EXTOL 8798271 TIG Torch Instruction Manual

8798271 TIG Torch
Instruction Manual

**** Translation of the original user‘s manual

Introduction

Dear customer,
Thank you for the confidence you have shown in the Extol® brand by purchasing this product. This product has been tested for reliability, safety and quality according to the prescribed norms and regulations of the European Union.
Contact our customer and consulting centre for any questions at: www.extol.eu [email protected]
Manufacturer: Madal Bal a. s., Průmyslová zóna Příluky 244, 76001 Zlín, Czech Republic
Date of issue: 30. 5. 2017

Features and purpose of use

Extol® Industrial 8798271 TIG Torch is intended for connection to a welding current source that enables welding with the TIG welding method and is equipped with quick-connect connectors 35-50, e.g. for DC welding inverters Extol® Industrial 8796011
(with max. welding current of 160 A) and 8796012 (with max. welding current of 200 A).
The necessary equipment and preparation preceding TIG welding should be described in the user‘s manual of the welding current source.
The connection of the torch to the power cable is via an elbow by means of which it the torch can be easily and finely handled regardless of the toughness of the power cable.
The TIG welding method is very effective for welding stainless steel and steel, primarily cast iron, and furthermore copper, titanium and nickel.

Length of power cable: approx. 3,8 m
The length of the hose for connection to argon: approx. 5,5 m
Diameter of tungsten electrode: 2.4 mm
Type of tungsten electrode: WC20 (grey) (we reserve the right to change the
colour designation of the electrode with respect to the specified type),
Electrode intended for metals: aluminium, stainless steel, carbon steel, bronze,
titanium, copper
Electrode holding collet: 2.4-3/32, length 50 mm.
Size of ceramic cup: 7 mm
Inner diameter of ceramic cup: 11 mm
Argon connection hose thread: G1/4″
The torch is intended for electrodes of diameter: 0.5-4 mm
Max. welding current: 200 A DC
Torch load factor: 60% 200 A (DC)/ 150 A (AC)
Rated ignition voltage: based on idle voltage U0 of the used welding power source (usually in
the range 60-70 V DC) Rate stabilisation voltage in relation to the set welding current according to formula: U=10+0,04 × I
Cooling: by air
Shielding gas: argon
Torch is manually guided
Meets requirements of standard: EN 60974-7
The torch is complete, ready for use

Parts and control elements

Fig. 1, position-description

1. Tungsten electrode
2. Ceramic cup
3. Tungsten electrode back cap (for setting the stick-out from the cup)
4. Shielding gas flow rate regulator
5. Handle
6. Flexible elbow
7. Supply line
8. Quick coupler 35-50 for connection to a welding unit
9. Shielding gas source connection nut

ASSEMBLY AND PARTS OF THE TIG TORCH

1. Screw the collet body B into the torch C.
2. Screw the ceramic cup A on to the thread of collet body B
3. Insert electrode E into collet D and then insert it into the collet body B in the torch
4. Set the length of the electrode‘s stick-out length from the nozzle and then fasten the electrode in place by tightening back cap F

WARNING
All installation and maintenance performed on the welding unit must be performed with the el. current into the welding unit disconnected.
a) Connect the TIG welding torch to the negative (-) quick coupler on the welding unit and the grounding cable with clamp to the positive (+) terminal on the welding unit. In this case, it is the reverse of the MMA method.

b) Loosen the back cap to set the length of the electrode‘s stick-out from the ceramic cup to 2-3 mm; in the case of corner welds it can be set up to 8 mm.
c) Connect the gas hose of the TIG torch to the outlet fitting on the flow meter connected to a reduction valve on a argon pressure bottle.
On the argon outlet from the bottle, use the first reduction valve to set a pressure of 5-10 bar and on the second argon outflow reduction valve set a pressure of 2 bar, however, no greater than 2.5 bar.
The set pressure will be shown by the hand on the pressure meter scale. Argon flow meters are usually designed for a max. pressure of 2.5 bar, but the maximum permitted argon pressure for the flow meter must, nevertheless, be checked against the information of the flow meter‘s manufacturer.
A bottle with argon of required purity (99.9%) and the reduction valve can be purchased from a vendor of technical gases and the flow meter for TIG/argon in a welding supplies store.
d) Use the flow meter to set the argon flow rate of the TIG welding torch according to the recommended flow rate provided in table 2.
The required flow rate differs based on the specifications provided in the table. The TIG welding torch is equipped with a valve for supplying argon to the torch.

Table 2

Welding current
(A)| Electrode diameter (mm)| Ceramic cup *)| Argon flow rate (I/min)
---|---|---|---
Size| Diameter
6-70| 1.0| 4; 5| 6.5; 8.0| 5-6
60-140| 2.| 4; 5; 6| 6.5; 8.0; 9.5| 6-7
120-240| 2.| 6;7| 9.5; 11.0| 7-8
190-250| 3.| 7;8| 1113.| 8-9

e) Before starting welding, it is necessary to thoroughly remove any present air in the TIG torch and supply hose by releasing argon into the torch and to allow it to flow through the system long enough to push all the air out of the system.
Argon serves as an anti-oxidation protection of metals against oxygen, which are in contact with the welding arc and with the welding puddle at high temperature to prevent their oxidation.
f) Connect the welding unit to the el. power source and set the power switch to the „On“ position. On the welding unit, set the welding method selection switch to the position with the TIG welding symbol and turn the control knob to set the required welding current.
The TIG welding method can be used to either melt together the edges of a welded material (i.e. without the use of additional material, i.e. without a filler rod), or with additional material by melting the end of a welding filler rod made with similar composition to the material being welded. Based on the type of material being welded, the filler rod can be purchased at a welding supply store. During manual TIG welding, the welder holds the filler rod in one hand and the TIG torch in the other, whilst gently pushing the end of the filler rod into the welding arc between the TIG torch electrode and the welded material, by which the end of the filler rod is melted and the welder self-regulates the amount of material added to the welding puddle as necessary.
The TIG welding principle is described in the following figure.Fig. 4, TIG method principle with the use of a filler rod
g) Assume a comfortable position, e.g. when sitting down, place the electric cable with the hose for the supply of el. current over your shoulder for easier handling of the TIG torch with you hand and to feel comfortable during work. Grasp the TIG torch in your hand like a writing implement, e.g. a pen. When adding melted metal into the welding puddle, hold the filler rod in your other hand similarly to that of a writing implement, e.g. a pen. Put the welding helmet shield over your face and with argon flowing, place the tip of the TIG torch electrode on to the welded material. Then lift the electrode 2-3 mm above the surface to ignite the welding arc between the electrode and the welded material. In the event that an arc is not ignited, gently scratch the surface of the surface of the welded material with the electrode tip and then lift the electrode 2-3 mm off the surface of the material. Once the arc is ignited, gently lead the TIG torch in the direction of the weld line, whilst each time you move the torch, insert the end of the filler rod into the welding arc to melt it. The filler rod is, therefore, not constantly inserted in the welding arc, but rather, must be inserted during the movement of the TIG torch to create a continuous weld bead from the added material, by which the quality of the weld can be
affected. To prevent its oxidation, the melted end of the filler rod must also be under the shielding flow of gaseous argon. In the event that you will use a filler rod when welding, it may be useful to first pre-weld the weld line only with the TIG torch without the additional material. This may contribute to a better connection of the welded material with additional material.
The following figure shows how the welding torch and the filler rod are held during the TIG welding process. h) After use, carefully disconnect the welding burner from the welding current source and prevent it from coming into contact with grounded parts. This welding method requires a certain degree of practice and personal experience with the welding of various types of materials. There are many illustrative videos on Youtube showing how to weld using this method and the necessary equipment and its preparation, for example an excellent video with commentary in English is „Welding Basics & How-to TIG Weld“ (part 1 and 2).
In the event that the electrode tip in the TIG torch melts off, it is necessary to precisely grind it into a point and a quality cone according to the procedure described in paragraph Maintenance and servicing.
ATTENTION
a) A welding current that is too low results in an unstable welding arc.
b) A welding current that is too high damages the tip of the electrode of the TIG torch, which results in disharmonious arc burning.
c) Deficiencies caused by the incorrect guidance of the TIG torch or incorrect addition of additional material from the filler rod.

BASIC SAFETY INSTRUCTIONS

**** WARNING
When using a welding unit, the welder must use a special welder‘s helmet equipped with welding filters with darkness levels based on the set welding current and based on the welding method used, as per table 3 below. For eye protection during welding, it is necessary to look through a welding helmet filter with a corresponding filter darkness in DIN units. This information must be shown on the helmet‘s welding filter. When using a welding helmet with an auto-darkening filter, the darkness of the filter is set using the manual control element to the required darkness, otherwise eye damage may result; in any case, the welding helmet must have the necessary darkness range in DIN units. The used welding helmet must meet the requirements of valid standards and respective annexes, namely standards EN 175, EN 169, EN 166 respectively EN 379+A1 (this norm applies only for auto-darkening welding filters), otherwise injury to the vision or face of the user could result. Set/select the filter darkness intensity based on the welding current according to the following table 3. Never look into the location of the weld without the required welding helmet with the required filter darkness and prevent access to persons without required protective equipment and access to animals. Do not use damaged or worn out personal protective equipment, e.g. a welding helmet with a cracked filter.

SYMBOL EXPLANATIONS

• SMAW = Shielded metal arc welding (manual arc welding with a coated electrode)
• MIG (heavy) = Metal inert gas welding (arc welding of heavy metals with an electrode in inert gas)
• MIG (light) = Metal inert gas welding (arc welding of light alloys with an electrode in inert gas)
• TIG, GTAW = Tungsten inert gas, Gas tungsten arc welding (arc welding with tungsten electrode in inert gas)
• MAG/CO2 = Metal active gas (arc welding with melting electrode in active gas)
• SAW = Submerged arc welding (automatic welding under flux)
• PAC = Plasma arc cutting
• PAW = Plasma arc welding
• Furthermore, other personal protective aids must be used: suitable protective work clothing, gloves, leather work footwear for protection against flying sparks, slag and burns. Likewise, it is necessary to ensure that the welder does not inhale the smoke emissions created during the welding process because they are damaging to health. The welder must use an appropriate breathing mask. Exhaust for the emissions and ventilation must be provided for. Consult the suitability of the usability of personal protective aids at a personal protective aids store. Prevent access to persons without the required personal protective aids to the welding location. Ensure sufficient distance of persons without personal protective aids and animals from the welding location, and when appropriate, inform persons without welding helmets that may come in the vicinity of the welding location not to look into the welding location, as otherwise their vision may be damaged. When appropriate, protect the welding location by means of suitable protection against unwanted views of passerbys into the welding location.
• Prevent the use of the welding unit by children, persons with reduced mobility, mental perception or mental disorders, or persons with insufficient experience or knowledge or persons not acquainted with these instruction to not use this equipment. Children must not play with the welding unit. National regulations may limit the age of the user.
• A welding unit creates an electromagnetic field during operation, which may negatively affect the operation of active or passive medical implants (pacemakers) and threaten the life of the user. Prior to using this power tool, ask a doctor or the manufacturer of the implant, whether you may work with this power tool. y Prior to welding, it is necessary to check that no hidden electrical wires or cables, gas or water lines, etc. will be impacted by the welding process. Otherwise there is a risk of injury, explosion or other damages.
• The welded workpieces, electrode clamps and the area around the welding unit are very hot and there is a risk of burns. Take steps to prevent burns. Also inform the people around you if there is a possibility of them coming into contact with the welding location. Prevent access to children.
• The work environment must be perfectly ventilated or the welder must wear protection against the inhalation of fumes.
• The safety instructions for welders, welders of metals and for arc welding are provided in national standards or directives; in the Czech Republic these standards are ČSN 050601, ČSN 050630 as further amended. In different states, other technical regulations and standards apply.
• Regular audits of electrical parts of the welding current source are performed by an electrical audit technician or an authorised qualified person in the extent and deadlines specified by Czech national standard ČSN 33 1500. Requirements may differ as per the regulations of a different state. Requirements for regular inspections and audits of arc welding equipment are governed by a European standard.
• Do not weld with power cords and welding cables with insufficient conductor core cross-section. For reason of cooling by ambient air, conductors (cables) must be unwound.
• In the event that the TIG burner or power cord or welding cables overheat, stop welding in order to prevent damaging the insulation.
• Never touch the charged parts of the electrical circuit. After use, carefully disconnect the welding burner from the welding current source and prevent it from coming into contact with grounded parts.
• When welding alloys and metals containing toxic metals such as lead, mercury, cadmium, zinc and beryllium, it is necessary to adhere to special safety regulations and prevent the inhalation of smoke emissions containing toxic metal fumes by means of gas masks, etc.
• To prevent the release of toxic gases while welding, thoroughly remove any paint coats, grease and other substances from the parts being welded.
• Always thoroughly ventilate work locations. Do not weld in locations where there is a suspicion of leaking natural gas or another flammable gas or in the vicinity of combustion engines.
• Do not weld in an environment or in the vicinity of liquid chlorofluorocarbons (e.g. in degreasing pans), since during the welding process UV radiation is created, which transforms chlorofluorocarbon fumes into highly toxic gases.
• For safety reasons, welding work must not be performed on tanks containing flammable substances (tanks storing gas, oils, fuels, etc.), pressure tanks, etc. This presents an explosion or fire hazard. Welding works must not be performed even on empty storage tanks used for flammable substances or empty pressure tanks. Welding must be performed pursuant to special regulations and the tanks must pass audit tests prior to being filled up. For welding in an environment with an explosion hazard, special safety regulations apply.
• In the event that it is necessary to use the source of the welding current on a sloping surface, it must be secured against overturning, sliding off or falling. The equipment has perfect stability up to an incline of 10 %.
• Welding current (arc) must not be used for defrosting pipes.
• When working in heights, it is necessary to ensure the secure stability of the welder, the source of the welding current and the welding cables, and to ensure that accidents cannot occur as a result of tripping on the welding cables or that long welding cables do not hang from a height and by their weight overturn or pull down the welding unit from the height downwards. It is necessary to minimise the risk of the welding unit and the welder falling from a height.
• For safety reasons, the welding work must not be performed on metals containing inner fillings (e.g. pipes filled with water, flammable substances, pressurised steam, pressure vessels filled with gases, etc.), otherwise this presents a fire, explosion and injury, etc. hazard.
• The welding current source must not be operated in an environment with an explosion or fire hazard. Do not weld materials that contained flammable substances, or materials that create toxic or flammable fumes when heated. Do not start welding before identifying the substances that the materials contained. Even a very small amount of flammable gas or liquid may be the cause of a fire or explosion.
• Never use a gas other than argon in the TIG torch.
• To minimise the risk of tripping over a welding cable or power cord, or burns, prevent access to persons without necessary protective aids as well as animals and children.
• Ensure that insulation on the power cord or welding cables cannot be damaged by flying sparks, slag, etc. It is necessary to adhere to fire safety rules when working (e.g. do not place flammable materials on hot surfaces, etc.).
• The user or the user‘s employer must assess the specific risks that may arise as the result of every use. The user bears responsibility for foreseeable incorrect use if according to experience it could occur.

Storage

• Store the cleaned equipment and cooled accessories in a safe location that is out of reach of children where temperatures do not exceed 40°. Protect the tool against direct sunlight, radiant heat sources, humidity and ingression of water.

Maintenance, servicing, warranty

GRINDING THE ELECTRODE

• If the electrode is not sharp as per fig.6A, then it is necessary to grind it into a point along its longitudinal axis with a regular cone so that the tip is centred, which is necessary to ensure that the welding arc does not deviate. Fine grinding with a perfect cone has a fundamental effect on the lifetime of the electrode, quality and the welding process. A cone with a rough surface burns away faster. An incorrectly ground electrode needs to be ground more frequently.The optimal grinding result with an even cone can be achieved by fastening the electrode into a cordless drill (at an appropriate low speed) and while the electrode is rotating, place it on a sanding belt of a belt grinder, on which a grinding line is marked and
  from which the electrode should not deviate during grinding. During the grinding process, it is necessary to maintain the angle of the cordless drill relative to the level of the grinder as required because the angle of the cone has an effect on the necessary  welding current. It generally applies that the greater the angle between the sides of the cone (fig.8), the greater the welding current that needs to be set than would otherwise be required for a cone with a lower pitch, see table 4.

The electrode will need to be reground regularly depending on the wear of the electrode or in the case of undesirable contamination occurring.
RELATIONSHIP BETWEEN GROUND CONE ANGLE ON THE TUNGSTEN ELECTRODE AND THE WELDING CURRENT Table 4

• Original parts from the manufacturer must be used for any repairs and the repairs must be performed by a person with necessary professional qualifications.
• For warranty repairs of the product, please contact the vendor from whom you purchased the product and they will organise repairs at an authorised service centre for the Extol® brand. For a post warranty repair, please contact the authorised service centre of the Extol® brand directly (you will find the repair locations at the website at the start of this user‘s manual).
• Original parts from the manufacturer must be used for any repairs and the repairs must be performed by a person with necessary professional qualifications.
• Free warranty repairs relate only to manufacturing defects on the product (hidden and external) and do not relate to the wear of the product as a result of excessive load or normal use or damage of the product caused by incorrect use.
• In the event of a dispute between the buyer and the vendor in respect to the purchase contract that was not resolved directly between the parties, the buyer has the right to the trade inspection authority for an out-of-court settlement of the a consumer dispute. At the website of the trade inspection authority there is a link to the tab „ADR-amicable dispute resolution“.

Waste disposal

PACKAGING MATERIALS
Throw packaging materials into a container for the respective sorted waste.
ELECTRICAL EQUIPMENT AND CONDUCTORS / TIG TORCH
Do not dispose of unserviceable commodities in household waste, but dispose of them in an environmentally safe manner. According to Directive 2012/19 EU, electrical appliances must not be thrown out with household waste, but rather handed over for ecological disposal at an electrical equipment disposal point. You can find information about collection points and collection conditions at your local town council office.

Reference to the pictogram and label

Table 5

| Read the user’s manual before use.
---|---
****| Meets respective EU requirements.
| Electrical waste (see above).
Max. 200 A| Max. current load on the TIG torch

EU Declaration of Conformity
Manufacturer Madal Bal a.s. • Bartošova 40/3, 760 01 Zlín • Company ID No.: 49433717 hereby declares that the device designated below, based on its concept and design, as well as designs sold on the market, comply with applicable safety requirements of the European Union.
This declaration becomes void in the event of modifications to the product that are not approved by us.
This declaration is issued under the exclusive responsibility of the manufacturer.

Extol® Industrial 8798271
TIG Torch
has been designed and manufactured in conformity with the following norms:
EN 60974-7:2013; EN 60974-12:2011; EN 62321:2008; and harmonisation directives:
2011/65 EU
2014/35 EU
Place and date of issue of EU Declaration of Conformity: Zlín, 31.5.2017
Person authorised to write up the EU Declaration of Conformity on behalf of the manufacturer (signature, name, function)

Martin Šenkýř
Member of the Board of the manufacturer

References

• | Extol.cz
• Extol
• | Extol.hu
• Köszöntjük a Madal Bal cégcsoportnál!

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