HW-18 & HW-18R TIG WELDING TORCHES

Transcription

1 INSTRUCTIONS for F-9886-S 06/2011 HW-18 & HW-18R TIG WELDING TORCHES HW-18 with 60 hard body, 12-1/2-ft. cable and hose...part No HW-18 with 60 hard body, 25-ft. cable and hose...part No HW-18R with 60 rubber body, 12-1/2-ft. cable and hose... Part No R HW-18R with 60 rubber body, 25-ft. cable and hose... Part No R These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc equipment, we urge you to read our booklet, Precautions and Safe Practices for Arc Welding, Cutting and Gouging, Form 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 pages 3 and 4 before installing or operating this equipment. RATING: With standard collet bodies: 300 amps. (ACHF or DCSP) continuous duty. Using HW-18 (with 12-1/2- ft., 3.8 m, cable) with gas lens collet bodies: 375 amps. (ACHF or DCSP) continuous duty. COOLING: Closed-loop water cooling system, no joints within torch body to leak. ELECTRODES: Uses.020-in. through 5/32-in. diameter electrodes, 3-in., or 7-in. long. Standard torch cap is designed for 7-in. electrodes. Short cap for 3-in. electrodes is available as option. See Table 1 for electrode diameter vs. current recommendations. COLLETS: Available for six electrode sizes. See Table 2. COLLET BODIES: Sizes to match collets; two styles, standard and gas lens, in each size. Large diameter gas lens available for 3/32-, 1/8-, 5/32-in. electrodes. See Table 2. CUPS: For use with standard collet bodies: standard ceramic in all sizes long ceramic in sizes 4 through 7, also high impact ceramic. For use with gas lens collet bodies: standard ceramic or high-impact ceramic. See Table 3. TORCH DIMENSIONS: Length, approx /2-in. (267 mm) Handle diameter /16-in. (27 mm) Height of torch head with short cap /16-in. (81 mm) with long cap /16-in. (189 mm) Be sure this information reaches the operator. You can get extra copies through your supplier.

2 Be sure this information reaches the operator. You can get extra copies through your supplier. caution These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, Precautions and Safe Practices for Arc Welding, Cutting, and Gouging, Form 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 before installing or operating this equipment. USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! 2

3 safety precautions Safety Precautions Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace. All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment. 1. Anyone who uses welding or plasma cutting equipment must be familiar with: - its operation - location of emergency stops - its function - relevant safety precautions - welding and / or plasma cutting 2. The operator must ensure that: - no unauthorized person stationed within the working area of the equipment when it is started up. - no one is unprotected when the arc is struck. 3. The workplace must: - be suitable for the purpose - be free from drafts 4. Personal safety equipment: - Always wear recommended personal safety equipment, such as safety glasses, flame proof clothing, safety gloves. - Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns. 5. General precautions: - Make sure the return cable is connected securely. - Work on high voltage equipment may only be carried out by a qualified electrician. - Appropriate fire extinquishing equipment must be clearly marked and close at hand. - Lubrication and maintenance must not be carried out on the equipment during operation. Enclosure Class The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not intended to be used outside during precipitation unless sheltered. CAUTION If equipment is placed on a surface that slopes more than 15, toppling over may occur. Personal injury and / or significant damage to equipment is possible. Maximum Tilt Allowed 15 3

4 safety precautions WARNING WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA. ELECTRIC SHOCK - Can kill. - Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards. - Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. - Insulate yourself from earth and the workpiece. - Ensure your working stance is safe. FUMES AND GASES - Can be dangerous to health. - Keep your head out of the fumes. - Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area. ARC RAYS - Can injure eyes and burn skin. - Protect your eyes and body. Use the correct welding / plasma cutting screen and filter lens and wear protective clothing. - Protect bystanders with suitable screens or curtains. FIRE HAZARD - Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. NOISE - Excessive noise can damage hearing. - Protect your ears. Use earmuffs or other hearing protection. - Warn bystanders of the risk. MALFUNCTION - Call for expert assistance in the event of malfunction. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! CAUTION This product is solely intended for plasma cutting. Any other use may result in personal injury and / or equipment damage. CAUTION To avoid personal injury and/or equipment damage, lift using method and attachment points shown here. 4

5 REQUIRED ACCESSORIES OR SERVICES: 1. Collet, Collet Body, Electrode, Cup - See Tables 1, 2 and Fuse Assembly, P/N 45V34, or Power Cable Adaptor, P/N 45V11 - For connecting torch power cable to power source. NOTE: The fuse assembly contains a standard fuse link (54N26) which is rated for welding currents up to 250 amps. If intending to use welding currents greater than 250 amps, replace fuse link with heavy-duty fuse link (54N30 supplied in a package of 5), instructions for replacement (Form ) are packed with the fuse assembly. 3. Water Hose, P/N 40V /2-ft., recommended for connecting fuse assembly or adaptor to drain. 4. Shielding gas regulator-flowmeter - R-502 (P/N ) or R-5007 (P/N ) if cylinder gas is used or L-32 flowmeter (P/N ) if shielding gas is piped. 5. 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 F (15 C) or less, is needed. To secure this flow, pressure of the water supply must be at least 25 psi (1.7 bars) if torch has 12-1/2-ft. (3.8 m) cable and hose, 36 psi (2.4 bars) if torch has 25-ft. (7.6 m) cable and hose. (If flow switch is used in system, 5 psi (.35 bars) more pressure upstream of switch is needed.) Pressure should not exceed 50 psi (3.4 bars) at inlet of the torch hose to prevent damaging the plastic hose. 6. Welding power and shielding gas supplies. OPTIONAL ACCESSORIES 1. Short Cap, P/N 57Y04 - for use with 3-in. (76 mm) electrodes. 2. V-30 Double Shut-Off Valve, P/N 16X21 - Shuts off both water and gas flow when torch is hung on valve arm. 3. Flow Switch (Torch Saver), P/N 40V50. Watermetering switch which can be connected 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.) 4. Braided Nylon Sheath, P/N (9-ft. long); P/N (20-ft. long) To protect service lines from abrasive wear. 5. Service Line Extensions: Water Hose (12-1/2-ft.), P/N 40V76 Water Hose Coupling, P/N 11N18 Gas Hose (12-1/2-ft.), P/N 40V77 Gas Hose Coupling, P/N 11N17 *Power Cable (12-1/2-ft.), P/N 40V78 Power Cable Coupling, P/N 11N19 Power Cable Insulator Sleeve, P/N 10N27 *Power cable extensions reduces torch rating to 250 amps. 6. Tig Accessory Kit, P/N includes three collets, three collet bodies, and three 7-in. 2% thoriated electrodes, each in 1/16-in., 3/32-in., and 1/8-in. sizes, three high impact cups. Nos. 5, 6 and 7, and one short torch cap. HW-18 TORCH V-30 VALVE - 16X21 INCLUDES (2) ARGON CONN.-74S76 (2) WATER CONN.-11N16 ARGON COUPLING-11N17 (5/8"-18) ARGON HOSE 40V77 (12-1/2 FT.) ARGON REGULATOR WITH FLOWMETER V-30 WELDING CABLE TO POWER SOURCE FUSE ASSEM. - 45V34 POWER CABLE ADAPTOR - 45V11 (7/8"- 14L.H. TO 5/8"-18L.H.) DRAIN FLOW SWITCH-40V50 WATER COUPLING- 11N18 (5/8"-18L.H.) WATER HOSE 40V76 (12-1/2-FT) ARGON CYLINDER ADAPTOR - 11N16 (5/8"-18L.H. TO 1/4" N.P.T.) STRAINER 96W69 WATER SUPPLY LINE Fig. 1 - Argon and Water Hose Connections for the HW-18 Torch 5

6 Table 1 Electrode and Cup Sizes for Different Welding Currents Welding Currents, Amps. ACHF* DCSP DCRP Using pure Using Using pure, or Electrode tungsten thoriated thoriated tungsten Diameter High-Impact Ceramic electrodes electrodes electrodes in. mm Cup No. Cup No / / ** ** / ** / * Values based on use of unbalanced wave transformer. If a balanced wave transformer is used, reduce maximum values in table by about 30 per cent or use the next larger size electrode. ** Exceeds the current rating of the torch (except (12-1/2-ft.) using gas lens). Balled electrode tip ends can best be formed and maintained at these a.c. current levels. Thoriated tungsten electrodes are recommended when a gas lens and high frequency starting are used. Table 2 - Collets and Collet Bodies Large Dia. Electrode Size Standard Gas Lens Gas Lens in. mm Collet Collet Body Collet Body* Collet Body** N21 10N29 45V N22 10N30 45V24 1/ N23 10N31 45V25 3/ N24 10N32 45V26 45V64 1/ N25 10N28 45V / N V28 45V63 * Collet Body insulator, P/N 54N01, is required when using gas lens collet bodies. ** Collet body insulator, P/N 54N63, is required when using large diameter gas lens collet bodies. Use of a gas lens collet body is recommended for this size. Table 3 - Gas Cups Cup No Short* High-Impact Cup 10N50 10N49 10N48 10N47 10N46 10N45 10N44 Ceramic Cup 105Z43 105Z42 105Z44 105Z45 08N78 08N79 08N80 Long Ceramic Cup 12N03 105Z60 12N02 105Z61 Gas Lens High-Impact Cup 54N18 54N17 54N16 54N15 54N14 54N19 Large Dia. Gas Lens High-Impact Cup 53N88 53N87 53N89 Gas Lens Ceramic Cup 54N35 54N34 54N33 54N32 54N31 54N36 * Short cups serve essentially as insulators. The short cup cannot be used with high-frequency or with currents greater than 300 amperes. 6

7 TORCH CAP "O" RING ELECTRODE ELECTRODE COLLET GAS LENS INSULATOR GAS LENS COLLET BODY GAS LENS CUP SET-UP AND INSTALLATION (See Figure 1) CUP Fig. 2 - Exploded View of HW-18 Torch TORCH BODY COLLET BODY 1. Set up the torch and accessories, following Figure 1 and 2 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, utilizing adaptor 11N16 supplied with torch.) 2. Connect the fuse assembly or power cable adaptor to the welding power source, either directly or through available length of welding cable fitted with lugs. Run a hose from the fuse or adaptor to a water drain. 3. Install collet body, collet, electrode, and cup on torch. (See Figure 2). Sequence of operations: a. Screw in collet body. (If using gas-lens, assemble insulator on collet body before installing.) b. Apply a thin coat of silicone grease to the surface of the cup that mates with the torch body and screw on the cup. c. Remove torch cap. d. Slide collet into position (tapered end first). e. Slip electrode down through hole in top of collet, until end of electrode extends beyond rim of cup. (Exact extension is variable; from as little as 1/8-in. for butt-welding with standard collet bodies to 3/4-in. for corner or fillet welds with gas lens collet bodies and cups.) NOTE: When using high frequency with the sleeved high-impact cup, arcing may sometimes occur between the electrode and the steel sleeve. To avoid this, it is advantageous to extend the electrode as far as possible consistent with the particular operation. f. Screw on torch cap and tighten. The cup will press down on the collet to grip the electrode securely. (To readjust electrode, loosen torch cap.) 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 5 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. 5. Open all shielding gas valves downstream from flowmeter or flowmeter/regulator, (valve on torch, lever operated shut-off valve, or solenoid-operated valve in power source). NOTE: Purge the gas hose by allowing the gas to flowlong 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. Close control switch at work position or at power source. 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.) If the test arc is satisfactory, commence welding. 7

8 OPERATION AND MAINTENANCE HINTS If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts. 1. 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 coat on the electrode after it has cooled, in welding aluminum, a dark gray deposit on or beside the weld bead. 2. Keep the torch hose away from hot metal. The plastic hose begins to lose strength at 125 F (52 C). 3. Do not try to repair a damaged power cable or gas or water hose. Replace it as directed below. 4. 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. 5. 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. 6. Keep an eye on the sealing O ring on the torch cap. If it shows signs of wear or distortion, cut it off. Then install a new ring (98W18). Apply a little silicone grease to the new ring before attempting to slide it over the cap threads. 3. Clean off the barbed fitting, and then brush on some 3M type 1711 adhesive onto the fitting. 4. Slide the new hose clamp over the new hose. 5. Place the end of the hose in hot water for a short time, and then slide the new hose all the way over the fitting, so it completely covers the ridges. 6. Orient the hose clamp so the tabs will not interfere with the handle, and position the clamp so it is over the ridges on the fitting. 7. Crimp both tabs using a crimping tool or pliers (see Fig. 3). REPLACEMENT OF GAS LENS SCREENS IN 45V63, , AND 45V64 (See Figure 4) Large diameter gas lens collet bodies contain replaceable screens. If plugged by spatter, replace as follows: 1. With the collet body removed from the torch, remove the outer snap ring, P/N 54N71. This can be done by using a small screwdriver, or an electrode with a diameter no greater than 3/32-in. Insert the tip in the slot on the outer sleeve of the collet body, and pry out the snap ring. 2. Using a pair of needle nose pliers, pry out the inner snap ring, P/N 54N Hold the collet body with the screens down, and gently tap the body on the work bench. The body contains three fine and one coarse screens, separated by spacers. If the screens are not badly fouled, they should drop out of the body. Excessive fouling may necessitate prying out the screens. 4. Inspect the screens and replace those which show plugging, or other damage. 5. Replace the screens and spacers making sure that a spacer is installed between each screen, and that the coarsest screen is inserted last. Replace the snap rings. REPLACING GAS OR WATER HOSE 1. Unscrew the torch handle and slide it back over the service lines to expose the hose clamp (see Fig. 5). 2. Clip off the hose clamp (98W43) and remove the hose. The rubber torch bodies do not use a clamp, the hose is retained with ferrule nuts. SCREEN (100 mesh) 54N67 INNER SPACER 54N68 SCREEN (250 mesh) 54N66 INNER SNAP RING 54N69 OUTER SNAP RING 54N71 OUTER SPACER 54N70 Fig. 3 - Crimping a Hose Clamp 8 Fig. 4 - Replaceable Parts in Collet Bodies 45V63, , and 45V64

9 REPLACEMENT PARTS SUPPLIED: WATER ADAPTOR (5/8-18 LH x 1/4 NPT) - 11N16 COLLET BODY WITH INTEGRAL GAS LENS COLLET BODY INSULATOR CAP ASSEM. (LONG) 57Y02 (includes) O RING - 98W18 (3/8" I.D.) O RING - 98W18 (3/8" I.D.) (INCLUDED IN 57Y02) GAS CUP COLLET GAS LENS ACCESSORIES HANDLE - 10N15 (HW-18) - 10N15A (HW-18R) GAS HOSE CLAMP - 98W43 (See Maint. Sect.) WATER IN SILVER SOLDER BODY (HW-18) R (HW-18R) 5/8"-18 L.H. ( B WATER) WATER INLET HOSE ASSEMBLY - 40V74, Q40V74 FOR R ONLY (12-1/2 FT.) 41V32, Q41V32 FOR R ONLY (25 FT.) ARGON INLET HOSE ASSEMBLY 40V75, Q40V75 FOR R ONLY (12-1/2 FT.) 41V30, Q41V30 FOR R ONLY (25 FT.) COLLET CUP (Accys. - See Tables 2 and 3) COLLET BODY (Accy. - See Table 2) 5/8" - 18 ( B - IG) 7/8" - 14 L. H. ( C ) POWER CABLE & HOSE ASSEMBLY 40V64 (12-1/2 FT.) 41V29 (25 FT.) Fig. 4 - HW-18 Torch, 60 phenolic body,12-1/2-ft. lines, P/N HW-18 Torch, 60 phenolic body, 25-ft., lines, P/N HW-18R Torch, 60 rubber body, 12-1/2-ft. lines, P/N R - HW-18R torch, 60 rubber body, 25-ft. lines, P/N R 9

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12 ESAB Welding & Cutting Products, Florence, SC COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800) / Fax: (800) Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE: Telephone: (843) / Fax : (800) Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations D. LITERATURE REQUESTS: Telephone: (843) / Fax: (843) E. WELDING EQUIPMENT REPAIRS: Telephone: (843) / Fax: (843) Repair Estimates Repair Status F. WELDING EQUIPMENT TRAINING Telephone: (843) / Fax: (843) Training School Information and Registrations G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) Hours: 7:30 AM to 4:00 PM EST Hours: 7:30 AM to 3:30 PM EST 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) Hours: 7:30 AM to 5:00 PM EST or visit us on the web at The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback & Support Genuine Heliarc is a registered trademark of ESAB Welding & Cutting Products.