HW-26, HW-26R, & HW-26F Tig Welding Torches: Instruction Manual
HW-26, HW-26R, & HW-26F Tig Welding Torches: Instruction Manual
HW-26, HW-26R, & HW-26F Tig Welding Torches: Instruction Manual
May, 2003
INSTRUCTION MANUAL
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 (Section 1) before installing or operating this
equipment.
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the
instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained
equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be
replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends
that a telephone or written request for service advice be made to the Authorized Distributor from whom
purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a
service facility designated by the manufacturer.
2
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for 5. Do not use equipment beyond its ratings. For example,
your protection. They summarize precautionary overloaded welding cable can overheat and create a fire
information from the references listed in Addi- hazard.
tional Safety Information section. Before per- 6. After completing operations, inspect the work area to
forming any installation or operating procedures, be sure to make certain there are no hot sparks or hot metal which
read and follow the safety precautions listed below as well as could cause a later fire. Use fire watchers when neces-
all other manuals, material safety data sheets, labels, etc. sary.
Failure to observe Safety Precautions can result in injury or 7. For additional information, refer to NFPA Standard 51B,
death. "Fire Prevention in Use of Cutting and Welding Pro-
cesses", available from the National Fire Protection Asso-
PROTECT YOURSELF AND OTHERS --
ciation, Batterymarch Park, Quincy, MA 02269.
Some welding, cutting, and gouging pro-
cesses are noisy and require ear protec-
ELECTRICAL SHOCK -- Contact with
tion. The arc, like the sun, emits ultravio-
live electrical parts and ground can
let (UV) and other radiation and can
cause severe injury or death. DO NOT
injure skin and eyes. Hot metal can cause burns. Train-
use AC welding current in damp areas,
ing in the proper use of the processes and equipment is
if movement is confined, or if there is
essential to prevent accidents. Therefore:
danger of falling.
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles 1. Be sure the power source frame (chassis) is connected
are also required. to the ground system of the input power.
2. Use a face shield fitted with the correct filter and cover 2. Connect the workpiece to a good electrical ground.
plates to protect your eyes, face, neck, and ears from 3. Connect the work cable to the workpiece. A poor or
sparks and rays of the arc when operating or observing missing connection can expose you or others to a fatal
operations. Warn bystanders not to watch the arc and not shock.
to expose themselves to the rays of the electric-arc or hot 4. Use well-maintained equipment. Replace worn or dam-
metal. aged cables.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve 5. Keep everything dry, including clothing, work area, cables,
shirt, cuffless trousers, high-topped shoes, and a welding torch/electrode holder, and power source.
helmet or cap for hair protection, to protect against arc 6. Make sure that all parts of your body are insulated from
rays and hot sparks or hot metal. A flameproof apron may
work and from ground.
also be desirable as protection against radiated heat and
sparks. 7. Do not stand directly on metal or the earth while working
4. Hot sparks or metal can lodge in rolled up sleeves, trouser in tight quarters or a damp area; stand on dry boards or
cuffs, or pockets. Sleeves and collars should be kept an insulating platform and wear rubber-soled shoes.
buttoned, and open pockets eliminated from the front of 8. Put on dry, hole-free gloves before turning on the power.
clothing 9. Turn off the power before removing your gloves.
5. Protect other personnel from arc rays and hot sparks with 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
a suitable non-flammable partition or curtains. for specific grounding recommendations. Do not mistake
6. Use goggles over safety glasses when chipping slag or the work lead for a ground cable.
grinding. Chipped slag may be hot and can fly far. By-
standers should also wear goggles over safety glasses. ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current
FIRES AND EXPLOSIONS -- Heat from flowing through any conductor causes
flames and arcs can start fires. Hot slag localized Electric and Magnetic Fields
or sparks can also cause fires and explo- (EMF). Welding and cutting current
sions. Therefore: creates EMF around welding cables
and welding machines. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non- 1. Welders having pacemakers should consult their physi-
flammable covering. Combustible materials include wood,
cian before welding. EMF may interfere with some pace-
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc. makers.
2. Hot sparks or hot metal can fall through cracks or crevices 2. Exposure to EMF may have other health effects which are
in floors or wall openings and cause a hidden smoldering unknown.
fire or fires on the floor below. Make certain that such 3. Welders should use the following procedures to minimize
openings are protected from hot sparks and metal.“ exposure to EMF:
3. Do not weld, cut or perform other hot work until the A. Route the electrode and work cables together. Secure
workpiece has been completely cleaned so that there are them with tape when possible.
no substances on the workpiece which might produce B. Never coil the torch or work cable around your body.
flammable or toxic vapors. Do not do hot work on closed C. Do not place your body between the torch and work
containers. They may explode. cables. Route cables on the same side of your body.
4. Have fire extinguishing equipment handy for instant use, D. Connect the work cable to the workpiece as close as
such as a garden hose, water pail, sand bucket, or
possible to the area being welded.
portable fire extinguisher. Be sure you are trained in its
use. E. Keep welding power source and cables as far away
from your body as possible.
3 11/95
FUMES AND GASES -- Fumes and any electrical work unless you are qualified to perform
gases, can cause discomfort or harm, such work.
particularly in confined spaces. Do 2. Before performing any maintenance work inside a power
not breathe fumes and gases. Shield- source, disconnect the power source from the incoming
ing gases can cause asphyxiation. electrical power.
Therefore: 3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
1. Always provide adequate ventilation in the work area by any equipment in faulty condition.
natural or mechanical means. Do not weld, cut, or gouge 4. Do not abuse any equipment or accessories. Keep equip-
on materials such as galvanized steel, stainless steel, ment away from heat sources such as furnaces, wet
copper, zinc, lead, beryllium, or cadmium unless positive conditions such as water puddles, oil or grease, corrosive
mechanical ventilation is provided. Do not breathe fumes atmospheres and inclement weather.
from these materials. 5. Keep all safety devices and cabinet covers in position and
2. Do not operate near degreasing and spraying operations. in good repair.
The heat or arc rays can react with chlorinated hydrocar- 6. Use equipment only for its intended purpose. Do not
bon vapors to form phosgene, a highly toxic gas, and modify it in any manner.
other irritant gases.
3. If you develop momentary eye, nose, or throat irritation ADDITIONAL SAFETY INFORMATION -- For
while operating, this is an indication that ventilation is not more information on safe practices for elec-
adequate. Stop work and take necessary steps to improve tric arc welding and cutting equipment, ask
ventilation in the work area. Do not continue to operate if your supplier for a copy of "Precautions and
physical discomfort persists. Safe Practices for Arc Welding, Cutting and
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for Gouging", Form 52-529.
specific ventilation recommendations.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
CYLINDER HANDLING -- Cylinders, if FL 33126, are recommended to you:
mishandled, can rupture and violently 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
release gas. Sudden rupture of cylin- 2. AWS C5.1 - "Recommended Practices for Plasma Arc
der, valve, or relief device can injure or Welding"
kill. Therefore: 3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
1. Use the proper gas for the process and use the proper 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
pressure reducing regulator designed to operate from the Gouging and Cutting"
compressed gas cylinder. Do not use adaptors. Maintain 5. AWS C5.5 - "Recommended Practices for Gas Tungsten
hoses and fittings in good condition. Follow manufacturer's Arc Welding“
operating instructions for mounting regulator to a com- 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
pressed gas cylinder. Welding"“
2. Always secure cylinders in an upright position by chain or 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
strap to suitable hand trucks, undercarriages, benches, 8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld-
walls, post, or racks. Never secure cylinders to work ing and Cutting of Containers That Have Held Hazardous
tables or fixtures where they may become part of an Substances."
electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve This symbol appearing throughout this manual
protection cap in place if regulator is not connected. means Attention! Be Alert! Your safety is
Secure and move cylinders by using suitable hand trucks. involved.
Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder. The following definitions apply to DANGER, WARNING, CAU-
5. For additional information, refer to CGA Standard P-1, TION found throughout this manual:
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas Used to call attention to immediate haz-
Association, 1235 Jefferson Davis Highway, Arlington, ards which, if not avoided, will result in
VA 22202. immediate, serious personal injury or loss
of life.
EQUIPMENT MAINTENANCE -- Faulty or im-
properly maintained equipment can cause Used to call attention to potential haz-
injury or death. Therefore: ards which could result in personal injury
or loss of life.
1. Always have qualified personnel perform the installation,
troubleshooting, and maintenance work. Do not perform Used to call attention to hazards which
could result in minor personal injury.
4
1.1 General 1.4 Electrodes
Each torch in the HW-26 family is rated at 160 A (ACHF Each torch model uses .020-inch thru 5/32-inch diam-
or DCSP) continous duty and 220 A at 50% duty cycle eter electrodes. The 3-inch and 7-inch long standard
(using standard collet bodies). With gas lens collet torch cap is designed for 7-inch electrodes. A short cap
bodies, each torch is rated at 200 A (ACHF or DCSP) for the 3-inch electrode is available as an optional
continous duty. The hard body on the HW-26 provides accessory. See Table 1-1.
the best heat and abrasion resistance. The HW-26R
has a silicone rubber body which provides good high
frequency resistance. For reaching hard-to-get-at ap- 1.5 Collets
plications, the HW-26F uses a flexible head. All the
torches are air-cooled.
Collets are available for each of the six electrode sizes.
The collet bodies come in both standard and gas lens
styles. A large diameter gas lens is available for 3/32-
1.2 Specifications inch and 5/32-inch electrodes. See Table 1-2.
5
Table 1-1. Electrode and Cup Sizes for Different Welding Currents
Welding Currents (Amps)
ACHF* DCSP** DCRP**
Using pure Using Using pure or thoriated Electrode Diameter High- Ceramic
tungsten thoriated tungsten electrodes in Inches Impact Cup Cup No.
electrodes electrodes *** No.
5-15 5-20 5-20 --- .020 (0.5 mm) 4 4-5
10-60 15-80 15-80 --- .040(1.0 mm) 4-5 4-5
50-100 70-150 70-150 10-20 1/16 (1.6 mm) 4-5-6 4-5-6
100-150 140-235 150-250 15-30 3/32 (2.4 mm) 5-6-7-8 6-7-8
150-210 225-325**** 250-400**** 25-40 1/8 (3.2 mm) 6-7-8-10 7-8-10
200-275 300-400**** --- 40-55 5/32 (4.0 mm) 8-10-12 10-12
* Values based on use of unbalanced wave transformer. If a balanced wave transformer is used, reduce maximum values in table by
about 30% or use the next larger size electrode.
** Exceeds the current rating of the torch (except 948361 (12-1/2 ft) using gas lens).
*** Balled electrode tip ends can best be formed and maintained at these ac current levels.
**** Thoriated tungsten electrodes are recommended when a gas lens and high frequency starting are used.
Electrode Size
Standard Gas Lens Large Dia. Gas Lens
in. mm Collet Collet Body Collet Body* Collet Body**
0.020 0.5 10N21 10N29 45V29 ---
0.040 1.0 10N22 10N30 45V24 ---
1/16 1.6 10N23 10N31 45V25 ---
3/32 2.4 10N24 10N32 45V26 45V64
1/8 3.2 10N25 10N28 45V27 995795
5/32 4.0 54N20 406488*** 45V28 45V63
* Collet body insulator (P/N 54N01) is required when using gas lens collet bodies.
** Collet body insulator (P/N 54N63) is required when using large diameter gas lens collet bodies.
*** Use of a gas lens collet body is recommended for this size.
6
2.1 Setup and Installation
TORCH CAP
A. Connect the regulator/flowmeter to a gas cylin-
der. Refer to the instructions supplied with the
regulator/flowmeter for details on attaching and "O" RING
adjusting the regulator.
ELECTRODE
B. Connect one end of the gas hose (P/N 40V77 or
34V38) to the regulator outlet and the other end
to the torch cable adaptor (P/N 45V62). On ELECTRODE COLLET
torches with separate power cables, connect the
torch gas hose directly to the regulator outlet or
add one of the extension hoses by connecting
COLLET BODY
the argon coupling (P/N 11N17) between the INSULATOR
torch hose and the extension hose.
GAS LENS
C. Connect the power cable adaptor or lug to the COLLET BODY TORCH BODY
welding power source, either directly or through
a suitable length of welding cable fitted with lugs.
GAS LENS
CUP
D. Install collet body, collet, electrode, and cup on COLLET BODY
torch (see Figure 2-1) as follows:
CUP
1. Screw in collet body. (If using a gas lens,
assemble insulator on collet body before
installing.)
2. Apply a thin coat of silicone grease to the Figure 2-1. Exploded View of HW-26 Torch
surface of the cup that mates with the torch
body and then screw on cup. 2.2 Operating Instructions
3. Remove torch cap and slide collet into posi-
tion (tapered end first). A. Make sure that all gas connections in the system
4. Slip electrode down through hole in top of have been securely tightened and that the torch
collet until end of electrode extends beyond cap has been well-tightened.
rim of cup. (Exact extension is variable from B. With the regulator flow-adjusting valve closed,
as little as 1/8 inch for butt welding with open the gas cylinder or station valve.
standard collet bodies to 3/4 inch or more for C. Set the power source for the desired welding
corner or fillet welds with gas lens collet current.
bodies and cups.) D. Open all shielding gas valves downstream from
the flowmeter or flowmeter/regulator (e.g., valve
NOTE on torch, lever-operated shutoff valve, or sole-
noid-operated valve in power source.)
When using high frequency with sleeved high- E. Set shielding gas flow to the desired level, as
impact cups, arcing may sometimes occur be- registered on flowmeter tube or gauge.
tween the electrode and the steel sleeve. To
avoid this, it is advantageous to extend the NOTE
electrode as far as possible consistent with the
particular application. 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
5. Screw on the torch cap and tighten. The cap help prevent weld contamination.
will press down on the collet to grip the
electrode securely. To readjust electrode, F. Close the control switch at work position or at
loosen torch cap. power source.
G. 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.)
H. If the test arc is satisfactory, commence weld-
ing.
7
3.1 Maintenance E. Keep an eye on the sealing "O" ring on the torch
cap. If it shows signs of wear or distortion, cut it
off. Then install new ring (P/N 98W18). Apply a
little silicone grease to the new ring before
attempting to slide it over the cap threads.
If this equipment does not operate properly, stop work
immediately and investigate the cause of the malfunc-
tion. Maintenance work must be performed by an expe- 3.2 Replacement of Gas Lens Screens In P/Ns
rienced person and electrical work by a trained electri- 45V63, 995795, and 45V64 (See Figure 3-1)
cian. Do not permit untrained persons to inspect, clean,
or repair this equipment. use only recommended re- Large diameter gas lens collet bodies contain re-
placement parts. placeable screens. If plugged by spatter, replace as
follows:
A. A poor shielding gas connection, or a leaky
hose, will not only waste gas but permit the entry A. With the collet body removed from the torch,
of minute amounts of air, sufficient to contami- remove the outer snapring (P/N 54N71). This
nate both the electrode and the weld. Trouble can be done by using a small screwdriver, or an
signs: a bluish cast on the electrode after it has electrode with a diameter no greater than 3/32
cooled; in welding aluminum, a dark gray de- in. Insert the tip in the slot on the outer sleeve of
posit on or beside the weld bead. the collet body, and pry out the snapring.
B. If the argon valve leaks or operates improperly, B. Using a pair of needle nose pliers, pry out the
disassemble the valve as follows: inner snapring (P/N 54N69).
1. Unscrew the valve stem assembly (P/N C. Hold the collet body with the screens down, and
598279) until it clears the torch body. gently tap the body on the work bench. The body
2. Lift out and inspect the valve stem assem- contains three fine and one coarse screens,
bly. If the stem or ball valve is damaged, separated by spacers. If the screens are not
replace the entire assembly with a new one. badly fouled, they should drop out of the body.
If the stem is in good condition, inspect the Excessive fouling may necessitate prying out
two "O" rings. If they are worn, replace with the screens.
new ones.
D. Inspect the screens and replace those which
NOTE show plugging or other damage.
Prior to installing the new "O" ring, apply a E. Replace the screens and spacers making sure
thin coat of silicone grease. that a spacer is installed between each screen,
and that the coarsest screen is inserted last.
3. Reinstall the valve stem assembly, making Replace the snaprings.
sure that the assembly is fully screwed into
SCREEN (250 mesh)
the torch body so that the ball valve will seat 54N66
properly when the valve is in the closed
position. SCREEN (100 mesh)
54N67
C. Do not try to repair concentric power cable,
replace it. Two piece cable and hose assemblies
INNER SPACER
may be repaired using the repair kits noted in 54N68
parts breakdown. The kits include replacement
fittings and lug for the cable and hose.
INNER SNAP-
RING
D. If an electrode becomes contaminated, shut off 54N69
power, then remove electrode from torch. Break
off the contaminated end (nicking with a grinding OUTER SNAPRING OUTER SPACER
wheel first will help) and replace electrode. 54N71 54N70
8
4.1 REPLACEMENT PARTS
A. Give the part number, description and quantity
The following illustrations of the HW-26, HW-26R, and of each part required.
HW-26F Torches identify each replacement part by
item number as tabulated in the related parts list. The B. Give part number and description of equip-
list identifies each part by part number, description, and ment on which the parts are to be used.
quantity used.
C. Indicate any special shipping instructions.
9
10 1
9
2
8
6 5/8" - 18RH
4
LD Gas Lens Access.
(See Tables 1-2, 1-3) Standard Access.
(See Tables 1-2, 1-3)
Gas Lens Access. 5
(See Tables 1-2, 1-3)
10
1
10 11
9 2
8
5/8" - 18RH
6
3
7
HW-26R, 25 ft 46V29R
HW-26RV, 25 ft 46V27R
11
10 11
9
1
8
7
2
6 5/8" - 18RH
HW-26F, 25 ft 33849
HW-26FV, 25 ft 33851