Tweco K4000 User Manual

ARCAIR

Cutting and Gouging Systems

VictorTechnologies.com/Arcair

K3000™, K4000

AIR CARBON-ARC MANUAL GOUGING TORCHES

Operating

Manual

English

Canadien Français

Americas Español

Revision: AA Issue Date: September 23, 2013 Manual No.: 89250012

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Victor Arcair® product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.

For more than 60 years Victor Arcair® has provided quality products you can trust, when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

Victor Arcair® is a Global Brand of Cutting Products for Victor Technologies™ Inc. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time.

We strive to enhance your productivity, efﬁciency and welding performance, enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions.

If you have any questions or concerns regarding your new Victor Arcair® product, please contact our friendly and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.victortechnologies.com/arcair

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Victor® Arcair® K3000™ & K4000® Air Carbon-Arc Manual Gouging Torches Operating Manual Operating Manual Guide Number: 89250012

Published by: Victor Technologies, Inc. 2800 Airport Rd. Denton, TX. 76208 940-566-2000 www.victortechnologies.com/arcair

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: September 23, 2013

Table of Contents

SECTION 1: INTRODUCTION ............................................... 1-1

1.01 Air Carbon-Arc Cutting/Gouging ................................................. 1-1

1.02 History ........................................................................................ 1-1

1.03 Applications ................................................................................ 1-2

1.04 The "BEST" Just Got Better... ....................................................... 1-2

SECTION 2: SAFETY AND HEALTH ........................................ 2-1

2.01 Proper Installation, Use, and Maintenance .................................. 2-1

2.02 Electrodes ....................................................................................2-1

2.03 Ventilation Hazards ..................................................................... 2-2

2.04 Personal Protective Equipment and Clothing .............................. 2-3

2.05 Shielding Booths ......................................................................... 2-4

2.06 Fire and Burn Hazards ................................................................. 2-4

2.07 Safety and Operating References ................................................ 2-5

SECTION 3: HOW TO USE THIS MANUAL ................................ 3-1

3.01 Receipt of Equipment .................................................................. 3-1

SECTION 4: INSTALLATION .............................................. 4-1

4.01 Installing the DC Welding Power Cable and Air Hose to the

Power and Air Connector ............................................................ 4-1

4.02 Installing the DC Welding Power Cable with Twist Lock Power

Connection and Air Hose to the Torch Swivel Cable Assembly .... 4-4

4.03 Connecting to DC or AC Welding Power Supplies ....................... 4-5

SECTION 5: TROUBLESHOOTING ......................................... 5-1

SECTION 6: REPLACEMENT PARTS ...................................... 6-1

6.01 K3000™ & K4000® TORCH REPLACEMENT PARTS ...................6-1

6.02 K3000™ & K4000® SWIVEL CABLE REPLACEMENT PARTS ......6-2

6.03 POWER & AIR HOOK-UP KIT ...................................................... 6-3

STATEMENT OF WARRANTY ......................... INSIDE BACK COVER

SECTION 1: INTRODUCTION

1.01 Air Carbon-Arc Cutting/Gouging

The air carbon-arc process (CAC-A) removes metal physically, not chemically as in oxy-fuel cutting (OFC). Gouging or cutting occurs when the intense heat of the arc between the carbon electrode and the workpiece melts part of the workpiece. Simultaneously, air passes through the arc quickly enough to blow the molten material away.

The air carbon-arc process does not require oxidation to maintain the cut, so it can gouge or cut metals that the OFC process cannot. Most common metals (e.g., carbon steel, stainless steel, many copper alloys and cast irons) can be cut using the air carbon-arc process. The metal removal rate depends on the melting rate and how efﬁciently the air jet removes molten metal. In the process, the air must lift the molten metal clear of the arc before the metal solidiﬁes.

1.02 History

Air carbon-arc gouging began in the 1940's, evolving from the existing carbon-arc cutting process. Myron Stepath, a welding engineer, developed air carbon-arc gouging to remove several hundred feet of ﬂat, cracked, stainless steel weld.

Previously, carbon-arc cutting removed overhead and vertical defective welds and rivet heads. The carbon-arc melted the metal, then gravity moved the molten metal away.

Stepath reasoned that an air jet could provide the force to remove metal lying ﬂat. So he tried a direct-current, electrode-negative carbon-arc with a second operator directing an air blast via air nozzle at the molten pool. However, this attempt was unsuccessful because the arc was less stable than a carbon-welding arc. So, Stepath tried a direct-current, electrode-positive arc, and the result was air carbon-arc gouging.

In 1948, Myron Stepath introduced the ﬁrst air carbon-arc torch to the welding industry. In 1949, Stepath and two associates founded the Arcair® Company.

Two operators were no longer needed. The compressed air now passed through the torch and exited beneath the electrode. This new tool saved time on weld backgouging, crack removal, and weld defect repair on carbon, alloy, and stainless steel. Previously, these tasks were performed by grinding or chipping.

Today, the basic principle remains the same, but with improved equipment and an expanded number of applications.

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1.03 Applications

The industry has enthusiastically adopted air carbon-arc gouging and found many uses for the process in metal fabrication and casting ﬁnishing, chemical and petroleum technology, construction, mining, general repair, and maintenance.

Victor® Arcair® Torches and Electrodes are used throughout the world, anywhere metal is gouged, grooved, severed, or removed from a surface.

The air carbon-arc process is ﬂexible, efﬁcient, and cost effective on practically any metal: carbon steel, stainless steel and other ferrous alloys; gray, malleable and ductile iron; aluminum; nickel; copper alloys and other nonferrous metals.

1.04 The "BEST" Just Got Better...

Victor® Arcair® is changing the game when it comes to the power and air connection design on their K-Series torch cable assemblies.

Since the invention of the air carbon-arc process in 1949, the torch and cable have always used a molded rubber "boot" to provide electrical protection for the power connection by preventing arcing against a grounded work surface. This boot design incorporates a large open rectangular end that allows the power cable and air hose space to connect to the torch cable. However, the boot can expose the power connection to the grounded work surface if it is not properly installed and kept in place over the connection.

Now, the improved boot design encapsulates the power/air connection, eliminating the chance of accidental arcing. It can accept one 4/0 welding cable from the power supply and one ¾” diameter air hose assembly that provides current and compressed air.

This new boot design is molded from a hard nylon reinforced ﬁber material that can withstand the abuse of everyday use in a fabrication shop.

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SECTION 2: SAFETY AND HEALTH

Safe practices in welding and cutting processes, such as air carbon-arc, are covered in ANSl Z49.1, “Safety in Welding and Cutting”, and ANSl 249.2, “Fire Prevention in Use of Welding and Cutting Processes.” Air carbon-arc operators and their supervisors should adhere to the safe practices discussed in these documents.

Other hazards in arc welding and cutting are brieﬂy discussed in this section.

2.01 Proper Installation, Use, and Maintenance

Serious injury or death may result if gouging and cutting equipment is not properly installed, used, and maintained. Misuse of this equipment and other unsafe practices can be hazardous. The operator, supervisor, and helper must read and understand the following safety warnings and instructions before installing or using any air carbon-arc torch or equipment.

The gouging/cutting process is used in many potentially dangerous environments, such as elevated heights, areas with limited ventilation, close quarters, areas around water, hostile environments, etc. The operator must be aware of the dangers associated with working in these types of conditions. The operator must be trained in safe practices for his work environment and be under competent supervision.

It is essential that the operator, supervisor, and others in the work area be aware of the dangers of the air carbon-arc process. Training and proper supervision are important for a safe work place. Keep these instructions for future use. Additional recommended safety and operating information is referenced in each section.

2.02 Electrodes

WARNING

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Install and maintain equipment in accordance with the National Electrical Code (NFPA 70) and local codes. Do not service or repair equipment with power on. Do not operate equipment with protective insulators or covers removed. Service or repair to equipment must be done by qualiﬁed and/or trained personnel only

2-1

Keep carbon electrodes dry. If electrodes become damp, bake them for 10 hours at 300˚ F (176˚ C). Wet electrodes may shatter.

Do not touch electrically live parts. Do not touch an electrode with bare skin and electrical ground at the same time. Always wear dry welding gloves that are in good condition. Aluminized protective clothing can become part of the electrical path. Keep oxygen cylinders, chains, wire ropes, cranes, hoists, and elevators away from any part of the electrical circuit. Check all ground connections periodically to determine if they are mechanically strong and electrically adequate for the required current.

If you are engaged in alternating current gouging/cutting under wet conditions or warm surroundings where perspiration is a factor, use reliable automatic controls for reducing no load voltage to reduce shock hazard. When the gouging/cutting process requires values of open circuit voltages in alternating current machines higher than 80 volts, and direct current machines higher than 100 volts, take precautions, such as using adequate insulation, to prevent the operator from making accidental contact with the high voltage.

If you are going to suspend gouging for any substantial period of time, such as during lunch or overnight, remove all electrodes from the torch and the put the torch in a safe location so that accidental contact cannot occur. Disconnect the torch from the power source when it is not in use. Never immerse air carbon-arc torches or electrodes in water.

2.03 Ventilation Hazards

WARNING

SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH

Keep smoke, fumes and gases from the breathing area. Fumes from the gouging process are of various types and strengths, depending on the kind of base metal being worked on. To ensure your safety, do not breathe these fumes. Ventilation must be adequate to remove smoke, fumes and gases during the operation to protect gouging operators and others in the area.

Vapors of chlorinated solvents can form the toxic gas phosgene when they are exposed to ultraviolet radiation from an electric arc. Remove all solvents, degreasers, and potential sources of these vapors from the operating area.

Fumes that are produced by cutting in particularly conﬁned places can cause discomfort and physical harm if inhaled over an extended period of time. Provide adequate ventilation in the gouging/cutting area. Use air-supplied respirators if there is not enough ventilation to remove all fumes and gases. Never ventilate with oxygen, because oxygen supports and vigorously accelerates ﬁre.

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