INSTRUCTIONS for
F-7015-W
March, 2002
HW-8 SPOT-WELDING TIG TORCH
CAUTION
!
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 equipment 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 supplied 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 cooling 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.) Pressure 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-metering 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.) Recommended 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)
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
Be sure this information reaches the operator.
You can get extra copies through your supplier.
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary 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 equipment 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 welding 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 explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable 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 produce 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.
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 necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, 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 movement 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 damaged 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 mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
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
2
from your body as possible.
10/98
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding 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 positive mechanical ventilation is provided. Do not breathe
fumes from these materials.
2. Do not operate near degreasing and spraying operations. 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 improve 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
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder, 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 regulator 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 connected. 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.
§25249.5 et seq.)
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, 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 electric 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, Miami, 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 Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used throughout 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.
3
SP98-10
SET-UP INSTALLATION (See Figure 1)
1. Set up the torch and accessories, following Figure
1 and observing all instructions supplied with regulator/flowmeter, fuse flow switch, and shut-of f 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 water drain. Plug switch-cord into the proper receptacle on the power source.
3. Install nozzle and then the electrode into the torch.
The electrode should be recessed between 0.050in. 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 electrode 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.
OPERA TING 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 current.
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 flowmeter or flowmeter/regulator, (valve on torch, leveroperated shut-off valve, or solenoid-operated valve
in power source).
6. Set shielding gas flow to the desired level, as registered 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 contamination.
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-welding.
OPERA TION AND MAINTENANCE HINTS
1. To get maximum weld strength, make sure the surfaces 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 thickness, 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 aluminum, a dark gray deposit on or beside the weld
bead.5. Keep the torch hose away from hot metal. The plastic hose begins to lose strength at 125-deg. F (52deg. 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 direction of water flow (that is, sending water in through
the power cable, out through the water hose). However, 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 of f
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 Compound (P/N 08N65).
10. If trigger begins to bind, lubricate with silicone grease.
REPLACEMENT OF COLLET AND SEA T (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)
4
ARGON
CYLINDER
INCLUDES
V-30 VALVE - 16X21
(2) ARGON CONN. 74S76
(12-1/2 FT.)
ARGON HOSE - 40V77
(2) WATER CONN. 11N16
(5/8"-18)
ARGON COUPLING - 11N17
ARGON REGULATOR WITH
FLOWMETER
V-30
STRAINER
96W69
ADAPTOR - 11N16
(5/8" - 18 L.H. TO 1/4" N.P.T.)
WATER SUPPLY LINE
WATER HOSE
40V79 (12-1/2 FT.)
WATER COUPLING -
11N18 (5/8"-18 L.H.)
DRAIN
FLOW SWITCH - 40V50
To torch switch receptacle on spot-weld circuitry of power source
HW-8 Torch -
16X29
FUSE ASSEM. - 45V34
POWER CABLE
ADAPTOR - 45V11
(7/8" - 14 L.H. TO 5/8"-18 L.H.)
Figure 1 - Argon and Water Hose Connections for the HW-8 Torch
WELDING CABLE TO POWER SOURCE
5
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 setting.
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.
6
7
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
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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
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
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Hours: 7:30 AM to 4:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
F-7015-W 3/02 Printed in U.S.A.
Hours: 7:30 AM to 5:00 PM EST
8
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