HW-9, HW-9R, & HW-9FTIG WELDING TORCHES

Covering the Hard Body, Silicone Rubber Body, and Flexible Head Models

Be sure this information reaches the operator.You can get extra copies through your supplier.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles ofoperation and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions andSafe Practices for Arc Welding, Cutting, and Gouging", Form 52-529. Do NOT permit untrained persons toinstall, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until youhave read and fully understand these instructions. If you do not fully understand these instructions, contactyour supplier for further information. Be sure to read the Safety Precautions (Section 1) before installing oroperating this equipment.

INSTRUCTION MANUAL

F-14-380-FJuly, 2000

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USER RESPONSIBILITYThis equipment will perform in conformity with the description thereof contained in this manual and accom-

panying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructionsprovided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment shouldnot 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 writtenrequest 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 manufac-turer. The user of this equipment shall have the sole responsibility for any malfunction which results from improperuse, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a servicefacility designated by the manufacturer.

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WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before

performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.

PROTECT YOURSELF AND OTHERS --Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.Training in the proper use of the processes and equip-ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any workarea, even if welding helmets, face shields, and gogglesare also required.

2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc andnot to expose themselves to the rays of the electric-arcor hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing

5. Protect other personnel from arc rays and hot sparkswith a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and ex-plosions. Therefore:

1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.“

3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.

SAFETY PRECAUTIONS

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5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.

6. After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when neces-sary.

7. For additional information, refer to NFPA Standard 51B,"Fire Prevention in Use of Cutting and Welding Pro-cesses", available from the National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.

1. Be sure the power source frame (chassis) is connectedto 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 fatalshock.

4. Use well-maintained equipment. Replace worn or dam-aged 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 fromwork and from ground.

7. Do not stand directly on metal or the earth while workingin tight quarters or a damp area; stand on dry boards oran 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 mis-take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —May be dangerous. Electric current flow-ing through any conductor causes lo-calized Electric and Magnetic Fields(EMF). Welding and cutting current cre-ates EMF around welding cables andwelding machines. Therefore:

1. Welders having pacemakers should consult their physi-cian before welding. EMF may interfere with some pace-makers.

2. Exposure to EMF may have other health effects which areunknown.

3. Welders should use the following procedures to minimizeexposure 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

from your body as possible.

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FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can cause asphyxiation.Therefore:

1. Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel,copper, zinc, lead, beryllium, or cadmium unless posi-tive mechanical ventilation is provided. Do not breathefumes from these materials.

2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene, a highly toxicgas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation is notadequate. Stop work and take necessary steps to im-prove ventilation in the work area. Do not continue tooperate 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 orcutting, produces fumes or gases whichcontain chemicals known to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety Code §25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, ifmishandled, can rupture and violentlyrelease gas. Sudden rupture of cylin-der, valve, or relief device can injure orkill. Therefore:

1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition. Followmanufacturer's operating instructions for mounting regu-lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chainor strap to suitable hand trucks, undercarriages, benches,walls, post, or racks. Never secure cylinders to worktables or fixtures where they may become part of anelectrical circuit.

3. When not in use, keep cylinder valves closed. Havevalve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitablehand 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 inCylinders", which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington,VA 22202.

EQUIPMENT MAINTENANCE -- Faulty orimproperly maintained equipment cancause injury or death. Therefore:

1. Always have qualified personnel perform the installa-tion, troubleshooting, and maintenance work. Do notperform any electrical work unless you are qualified toperform such work.

2. Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.

3. Maintain cables, grounding wire, connections, powercord, and power supply in safe working order. Do notoperate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keepequipment 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 positionand in good repair.

6. Use equipment only for its intended purpose. Do notmodify it in any manner.

ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices for elec-tric arc welding and cutting equipment, askyour supplier for a copy of "Precautions andSafe Practices for Arc Welding, Cutting andGouging", Form 52-529.

The following publications, which are available from theAmerican Welding Society, 550 N.W. LeJuene Road, Mi-ami, 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 Tung-

sten Arc Welding“6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have HeldHazardous Substances."

MEANING OF SYMBOLS - As used through-out this manual: Means Attention! Be Alert!Your safety is involved.

Means immediate hazards which, ifnot avoided, will result in immediate,serious personal injury or loss of life.

Means potential hazards which couldresult in personal injury or loss of life.

Means hazards which could result inminor personal injury.

SP98-10

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a. Éloigner suffisamment tous les matériaux combus-tibles du secteur où l’on exécute des soudures ou descoupes à l’arc, à moins de les recouvrir complètementd’une bâche non-inflammable. Ce type de matériauxcomprend notamment le bois, les vêtements, la sciure,l’essence, le kérosène, les peintures, les solvants, legaz naturel, l’acétylène, le propane et autres sub-stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-cent peuvent tomber dans des fissures du plancher oudans des ouvertures des murs et y déclencher uneignition lente cachée. Veiller à protéger ces ouverturesdes étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérationsde gougeage ou autres travaux à chaud à la surfacede barils, bidons, réservoirs ou autres contenantsusagés, avant de les avoir nettoyés de toute trace desubstance susceptible de produire des vapeursinflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, ilconvient de disposer d’un matériel d’extinction prêt àservir immédiatement, tel qu’un tuyau d’arrosage, unseau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteurde façon à vous assurer qu’aucune étincelle ou projec-tion de métal incandescent ne risque de provoquerultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arcau plasma exige l’emploi de tensions à viderelativement importantes; or, celles-ci risquent decauser des dommages corporels graves et mêmemortels en cas d’utilisation inadéquate. La gravité duchoc électrique reçu dépend du chemin suivi par lecourant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-sion venir au contact direct de la peau ou devêtements humides. Veillez à porter des gants biensecs.

b. Si vous devez effectuer un travail sur une surfacemétallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secset des chaussures à semelles de caoutchouc et envous tenant sur une planche ou une plate-formesèche.

c. Mettez toujours à la terre le poste de soudage/coupageen le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Nesurchargez jamais le câble. Utilisez toujours unéquipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas enservice. une mise à la masse accidentelle peut en effetprovoquer une surchauffe de l’équipement et un dan-ger d’incendie. Ne pas enrouler ou passer le câbleautour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce enun point aussi proche que possible de la zone detravail. Le branchement des câbles de masse àl’ossature du bâtiment ou en un point éloigné de lazone de travail augmente en effet le risque de pas-sage d’un courant de sortie par des chaînes delevage

PRÉCAUTIONS DE SÉCURITÉAVERTISSEMENT: Ces règles de sécurité ont pour objetd’ assurer votre protection. Veillez à lire et à observer lesprécautions énoncées ci-dessous avant de monter l’équipement ou de commercer à l’utiliser. Tout défautd’observation de ces précautions risque d’entraîner desblessures graves ou mortelles.1. PROTECTION INDIVIDUELLE-- Les brûlures de la

peau et des yeux dues au rayonnement de l’arcélectrique ou du métal incandescent, lors du soudageau plasma ou à l’électrode ou lors du gougeage àl’arc, peuvent s’avérer plus graves que cellesrésultant d’une exposition prolongée au soleil. Aussiconvient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaquesprotectrices et des verres filtrants appropriés afin devous protéger les yeux, le visage, le cou et les oreillesdes étincelles et du rayonnement de l’arc électriquelorsque vous effectuez des soudures ou des coupesou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximitéde façon à ce qu’elles ne regardent pas l’arc et à cequ’elles ne s’exposent pas à son rayonnement, ni àcelui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tuniqueépaisse à manches longues, des pantalons sansrebord, des chaussures à embout d’acier et uncasque de soudage ou une calotte de protection, afind’éviter d’exposer la peau au rayonnement de l’arcélectrique ou du métal incandescent. ll est égalementsouhaitable d’utiliser un tablier ininflammable defaçon à se protéger des étincelles et du rayonnementthermique.

c. Les étincelles ou les projections de métal incandes-cent risquent de se loger dans des manchesretroussées, des bords relevés de pantalons ou dansdes poches. Aussi convient-il de garder boutonnés lecol et les manches et de porter des vêtements sanspoches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arcélectrique les autres personnes travaillant à proximitéà l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécuritélorsque vous vous trouvez dans un secteur où l’oneffectue des opérations de soudage ou de coupage àl’arc. Utilisez des lunettes de sécurité à écrans ouverres latéraux pour piquer ou meûler le laitier. Lespiquetures incandescentes de laitier peuvent êtreprojetées à des distances considérables. Lespersonnes se trouvant à proximité doivent égalementporter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasmaproduisent un niveau de bruit extrêmement élevé (de100 à 114 dB) et exigent par conséquent l’emploi dedispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections delaitier incandescent ou d’étincelles peuventprovoquer de graves incendies au contact dematériaux combustibles solides, liquides ou gazeux.Aussi faut-il observer les précautions suivantes:

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des câbles de grue ou divers chemins électriques.g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement detravail, des câbles, du porte-électrode et du poste desoudage/coupage. Réparez immédiatement toutefuite d’eau.

4. VENTILATION-- La respiration prolongée des fuméesrésultant des opérations de soudage/coupage, àl’intérieur, d’un local clos, peut provoquer des mal-aises et des dommages corporels. Aussi convient-ild’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate del’emplacement de travail en maintenant une ventila-tion naturelle ou à l’aide de moyens mécaniques.N’effectuez jamais de travaux de soudage ou decoupage sur des matériaux de zinc, de plomb, deberyllium ou de cadmium en l’absence de moyensmécaniques de ventilation capables d’empêcherl’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou decoupage à proximité de vapeurs d’hydrocarburechloré résultant d’opérations voisines de dégraissageou de pulvérisation. La chaleur dégagée ou lerayonnement de l’arc peut déclencher la formation dephosgène -- gaz particulièrement toxique -- et d’autresgaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de lagorge constatée au cours de l’utilisation del’équipement dénote un défaut de ventilation. Arrêtez-vous de travailler afin de prendre les mesures néces-saires à l’amélioration de la ventilation. Ne poursuivezpas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisationsoù circule de l’hydrogène. L’armoire de commande estmunie d’un ventilateur destiné à empêcher la forma-tion de poches d’hydrogène, lesquelles présentent undanger d’explosion; ce ventilateur ne fonctionne quesi l’interrupteur correspondant du panneau avant setrouve placé en position ON (Marche). Veillez àmanœuvrer cette commande en vérifiant si lecouvercle est bien en place, de façon à assurerl’efficacité de la ventilation ainsi réalisée. Ne jamaisdébrancher le ventilateur.

e. Les fumées produites par l’opération de soudage oude coupage peuvent s’avérer toxiques. Aussi est-ilnécessaire de disposer en permanence d’un dispositifadéquat de ventilation de type aspirant, afin d’élimi-ner du voisinage de l’opérateur tout dégagement defumée visible.

f. Consultez les recommandations particulières enmatière de ventilation indiquées à l’alinéa 6 de lanorme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipemententretenu de façon défectueuse ou inadéquate risquenon seulement de réaliser un travail de mauvaisequalité mais, chose plus grave encore, d’entraîner des

dommages corporels graves, voire mortels endéclenchant des incendies ou des chocs électriques.Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-lifié l’installation, le dépannage et l’entretien du postede soudage et de coupage. N’effectuez aucuneréparation électrique sur l’équipement à moins d’êtrequa-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretienquelconque à l’intérieur du poste de soudage/coupage, avant d’avoir débranché l’alimentationélectrique.

c. Maintenez en bon état de fonctionnement les câbles,le câble de masse, les branchements, le cordond’alimentation et le poste de soudage/coupage.N’utilisez jamais le poste ou l’équipement s’il présenteune défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et deséquipements accessoires. Gardez-les à l’écart dessources de charleur, notamment des fours, del’humidité, des flaques d’eau maintenez-les à l’abri destraces d’huile ou de graisse, des atmosphères corro-sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tousles panneaux de l’armoire de commande en veillant àles garder en bon état.

f. Utilisez le poste de soudage/coupage conformément àson usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVESÀ LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur lesrègles de sécurité à observer pour le montage etl’utilisation d’équipements de soudage et de coupageélectriques et sur les méthodes de travailrecommandées, demandez un exemplaire du livret N°52529 “Precautions and Safe Practices for Arc Weld-ing, Cutting and Gouging” publié par ESAB. Nousconseillons également de consulter les publicationssui-vantes, tenues à votre disposition par l’AmericanWelding Society, 550 N.W. LeJuene Road, Miami, FL32126:

a. “Safety in Welding and Cutting” AWS Z49.1b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.d. “Recommended Safe Practices for Plasma Arc Cutting”

AWS-A6. 3.e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

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SECTION 1 INTRODUCTION

1.5 Collets

Collets are available for each of the five electrode sizes.The collet bodies come in both standard and gas lensstyles. See Table 1-2.

1.6 Cups

For use with standard collet bodies: standard ceramicor high-impact ceramic. For use with gas lens colletbodies: high-impact ceramic only. See Table 1-3.

1.7 Optional Accessories

A. Short Cap (41V33) for use with 2-in. electrodes;long cap (41V24) for use with 7-in. electrodes.

B. Braided nylon sheath to protect service lines -P/N 2075198 (9-ft long) and P/N 2075200 (20-ftlong).

C. Gas lens collet body wrench (59K07).

D. Tig Accessory Kit (999127) includes three collets,three collet bodies, three 7-in. long 2% thoriatedelectrodes (each in 1/16-in., 3/32-in., and 1/8-in.sizes), three high impact cups (Nos. 5, 6, and 7),and one long torch cap.

1.1 General

During DCSP operation, each torch in the HW-9 family israted at 120 A continuous duty and 140 A at 50% dutycycle. During ACHF operation, each torch is rated at 85A continuous duty and 100 A at 50% duty cycle. All thetorches are air-cooled.

1.2 Torch Dimensions

Overall Length .............................. 6-7/8 in. (175 mm)Handle Diameter ................................ 3/4 in. (19 mm)Head Diameter .................................. 3/4 in. (19 mm)Height of Torch Head ................... 3-9/32 in. (83 mm)- with Std. Medium Cap ................ 3-9/32 in. (83 mm)- with Opt. Short Cap .................... 2-5/16 in. (59 mm)- with Opt. Long Cap ................... 7-5/16 in. (186 mm)Weight (less cable and hose) ........... 3.5 oz (100 gm)Head Angle .................................................... 70 deg.

1.3 Required Accessories/Services

A. Collet, collet body, electrode, and cup. Seebelow.

B. Shielding gas regulator/flowmeter (if cylindergas is used) OR flowmeter (if gas is piped).

C. Gas hose, 12-1/2-ft long (P/N 40V77) or 25-ftlong (P/N 34V38) connects between regulator/flowmeter and torch cable and hose assembly.

D. Welding power source and shielding gas supply.

E. Power Cable Adaptor (P/N 105Z57) for connect-ing torch power cable to power source and gassupply. Not required on HW-9R part numbers34561 and 34562.

1.4 Electrodes

Each Torch model uses .020-inch thru 1/8-inch diameterelectrodes. The 2-inch, 3-inch, and 7-inch long standardtorch cap is designed for 3-inch electrodes. A short capfor the 2-inch electrode and a long cap for the 7-inchelectrode are available as optional accessories. SeeTable 1-1.

SECTION 1 INTRODUCTION

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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-Impact Cup Ceramic Cup No.tungsten thoriated electrodes tungsten electrodes in Inches No.

electrodes ***

5-15 5-20 5-20 --- .020 (0.5 mm) 4 4-510-60 15-80 15-80 --- .040 (1.0 mm) 4-5 4-5

50-100 70-150 70-150 10-20 1/16 (1.5 mm) 4-5-6 4-5-6100-160** 140-235** 150-250** 15-30 3/32 (2.4 mm) 5-6-7-8 6-7-8

--- --- --- 25-40 1/8 (3.2 mm) 6-7-8-10 7-8-10

* The maximum current values shown in the table for ACHF have been determined using an unbalanced wave transformer. If a balanced wave transformer isused, either reduce the maximum values in the table by about 30 per cent or use the next larger size electrode. This is necessary because of the higher heatinput to the electrode in a balanced wave setup.

NOTE: All current values are metered readings. Most transformers deliver about 15 per cent more current than shown on their scale readings.

** Exceeds the rated capacity of the torch.*** Balled electrode tip ends can best be formed and maintained at these AC current levels.

Table 1-3. Gas Cups

Cup No. 4 5 6 7 8 10High-Impact Cup 13N08 13N09 13N10 13N11 13N12 13N13Ceramic Cup 13N14 13N15 13N16 13N17 13N18 13N19Gas Lens High-Impact Cup 53N58 53N60 53N60 53N61 --- ---

Table 1-2. Collets and Collet Bodies

Size (In.) .020 .040 1/16 3/32 1/8Collet 13N20 13N21 13N22 13N23 13N24Collet Body 13N25 13N26 13N27 13N28 13N29Gas Lens Collet Body* 45V41 45V42 45V43 45V44 45V45

* To prevent damage to gas lens in dc welding applications, use thoriated electrodes.

SECTION 2 INSTALLATION AND OPERATION

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2.1 Setup and Installation

A. Connect the regulator/flowmeter to a gas cylin-der. Refer to the instructions supplied with theregulator/flowmeter for details on attachingand adjusting the regulator.

B. Connect one end of the gas hose (P/N 40V77or 34V38) to the regulator outlet and the otherend to the torch cable adaptor (105Z57).

C. Connect the power cable adaptor to the weld-ing power source, either directly or through asuitable length of welding cable fitted with lugs.

D. Install collet body, collet, electrode, and cup ontorch (see Figure 2-1) as follows:

1. Screw in collet body.

2. Screw on cup. (The gasket assembled tothe torch body, as supplied, will seal bothstandard and gas lens cups. For welding inargon chambers, this gasket, however, isnot suitable. See NOTE on parts drawingfor substitutions for chamber welding.)

3. Remove torch cap and slide collet intoposition (tapered end first).

4. Slip electrode down through hole in top ofcollet until end of electrode extends be-yond rim of cup. (Exact extension is vari-able from as little as 1/8 inch for buttwelding with standard collet bodies to 3/4inch or more for corner or fillet welds withgas lens collet bodies and cups.)

5. Screw on the torch cap and tighten. Thecap will press down on the collet to grip theelectrode securely. To readjust electrode,loosen torch cap.

2.2 Operating Instructions

A. Make sure that all argon connections in thesystem have been securely tightened and thatthe torch cap has been well-tightened.

B. With the regulator flow-adjusting valve closed,open the gas cylinder or station valve.

C. Set the power source for the desired weldingcurrent.

Figure 2-1. Exploded View of HW-9

D. Open all shielding gas valves downstreamfrom the flowmeter or flowmeter/regulator (e.g.,valve on torch, lever-operated shutoff valve, orsolenoid-operated valve in power source).

E. Set shielding gas flow to the desired level, asregistered on flowmeter tube or gauge.

NOTE

Purge the gas hose by allowing the gas to flow longenough (up to 15 minutes on new torch; less than 5minutes thereafter) to drive out air and moisture. Thiswill help prevent weld contamination.

F. Close control switch at work position or atpower source.

G. Draw a test arc on a heavy piece of scrap steelor copper. (Do not use a carbon block. It willtend to contaminate the electrode.)

H. If the test arc is satisfactory, commence weld-ing.

(2) CAP "O" RINGMEDIUM TORCH CAP

3 INCH ELECTRODE

ELECTRODE COLLET

TORCH BODY

CUP GASKET

COLLET BODY

"O" RING

CUP

SECTION 3 MAINTENANCE

10

3.1 Maintenance

If this equipment does not operate properly, stopwork immediately and investigate the cause of themalfunction. Maintenance work must be performedby an experienced person and electrical work by atrained electrician. Do not permit untrained per-sons to inspect, clean, or repair this equipment.Use only recommended GENUINE HELIARC re-placement parts.

A. A poor shielding gas connection, or a leakyhose, will not only waste gas but permit theentry of minute amounts of air, sufficient tocontaminate both the electrode and the weld.Trouble signs: a bluish cast on the electrodeafter it has cooled; in welding aluminum, a darkgray deposit on or beside the weld bead.

B. Keep the torch power cable away from hotmetal.

C. Do not try to repair concentric power cable,replace it. Two piece cable and hose assem-blies may be repaired using the repair kitsnoted in parts breakdown. The kits includereplacement fittings and lug for the cable andhose.

D. If an electrode becomes contaminated, shutoff power, then remove electrode from torch.Break off the contaminated end (nicking with agrinding wheel first will help) and replace elec-trode.

E. Keep an eye on the sealing "O" ring on the torchcap. If it shows signs of wear or distortion, cutit off. Then install new ring (P/N 181W53) usingthe assembly tool (P/N 13N42) supplied withthe torch. Apply a little silicone grease to thenew ring before attempting to slide it over thetool and into the cap groove.

SECTION 4

4.1 Replacement Parts

The following illustrations of the HW-9, HW-9R, andHW-9F Torch identify each replacement part by itemnumber as tabulated in the related parts list. The listidentifies each part by part number, description, andquantity used.

4.2 Ordering

To assure proper operation, it is recommended thatonly genuine ESAB parts and products be used with thisequipment. The use of non-ESAB parts may void yourwarranty.

Replacement parts may be ordered from your ESABdistributor or from:

ESAB Welding & Cutting ProductsAttn: Customer ServiceP.O. Box 100545411 S. Ebenezer RoadFlorence, SC 29501-0545

A. Give the part number, description and quantityof each part required.

B. Give part number and description of equip-ment on which the parts are to be used.

C. Indicate any special shipping instructions.

For technical assistance directly from an ESAB servicerepresentative, call (803)664-4416. Additionally, ESABoffers a toll free facsimile (FAX) service via 1-800-446-5693.

PARTS

11

SECTION 4 PARTS

Figure 4-1. HW-9 Hard Body Torch Components

ITEM QTY. PARTNO. REQ. NO. DESCRIPTION

1 1 53N06 HANDLE2 1 997022* POWER CABLE RUBBER (12-1/2 FT.)

1 997023* POWER CABLE RUBBER (25 FT.)3 1 105Z57 POWER CABLE ADAPTER (Required Accessory)4 1 598882 CUP GASKET (See Note in illustration above)5 1 19686 BODY (includes “O” ring 85W49 & cup gasket 598882)6 1 41V33 CAP, SHORT (includes “O” ring 181W53) (Optional)7 1 41V35 CAP, MEDIUM (includes “O” ring 181W53)8 1 41V24 CAP, LONG (includes “O” ring 181W53) (Optional)

Table 4-1. HW-9 Hard Body Assemblies

HW-9, 70 deg., 12-1/2 ft. 19684HW-9, 70 deg., 25 ft. 19685

6 78

4 (See Note)

5

Gas Lens Access.(See Tables 1-2, 1-3)

Standard Access.(See Tables 1-2, 1-3)

3

2

1

NOTE: For chamber welding, replace 598882 with Gasket 598563 for stan-dard cup, with “O”ring 526185 for gas lens cup.

*Optional PVC Power Cable 57Y01 (12 1/2 ft.); 57Y03 (25 ft.)

3/8 - 24 3/8 - 24

SECTION 4 PARTS

12

Figure 4-2. HW-9R Silicone Rubber Torch Components

ITEM QTY. PARTNO. REQ. NO. DESCRIPTION

1 1 105Z55R HANDLE, RIBBED2 1 33946 TWO PIECE CABLE & HOSE ASSY. (12-1/2 FT.)

1 33947 TWO PIECE CABLE & HOSE ASSY. (25 FT.)1 34651 REPAIR KIT FOR TWO PIECE CABLE & HOSE ASSY.

3 1 598882 CUP GASKET (See Note in illustration above)4 1 34563 BODY W/VALVE (includes valve stem 19621)

1 19621 VALVE STEM (includes “O” ring 598869)5 1 41V33 CAP, SHORT (includes “O” ring 181W53)6 1 41V35 CAP, MEDIUM (includes “O” ring 181W53)7 1 41V24 CAP, LONG (includes “O” ring 181W53)8 1 19686 BODY

Table 4-2. HW-9R Silicone Rubber Assemblies

HW-9RV-2, 70 deg., 12-1/2 ft. 34561HW-9RV-2, 70 deg., 25 ft. 34562HW-9-2, 12-1/2 ft. 37740HW-9-2, 25 ft. 37741

5 67

4

1

2

3 (See Note)

Lg. Dia.Gas LensAccess.(See Tables 1-2, 1-3)

Standard Access.(See Tables 1-2, 1-3)

NOTE: For chamber welding, replace 598882 with Gasket 598563 for stan-dard cup, with “O”ring 526185 for gas lens cup.

3/8 - 245/8 - 18

8

13

SECTION 4 PARTS

Figure 4-3. HW-9AF Flexible Head Torch Components

ITEM QTY. PARTNO. REQ. NO. DESCRIPTION

1 1 105Z55 HANDLE2 1 997022* POWER CABLE RUBBER (12-1/2 FT.)

1 997023* POWER CABLE RUBBER (25 FT.)3 1 105Z57 POWER CABLE ADAPTOR (Required Accessory)3 1 598882 CUP GASKET (See Note in illustration above.)4 1 19924 BODY, FLEX5 1 41V33 CAP, SHORT (includes “O” ring 181W53) (Optional)6 1 41V35 CAP, MEDIUM (includes “O” ring 181W53)7 1 41V24 CAP, LONG (includes “O” ring 181W53) (Optional)

6 7 8

1

2

3

Standard Access.(See Tables 1-2, 1-3)

Gas LensAccess.(See Tables 1-2, 1-3)

NOTE: For chamber welding, replace 598882 with Gasket 598563 for stan-dard cup, with “O”ring 526185 for gas lens cup.

Table 4-3. HW-9AF Flexible Head Torch Assemblies

HW-9AF (variable), 12-1/2 ft. 19922HW-9AF (variable), 25 ft. 19923

5

4 (See Note)

3/8 - 24

3/8 - 24

* Optional PVC Power Cable 57Y01 (12 1/2 ft.); 57Y03 (25 ft.)

SECTION 4 PARTS

14

15

SECTION 4 PARTS

F-14-380-F 7/2000 1M Printed in U.S.A

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

A. CUSTOMER SERVICE QUESTIONS:Order Entry Product Availability Pricing DeliveryOrder Changes Saleable Goods Returns Shipping Information

Eastern Distribution Center Telephone: (800)362-7080 / Fax: (800) 634-7548

Central Distribution Center Telephone: (800)783-5360 / Fax: (800) 783-5362

Western Distribution Center Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM ESTWarranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM ESTPerformance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:Telephone: (843)664-4428 / Fax: (843) 679-5864Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:Telephone: (800) ESAB-123 / Fax: (843) 664-4454 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

ESAB Welding & Cutting Products, Florence, SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES