ESAB Nozzle Assemblies Troubleshooting instruction

F-9784-J
INSTRUCTIONS for
F-9784-J
March, 1995
NOZZLE
ASSEMBLIES
for use with
EH-10 & EH-11
WELDING HEADS
I. INTRODUCTION
In submerged arc welding, the welding current is transfer-
red from the welding cable to the welding wire through a
copper busbar and a contact nozzle. Nozzles are preferred
for sheet metal welding or where the wire must be carried
to a confined space.
Il. ASSEMBLY INSTRUCTIONS
In the following assemblies, the same wire guide, busbar,
and busbar adaptor are used. The wire guide is screwed into
the upper end of the busbar adaptor, and the adaptor is
inserted into the busbar. When the shoulder on the adaptor
contacts the busbar, secure the busbar in place by tighten-
ing the hex nut onto the capserew (No. 6134-0188) sup-
plied with each busbar.
A. BUSBAR AND STRAIGHT NOZZLE ASSEMBLY -
Part No. 28V38
The busbar and straight nozzle assembly is recommended
for welding in narrow and confined spaces. The straight
nozzle has a current carrying capacity of approximately
1200-amperes maximum. If a straightener is included in an
installation, a slight amount of curvature imparted to the
welding wire after it emerges from the straightener is
recommended.
The busbar and straight nozzle assembly consists of the
standard wire guide, busbar, and busbar adaptor, plus a
converting nozzle (7/8- to 5/8-in. thread), a S-in. extension,
tipnut, insulating sleeve, and two cable lugs. Table 1 lists
all the contact tips which can be used with the busbar and
straight nozzle assembly.
To assemble:
l. Screw the 7/8-in. threaded end of the converting nozzle
(Figure 1), into the busbar adaptor. Slip on the corres-
ponding insulator sleeve.
2. Screw extension onto the bottom of the converting noz-
zie. Tighten, and slip on the corresponding insulator
sleeve.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
3. Select the proper size tip for the welding wire to be used,
and insert the tip into the tip nut so that the flared end
of the contact tip is flush against the end of the exten-
sion when attached. Table 1 Lists all the tips that can be
used with this assembly. The wire size is stamped on
each tip.
4. The cable lugs provided for connecting the welding cable
to the nozzle assembly can be fastened by bolting them
to any of the tapped holes in the busbar.
Table 1 - Contact Tips
Wire Diameter (Inches) Part No.
1116 19N45
3/32 19N 47
1/8 19N48
5/32 19N49
3/16 19N50
1/4 19N51
B. BUSBAR AND CURVED NOZZLE ASSEMBLY
Part No, 28V25
The curved nozzle is preferred for sheet metal welding and
non-positioned fillet welding. The curve in the nozzle per-
mits the “trailing” of the nozzle along the weld joint.
A maximum of 1200-amperes welding current is recom-
mended when using a curved nozzle.
The busbar and curved nozzle assembly consists of the
standard wire guide, busbar, and busbar adaptor, plus a
curved nozzle assembly and two cable lugs. The curved noz-
zle assembly consists of a 25-degree curved nozzle, tip nut,
and insulator sleeves. It is designed to handle 3/32 to 5/32-
in. wire.
l. Screw the 7/8-in. threaded portion of the extension
adaptor (Figure 1), into the busbar adaptor. Tighten and
slip on the corresponding insulator sleeve.
2. Screw the curved nozzle into the bottom of the extension
adaptor and tighten the locknut. Slip on the nozzle in-
sulator sleeve. For sheet metal welding, attach the
curved nozzle so that the large-diameter portion of the
nozzle is away from the weld zone, (nearest the exten-
ESAB Welding &
Cutting Products
afl
ESAB
за
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for your protection. Before perform-
ing any installation or operating procedures, be sure to read and follow the
Safety precautions listed below. Failure to observe these Safety Precautions
can resultin personal injury or death,
1. PERSONAL PROTECTION- - Skin and eye burns from exposure to rays from
an electric-arc or hot metal can be more severe than sunburn. Therefore:
a.
Use a face shield fitted with the correct filter and cover plates to protect
your eyes, face, neck, and ears from sparks and rays of the arc when
operating or observing operations. WARN bystanders not to watch the
arc and not expose themselves to the rays of the electric-arc or hot
metal.
Wear flameproot gauntlet type gloves, heavy long-sleeve shirt, cuffless
trousers, high-topped shoes, and a welding helmet or cap for hair pro-
tection, to protect against arc rays and hot sparks or hot metal. A
flameproof apron may also be desirable as protection against radiated
heat and sparks.
Hot sparks or metal can iodge in rolled up sieeves, 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 suit-
able non-flammabie partition.
Always wear safety glasses or goggles when in a work area. Use safety
glasses with side shields or goggles when chipping Slag or grinding.
Chipped slag may be hot and can travel considerable distances. Bystan-
ders should also wear safety glasses or goggles.
Some gouging and cutting processes produce excessively high noise
leveis and require ear protection.
2. FIRE PREVENTION - - Hot slag or sparks can cause serious fires when in
contact with combustible solids, liquids or gases. Therefore:
Remove all combustible materials well away from the work area or com-
pletely cover the materials with a protective non-flammable covering.
Such combustible materials include wood, clothing, sawdust, gasoline,
kerosene, paints, solvents, natural gas, acetylene, propane, and similar
combustible articles.
Hot sparks or hot metal can fall into cracks in fioors or wall openings
and cause a hidden smoldering fire. Make certain that such openings
are protected from hot sparks and metal.
Do not weld, cut or perform other hot work until the workpiece has been
completely cleaned so that there are no substances on the workpiece
which might produce flammable or toxic vapors.
For fire protection, have fire extinguishing equipment handy for instant
use, such as a garden hose, water pait, sand bucket, or portable fire ex-
tinguisher.
After compieting operations, inspect the work area to make certain there
are no hot sparks or hot metal which could cause a later fire.
For additional information, refer to NFPA Standard 51B, “Fire Preven-
tion in Use of Cutting and Weiding Processes”, which is available from
the National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269,
3. ELECTRICAL SHOCK - - Contact with live electrical parts 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:
а.
b.
Never allow live metal parts to touch bare skin or any wet clothing. Be
sure gloves are dry.
When standing on metal or operating in a damp area, make certain that
you are well insulated. Wear dry gloves and rubber-soled shoes and
Stand ona dry board or platform.
Always ground the power supply by connecting a ground wire between
the power supply and an approved electrical ground.
Do not use worn or damaged cables. Do not overload the cable. Use well
maintained equipment.
When not operating, turn off the equipment. Accidental grounding can
cause overheating and create a fire hazard. Do not coil or loop cable
around parts of the body.
f. Be sure the proper size ground cable is connected to the workpiece as
close to the work area as possible. Grounds connected to building
framework or other remote locations from the work area increase the |
possibility of output current passing through lifting chains, crane ca-
bles, or various electrical parts.
g. Keep everything dry, including clothing, work area, cables, electrude
holder, and power supply. Fix water leaks immediately.
В. Refer to AWS Standard 249.1 in tem 6 below for specific grounding re-
commendations. Do not mistake the work lead for a ground cable.
4. VENTILATION -- Fumes, particularly in confined spaces, can cause discom-
fort and physical harm. Do not breathe fumes. Therefore:
a. At ali times provide adequate ventitation in the work area by natural or
mechanical ventilation means. Do not weid, cut, or gouge on materials
such as galvanized steel, zinc, lead, beryllium, or cadmium unless posi-
tive mechanicai ventilation is provided. Do not breathe fumes from
these materials.
b. Do not operate in locations close to chlorinated hydrocarbon vapors
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.
с. If you develop momentary eye, nose, or throat irritation while operating,
this is an indjcation that ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work area. Do not continue
to operate if physical discomfort persists.
d. Refer to AWS Standard 249.1 in Item 6 beiow for specific ventilation re-
commendations.
. EQUIPMENT MAINTENANCE - - Faulty or improperly maintained equipment
can result in poor work, but most importantly it can cause physical injury
or death through fires or electrical shock. Therefore:
a. Always have qualified personnel perform the installation, troubleshoot-
ing, and maintenance work. Do not perform any electrical work unless
you are qualified to perform such work.
b. Before performing any maintenance work inside a power supply, dis-
connect the power supply form the electrical power source.
¢. Maintain cables, grounding wire, connections, power cord, and power
Supply in safe working order. Do not operate any equipment in faulty
condition.
d. Oo not abuse any equipment or accessories. Keep equipment away
from heat sources such as furnaces, wet conditions such as water pud-
dies, oil or grease, corrosive atmospheres and inclement weather.
e. Keep ail safety devices and cabinet covers in position and in good re-
pair,
f. Use equipment forits intended purpose. Do not modify itin any manner.
. ADDITIONAL SAFETY INFORMATION - - For more information on safe prac-
tices for setting up and operating electric welding and cutting equipment
and on good working habits, ask your welding equipment Supplier for a
copy of “Precautions and Safe Practices for Electric Welding and Cutting”,
Form 52-529. The following publications, which are available from the Amer-
ican Welding Society, 550 N.W. LeJuene Rd., Miami, FL 33126, are recom-
mended to you:
a. “Safety in Welding and Cutting” - AWS 249.1 (ANSI)
b. “Recommended Safe Practices for Gas-Shielded Arc Welding” - AWS
A6.1
c. “Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping That Have Held Hazardous Substances”
AWS F4.1
d. “Recommended Safe Practices for Plasma Arc Cutting” - AWS A6.3
e. "Recommended Safe Practices for Plasma Arc Welding” - AWS C5.1
f. “Recommended Safe Practices for Air Carbon Arc Gouging and Cut-
ting” - AWSC5.3
sion adaptor). For fillet welding attach the nozzle so that C. EH-11 PARALLEL WIRE KIT - Part No. 600501
its large-diameter portion is near the weld zone (farth- This parallel wire kit is designed to feed two wires using
erest away from the extension adaptor). The arrange- one EH-11 welding head, one control, and one power sup-
ment pictured in Figure 1, illustrates the connection ply, and is capable of handling 3/32-in. through 5/32-in. di-
preferred for fillet welding. ameter wire. For complete coverage on the parallel wire
3. Select the proper size contact tip for the welding wire to kit, refer to instruction booklet F-12-817.
be used, and insert the tip into the tip nut so that the
flared end of the tip will contact the curved nozzle when D. EH-10 SMALL PARALLEL WIRE KIT - Part No. 600228
the nut and tip are attached. Attach the tip and nut to This parallel wire kit provides a means of feeding two
the nozzle and tighten, | wires, from .052-in. through 3/32-in. diameter, using one
4. The cable tugs provided with the assembly for con- EH-10 welding head, one control, and one power supply.
necting the welding cable to the busbar, can be fasten- For complete coverage on this kit, refer to instruction book-
ed by bolting to any of the three tapped holes in the let F-12-819.
busbar.
Hl. REPLACEMENT PARTS
All replacement parts are keyed in Fig. 1. Order parts by part number and description as given in the illustrations. DO
NOT ORDER BY PART NUMBER ALONE. Parts may be ordered from your nearest ESAB welding equipment dis-
tributor or from ESAB Welding & Cutting Products, Customer Service Dept., Florence, SC 29501.
WIRE GUIDE — 28131 —® e
+} „ BUSBAR ADAPTOR — 29N20
BUSBAR-29N19
includes:
SCREW - 1/2 —13x 2” SOCK., HD.
NUT-1/2”—13
WASHER- 1/2”
SCREW — No. 10—32 x 3/8”
CONVERTING 2.IN. INSULATING
NOZZLE — 29N21 ™ SLEEVE — 29024 Y 7/8°—14
. A A + 2-IN, EXTENSION
INSULATING E ADAPTOR — 29N22
SLEEVE — 16N40 — $
7/81
SCREW - No. 8—32 x 3/8”
de 5/8"-11
| ¥~-S.1N. EXTENSION
М
5-IN. INSULATING 41W30
i .~19V52
SLEEVE — 41W76 E CURVED NOZZLE ASSY.—19V5
includes:
CURVED NOZZLE - 19V50
INS. SLEEVE -41W99
TIP NUT — 999398
LOCKNUT-5/8"—11
2-IN. INSULATING |
SLEEVE - 41W9 —— €}
32 5/8" —11
| poz EXTENSION sa \
о СОМТАСТТИР** — =
19N47 (3/32"")
4 sg” _ 11 19N48 (1/8”) ®- TIP NUT — 999398
(SEE TABLE 1}
Sn INSULATING
SLEEVE — 41W99 ~—» |
NOZZLE ASSEMBLY
*BUSBAR & STRAIGHT 28V25
NOZZLE ASSEMBLY
28V38 “includes cable lugs.
*“NOT SUPPLIED WITH ASSEMBLY
A Optional Accessory
Fig. 1 - Busbar and Contact Nozzle Assemblies for EH-10 & EH-11 Welding Heads
3
rp”
ESAB 5548 Welding & Cutting Products
F-9784-J 3/95 Printed in U.S.A. PO Box 100545, Florence SC 29501-0545