Page 1 OPERATING & MAINTENANCE INSTRUCTION MANUAL REDHEAD WELD HEADS MODELS 427A (R-1), 428A (R-2), 429A (R-3) FOR USE WITH 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLIES Signature on File 7/18/2014 J.G. Emmerson Date President Signature on File 7/21/2014 Tom Denner Date...
Page 2 MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY Copyright Notice This manual and the information contained herein is the property of Magnatech, LLC. It is proprietary and shall not be copied in whole or in part without the prior express written permission of Magnatech, LLC. Information and instructions in the document are subject to change and Magnatech, LLC reserves the right to change specifications and data without notice.
Page 3 Tungsten Material & Ordering Information. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 4: Table Of Contents
5.2.2 Buildup of Gas ..............................14 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 5 Adjust the Tension on the Torch Pivoting Arm......................32 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 6 14.0 ACRONYMS ..............................49 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 7 Table 12 - Tip Diameter ............................... 38 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 8 The mechanical arc length control maintains a uniform arc gap even on out-of-round pipe. There are three models of Weld Heads in the Redhead line, designated R-1 (427A), R-2 (428A), and R-3 (429A). The Redheads can be operated off of virtually any of Magnatech's control/power supply models including: ...
Page 9: Technical Support
MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY TECHNICAL SUPPORT Now that you have purchased a Magnatech product, our goal is to provide prompt service and technical support. If technical assistance is needed following equipment delivery, please contact us and our staff will take every measure to resolve the issue.
Page 10: Magnatech Limited Warranty For Models 427A, 428A & 429A
Magnatech shall not be liable for any consequential, indirect or incidental losses or damages incurred as the result of any breach of warranty or as a result of any repair or replacement activity, including, but not limited to any losses due to down time or loss of use. Magnatech shall not be liable for any losses, injuries or damages sounding in tort, whether for the negligence of Magnatech or its agents, officers or employees or in a strict liability theory.
Page 11: Magnatech Product Warranty Registration
S/N: Product Name: S/N: THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 12: Reference Documents
Repeat Tests on Electrical Appliances THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 13: Safety Instructions And Warnings For Operation Of Arc Welding Equipment
5.0, Safety Precautions for other guides and publications for what you should learn before operating this equipment. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 14: Shock Prevention
Note: All Magnatech manufactured power sources completely shield the output terminals when the Torch Cable is connected. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 15: Service And Maintenance
Provide ventilation in accordance with ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 16: Weldments
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 17: Spares And Expendable Parts
Head around prior to striking an arc and carefully observe for interference THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 18: Safety Precautions
If AC output is required, use remote output control if present on unit THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 19 Maintenance Section before touching any parts. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 20: Hot Parts
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 21: Welding
Wear approved safety glasses with side shields even under your welding helmet. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 22: Buildup Of Gas
Section 5.5, Principle Safety Standards. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 23: Additional Symbols For Installation, Operation And Maintenance
Do not point gun toward any part of the body, other people, or any metal when threading welding wire. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 24: Battery Explosion
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 25: California Proposition 65 Warnings
Standards Institute, (phone: 212-642-4900, website: www.ansi.org). THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 26: Emf Information
If cleared by your doctor, then following the above procedures is recommended. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 27: Redhead Weld Head Component Inventory
105451-1 Shipping Case 5751 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 28: Specifications
This minimizes potential damage to the cable if it comes in contact with the hot surface of a pipe. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 29: Filler Wire Feed Module
÷2= Radial Clearance ÷2= Radial Clearance THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 30: Functional Description
The electrode cable, carrying power to the torch, is located inside the water return hose. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 31: Filler Wire Feed Module
Wire aim is adjusted prior to welding using tools provided in the tool kit. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 32: Weld Head Set-Up/Preparation For Welding
WELD HEAT INPUT = CURRENT X VOLTS X TIME. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 33 Proper selection of weld gas and awareness of the need for gas purity are essential for optimum results. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 34: Adjusting The Clamp For A New Pipe Size
Figure 1 - Adjusting the Clamp for a New Pipe Size THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 35 MODEL 514 TUBEMASTER OR 515/516 PIPEMASTER POWER SUPPLY THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 36: Install Tungsten Electrode And Adjust Arc Gap
Figure 2 - Tungsten Electrode and Adjust Arc Gap THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 37: Adjust Torch Lead/Lag Angle
Plant)). If a specific workpiece size is not shown on the table, choose the hole location closest to that workpiece size. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 38 Figure 5 - Mounting Locations R-1 Head Only (Pivoting Arm Assembly on Rotary Plant) THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 39: And R-3 Lead/Lag Adjustment
There are no alternate pivot post locations required on the R-2 and R-3. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 40: Preparing The Workpiece
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 41: Adjust Filler Wire Nozzle Position
The Redhead uses a special spool size. Empty spools (P/N 8831) are inexpensive and may be purchased from Magnatech. Magnatech can also provide spools with all available alloys of filler wire. Wire is provided with typical "Mill" certs suitably labeled and packaged.
Page 42: Pre-Wrap The Torch Cable
Figure 6 - Filler Wire Aiming Adjustments THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 43: Weld Head Maintenance
This performs well as antifreeze as well as an algaecide. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 44: Maintenance Of Wire Feed Nozzle
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 45: Tungsten
The larger the flat diameter, the more difficult it will be to start the arc. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 46: Tungsten Material & Ordering Information
Angle Length Inches -0.975 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 47: Developing Weld Procedures/Process Parameters
Joint design including bevel geometry and fit-up gap are nonessential variables for both GTAW and GMAW weld processes as defined by QW-415 welding variables. In summary, the use of Magnatech's Mechanized Orbital TIG and MIG Pipe Welding Systems do not require a new Procedure Qualification Record and attendant Weld Procedure Specification. For the individual Welder Performance Qualification test, the welder would qualify as a "Welding Operator"...
Page 48: The Misconception Of "Automatic" Pipe Welding
("J" with .100" land extension matched to 37-1/2° with a 1/16" land). THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 49: Tungsten Geometry
Average Current - (Average Current/3) = Low-Pulse Current THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 50: Setting Filler Wire Speed
THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 51: Hot Pass Procedure
(Increasing amounts of helium in the mixture will degrade arc starting.) THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 52: Fit-Up Requirements Maximum Wall Mismatch
 Change insert fit-up if possible THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 53: Tack Welding Programs
The low pulse amperage should not be enough to melt metal. THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 54 Figure 7 - Example of Tack Weld Programs THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 55: Common Weld Defects: Identification And Prevention
 I.D. purge gas pressure too high – create larger gas exit hole THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 56  Gas flow rate I.D. or O.D. too low THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 57: Acronyms
Material Safety Data Sheet THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 58 BILL OF MATERIALS/DRAWINGS APPENDIX A THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 59 Expendables Kit, 45 Deg. Fillet Kit A–1 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 60 THE BOTTOM OF THE SLOT .064/.068 .068 SLOT - CENTRAL TO SHAFT W/IN .003 T.I.R. .064 .260 .520 .515 FULL RADIUS MAGNATECH Limited Partnership East Granby, CT 06026 DESCRIPTION GEARBOX, PLANETARY XXmm X NN:1 DIMENSION LIMITS UNLESS OTHERWISE SPECIFIED DRAWN BY ANGLES 0.01...
Page 71 Weld Head Assembly Model 427A, R1 A–2 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 73 PAGE 1 OF 1 MAGNATECH LIMITED PARTNERSHIP 08/05/05 EAST GRANBY, CONNECTICUT 06026 BILL OF MATERIALS ACCESSORY LIST - R1 102392-1 PART QUANTITY NUMBER DESCRIPTION USED 5630-17 Collet Body Linde 45V44 7311-17 Collet - Make From Linde 7312 Gas Cup 8835...
Page 74 Sht 1 of 2 ARM ASSEMBLY, TORCH POSITIONING MAGNATECH LIMITED PARTNERSHIP 04-May-2010 MODEL 427, R1 EAST GRANBY, CT 06026 104631-1-PL 104631-1 Rev. AA...
Page 75 Sht 2 of 2 ARM ASSEMBLY, TORCH POSITIONING MAGNATECH LIMITED PARTNERSHIP 04-May-2010 MODEL 427, R1 EAST GRANBY, CT 06026 104631-1-PL 104631-1 Rev. AA PART # DESCRIPTION TYPE 101046 PIN, REACTION - R1 PART 101122-2 CONE BUSHING - PART 101123-2 CONE WEDGE -...
Page 79 HORSESHOE BASE & MOTOR ASSEMBLY Sht 1 of 2 MAGNATECH LIMITED PARTNERSHIP MODEL 427, R1 104888-1-PL EAST GRANBY, CT 06026 104888-1 REV AA...
Page 80 HORSESHOE BASE & MOTOR ASSEMBLY Sht 2 of 2 MAGNATECH LIMITED PARTNERSHIP MODEL 427, R1 104888-1-PL EAST GRANBY, CT 06026 104888-1 REV AA PART # DESCRIPTION TYPE 1001503 DRIVE CHAIN ASSEMBLY - 13.75 LONG ASSEMBLY 102302-1 UPPER BUSHING - POWER MODULE...
Page 81 Sht 1 of 2 WIRE DRIVE ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 24-Apr-09 EAST GRANBY, CT 06026 104889-1-PL 104889-1 1"...
Page 82 WIRE DRIVE ASSEMBLY Sht 2 of 2 MAGNATECH LIMITED PARTNERSHIP 24-Apr-09 EAST GRANBY, CT 06026 104889-1 104889-1-PL PART # DESCRIPTION TYPE 101233 GEARBOX COVER - PART 101234-2 GEARBOX, PLANETARY - 23MM X 43:1 PART 101240 REDUCER BUSHING - PART 101244...
Page 83 Sht 1 of 3 WELDHEAD ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 104890-1-PL MODEL 427A, R1 EAST GRANBY, CT 06026 Rev. AA 104890-1...
Page 84 Sht 2 of 3 WELDHEAD ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 104890-1-PL MODEL 427A, R1 EAST GRANBY, CT 06026 Rev. AA 104890-1 WHEN ATTACHING "CHILL BLOCK"- P/N:104667-1 TO THE WELD HEAD, APPLY "THERMAL COMPOUD"- P/N:3952 IN THE AREA SHOWN.
Page 85 WELDHEAD ASSEMBLY Sht 3 of 3 MAGNATECH LIMITED PARTNERSHIP MODEL 427A, R1 104890-1-PL EAST GRANBY, CT 06026 104890-1 Rev. AA PART # DESCRIPTION TYPE 101000 COVER,TORCH BLOCK - PART 101012-5 NOZZLE - 0.030 x 1-1/8 PART 102530 NUT PLATE - TORCH LEAD/LAG...
Page 86 Weld Head Assembly Model 428A, R2 A–3 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 87 MAGNATECH LIMITED PARTNERSHIP PAGE 1 OF 1 EAST GRANBY, CONNECTICUT 06026 5/27/2011 Rev.AA KEY SHEET MODEL 428A R2 REDHEAD W/ ENCODERS PART NUMBER DESCRIPTION 428ARBB0J0 MODEL 428A WELDHEAD W/ WIRE & ACCESSORIES 104886-1 WELDHEAD ASSEMBLY - MODEL 428A, R2 104621-25...
Page 88 PAGE 1 OF 1 MAGNATECH LIMITED PARTNERSHIP 08/08/05 EAST GRANBY, CONNECTICUT 06026 BILL OF MATERIALS ACCESSORY LIST - R2, 428 102392-4 PART QUANTITY NUMBER DESCRIPTION USED 5630-17 Collet Body Linde 45V44 7311-17 Collet - Make From Linde 1 7312 Gas Cup...
Page 89 Sht 1 of 2 ROTARY PLATE ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 04-May-2010 EAST GRANBY, CT 06026 104613-1-PL 104613-1 Rev. AA...
Page 90 Sht 2 of 2 ROTARY PLATE ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 04-May-2010 EAST GRANBY, CT 06026 104613-1-PL 104613-1 Rev. AA PART # DESCRIPTION TYPE 101122-2 CONE BUSHING - PART 101123-2 CONE WEDGE - PART 101124-2 PIVOT POST - PART 101290-1 CROSS SEAM NUT -...
Page 92 Sht 1 of 2 WIRE DRIVE ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 24-Apr-09 428/9 EAST GRANBY, CT 06026 104884-1-PL 104884-1 1"...
Page 93 WIRE DRIVE ASSEMBLY Sht 2 of 2 MAGNATECH LIMITED PARTNERSHIP 428/9 24-Apr-09 EAST GRANBY, CT 06026 104884-1 104884-1-PL PART # DESCRIPTION TYPE 101233 GEARBOX COVER - PART 101234-2 GEARBOX, PLANETARY - 23MM X 43:1 PART 101240 REDUCER BUSHING - PART...
Page 94 HORSESHOE BASE & MOTOR ASSY Sht 1 of 2 MAGNATECH LIMITED PARTNERSHIP MODEL 428 104885-1-PL EAST GRANBY, CT 06026 104885-1 REV AA...
Page 95 HORSESHOE BASE & MOTOR ASSY Sht 2 of 2 MAGNATECH LIMITED PARTNERSHIP MODEL 428 104885-1-PL EAST GRANBY, CT 06026 104885-1 REV AA PART # DESCRIPTION TYPE 1001502 DRIVE CHAIN ASSEMBLY - 17.25 LONG ASSEMBLY 102302-1 UPPER BUSHING - POWER MODULE...
Page 96 Sht 1 of 3 WELDHEAD ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 104886-1-PL MODEL 428A, R2 EAST GRANBY, CT 06026 Rev. AA 104886-1...
Page 97 Sht 2 of 3 WELDHEAD ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 104886-1-PL MODEL 428A, R2 EAST GRANBY, CT 06026 Rev. AA 104886-1 WHEN ATTACHING "CHILL BLOCK"- P/N:104667-1 TO THE WELD HEAD, APPLY "THERMAL COMPOUD"- P/N:3952 IN THE AREA SHOWN.
Page 98 WELDHEAD ASSEMBLY Sht 3 of 3 MAGNATECH LIMITED PARTNERSHIP MODEL 428A, R2 104886-1-PL EAST GRANBY, CT 06026 104886-1 Rev. AA PART # DESCRIPTION TYPE 101000 COVER,TORCH BLOCK - PART 101012-6 NOZZLE - 0.030 x 1-1/2 PART 102530 NUT PLATE - TORCH LEAD/LAG...
Page 99 Weld Head Assembly Model 429A, R3 A–4 THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 100 MAGNATECH LIMITED PARTNERSHIP PAGE 1 OF 1 EAST GRANBY, CONNECTICUT 06026 5/27/2011 Rev.AA KEY SHEET MODEL 429A R3 REDHEAD W/ ENCODERS PART NUMBER DESCRIPTION 429ARBB0J0 MODEL 429A WELDHEAD W/ WIRE & ACCESSORIES 104880-1 WELDHEAD ASSEMBLY - MODEL 429A, R3 104621-25...
Page 101 PAGE 1 OF 1 MAGNATECH LIMITED PARTNERSHIP 08/05/05 EAST GRANBY, CONNECTICUT 06026 BILL OF MATERIALS ACCESSORY LIST - R3, 429 102392-5 PART QUANTITY NUMBER DESCRIPTION USED 5630-17 Collet Body Linde 45V44 7311-17 Collet - Make From Linde 7312 Gas Cup...
Page 102 Sht 1 of 2 ROTARY PLATE ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 04-May-2010 EAST GRANBY, CT 06026 104624-1-PL 104624-1 Rev. AA...
Page 103 Sht 2 of 2 ROTARY PLATE ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 04-May-2010 EAST GRANBY, CT 06026 104624-1-PL 104624-1 Rev. AA PART # DESCRIPTION TYPE 101122-1 CONE BUSHING - PART 101123-1 CONE WEDGE - PART 101124-1 PIVOT POST - PART 101290-1 CROSS SEAM NUT -...
Page 105 HORSESHOE BASE & MOTOR ASSY Sht 1 of 2 MAGNATECH LIMITED PARTNERSHIP MODEL 429 104883-1-PL EAST GRANBY, CT 06026 104883-1 REV AB...
Page 106 HORSESHOE BASE & MOTOR ASSY Sht 2 of 2 MAGNATECH LIMITED PARTNERSHIP MODEL 429 104883-1-PL EAST GRANBY, CT 06026 104883-1 REV AB PART # DESCRIPTION TYPE 1001505 DRIVE CHAIN ASSY - 25.75" LONG ASSEMBLY 102302-1 UPPER BUSHING - POWER MODULE...
Page 107 Sht 1 of 2 WIRE DRIVE ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 24-Apr-09 428/9 EAST GRANBY, CT 06026 104884-1-PL 104884-1 1"...
Page 108 WIRE DRIVE ASSEMBLY Sht 2 of 2 MAGNATECH LIMITED PARTNERSHIP 428/9 24-Apr-09 EAST GRANBY, CT 06026 104884-1 104884-1-PL PART # DESCRIPTION TYPE 101233 GEARBOX COVER - PART 101234-2 GEARBOX, PLANETARY - 23MM X 43:1 PART 101240 REDUCER BUSHING - PART...
Page 109 Sht 1 of 3 WELDHEAD ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 104886-1-PL MODEL 428A, R2 EAST GRANBY, CT 06026 Rev. AA 104886-1...
Page 110 Sht 2 of 3 WELDHEAD ASSEMBLY MAGNATECH LIMITED PARTNERSHIP 104886-1-PL MODEL 428A, R2 EAST GRANBY, CT 06026 Rev. AA 104886-1 WHEN ATTACHING "CHILL BLOCK"- P/N:104667-1 TO THE WELD HEAD, APPLY "THERMAL COMPOUD"- P/N:3952 IN THE AREA SHOWN.
Page 111 WELDHEAD ASSEMBLY Sht 3 of 3 MAGNATECH LIMITED PARTNERSHIP MODEL 428A, R2 104886-1-PL EAST GRANBY, CT 06026 104886-1 Rev. AA PART # DESCRIPTION TYPE 101000 COVER,TORCH BLOCK - PART 101012-6 NOZZLE - 0.030 x 1-1/2 PART 102530 NUT PLATE - TORCH LEAD/LAG...
Page 112 WELD HEAD WIRING DIAGRAM APPENDIX B THESE DOCUMENTS, AND THE CONTAINED INFORMATION HEREIN, ARE PROPRIETARY AND ARE NOT TO BE REPRODUCED, USED OR DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, EXCEPT AS SPECIFICALLY AUTHORIZED, IN WRITING, BY MAGNATECH, LLC...
Page 113 10.0 WELD HEAD WIRING DIAGRAM...

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