INSTRUCTIONS for HW-8 SPOT-WELDING TIG TORCH F-7015-W March, 2002! CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding equipment, we urge you to read our booklet, Precautions and Safe Practices for Arc Welding, Cutting and Gouging, Form 52-529. Do not permit untrained persons to install, operate, or maintain this equipment. Do not attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment. RATING: 250 amps continuous duty DCSP; 300 amps at 50% duty DCSP. COOLING: Closed-loop water cooling system; no joints within torch to leak. ELECTRODES: Uses 1/16 to 5/32-in. (1.6 to 4.0 mm) diameter electrodes; 7-in. (178 mm) long. See Table 1 for electrode diameter vs. current recommendations. COLLETS: Available for four electrode sizes. See Table 2. COLLET SEAT: Sized to match each collet. NOZZLES: Made of chrome copper material. Available sizes 8, 10, and 12. TORCH DIMENSIONS: Overall length...10-in. (254 mm) Barrel diameter... 1-5/16-in. (33 mm) Nozzle diameter...7/8-in (22 mm) Service lines... 25-ft. (7.6 m) REQUIRED ACCESSORIES OR SERVICES: Collet, collet seat, electrode, nozzle. HW-8 is supplied with the 1/8-in. (3.2 mm) size collet and collet seat. Refer to Table 2 for other size. Select nozzle from Table 3. Fuse assembly (45V34) or power cable adaptor (45V11). Water hose (to connect fuse assembly or adaptor to drain). Recommended: 40V76. Shielding gas regulator-flowmeter if cylinder gas is used or flowmeter (if shielding gas is piped). Adequate Water Supply - For adequate torch cooling at maximum rating, a water flow of one quart/ min. (0.95 l/min) with inlet temperature 60-deg. F (16-deg. C) or less, is needed. To secure this flow, pressure of the water supply must be at least 35 psi (2.4 bars). (If flow switch is used in system, 5 psi (0.4 bars) more upstream of switch is needed.) Pressure should not exceed 50 psi (3.5 bars) measured at inlet of the torch hose, lest the plastic hose be damaged. Welding power and shielding gas supplies. OPTIONAL ACCESSORIES V-30 Double Shut-Off Valve (16X21): Shuts off both water and gas flow when torch is hung on valve arm. Flow switch (Torch Saver) P/N 40V50: Water-metering switch which can be interconnected to the welding contactor coil to cut off welding power if flow rate drops below 0.2 gal./min. (0.75 l/min.) Recommended for use when water pressure may fluctuate severely. Use in conjunction with, or instead of, fuse. (See Figure 1). Braided Nylon Sheath (20-ft., 6.1 m long), P/N 2075201, or Zipper Sheath (8-ft., 2.5 m long), P/N 41V98: To protect services lines. Service Line Extensions: Water Hose, 12-1/2-ft., 3.8 m (40V76) Water Hose Coupling (11N18) Gas Hose, 12-1/2-ft., 3.8 m (40V77) Gas Hose Coupling (11N17) Power Cable, 12-1/2-ft. (40V78) Power Cable Coupling (11N19) Power Cable Insulator Sleeve (10N27) Table 1 - Recommended Welding Conditions on Lap Joints Using 1/8-in. (3.2 mm) Electrodes Plate Argon Arc Time Thickness Gas Flow Interval, Current, Material in. CFH Sec. Amps Stainless 0.020 1/2 115 Steel 0.030 8 3/4 115 0.050 1 130 0.061 1-1/4 130 Low Alloy 0.032 1 130 & Mild 0.045 8 1-1/4 160 Steel 0.056 1-1/2 145 Table 2 - Table 3 - Collets and Collet Seats Nozzles Electrode Collet Collet Seat Nozzle Part diam., in. (mm) Part No. Part No. No. No. 1/16 (1.6) 56Y16 81Z82 8 105Z21 3/32 (2.4) 56Y17 81Z84 10 105Z22 1/8 (3.2) 55Y86* 79Z92* 12 105Z23 5/32 (4.0) 56Y18 81Z86 *Supplied with the HW-8 Torch Be sure this information reaches the operator. You can get extra copies through your supplier.
SAFETY PRECAUTIONS WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death. PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore: 1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required. 2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal. 3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks. 4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing 5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains. 6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses. FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore: 1. Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc. 2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal. 3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode. 4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use. 2 5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard. 6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary. 7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 2. Connect the workpiece to a good electrical ground. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. 4. Use well-maintained equipment. Replace worn or damaged cables. 5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source. 6. Make sure that all parts of your body are insulated from work and from ground. 7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes. 8. Put on dry, hole-free gloves before turning on the power. 9. Turn off the power before removing your gloves. 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable. ELECTRIC AND MAGNETIC FIELDS May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. 2. Exposure to EMF may have other health effects which are unknown. 3. Welders should use the following procedures to minimize exposure to EMF: A. Route the electrode and work cables together. Secure them with tape when possible. B. Never coil the torch or work cable around your body. C. Do not place your body between the torch and work cables. Route cables on the same side of your body. D. Connect the work cable to the workpiece as close as possible to the area being welded. E. Keep welding power source and cables as far away from your body as possible. 10/98
FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. Therefore: 1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials. 2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases. 3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists. 4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations. 5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code 25249.5 et seq.) CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder. 2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit. 3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders. 4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder. 5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202. EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power. 3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition. 4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather. 5. Keep all safety devices and cabinet covers in position and in good repair. 6. Use equipment only for its intended purpose. Do not modify it in any manner. ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529. The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding" 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances." MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved. Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life. Means potential hazards which could result in personal injury or loss of life. Means hazards which could result in minor personal injury. 3 SP98-10
SET-UP INSTALLATION (See Figure 1) 1. Set up the torch and accessories, following Figure 1 and observing all instructions supplied with regulator/flowmeter, fuse flow switch, and shut-off valve. (In the simplest installation, the torch gas hose is attached directly to the flowmeter outlet, and the water hose is attached to a water line.) 2. Connect the fuse assembly or power cable adaptor to the welding power source, either directly or through a suitable length of welding cable fitted with lugs. Run a hose from the fuse or adaptor to a water drain. Plug switch-cord into the proper receptacle on the power source. 3. Install nozzle and then the electrode into the torch. The electrode should be recessed between 0.050- in. and 0.080-in. (1.3 to 2.0 mm) inside the nozzle as shown in Figure 2. To simplify the setting of this gap. The nozzle can then be placed over the gauge. Press the electrode release button to allow the electrode to drop to the setting. 4. If desiring to use another electrode size other than 1/8-in., refer to Replacement of Collet and Seat on page 4. OPERATING INSTRUCTIONS 1. Make sure that all argon and water connections in the system have been securely tightened and that the torch cap has been well-tightened. 2. Turn on the water. (See Page 1 for pressure and flow requirements.) 3. With the regulator flow-adjusting valve closed, open the shielding gas cylinder or station valve. 4. Set the power source for the desired welding current. IMPORTANT: Please note that the high frequency spark gaps setting in your power source should not exceed 0.016-in. when this torch is used. 5. Open all shielding gas valves downstream from flowmeter or flowmeter/regulator, (valve on torch, leveroperated shut-off valve, or solenoid-operated valve in power source). 6. Set shielding gas flow to the desired level, as registered on flowmeter tube or gauge. NOTE: Purge the gas hose by allowing the gas to flow long enough (up to 15 minutes on new torch; less than 5 minutes thereafter) to drive out air and moisture. This will help prevent weld contamination. 7. Turn on control switch at power source to energize spot-weld timing circuitry. 8. Draw a test arc on a heavy piece of scrap steel or copper. (Do not use a carbon block, which will tend to contaminate the electrode). 9. If the test arc is satisfactory, commence spot-welding. OPERATION AND MAINTENANCE HINTS 1. To get maximum weld strength, make sure the surfaces to be joined are clean. Paint, scale, or oil film may cause porosity or refractory oxide inclusions in the weld. 2. Lap welds give maximum strength for spot welds. When two pieces to be welded are of different thickness, weld on the side of the thin plate. 3. Always hold the torch exactly perpendicular to the work so that the end of the nozzle touches the work all around its edge. 4. A poor shielding gas connection, or a leaky hose, will not only waste gas but permit the entry of minute amounts of air, sufficient to contaminate both the electrode and the weld. Trouble signs; a bluish cast on the electrode after it has cooled; in welding aluminum, a dark gray deposit on or beside the weld 5. bead. Keep the torch hose away from hot metal. The plastic hose begins to lose strength at 125-deg. F (52- deg. C). 6. Do not try to repair a damaged power cable or gas or water hose. Replace it. Then send the damaged assembly, if it appears worth salvage, to a repair station, which has special tools for making up tight connections. 7. If the torch water passages become clogged, they can sometimes be cleared by reversing the direction of water flow (that is, sending water in through the power cable, out through the water hose). However, never weld with the flow reversed. A strainer in the water inlet line (such as P/N 96W69) is good insurance against clogging. 8. If an electrode becomes contaminated, shut off power, then remove electrode from torch. Break off the contaminated end (nicking with a grinding wheel first will help) and replace electrode. 9. Remove spatter from inside of the nozzle with a reamer or file, exercising care so that it does not drop back into the torch. Adherence of spatter can be minimized, and removal made easier, by coating the inside of the nozzle with No. 65 Nozzle Compound (P/N 08N65). 10. If trigger begins to bind, lubricate with silicone grease. REPLACEMENT OF COLLET AND SEAT (See Figure 2). Remove the body and tube assembly (56Y94) from the torch. Compress the lever (79Z96) and unscrew the collet seat (79Z92). Remove the clip (85W18) and pin (79Z94) from the block (79Z93). Drive out the collet pin (79Z95) taking care not to let it spring out because it is under compression from spring (85W16). Remove the collet. (Continued on page 6) 4
To torch switch receptacle on spot-weld circuitry of power source V-30 VALVE - 16X21 INCLUDES (2) ARGON CONN. 74S76 (2) WATER CONN. 11N16 ARGON COUPLING - 11N17 (5/8"-18) HW-8 Torch - 16X29 V-30 FUSE ASSEM. - 45V34 WATER COUPLING - 11N18 (5/8"-18 L.H.) WATER HOSE 40V79 (12-1/2 FT.) WELDING CABLE TO POWER SOURCE POWER CABLE ADAPTOR - 45V11 (7/8" - 14 L.H. TO 5/8"-18 L.H.) DRAIN FLOW SWITCH - 40V50 Figure 1 - Argon and Water Hose Connections for the HW-8 Torch ARGON HOSE - 40V77 (12-1/2 FT.) ARGON REGULATOR WITH FLOWMETER ARGON CYLINDER ADAPTOR - 11N16 (5/8" - 18 L.H. TO 1/4" N.P.T.) STRAINER 96W69 WATER SUPPLY LINE 5
When installing the new collet, a new O ring (85W11) should be used. Be sure the compression spring is in place. Lubricate the O ring on the collet with silicone grease and insert the collet into the body tube. Using a 1/8" electrode or the same size rod, press the collet in far enough to align the collet-pin hole with the slots in the body tube. Insert the pin. Put the lever in the block and pit it. Then press the lever to pull the collet back, and screw in the collet seat. With an electrode in the collet, set the lever so that it does not extend more than 7/32-in. (5.5 mm) from the body tube when the electrode is held tightly. If the lever extends more that 7/32-in. (5.5 mm) remove the clip and pin and screw the body block in towards the collet pin to get the proper setting. If the lever extends less that 7/ 32-in. (5.5 mm) unscrew the block to get the proper setting. NOTE: When reinstalling Sheath 81Z90, use silicone spray lubricator to aid installation. REPLACING NOZZLE ADAPTOR BUSHING (See Fig. 2). If the nozzle adaptor bushing (86Z19) must be replaced, remove the nozzle body assembly (56Y96) and unscrew the adaptor bushing. Be sure to replace the nozzle seating gasket (81Z19) when putting on the new bushing. 6
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ESAB Welding & Cutting Products, Florence, SC Welding Equipment COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Order Entry Product Availability Pricing Delivery Order Changes Saleable Goods Returns Shipping Information Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548 Central Distribution Center Telephone: (800)783-5360 / Fax: (800) 783-5362 Western Distribution Center Telephone: (800) 235-4012/ Fax: (888) 586-4670 B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST Performance Features Technical Specifications Equipment Recommendations D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST F. WELDING EQUIPMENT TRAINING: Telephone: (843)664-4428 / Fax: (843) 679-5864 Training School Information and Registrations G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 4:00 PM EST Hours: 7:30 AM to 4:00 PM EST Hours: 7:30 AM to 5:00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com Hours: 7:30 AM to 5:00 PM EST F-7015-W 3/02 Printed in U.S.A. 8