Miller | MC000000L | Owner Manual | Miller WP-280 TORCHES User manual

Miller WP-280 TORCHES User manual
Hand-Held Water-Cooled TIG
(GTAW) Torches
Torches manuelles TIG refroidies
par eau
Antorchas manuales enfriadas
por agua para TIG (GTAW)
Owner’s Manual
Manuel de L’utilisateur
Manual del Operador
File: TIG (GTAW)
ESPAÑOL
WP−280−12−RM
WP−280−25−RM
WP28012RMD50
WP28025RMD50
FRANÇAIS
2012−07
ENGLISH
OM-254 691B
TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GTAW TORCHES − READ BEFORE USING . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3. Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SECTION 2 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2-2. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
3-1. Required Torch Parts And Torch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
3-2. International Style Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
3-3. Connecting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
SECTION 4 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
4-2. Gas And/Or Water Hose Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
4-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
SECTION 5 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . . . 10
5-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 6 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
Weldcraft, 2741 N. Roemer Rd., Appleton, WI 54911 U.S.A. declares that the product(s) identi­
fied in this declaration conform to the essential requirements and provisions of the stated
Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
WP­280­12­RM
WP­280­25­RM
WP28012RMD50
WP28025RMD50
Product
Torch Package, 12.5‘ (3.8m), Braided
Torch Package, 25‘ (7.6m), Braided
Torch Package, 12.5‘ (3.8m), Braided, 50mm
Torch Package, 25‘ (7.6m), Braided, 50mm
Council Directives:
 2006/95/EC Low Voltage
Standards:
 IEC 60974­7:2005 Arc welding equipment – Part 7: Torches
Signatory:
January 31, 2012
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
WC0190 Rev A
−1−
SECTION 1 −SAFETY PRECAUTIONS FOR GTAW
TORCHES − READ BEFORE USING
WC000038 − 2011-10
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the welding power source Owner’s Manual. Read
and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrode or electrical parts.
Before welding, verify torch head is firmly attached to the torch
body.
Do not wrap torch hoses and power cable together with tape or
plastic wire ties. Wrapping restricts water flow which may cause
power cable to overheat and torch hose to burst.
Repair or replace worn, damaged, or cracked torch or cable
insulation.
Turn off welding power source before changing tungsten electrode or torch parts.
Keep all covers and handle securely in place.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
FUMES AND GASES can be hazardous.
Keep your head out of the fumes.
Ventilate area, or use breathing device.
Read Material Safety Data Sheets (MSDSs) and manufacturer’s
instructions for material used.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in
use.
Always ventilate confined spaces or use approved air-supplied respirator.
WELDING can cause fire or explosion.
Do not weld near flammable material.
Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes
unless they are properly prepared according to AWS F4.1 and
AWS A6.0 (see Safety Standards).
Watch for fire; keep extinguisher nearby.
HOT PARTS can burn.
Allow torch to cool before touching.
Do not touch hot metal.
Protect hot metal from contact by others.
NOISE can damage hearing.
Check for noise level limits exceeding those
specified by OSHA.
Use approved ear plugs or ear muffs if noise level is high.
Warn others nearby about noise hazard.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating,
or servicing unit. Read the safety information
at the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OM-254691 Page 1
1-3. Proposition 65 Warnings
Welding or cutting equipment 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 Section 25249.5 et seq.)
This product contains or produces a chemical known to the
State of California to cause cancer or birth defects (or other
reproductive harm). (California Health & Safety Code Section
25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
1-5. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
1. Keep cables close together by twisting or taping them, or using a
cable cover.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-254 691 Page 2
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
ENGLISH
SECTION 2 − SPECIFICATIONS
2-1. Specifications
Model
WP-280-12-RM
WP28012RMD50
WP-280-25-RM
WP28025RMD50
25 Ft (7.6 m)
25 Ft (7.6 m)
280 Amps
Max Rating*
12.5 Ft (3.7 m)
Length
12.5 Ft (3.7 m)
Tri-Flex Braided Rubber
Hose/Cable Options
Cooling Method
Liquid (Distilled/Deionized Water or Low Conductivity Coolant, Miller Part No. 043 810)
Electrode Range
.020 in. Thru 1/8 in. (0.5 Thru 3.2 mm)
Length 7 in. (178 mm); Handle Diameter 7/8 in. (22.2 mm); Weight 4.1 oz (117 g)
Dimensions
Method Of Guidance
Manual/Hand Held
Peak Voltage Rating
113 V
Peak Striking/Stability Voltage
15 KV
.25 GPM
Min Flow Rate
.379 MPa (55 psi) Min; .482 MPa (70 psi) Max
Min And Max Inlet Pressure
2620 W
Min Cooling Power
* Max rating based on 25 C (77 F) environment at maximum handle temperature rise of 30 C (86 F) or power cable temperature rise of 40
C (104 F). 100% Argon gas, 100% duty cycle, 1/8 in. (3.2 mm) 2% Ceriated electrode and Miller Coolmate 4.
2-2. Duty Cycle
400
Amperage A
350
300
250
200
150
100
50
0
0
10
30
40
50
Definition
60
70
Duty Cycle %
80
90
100
100% Duty Cycle At 280 Amperes Using Argon Gas For 12 Ft Models
100% Duty Cycle At 280 Amperes Using Argon Gas For 25 Ft Models
Duty Cycle is percentage of 10
minutes that torch can weld at
rated load without overheating.
Minutes
Continuous Welding
sb1.5* 8/93
NOTICE − Exceeding rated amperage can damage torch and void warranty (see Section 2-1).
OM-254 691 Page 3
SECTION 3 − INSTALLATION
3-1. Required Torch Parts And Torch Assembly
Assembling Torch Parts
7
6
5
4
8
3
2
9
1
Cup
2
Collet Body
3
Insulator
4
Back Cap Insulator
5
Collet
6
O-Ring
7
Backcap
8
Torch Body
9
Handle
10 Gas Hose
1
11 Water Hose
12 Power Cable
17
13 Power Cable Adapter
16
10
11
15
14 International Style Adapter
15 Water Hose For International
Style Adapter
16 Weldcraft QCS (Optional)
Assembling Torch Body
Keep connections tight. Replace
cup, heat shield, and backcap as
needed.
17 Tungsten Electrode (See Section 6)
Installing Tungsten
12
To adjust tungsten position, loosen
backcap.
13
14
WC0174-A
3-2. International Style Connector Assembly
1
1
3
2
1 in
(26 mm)
5
4
3
Weld Output Cable
2
Insulating Boot
3
Sleeve
Slide insulating boot onto cable;
strip cable and install sleeve.
4
Connector Body
5
Setscrew
Insert cable with sleeve fully into
connector body, tighten setscrew,
and slide insulating boot over connector.
Tools Needed:
ST-156 496
OM-254 691 Page 4
ENGLISH
3-3. Connecting Torch
A. Connecting Torch When Using A Freestanding Coolant System
If applicable, install high-frequency unit.
2
1
3
4
11
7
10
12
6
8
9
5
Tools Needed:
5/8, 7/8, 1-1/8 in.
802 560
!
Turn Off welding power source and
cooling system power before installing torch.
5
Torch
9
6
Power Cable Adapter
7
Coolant Hose (Customer Supplied)
10 Coolant-Into Torch Hose (Blue)
1
Welding Power Source
2
Regulator/Flowmeter
Obtain correct length with 5/8-18 left-hand
fittings.
3
Gas Cylinder
8
4
Gas Hose (Customer Supplied)
Obtain correct length with 5/8-18 right-hand
fittings.
Coolant-Out Of Torch/Power Cable
(Red)
Connect coolant-out of torch/power cable
to power cable adapter, and connect adapter to weld output terminal.
Torch Gas Hose
11 Cooling System
12 Work Clamp
Connect work clamp to a clean, paint-free
location on workpiece, close to the weld.
Use wire brush or sandpaper to clean weld
joint area.
OM-254 691 Page 5
B. Connecting Torch To A Dynastyt 300 DX Or Maxstar 300 DX TIGRunnert Unit
2
11
1
3
!
Turn Off welding power source
power before installing torch.
1
Gas Hose With 5/8-18 Right-Hand
Fittings (Customer Supplied)
Connections:
9
7
8
6
2
Regulator/Flowmeter
3
Gas Cylinder
4
Coolant System
5
Torch
6
Coolant-Into Torch Hose (Blue)
7
Torch Gas Hose
8
Coolant-Out Of Torch/Power
Cable (Red)
9
International Style Adapter
Connect coolant-out of torch/power
cable to power cable adapter, and connect adapter to weld output terminal.
5
4
10 Work Clamp
Connect work clamp to a clean, paintfree location on workpiece, close to the
weld.
Tools Needed:
Use wire brush or sandpaper to clean
weld joint area.
10
11 Welding Power Source
12 Foot Control
12
803 311
5/8, 7/8, 1-1/8 in.
C. Connecting Torch To A Syncrowave 250 DX Or 350 LX w/Integrated Cooler
4
3
2
9
7
6
Turn Off welding power source
power before installing torch.
1
Gas Hose With 5/8-18 Right-Hand
Fittings (Customer Supplied)
Connections:
5
8
!
2
Gas Cylinder
3
Regulator/Flowmeter
4
Power Source
5
Coolant System
6
Torch
7
Coolant-Into Torch Hose (Blue)
8
Coolant-Out Of Torch/Power
Cable (Red)
Connect torch coolant-out of torch/power cable to power cable adapter, and
connect adapter to weld output terminal.
1
9
Torch Gas Hose
10 Work Clamp
Connect work clamp to a clean, paintfree location on workpiece, close to the
weld.
10
Tools Needed:
5/8, 7/8, 1-1/8 in.
Use wire brush or sandpaper to clean
weld joint area.
11 Foot Control
11
803 601-B
OM-254 691 Page 6
4-1. Routine Maintenance
!
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Disconnect torch before maintaining.
= Replace
Daily
Nozzle For Cracks −
If Necessary
Collet For Wear −
If Necessary
Collet Body Threads −
If Necessary
Check Tungsten Preparation (See Section ??)
Weekly
Monthly
Power Cable For Cracks,
Wear −
If Necessary
Gas Hose For
Cracks, Leaks, Wear −
If Necessary
Power, Gas, And Water
Cable Connections To Ensure They Are Tight
Gas Lens Screen −
If Necessary
Gas Valve, If Applicable −
If Necessary
Water Hose, If Applicable, For Cracks, Leaks,
Wear −
If Necessary
Back Cap O-Ring −
If Necessary
Cable Cover For
Tears, Holes, Or Wear −
If Necessary
When using a water-cooled torch, maintain cooling equipment according to the manufactures recommendations.
4-2. Gas And/Or Water Hose Maintenance
1
!
Disconnect torch
maintaining.
1
Gas Hose
2
Water Hose
before
Whenever a gas or water hose
is removed from its fitting, it is
required that 1−1/4 in. (32 mm)
of hose be cut off before reattaching the hose to its fitting.
Hose Nut
2
Cut 1-1/4 in.
WC188 00
OM-254 691 Page 7
ENGLISH
SECTION 4 − MAINTENANCE & TROUBLESHOOTING
4-3. Troubleshooting
Before using troubleshooting table, check selection and preparation of tungsten electrode according to Section 6.
Trouble
Remedy
Arc will not start. High frequency present Check cable and work connections. Be sure weld circuit is complete (see Section 3-3).
and visible at the torch.
Check and be sure shielding gas is present.
Lack of high frequency; difficulty in es- Select proper size and type tungsten. Properly prepare tungsten according to Section 6.
tablishing arc.
Check cables and torch for cracks or bad connections. Be sure that torch cables are not close to any
grounded metal. Repair or replace necessary parts.
Check torch consumables. Be sure collet and collet body are correctly installed and tightened (see Section 3-1).
Check welding power source High Frequency control, and if necessary, check and adjust spark gaps.
Torch gas valve not working properly (if Have Factory Authorized Service Station/Service Distributor check valve.
applicable).
No shielding gas flow from torch.
Be sure valves on gas supply are open.
Check cable for kinks or blockage.
Check and tighten all gas supply fittings.
Check cables and torch for cracked insulation or bad connections. Repair or replace (see Section 4-1).
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time.
Increase gas flow rate. Check manufacture’s recommendations.
Check and tighten all gas fittings.
Check gas valve and flow meter/regulator.
Select proper size and type tungsten. Properly prepare tungsten (see Section 6).
Excessive tungsten electrode con- Select proper size and type tungsten. Properly prepare tungsten according to Section 6.
sumption.
Check polarity setting on welding power source (see welding power source Owner’s manual).
Check for proper gas flow rate. Check manufacture’s recommendations.
If torch is water cooled, check torch and cables for water leaks. Repair or replace if necessary (see Section 4-1).
Wandering arc
Shield weld zone from drafts.
Reduce gas flow rate.
Select proper size and type tungsten. Properly prepare tungsten according to Section 6.
When using AC, check welding power source High Frequency control setting, and increase setting if necessary.
Yellow powder or smoke on cup.
Use proper type shielding gas.
Check for proper gas flow rate. Check manufacture’s recommendations.
Increase postflow time.
Check torch cup size. Match cup size to joint being welded.
Erratic arc
When using DC, check polarity, and/or polarity of welding cables.
When using AC, check welding power source High Frequency control setting, and be sure it is operating
continuously.
Select proper size and type tungsten. Properly prepare tungsten according to Section 6.
Use proper arc length. Arc length may be too long or too short.
Make sure base material is clean and free of contaminates.
When using AC, slow travel speed can cause erratic arc. Adjust travel speed.
OM-254 691 Page 8
Porosity in weld.
ENGLISH
Trouble
Remedy
Check for proper gas flow rate. Check manufacture’s recommendations.
Check and tighten gas fittings.
Make sure base material and filler material is clean and free of contaminates.
Check for impurities and moisture in gas lines. Purge if necessary.
If torch is water cooled, check torch and cables for water leaks. Repair or replace if necessary (see Section 4-1).
Notes
OM-254 691 Page 9
SECTION 5 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2011-06
Whenever possible and practical, use DC weld output instead of AC weld output.
5-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
Amperage Range - Gas Type - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (1 mm)
Up to 25
Up to 20
.020 in. (1 mm)
15-40
15-35
.040 in. (1 mm)
25-85
20-80
1/16 in. (1.6 mm)
50-160
50-150
3/32 in. (2.4 mm)
130-250
135-235
1/8 in. (3.2 mm)
250-400
225-360
5/32 in. (4.0 mm)
400-500
300-450
3/16 in (4.8 mm)
500-750
400-500
1/4 in. (6.4 mm)
750-1000
600-800
Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
5-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC
Welding With Inverter Machines
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Radial Grinding
Causes Wandering Arc
2-1/2 Times
Electrode Diameter
1
3
2
1
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
Wrong Tungsten
Preparation
4
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
OM-254 691 Page 10
SECTION 6 − GUIDELINES FOR TIG WELDING (GTAW)
6-1. Positioning The Torch
!
Grinding the tungsten electrode
produces dust and flying sparks
which can cause injury and start
fires. Use local exhaust (forced
ventilation) at the grinder or wear
an approved respirator. Read
MSDS for safety information.
Consider using cerium or lanthanum based tungsten instead of
thoriated. Thorium dust contains
low-level radioactive material.
Properly dispose of grinder dust
in an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
1
Workpiece
3
2
4
90
Make sure workpiece is clean before
welding.
1
2
Work Clamp
Place as close to the weld as possible.
3
4
5
6
10−15
4
5
6
10−25
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten according
to Section 5.
Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
if tungsten is 1/16 in. diameter, gas cup
should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the
tungsten extends out gas cup of torch.
1/16 in.
3/16 in.
Bottom View Of Gas Cup
The tungsten extension should be no
greater than the inside diameter of the
gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-254 691 Page 11
6-2. Torch Movement During Welding
Tungsten Without Filler Rod
75
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75
Welding direction
Form pool
15
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
6-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20
90
70
75
20
10
15
Corner Joint
Lap Joint
20-40
90
75
75
15
15
30
ST-162 003 / S-0792
OM-254 691 Page 12
Notes
OM-254 691 Page 13
SECTION 7 − PARTS LIST
19
16
21
22
23
18
17
20
24
4
15
25
14
13
3
8
12
7
2
1
11
10
6
26
9
5
27
28
29
WC0175-A
Figure 7-1. Complete Torch Assembly
OM-254 691 Page 14
Quantity
WP−280
Item
No.
Dia.
Mkgs.
Part
No.
Description
12-RM 25-RM
12
25
RMD50 RMD50
Figure 7-1. Complete Torch Assembly
...
...
...
...
1
1
1
1
.
.
.
.
..............
..............
..............
..............
NOZZLE, large gas lens alumina #6 . . . . . . . . . . .
NOZZLE, large gas lens alumina #8 . . . . . . . . . . .
NOZZLE, large gas lens alumina #10 . . . . . . . . . .
NOZZLE, large gas lens alumina #12 . . . . . . . . . .
1
1
1
1
....
....
....
....
1
1
1
1
....
....
....
....
1
1
1
1
....
....
....
....
1
1
1
1
. . . 2 45V0204S . . . . . . . . . . . .
..............................
. . . 2 45V116S . . . . . . . . . . . . .
. . . 2 . 45V64S . . . . . . . . . . . . .
. . . 2 995795S . . . . . . . . . . . . .
. . . 3 . 13N20L . . . . . . . . . . . . .
. . . 3 . 13N21L . . . . . . . . . . . . .
. . . 3 . 13N22L . . . . . . . . . . . . .
. . . 3 . 13N23L . . . . . . . . . . . . .
. . . 3 . 13N24L . . . . . . . . . . . . .
. . . 4 54N63-20 . . . . . . . . . . . .
. . . 5 . 13N14 . . . . . . . . . . . . . .
. . . 5 . 13N15 . . . . . . . . . . . . . .
. . . 5 . 13N16 . . . . . . . . . . . . . .
. . . 5 . 13N17 . . . . . . . . . . . . . .
. . . 5 . 13N18 . . . . . . . . . . . . . .
. . . 5 . 13N19 . . . . . . . . . . . . . .
. . . 6 . 796F74 . . . . . . . . . . . . .
. . . 6 . 796F75 . . . . . . . . . . . . .
. . . 6 . 796F76 . . . . . . . . . . . . .
. . . 6 . 796F77 . . . . . . . . . . . . .
. . . 7 . 53N58 . . . . . . . . . . . . . .
. . . 7 . 53N59 . . . . . . . . . . . . . .
. . . 7 . 53N60 . . . . . . . . . . . . . .
. . . 7 . 53N61 . . . . . . . . . . . . . .
. . . 7 . 53N61S . . . . . . . . . . . . .
. . . 8 . 45V41 . . . . . . . . . . . . . .
. . . 8 . 45V42 . . . . . . . . . . . . . .
. . . 8 . 45V43 . . . . . . . . . . . . . .
. . . 8 . 45V44 . . . . . . . . . . . . . .
. . . 8 . 45V45 . . . . . . . . . . . . . .
. . . 9 . 796F70 . . . . . . . . . . . . .
. . . 9 . 796F71 . . . . . . . . . . . . .
. . . 9 . 796F72 . . . . . . . . . . . . .
. . . 9 . 796F73 . . . . . . . . . . . . .
. . . 9 A796F70 . . . . . . . . . . . . .
. . . 9 A796F71 . . . . . . . . . . . . .
. . . 9 A796F72 . . . . . . . . . . . . .
. . . 9 A796F73 . . . . . . . . . . . . .
. . . 10 . . 13N11 . . . . . . . . . . . . . . .
. . . 10 . 13N13 . . . . . . . . . . . . . .
. . . 10 . 13N12 . . . . . . . . . . . . . .
. . . 10 . 13N10 . . . . . . . . . . . . . .
. . . 10 . 13N09 . . . . . . . . . . . . . .
. . . 10 . 13N08 . . . . . . . . . . . . . .
. . . 11 . . 13N28 . . . . . . . . . . . . . . .
. . . 11 . 13N25 . . . . . . . . . . . . . .
. . . 11 . 13N29 . . . . . . . . . . . . . .
. . . 11 . 13N26 . . . . . . . . . . . . . .
. . . 11 . 13N27 . . . . . . . . . . . . . .
GAS LENS COLLET BODY, large .020 & .040
(0.5 & 1.0 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAS LENS COLLET BODY, large 1/16 (1.6 mm)
GAS LENS COLLET BODY, large 3/32 (2.4 mm)
GAS LENS COLLET BODY, large 1/8 (3.2 mm) .
GAS LENS COLLET, large .020 (0.5 mm) . . . . . .
GAS LENS COLLET, large .040 (1.0 mm) . . . . . .
GAS LENS COLLET, large 1/16 (1.6 mm) . . . . . .
GAS LENS COLLET, large 3/32 (2.4 mm) . . . . . .
GAS LENS COLLET, large 1/8 (3.2 mm) . . . . . . .
INSULATOR, cup large diameter . . . . . . . . . . . . . .
NOZZLE, lava #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava #8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava #10 . . . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava long #3XL . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava long #4XL . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava long #5XL . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava long #6XL . . . . . . . . . . . . . . . . . . . . .
NOZZLE, small alumina #4 . . . . . . . . . . . . . . . . . . .
NOZZLE, small alumina #5 . . . . . . . . . . . . . . . . . . .
NOZZLE, small alumina #6 . . . . . . . . . . . . . . . . . . .
NOZZLE, small alumina #7 . . . . . . . . . . . . . . . . . . .
NOZZLE, small alumina #8 . . . . . . . . . . . . . . . . . . .
GAS LENS, small, .020 (0.5 mm) . . . . . . . . . . . . . .
GAS LENS, small, .040 (1.0 mm) . . . . . . . . . . . . . .
GAS LENS, small, 1/16 (1.6 mm) . . . . . . . . . . . . . .
GAS LENS, small, 3/32 (2.4 mm) . . . . . . . . . . . . . .
GAS LENS, small, 1/8 (3.2 mm) . . . . . . . . . . . . . . .
NOZZLE, lava long #3L . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava long #4L . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava long #5L . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, lava long #6L . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, alumina long #3L . . . . . . . . . . . . . . . . . . .
NOZZLE, alumina long #4L . . . . . . . . . . . . . . . . . . .
NOZZLE, alumina long #5L . . . . . . . . . . . . . . . . . . .
NOZZLE, alumina long #6L . . . . . . . . . . . . . . . . . . .
NOZZLE, #7 alumina . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, #10 alumina . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, #8 alumina . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, #6 alumina . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, #5 alumina . . . . . . . . . . . . . . . . . . . . . . . .
NOZZLE, #4 alumina . . . . . . . . . . . . . . . . . . . . . . . .
COLLET BODY, 3/32 (2.4 mm) . . . . . . . . . . . . . . . .
COLLET BODY, .020 (0.5 mm) . . . . . . . . . . . . . . . .
COLLET BODY, 1/8 (3.2 mm) . . . . . . . . . . . . . . . . .
COLLET BODY, .040 (1.0 mm) . . . . . . . . . . . . . . . .
COLLET BODY, 1/16 (1.6 mm) . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
57N75
57N74
53N88
53N87
OM-254 691 Page 15
Quantity
WP−280
Item
No.
Dia.
Mkgs.
Part
No.
Description
12−RM 25−RM 12
25
RMD50 RMD50
Figure 7-1. Complete Torch Assembly (continued)
. . . 12 . . 13N23 . . . . . . . . . . . . . . . COLLET, 3/32 (2.4 mm) . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 12 . 13N20 . . . . . . . . . . . . . . COLLET, .020 (0.5 mm) . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 12 . 13N21 . . . . . . . . . . . . . . COLLET, .040 (1.0 mm) . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 12 . 13N22 . . . . . . . . . . . . . . COLLET, 1/16 (1.6 mm) . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 12 . 13N24 . . . . . . . . . . . . . . COLLET, 1/8 (3.2 mm) . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 13 . 598 882 . . . . . . . . . . . . . . INSULATOR, cup . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 14 . WP-280 . . . . . . . . . . . . . . TORCH BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 15 . . . 9−4 . . . . . . . . . . . . . . . . INSULATOR, Back Cap . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 16 . . 41V24 . . . . . . . . . . . . . . . BACK CAP, long (includes) . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 17 . 41V35 . . . . . . . . . . . . . . BACK CAP, medium (includes) . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 18 . 41V33 . . . . . . . . . . . . . . BACK CAP, button (includes) . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . . . . . . 98W77 . . . . . . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 19 WP-280-H . . . . . . . . . . . . . HANDLE, Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 20 . . 20-10N . . . . . . . . . . . . . . MECHANICAL NUTS . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . 21WP-280-12W . . . . . . . . . . . . HOSE, water 14 ft (4.2 m), Braided . . . . . . . . . . . . 1 . . . . . . . . . . . 1
. . . 21WP-280-25W . . . . . . . . . . . . HOSE, water 26.5 ft (8.0 m), Braided . . . . . . . . . . . . . . . . 1 . . . . . . . . . . .
. . . 22 WP-280-12G . . . . . . . . . . . . HOSE, gas 13.25 ft (4.0 m), Braided . . . . . . . . . . . 1 . . . . . . . . . . . 1
. . . 22 WP-280-25G . . . . . . . . . . . . HOSE, gas 25.75 ft (7.8 m), Braided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23WP-280-12PC . . . . . . . . . . . CABLE, power 12.5 ft (3.8 m), Braided . . . . . . . . . 1 . . . . . . . . . . . 1
. . . 23WP-280-25PC . . . . . . . . . . . CABLE, power 25 ft (7.6 m), Braided . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . .
. . . 24 . WC0183 . . . . . . . . . . . . . . CABLE COVER, 10 ft (3.0 m) . . . . . . . . . . . . . . . . . 1
. . . 24 . WC0182 . . . . . . . . . . . . . . CABLE COVER, 22 ft (6.7 m) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . WC0185 . . . . . . . . . . . . . . CABLE COVER, 12.75 ft (3.9 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . WC0184 . . . . . . . . . . . . . . CABLE COVER, 25.25 ft (7.7 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . Q5W . . . . . . . . . . . . . . . CONN, Quick, 350A, 50 mm, W/C (Includes) . . . . 1 . . . . 1
. . . . . . PCA-5-17 . . . . . . . . . . . . . . HOSE, water 18 in. (0.2 m) RH . . . . . . . . . . . . . . 1 . . . . 1
. . . 27 Q5WGT . . . . . . . . . . . . . CONN, Quick, 350A, 50 mm, W/C (Includes) . . . . 1 . . . . 1
. . . . . . PCA-5-16 . . . . . . . . . . . . . . HOSE, Gas 18 in. (0.2 m) RH . . . . . . . . . . . . . . . 1 . . . . 1
. . . 28 . 195 377 . . . . . . . . . . . . . ADAPTER, torch−intl style water(#18, 20) (Includes) . . . . . . . . . . 1 . . . .
. . . . . . . 222 809 . . . . . . . . . . . . . . . HOSE, water 18Lh (intl style water #18, 20) . . . . . . . . . . . . . . . . 1 . . . .
. . . 29 . 45V11 . . . . . . . . . . . . . . ADAPTER, power cable . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
. . . . . . . . AK4C . . . . . . . . . . . . . . ACCESSORY KIT (cerium) . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . .
OPTIONAL
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-254 691 Page 16
1
1
1
1
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1
1
1
1
1
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1
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ENGLISH
Notes
ENGLISH
Notes
ENGLISH
Notes
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Number.
Contact your Distributor for:
Welding Supplies and Consumables
Weldcraft
Options and Accessories
An Illinois Tool Works Company
2741 N. Roemer Rd
Appleton, WI 54911 USA
Personal Safety Equipment
Service and Repair
1-800-752-7620 Toll Free
1-920-882-6800 Phone
1-920-882-6844 FAX
Replacement Parts
www.Weldcraft.com
Welding Process Handbooks
To locate a Distributor or Service Agency call 1-800-752-7620 or 920-882-6800
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2012 Weldcraft Products Inc.
1/2012
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