Campbell Hausfeld WT6100 User Manual
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.
IN971800AV 4/03
Operating Instructions Model WT6100
TIG Torch
Description
The WT6100 TIG torch allows you to
convert your Arcitech 110 inverter
technology welder to a TIG (GTAW)
welder. TIG stands for Tungsten Inert
Gas. GTAW is Gas Tungsten Arc
Welding. TIG is also commonly call
Heliarc
®
welding, but Heliarc®is a brand
name of the Linde Company, not a
process. Heliarc
®
comes from Helium
Arc Welding, as helium is an inert gas
used to keep impurities from the weld.
Today most TIG welding is done with
100% Argon shielding gas.
TIG welding gives the most beautiful
and clean welds with the most
precision and control. It is the best
process for welding dissimilar size items
together. The drawback to TIG welding
is that it takes a high skill level, and it is
slow.
TIG welding is often used in welding
Aluminum, however welding
Aluminum with TIG requires an AC
high frequency power source. The
Campbell Hausfeld Arcitech 110 has DC
only output, so it can not weld
Aluminum with the TIG process.
Unpacking
When unpacking, inspect carefully for
any damage that may have occurred
during transit. Make sure any loose
fittings and screws, etc. are tightened
before putting unit into service.
The electrode
holder is "live"
(has current potential) when machine is
turned on.
Components of the WT6100
TIG Torch:
1. 2% Thoriated Tungsten Electrode -
1/16” (1.6 mm)
2. Nozzle #7 use with 1/16” (1.6 mm)
electrode
3. Collet Body - match to electrode size
(1.6 mm)
4. Collet - matched to electrode size
(1.6 mm)
5. Insulator
6. Torch Head
7. Gas Valve
8. O-rings (for gas valve and back cap)
9. Back Cup
10. 12.5’ Torch hose
11. Dinse plug power connector
(connect to negative (-) output on
welder)
12. Gas connector (connect to gas
regulator on 100% Argon tank)
For parts, manuals, product & service information
visit www.chpower.com
or call 800-746-5641
Figure 1 - Welder Components and
Controls
© 2003 Campbell Hausfeld/Scott Fetzer
Figure 2
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Figure 3
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REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
BUILT TO LAST
!
WARNING
2
Operating Instructions
GTAW Arc Welding Torch
General Safety
Danger means a
hazard that will
cause death or serious injury if the
warning is ignored.
Warning means a
hazard that could
cause death or serious injury if the
warning is ignored.
Caution means a
hazard that may
cause minor or moderate injury if the
warning is ignored. It also may mean a
hazard that will only cause damage to
property.
Note: Note means any additional
information pertaining to the product
or its proper usage.
Always
keep a
fire extinguisher accessible
while performing arc
welding operations.
● Before starting or servicing any
electric arc welder, read and
understand all instructions. Failure
to follow safety precautions or
instructions can cause equipment
damage and or serious personal
injury or death. For additional
safety information, obtain a copy of
ANSI Standard Z49.1 - Safety in
Welding and Cutting. This
publication may be ordered from
the American Welding Society, 550
NW. LeJune Rd., Miami, FL 33135.
● All installation, maintenance, repair
and operation of this equipment
should be performed by qualified
persons only in accordance with
national, state, and local codes.
Im-
proper
use of electric arc welders
can cause electric shock,
injury, and death! Take all
precautions described in
this manual to reduce the possibility of
electric shock.
● Verify that all components of the
arc welder are clean and in good
condition prior to operating the
welder. Be sure that the insulation
on all cables, electrode holders, and
power cords is not damaged.
Always repair or replace damaged
components before operating the
welder. Always keep welder panels,
shields, etc. in place when operating
the welder.
● Always wear dry protective clothing
and welding gloves, and insulated
footwear.
● Always operate the welder in a
clean, dry, well ventilated area. Do
not operate the welder in humid,
wet, rainy, or poorly ventilated
areas.
● Be sure that the work piece is
properly supported and grounded
prior to beginning any electric arc
welding operation.
● Coiled welding cable should be
spread out before use to avoid
overheating and damage to
insulation.
Never immerse the
electrode or torch
in water. If the welder becomes wet for
any reason, be absolutely certain that
it is completely clean and dry prior to
attempting use!
● Always shut the equipment off and
unplug the power prior to moving
the unit.
● Always attach the ground lead first.
● Verify that the work piece is
securely grounded.
● Always shut off electric arc welding
equipment when not in use and
remove the electrode from the
holder.
● Never allow any part of the body to
touch the electrode and ground or
grounded work piece at the same
time.
● Awkward welding conditions and
positions can be electrically
hazardous. When crouching,
kneeling or at elevations, be sure to
insulate all conductive parts, wear
appropriate protective clothing, and
take precautions to prevent injury
from falls.
● Never attempt to use this
equipment at current settings or
duty cycles higher than those
specified on the equipment labels.
● Never use an electric arc welder to
thaw frozen pipes.
Flying
sparks
and hot metal can cause
injury. As welds cool, slag
can be thrown off. Take all precautions
described in this manual to reduce the
possibility of injury from flying sparks
and hot metal.
● Wear ANSI approved face shield or
safety glasses with side shield
protection when chipping or
grinding metal parts.
● Wear ear plugs when welding
overhead to prevent spatter or slag
from falling into ears.
Electric
arc
welding operations
produce intense light and
heat and ultraviolet (UV) rays. This
intense light and UV rays can cause
injury to eyes and skin. Take all
precautions described in this manual to
reduce the possibility of injury to eyes
and skin.
● All persons operating this
equipment or in the area while
equipment is in use must wear
protective welding gear including:
welding helmet or shield with
proper shade as specified in the
following chart, flame resistant
clothing, leather welding gloves,
and full foot protection.
Current Filter
e
Up To 160 Amps 10
160 To 250 Amps 12
Never look at arc
welding operations
without eye protection as described
above. Never use a shade filter lens
that is cracked, broken, or rated below
number 10. Warn others in the area not
to look at the arc.
Electric
arc
welding operations cause
sparks and heat metal to
temperatures that can cause
severe burns! Use protective gloves
and clothing when performing any
metal working operation. Take all
precautions described in this manual to
reduce the possibility of skin and
clothing burns.
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Current Filter
(Amps) Shade
!
DANGER
!
WARNING
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CAUTION
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WARNING
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WARNING
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DANGER
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WARNING
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WARNING
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WARNING
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WARNING
Safe Handling of Compressed Gases
in Cylinders
CGA Pamphlet P-1, from Compressed
Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA
22202
Code for Safety in Welding and
Cutting
CSA Standard W117.2, from Canadian
Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
Cutting And Welding Processes
NFPA Standard 51B, from National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269
Safe Practices For Occupational And
Educational Eye And Face Protection
ANSI Standard Z87.1, from American
National Standards Institute, 1430
Broadway, New York, NY 10018
Refer to the Material Safety Data Sheets
and the manufacturers instructions for
metals, electrodes, coatings and
cleaners.
Installation
LOCATION
Selecting the proper location can
significantly increase performance,
reliability and life of the arc welder.
● For best results locate the welder in
an environment that is clean and dry.
Avoid locations exposed to high
temperature, high humidity, dust
and corrosive fumes. High humidity
causes moisture condensation on
electrical components. Moisture can
contribute to corrosion and short
electrical components. Dust and dirt
in the welder retain moisture and
increase wear of moving parts.
● Place the welder in an area that
provides at least twelve inches (305
mm.) of ventilation space at both the
front and rear of the unit. Keep all
obstructions away from this
ventilation space.
● Store electrodes and filler metal in a
clean, dry location with low
humidity.
● The welder control panel contains
information regarding proper input
● Make sure that all persons in the
welding area are protected from
heat, sparks, and ultraviolet rays.
Use additional face shields and
flame resistant barriers as needed.
● Never touch work pieces until
completely cooled.
Heat and
sparks
produced during electric arc
welding and other metal
working operations can
ignite flammable and explosive
materials! Take all precautions
described in this manual to reduce the
possibility of flames and explosions.
● Remove all flammable materials
within 35 feet (10.7 meters) of
welding arc. If removal is not
possible, tightly cover flammable
materials with fire proof covers.
● Do not operate any electric arc
welder in areas where flammable or
explosive vapors may be present.
Take precautions to be sure that
flying sparks and heat do not cause
flames in hidden areas, cracks,
behind bulkheads, etc.
Fire
hazard!
Do not weld on containers or
pipes that contain or have
contained flammable
materials or gaseous or liquid
combustibles.
Arc
welding
closed cylinders or
containers such as tanks or
drums can cause explosion if
not properly vented! Verify that any
cylinder or container to be welded has
an adequate ventilation hole, so that
expanding gases can be released.
Do not
breathe
fumes that are produced by
the arc welding operation.
These fumes are
dangerous. If the welding area cannot
be adequately ventilated, be sure to
use an air-supplied respirator.
● Keep the head and face out of the
welding fumes.
● Do not perform electric arc welding
operations on metals that are
galvanized or cadmium plated, or
Model WT6100
contain zinc, mercury, or beryllium
without completing the following
precautions:
a. Remove the coating from the
base metal.
b. Make sure that the welding area
is well ventilated.
c. Use an air-supplied respirator.
Extremely toxic fumes are created
when these metals are heated.
The
electromagnetic field that is
generated during arc
welding may interfere with the
operation of various electrical and
electronic devices such as cardiac
pacemakers. Persons using such devices
should consult with their physician
prior to performing any electric arc
welding operations.
● Route the electrode and work
cables together and secure with
tape when possible.
● Never wrap arc welder cables
around the body.
● Always position the electrode and
ground leads so that they are on
the same side of the body.
● Exposure to electromagnetic fields
during welding may have other
health effects which are not known.
Always be sure
that the welding
area is secure and free of hazards
(sparks, flames, glowing metal or slag)
prior to leaving. Be sure that
equipment is turned off and electrode
is removed. Be sure that cables are
loosely coiled and out of the way. Be
sure that all metal and slag has cooled.
ADDITIONAL SAFETY STANDARDS
ANSI Standard Z49.1 from American
Welding Society, 550 N.W. LeJune Rd.
Miami, FL 33126
Safety and Health Standards
OSHA 29 CFR 1910, from
Superintendent of Documents, U.S.
Government Printing Office,
Washington, D.C. 20402
National Electrical Code
NFPA Standard 70, from National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269
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3
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WARNING
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WARNING
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WARNING
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WARNING
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WARNING
100% Argon shielding gas is connected
to the torch at a regulated rate of 15 30 cubic feet per hour (cfh.) If you have
too little gas, you will see porosity of
your weld. Too much flow is just a
waste of gas.
Filler metal is applied to the TIG weld
by hand feeding as is done with oxyacetylene (flame power) welding. The
filler metal must match the material
you are welding. For welding mild
steel, use an un-coated steel rod such
as Welco W-1200, AWS A5.2-69, class
RG60, or E70S-6 MIG wire. The
diameter of the filler metal is based on
the thickness of the material being
welded (See chart).
Tungsten Electrodes come in a variety
of compositions and sizes. Since the
Arcitech 110 welder with WT6100 torch
is a DC TIG welder, you should use only
2% Thoriated tungsten electrodes.
These electrodes have a red
identification mark. The diameter of
the electrode is determined by the
thickness of the material being welded.
(See chart).
THE COLLET AND COLLET BODY SIZE
MUST MATCH THE DIAMETER OF
THE TUNGSTEN ELECTRODE.
Before installing the Tungsten
Electrode you must grind a point on
the welding end of the electrode. A
point of 15 - 30 degrees is desired. It is
important to grind the point with
grinding marks running lengthwise as
opposed to running the direction of
the diameter.
4
Operating Instructions
GTAW Arc Welding Torch
voltage and amperage. Follow the
specifications on the welder front
panel.
● The receptacle used for the welder
must be properly grounded and the
welder must be the only load on the
power supply circuit.
The Components of TIG
Welding (not included with
your WT6100 TIG torch) are:
1. A constant current power supply
such as the Arcitech 110 inverter
technology arc welder.
2. A bottle of 100% Argon Shielding
gas
3. An Argon regulator with proper
connections from the regulator to
the TIG torch.
4. Filler metal
5. Proper safety equipment such as a
welding helmet and gloves.
Set Up:
Torch connection to power supply - The
WT6100 torch comes with a quick
connect Dinse plug that is plugged in
to the NEGATIVE (-) receptacle on the
power supply.
The Work clamp is plugged in to the
POSITIVE (+) receptacle of the power
supply.
A beginning heat output amp setting is
selected based on the thickness of the
steel to be welded (See chart below).
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Install the Tungsten Electrode in the
torch by hand tightening the collet
body first, and then the back cap.
Install the electrode so that the pointed
end sticks out past the nozzle about
3/16”.
Steel Thickness Tungsten Electrode Diameter Filler Wire Diameter DC Amp
Inches Inches Millimeters Inches Millimeters Setting
.020" - .040" .020" 0.5 1/16" 1.6 2 - 20
.040" - 1/16" .040" 1 1/16" 1.6 10 - 75
1/16" - 1/8" 1/16" 1.6 1/16" 1.6 60 - 150
1/8" - 3/16" 5/64" 2 3/32" 2.4 100 - 200
3/16" - 1/4" 3/32" 2.4 1/8" 3.2 170 - 250
TIG Consumable Selection Chart
Figure 4 - Tungsten should stick out
3/16”
Figure 5- Install Back Cap
Electrode Direct Current (amps) Alternating Current
Diameter Electrode Negative Electrode Positive (amps)
Polarity Polarity
Tungsten Tungsten Tungsten
(in) (mm) Pure with Pure with Pure with
Tungsten Oxides Tungsten Oxides Tungsten Oxides
0.02 0.5 2-20 2-20 N/A N/A 2-15 2-15
0.04 1.0 10-75 10-75 N/A N/A 15-55 15-70
1/16 1.6 40-130 60-150 10-20 10-20 45-90 60-125
5/64 2.0 75-180 100-200 15-25 15-25 65-125 85-160
3/32 2.4 130-230 170-250 17-30 17-30 80-140 120-210
1/8 3.2 160-310 225-330 20-35 20-35 150-190 150-250
5/32 4.0 275-450 350-480 35-50 35-50 180-260 240-350
3/16 5.0 400-625 500-675 50-70 50-70 240-350 330-460
1/4 6.3 550-875 650-950 65-100 65-100 300-450 430-575
Striking an arc:
Turn on the welder and the gas valves
on the gas bottle, regulator, and torch.
Rest the torch nozzle on the base
metal to be welded without the
Tungsten electrode touching the base
metal.
Rotate the torch so that the Tungsten
electrode lightly touches the base
metal and immediately lift off or rotate
off as the arc ignites.
Keep the Tungsten 1/8” - 3/16” from
the work piece while maintaining the
arc.
As the metal gets hot, it becomes a
shiny orange molten puddle. Dip the
filler metal rod in the puddle to add
filler metal.
Model WT6100
5
Pre-TIG Welding tips:
TIG welding is much harder to master
than other welding processes.
Experience welding with an OxyAcetylene (flame power) torch will help
greatly with learning TIG welding.
CLEAN the area to be welded.
Cleanliness is imperative. You can’t get
the base metal too clean. There is no
flux to float off impurities with the TIG
process.
Cut filler metal rods to shorter lengths
for easier control. Usually TIG filler
metal comes in 36” lengths. It is much
easier to handle if it is 18” or 12”. Clean
the filler metal with alcohol and a clean
white cloth. Dirt and dust contaminate
a weld.
TIG welding gives off less light than
other arc welding processes, but you
must still use a #10 minimum shade
welding lens to protect your eyes.
Get yourself into a comfortable
position to weld. Seated with your arms
supported by a welding table or by the
work-piece.
Tips while TIG welding:
Always let the filler metal rod be
melted by the molten puddle. NOT
by the torch.
Never touch the hot Tungsten
electrode to the molten puddle. The
molten steel will be wicked up by the
Tungsten, contaminating the electrode.
When you contaminate the Tungsten
with steel, stop welding and re-grind
the point of the electrode, removing
the steel contamination.
When you burn a hole through the
base metal, stop welding and let the
weld cool before re-starting the arc.
Before making an important TIG weld,
practice on a test piece. TIG welding is
an art, and practice improves quality.
There is a lot of self-satisfaction to
mastering this welding process and
seeing that perfect weld.
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Identifcation
Color
Oxide
Green None
Blue 0.4% ThO
2
Yellow 1.0% ThO
2
Red 2.0% ThO
2
Violet 3.0% ThO
2
Orange 4.0% ThO
2
Brown 0.3% ZrO
2
White 0.8% ZrO
2
Black 1.0% LaO
2
Grey 2.0% CeO
2
TIG Electrode Identification Recommended TIG Parameters for Optional Electrodes
6
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Operating Instructions
AC or Alternating Current - electric
current that reverses direction periodically.
Sixty cycle current travels in both directions
sixty times per second.
Arc Length - the distance from the end
of the electrode to the point where the arc
makes contact with the work surface.
Base Metal - the material to be welded.
Butt Joint - a joint between two
members aligned approximately in the
same plane.
Crater - a pool, or pocket, that is formed
as the arc comes in contact with the base
metal.
DC or Direct Current - electric current
which flows only in one direction. The
polarity (+ or -) determines which direction
the current is flowing.
DC Reverse Polarity - occurs when the
electrode holder is connected to the
positive pole of the welding machine.
Reverse Polarity directs more heat into
melting the electrode rather then the work
piece. It is used on thinner material.
DC Straight Polarity - occurs when the
electrode holder is connected to the
negative pole of the welding machine.
With straight polarity more heat is directed
to the work piece for better penetration
on thicker material.
Electrode - a coated metal wire having
approximately the same composition as
the material being welded.
Fillet Weld - approximately a triangle in
cross-section, joining two surfaces at right
angles to each other in a lap, T or corner
joint.
Flux - a coating, when heated, that
produces a shielding gas around the
welding area. This gas protects the parent
and filler metals from impurities in the air.
Flux Cored Arc Welding (FCAW) also called Gasless, is a welding process
used with a wire-feed welding machine.
The weld wire is tubular with flux material
contained inside for shielding.
Gas Metal Arc Welding (GMAW) also called MIG, is a welding process used
with a wire feed welding machine. The
wire is solid and an inert gas is used for
shielding.
Gas Tungsten Arc Welding (GTAW)
- also called TIG, is a welding process used
with welding equipment with a high
frequency generator. The arc is created
between a non-consumable tungsten
electrode and the work piece. Filler metal
may or may not be used.
Lap Joint - a joint between two
overlapping members in parallel planes.
MIG - see Gas Metal Arc Welding.
Open Circuit Voltage (OCV) - the
voltage between the electrode and the
ground clamp of the welding machine
when no current is flowing (not welding).
The OCV determines how quickly the arc is
struck.
Overlap - occurs when the amperage is
set too low. In this instance, the molten
metal falls from the electrode without
actually fusing into the base metal.
Porosity - gas pockets, or cavities,
formed during weld solidification. They
weaken the weld.
Penetration - the depth into the work
piece that has been heat effected by the
arc during the welding process. A good
weld achieves 100% penetration meaning
that the entire thickness of the work piece
has been heated and resolidified. The heat
effected area should be easily seen on the
opposite side of the weld.
Shielded Metal Arc Welding
(SMAW) - also called Stick, is a welding
process with uses a consumable electrode
to support the arc. Shielding is achieved by
the melting of the flux coating on the
electrode.
Slag - a layer of flux soot that protects
the weld from oxides and other
contaminants while the weld is solidifying
(cooling). Slag should be removed after
weld has cooled.
Spatter - metal particles thrown from the
weld which cool and harden on the work
surface. Spatter can be minimized by using
a spatter resistant spray on the work piece
before welding.
Stick - see Shielded Metal Arc Welding.
Tack Weld - weld made to hold parts in
proper alignment until final welds are
made.
TIG - see Gas Tungsten Arc Welding.
Travel Angle - the angle of the
electrode in the line of welding. It varies
from 5º to 45º depending on welding
conditions.
T Joint - made by placing the edge of
one piece of metal on the surface of the
other piece at approximately a 90º angle.
Undercut - a condition that results when
welding amperage is too high. The
excessive amperage leaves a groove in the
base metal along both sides of the bead
which reduces the strength of the weld.
Weld Pool or Puddle - a volume of
molten metal in a weld prior to its
solidification as weld metal.
Weld Bead - a narrow layer or layers of
metal deposited on the base metal as the
electrode melts. Weld bead width is
typically twice the diameter of the
electrode.
Work Angle - the angle of the electrode
from horizontal, measured at right angles
to the line of welding.
Welding Terms
WP17FV
7
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WT6100
For Replacement Parts, Call 1-800-746-5641
Replacement Parts List
Please provide following information: Address parts correspondence to:
- Model number The Campbell Group
- Serial number (if any) Attn: Parts Department
- Part description and number as shown in parts list 100 Production Drive
Harrison, OH 45030 U.S.A.
1 1.6 mm 2% Thoriated tungsten electrode - (10 per package) WC250033AV 1
2 7/16” ID Ceramic nozzle #7 WC250123AV 1
3 1.6 mm Collet body WC250103AV 1
4 1.6 mm Collet WC250113AV 1
5 Back cup WC250130AV 1
6 Dinse connector with gas port WC250131AV 1
Ref. No Description Part Number Qty.
1
2
3
4
5
6
WP17FV
8
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1. Duration: The manufacturer warrants that it will repair, at no charge for parts or labor, Welding Torch, or Cables, proven
defective in material or workmanship, during the following time period(s) after date of original retail purchase:
90 Days: The TIG Welding Torch
2. Who Gives This Warranty (Warrantor):
Campbell Hausfeld
The Scott Fetzer Company
100 Production Drive
Harrison, OH 45030
Telephone: (513)-367-4811
3. Who Receives This Warranty (Purchaser): The original purchaser of the Campbell Hausfeld product.
4. What is covered under this warranty: Defects in material and workmanship which occur within the duration of the
warranty period. This warranty extends to the TIG Welding Torch only.
5. What is not covered under this warranty:
A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN
DURATION TO THIS EXPRESS WARRANTY. After this period, all risks of loss, from whatever reason, shall be on the
purchaser. Some states do not allow limitations on how long an implied warranty lasts, so above limitations may not apply
to you.
B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECT
FAILURE OR MALFUNCTION OF THE CAMPBELL HAUSFELD PRODUCT. Some states do not allow limitations on how long an
implied warranty lasts, so above limitations may not apply to you.
C. This warranty does not apply to any accessory items included with the product which are subject to wear from usage; the
repair or replacement of these items shall be at the expense of the owner. These TIG items include but are not limited to;
Tungsten, Collet, Collet Body, Ceramic Nozzles. In addition, this warranty does not extend to any damage caused by the
untimely replacement or maintenance of any of the previously listed CONSUMABLE parts.
D. Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in accordance with
instructions provided in the owner’s manual(s) supplied with the product.
E. Pre-delivery service, i.e. assembly and adjustment.
7. Responsibilities of Warrantor under this warranty: Repair or replace, at Warrantor’s option, products or components
which have failed within duration of the warranty period.
8. Responsibilities of purchaser under this warranty:
A. Deliver or ship the Campbell Hausfeld product or component to Campbell Hausfeld. Freight costs, if any, must be borne by
the purchaser.
B. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).
9. When Warrantor will perform repair or replacement under this warranty: Repair or replacement will be scheduled
and serviced according to the normal work flow at the servicing location, and depending on the availability of replacement
parts.
This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state.
Limited Warranty
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