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i 35-1195-WCP-6, November 23, 1977 Revision 0, November 23, 1977
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COMANCHE PEAK STEAM ELECTRIC STATION CONSTRUCTION PROCEDURE 35-1195-WCP-6 ELECTRONIC ALIGNMENT, PERFORMANCE VERIFICATION AND MAINTENANCE OF DIMETRICS GOLD TRACK II AUTOMATIC WELDING SYSTEM
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4 APPROVED BY APPROVED BY:
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J. A. Jardine H. C. Dodd, Jr.
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i Project Welding Engineer Construction Project Manager l
i APPROVED BY:
APPROVED BY:
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ARMS JOB 35-1195 Comanche Peak Steam Electric StatlBOEXED
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Construction Procedusarsi INTERIM CHANGE NOTICE NUMBER 2 This notice applies to Construction Procedure No. 35-1195-WCP 6
, Revision 0.
The intent of this change will (X) / will not ( ) be incorporated in the next revision to the procedure.
This Change applies:
Until Further Notice ( )
Until the next revision is issued (X)
Only as follows:
Change the procedure as follows:
1.3.1 To insure the continued repeatability of the Welding System, only Manufacturer's Service Engineer (s), Dimetrics Factory - trained Brown
& Root Personnel or Maintenance Technician (s) and Maintenance Tech-nician(s) who have had six (6) months of on the job training working with Dimetrics factory-trained Brown & Root personnel who are perinit-ted to accomplish any operations on the welding systems requiring ),
internal check (s), adjustment of electrical or mechanical system (s necessary repair (s) or required periodic maintenance.
2.1.4 Welding operator - Brown & Root employee specially trained in the operation of the Dimetrics Welding System.
t 2.1.7 Maintenance Technician - Brown & Root employee specially trained the (Add) maintenance of the Dimetrics Welding System.
4.1.4 Any items not meeting the manufacturer's recommended limits which can not be corrected by the maintenance Technician assigned to the system shall be reported to the foreman in charge of the Automatic Welding maintenande or his. designee. The maintenance foreman or his designee shell. determine' the action to be taken.
If major electronics repair l
is done,the per.formance verification in accordance with Section 4.2 will have to be perforined.
i NOTE: Ali major or minor repair (s) made will be logged in the equipment history log.
4.2.1 Change.every 30* days to every 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of arc time as recorded on
, arc time meter.
Reason for change:
To update Specification.
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This change approved by:
J AW bbs/
Department Head paTity Assurance Reviewed By:
}//( M 9%27-77 Procedures & Reports Date j
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4.2.3 The perfonnance verification will be accomplished by the Welding i
Engineering Department with the assistance of the Welding Operator (s) orMaintenanceTechnician(s). A log of the verifications will be i
maintained for each Automatic Welding System.
4.2.5 Change Automatic Welding Group Supervisor to read Automatic Welding Group Maintenance Foreman.
Change last sentence in paragraph to read as follows: The Maintenance Foreman or his designee involved in the test should be present during any adjustments.
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4.4.1 Only Manufacturer's Service Engineer (s), Dimetrics trained, Brown &
J Root personnel and Maintenance Technician (s) completing on the job l
training are authorized to make any adjustments or repairs to the Dimetrics Automatic Welding System.
-l 4.4.2 Change Automatic Welding Group Supervision to Automatic Welding Group Maintenance Foreman.
4.5.2 Only Manufacturer's Service Engineer (s), Dimetric Factory trained personnel and Maintenance Technician (s) completing on the job training are authorized to perform the required preventive maintenance.
5.2 Change item 3 under Reference from 35-1195-WCP-3 to 35-1195 CF-CPM 6.9.
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JOB 35-1195 Comanche Peak Steam Electric Station Construction Procedure INTERIM CHANGE NOTICE NUMBER 1
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l This notice applies to Construction Procedure No. 35-1195-WCP-6
, Revision 0 f
The intent of this change will (X) / will not ( ) be incorporated in the next revision to the procedure.
i This Change applies:
Until Further Notice (x)
Until the next revision is issued ( )-
Only as follows:
4 i
Change the procedure as follows:
l To insure the continued repeatability of the Welding System only l
1.3.1 Manufacturer's Service Ertgineer(s), Dimetrics factory-train,ed Brown &
Root Engineer (s)/ operators, or Technician (s) who have had six (6) months of on the job training working with Dimetrics factory-trained i
Brown & Root Engineer / operator are pemitted to accomplish any oper ations on the welding systems requiring internal check (s), adjustment of electrical or mechanical system (s), necessary repair (s) or required periodic maintenance.
1.3.3 All activities associated with the Dimetrics Welding System shall be coordinated through the Project We1. ding Engineer, Supervisor of Automatic Welding Group or their designee. The Automatic Welding Coordinator- (Houston) should be advised of activities.
]j 2.1.5 Welding Technician - Brown & Root employee, trained in the operation i
of the Dimetrics Welding System.
4.1.4 Any items not meeting the Manufacturer's recomended limits which
cannot be corrected by the Welding operator /Technicfan assigned to j
9.
the system, shall be reported to the Automatic Welding Group Super-i visor or his designee. The Automatic Welding Group Supervisor or his designee shall detemine the action to be taken.
If major electronic 4
. repair is done the performance verification in accordance with Section 4.2 will have to be performed. NOTE: All major or minor repair (s) a j
made will be logged in the equipment history log.
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Reason for change:
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For adding clarification and update procedure.
This chan ved by:
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yaf :fient' Head quality Assurance 1
Reviewed By:
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$~22. ~Y Procedures & Reports Date i
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ICN #1 WCP-6, Rev.0 Page 2 ef 1 j
The performance verification will be accomplished by the QA/QC Depa i
the assistance of the Welding operator (s) or Technician (s).
- 4. 2. 3.
fication will be maintained for each Automatic Welding System.
If the accuracy of one or more of the functions cannot be verified, the Auto tic Welding Group Supervisor or his desinee shall be notified and actio 4.2.5 The Welding Group Supervisor involved in the be taken to correct the problem.
test should be present during any adjustments.
made with the D1 metrics Automatic Welding System will be sub-Weld ject to the same monitoring program as all other w Production welds 4.3.1 Weld Technical Group as outlined in Reference 3.
Weld parameter monitoring procedure is outlined in Appendix 3 of th i
4.3.2 Only(s)anufacturer's Service Engineer (s). Dime or Welding operator (s) and Weld Technician (s) completing on the job M
4.4.1 training are authorized to make any adjustment or repairs to the Dimetri eer Automatic Welding System.
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Any problem / malfunction (s) that cannot be so 4.4.2 ted to the Automatic Welding Group Supervisor for disposition.
The Automatic Welding Coordinator shall be notified of major proble 4.4.3 the Project Welding Engineer or his designee.
Only(Manufacturer's Service Engineer (s), Dim 1
4.5.2 ing are authorized to perform the required preventive maintengnce.
l Any additional maintenance will be accomplished as outlined in Re 4.5.3 5.2
REFERENCE:
1.
B&R Construction Procedure 35-1195-ICP-1.
(Now CP-CPM-13.1)
Dimetrics Gold Track II Operation and Maintenance Manual 2.
3.
B&R Construction Procedure 35-1195-WCP-3 I
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35-1195-WCP-6, November 23, 1977 Revision 0, November 23,1977 PAGE 2 3
U LIST OF EFFECTIVE PAGES The total number of pages in this document is 36. The page numbering sequence and revision status of each page is as follows:
PAGE REVISION STA'1JS DATE Title Original November 23,1977 2 through 36 Original November 23, 1977 9
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sW.
TABLE OF CONTENTS l
SECTION TITLE PAGE r
4 l
1.
INTRODUCTION 1.1 PURPOSE........................
4 1.2 SCOPE........................
4 1.3 GENERAL DISCUSSION AND RESPONSIBILITIES.......
4 l
2.
DEFINITIONS OF TERMS, ABBREVIATIONS AND SYMBOLS...
5 E
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2.1 DEFINITIONS OF TERMS................
5 2.2 A8BREVIATIONS....................
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2.3 SYMBOLS.......................
6 l
3.
SPECIAL ITEMS AND OPERATIONS l
3.1 MATERIALS......................
6 6
3.2 PROCESSES......................
3.3 TOOLS AND EQUIPMENT.................
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4.
PROCEDURES l
7
'~h 4.1 ELECTRONIC ALIGNMENT................
7 4
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4.2 PERFORMANCC VERIFICATION..............
8 l
4.3 MONITORING OF PRODUCTION ~ WELDING 8
4.4 TROUBLESHOOTING / REPAIR...............
8 4.5 PREVENTIVE MAINTENANCE...............
9 5.
SUPPORTING INFORMATION...............
5.1 ATTACHMENTS.....................
9 9
5.2
. REFERENCES i
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35-1195-WCP-6, November'23,1977 Revision 0, November 23,1977 PAGE 4 h.
b' 1.
INTRODUCTION l
1.1 PURPOSE 1.1.1 The purpose of this procedure is to establish a program for the electronic alignment, perfomance verification and maintenance of the Dimetrics Gold Track II Welding Systen.
1.2 SCOPE 1.2.1 The scope of this procedure includes the operations to be perfomed on the Dimetrics Welding System that are necessary in order to assure that quality production welding may be accomplished. These necessary operations include the following:
1.
Electronic Alignment
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2.
Perfomance Verification I
3.
Monitoring of Production Welding 4.
Troubleshooting / Repair 5.
Maintenance 1.2.2 Although the tem " calibration" may be used in some instances when referring to the electronic alignment procedure,the Dimetrics Welding System will not be considered a calibrated itam.
1.3 GENERAL DISCUSSION AND RESPONSIBILITIES 1.3.1 To insure the continued repeatability of the Welding Systam, only
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Manufacturer's Service Engineers or Dimetrics factory-trained, i
Brown & Root Engineer's/ Operators are pemitted to accomplish any operations on the welding system requiring internal checks, I
adjustment of electrical or mechanical systems, necessary repairs or required periodic maintenance.
i 1.3.2 The Brown & Root Engineer / Operators assigned to the Dimetrics Welding System will perform all functions necessary to meet the requirements of this procedure.
1.3.3 All activities associated.with the Dimetrics Welding System shall be coordinated through the Project Welding Engineer.
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'f DEFINITIONS OF TERMS, ABBREVIATIONS AND SYMBOLS 2.
2.1 DEFINITIONS OF TERMS l
Dimetrics Welding System - the complete, programable automatic gas tungsten arc welding system manufactured by Dimetrics, Inc.
2.1.1 This welding system includes the of Sepulveda, California.
capability for welding pipe, using the pipe track system and for welding plate, using the vacuum flat track system.
Perfonnanch Verification - a periodic check of the four basic welding variables which are critical to the assurance of quality 2.1. 2 These variables are (1.) current, (2.) are voltage, welds.
(3.) fixture travel speed and (4.) wire feed speed.
Automatic Welding Coordinator - Engineer from Materials Engineering.
Houston, specially trained in the operation and maintenance of the 2.1.3 Dimetrics Welding System.
Welding Operator - Brown & Root employee, specially trained in 2.1.4 the operation and maintenance of the Dimetrics Welding System.
Welding Technician - as defined in 2.2.1 of Reference 5..
2.1. 5 Electronic Alignment - periodic check (and adjustments, if necessary), to assure that all systems are within acceptable T
2.1.6 J
specification limits.
2.2 ABBREVIATIONS 2.2.1 M & TE - Measuring and Test Equipment 2.2.2-DVM - Digital Volt Meter 2.2.3 PM - Preventive Maintenance 2.2.4 PWE - Project Welding Engineer 2.3 SYMBOLS 2.3.1 None
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35-1195-WCP-6, November 23,1977 Revision 0, November 23,1977 PAGE 6
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SPECIAL ITEMS AND OPERATIONS 3.1 MATERIALS 3.1.1 None 3.2 PROCESS 3.2.1 The weld.ing process of concern in this procedure is the automatic gas tungsten arc welding (GTAW) process.
3.3 TOOLS AND EQUIPMENT All necessary hand tools for proper operation / maintenance of i
3.3.1 e
the Dimetrics Welding System are available and considered a portion of the System itself. The Dimetrics Welding System and all associated tools are the property of the Client.
M & TE for the electronic alignment, maintenance All necessary(if necessary), shall be provided by the Project 3.3.2 and repair, and shall conform to all requirements of Reference 1.
3.3.3 If the required test equipment is not available on the Project,
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alternate test equipment may be provided by an outside source that is approved by the Project and meets all Project requirements.
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Revistor,O, November 23, 1977 PAGE 7 i
4.
PROCEDURES N
ELECTRONIC ALIGNMENT 4.1 4.1.1 The Dimetrics System shall be checked periodically to insure 4
that its perfonnance is within Manufacturer's specified ifmits.
This electronic alignment (calibration) shall be accomplished in accordance with the instructions included in this procedure (Attachment 1).
4.1.2 The electronic alignment procedure shall be accomplished every 1
6 months.
4.1.3 A record of the 6 month check shall be kept on the electronic alignment (calibration) record included in this procedure (Attachment 2).
4.1.4 Any items not meetir.g the Manufacturer's recomended limits, which cannot be corrected by the Welding Operator's assigned to the System, shall be reported to the Automatic Welding Coordinator, through the Project Welding Engineer. The Automatic Welding Coordinator shall determine the action to be taken. If major or minor electronic repair is deemed necessary, Q.A. shall be notified so they can accomplish their performance verification in accordance with Section 4.2.
l 4.1.5 The following list shall serve as a guideline in detennining the need for more frequent checks of the electronic systems after any necessary repair work has been done on the Welding System. Each case shall be considered individually:
1 Example of Repair Additional Checks Recuired l
(1) Nonelectronic Systen None Required (torchcoolant,aircooling, l
i etc.)
i (2) Minor Electronics Only System Worked On (motorrepair, component replacement,etc.)
(3) Major Electronics Complete System Check i
(low voltage supply repair, board replacement, etc.)
f 4.2 PERFORMANCE VERIFICATION 4.2.1 As a continuing assurance of the accuracy of the four basic welding variables critical to quality production welding (See 2.1.2), a perfonnance verification will be accomplished every 30 days.
The perfonnance verification will be accomplished in accordance 4.2.2 with the instructions contained in Attachment 3 of this procedure.
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4.2.3 The pei fonnance verification will be accomplished by the Q.A. Department with the assistance of the Welding Operators.
A log of the verification will be attached to the welding l
l power supply.
l 4.2.4 The verification procedure shall not require access to the t
internals of the equipment.
i 4.2.5 If the accuracy of one or more of the functions cannot be verified, the Automatic Welding Coordinator shall be notified, i
through the PWE, and action shall be taken to correct the l
problem. The electronic alignment of the function in question shall be rechecked.
4.3 MONITORING OF PRODUCTION WEl.0ING I
4.3.1 Production welds made with the Dimetrics Welding System will be subject to the same monitoring program as all other welding operations on the Project. Weld parameters shall be periodically monitored by Weld Technicians as outlined in Reference 5.
4.3.2 Weld parameter monitoring procedures are outlined in Appendix 3.
l These procedures will be followed by the Weld Technicians.
3 4.4 TROUBLESHOOTING / REPAIR 4.4.1 Only Manufacturer's Service Engineers or Dicletrics trained, l
Brown & Roo Engineers or Welding Operators are authorized f
to make any adjustment or repairs to the Dimetrics Automatic Welding System.
4.4.2 Any problems / malfunctions that cannot be solved by the Welding Operators assigned to the Dimetrics System shall be reported to the Automatic Welding Coordinator, through l
the PWE, for disposition.
4.5 PREVENTIVE MAINTENANCE
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4.5.1 Preventiva maintenance will be perfonned on the Gold Track II Welding Systen as outlined in Attachment 4 b
4.5.2 Only Manufacturer's Service Engineers or Dimetrics trained, Brown & Roct Engineers or Welding Operators are authorized to perfonn the required preventive maintenance.
4.5.3 Any additional maintenance will be accomplished as outlined in Reference 4.
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35-1195-WCP-6, November 23, 1977 Revision 0, November 23,1977 PME 9
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5.
SUPPORTING INFORMATION 5.1 ATTAC)MENTS 1.
Electronic Alignment (Calibration) 2.
Calibration Record 3.
Perfomance Verification / Weld Parameter Mcnitoring 4.
Preventive Maintenance
5.2 REFERENCES
1.
BAR Construction Procedure 35-1195-ICP-1
" General Calibration Procedure" 2.
Quality Control Procedure CP-QCP-1.3 3.
B&R Construction Procedure 35-1195-ICP-8
" Qualification & Certification of Calibration i
Facility Personnel" 4.
Dimetrics Gold Track II Operation and Maintenance Manual 5.
B&R Construction Procedure 35-1195-WCP-3
" Administration and Organization of Field Welding Technical Center" m
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ATTACHMENT 1 ELECTRONIC ALIGNMENT k
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4 ELECTRONIC ALIGNMENT
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(CALIBRATION)
Section 1 INTRODUCTION The following sections describe the procedure for aligning the electronic circuits in this system so that the perfor-i mance is within specified limits. Under nomal operation, I
only a small adjustment should be required if at all, to bring the system back into acceptable specification limits.
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If a subassembly has been replaced to correct a malfunction, a
the electronic circuitry associated with that function should i
be recalibrated. Some calibration adjustments, such as the low voltage per supplies may affect the calibration of other functions.
4 1.1 GENERAL INFORMATION AND PRECAUTIONd Because of the complexity of the system, the calibration procedures are given in step by step format. Error may e
result if the procedure is not rigidly adhered to.
The sequence should never be initiated in the operate 3
mode unless a torch is. properly positioned and connected, or a load bank is connected across the power supply output.
Some of the test points can cause improper operation or compnnent failure if inadvertently grounded or shorted to adjacent points so care should be taken in connecting test l
equipment. The system should be energized for at least fifteen (15) minutes prior to starting the calibration
+
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t 1.2 EQUIPMENT REQUIRED 3
A.
Digital voltmeter (DVM) 3-1/2 decade Dana Model 2000 or equivalent.
B.
Digital counter interval Timer Hewlett Packard Model 5304 or eouivalent.
C.
A six-foot tape measure i
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Vernier Dial Calfper i
Section 2 LOW VOLTAGE SUPPLIES i
NOTE: Unless otherwise stated all calibrations te be y
done in Test Mode I
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+24 VOC Supply i
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A.
Connect sense lead of DVM to A13-A7-TP2. Connect return lead to A13 chassis GND.
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8.
Verify presence of +24.0 plus or minus 3.0 VDC.
Record reading on record sheet.
l 2.2
-24 VDC Supply i
A.
Connect sense lead of DVM to A13-A7-TP4 Connect return lead to A13 chassis GNO.
8.
Verify presence of -24.0 plus or minus 3.0 VDC.
Record reading.
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+15 VDC Supply
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A.
Connect sense lead of DVM to A13-A7-TP3. Connect return lead to A13 Chassis GND.
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8.
Observe voltage and adjust A13-A7-R6 for +15.00 plus or minus.02 VDC.
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2.4
-15 VDC Supply i
A.
Connect sense lead of DVM to A13-A7-TP5. Connect l
return lead to A13 chassis GNO.
8.
Observe the voltage. AdjustA13-A7-R6 for -15.00 l
plus or minus.02 VDC.
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NOTE: R6 is the balance control for the 15 VDC l.
rsgulator. If adjustment is r.aeded,
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recheck the +15 VDC after adjustment.
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Record +15 VDC D.
Record -15 VOC 2.5
+32 VDC Supply A.
Connect sense lead of DVM to A13-T82-1. Connect return lead to A13 chassis GNO.
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Verify presence of +32.0 plus 10.0 or minus 0.0 VOC.
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C.
Record reading.
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2.6
-32 VOC Supply A.
Connect sense lead of DVM to A13-TB2-9. Connect return lead to A13 chassis GND.
8.
Verify presence of -32.0 plus 10.0 or minus 0.0 VOC.
C.
Record reading.
2.7
+12 VOC Supply A.
Connect sense lead of DVM to A13-TB2-4. Connect return lead to A13 chassis GND.
8.
Verify presence of +12.0 plus or minus 2.0 VDC.
C.
Record reading.
2.8
+5 VOC Supply A.
Connect sense lead of DVM to A13-A7-TPl. Connect return lead to A13 chassis GND.
8.
Verify presence of +5.00 plus or minus.20 VDC.
C.
Record reading.
Section 3 WELD CONTROL BOARD A1 3.1 Pre-PurgeTime(A16ServicePanel) l A.
Set pre-purge switch to 5 seconds. Set upslope and downslope switches to 00 seconds.
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Connect stop trigger of interval counter to Al-J6-1.
8.
Connect start trigger to Al-J6-4. Connect return lead to Al-J7-10. Set start trigger to positive slope and stop t-igger to negative slope. Set counter mode to separate.
i C.
Initiate sequence start switch on weld head and observe pre-purge time. Adjust Al-R38 for a time of 5.0 seconds plus or minus.5 seconds.
NOTE: It is necessary to initiate sequence stop, I
either automatically or man' sally, after each measurement.
D.
Repeat sequence several times and verify repeatability.
Record final reading.
u E.
Set pre-purge switch to 3 seconds. Initiate sequence and record reading.
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35-1195-WCP-6, Nov eber 23,1977 Revision 0, Nov eber 23, 1977 PAGE 14 Section 3 CONTINUED F.
Set pre-purge switch to 15 seconds. Initiate F
sequence and record reading.
3.2 POST PURGE. TIME A.
Set counter stop trigger slope to negative. Initiate sequence. After upslope, reset counter and initiate sequence stop. Observe post purge time of 45 seconds.
I 8.
Record reading.
i C.
Set pre-purge switch to 5 seconds. Initiate sequence j
stop. Observe and record post purge time of 15 seconds. Record reading.
3
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D.
Set pre-purge switch to 3 seconds. Initiate sequence i
stop. Observe and record post purge time of 9 seconds.
s Record reading.
y 3.3 UPSLOPE TIME A.
Connect start trigger of interval counter to Al-J1-10 (cathode CR7 or CRI). Connect stop trigger to Al-J7-7.
Connect return lead to Al-47-10. Set start and stop trigger slopes to negative. Set mode to separate.
+
8.
Set pre-purge switch to 3 seconds. Set upstope switch on ruota programer to 10 seconds. Set downslope time to 00 seconds.
C.
Initiate sequence and observe upslope time. Adjust A18-511-R9 remote programer (model "A") or A18-52-R9 l
(model "B") for 10.0 plus or minus.1 seconds. Repeat sequence several times and verify repeatability.
D.
Record reading.
E.
Check each digit on upstope switch for proper time.
3.4 00WNSLOFE TIME A.
Connect start trigger of interval counter to Al-J1-10 (cathodeCR7orCRI). Connect stop trigger to Al-J1-9.
Connect return lead to Al-J7-10. Set start trigger for positive slope and stop trigger for negative slope.
4 Set mode to separate.
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35-1195-WCP-6, November 23,1977 Revision 0, November 23,1977 PAGE 15 3:.';
3.4 CONTINUED B.
Set upslope switch to 00 seconds. Set downslope switch to 10 seconds. Initiate sequence, reset counter, initiate sequence stop and observe downslope time.
Adjust A18-512-R9 remote programer (model "A") or A18-55-R9 (model "B"), for a time of 10.0 plus of i
minus.1 seconds.
C.
Repeat sequence several times to verify repeatability and record final reading.
2 D.
Check each digit on downslope switch for proper time.
3.5 HI PULSE A.
Connect frequency counter sense lead to Al-J7-4.
Connect return lead to Al-J7-10. Observe hi pulse frequency of 16,000 plus or minus 500 hertz.
i; I
8.
Record reading.
I 3.6 PULSED ARC GENERATOR A.
Connect start and stop triggers of interval counter to Al-J7-5. Connect return lead to Al-J7-10. Set i
j counter slopes to negative.
8.
Set low pulse niode switch on remote programer to P.A.
Set low pulse frequency switch to 9.9 PPS.
C.
Set low pulse width to 50% trigger counter to read one pulse and adjust Al-R1 for a time of 101 ms plus or l
minus 1 ms. Record final reading.
d D.
Set low pulse frequency to 0.2 pps and adjust Al-R8 for 5000 ms plus or minus 50 ms. Record final reading, s
E.
Check each digit on pulse frequency switch for proper time.
l F.
Connect interval counter start and stop leads to i
Al-J6-7. Connect return lead to Al-J7-10. Set low pulse width switch to 05%. Set low pulse frequency switch to 0.5 pps.
G.
Measure negative pulse of one cycle. Adjust Al-R20 for a reading of 100 ms plus or minus 1 ms. Record final reading.
H.
Check each digit on pulse width switch for proper reading.
M
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o 35-1195-WCP-6, November 23, 1977 Revision 0, Novaber 23,1977 PAGE 16
]
Section 4 MODEL "A" TIMING NOTE: This section for model "A" machines only.
4.1 MASTER OSCILLATOR A.
Connect frequency counter sense lead to A18-A14-TP2 (remote programer). Connect return lead to A18-A14 chassis GNO. Adjust A18-A14-R10 for 10,000 hertz plus or minus 100 hertz.
B.
Record final reading.
4.2 AUTO SEQUENCE MODE A.
Set up remote programer and service panel as follows:
fixture mode = off test / operate = test purge mode = 3 seconds upslope time = 00 seconds 1st thru 4th level period = 015 seconds oscillator amp = 00 downslope time = 00
}
time-off-distance = time 8.
Initiate sequence and verify that system goes into 3
i 1st level for 15 seconds, then to 2nd, 3rd and 4th and then downslopes and post purges.
Section 5 SERYO J0GS 5.1 SERVO J0GS A.
The manual fixture Jog speed is controlled by A2-R26-forward, and A2-R27 reverse.
6.
The adjustment of these should be sat by servica personnel to the operators desires.
C.
The manual wire feed Jogs speed is controlled by l
A3-R26-feed, and A3-R27-retract.
D.
The manual AVC Jog speed is controlled by A4-R26-down and A4-R27-up.
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i 35-1195-WCP-6, November 23,1977 Revision 0,' November 23,1977 PAGE 17 Section 6 FIXTURE SERVO 6.1 FIXTURE DELAY TIMER A.
Connect interval counter start trigger to A2-J5-3 (anede CR33).. Connect stop trigger to A2-J6-9. Connect return to A2-J6-12. Set t
counter slopes to negative. Set mode to separate.
8.
Set fixture start delay to 10 seconds. Set pre-purge to 3 seconds. Set upslope to 00 j
seconds. Set downslope to 5 seconds. Set single level speed switch (model "B") or 1st l
through 4th level speed switch (model "A")
1 to 01.0 I.P.M. Set fix mode to fwd., time l
mode switch to off (model "A").
C.
Initiate sequence and observe the delay time i
after pre-purge and before the fixture starts j
into motion.
i D.
Adjust A2-R69 for a delay time of 10.0 plus
~ or minus 0.1 seconds. Repeat several times i
to verify repeatability. Record final reading, i
h j
E.
Stop delay. Observe that fixture continues to' l
run for length of downslope time.
6.2 NULLS AND 0FFSET CIRCUITRY l
NOTE: Section 5.2 is a factory initial adjustment and should not need to be perfomed in the course of normal calibration. However, in case of a repair of fixture drive circuitry or if section 5.3 does not calibrate properly, perform the r
i following steps, i
}
A.
Insure that fixture drive motor is not running.
connect a jumper between A2-J2-13 (junction-R19, i
R16) and ground side of A2-R30. Connect return lead of DVM to ground side of A2-J6-8.
~
8.
Adjust A2-R82 for 0.00 plus or minus 0.002 VDC.
l Record reading.
i l
C.
Remove jumper between A2-J2-13 ami A2-R30 ground.
Connect a 2 microfarad capacitor across the sense and return leads of the DVM. Connect a 2 meg ohm resistor in series with the sense lead of DVM.
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35-1195-WCP-6, Novencer 23, 1977 Revision 0, November 23, 1977 PAGE 18 c3 6.2 CONTINUED 0.
Connect sense lead of DVM to wiper of A2-K4 (junction R28). Connect return lead of DVM to ground side of I
A2-R30. Set fixture speed switch cr switches to 00.0 IPM. Set start delay to 00 seconds.
E.
Initiate sequence. Allow several seconds for the R.C.
network to charge and stabilize and adjust A2-R37 for a reading of 0.00 VOC plus or minus 0.002 VOC.
F.
Record final reading.
6.3 FIXTURE SPEED CALIBRATION A.
Connect DVM sense lead to A2-J6-8. Connect return lead i
to A2-J6-12.
8.
Accurately mark off 20 inches on the circumference of the. fixture track.
i C.
Select an arbitrary reference point on the weld head fixture and Jog it to the 1st or 0 inch mark in the fonvard direction of travel.
D.
Set the single fixture speed switch (model "B") or
)
the 1st through 4th level speed switches (model "A")
to 20.0 IPM. Set fixture start delay to 00 seconds.
Set upslope and downslope switches to 00 seconds.
Set fixture mode switch to fwd. Set time mode switch switches to 015 seconds (model "A")gh 4th level period to Time (model "A").
Set 1st throu Set test / operate i
to Test.
E.
Initiate sequence, after 60 seconds (one minute),
initiate sequence stop (model "B").
L NOTE: Model "A" machines should do this automatically.
A Model "B" machines need to be stopped manually.
1 F.
Measure the distance traveled and adjust A19-R4 (wald head) for a distance of 20.0 plus or minus.2 inches.
Repeat step E several times to verify repeatability.
G.
Set Fixture speed switch (es) to 02.0 IPM. Repeat Step E.
H.
Measure the distance traveled and adjust A19-R2 (weld head) for a distance of 2.0 plus or minus.040 inches.
I.
Repeat step E and F at 20 inches and readjust if necessary. Recheck 2 IPM and readjust if necessary.
j Continue nulling the adjust pots A19-R2 and R4 back a
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and forth until both 20 and 2 IPM are within specifications.
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35-il95-WCP-6, November 23,1977 Revision 0, November 23,1977
?.;
PAGE 19 6.3 CONINTUED J.
Record final DVM reading and distance traveled for both settings.
K.
Set fixture speed switch (es) to 010 IPM and initiate sequence. Monitor fixture speed meter on service panel and adjust A2-R81 for a reading of 10 plus or minus.5 IPM.
Section 7 WIRE FEED SERVO 7.1 WIRE FEED del.AY TIMER A.
Connect interval counter start trigger to A3-J5-3 (anodeCR33). Connect stop trigger to A3-J6-9.
Connect return lead to A3-J6-12. Set counter slopes to negative. Set mode to separate.
B.
Set wire feed stop switch (weld head) to on.
Set wire start delay switch to 10 seconds.
Set upslope to 00. Set pre-purge to 3 seconds.
3 C.
Initiate sequence and observe the delay time '
after pre-purge and before wire feed motor i
i starts to run. Adjust A3-R69 for a delay
. time of 10.0 plus or minus 0.1 seconds.
j D.
Repeat several times and record final reading.
l 7.2 WIRE FEED RETRACT l
l A.
Set A20-R3 to minimum (retract pot). Set j
downslope to 10 seconds. Initiate sequence.
After start delay initiate sequence stop.
Observe that wire feed motor stops imediately, upon start of downslope and than --tracts for an j
extremely short period of time.
8.
Set A20-R3 to maximum (retract pot). Initiate l
sequence. After start delay, inttiate sequence l
stop. Observe that wire feed motor stops im-mediately upon start of downslope and then retracts for approximately one second.
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35-1195-WCP-6, November 23,1977 l
Revision 0, November 23,1977 PAGE 20 7.3 NULL AND OFF5ET NOTE: Section 6.2 is a factory initial adjustment and t
should not need to be performed in the course of normal calibration. However, in case of a repair to wire feed drive circuitry or if section 6.4 j
does not calibrate properly, perform the 'following f
steps.
Insure that wire feed motor is not runnin Connect t
- a. jumper from A3-J2-13 (Junction R16-R19)g.
A.
to ground i
l side of A3-R30. Connect DVM sense lead to A3-J6-8.
Connect return lead to ground side of A3-R30.
1 8.
Observe voltage and adjust A3-R97 for a reading of J
0.00 plus or minus 0.002 VDC. Record final reading.
1 C.
Remove jumper between A3-J2-13 and A3-R30 ground.
Connect a 2 microfarad capacitor between the sense i
and return leads of a DVM. Connect a 2 meg ohn i
resistor in series with the sense lead of DVM.
Connect the sense lead of DVM to wiper of A3-K4 (junction R28). Connect return lead of DVM to j
A3-R30 ground side. Set wire feed primary and background switch to 00 IPM. Initiate sequence.
l D.
Allow several seconds for R.C. network to chahje and stabilize and adjust A3-R37 for a reading of 0.00 plus or minus 0.002 VOC.
i I
E.
Record final reading.
L 7.4 WIRE FEED SPEED CALIBRATION A.
Connect DVM sense lead to A3-J6-8. Connect return lead to A3-J6-12. Prepare wire feed mechanism to feed wire. Set wire feed primary speed switch to J
99 IPM. Set upslope to 00 seconds. Set wire feed start delay to 00 seconds. Set downslope to 00 seconds. Set wire feed retract A20-R3 to minimum.
f Set low pulse mode to off. Set time mode to time t
(model "A").
$ct 1st through 4th level periods to 015 seconds.
b 8.
Initiate s uence and al1 N wire to feed for exactly 60 seconds oneminute). Initiate tequence stop.
l (model"5")
NOTE: Model "A" systens should end sequence automatically.
t Model "5" - it is necessary to do it manually.
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35-1195-WCP-6, November 23, 1977 Revision 0, November 23, 1977 PAGE 21
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7.4 CONTINUED C.
Measure the amount of wire fed out and adjust A19-RS for 99 inches plus or minus 2 inches.
D.
Set primary wire speed to 10 IPM and initiate sequence, after 60 seconds, initiate sequence i
stop.
E.
Measure wire fed out and adjust A19-R3 for 10.0 4
inches plus or minus 0.2 inches.
F.
Repeat steps 5 and C at 99 inches per minute.
i G.
Repeat steps 0 and E at 10 IPM.
H.
Continue nulling between A19, R3 and R5 until both speeds are within specification. Record final DVM reading and amount of wire fed.
i I.
Set primary wire speed to 50 IPM. Initiate sequence and monitor wire speed meter on service panel. Ad-just A3-R89 for 50.0 plus or minus 1.0 IPM. Initiate sequence stop.
,b J.
Set low pulse mode switch to P.A.
Set pulse frequency to 1.0 pps. Set width to 50%. Set primary wire to 80 IPM. Set background wire to 40 IPM. Initiate sequence and allow wire to feed fcr 60 seconds (one minute).
Measure and record amount of wire fed. It should be 60.0 plus or minus 1.2 inches.
Section 8 OSCILLATOR SERVO l
8.1 OSCILLATOR MECHANICAL CENTER A.
Connect DVM sense lead to AS-48-4. Connect return lud to A5-J6-12. Set oscillator amplitude switch to 00 inches. Adjust vernier slide (weld head) for l
a reading of 0.00 VOC on DVM.
5.
Measure. distance from rear of AVC housing to front I
of fixture carriage. The distance should be 1.00 inches plus or minus 0.010 inches. If adjustment is needed, loosen set screw on wiper shaft of i
A19-R11 oscillator feed back pot and move shaft I
until distance is within specification.
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35-1195-WCP-6, November 23,1977 Revision 0, November 23,1977 PAGE 22
,.7 1
y 8.2 OSCILLATOR VC0 A.
Connect start and stop triggers of interval counter to A9-42-5. Set triggers to positive slope. Set in/out and excursion switches to 0.9 seconds. Set amplitude switch to 0.20 inches.
B.
Initiate sequence and adjust A9-R16 for a reading of 9 as plus or minus 0.09 ms on counter. Record reading.
1 C.
Set in/out and excursion switches to 0.1 seconds.
Adjust A9 R25 for a reading of 1 ms plus or minus i
0.001 as. Record final reading.
1 9.1 MININJM CURRENT A.
Connect DVM sense lead to Al-J6-11. Connect return 1eed to Al-J7-10. Set test / operate switch to test.
Set primary current (model "8") or 1st through 4th level current (model "A") to 000 amps. Set low I
pulse mode to off.
B.
Initiate sequence and after upslope adjust Al-A166 for a reading of -0.050 plus or minus 0.005 VDC.
Record final reading.
i 9.2 CURRENT GAIN A.
Set up sequence panel and remote programer as follows:
Pre-purge = 3 seconds 4
i Primary current = 020 amps (model "S")
1st through 4th level = 020 amps (model "A")
Background current = 020 amps Time mode = off (model "A")
j Low pulse mode = off Pulse width = 501 AVC mode = Lock Pulse Frequency = 1.0 pps 0$C. amp = 00 inches Test / operate = operate Upslope = 2 seconds wire feed stop = stop B.
Connect up suitable ground and prepare weld head to strike an arc. Set tungsten to work GAP of approxi-mately 1/8 inch. Set argon gas flow of 20 CFH.
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35-1195-WCP-6, Noveber 23, 1977 Revision 0, Nov aber 23,1977 PAGE 23
,p..)
9.2 CONTINUED C.
Initiate sequence. After arc is stabilized connect DVM sense lead to Al-J6-10 and return to Al-47-3.
WARNING: 00 NOT connect up OVM before an arc is established. The r.f. arc start used by this system will damage or disable a solid state digital voltmeter.
D.
Observe the voltage on DVM and adjust Al-R90 for 0.020 plus or minus 0.001 VDC. (1MV/ AMP) Record reading.
E.
Momentarily set primary current to 150 amps.
Observe DVM for reading of 0.150 plus or minus 0.001 VOC. Record reading.
F.
Observe weld current meter on service panel.
Adjust Al-R96 for a 150 plus or minus 1 amp reading on meter. Initiate sequence stop.
Section 10 ARC VOLTAGE CONTROL 10.1 SAMPLE AND HOLD OFFSET f
A.
Connect a jumper between A4-J7-3 (R79) and A4-J7-4 (R78).
Connect sense lead of DVM to A4-J8-4. Connect return l
1ead to A4-J6-12. Measure and record voltage.
8.
Connect DVM sense lead to A4-J8-2. Connect return lead f
to A4-J6-12. Adjust A4-R93 for same voltage as recorded in Step A.
10.2 OVERALL OFFSET A.
Connect sense lead of O'.?. to M-J8-6. Connect return lead to A4-J6-12. Set primary and background are voltage switches to 00.0 volts.
8.
Observe the voltage and adjust A4-R95 for a reading of 0.000 plus or minus 0.1 VOC. Record final reading.
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i 35-1195-WCP-6, November 23, 1977 Revision 0, November 23,1977 PAGE 24 D
us 10.3 AVC Gain A.
Remove jumper between A4-47-4 and A4-J7-3. Set up remote programer as in Step 9.2A with the following i
changes:
Set AVC mode to cont.
i Set primary ARC volts to 11.0 volts Set primary current to 050 amps Set response fully CCW B.
Prepare weld head to strike an arc. Set argon gas flow to 20 cfh. Set tungsten to work GAP of 1/8 inch.
C.
Initiate sequence and strike an arc. After arc is stabilized, connect DVM sense lead to A4-J7-3 and return lead to A4-J7-4.
l' WARNING: Do Not connect DVM before striking arc.
i TIIe T f. arc start used in this system will damage or disable a solid state digital voltmeter.
)
D.
Observe voltage and adjust A4 R103 for a reading of 11.0 plus or minus 0.1 volts. Record final reading.
E.
Monitor are voltage meter on service panel and adjust A4-R105 for a reading of 11.0 volts plus or minus 0.5 volts.
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Revision 0, Novenber 23,1977 N
PAGE 25 W
ATTACHMENT 2 ELECTRONIC ALIGl#9ENT (CALIBRATION) RECORD
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CALIBRATION RECORD Section Function Date/ Accept Date/ Accept Date/ Accent Date/ Accept 2.1-8
+24VDC 2.2-8
-24VDC 2.4-C
+15VDC 2.4-0
-15VDC 2.5-C
+32VDC 2.6-C
-32VDC 2.7-C
+12VDC 2.8-C
+ SVDC 3.1-0 Propurge 5 sec.
h 3.1-E Propurge 3 sec 3.1-F Propurge 15 sec 3.2-8 Postpurge 45 sec 3.2-C Postpurge 15 sec 3.2-0 Postpurge 9 sec 3.3-0 Upslope 10 sec 3.4-C Downslope 10 sec 3.5-8 Hi Pulse 1610iz 3.6-C Lo Pulse 9.9 pps 3.6-D Lo Pulse 0.2 pps e.
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CALIBRATIONRECORD(Continued)
Section Function Date/ Accept Date/ Accept Date/ Accept Date/ Accept I
3.6-G Pulse t
l Width 5%
i 4.1-8 Master OSC.10 KHz
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6.1 -0 Fix. Start Delay 10 sec.
6.2-8 Null 6.2-F Offset 6.3-J Speed 2 1pm f
6.3-J Back emf l
2 ips 6.3-J Speed 20 ipm 6.3-J Back amf J
20 ipm 7.1-0 Wire start delay 10 sec.
7.3-8 Wire null 7.3-E Wire offset 7.4-H Speed 99 ips 7.4-H Back emf
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99 1pm 7.4-H Speed 10 ipm 7.4-H Back emf 10 ipm l
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35-1195-WCP-6, November 23,1977 Revision 0, November 23,1977 PAGE 28 1
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CALIBRATION RECORD (Continued)
Section Function Date/ Accept Date/ Accept Date/ Accept Date/ Accept 1-7.4-J Pulsed wire 8.4-8 OSC VC0 0.9 sec 8.4-C OSC VC0 0.1 sac 9.1-8 Minimum Current
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9.2-0 Current gain l
20 amps i
9.2-E Current gain 150 amps 10.1 -A AVC sample
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10.2-8 AVC offset 10.3-0 AVC gain i
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ATTAC}NENT 3 PERFORMANCE VERIFICATION / WELD PARAMETER MONITORING
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_..m 35-1195-WCP-6, November 23, 1977 Revisicn 0, November 23,1977 PAGE 30 PERFORMANCE VERIFICATION / WELD PARAMETER MONITORING The folicwing four functions should be checked every 30 days per 4.2 of this procedure and at a frequency detemined by Reference 6 for production weld monitoring. These four functions are the main itens of interest where quali-I ty welds, made in accordance with a qualified W.P.S., are to be assured.
WARNING: DVM sense leads should not be connected to the test points until the welding arc is established.
The high frequency are start used in this system will damage the meter.
1.
WELD CURRENT 1.1 Weld current may be checked while welding on a scrap workpiece or during production welding. Weld current may be checked while welding in any)of the three modes, (1) continuous current, (2) pulsed arc (PA or (3) sync pulse.
1.2 After the arc is stabilized (upslope is complete) connect the DVM sense leads to the yellow teminal jacks provided on the side of the machine. These two jacks will give a millivolt reading corresponding to the welding current, e.g. 50 mv = 50 amps, 150 av =
150 amps, etc. These two jacks are connected across the internal shunt of the welding machine and correspond to the teminal con-nections Al-J6-10 and Al-J7-3 (See APPENDIX 1, 9.2C or REFERENCE 5, 9.2C).
1.3 While welding in the continuous current mode (no pulsing), the DVM should indicate a millivolt reading that equates to the value set on the primary current thumbwheel of the remote programer pendant.
1.4 While welding in either pulsed arc (PA) or sync pulse (SP) modes the DVM should give two millivolt readings, one corresponding to the value set on the primary current thumbwheel and the other corresponding to the value set on the background current thumbwheel.
Jolerance for perfomance verification of current by this method is 1.5
- 1 av (1mv/ app).
2.,
ARC YOLTAGE 2.1 The are voltage may be checked while welding on a scrap workpiece or during production welding.
I 2.2 All welding procedures for the automatic welding system have been accomplished with the are voltage response in the sampled mode.
With this type of mode, voltage checks with continuous current and pulsed current will yield the corresponding results as
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35-1195-WCP-6, November 23, 1977 Revision 0, November 23,1977 PAGE 31
,a 2.3 After the arc is stabilized (upslope is complete), attach the DVM sease leads to the red and black terminal jacks provided on the v.-
side of the machine. These two jacks will give a voltage reading corresponding to the actual arc voltage, e.g. 9.5v = 9.5 arc volts.
These two jacks are connected internally to terminals A4-J7-3 and A4-J7-4 (See Appendix 1 Section 10 or Reference 5, Section 10).
2.4 While welding with continuous current (no pulsing), the DVM should indicate a voltage reading corresponding to the primary are voltage setting on the thumbwheel of the remote programer pendant.
2.5 While welding in pulsed arc (PA) and the sync pulse (SP) mode the DVM should give two readings. The first reading, indicating the are voltage during primary current pulse, should correspond to the primary arc voltage thumbwheel setting on the remote prcgranner pendant. The second reading will be meaningless due to the fact that the physical arc length is locked during the background current pulse while operating in the sampled mode.
2.6 Tolerance for perfonnance verification of are voltage by this method is t 0.1 volts.
3.
FIXTURE TRAVEL. SPEED
~
3.1 Travel speed may be checked with the welding head attached to either the flat track system or the pipe track system.
In all cases, the travel speed setting on the thumbwheels of the remote programer pendant corresponds to the movement of the head with respect to the surface of the track.
~
3.2 To measure travel speed, set the following switches to the positions /
settings as indicated:
Fixture Delay'- 00 Seconds Upslope - 00 Seconds Fixture Mode Switch - Fonvard Wire Feed Switch - Off Time Mode Switch - Off Test / Operate Switch - Test 3.3 Mark an arbitrary start point on the surface of the workpiece.
Position the tungsten electrode directly over the mark, initiate sequence, and after 60 seconds, mark the position of the electrode.
Measure the distance traveled on the surface of the workpiece.
This distance, divided by the time traveled, gives travel speed at the surface of the workpiece.
3.4 When checking travel speed with the head on the flat track
',1 system, the measured travel speed should correspond to the i
travel speed setting on the thumbwheel of the remote pro-granner pendant.
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35-1195-WCP-6, November 23,1977 Revision 0, November 23,1977 PAGE 32
. ;i 3.5 When checking travel speed with the welding head on the pipe track system, the measured travel speed corresponds to the travel speed on the surface of the pipe and must be modified I,
by the following formula:
SThumbwheel = S easured X CT M
k where Cy = Circumference of Track (stamped on track)
Cp = Circumference of Pipe 3.6 Tolerance for travel speed detennined by this method is
- 10%.
4.
WIRE FEED SPEED 4.1 To measure wire feed speed set the following switches to the position / settings as indicated:
4 Upslope - 00 Seconds Wire Feed Delay - 00 Seconds Downslope - 00 Seconds Low Pulse Mode - Off Time Mode - Off Test / Operate Switch - Test.
4.2 To measure wire feed speed, retract the wire until it is even with the end of the wire feed nozzle, initiate sequence and
- time exactly 60 seconds. Measure the amount of wire fed out and divide by the time. This value should correspond to the l
value set in the primary wire feed speed thumbwheel of the I
remote programer pendant.
4.3 Tolerance for wire feed speed determined by this method is
- 2%.
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35-1195-WCP-6, November 23 1977 Revision 0, Novenber 23,1 77 PAGE 33 r3 ss
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ATTACHMENT 4 PREVENTIVE MAINTENANCE b
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C MAINTENANCE section 1 PREVENTIVE MAINTENANCE 1.1 GENERAL INFORMATION A.
There are two classes of maintenance required on this system, preventive and corrective. This section deals l
with all aspects of preventive maintenance as follows:
l 1.
Cooling system 2.
Cables and connectors 3.
Remote programer j
4.
Power supply console and filter i
5.
Pipe / Tube weld heads 6.
Remote junction box s
The few short minutes it takes to do these steps will save hours of work at a later date.
1.2 COOLING SYSTEM:
A.
As described in the installation section, the torch coolant systes requires a 25% to 50% anti-freeze (1.7 gallons total) solution, to' be mixed with the water o
j coolant. The water does not have to be distilled, but should be filtered before being put in coolant tank.
j The anti-freeze, in addition to preventing freeze up in cold climates, also lubricates the coolant pump j
and prevents rust on water connections, i
8.
Every six months from date of installation, the coolant tank and hoses should be drained and flushed and a new i
fill of coolant added.
i' C.
The water level should be checked at least once a week and added to at once if level is low.
D.
All quick disconnects should be checked for fit and leaks periodically. Replace quick disconnects if their plunger seals fail to close properly. Clean the connects off with a wire brush if corrosion appears.,
i E.
Check the torch water connections IN/0UT at torch body
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for old and brittle hose and cut back and remount l
l clamps when necessary.
l F.
The fifty foot weld head cable requires about 0.6 gallons to fill. If new torches are connected to
_/
the system, be sure to refill tank.
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35-1195-WCP-6, November 23,1977 Revision 0, November 23,1977 PAGE 35 m
i.3 CA8LE AND CONNECTORS A.
Even though the weld head cable is covered with a rugged flex hose shield, the cable cannot be abused. Caution should be taken to protect the cable in any situation where machinery or heavy objects are present. Whenever possible, hang the cable. Avoid laying cable on concrete slabs where traffic or moisture is usually present. Put j
cables in clean dry area when not in use.
8.
9e aware that the cable will melt if layed directly on hot pipe or plate. If wrapping cable on preheated pipe, insulate first with asbestos. Always unwrap cable the same way it was prewrapped.
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C.
All exposed connectors should be protected when not in use. The threads or bayonet locks will be damaged and l
require replacement if not taken care of.
I D.
All connector pins should be cleaned with a soft brush and blown off with dry air, argon, or dry nitrogen whenever they become dirty. Check at least once a week.
E.
Check al.1 strain reliefs on connectors for tightness and effectiveness at least once a week.
i 3
' F.
Exercise extreme care when inserting and removing 1
connectors.
f 1.4 REMOTE PROGRAlt9ER A.
The remote programer is housed in a rugged metal case i
and supplied with a latching cover. When not in use, cover the remote programer to prevent the programing switches and dials from damage. Even though it is housed in a rugged package, do not throw or drop the L
remote programer.
B.
At least once a week the programer switches shculd be i
l air blown clean with hi pressure, clean, Jdr air, argon or dry nitrogen. Do not use any type of cleaning soNent on switches.
If C.
Do not grind in the vicinity of the pendant.
Exercise extreme care when inserting or removing the O.
cable connector.
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35-1195-WCP-6, November 23,1977 Revision 0, November 23, 1977 PAGE 36 1.5. POWER SUPPLY CONSOLE AND FILTER A.
At least once a week, check that the input power cable clamp is tight and that the power cable is not frayed or cracked.
B.
All weather sealed. covers should have all screws in and tightened down at all times except when under repair or calibration.
C.
At least once a month, remove the louvered grill above A15 connect panel and remove and clean air filter.
If in an extranely dusty environment do at least once i
a week.
D.
Use extreme care when inserting or removing connectors.
E.
WARNING: Disconnect 480 VAC line from wall or turn off wall mounted breaker before removing power supply covers. Even with machine circuit breaker off, 480 l
volts is present in the machine.
1.6 PIPE / TUBE WELD HEAD A.
The welding heads should be cleaned off with a soft 3
brush and dry air pressure after each days use..
8.
Store head when not in use in the rugged container that it was shipped in.
C.
REFER TO THE OPERATION SECTION OF MANUAL FOR OTHER GUIDELINES FOR CARE OF WELD HEADS.
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Septd+ r 29. 1952 b - M MEMORENDlM FOR: J. E. Gagitardo FROM : R. G. Ta f 77-3 3 # /
SUBJECT:
Allegation Regarding Irregularities in Comanche Peak Radiographic Operations b
At approximately 0915 this date, the writer was contacted by telephone by a person
,l l
who would identify himself only as Oith scoe interesting allegations regarding 1
site radiography operations.
- a. Changing the film automatic processer speed so as to get the correct film density.
i
' h. "T" holes in pentrameters have been reamed to a larger size to give
-the appearance of adequate film sensitivity.
j
- c. Defective welds havi been ausked out when shooting adjacent thin wall j
I repairs.
- d. Others heated that he could be contacted at Clebume phone numberM !
told W that I would forward the allegation t.o the Region IV office and that either Herr, Driscoll or sayself would get in contact with him in the near future.
6t'ed that he was still employed at the site but was scheduled for termina;io on October 1.1982 which was why he refused to give his last name.
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l n ll Assuming that W currently employed a radiographer (as he stated), I have i
deduced that his name is N hru the use of the personnel roster and
)1 site telephngdirectory.
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I Allegation b. could be a "biggy" and move on as soon as possible. a. and c. could be legal if somewhat irregular.
I 1 will take no action in this matter unless directed to do so.
1
' Noter Please copy this to Madsen/ Westerman
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.m INTEROFFICE MEMO
- , W 25594~,
May 24, 1983 TO:
Document Control Center FROM:
W.E. Baker A
SUBJECT:
Recall of Welding Construction Procedure t
-?8 3
Brown & Root Welding Engineering is recalling WCP-6, Rev.1 as it is no longer needed for production work.
9 g?
5 f)$ b
/
W.E. Baker 3
Sr. Project Welding Engineer i
WEB /pam
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