Lincoln Electric ED026090 Use and Care Manual
Contents
1. TABLE OF CONTENTS SAFETY PRECAUTIONS 3 11 INTRODUCTION 12 PRODUCT ADVANTAGES 13 15 RECOMMENDED EQUIPMENT 15 WELDING PREPARATIONS 0 0 0 16 17 Choose the Proper Innershield Gun 16 Prepare the Work 17 Optimizing Feeding 17 WELDING TECHNIQUES 00 ee 18 24 SELLE CU WD oremi 18 Set the Wire Feed Speed WFS 19 Start THE ANG secectecet teen tste peneeescteesnensbestauestuntes 19 DOL the Voltage ic certs cece fct ene lt te unisi annia 19 Travel SPO iinis nnd eiia aaia 19 Loading 13 14 Lb Coils on a 2 Spindle 20 Handling Poor FR p n2228 remaniement 21 Use the Proper Drag Angle 21 Use the Proper Wire Angle to Joint 21 Making Vertical Up Welds aansssnenesrnnnersnnenernnnns 22 23 Making Downhill and Vertical Down Welds23 Working with NS 3M eeescceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeenaaes 24 OPERATING GUIDE 00000 00 eee 25 29 TroubISSNOOTINd sssssssssssssersssmantsrerenereserenresstn 25 26 Effect of Operating Variables 26 27 Welder Qualification Test 27 Storing Innershield Electrode 28 29 WELDING PROCEDURES 30 39 OPERATING PROCEDURES 40 45 INNERSHIELD GUN PARTS 46 47 LINCOLN WELDING SCHOOL 48 49 The serviceability of a product or structure utilizing this type of inform2. Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user 37 NR 232 5 64 WELDING PROCEDURES FLAT AND HORIZONTAL BUTT WELDS Plate Size T in 3 8 amp up Pass 19 2 amp Up Polarity 5 64 NR 232 DC CTWD 1 1 4 1 1 2 1 Drag Angle 5 30 5 30 Wire Feed Speed 65 70 180 in min Arc Volts 17 17 5 22 23 Travel Speed in min As Req d 5 9 Deposit Rate Ibs hr 2 9 3 2 8 7 With a steel backup start with the second pass procedure and a minimum root opening of 5 16 VERTICAL UP BUTT WELDS OPEN ROOT Plate Size T in 3 8 amp up Pass 1 2 3 amp up Polarity 5 64 NR 232 DC CTWD 1 1 4 1 1 2 Tre re Drag Angle 5 40 0 30 0 30 Wire Feed Speed 60 65 115 130 in min Arc Volts 16 17 19 20 20 21 Travel Speed in min As Req d 3 5 3 5 Deposit Rate lbs hr 2 7 2 9 5 5 6 2 For best slag control start at 1 1 4 then reduce Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user 98 NR 232 5 64 WELDING PROCEDURES VERTICAL UP AND OVERHEAD BUTT WELDS STEEL BA
3. 3 Keep the cable clean per instructions in the wire feeder operating manual 4 Innershield wire has proper surface lubrication on it Use only clean rust free wire 5 Replace the nozzle contact tip when it becomes worn or the end appears fused or deformed 17 WELDING TECHNIQUES SET THE CONTACT TIP TO WORK DISTANCE CTWD WARNING When inching the wire is always electrically hot to ground except on wire feeders with a cold inch feature CTWD is measured from the end of the contact tip to the work Maintain this length within 1 8 8 2mm for CTWD lt 1 25 mm or within 1 4 6 4 mm for CTWD gt 1 25 mm during welding To obtain the proper CTWD when using an insulated guide 1 Remove the insulated guide from the end of the gun tube 2 Inch the wire out beyond the end of the contact tip until you obtain the CTWD specified for each size and type electrode 8 Replace insulated guide 4 The length of wire protruding from the end of the guide is visible stickout Maintaining this visible CTWD with the guide in place gives the correct CTWD while welding For wires using the 112313 Thread Protector the contact tip is exposed This tip should NEVER be allowed to touch the work when the power source output contactor is closed as it is electrically hot Gun Tube Nozzle q bd x bY N SS 2 K ZZA Rey A Insulated Guide N oe
4. 1 1 2 3 4 1 1 4 3 4 1 1 4 Drag Angle 5 30 0 30 0 30 Wire Feed Speed 85 110 220 250 155 170 in min Arc Volts 17 18 20 22 20 21 Travel Speed in min As Req d As Req d As Req d Deposit Rate Ibs hr 3 3 4 5 8 5 9 5 6 0 6 5 Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user 36 NR 232 5 64 WELDING PROCEDURES ALL POSITION FILLET WELDS Plate Size T in 5 16 3 8 1 2 Over 1 2 Leg Size L in 1 4 5 16 3 8 Over 3 8 Pass 1 1 1 As req d Electrode m Polarity 5 64 NR 232 DC CTWD 3 4 3 4 7 8 7 8 Drag Angle 0 0 20 0 20 0 20 Wire Feed Speed 120 130 130 130 in min Arc Volts 19 20 20 21 20 21 20 21 Travel Speed in min 8 6 4 5 As Req d Deposit Rate Ibs hr 5 7 6 2 6 2 6 2 For best slag control start at 1 then reduce FLAT AND HORIZONTAL FILLET WELDS Plate Size T in 5 16 3 8 Over 3 8 Leg Size L in 1 4 5 16 over 5 16 Pass 1 1 As req d Electrode Polarity 5 64 NR 232 DC CTWD 1 1 AP Drag Angle 20 30 20 30 20 30 Wire Feed Speed 175 175 175 in min Arc Volts 21 5 22 5 21 5 22 5 20 5 21 5 Travel Speed in min 14 10 5 As Req d Deposit Rate lbs hr 8 4 8 4 8 4
5. parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover EE plates to protect your eyes from sparks and LT the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 9 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using l
6. Contact Tip wall LL gt D Z _ NN xX COLL CXKKK KMART ROLES TLL Contact Tip to Work Distance Wire CTWD Electrode gt Visible Ee cD 18 WELDING TECHNIQUES SET THE WIRE FEED SPEED Adjust the wire feed speed using the WFS control on the wire feeder Set to the suggested procedures See pages 30 39 The approximate amperage corresponding to each WFS at the specified CTWD is also listed in the table Amperage depends on wire feed speed and CTWD If the CTWD is shortened amperage will increase If a wire feed speed meter is not available it may be measured by running the wire out for 6 seconds then measure the length of wire fed and multiply by 10 to get the WFS in inches per minute in min START THE ARC With the proper visible CTWD set position the gun with the wire lightly touching the work Avoid pushing the wire into the joint before starting the arc Press the gun trigger to start the weld Release the trigger and pull the gun from the work to stop the arc Some welders accustomed to manual welding with stick electrode tend to push the wire into the joint as it burns away Since the wire is mechanically fed this must be avoided SET THE VOLTAGE Adjust the voltage to the suggested procedures as measured by the wire feeder voltmeter or voltmeter placed between the wire feeder contact block and workpiece See pages 30 39 The presence of surface porosi
7. PRODUCT ADVANTAGES INNERSHIELD FEATURES e Can be used in wind speeds of up to 30 mph without losing mechanical properties e Gas bottles are unnecessary e Stiff wire with high column strength BENEFITS OVER GAS SHIELDED PROCESSES e Innershield does not require gas shielding e No external shielding eliminates gas cost e No shielding gas means no cylinder handling changeout and rental saving time and money e No shielding gas means simpler guns and feeders for lower maintenance costs e No shielding gas means no tenting to keep wind away saving labor costs e Innershield Wires are stiff e Stiff wire is excellent for feedability e Stiff wire allows for longer guns to be used saving labor costs moving feeders and welders e Stiff wire allows the welder to break off the wire without clippers BENEFITS OVER STICK WELDING e Innershield is a continuous process e This means less starts and stops saving money and increasing quality e This allows the welder to spend more time welding not changing rods decreasing labor costs e Innershield has higher deposition efficiency e Innershield does not produce stubs like the stick process Stubs are materials you purchase and then throw away _ 13 PRODUCT LIMITATIONS SEISMIC APPLICATIONS Constant voltage CV power sources are recommended for use with all Innershield electrodes NR 211 MP THICKNESS RESTRICTIONS Wire Diameter Max Plate Thi
8. Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting Cont d on page 5 ELECTRIC SHOCK can kill icona kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment e Semiautomatic DC Constant Voltage Wire Welder e DC Manual Stick Welder e AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot
9. in 16 GA 12 GA Pass 1 1 Electrode CTWD 1 1 Wire Feed Speed 40 60 in min Arc Volts 15 16 Travel Speed in min As Req d As Req d Deposit Rate Ibs hr Mee 2 6 Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user 30 NR 232 068 WELDING PROCEDURES VERTICAL UP AND OVERHEAD BUTT WELDS OPEN ROOT Plate Size T in 3 4 and up Pass 1 2 amp up Electrode Polarity 068 NR 232 DC CTWD 1 1 1 2 3 4 1 Drag Angle 5 30 0 30 Wire Feed Speed 110 135 150 170 in min Arc Volts 18 19 19 21 19 21 20 22 Travel Speed in min As Req d As Req d Deposit Rate Ibs hr 3 8 4 7 5 2 6 0 FLAT AND HORIZONTAL FILLET WELDS Plate Size T in 5 16 3 8 3 8 amp Up Leg Size L in 1 4 5 16 over 5 16 Pass 1 1 As req d Electrode Polarity 068 NR 232 DC CTWD 3 4 1 1 4 Drag Angle 20 30 Wire Feed Speed 165 320 165 250 in min Arc Volts 20 22 25 27 20 22 23 24 Travel Speed in min 15 17 As Req d Deposit Rate Ibs hr 5 9 11 3 5 9 8 6 Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the respon
10. applications 42 OPERATING PARAMETERS Wire Polarity AWS Class Wire Feed Arc Approx Deposit CTWD In mm Speed Voltage Current Rate Wire Weight in min m min volts amps Ibs hr kg hr 068 NR 232 DC E71T 8 1 25 75 lbs 1000 072 NR 232 DC E71T 8 1 25 78 lbs 1000 5 64 NR 232 DC E71T 8 1 25 1 00 Ibs 1000 5 64 NR 305 DC E7OT 6 1 3 8 35 1 05 Ibs 1000 3 32 NR 305 DC E70T 6 1 3 4 44 1 39 Ibs 1000 5 64 NR 311 5 0 DC E7OT 7 8 0 1 1 2 88 12 4 1 07 lbs 1000 15 8 3 32 NR 311 5 4 DC E70T 7 10 2 1 3 4 44 11 4 1 62 lbs 1000 22 0 10 0 HAZ OPERATING PARAMETERS Wire Polarity AWS Class Wire Feed Arc Approx Deposit CTWD In mm Speed Voltage Current Rate Wire Weight in min m min volts amps Ibs hr kg hr 7 64 NR 311 DC E7OT 7 1 3 4 44 2 05 lbs 1000 5 64 NR 311 Ni DC E7OT7 K2 1 1 4 82 98 Ibs 1000 3 32 NR 311 Ni DC E7OT7 K2 1 1 2 38 1 39 lbs 1000 7 64 NR 311 Ni DC E7OT7 K2 1 3 4 44 1 89 Ibs 1000 5 64 NS 3M DC E7OT 4 2 1 4 57 1 03 Ibs 1000 3 32 NS 3M DC E7OT 4 3 76 1 53 Ibs 1000 120 NS 3M DC E7OT 4 3 76 2 34 Ibs 1000 120 NS 3M DC E7OT 4 4 102 2 84 Ibs 1000 _44 OPERATING PROCEDURES The suggested ope
11. mating surfaces of backing and test plates Preheat to 300 F for 3 8 10 mm thick welder qualification test Attach backing so that it is tight NO GAP Use the least drag angle to keep the slag back from the arc Aging at 220 F 104 C for 48 hrs is permitted by AWS A5 20 95 paragraph A8 3 A naturally aged specimen may take months to achieve the specified properties Gi ee pP Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user STORING INNERSHIELD ELECTRODES In general Innershield electrodes will produce weld deposits which achieve diffusible hydrogen levels below 16 ml per 100 grams deposited metal These products like other products which produce deposits low in diffusible hydrogen must be protected from exposure to the atmosphere in order to a maintain hydrogen levels as low as possible b prevent porosity during welding c prevent rusting of the product Accordingly the following storage conditions are recommended for Innershield electrodes in their original unopened packages The recommended storage conditions are such that they maintain environmental conditions above the dew point to prevent moisture condensation on product For best results electrode should be consumed as soon as practicable Properly stored electrode may be kept th
12. weave MAKING DOWNHILL AND VERTICAL DOWN WELDS With NR 202 NR 203 types NR 207 NR 208 H NR 211 MP NR 212 Make 1 4 6mm or smaller welds using vertical down techniques The excellent high speed welding characteristics are best utilized for low cost single pass welds by positioning the work downhill or vertical down About a 60 downhill angle with 5 64 or 3 32 2 0 or 2 4mm electrode usually provides maximum speed Use stringer beads and currents in the middle to high portion of the range Tip the electrode up so that arc force helps hold the molten metal in the joint Move as fast as possible consistent with desired bead shape 39 WELDING TECHNIQUES WORKING WITH NS 3M To calculate electrical stickout subtract 1 4 from CTWD 120 3 0mm NS 3M When using the long CTWD of 3 to 4 75 to 100mm the long length of wire beyond the contact tip has greater electrical resistance Because of the greater resistance the wire is heated to a higher temperature so it melts more rapidly in the arc to increase deposition rates and lower weld cost Using a long CTWD reduces penetration and makes starts more difficult The long distance from the contact tip to the work also allows the wire to wander more than if a shorter CTWD is used Linc Fill welding with 4 100mm CTWD is generally limited to 9 16 8mm leg and larger flat fillets multiple pass flat fillets and the fill passes of flat dee
13. 02 DC E71T 7 1 1 4 82 1 09 Ibs 1000 068 NR 203MP DC E71T 8J 1 25 78 lbs 1000 5 64 NR 203MP DC E71T 8J 1 25 1 08 lbs 1000 5 64 NR 203 Ni 1 DC E71T8 Nit 1 25 1 52 llbs 1000 3 32 NR 208 Ni 1 DC E71T8 Nit 1 25 1 52 llbs 1000 2 068 NR 207 DC E71T8 K6 1 25 78 lbs 1000 2 This electrode has been specifically designed for the demanding needs of pipe welding _41 OPERATING PARAMETERS Wire Polarity AWS Class Wire Feed Arc Approx Deposit CTWD In mm Speed Voltage Current Rate Wire Weight in min m min volts amps Ibs hr kg hr 5 64 NR 207 amp NR 207 H 70 2 DC E71T8 K6 90 1 1 8 29 110 1 04 lbs 1000 130 085 NR 211 MP 50 DC E71T 11 70 5 8 16 90 250 Ibs 1000 045 NR 211 MP DC E71T 11 5 8 16 39 Ibs 1000 068 NR 211 MP DC E71T 11 1 25 89 Ibs 1000 5 64 NR 211 MP DC E71T 11 1 25 17 Ibs 1000 3 32 NR 211 MP DC E71T 11 1 1 4 32 66 1bs 1000 045 NR 212 DC E71TG G 5 8 16 39 Ibs 1000 068 NR 212 DC E71TG G 1 25 82 Ibs 1000 5 64 NR 212 DC E71TG G 1 25 1 06 Ibs 1000 2 This electrode has been specially designed for the demanding needs of pipe welding Note These are typical operating procedures and are not intended to serve as specific procedures for any
14. 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS Mar 95 FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasolin
15. B1 120 Electrode Sizes Gun Tube 45 Gun Tube For Gun Inches mm Nozzle Part No Nozzle Part No KP1920 1 K126 amp K309 KP1914 2 K126 amp K309 062 068 072 KP1914 1 K126 5 64 3 32 KP1909 1 K206 KP1921 1 K115 5 64 KP1919 2 KP1919 1 3 32 KP1907 2 KP1910 2 7 64 120 KP1907 1 KP1910 1 3 32 KP1908 2 7 64 120 KP1908 1 3 32 KP1915 4 KP1915 2 7 64 120 KP1915 3 KP1915 1 Electrode Sizes Gun Tube For Gun Inches mm Nozzle Part No K345 10 068 072 90 nozzle KP1920 1 amp 5 64 62 nozzle KP1909 1 K355 10 30 Standard KP1914 2 30 Long KP1914 1 Several standard cable lengths nozzles and wire sizes are available See price book or your local Lincoln distributor for more detailed information _ 47 LINCOLN WELDING SCHOOL NEED WELDING TRAINING The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 men and women have graduated from this premier school Tuition is affordable and class schedules are flexible to meet your needs For more information on the Lincoln Welding School please write to Lincoln Welding School 22801 St Clair Avenue Cleveland Ohio 44117 1199 Ask for bulletin ED122 You may reach us at 216 383 2259 Classes are in Session from 8 00 AM to 2 30PM Basic Plate amp Sheet Metal 5 Weeks Plasma Oxy fuel Allo
16. CKUP Plate Size T in 3 8 amp up Pass 1 2 amp Up Polarity 5 64 NR 232 DC CTWD 1 0 Drag Angle 0 30 0 30 Wire Feed Speed 115 130 in min Arc Volts 19 20 20 21 Travel Speed in min 3 5 3 5 Deposit Rate Ibs hr 5 5 6 2 For best slag control start at 1 1 4 then reduce Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user 30 OPERATING PARAMETERS Wire Polarity AWS Class Wire Feed Arc Approx Deposit CTWD In mm Speed Voltage Current Rate Wire Weight in min m min volts amps Ibs hr kg hr 1 420 NR 1 or NR 5 DC E70T 3 1 3 8 35 2 63 lbs 1000 5 32 NR 1 DC E70T 3 1 1 2 38 4 07 lbs 1000 3 32 NR 5 DC E70T 3 1 1 4 82 1 60 Ibs 1000 3 32 NR 131 DC E7OT 10 1 1 2 88 1 58 Ibs 1000 045 NR 152 DC E71T 14 5 8 16 39 lbs 1000 062 NR 152 DC E71T 14 5 8 16 74 llbs 1000 068 NR 152 DC E71T 14 3 4 19 91 lbs 1000 5 64 NR 152 DC E71T 14 1 25 1 15 Ibs 1000 1 Single pass welding only _ 40 OPERATING PARAMETERS Wire Polarity AWS Class Wire Feed Arc Approx Deposit CTWD In mm Speed Voltage Current Rate Wire Weight in min m min volts amps Ibs hr kg hr 5 64 NR 2
17. ING TECHNIQUES MAKING VERTICAL UP WELDS Use 5 64 2 0mm size and less NR 202 NR 203M NR 203MP NR 203 Nickel 1 NR 211 MP NR 212 NR 232 NR 233 Smaller sizes 5 64 and less are recommended for all position welding When welding out of position don t whip break the arc move out of the puddle or move too fast in any direction Use WFS in the low portion of the range General techniques are illustrated below Experience will show how much hesitation and upward step is required for high quality welds Generally keep the wire nearly perpendicular to the joint as illustrated The maximum angle above perpendicular may be required if porosity becomes a problem Groove Welds 1 Make a distinct hesitation at the outer edges of bevel 2 Minimize each upward step Do not step up at the edges Come straight out from the hesitation point and move up across the weld _29 WELDING TECHNIQUES Vertical Up Fillet and Lap Welds 1 Make larger welds with the following techniques a On 1 4 6mm welds a short side to side motion is usually sufficient b On larger welds use a triangular weave see number 1 in the sketch below with a distinct hesitation at the outer edges for the first pass c Use a side to side weave see number 2 in the sketch below similar to that used for butt welds on the second and later passes The first pass should have a face width of 5 16 3 8 8 10mm before starting this
18. RSHIELD GUNS CHOOSE THE PROPER INNERSHIELD GUN Lincoln Innershield Guns Rated Amperage Duty Cycle and Wire Sizes Innershield Guns K115 1 2 3 4 5 Guns with 82 Nozzle 450 Amps at 60 Duty Cycle Wire Size 068 120 1 7 3 0mm K115 8 10 Guns with 45 Nozzle 450 Amps at 60 Duty Cycle Wire Size 068 120 1 7 3 0mm i i K116 2 Gun 600 Amps at 60 Duty Cycle Wire Size 120 7 64 3 0 2 8mm K126 1 2 Gun with 62 Nozzle 350 Amps at 60 Duty Cycle Wire Size 062 3 32 1 6 2 4mm K361 10 Gun 350 Amps at 60 Duty Cycle Wire Size 068 5 64 1 7 2 0mm Fume Extraction Gun TR K289 1 4 500 Amps at 60 Duty Cycle Wire Size 120 7 64 3 0 5 6mm Fume Extraction Guns K206 Gun 350 Amps at 60 Duty Cycle Wire Size 062 3 32 1 6 2 4mm TR K309 Gun 250 Amps at 60 Duty Cycle Wire Size 062 3 32 1 6 2 4mm LN 23P Guns K264 8 Gun with 30 Long Tube for LN 23P 250 Amps at 60 Duty Cycle Wire Size 068 5 64 1 7 2 0mm K345 10 Gun with 90 Standard Tube for LN 23P 350 Amps at 60 Duty Cycle Wire Size 068 5 64 1 7 2 0mm K355 10 Gun with 90 Tube for LN 23P 250 Amps at 60 Duty Cycle Wire Size 068 5 64 1 7 2 0mm For proper CTWD use the appropriate insulated guide For specific information on wire size and cable length please see your local Lincoln representative WELDING PREPARATIONS PREPARE THE WORK Clean the join
19. Wire Feed Speed WFS or welding current If arc voltage travel speed and CTWD are held constant WFS variations have the following major effects 1 Increasing the WFS increases melt off and deposition rates 2 Excessive WFS produces convex beads This wastes weld metal and results in poor appearance 05 OPERATING GUIDE 8 Increasing WFS also increases the maximum voltage which can be used without porosity Lowering the WFS requires lowering the voltage to avoid porosity As the WFS is increased the arc voltage must also be increased to maintain proper bead shape Travel Speed If arc voltage WFS and CTWD are held constant travel speed variations have the following major effects 1 Too high a travel speed increases the convexity of the bead and causes uneven edges 2 Too slow a travel speed results in slag interference slag inclusions and a rough uneven bead Contact Tip to Work Distance CTWD If the voltage and wire feed speed setting and the travel speed are held constant variations in CTWD have the following major effects 1 Increasing CTWD reduces the welding current Decreasing CTWD increases current 2 Increasing CTWD reduces actual arc voltage and results in more convex beads and reduces the tendency of porosity 8 Momentarily increasing CTWD can be used to reduce burn through tendency when poor fitup is encountered WELDER QUALIFICATION TEST 1 Remove mill scale and other contaminants from
20. amping collar To prevent the wire from dereeling keep the reel from turning and tighten the clamping collar securely 6 See wire feeder operating manual for instructions on loading the wire into the drive roll and guide tubes _20 WELDING TECHNIQUES HANDLING POOR FITUP Innershield bridges gaps better than most welding processes When using NS 3M at 3 76mm CTWD temporarily increasing the visible CTWD to as much as 3 1 4 83mm helps reduce penetration and burnthrough to bridge gaps Poor fitup may require a small temporary increase in visible CTWD or a reduction in WES setting USE A DRAG TECHNIQUE Tilt the gun back away from the weld puddle in the direction of travel about the same as required in stick electrode welding If slag tends to run ahead of the arc increase the drag angle However if the drag angle becomes too great erratic arc action and excessive arc blow will result in porosity and poor bead shape DRAG ANGLE TRAVEL USE THE PROPER WIRE ANGLE TO JOINT Horizontal Fillets For 1 4 6mm and smaller fillets point the wire at the joint The wire angle to the joint should be about 40 For best bead shape on 5 16 8mm and large horizontal fillets point the wire at the bottom plate close to the corner of the joint The angle between the wire and the bottom plate should be less than 45 Using this position the molten metal washes onto the vertical plate _21 WELD
21. ation is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio
22. ckness 035 045 0 9 1 2mm 5 16 7 9mm 068 5 64 3 32 1 2 12 7mm 1 7 2 0 2 4mm NR 212 is designed to be used on plate up to 3 4 19 1mm thick SINGLE PASS LIMITATIONS Certain FCAW S electrodes are limited to single pass applications These include but are not limited to NR 1 NR 5 NR 131 and NR 152 APPLICATION INFORMATION SEISMIC STRUCTURAL WELDING APPLICATIONS The electrodes below have been tested in accordance with FEMA 858 Recommended Specifications and Quality Assurance Guidelines for Steel Moment Frame Construction for Seismic Applications FEMA 353 test certificates are available upon request These certificates contain mechanical test results at low and high heat input levels and diffusible hydrogen classifications The electrodes indicated with a also have electrode exposure time on the certificate Electrode Diameters NR 203 MP 068 5 64 NR 203 Nickel 1 5 64 3 32 NR 232 068 072 5 64 NR 305 3 32 NR 311Ni 5 64 3 32 7 64 ELECTRODE EXPOSURE FEMA 358 and other specifications which limit electrode exposure may require monitoring electrode exposure time and or conditions after removal from a sealed package 14 PRODUCT LIMITATIONS INTERMIXING When Innershield FCAW S weld deposits are intermixed with weld deposits from other welding processes a decrease in weld metal Charpy V notch CVN toughness properties may occur For applicat
23. des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles 7 Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu a ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret v
24. ding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located e Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame CYLINDER may explode if damaged Cont d 7 d 7 e 7A Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Je
25. e engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 39 ELECTRIC AND MAGNETIC FIELDS SR may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known 2 d All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing
26. ed arc welding is generally considered to be a low hydrogen welding process Further these specifications make available optional supplemental designators for maximum diffusible hydrogen levels of 4 8 and 16 ml per 100 grams of deposited weld metal Some Innershield products have been designed and manufactured to produce weld deposits meeting these more stringent diffusible hydrogen requirements These electrodes are usually distinguished by an H added to the product name These electrodes will remain relatively dry under recommended storage conditions in their original unopened package or container For applications in which the weld metal hydrogen must be controlled usually H8 or lower or where shipping and storage conditions are not controlled or known only hermetically sealed packaging is recommended Many Innershield electrodes are available in hermetically sealed packages Once the package has been opened the electrode should be used as soon as practicable 20 NR 211 MP WELDING PROCEDURES HORIZONTAL FLAT DOWNHILL AND VERTICAL DOWN Plate Size T in 14 GA 10 GA Pass 1 1 oie CTWD 1 1 Wire Feed Speed 50 75 in min Arc Volts 16 18 Travel Speed in min As Req d As Req d Deposit Rate Ibs hr 2 9 4 5 1 Use 1 volt lower for Vertical Down and Overhead HORIZONTAL FLAT DOWNHILL VERTICAL DOWN AND OVERHEAD Plate Size T
27. el speed Increase WFS 5 Decrease drag angle Decrease voltage 25 OPERATING GUIDE To Minimize Arc Blow In order of importance Arc blow occurs when thr arc stream does not folow the shortest path between the electrode and the workpiece 1 Move work connection locations Decrease drag angle Increase CTWD Decrease WFS and voltage Decrease travel speed aR amp D To Eliminate Stubbing In order of importance Stubbing occurs when the wire drives through the molten puddle and hits the bottom plate tending to push the gun up 1 Increase voltage 2 Decrease WFS 3 Decrease CTWD 4 Decrease drag angle Equipment Troubleshooting Instructions are included in the operating manuals for the wire feeder and power source Be sure to confirm the equipment is operating properly EFFECT OF OPERATING VARIABLES The four major operating variables arc voltage wire feed speed WFS travel speed and CTWD are interdependent If one is changed usually the other three must also be adjusted Arc Voltage If WES travel speed and CTWD are held constant changing the arc voltage will have the following effects Higher arc voltage results in a wider and flatter bead Excessive arc voltage causes porosity Low voltage causes a convex ropey bead Extremely low voltage will cause the wire to stub on the plate That is the wire will dive through the molten metal and strike the joint bottom tending to push the gun up PO Nes
28. fferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de sdret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnemen
29. for steel fabrication in many markets Innershield is the primary means for structural steel building erection in the United States In any shop or shipyard where wind is a problem Innershield can be a viable solution Pipeline fabrication is often done with Innershield because it is done outdoors and shielding gas is sometimes difficult to get to these ocations Lincoln Electric the originator of the Innershield process makes Innershield wire in a proprietary manner The manufacturing processes that Lincoln Electric uses has specific benefits that you can see in every pound of wire you use The Innershield wires Lincoln Electric produces are very stiff and have excellent column strength This allows for excellent feedability Lincoln Electric also fills the wire in a proprietary manner This step ensures that you get the right amount of fill in every inch of wire Lincoln Electric is the worldwide leader in Innershield You can see that when you use our products meet with our sales reps or call the factory for support Current carrying contact tip YJ lt Insulated Guide Wire core consists of powdered metal vapor or gas forming materials deoxidizers and scavengers Molten slag Solidified slag Arc shield composed of vaporized and slag forming compounds protects metal transferring through arc Metal droplets covered with a thin slag coating forming molten puddle Molten weld metal a4
30. ilder user 4x NR 232 072 WELDING PROCEDURES VERTICAL UP AND OVERHEAD BUTT WELDS STEEL BACKUP Plate Size T in 3 8 amp up Pass 1 2 amp Up cap Electrode Z Polarity 072 NR 232 DC CTWD 3 4 3 4 3 4 Drag Angle 0 5 20 5 20 Wire Feed Speed 155 155 155 in min Arc Volts 22 22 20 Travel Speed in min As Req d As Req d As Req d Deposit Rate Ibs hr 6 0 6 0 6 0 FLAT AND HORIZONTAL FILLET WELDS Plate Size T in 5 16 3 8 3 8 amp up Leg Size L in 1 4 5 16 over 5 16 Pass 1 1 As req d Electrode nu 3 PAR 072 NR 232 DC CTWD 3 4 1 1 4 3 4 1 1 4 3 4 1 1 4 Drag Angle 20 30 20 30 20 30 Wire Feed Speed 290 290 250 in min Arc Volts 23 24 23 24 21 22 Travel Speed in min 16 11 5 As Req d Deposit Rate Ibs hr 11 11 9 5 For maximum penetration point the electrode into the corner or slightly into the butting corner Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user 35 NR 232 072 WELDING PROCEDURES FLAT AND HORIZONTAL BUTT WELDS Plate Size T in 3 4 amp up Pass 1 2 cap Cap Passes Horizontal Electrode Polarity 072 NR 232 DC CTWD 1 1 4
31. insulated guides NOT SHOWN order specific length needed by part number Insulated Guide for K126 KP2090 1 for 2 3 4 70 mm CTWD Length 2 3 4 70 mm Contact Tip KP2100 xx Electrode Part No 062 1 6 068 072 1 7 1 8 5 64 2 0 KP2100 4B1 5 64 3 32 2 4 KP2100 3B1 3 32 Size stenciled on each tip Contact Tip Sizes mm KP2100 2B1 1 16 KP2100 1B1 072 Thread Protector KP2089 1 Thread Protector for 3 4 to 1 1 2 19 to 38 mm CTWD Note When using the KP2089 1 Thread Protector on a K126 or K309 gun with 062 through 3 32 1 6 through 2 4 mm electrode visible CTWD and CTWD are identical _ 46 INNERSHIELD GUN PARTS Full Size Drawings of Parts for K115 K116 and K289 Guns Insulated Guide for K115 amp K116 Insulated Guide for K115 amp K116 3 32 amp 120 NS 3M KP1965 1 for 2 3 4 70 mm CTWD Shown KP1971 1 for 1 1 2 88 mm CTWD KP1954 2 for 3 3 4 95 mm pation Extension Guide for Sane K289 KP1994 1 5 64 2 0 mm for 3 4 19 mm CTWD 84 mm All sizes of insulated guides Electrode Contact Tip NOT SHOWN order specific Sizes mm Part No length needed by part number 1 16 7 KP2103 2B1 1 16 KP2103 1B1 072 Contact Tip KP2103 xx 5 64 i KP2103 5B1 5 64 Size stenciled on each tip 3 32 KP2103 4B1 3 32 7 64 f KP2103 6B1 7 64 120 KP2103 3
32. ions requiring CVN properties intermix testing with the specific electrodes is recommended to ensure the intermixed weld metal meets the required CVN requirements TACK WELDING The following electrodes are recommended for tack welding prior to Innershield welding e All Innershield FCAW S wires e SMAW Fleetweld 35LS Jetweld LH70 Jetweld 2 Excalibur 7018 e GMAW solid electrodes AGING The AWS filler metal specification for these products A5 20 amp A5 29 permit aging of test specimens When conducting welding procedure or operator qualification tests it is recommended that aging be applied whenever permitted by the appropriate code For example when qualifying procedures to AWS D1 1 Structural Welding Code see Paragraph 5 10 4 Preheat and interpass temperature control are recommended for optimum mechanical properties crack resistance and hardness control This is particularly important on multiple pass welds and heavier plate Job conditions prevailing codes high restraint alloy level and other considerations may also require preheat and interpass temperature control ARC GOUGING When Arc Gouging Innershield welds black smudges or spots may appear on the surface of the groove The condition is aggravated when the carbon is allowed to touch the surface This black residue does not indicate the presence of porosity or poor weld quality It can be easily removed by wire brushing or light grinding _15 INNE
33. ocal exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b 7 WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situati
34. oir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PRECAUTIONS DE SURETE POUR LES MACHINES A SOUDER A TRANSFORMATEUR ET A REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece a souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 8 Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place 1 INTRODUCTION INNERSHIELD Innershield is an arc welding process that uses a continuously fed wire to supply filler metal to the arc The wire is not solid but is tubular Agents necessary to shield the arc from the surrounding atmosphere are placed inside the tube No additional shielding is required Innershield was originally used as a replacement for stick welding Innershield can provide higher productivity and enhance quality when compared to stick welding It offers increased arc on time due to the continuous nature of the process There are also fewer starts and stops which are frequent sources for defects Although the Innershield process has been displaced in many areas by gas shielded processes Innershield continues to be an important process
35. om random samples of representative material Your results may vary within AWS specification limits depending on a variety of conditions CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equipment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such information or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results ob
36. ons Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used WELDING SPARKS can cause fire or explosion Cont d 6 c When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the wel
37. p groove butt joints When changing the insulated guide tips to increase CTWD from 3 to 4 75 to 100mm the meter voltage reading must be increased by 2 or 3 volts to maintain a good flat bead The current or WFS control setting must also be adjusted to increase the wire feed speed to obtain the same welding current For welding with 4 100mm CTWD follow the basic instructions under Start The Arc on page 19 Start with 3 4 19mm visible CTWD When the arc is established increase the CTWD to the normal 1 5 8 41mm visible CTWD using the proper insulated guide See the tables on pages 30 39 for the proper CTWD for each size wire OPERATING GUIDE Well made Innershield welds have excellent appearance TROUBLESHOOTING To Eliminate Porosity In order of importance 1 oar WN Clean the joint from moisture rust oil paint and other contaminants Decrease voltage Increase CTWD Increase WFS Decrease drag angle Decrease travel speed te To Eliminate a Ropey Convex Bead In order of importance 1 2 3 4 5 Increase voltage within wire specifications Decrease CTWD Decrease WFS Decrease travel speed Decrease drag angle To Reduce Spatter In order of importance 1 2 3 4 5 Adjust voltage Decrease drag angle Decrease CTWD Increase WFS Decrease travel speed To Correct Poor Penetration In order of importance fle 2 3 Decrease CTWD 4 Decrease trav
38. rating parameters listed in this publication are not intended to serve as specific procedures for any application These suggested procedures represent the approximates the procedure range of each individual electrode Arc voltage and or wire feed speed may need to be adjusted depending upon welding position type of weld base steel surface condition or other factors In general use the highest voltage possible consistent with porosity free welds CTWD is measured from the work surface to the contact tip Maintain this length within 1 8 3 2mm for CTWD 1 25 mm or within 1 4 6 4 mm for CTWD gt 1 25 mm during welding Contact your Authorized Lincoln Distributor or your local Lincoln Representative for specific procedures and techniques For more information on a particular Innershield wire consult the C3 200 45 INNERSHIELD GUN PARTS Full Size Drawings of Parts for K126 and K206 Guns Insulated Guide for K126 KP1995 1 for 2 51 mm CTWD Length 1 7 8 48 mm Insulated Guide for K206 KP2099 3 for 2 3 4 70 mm CTWD Length 2 1 2 64 mm KP2099 4 for 2 61 mm CTWD Length 2 1 8 64 mm KP2099 2 for 1 1 2 88 mm CTWD Length 1 5 8 42 mm KP2099 1 for 3 4 1 19 25 mm CTWD Length 1 25 mm V7 Nose Cone Assembly for K126 K264 K345 K355 K361 KP1987 1 Length 1 3 8 35 mm Il sizes of
39. ree years or more from the date of manufacture Consult your Lincoln distributor or sales representative if there is a question as to when the electrode was made Once the electrode packaging is opened Innershield electrodes can be contaminated by atmospheric moisture Care has been taken in the design of these products to ensure that they are resistant to moisture pick up however condensation of moisture from the atmosphere onto the surface of the electrode can be sufficient to degrade the product The following minimum precautions should be taken to safeguard the product after opening the original package Electrode should be used within approximately 1 week after opening the original package Opened electrodes should not be exposed to damp moisture conditions or extremes in temperature and or humidity where surface condensation can occur Electrodes mounted on wire feeders should be protected against condensation It is recommended that electrode removed from its original packaging be placed in poly bags 4 mil minimum thickness when not in use Innershield electrodes will evidence high moisture levels in the form of gas tracks higher spatter and porosity Any rusty electrode should be discarded 98 STORING INNERSHIELD ELECTRODES Innershield Products Used for Applications Requiring More Restrictive Hydrogen Control H Electrodes The AWS specifications for flux cored electrodes AWS A5 20 and A6 29 state that Flux cor
40. sibility of the builder user o NR 232 068 WELDING PROCEDURES ALL POSITION FILLET WELDS Plate Size T in 5 16 3 8 3 8 amp Up Leg Size L in 1 4 5 16 over 5 16 Pass 1 1 As req d Electrode ii Polarity 068 NR 232 DC CTWD 3 4 1 Drag Angle 0 30 Wire Feed Speed 130 165 in min Arc Volts 19 21 21 23 Travel Speed in min 6 5 9 5 5 7 As Req d Deposit Rate lbs hr 4 5 5 9 VERTICAL UP AND OVERHEAD BUTT STEEL BACKUP Plate Size T in 3 8 amp up Pass 1 2 amp Up Electrode 7 Polarity 068 NR 232 DC CTWD 3 4 1 1 4 Drag Angle 5 20 Wire Feed Speed 155 165 in min Arc Volts 21 22 Travel Speed in min 4 3 5 6 As Req d Deposit Rate Ibs hr 5 5 5 9 Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user 32 NR 232 068 WELDING PROCEDURES FLAT AND HORIZONTAL BUTT WELDS Plate Size T in 3 4 amp up Pass 1 2 amp up Cap Passes Horizontal Electrode Polarity 068 NR 232 DC CTWD 1 1 1 2 3 4 1 1 4 Drag Angle 5 30 0 30 Wire Feed Speed 110 135 250 275 180 195 in min Arc Volts 18 20 19 21 20 22 23 25 20 21 23 24 Travel Speed in min 4 3 5 6 As Req d As Req d Depo
41. sit Rate Ibs hr 3 8 4 6 8 6 9 5 6 2 6 8 Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the builder user 32 NR 232 072 WELDING PROCEDURES ALL POSITION FILLET WELDS Plate Size T in 5 16 3 8 1 2 amp up Leg Size L in 1 4 5 16 3 8 amp up Pass 1 1 As req d Electrode m Polarity 072 NR 232 DC CTWD 3 4 1 3 4 1 3 4 1 Drag Angle 0 0 30 0 30 Wire Feed Speed 155 170 155 170 155 170 in min Arc Volts 20 23 20 23 20 23 Travel Speed in min 9 5 6 5 As Req d Deposit Rate Ibs hr 6 0 6 5 6 0 6 5 6 0 6 5 VERTICAL UP AND OVERHEAD BUTT WELDS OPEN ROOT Plate Size T in 3 4 amp up Pass 1 2 amp up cap Electrode T Polarity 072 NR 232 DC CTWD 1 1 1 2 3 4 1 3 4 1 Drag Angle 5 30 0 30 0 30 Wire Feed Speed 85 110 155 155 in min Arc Volts 17 18 22 20 Travel Speed in min As Req d As Req d As Req d Deposit Rate Ibs hr 3 3 4 3 6 0 6 0 At a travel speed of 10 in min a slight push angle is preferred Because design fabrication erection and welding variables affect the results obtained in applying this type of information the serviceability of a product or structure is the responsibility of the bu
42. t Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes Toujours porter
43. t by removing excessive scale rust moisture paint oil and grease from the surface As with all welding applications joint cleanliness is necessary to avoid porosity and to attain the travel speeds indicated in the procedures Tack weld with Innershield wire or Fleetweld 35LS Jetweld LH 70 or Jetweld 2 manual stick electrodes If other electrodes are used Innershield slag removal may be difficult in the area of the tacks The work connection can be placed either at the beginning or at the end of the weld depending upon the application If necessary try different locations until the best weld quality is obtained Clamp the work cable to the work so there is a positive and clean metal to metal contact point Poor work connections raise system voltage losses and can result in convex or ropey beads typical of low voltage even if the machine meters indicate proper voltage Never use undersize or badly worn work cables Choose the cable size per the following table Current Amps Total Work and Electrode Cable Length 60 Duty Cycle 9 50 ft 0 15m 50 100 ft 15 30m mm equivalent according to IEC International Electrical Code OPTIMIZING FEEDING Most feeding problems are caused by improper handling of the gun cable or wire 1 Do not kink or pull the cable around sharp corners Keep the gun cable as straight as possible when welding 2 Do not allow two wheelers fork lift trucks etc to run over the cables
44. tained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information LINCOLN ELECTRIC THE WELDING EXPERTS THE LINCOLN ELECTRIC COMPANY 22801 St Clair Avenue Cleveland OH 44117 1199 e U S A Phone 1 216 481 8100 www lincolnelectric com Publication C3 2400 Issue Date 02 11 Lincoln Global Inc All Rights Reserved
45. ty indicates that the arc voltage is too high and should be lowered An excessively convex or ropey bead indicates that the voltage is too low Increase the voltage setting to reduce the convexity or ropey appearance of the bead Also check for poor work cable connections undersized or damaged work cables and poor cable clamps TRAVEL SPEED As in all welding processes use a travel speed which keeps the arc at the front edge of the weld puddle and produces the desired weld size Maintain a uniform travel speed The best way to do this is to maintain a uniform distance between the wire and the molten slag behind the wire Travel speed is usually faster with Innershield wire than with stick electrodes because of the higher deposit rate Many welders tend to move too slowly when they first weld with Innershield wire 19 WELDING TECHNIQUES LOADING 13 14 LB 5 9 6 5 kg COILS ON A 2 50mm SPINDLE 1 Remove the locking collar and the cover plate from K435 spindle adapter 8 Unpack the 14 lb 6 4kg coil of wire Be sure not to bend the side tabs of the coil liner Straighten any tabs that may have been bent 4 Remove the start end of the coil cut off the bent end straighten the first six inches Be sure the cut end of the wire is round and burr free before the new coil into the drive rolls Thread it through the feeding wire feed liner until about four inches of wire is exposed 5 Replace the front reel cover and center cl
46. y amp Hardfacing 3 Weeks Pipe select ASME or API 3 Weeks Price covers machine beveled pipe nipples used each week Prerequisite Passing Basic Plate amp Sheet Metal 5th Week Test Gas Tungsten Arc Welding GTAW TIG 1 Week Price covers special alloy aluminum gas etc used each day Gas Shielded Arc Welding GMAW MIG Semi Automatic 1 Week Flux Cored Arc Welding FCAW Semi Automatic Self Shielded Gas Shielded 1 Week e Submerged Arc Welding SAW Semi Automatic Full Automatic 1 Week e Comprehensive Arc Welder Course 15 Weeks Includes All Above Courses _48 Low Hydrogen Pipe Module GMAW FCAW SMAW 1 Week GTAW SMAW 1 Week Qualification Test Training AWS Test Semi Automatic Flux Cored Arc Welding Self Shielded FCAW 1 Week 3 8 AWS Fillet Test Shielded Metal Arc Welding SMAW Stick 1 Week AWS Test Shielded Metal Arc Welding SMAW Stick 1 Week ASME Test Shielded Metal Arc Welding SMAW Stick 1 Week ASME or API Pipe Welding Test Training 1 Week Low Hydrogen Pipe Welding Test Training 1 Week Certified Welding Inspector Course 1 Week Actual Testing done in customer s plant or Independent Testing Laboratory 49 50 NOTES 51 TEST RESULTS Test Results for Mechanical Properties Deposit or Electrode Composition and Diffusable Hydrogen levels were obtained at a single point in time under laboratory conditions fr
Download Pdf Manuals
Related Search