ESAB HWM-3 Contour Welder Troubleshooting instruction

F-841-D
INSTRUCTIONS for FORM 841-D
AUGUST, 1978
HWM-3
CONTOUR WELDER
H >. Including
STA Ry A
‘OPY HWH-1 Welding Head
DO poo yy Motorized Cold Wire Feeder
HW-27 /Long-Barrel Torch
(See F-807 for HWC-2 Control Instructions)
CONTENTS
PAGE
1. Introduction ........_ 24204224 4 410 5 1 4100 1
IH. installation Instructions . .......— eo aerea 1
NI. Operating Instructions . . . ................ 14
tV. Maintenance and Trouble-Shooting .......... 27
V. Replacement Parts Information .. .. ......... 35
уМ1ЮМ WELDING
(5.1:1:111158 PRODUCTS
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. Before
performing any installation or operating procedures, be sure to read and
follow the safety precautions listed below. Failure to observe these
Safety Precautions can result in personal injury or death,
1. PERSONAL PROTECTION - - Skin and eye burns resulting from
body exposure to the electric-arc welding rays or hot metal can be
more severe than sunburn. Therefore:
Use a proper face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck and ears from sparks and
rays of the welding arc when welding or observing welding.
WARN bystandédrs not to watch the arc and not expose them-
selves to the welding-arc rays or to hot metal.
Wear flameproof gauntlet type gloves, heavy long-sleeve shirt,
cuffiess trousers, high-topped shoes and a welding helmet or cap
for hair protection to protect the skin from arc rays and hot
sparks or hot metal. A flameproof apron may also be desirable
as protection against radiated heat and sparks.
Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs
or pockets. Sleeves and collars should be kept buttoned, and
pockets eliminated from the front of clothing.
. Protect other nearby personnel from arc rays and hot sparks
with a suitable non-flammable partition.
Always wear safety glasses or goggles when in a welding area.
Use safety glasses with side shields or goggles when chipping slag
or grinding. Chipped slag is hot and may travel considerable
distances. Bystanders should also wear safety glasses or goggles.
FIRE PREVENTION - - Hot slag, or sparks, can cause serious fires
when in contact with combustible solids, liquids or gases. There-
fore:
Remove all combustible materials well away from the welding
area or completely cover the materials with a non-flammable
covering. Such combustible materials include wood, clothing,
sawdust, gasoline, kerosene, paints, solvents, natural gas, acety-
lene, propane and similar combustible articles.
. Hot sparks or hot metal can fall into cracks in floors or wall
openings and cause a hidden smouldering fire. Make certain that
such openings are protected from hot sparks and metal.
Do not weld, cut or perform other hot work on used barrels,
drums, tank or other containers untit they have been completely
cleaned so that there are no substances in the container which
might produce flammable or toxic vapors.
For fire protection, have fire extinguishing equipment handy for
instant use, such as a garden hose, water pail, sand bucket or
portable fire extinguisher.
After completion of welding, inspect the work area to make cer-
tain there are no hot sparks or hot metal which could cause a
later fire.
ELECTRICAL SHOCK - - Voltages of 110 volts or less can cause
severe burns to the body or fatal shock. Severity of electrical shock
is determined by the path and amount of current through the body.
Therefore:
b.
Never allow live metal parts to touch bare skin or any wet
clothing. Be sure gloves are dry.
When standing on metal or welding in a damp area, make certain
that you are well insulated by wearing dry gloves and rubber-
soled shoes and standing on a dry board or platform.
Always ground the welding machine by connecting a ground
wire between the machine and a good electrical ground.
. Do not use worn or damaged welding cables. Da not overload
the cable. Use well maintained equipment.
When not welding, turn off the equipment. Accidental ground-
4.
ing can cause overheating and create a fire hazard. Do not coil
or loop the welding cable around parts of the hody.
f. Be sure the ground cable is connected to the workpiece as
close to the welding area as possible. Grounds connected to
building framework or other remote locations from the welding
area increase the possibility of the welding current passing
through lifting chains, crane cables or various electrical paths.
g. Keep everything dry, including clothing, work area, welding
cables, electrode holder and welding machine. Fix water leaks
immmediately.
VENTILATION - - Welding fumes, particularly in confined spaces,
can cause discomfort and physical harm if breathed over an extend-
ed period of time. Therefore:
a. At all times provide adequate ventilation in the welding area by
natural ventilation or mechanical ventilation means. Do not weld
on galvanized, zinc, lead, beryllium or cadmium materials unless
positive mechanical ventilation is provided to prevent breathing
fumes from these materials.
b. Do not weld in locations close to chlorinated hydrocarbon va-
pors coming from degreasing or spraying operations. The heat or
arc rays can react with solvent vapors to form phosgene, a highly
toxic gas, and other irritant gases.
c. If you develop momentary eye, nose or throat irritation during
welding, this is an indication that ventilation is not adequate.
Stop work and take necessary steps to imprave ventilation in the
welding area. Do not continue to weld if physical discomfort
persists,
а. Refer to AWS Standard 249.1 in Item 6 for specific ventilation
recommendatians.
. EQUIPMENT MAINTENANCE -- Faulty or improperly maintained
welding equipment can result in poor welding work, but most im-
portantly it can cause physical injury or death through fires or
electrical shock. Therefore:
a. Whenever possible, have qualified personnel perform the installa-
tion, troubleshooting and maintenance work on the welding
machine. Do not perform any electrical work on the welding
machine unless you are qualified to perform such work,
b. Before performing any maintenance work inside the welding
machine, disconnect the machine from the electrical power
source,
c. Maintain welding cables, grounding wire and connections, power
cord and welding machine in safe working order. Do not operate
the welding machine or equipment in a faulty condition.
d. Do not abuse the welding machine or accessory equipment. Keep
the equipment away from heat sources such as furnaces, wet
conditions such as water puddles, oil or grease, corrosive atmos-
pheres and inclement weather.
e. Keep all safety devices and cabinet covers in position and in
good repair.
f. Use the welding machine for its intended purpose and do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION - - For more information
on safe practices for setting up and operating electric welding equip-
ment and on good working habits, ask for a copy of Linde's “Pre-
cautions and Safe Practices for Electric Welding and Cutting”,
Form 52-529. The following publications which are available from
the American Welding Society, 2501 N.W. 7th Street, Miami, FL.
32125, are recommended to you:
a. "Safety in Welding and Cutting” - AWS 749.1
b. “Recommended Safe Practices for Gas-Shielded Arc Welding”
- AWS AG.1
с. “Safe Practices for Welding and Cutting Containers That Have
Held Combustibles" - AWS AG.O.
TORCH CHANGE
Effective October, 1973, the HW-27/Long Barrel Torch
(P/N 593731) has replaced the HW-23 Torch (P/N 444141)
on the HWM-3 Tig Contour Welder. The HW-27/L B. uses
the same accessories as the standard HW-27 torch, such as
gas lens collet bodies and .040-in. to 1/4-in. dia. electrodes.
The torch is rated up to 400 amps (AC or DC) continuous
duty with high impact cups and up to 500 amps AC or DC
with metal nozzles. The mounting and the installation of the
torch is identical to the HW-23 torch. However, the installa-
tion of collet, collet body, and electrode differs in that the
ribbed insulator, supplied with the gas lens collet body, is
used for tightening the collet to the electrode on the HW-27/
L.B. instead of the collet locking lever.
|. INTRODUCTION
The HWM-3 Mechanized a.c.-d.c. Contour Welder consists
of an HWH-1 Welding Head, and HW-27/Long-Barrel
Torch, and an HWC-2 a.c.-d.c. Voltage Control. Also in-
cluded are an electronic governor controlled cold wire feeder,
a cold wire attachment, and timers for controlling the wire
feeder and travel carriage. The welding head moves the torch
up and down in response to signals generated in the control
by the arc. It thereby maintains a constant electrode to
work distance.
Separately available equipment packages contain the neces-
sary components for mounting the contour welder on either
an OM-48 Side Beam Carriage or a stationary boom. A
typical OM-48 installation is shown in Figure 1.
This booklet contaíns complete details on the installation
and operation of the complete HWM-3 Contour Welder. It
also includes information on the design, maintenance and
repair of the mechanical components such as the head,
torch and wire feeder. Full details on the HWC-2 Control,
OM-48 Carriage, and electronic governors for the carriage
and wire feeder are included in the booklets listed below.
F-807 Instructions for the HWC-2 AC-DC Voltage
Control
F-9160 Instructions for the OM-48 Side-Beam Carriage
F-11-656 Instructions for Type “E” Electronic Governor
(Used with OM-48 Carriage and Cold Wire
Feeder)
Il. INSTALLATION INSTRUCTIONS
The HWM-3 will operate with either a.c. or d.c. welding
power. The control is designed for use with high frequency
starting only. The equipment used with the HWM-3 Contour
Welder is described below.
A. Equipment Supplied
The basic HWM-3 machine and control assembly, Part No.
495763, consists of the following eight basic items:
. HWH-1 Welding Head, 433573
. HW-27/L.B. Mechanized Torch, 593731
. HWC-2 (Series 2) AC-DC Voltage Control, 434041
. Motorized Cold Wire Feeder, 433688
. Cold Wire Attachment, 458259
. Type “E” Electronic Governor for Cold Wire Feeder,
37V87
7. Shielded extension cable (wire feeder motor to governor),
495060
8. Timer Assembly (for travel carriage and wire feeder),
490214
O Bd pd —
The basic assembly is put together at the factory with all
internal and external connections made.
Two complete machine mounting packages are available;
one utilizes the OM-48 Side-Beam Carriage, the other is a
boom type mounting.
The mounting accessories for a carriage type mounting are
sold under Part No. 495858. This equipment package in-
cludes the following seven items.
1. OM-48 Side-Beam Carriage and Governor Assembly,
3-80 ipm (other speeds available), 01ES53
. Shielded extension cable, 25 ft., carriage to governor,
495051
. Mounting plate for OM-48 Side-Beam Carriage, 493388
. Angle bracket, 29N04
. Governor mounting bracket (2), 493424
. Angle bracket for cold wire feeder, 486332
. Adjustment slide assembly, 25V39
t-2
3 Os A PR QU
The equipment package for a boom type mounting, Part No.
495859, includes the following three items:
1. Mounting plate for HWH-1 Head, 433690
. “2” adaptor bracket, 433691
. Adjustment slide assembly, 25V39
Li t9
B. Required Accessories
The following required accessories must be provided for all
HWM-3 installations.
. R-502 Argon Regulator and Flowmeter, 639296
. Water Hose, 12-1/2 ft. (4 required), 40V76
. Argon Hose, 12-1/2 ft. (2 required), 40V77
. Drain Adaptor, 11N16
. Argon Hose Coupling, 11N17
. Water Hose Coupling (2 required), 11N18
. Current Transformer (required for use with a.c. meter in
remote control box), Weston Model 604, Type 1; not
available from Linde.
8. 4/0 cable, as required.
-] NAL WD
C. Optional Accessories
The following optional accessories are intended for use with
some, but not all HWM-3 installations.
1. Torch Saver II, Flow Switch, 40V51
2. 3 Conductor shielded cable, 25 ft., connects Torch Saver
(Item 1 above) to control, 495053
3. Cable grip (strain relief for [tem 2 above), 96W85
Fig. 1 - Typical HWM-3 Installation Using OM-48 Carriage
. Ammeter for d.c. welding, 90W59
. 500 ampere meter shunt (required with Item 4), 180W27
. Fillet angle adjustment assembly, 29V95
. Track assembly for OM-48 carriage, 10-ft. lengths,
38V16
8. Shielding (for Electrical Grounding), 75 ft., 7300-6768
—) © LA Æ
D. Welding Power Supply
For d.c. operation, any suitable 500 ampere d.c. welding
power supply may be used. À source of high frequency cur-
rent must be provided for starting purposes. For a.c. opera-
tion, a balanced wave power supply must be used. A high
frequency generator is also required for arc starting. For
both a.c. and d.c. operation a 115 volts a.c. power source
must be provided for operation of the HWC-2 control.
E, Mounting Instructions
The welding head may be mounted on an OM 48 Side-Beam
Carriage or a boom or other stationary support. Cold wire
feed may be used with either the movable or stationary
type of mounting.
1. OM-48 Carriage Mounting
The equipment package for an OM-48 carriage mounting,
Part No. 495858, includes the OM-48 carriage and all
parts needed to mount the HWH-1 head, motorized wire
drive assembly, travel carriage and wire feed governors,
and remote control box on the carriage. Refer to Figure 2
and proceed as follows:
d.
Mounting plate 493388, which is drilled to accommo-
date the other mounting accessories, should be
attached to the face of the side-beam carriage.
. Bolt angle bracket 29N04 to the carriage with the
bolts supplied.
. Mount the adjustment slide assembly, 25V39, on the
angle bracket.
. Remove mounting plate 431086 which is the back
cover of the welding head.
. Using the four screws which are provided, screw the
plate to the slide assembly and put the head back on
the mounting plate.
MOUNTING BRACKET
486332
COLD WIRE FEEDER
433688
{SEE Fis 73}
GOVERNOR MOUNTING
E. N
[|
ELECTRONIC Do |
GOVERNCH-29VTS
(TRAVEL CARRIAGE] \ |
HW-27 С. в TORCH
593731
(SEE FIG. 27)
O
Ми
HWH-1 WELDING HEAQ ASSEM.
433573
{SEE FIG. 12)
|
ELECTRONIC |
GOVERNOR-37v87 1
{WIRE FEEDER) | ofl
“x FLEXIBLE CABLE ASSEM.
Se, <<
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) —
444599
(SEE FIG El |
N
MOUNTING PLATE -493388
EMOUNT ON OM -48 SIDE BEAM
CARRIAGE}
ZA ANGLE
ADJ. ASSEM.-29Y95
SLIDE ASSEMBLY-25V 39
ANGLE BRACKET -29NO4
COLD WIRE ATTACHMENT
458259
(SEE FIG. JO)
Fig. 2 - HWH-1 Head, HW-23 Torch, Cold Wire Feeder, Carriage and Wire Feed Governors,
and Remote Control Box Mounted on OM-48 Carriage
Attach the wire drive assembly mounting bracket,
486332, to the top of the side-beam carriage by means
of the three sets of capscrews and washers supplied.
. Bolt the motorized wire drive assembly, 433688, to
the mounting bracket using the two sets of capscrews,
washers, lockwashers and nuts provided.
. Mount the travel carriage and wire feed speed gov-
ernors in place using brackets, 493424.
. Boom or Stationary Mounting
The equipment package for a boom or stationary mount-
ing, 4947535, includes a mounting plate, adaptor bracket,
and adjustment slide assembly. Refer to Figure 3 and
proceed as follows:
a.
Fasten the adjustment slide assembly, 25V39, to the
boom or stationary mounting, using the cap screws
supplied.
. Fasten mounting plate 433690 to the adjustment
slide with the projecting tabs (ears) at the top as
shown in Figure 3. Also see Figure 25.
Remove mounting plate 431086 which is the back
cover of the welding head.
. Fasten the welding head to mounting plate 433690
using the screws which were just removed from the
head.
Fasten adaptor bracket 43369! (see Figure 23) to
one of the protruding tabs on mounting plate 433690
using the hardware supplied.
. Bolt the motorized wire drive assembly, 433688, to
the adaptor bracket, 433691, using the hardware sup-
plied.
The mounting plate, 433690, may be fastened directly to
the boom or stationary mounting if an adjustable slide is
not used. The HWH-1 head may be bolted in place without
mounting plate 433690 if cold wire addition is not desired.
F. Electrical Connections
The HWC-2 control is assembled with factory installed
cables for connection ot the remote control box, high
frequency unit, contactor, power input, arc voltage pickup,
welding current relay, cold wire feed governor, carriage
governor, and current transformer or shunt.
The welding head includes two shielded eight conductor
cables which connect it to the control. It also contains a
head to work cable,
The electrical connections should be made in accordance
with the step-by-step procedure which follows. Refer to
the General Diagram, Figure 4, which shows the connec-
tions to be made when using a typical balanced wave
a.c-d.c. power supply. Note that the welding current
relay, 495058, which is supplied with the HWM-3, is
mounted inside the power supply case.
Facing the rear of the control cabinet:
1. Locate the 25 foot shielded 3 conductor a.c. pickup
cable which passes through the lower left hand strain
relief bushing on the control. Insert the cable through
the case of the BW-400 power supply as shown in Figure
4. Connect the black lead to terminal 26 and the white
MOTORIZED COLD
WIRE FEEDER
433688
(SEE FIG 13)
SEE NOTE
38
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FLEXIBLE CABLE ASSEMBLY
9"MIN.— 27"MAX.
18" STROKE
ADAPTOR BRACKET-43369!
HWH-| WELDING HEAD ASSEMBLY
433573
(SEE FIG. 12)
COLD WIRE ATTACHMENT-458259
(SEE FIG. 30)
HW -27/LONG-BARREL TORCH ASSY.
593731
(SEE FIG. 27)
NOTE:
MOUNTING PLATE 433690 REPLACES MOUNTING PLATE-
431086 WHEN MOTORIZED WIRE DRIVE IS USED.
Fig. 3- HWH-1 Head, HW-27 Torch and Cold Wire Feeder Mounted on Boom or Stationary Mounting
lead to terminal 27 of terminal board TI. Ground the
two green leads to the case of the power supply. Be
certain that the terminals lugs make firm contact with
bright metal.
. Locate the 25-foot shielded 3 conductor 115 volt acc.
input cable which passes through the strain relief bushing
which is next to the bottom on the left side of the con-
trol. Insert the cable through the case of the power
supply as shown and connect the black lead to terminal
1 of terminal board T1. Connect the white lead to
terminal 2 and the long green lead to terminal 3, Ground
the green lead attached to the bond clamp to the case of
the power supply, being sure to make a good electrical
connection.
. Locate the 25-foot shielded 3 conductor current relay
cable which passes through the strain relief bushing
which is second from the bottom on the left side of the
control. Insert the cable through the bushing indicated
in the lower left hand comer of the General Diagram.
Connect the black lead to terminal 1 and the white lead
to terminal 2 of the current relay terminal board, T541,
Ground the two green leads to the case of the power
supply. Remove the jumpers between terminals 10 and
11 and terminals 17 and 18 on terminal board T1 in the
welding power supply.
. Locate the 25-foot shielded 3 conductor cable which
passes through the middle (third from the bottom)
strain relief on the left side of the control. Insert the
cable through the case of the power supply as shown
and connect the black wire to terminal 11. Connect
the white wire to terminal 18 and ground both green
leads to the case. Remove the jumpers between terminals
12 and 13 and terminais 15 and 16 on terminal board
T1 in the power supply.
. Locate the remaining 25-foot shielded 3 conductor high
frequency cable which passes through the top bushing
on the left side of the control. Insert the cable through
the case of the power supply and connect the black lead
to terminal 13. Connect the white lead to terminal 15
and ground both green leads.
Facing the front of the HWH-1 welding head :
6. Locate the cable passing through the elbow on the left
side of the head. Pass the left hand cable from the head
through the strain relief which is next to the top of the
left side of the control. Connect the green, blue, yellow,
black, red, white, brown and orange leads to terminals l
through 8 of terminal board 302 on the auxiliary control
chassis. Thread the right hand head cable through the
next lower strain relief and connect the yellow, green,
red, white, orange, blue, brown and black leads to
terminals 9 through 16 of terminal board 302. Ground
the shielding of both cables by connecting the green
bonding leads to the cable shield ground screw in the
cabinet.
. Locate the 25-foot shielded 3 conductor current trans-
former or shunt cable passing through the bottom
strain relief bushing on the right hand side of the control.
The black wire is connected to the positive terminal of
the ammeter if an optional d.c. ammeter is used. It
should, accordingly, be connected to the positive side of
10.
11.
13.
the ammeter shunt when d.c. welding power is used.
(If a.c. welding power and the a.c. ammeter supplied with
the HWM-3 are used, the cable is connected to a current
transformer.)
. Locate the 25 foot cable with a 4 prong female plug on
the end. If an OM-48 side-beam carriage is used, this cable
is plugged into the matching male receptacle on the car-
riage governor. If a boom or stationary type of mounting
is used, make the connections as shown to obtain con-
tinuous or timed 115 volts a.c. which may be used to
pilot operate a fixture circuit.
. Locate the 25 foot shielded 3 conductor control to wire
feed governor cable which passes through the next to the
top strain relief bushing on the right hand side of the
control. Connect the black lead to terminal 14, the white
lead to terminal 10, the red lead to terminal 9, and the
green lead to terminal 7 of the governor terminal board.
Connect the timer cable as shown in the General Diagram,
securing the white lead to T301-2, the black lead to
T301-16, the blue lead to T301-11, the red lead to
T307-4, the brown lead to T3019 and the yellow lead
to T307-3.
If welding with d.c. current, connect the shielded to d.c.
voltage pickup cable, 444656, between the torch and the
filter box in the drive head as shown in Figure 26. Also
connect the work lead, 39V02, between T701-2 in the
head and the workpiece.
IMPORTANT NOTE: When welding with a.c., these
leads MUST BE disconnected from the torch and the
work.
. If à flow switch is used, its contacts should be connected
in series with the contactor coil. Refer to Note 3 on the
General Diagram, Figure 4. The flow switch is mounted
externally,
IMPORTANT: For proper operation of the HWC-2
control, OM-48 side seam carriage and cold wire feed
electronic governors, the field voltages of the head
motor, carriage motor and cold wire feed motor should
be adjusted to 110 volts DC after the units have been
turned on for approximately one half hour.
When the 115 volt AC for control and electronic governor
operation is obtained from the welding power supply,
the voltage should be checked during the welding cycle
to make certain that it does not drop below 105 volts AC.
[f any additional control cables are used in the installa-
tion, it is important that they are shielded and grounded.
G. Instaliing the Torch
To attach the torch to the head, remove the cap (434171)
from the end of the torch barrel where the leads enter the
torch. Turn on the Main Power Switch (MPS) and the Main
Line Switch (MLS) located on the front panel of the con-
trol cabinet. (See Figure 5.) Thread the torch power cable,
argon hose, water inlet hose and voltage pickup lead through
the bottom of the head. Then feed the torch up from the
bottom of the head until the teeth of the rack on the torch
engage the pinion gear. (See Figure 8.)
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Inch the torch into position using the Inching Switch on
the remote control box. (See Figure 6.) Replace the cap on
the end of the torch. Connect the torch argon hose to one
of the 12-1/2 foot lengths of argon hose, 40V77, supplied
with the HWM-3 package. Connect the free end of the hose
to the argon fitting on the right hand side (as you face the
panel) of the control using argon hose coupling 11N17.
Connect the torch water inlet hose to a 12-1/2 foot length
of water hose, 40V76. If an optional flow switch, 40V51, is
used, connect the torch hose to the outlet side of the flow
switch and the extension hose to the inlet side of the flow
switch. Connect the free end of the water hose to the water
inlet fitting on the right side of the control using coupling
11N18. Connect the torch water outlet hose to a drain by
means of two lengths of water hose, 40V76, an 11N18 hose
coupling, and a drain adaptor, 11N16.
H. Argon, Water and Welding Power Connections
Connect the argon or helium cylinder and regulator to the
argon inlet fitting on the left side of the control, using the
second length of argon hose supplied with the package.
Similarly, connect the water supply to the water inlet con-
nection on the left side of the control cabinet using the re-
maining length of water hose provided. Finally, run a length
of 4/0 welding cable from the power supply to the welding
current ammeter shunt or current transformer and from
there to the workpiece. Run another length of 4/0 cable
from the power supply to the power cable adaptor on the
torch water outlet hose. Keep the length of cable between
the high-frequency unit and the torch as short as possible.
This cable should be suspended from insulated hangers and
not run over the floor or over or near metal surfaces. Avoid
loops in this cable. Also, keep this cable away from other
cables to avoid high-frequency pick up by the other cables.
Connect the welding power supply to the power line in
accordance with the instructions provided with the power
supply.
BE SURE THAT THE CASE OF THE WELDING POWER
SUPPLY 1$ SECURELY CONNECTED TO A GOOD
EARTH GROUND.
|. Cold Wire Attachment
The cold wire attachment fits directly on the torch as shown
in Figure 7. Refer to Section III for listings of accessories
for the attachment and recommended gear arrangements.
J. Installation of Plug-In Components
Fragile components such as tubes and plug-in time delays
are normally packed in separate cartons to prevent damage
in shipment. Tubes RVR75, VTI, VT2, TT1 and TT2 and
time delay TDI are packed separately. The sockets are
identified by chassis markings.
Be sure that all components are firmly seated in the proper
socketsand that TT1 and TT2 are turned to the locked posi-
tion. Be sure that the caps are securely placed on the thyra-
trons with the orange lead on TT1 and the brown lead on
TT2. If these caps are reversed, the unit will not operate
properly.
K. Removal of Packing
All blocks and packing must be removed to permit free
operation of moving parts such as relay contacts.
11. OPERATING INSTRUCTIONS
A. Safety Precautions
The voltages used in the HWM-3 Mechanized Contour
Welder are as high as 250 volts. The welding operator must
be cautious.
The HWM-3, if properly used, is a safe unit. Only one live
part, the tip of the electrode, is exposed during operation.
The operator is in no danger of electric shock if he observes
three common sense safety precautions.
1. Always turn off the welding power supply before touch-
ing the electrode.
2. Always turn off the welding power supply and the Main
Power Switch, MPS, in the HWC-2 Control, before
reaching inside the drive head enclosure or voltage con-
tro! cabinet.
3. Be sure that the case of the welding power supply is con-
nected to a good electrical earth ground. The cases of
the other components are bonded to each other by means
of grounded shield braids.
B. Main Cabinet Controls (See Figure 5)
The switches, pilot lights, and potentiometers listed below
are located on the front panels of the main control cabinet.
1. Main Power Switch, MPS — This switch controls the ap-
plication of primary power to the entire control assem-
bly. It has two positions, “On” and “Off”.
2. Pilot Light, PL301 -- This light is an indicator which
glows when MPS is “On”.
3. AC-DC Selector Switch, ACDCS - This switch adapts
the control to a.c. or d.c. welding power. H has two posi-
tions, “A.C.” and “D.C.”
4. Weld Start Selector Switch, WSSS -- This switch provides
the means for starting with either a delayed controlling
action or a stepped up starting voltage. It has two posi-
tions, “Delay” and “Step”.
5. Delayed Start Time Delay, DSTD -
a. DELAY -- This timer is used to delay the automatic
controlling of the arc length until the arc has become
stabilized and thereby prevents the electrode from
plunging into the workpiece.
b. STEP -- This timer is now used to start the arc and
control at a higher voltage -- then control at the
desired voltage.
6. Step Voltage Adjust Potentiometer, SV AP -- This con-
trol is used to set the starting (step) voltage.
7. Main Line Switch, MLS -- This switch controls the 115
volt primary power to the basic electronic control as-
sembly. It has two positions, “On” and “Off”.
8. Pilot Light, PL1 -- This lights when MLS is on.
9. AC/Straight Polarity - Reverse Polarity Switch,
ACSPRPS - This switch adapts the control to A.C.,
DCSP, or DCRP. It has two positions, “AC/SP” and
“RP”.
10. Sensitivity Potentiometer, SP -- This control varies the
11.
sensitivity of the voltage control to changes in arc vol-
tage.
Inch Down Speed Potentiometer, IDSP -- This control
regulates the speed at which the torch is lowered.
C. Remote Controls (See Figure 6)
The items listed below are located on the remote control
box panel.
1. Weld Start Switch, WSS -- This switch controls the ver-
tical motion of the torch, the starting and stopping of
the weld. It has three positions, “Down”, “Neutral”
and “Up”.
. Voltmeter Pushbutton, VMPB -- This switch connects
the voltmeter across either the arc or the reference vol-
tage. When it is pressed, it indicates the voltage set by
VAP only.
. Meter Range Switch, MRS -- This switch connects the
low and high ranges of the meter into the circuit. It has
two positions, “LO” (0-10 volts) and “HI” (0-30 volts).
. Voltage Adjust Potentiometer, VAP - This control is
used to set the welding voltage.
D. Selection and Installation of Torch Accessories
The HW-27/Long-Barrel is a water-cooled in-ine torch that
is rated up to 400 amps (AC or DC) at 100% duty cycle
2. Auxiliary Weld Start Switch, AWSS -- This switch con- CE
trols raising of the head, start and stop of welding action, with high impact cups and 500 amps (AC or DC) with metal
and HF generator. It is used for starting the welding at nozzles.
any point on a contour. It has three positions, “Down”,
“Neutral” and “Up”. Use Tables I-A, -B & -C to select electrode, collet, collet
NOTE: When this switch is used for starting, the torch body, and cups/nozzle. Referring to Fig. 4A, install these
must be positioned in a starting position with the accessories as follows:
“inch-up-down” IUDS switch. 1. Insert an electrode into a collet of corresponding size.
3. Inch Up-Down Switch, IUDS -- This switch controls 2. Insert the collet and electrode into the correct size
the raising and lowering of the torch when the welding collet body.
power is turned off. It has three positions, “Down”, 3. Screw the collet body into the torch body.
“Neutral” and “Up”. 4. Install a high impact cup or metal nozzle. (If a metal
4. Carriage Travel Switch, CTS -- This switch enables the nozzle is used, Part No. 57N76, is installed before the
operator to select manual or automatic control of car- nozzle.)
riage travel. It has three positions, “Manual”, “Neutral” 5. Position the electrode to extend a minimum of 3/8-in.
and “Auto”, beyond the high impact cup, and a minimum of 1/4-in,
5. Cold Wire Switch, CWS -- This switch enables the opera- beyond a metal nozzle. These minimum extensions insure
tor to select manual or automatic control of cold wire good nozzle and cup life, and excellent shielding is pro-
feed. It has three positions, “Manual”, “Neutral” and vided by the gas lens. (When using high frequency with
“Auto”. metal nozzles, arcing may sometimes occur between the
Tabie I-A
Electrode and Cup Sizes for Different Welding Currents
Welding Currents, Amps.
ACHF* DCSP — | DCRP
Using pure Using Using Electrode
tungsten thoriated thoriated tungsten Diameter High-Impact Metal
electrodes electrodest electrodes tt in. mm. Cup No. Nozzle No.
10-60 60-80 15-80 “ee .040 1.0 6 --
50-100 100-150 70-150 10-20 1/16 1.6 6
100-160 160-235 150-250 15-30 3/32 2.4 6,8 -
150-210 225-325 250-400 25-40 1/8 3.2 8
200-275 300-425 400-500 a 40-55 5/32 4.0 8 a
250-350 400-525 a 500-800 b 55-80 3/16 4.8 8, 10 10
325-475 500-700 b 800-1100 b 80-125 1/4 6.4 10, 12 10, 12
* Values based on use of unbalanced wave transformer. 1f a balanced wave transformer is used, reduce maximum values
in the table by about 30 per cent or use the next larger size electrode.
T Balled electrode tip ends can best be formed and maintained at these a.c. current levels.
TT To avoid damaging the gas lens collet bodies, pure tungsten electrodes are not recommended for d.c. welding operations.
a.- Exceeds the rated capacity of torch when a high impact cup is used.
b.-Exceeds the rated capacity of the torch.
10
Table 1-B - Collets and Collet Bodies
Electrode Collet Collet Body
Size, in. Part No. Part No.
.040 57N45 49V 22
1/16 57N46 49V23
3/32 5/N47 49V24
1/8 57N48 49V25
5/32 57N49 49V26
3/16 57N50 49V 27
1/4 57N51 49V 28
Table 1-C - Cups and Nozzles
High Impact Cut Metal Nozzie
No. Part No. Part No.*
6 57N75 a
8 57N74 _--
10 53N88 57N78
12 53N87 57N77
Short t 53N89 ---
* Adaptor 57N76 is required if metal nozzles
are used.
t Short Cup 53N89 serves as an insulator only,
and cannot be used with high frequency.
TORCH BARREL
TORCH BODY 7
TUBE ASSEM.
ELECTRODE COLLET BODY
COLLET Za CUP
Fig. 4A - Exploded View of HW-27 Torch
electrode and the nozzle, To avoid this, it is advantageous
to extend the electrode as far as possible consistent with
the particular application.)
6. Tighten the ribbed insulator, on the collet body, until
the electrode is held securely.
E. Limit Switch Cam Adjustments
The high frequency, head down and head up limit switch
cams must be adjusted to conform to the size, shape and
position of the work piece.
The high frequency limit switch is used to turn on the high
frequency generator at just the right time to initiate the
welding cycle. This reduces to a minimum the period when
the high frequency generator is capable of creating radio
interference.
The head down limit switch prevents the torch from being
lowered too far if no workpiece is in position. Failure to
stop the downward motion might result in tipping of the
carriage as well as damage to the torch.
The head up limit switch is a time-saving device which pre-
vents the torch from being raised so high above the work
that time is wasted waiting for it to be lowered.
Once the cams have been adjusted for a given workpiece,
they need not be changed unless a workpiece of a different
size or shape is to be welded.
11
1. Setting the High Frequency Limit Switch Cam (See
Figure 8): The position of the high frequency limit
switch cam is determined by the starting method to be
used. For both a.c. and d.c. welding with short arc
lengths, it is necessary for the arc to become stabilized
before the arc length can be controlled. If the arc length
is controlled as soon as the arc is established, the elec-
trode tends to plunge into the workpiece and will either
stick or become contaminated. For this reason, a choice
of two methods of delaying the controlling of the de-
sired arc length is provided.
One method is to start at a higher voltage until the arc
becomes stabilized and then transfer to the desired arc
voltage.
The second method is to delay the automatic controlling
of the arc length until the arc becomes stabilized and then
transfer to automatic arc length control.
When the higher voltage or “Step” start is used, if is rec-
ommended that the high frequency limit switch cam be
adjusted so that the limit switch cioses when the elec-
trode is approximately 1/4 inch from the workpiece.
When a “Delayed” type of start is used, the cam switch
should be adjusted so that the switch closes when the
electrode tip is approximately 1/32-inch above the
desired arc length. It is recommended that trial starts be
made on scrap material to obtain optimum results.
AC7 STRAIGHT
POLARITY- REVERSE
POLARITY SWITCH
PILOT LIGHT - RP
LU (ACSP-RPS)
SENSITIVITY
POTENTIOMETER
(SP)
MAIN LINE
SWITCH INCH DOWN SPEED
(MLS) POTENTIOMETER
MDSP)
AC-DC STEP VOLTAGE ADJUST
SWITCH POTENTIOMETER
(AC- DCS) [SVAP)
PILOT LIGHT
{Pt 301) WELD START SELECTOR
SWITCH (W555/
MAIN POWER
SWITCH DELAYED START
(MPS) TIME DELAY
(DSTD)
Fig. 5 - HWC-2 Control Cabinet, Front View
VOLTMETER PUSHBUTTON VOLTAGE ADJUST POTENTIOME TER
(VMPB) |
AMMETER e VOLTMETER
(AM) Ny (IV PLA NE о WELDING COMTROL (VM)
ue У ё
Г =
E
i
>
Lo À 7
C
e = *
tas ZE Now Le
WELD START SWITC COLD WIRE SWITCH
(WS5) fCWS)
CARRIAGE TRAVEL SWITCH
(ETS)
INCH UP-DOWN SWITCH METER RANGE SWITCH
(VDS) MAS)
AUXILIARY WELD START SWITCH
frAWSS)
Fig. 6 - Remote Control Box
12
COLLET LOCKING
LEVER
WIRE
GUIDE TUBE
XHw-23 TORCH
*HW-23 supplied up to
10/73. HW-27/ Long Barrel
torch supplied since that
time and it is not equipped
with collet locking lever.
COLD WIRE ATTACHMENT
GUIDE TIP
Fig. 7 - HW-23 IN-Line Torch with Cold Wire Attachment
"ри
CAM FOLLOWER BEARING 8 ADJ.
BRACKET
HEAD DOWN
LIMIT SWITCH
HIGH FREQUENCY
LIMIT SWITCH
CONDENSER
CAM FOLLOWER
CHOKE
CONDENSER
RACK 4
TUBE 8 BUSHING
ASSEMBLY 4
A THESE PARTS ARE INCLUDED
INTHE HW -23 OR HW -27
L. 8 TORCH ASSEMBLY
HEAD UP
LIMIT SWITCH
CAM FOLLOWER
BEARING & ADJ.
BRACKET
Fig. 8 - HWH-1 Welding Head, Cover Removed
13
For d.c. arc voltages of 10 volts and higher, it is not
necessary to have either the higher starting voltage or
delayed control. In this situation, set the HFLS cam so
that the switch will close when the electrode is approxi-
mately 1/8-inch above the desired arc length.
Make certain that the Weld Start Switch (WSS) and the
Auxiliary Weld Start Switch (AWSS) are in the center or
“Neutral” position. Turn the Main Power Switch (MPS)
“On”. Pilot Light PL301 will light. Put the Main Line
Switch (MLS) in the “On” position. Pilot Light PL1 will
light. Set the AC-DC Selector Switch (ACDCS) to “AC”
or “DC” depending upon the welding power supply to
be used. Similarly, set the AC/Straight Polarity-Reverse
Polarity Switch (ACSPRPS) to the ACSP position
whether the the welding power is AC, or DCSP. Set the
Inch Down Speed Potentiometer (IDSP) at its minimum
position by turning it counterclockwise as far as it will
go. Substitute a block of wood for the workpiece. The
wooden block should be placed so that its upper surface
will be at the same level as the workpiece surface on
which the weld would be started. This will prevent the
torch from striking an arc while the operator is adjusting
the cam. Disconnect the high frequency generator by
disconnecting the high frequency control cable from
terminal T301-16 on the auxiliary control chassis. Place
WSS in the “Down” position and lower the torch until
the electrode is about 1/4-inch above the workpiece if a
higher voltage or *‘Step’ start is to be used. When using a
“Delayed” type start, lower the torch until the electrode
is about 1/32-inch plus the desired arc length above the
wooden block. Switch WSS to the “Neutral” position.
Adjust the high frequency limit switch cam so that the
switch clicks just as the electrode comes within 1/8-inch
plus the arc length of the block. Test by raising and
lowering the torch with WSS. The minimum arc length
that can be controlled is approximately 5/64-in. It
is the reversal of the length vs voltage curve of the arc
and not a control deficiency which limits the minimum
controllable arc length. Reconnect the disconnected lead
to T301-16.
NOTE: The head up-down-switch “HUDS” permits the
torch to be raised or lowered beyond the up/down limit
switches. This is useful when it is desired to make repairs
to the torch and not disturb the up or down limit switch
adjustment.
2. Setting the Head Down Limit Switch Cam: Set the con-
trol as directed on page 20. Place the Weld Start Switch
(WSS) in the “Down” position and lower the torch until
the electrode touches the block of wood. Switch WSS to
“Neutral” and adjust the head down limit switch cam so
that the switch will open just after, but not before, the
electrode touches the work, Test by removing the block
and running the torch up and down a few times. Where
contour following is used, the cam should be set for the
lowest point on the workpiece.
3. Setting the Head Up Limit Switch Cam: Set the controls
as in paragraph 1. Put the Weld Start Switch (WSS) in
the “Up” position and run the torch up until it clears
the workpiece. Put WSS in the “Neutral” position and
adjust the head up limit switch cam so that the upward
motion of the torch will be held at the desired point.
F. Cold Wire Feeder Assembly (See Figures 1, 2 and 3)
The cold wire feeder consists of a drive motor, feed roll
assembly, spindle and spool enclosure. The entire unit is
attached to a bracket and mounted on the movable carriage
or stationary stand that is used.
The motor drives the feed rolls which pull the wire from
the free wheeling spool. The plastic cover protects the wire
from dirt and dust. The wire is fed through a liner to a cold
wire attachment mounted on the HW-23 torch. The rate of
wire feed is regulated by an electronic governor.
Table Hl shows the gear ratios and the wire feed speeds
attainable with the four gears provided with the wire feeder.
Figure 20 shows the gear arrangements between the drive
shaft and the feed roll shaft. The wire feed speed listed is
the maximum speed attainable for each gear ratio when the
drive motor is running at its maximum speed of 6000 rpm.
Table III lists the accessories used with the cold wire feed
attachment.
. Starting Procedure (See Figures 5 and 6)
- Turn on the argon and water.
. Turn on the welding power supply.
. Put the AC-DC Selector Switch on the auxiliary control
panel in the “A.C.” position for a.c. power and in the
“D.C.” position for d.c. power.
boo == ($
Table II - Gear Ratios
Driver Gear Driven Gear Gear Ratio Max. Wire Speed. ipm*
04N86 (14T) 05N23 (307) 2.14:1 30.5
05N23 (30T) 04N86 (14T) 1:2.14 139
433682 (48T) 04N29 (127) 1:4 262
04N29 (127) 433682 (45T) 4:1 16.3
* Attained when motor speed is 6000 rpm.
Table [II
Wire Feed Accessories for Cold Wire Guide Attachment (458259)
+ 05N56 standard for ail inlet guides,
tt For some aluminum applications, ‘’U’’ Groove Feed Roil (08N07) and Pressure Roll {49N38) may be used.
Use 97W15 Pressure Roll with al! °“V’° Groove Feed Rolls.
* Supplied with Wire Feeder, 433688.
Inlet “NY Outlet Outlet Wire Wire
Wire Size Guide Feed Pressure Hote Guide | Outlet | Guide Conduit | Guide Guide
& Type insertt Roll Spring | Position | Tip Guide | Insert Conduit | Liner Tube Tip
038" All 49N46 49N30 12N29 49N45 | 12N21 | 49N46 38V86 12N72 | 458246 | 458250
045" N v 55N14 | 49N32 | 12N29 c | 55N15|412N21/55N14 | 38V86 | 12N72 | 458246 | 458251
3/64" | 55N14 49N32 12N29 S 55N15 | 12N21 | 55N 14 28V 86 12N72 | 458246 | 458251
1/16” 1 12N75% | 04N12 92W17 C ---. 04N21 =-=- 461154 12N73 | 458246 | 458252
1/16‘ 1! to V | 12N75* | 04N12 92W17 C 04N21 461154 12N73 | 458247 | 458252
NOTES:
Wire Types
|. Aluminum and Magnesium Wires
ll. Copper Base Alloys
НН.
Heat and Corrosion Resistant Alloys
IV. Copper Coated Carbon Steel
V. Bare Low Alloy Steel
. Put the AC/SP-RP switch in the “AC/SP” position for
A.C. or DCSP power. (With DCSP, the positive welding
current terminal is connected to the work.)
. The arc voltage pickup leads for d.c. operation should be
connected as shown on the General Diagram, Figure 4.
This is recommended so that the arc voltage signal to
the control will not include the voltage drop of the torch
cable and the welding cables.
. Place the Weld Start Switch (WSS) and the Auxiliary
Weld Start Switch (AWSS) on the remote control box in
the “Neutral” position.
. Turn the Main Power Switch (MPS) and the Main Line
Switch (MLS) on. Pilot Lights PL1 and PL301 will light.
. Press the Voltmeter Pushbutton (VMPB) located on the
remote control box and set the Voltage Adjust Potenti-
ometer (VAP) to give a reading of approximately 10
volts on Voltmeter (VM), if the correct operating voltage
is not known. (Use the “LO” position on the meter
range switch for voltages between O and 10 volts and the
“HI” position for voltages between 10 and 30 volts.)
The operator will gradually determine the exact voltage
which gives the best results under a given set of welding
conditions.
. Set the Sensitivity Potentiometer (SP) at about 40. The
optimum setting will depend upon welding conditions
such as current, voltage, gas composition, and rate of gas
flow. The position of maximum sensitivity is at approxi-
mately 65 to 70 on the dial. In general, a higher setting
may be used at lower welding currents and at low vol-
tages. Lower than recommended settings will cause the
control to act sluggishly. Higher than recommended set-
tings will cause the control to hunt and plunge the torch
into the work.
10. Put the Inch Up-Down Switch (IUDS) in the “Down”
11.
position, and lower the torch to within an inch or two of
the workpiece. Release the switch. The speed of descent
may be controlled by the Inch Down Speed Potentiometer
(IDSP). Position the torch or work so that the electrode
is directly over the desired starting point.
As previously explained, for all a.c. welding and for d.c.
welding with short arc lengths (less than 10 volts), it is
necessary for the arc to become stabilized before the arc
length can be controlled.
Either of two starting methods may be used, as desired.
One method is to start at a higher voltage until the arc
becomes stabilized and then transfer to the desired vol-
tage. The second method is to delay the automatic con-
trolling of the arc length until the arc becomes stabilized
and then transfer to automatic arc length control.
a, Starting at a Higher Voltage
To start at a higher voltage (or make a “Step” start),
set the Weld Start Selectro Switch (WSSS) in the
“Step” position, Set the Step Voltage Adjust Poten-
tiometer (SVAP) approximately 5 or more divisions
on the dial plate higher than the dial setting for VAP.
Set the Delayed Start Time Delay (DSTD) by rotating
the dial pointer in a counterclockwise direction. It is
recommended that the timer be set for approximately
3 seconds when first setting up the control. The timer
can be readjusted for a longer or shorter period of
time as required. If the time delay period is too short,
the electrode will plunge into the workpiece. The
HFLS cam should be set so that the switch closes
when the electrode tip is approximately 1/4 inch
from the workpiece, as described in Section E.
12.
13.
b. Delayed Start of Automatic Control
To initiate a “delayed” start, set the Weld Start
Selector Switch (WSSS) in the “Delay” position.
Adjust the period during which the arc length is fixed
by means of the dial pointer on the Delayed Start
Time Delay (DSTD). Set the timer by rotating the
dial pointer in a counterclockwise direction. It is
recommended that the timer be set for approximately
3 seconds when first setting up the control. The high
frequency limit switch cam should be set so that the
switch closes when the electrode tip is approximately
1/32-inch above the arc length desired as in Section
HI-E.
c. D.C. Arc Voltages of 10 Yolts and Higher
For d.c. arc voltages of 10 volts or higher, it is not
necessary to use either the higher starting voltage or
the delayed control. SVAP may be set the same as
VAP or timer DSTD may be set for “zero” time.
Put the Carriage Travel Switch (CTS) and the Cold Wire
Switch (CWS) in the “Auto” position if automatic con-
trol of the carriage and cold wire feeder is desired. If
manual control of the carriage and cold wire feeder is
desired, these switches should be placed in the “Manual”
position to start these devices.
Delayed start of carriage travel and cold wire feed may
be controlled by hand, or by means of timers if auto-
matic delayed start is preferred. To use automatic delayed
start, put CTS and CWS in the “Auto” position and set
the Travel Carriage Time Delay (TCTD) and the Cold
Wire Time Delay (CWTD) for the desired intervals. This
feature is of particular value when a delayed start is used
for the arc because it permits the arc to become stabilized
before carriage travel and cold wire feed commence.
Be sure that everyone in the vicinity has suitable protec-
tion for his eyes, Put WSS in the “Down” position. The
torch will come down and make a high frequency start.
Welding will proceed automatically under the control of
the voltage control and whatever head or work moving
equipment or wire feed equipment may be used.
NOTE: AWSS must be in the “Neutral” position when
WSS is in use. IF AWSS is put in the “Up” or “Down”
position, WSS will be locked out and the entire opera-
tion will be stopped.
H. Stopping Procedure
Welding may be stopped by putting WSS in either the
“Neutral” or “Up” position. In the “Neutral” position the
torch will instantaneously come to rest. In the “Up” posi-
tion the torch will rise until the head up limit switch, HULS,
is tripped.
The equipment is shut down by turning off switches MPS
and MLS, turning off the gas and water and turning off all
auxiliary electrical equipment which does not have its
primary power controlled by the voltage control circuits.
I. Operating Hints
1.
Auxiliary Weld Start Switch (AWSS)
The Auxiliary Weld Start Switch (AWSS) located in the
remote contro! box permits the operator to establish an
arc at any point along the weld without having to actuate
the high frequency limit switch. This feature is desirable
in contour welding where the welding action has been
stopped due to electrode failure, cold wire stoppage or
burn through. If the contour is steep, it may be neces-
sary to start at a higher arc voltage, as explained in
Section G, 11,
WSS must be in the “Neutral” position when AWSS is in
use. If WSS is in the “Up” or “Down” position, AWSS
will be locked out and the entire operation will be
stopped and vice-versa.
. Voltmeter (VM)
The voltmeter is only an indicator when welding with a.c.
It does not read the true ac, arc voltage. It reads much
lower than the a.c. value of the arc voltage because of
the half wave rectifier which isin the circuit. For example,
an arc length of 1/8-inch will indicate 16 to 22 volts a.c.
on an iron vane type meter. The half wave rectified vol-
tage used in the control causes the meter to indicate
approximately 3 volts.
If the voltmeter reads backwards, it means either that
the welding power supply polarity is wrong or the torch
and work leads are reversed.
. Argon Flow
It has been found with ac. balanced wave that lower
than usual argon flows are required. Argon flows that are
too high cause erratic arcs and this causes the unit to lose
control.
. Electrodes
Electrodes must be derated from their usual a.c. current
capacities when used with balanced wave. Use pure
tungsten electrodes for currents below 100 amperes.
If an electrode is contaminated, it should be “burned
clean” before an attempt is made to weld the next
workpiece. If this is not done, the electrode may plunge
into the work or “stitch” on the next weld.
Thoriated tungsten electrodes start easier and are less
likely to become contaminated than tungsien electrodes.
The upper half of the current range should be used with
both types.
. Inch-Down Speed
The maximum rate of inch-down speed which can be
successfully used is dependent upon various factors such
as:
a. The electrode size, the shape of the end of the elec-
trode, and the composition of the electrode.
b. The material on which the arc is struck.
c. The short-circuit current, which in turn depends upon
the type of power supply and its setting.
. Motor Field Voltage
For proper operation of the HWC-2 control, OM-48 side
beam carriage and cold wire feed electronic governors,
the field voltages of the head motor, carriage motor and
cold wire feed motor should be adjusted to 110 volts DC
after the units have been turned on for approximately
one half hour.
When the 115 volt AC for control and electronic governor
operation is obtained from the welding power supply,
the voltage should be checked during the welding cycle
to make certain that it does not drop below 105 volts AC.
. Factors Affecting High-Frequency Starting in HELIARC
Welding
Properly applied, high-frequency starting should give
quick, clean, positive starts. However, there are many
factors which influence starting performance. Since most
of these factors are relatively easy to control, there should
be no difficulty in obtaining good starts. The following
are some of the items which should be checked:
a. Thoriated tungsten electrodes will usually provide
better starting than pure tungsten electrodes.
b. Use the proper size electrode. Grinding a point on the
end of the electrode will usually improve the starting
performance of an oversize electrode.
c. If the torch uses a metal nozzle, ground the nozzle to
the torch mounting or to the work through a resistor.
The value of this resistor is not critical and a resistor
on the order of 10,000 ohms, 25 watts, will be en-
tirely satisfactory. Do not use the small radio-type
resistor since they will usually be damaged by the high
voltage, high frequency. The use of this grounding
method will sometimes double the electrode-to-work
distance over which a start can be consistently made,
and it usually eliminates failure to start.
d. Where a modem low-power high-frequency unit is
used and where the torch is equipped with a shielded
cable, remove the shield from the torch cable. If this
can not be done easily, removing the ground connec-
tion from the shield will usually help.
e. Gas flow is an important factor. Too high or too low
a gas flow will make high-frequency starting more
difficult.
f. Some high-frequency units including the early model
of Linde Part No. 22N36 use a small size bypass con-
denser. Increasing the size of this condenser to 10 or
20 mfd will usually improve the starting reliability
because it permits more of the low frequencies gener-
ated by the high-frequency unit to pass through the
spark. These low frequencies add considerable energy
to the spark and help develop the cathode spot re-
quired for starting.
g. Check the spark gaps to make certain that they are
clean and properly adjusted.
h. Periodically blow out the high-frequency unit to
prevent accumulations of dust which might cause
leakage.
i. Keep the length of cable between the high-frequency
unit and the torch as short as possible. This cable
should be suspended from insulated hangers and not
run over the floor or over or near metal surfaces. Avoid
loops in this cable. Also, keep this cable away from
other cables to avoid high-frequency pick up by the
other cables.
IV. MAINTENANCE AND TROUBLESHOOTING
A. Routine Checks
1. Mechanical Operation
The guide bar should move smoothly with no perceptible
difference between the upward and downward motion.
Any erratic motion or any indication of strain such as an
overheated motor, excessive fuse blowing or noisy opera-
tion call for more thorough investigation such as that
outlined in paragraph B. If the guide bar is too tight, the
motor armature current will be high even at SP settings
as low as 20 or 30.
. Ground Connections
Check all ground connections. This is particularly impor-
tant in the case of high-frequency starting equipment.
The lack of proper grounds may cause severe and exten-
sive damage to the voltage control.
. Terminal Board and Soldered Connections
Check all terminal board screws and all soldered connec-
tions. Many difficulties are caused by loose or broken
connections.
. Bias Battery Qutput Voltage
An EVEREADY Battery No. 773 is used to bias the
thyratrons TT1 and TT2 (see Figure 9). The orange lead
from terminal T3-1 is connected to the -3 terminal of
the battery, and the red lead from T3-2 is connected to
the plus terminal of the battery. Thus there is a potential
difference of 3 volts d.c. between terminals T3-1 and
T3-2. The purpose of this bias is to completely prevent
TT1 and TT2 from firing when WSS and AWSS are in
the “Neutral” position. Firing is evidenced by a blue glow
within the tube.
(A bias of 1-1/2 volts is sometimes used to increase the
sensitivity of the control. In this case the orange wire is
connected to the —1-1/2 volt tap.)
If the bias drops too low in either situation, one or both
tubes may fire and cause the motor to drift. Therefore,
this battery should be replaced when the voltage drops
so low that the bias will no longer cut off the tubes. IN
ANY EVENT, REPLACE THIS BATTERY EVERY SIX
MONTHS FOR CONSISTENT TROUBLE-FREE PER-
FORMANCE.
. Mechanical Trouble-Shooting
. Armature Current Test
a. Most possible causes of mechanical trouble can be
isolated by taking motor armature current readings.
Run the torch up as far as it will go. Turn off the
welding power source and the Main Power Switch
(MPS). Disconnect the green lead from terminal 3 of
terminal board T701 (see Figure 26). Connect the
white lead to the negative {-) terminal of a 0-3 ampere
D’Arsonval type d.c. ammeter. À Weston type 301 or
Type 489 meter having the specified range will be
satisfactory. Connect the positive (+) meter terminal
BATTERY
(BAT 1)
TUBE
(772)
ТУВЕ
(TT)
Fig. 9 - Basic Electronic Assembly Chassis, Top View
to terminal 3 of terminal board T701. It is important
that these connections be made exactly as directed to
prevent damage to the meter.
. Turn on the welding power supply and MPS. Lower
the torch and note the armature current. It should be
approximately 0.25 to 0.35 amperes under normal
conditions.
Turn off MPS and the welding current source, and
reverse the leads on the meter. Turn on MPS and the
welding current source. Raise the torch and note the
armature current. It should be approximately 0.35 to
0.5 amperes.
. If either of these readings is too high, follow the pro-
cedure outlined in the next section.
. Isolation of Faulty Unit
a.
The motor and gear reduction units are joined to a
rack and tube assembly by means of a slip clutch
assembly as shown in Figures 12 and 15. A slight mis-
alignment of the elements will cause excessive friction
between the clutch assembly and the rack and tube
assembly.
. Loosen the mounting screws and check the alignment.
Tighten the screws and verify the effect of any adjust-
ment by means of the ammeter. Be sure that the white
lead is connected to the negative (-) terminal when
the tube is going down and to the positive (+) terminal
when the tube is going up.
. If realignment fails to produce normal armature cur-
rent in both directions, loosen the mounting screws
and completely disconnect the motor and gear
18
reduction unit from the rack and tube assembly. When
disconnecting the motor and gear box be sure to put
a clamp on the tube to prevent it from dropping and
damaging the torch. If the armature current drops to
a maximum of 0.3 to 0.4 amperes when the motor
drives just the gear reduction assembly, it is an
indication of trouble in the coupling or in the rack
and tube assembly, or could mean that the tube is too
tightly held. If more than 0.3 to 0.4 amperes is ob-
tained, it is an indication of trouble in either the gear
reduction unit or the motor itself. Be sure to observe
the proper polarity on the armature current test. The
following paragraphs discuss the maintenance of the
individual units in the head drive assembly.
3. Adjustment of the Rack and Tube Assembly
a. If disconnecting the rack and tube assembly causes
the armature current to drop to approximately 0.3 to
0.4 amperes, it is an indication of excessive friction.
This may be caused by gum, grit, or improper adjust-
ment. If the tube presses against the rack too tightly,
it may cause erratic movement resulting from bot-
toming of the drive gear in the rack on the guide tube,
If the tube rises smoothly, but chatters when dropping,
it is an indication of excessive friction between the
gear and the rack.
. To correct the above conditions, adjust the bearing
brackets, 433845, and the springs 433582 shown in
Figure 12. The five springs may be tightened or
loosened by means of individual adjustment screws.
c. Realign the rack and tube assembly with the slip
clutch assembly and once more check the armature
currents.
4. Armature Shaft Bearings
After the unit has been in service for a considerable
length of time, the armature shaft bearings may work
loose in the motor housing. When this occurs, the unit
may appear sluggish during the operation. This is caused
by the armature shifting in the motor housing when the
direction of rotation is changing. This shifting causes a
delay in torch movement and gives the appearance of
sluggish operation. This can be determined by actuating
the inch up-down switch up and then down several times
and noting the armature through the inspection hole in
the HWH-1 head. This condition can be corrected by
means of a brass set screw (size 6-32 is recommended)
placed at the brush-end of the motor housing. The
brass set screw should be tightened just enough to engage
the outer race of the armature shaft bearing so as to pre-
vent the armature from shifting. Too much pressure will
deform the bearing race and cause erratic operation.
(See Figure 10.)
The motor should be disassembled when drilling and tap-
ping for the set screw. See Section B — Mechanical
Trouble-Shooting, sub-section 5 and 6 below for instruc-
tions. See Figure 23.
. Dismounting the Motor and Gear Reducer Unit
a. If the armature current drawn when the motor drives
the gear reducer alone is more than 0.3 to 0.4 amperes,
it is an indication of trouble in the motor or gear box.
The normal current of the motor alone with the
gear head should be 0.2 to 0.25 amps.
b. Remove the green, white with red tracer, black, and
red motor leads from terminals 3, 4, 5, and 6 respec-
tively of terminal board T701.
c. Dismount the motor and gear reduction unit from the
base plate by unscrewing the four socket head mount-
ing screws located around the drive pinion shaft.
d. Disengage the slip clutch assembly from the pressure
roll assembly and slide the motor and gear reduction
unit off the base plate.
. How to Disassemble the Motor - 994176 (Refer to
Figure 22)
a. Separate the gear reduction unit from the motor by
removing the four screws holding it to the motor
housing. (Two screw heads are on the motor side and
two on the reduction unit side.) If the gasket seal
between the unit and the motor housing does not
separate easily, tap the unit on several sides with a
rawhide mallet.
b. Unscrew the brush holder plugs and caps. Withdraw
the brush assembly 994213. Note position of each
brush in its holder so it can be returned to its original
position. When reassembling, refer to paragraph 8 on
“Motor Brush Replacement”.
c. Unscrew the motor housing screws 56W24 located
next to the output worm.
d. Withdraw the motor end housing 56W34.
e. Remove the armature shaft and fan assembly S6W29
by pulling it free from the housing.
SIDE VIEW
J
1
at
DA
L om i am mm ow Ё
END VIEW HWH-I
HEAD MOTOR HOUSING
——DRILL 8 TAP
FOR 6-32 BRASS
SET SCREW
Fig. 10 - Installation of Armature Bearing Set Screw
19
f. The motor can be reassembled by reversing this pro- Before removing Texaco Regal Starfak grease from a
cedure. supply container, stir it up well. Any free oil on the
g. When reconnecting the motor to the control, caution top of the grease should be mixed in thoroughly.
should be used to make certain that the leads are Never pour off free oil from the top of the can.
placed on their proper terminals. Failure to do so will
cause the motor to rotate in the wrong direction and
8. Motor Brush Replacement
may cause damage to the mechanical components.
a. Unscrew the brush plugs. Withdraw the metal disk
and the brush and spring assembly, noting the posi-
tion of each brush in its holder so that it can be re-
placed in its original position. Examine the brushes.
Make sure that each surface in contact with the motor
commutator has the polished finish that indicates
good contact. The polished area should cover essen-
tially all of the contacting surface of the brush. With
brushes removed, inspect the surface of the commuta-
tor. It should appear clean and smooth, with a polished
chocolate brown color where the brushes ride it. If
the surface appears to be rough, disassemble the motor
and remove the armature (see disassembly procedure
in Paragraph 6). Polish the commutator surface with
No. 00 sandpaper. Preferably, the armature should be
. How to Disassemble the Gear Reduction Unit - 50V 18
(Refer to Figure 21)
a. Clean out the grease that fills the gear unit.
b. Unscrew the three bearing caps 994200 on the housing
and carefully remove the bearing parts.
c. Loosen the two socket-head setscrews 54W98 visible
in the hub of the front gear 52W68. Slide the counter-
shaft and worm 53W36 through the gear and out
through one of the bearing openings.
d. Drive out the pin in the hub of the worm gear 53W41
remaining in the housing. Slide the gear down and slide
the extension shaft 994226 out through the bearing
opening on the output side of the housing.
The gear reduction unit is reassembled by reversing rotated in a lathe for this operation.
the procedure. If the bearing parts have become sep-
arated, they may be reassembled in the following CAUTION: Never use emery cloth or an emery stone for
order: pivot, nine ball bearings (use grease to hold this operation. Emery is a conductor of electricity, and any
them in place), cup, felt pad, then the bearing cap residual loose particles may short-circuit the commutator
and gasket. segments during operation of the motor.
IMPORTANT: The gear reduction housing should be b. See that the mica strips between the commutator
packed with approximately seven ounces of well segments do not extend above the segments. If this
stirred Texaco Regal Starfak grease as indicated by condition exists, the excess mica must be removed,
the crosshatched areas in Figure 11. The level of the and the strips should be undercut slightly.
grease should be even with the center of the output c. When replacing a brush in the motor, be sure to put it
shaft. back in the same brush holder, and in its original posi-
tion. Be sure also that the brush rides freely in its
A free air passage must extend through the body of holder.
the grease to the vent plug. d. New brushes are approximately 3/4-in. long. When
they have worn down to about 1/2-in. in length, they
The vent plug must be placed at the highest point on should be replaced with new ones.
the housing to prevent grease leakage. When the gear e. Replacement of brushes, and commutator main-
unit requires special mounting, it may be necessary to tenance, should be performed only by an experienced
relocate the vent plug to prevent grease leakage. electrician.
ay POSITION C"
POSITION B HOUSING ASSEM- 05N72
(WITH BEARINGS) \
|
|
|
Mi
A
|
|
|
||
|
|
OUT PUT
SHAFT
|
|
|
|
il
I
i
ili
i Js
MOUNTING FACE
>
>
o |
> | |
o
m
POSITION "А Jd
INDICATES GREASE LEVEL NOTE - INSTALL VENT PLUG- 52W63 IN POSITION "8"
{ROYCO 64) USE SOLID PLUG-55W04 IN REMAINING HOLES
|!
Fig. 11 - Lubrication of Gear Reduction Unit Used with HWH-1
20
V. REPLACEMENT PARTS INFORMATION
1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and part name,
as shown on illustrations. DO NOT ORDER BY PART NUMBER ALONE.
2. Many of the parts on the illustrations, particularly electronic parts, are “vendor items”. This means that they are standard
commercial parts made by and purchased from other manufacturers. If you order from these sources use the manu-
facturer's part number or designation shown stamped on the electrical component itself.
3. Always state the series or serial number of the machine on which the parts are to be used. The serial number is stamped
on the unit nameplate.
4. Indicate any special shipping instructions.
5. Order replacement parts from the Linde office or distributor nearest you.
VENDOR ITEMS LIST FOR HWH-1 WELDING HEAD
Part No. Description
429957 Cam follower, McGill Mfg. Co., Inc., sealed cam follower, scf camrol bearings, McGill Bearing No. CF-7/8-5
433582 Spring, Hardware Products Co., Boston, Mass. Spring-compression, Cat. No. SC 1/2” Lg. x 1/2" O0.D. x .062"
wire dia.
433585 Strain relief with spring guard, Eastman Atlantic Mfg. Co., Wilmington, Del., Cat. No. 45, type No. 110 x 3/4
male
519746 Clamp, Tinnerman Prod. Inc. 1/4” No, C29802-4
92W05 Plug, button, United Fastner Corp. Cat. No, 48143
95W61 Choke, National Radio Prod. Inc., High Freq. No, R152
95W68 Clamp, Tinnerman Prod. Inc, 3/16” No. C-2980-3
95W69 Terminal Strip, Jones Company, No. 15-141
6110-1848
6130-1736
6130-1848
6130-1850
6130-1852
6130-1853
6130-1861
6130-1877
6130-1880
6130-1902
6130-1904
6130-2562
6130-3113
6130-3418
6130-3852
6130-3853
6132-2821
6133-3095
6133-4960
6134-0113
6134-0165
6134-0361
6134-0462
6134-0733
6134-0902
6134-0903
6134-1113
6134-4088
6134-4133
6134-4361
6135-3903
COMPOSITE HARDWARE LIST
No. 6-32 x 3/16” Ig. round head, machine screw, brass
No. 10-24 x 2-3/4" lg. round head, machine screw
No. 6-32 x 3/16" lg., round head, machine screw
No. 6-32 x 5/16” lg, round head, steel machine screw
No. 6-32 x 1/2" |lg., round head, machine screw
No, 6-32 x 5/8” Ig., round head, machine screw
No. 6-32 x 1” lg., round head, machine screw
No. 8-32 x 5/16 Ig., round head, steel machine screw
No. 8-32 x 1/2" lg., round head, machine screw
No. 10-24 x 1/2" lg., round head, machine screw
No. 10-24 x 5/8” Ig., round head, machine screw, steel
5/16-18 x 1-1/8” Ig., oval head, machine screw
5/16-18 x 1°’ la., flat head, machine screw
3/8-16 x 2-1/4" Ig., flat head, machine screw
No. 6-32 x 1/2 ig., fiat head, machine screw
No. 6-32 x 5/8” lg., flat head machine screw
No. 4 x 1/4” Ig., parker kalon, type “Z” binding hd., self tapping screw
1/4"-28 x 3/8” Ig., hex socket, half dog point, set screw
No. 4-40 x 3/16” Ig., hex socket, flat pt., setscrew
5/16-18 x 1” Ig., socket head, cap screw
5/16-18 x 5/8” lg., socket head, cap screw
5/16-18 x 3/4" lg., socket head, cap screw
1/4'-28 x 3/4" Ig., socket head, cap screw
No. 10-24 x 7/8” Ig., socket head, cap screw
No. 10-24 x 1/2" Ig., socket head, cap screw
No. 10-24 x 5/8” Ig., socket head, cap screw
5/16-18 x 1 Ig., hex head, cap screw
1/4'-20 x 5/8” lg., flat head, cap screw
3/8-16 x 1” Ig., socket, flat head, cap screw
5/16-18 x 3/4" Ig., hex socket, flat head, cap screw steel
No. 10-24 x 5/8” Ig., parker kalon, thumb screw, type “5S”
21
6139-9075
6230-0030
6235-0001
6235-0024
6235-0036
6235-0081
6235-0516
6239-9029
6330-0121
0330-0862
6330-0886
6330-0916
6331-1137
6430-0125
6430-0993
6430-0994
6430-0995
6430-0996
6430-2037
6430-2075
6430-2110
6430-2125
6430-2887
6430-2920
6430-4004
6430-4110
6430-4125
6430-4050
6430-4860
8600-1009
COMPOSITE HARDWARE LIST — CONTINUED
10-24 x 1/4” 1g., socket head, shoulder screw, shoulder dia. 5/8"
1/8" x 1/2" \q., std. cotter pin
3/32" dia. x 3/4" lg. roll pin
1/8” dia. x 5/8” lg, roll pin
No. 52-028-125-0625 Esna rol! pin
1/4” dia. x 2” !g. roll pin
1/4” dia. x 1/27 Ig. roll pin
1/8” dia. x 7/8” Ig. spirol pin
5/16-18 hex nut
No. 6-32 hex, nut
No. 8-32 hex, nut
No. 10-24 hex nut
3/8''-24 elastic stop nut, type “E”
3/3” Amer. std. plain washer, steel
5/32" |.D. x 5/16 0.D. x .035 thk. plain washer
7/16” 1.0. x 7/8" O.D. x .083 thk. plain washer
11/32" 1.0. х 11/16” O.D. x 1/16” thk. plain washer
2-3/4" O.D. x 1-1/4” 1.D. x 5/32” thk. plain washer
3/8" Amer. std. med. lockwasher, steel
1/4” std., med. lockwasher
5/16" std. med. lockwasher
3/8” std., lockwasher
No. 8 std. med. lockwasher
No. 10 std. med. lockwasher
No. TO S.A.E. plain washer
5/16 S.A.E. plain washer
3/8" S.A.E. std., plain washer
3/16" S.A.E. plain washer steel
No. 6 S.A.E. plain washer steel
3/32" dia. x 1/4" lg, spring packing, {ungraphited)
22
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99417 7
SEE FIGZ2)
PS
GEAR UNIT
433683
{SEF F16.27)
SEE FIG. 19)
|
GEAR SET-UPS—/]
12” SPOOL ENCLOSURE ASSEM -433862
(SEE FIG}
A
4)5CREW-6134-0462
MASHER-6430-2075
UARD - 433697
3)SCREW—6130-—1736
SPACER-433695
SUPPORT -433692
(3)SCRE W-6134-0165
(3) WASHER -6430-2110
PICK-OFF TUBE-40Q7284
NUT-407285
2156
SUPPLIED
SPRING TZN 73]
2}WASHER-6430—2110
- = “uy
GUIDE HOLDER -05N56 НЕ 4
GUIDE -O5NSB _ ых | >
SPACER o - -— A
433696 7 = о
FUI IE
BRACE- 433877 —
[2)SCREW- 6134-0902 | .
(2)WASHER-6430-405 {== Е (2)SCREW-6130-3418
FEED ROLL ASSEMBLY — == 9
433664 gy
(SEE FIG16) | INS. PLATE— 433689
ws PLATE 433605
REW— 6134-0361 MONTO, PLATE SPACER— 05N40
{2} SCREW ~6130 -1903
(2) NUT— 6330-0916
(2) WVASHER - 6430-2920
(2) WASHER- 6430-4004
(3)SCREW-6130-1902
COVER ASSEMBLY-433685
(3) WASHER- 6430-4004
(SEE FIG 20)
Fig. 13 - Cold Wire Feeder, 433688
MOTOR ASSEMBLY
994176
(See Fig. 22)
CLUTCH-07N34
(MALE END}
SPRING-07N52
GEAR REDUCTION
UNIT—994223
(See Fig. 21)
PLATE- 429961 oC —
PIN f CLUTCH
6239—9029 444001
(FEMALE END)
(2)BALL-72AL8
SNAP RING-07N54
ASSEMBLY 433847
(See Fig. 15) (4) SCREW-—433887 Fig. 15 - Slip Clutch Assembly, 433847
Fig. 14 -Motor, Adaptor and
Slip Clutch Assembly, 429962
24
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(AYOSS3227 f | vo Ot NBO — 1H3SNI CeNtO TENVO JSSNPO) CL/C
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25
FLANGE AND
SHAFT ASSEMBLY -19v91
( INCLUDES ) |
PIN-6235- 0081
PARTS SUPPLIED
(4) NUT-6330—0121
(4)SCREW-6134-1113
(4)LOCKWASHER 6430-2110
DISK —18N25
SPINDLE — 38V67
(INCLUDES)
PIN-6235-0516
(2)SCREW-6132-2821
SPRING — 92WI2
WASHER — O6NIS
SPRING — 06N17
= SPRING GUIDE
me Е O6N16
SCREW&8 STOP-48N90
(INCLUDES)
PIN-6235-0001
SLEEVE - O6N15
DISK — O6N19
INS BUSHING — OBN20
Fig. 17 - Spindle Assembly, 433659
BASE PLATE—48N91
nf ll
E се ео не
==]
ENCLOSURE-48N92
RETAINING RING
99W46
SPACER-48N95
_ 48N94
KNOB
SPRING
28Z34
WASHER
6430-0996
SPACER
Г 48N89
SPINDLE ASSEMBLY-433659
(SEE FIG. 17)
Fig. 18 - Spool Enclosure Assembly, 433662
26
SPACER- O4N27
SNAP RING-92W22
KEY—04N30
7 SNAP RING —92W22
("A") DRIVER GEAR-05N23(30T)
(“B"} DRIVER GEAR- 433682 (48 T.)
1
2.500 FEED ROLL SHAFT
GEAR UNIT SHAFT
i
("A") DRIVEN GEAR-04NB86(14T)
("8") DRIVEN GEAR—Q4N29(12T)
NOTE = /TEMS KEYED ON THIS DRAWING ARE SUPPLIED UNASSEMBLED WITH MOTORIZED
WIRE DRIVE ASSEMBLY — 433688
Fig. 19 - Gear Set Up for Wire Feeder
(4) SCREW-6130-1880
(4) LOCKWASHER-6430-— 288 7
(4) NUT- 6330-0886
UPPER SPRING
CLIP —05N86
Fig. 20 - Cover Assembly, 433685
27
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SUPPLIED HARDWARE
(2) $СВЕМ — 6130—3113
(2) 5СВЕМ — 6134 — 0113
(2) WASHER— 6430 — 4110
Fig. 23 - Adaptor Bracket, 433691
1%
PLATE ¥g THICK
po
MOUNTING HOLES FOR GEAR UNIT
24 — WHEN USING A" GEARS
A —WHEN USING 'B" GEARS
Fig. 24 - Cold Wire Feed Mounting Plate, 433687
30
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32
SCREW-"6-32X3/4" Lg
TUBE 8 BUSHING ASSY-445593 3
LOCKWASHER-"6
BODY & TUBE ASSY-49V30 \ rr TUBE INSULATOR-533732 x NUT-"6-32
\ ISCREW-"6-32X 3/16"Lg
Y ASSY \ , — RACK-430798 (20 Fitch)
vo) able 18) au VOLTAGE PICKUP CABLE j
\ $5Y-444656 /
Do N . } TUBE CAP-43417i
COLLET (Accessory La \ SAS ETSTOP /
See Table 1B) 7 Ns x
\ X nf
CUP {Accessory 7 à N SSN AY
N See Table 1C} / Cr da Sn
Cu E OC ———— он — ar AA ь
TED) ma > À EN
NN \— PLUG-57N65 *
INSULATOR SLEEVE-593733
ADAPTOR & NOZZLE \
(Accessory - See Table 1C} (3) NYLON SCREW-6190-3004
MOUNTING NUT-4 34017
TORCH ADAPTOR
SLEEVE-563647 WATER HOSE-40V83
(12172 FI)
X included in 49V30 ARGON HOSE- 49VvB2? 72-472 FI)
ACCESSORIES
PART NO | DESCRIPTION
| aivse | SHEATH
45VIl | POWER CABLE ADAPTOR
| 45v34 | FI-FUSE ASSY
POWER CABLE 40V8B4//2-/2 €1)
—_———— ——————
RL A —
Fig. 27 - HW-27/Long Barrel Torch, Part No. 593731
REPLACEMENT OF GAS LENS SCREENS
(See Figure 28.)
It may be necessary, at intervals, to replace screens which
have become plugged from excessive spatter. Replacement
may be done as follows:
1. With the collet body removed from the torch, remove
the outer snap ring, Part No. 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.
LEGEND
Is Used on Used On Usi ; f al li he i
em . . . u u м 17"
No. Qty Description ere de HE E 2. sing a pair N nee N nose pliers, pry out the inner
1 3 Outer Spacer 54N70 54N70 snap ring, Part No. 54N69.
2 1 Outer Snap Ring 54N71 54N71
3 : inner Snap Ring NE ones 3. Hold the collet body with the screens down, and gently
5 1 Screen, 100 mesh 54N67 57N57 tap the body on the work bench. The body contains
; : poser, 250 mesh | aa | 3 Wed three fine and one coarse screens, separated by spacers.
8 1 Gasket * 57N56 57N56 If the screens are not badly fouled, they should drop
out of the body. Excessive fouling may necessitate
Fig. 28 - Common Replaceable Parts in Collet Bodies 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.
33
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34
NUT -430883
SPRING-444443
LINK-430873
CAP-458244
©
\
NTT C— SHAF T~4582 37(FLAT ON SHAFT MUST BE IN POSITION SHOWN)
(SEE NOTE 1)
WASHER — SPRING — 458243
6430-0995 ya
SCREW-430872 WASHER-6430-0992
| Po SHAFT & SPACER ASSEMBLY
— === 458240 (SUPPL IED)
4 0 [yy (SEE NOTE 2)
BRACKET- 458242
(4)SCREW-6134-4851
KNOB -458378
PELLET-446733
SCREW-6133-4875
ROD & BLOCK
ASSEM- 458236
INCLUDES
ROD- 458234
BLOCK- 458235
(2)PIN-6225-0013
gy
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SCREW-6133-0084
GUIDE TUBE 7
(ACCESSORY
SEE TABLE itl) a SCREW ~ 6130-0849
WASHER-64 30-3270
Ee > BLOCK-458255
_
— GUIDE TIP —
(ACCESSORY SCREW-6133-2468
SEE TABLE 111)
J
u — J —-
FOR ANGULAR ADJUSTMENT OF FOR ANGULAR ADJUSTMENT OF
+45*% TO +20”, USE CLEVIS SHAFT +25° TO -15°USE CLEVIS SHAFT
458237 AND POSITION SPRING AND SPACER 456240 IN PLACE OF
SUPPORT BRACKET 458242 IN CLEVIS SHAFT 458237 AND POSITION
UPPER (4) MOUNTING HOLES IN SPRING SUPPORT BRACKET 458242
CLEVIS. IN LOWER (4) MOUNTING HOLES IN
CLEVIS.
NOTES:
/ USED ONLY FOR ANGUL AR ADJUSTMENT OF +45° TO +20°
2USED ONLY FOR ANGULAR ADJUSTMENT OF +25° TO -15°
L —
Fig. 30 - Cold Wire Attachment, 458259
35
UNION WELDING UNION CARBIDE CORPORATION
7: :1:11115 PRODUCTS LINDE DIVISION
Box 6000, Florence, SC 29501
F-841-D 87-0853 8/78 DC Printed in U.S.A.