manually adjusted to ride tank diameters down to a minimum of 30 ft. (9M.) Distance
between wheel flanges is 1-7/8 inches (47.6 mm) so tank plate can be as thick as 1-3/4"
(44.5 mm.) One of the wheels is driven by a positive drive gear train (no secondary chain
reduction.) The gear train consists of a 3/4 HP T.E.N.V. electronically controlled shunt
motor that drives a double reduction gear reducer. Machine speed range is 4 to 105 IPM.
(.10 - 2.67 M/Min.)
Both the master and slave side frame have a hand railed operator's platform with seat. A
ladder provides a means for operator movement from one side of the machine to the other
and for access to the primary separator tank. Small diameter wheels at the lower end of the
tubular legs simplify loading and unloading the machine on the tank. Canvas curtains offer
arc and operator protection on windy days or during inclement weather.

WELDING PROCESS AND EQUIPMENT

The standard welding equipment supplied is the Lincoln NA-3S solid state control and
welding head fitted with nozzle, wire feed rolls, wire straightener and 50 lb. (22.7 Kg) wire
reels for feeding 3/32 or 1/8 inch dia. wire (2.38 mm-3.2 mm)
The welding nozzle is mounted on a manual cross slide system that allows the operator
complete control of wire placement and joint follow. Welding conditions, wire and flux are
those recommended by the Lincoln Electric Co. for this process. The welding head
assembly includes a submerged arc flux belt mechanism.

WELDING POWER SUPPLY

Lincoln DC-600 Amp power supplies supply the welding power. Input power is 230-380-
460V/ 3PH/ 50-60HZ and line power requirement is 45 KVA for each power supply. The
voltage is stepped down in the power source to 115V AC, which is required at the welding
machine. The power supplies are installed on a steel skid with weather curtains for
protection. Lincoln NA-3S Welding Equipment is mounted on each side of the machine, and
is under the control of the individual operator.
A K. B. electronic control, used to drive the machine around the tank, is located on the
master side of the welding machine and includes all necessary controls, i.e. speed control
potentiometer, direction switch and rapid travel pushbutton. A travel speed tachometer is
included.
The unit also includes a 100 pound (45 Kg) flux recovery vacuum unit for each side.
The flux, which falls from the flux belt into a flux hopper mounted on the platform, is
recirculated to a primary separator tank mounted on the roof of the AGW by a vacuum unit
mounted on the platform.

MODEL AGW-I SINGLE SIDED SYSTEM to include:

1.1. Operator's Platform with seat.
1.2. Lincoln NA-3 Wire Feeder and Control.
1.3. Lincoln DC-600 Power Source.
1.4. Vertical Adjuster
1.5. Horizontal Adjuster
1.6. Flux Belt Assembly
1.7. Flux Recirculating System
1.8. Pre-Heat Torch
1.9. Service Skid with Disconnect
1.10. Tropicalized Controls.
1.11. Weather Curtains.
1.12. 200 Feet of Control Cable Assembly
1.13. 220/380/440V - 3PH - 50/60HZ.
1.14 Loading Safety Wheels.

Shipping dimension and weights

AGW I.....168 CM high X 231 CM wide X 310 CM long…………Weight 1384 KG
SKID....…166 CM high X 132 CM wide X 178 CM long………...Weight 1090 KG

MODEL AGW-II DOUBLE SIDED SYSTEM to include:

2.1. Operator’s Platform with Seat. (2)
2.2. Lincoln NA-3 Wire Feeder and Controls. (2)
2.3. Lincoln DC-600 Power Sources. (2)
2.4. Vertical Adjusters. (2)
2.5. Horizontal Adjusters. (2)
2.6. Flux Belt Assemblies. (2)
2.7. Flux Recirculating Systems. (2)
2.8. Pre-Heat Torches. (2)
2.9. Service Skid with Disconnects. (2)
2.10. Tropicalized Controls.
2.11. Weather Curtains. (2)
2.12. 200 Feet of Control Cable Assemblies. (2)
2.13. 220/380/440V - 3PH - 50/60HZ.
2.14. Loading Safety Wheels.
2.15. Operator Communication System.
AGW Dimension and Weights. Export Crated add $1,000.00 per machine
AGW II....310 cm high X 231 cm wide X 224 cm long..Weight 1905 kg
SKID......166 cm high X 132 cm wide X 178 cm long..Weight 1542 kg

Weld Speed and Deposition Rate

Average welding speed is approximately 30 inches per minute with a deposition rate of
11# per hour for each side.

TRAINING & START UP

Customer is encouraged to send their Operators and/or Supervisors to Houston for
inspection and training, during Ransome's final tests of the equipment. This usually requires
2-3 days, and there is no cost for this service, except for travel and living expenses. If start
up supervision is required at customer's jobsite, the charge for this service is $960.00 per day
plus travel and living expenses.

* Payment Terms: Confirmed Irrevocable Letter of Credit on an U.S. Bank payable in full
at sight upon presentation of shipping documents. All banking charges are for the account
of the buyer.
 DC-600

For MIG, Stick & Flux-Cored Welding


The DC-600 is a multiprocess DC arc
welding power source that produces
outstanding arc characteristics on
both constant voltage and constant
current processes. This provides
great welding versatility in a single
power source.
The DC-600 is designed for GMAW
(MIG), FCAW, and submerged arc
welding processes within the capacity
of the machine, plus the capability of
stick, and air carbon arc gouging up
to 3/8” (10mm) diameter. It produces
outstanding performance with a single
range full output control potentiome-
ter.
The precise output of the DC-600
enhances productivity and quality
control when used with Lincoln LN-7,
LN-7 GMA, LN-742, LN-8, LN-9,
LN-9 GMA, LN-10, DH-10, and LN-25
semiautomatic wire feeders, the NA-3,
NA-5 and NA-5R automatic wire feed-
ers, and the LT-56 and LT-7 tractors.
DC-600
R
LISTED
UL
R
170G
Field and factory installed Multi-
Process Switch option for versatility in
your welding applications is available.
This 3-position switch allows quick
and easy change from electrode posi-
tive or negative semiautomatic/auto-
matic wire feed welding to stick or air
carbon arc gouging.
ADVANTAGE
LINCOLN
• Solid state circuitry provides extra
long life for repetitive welding
applications.
• Full range output voltage control for
easy operation and precise output
control.
• Standard ammeter/voltmeter.
• Mode switch used to select the
desired output characteristics for
the process being used.
• Output terminals on/remote switch
for easier selection of welding
processes.
• 115V auxiliary power receptacle.
Operate grinders, drills, etc. on 15A
duplex receptacle.
• Line voltage compensation for main-
taining weld consistency, even with
line voltage changes of ±10%.
• Low profile case allows installation
of the DC-600 under a workbench
and for stacking up to 3 machines
to conserve floor space.
• Removable side panels for easy
access to internal parts.
• Fan cooled with electronic and
thermostatic protection from current
overload and excessive temperatures.
• Windings and rectifiers protected
against moisture and corrosive
environments.
• Function lights built into the printed
circuit boards speed diagnostics.
• Recessed front panel protects
operating controls.
• 14 pin Amphenol or terminal strip for
remote wire feeder connections.
• Fuse protected 42V and 115V wire
feeder auxiliary power.
• Power on/off toggle switch with pilot
light.
• 3 year warranty on parts and labor.
• Manufactured under a quality
system certified to ISO 9001
requirements.
TECHNICAL SPECIFICATIONS
Rated DC Output(1) Weight Dimensions
Product Name Amps/Volts/Duty Cycle Output Range (net) HxWxD
DC-600 600A / 44V / 100% Volts: 522 lbs. 30.7 x 22.2 x 38.0 in.
680A / 44V / 60% 13-44 (CV), 24-42 (CC) (237 kg) (781 x 565 x 965 mm)
Amps:
70-780 (CV), 90-780 (CC)
(1) NEMA Class I Rated Output / Based on a 10 min. period.

Standard Input Current at

ORDERING Voltage Rated DC Output Product Number

INFORMATION 230/460/3/60
230/460/3/60
108/54
108/54
K1288-17
K1288-18
220/380/440/3/50/60 117/68/58.5 K1365-23
380/500/3/50/60 67.8/51.5 K1365-24

OPTIONS
AVAILABLE
Multi-Process Switch Remote Control Cable Adapter TIG Module
Recommended when using the Y connection adapter for connecting Supplies high frequency for superior
DC-600 for both semi-auto welding K857 Remote Voltage Control (6 pin starting, contactor control, remote
and stick/air carbon arc welding. plug connection) and wire feeder control capability and a gas valve for
Order K804-1. input cable (14 pin plug connection) DC TIG welding. Order K930-2.
to DC-600 14 pin receptacle.
Order K864.

Remote Output Control
For remote adjustment of output.
Consists of a control box with 28 ft.
(8.5m) of four conductor cable for ter-
minal strip connection. Order K775.
Remote Output Control
Provides 25 ft. or 100 ft. (7.6m or
30m) of remote output control (6 pin
plug connection). Requires K864
Remote Control Cable Adapter.
For 25 ft. (7.6m), Order K857
For 100 ft. (30m), Order K857-1.
Undercarriage
A mounting frame and three wheels
for hand moving. Order K817P.
Undercarriage
Platform undercarriage with mount-
ings for two gas cylinders at rear of
welder. Order K842.
Paralleling Kit
Permits paralleling of two DC-600’s
for welding currents of up to 1200
amps, 100% duty cycle. The “mas-
ter” DC-600 controls both paralleled
machines. Order K1611-1.
Water Valve
For use with TIG Module. Shuts off
water flow when the arc is extin-
guished when using Magnum® water-
cooled TIG torches. Order K844-1.
Control Cable Extension
Allows the TIG Module to be operated
at up to 22.5 -45 ft. (6.9-13.7m) from
DC-600. Connects between the 2 ft.
(0.6m) control cable and the TIG
Module.
22.5 ft. Order K937-22.5
45 ft. Order K937-45.
Docking Kit
Provides a means to “dock” the TIG
Module on top of a flat-roofed power
source, or any other flat surface mea-
suring at least 10 x 15 in. (254 x
381mm). It includes a latch and provi-
sions for a user-supplied padlock to
lock the TIG Module in place.
Order K939-1.
DC-600 ORDER FORM

PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE

DC-600 K1288-17
DC-600 w/ Multi Process Switch K1288-18

Stick Welding
Accessory Kit - cables, clamps, helmet, 400 Amp K704

For MIG or Flux-Cored Welding

LN-7 GMA Industrial Wire Feeder See Literature E8.10
LN-10 Advanced 4 Drive Roll Feeder See Literature E8.200
DH-10 Dual Head Version of LN-10 See Literature E8.200
Cobramatic® Deluxe Aluminum Feeder See Literature E8.300
LN-25 Portable Field Wire Feeder See Literature E8.100
LN-742 Industrial Wire Feeder See Literature E8.20
MIG and Flux-Cored Guns See Literature E12.10
and E12.100
Optional Features
Multi-Process Switch K804-1
Adjustable Gas Regulator K586-1
Paralleling Kit K1611-1
Water Valve K844-1
Control Cable Extension
Remote Output Control - Terminal Strip K775
Remote Output Control - MS Connector (use with K864):
for 25 ft. (7.6m) K857
for 100 ft. (30m) K857-1
Remote Control Adapter (6 and 14 pin to 14 pin) K864

Undercarriage
for hand moving K817P
for moving with two gas cylinders K842
All-Terrain Undercarriage K1737-1
Factory Undercarriage K1770-1
Roll Cage K1788-1
Gas Cylinder Holder (not compatible with Roll Cage) K1745-1

TOTAL:

Customer Assistance Policy

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in
our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information of advice. We expressly disclaim any warran-
ty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any respon-
sibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our
products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results obtained in applying this type of fabrication methods and service requirements.

CV Welders
E5.40 7/01
˚ ˚
˚ ˚
X

Flux Dam

Wire
Feed AC W eld
W eld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
X (225) 80 18 - 5/8 NR203M 5/64 --- 14
All (725) 130 29 + 3/4 L61 2 5/64 860 30

COMMENTS
Land is approximately 1/8-inch.
Root-gap is approximately 1/8-inch.

WFS shown for one wire.

Total deposit is 260 inches per minute, approximately 28 pounds per hour.

Horizontal and vertical adjusters set the fixed wire angle.

Flux on the backside for the first automatic pass will control any burn –thru

Good slag removal

NOTE: Because of the many variables in

design, fabrication and service conditions affect
the results obtained in applying this type of
information, the testing and serviceability of a
product or structure are the responsibility the
builder.

1
 Wire
Feed AC Weld
Weld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
st
1 400 90 28 + 1 L-60 3/32 780 18
Others 450 110 28 + 1 L60 3/32 780 18

COMMENTS
Electrode 10˚ to floor, 90˚ drag angle.
45˚ minimum cut angle 1/6-inch land maximum.
Six (6) passes each side.

NOTE: To accomplish full penetration, the following is required:

45˚ minimum bevel cut angle
1/6-inch maximum root face.

Samples received were not in this condition.

NOTE: Because of the many variables in

design, fabrication and service conditions affect
the results obtained in applying this type of
information, the testing and serviceability of a
product or structure are the responsibility the
builder.

2
 Wire
Feed AC Weld
W eld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type W ires Size Type (IPM)
5/16 400 90 28 + 1 L-60 3/32 780 18
3/8 400 90 28 + 1 L-60 3/32 780 18
1ST Pass 350 70 28 + 1 L-60 3/32 780 18
1” All Others 450 110 28 + 1 L-60 3/32 780 18
COMMENTS
Electrode 10˚ to floor.

Five (5) passes are required on the 1-inch plate. 7/8-inch plate may require only four (4).
W FS shown for one wire.

NOTE: 1/16-inch land may be used on the prepared plates.

NOTE: Because of the many variables in

design, fabrication and service conditions affect
the results obtained in applying this type of
information, the testing and serviceability of a
product or structure are the responsibility the
builder.

3
 Wire
Feed AC Weld
Weld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 400 26 + 1-1/8 L-61 1/8 780 26
2 600 32 + 1-1/8 L-61 1/8 780 32

COMMENTS
Flux shelf distance from weld is important.

(1) Weld on this side is raised slightly or flush.

Each weld on this test was made separately.

NOTE: Because of the many variables in

design, fabrication and service conditions that
affect the results obtained in applying this type
of information, the testing and serviceability of a
product or structure are the responsibility the
builder.

4
 Butts are square-edged and tight. Flux
dams are 1/2-inch below seam. Dam is
movable belt on production runs.

Electrode angle is 20˚ from horizontal.

Note that the centerline of the electrode
is just below the seam.

Sagging tendency appears to be about

the same with either flux and occurs
because the metal has no place to go.

Wire
Feed AC Weld
Weld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 400 26 + 1-1/8 L-61 1/8 780 26
2 600 32 + 1-1/8 L-61 1/8 780 32

COMMENTS
Flux shelf distance from weld is important.

(1) Weld on this side is raised slightly or flush.

NOTE: Because of the many variables in

design, fabrication and service conditions that
affect the results obtained in applying this type
of information, the testing and serviceability of a
product or structure are the responsibility the
builder.

5
 45˚

1/16
20˚

W ire
Feed AC Weld
W eld Speed (+) Stickout W ire No. of W ire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 725 29 + 7/8 L-61 2 5/64 860 30
2 725 29 + 7/8 L-61 2 5/64 860 30
3 725 29 + 7/8 L-61 2 5/64 860 30
4 725 29 + 7/8 L-61 2 5/64 860 30
5 725 29 + 7/8 L-61 2 5/64 860 30
COMMENTS
A. Stringer made with 3/32 NR20.
B. Wires in line – if any skew trail wire should be lower.
C. Aiming point of lead wire should be lower than expected.
-- metal seems to have more than normal tendency to climb and wash up.
D. Welds were made away from ground.
E. No back-gouging was done.
F. First automatic pass cleaned easily on both sides.
G. Same angle was used on all five passes each side.

NOTE: Because of the many variables in

design, fabrication and service conditions that
affect the results obtained in applying this type
of information, the testing and serviceability of a
product or structure are the responsibility the
builder.

6
 LEADING TRAILING 1-1/2 Inch Gap 0-1/32
3/32 L-61 or L-60 3/32 L-61 or L-60 or 760 50 IPM
400Amp 27v 400Amp 27v
(+) (+)

TRAILING 1-1/2 Inch Gap 1/32

LEADING
3/32 or 1/8 L-61 or L-60 or 760 46 IPM
3/32 L-61 or L-60
400Amp 27v 400Amp 27v
(+) (+)

LEADING TRAILING 1-1/2 Inch Gap 1/16

3/32 L-61 or L-60 3/32 L-61 or L-60 or 760 44 IPM
400Amp 27v 400Amp 27v
(+) (+)

TRAILING 1-1/2 Inch Gap 1/16

LEADING
3/32 or 1/8 L-61 or L-60 or 760 40 IPM
3/32 L-61 or L-60
400Amp 27v 425Amp 27v
(+) (+)

LEADING TRAILING 1-1/2 Inch Gap 1/16

3/32 L-61 or L-60 3/32 L-61 or L-60 or 760 38 IPM
425Amp 27v 425Amp 27v
(+) (+)

LEADING TRAILING 1-1/2 Inch Gap 1/16

3/32 L-61 or L-60 3/32 or 1/8 L-61 or L-60 or 760 34 IPM
425Amp 27v 450Amp 28v
(+) (+)

LEADING TRAILING 1-1/2 Inch Gap 1/16

3/32 L-61 or L-60 3/32 L-61 or L-60 or 760 32 IPM
450Amp 27v 450Amp 28v
(+) (+)

LEADING TRAILING 1-1/2 Inch Gap 1/16

3/32 L-61 or L-60 3/32 or 1/8 L-61 or L-60 or 760 30 IPM
450Amp 27v 500Amp 29-30v
(+) (+)

7
 Wire
Feed AC Weld
W eld Speed (+) Stickout Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1-5 700 130 29 + 7/8 L-61 2 5/64 860 30

COMMENTS
“X” stick pass with 1/8 E7018

First pass slag removed hard.

Filled second side with flux.

X-rays were good on samples returned.

Note: Electrode placement for the first sub-arc pass. It was located at the very bottom edge of
stick pass and plate. Location was the same on the second side.

NOTE: Because of the many variables in

design, fabrication and service conditions that
affect the results obtained in applying this type
of information, the testing and serviceability of a
product or structure are the responsibility the
builder.

8
 1 2 Electrode angles range between
1
0 and10˚ from horizontal.

Spacing between electrode and

2
lower plate must be 1/32 inch.

Used on 1/2-inch plate only.

Wire
Feed AC Weld
Weld Speed Stickout
(+) Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (Inches)
(-) Type Wires Size Type (IPM)
1-Flush 650 28 + 1/2 L-50 2 1/16 780 91
1/4 &
2-Fillet 750 28 + 1/2 L-50 2 1/16 780 91
3/8 1-Flush 800 29 + 1/2 L-50 2 1/16 780 70
2-Fillet 850 29 + 1/2 L-50 2 1/16 780 70
3/8 & 1-Flush 850 29 + 1/2 L-50 2 1/16 780 68
1/2 2-Fillet 900 29 + 1/2 L-50 2 1/16 780 68
COMMENTS
1/2 & 5/8 *only
80% penetration Spacing between electrodes and lower plate must be 1/32”.

At 31 volts, undercut will result on the upper 1/4” plate.

*Above procedures are for CP type power source moreover only 80% penetration will result with a ropey
bead.

Variable voltage consisting of (2) R3M 650 paralleled was also tried on the 1/2” and 5/8” joint. The
following results were obtained while using 3/16” – 1/4” angle bevel on the1/2” plate (refer to drawing
#2).
1 – Flush 1025 30 + 60in/min 1/2” L-50 2 5/64”
2 – Fillet 1025 30 + 68in/min 1/2” L-50 2 5/64”
Only 80% penetration resulted.

NOTE: Because of the many variables in

design, fabrication and service conditions that
affect the results obtained in applying this type
of information, the testing and serviceability of a
product or structure are the responsibility the
builder.

9
 75% Penetration

Difficult to make a 100% weld

Wire
Feed AC Weld
W eld Speed (+) Stickout Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 700 28 + 3/4 L-50 2 1/16 780 50
2 500 30 + 3/4 L-50 2 1/16 780 50
3 700 28 + 3/4 L-50 2 1/16 780 50
4 500 30 + 3/4 L-50 2 1/16 780 50

COMMENTS
Any gap with 700amps will burn through.

Slag was removed easily on passes 1 and 3.

Lower current on the cap pass gave a better-looking bead.

Flux shelf must be as close to the weld as possible.

NOTE: Because of the many variables in

design, fabrication and service conditions that
affect the results obtained in applying this type
of information, the testing and serviceability of a
product or structure are the responsibility the
builder.

10
 Wire
Feed AC Weld
Weld Speed (+) Stickout Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type W ires Size Type (IPM)
1 600 28 + 3/4 L-50 2 1/16 780 50
2 600 28 + 3/4 L-50 2 1/16 780 50
3 600 28 + 3/4 L-50 2 1/16 780 50
4 600 28 + 3/4 L-50 2 1/16 780 50

COMMENTS
Passes 1 and 3 slag must be chipped off.

Passes 2 and 4 slag falls off.

NOTE: Because of the many variables in

design, fabrication and service conditions that
affect the results obtained in applying this type
of information, the testing and serviceability of a
product or structure are the responsibility the
builder.

11
 Direction of travel

Side view showing flux nozzle

Shelf located 3/8 to 1/2-inch down.

Greater than this causes drip-off.

Wire
Feed AC Weld
Weld Speed (+) Stickout Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 700 28 + 3/4 L-50 2 1/16 780 50
2 750 28 + 3/4 L-50 2 1/16 780 50

COMMENTS
1 leads 2 by 7 inches

Ground start

Electrodes in line

25˚ is required to have the flux shelf 3/8-inch from seam.

Electrodes 90˚ to face are better but present a flux problem.

Carriage direction is from right to left.

NOTE: Because of the many variables in

design, fabrication and service conditions that
affect the results obtained in applying this type
of information, the testing and serviceability of a
product or structure are the responsibility the
builder.

12
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Girth Seams - 17.5M (57.4 ft) - METER DIAMETER TANK

Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint

WELD 1 14mm to 12mm Double "V" 69.617 0.108 233.5 66 132 6 1 5

WELD 2 12mm to 10mm Double "V" 56.673 0.088 190.1 54 108 5 1 4
WELD 3 10mm to 10mm Double "V" 47.629 0.074 159.8 45 90 4 1 3
WELD 4 10mm to 8mm Single "V" 50.859 0.079 170.6 48 97 4 1 4
WELD 5 8mm to 7mm Single "V" 36.711 0.057 123.1 35 3 Manual
WELD 6 7mm to 7mm Single "V" 33.503 0.052 112.4 32 3 Manual
WELD 7 7mm to 7mm Single "V" 33.503 0.052 112.4 32 3 Manual
17.5H.xls 12/26/96
Travel speed 30-IPM TOTAL 312 427 28
Deposition rate 11 lbs./ HR each side

Girth Seams - 20M (65.6 ft) - METER DIAMETER TANK

Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 12mm to10mm Single "V" 69.62 0.108 266.9 76 151 7 1 5
WELD 2 10mm to 10mm Single "V" 56.67 0.088 217.2 61 123 6 1 4
WELD 3 10mm to 8mm Single "V" 47.63 0.074 182.6 52 103 5 1 3
WELD 4 8mm to 7mm Single "V" 50.86 0.079 195.0 55 110 5 1 4
WELD 5 7mm to 7mm Single "V" 36.71 0.057 140.7 40 4 Manual
WELD 6 7mm to 7mm Single "V" 33.50 0.052 128.4 36 3 Manual
WELD 7 7mm to 7mm Single "V" 33.50 0.052 128.4 36 3 Manual
20H.xls 12/26/96
Travel speed 30-IPM TOTAL 356 488 32
Deposition rate 11 lbs./ HR each side
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Girth Seams - 22.5M (73.8 ft) - METER DIAMETER TANK

Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 12mm to 11mm Single "V" 60.23 0.093 259.7 74 147 7 1 4
WELD 2 11mm to 10mm Single "V" 51.86 0.080 223.6 63 127 6 1 4
WELD 3 10mm to 8mm Single "V" 50.86 0.079 219.3 62 124 6 1 4
WELD 4 8mm to 8mm Single "V" 41.71 0.065 179.9 51 102 5 1 3
WELD 5 8mm to 8mm Single "V" 41.71 0.065 179.9 51 102 5 1 3
WELD 6 8mm to 7mm Single "V" 36.71 0.057 158.3 45 4 Manual
WELD 7 7mm to 7mm Single "V" 33.50 0.052 144.5 41 4 Manual
AIH22.5 12/26/96
Travel speed 30-IPM TOTAL 386 601 35
Deposition rate 11 lbs./ HR each side

Girth Seams - 30M (98.4 ft) - METER DIAMETER TANK

Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 22mm to 16mm Double "V" 128.60 0.199 739.4 209 419 19 2 5
WELD 2 16mm to 14mm Double "V" 87.19 0.135 501.4 142 284 13 2 3
WELD 3 14mm to 12mm Double "V" 69.62 0.108 400.3 113 227 10 2 2
WELD 4 12mm to 11mm Double "V" 56.67 0.088 325.9 92 184 8 2 2
WELD 5 11mm to 10mm Double "V" 49.91 0.077 287.0 81 162 7 2 2
WELD 6 10mm to 7mm Single "V" 45.11 0.070 259.4 73 147 7 1 3
WELD 7 7mm to 7mm Single "V" 33.50 0.052 192.6 55 109 5 1 2
30H.xls 12/26/96
Travel speed 30-IPM TOTAL 766 1532 70
Deposition rate 11 lbs./ HR each side
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Girth Seams - 36M (118.08 ft) - METER DIAMETER TANK

Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Horizontal Passes
Time
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 22mm to 20mm Double "V" 166.39 0.258 1148.1 325 650 30 2 6
WELD 2 20mm to 16mm Double "V" 126.21 0.196 870.8 246 493 22 2 5
WELD 3 16mm to 14mm Double "V" 94.61 0.147 652.8 185 369 17 2 3
WELD 4 14mm to 11mm Single "V" 96.55 0.150 666.2 189 377 17 2 3
WELD 5 11mm to 10mm Single "V" 68.16 0.106 470.3 133 266 12 1 5
WELD 6 10mm to 8mm Single "V" 60.63 0.094 418.4 118 237 11 1 4
WELD 7 8mm to 7mm Single "V" 38.02 0.059 262.4 74 148 7 1 3
36H.xls 12/26/96
Travel speed 30-IPM TOTAL 1270 2541 115
Deposition rate 11 lbs./ HR each side

Girth Seams - 48M (157.44 ft) - METER DIAMETER TANK

Plate Typical Area of Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Joint
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 28 to 24mm Double "V" 245.08 0.380 2254.7 638 1276 58 2 9
WELD 2 24mm to 22mm Double "V" 197.66 0.306 1818.5 515 1029 47 2 7
WELD 3 22mm to 18mm Double "V" 151.01 0.234 1389.3 393 786 36 2 5
WELD 4 18mm to 14mm Double "V" 89.88 0.139 826.9 234 468 21 2 3
WELD 5 14mm to 11mm Single "V" 91.05 0.141 837.6 237 474 22 2 3
WELD 6 11mm to 10mm Single "V" 71.42 0.111 657.0 186 372 17 1 5
WELD 7 10mm to 8mm Single "V" 54.39 0.084 500.4 142 283 13 1 4
48H.xls 12/26/96
Travel speed 30-IPM TOTAL 2344 4689 213
Deposition rate 11 lbs./ HR each side
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400
Girth Seams - 51M (167.28 ft) - METER DIAMETER TANK
Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 34mm to 30mm Double 260.69 0.404 2548.2 721 1442 66 2 9
"V"
WELD 2 30mm to 25mm Double 196.72 0.305 1922.9 544 1088 49 2 7
"V"
WELD 3 25mm to 18mm Double 159.47 0.247 1558.8 441 882 40 2 6
"V"
WELD 4 18mm to 14mm Double 120.26 0.186 1175.5 333 665 30 2 4
"V"
WELD 5 14mm to 10mm Single "V" 78.86 0.122 770.8 218 436 20 2 3
WELD 6 10mm to 8mm Single "V" 57.16 0.089 558.7 158 316 14 1 4
WELD 7 8mm to 8mm Single "V" 42.27 0.066 413.2 117 234 11 1 3
51H.xls 12/26/96
Travel speed 30-IPM TOTAL 2532 5065 230
Deposition rate 11 lbs./ HR each side

Girth Seams - 55M (180.4 ft) - METER DIAMETER TANK

Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint joint sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 31mm to 28mm Double "V" 299.45 0.464 3156.6 893 1787 81 2 11
WELD 2 28mm to 24mm Double "V" 235.77 0.365 2485.3 703 1407 64 2 8
WELD 3 24mm to 20mm Double "V" 173.95 0.270 1833.6 519 1038 47 2 6
WELD 4 20mm to 16mm Double "V" 123.39 0.191 1300.7 368 736 33 2 4
WELD 5 16mm to 12mm Double "V" 80.02 0.124 843.5 239 477 22 2 3
WELD 6 12mm to 8mm Single "v" 58.36 0.090 615.2 174 348 16 1 4
WELD 7 8mm to 8mm Single "v" 44.17 0.068 465.7 132 264 12 1 3
AIH55.xls 12/26/96
Travel speed 30-IPM TOTAL 3028 6057 275
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400
Girth Seams - 57M (186.96 ft) - METER DIAMETER TANK
Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 34mm to 30mm Double 342.11 0.5303 3737.5 1058 2115 96 2 12
"V"
WELD 2 30mm to 25mm Double 259.00 0.4014 2829.5 801 1601 73 2 9
"V"
WELD 3 25mm to 18mm Double 162.88 0.2525 1779.4 504 1007 46 2 6
"V"
WELD 4 18mm to 14mm Double 99.10 0.1536 1082.7 306 613 28 2 4
"V"
WELD 5 14mm to 10mm Double 65.19 0.1010 712.2 202 403 18 1 5
"V"
WELD 6 10mm to 8mm Single "V" 49.95 0.0774 545.7 154 309 14 1 4
WELD 7 8mm to 8mm Single "V" 44.17 0.0685 482.6 137 273 12 1 3
57H.xls 12/26/96
Travel speed 30-IPM TOTAL 3161 6322 287
Deposition rate 11 lbs./ HR each side

Girth Seams - 66M (216.48 ft) - METER DIAMETER TANK

Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 32mm to 28mm Double "V" 303.30 0.470 3836.7 1086 2172 99 2 11
WELD 2 28mm to 28mm Double "V" 273.23 0.424 3456.2 978 1956 89 2 10
WELD 3 28mm to 22mm Double "V" 218.91 0.339 2769.1 784 1567 71 2 8
WELD 4 22mm to 18mm Double "V" 148.24 0.230 1875.2 531 1061 48 2 5
WELD 5 18mm to 14mm Double "V" 98.86 0.153 1250.5 354 708 32 2 4
WELD 6 14mm to 10mm Single "V" 83.50 0.129 1056.2 299 598 27 1 6
WELD 7 10mm to 10mm Single "V" 69.62 0.108 880.7 249 498 23 1 5
66H.xls 12/26/96
Travel speed 30-IPM TOTAL 4280 8561 389
Deposition rate 11 lbs./ HR each side
 KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400

Girth Seams - 92M (301.76 ft) - METER DIAMETER TANK

Plate Typical Area of Joint Area of Joint Volume of joint Lbs. Flux Arc on Time Horizontal Passes
Size Joint mm2 sq. inches cubic inches Required Per Joint Equipment Per Joint
WELD 1 42mm to 41mm Double "V" 558.31 0.865 9844.7 2786 5572 253 2 20
WELD 2 41mm to 33mm Double "V" 453.31 0.703 7993.1 2262 4524 206 2 16
WELD 3 33mm to 33mm Double "V" 368.78 0.572 6502.8 1840 3681 167 2 13
WELD 4 33mm to 24mm Double "V" 270.10 0.419 4762.6 1348 2696 123 2 10
WELD 5 24mm to 18mm Double "V" 158.21 0.245 2789.7 789 1579 72 2 6
WELD 6 18mm to 12mm Single "V" 125.75 0.195 2217.3 627 1255 57 2 5
WELD 7 12mm to 10mm Single "V" 71.80 0.111 1266.1 358 717 33 2 3
92H.xls 12/26/96
Travel speed 30-IPM TOTAL 10011 20023 910
Deposition rate 11 lbs./ HR each side
Ransome AGW-II – 3 O’clock Automatic Girth Welding System for horizontal joints on Field Erected Storage Tanks – Dual Lincoln NA3 Heads
and Controls.
Koike Aronson, Inc. / Ransome
Houston Sales Center
1285 North Post Oak, Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400
Ransome AGW-II – 3 O’clock Automatic Girth Welding System for horizontal joints on Field Erected Storage Tanks – Dual Lincoln NA3 Heads
and Controls.
Koike Aronson, Inc. / Ransome
Houston Sales Center
1285 North Post Oak, Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400
Ransome AGW II 3 O’clock Automatic Girth Welding System for horizontal joints n Field Erected
Storage Tanks – Dual Lincoln NA3 Heads and Controls.