ESAB HW-8 Spot-Welding Tig Torch Troubleshooting instruction

Brand: ESAB

Model: HW-8 Spot-Welding Tig Torch

Category: Welding System

Type: Troubleshooting instruction

INSTRUCTIONS for

F-7015-W

March, 2002

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for

arc welding equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting and Gouging,” Form

52-529. Do not permit untrained persons to install, operate, or maintain this equipment. Do not attempt to install or operate this equip-

ment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier

for further information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment.

RATING: 250 amps continuous duty DCSP; 300 amps

at 50% duty DCSP.

COOLING: Closed-loop water cooling system; no joints

within torch to leak.

ELECTRODES: Uses 1/16 to 5/32-in. (1.6 to 4.0 mm)

diameter electrodes; 7-in. (178 mm) long. See Table 1

for electrode diameter vs. current recommendations.

COLLETS: Available for four electrode sizes. See Table 2.

COLLET SEAT: Sized to match each collet.

NOZZLES: Made of chrome copper material. Available

sizes 8, 10, and 12.

TORCH DIMENSIONS:

Overall length ............................. 10-in. (254 mm)

Barrel diameter ..................... 1-5/16-in. (33 mm)

Nozzle diameter ...........................7/8-in (22 mm)

Service lines ................................... 25-ft. (7.6 m)

REQUIRED ACCESSORIES OR SERVICES:

• Collet, collet seat, electrode, nozzle. HW-8 is sup-

plied with the 1/8-in. (3.2 mm) size collet and collet

seat. Refer to Table 2 for other size. Select nozzle

from Table 3.

• Fuse assembly (45V34) or power cable adaptor

(45V11).

• Water hose (to connect fuse assembly or adaptor

to drain). Recommended: 40V76.

• Shielding gas regulator-flowmeter if cylinder gas is

used or flowmeter (if shielding gas is piped).

• Adequate Water Supply - For adequate torch cool-

ing at maximum rating, a water flow of one quart/

min. (0.95 l/min) with inlet temperature 60-deg. F

(16-deg. C) or less, is needed. To secure this flow,

pressure of the water supply must be at least 35 psi

(2.4 bars). (If flow switch is used in system, 5 psi

(0.4 bars) more upstream of switch is needed.) Pres-

sure should not exceed 50 psi (3.5 bars) measured

at inlet of the torch hose, lest the plastic hose be

damaged.

• Welding power and shielding gas supplies.

OPTIONAL ACCESSORIES

• V-30 Double Shut-Off Valve (16X21): Shuts off both

water and gas flow when torch is hung on valve arm.

• Flow switch (Torch Saver) P/N 40V50: Water-me-

tering switch which can be interconnected to the

welding contactor coil to cut off welding power if flow

rate drops below 0.2 gal./min. (0.75 l/min.) Recom-

mended for use when water pressure may fluctuate

severely. Use in conjunction with, or instead of, fuse.

(See Figure 1).

• Braided Nylon Sheath (20-ft., 6.1 m long), P/N

2075201, or Zipper Sheath (8-ft., 2.5 m long), P/N

41V98: To protect services lines.

• Service Line Extensions:

Water Hose, 12-1/2-ft., 3.8 m (40V76)

Water Hose Coupling (11N18)

Gas Hose, 12-1/2-ft., 3.8 m (40V77)

Gas Hose Coupling (11N17)

Power Cable, 12-1/2-ft. (40V78)

Power Cable Coupling (11N19)

Power Cable Insulator Sleeve (10N27)

Be sure this information reaches the operator.

You can get extra copies through your supplier.

Table 1 - Recommended Welding Conditions on Lap

Joints Using 1/8-in. (3.2 mm) Electrodes

Plate Argon Arc Time

Thickness Gas Flow Interval, Current,

Material in. CFH Sec. Amps

Stainless 0.020 1/2 115

Steel 0.030 8 3/4 115

0.050 1 130

0.061 1-1/4 130

Low Alloy 0.032 1 130

& Mild 0.045 8 1-1/4 160

Steel 0.056 1-1/2 145

Table 2 - Table 3 -

Collets and Collet Seats Nozzles

Electrode Collet Collet Seat Nozzle Part

diam., in. (mm) Part No. Part No. No. No.

1/16 (1.6) 56Y16 81Z82 8 105Z21

3/32 (2.4) 56Y17 81Z84 10 105Z22

1/8 (3.2) 55Y86* 79Z92* 12 105Z23

5/32 (4.0) 56Y18 81Z86

*Supplied with the HW-8 Torch

HW-8 SPOT-WELDING TIG TORCH

CAUTION

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary information from the references listed in

Additional Safety Information section. Before

performing any installation or operating procedures, be

sure to read and follow the safety precautions listed below

as well as all other manuals, material safety data sheets,

labels, etc. Failure to observe Safety Precautions can result

in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.

Training in the proper use of the processes and equip-

ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles

are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from

sparks and rays of the arc when operating or observing

operations. Warn bystanders not to watch the arc and

not to expose themselves to the rays of the electric-arc

or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld-

ing helmet or cap for hair protection, to protect against

arc rays and hot sparks or hot metal. A flameproof apron

may also be desirable as protection against radiated

heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be

kept buttoned, and open pockets eliminated from the

front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot slag

or sparks can also cause fires and ex-

plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable covering. Combustible materials include wood,

cloth, sawdust, liquid and gas fuels, solvents, paints and

coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden

smoldering fire or fires on the floor below. Make certain

that such openings are protected from hot sparks and

metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might pro-

duce flammable or toxic vapors. Do not do hot work on

closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or

portable fire extinguisher. Be sure you are trained in its

use.

SAFETY PRECAUTIONS

10/98

5. Do not use equipment beyond its ratings. For example,

overloaded welding cable can overheat and create a fire

hazard.

6. After completing operations, inspect the work area to

make certain there are no hot sparks or hot metal which

could cause a later fire. Use fire watchers when neces-

sary.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Pro-

cesses", available from the National Fire Protection Asso-

ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live

electrical parts and ground can cause

severe injury or death. DO NOT use AC

welding current in damp areas, if move-

ment is confined, or if there is danger of

falling.

1. Be sure the power source frame (chassis) is connected

to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or

missing connection can expose you or others to a fatal

shock.

4. Use well-maintained equipment. Replace worn or dam-

aged cables.

5. Keep everything dry, including clothing, work area, cables,

torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from

work

and from ground.

7. Do not stand directly on metal or the earth while working

in tight quarters or a damp area; stand on dry boards or

an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)

for specific grounding recommendations. Do not mis-

take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —

May be dangerous. Electric current flow-

ing through any conductor causes lo-

calized Electric and Magnetic Fields

(EMF). Welding and cutting current cre-

ates EMF around welding cables and

welding machines. Therefore:

1. Welders having pacemakers should consult their physi-

cian before welding. EMF may interfere with some pace-

makers.

2. Exposure to EMF may have other health effects which are

unknown.

3. Welders should use the following procedures to minimize

exposure to EMF:

A. Route the electrode and work cables together. Secure

them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded.

E. Keep welding power source and cables as far away

from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in confined spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by

natural or mechanical means. Do not weld, cut, or gouge

on materials such as galvanized steel, stainless steel,

copper, zinc, lead, beryllium, or cadmium unless posi-

tive mechanical ventilation is provided. Do not breathe

fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly toxic

gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation

while operating, this is an indication that ventilation is not

adequate. Stop work and take necessary steps to im-

prove ventilation in the work area. Do not continue to

operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which

contain chemicals known to the State of

California to cause birth defects and, in

some cases, cancer. (California Health &

Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if

mishandled, can rupture and violently

release gas. Sudden rupture of cylin-

der, valve, or relief device can injure or

kill. Therefore:

1. Use the proper gas for the process and use the proper

pressure reducing regulator designed to operate from

the compressed gas cylinder. Do not use adaptors.

Maintain hoses and fittings in good condition. Follow

manufacturer's operating instructions for mounting regu-

lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain

or strap to suitable hand trucks, undercarriages, benches,

walls, post, or racks. Never secure cylinders to work

tables or fixtures where they may become part of an

electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, troubleshooting, and maintenance work. Do not

perform any electrical work unless you are qualified to

perform such work.

2. Before performing any maintenance work inside a power

source, disconnect the power source from the incoming

electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do not

operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do not

modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for elec-

tric arc welding and cutting equipment, ask

your supplier for a copy of "Precautions and

Safe Practices for Arc Welding, Cutting and

Gouging", Form 52-529.

The following publications, which are available from the

American Welding Society, 550 N.W. LeJuene Road, Mi-

ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used through-

out this manual: Means Attention! Be Alert!

Your safety is involved.

Means immediate hazards which, if

not avoided, will result in immediate,

serious personal injury or loss of life.

Means potential hazards which could

result in personal injury or loss of life.

Means hazards which could result in

minor personal injury.

SP98-10

SET-UP INSTALLATION (See Figure 1)

1. Set up the torch and accessories, following Figure

1 and observing all instructions supplied with regu-

lator/flowmeter, fuse flow switch, and shut-off valve.

(In the simplest installation, the torch gas hose is

attached directly to the flowmeter outlet, and the

water hose is attached to a water line.)

2. Connect the fuse assembly or power cable adaptor

to the welding power source, either directly or

through a suitable length of welding cable fitted with

lugs. Run a hose from the fuse or adaptor to a wa-

ter drain. Plug switch-cord into the proper recep-

tacle on the power source.

3. Install nozzle and then the electrode into the torch.

The electrode should be recessed between 0.050-

in. and 0.080-in. (1.3 to 2.0 mm) inside the nozzle

as shown in Figure 2. To simplify the setting of this

gap. The nozzle can then be placed over the gauge.

Press the electrode release button to allow the elec-

trode to drop to the setting.

4. If desiring to use another electrode size other than

1/8-in., refer to “Replacement of Collet and Seat”

on page 4.

OPERATING INSTRUCTIONS

1. Make sure that all argon and water connections in

the system have been securely tightened and that

the torch cap has been well-tightened.

2. Turn on the water. (See Page 1 for pressure and

flow requirements.)

3. With the regulator flow-adjusting valve closed, open

the shielding gas cylinder or station valve.

4. Set the power source for the desired welding cur-

rent.

IMPORTANT: Please note that the high frequency

spark gaps setting in your power source

should not exceed 0.016-in. when this

torch is used.

5. Open all shielding gas valves downstream from flow-

meter or flowmeter/regulator, (valve on torch, lever-

operated shut-off valve, or solenoid-operated valve

in power source).

6. Set shielding gas flow to the desired level, as regis-

tered on flowmeter tube or gauge.

NOTE: Purge the gas hose by allowing the gas to flow

long enough (up to 15 minutes on new torch; less

than 5 minutes thereafter) to drive out air and

moisture. This will help prevent weld contamina-

tion.

7. Turn on control switch at power source to energize

spot-weld timing circuitry.

8. Draw a test arc on a heavy piece of scrap steel or

copper. (Do not use a carbon block, which will tend

to contaminate the electrode).

9. If the test arc is satisfactory, commence spot-weld-

ing.

OPERATION AND MAINTENANCE HINTS

1. To get maximum weld strength, make sure the sur-

faces to be joined are clean. Paint, scale, or oil film

may cause porosity or refractory oxide inclusions in

the weld.

2. Lap welds give maximum strength for spot welds.

When two pieces to be welded are of different thick-

ness, weld on the side of the thin plate.

3. Always hold the torch exactly perpendicular to the

work so that the end of the nozzle touches the work

all around its edge.

4. A poor shielding gas connection, or a leaky hose,

will not only waste gas but permit the entry of minute

amounts of air, sufficient to contaminate both the

electrode and the weld. Trouble signs; a bluish cast

on the electrode after it has cooled; in welding alu-

minum, a dark gray deposit on or beside the weld

bead.5. Keep the torch hose away from hot metal. The plas-

tic hose begins to lose strength at 125-deg. F (52-

deg. C).

6. Do not try to repair a damaged power cable or gas

or water hose. Replace it. Then send the damaged

assembly, if it appears worth salvage, to a repair

station, which has special tools for making up tight

connections.

7. If the torch water passages become clogged, they

can sometimes be cleared by reversing the direc-

tion of water flow (that is, sending water in through

the power cable, out through the water hose). How-

ever, never weld with the flow reversed. A strainer in

the water inlet line (such as P/N 96W69) is good

insurance against clogging.

8. If an electrode becomes contaminated, shut off

power, then remove electrode from torch. Break off

the contaminated end (nicking with a grinding wheel

first will help) and replace electrode.

9. Remove spatter from inside of the nozzle with a

reamer or file, exercising care so that it does not

drop back into the torch. Adherence of spatter can

be minimized, and removal made easier, by coating

the inside of the nozzle with No. 65 Nozzle Com-

pound (P/N 08N65).

10. If trigger begins to bind, lubricate with silicone grease.

REPLACEMENT OF COLLET AND SEAT (See Figure

2). Remove the body and tube assembly (56Y94) from

the torch. Compress the lever (79Z96) and unscrew the

collet seat (79Z92). Remove the clip (85W18) and pin

(79Z94) from the block (79Z93). Drive out the collet pin

(79Z95) taking care not to let it spring out because it is

under compression from spring (85W16). Remove the

collet.

(Continued on page 6)

HW-8 Torch -

16X29

WELDING CABLE TO POWER SOURCE

WATER COUPLING -

11N18 (5/8"-18 L.H.)

ARGON HOSE - 40V77

(12-1/2 FT.)

ARGON

CYLINDER

ADAPTOR - 11N16

(5/8" - 18 L.H. TO 1/4" N.P.T.)

ARGON COUPLING - 11N17

(5/8"-18)

V-30 VALVE - 16X21

INCLUDES

(2) ARGON CONN. 74S76

(2) WATER CONN. 11N16

ARGON REGULATOR WITH

FLOWMETER

STRAINER

96W69

WATER SUPPLY LINE

DRAIN

FLOW SWITCH - 40V50

WATER HOSE

40V79 (12-1/2 FT.)

POWER CABLE

ADAPTOR - 45V11

(7/8" - 14 L.H. TO 5/8"-18 L.H.)

FUSE ASSEM. - 45V34

V-30

Figure 1 - Argon and Water Hose Connections for the HW-8 Torch

To torch switch receptacle on spot-weld circuitry of power source

When installing the new collet, a new “O” ring (85W11)

should be used. Be sure the compression spring is in

place. Lubricate the “O” ring on the collet with silicone

grease and insert the collet into the body tube. Using a

1/8" electrode or the same size rod, press the collet in

far enough to align the collet-pin hole with the slots in

the body tube. Insert the pin. Put the lever in the block

and pit it. Then press the lever to pull the collet back,

and screw in the collet seat.

With an electrode in the collet, set the lever so that it

does not extend more than 7/32-in. (5.5 mm) from the

body tube when the electrode is held tightly. If the lever

extends more that 7/32-in. (5.5 mm) remove the clip and

pin and screw the body block in towards the collet pin to

get the proper setting. If the lever extends less that 7/

32-in. (5.5 mm) unscrew the block to get the proper set-

ting.

NOTE: When reinstalling Sheath 81Z90, use silicone

spray lubricator to aid installation.

REPLACING NOZZLE ADAPTOR BUSHING (See Fig.

2). If the nozzle adaptor bushing (86Z19) must be re-

placed, remove the nozzle body assembly (56Y96) and

unscrew the adaptor bushing. Be sure to replace the

nozzle seating gasket (81Z19) when putting on the new

bushing.

F-7015-W 3/02 Printed in U.S.A.

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

A. CUSTOMER SERVICE QUESTIONS:

Order Entry Product Availability Pricing Delivery

Order Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center

Telephone: (800)362-7080 / Fax: (800) 634-7548

Central Distribution Center

Telephone: (800)783-5360 / Fax: (800) 783-5362

Western Distribution Center

Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST

Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548

Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: (843)664-4428 / Fax: (843) 679-5864

Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

ESAB HW-8 Spot-Welding Tig Torch Troubleshooting instruction

Brand: ESAB

Model: HW-8 Spot-Welding Tig Torch

Category: Welding System

Type: Troubleshooting instruction

Download PDF

report

ESAB HW-8 Spot-Welding Tig Torch Troubleshooting instruction

ESAB HW-8 Spot-Welding Tig Torch Troubleshooting instruction

Related papers

Other documents