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FREQUENTLY ASKED QUESTIONS

REGARDING THE ROTOWELD

REVISED : SEPTEMBER 28TH, 2006

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Page 1 of 1
FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD

TABLE OF CONTENT
(Please click on one question in this table to access directly to its answer)

1. WHO IS THE MANUFACTURER OF THE ROTOWELD AND WHERE IS IT


MANUFACTURED? _______________________________________________________________ 3
2. WHAT ARE THE MAIN FEATURES WHICH MAKE THE ROTOWELD SO UNIQUE? ___ 3
3. HOW DOES THE ROTOWELD VISION SYSTEM WORKS? __________________________ 4
4. WHAT ARE THE MAIN APPLICATIONS FOR THE ROTOWELD? ___________________ 5
5. WHAT IS THE ROTOWELD PRODUCTION CAPACITY AND HOW DOES IT COMPARE
TO MANUAL OR SEMI-AUTOMATIC WELDING? _____________________________________ 5
6. WHAT TYPE OF JOINT PREPARATION AND TOLERANCE IS REQUIRED FOR THE
ROTOWELD? _____________________________________________________________________ 6
7. WHAT ARE THE LIMITATIONS OF THE ROTOWELD IN TERMS OF EQUIPMENT
CAPACITY? ______________________________________________________________________ 7
8. WHAT MATERTIAL CAN BE WELDED WITH THE ROTOWELD? ___________________ 8
9. WHAT SHILDING GAS IS REQUIRED WITH THE ROTOWELD? ____________________ 8
10. WHAT IS THE WELD QUALITY AND DEFECT RATE TO BE EXPECTED WITH THE
ROTOWELD? _____________________________________________________________________ 8
11. WHAT ARE THE DIFFERENT ROTOWELD MODELS? __________________________ 8
12. WHAT IS THE PAST TRACK RECCORD (PTR) OF THE ROTOWELD AND HOW MANY
HAVE BEEN SOLD SO FAR? _______________________________________________________ 9
13. HOW MANY WORKERS ARE REQUIRED TO OPERATE THE ROTOWELD? ________ 9
14. WHAT SKILL AND TRAINNING IS REQUIRED TO OPERATE THE ROTOWELD? __ 10
15. WHAT IS THE « PRODATALOG » SOFTWARE USED WITH THE ROTOWELD? ____ 10
16. WHAT SORT OF SHOP LAYOUT IS RECOMMENDED FOR THE ROTOWELD? ____ 10
17. WHAT FLOOR SPACE IS REQUIRED FOR THE ROTOWELD? ___________________ 11
18. WHAT ELECTRICAL OUTLET IS REQUIRED FOR THE ROTOWELD?____________ 11
19. WHAT UNLOADING EQUIPMENT IS REQUIRED FOR THE ROTOWELD? ________ 12
20. WHAT SPARE PARTS ARE REQUIRED FOR THE ROTOWELD? _________________ 12

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
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FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD

1. WHO IS THE MANUFACTURER OF THE ROTOWELD AND WHERE IS IT


MANUFACTURED?

ANSWER: The Rotoweld is made in Canada by Tecnar Automation (www.tecnar.com).


Tecnar is located in Saint-Bruno (south shore of Montreal), Province of Quebec, Canada

2. WHAT ARE THE MAIN FEATURES WHICH MAKE THE ROTOWELD SO UNIQUE?

ANSWER: There are two main features which make the Rotoweld so unique.

The core of the Rotoweld technology is its capacity to perform a full penetration root pass in
an open bevel joint. Integrating machine vision and adaptive feedback, it actually controls the
penetration of the root, constantly varying welding parameters to compensate for changes in
weld preparation.

The vision system acts as the welder’s eyes: a miniature video camera incorporated in the
welding arm continuously captures the image of the weld pool. Unique algorithms analyze
the images and adjust welding parameters, constantly adapting the process to varying
conditions such as changes in gap, alignment, root face or temperature. The computer’s fast
reaction time allows the machine to work at high deposition rates and travel speeds where
weld pool conditions are much too critical to be sustained by hand. All major axis’ are
equipped with full encoder feedback servo-drives which act as the welder’s arm and
hands to ensure absolute precision and repeatability of all programmed variables. Because
the rotator is also servo-driven, it ensures a controlled rotation of the spool at all time, even
with off balanced loads.

In addition, the entire Rotoweld system is specifically designed to weld pipe spools in a pipe
prefabrication shop environment. Therefore, the system is engineered to minimize the down
time and maximize productivity (twin bay design, diameter-calibrated idler rolls, bracket to fix
elbow on rotator, ruggedness of the equipment, standard tolerances for joint fit-up, integration
of two welding processes).

The twin bay design of the Rotoweld consists of two separate work-bays each equipped with
its own independently operated rotator. This configuration allows unloading, reloading and
work preparation to be performed in one bay without interfering with the ongoing welding in
the other bay. A continuous track system allows the welding carriage to travel to either bay.

The Rotoweld also includes a set of hydraulically adjustable, diameter calibrated idler rolls
that circulate along parallel tracks aligned on each rotator’s center line. Therefore, spools
mounted into the rotator’s chuck and laid on the calibrated idler rolls are automatically
centered on the rotation axis.

Finally, a custom designed mechanical adaptor allows attachment of elbows to the rotators.

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
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FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD

3. HOW DOES THE ROTOWELD VISION SYSTEM WORKS?

ANSWER: As we all know, welding a root pass is a complex and delicate operation. The
geometry of the joint preparation varies within the limits of dimensional tolerances; the root
opening changes while welding due to weld-induced deformation; and the temperature of the
work piece varies as it heats during welding. Constantly changing factors require a
continuously adapting process and, therefore, a capacity to monitor changes in the system
and react accordingly. This requires from a manual welder, extraordinary concentration, a
huge, empirically derived, skill-base, excellent coordination and fast decision capability. The
manual welder knows very little of dynamic changes in base metal temperature, arc current,
weld pool mass or joint geometry. Instead he observes the weld pool shape or the level to
which it sinks in the bevel and he reacts accordingly.

With the Rotoweld, this specific function of observing the weld pool is performed with a
dedicated vision system. An industrial, solid-state, video camera is aimed directly at the weld
pool, and is equipped with optical elements that enhance the contrast between the liquid
metal and its surroundings. The camera is located under the GMAW torch which allows a
perfect view of the pool. In fact, this view is much better than the view available to the manual
welder. The video signal is then fed to a frame grabber that digitizes one out of every two
video frame (15 frames/sec).

The above picture presents the typical image of the weld pool as seen by the computer and
displayed on a monitor for the operator to see. The colors and shapes represent various
intensity levels used to detect the position of certain objects in the image, such as, the arc,
the wire tip, the joint’s side walls and the weld pool shape along with its hottest spot. From
this image, the computer can localize the hottest spot of the weld pool precisely and identify it
on the screen by a square. A cross hair (horizontal and vertical line) is superposed on the
monitor. Each frame is analysed by the computer which controls the various welding
parameters (welding speed, wire feed speed, voltage, amperage) to ensure that the hottest
spot of the weld pool (the square) is always kept at the junction of the cross hair. Therefore,
from a practical point of view, the cross hair is steady at one location on the screen where as,
because of the dynamic action of the weld pool, the square (hot spot of the weld pool) is
always moving on the screen but constantly gravitating around the cross hair intersection.

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


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Page 4 of 4
FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD
The operator use a “joy-stick” to move the cross hair as he wishes. Since the computer is
always modifying the welding parameters to maintain the hot spot at the cross-hair
intersection, it is easy for the operator to use the “joy-stick” to control the position of the weld
pool (both vertically and horizontally). Therefore, the horizontal displacement of the cross hair
is used to keep the weld pool in-line with the joint (joint tracking) and the vertical displacement
is used to prevent the weld pool from sinking too much or from being to high (weld penetration
control).

4. WHAT ARE THE MAIN APPLICATIONS FOR THE ROTOWELD?

ANSWER: Because the core of the Rotoweld technology is its ability to automatically weld a
full penetration open butt joint root pass, pipe spool prefabrication immediately appeared
to be the ideal application. Therefore, the technology was tailored for this specific
application. However, this does not prevent the use of the Rotoweld’s adaptive vision system
for other applications such as pressure vessels, drilling platform legs, etc..

5. WHAT IS THE ROTOWELD PRODUCTION CAPACITY AND HOW DOES IT COMPARE


TO MANUAL OR SEMI-AUTOMATIC WELDING?

ANSWER:

APPROXIMATE WELDING TIME FOR DIFFERENT PIPE DIAMETERS


AND WALL THICKNESSES*

Standard wall (STD) Heavy wall (XS) Extra Heavy wall (XXS)
Rotoweld Rotoweld Rotoweld Rotoweld Rotoweld
2000 2500 Wall 2000 2500 Wall 2500
Wall
Pipe Ø Thickness Welding time Welding time Thickness Welding time Welding time Thickness Welding time
(Inches) (Inches) (Minutes) (Minutes) (Inches) (Minutes) (Minutes) (Inches) (Minutes)
2 0,154 1,9 N\A 0,218 2,7 N\A N\A
4 0,237 2,9 N\A 0,337 4,7 N\A N\A
6 0,28 4,9 3,8 0,432 8,7 6,4 0,864 19,8
8 0,322 7,7 5,8 0,5 12,7 10,5 0,875 27,0
10 0,365 10 8,5 0,5 15,5 13,1 1 43,1
12 0,375 12 10,5 0,5 18,5 15,8 1 51,8
14 0,375 13,8 12,3 0,5 21,4 18,4 1,094 71,4
18 0,383 17 16,2 0,51 26,5 24,4 1,094 91,8
20 0,383 20 18,0 0,51 29,4 27,1 1,094 102,0
24 0,383 24,9 21,6 0,51 34 32,5 1,094 122,4
* NOTE: Calculations with the following assumptions GMAW (root pass):10 IPM; Deposition rate for SAW:10 lbs\min.

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
Page 5 of 5
FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD
The maximum production recorded with the Rotoweld is 350 diameter inches per 8-hour shift.
However, the capacity of the Rotoweld largely depends on the capacity of the shop to feed
the machine with preassembled weldments. The material flow is extremely crucial to take full
benefit of the Rotoweld capacity. In an average work shop, 200 diameter inches per 8-hour
shift is a more realistic figure.

Of course, another variable which does affect the production capacity of the machine is the
average pipe diameter and schedule to be welded. Daily production, in terms of diameter-
inches, increases with bigger pipe diameters and smaller wall thicknesses. The rule of thumb
for welding time (complete joint) is 1 minute per diameter inch for stand wall thickness
and 1.5 for heavy wall.

The Rotoweld can replace 4 - 5 well experienced manual welders (GTAW at the root and
SMAW for filler passes) or 2 – 2 ½ experienced semi-automatic welders (GMAW &
FCAW).

6. WHAT TYPE OF JOINT PREPARATION AND TOLERANCE IS REQUIRED FOR THE


ROTOWELD?

ANSWER: The Rotoweld is designed to operate with standard open root (3 mm) single
vee groove butt joints (37.5°bevels along with 2 mm a root face).

The Rotoweld has a strong reputation to be quite tolerant for joint preparation. No
fancy or machined joint preparation is required. A regular joint preparation acceptable for
manual GTAW is perfectly acceptable for the Rotoweld. Flame-cut, hand ground or machined
bevels are equally acceptable.

The tolerances on joint preparation are as follows:

PIPE DIAMETER ROOT FACE (landing) ROOT GAP MISALIGNMENT


50 – 150 mm 1.5 – 3 mm 2 – 3 mm ½ root gap (max.)
200 – 600 mm 1.5 – 3 mm 3 – 4 mm ½ root gap (max.)

All the joints need to be tack welded prior to be welded with the Rotoweld. Even though the
Rotoweld can remelt the tack welds, it cannot be guaranteed that it does so all the time.
Therefore, in order to ensure Xray quality welds, the Rotoweld requires full penetration (100%
penetration) tack welds. The size of the tack welds is the same as with manual GTAW.

Prior to welding with the Rotoweld, the stop and start of each tack weld must be ground to a
taper in order to ensure smooth transition. For the root pass, the Rotoweld starts on the top
of any tack weld and will run continuously until it slightly overlaps the beginning of the weld.

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
Page 6 of 6
FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD
If, for some reason, the Rotoweld burns through the joint, the operator stops the machine,
grinds the end of the weld and simply starts welding where it stopped as if it was a tack weld.
That’s all there is to it !!

If the joint is prepared with a too small root opening or if the joint closes too much during
welding (like it’s often the case with welding stainless steel), the operator can simply open the
joint using an hand grinder.

7. WHAT ARE THE LIMITATIONS OF THE ROTOWELD IN TERMS OF EQUIPMENT


CAPACITY?

ANSWER: The positioner and the idler rolls can handle pipe diameters ranging from either
2” to 24” or 8” to 42”. However, the SAW process (model Rotoweld 2500) cannot handle pipe
diameters below 6”.

In average, the Rotoweld can weld about 75% of a normal pipe shop production. Typical
joints which cannot be welded are : Non circular welds, all the « O let » welds (weldolet,
latrolet, …), branch welds, saddle welds, small diameter welds (below 6“Ø for Rotoweld 2500
and below 2“Ø for Rotoweld 2000) and return bends.

Both Rotoweld models (2000 and 2500) use the same base platform which has the following
technical specifications:

ROTATION:
Load Capacity 3000 lbs
Speed 0 to 3 RPM
Torque 3750 ft-lbs
Drive 3 HP servo-motor with encoder feedback
Backlash 0.2 degrees
Chuck range Self centering, 2” to 24” or 8” to 42”
Center-line height clearance 60”
IDLER ROOLS:
Capacity 5 Tons
Range 2” to 24” or 8” to 42”
Diameter adjustment Hydraulic, calibrated for STD wall pipe sizes
Center-line height clearance 60” or 72”
TRACK SYSTEM:
Length Standard: 60’ (1 X 40’ & 1 X 20’)
Maximum: 80’ (2 X 40’)
Width 6’
Height 4“
Precision 1/32”

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


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FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD

8. WHAT MATERTIAL CAN BE WELDED WITH THE ROTOWELD?

ANSWER: The Rotoweld can weld Carbon Steel, Low Alloy Steel, Stainless Steel and
Duplex Stainless Steel.

9. WHAT SHILDING GAS IS REQUIRED WITH THE ROTOWELD?

ANSWER: For the root pass on carbon steel, 100% CO2 can be used. This being said, a
small quantity of argon mixed to CO2 (75% CO2 / 25% Argon) provides a better “wetting
action” to the puddle at the root pass. However, this gas mixture is not stable and therefore is
not available on the market. For this reason, a gas mixer is required when such a gas mixture
is being used. Such a gas mixture doesn’t come standard with the Rotoweld and needs to be
ordered as an option.

For the filler and cap passes on carbon steel, 92% Argon / 8% CO2 is used for either GMAW
(spray transfer) or FCAW (Metal Core).

For the root, filler and cap passes on Stainless or Duplex Steel, a mixture of three gases such
as Argon (60%) – He (37 ½%) - CO2 (2 ½%) is recommended.

10. WHAT IS THE WELD QUALITY AND DEFECT RATE TO BE EXPECTED WITH THE
ROTOWELD?

ANSWER: The Rotoweld is designed to deliver 100% Xray quality welds. The defect rate is
normally in the neighborhood of 0.1% however, this defect rate is obviously dependent of the
care taken during the joint preparation.

Charpy V notch impact tests results at -45°C are above 30 joules for all sizes tested. Results
are available upon requests.

11. WHAT ARE THE DIFFERENT ROTOWELD MODELS?

ANSWER: The ROTOWELD is designed to always use GMAW (short circuit with STT
technology) for the root pass. However, different versions were developed to use different
welding process for the filler and cap passes. The ROTOWELD 2000 uses GMAW (spray
transfer) or FCAW (metal core) for the filler and cap passes where as the ROTOWELD 2500
uses the SAW for these passes.

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
Page 8 of 8
FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD
Here is the description of the two Rotoweld models:

MODEL PROCESS / PASSES POWER SOURCE


Rotoweld 2000 GMAW (root pass) Lincoln STT
GMAW or Metal Core (filler & cap passes) Lincoln CV 400

Rotoweld 2500 GMAW (root pass) Lincoln STT


SAW (filler & cap passes) Lincoln DC-655

The Rotoweld 2500 is the latest version of the Rotoweld. It was developed for Rotoweld
users who handle mostly high thickness piping and who wish to maximize the machine’s
deposition rate. With this new version of the Rotoweld, the root pass is still performed with
the GMAW process using Tecnar’s well known vision system but the filler and cap passes are
now performed with the SAW process. The Rotoweld 2500 retains all the features and
advantages of the Rotoweld 2000 (integration of machine vision, expert system and robotics
technology).

The Rotoweld 2500 consists of a single weld station (carriage) which incorporates both the
GMAW and the SAW process. The GMAW head is mounted on a retractable arm while the
SAW head is mounted on a vertically adjustable column. Once the root pass is completed,
the GMAW arm is retracted and the SAW head is simply lowered in place to fully complete
the joint.

Just like with the Rotoweld 2000, the Rotoweld 2500 is a twin station (two rotators) with a
continuous track system which allows to move the weld carriage to either work bay.

12. WHAT IS THE PAST TRACK RECCORD (PTR) OF THE ROTOWELD AND HOW MANY
HAVE BEEN SOLD SO FAR?

ANSWER: Over 70 Rotoweld have been sold world-wide for well over 15 years. The
Rotoweld enjoys an excellent Past Track Record (PTR). Tecnar’s WEB site
(www.tecnar.com) offers the list of the major companies that have purchased a Rotoweld.
From this list, it is easy to understand that the Rotoweld was used extensively on several
major projects in the world (namely petrochemical plant & offshore plate-forms).

13. HOW MANY WORKERS ARE REQUIRED TO OPERATE THE ROTOWELD?

ANSWER: Usually one welding operator and one helper are sufficient to operate the
Rotoweld correctly. The welding operator will always follow the weld carriage and perform the
welding operation while the helper is loading and unloading the spool assembly on the other
bay.

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
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FREQUENTLY ASKED QUESTIONS
REGARDING THE
14. WHAT SKILL AND TRAINNING IS REQUIRED TO OPERATE THE ROTOWELD?

ANSWER: Training welding operators will take a few days. However, it is important to
assign a welding technician to the Rotoweld. This technician will receive a more exhaustive
training to be able to trouble shoot different problems on the Rotoweld or to set additional
welding parameters. Basic training for a welding technician will take about one week.

After this basic training, the shop will be able to operate the Rotoweld on its own. However, it
is obvious that a learning curve is to be expected to take full advantage of the Rotoweld.
Normally, after a period of a few months, the shop is able to operate the Rotoweld to its full
potential. From experience, it is not so much learning to operate the Rotoweld that will take
time as much as the operation of the entire shop to ensure a constant and sufficient material
flow.

15. WHAT IS THE « PRODATALOG » SOFTWARE USED WITH THE ROTOWELD?

ANSWER: During operation, the Rotoweld continuously generates a “time stamped event
list”. This is the list of events with occurs during Rotoweld operation. The “Prodatalog” is a
software which analyzes the list of events and generates two type of reports: 1) the Daily
Production Report 2) the Weld Detail Report. These reports provide the key information
needed to efficiently manage the operation of Rotoweld systems.

The Daily Production Report summarizes the production of the day in terms of total setup
time, production time, welding time, diameter inch, etc., thus giving a first glance evaluation of
the machine’s overall performance. The report also lists all the individual welds with their
corresponding welding times and setup times so that performance issues can be related to
specific welds.

Those welds can be further examined using the corresponding Weld Report which gives the
value of welding parameters such as travel speed, wire feed rate, etc. for each welding pass.
The report also gives the time, duration and angular position of all interruptions, if any, that
occurred during that weld. The angular position can be matched to specific areas on the
weld’s X-ray film to detect if specific features correlate to interruptions.

16. WHAT SORT OF SHOP LAYOUT IS RECOMMENDED FOR THE ROTOWELD?

ANSWER: The shop layout can vary from one shop to another depending of the specific
needs (spool sizes, pipe diameters and thickness, production requirements, etc…). There are
several ways to lay the Rotoweld in a shop. The Rotoweld itself may be ordered in different
bay configuration (back to back; in-line; face to face) and track length to accommodate the
desired shop layout.

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
Page 10 of 10
FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD
One important point is to place the assembly tables near the Rotoweld in order to ensure a
constant and easy material flow to the workcell. To maximize the % of joints welded on the
Rotoweld, partial assemblies often need to travel back and forth from the fitting table to the
workcell before spool completion. A minimum of four assembly tables (two per work bay) are
normally required to feed the Rotoweld correctly. Some shops will use much more assembly
tables to stack the shop with spools during the day shift and continue working with the
Rotoweld during the night shift using a minimum work force.

One good way to ensure a proper material flow is to set up the work shop like a production
line. In this setup, the pipes and fittings will enter the shop from one end where they will be
prepared (cut, beveled, etc…). At this point, it is important to use equipment that will ensure
sufficient material flow to feed the Rotoweld properly. In this environment, the Rotoweld and
the assembly tables would be placed in the middle of the work shop. The NDE, painting and
expedition activities would be performed at the other end of the work shop.

17. WHAT FLOOR SPACE IS REQUIRED FOR THE ROTOWELD?

ANSWER: Approximately 75 meter2 is required

8m
SHOPWALL

outlets (electric, phone)


3m

20meters

Rotoweld2000TwinWorkstationfoot print

18. WHAT ELECTRICAL OUTLET IS REQUIRED FOR THE ROTOWELD?

ANSWER: 230 Volt, 3ph, star configuration, 50/60Hz, 75kVA

NOTE: Maximum acceptable voltage peak 240V


Minimum acceptable voltage drop 210V

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
Page 11 of 11
FREQUENTLY ASKED QUESTIONS
REGARDING THE ROTOWELD
19. WHAT UNLOADING EQUIPMENT IS REQUIRED FOR THE ROTOWELD?

ANSWER: One five (5) tons capacity Forklift Truck, operator and helpers

20. WHAT SPARE PARTS ARE REQUIRED FOR THE ROTOWELD?

ANSWER: Apart from the consumable parts for the welding torches, there is really no spare
part suggested. The Rotoweld is quite rugged and parts don’t brake often. In addition,
Tecnar has a good inventory of the electronic boards which can easily be sent overnight by
courier.

1321, Hocquart St., St-Bruno, QC, Canada, J3V 6B5


Tel.: (450) 461-1221, Fax: (450) 461-0808 www.tecnar.com September 28th 2006
Page 12 of 12

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