Man#449 Rev B - Thermatool-Descripción

Thermatool Corp. info@thermatool.
com
tel: 203.468.4100
31 Commerce Street
fax: 203.468.4281 www.thermatool.com
East Haven, CT 06512
TECHNICAL SUPPORT MANUAL FOR:
THERMATOOL CFI *This manual contains safety information

and warnings that MUST be observed by
SOLID STATE WELDER the user to ensure safe operation and to
retain the equipment in a safe condition.
#449 Rev B
31 Commerce Street tel: 203.468.4100 info@thermatool.com 2016

East Haven, CT 06512 fax: 203.468.4281 www.thermatool.com
Thermatool Corp. info@thermatool.com
tel: 203.468.4100
31 Commerce Street
Contents
NOTICE ............................................................................................................................................................................................................... 1
CUSTOMER SERVICE...................................................................................................................................................................................... 2
INSTALLATION................................................................................................................................................................................................. 3
Pre-Installation Production Considerations......................................................................................................................................... 3
Plant Power and Water ............................................................................................................................................................................. 9
CFI Installation Timeline ............................................................................................................................................................................ 9
Preliminary Installation Procedures ..................................................................................................................................................... 10
Pre-Start-Up Checklist............................................................................................................................................................................. 16
Field Service Engineer's Visit and Start-Up ....................................................................................................................................... 17
GENERAL ......................................................................................................................................................................................................... 18
Overview ..................................................................................................................................................................................................... 18
System Components ............................................................................................................................................................................... 19
Additional System Features ................................................................................................................................................................... 37
System Protection Features ................................................................................................................................................................... 39
System Options ......................................................................................................................................................................................... 39
OPERATION....................................................................................................................................................................................................40
Introduction................................................................................................................................................................................................40
Safety ........................................................................................................................................................................................................... 41
Setup ............................................................................................................................................................................................................43
General Operating Information ............................................................................................................................................................ 47
Operating Sequences.............................................................................................................................................................................. 52
MAINTENANCE & TROUBLESHOOTING ............................................................................................................................................... 59
Basic Principles of Good Maintenance ............................................................................................................................................... 59
Daily Maintenance Check ....................................................................................................................................................................... 61
Weekly Maintenance Check .................................................................................................................................................................. 62
Good Troubleshooting Practices.......................................................................................................................................................... 63
Troubleshooting Welder Operation ....................................................................................................................................................64
Troubleshooting Welder Quality .......................................................................................................................................................... 65
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NOTICE
This manual is for the use of employees and licensees of THERMATOOL CORP. It is for any employees of these licensees
who are involved in planning, installing, maintaining or operating a CFI welder. This usually includes engineers, mill
operators, setup and maintenance personnel. It is urged that this manual be made available to authorized persons at
all times.
Neither this manual, nor anything contained in this manual, is intended, or should be construed as, constituting a
representation, warranty or guaranty by THERMATOOL CORP. as to the quality, performance or use of Thermatool
products. There are too many factors connected with the installation, operation, maintenance and the uses of
Thermatool's products which are beyond either the estimation or the control of THERMATOOL CORP. (not the least of
which includes strip condition, material composition, edge condition, excessive or fluctuating voltage, human factors of
skill, ability, technique and care, etc.) and make it impossible to predict or insure proper operation and performance at
any particular time. The data and information in this manual are confidential. Employees and licensees are requested
not to disclose this information outside their own organization or to any other unauthorized persons.
This document is based on information available at the time of its publication. While we try to make it as accurate as
possible, we make no representation or warranty express or implied, and assume no responsibility for the accuracy,
completeness or sufficiency of the information contained herein. Information in this document is subject to change
without notice.
The software described in this manual is furnished under appropriate license and nondisclosure agreements.
No part of this manual, or the software, may be copied without authorization by THERMATOOL CORP.
Copyright Thermatool Corp., 2016 East Haven, CT 06512

All rights reserved. Document # 449
#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 1

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CUSTOMER SERVICE
Experienced field service personnel provide prompt service anywhere in the world to minimize down-time. Our
24-hour hot-line provides customers with immediate troubleshooting response capabilities. You can reach us at
203.468.4100.
Comprehensive spare part inventories are maintained in our facilities located globally to guarantee fast delivery to keep
production lines moving. For standard components we receive an order before 3:00 pm. (EST). Monday through Friday,
the part will be shipped that day.
Getting a customer back into production takes precedence over all else at Thermatool.
Our Service Department is always ready to send a competent service person when required. One of our goals is to
help you avoid downtime and the expense of service trips by giving you as much help as possible over the phone.
You can help: when you call for service, have your records ready, including equipment serial number; have all the facts
that are available about the trouble and its symptoms; have all the details on what has been done to find it.

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INSTALLATION
Pre-Installation Production Considerations
Minimum Space Requirements on Production Floor
The CFI system has been designed to fit easily into existing production environments. Because it is composed of only
four basic components which allow maximum flexibility of positioning, it is possible to adapt the system to a variety of
settings. When a system is ordered from Thermatool, we ask for the distance from the mill floor to the tube mill
centerline and the distance from the tube mill centerline to the pro- posed placement of the Generator cabinet (see
drawing: Customer Lead Set Data). Because the positioning of the induction coil is critical, and the induction coil is
mounted on the lead set assembly extending from the Generator cabinet, the positioning of the adjust-able support
table for the Generator will be determined once Thermatool- receives the above dimensions. The Generator must be
positioned to allow access to side and rear doors for maintenance and removal of lead sets' covers. The positioning of
the Power Supply, Heat Exchanger and the Control Panel is more flexible and will be somewhat determined by plant-
specific considerations. The Power Supply should be positioned so as to provide free access to the front panel doors.
NOTE: To determine precise placement, consult the component outline drawings in the drawing package.
Door Clearances for Power Supply and Generator Cabinets detailed in RED in the following photo.

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For efficiency, the Heat Exchanger should be mounted as close as possible to the Power Supply. Thermatool will supply
drawings which indicate requirements for:
• Cabling,
• Plumbing (cooling and water flow), and
• Electrical KVA.
Any questions regarding installation should be directed to Thermatool Field Service.
Tube Mill Considerations
Mill Alignment
The alignment of the mill itself is essential to good weld quality. The roll shaft shoulders should be correctly lined up
and the top and bottom roll shafts should be parallel to the machined top base plate. The weld roll box should be
accurately mounted in line with the mill centerline and the weld rolls should be accurately aligned with each other.
Aligning the roll shaft shoulders
Getting the roll shaft parallel
Aligning the tooling

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Sizing Section
Even the sizing section of the mill, although downstream of the weld area, may affect weld quality. A badly misaligned
sizing section causes the tube to twist. The twist may be transmitted back along the stiff welded tube, forcing the seam
sideways under one of the weld rolls. The sizing section should therefore be as carefully aligned as the rest of the mill.
Forming Tooling Considerations
Slitting the Strip
Edge quality begins with the slitting of the strip. Good slitting practice should produce satisfactory edges with little or
no camber. Strips should enter the mill with the burr down. This way, any problem from the burr will be on the outside
where it can be seen, and the inside bead will be marginally reduced.
Edge Break
Straight or modified edge breaking is recommended for HF welding. This gives the top of the tube its final radius in the
first one or two fin passes. With HF welding, it is essential that the edges are fully parallel before they get to the weld
rolls. Sometimes thin wall tube is over-formed to allow for springback. The fin passes should not be relied upon to form
this radius, as they cannot overform without damaging the edges so that they do not come out parallel.
Top roll designed for thin wall
Top roll designed for thick wall
Top roll designed for thick roll

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Compatibility of Fin Passes
The progression of the fin passes should lead smoothly to the last fin pass shape. Each fin pass should do approximately
the same amount of work. This avoids damaging the edges in an overworked fin pass.
Last Fin Pass
The last fin pass should present the tube to the weld rolls with the radius formed. The edges should be parallel and the
"Vee" opening should be satisfactory for welding completely (imagine a completely closed tube that has been
constructed of two halves, connected by a piano hinge, and simply swung apart at the top).
"Imagined" hinge
Recommended shape for the last fin pass

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Seam Guide
A seam guide is used to prevent the seam from rolling under the edge of the weld rolls. The seam guide should not,
however, do any more than guide the seam. It should not be used as a spreader or as a forming device to make up
for deficiencies further back in the mill.
This, again, is to avoid damage to the edge and the formation of slivers.
How elaborate a seam guide system you need depends upon a number of factors including:
• O.D. and wall of tube;

• Desired weld quality and strip camber;
• Distance from last fin pass to weld roll centerline;
• How well the forming section does its job.
For most of the tube sizes welded with HF welding (i.e., up to

about 2.5" [163 mm] O.D. by 0.100" [2.5 mm] wall), a simple
sliding seam guide is usually adequate.
For larger sizes, a rotary seam guide is generally preferable.

Either type may be supplemented with side rolls which help
to overcome springback and provide additional control.
The best position for the seam guide is immediately upstream of the HF welding coil.
Note: The seam guide must be insulated so that the tube edges are not electrically connected.
Weld Rolls
The function of the weld roll is to force the heated edges of the seam together, thereby forming the weld. The fin rolls
should deliver the tube to the induction coil and the weld rolls completely formed (including radius near edges), but
open at the top.

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The simplest and most economical weld arrangement is a

two-roll box
A three-roll arrangement may be used where a two-roll

configuration may result in undesired swirling
For larger O.D. and thick walls, a four-roll configuration is

generally recommend
Hardened steel rolls can be used, but at the expense of power loss and the danger of overheating due to their close
proximity to the induction coil. Hard bronze weld rolls are better for Thermatool induction welding.
• Bronze is non-magnetic and has lower electrical resistivity and a higher thermal conductivity than steel.
• Rolls of hard bronze are less susceptible to being induction heated by the stray magnetic field from the coil
air gap than are steel rolls, and they conduct the heat away more rapidly.
Weld rolls are generally cooled by spraying mill coolant on the downstream surfaces (the side away from the weld
point). Hard felt or stainless steel wool wipers are useful for keeping too much of the coolant from being dragged
around into the weld zone. Uniform cooling helps reduce thermal stresses which may cause heat checking or cracking.
Weld rolls should not be insulated. The heating which takes place in them is by induction from the stray field from the
coil, and not from currents conducted through the bearings.
SUMMARY
Analysis of the production process as it affects weld quality for HF welding is focused on a single objective - delivering
correctly formed, parallel edge tubing that is free of slivers, to the welding coil and welding rolls. Because the precise
formation of the tubing at the induction coil is so essential an element in the overall quality of the process, it is desirable
that these elements of production be examined as part of a pre-installation checklist.

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Plant Power and Water
In preparation for the delivery and preliminary installation of the welder, plant power and water supplies should be
reviewed. The plant should be prepared to meet the welder's power and water requirements before installation begins.
Upgrades to the plant power system, if necessary, should be completed immediately to avoid installation delays.
Main power for the Power Supply unit should be supplied by a suitable disconnect circuit breaker. This circuit breaker
must remain OFF until after the arrival of the Thermatool Field Service Engineer for Commissioning.
If available line voltage differs from the equipment voltage rating by greater than 土7%, a suitable auto-transformer
should be used. Thermatool is able to supply such equipment.
If available line voltage is delta, with one leg grounded, the Thermatool Field Service Representative must be informed
of this condition before energizing equipment.
Plant raw water plumbing must be able to deliver the required flow to the Heat Exchanger at a constant 50 psi. Refer
to the installation and water routing drawing for correct flow requirements.
CFI Installation Timeline
FIELD
PURCHASE DELIVERY SERVICE
ENGINEER
This timeline summarizes the basic sequence of tasks in a Thermatool CFI welder installation. The remainder of this
section will present step- by-step instructions for the preliminary installation of CFI components once they have arrived.

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Preliminary Installation Procedures
The following drawings where applicable are included with each unit and should be used as needed during installation:
• CFI Welder Control Panel Assembly

• Schematic, Electrical, CFI Solid State Welder
• Standard Electrical Device Descriptions and Prefixes
• Physical Outline Drawing, Tachometer Generator
• Physical Outline Drawing, Power Supply Cabinet
• Schematic, Plumbing CFI Solid State Welder
• CFI Welder Display Panel
• Physical Outline Drawing, Heat Exchanger
• Assembly, CFI Meter Panel
• CFI Operator Controls
• Installation Layout
• Interconnect Cable List, CFI Welder Installation
• Welder Controls
• Physical Outline Generator Cabinet
• Lead Layout
NOTE: Refer to drawings and specification sheets for all dimensions, power, water requirements and installation details.
Uncrating and Positioning
The welder system cabinets may be shipped skidded. For some installations, the components may be crated as well.
After positioning the skids in their approximate desired location, uncrate and remove equipment from skids. Visually
inspect equipment and report any evident damage immediately to the carrier.
Power Supply
Position the Power Supply cabinet to allow effective access and interconnection. For installation details, refer to:

• Physical Outline Drawing, Power Supply Cabinet

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Generator and Positioning Table (Optional)
The Generator and optional Positioning Table must be positioned according to the Lead Layout Drawing supplied by
Thermatool for the particular installation. Positioning should be done with great care. The purpose of the optional
Positioning Table is to provide adjustment of the coil position relative to the mill and weld rolls, and to the mill centerline,
so as to accommodate different coil configurations, tube configurations and weld conditions. The table should be
positioned so that it provides the necessary adjustment range for alignment of the coil.
Clearance should be maintained at the front of the Power Supply and on all sides of the RF Generator to allow free
movement around access doors and panels. Refer to the Physical Outline Drawings for appropriate clearances.
CAUTION: Do not attempt to install interior components which have been removed from the generator for shipping.
This operation is to be performed by the Thermatool Field Service Engineer.
For installation details, refer to:
• Physical Outline Generator Cabinet
• Lead Layout
Heat Exchanger (Cooling System)
The Heat Exchanger should be positioned as close to the Generator as practical. For installation details, refer to:
• Physical Outline Drawing, Heat Exchanger

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Control Panel
IF the CFI control panels and optional pushbuttons are to be mounted in an existing plant console, the installation
should be performed as indicated on the control panel assembly drawing.
If the control panel is pre-mounted in an optional operator console provided by Thermatool, the operator console
should be positioned where it will provide optimum operator access and good sight lines to the weld area. For
installation details, refer to:
• CFI Welder Control Panel Assembly
• Standard Electrical Device Descriptions and Prefixes
• Welder Controls
Tachometer Generator (Optional Item)
The tachometer generator should be installed at a suitable point on the tube mill drive. If possible, it should be mounted
on the final driven stand before the weld point. The generator should be driven with a belt drive to provide
approximately 1500 RPM at maximum mill speed. For installation details, refer to:

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• Welder Controls
Electrical Interconnections
NOTE: The main auxiliary circuit breakers to the Power Supply cabinet must remain OFF and locked/tagged out until
the arrival of the Thermatool Field Service Engineer.
Once equipment has been correctly positioned on the plant floor, electrical interconnections should be made as
specified in the drawings. Interconnections should be made between the Power Supply and Generator, between the
Power Supply and welder Control Panel, between the Power Supply and Heat Exchanger and between the Power
Supply and Mill Interlock.
All electrical and plumbing connections to the Generator must include flexible cable in order to allow positioning
adjustments via the adjustable support table. Refer to drawings for all interconnections, wire specifications and ratings.
NOTE: All cable entries to the DC Power Supply and the Generator must be made with watertight seals to insure that
the cabinets are sealed against ambient air.
Grounding Precautions
The HF Generator must be connected to ground in accordance with local code requirements. The following precautions
should be observed in making ground connections:
• A ground rod should be provided that is independent of other devices. As with all high frequency
installations, a ground rod is required to minimize the risk of interference from drive system electronics.
• The common grounding point between major system components is located in the immediate proximity of
the HF Generator cabinet.
• The mill base should also be connected to ground, in order to minimize high frequency voltages that may
occur when induction coil insulation is worn or defective, etc. To reduce impedance, ground connections
should be multiplied. The HF Generator cabinets are designed for four "ground" connections to the mill
structure, in order to reduce the impedance to the ground in the event of accidental contact between the
induction coil and the workpiece or structure.
The Generator cabinet internal ground terminal must be connected directly to the Ground Rod. The Power Supply
internal ground terminal must be connected to the Generator cabinet internal ground terminal with an appropriate size
cable as indicated on the interconnect drawings.
All grounding connections are indicated on interconnect drawings.

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System Grounding
Plumbing
Refer to the installation and water line routing drawing for connecting the distilled water piping between the Heat
Exchanger, the Power Supply and the Generator cabinets. Water connections to the Generator must include flexible
hose to allow for positioning adjustments. All distilled water piping and valves must be plastic ABS, PVC, or non-ferrous
material (copper or stainless steel). Unions and shut-off valves should be installed as indicated in the installation drawing.
Raw water supply and return pipes should be connected to the Heat Exchanger as specified in the installation drawing.
Galvanized pipe is suitable for raw water piping. Refer to installation drawing for correct piping diameters.
CAUTION: Flush the supply and return pipes to remove any foreign matter prior to connecting them to the heat
exchanger fittings.
All piping to provide mill coolant to the weld area and work coil should be installed.

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Coolant Preparation
If the system will be subjected to ambient temperatures below freezing, the distilled water coolant must be mixed with
propylene glycol.
Inspection
Inspect all equipment interconnections and make sure all electrical and plumbing connections are tight. Refer to the
pre-start-up checklist to see that all operations have been performed.

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Pre-Start-Up Checklist
The purpose of this checklist is to determine if all items are accomplished prior to the arrival of Thermatool's Field
Service Engineer. It will ensure a smooth installation and get you in production in a more timely and efficient manner.
Welder % Complete Scheduled Completion

1. Positioning of the Power Supply cabinet? (________) (________)
2. Positioning of the Generator cabinet? (________) (________)
3. Positioning of the Heat Exchanger? (________) (________)
4. Interconnecting wiring for welder:
a. Between Power Supply and Generator? (________) (________)
b. Between Power Supply and operator control station? (________) (________)
c. Between Power Supply and Operator (________) (________)
d. Message Display/Thermaview™? (________) (________)
e. Between Power Supply and Heat Exchanger? (________) (________)
f. Between Power Supply and mill interlock? (________) (________)
g. Between table motors and control panel? (________) (________)
5. Plumbing from Heat Exchanger to Power Supply? (________) (________)
6. Plumbing from Power Supply to Generator? (________) (________)
7. Plumbing from cooling tower to Heat Exchanger? (________) (________)
8. Coolant from mill to work coil and nosepiece? (________) (________)
Thermasure™ (Optional) % Complete Scheduled Completion

9. Mounting of the pyro's sensing head (sight tube)? (________) (________)
10. Mounting of the chart recorder? (________) (________)
11. Mounting of the Thermasure control panel? (________) (________)
12. Interconnecting wiring for Thermasure:
a. Between Thermasure panel and chart recorder? (________) (________)
b. Between Thermasure panel and pyro sensing head?? (________) (________)
c. Between Thermasure panel and pyro control? (________) (________)
d. Between Thermasure panel and mill interlock? (________) (________)
Tachometer Generator % Complete Scheduled Completion

13. Mounting of tachometer generator? (________) (________)
14. Interconnecting wiring between tachometer generator to Power Supply? (________) (________)
Output Lead % Complete Scheduled Completion

15. Mounting of the output lead and support stand? (________) (________)
16. Mill coolant to the nosepiece? (________) (________)
Mill % Complete Scheduled Completion

17. When will mill be ready to be threaded with strip? (________) (________)

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Field Service Engineer's Visit and Start-Up
The Field Service Engineer will supervise the installation of the lead set assembly between the Generator and the mill.
He will also supervise the installation of the internal parts of the Power Supply and Generator. All plumbing connections
will be checked for leaks. All components, interlocks and control circuits will be checked for proper operation.
The Field Service Engineer will supervise the connection of the Power Supply to the power source circuit breaker. The
power cables enter the cabinet through the roof. The access cover must be modified to provide water tight seals for
the power cables. The power cable is connected to the line side of main circuit breaker (refer to drawings).
Finally, the Thermatool Installation Engineer will energize the equipment for the first time. He will check all voltages and
coolant flow. He will supervise the selection and adjustment of the work coil and start the welder in production.
Once the welder has been energized and fully tested, and adjustments have been made as required, the Thermatool
Field Service Engineer will instruct plant personnel in its proper operation.

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GENERAL
Overview
Advantages of Thermatool’s Current Fed Welder with CFI Technology
Feature Thermatool’s CFI Current Fed Welder Voltage Fed Inverter

Increased susceptibility & reduced
Tolerant to Coil Arcs Yes – Inherently short circuit proof
reliability
Yes – inherent short circuit protection & Requires additional short circuit
Highest reliability
no RF transformer protection and RF transformer
Larger inverter & limited length RF
Most efficient use of mill space Yes – most compact inverter
connection to Mill
Best Match to Work Coil Load Yes – low voltage, high current output No – Needs RF transformer
Continuous Load Matching at all Yes – AutoMatch™ system works well at No – must change RF transformer
power levels all power levels taps at low power
The image below shows a typical layout of the CFI welder. This section provides a detailed look at the major welder
components shown here.

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System Components
The CFI welding system consists of:
• DC POWER SUPPLY
The DC Power Supply DC power and control voltage. The DC Power Supply also houses:
o Programmable Logic Control (PLC) The PLC performs all operation sequencing control interlocking,
and provides fault diagnostics.
o Ripple Filter
o DC Power Control Circuit Boards
o Speed /Power Control Board
• HF GENERATOR
The HF Generator converts the DC power provided by the DC power supply to high frequency AC power
which drives the induction coil. It is positioned at the tube mill, near the squeeze roll box. A set of output
leads, extends from the HF Generator cabinet to an adapter on which the induction coil is mounted. The
configuration of the lead set is customized to the particular installation. Integral with the lead set assembly are
the AutoMatch™ components which are used to achieve the best match between induction coil and
generator output while holding the rated welding frequency constant.
• HEAT EXCHANGER
Distilled water is circulating in a closed system through a Heat Exchanger and delivered to the Power Supply,
the Generator and the lead set. Nonferrous piping is required in the closed Cooling System.
• OPERATOR CONTROLS
Control panels, including the Operator Message Display, may be either mounted in a separate console
provided by Thermatool Corp., or integrated with the tube mill control console.

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Power Supply
The power supply consists of:
• Power Components
o Circuit Breaker and Contactor
o Power Line transformer
o SCR 3 Phase Bridge Rectifier &Control
o Boards (DC1 & DC2)
o DC Choke
o Ripple Filter
• Control Components
o Programmable Logic Controller (PLC)
o Speed Power Control
o Circuit Breakers
• Interfaces for Optional Equipment

o Interfaces for Optional Equipment
o ThermaSure™
o ThermaView™

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Power Components
The DC Power Supply accept - 3 phase AC electric power at customer specified line voltage. (See Fig. 1, page GEN-4)
Incoming AC electric power input is controlled by the main circuit breaker and contactor. When the circuit is energized:
• Power is fed to the primary of a step-down power transformer;
• The transformer converts the incoming line voltage to the voltage level necessary to supply the inverters;
• The AC power is rectified to give a maximum of 250 volts DC power at the output.
A key feature of the DC supply system is the low operating voltage, which is only 300 VDC maximum. This low voltage
(compared to 10,000 VDC typical of the vacuum tube system) will relieve many difficulties users may have experienced
with insulation breakdown and corona.
Safety features include:
• Overcurrent and overvoltage protection;
• Complete protection against short circuits and open circuits at the lead set;
• EMERGENCY STOP button mounted directly on the outside of the cabinet;
• Interlock switches on all doors to shut system if any door is opened;
• Power Supply cabinet equipped with interior lighting and Fitted with lift-off doors P or ease of access;
• Low voltage operation of solid state devices eliminates insulation breakdown and corona problems.

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Power Supply Door Switch Generator Door Switch
Door switches are fitted to all cabinet doors that allow access. Opening a door will open the main circuit breaker. Power
is still present at the control transformer circuit breaker, the primary of the control transformer, and part of the 115 V
control circuit not disconnected by the main circuit breaker. These can be disconnected by the manual auxiliary
disconnect switch integrated with the DC Power Supply's control section door latch for safe maintenance of the
equipment.
The 3-phase AC output from the power transformer is rectified to a variable DC voltage by phase controlled SCRs
(thyristors) connected in a full wave, 6 pulse SCR bridge.
The SCR's are controlled by a trigger circuit system composed of the DCI and DC2 power control circuit boards. The
command input for this system comes from either the WELD POWER control potentiometer for manual power settings,
or from the speed power control system for automatic setting. The speed power control is driven from a tachometer
generator connected to the mill drive so that welder power changes directly with mill speed.
The power supply system includes full regulation of the DC output to maintain a constant voltage even as the AC input
voltage varies ±7%. The DC output is filtered to remove ripple which is important in order to maintain a constant bead
and smooth weld in the tube.

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Control Components
• Programmable Logic Controller (PLC)
The PLC handles all control logic and diagnostic dis- plays. Located in the Power Supply cabinet, it is the primary
control and fault monitoring system of the welder. If there is a fault, a message is sent to the Operator Message
Display.
Programmable Logic Controller (PLC)
• Speed-power Control
Allows welder output power to track mill sped automatically.
• Auxiliary circuit breakers and motor starters
Provide protection for motors, transformers, and other electrical components.
Interfaces for Optional Equipment
• ThermaSure™ Connections for linking power control with the optional ThermaSure™ dual wave length optical
pyrometer which regulates weld temperature. This provides increased pipe or tube quality by varying the weld
power to achieve constant weld temperature.
• ThermaView™ Connections for linking monitors of power, safety interlocks, and temperatures to the optional
ThermaView™ computer systems. These systems provide:
• Monitoring and historical trend display of the key welder parameters, output current, weld power and weld
frequency.
• In depth diagnostic operator prompting for rapid recovery from fault conditions.
• Several tooling and production data base features.

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HF Generator
High Frequency, High

power capacitor bank
Watercooled high-frequency 50kw module pairs
The HF Generator consists of:
• HF Control Card
• Positive & Negative Power Modules
• Auxiliary Power Supply
• Positioning Table
• Cooling System
• Parallel & Series Output Capacitors (Cp,Cs)
• Lead Set, AutoMatch™ Components & Induction Coil

o Series load Match Inductor
o Single turn Inductor
o Motor Drive Mechanism
o Plate system
• Parallel load Match Inductor

o Coil
o Motor Drive Mechanism
o Slug

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The HF Generator uses MOSFET (Metal Oxide Semiconductor Field Effect Transistor) switches to convert the DC power
provided by the Power Supply to high frequency AC power that drives the induction coil. This is fed to a parallel
oscillating circuit, consisting of the induction coil, and parallel and series load match inductors, and series and parallel
capacitors, that resonates at the welding frequency.
Power Modules

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• Positive & Negative Power Modules
Power Modules house the MOSFET switches. They are switched at the welding frequency which is determined
by the resonance of the output circuit. The forced switching action results in a sinusoidal AC voltage being
generated across the induction coil. There are two types of power modules, positive modules and negative
modules. Facing the HF Generator from the rear, the positive modules are on the left and the negative on the
right. Positive modules switch the positive leg of the incoming DC power, while negative modules switch the
negative leg. Positive and negative modules are not interchangeable.
HF Control Card

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• HF Control Card
The timing control for driving the MOSFET switches is accomplished by a High Frequency Control Card. The
control card monitors the resulting voltage across the output circuit and switches the HF current to keep the
two in phase.
The phase relation is defined by the resonant frequency of the output circuit. Switching the output circuit at its
resonant frequency is the point of most efficient power conversion.
The circuit continuously monitors the control signals for range and limits. If the design limits of voltage, phase
or frequency are exceeded, this circuit will safely shut down the welder and send this information to the PLC for
fault reporting.
The output of the HF Generator is fully protected against short circuits and arc overs. The control design allows
the welder to "ride through" most arc overs in the "Vee" of the pipe. Hard arc overs on the leads or coil will
automatically shut down the welder, to protect the high frequency power components from overcurrent and
power surges.
• Parallel & Series Output Capacitors
The Parallel and Series Capacitors are mounted in the output section of the welder. They form the capaci- tance
of the resonant output circuit. They also boost the output voltage of the modules to the value needed to drive
the induction coil.
• Auxiliary Power Supplier
The auxiliary Power Supplies ore used to power the drive networks of the power modules and the HF Control
card. They are located in the rear of the Generator enclosure.
• Positioning Table (Optional)
Because the lead sets are attached directly to the generator cabinet, the cabinet is usually mounted on an
adjustable table. The positioning table can be specified for single or multiple directions of movement. In order
to control the positioning of the coil relative to the tube being welded, the table can generally be moved on
two axes and may be either motorized or manually controlled by means of screw mechanisms. This helps obtain
the best "Vee" length, and position the coil for a range of tube sizes.
• Positioning Table

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• Cooling System
Cooling water distribution and monitoring is located in the bottom of the HF Generator. It consists of two
separate water circuits, one for the HF Generator and one for the load match inductors and lead set. Each water
circuit has a control valve, set to supply the correct flow and to balance the flow between the two circuits. Each
circuit contains a flow switch which will cause an alarm and shut off the welder should cooling water flow rate
drop below the required level.
• Lead Set, AutoMatch™ Components & Induction Coil
Output leads transfer the HF Generator's power to the induction coil. Lead Sets are custom configured to the
installation in order to achieve optimum placement of the HF Generator. Lead Sets are constructed in line with
the long axis of the generator cabinet and are enclosed in an aluminum housing. The size and length of the
leads are scaled to the output power of the welder, and the mill application. The leads must be carefully de-
signed because the HF energy only passes on the surface of the copper conductors, due to the high frequency
"skin effect". Water cooling of these conductors is necessary because of the high current density experienced
with HF currents.
The CFI welder has the ability to adjust itself automatically to the load. We call this the AutoMatch™ system, it
can be set manually, or automatically, from the control console, through a set of switches.
The Lead Set also contains the Series AutoMatch™ inductor and the Parallel AutoMatch™ inductor. Series
Inductor plates move IN and OUT and the Parallel Slug moves UP and DOWN. The Series inductor is composed
of a high current water cooled Single Turn Inductor and moving plates (shorted turn). The plates move IN
toward or OUT away from the Single turn inductor and their position determines the Single turn inductor’s
inductance. The plates are moved to adjust the Series inductance of the output circuit to MATCH the load.
Moving the plates IN reduces Series Inductance and causes Voltage to decrease while Current increases.
Moving the plates OUT increases Series Inductance, increasing Voltage and decreasing Current. The Parallel
inductor is composed of a high current water cooled copper coil. A ferrite slug is inserted into each coil and its
position determines the coil's inductance. The slug is moved to adjust the total inductance of the output circuit,
so that its resonance is at the rated weld frequency. Moving the slug DOWN causes the output frequency to
decrease and moving the slug UP causes the output frequency to increase. The slug and plates are moved
electrically via a motor drive mechanism mounted on either side of the lead set.

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AutoMatch™
The induction coil is an essential part of the welding system. Thermatool provides coils in a variety of designs
and sizes. The precise configuration of the coil is dependent upon the size, wall thickness and composition of
the tube being welded. Coils used in CFI applications are made of hard drawn, hollow copper tubing, banded
copper tubing, or copper strip and are insulated to protect against flashover and to give the longest life. One
turn coils are provided for larger tube diameters and two or three turn coils are provided for smaller tube
diameters. Coils are cooled by mill coolant circulated through the hollow tubing or through cooling tubes
attached to the coil.
Coils are most often used with an impeder, in order to maximize welder performance and minimize power
consumption. The impeder must be correctly matched to the pipe or tube being welded. Only Thermatool
supplied coils should be used with the welder.
Induction coils

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Heat Exchanger and Coolant
The Heat Exchanger system draws away the heat generated by power losses in the welder system. Distilled water is
circulated through heat sink in the equipment and then through the Heat Exchanger. Plates in the Heat Exchanger
assembly pass the heat recovered from the equipment to the external cooling water. A cooling tower may be used to
pass this heat to the outside air, or ground water.
Thermatool requires distilled water in the closed loop from the Power Supply and HF Generator to the tank and pump
of the Heat Exchanger. A stainless steel pump, stainless steel cooling plates, and industrial stainless steel tank and PVC
fittings are used on the Heat Exchanger itself. Only nonferrous materials are used for the internal water pipes in the
Power Supply and HF Generator in order to keep particles of rust from the water.
The water temperature is regulated by an automatic control valve in the Heat Exchanger. It acts to increase or decrease
the flow of outside cooling water as needed to maintain the proper water temperature for the welder.
Heat Exchanger

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Cooling System Controls
The Cooling System has automatic controls. There is no manual control, nor are there manual overrides.
The water tank level indicator switch is mounted in the tank to monitor the cooling water level. A low level will prevent
the breaker from closing, but after it is closed, only an uptime warning message will occur unless the low level occurs
in conjunction with a low water flow condition. This will then trip the breaker.
The pump is switched on automatically during the start-up sequence of the welder (automatically supplying proper
water pressure and flow to the closed loop of the distilled water circuit).
Pump
Water Tank
Level Indicator

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Operator Controls
All controls for the system are mounted on panels which can be located in a separate cabinet or mounted at the mill
control panel. The control unit features an alphanumeric operator message display, controls to operate the welder,
switches, potentiometers, and meters for current and voltage. The panels should be mounted where they can be easily
tended by the operator while maintaining good sight lines to the welding area. Where possible, it may be desirable to
mount the panel together with the mill control panel for operator convenience.

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Additional System Features
Water Flow Switches

Water flow switches are provided to protect against water flow failure in each critical circuit. Separate switches are
provided for the Power Supply, HF Generator, and the Lead Set. Each water flow switch assembly contains a reed switch.
This switch will be closed when the correct flow is passing through the circuit. The reed switch must be open to allow
the start-up sequence to function correctly. A flow switch "stuck" in the closed condition will inhibit start-up of the
welder.
Thermal Switches
Each High Frequency Inverter Module has a 55ºC self-resetting Thermal Switch mounted on its heat sink. If the module's
heat sinks exceed this temperature, an "HF GENERATOR FAULT" message will be displayed on the Operator Message
Display and a fault light will light on the module.
Three manual reset, thermal switches are mounted on the RF bus work which trip at 52°C or 63ºC depending on
location. If any of these switches activate due to over temperature, they must be reset by pressing the red button
located in the center of the switch. The alarm message is:
ALARM: RF CABINET
HIGH WATER TEMP 2TS1
Four manual reset thermal switches are mounted on the lead set and load matching inductors. These trip at 52º C. If
any of these switches activate due to over temperature, they must be reset by pressing the red button located in the
center of the switch. The alarm message is:
ALARM: RF LEADS
In DC Power Supply there is an ambient temperature switch and a temperature switch monitoring the incoming water
temperature.
The incoming water temperature switch trips at 38º C. Ambient temperature switch trips at 66º C and gives message:
ALARM: RF LEADS
If the ambient temperature trips while welding, a warning message will first be displayed allowing the operator to take
action. If no action is taken within 5 minutes, the welder will shut off, displaying this message:

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WATER TEMP HIGH WELD

POWER= 111 KW
If the water level in the water tank in the Cooling System drops below a preset level, the water level switch opens.
Water Tank level

indicator switch
Tachometer Generator (Optional)
A tachometer generator is supplied to be mounted on the tube mill drive. It is connected to the speed/power control
board mounted in the Power Supply cabinet and provides mill speed information used by the control when it is in the
Automatic mode.
NOTE: If your weld line uses a different tachometer generator, make sure to check specifications with Thermatool's
Customer Service prior to installation.
Tachometer

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System Protection Features
EMERGENCY STOP PUSHBUTTON
EMERGENCY OFF PUSHBUTTON (with pull to reset)
Location:
• One (1 ) on the Power Supply center panel adjacent to the switch gear access door (1 -PB1)
• One (1) on the HF Generator cabinet (2-PB1)
DOOR SWITCH
Door switches (1 -DS1 and 2) are fitted to the doors which allow access to the Power Supply (the control section door
is protected by the control circuit isolator 1 -SI). Opening of a door will open the main circuit breaker. Power is still
present at the control transformer circuit breaker, the primary of the control transformer, and part of the 115 V control
circuit which can be disconnected by the control circuit isolator switch (I 61).
Door switches (2 -DS1,2,3,4 and 5) are fitted to the Generator doors. Opening of a door will also open the contactor.
Door Switch
System Options
ThermaSure™
Please refer to the supplemental manual if ThermaSure option for Thermatool Monitoring has been purchased.

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OPERATION
Introduction
The Operation Section provides step-by-step assistance for the daily and routine operation of the CFI welder. The
section is divided into four parts:
• Safety;
• General Setup;
• General Operating Information;
• Operating Sequences.
For a more detailed discussion of system faults and corrective actions see the Troubleshooting Guide.

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Safety
Safety Rules
1. CAUTION: THE ELECTRICAL POWER USED IN THIS EQUIPMENT CAN KILL OR SERIOUSLY INJURE AND
CAUTION MUST BE USED DURING OPERATION AND OR MAINTENANCE OF THE WELDER.
2. During operation, the High Frequency voltage at the leads and induction coil is strong enough to kill. Never
touch the leads or the induction coil when the welder is on.
3. The safety interlocks of the welder are controlled by logic control circuits. Do not modify this logic control. Any
errors could jeopardize safety and damage the welder. Modification of the logic control circuit will invalidate all
warranties.
4. Access to the equipment should only be by authorized, competent personnel. The keys for the equipment
should be entrusted to a responsible person.
5. Maintenance, fault detection and troubleshooting should be done by qualified persons, following the
instructions of this manual, as well as the drawings and documents specific to the system.
6. All doors and covers should be closed and locked when the equipment is powered. Do not try to defeat or
bypass the internal safety locking systems.
7. Always turn off the main breakers before opening the doors or removing the sides.
8. Always lock and tag the breakers in the open position before working on the equipment. Place warning signs
on the breakers, leads or substations.
9. Report all faults immediately and take the equipment out of service until an inspection is conducted by qualified
personnel. When in doubt, contact Thermatool Customer Service.
10. Protect yourself from the danger of electric parts, wires, cables and other risks, such as hot or sharp parts.
11. Do not operate the equipment if wires are cut, pans loosened or water is leaking.
12. The water supply valves should be operated slowly to avoid the water hammer effect and allow a normal rise
in pressure of the lines.
13. Be mindful of the possibility that strong streams of water could leak from an electrical part when the Power
Supply or Generator cabinet doors are open. Maintain a safe distance (6 feet / 2 meters minimum) when the
DC power is on.

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14. Never perform maintenance alone. During testing, make sure that your hands and the special footwear
designed for this purpose are dry.
15. If any safety interlock is broken or not working, all troubleshooting should be suspended until the interlock is
repaired.
16. Never disconnect or connect the measurement cables when the welder is powered. Never change the
measurement range or function of the measurement instrument when the welder is powered.
17. All apparatus and tools used on the unit should have a grounded power cable.
18. It is possible that heart pacemakers will be affected when in close proximity to the equipment, particularly under
test conditions with the doors open and/or panels open.
SAFETY SUMMARY
There are always potential risks when working in the presence of magnetic fields and dangerous voltages. All mill
operators, maintenance personnel and supervisors should be aware of the safety measures presented in this manual.
Copies of these safety measures should be posted in a prominent place at the work site so that everyone working
around the equipment has access to them.
Failure to obey all warnings given in this manual may result in serious injury or damage to the equipment.
The safety measures summarized here are only recommendations and should not supplant or replace the official
regulations issued by the national government, the local authorities, governmental or internal bodies imposed by the
company.
The procedures for operation, maintenance, and safety should be strictly observed.
CAUTION: Unsafe practices can undo even the most thorough safety protection devices. Think safety first.
• Do not operate the welder or the mill with any safety interlock switches bypassed or wired out.
• Do not operate with doors open or when protective devices have been deactivated or compromised in any
way.
• Do not operate when protective panels have been removed from any part of the equipment.
• Maintain good housekeeping around both welder and mill - clean up spills immediately to avoid risk of slipping.
• Avoid loose clothing and hair - do not wear ties or jewelry.

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• Always wear safety glasses and other safety equipment.
• Look up and down the length of the mill before starting or jogging it.
Setup
The general setup procedure includes:
• Induction coil Selection
• Impeder Selection
• Determining Required Welding Power
Induction Coil Selection
NOTE: A Thermatool installation engineer assists in determining the optimum induction coil position.
The appropriate induction coil must be properly attached to the output leads. Because the induction coil itself is part
of the Generator's high frequency resonant circuit, selecting the correct induction coil configuration is crucial to the
operation of the welder. An inappropriately configured or positioned induction coil can harm weld quality and may
even prevent the welder from starting.
Select the induction coil for the size of pipe or tube to be welded from the table on the following page.
Induction Coils

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Coils for Standard CFI Welders

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The induction coil should be positioned so that there is symmetrical clearance around the tube. Position the induction
coil directly upstream of the weld rolls, leaving at least 3/16" clearance (depending on size and application) between
the nearest part of the induction coil and the rolls.
A = 1/4 inch (6.25 mm) B = 3-4 x induction coil diameter D = one tube outside diameter
CL = Coil Length CID = Coil Inside Diameter
The induction coil should be positioned so that the "Vee" length measured from the apex of the "Vee" to the edge of
the induction coil is about one tube outside diameter (see Figure 1). This can be accomplished using the positioning
table and by forming the leads of the induction coil. Coil leads between the induction coil and the induction coil holder
should be as short as possible and the gap between induction coil holder and the nose piece should be minimized.
Minimize gap between Induction Coil Holder

and Nose Piece
Minimize gap between Induction Coil and

Induction Coil Holder

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Impeder Selection
The impeder must be of high quality low loss ferrite with a minimum 5000 gauss saturation limit. Position the impeder
so that the ferrite extends beyond the "Vee" by about 1 /4" (Dimension A, Figure 1). It should protrude at least one
induction coil diameter from the rear of the induction coil for efficient operation of the welder.
Determining Required Welding Power
The weld speed, pipe diameter, pipe wall thickness and welder output power are all interrelated. The accuracy of the
relationships depends on the proper location and dimensions of the induction coil and impeder, and correct
presentation of the edges of the incoming strip.

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General Operating Information
This section includes:
• Speed Power Control:

o Manual
o Automatic
• Load Matching
• Fault Clearing/Resetting Welder
• Test Mode
Speed Power Control
Manual Mode
In MANUAL mode, power output is controlled by the operator, rather than having power change automatically with
mill speed. The Meld temperature control dial sets the amount of power delivered to the weld.
When in MANUAL mode, the operator must activate mill start prior to pressing heat on; the welder operates
independently from mill speed.
Start the mill and then press the HEAT ON pushbutton. After the HEAT ON button is pressed, the welder output is
powered, and will operate at the weld temperature set by the operator. If the HEAT ON pushbutton is pressed while
the mill is running and the welder is on, the HF output power will be temporarily shut off as long as the button is held
in. This is usually done when a questionable length of material goes through the mill. Once the pushbutton is released,
the normal amount of HF power returns.
Pressing the HEAT OFF pushbutton will stop the welder only.
NOTE: Bring welder power down as the mill slows down or the tube will be damaged!
It is difficult to control weld power exactly with the mill speed in MANUAL mode. Expect lost product at start up and
shut down.

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Automatic Mode
The normal and preferred mode of operation is AUTOMATIC. When in AUTOMATIC mode, the welder waits for the
mill to start before delivering HF heating power to the tube or pipe. Also, the amount of power will change automatically
with the mill speed.
When the welder is ready to run, it will provide a welder OK interlock signal to the mill. This will permit mill start-up.
The normal practice is to set up the welder, press the HEAT ON button, then start the mill.
Setting the PREHEAT control provides the additional power necessary to bring the cold tube to temperature as the mill
speeds up. As the mill comes up to speed, the output power will increase automatically. The weld temperature control
dial sets the amount of power delivered to the weld when the desired mill speed is achieved.
As the mill slows down, the HF welding power will automatically reduce. As the mill comes to a stop, the HF welding
power is automatically shut off. The signal from the Tachometer Generator controls this process through the Speed
Power Control board.
If the HEAT ON pushbutton is pressed while the mill is running and the welder is on, the HF output power will be
temporarily shut off as long as the HEAT ON button is held in. This is usually done when a questionable length of
material goes through the mill. Once the pushbutton is released, the normal amount of HF power returns.
If the HEAT OFF pushbutton is pressed while the mill is running, or if a fault Develops in the welder system, the HF
output power is shut off, and the WELDER OK interlock to the mill drive is opened. This will stop the mill.

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Load Matching
On standard CFI welders, two variable inductors are provided in the lead set to match the load presented by the
induction coil to the characteristics of the welder. The series inductor consists of a single turn inductor and plates,
actuated via a motor and pulley system, mounted in the output lead set. The parallel inductor is a coil inductor with
ferrite core slug actuated via a motor and belt system, mounted on the lead set in the vertical position.
Series AutoMatch™
The series inductor is used to adjust the match between % voltage and % current. It also affects the output frequency.
The parallel inductor maintains rated welder frequency once the series inductor is adjusted. While the primary control
far matching current lies in the dimensions and configuration of the induction coil itself, the series inductor provides
a means of fine tuning the circuit to correct for variations in impeder configuration and tube size and wall thickness. It
may also provide adjustment when switching between multiple-turn induction coils used for small tube sizes and the
single-turn coils used for the larger tube sizes.
When the welder is run at full power, the goal of series inductor adjustment will be to achieve equality between the %
voltage and the % current. In a situation which calls for welding at less than full output power, efficiency will be improved
somewhat by increasing the % voltage while decreasing the % current. For less than full power welding, the series
inductor may be used to improve welding efficiency.
The parallel inductor is adjusted to maintain rated welder frequency after the series inductor is adjusted.

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Fault Clearing / Resetting Welder
The RESET button is pressed after a system fault interrupts operation. The light on the RESET button should be out in
order for the welder to start. Pressing RESET with the "STANDBY/READY" switch in the correct position should reset the
welder's control logic and extinguish the light, if all faults have been cleared. The Operator Message Display will indicate
which fault is present. When a fault occurs, corrective action must be taken (see Troubleshooting Guide) and then the
welder must be reset.
When RESET is pressed, all lamps should light (lamp test) and the meters should read full scale (meter test).
The following welder faults require a welder reset:
ALARM: POWER SUPPLY DOOR OPEN
ALARM: RF GENERATOR DOOR OPEN
ALARM: RF GENERATOR EMERGENCY STOP
ALARM: POWER SUPPLY EMERGENCY STOP
ALARM MILL EMERGENCY STOP
ALARM MAIN BREAKER TRIPPED/OPEN 1 -CB1
ALARM CONTACTOR TRIPPED/OPEN 1 -CON 1
ALARM: CHOKE/EXCH WATER FLOW LOW 1-FLS2
ALARM: SCR WATER FLOW LOW 1 -FLSl
ALARM: POWER SUPPLY AMBIENT TEMP HIGH
FAULT: AUX CIRCUIT BREAKER OPEN
E-STOP RELAY 1 –ESR1 OPEN, PRESS "RESET"
ALARM AC LINE VOLTAGE/ PHASE LOSS
ALARM DC OVERCURRENT DETECTED
ALARM RF GENERATOR PROTECTION ACTIVATED
ALARM 1 -DC 1 CARD FAILURE (K3)

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FAULT: HEAT OFF SWITCH OPEN (4-PB2)
FAULT: HEAT ON SWITCH CLOSED (4PB1)
ALARM RF LEADS HIGH WATER TEMP 2TS2 RESET TEMP SW.
ALARM: RF CABINET HIGH WATER TEMP 2TS1 RESET TEMP SW.
ALARM: POWER SUPPLY DOOR OPEN
ALARM MODULE FAULT SWITCH TO "SHUT DN"
If the RESET button is pressed while not welding, the Operator Message Display will show:
"RESET" PB PRESSED LAMP

AND METER CHECK
If there is more than one fault accounting for the shutdown, the Operator Message Display will show fault messages
according to a predetermined hierarchy. Once the RESET pushbutton has been pressed for one fault, the unit will
continue in shutdown and the next fault message will be displayed.
NOTE: If the reason for the shutdown is a fault somewhere in the mill and not in the welder, the condition will have to
be remedied before normal operations can resume.

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Operating Sequences
Operation of the equipment is controlled from the operator control panel.
The main operating sequences include:
• START UP SEQUENCE - SPEED POWER CONTROL IN MANUAL MODE
• SPEED/POWER CONTROL - SWITCHING FROM MANUAL TO AUTOMATIC MODE
• START UP SEQUENCE - SPEED POWER CONTROL IN AUTOMATIC MODE
• LOAD MATCH ADJUSTMENT - MANUAL MODE
• LOAD MATCH ADJUSTMENT - AUTOMATIC MODE
• SHUTDOWN
• EMERGENCY STOP
CAUTION: All doors and panels must be closed. All emergency stop buttons must be functioning properly.

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Start-Up Sequence - Speed Power Control in Manual Mode
1. Verify that the MODE switch on the SPEED/POWER control board in the Power Supply cabinet is set to
MANUAL. (Be sure to lock cabinet doors after checking.)
2. Ensure that the mill is ready to run.
3. Visually check water level in the Heat Exchanger tank and determine that cooling water is available to the
primary loop of the Heat Exchanger.
4. Make other pre-start checks as necessary.
5. Insure that WELD TEMP control is set at the minimum.
6. Close the auxiliary and the external main circuit breaker to the welder. This powers circuits and allows the
PLC to be energized so that system diagnostics can take place. Power is not delivered to the weld head.
The Operator Message Display will display a message identifying the welder:
THERMATOOL CORP. @
COPYRIGHT 1995
CFI WELDER
NOTE: If no message appears in the Operator Message Display, check internal circuit breakers for the PLC
and Operator Message Display.
The welder will then go through a self-test during which the PLC checks for a preexisting fault. If a fault is
found, a fault message will be displayed on the Operator Message Display. See the Trouble- shooting Guide
for description and recommended action.
Once the self-test is completed (approximately 3 seconds) the Operator Message Display will display the
following message:
WELDER SELF TEST OK

SWITCH TO "STANDBY"

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7. Set the SHUTDOWN/STANDBY switch on the control panel to SHUT DOWN and then to STANDBY. The
Operator Message Display will now read:
STARTING COOLING SYSTEM
MANUAL POWER CONTROL

START MILL
PRESS WELDER "HEAT ON"
8. Check the positioning of the induction coil. If necessary, readjust it, in order to achieve optimal positioning
of the induction coil relative to the work and the mill. If the adjustable table is motorized, use the positioning
control knobs to move the generator and bus bar assembly. If the table is not motorized, use the manual
control mechanism to make the necessary adjustment.
Start the mill and then:
9. Power the welder by pressing the HEAT ON button. The weld head will now be powered. The Operator
Message Display will display the message:
WELDER HEAT ON PUSH

BUTTON PRESSED
The welder will now perform a diagnostic to determine whether welding can proceed. If the welder is not
able to weld after the HEAT ON button is pressed, a message will be displayed on the Operator Message
Display. (See the Troubleshooting Guide for a list of fault messages and corrective actions.) In MANUAL,
the mill must first be running before the welder will start and the welder will shut off if the mill stops.
FREQUENCY = ### KHZ

WELD POWER = ###KW

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10. Increase the weld temperature control to achieve the desired weld temperature. The Operator Message
Display will continue to display the power delivered and the welding frequency.
FREQUENCY = ### KHZ

WELD POWER = ###KW
11. Continue to adjust the weld temperature control as necessary to maintain a good weld.
Speed/Power Control - Switching From Manual to Automatic Mode
1. Once optimum weld temperature has been determined, turn the MANUAL/AUTO control knob on the
SPEED/POWER Control card inside the DC Power Supply cabinet to AUTO. The PLC will then use the
tachometer on the mill to measure mill speed. The PLC will then adjust the temperature accordingly as mill
speed changes.
2. In automatic mode, weld power control is managed by the welder; the weld temperature control can only
be used as fine tune adjustment to the weld heat.
Start Up Sequence - Speed Power Control in Automatic Mode
CAUTION: ALL DOORS AND PANELS MUST BE CLOSED. ALL EMERGENCY STOP BUTTONS MUST BE FUNCTIONING
PROPERLY.
1. Verify that the MODE switch on the SPEED/POWER control circuit board is set to AUTO. In automatic mode,
weld temperature will be controlled by mill speed. The power level will be based on the weld temperature
control setting.
2. Ensure that the mill is ready to run.
3. Visually check water level in the Heat Exchanger tank and determine that cooling water is available to the
primary loop of the Heat Exchanger.
4. Make other pre-start checks as necessary.
5. Close the external main circuit breaker to the welder. This applies power to the welder's circuitry and allows
the PLC to be energized so that system diagnostics can take place. Power is not delivered to the weld head.
The Operator Message Display will display (for 10 seconds) a message identifying the welder:

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THERMATOOL CORP.
@ COPYRIGHT 1994
NOTE: If no message appears in the Operator Message Display, check internal fuses for the PLC and
Operator Message Display.
The welder will then go through a self-test during which the PLC checks for a preexisting fault. If a fault is
found, a fault message will be displayed on the Operator Message Display. (See the Trouble- shooting
Guide for description and recommended action.) Once the self-test is completed the Operator Message
Display will display the following message:
WELDER SELF TEST OK SWITCH

TO "STANDBY"
6. Switch from SHUTDOWN to STANDBY. The Operator Message Display will read:
STARTING COOLING SYSTEM
7. Check the positioning of the induction coil. If necessary, readjust it, in order to achieve optimal positioning
of the induction coil relative to the work and the mill. If the adjustable table is motorized, use the positioning
control knobs to move the generator and bus bar assembly. If the table is not motorized, use the manual
control mechanism to make the necessary adjustment.
8. The following message will be displayed while adjustment is made to the weld table and load match
inductors:
MILL READY PRESS "HEAT ON"
9. The operator will start the mill. The message will read:
FREQUENCY = nnn KHZ

WELD POWER = nnnn KW

tel: 203.468.4100
31 Commerce Street
10. The mill will start the welder if the "HEAT ON" pushbutton has previously been pressed and the welder is
ready. The following message will be displayed:
SYSTEM READY START MILL
11. In automatic mode, gross temperature regulation is controlled by the welder to match mill speed. However,
slight adjustments can be made by adjusting the temperature control.
Load Match Adjustment - Manual Mode
To adjust the series and parallel inductors manually:
1. Place the "AUTO MANUAL" switch in the "MANUAL POSITION".
2. Start the welder and use the pushbuttons for the series inductor to adjust the voltage and current meters
so that the indicator needles are at the same angle.
3. Use the pushbuttons for the parallel inductor to adjust the weld frequency until the welder's rated value is
displayed. When pushing the "IN" or "OUT" pushbutton the inductor will move in the appropriate direction
until the limit switch is reached. This will light the pilot on the pushbutton.
Now, readjust the series inductor as described above, then use the parallel inductor buttons to "touch up" the frequency
adjustment. It generally takes more than one pass to satisfactorily adjust the inductors.
Load Match Adjustment - Automatic (AutoMatch™) Mode
CFI welders have an AutoMatch™ feature which automatically adjusts the series and parallel inductors while the welder
is operating. AutoMatch™ is in effect when in AUTO and weld power is greater than 10%. The load match is checked
every 90 seconds for a duration of 15 seconds. In effect it is on for 15 seconds, off for 90 seconds. The match is
immediately checked when power initially goes above 10% or when it is switched from MANUAL to AUTO.
You are under automatic control when the following conditions exist:
a. AUTO/MANUAL switch is in AUTO

b. Weld power is greater than 10%.
1. If, when starting the welder, the series and parallel inductors are in a position where the welder cannot be
operated within its design frequency range, the welder will not start when the HEAT ON button is pressed.

tel: 203.468.4100
31 Commerce Street
This message will be displayed:
RF PROTECTION ACTIVE
ADJUSTING LOAD MATCH
2. The inductors will be automatically repositioned.
3. Once this happens, pressing “HEAT ON” should start the welder.
If this does not happen, the induction coil needs to be changed to one that is appropriate for the pipe or tube being
fabricated or the impeder needs to be correctly positioned or replaced.
Shut Down
For normal shutdown, press the HEAT OFF button on the welder control. HF power will no longer be delivered to the
lead set while power to most other systems will be maintained, thus placing the unit in Standby mode.
If the system is shut down in MANUAL mode, the welder is first shut off by pressing HEAT OFF and then the mill is
stopped by pressing the MILL STOP button on the mill drive control panel. The welder is shut off before the mill is
stopped to prevent overheating and burning of the tube, and possibly damaging the induction coil and the impeder.
Shutting down in the MANUAL mode results in open seam tube as the mill slows down.
Pressing the HEAT OFF pushbutton will immediately turn the welder off in both modes.
In AUTO mode the welder will continue to produce heat until the mill stop, unless the HEAT OFF button is pressed.
Emergency Stop
Unlike the HEAT OFF control, the EMERGENCY STOP button opens the main contactor in the power supply. There will
be an open seam in the tube as the mill slows down.

tel: 203.468.4100
31 Commerce Street
MAINTENANCE & TROUBLESHOOTING

Basic Principles of Good Maintenance
Safety Warning
Equipment maintenance should only be conducted under the supervision of a trained and authorized engineer.
Maintenance procedures should only be carried out as directed by Thermatool’s Service Department.
Read and understand the safety warnings contained in the Operation section of this manual before undertaking any
maintenance task. Appropriate safety measures must be taken to protect all personnel when operating this equipment
with doors open and/or panels open.
All mechanical and electrical interlocks MUST be checked for proper operation before any maintenance function is
performed.
Under NO circumstances should any interlock be bypassed, jumped, have its function compromised in any way.
ALL testing will be performed with safety devices in place and functioning.
In the event that any safety interlock is found to be nonfunctional, all further troubleshooting will cease until said device
is restored to its normal functioning state.
Equipment must be locked out and tagged out prior to any maintenance.
Preventive Maintenance
The most important maintenance is preventive maintenance. This can be practiced by the operator in maintaining a
clean mill environment, and in conducting routine daily and weekly equipment and operational checks.
Cleanliness is Critical
Running a clean mill is essential to producing good welds. Chips, slivers, and dirt which tend to accumulate around the
forming stands of the mill must be routinely removed, so that they do not migrate to the weld area. If they get into the
"Vee" of the tube, dirt, chips or other foreign matter may become trapped in the weld and cause defects. Slivers are a
constant threat in the welding area and must be guarded against at all times. Slivers can cause pre-arcing in the "Vee",
leading to weld defects, and can damage the induction coil or the Generator itself by creating arcing conditions. Remove
accumulations of dirt, tailings, slivers and chips on a regular basis.

tel: 203.468.4100
31 Commerce Street
Routine Maintenance Checks
The operator, who is in daily contact with the equipment, is generally the first person to observe maintenance problems.
Maintaining an awareness of the operating condition of the welder and observing any changes in that condition should
be part of the operator's normal activity. Early detection and reporting of changes in the welder's condition will allow
problems to be dealt with before more serious problems develop.
NOTE: An operator who pays attention to the condition of the equipment and conducts routine maintenance checks
on a regular basis, can be the key to maintaining the welding equipment in top working order and preventing material
waste and downtime.

tel: 203.468.4100
31 Commerce Street
Daily Maintenance Check

tel: 203.468.4100
31 Commerce Street
Weekly Maintenance Check

tel: 203.468.4100
31 Commerce Street
Good Troubleshooting Practices
The troubleshooting section covers the most common problems that occur with welder operation and weld quality.
These are problems for which the operator must be watchful during mill operation.
The sooner a problem is identified, the sooner it can be solved, with the least damage to equipment and least loss of
material.
We recommend the following good troubleshooting practices:
1. For each condition, complete only one corrective action. Then observe the result. Go down the list,
completing each corrective action one at a time, and observing the result. By this method, you will isolate
exactly which action was effective in solving the problem, and thereby determine which condition caused
the problem.
2. Take careful notes as you go through your troubleshooting procedures. Even if you do not succeed in
solving the problem, this information will be valuable to the Maintenance Engineer or the Thermatool
Engineer in continuing the troubleshooting process.
3. As with all equipment, there will be times when something goes wrong which seems to defy diagnosis, such
as:
a. Overloads tripping for what seems like no reason;
b. Welder will not start up;
c. Weld defects in spite of the mill and meters running properly.
No matter what the problem, if your troubleshooting efforts cannot find the cause, do not hesitate to call Thermatool's
Customer Service Department.

tel: 203.468.4100
31 Commerce Street
Troubleshooting Welder Operation

tel: 203.468.4100
31 Commerce Street
Troubleshooting Welder Quality

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Thermatool Corp. info@thermatool.

TECHNICAL SUPPORT MANUAL FOR:

THERMATOOL CFI *This manual contains safety information

31 Commerce Street tel: 203.468.4100 info@thermatool.com 2016

Copyright Thermatool Corp., 2016 East Haven, CT 06512

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 1

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 2

Minimum Space Requirements on Production Floor

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 3

Any questions regarding installation should be directed to Thermatool Field Service.

Tube Mill Considerations

Aligning the roll shaft shoulders

Getting the roll shaft parallel

Aligning the tooling

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 4

Forming Tooling Considerations

Slitting the Strip

Top roll designed for thin wall

Top roll designed for thick wall

Top roll designed for thick roll

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 5

Compatibility of Fin Passes

Last Fin Pass

Recommended shape for the last fin pass

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 6

• O.D. and wall of tube;

For most of the tube sizes welded with HF welding (i.e., up to

For larger sizes, a rotary seam guide is generally preferable.

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 7

The simplest and most economical weld arrangement is a

A three-roll arrangement may be used where a two-roll

For larger O.D. and thick walls, a four-roll configuration is

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 8

Plant Power and Water

CFI Installation Timeline

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 9

Preliminary Installation Procedures

• CFI Welder Control Panel Assembly

Uncrating and Positioning

• Schematic, Electrical, CFI Solid State Welder

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 10

Generator and Positioning Table (Optional)

For installation details, refer to:

• Schematic, Electrical, CFI Solid State Welder

• Schematic, Plumbing CFI Solid State Welder

• Interconnect Cable List, CFI Welder Installation

• Physical Outline Generator Cabinet

Heat Exchanger (Cooling System)

• Schematic, Plumbing CFI Solid State Welder

• Physical Outline Drawing, Heat Exchanger

• Interconnect Cable List, CFI Welder Installation

#449 Rev B MANUAL FOR THERMATOOL CFI SOLID STATE WELDER | 11

• CFI Welder Control Panel Assembly

• Schematic, Electrical, CFI Solid State Welder

• Standard Electrical Device Descriptions and Prefixes

• CFI Welder Display Panel

• Assembly, CFI Meter Panel

• CFI Operator Controls

• Interconnect Cable List, CFI Welder Installation

Tachometer Generator (Optional Item)

• Schematic, Electrical, CFI Solid State Welder

• CFI Welder Display Panel

• Assembly, CFI Meter Panel

• CFI Operator Controls