Frame Size
Frames vary from 6" to 84" deep, with 4”-20” wide and 3/16" to 1 ½” thick flanges. The web material may be 11 gauge to 1/2" thick. For non-prismatic frames, flanges must be of equal width, but not equal thickness. Prismatic frames can be
welded with unequal width flanges.

Conveyors
Conveyors are provided for horizontal materials movement throughout the machine. Conveyors are constructed using a combination of powered, driven and idler
units. Power units come complete with hydraulic motor drive. Individual conveyor rollers are driven by heavy roller chain between all rolls. The conveyor system is designed to
support 300 pound-per-foot beams. Each roller is designed to support 1,000 pounds.

Web Material Movement
Precut web members are placed on conveyors for movement and alignment. Hydraulically powered clamps at the seam welder hold adjacent web members to assure horizontal and vertical alignment during welding. A copper backup bar provides consistent, high-quality submerged arc welds. After welding, the conveyor
moves the welded web forward to receive the next web for welding or onward to the flange/web tack unit. Web seam welder conveyors are powered for forward and reverse.

Flange & Web Assembly
Pre-welded web members and flanges are joined at the flange/web tack unit. Frame flanges are held vertically by magnetic rollers. The web is lifted to the flange centerline and pressed between the flanges for the operator to manually weld the leading edges. The tack unit allows for fine adjustment to
ensure exact centering of the flange/web connection.

Welder Control
The final welder utilizes an Allen Bradley PLC control system for all machine functions. The PLC includes a touch screen to allow easy control of all welding clamping, movement, speed and welding functions. The PLC directly interfaces with hydraulic units and welding controls to provide an easy-to-learn operator interface. Weld start and stop is automatically controlled by the PLC.

The flange/web tack unit and web seam welder include push-button control consoles. All electric controls are mounted in NEMA 12 enclosures in a high quality, workman-like manner.

Hydraulic Power
Multiple hydraulic power units are provided for a complete welder. Welder clamping, drive and conveyor power functions are isolated to prevent interference or problems with maintaining an accurate welding speed.

Final Welder Welding Head Guidance
The final welder includes two self-guiding welding head assemblies, utilizing standard Lincoln weld consumables. Our guidance system utilizes sealed bearings physically contacting the flange and web to maintain weld alignment. The complete assembly pivots to maintain alignment with small flange imperfections and for the taper side. The operator manually positions the welding heads prior to weld start utilizing the PLC. At weld termination, welding stops automatically and the welding heads move up and
away from the weld point to prevent accidental welding head damage.

Welding Wire
Standard 60 pound wire dereeling equipment at the flange/web tack unit and web seam welder are included. For the final welder unit, up to four 1,000 pund AWS wire reels or drums can be utilized. The dereelers contain automatic brake and wire tension controls to prevent overrunning and wire tangling.

Machinery Location
The final welding unit is designed as a mezzanine assembly with the hydraulic reservoir, flux recovery units, 1,000 pound wire dereelers and final welder power sources mounted above the final welding unit. The mezzanine saves valuable floor space. Personnel handrail, a gate and ladder are provided to allow easy and safe raw materials access to the mezzanine.

Welding Specifications
Welding speeds may vary from 24”-120” per minute, depending upon the welding equipment specified, frame member size and welding wire and flux consumables used. Both flange/web welds are completed in a single pass, with welding performed on top of the web. Typically, 1/16” wire is used for the twin wire final welding equipment.

Installation
Kentex provides three employees for machinery installation.

Electrical Supply
The welder requires three-phase electrical supply. The welder components can be operated from 230/3/60 or 460/3/60 supply. Other voltage and HZ options are available.

Welder Finish
After fabrication, the welder is machine cleaned and powder-coated, when possible. For larger sections that cannot be powder-coated, the parts are sand blasted and painted with DTM water-based equipment enamel. A typical finish includes two contrasting colors, such as royal blue and gloss black. A “typical” color selection range is offered.

Availability
The typical delivery schedule is 24-26 weeks after a firm order and deposit receipt. The delivery schedule varies with our backlog.