Flange Splice Welder

General Description
The flange clamp unit is composed of a
rigid base assembly. The base includes
leveling bolts and holes for concrete expansion anchors. The fixture is approximately 32 inches wide x 60 inches deep front to back. The flange welder is designed to single side splice weld
flanges up to 16 inches wide and 1½ inches thick.

Two flange clamps are fabricated from a heavy bar. The clamps are moved by pneumatic force. Round rods hold the clamp bar in alignment during operation and transmit the clamping forces. The rods pass through line-bored structural steel tubes supporting precision, replaceable bushings.

Clamps
Pneumatic cylinders provide clamping force. Maximum clamping force is limited by air
maximum PSI. With 125 PSI air, each clamp provides 2,450 pounds of clamp force.

Backer Bar
Flange ends are manually located over the copper backer bar. Pneumatic force raises and lowers the backer bar to contact the underside of the flanges being welded. The backer includes a groove machined in two sides. The groove holds flux and controls back bead shape. Each backer bar is composed of three short, replaceable segments.

The copper backer bars include flanges for positive attachment. The flanges maintain copper alignment, prevent the copper from sticking to the welded flanges when pulled away from the welded flanges and allow easy removal when needed. There is approximately 400 pounds of separation force between the backer bar and the welded flanges.

Backer Bar Cooling
A heat exchanger cools the backer bar. The coolant does not directly touch the copper. Coolant is contained within a sealed chamber to prevent leaks and make copper bar maintenance faster and easier.

Clamp Control
Each flange clamp and the copper backer bar are controlled by manual, detented air valves mounted at the operator station. The welder can control each clamp and the backer bar separately. A combination pneumatic filter/regulator/lubricator is included to extend cylinder and valve life.

Welding Equipment
A Lincoln DC 1000 power source, Lincoln NA-5 digital control with start and crater modules, a Lincoln NA-5 wire feeder and a Lincoln automatic flux dispensing hopper are included.

Weld Head Positioning
Weld head assembly power is provided by a gear-reduced, variable-speed drive system. Vertical weld head adjustment is included to allow for varying flange thickness.

Welding Shape Control
Disposable end dams are used to control weld bead shape at the ends of the weld. The end dams are easily positioned and removable after welding completion.

Flux Recovery
A Kentex Model SA-2 flux recovery unit is included. Flux recovery is electrically powered, includes two stage air filtration and returns recycled flux directly to the Lincoln flux dispensing hopper. The Kentex flux recovery and Lincoln hopper hold a total of 50 pounds of flux.

General Construction
All frames are fully welded. After fabrication, the framing is machine-cleaned and powder-coated.

Equipment Warranty and Spare Parts
Kentex provides a one year equipment warranty, to the extent of the supplier components utilized. Lincoln Electric provides a three year warranty. English language operator manuals include spare parts lists and maintenance aids. “Mission critical” spare parts and extra consumable items are included with the welder to ease maintenance requirements. Kentex designs parts using standard, easily-available parts whenever possible.

Equipment Installation
Kentex provides complete, English-language installation instructions. A competent maintenance person can install the flange welder in one day.

Delivery Schedule
Flange welders are made to order. Typical delivery schedule is 7-8 weeks. If the delivery time is extremely important, please confirm a delivery schedule at the time of your order. The delivery schedule is approximate and often varies by one week due to the nature of custom equipment manufacture and Kentex vendor delivery schedule changes.