FMI PTW72 User Manual

Franklin Manufacturing Inc.

* Job# F3138 *

Model# PTW72 Horizontal

Welding Machine For 72" Wide Webs

Serial# 2724-A819600

PO Drawer 998 / Russellville, AL. 35653 / [phone]

DETAILED WARRANTY

Franklin Manufacturing, Inc. warrants the machine tools and systems manufactured and shipped by Franklin to

be free from defects in material and workmanship for twelve (12) months from shipment date from Seller’s
factory or 2000 operating hours which ever comes first provided: (a) they are used only by the original Buyer,
(b) they are given normal and proper usage, care and maintenance as specified by Seller, (c) all electrical and
mechanical connections are made in accordance with Seller’s specifications, and (d) proper installation and
start up procedures are employed by qualified personnel (in the case of CNC units, only Franklin
Manufacturing Inc. trained personnel will be considered qualified).

Consumable items, such as light bulbs, fuses, switches, plasma torch consumables, shear blades, hard tooling,

and filters, etc. are not warranted.

This warranty does not cover (by way of example): (a) any component damaged by improper Buyer-supplied

voltages, improper electrical connections to the machine, or improper electrical grounding techniques, (b) any
component damaged by arc welding on or near the machine, or (c) the routine replacement of consumable
mechanical and electrical components and the adjustments necessary for optimum machine performance,
which are the responsibility of the Buyer.

Notice of any warranty claim must be presented to Seller immediately upon Buyer’s discovery of the defect and

right of inspection must be given to Seller while the product is in the claimed defective condition, and
operation of the product must be suspended until written clearance is issued for continued operation. During
this time the seller will not be responsible for “Down Time”. For a warranty claim notify the Seller’s
customer service office [phone].

Upon receipt of a warranty claim notice, Seller will proceed without unreasonably delay to remedy any defect

found to exist under the terms of warranty. During the warranty period, parts found to be defective after
Seller’s inspection, will at Seller’s option be repaired, or replaced with new or factory rebuilt parts free of
charge, except that freight charges, Custom charges, or other associated fees involved with returning the
defective component to Seller, and the shipment of the replacement component, will be the responsibility of
the Buyer.

During the twelve (12) months or 2000 operating hours warranty period if Seller’s service technicians are

required to perform any function at the Buyer’s facility, there will be no charge for labor. However, Buyer
will compensate Seller for the cost of travel (time and expenses) and living expenses.

VENDOR SUPPLIED GOODS: Vendor supplied items shall be warranted in accordance with the available

Warranty, if any, provided to Franklin Manufacturing Inc., by the vendor. Claims relating to vendor supplied
items will be dealt with on a case-by-case basis.

THERE ARE NO WARRANTIES, WHICH EXTEND BEYOND THE DESCRIPTION AND THE

WARRANTIES CONTAINED HEREIN. THE WARRANTIES EXPRESSED HEREIN ARE IN LIEU OF
ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED. ANY IMPLIED WARRANTY OF
MERCHANTABILITY AND IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE
ARE HEREBY EXCLUDED. BUYER’S REMEDY IS LIMITED TO, AND SELLER’S MAXIMUM
LIABILITY SHALL NOT EXCEED, EITHER (1) REPAIR OR REPLACEMENT OF THE DEFECTIVE
PART OF PRODUCT OR, AT SELLER’S OPTION, (2) RETURN OF THE PRODUCT AND REFUND OF
THE PURCHASE PRICE SUCH REMEDY SHALL BE BUYER’S ENTIRE AND ONLY REMEDY.

WARRANTY START DATE:

MACHINE HOURS:__________ MACHINE SERIAL NUMBER

At installation ACCEPTED BY BUYER:_______

2724

CONTENTS

Introduction:

Operation & Maintenance Manual
Terms & Conditions of Sale
FMI Equipment Sheet

Section #1: Operation & Maintenance

Section #2: Assembly & Parts List

Section #3: Electrical Information

Section #4: Hydraulic Power Unit Information

Section #5: Pneumatic Information

Warning: cThe hydraulic power unit must be locked off before performing any

maintenance or tool change. d Keep hands clear from any moving object on the
machine. e Safety glasses are recommend for operators or anyone near the machine
during operation.

 Operating and Maintenance Manual

This manual contains essential information regarding recommended operational and

maintenance procedures. It should be thoroughly read by persons operating and
maintaining this equipment.

WARNING NOTE: In accordance with OSHA standards we recommend the use of

eye protection equipment during the operation of this machine. The hydraulic power
unit should be locked in the OFF position during any maintenance or tool change.

Seller shall not be liable to buyer or any other person for any damage, injury, or loss

arising out of the use of the goods whether by reason of any defect in the goods or
otherwise if, prior to such damage, injury or loss, such goods are: c Damaged or
misused following shipment; or d Repaired, altered, or modified without sellers
written consent; or e Not installed, maintained and operated is strict compliance
with the instructions furnished by seller.

Indemnification - Safe Operation: Buyer shall comply with and require its employees

to comply with directions set forth in manuals, drawings, or instruction sheets
furnished by seller. Buyer shall use and require its employees to use reasonable care
and all safety equipment in the operation and maintenance of the goods. Buyer shall
not remove or permit anyone to remove any safety equipment or warning signs
unless suitable alternate safeguarding equipment is provided by the buyer. Buyer
shall operate goods in compliance with existing applicable laws and/or regulations.
In the event of bodily injury or damage followed by prompt written confirmation,
buyer shall cooperate with seller in investigating any such injury or damage and in
the defense of any claims arising therefrom.

If buyer fails to observe any obligation in this section, or if any injury or damage is

caused, in whole or in part, by buyer's failure to comply with applicable federal,
state, or local safety requirements, seller shall have no obligation to buyer and buyer
shall indemnify and hold seller harmless against any claims, loss, or expense for
injury or damage arising from the use of the goods.

(a) F.O.B. Point of origin.

1. Prices:

Conditions of Sale

(b) Subject to change without notice at any time prior to acceptance of purchaser’s order by seller’s home office, as evidenced by seller’s formal

acknowledgment.
(c) Firm upon seller’s acceptance of purchaser’s order as evidenced by seller’s formal acknowledgment unless escalation terms are included in terms of sale.
(d) Prices do not include sales, use, excise, or similar taxes. Consequently, in addition to the prices specified, the amount of any prese nt or future sales, use,

excise or other similar tax applicable to the sale or use of the equipment shall be the responsibility of a nd paid by the purchaser; or in lieu thereof, the

purchaser shall provide the seller with a tax-exemption certificate acceptable to the taxing authorities.

2. Shipping Schedule:

(a) Computed from the date of acknowledgment of the order or, in the case of special items, from the date seller receives complete information necessary to

proceed with design and manufacture.
(b) The shipping date specified is:

1. Subject to prior sale before seller’s receipt of order.

2. Subject to any mandatory changes that may be caused by procedures or priorities which may be set up by the U.S. Government or any of its
agencies.

3. Seller shall have no liability for loss or damage resulting from a delay in scheduled delivery caused by wa r, riots, strikes, labor disputes, fires,
serious accidents, delays in receipt of parts or materials for suppliers or subcontractors, design or engineering problems relating to purchaser’s
order, natural disasters, delay in shipping items needed by seller to test or complete purchaser’s order, or any other circumstances beyond seller’s
control. Franklin Manufacturing Inc. will honor your position in our production, and do our very best to deliver at the earliest date after thorough
inspection.

4. Under no circumstances shall seller have any liability whatsoever for loss of use or for any direct, indirect or consequential damages due to delay in
scheduled delivery.

3. Electrical Equipment:

(a) Supplied by seller and will be the make mutua lly agreed.
(b) When not supplied by seller, is to be purchased in accordance with seller’s detailed specifications, and will be subject to an installation charge for

mounting and wiring at seller’s factory.

(c) Wiring and protecting conduit from purchaser’s power supply to the machine control is not included in seller’s quotation.

4. Warranty:

(a) Any product or part thereof covered by selle r’s quotation which, under normal operating conditions in the plant of the original purchaser thereof, proves

defective in material or workmanship within one (1) year from the date of shipment from seller’s plant, (as determ ined by an inspection by seller) will
be replaced free of charge, F.O.B. factory, provided that purchaser promptly sends to seller notice of the defect and establishes that the product has been
properly installed, maintained and operated within the limits of rated and normal usage. Electrical equipment not manufac tured by Franklin
Manufacturing Inc. is not included in this warranty, those motors, controls, plus hydraulic items being covered by the warranty of the respective
manufacturer.

(b) Said warranty in respect of replacement of defective parts and any such additional w arranty or representation expressly made a part of seller’s quotation

are in lieu of all other warranties expressed or implied including any implied warranty of merchantability.

(c) Under no circumstances shall seller, (any subsidiary or any division thereof), have any liability whatsoever for loss of use or for any direct, indirect or

consequential damages.

(d) The warranty is limited to the first purchaser and is not transferable.

5. Production Estimates and Perfor mance:

(a) All working drawings or other materials provided by seller are for general information purposes only, and may not relate to purchaser’s order or other

machines or equipment. Any spec i fications contained therein are not binding on seller except as expressly so stated in this form or other written form.
Seller reserves the right to make, at any time, such changes in detail of design or construction as shall in the sole judgment of seller constitute an
improvement in operation and/or safety ove r former practice.

(b) Production data, where given is based on seller’s careful analysis and understanding of the specific re quirement, material spec i fications, required

accuracy and handling facilities is nonetheless an estimate only and is not guaranteed or warranted. Franklin Manufacturing Inc. reserves the sole right
to determine machine capacity, and in no event shall sellers be responsible for capa city figures supplied by seller’s suppliers
parties.

6. Cancellation:

(a) Following acceptance by seller, this order may not be canceled without written consent of the seller.
(b) Seller shall have the absolute right to cancel and refuse to complete this order (1) if any time all terms and conditions governing this order (including any

requirement of progress payments) are not strictly complied with by the purchasers, and/or (2) if at any time the purchaser becomes bankrupt or
insolvent.

(c) In the event of cancellation by seller as above set forth or of a request by the purchaser to stop work or to cancel the whole or any part of an order, the

purchasers shall make payments to the seller as follows:

1. Any and all work that can be completed within 30 days from date of notification to stop work on account of cancellation shall be completed, shipped
and paid for in full.

2. For work in progress and any materials and supplies procured or for which definite commitments ha ve been made by seller in connection with the
order, the purchaser shall pay to the seller the actual costs and overhead expenses determined in accordance with generally accepted accounting
practice plus 15%.

7. Payment Terms:

Net 30 days from date of invoice, shipment date. (Interest added after 30 days at 1¾ % pe r month.)

All orders must clearly state name and address of purchaser, shipping instructions, and all conditions, mechanical and otherwise with which the manufacturer is

Delivery of items of any order to the carrier by seller consigned to purchaser, or as purchaser shall direct, shall constitute transfer of title, ownership, possession

The foregoing comprises seller’s and purchaser’s entire agreement. On any order placed pursuant hereto, the above provisions entirely supersede any prior oral

Wherever used herein, SELLER shall mean Franklin Manufacturing Inc.; PURCHASER shall mean the customer placing the purchase order

8. Acceptance of Orders:

expected to comply. The seller shall furnish written “order acknowledgment” which shall constitute the seller’s acceptance of the order upon the terms and
conditions specified in the “order acknowledgme nt”.

9. Title:

and property in and to such items at such point of delivery; such carrier shall thereafter be deemed to be acting for the purchaser and the said items thereafter
shall be at the purchaser’s risk; provided, however, that seller reserves all right to stoppage in transit and to repossess said items, notwithstanding delivery to
the carrier, until full payment of purchase price is made to the seller.

10. General:

or written correspondence, quotation or agreement. There are no agreements between seller and purchaser in respect of the product quoted herein except as
set forth in writing and expressly made part of this quotation. There shall be no modification to the foregoing except as entered into by writing, signed by
seller and purchaser. The designs and specifications of all products sold by seller are subject to change without notice and, in the event of any such changes,
seller will have no obligation whatsoever to make similar changes in a product previously ordered by purchaser.

with seller.

or other cooperating

Section #1: Operation and Maintenance

Operation & Console Functions

Web Splice Station Console

Figure 1

Web Splice Button Layout

a. E-STOP/CONTROL POWER - Removes AC power to all PLC outputs.

Pull UP to enable.

b. INFEED Off/On - A selector switch that controls power to the infeed

conveyor.

c. OUTFEED Off/On - A selector switch that controls power to the outfeed

conveyor.

d. SPEED Lo/Med/Hi - A selector switch that controls conveyor speed.
e. JOG MOVE DIRECTION Forward/Reverse - Two push buttons that control

direction of conveyor(s). The "INFEED" and/or "OUTFEED" selector
switch(s) must be on the "On" position.

f. Outfeed Control Web\Tack Placing switch in the Web position will allow

control of the outfeed conveyor at the web splice station control panel.
Placing switch in the Tack position will allow control of the outfeed
conveyor from the Tack station control panel.

g. GANTRY SPEED-LO-MED-HI—Use to select low, medium, or high speed

for gantry traverse movement

h. GANTRY MAGNET POWER—Use to vary the strength of the magnets on

the gantry lift beam.

i. GANTRY TRAVERSE-ENABLE-DISABLE—Place switch in the ENABLE

position to allow gantry traverse movement. Place this switch in DISABLE to
prevent gantry traverse movement.

j. UP-DOWN-REV-FWD—Use to manually jog the gantry traverse in the

forward and reverse direction. Also use to manually move the lift beam up
and down.

2

3

Franklin Tack Station

a. E-STOP/CONTROL POWER - Removes and restores power to all control

functions of the machine. Pulling UP fully on the button will start the
hydraulic unit and enable all functions of the machine. Push in on the
button to stop the hydraulics and disable all machine functions.

b. DATUM SIDE MAG-CON-REV/FWD- Allows movement of the magnet

rollers forward and reverse. Use to position the flange closest to the
operator once it has been placed on end.

c. DATUM SIDE FLANGE UPENDERS- UP/DOWN- Switch to UP to bring

the flange on the datum side up on it’s end.

d. FLANGE UPENDERS-1 IN/OUT- Use to position the flange upender

assemblies on the first conveyor. Allows positioning of the flange across

the conveyor.
e. STOP GATE Down/Up - Turn switch to control Stop Gate position.
f. OUTFEED CONVEYOR; INFEED CONVEYOR; On/Off - Each selector

switch controls the power to the appropriate conveyor drive. Used to jog

the conveyors that are selected to run.
g. CONVEYORS REV/FWD – Place switch in FWD to move conveyors in the

forward direction. REV moves conveyors in the reverse direction.
h. CONVEYOR SPEED- LOW/MED/HIGH- Use to select between three

ranges of conveyor speeds. Conveyors will travel at the slowest rate when

LOW is selected.
i. ALL CONVEYORS FORWARD—Use to jog all conveyors forward

simultaneously.
j. WEB LIFT Down/Up - Turn switch to control Web Lift position.
k. FLANGE CLAMP-CLOSE-OPEN—Use to open and close the flange

clamp.

l. FLANGE UPENDERS-2 IN/OUT- Use to position the flange upender

assemblies on the second conveyor. Allows positioning of the flange across
the conveyor.

m. OPOSITE DATUM SIDE FLANGE UPENDERS- UP/DOWN- Switch to

UP to bring the flange opposite the datum side up on it’s end.

n. OPOSITE DATUM SIDE MAG-CON-REV/FWD- Allows movement of the

magnet rollers forward and reverse. Use to position the flange opposite the

operator once it has been placed on end.
o. BEAM CLAMP- OUT/IN- Closes and opens the beam clamp. Use to clamp

front of beam in preparation for welding.
p. MAGNET- OFF/ON- Select ON to turn on the web magnets. Use to pull

down and hold the web, once positioned, in preparation for welding.
q. Tack\PTW - Place switch in Tack position to allow operation of the outfeed

conveyor from the tack station control panel. Placing switch in PTW position

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enables control of the outfeed conveyor from the pull thru welder control
panel.
r. Web Outfeed – Use to control the direction of the outfeed conveyor.

Pull Thru Welder Controls

Pull-Thru-Welder Operator Controls

a. E-STOP/CONTROL POWER - Removes AC power to all PLC outputs.

Pull UP to enable.
b. PTW INFEED Jog/Run - PTW OUTFEED Jog/Run - Selector switch to

activate manual control of conveyor. When in Jog conveyor will be

operated by the PTW INFEED(or OUTFEED)-Rev/Fwd selector switch.

When RUN is selected the conveyor(s) will run continuous and at a higher

rate than when JOG is selected.
c. PTW INFEED- REV/FWD; PTW OUTFEED-REV/FWD- Use to manually

jog the infeed and outfeed conveyors. Hold PTW INFEED in REV to move

the infeed conveyor in the reverse direction. Hold the PTW INFEED in

FWD to move the infeed conveyor in the forward direction. Conveyor(s)

5

will stop when switch is released. The PTW OUTFEED switch performs

the same functions for the outfeed conveyor.
d. WELDER Jog - Use to bring material into weld to position for weld.

Conveyors jog with this function.
e. WELDER ON – This is an indicator that will be illuminated when one or

both of the welders are welding.
f. WELD DIRECTION Rev/Fwd – Use to run the welder drive wheels either

forward or reverse.
g. CYCLE START – Use to start the machine automatic processing mode.

Pressing Cycle-Start will cause the machine to begin automatic processing.
h. CYCLE HOLD – Use to stop the machines automatic operation. Pressing

the

button will discontinue the automatic machine processing.

i. PRESSURE WHEELS Open/Close – These two switches control the

pressure wheels on the movable side of the machine. The left switch will

cause the infeed side of the pressure wheel assembly to move in or out. The

switch on the right will cause the outfeed side of the pressure wheel

assembly to move in or out.
j. COPPER WHEELS Out/Weld – The switch on the left is used to open or

close the copper backup wheel on the stationary side of the machine. The

switch on the right is used to open or close the copper backup wheel on the

movable side of the machine.
k. ELECTRODES Up/Weld – Placing the switch on the left in Weld will cause

the electrode head on the stationary side of the machine to move down and

in against the beam. Placing the switch on the left in UP will cause the

electrode head on the stationary side of the machine to move up and out.

The switch on the right performs the same functions for the electrode head

on the movable side of the machine.
l. FLUX VALVES Off/Weld - Selector switch to control flow of flux through

welding head. Placing the switch on the left in Weld will allow flux to flow

from the head on the stationary side of the machine. Placing the switch on

the left in Off will stop the flow of flux on the stationary side. The switch

on the right performs the same functions for the flux system on the movable

side of the machine.
m. CARRIAGE Up/Down - Push buttons to control carriage position. Pressing

UP will cause the internal machine assembly(carriage) to move up.

Pressing DOWN will cause the carriage to move down. The position of

carriage will depend on the width of the flange for a particular beam. (See

sequence of operation step 8).
n. HYDRAULICS Start/Stop - The START button activates the hydraulic

power unit and STOP button shuts hydraulic power unit down. The START

button will be illuminated when the power unit is in operation.

6

o. VACUUM UNIT - On/Off – Switching to On activates the Vacuum Unit

and Off shuts Vacuum Unit down.
p. TACK OUTFEED- Rev/Fwd- Use to move the tack station outfeed

conveyor forward or reverse. This is used to bring the tacked beam up to

the welder infeed conveyor. This function will not operate if the tack

station OUTFEED CONTROL is set to TACK.

q. DATUM & OPPOSITE TORCH Up/Down - Joystick used to finely adjust

the height of the welding heads. The joystick on the left controls the

welding head on the stationary side of the machine. The joystick on the

right controls the welding head on the movable side of the machine. Note:

The positive electrodes must be well insulated.
r. INFEED/OUTFEED Off/Ground - This function allows for the placement

of the ground shoes. Placing the INFEED selector in GROUND will cause

the ground shoes on the infeed side of the machine to close. Placing in OFF

will cause the ground shoes on the infeed side of the machine to open.

Placing the switch in the center(between GROUND and OFF) will allow

ground shoes to be in a relaxed state neither opened nor closed. The

OUTFEED selector performs the same functions for the ground shoes on

the outfeed side of the machine.
s. INFEED HOLD DOWN-UP/DOWN; OUTFEED HOLD DOWN

UP/DOWN- Placing INFEED HOLD DOWN switch in DOWN will cause

the hold down roller on the infeed side of the machine to move down.

Placing INFEED HOLD DOWN in UP will cause the hold down roller on

the infeed side of the machine to move up. Placing switch in the

center(between UP and DOWN) will cause the hold down to be in a relaxed

state(somewhere between up and down). The OUTFEED HOLD DOWN

switch performs the same function for the outfeed hold down roller.
t. WEB LIFTS Up/Down – Placing the switch on the left in UP will bring up

the web lift roller on the infeed conveyors stationary side. Placing the

switch in DOWN will cause the web roller to go down. Use the switch on

the right to operate the web lift roller on the movable side of the infeed

conveyor.
u. (Optional)PUSHERS; OPEN;CLOSE –

Use to open and close material

pushers

v. (Optional)BRUSH; MANUAL; AUTO – Place switch in Auto and the
cleaning brush will automatically activate when material has reached a
position where cleaning is needed. Place switch in Manual to allow manual
control of the brush operation.

w. (Optional)BRUSH; ON; OFF – When Brush; Manual; Auto switch is in

7

Manual, switching to On will activate the material cleaning brush. This

switch has no function when the Brush; Manual; Auto switch is in Auto.

Pull-Thru-Welder Sequence Of Operation

1. Make sure machine area clear of any obstructions, foreign materials or
coworkers. Infeed and outfeed area must be clear.

2. Energize welder. Whenever welders are energized the NA5s should power
up also.

3. Make sure NA5s are set correctly.

4. Turn all switches to neutral(center position) (if 3 position switch).

5. Pull E-Stop.

6. Press hydraulic start button power unit on.

7. Position beam to datum line at last roller of infeed conveyor.

8. Set carriage to desired height. 1/2 flange width-1/2 web thickness.
Example: 5” flange + .25” web (5-0.25/2) = 2.375” or 2 3/8”

9. Position pressure wheels to approximate width of beam. Relax pressure
wheels (position switch to center position) when bean is in desired

position.

10. Close infeed ground shoes until beam can be conveyed without conflicting
with infeed ground shoes or web roller. Relax infeed ground shoe(center
position) to keep in position. Then use the infeed conveyor to move beam
into the welder to the first set of pressure wheels. Convey beam to start
position. (Front of material is on the outfeed side of the 1

st

welding head.)

11. Lower infeed hold down roller down until it contacts flange. This will help
to hold the beam down. Once roller is down on flange it should be relaxed
(switch in center position). Then energize the first set of pressure wheels.
Energize datum side copper back up wheels. Lower datum side electrode.

NOTE: If wire height needs to be adjusted, it should be done before starting welder.
This should also be done for both electrodes before welding. This is done by
positioning and clamping beam into place, bringing electrodes into place and
adjusting wire head until wire is contacting beam at the desired location. To
lengthen or shorten wire use the NA5’s wire up and down button to achieve
desired wire length.

12. Once above items have been completed energize the datum side flux valve.

8

Move beam forward until wire is covered with flux. Turn vacuum on.

13. To begin welding turn the weld direction selector switch to the forward
position and push the start button on the NA5.

NOTE: To adjust the speed of the beam use the increase and decrease buttons on the
E200. This will adjust the speed percent to the desired speed.

14. As the beam moves past the opposite side electrode, energize the second

set
of pressure wheels, energize the copper back up wheels on opposite side,
lower opposite side electrode, turn opposite side flux valves on and press
the start button on the NA5.

15. Energize the outfeed grounding shoes. Lower the outfeed hold down roller.

16. When beam is nearing the end raise the infeed hold down roller; relax the
infeed ground shoes by turning switch to center position.

17. When datum side electrode reaches the end of the beam press stop on the
NA5, this will stop the electrode from welding.

18. Then relax first set of pressure wheels by turning the switch to the center
position, turn the datum side flux valves off by turning switch to the center
position, relax datum side copper back up wheels by turning switch to the
center position. Raise the datum side electrode.

19. When opposite side electrode reaches the end of the beam press stop on the
NA5; this will stop the electrode from welding.

20. Then turn the weld direction selector switch to the center position to stop
the beam from traveling. Turn off opposite side flux valve by turning
switch to center position. Relax the second set of pressure wheels by
turning switch to center position. Relax opposite side copper back up
wheels by turning switch to the center position. Raise the opposite side
electrode.

21. Then relax the outfeed ground shoes by turning the switch to the center
position. Then raise the outfeed hold down roller.

22. Repeat steps 1-21 to weld another beam.

PTW Auto Mode:

1. Auto mode can only be run once prep sequence has been completed and beam is at
start position. See Pull- Thru- Sequence of operation steps 1-9.

2. All selector switches should be in center position after start position has been
reached. Also wire height should be set before auto sequence is started. See note on
step 11 in the Pull- Thru- Sequence of operation section.

3. Press Cycle start button to start auto sequence.

4. Once auto sequence has started operator should constantly monitor machine
operation. Use datum side and opposite side torch joy sticks to adjust wire height
during automatic sequence.
NOTE: - Cycle stop can be used to halt the auto sequence. E-stop will stop the auto

9

sequence and turn hydraulics off. Manual operations override automatic
operations.

Example: When beam already has weld on bottom side copper wheels should
not be used thus can be locked out by positioning switch to retract

them.
NOTE: See programming section to set time durations for automatic mode.

PTW Programming

Main Screen

Speed Percent
This parameter is used during welding and welder JOG sequence.

Example: 100% = 120 inch / minute
50% = 60 inch / minute
0% = 0 inch / minute
Note: To change speed percent variable; move cursor to variable, type number

and press enter or use increase button (F1) and decrease button (F2).

Welder Actual

This is the actual speed that the pressure wheels are turning in inches / minutes.
Welder actual is determined by adjusting speed percent.

Increase
This increased speed percent. Press button F1.

Decrease
This decreases speed percent. Press button F2.

Note: All main screen parameters may be used in manual or automatic mode.

10

Note: The Setup Screen may be accessed from the Main Screen by pressing

the F4 button.
Note: The Feet / Time Welded Screen may be accessed from the Main Screen

by pressing the F3 button.

Set-Up

Wheel #1 On

This is the time pressure wheel #1 is energized in auto mode.

Wheel #1 Relax
This is the time pressure wheel #1 is relaxed in auto mode.

Wheel #2 On

This is the time pressure wheel #2 is energized in auto mode.

Wheel #2 Relax
This is the time pressure wheel #2 is relaxed in auto mode.

Head #1 Down Time
This is the time delay for head #1 to get into position before activating flux valve #1
in auto mode.

Head #2 Down Time
This is the delay time for head #2 to get into position before activating flux valve #2
in auto mode.

Note: All of the above set up parameters have time durations of seconds.

Inch to Start

This is the distance the beam will travel after flux valves #1 and #2 are turned
on to insure wire is covered with flux before welding is started with the respective

welding head in auto mode.

Inch to Stop 1
This is the distance the trailing end of the beam will travel after clearing beam
reference point sensor and will turn off Head #1 welding in auto mode.

Inch to Stop 2

11

This is the distance the trailing end of the beam will travel after clearing beam
reference point sensor and will turn off Head #2 welding in auto mode.

In Down Time
This is the time the infeed hold down is energized in auto mode. The
and the

In Relax Time is used to control the frequency and the duration of the pulse.

In Down Time

In Relax Time

This is the time the infeed hold down is relaxed in auto mode. The infeed hold down
pulsates during automatic operation. The

In Down Time and the In Relax Time is

used to control the frequency and the duration of the pulse.

The following applies only for those with the Brush option.

Brush on Distance

This is the distance the leading end of the beam travels after making beam end

point sensor, to activate brush in auto mode.

Brush Off Dist

This is the distance the trailing end of the beam travels, after clearing beam end
point sensor, to deactivate brush in auto mode.

General Information

• To change any of the setup parameters, using arrows move cursor to the

desired variable. Type desired number and press enter.

• All setup parameters can be used only in automation mode.

• To return to main screen press F5.

Production

Feet Welded
This variable records linear travel of beam during weld cycle. This measurement is

recorded in feet.

Note: This parameter is available in manual and automatic mode. This parameter
needs to be reset periodically.

Note: Press F1 to reset Feet Welded.

Time Welded

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This variable records time during weld cycle. This measurement is recorded in

minutes.

Note: This parameter is available in manual and automatic mode. This parameter
needs to be reset periodically.

Note: Press F2 to reset Time Welded.

Fabricator Specifications

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Web Splice Station Infeed Conveyor

a. AC variable speed drive
b. 7' wide x 45' long
c. rollers

1. 3 1/2" diameter

2. 5/16" roller wall thickness

3. 18" centers
d. #60 chain and sprockets

Web Splice Station

a. Single head welder
b. DC 1500 Lincoln Power Supply
c. 50lb Wire Reel and Shaft Assembly
d. HC-5 Travel Carriage
e. Contact Nozzle Assembly
f. Vertical Lift Adjuster
g. Input Cable Assembly 15' long
h. NA-5 Sub Arc Head Controls
i. K-346-A Head
j. K-356 Controls
k. T-14469 Mount Kit
l. Flux Recovery System

Outfeed Conveyor to Web Splice

a. AC variable speed drive
b. 84” wide x 45' long
c. rollers

1. 3 1/2" diameter

2. 5/16" roller wall thickness

3. 18" centers

4. d. #60 chain and sprockets

Tack Station w/80-5Hp Hydraulic Power Unit

a. 6" to 72” wide webs
b. 5" to 1'-6" wide flanges
c. 15° pivot for inclined flanges

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Pull Thru Welder Infeed Conveyor

a. AC variable speed drive
b. 7' wide x 60' long
c. rollers

1. 3 1/2" diameter

2. 5/16" roller wall thickness

3. 18" centers
d. #60 chain and sprockets
e. 5 sets of side guide rollers
f. Hydraulic web lifts @ welder entrance

PTW72 Pull Thru Welder

a. 545-20Hp Hydraulic Power Unit
b. automatic start function, PTW, and Outfeed drive systems
b. 6" to 72” wide beams
c. 5" to 1'-6" wide flanges
d. adjustable roller for inclined flange - moveable side only
e. rotating welding head (15° each direction - 30° maximum) moveable side only
f. 120IPM Max
g. Barrel typer wire feeders

Pull Thru Welder Outfeed Conveyor

a. AC variable speed drive
b. 7' wide x 30' long
c. rollers

1. 3 1/2" diameter

2. 5/16" roller wall thickness

3. 18" centers
d. #60 chain and sprockets

Customer Responsibility

1. Supply disconnects: 380 volt-3 phase-60 Hertz (100 amp) and connecting wire to

FMI main panels.

2. Supply disconnects: 380 volt-3 phase-60 Hertz (60 amp) and connecting wire to

welder power source.

3. Air supply: 100 PSI

4. Supply adequate foundation work & installation equipment

5. Follow all safety guidelines in this manual

6. Follow maintenance procedures in this manual

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Safety Information & Procedures

Operation of Machinery

FMI equipment is designed and manufactured with consideration and cares to

generally accepted safety practices and standards. The proper and safe performance
of the equipment depends on the use of prudent operating, maintenance, and servicing
procedures by trained personnel under competent supervision. For your protection
and the protection of others read, understand, and follow these safety rules. Observe
warnings, cautions, and danger stickers and act accordingly.

Safety is an attitude. Training, good judgment, and the operator attentiveness

to the job he is performing are the best way to prevent injury. The following
comments contain a basic list of things the operator and maintenance personnel
should be aware of before operating or servicing machinery.

1> Before Starting Operations

a. Ensure that all guards and safety devices are installed and operative and all

doors that carry warning labels are closed and locked.

b. Ensure that all personnel are clear of those areas indicated and potentially

hazardous.

c. Remove (from the operating zone) any materials, tools or other objects that

could cause injury to personnel or damage the system.

d. Make sure that the system is in a good operational condition.
e. Make certain that all indicating lights, horns, pressure gauges or other safety

devices or indicators are in working order.

2> After Shutdown

Make certain all equipment in the plant is safe and the associated electrical,
hydraulic, and pneumatic is locked in the Off position. It is permissible for the
control equipment contained in enclosures to remained energized provided this
does not conflict with safety instructions found in this manual.

3> Operating Safety

a. Do not operate the control system until you read and understand the operating

instructions and become thoroughly familiar with the system and controls.

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b. Never operate the system while a safety device or guard is removed or

disconnected.

c. Never remove warnings that are displayed on the equipment. Torn or worn

labels should be replaced.

d. Do not start machines until all personnel in the area have been warned.
e. Never sit or stand on anything that might cause you to fall.
f. Horseplay around equipment is dangerous and should be prohibited.
g. Know all E-Stop button locations on your machine.
h. Never operate the equipment outside specification limits.
i. Keep alert and observe indicator lights, system messages, and warnings that are

displayed on the system.

j. Do not operate faulty or damaged equipment. Make certain proper service and

maintenance procedures have been performed.

h. Do NOT place hands in the point of operation with hydraulic power unit

running.

l. Do NOT feed short or small pieces into machine without the use of hand tools.
m. Do NOT attempt to change tooling with hydraulic power unit running.
n. Do NOT do any maintenance on machine with the hydraulic power unit

running.

o. Do NOT modify machine controls in any way.
p. Do NOT press dies into place.
q. Do NOT punch or shear more than one piece of material at a time.
r. Do NOT install dies upside down.
s. Do NOT use dies that are of larger diameter than slug holes in press.
t. Do NOT remove any safety devices from the machine.
u. Do NOT reach around any safety devices.
v. Do NOT wear loose clothing around moving parts.
w. Be aware of gauge readings and pressure settings, and do not adjust without

written authorization.

x. Be aware of material movement during operations being performed and

creating pinch points, especially bowed or bent material.

y. Be aware of hold-downs, centering or guiding devices that may become a pinch

point because of material variations.

z. Be aware of normal machine sounds and advise the supervisor when these

sounds change.

4> Service & Maintenance Safety

a. All electrical, hydraulic, pneumatic, etc., should be performed by trained and

authorized personnel only.

b. It should be assumed at all times that the Power is ON and all conditions

treated as live. This practice assures a cautious approach that may prevent

17

accident or injury.

c. Before applying power to any equipment, make certain that all personnel are

clear of associated equipment.

d. Do not by-pass a safety device.
e. Always use proper tools for the job.
f. All electrical, hydraulic, and pneumatic lockout devices should be locked in the

OFF position with a zero energy state before attempting to service &
maintenance.

5> Manual Cleaning Procedure

a. Do not use toxic or flammable solvents to clean control system hardware.
b. All power sources must be locked off with zero energy state before attempting

to clean equipment.

c. Never use water to clean electrical equipment. Water is a very good conductor

of electricity and the single largest cause of death by electrocution.

d. Keep electrical panel covers closed when cleaning an enclosure.

Color Codes / Locking Devices

Be aware of the meanings of different colors on safety stickers and painted

machinery:

Red: DANGER - A means used to call attention to an immediate hazard which

will result in severe personal injury or death. (ANSI B11.18-1985, 3.11)

Note: Stop buttons or electrical switches which letters or other markings appear,

used for emergency stopping of machinery shall be red. (OSHA, 29 CFR

1910.144 (a) (1) (iii))

Orange: WARNING - A means used to call attention to a hazard or unsafe

practice which could result in severe personal injury or death. (ANSI B11.18­1985, 3.47)

Yellow: CAUTION - A means used to call attention to a hazard or unsafe practice

which could result in minor personal injury or product or property damage.
(ANSI B11.18-1985, 3.7)

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Yellow shall be the basic color for designating caution and for marking physical

hazards such as: Striking against, stumbling, falling, tripping, and "caught in
between." Solid yellow , yellow and black stripes, yellow and black checkers
(or yellow with suitable contrasting background) should be used
interchangeably, using the combination which will attract the most attention in
the particular environment. (OSHA, 29 CFR 1910.144 (a) (3))

Locking Devices: Whenever a machine is delivered with a locking device

(mechanical, electrical, hydraulic, or pneumatic), the key should be placed
under the care of the supervisor (such as a foreman) and not the operator.

Sticker Cautions, Warnings, and Dangers

(Operator should be aware of all stickers located on the machine. Pay special

attention to type of sticker and location of each sticker.)

a. Caution - Do Not Operate Without Guards

b. Danger - This Machine Starts Automatically

Caution - Keep Hands Clear

c. Caution - Keep Hands Clear (General Rules)

Danger - POWER UNIT. Must Be OFF During Tool Change

d. Warning - This Control Must NOT Be Modified,

This Equipment Must Be Grounded

e. Remove Power Before Unplugging

Do Not Weld On Equipment ...

Safety Stickers

Operator should be aware of all stickers located on the machine. Certain

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stickers are used on different machines so identify and be familiar with

stickers on your specific machine. Pay special attention to type of sticker and

its location.

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21

Infeed/Outfeed Conveyors

a. Gear Reducer: One (1) Radicon® motor/reducer is used on each conveyor.

Recommended lubricants are as follows under applying working conditions:

Ambient Temp Range: 14 to 86°F ------ ISO Visc Grade#: 220

Ambient Temp Range: 32 to 113°F ---- ISO Visc Grade#: 320

Ambient Temp Range: 50 to 122°F ----- ISO Visc Grade#: 460

Mineral Oils

Supplier

Chevron Oil Co. Chevron Gear Compounds EP

Esso Petroleum Co. Spartan EP

Mobil Oil Co. LTD MobilGear 600 Series

Shell LTD Omala

Tribol (ICI) LTD Tribol 1100

Synthetic Oils

Supplier

Chevron Oil Co. Synthetic DBH

Esso Petroleum Co. Spartan SEP

Mobil Oil Co. LTD MobilGear SHC

Shell LTD Hyperia S

Tribol (ICI) LTD Tribol 1510

After an initial operating period of approximately 250 hours, the reducer housing

should be drained, preferably while warm. Refill with approximately 5/8 gallon

(2.4 liters) of fresh oil. Thereafter, change oil at 10,000 hours of operation for

mineral oil and 20,000 hours of operation for synthetic oil.
b. Roller Chain: Inspection on the chain return bearing should be made occasionally

to insure sufficient wear has not accumulated causing the chain to drag against

metal. The chain may be tightened at the Take-Up Bracket located near the

motor/reducer section of the machine. As the drive chain becomes stretched

beyond adjustment, links may be removed from the chain loop. Caution must be

observed to avoid a binding effect between the chain rollers and sprockets. It is

advisable to replace the chain rather than damage the sprockets because the

sprockets are not replaceable without ordering new rollers. Spray with light oil as

needed.
c. Roller Bearings: There are two types of bearings used on the conveyors. One

type contains lifetime lubricated bearings and the rest contain grease fittings in the

end of the hex shafts on each side of the conveyors. For rollers with grease fittings,

ubricate with a lithium base grease approximately once every two-hundred (200)

hours of operation.

Range Name

Range Name

General Maintenance

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Flux Recovery Equipment (on Weld Splice Station & Pull Thru Welder)

a. Filter & Dust Bag: Particular attention should be given the filter or dust bag on

flux recovery equipment. To assure efficiency and performance it is imperative
that the dust bag be manually agitated at regular intervals; at least every eight (8)
hours if the equipment is in continuous operation. To agitate or shake the dust bag

- remove dust tank cover, grasp the steel spider, lift up and shake , then replace
spider in position. This action will dislodge any accumulation of dust and keep the
pores of the filter cloth open. Note: Failure to agitate the dust bag at regular
intervals will result in lack of performance and premature dust bag failure.

After the installation has been properly adjusted, the next step is to determine the
amount of flux fused during a given period, for example; if 100 pounds of flux is
fused during an 8 hour run, 100 pounds of new flux must be added to the primary
tank at this time, thereby assuring ample reserve and prevent a shutdown for
refilling the tank while work is in process. The equipment should be serviced at
regular intervals, for example; at the end of each 8 hour shift:

1> Empty slag screen in primary tank.
Note: The only purpose of the slag screen is to collect such fused particles

that may be recovered from the weld. Do not chip off the slag seam or
attempt to recover slag in volume. To do so will overload the screen, thereby
preventing the unfused flux from passing through the screen. The result will
be excess carry-over of usable material to secondary tank.

2> Refill primary tank, replacing the amount of flux consumed during the past 8

hour run.
3> Agitate the dust bag.
4> In case of dust bag failure, shut down machine and replace at once. DO NOT

OPERATE THE UNIT WITHOUT DUST BAG OR WITH FAULTY DUST

BAG. A discharge of fine, white dust from the exhaust indicates dust bag

failure of that material is being passed through the vacuum producer unit.

Failure to correct immediately will result in expensive repairs.

b. Electric Motor Sleeve Bearing: The bearing sleeve is steel on the outside for

strength with a tin base babbit lining on the inside for low friction and long

wear. The initial factory lubrication is normally adequate for approximately

one year under normal operation. Thereafter, lubricate approximately once

every one thousand (1000) hours of operation. This requires about 3 to 4

squirts from a 4 inch oil can. Use only a light grade minerial oil (similar to

SAE 10W) having a viscosity of 210 sec. at 100° F.

Tack Station

23

Stop Gate Arm: The arm pivots on a shaft to allow it to drop out of the way until
needed. At the pivot point there are two (2) grease fittings; one at each end of the
arm. Two (2) grease fittings should be lubricated with a good lithium base grease
approximately once every forty (40) hours of operation.

Pull Through Welder

a. Wire Drive: The Lincoln® brand Wire Drive Gearbox contains gears that should

be recoated with a non-fluid type lubricant (Lincoln Spec. E2322) approximately
once every two-thousand (2000) hours of operation. For access to the gears in one
chamber, remove the adapter plate and motor assembly. To lubricate the gears in
the other chamber, remove one of the pipe plugs and feed grease in contact with
the bevel gear teeth while rotating the output shaft until all teeth are lubricated.

b. Linear Motion Bearings: Eight (8) bearings are used on the welding heads (4 per

welding head). These bearings have a grease fitting in the end that should be
greased with a (No.2) lithium type soap base grease approximately every one­thousand (1000) hours of operation.

c. Gear Reducer: Two (2) Winsmith® reducers are used on the drive roller motor.

One is located on the stationary side and one on the moveable side. Recommended
lubricants are as follows under applying working conditions:

Ambient Temp Range: 14 to 86°F ------ ISO Visc Grade#: 220
Ambient Temp Range: 32 to 113°F ---- ISO Visc Grade#: 320
Ambient Temp Range: 50 to 122°F ----- ISO Visc Grade#: 460

After an initial operating period of approximately 250 hours, the housing should be
drained, preferably while warm. Refill to midpoint plug level with fresh oil. Under
normal conditions, the drive should be re-lubricated at intervals of once every two­thousand (2000) hours of operation.

d. Roller Chain: Inspection on the drive roller chain should be made occasionally to

insure sufficient wear has not accumulated causing the chain to stretch. As the
drive chain becomes stretched, it may be adjusted by loosing the motor/reducer
mounting
bracket enough to slide the bracket back until chain is tight; then re tighten bracket
5/8-11NC hex bolts to approximately 150 ft/lbs. To reduce friction, spray chain
with light oil as needed.

e. Moveable Arc Base: The moveable arc base contains a bronze bearing at each

corner (4 total) allowing it to slide on two (2) round tubes welded to the lift
carriage frame. The sliding base contains one grease fitting per bearing. There is
one (1) grease fitting in the pivot shaft bearing. A total of five (5) grease fittings
should be lubricated with a lithium base grease approximately once every forty

24

(40) hours of operation.

f. Jack Screws & Nuts: The lift carriage frame is horizontally positioned by a total

of four (4) jack screws (1 at each corner of the frame). Each jack screw and each
jack nut contain a grease fitting for lubrication. A total of eight (8) grease fittings
should be lubricated with a lithium base grease approximately once every one­hundred sixty (160) hours of operation.

Hydraulic Power Units

Today's hydraulic systems will give many years of trouble free operation when properly
maintained. Studies have shown that over 60% of all hydraulic systems down time can
be attributed to untidy maintenance, and lack of proper filtration. If the hydraulic fluid
becomes contaminated, orifice blockage, valve sticking, internal wear of hydraulic
components, pressure loss, and even pump failure can occur. The following guidelines
are given as minimal requirements under normal shop conditions.

a. Initial Oil Change: Change the hydraulic oil, clean the tank, and replace the return line

filter cartridge after the first two-hundred fifty (250) hours of operation. See tag on
power unit for proper type of hydraulic oil. Various pumps are used on FMI power
units; so see tag for the type of oil used in your particular units.

b. Oil Change Requirements: Replacing system fluid is dependent on several factors

according to the degree of aging or contamination of the oil. Franklin recommends in
the absence of other checks that the oil be changed every 2000 hours of operation for
normal shop conditions. Keep a running check on the oil conditions, take a sample of
the oil and pass it through filter paper or clean cloth. The coloring of the residue will
indicate the degree of aging. If the color is blue/black, an oil change is required
immediately. Old and contaminated oil cannot be improved by topping up with fresh
oil. The used oil should be completely drained while at working temperature and
properly disposed of.

c. Filter Element: The hydraulic filter element must be replaced when dirty. Standard

FMI power units contain a Differential Pressure Indicator. This is simply a gauge on
the filter that indicates pressure buildup on the front side of the element. Check the
Differential Pressure Indicator at least once a week. The element must be replaced
when the Differential Pressure Indicator indicates service is required. The following
steps should be followed when changing a filter element:

1. Lock-out power from the power unit. Check gauges to be certain all pressure is
removed.

2. Remove cover.

3. Remove insert (bridge which holds the element in place).

4. Remove bypass spring assembly from the stud.

5. Remove contaminated cartridge with a twisting motion.

6. Discard disposable element cartridge.

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