Weldclass PP365 Platinum Push Pull Torch User Manual

PP365 Platinum Push-Pull Torch
User Manual

Safety

Before using this product, read the instructions and any related data sheets. (See www.parweld.com).
| Fumes and Gases
Fumes and gases emitted during welding may be dangerous, use adequate ventilation and extraction equipment.
| Arc Rays
Arc rays may burn eyes and skin. Wear protective clothing.
| Electric Shock
Electric shocks can kill, use adequate protective equipment. Ensure a safe earth connection. Do not touch electrical parts or electrode.
| Burn and Fire Hazard
Weld and metal parts are hot and cause serious burn injuries if touched. Sparks can cause burns and fire. Remove all flammable materials from the welding area.
| Injury can occur from bodily contact with hot parts, sparks, fumes, dust, noise, and vibration.
| Protect your eyes and face with a mask fitted with a filter lens. Use welding screens.
| Wear protective clothing to protect your body and ears.
| Use adequate ventilation or wear respirator equipment to prevent dust, fumes and gases from entering your lungs.

Push-Pull Torch Introduction

Function
The Push-Pull MIG welding torch consists of a mechanical drive block that incorporates a DC drive motor. This drives feed rolls that pull the welding wire push fed from a wire feeding unit and power source, feeding it through a MIG welding swan neck front end.
Swan Neck
The welding torch is supplied with a neck fitted. All necks are fully rotatable through 360°.
Wire Feed Speed Control
Fine-tuning of wire feed rates can be made via a speed control mounted on the separate drive module. The drive module is fitted to the torch control input lead. For more details see further information n this manual.

Technical Data

Reference Torch Wire Feed Data

Nominal Wire Feed Speed| M/Min| Ft/Min|
---|---|---|---
Min| 1.5| 4.9| +/- 10%
Max| 28.5| 93.5| +/- 10%

Torch Maintenance

Neck Fitting
Disconnect the torch from the power supply so that it can not be triggered accidentally.

• At the neck, the root slackens the nut which secures the neck to the torch mount.
• The mount tapered design creates a strong fit. To remove the neck twist to release it.
• The neck liner and nipple combination will also need to be removed.
• The new neck will have a new neck liner and choice of nipples supplied, select the nipple for the push-pull torch.
• Fit the neck liner and nipple into the neck. trim the liner material if necessary to correct the length as detailed below.
• Fit both the neck and neck liner into the torch neck mount.
• Tighten the neck nut. If a swan neck, before fully tightened position the neck in the orientation required. Then fully tighten the nut to secure.

Nozzle and Front End Consumables
Remove the nozzle from the front of the neck. Remove all spatter from the head, gas diffuser, and the nozzle. These components must be clean and free of all debris to ensure efficient gas flow and to prevent short circuits. Check all front-end consumables for damage and wear. Replace with new if necessary.
To maintain the best performance repeatedly check and clean the front-end consumables periodically. Also, use an anti-spatter spray on the consumables to reduce the build-up of debris.
Torch Feed Unit
Open the torch feed unit hatch and inspect. Wire scale debris will build up inside the torch around the feed unit mechanism. Regularly clean out the torch feed unit using an air blow gun to blow out this debris.
To maintain the best operation of the torches feed mechanism clean out the debris daily before use at the very least. Feed Rolls
The feed rolls will wear over time. Check the roll grooves for wear and debris. Debris can be removed with a wire brush. If the groove is excessively worn, replace it.
To change the feed rolls;

• Use a flat blade screwdriver to slacken off and remove the retaining screws for both the pressure roll and the feed roll.
• The drive roll has a retaining cap to lock the roll to the drive shaft. This will lift off.
• The rolls can then be retracted off their shaft mounts. Use the flat blade screwdriver to lever them if they are tight.
• Replace the rolls with the required size.
• The pressure roll has an internal bearing fitted and will only fit the pressure arm shaft mount.
• The drive roll is slotted and must be fitted to the drive shaft with the slot aligned with the shaft slot. Then the retaining cap is fitted on top.
• Secure both rolls with the screws, tightening with a screwdriver.

Neck Wire Inlet Guide
The neck guide will wear as the wire is fed through into the neck. To maintain trouble-free wire feeding periodically check and renew this guide.
To remove the guide;

• Remove the retaining screw using a hexagonal key. 2mm A/F.
• Lift the guide out of its location. Removing the feed rolls will make this easier.
• There is a renewable liner inner that can be replaced. Remove the gas seal 0 ring and then withdraw the guide liner.
• Replace the liner inner with new and fit an 0 ring.
• Return the guide assembly into the drive unit location ensuring the 0 rings and liner tube locate correctly. Secure using the retaining screw.

Liner Fitting
To fit a new liner;

• Lay the torch out straight on a flat surface.
• Remove the liner retaining nut from the gun plug body liner stem.
• Remove the old liner by pulling it out of the stem.
• Feed the new liner into the gun plug liner stem. Push up the torch until it hits the guide in the torch handle. The liner should be visible through the inspection hole of the guide.
• Now position the liner nipple and 0 rings in the liner stem, fit and tighten the retaining nut over the nipple.
• Trim the excess liner length to suit the machine feed unit configuration into which the torch will be fitted.

Torch Set Up

Roll Pressure
Before changing the feed rolls or feeding the wire through the torch the pressure on the pressure roll must be reduced.

• First, check to see if there is any pressure on the pressure roll by opening the feed unit hatch and pulling on the release arm. If there is pressure on the roll the lever will be stiff and will not make the pressure roll move.
• To slacken off the pressure, turn the pressure adjustment knob on the side of the torch anti-clockwise. Turn two or three times and check the pressure release lever again. If the feed roll moves away from the drive roll easily then enough pressure has been taken off.

Wire Feed Set Up
For best feeding results lay the torch flat and straight on the ground. Setup the wire in the power source feed unit ready to be fed through the torch. If the wire has a strong cast, feeding can be improved by adding a slight bend at the end of the wire to straighten it, before clamping in the feed rolls.
To feed the wire through the torch;

• Turn on the power source.
• Press the torch trigger. This should start the power source feed unit drive and the torch feed unit drive simultaneously.
• The wire will be fed up through the torch. Use the speed control of the power source wire feed unit to vary the wire feed speed, slowing the wire as it reaches the end of the torch.
• As the wire feeds into the torch feed unit have the rolls in the open position by pulling on the roll pressure release lever, which should be adjusted to a low-pressure load.
• When the wire passes between the rolls release the trigger to stop the drive.
• Release the lever to close the rolls together. You may need to push the wire between the rolls, into the roll grooves, using a flat blade screwdriver.
• Operate the torch trigger again to feed the wire into the neck guide and through the neck.
• When the wire is visible from the end of the contact tip release the trigger to stop the wire from feeding.

Roll Pressure Adjustment
Before welding, the pressure roll will need to be tightened against the wire sat in the groove of the two feed rolls.
To adjust;

• Turn the pressure adjustment knob on the side of the torch in the clockwise direction. Turn one, two, or three times to load up the pressure on the rolls.
• If during welding the rolls appear to be losing grip on the wire, add more pressure to the rolls by additional clockwise turns on the adjustment knob.

Do not over-tighten as this may damage the wire and cause excessive debris build-up in the drive unit.
Identifying drive balance condition:
With the pressure roll slackened off, watch the torch pull drive roll rpm relative to the wire feed speed. If the wire is moving faster than the roll rotates, this is an “Under’ speed condition which may lead to the wire tangling and nesting at the back of the rolls.
If the wire is moving slower than the roll rotates, this is an “Over” speed condition leading to a wire stretching and excessive debris build-up in the drive chamber.
The ideal condition is a slight over-speed condition. Enough speed to pull on the wire but not too much that the rolls skid excessively over the wire and wear.

Initial Drive Speed Balancing

To correct the pull torch drive speed the adjustment is made on the control lead in-line voltage drive module.
Trimming drive module to balance speed:
Locate the adjustment trimmer screw access port found on the body of the drive enclosure, see image below.
To make the adjustment, use a small flat blade screwdriver that fits into the access port and reaches the white slotted trimmer screw.
Turn the trimmer screw slightly in the direction to suit the speed adjustment required.
Over speed:
Turn the screw slightly counter-clockwise to reduce speed.
Under speed:
Turn the screw slightly clockwise to increase speed.
Warning:
Do not make large adjustments as this may cause an over-voltage condition that will damage the torch drive motor.
Test the adjusted speed by operating the torch and assessing the wire feed ratio to the drive roll rotation.

Trouble Shooting

and secure torch gun plug connection with the feeding machine
Check torch trigger is operating and the connection is made through the torch
Check the feeding machine via the users manual
The wire feeder activates when the torch trigger is operated but the torch drive does not feed| Check and secure the control lead connection with the drive module
Check the input voltage and drive signal lead connection are made to the correct terminals in the source feeder machine.
Check the speed control selector switch is in the correct position for the torch configuration connected.
Adjust the speed control trimmer, either on the drive module or the torch depending on the torch configuration
Torch drive speed running at maximum when the trigger is operated, speed trimmer is not affecting the speed when adjusted| Torch control lead wires may be connected incorrectly.
Torch drive is not running when the trigger is operated, speed trimmer is not affecting the speed when adjusted| Torch control lead wires may be connected incorrectly.
The remote speed control trimmer fitted to the torch is not affecting the drive speed when adjusted| Check the connections as secure through the torch and with the control lead to the drive module
Wire “birds nests” in torch feed unit behind the feed rolls| Pull drive speed is too slow. Adjust the speed using the local or remote controls depending on the torch set up.
Excessive debris build-up in the torch drive unit| Pull drive speed is too fast, slipping on the wire and abrading the wire surface. Adjust the pull feed speed
using the local or remote speed controls depending on torch set up.
Wire feeding erratic| If roll pressure is too low, adjust the pressure by tightening the adjustment knob on the side of the torch.
Torch feed rolls may be worn or the wrong feed rolls fitted for the wire. Check the feed roll condition and replace it if necessary.
Torch drive roll rotates counter-clockwise, against the direction of wire feeding.| Drive motor power supply is connected in reverse polarity. Open the torch
gun plug housing and swap the wire connections for the drive motor. The “Red” and “Black” leads.

References

• Parweld - Welding the Future

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