MAGNATECH R-2 Manuals

Manuals and User Guides for MAGNATECH R-2. We have 1 MAGNATECH R-2 manual available for free PDF download: Operating & Maintenance Instruction Manual

MAGNATECH R-2 Operating & Maintenance Instruction Manual (113 pages)

REDHEAD WELD HEADS

Brand: MAGNATECH | Category: Welding Accessories | Size: 8.29 MB

Table of Contents
4
Technical Support
9
Magnatech Limited Warranty for Models 427A, 428A & 429A
10
Magnatech Product Warranty Registration
11
Reference Documents
12
Standards
12
Regulations (Repairs and Maintenance)
12
Safety Instructions and Warnings for Operation of Arc Welding Equipment
13
Important Notice
13
Owner/Operator Obligations
13
Safety Precautions (General)
13
Shock Prevention
14
Installation and Grounding of Electrically Powered Equipment
14
Torch and Work Cables
14
Power Source Output Terminals
14
Service and Maintenance
15
Fuse and Circuit Breakers
15
Burn Prevention
15
Protective Clothing
15
Eye and Head Protection
15
Hazards from Flying Sparks
15
Toxic Fume Prevention
15
Weldments
16
Coated Weldments
16
Vessels that Have Contained Toxic Materials
16
Welding Area
16
Compressed Gas Cylinder Handling
16
Cylinders
16
Pressure Regulators
16
Equipment Warning Labels
16
Inspection
16
Spares and Expendable Parts
17
Safety Precautions in Normal Operation
17
Turn Power off before Connecting/Disconnecting Cables
17
Always Stop Motors before Reversing
17
Abrasive Grinding Dust will Cause Premature Wear
17
Be Cautious about Heat Damage to Head
17
Do Not Expose System to Rain
17
Check to Ensure that Weld Head Rotation will Not be Obstructed
17
Safety Precautions
18
Symbol Usage
18
Arc Welding Hazards
18
Electric Shock
18
Hot Parts
20
Fumes and Gases
20
Arc Rays
20
Welding
21
Flying Metal or Dirt
21
Buildup of Gas
22
Electric and Magnetic Fields (EMF)
22
Noise
22
Cylinders
22
Additional Symbols for Installation, Operation and Maintenance
23
Fire or Explosion Hazard
23
Falling Equipment
23
Overuse
23
Static (ESD)
23
Moving Parts
23
Welding Wire
23
Battery Explosion
24
Moving Parts
24
Read Instructions
24
Radiation
24
Arc Welding
24
California Proposition 65 Warnings
25
Principal Safety Standards
25
EMF Information
26
Redhead Weld Head Component Inventory
27
Component Inventory
27
Specifications
28
Tube and Pipe Size Range
28
Speed Range
28
Arc Gap Control
28
Torch Cross Seam Adjustment
28
Torch and Torch Cable Assembly
28
Filler Wire Feed Module
29
Weld Head Weight
29
Clearance Requirements
29
Functional Description
30
Basic Weld Head Assembly
30
Weld Head Control Cable Assembly
30
Torch and Cable Assembly
30
Filler Wire Feed Module
31
Filler Wire Feed Module Assembly
31
Wire Spool Mount Assembly
31
Filler Wire Conduit
31
Wire Aimer Mechanism
31
Weld Head Set-Up/Preparation for Welding
32
Connect Weld Head to Controller/Power Source
32
Connect Gas
32
Adjusting the Clamp for a New Pipe Size
34
Install Tungsten Electrode and Adjust Arc Gap
36
Adjust Torch Lead/Lag Angle
37
Lead/Lag Adjustments
37
And R-3 Lead/Lag Adjustment
39
Preparing the Workpiece
40
Clamp Head on Pipe
40
Adjust the Tension on the Torch Pivoting Arm
40
Install the Wire Spool
40
Adjust Filler Wire Nozzle Position
41
Check Torch Cross-Seam Adjustment
41
Pre-Wrap the Torch Cable
42
Recheck Arc Gap and Torch Centering
42
Purge the Gas Lines
42
Start Welding
42
Welding/Downslope
42
Unclamp Head
42
Weld Head Maintenance
43
Cleaning
43
Torch Cable Replacement
43
Water Cooler Maintenance/Flushing Procedure for Torch Cable
43
Maintenance of Wire Feed Nozzle
44
Adjusting the Chain Tensioner
44
Maintenance of Torch Components
44
Tungsten
45
Tungsten Diameter and Length
45
Tungsten Diameter
45
Arc Gap to be Used
45
Tungsten Tip Angle and Flat Diameter to be Used
45
Tungsten Material & Ordering Information
46
Tungsten Material
46
How to Specify Part Number
46
Developing Weld Procedures/Process Parameters
47
Goal
47
Mechanized Versus Manual: Implications to Wps/Pqr
47
The Misconception of "Automatic" Pipe Welding
48
Weld Development - 5G
48
Type of Material
48
Joint Design and Fit-Up Tolerance
48
Tungsten Geometry
49
Setting Tungsten Rotation Speed
49
Setting Current Level
49
Setting Filler Wire Speed
50
Root Pass Procedure
50
Hot Pass Procedure
51
Fill Passes
51
Shield Gas Effects
51
Fit-Up Requirements Maximum Wall Mismatch
52
Tack Welding Programs
53
Common Weld Defects: Identification and Prevention
55
Acronyms
57

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MAGNATECH R-2 Operating & Maintenance Instruction Manual (113 pages)

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