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TALON TW-3 AUTOMATIC TIP WELDEROWNERS MANUAL

TW-3 AUTOMATIC TIP WELDER�

CONTENTSLIMITED WARRANTY .......................................................................................................... 1GENERAL SAFETY RULES ................................................................................................. 2SPECIFICATIONS ................................................................................................................. 4STANDARD EQUIPMENT .................................................................................................... 4OPTIONS .............................................................................................................................. 5COMMON REPLACEMENT PARTS ................................................................................... 6CONTROL PANEL ................................................................................................................ 8RESISTANCE WELDING.......................................................................................................9INDUCTIVE ANNEALER......................................................................................................19OPERATIONS SCREENS....................................................................................................29MAINTENANCE...................................................................................................................43ELECTRICAL SCHEMATIC.................................................................................................46ELECTRICAL SUB PANEL..................................................................................................51AIR SYSTEM DIAGRAM......................................................................................................53VACUUM DIAGRAM............................................................................................................54MECHANICAL ASSEMBLIES..............................................................................................55


GENERAL SAFETY RULESFailure to follow the Safety Rules and other basic precautions, may re-

sult in serious injury.

Always use eye protection: When operating this machine, eye protection should be worn. Also face or dust mask if operation is dusty. Use adequate ventilation.

Use ear protection: If operation is creating excessive noise.

Disconnect power: To machine when NOT in use.

Keep clear: Of pinch points when machine is running.

Saws are sharp: Wear appropriate personal protective equipment when han-dling saw blades.

Hot metal and sparks: Can cause burns. Wear correct eye, ear, and body protection. Allow equipment and work to cool before handling.

Dress properly: Do not wear loose clothing or jewelry. Nonskid foot wear is recommended. Wear protective hair covering to contain long hair.

Avoid dangerous environments: Don’t use in wet location. Keep work area well lit. Do not use this machine in the presence of flammable liquid or gases.

Keep children away: Do not let VISITORS contact this machine.

Keep work area clean: Cluttered areas invite accidents.

Never stand on this machine: Serious injury could occur if the machine is tipped.

No Magnetic Devices Near the Operator Interface (OP73): The OP73 or push button Operator Interface contains internal circuitry along with an LCD Display that is sensitive to high magnetic fields. There must be a minimum distance of � meters from any magnetic device and the OP73 operator interface.

TW-3 AUTOMATIC TIP WELDER3

GENERAL SAFETY RULES(CONTINUED)

All electrical covers: Must be in place before applying electrical power to this machine. Electrical service must be locked out prior to removing any electrical covers or machine guards. Access to electrical components must be restricted to trained personnel only to avoid possible electrical shock.

Voltage greater: Than specified on name plate can result in serious injury to user.

WARNING!Magnetic fields from high currents can affect pacemaker operation. Wear-ers should consult with their doctor before going near this welding ma-chine.

Due to the nature of weld operation, a noncombustible floor is required. Saw dust and other flammable materials must be kept at a safe distance from this machine.

Follow safety precautions for the coolant and material being welded. This infor-mation is available on the Safety Data sheet for each of these products.


SPECIFICATIONS

TW-3 Automatic Saw Tip Welder for Bands or Circular Saws.

STANDARD VOLTAGE: �30 Volt, � Phase, 50/60 HZ

OPTIONAL VOLTAGE: As requested.

SHIPPING WEIGHT: �,000 lbs / �000 kg

CRATE SIZE: L 9�” X W �8” X H 63” L ��8 X W ��0 X H �57 cm

AIR REQUIREMENTS: � CFM at 80 psi / 6 bar

STANDARD BAND SAW SIZE: Up to �6” / �06 mm

STANDARD CIRCULAR SAW DIA.: 7” to 36” / �78 to 9�� mm

OPTIONAL CIRCULAR SAW SIZE: As Requested

STANDARD EQUIPMENT

Cup and Cone Saw Center: 5/8” to �-�/�”


OPTIONS

Large Bore Option: W-50 (For smooth bores �” to �0”) W-7� (�0”-��-�/�” bore extension)

3 Pin Spline Saw Center: W-�50

Spline Bore Saw Center: W-�60

Short Band Saw Support Assembly: W-�083

Sash Gang Option: W-��5

Band Saw Carrier: C-6850-TW

Band Saw Carrier (Sliver Tooth Double Cut): C-6850-TWDCO

Stands: W-��59 Back Feed W-��60 Back Stand W-��6� Guide Stand W-��6� Slave Stand

Double Cuts Saw Carrier for Back Stands: W-��65

Small Band Saw Option 2” to 6”: W-��98-�

54” Saw Option / 1372 mm: W-�3�9


COMMON REPLACEMENT PARTS

End Cap: W-�9��Vacuum Block: W-�9�5Tip Nozzle: W-�9�7Index Finger Assembly: W-�339-AOutboard Clamp Jaw: W-36�6-�Fixed Clamp Jaw: W-�3�7-� Anneal Contact: W-�377 Coolant Hose 3/8 Clear �0 ft.: F-66� Anneal cable W-�390-AInner ground cable - � eye W-�390-GIOuter ground cable - � eyes W-�390-GOWeld cord W-�390-W

PRE - SET UP �. Do not remove crate if machine is going to be lifted with straps or chains. Once un-crated the machine must only be lifted by forks under the base of the machine or appropriate eye attached to feet.

�. Connect airline with 80 PSI � CFM to the lower rear door. A disconnect is provided and air hose to machine should be �/�” or larger.

3. Connect appropriate power to the machine. This must conform to national electrical code or local code if applicable and include ground and disconnect.

W-2390-GI

W-2390-GO

W-2390-W


RECOMMENDED FLOOR SPACE FOR MACHINE AND OPERATOR

CLEAR AREA96”

62”

34”

60”

MACHINE

OPERATOR’S POSITIONCLEAR AREA

The machine should be positioned so that there is adequate room behind to open the rear door and perform maintenance. The operator should have plenty of space in front of the machine. Crowding can be hazardous!


A-4010/A-4011WELD UNIT A-4001

ANNEAL UNIT

W-3063ANNEAL TEMPERATURESENSOR

W-3062INTERFACE

A-5680, A-6705 X 2E-STOP

W-735JOY STICK

W-4100PUSH/PULL BUTTON

CONTROL PANEL


The High Frequency Inverter (HFI) is a � KHz, three-phase, state-of-the-art inverter welding control for joining precision small parts at high speed with controllable rise times using � KHz output pulses superimposed on pure DC welding energy. High speed (�50 micro-second) digital feedback auto-matically controls weld current, voltage, or power, providing more welding consistency compared to traditional direct energy (AC) or stored energy (CD) technologies. Microprocessor technology automatically compensates for changes in workpiece resistance, load inductance, weld transformer saturation, and ñ �3% changes in line voltage. The High Frequency Inverter uses IGBT power device technology for precisely controlling the weld en-ergy at both high and low energy levels.Easy to use constant weld current, voltage or power feedback ensures repeatable welding and has proven to extend electrode life in many appli-cations by a factor of five or more. A selectable weld energy limiting feature also contributes to repeatable welds and high nugget quality. The user can program the High Frequency Inverter using a graphical or numerical inter-face. The Weld Graph Program Mode emulates many of the popular word processing programs by using the front panel cursor keys to easily modify any time period, current, voltage, or power value. The Weld Graph Run Mode gives the user instant visual feedback on the actual current, voltage or power used to make each weld. The High Frequency Inverters exclusive, context sensitive, User Help Screens quickly guide the user through even the most complex program. Each weld schedule can use any one of �0 different Weld Functions, thus matching the appropriate weld energy profile to the application.

HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

TW-3 AUTOMATIC TIP WELDER�0

WELD CONTROL FRONT PANEL

KEY DESCRIPTION[KEYPAD] Use the numeric keys to enter numeric information. Use the [ . ] to enter decimal values.

[KEYPAD] Use the numeric keys to change weld schedules without the need to use the keys. For example, pressing [�] [0] will recall weld schedule �0. In the RUN State, press to select a higher number weld schedule or press to select a lower number weld schedule.

In PROGRAM and MENU States, use both to move up and down on the LCD Display to select user options.

In the PROGRAM and MENU States, use to select user options.

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TW-3 AUTOMATIC TIP WELDER��

[PROG] In the RUN State, press [PROG] to enter the Graphical PROGRAM State to make changes to the selected weld schedule fields. Press [PROG] a second time to make changes using the AlphanumericPROGRAM State. Press [PROG] a third time to make changes to the Weld Sentry programs related to the selected weld schedule. Press [PROG] a fourth time to return to the HFI Graphical Program screen.

[RUN] In the PROGRAM State, press [RUN] to exit the PROGRAM State without saving the changed weld schedule. The changed weld schedule will become Weld Sched ule 0 and will not be written to permanent memory. Welding parts is done in the RUN State.

[RUN] In the MENU State, press [RUN] to exit the MENU State and begin welding parts.

[SAVE] In the PROGRAM State, press [SAVE] to save the selected weld schedule and its related Weld Sentry programs to permanent memory. The HFI Weld Control will then automatically exit the PROGRAM State and return to the RUN State.[SAVE] has no function in the RUN State.

[MENU] In either the RUN or PROGRAM States, press [MENU] to provide a menu list of user options which are common to all weld schedules.[HELP] Press this key whenever you need HELP or additional information on any user menu option or flashing user programmable field. The HFI contains a built-in operat ing manual. Press [HELP] a second time to return to the original State.

[CHNG] In the PROGRAM State, press [CHNG] to restore the previous contents of a user programmable field.

[CHNG] In the MENU State, press [CHNG] to select different menu options.

[CHNG] In the RUN State, press [CHNG] to change the Graphical RUN State screen to the Alphanumeric RUN State screen.

[ENTER] Press [ENTER] after keying in numeric program data.

WELD/NO Weld current will not flow when this switch is in

WELD the NO WELD position.SWITCH However, operation in the NO WELD switch position permits the HFI to initiate and execute a complete welding sequence without weld current flowing. Operating the HFI in the NO WELD position is required to adjust Weld Heads. This switch must be in the WELD position in order to make a weld.


PROGRAMMING MODES

Help Screens1 The HFI Weld Control offers the user context sensitive HELP when running or programming. Press [HELP] whenever you want information about a Menu Option or program variable. Press [HELP] again to return to the original screen. For example, if you press [HELP] from the RUN State, information on the function of the Weld Graph and Alphanumeric screens will appear.2 To read the second page of help information, press the right horizontal cursor key .3 To return to the first page of help information, press the left horizontal cursor key .Machine StatesThe HFI Weld Control has eight Machine States: RUN, NO WELD, STANDBY, ALARM, FIRE, MENU, PROGRAM, and HELP. The NO WELD State represents the positional status of the WELD/NO Switch on the front panel. The STANDBY, ALARM, and FIRE states are functions of MECHANI-CAL FIRING, OPTICAL FIRING, and FOOT SWITCH input states. The operator can force the HFI Weld Control into the RUN, MENU, PROGRAM, and HELP states by pressing the

[RUN], [MENU], [PROG] or [HELP] keys.

Weld Graph RUN StateIn the Weld Graph RUN State, the HFI WeldControl is ready to make a weld. You can select,but not change, any weld schedule by using thevertical cursor keys or on the FrontPanel. Weld schedules may also be selected byusing the numeric keypad to key in the desiredweld schedule number: 000 through 127.

HELP---RUN WELD GRAPH PAGE �/�THIS IS THE GRAPHICAL REPRESENTATION OF THE WELD SCHEDULE. HORAZONTAL AXIS IS TIME AND THE VERTICAL AXIS IS ENERGY. AFTER A WELD IS MADE, THE ACTUAL WELD PROFILE IS DISPLAYED AS A SERIES OF WHITE VERTICAL LINES

HELP to return Next >

HELP---RUN WELD GRAPH PAGE �/�* PRESS CHNG TO TOGGLE BACK TO THE ALPHA-NUMERIC RUN SCREEN.* PRESS PROG TO CHANGE THE SCHEDULE IN THE WELD GRAPH MODE. < Last HELP to return

CURRENT SCH : 000 BASIC WELD�.00.80.60.�0.�0.0 Select Schedule


BASIC WELD MONITORSCHEDULE: 000 BASIC WELD� MEASUREMENT : CURRENT UPPER LIMIT : none KA READING : n/a KA LOWER LIMIT : none KA INHIBIT WELD POWER : OFF Select Schedule *RUN*

Basic Weld Monitor Run StateWhen MENU, OPTIONS �, WELD MONITOR:is set to BASIC, pressing [CHNG] will cause thedisplay screen to switch from the Weld GraphRUN screen to the Basic Weld Monitor RUNscreen. Setting WELD MONITOR to LIMITcauses the Energy Limit Monitor screen to bedisplayed. See Chapter 7 and Chapter 8 fordetailed instructions.

Pressing [CHNG] again causes the Basic Weld Monitor RUN screen to switch to the Alphanu-mericRUN screen. Pressing [CHNG] once more returns the display screen to the Weld Graph RUN screen.

Alphanumeric RUN StatePressing [CHNG] will cause the display screento change from the Basic Weld Monitor RUNscreen, if this option has been set to ON, to theAlphanumeric RUN screen. Pressing [CHNG]again will return the HFI Weld Control to theWeld Graph screen. Welding can be performedin any RUN screen.

NO WELD StateSwitching the WELD/NO WELD front panelswitch to the NO WELD position prevents weldcurrent from flowing but does permit the HFIWeld Control to performing its electronicfunctions. Use the NO WELD State whenadjusting the air regulators on Air ActuatedWeld Heads.

STANDBY StateThe HFI Weld Control is waiting for amandatory event to occur such as: (a) the FiringSwitch in a Unitek Peco Air Actuated WeldHead to close; (b) the second level of a �-LevelFoot Switch to close; or (c) waiting to be reset toanother schedule after a STOP Command in aChained Schedule.

CURRENT SCH : 000 BASIC WELD�.00.80.60.�0.�0.0 Select Schedule *STANDBY*

CURRENT SCH : 000 BASIC WELD�.00.80.60.�0.�0.0 Select Schedule *NO WELD*

SCHEDULE: 000 BASIC WELD SYSTEM: AIR AUTO WELD:000000 SQZ WELD HOLDTIME (ms) :0000 000� 0000CURRENT : 0.05KAAMP*SECONDS LOWER UPPER SENTRY: none none off Select Schedule *RUN*


ALARM StateThe HF� Weld Control automatically recognizesmany alarm conditions which are described indetail under Appendix C, Alarm Messages. TheALARM FIRING SWITCH screen shown on theright is displayed when the Firing Switch of aUnitek Peco Air Actuated Weld Head does notclose within �0 seconds.

FIRE StateOnce weld current is flowing, the HF� WeldControl is in the Fire State. Weld current can beterminated by: (a) removing the first level of asingle-level Foot Switch; (b) removing thesecond level of a two-level Foot Switch; or (c)shorting the Emergency Stop Control SignalsInput Pin �0 to Pin ��. Completion of the FiringState is indicated by momentary appearance ofthe END status message as shown in the exampleto the right.

MENU StatePressing [MENU] puts the HF� Weld Control inthe MENU State, which offers you differentoptions common to all weld schedules such ashow the HF� Weld Control interfaces with theFiring Switch, Foot Switch, and Weld Head.Like a tree with many branches, there aremultiple Menu levels. Each new level isaccessed by making an option selection, thenpressing [ENTER]. To return to a previousMenu level, press [MENU].

CURRENT SCH : 000 BASIC WELD�.00.80.60.�0.�0.0 Select Schedule *END*

CURRENT SCH : 000 BASIC WELD�.00.80.60.�0.�0.0 Select Schedule *ALARM FIRING SWITCH*

OPTIONS MENU SENTRYWELD COUNTER CALIBRATE HFICOPY A SCHEDULE RESET TO DEFAULTSSYSTEM SECURITY INSTALLATIONSYSTEM HELP TRANSFORMER MODEL

Select then ENTER


PROGRAM State1 In the PROGRAM State, the HF2 Weld Control allows the user to change and save any weld schedule. In those units which include the Weld Sentry Option, the PROGRAM State also allows the user to change the Measurement Unit, the Limits related to each Weld Sentry program, as well as the other parameters associated with the Weld Sentry.

2 A single weld schedule uses one Weld Function. A Weld Function is defined as a series of user programmable time periods, some of which have programmable weld current, voltage, or power levels. Some periods such as SQUEEZE, COOL, QUENCH, HOLD, and OFF do not have any weld current values associated with them. For a complete description of all Weld Functions, their time periods, and limit values, refer to Chapter 6, Advanced Welding Functions.

3 SQUEEZE Time is automatically included as a weld schedule program variable when MENU OPTIONS 2, WELD HEAD TYPE: is set to AUTO, AIR, or DUAL AIR and an Air Actuated Weld Head is connected to the HF2 Weld Control. Squeeze Time allows sufficient time for a non-force fired Weld Head to apply the required weld force to the work pieces. Squeeze Time is not normally used with Unitek Peco force fired Weld Heads. The weld period will start as soon as the Squeeze Time expires. Squeeze Time can be set to any number between 0 and 2000 ms.NOTE: There are two methods of programming the HF2 Weld Control: (a) use the WeldGraph PROGRAM State; or (b) use the Alphanumeric PROGRAM State.Weld Graph PROGRAM State1 Use the vertical cursor keys to select the weld schedule that you want to modify. Press [PROG] to enter the Weld Graph PROGRAM State.

2 Press [ENTER] to select the period that you want to modify. Note: the upper right-hand corner shows the selected period. Use the horizontal cursor keys to increase or decrease the period time base which is alsodisplayed in the upper right-hand corner following the selected period. You can also changethe period time base by using the keypad to directly enter the exact time. Periods such asSQUEEZE, COOL, QUENCH, HOLD, and OFF do not have any weld current, voltage, orenergy values. This example shows an Air Actuated Weld Head schedule with the SQUEEZEperiod set to 0000 ms.

CURRENT : (none) SCH : 000 BASIC WELD�.0 SQUEEZE : 0000ms0.80.60.�0.�0.0 KA, Time, ENTER Next, CHNG Function

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CURRENT : 0.5KA SCH : 000 BASIC WELD�.0 SQUEEZE : 00�5ms0.80.60.�0.�0.0 KA, Time, ENTER Next, CHNG Function

3 Periods such as WELD, WELD1, WELD2, and TEMPER have user programmable time base values and weld current, voltage, or energy values. To change the Feedback Type for any of these weld periods, press the keypad decimal point [.] multiple times until the upper left-hand portion of the screen shows the desired Feedback Type. This example shows a WELD period of 15 ms with the weld CURRENT set to 0.5 kA.

4 To change the weld current, use the vertical cursor keys to increase or decrease the weld CURRENT. Note: when holding the vertical cursor keys down to change the weld CURRENT, the horizontal bar representing the weld CURRENT will not move to its new position until the vertical cursor keys are released. However, the weld CURRENT value displayed in the upper left-hand corner will automatically scroll during this change process. In this example, weld CURRENT has been increased to 0.7 kA and WELD time has been increased to 20 ms.

5 Press [SAVE] to save the updated weld schedule. You are now back in the Weld Graph RUN State.Alphanumeric PROGRAM State1 Use the vertical cursor keys to select the weld schedule that you want to modify. From the Weld Graph RUN State or Basic Weld Monitor RUN State, press [PROG] multiple times to enter the Alphanumeric PROGRAM State. If you are already in the Alphanumeric PROGRAM State, press [PROG] once.2 Use the vertical cursor keys and horizontal cursor keys to select the program value that you want to change. Use [CHNG] to select CURRENT, VOLTAGE or POWER Feedback. Use the numeric keypad to enter variable values. This example shows the alpha-numeric version of weld schedule 000 in the middle of this page. Weld CURRENT is set to 0.7 kA and WELD time to 20 ms.3 Press [SAVE] to save the updated weld schedule.

CURRENT : 0.7KA SCH : 000 BASIC WELD�.0 SQUEEZE : 00�0ms0.80.60.�0.�0.0 KA, Time, ENTER Next, CHNG Function

SCHEDULE: 000 BASIC WELD SYSTEM: AIR AUTO WELD:000000 SQZ WELD HOLDTIME (ms) :0000 00�0 0000CURRENT : 0.70KAAMP*SECONDS LOWER UPPER SENTRY: none none off Select , numbers Change PROGRAM

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4 Press [CHNG] To operate the HFI Weld Control in the Weld Graph State.Output RelaysThe HFI Weld Control has two solid state relays which can be used to provide status or timing signalsto a user Programmable Logic Control (PLC). For a full description on how to connect Relay K1 andRelay K2, refer to Chapter 4, Control Signals, Output Relays.

1 Relay K1 and Relay K2 can only be programmed in the Alphanumeric PROGRAM State.2 Use the vertical cursor keys to select the weld schedule that you want to modify. From the Weld Graph RUN State or Basic Weld Monitor RUN State, press [PROG] multiple times to enter the Alphanumeric PROGRAM State. If you are already in the Alphanumeric PROGRAM State, press [PROG] once.3 Press until the RELAY 1 and RELAY 2 legends are displayed. Both relays can be activated in the SQUEEZE, WELD, and HOLD periods. Press [CHNG] to select ON. In this example, RELAY 1 will turn on during the WELD period.4 There are four more RELAY 1 options listed under the SQZ period column. Press [CHNG] to select the RUN STATE option. In this example, notice that the RELAY 1 options for the WELD and HOLD periods disappear. Selecting the RUN STATE option will cause RELAY 1 to always be on when the HFI is not making a weld.5 Press [CHNG] until the ALARM (NO) option appears. An ALARM condition causes RELAY 1 to switch from the normally open (NO) state to the closed state. RELAY 1 automatically opens when the alarm condition is cleared by pressing [RUN] or when the next welding sequence begins.6 Press [CHNG] until the ALARM (NC) option appears. An alarm condition causes RELAY 1 to switch. An alarm condition causes RELAY 1 to switch from the normally closed state (NC) to the normally open state. RELAY 1 automatically closes when the alarm condition is cleared by pressing [RUN] or when the next welding sequence begins.

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SCHEDULE: 000 BASIC WELD SYSTEM: AIR AUTO WELD:000000 SQZ WELD HOLDTIME (ms) :0000 00�0 0000CURRENT : 0.70KARELAY � : OFF ON OFFRELAY � : OFF OFF OFF Select , numbers Change PROGRAM

SCHEDULE: 000 BASIC WELD SYSTEM: AIR AUTO WELD:000000 SQZ WELD HOLDTIME (ms) :0000 00�0 0000CURRENT : 0.70KARELAY � : RUN STATERELAY � : OFF OFF OFF Select , numbers Change PROGRAM

SCHEDULE: 000 BASIC WELD SYSTEM: AIR AUTO WELD:000000 SQZ WELD HOLDTIME (ms) :0000 00�0 0000CURRENT : 0.70KARELAY � : ALARM (NO)RELAY � : OFF Select , numbers Change PROGRAM


ADVANCED WELD FUNCTIONSWeld FunctionsA weld function is a unique heat profile created by weld current, voltage, or power that is applied over a fixed time period, to resistance weld different parts. Welding applications requiring the use of specialized weld functions include: (a) parts plated with cadmium, tin, zinc, or nickel; b) parts with heavy oxide coatings such as aluminum; (c) parts that are round or not flat; or (d) parts made of refractory metals such as molybdenum or tungsten.The HFI Weld Control is shipped with ten pre-programmed weld functions that are saved in WeldSchedules 00� through 0�0. While these factory pre-programmed weld functions do not containsufficient weld time or weld energy for most welding applications, they are a useful starting point to begin welding. Please note that WELD/REPEAT will only work with Air Actuated Weld Heads. The table below lists each Weld Function and its general application.

Weld Function Pre-Prog Schedule Typical Application.

BASIC WELD 00� Make single spot welds on simple flat parts without plating.

WELD/REPEAT 00� Make multiple semi-automatic spot welds using an operator.

QUENCH/TEMPER 003 Spot weld flat or round parts that have minimum plating thickness.

PRE/POSTHEAT 00� Forge weld heavily oxidized or refractory parts such as molybdenum or tungsten.

UP/DOWNSLOPE 005 Weld round parts, parts that are not flat, spring steel parts, or heavily plated or oxidized parts such as aluminum.

BRAZE 006 Reflow two parts together using a braze material.

ROLLSPOT 007 Make automated multiple weld spots using automatic feeders and PLC or host computer.

SEAM 008 Make automated hermetic seam welds using automatic feeders, and PLC or host computer control. Make manual or semi-automatic non- hermetic seam welds using an operator.

DUAL PULSE 009 Use for best control of miniature and small parts spot welding with or without plating. This setting is recomended for thin bands also.

PULSATION 0�0 Use only for spot welding simple parts where the total weld energy or weld time required to make an acceptable weld using any other Weld Function is marginal. Using the Pulsation Weld Function can damage the crystal structure of the parts.


INDUCTIVE ANNEALER


INDUCTIVE ANNEALERSAFETY - Never carry out annealing operations on metal pieces that have been in contact with toxic combustible products; such pieces must be carefully cleaned before undergoing any soldering operations.

- Maximum care should be taken to avoid incandescent metals coming into contact with combustable materials.

- Ensure that there is adequate fire-fighting equipment sufficiently close to the working area.

- All combustible materials must be removed from the working area and place at a safe distance.

- During the generating phase do not allow limbs or other parts of the body bearing metal to come near the annealing coil. The minimum safety distances of �0” inches must be maintained during generator activation.

MAINTENANCE WARNINGS- Do not wash the devise with liquid detergents or chemical sunstances. Any cleaning should be done using a lightly-damp non-abraisive cloth.

- Before any mainenance, cleaning or movement, the devise should be first disconnected from all sources of power.

RESIDUAL RISKS- In particular, direct or indirect contact with the annealing inductor must be prevented, and the following minimum safety distances must be maintained during generator activation: �” inches for metal objects and parts of the body. Risk of burns may occur at distances less than the above limit.

STRONG MAGNETICFIELDS can affect pacemakers. wearers of pacemakers, cardiac defibrilla-tors and other life supports shall not operate in proximity of the annealer. Wearers should consult their doctor before operating.


DISPLAY MESSAGES Machine in stand-by When working normally, with the generator in stand-by, the Annealer display shows which head of the two has been selected and which was the power programmed for the head. Self-diagnosis messages In case of failure, the display shows a message referred to the problem; for decoding this message and solving the problem, please see fault codes listed below.

H1 99 H1 Head 1 selected,delivered power = 99%

A1Self diagnosis message A1:water temperature to high

ANNEALER MAINTENANCE

DISPLAY FAULT CAUSE POSSIBLE INTERVENTION

A1Water temperature too high. The display give the temperature of the cooling water, alternating to the self diagnosis message.

Tuning failure

Absence of water cooling

Short circuit of lead wire

Decrease coil size

Power circuit failure

Malfunction of the cooling unit

The flow of cooling water has stopped

Short circuit in the inductorSmall dimensions of the inductor

Too big dimen-sions of the induc-tor

Possible break down of an inter-nal component

Check the temperature of cooling water that have to be less than 50° (intervention threshhold = 65°C

Contact Wright Machine Tool

Check for water in the cooling unit.Check the presence of blocking-up in the generator inlets and outlets.

Check the absence of short circuit of lead in wires

Increase coil dimensions

Decreas coil dimensions. Decrease at the maxi-mum the distance between the rims of the head. Diminish the length (centimeter by centmeter). The reduction of length of the head spouts must be car-ried out only in the event that the shape of the coil cannot be changed for the type of process-ing in progress and when the distance between the lead-in wires has been checked.

Contact Wright Machine Tool

A2

A3

A4

A5

A6


ANNEALER MAINTENANCE

DISPLAY FAULT CAUSE POSSIBLE INTERVENTION

A7Disconnected head

Line voltage too low

Line voltage too high

Slave unit not availbable

Communication failure

Duty cycle to high (only on Spec-tacle Frames line Models)

Disconnected head

The slave unit is not connected cor-rectly, is turned off, or signals a self di-agnosis message(A-� or A-3)

The SLAVE unit is not correctly re-cieving data from the MAIN UNIT.

Continuous activa-tion of the genera-tor or insufficient pause among consecutive work-ing cycles.

Check the connections between the heads and the electronic unit.

Insert (between the mains and the heater) a trans-former with an input voltage equal to that available on the line and an output voltage ��0V~

Check and, if necessary, reset the presence of the three power supply phases and the correct ignition of the three generator units.In the event that either one or both of the SLAVE units presents a self diagnosis message(A-� or A-3), carry out the related tests as indi-cated in this table.Check and, if necessary, reset the connection of the CO�� serial cables between the generator units.

Check and, if necessary, reset the presence of the three power supply phases and the correct ignition of the three gennerator units.Check and, if necessary, reset the connection of the CO�� serial cables between the generator units.

Start the genorator up in an intermittent way.

A10

A11

A12

T0


SAW PREPARATIONAs in any weld operation several factors control the strength of the weld. To have the strongest weld possible, the following must be done.

�. The saw MUST be free of grinding grit, pitch or other contaminates at the weld zone. If this is not done, gas pockets may form in the weld.

�. The shape of the saw tooth should minimize the amount of saw plate displaced during the weld process. A pocket on the tooth will give the following benefits: a. Cleans impurities from weld zone thus reducing weld contamination. b. Reduces displacement of the saw plate (Flash) which dramatically increases weld strength. c. Less flash will reduce grinding time and wheel cost. d. Less internal stress in the saw tooth which means less chance for tip failure. e. If the saw is not pocketed, it is possible that the saw tip will micro- crack from the extreme heat & pressure caused from excessive displacement into the tooth. f. A pocket will reduce mixing of the tip with the saw tooth. This mixing will make the tooth brittle up to �/3�” below the tip.

Note: The saw must be clean of saw dust on the back side of the saw plate for good anneal and weld results. Clean the fixed copper clamp jaw with a wire brush AFTER EACH SAW.�. Install the proper centering device for circular saws or band carrier if bands are to be welded.

�. Use the following procedure to fill the tip loader tray: Ensure that the Emergency Stop switch is on by turning it to the right. Remove the cover of the tip loader tray and fill the spiral groove with new tips. Make sure all of the tips in the tray have the points down in the grove with a flat side on top. Starting at the end of the groove in the center of the tray push the tips clockwise around the tray until they are all lined up neatly and all of the spaces are gone. Re-place the cover on the tray with the push rod in the groove behind the last tip. Pull the Start/Stop switch on the panel so that the green light comes on, then place the joy stick in the man-ual weld position. The push rod should move up against the last tip and stop. Place the joy stick in the neutral position and push the Start/Stop switch to turn the green light off. (Normally the feed tray is refilled while the saw is annealing.)

3. Mount the saw on the centering device or band carrier. Pull the black knob on the clamp jaw arm and swing the clamp jaw down until it locks into place.

SETUP TO WELD AUTOMATICALLY


�. Loosen the lock bolt on the index assembly and position it at the appropriate angle for the type of saw to be welded, then tighten the bolt.

Slight up-angle for Band SawsSlight down-angle for Circular Saws

(Match angle of saw blade)

SETUP TO WELD AUTOMATICALLY(Continued)

5. Set the index pitch by turning the hand wheel on the end of the index arm and reading the scale on the top of the arm. 6. Use the following procedure to set the saw height: a. Make sure the green light on the Start/Stop switch is off. b. Move the Joy Stick to “INDEX”. The clamp should activate and the index finger should move forward. c. Using the hand crank on the saw lift, raise the saw until the tooth is about halfway up the feed finger. d. Move the Joy Stick back to the neutral position and check the index pitch length.7. Set side clearance for the back side of the saw.


8. With the green light on the Start/Stop switch OFF, place the joy stick in the “WELD” position. Push the tip clamp out of the way and check the position of the tooth in the triangular notch. The tooth should fit into the notch. Raise or lower the saw for top clearance, and use the micro adjustment on the index finger for left/right adjustment. (See page ��)


�0. When the tooth position appears to be correct return the Joy Stick to the neutral position and pull the Start/Stop switch to turn on the green light. This will activate the vacuum and coolant pumps. Manually weld a tooth by moving the Joy Stick to the “WELD” position and hold it there until the weld finishes. Check the tooth. If the tooth placement was correct and the weld is good move the Joy Stick to the “AUTO” position to weld the rest of the saw. If the tooth placement was not correct then readjust the position using the following procedure before welding the rest of the saw. a. To adjust the height of the tip, raise or lower the saw. b. To adjust the forward/back location, the index finger must be adjust ed. c. To adjust from side to side on the plate use the plate thickness adjust ment.



In order to make future setups easier and quicker many operators use the following procedure. Once the first saw is set up correctly with the tooth in the proper position to weld, loosen the locking collar and rotate the weld shaft so that the top edge of the index finger is even with the top edge of the saw plate. Then next time you get ready to set up a plate you will only have to raise the saw to the top edge of the index finger and it should be very close to the correct position.

MANUAL MODE OPERATION

To weld or anneal a single tooth, place the joy stick in to the appropriate position and hold it there until the weld or anneal is complete.


WHY ANNEAL?BECAUSE “TEMPER” IS REQUIRED

After the saw tip is welded, it is necessary to temper the saw plate. Because the saw was heated above the hardening temperature - �,350 degree F (dark red) - the saw steel has become hard and brittle. To return the saw to a tough and strong state it is necessary to allow the steel to cool to approximately �50 degree F, then heat the saw steel to 850 degree F (Black to barely red) and then allow the steel to cool. If any of the saw steel is heated above �,300 degree F (Dull red) during the temper, the saw will again become hard and brittle and must cool below �50 degree F and be tempered again. The Cobalt Alloy saw tip hardness will not change and does not require tempering.


SET UP TO ANNEAL AUTOMATICALLY(CONTINUED)

�. Use a file to find the “Chill Line” on the tooth. File a small portion off the edge of the saw plate starting on the back side of the tooth about �/�” from the tip and moving forward toward the tip. When you reach the boundary between the soft metal of the saw and the hard, brittle portion where the tip was welded on the file will stop cutting. This is the chill line.

�. Move the Joy Stick to “ANNEAL” and hold it there until the heat line goes past the chill line you marked with the file, then move the stick back to the neutral position. You can allow the tip to become red, but not the saw plate. Allow the tip to cool and then check with the file to see if you took the chill line out.

3. Move the Joy Stick to “AUTO” to begin annealing the saw. When the stick is moved to “AUTO” the machine will remember how much time it took to anneal the first tooth manually and it will anneal the remaining teeth accordingly.

NOTE: If you are not satisfied with the anneal you can move the Joy Stick to neutral and change the parameters. Then pull the Start button and move the Joy Stick to auto and it will reset the number of teeth and redo the entire saw with the new settings.


Screen Operations MENU SCREEN: The TW3 displays the Menu screen when powered up:

Pressing the button below each text entry opens a corresponding screen for that label. The Weld, Anneal, W&A (Weld and Anneal) and MM (Manufacturing Mode) buttons open the screen for that function. The Options button (F2) opens a sub-menu. Those options are described below:

OPTIONS:


Each input and output screen contains component names and their corresponding status indicators. Inputs are in a series of 3 screens which can be accessed by using the up/down arrow keys. The fixed arrow options are displayed by the symbol or symbols to the right of the Inputs label. In this case the down arrow is displayed. Pressing the fixed down arrow key opens another input screen. Output screens are accessed by pressing the Outputs button. There are 4 of these screens which can be toggled through by also using the up/down arrow keys. The following is a sample:

TW-3 AUTOMATIC TIP WELDER3�

VACUUM: The Vacuum button opens the following screen:

CALIBRATED VACUUM: The value the machine uses to calculate if a tip has been pulled into place. This value will rise over time as the vacuum filter becomes filled with debris. A calibration routine is run each time the machine is powered up with the last 16 calibrated values stored in a Log accessible by pressing F2. The filter condition can be monitored by viewing these values:

RECALIBRATION: Press the F5 button to recalibrate.


TIMINGS: F3 opens the following screen from which values can be seen and changed:

These values are in milliseconds therefore a value of 1000 = 1 second. When the vacuum pump is turned on there is vacuum in the system that needs to be relieved to keep the pump from having to fight through a vacuum lock condition. The VACUUM LOCK RELIEF value opens the vacuum stop valve to relieve this pressure. The value from the factory is 750 MS. The TIP STABILIZATION value allows the vacuum pressure to equalize each time the stop valve is opened before looking to see if a tip has been pulled into place. The factory value is 900 MS.

Pressing the Loader button (F4) from the Options screen opens the following:


Tip Forward Time refers to the time the tips can be moved forward before an error is generated. Times are in Milliseconds. The factory setting for this value is 2500 or 2 ½ seconds. After the tip is pulled into place the tip motor reverses to relieve pressure from the row of tips. This is referred to as the Tip Reverse Time. The factory setting is 200. These settings are applicable when the machine is in run mode. To manually run the tip motor forward (F3) or in reverse (F4) the machine must not be in run mode with the green light on. The vacuum motor will come on and the motor will run in the desired direction as long as the button is pushed.

Each of the main screens - Weld, Anneal, W&A (Weld and Anneal) and MM (Manufacturing Mode) has similar display and function characteristics. These include the following as seen on the Weld screen:

A main dialog field that walks the operator through the operation sequence and supplies error description and correction information.

Entry fields for entering values such as Weld Tips. Available fields for entry are displayed one at a time and are highlighted by a dotted line box surrounding the value as seen below. Available fields are viewed by using the up/down arrow keys. When the value to be changed is highlighted, pressing the enter button accesses the value. The value can then be changed by selecting the correct placeholder in the field with the left/right arrow keys and pressing the number desired using the values located on the F keys. Pressing enter when finished saves the value.

Informational display values such as Tips Remaining. These values are updated automatically and cannot be changed by operator entry.

The bottom of each screen contains labels that correspond to pages that can be accessed by pressing the F key immediately below that label. A timing or setup screen is available for each of the main pages.

WELD:


WELD TIMINGS:

TIP CLAMP TIME: This value in milliseconds refers to the time after the weld head is told to move down until the tip clamp is turned on. Changes in mac valve and air pressure settings may require changes to this time value. The value from the factory is 260.

PRE WELD TIME: This is the time in milliseconds that the weld is started after the tip clamp is turned on. This gives the clamp time to engage. The value from the factory is 110. The weld unit has a non-adjustable time (squeeze) that can be seen at the beginning of each weld. The squeeze time is automatically lengthened with the weld time. Time the pause between the tip touching the saw plate and the beginning of the weld by adjusting the overall weld time on the weld unit and/or the PRE WELD TIME.

Weld teaching procedure: Only available when the machine is in WELD.

Index the saw. This also closes the clamp jaws. Pull the start button. This will turn on the green light Move the joystick to the weld position and hold it there. A tip will be pulled in and manually

welded on the tooth. The joystick must be released before another manual weld is attempted.

Automatically changing modes: Changing from WELD to ANNEAL and back again can be accomplished by moving the joystick to the desired mode. This movement toggles between the two operating modes. These changes only take place from the WELD or ANNEAL screens.


ANNEAL:

ANNEAL SETUP:

The anneal process for the TW3 can be done using either time or temperature methods. Press the Method (F3) button to toggle between the options. The value for the visible option can be entered manually or the value will be entered automatically when a tooth is annealed using the anneal teaching procedure.


ANNEALING BY TEMPERATURE:

The anneal temperature sensor is a noncontact infrared temperature sensor that calculates the surface temperature based on the emitted infrared energy of the saw plate. Two lasers are used to target exactly where the temperature will be measured. They are used for setup purposes only and are not necessary to be on while the machine is annealing. The F5 button toggles the lasers on and off or they will shut off automatically after 5 minutes. The SSS-Laser has an integrated double laser aiming. Both of the laser beams are marking the exactly location and size of the measurement spot, independent from the distance. At the focus point (70mm) of the according optics both lasers are crossing and showing as one dot the minimum spot. This enables a perfect alignment of the sensor to the saw plate.

Anneal teaching procedure: Only available when the machine is in ANNEAL.

Index the saw. This also closes the clamp jaws and lowers the anneal arm.. Pull the start button. This will turn on the green light Adjust the anneal coil until the tip to be annealed is located at the weld line.


Go to the setup page and turn on the laser. Position the laser spot on the tooth just below the coil.

Move the joystick to the anneal position and hold it there until the desired anneal is achieved. Release the joystick.

There will now be a value displayed on the anneal screen. This is an analog value sent to the PLC by the temperature sensor. Each time a tooth is annealed this value is met before the anneal turns off. Each tooth annealed will then reach exactly the same temperature.

The analog value can be entered in manually rather than “teaching” the machine as we have done above however Changes in the intensity of infrared radiation, emitted by different saw plates (emissivity) as well as the location where the temperature is measured on the tooth will have a great influence on this value.

ANNEALING BY TIME:

Optionally the TW3 can perform the anneal process by strictly a time value. Perform the teaching procedure with Time visible as the method and a time value in milliseconds (1000=1 second) will be calculated when the manual anneal is completed. Omit the laser setup as it is not used for time calculations.


WELD & ANNEAL:

The Weld Then Anneal process welds all the tips on a saw, indexes a number of teeth (Staging #) until the first tooth welded is under the anneal coil and then anneals all the teeth that were welded. This process allows the welded teeth to cool before annealing.

W&A SETUP:


TIME and TEMPERATURE values can be viewed and manually entered from this setup screen. Index Time is the time given to index the Staging #.

MANUFACTURING MODE (MM): Designed primarily for band saw manufacturers the process welds tips on several teeth and then begins welding and annealing at the same time. The “Tips to index before Annealing” allow the welded tips to cool while moving to the anneal arm. When the total tips are welded the machine will continue to anneal tips until all welded tips are annealed.


TW3 Tag Descriptions & Factory Values

Tag Description Factory Setting Anneal Time Time allotted to anneal using “time” method Variable Index Time Time allotted to index teeth between welding and

annealing 800MS

Tip Forward Time Time allowed when tip forward active until an error is flagged

2S_500MS

Tip Reverse Time Time tip reverse motor is on after tip is pulled in 200MS Anneal Temperature Analog value corresponding to temperature when

annealing with the sensor Variable

Vacuum Relief Time The stop valve is opened for this time to allow the vacuum pump to come on without vacuum locking

750MS

Tip Stabilization Time Time allows vacuum pressure to become stable before checking for a tip

900MS

Tip Clamp Time Time from activation of weld head until tip clamp activation

260MS

Pre Weld Time Time after tip clamp closes until weld begins

110MS


TIP FAILURE(CONTINUED)

ANNEAL FAILURE

This failure is caused by improper anneal or no anneal at all. If multiple tips fail in a row then possibly the tooth counter was set at less teeth than the number of teeth in the saw. If saws were chrome plated additional care must be taken when annealing. If failed teeth are randomly spread through the saw then the anneal temperature is probably too high.

WELD FAILURE

This failure is caused by contaminated weld, most likely oil, pitch or grinding grit. Weld zone failure always leaves a small amount of Tip Material attached to the saw plate.


TIP FAILURE(CONTINUED)

TIP MATERIAL FAILURE

When the corner of the complete cutting edge breaks, the failure is normally caused by one of the following...

�. Too steep of a back angle. Over 8° is not recommended.

�. Too rough of a profile grind finish. This causes stress risers that substantially weaken the tip.

3. Overheating the tip material when grinding. This usually occurs when improper or glazed grinding wheels are used.


MAINTENANCEONCE PER SAW: Clean clamp and anneal contact with a wire brush. This is necessary for consistent anneal. DO NOT clean weld contact with wire brush, as it is not exposed to contaminates and brushing will shorten the contact life.

ONCE PER DAY: Check coolant level and add coolant as necessary. Every effort should be made when adding coolant to keep it as pure as possible. If using water based coolants, the use of distilled water is highly recommended.

ONCE PER WEEK:�. Check weld contact for excessive wear. Check side clearance calibration for accuracy. Normal wear of the weld contact and the fixed clamp jaw chang-es the location of the tip. To calibrate loosen the set screw on the plate thick-ness knob and turn the knob to the desired position then tighten the set screw.

�. Drain the incoming air water trap. This is located behind the rear door at bottom. Push black button on the bottom of the trap to drain. Power must be disconnected to the machine before opening the rear door.

ONCE PER MONTH: Disconnect power to the machine. Use a pipe cleaner and clean the weld contact nozzle, as the suction hole will slowly plug with soot.

ONCE EVERY 6 MONTHS: Drain and replace coolant in Cooler. Every effort should be made when adding coolant to keep it as pure as pos-sible. If using water based coolants, the use of distilled water is highly recom-mended.

WARNING: Never place fingers in area of weld contact or index finger when the machine is on. Injury may occur as several pinch points exist. The weld contact as well as the saw can be hot and cause sever burns.


Adjusting the Weld Forward Limit Switch With the Red E-stop button in the normal working position (not depressed) make sure that the green push/pull button is Off.

Select the Menu option on the HMI, then select Options and IO. The forward limit switch is status indicated on the screen:

Place the joystick to the WELD position. The status should change to On when the limit switch is tripped and back to Off when the joystick is returned to the center position.

If adjustment is needed, insert a 1/8” allen wrench in the ¼” hole located on the upper end of the weld head unit (see photo below). This access hole allows the operator to adjust the set screw that trips the weld head limit switch.


While holding the joystick to WELD, back the set screw out (counter clockwise) until the output changes to Off. Turning the set screw in (clockwise) should turn the output back on. When the output comes on, tighten the set screw about 1/3 of a turn past the tripped position.

Once the set screw is adjusted, release the joystick back to the center position and check the adjustment by alternating the joystick between the two positions.

ADJUSTING WELD FORWARD LIMIT SWITCH


ELECTRICAL SCHEMATIC

CR2

E Stop

3

1

CR112 8

11 7

CR1

L2

L1

T2

T1

PR215 amps

L3

L2

L1

T3

T2

T1

PR1

30 amps

30 amps

30 amps

TW3

230 vtransformer

6 amps

X1

X2

Disconnectswitch

230 VAC3 phase30 AmpService

L3

L2

L1

Jumpers

5A

10 6

16 guage 16 guage

H4H2H3H1

10 Guage

Machine Ground MiyachiPower Supply30 amps

30 amps

30 amps

6 amps

white

15 amps

9 5 5

Vacuum Pump

white

Tip Drive Motor

110 V

12 V

CR2

CR2

9 1

CR312 8

12 8

CR3

9 5

9 5

1/2A

Solder black to#1, red and green

to #3 on plugs

A-6753Fuse holders

6 1/4A



17

7

4

Cr6

10 6

4A

3A

TW3 (2)

CR711 7

12 8 8 Anneal Cooling Pump& Fan

3A

24 VDCPower Supply

Anneal Cube Input

13 15

-24 VDC +24 VDC

White

29

S7-1200Input 1.5

6

Cr5

Cr4

Index

Saw Carrier (RollerH.D.)

Cr5

Drag

5 9

5 9

8 12

Cr8

10 6

Miyachi Weld UnitRear View

18

Mechanical FiringSwitch

9

Vacuum Stop Valve

11

Cr9

5 9

24 -

L1

24 +

N

192

Air Backfeed

Cr4

8 12

120 VAC



LS3

LS2

LS1D

B

A

C22

21

20

White

-24 VDC

23

Start/Stop

24

Joy Auto

25

26

27

28

Clamp

CR4 Index

14 13 Weld Head

Anneal Arm

+24 VDC

10Start

White

CR7Cooling Pump

PR2Anneal Power

PR1Weld PowerA2 A1

A2 A1

CR113 14

Vacuum Pump

CR2Tip Reverse

13 14CR3

13 14

Tip Forward

CR5Drag

13 14

CR613 14

13 14

14Tip Clamp

12

CR813 14

Weld

Joy Index

Joy Anneal

Joy Weld

Index Forward

Head Down

Head Up

TW3 (3)

SimaticS7-1200

SM 1222

Analog VacuumSwitch

W-2385-3

Anneal

O G I

1 K ohm1 K ohm

29Ceia Alarm

E-1

F-1

PSC AnalogTemperature

Sensor

See TW3 (4)

2 1

CR913 14

Vacuum valve

CR1013 14

Laser



+24 VDC-24 VDC

S7-1200Analog input 1

TW3 (4)

CR10

9 5

Disconnect pink sensor wirefrom 3V SW, run to CR10 #9

and back to 3V SW fromCR10 #5


A-5707 1 K

Gold

Red

Black

Brown

Analog Vacuum Switch

A-5706

W2385-3

17"To

24VDC+

17"To

2M on S7-1200

24"To AI

0 on S7-1200

24"To

24VDC-

Short piece of¼” clear plastic hose on nipple

Drill #30 or #7hole forscrews.

F-331 x 2F-9 x 2

F-342 x 4F-9 x 8

I G O



SUB PANEL DIAGRAM

W-1539

W-68-G

W-1538-24

W-1464

W-1463

W-2386-3

W-3016W-3020-1

W-3021

A-3250W-877

W-1152-2

W-4012W-4063

W-2384A-5755A-5756

A-6753


COOLANT TANK

C-5800-6

W-4067


AIR SYSTEM DIAGRAM


VACUUM SYSTEM DIAGRAM


MECHANICAL ASSEMBLIES


WELD HEAD HOUSING ASSEMBLYItem

NumberPART NUMBER Quantity

1 W-3661 1

4 W-1460 1

6 A-5304 2

8 W-3657 1

9 W-3656 1

10 W-3658 1

11 W-3660 1

17 W-357 3

22 W-3666 1

23 W-3665 1

25 W-1942 1

26 W-632-2 2

27 F-106 3

28 F-139 3

38 W-3651-1 1

40 F-102 4

41 F-313 2

42 F-398 2

43 F-12 2

49 W-2394-M 4

51 F-104 2

41

251

494

381

91

8110

1

11

231

221

62

262

404

512

273

432

283

412

422

173

111


WELD HEAD HOUSING ASSEMBLY

ItemNumber

PART NUMBER Quantity

1 W-3661 1

2 W-3663 2

3 W-191 1

5 A-5304 2

7 F-638 2

12 W-190 1

17 W-3655 1

18 W-2388-1 1

26 F-139 4

31 F-103 3

32 F-158 1

33 F-327 2

34 F-99 2

35 F-9 2

50 F-647 2

121

31

181

171

11

22

52

313

264

321

332

72

502

352

342


WELD HEAD TRUCK PLATE ASSEMBLY104

131

71

51

21

31

12

82

64

142

48

91

121

111

ItemNumber

Part Number Quantity

1 A-6953 2

2 W-3659 1

3 W-3660 1

4 F-152 8

5 W-3653 1

6 F-104 4

7 W-3652 1

8 F-103 2

9 F-160 1

10 W-2394-M 4

11 F-382 1

12 F-375 1

13 W-3652-1 1

14 F-137 2


WELD HEAD TIP APPLICATOR ASSEMBLY

31

21

11

61

42

52

72

91

81

103

ItemNumber


1 W-1918 1

2 W-1917 1

3 W-1915 1

4 W632-3 2

5 F-104 2

6 W-3634 1

7 F-105 2

8 F-140 1

9 F-137 1

10 F-620 3


WELD HEAD TIP CLAMP ASSEMBLY

41

31

11

131

151

141

161

22

61

71

51

102

92

112

ItemNumber


1 W-1911 1

2 W-2263 2

3 W-1910 1

4 W-1910-1 1

5 F-436 1

6 W-2394 1

7 W-462 1

8* F-393 1

9 F-631 2

10 F-631 2

11 F-638 2

12* W-1912-2 1

13 W-1912-1 1

14 W-1913 1

15 W-1912 1

16 W-1914-1 1

17* F-380 1


WELD HEAD TIP LOADER ASSEMBLY

1.101

1.111

1.15.41

1.15.51

1.15.1111.15.2

1

1.15.1211.21.8

1

1.1.41

1.21.51

1.221

1.21.21

1.21.11

1.121

1.21.31

1.92

1.84

1.15.101

1.21.63

1.242

1.15.131

1.142

1.232

1.15.81

1.1.31


WELD HEAD TIP LOADER ASSEMBLY

1.111

1.15.41

1.15.51

1.15.11

1.15.111

1.15.21

1.15.121

1.181

1.21.81

1.21.51

1.221

1.21.21

1.21.11

1.21.31

1.161

1.1.21

1.31

1.1.11

1.15.61

1.15.91

1.52

1.15.101

1.41

1.21.63

1.242

1.15.32

1.201

1.21.74

1.171

1.62

1.15.131

1.15.71

1.193

1.1.31


ItemNumber


1.1.1* W-3666 1

1.1.2* W-3665 1

1.1.3 W-1920 1

1.1.4 W-1942 1

1.1.5* W-632-2 2

1.1.6* F-106 2

1.1.7* F-327 2

1.1.8* F-9 1

1.1.9* F-313 1

1.2* F-436 2

1.3* W-3666-1 1

1.4* F-115 1

1.5* W632-3 2

1.6* F-359 2

1.7* F-103 6

1.8 W-661-A 4

1.9 W-660 2

1.10 W-1916 1

1.11 W-1919 1

1.12 W-1945 1

1.13* F-380 2

1.14 F-386 2

1.15.1* W-1933 1

1.15.2 W-1936 1

1.15.3* F-310 2

1.15.4 W-1930 1

1.15.5 W-1931 1

1.15.6* W-490 1

1.15.7* F-419 1

1.15.8 F-61-M 1

1.15.9* W-632-2 1

1.15.10 F-102 1

1.15.11 W-1935 1

1.15.12 W-1937 1

ItemNumber


1.15.13 F-380 1

1.16* W-1949 1

1.17* F-338-1 1

1.18* W-1939 1

1.19* F-56 3

1.20* F-333 1

1.21.1 W-1944 1

1.21.2 W-1944-3 1

1.21.3 W-1946 1

1.21.4* F-380 1

1.21.5 W-1944-1 1

1.21.6 F-138 3

1.21.7* F-336 4

1.21.8 W-1941 1

1.22 W-1944-2 1

1.23 F-58 2

1.24 F-20 2

TIP LOADER PARTS LIST


WELD HEAD PLATE THICKNESS ASSEMBLY

291

381

151

301

471

46231

1335

441

322

531

161

ItemNumber


15 W-3651 1

16 W-1356 1

29 W-1341-1 1

30 W-3654 1

31 W-672 1

32 F-125 2

33 F-103 5

38 W-3651-1 1

44 F-119 1

46 W-437 2

47 W-436 1

53 W-1339-4 1


INNER CLAMP JAW ASSEMBLY

71

81

21

11

32

41

91

62

52

102

ItemNumber


1 W-3649 1

2 W-3647 1

3 F-102 2

4 F-107 1

5 F-276 2

6 F-12 2

7 W-3646-4 1

8 W-3646-5 1

9 F-108 1

10 F-436 2


CLAMP ARM PIVOT ASSEMBLY

91

71

11

41

21

51

62

81

33

ItemNumber


1 W-3642 1

2 W-3645 1

3 F-442 3

4 W-3644 1

5 F-112 1

6 F-116 2

7 W-3640 1

8 F-175 1

9 W-3640-1 1


52

162

62

131

121

12

141

31

71

112

102

152

88

22

92

41

ItemNumber


1 W-3646-1 2

2 F-312 2

3 W-3646 1

4 W-357 1

5 W-186 2

6 W-1412 2

7 C-6004-2 1

8 F-148 8

9 F-647 2

10 C-6004-7 2

11 C-6004-4 2

12 W-3645-1 1

13 W-3643 1

14 W-3646-2 1

15 F-102 2

16 W-1411 2

CLAMP ARM ASSEMBLY


INDEX TRUCK PLATE ASSEMBLY71

62

201

81

91

41

31

51

11

121

24

138

142

222

1016

161

231

241

171

211

261

ItemNumber


1 W-3626 1

2 A-6953 4

3 W-3624 1

4 W-3623 1

5 W-3625 1

6 W-1051-2 2

7 W-1051-1 1

8 W-3620 1

9 W-3621 1

10 F-152-2 16

11* F-102 4

12 W-3633 1

13 F-101 8

14 F-104 2

15* F-110 1

16 F-160-1 1

17 F-378 1

18* W-188 2

19* W632-3 2

20 W-2339 1

21 F-398 1

22 F-12 2

23 F-277-1 1

24 F-330-1 1

25* F-436 3

26 W-883 1


INDEX HOUSING ASSEMBLY BOTTOM VIEW

31

101

191

281

291

241

11

111

61

51

41

231

131

301

176

251

261

151

168

271

311

92

212

201

141

222

82

74

22

ItemNumber


1 W-3622 1

2 C5400-17 2

3 W-191 1

4 W-3630 1

5 W-3629 1

6 W-3628 1

7 W-435 4

8 W-434 2

9 F-22 2

10 W-198 1

11 W-3627 1

13 W-3632 1

14 F-62 1

15 F-119-1 1

16 F-139 8

17 F-106 6

18* F-436 2

19 W-1000 1

20 F-424 1

21 F-330 2

22 F-8 2

23 W-3631 1

24 W-3622-3 1

25 F-108 1

26 F-110 1

27 F-156 1

28 W-3622-1 1

29 W-3622-2 1

30 F-105 1

31 F-158 1


SAW LIFT ASSEMBLY FRONT VIEW

123

241

21

216

1521

226

234

204

45 1

1

51

61

131

81

91

71

141

101


SAW LIFT ASSEMBLY BACK VIEW

123

192

241

31

21

216

1521

226

234

181

171

11

161

131

111

81

91

71

141

101 Item

NumberPART NUMBER Quantity

1 C-5100-1 1

2 W-3685-7 1

3* W-3685-6 1

4 F-319 5

5 W-1406-1 RAIL 1

6 W-1406-1 TRUCK 1

7 W-3685-4 1

8 W-3685-2 1

9 W-3685-3 1

10 W-3685 1

11* W-3685-1 1

12 W-169 3

13 W-1543 1

14 W-3685-8 1

15 F-102 21

16* C-5100-4 1

17* W-357 1

18* F-638 1

19* W-1318 2

20 F-133 4

21 W-632-2 6

22 F-105 6

23 F-131 4

24 W-233 1


BAND SAW CARRIER ASSEMBLY

341

52

62

42

92

171

11

161

152

133

111

143

121

25

32

72

84

321

272

2512

184

202

221

2612

244

212

301

293

331

311

282

102

ItemNumber


1 C-6005-4 1

2 C-6029 5

3 C-6035-1 2

4 W-253 2

5 W-2171-1 2

6 W-2171 2

7 C-6035-2 2

8 W-733 4

9 W-2388 2

10 F-648 2

11 C-6008-5 1

12 C-6008-7 1

13 C-6008-4 3

14 C-6008-6 3

15 C-6008-3 2

16 C-6008-2 1

17 C-6004-5 1

18 F-107 4

19* F-105 4

20 F-110 2

21 F-436 2

22 F-164 1

23* F-407 1

24 F-269 4

25 F-106 12

26 F-25 12

27 F-102 2

28 F-647 2

29 F-614 3

30 F-613 1

31 F-640 1

32 W-745 1

33 F-634 1

34 W-68 1


C-6850-TW BAND SAW CARRIER ASSEMBLY

271

361

371

124

132

251

814

241

68

35

11

152

44

401

202

112

102

231

58

211

164

412

291

182

281

391

78

98

172

312 30

2 332

322

224

194

ItemNumber


1 C-6856-3 1

2 W-284 24

3 A-6865 5

4 C-6858 4

5 F-102 8

6 W-733 8

7 F-269 8

8 C-5386 14

9 F-366 8

10 C-6871-1 2

11 C-6870-1 2

12 W-1797 4

13 W-231 2

14* W-1408 4

15 C-6856-4 2

16 F-104 4

17 F-391 2

18 F-12 2

19 W-357 4

20 C-6869 4

21* F-104-1 4

23 W-987 1

24 A-5965 2

25 W-2371 2

26* F-383 2

27 W-61 2

28* F-13 2

29* F-110 2

30 F-614 2

31 F-613 2

32 F-647 4

33 F-640 2

34 W-987 2

35* F-441 2

ItemNumber


36 W-1794-1 1

37 W-1795 1

38* F-115 2

39 F-147 1

40 C-6867 1

41 F-108 2

42* F-407 1


ANNEAL ARM ASSEMBLY

ItemNumber


1 W-3648-7 1

2 F-116 1

3 F-122 1

4* F-104 1

5 W-3063 1

7* W-667 2

8 W-240 1

9* A-4001 1

10 A-4002 1

11 W-4002-4 2

12 W-4002-4 1

13 W-4002-4 2

14 A-4004 1

15 F-149 2

16 W-3648-6 1

7 W-667 2

17 W-3648-3 1

18* F-19 1

19 F-61-M 1

20 F-104-1 1

81

51

171

161

11

141

132

121

112

72

201

21

31

152

191

91


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