A-Hand Technology G85J Operation Instructions Manual

© 2009 The company reserves the rights of changing and explaining. Revised date: Dec. 9th, 2009

Model G85J

Operation instructions

Fixed Core Position Tube Plate Welder

A-Hand Technology Co., LTD. of Suzhou Industrial Park

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

Content

1. Security matters ........................................................................................ 错误！未定义书签。

2. Equipment details ..................................................................................... 错误！未定义书签。

2.1. Overview .......................................................................................................................... 4

2.2. Technical parameters ....................................................................................................... 4

2.3. Components and operation .............................................................................................. 5

2.3.1 Positioning assembly .................................................................................................. 6

2.3.2 Welding torch nozzle assembly .................................................................................. 8

2.3.3 Multifunction attitude adjusting assembly ................................................................. 9

2.3.4 Dual size wire feeding output assembly ................................................................... 11

2.3.5 Full-function airborne controller assembly .............................................................. 11

2.3.6 Conversion interface core assembly ......................................................................... 12

2.3.7. Rotary Drive Assembly ........................................................................................... 13

2.3.8. Lag gas protection assembly (optionally purchased assembly) .............................. 14

3 .Operation of Equipment ............................................................................................................ 14

3.1. Welding Preparation ........................................................................................................ 14

3.2. Adjusting Welding Torch ................................................................................................. 14

3.3. Starting Up ....................................................................................................................... 15

3.4. Setting Welding Parameter .............................................................................................. 15

3.5. Starting Welding .............................................................................................................. 15

4 Maintenance ............................................................................................................................ 15

4.1. Cleaning ........................................................................................................................... 16

4.2. Maintenance ..................................................................................................................... 16

4.3. Repair ............................................................................................................................... 17

5. Reference Process Parameters ................................................................................................ 17

6. Acknowledgements! .................................................................................................................. 20

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

.1. Security Matters

Warning: For your personal safety:

Arc welding is dangerous.

 In order to avoid unnecessary casualties, please protect you and other people's personal

safety. Children should stay away from welding site. The operator must wear protective
clothing and protective glasses to operate!

Electric shock can wound people

 Before the use of equipment, power and water must be grounded!
 In the welding process, electrode and workpieces‘ temperature are very high. Please do not

touch the hot workpieces with your skin and wet cloth. In order to prevent the damage to
your hands, please wear dry gloves during construction!

 Insulate yourself with dry insulating materials from the workpiece and ground, and the area

of insulation materials must be large enough!

 During the automatic welding process, the temperature of the electrodes, welding head,

welding nozzle and welding torch is very high!

 Ensure that the work cable is contacted well to welded workpiece and be as close as

possible to the workpiece‘s welded spot!

 Workpiece and welded metal needs to be grounded well!
 In a safe mode of operation, please check that the electrode, ground wire clamp, welding

cable and welder is intact and replace the damaged device!

 Electrode can not be cooled by water!
 Do not touch the conductive parts connected to the two welding electrodes at the same

time!

Arc ray is harmful to human body

 During the welding process, please wear protective glasses to avoid spark and arc ray

damage!

 Please wear protective clothing made of flame-retardant materials and make sure that your

skin avoids the arc rays damage!

Smoke and dust is harmful to health.

 Smoke and dust produced during welding is harmful to health, avoid inhaling it!

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

 Protective gas for welding may be inhaled and damage people's health, so welding site

must be well ventilated to ensure that the inhaled air is clean!

Welding spark can cause fire hazard

 Move inflammables away from the welding site. Otherwise, cover them with fire-retardant

material!

 Remember that welding sparks and heat metal is very easy to splash during welding. Please

prepare fire extinguisher around!

 If using compressed air during the welding process, please take corresponding special

protective measures!

 When no welding, the electrode do not touch the workpiece to avoid overheating the

workpiece!

If gas bottle is damaged, it might cause an explosion

 Use compressed gas cylinders in good condition and install sound control valve. All the air

tubes and filters should be sound and suitable!

 Gas cylinders must be installed and fixed!
 There must be enough space when installing gas cylinders to avoid collisions and resulting

in physical damage!

 Gas cylinders must be removed from the welding site or other fire sources!
 Prohibit contacting gas cylinders with electrodes, electrode holders, or other electriferous

parts!

 When you open the cylinder valve, don‘t plumb your head and face in the face of the

valve‘s outlet!

 Do not remove valve protection cap and the handle, unless the cylinder is in use or ready to

be used!

The noise over 70 db can cause permanent harm

 Please wear suitable earmuffs or earplugs!
 Ensure that the noise does not affect other people passing the work areas!

Electromagnetic interference may affect the welder’s normal use

 Welder must have a regular maintenance!
 Wire should be as short as possible and should cling to or contact with the ground!
 The protection of other wires and equipment around can reduce the effects of radiation!

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

 During working, the welder may cause electromagnetic interference to electronic

product around

 Make sure to remove the possibly interfered electronic products when welder works!
 If the welder works around computer and susceptibly interfered electronic products, related

electronic equipment should be closed first!

 Violation of operation process may cause danger

 Make sure to read the instructions carefully before using the equipment!
 Laypeople are prohibited from using the equipment!

Our instructions introduce you the safe use of equipment, which can reduce the occurrence

of accidents. So please carefully read the instructions before you use the equipment!

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

.2. Equipment Details

.2.1 Overview

This machine is a private welding head designed for tube / plate automatic TIG welding. It
can be used to a variety of tube / plate automatic welding. It can weld carbon steel, stainless
steel and tube / plate joint of other forms, including the flush end connection, stretching fillet
connection. Two welding forms of feeding wire and self-melting can be used.

The machine has vector automatic arc length control system. Through collecting the arc
voltage signal, the feedback principle automatically correct electric arc voltage, to maintain
stable space between the tungsten electrode and welding surface. The function of automatic arc
length control can also be turned off. Through the 2 multifunction controller knobs, the space
between the tungsten electrode and welding surface can be manually intervened to meet the
needs under different conditions.

The welder adopts fast install and remove modular design, which is easy to maintain and
install. It has dual-loop water cooling system and long sustained working hours. The perfect gas
protection system ensures a good protection of weld puddle during the whole process of
welding.

The welder‘s movement is adjusted by dual-mode of pulse and constant speed, which
greatly increases the depth of fusion, effectively improves the welding efficiency, makes weld
lines appearance uniform and beautiful, and need no grinding or cleaning. The welder adopts
high load rate design and sustained working hour is long. Under the guarantee of a good
process, the repair rate is very low. The welder can greatly improve the process repeated
welding. Also the welder has good control power matching, can precisely achieve all position
TIG tube / plate welding and achieve the desired welding effect.

.2.2. Technical Parameters

Items

Technical parameters

Tube Plate

connection form

Tube flush, tube stretch(minimum pipeline bridge 5mm,

maximum stretching 4mm )

Main distributing

power

PC506/PC508 Main engine of digital automatic welding

Rotary speed of

welding torch

0.15—5.58RPM

Axial electric control

displacement

18mm

Radial electric

control displacement

30mm

Vector arc length

adjusting space

18mm(shut down radial automatic control; axial response)

25mm(axial displacement/radial displacement =1 maximum

vector movement)

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

Welding torch‘s angle

of inclination

0º～30º

Maximum welding

current

(Arcing time factor 60%)

Welder head code R

84

Maximum wire

feeding speed

2000mm/min

Diameter of welding

wire

0.8mm/1.0mm(Optional)

Welding protective

gas

Industrial pure argon

Cooling type

Water cooling

Diameter of welding

tube

Internal diameter － （can

customize internal diameter of － ）

weight

≈18kg

Overall dimensions

455.5×195×237mm

Application fields

Boiler, chemical industry, heat change, air conditioning,

nuclear electricity etc.

.2.3 Components and Operation

Dual size wire feeding output assembly

Multifunction attitude adjusting assembly

Fixed core positioning assembly

Welding torch nozzle assembly

Include: Conversion interface core assembly

Rotary Drive Assembly
Sampling inductance assembly

Flip casing assembly

Multifunction airborne controller assembly

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

This machine is mainly
composed of the fixed core
tube positioning assembly;
welding torch wire feeding
assembly; multifunction attitude

adjusting assembly; Dual size
wire feeding output assembly; flip

casing assembly; multifunction

airborne controller assembly;
Conversion interface core

assembly; Rotary Drive Assembly; roundabout drive components and sampling inductance assembly.

.2.3.1 Positioning Assembly

●G85J positioning assembly is
composed of the right positioning
assembly (copper tubing; ―O‖seal ring
18×1.8; positioning seat; passing tube;
3-M3 × 6, etc.), the left optional
interchangeable assembly (nuts;
positioning core head; core rod).

Plain nuts

Positioning
core head

Core-rod

Copper
tubing

Seal ring

Positioning seat

Copper pipe

3-M3x6
socket head screw

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

●Optional assembly in
the figure from top to
down can be 8- locator;
factory default installed
10-core rod locator can be
directly used to weld the
workpiece‘s welded
pipe internal diameter of
14~32. When workpiece‘s
welded pipe internal
diameter of 13, 8-core rod
locator can be chosen.

When workpiece‘s

welded pipe internal
diameter of36~57,
12-core rod locator can be
chosen (8-core rod and
12-core rod locator is
separately configured as
special needs. The
following table provides
customer‘s corresponding
part number)

●Fixing assembly‘s
maintenance: removable
3-M3 × 6 sunk screw;
remove the two silicone
tubes behind the
positioning seat (cut off
the strap), you can
determine whether the
water –cooling channel
has failures.

Classification

Size

Internal

diameter

G85J fixed welding torch matching

parts‘ choice

Positioning

head

Nut

Core-rod

Small size
16×2.5

11

GD16×2.5

M5

nut

GD-D8
16×2

12

GD16×2

16×1.5

13

GD16×1.5

Stock

16×1

14

GD16×1

M5

nut

GD-D10

19×2.5

16×0.9

14.2

GD16×0.9

19×2

15

GD19×2
20×2.5

19×1.5

16

GD19×1.5

25×3

19

GD25×3

25×2.5

20

GD25×2.5

25×2

21

GD25×2

28×2.5

23

GD28×2.5

28×2

24

GD28×2

32×3.5

25

GD32×3.5

30×2

26

GD32×3
32×3

32×2.5

27

GD32×2.5

38×3.5

31

GD38×3.5

38×3

32

GD38×3

Large size

42×3

36

GD42×3

M10

nut

GD-D20

45×3.5

38

GD45×3.5

45×3

39

GD45×3

51×5

41

GD51×5

51×4

43

GD51×4

51×3.5

44

GD51×3.5

51×3

45

GD51×3
57×6

57×3.5

50

GD57×3.5

57×3

51

GD57×3

60×3.5

53

GD60×3.5

60×3

54

GD60×3

63×3.5

56

GD63×3.5

63×3

57

GD63×3

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

●Installation of fixing assembly: insert the two silicone inside the pass tube into the seat‘s rear
part (no direction); tie it with small plastic cable (to prevent water seepage under high pressure);
insert positioning seat into the pass tube; slightly rotate positioning seat to make the three
mounting holes align with each other (to prevent the two silicone tube‘s over winding within
the main core rod); tighten the 3-M3 × 6 screw. Note to check whether the ―O‖ seal ring is
damaged or lost.

●Positioning core head / core rod: The two should be used with the welded part. The core rod
with cooling water can take away their heat accumulation. Placing the sealing wire of welding
parts in the middle of the part can effectively prevent the adhesions inside the welded tube due
to retraction and welding(default value of random accessories = nominal diameter of welding
tube subtract 0.3~0.4), If the customer finds bad adaptability with the actual diameter, you can
be trimmed it with this formula . Please replace it timely when there is positioning core damage,
such as surface damage.

2.3.2 Welding
torch nozzle
assembly

●Installation of
tungsten electrode
and accessory
selection (see
above figure for the number corresponding to name)

▲The installation process of tungsten electrode is as follows: join the 7 step surface with 1;
tighten 8 (with a matching model requirement); tighten 6 (with a
matching model requirement); insert ground 4(diameter decided by
welding process and working conditions) into 5 (with a matching
model requirement); align the right end chamfered surface of 5 with
the left chamfered surface of 9 (no deviation); screw installed 10 and
9 into 1 (before installation ―O‖ seal ring check whether there is
defect), then folder 5 lock 4 through inside cone of 8, the distance
from the installed tungsten electrode‘s front-end to ceramic nozzle

No.

Code

Name

Material

Quantity

Remark

1

G85-9002-1

Welding torch head‘s shell

H59 1 Work piece

2

G85-9004

Arcing ring

SUS304 1 Work piece

3

G85-9005

Plug ring

Black POM

1

Work piece

4

TBHJ-Z D2.4L85

Tungsten needle

Cerium tungsten

1

Purchased components

5

TBHJ-Z D2.4L50

Tungsten electrode clamp

Cr-Zr-Cu alloy

1

Purchased components

6

TBHJ-J54N16

6#Ceramic nozzle

Ceramic

1

Purchased components

7

TBHJ-JFA

Shoulder closure

PTFE 1 Work piece

8

TBHJ-FLO.375‖-0.75‖D2.4L34

Shunt

H59 1 restructuring part

9

TBHJ-QDO.375‖L16.5

Plug screw

H59

1

Purchased components

10

GB-T3452.1G10×1.8

―O‖ seal ring

Chemigum

1

Purchased components

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

should be 6-10mm (as shown), see the technological parameter table behind for the values‘ choice.

▲Tungsten electrode‘s grinding

requirements

1: the diameter D of discharge tipped
platform is 0.2~0.8mm according to
different welding current (see process
table), equally, see process table for the
taper A.

2:Grinding marks on the cone is

required to array in radial order as shown.

3:G85E allows the tungsten electrode‘s
maximum cut-off length of 85mm, so the
purchased tungsten electrode of standard
length of 150mm can cut off 2 (75mm
each), maximumly reduce the loss of
tungsten electrode cut-off.

● Adjustment of welding torch head‘s

obliquity

Loosen two M4 × 16 screws, we can make welding torch head‘s axis and the axis of welded
tube of 1~30 degrees angle. In principle, it can achieve making welding torch head‘s axis and
the axis of welded tube parallel and achieve vertical welding of weld plate. The angle of 1~30
degrees is defined as angle adjustment range here. Refer to the table of processing technical for
the angle value of specific welding process values.

●Position adjustment of the wire nozzle

▲Releasing the flat head setting screw M5 × 8 can make the whole wire feeding joints rotate

around the ceramic nozzle axis through the insulation clip, to adjust the deflection angle of wire
into the weld crater. That is generally only used in the first coarse adjustment. The product is
adjusted well when out of the factory.

▲Releasing M4 × 10 inner hexagon fillister head screw can adjust the shaft to do
fore-and-aft displacement adjustment. The adjustment shaft has been done non-skid treatment.
So you need not tighten the screws with too much preload to avoid the clip‘s crack.

▲Loosen the inner hexagon fillister head screw M4 × 8 of adjustment shaft, you can adjust
the angle between output wire rod and the ceramic nozzle axis (that is the angle between
tungsten electrode‗s axis and the wire axis, Refer to the table of processing technical for the
angle value)

▲Release the M4 × 8 inner hexagon fillister head screw of the lower part of the figure; you
can adjust the distance between the wire nozzle and the weld crater.

.2.3.3 Multifunction attitude adjusting assembly

Welded tube

Regulating range of angle between welding torch
head‘s axis and the axis of welded tube

2-M4x16 inner hexagon
fillister head screw
2-D4 flat gasket
2-D4 spring gasket

Pan head holding screws

Clip

Adjustment shaft

Socket head screw

Socket head screw

Socket head screw

Ceramic nozzle

The wire nozzle

The wire rod

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

●The assembly uses the combination of two sets of modularized single-axis numerical control
linear movement
mechanisms. Each
set of mechanism
adopts dual row
precise linear
guideway for
movement guiding, is
driven by precise
stepper motor, which
greatly improves the
stability and rigidity
of movement. The
dual guideway with the stainless steel guard can greatly improve the service life of the
assembly.

.

●The assembly can work in 2 different modes through the numerical control setting:

▲During the adjustment phase of the welding torch head before welding, the assembly

can trim tungsten electrode‘s position relative to welded part through the corresponding knob of

full-function controller assembly. (on the promise that the angle of welding torch head and the
stretching length of tungsten electrode have been adjusted well.)

Compared to the previous models‘ adjustment of the mode of the welding radius, G85E
has been greatly improved in adjustment. The old caliber and the current caliber in the market
achieves the adjustment of welding radius by mechanical bolt or screw and the abuses are that
the slip block gap gradually increases and results in short service life. Although some caliber
has set locking screw after adjustment, it is bad to the simplified operation. The welder can

achieve coarse adjustment of the welding torch head‘s position of 10mm on the welding torch

head‘s connecting plate through two M4 × 16 inner hexagon fillister head screw. With the

Y-axis‘ 30mm large displacement adjustment, it can of the radius can achieve a wide range of
welding radius adjustment.

The relative position of the tungsten electrode tipped end and the welded parts can be
manually intervened during the welding process. In the state that you don‘t open the arc
tracking (the welded parts is of poor working conditions, the size is discrete, and the shape is
irregular etc.), facilitate to adjust and response quickly.

▲The welder adopts a vector arc length tracking technology. By detecting the arc voltage
between tungsten electrode and weldment, the CPU controls the X, Y-axis displacement
respectively. Through the pre-set displacement ratio, the axis of tungsten electrode and the axis
of welded tube can form an angle and automatically adjust the discharge distance to prevent the
"crawl tube" phenomenon caused by the pure X direction arc tracking model.

Welding tube diameter direction

The welding torch head assembly

Welded tube

Welded plate

Dual row precise linear guide rail

The welding torch head‘s connecting plate

Dual row precise linear guide rail

Maximum electric control displacement 30.0mm

Axial direction of welding tube

Precise stepping

motor control knob

Precise stepping

motor control knob

Maximum electric control displacement 18.0mm

Full-function controller assembly

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

.2.3.4 Dual size wire feeding output assembly

●Integrated wire plate‘s installation
Pull the lock wrench straightly like the left
figure, after wire plate to be installed is inserted
into the wire plate shaft; you can pull the lock
wrench levelly, as shown on the right figure.
The disassembly is just the inverse operation.

●Wire feeder‘s operation and adjustment

▲ Instruction of main parts‘ function:
Adjust handle (compress or release the wire
pressing racks, adjust the pressing by its scale)
Dual-rail guide wire wheel (it has 0.8 and 1.0 of
the guide wire slot. For wire of different diameter,
as long as twist off a screw of the top, manually
pull it out, and install reversely)

▲ wire‘s loading: handle up the hand knob
90 degrees (as shown in top figure), pressure wire
wheel will swing to the right at a certain angle
round the swing axis (as shown in bottom figure),
thread the wire loaded into the wire plate box into
the wire nozzle, then send the wire from the wire
nozzle into the back wire feeding tube (the
loading direction as shown in the bottom figure),
and then adjust the hand knob back to horizontal
position, appropriately adjust the pressure. Press the corresponding button of the full-function
controller assembly, the wire will be automatically sent out of the final wire nozzle by stepper
motor. If the wire can not be properly sent out of the wire nozzle, this is because of a big
knuckle within a short distance. If no failure, Unscrew the wire nozzle of the front wire rod,
then after the wire is sent out, screw the wire nozzle.

2.3.5 Full-function airborne controller
assembly

G85G is equipped with a full-function
controller to replace the remote controller of
old model, which reduces the sense drag of

Inner hexagon sunk screw
Aluminum wire plate box

Locking wrench

1.5kg Standard wire plate

Installed wire plate

Wire plate to be installed

Pinch roller

Dual-rail guide wire wheel

Precise stepping motor

Wire for welding

The swing axis

Adjusting handle

Inputting direction of wire

Feeding direction of wire

The wire pressing rack

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

multi-functional accessories, and reduces the incidence of failure, and is very convenient for the
operator. The functional key‘s functions are described as follows:

No.

Icon

Function name

Function description

1

88

LED display screen

Display present procedure code( 00…99).

2 Wire feeding mode

Manual feeding(left LED light always bright)/
automatic feeding(left LED light is out)

3 emergency stop

If experience a state of emergency, shut off the main
power.

4 Reverse feeding

When wire feeding mode is manual, manually adjust
the wire‘s output position. When wire feeding mode is
automatic, increase or decrease the wire feeding
speed.

5 Forward feeding
6 Decay stop

Turn off function and stop the welder according to the
system‘s pre-set sequence

7

Test of gas/current＋

Test protective gas (or cooling water) before start
welding, when start welding, increase or decrease
welding current.

8 Test of water/current
－

9 Strat welding

After all the preparation work, implement automatic
welding process.

10 Engine head positive
rotation

Manually control head‘s swing, carry out forward /

reverse operation, observe whether the head is of
normal operationor adjust the head.

11 Engine head reverse
rotation

12 Procedure increase

Execute the work of procedure code‘s increase or
decrease.

13 Procedure decrease

14 Radial adjustment

Control attitude adjustor‘s Y-axis movement

15 Axial adjustment

Control attitude adjustor‘s X-axis movement

2.3.6 Conversion interface core assembly

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

This assembly consists of an integrated converter and a front rotary output interface, completes
the 300A main electrode; circulating cooling water; dual protective gas; 3-way 12-core stepper
motor control cables, from relatively fixation to no wound involution states switching.
Locations of all interfaces are shown above.

Important Notice
The assembly integrated transducer is composed of high precise parts. The handling and

redeployment needs professionals. So the business or individual who purchases the

product is prohibited to disassemble and reform the welder, and the company will have
the right to refuse to provide services of solving the failures of the resulting leakage of air
and water, ignition etc. Please contact the company when the welder breaks down. The
company will send people for maintenance as soon as possible.

2.3.7 Rotary Drive Assembly

It adopts a special precise stepper motor combined of special
precision reducer, which runs smoothly and the torque is high;
drive rotary motion is of high precision. According to the
customer‘s specific required speed, shift configuration can be
provided.

Electrode output post

Output silicone tube of the welding
torch head protective gas

Arcing ring accessing bolt

Swing cable protective casing

Stand-by protective gas output connector

Integrated converter(circulating cooling water, dual protective gas,

300A working electrode, 3-way stepping motor cables)

Water-cooling electrode

switching block(paired setting)

Electrode input

connector(paired setting)

Cooling water output connector
Cooling water input connector

Stand-by protective gas input connector

The welding torch head protective gas input connector

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

2.3.8 Lag gas protection assembly (optionally purchased assembly)

To protect easily oxidized weld pipe fittings (titanium, etc.), the welder is equipped with a
delayed gas protection mechanism.

3 .Operation of Equipment

3.1 Welding Preparation

3.1.1 Prepare the following parts or welding materials;

a．Core rod locator matched with the internal diameter of the pipe

b．The corresponding workpiece‘s welding wire (0.8)
c．Tungsten electrode (common use 2.4)

d．Compressed air (bottled gas may be temporarily used when equipped with decrement

gauge);

e. Argon.

3.1.2 Essential tools:

a. One inner hexagon spanner of M3; M4; M5 respectively;
b. A diagonal cutting pliers;

3.1.3 Check the water in the tank is adequate; otherwise, make up the amount of coolant;

3.1.4 Connect tube and welding cable of water, electric and gas related to welding torch head,
power and water tank.

3.1.5 Install earth wire clamp.

3.2 Adjusting Welding Torch

Select the appropriate core rod locator and install it to the core rod according to the diameter of
the workpiece;
Loosen the lock head‘s pin roll screw, rotate the head, adjust the required angle of welding, and
then lock pin roll;
Install wire plate in the wire box;

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
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Screw the wire feeding hose into the wire feeding output tube, and the other end of hose is
connected to wire feeder;
Install the wire feeding wheel appropriate to wire diameter, and adjust the tight hand knob;
Thread the welding wire into the fast-assembly lead hole, start and press the feeding button on
the remote controller until the wire is sent to wire nozzle. (If directly thread the wire, pay
attention to rounding the wire end to avoid damage to the wire feeding tube‘s inside wall)
Install arcing ring;
Adjust the arc length;
Switch the welding torch to the starting position;
Cut the stretching wire to 5mm to feeding nozzle.

3.3 Starting Up

Turn on the power, operate the controller, check whether the rotation, wire feeding, arc
length control is normal or not. (Refer to power instructions for the remote controller‘s
operation)

Check whether the coolant flow is normal.

3.4 Setting Welding Parameter

Please refer to the power instructions for setting welding parameters.

3.5 Starting Welding

Before the first welding starting, welding simulation must be done to observe that whether
the torch is in good condition and protective gas is normal. If everything goes well, ignite and
start arc.

4 Maintenance

Under normal using circumstance, the welder can be used at will and only needs

minimum maintenance. However, to ensure correctness during the welding process, some

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
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issues must be paid attention to, which includes regular cleaning and inspection. Of course,
as described below, it depends on the amount of pollutants in the surrounding environment
and the welder‘s using hours.

The cleaning, inspection and maintenance of the welder must all be carried out by
professionals. If you do not follow the requirements of operation and result in failures,
please don‘t operate the welder again until the error is corrected.

4.1 Cleaning

Before cleaning, make sure that he welding power is away from the electric

fence. Pull out the power plug!
(Cut or remove the fuse does not guarantee absolute insulation) pull out all the

connecting plugs of the welder head to power.

Welder head should be operated as follows:

 If there is much dust, clean with dry compressed air.
 The outer surface of welder head should be wiped with a piece of dry cloth.
 The attached dirt of electrodes, welding torch head and other parts can be cleaned

after sand papering.

4.2 Maintenance

 Cooling system

Regularly check the cooling system of the head to ensure that there is no leakage under
the pressure of 0.5mpa and check it every month to ensure that the normal flow is no less than
450ml/min. The proposed replacement of the coolant is once every quarter and distilled water
or deionized pure water if available can be used to replace the ordinary coolant. In cold district
the coolant should be added a certain amount of alcohol (concentration 75%) in winter.

 Rotary system

Rotation system should be kept in smooth operation state, no abnormal sound
in rotating. Regularly clean dirt produced by wear between the two bearings and
gear inside the head, and adds an appropriate amount of molybdenum disulphide
grease yearly.

 Arc length control device

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
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Under normal circumstances, arc tracking control is sensitive. When manually
operate the device, you should feel relaxed and easy, but there should be no beating
gap. To ensure the above state, maintenance must be conducted every quarter, clean
arc length control screw rod and slider rod and add molybdenum disulphide grease.

 Welding torch and cable assembly

Keep the tungsten electrode, ceramic nozzles and current divider clean, and
ensure welding torch head‘s good airtight and watertight. Woven wire inside the
water and electricity pipe should be no breakage and contact well. Tungsten
electrode holds tightly and conducts well.

 Wire feeding system

Wire feeder‘s wire wheel, roller should be kept clean. The entire wire feeding system must

be cleaned when install wire every time. And clean and maintain the wire feeder weekly. When
wire feeding nozzle is obviously worn, it must be replaced. Wire feeding tube must be kept
smooth. The gears and bearings inside the wire feeder must be cleaned every year, and add an
appropriate amount of molybdenum disulphide grease to ensure the whole feeding system‘s
smooth.

4.3. Repair

Maintenance must be carried out by professionals.

All system failures are generally resolved by the equipment supplier.
The only way of the return of equipment with failure on deliver is through the dealer.
When replace parts, please use the original accessories.
When order accessories, you must clearly write the welding machine‘s model, serial number and required
quantities. You‘d better describe the accessories‘ body clearly.
If the equipment‘s repair and maintenance is carried out by non-professionals, require them to act in
accordance with the above considerations.

5. Reference Process Parameters

Our company has many years‘ experience of welding carbon steel tube sheet, and we also

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
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recorded a number of process parameters which have been verified, modified and summarized
below for reference in the process of operation. For there are still some uncertain factors, the
customer should make some adjustments in the process of operation according to the specific
circumstances.

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
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Typical welded tube(external diameter×wall thickness)

16×2

19×2

25×2

32×3

38×3

45×3

51×3

57×3

welds prepares

1

Tube stretching(mm)

2.5-4

3-4

3.5-4

4-6

5-8

5-8

6-9

5-9

2

Tube bridge(mm)

≥4

≥5

≥6

3

Welding wire‘s

diameter(mm)

0.8

1

4

Protective gas
flow(L/min)

8

10

5

Tungsten electrode‘s
diameter(mm)

ф2.4

ф3.2

6

Stretching length(mm)

10

7

Tungsten electrode‘s
height(mm)

2

2.5

8

Ceramic nozzle ode(#)

6

6/8

8

9

Tungsten electrode‘s
taper angle

20

30

10

Tungsten electrode‘s
platform height(mm)

0.2-0.4

0.2-0.4

0.3-0.6

0.4-0.6

0.4-0.6

0.5-0.8

0.5-0.8

0.5-0.8
11

Welding torch angle( º)

20

Main parameters

setting of single coil

welding

1

Pre-ventilation(s)

3

2

Lag gas (s)

3

5 8 3

Premelting time(s)

2

4

Premelting current(A)

90

100

160A

180

5

Running angle( º)

368

6

peak time(ms)

150

180

200

250

250

250

300

300

7

Peak current(A)

135

135

170

245

255

255

265

260 8 Background time(ms)

150

180

200

250

250

250

300

300

9

Background current(A)

50

55

50

60

75

75

80

80

10

decay time(s)

4

11

Welding
speed( mm/min)

86

93

99

97

88

84

77

73
12

Feeding start( º)

1

13

Wire feeding
speed( mm/min)

310

490

600

800

900

14

Stop feeding angle( º)

360

15

back suction time(s)

0.4

Two continuous

welding; Main

parameters between

0~360

1

Peak time(ms)

200

250

250

250

300

300

2

peak current(A)

170

230

245

245

255

255

3

Background time(ms)

200

250

250

250

300

300

4

Background current(A)

50

60

75

75

80

80

5

Welding
speed( mm/min)

99

97

88

88

77

73
6

Wire feeding
speed( mm/min)

300

250

250

250

250

250

Two continuous

welding; Main

parameters between

360~720

1

Peak time(ms)

200

250

250

255

300

300

2

peak current(A)

170

245

255

255

265

265

3

Background time(ms)

200

250

250

250

300

300 4 Background current(A)

50

60

75

75

80

80

5

Welding
speed( mm/min)

99

97

99

99

77

73
6

Wire feeding
speed( mm/min)

400

800

900

900

900

900

Note: If there is groove of 45 º× 2 in the tube plate, the user can ues continuous two welding procedures of different partition section with the welding angle set at
730 º, while the first section is 0~360 º and the second section is 360~720 º.

A-hand Technology Co., Ltd of Suzhou Industrial Park(215021) Operation instructions
Address: NO.88 Tangzhuang Road Suzhou-Singapore Industrial Park China
Tel: [phone] Fax: [phone]
URL:http:// www.a-hand.com

6. Acknowledgements!

Thank you for purchasing the products of A-Hand Technology. Thank you for your support and deeply love!
If you have any needs, please call our service hotline.

A-Hand Technology Co., LTD. of Suzhou Industrial Park
Post Code: 215021
Add: No.88 Tangzhuang Road, Loufeng North District, Suzhou-Singapore
Industrial Park, China

Tel: [phone]
Fax: [phone]

Web:http:// www.a-hand.com

Service Hotline：[phone]