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PTA-3500

PROCESS MANUAL

P T A - 3 5 0 0 P r o c e s s M a n u a l

W e l d T e c h | 1

IMPORTANT!

BEFORE ATTEMPTING TO OPERATE

THE WELDTECH PTA-3500,

BE SURE TO READ AND UNDERSTAND

THE ENTIRE SAFETY SECTION

THAT FOLLOWS.

IMPORTANT!


W e l d T e c h | 2

Table of Contents

1. Safety Rules for Plasma Transferred-Arc Welding .......................................................................................................... 4

1.1 INTRODUCTION .................................................................................................................................................. 4

1.2 WORKER’S RIGHT TO KNOW ........................................................................................................................... 4

1.3 ELECTRIC SHOCK PREVENTION ..................................................................................................................... 5

1.4 SAFETY DEVICES ................................................................................................................................................ 5

1.5 POWDER FEEDER ................................................................................................................................................ 6

1.6 PROTECTION FOR WEARERS OF ELECTRONIC LIFE SUPPORT DEVICES (PACEMAKERS) ............... 6

1.7 PERSONAL PROTECTION .................................................................................................................................. 6

1.8 PROTECTION OF NEARBY PERSONNEL ........................................................................................................ 7

1.9 VENTILATION-Toxic Fume Control .................................................................................................................... 7

1.10 SAFE HANDLING OF COMPRESSED GASES AND Equipment ...................................................................... 7

1.11 FIRE AND EXPLOSION PREVENTION ............................................................................................................. 9

1.12 REFERNECES AND STANDARDS ................................................................................................................... 10

2. WELDTECH PTA-3500 Overview .................................................................................................................................. 12

3. Equipment Description ..................................................................................................................................................... 14

3.1 INTRODUCTION ................................................................................................................................................ 14

3.2 POWER SOURCE – WT-3500 ............................................................................................................................ 14

3.3 WELDTECH CONTROL CONSOLE ................................................................................................................. 14

3.4 WATER COOLER WELDTECH......................................................................................................................... 14

3.5 CABLES AND AUXILIARY HARDWARE ...................................................................................................... 15

3.6 WELDTECH TORCHES ..................................................................................................................................... 15

WT-200 ID TORCH ......................................................................................................................................................... 16

4. System Installation ........................................................................................................................................................ 21

4.1 INTRODUCTION ................................................................................................................................................ 21

4.2 PTA SYSTEM ARRANGEMENT ....................................................................................................................... 21

4.3 WT-3500 Dimensions ........................................................................................................................................... 22

4.4 WT-3500 Power Source Electrical Service Guide ................................................................................................ 22

4.5 Connecting Input Power for 3500 Models ............................................................................................................ 24

4.6 INSTALLING THE CONSOLE ........................................................................................................................... 27

4.7 GAS SUPPLY HOOK-UP .................................................................................................................................... 28


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4.8 INSTALLING THE WELDTECH WATER COOLER ....................................................................................... 28

4.9 TORCH AND TORCH CABLE INSTALLATION ............................................................................................. 28

5. Operating Instructions ...................................................................................................................................................... 30

5.1 INTRODUCTION TO OPERATING PROCEDURES ........................................................................................ 30

5.2 OPERATING SEQUENCE .................................................................................................................................. 30

6. Process Parameters ............................................................................................................................................................ 32

6.1 WORKPIECE ....................................................................................................................................................... 32

6.2 PREHEATING...................................................................................................................................................... 33

6.3 DILUTION ........................................................................................................................................................... 33

6.4 WELD BEAD CONFIGURATION ..................................................................................................................... 33

6.5 STRINGER BEAD PATTERN ............................................................................................................................ 33

6.6 WEAVE BEAD PATTERN ................................................................................................................................. 33

6.7 PART PREPARATION AND FIXTURING ........................................................................................................ 34

6.8 KEY WELDING VARIABLES ........................................................................................................................... 34

6.9 WELDING PARAMETERS ................................................................................................................................. 35

7. Equipment Maintenance ................................................................................................................................................... 37

7.1 TORCH DESIGN AND SERVICING.................................................................................................................. 37

7.2 POWER SOURCE 350 ......................................................................................................................................... 37

7.3 CONTROL CONSOLE ........................................................................................................................................ 37

7.4 WELDTECH WATER COOLER ........................................................................................................................ 38

7.5 TORCH AND POWER CABLES ........................................................................................................................ 38

8. Troubleshooting ................................................................................................................................................................ 39

9. Warranty and Service Information .................................................................................................................................... 42

10. EQUIPMENT SPECIFICATIONS ................................................................................................................................. 43

APPENDIX ‘A’ PTA 3500 PROGRAMMING ................................................................................................................... 48


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1. Safety Rules for Plasma Transferred-Arc Welding

1.1 INTRODUCTION

We learn by experience. Learning safety through personal

experience, like a child touching a hot stove is harmful,

wasteful and unwise. Let the experience of others teach you.

Safety is a combination of good judgment and proper training.

Operation and maintenance of any arc welding equipment

involves potential hazards. Individuals who are unfamiliar

with welding equipment, use faulty judgment or lack proper

training, may cause injury to themselves and others.

Safe practices developed from experience in the use of

welding are described in this section. Research, development

and field experience have evolved reliable equipment and safe

installation, operation and servicing practices. Accidents occur

when equipment is improperly used or maintained. The reason

for the safe practices may not always be given. Some are

based on common sense, others may require technical volumes

to explain. It is wise to follow the rules.

READ AND UNDERSTAND THESE SAFE PRACTICES

BEFORE ATTEMPTING TO INSTALL, OPERATE OR

SERVICE THE EQUIPMENT.

Different arc welding processes and powdered alloys can

produce different fumes, gases, and radiation levels. In

addition to the information in this Manual, be sure to consult

Weld Tech’s Material Safety Data Sheet for specific technical

data and precautionary measures concerning each alloy.

In addition, before operating this equipment, you should be

aware of your employer’s safety regulations. BE SURE TO

READ AND FOLLOW ALL AVAILABLE SAFETY

REGULATIONS BEFORE USING THIS EQUIPMENT.

Published standards on safety are also available for additional

and more complete procedures than those given in this

manual. They are listed in Section 1.7, References and

Standards. ANSI Z49.1 is the most complete.

The National Electrical Code, Occupational Safety and Health

Administration, local industrial codes, and local inspection

requirements also provide a basis for equipment installation,

use and service.

Failure to observe these safe practices may cause serious

injury or death. When safety becomes a habit, the equipment

can be used with confidence. Safety instructions specifically

pertaining to this unit appear throughout this manual

highlighted by the signal words WARNING and CAUTION

which identify different levels of hazard.

WARNING statements include installation, operating and

maintenance procedures or practices which if not carefully

followed could result in serious personal injury or loss of life.

CAUTION statements includes installation, operating and

maintenance procedures or practices which if not carefully

followed could result in minor personal injury or damage to

this equipment.

A third signal word, IMPORTANT, highlights instructions

which need special emphasis to obtain the most efficient

operation of this equipment.

1.2 WORKER’S RIGHT TO KNOW

The WELD TECH PTA-3500 will produce during its normal

use, one or more toxic substances. The composition and nature

of these substances will be significantly affected by the

operating parameters, by the composition of the material being

welded and by the presence of any contaminants or coating on

the material. Some of the possible toxic substances which may

be produced include the following: Aluminum; Borates; Boron

Oxide; Carbon Monoxide; Chromium; Chromic; Chromous

and Chromate Salts; Cobalt; Copper; Copper compounds;

Ferrovanadium; Iron; Iron Oxide; Lead; Lead compounds;

Magnesium Oxide; Manganese; Manganese compounds;

Molybdenum; Nickel; Nickel compounds; Nitrogen Oxides;

Ozone; Silicon; Tin; Tin compounds; Tungsten; Welding

Fume; Zinc; and Zinc compounds.

For detailed, specific information on a specific product, read

the Material Safety Data Sheet which is on file with your

employer.

See American National Standard Z49.1 “ Safety in Welding

and Cutting” and Chapter 11 of “Thermal Spraying,” both

published by the American Welding Society,550 N.W.

LeJenune Road, Maimi, Florida 33126. OSHA Safety and


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Health Standards, 29 CFR 1910, available from

U.S.Government Printing Office, Washington, D.C. 20402.

WARNING:

VOLTAGES OF 115 OR LESS CAN CAUSE SEVERE

BURNS TO THE BODY OR FATAL SHOCK.

SEVERITY OF ELECTRICAL SHOCK IS

DETERMINED BY THE PATH AND AMOUNT OF

CURRENT THROUGH THE BODY.

1.3 ELECTRIC SHOCK PREVENTION

Exposed hot conductors or other bare metal in the welding

circuit or ungrounded, electrically HOT equipment can fatally

shock a person whose body becomes a conductor. DO NOT

STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface

when welding without suitable protection. Fix water leaks

immediately. Do not operate equipment sitting in water.

Keep body and clothing dry. Never work in damp area without

adequate insulation against electrical shock. Stay on a dry

duckboard, or rubber mat when dampness or sweat cannot be

avoided. Sweat, sea water or moisture between body and an

electronically HOT part – or grounded metal – reduces the

body’s surface electrical resistance, enabling dangerous and

possibly lethal currents to flow through the body.

Grounding the Equipment

When Arc welding equipment is grounded according to the

National Electrical Code (USA Standard C1) and the work is

grounded according to ANSI Z49.1 “Safety in Welding and

Cutting,” a voltage may exist between the electrode and any

conducting object. Examples of conducting objects include,

but are not limited to, buildings, electrical tools, work

benches, welding power source cases, work pieces, etc. Never

touch the electrode and any metal object unless the welding

power source if OFF.

When installing, connect the frames of each unit such as

welding power source, control, worktable and water circulator

to the building ground. Conductors must be adequate to carry

ground currents safely. Equipment made electrically HOT by

stray current may shock, possibly fatally. Do NOT GROUND

to electrical conduit, or to a pipe carrying ANY gas or a

flammable liquid such as oil or fuel.

Check phase requirements of equipment before installing. If

only 3-phase power is available, connect single-phase

equipment to only two wires of the 3-phase line. Do NOT

connect the equipment ground lead to the third (live) wire, or

the equipment will become electrically HOT – a dangerous

condition that can shock, possibly fatally.

Before welding, check ground for continuity. BE sure

conductors are touching bare metal of equipment frames at

connections. If a line cord with a ground lead is provided with

the equipment for connection to a switchbox, connect the

ground lead to the grounded switchbox. If a three-prong plug

is added for connection to a grounded mating receptacle, the

ground lead must be connected to the ground prong only. If

the line cord comes with a three-prong plug, connect to a

grounded mating receptacle. Never remove the ground prong

from a plug, or use a plug with a broken off ground prong.

Be sure the ground cable is connected to the work piece as

close to the welding areas as possible. Grounds connected to

building framework or other remote locations from the

welding area reduce efficiency and increase the potential

electric shock hazard. Avoid the possibility of the welding

current passing through lifting chains, crane cables or various

electric paths.

Connectors

Fully insulated connectors should be used to join welding

cables.

Cables

Do not overload the cables. Frequently inspect cables for

wear, cracks and damage. IMMEDIATELY REPLACE those

with excessively worn or damaged insulation to avoid possibly

lethal shock from bared cable. Cables with damaged areas

may be taped to give resistance equivalent to original cable.

Keep cable dry, free of oil and grease and protected from hot

metal and sparks.

Do not coil or loop the welding cable around parts of the body.

Terminals and Other Exposed Parts

Terminals and other exposed parts of electrical units should

have insulating covers secured before operation.

1.4 SAFETY DEVICES

Safety devices such as interlock and circuit breakers should be

disconnected or shunted out.


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Before installation, inspection or service of equipment, shut

OFF all power and remove line fuses (or lock or red-tag

switches) to prevent accidental turning ON of power.

Disconnect all cables from welding power sources, and pull all

115 volt line-cord plugs.

Do not open power circuit or change polarity while welding. If

in an emergency, it must be disconnected; guard against shock

burns or flash from switch arcing.

Leaving equipment unattended, always shut OFF and

disconnect all power to equipment.

Power disconnect switch must be available near the welding

power source.

1.5 POWDER FEEDER

Never use a combustible gas, oxygen or air as a carrier gas in

the feeder.

Always have the carrier gas ON before activating the powder

feed. Always turn the powder feeder off first before the carrier

gas.

1.6 PROTECTION FOR WEARERS OF ELECTRONIC

LIFE SUPPORT DEVICES (PACEMAKERS)

Magnetic field from high currents can affect pacemaker

operation. Persons wearing electronic life support equipment

(pacemaker) should consult with their doctor before going

near arc welding operations.

1.7 PERSONAL PROTECTION

WARNING

SKIN AND EYE BURNS RESULTING FROM BODY

EXPOSURE TO THE ELECTRIC-ARC RAYS OT HOT

METAL CAN BE MORE SEVERE THAN SUNBURN.

The welding arc is intense and visibly bright. Its radiation can

damage eyes, penetrate lightweight clothing, reflect from light

colored surfaces and burn the skin and eyes. Skin burns

resemble acute sunburn; those from gas-shielded arcs are more

severe and painful. DON’T GET BURNED- COMPLY WITH

PRECAUTIONS.

First aid facilities and a qualified first aid person should be

available for each shift unless medical facilities are close by

for immediate treatment of flash burns of the eyes and skin

burns.

Eye and Head Protection

Protect eyes from exposure to arc. NEVER LOOK AT AN

ELECTRIC ARC WITHOUT PROTECTION.

Welding helmet or shield containing a filter plate shade No. 12

or darker must be used when welding. Place over face before

striking arc.

Protect filter plate with a clear cover plate. Cracked or broken

helmet or shield should NOT be worn; radiation can pass

through to cause burns.

Cracked, broken or loose filter plates must be replaced

IMMEDIATELY. Replace clear cover plate when broken,

pitted or spattered.

Flash goggles with side shields MUST be worn under the

helmet to give some protection to the eyes should the helmet

not be lowered over the face an arc is struck. Looking at an arc

momentarily with unprotected eyes (particularly a high-

intensity gas-shielded arc) can cause a retinal burn that may

leave a permanent dark area in the field of vision.

Always wear safety glasses or goggles when in a welding area.

Use safety glasses with side shields or goggles when chipping

slag or grinding. Chipped slag is hot and may travel

considerable distances. Bystanders should also wear safety

glasses or goggles.

A hard hat should be worn when others work overhead.

Flammable hair preparations should not be used by persons

intending to weld.

Ear Protection

Wear ear plugs or other ear protection devices when operating

welding equipment.

Protective Clothing

Wear protective clothing- gauntlet gloves designed for use in

welding, hat and high safety-toe shoes. Button shirt collar and

pocket flaps, and wear cuff-less trousers to avoid entry of

sparks and slag. Wear long-sleeve, dark, substantial clothing.

As necessary, use protective clothing such as leather jackets or

sleeves, flame-proof apron and fire-resistant leggings. Avoid

outer garments of untreated cotton.


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Avoid oily or greasy clothing. A spark may ignite them.

Hot metal such as electrode stubs and work pieces should

never be handled without gloves.

1.8 PROTECTION OF NEARBY PERSONNEL

Enclose welding area. For protection welding, a separate room

or enclosed bay is best. In open areas, surround the operation

with low-reflective. Non-combustible screens or panels. Allow

for free air circulation, particularly at floor level.

Provide face shields for all persons who will be looking

directly at the weld.

See that all persons are wearing flash goggles.

Before starting to weld, make sure that screen flaps or bay

doors are closed.

Warn bystanders not to watch the arc and not to expose

themselves to the welding-arc rays or to hot metal.

1.9 VENTILATION-Toxic Fume Control

WARNING –

WELDING FUME AND GASES, PARTICULARLY IN

CONFINED SPACES, CAN CAUSE DISCOMFORT

AND CAN BE HARMFUL TO YOUR HEALTH.

Keep your head out of the fumes. At all times, provide

adequate ventilation in the welding area by means of either

natural or mechanical ventilation. The use of a Fume

Eliminator is recommended for local ventilation.

If you develop momentary eye, nose or throat irritation during

welding, this is an indication that ventilation is not adequate.

Stop work and take the necessary steps to improve ventilation

in the welding area. Do not continue to weld if physical

discomfort persists.

Use an air supplied respirator if ventilation is not adequate to

remove all fumes and gases.

Severe discomfort, illness or death can result from fumes,

vapors, heat or oxygen enrichment or depletion that welding

may produce. Prevent this with adequate ventilation as

described in ANSI Z49.1. NEVER ventilate with oxygen.

Lead-cadmium-, zinc-, mercury-, and beryllium-bearing and

similar materials, when welded, may produce harmful

concentrations of toxic fumes. Adequate local exhaust

ventilation must be used, or each person in the area as well as

the operator must wear an air-supplied respirator. For

beryllium, both must be used.

Metals coated with or containing material that release toxic

fumes should not be heated unless coating is removed from

the work surface, the area is well ventilated, or the operator

wears an air-supplied respirator.

Note that inert shielding gases can displace air in confined

spaces and result in asphyxiation due to oxygen deficiency.

Gas leaks in a confined space should be avoided. Leaked gas

in large quantities can change oxygen concentration

dangerously. Do not bring gas cylinders into a confined space.

Leaving a confined space, shut OFF gas supply at source to

prevent possible accumulation of gases in the space if

downstream valves have been accidentally opened or left

open.

Check to be sure that the space is safe before re-entering it.

Vapors from chlorinated solvents can be decomposed by the

heat of the arc (or flame) to form PHOSGENE, a highly toxic

gas, and other lung and eye irritating products. The ultraviolet

(radiant) energy of the arc can also decompose

trichloroethylene and perchloroethylene vapors to form

phosgene.

DO NOT WELD where solvent vapors can be drawn into the

welding atmosphere or where the radiant energy can penetrate

to atmospheres containing even minute amounts of

trichloroethylene or perchloroethylene.

1.10 SAFE HANDLING OF COMPRESSED GASES AND

Equipment

Comply with precautions in this manual and those detailed in

GCA Standard P-1, PRECAUTIONS FOR SAFE

HANDLING OF COMPRESSED ASES IN CYLINDERS.

Pressure Regulators

Regulator relief valve is designed to protect only the regulator

from over-pressure; it is not intended to protect any


W e l d T e c h | 8

downstream equipment. Provide such protection with one or

more relief devices.

Never connect a regulator to a cylinder containing gas other

than that for which the regulator was designed.

Remove faulty regulator from service immediately for repair

(first close cylinder valve). The following symptoms indicate a

faulty regulator:

LEAKS – if gas leaks externally.

EXCESSIVE CREEP - if delivery pressure continues to rise

with downstream valve closed.

FAULTY GAUGE- if gauge pointer does not move off stop

pin when pressurized, nor returns to stop pin after pressure

release.

Do NOT attempt repair. Send faulty regulators for repair to

manufacturer’s designated repair center, where special

techniques and tools are used by personnel.

Cylinders

Cylinders must be handled carefully to prevent leaks and

damage to their walls, valves or safety devices.

Avoid electrical circuit contact with cylinders including third

rails, electrical wires or welding circuits. They can produce

short circuits arcs that may lead to a serious accident.

ICC or DOT marking must be on each cylinder. It is an

assurance of safety when the cylinder is properly handled.

Identify gas content. Use only cylinders with name of gas

marked on them; do not rely on color to identify gas content.

Notify supplier if unmarked. NEVER DEFACED or alter

name, number or other markings on a cylinder. It is illegal and

hazardous.

Empties – keep valves closed; replace caps securely; mark

MT; keep them separate from FULLS and return promptly.

Never use a cylinder or its contents for other than its intended

used. NEVER as a support or roller.

Locate or secure cylinders so they cannot be knocked over.

Use safety chains.

Keep cylinders clear of areas where they may be struck, such

as passageways and work areas.

Transporting cylinders- with a crane, use a secure support

such as a platform or cradle. Do NOT lift cylinders off the

ground by their valves or caps or by chains, slings or magnets.

Do NOT expose cylinders to excessive heat, sparks, slag and

flame, etc. that may cause rupture. Do not allow contents to

exceed 130°F. cool with water spray where such exposure

exists.

Protect cylinders, particularly valves, from bumps, falls,

falling objects and weather. Replace caps securely when

moving cylinders.

Stuck valve- do NOT use a hammer or wrench to open a

cylinder that cannot be opened by hand. Notify your supplier.

Mixing gases- Never try to mix any gases in cylinder.

Never refill any cylinder.

Cylinder fittings should never be modified or exchanged.

Hoses

Use ferrules or clamps designed for the hose (not ordinary

wire or other substitute) as a binding to connect hoses to

fittings.

No copper tubing splices. Use only standard brass fittings to

splice hose.

Avoid long runs. To prevent kinks and abuse, suspend hose

off ground to keep it from being run over, stepped on, or

otherwise damaged.

Coil excess hose to prevent kinks and tangles.

Protect hose from damage by sharp edges and by sparks, slag

and open flame.

Examine hose regularly for leaks, wears and loose

connections. Immerse pressured hose in water; bubbles

indicate leaks.

Repair leaky or worn hose by cutting area out and splicing. Do

NOT use tape.

Proper Connections

Clean cylinder valve outlet of impurities that may clog orifices

and damage seats before connecting regulator. Except for

hydrogen, crack valve momentarily, pointing outlet away from

people and sources of ignition. Wipe with a clean, lintless

cloth.


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Match regulator to cylinder. Before connecting, check that the

regulator label and cylinder marking agree, and that the

regulator inlet and cylinder outlet match. NEVER CONNECT

a regulator designed for a particular gas or gases to a cylinder

containing any other gas.

Tighten connections. When assembling threaded connections,

clean and smooth seats where necessary. Tighten. If

connection leaks, disassemble, clean and retighten using

proper fitting wrench.

Adapters- use a CGA adapter (available from your supplier)

between cylinder and regulator, if one is required. Use two

wrenches to tighten adapter marked RIGHT and LEFTHAND

threads.

Pressurizing Steps

Drain regulator of residual gas through suitable vent before

opening cylinder (or manifold valve) by turning adjusting

screw clockwise. Draining prevents excessive compression

heats at high pressure seta by allowing seat to open on

pressurization. Leave adjusting screw engaged slightly on

single-stage regulators.

Stand to side of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure

increases slowly. When gauge is pressurized (gauge reaches

regulator maximum) leave cylinder valve in following

positions:

For oxygen and inert gases open fully to seal stem against

possible leak. For fuel gas, open to less than one turn to

permit quick, emergency shutoff.

Use pressure charts (available from your supplier) for safe and

efficient recommended pressure settings on regulators.

Check for leaks on first pressurization and regularly thereafter.

Brush with soap solution (capful of Ivory Liquid* or

equivalent per gallon of water). Bubbles indicate leak. Clean

off soapy water after test; dried soap is combustible.

User Responsibilities

Remove leaky or defective equipment from service

immediately for repair. See User Responsibility statement in

equipment manual.

Leaving Equipment Unattended

Close gas supply at source and drain gas.

*Trademark of Proctor & Gamble.

1.11 FIRE AND EXPLOSION PREVENTION

WARNING

HOT SLAG OR SPARKS CAN CAUSE A SERIOUS FIRE

WHEN IN CONTACT WITH COMBUSTIBLE SOLIDS,

LIQUIDS OR GASES.

Remove all combustible materials well away from the welding

area or completely cover materials with a non-flammable

covering. Such combustible materials include wood, clothing,

sawdust, gasoline, kerosene, paints, solvent, natural gases,

acetylene, propane and similar combustible materials.

For fire protection, have fire extinguishing equipment handy

for instant use, such as portable fire extinguisher or garden

hose, water pail or san bucket.

Causes of fire and explosion are: combustibles reached by the

arc, flame, flying sparks, hot slag or heated material, misuse of

compressed gases and cylinders and short circuits.

BE AWARE THAT flying sparks or falling slag can pass

through cracks, along pipes, through windows or doors and

through wall or floor openings out of sight of the goggled

operator. Sparks and slag can fly 35 feet!

To prevent fires and explosion:

Keep equipment clean and operable, free of oil, grease and (in

electrical parts) of metallic particles that can cause short

circuits.

If combustibles are in area, do NOT weld. Move the work if

practicable, to an area free of combustibles. Avoid paint spray

rooms, dip tanks, storage areas and ventilators. If the work

cannot be moved, move combustibles at least 35 feet away out

of reach of sparks and heat; or protect against ignition with

suitable and snug-fitting fire-resistant covers or shields.

Walls touching combustibles on opposite sides should not be

welded on. Walls, ceilings and floor near work should be

protected by heat-resistant covers or shields.

A fire watcher must be standing by with suitable fire

extinguishing equipment during and for some time after

welding if:


W e l d T e c h | 10

a) Appreciable combustibles (including building construction)

are within 35 feet,

b) Appreciable combustibles are further than 35 feet but can

be ignited by sparks,

c) Opening (concealed or visible) in floors or walls within 35

feet may expose combustibles to sparks,

d) Combustibles adjacent to walls, ceiling, roots or metal

partitions can be ignited by radiant or conducted heat.

Hot work permit should be obtained before operation to ensure

supervisor’s approval that adequate precautions have been

taken.

After work is done, check that area is free of sparks, glowing

embers and flames.

An empty container that held combustibles or that can produce

flammable or toxic vapors when heated must never be welded

unless container has been first been cleaned as described in

AWS Standard A6.0, “WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUSTIBLES.”

This includes: a thorough steam or caustic cleaning (or a

solvent or water washing, depending on the combustible’s

solubility) followed by purging and inerting with nitrogen or

carbon dioxide and using protective equipment as

recommended. Water filling just below working level may

substitute for inerting.

A container with unknown contents should be cleaned (see

paragraph above). Do NOT depend on sense of smell or sight

to determine if it is safe to weld.

Hollow casting or containers must be vented before welding.

They can explode.

Explosives atmospheres- never weld where the air may

contain flammable dust, gas or liquid vapors (such as

gasoline).

Do not overload arc welding equipment. It may overheat

cables and cause a fire.

Loose cable connections may overheat or flash and cause a

fire.

Never strike an arc on a cylinder or other pressure vessel. It

creates a brittle area that can cause a violent rupture or lead to

such a rupture later under rough handling.

1.12 REFERNECES AND STANDARDS

For more information, refer to the following standards or their

latest revisions and comply as applicable:

1. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING obtainable from the American Welding

Society, 550 LeJeune Road, P.O.Box 351040, Miami, FL

33135

2. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING obtainable from

the superintendent of Documents, U.S. Government

Printing Office, Washington, DC 20402

3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the U.S. Government Printing

Office, Washington, DC 20402.

4. ANSI Standard Z87.1 SAFE PRACTICES FOR

OCCUPATION AND EDUCATIONAL EYE AND

FACE PROTECTION obtainable from the American

National Standards Institute, 1430 Broadway, New York,

NY 10018.

5. ANSI Standard 241.4 STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR obtainable from the

American National Standards Institute, 1430 Broadway,

New York, NY 10018.

6. ANSI Standard Z49.2 , FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES

obtainable from the American National Standards

Institute, 1430 Broadway, New York, NY 10018.

7. AWS standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD

COMBUSTIBLES obtainable from the American

Welding Society, 550 LeJeune Road, P.O.Box 351040,

Miami Fl 33135

8. NFPA Standard 51, OXYGEN-FUEL-GAS SYSTEMS

FOR WELDING AND CUTTING obtainable from the

National Fire Protection Association, 470 Atlantic

Avenue, Boston, MA 02210.

9. NFPA Standard 70-1978, NATIONAL ELECTRICAL

CODE obtainable from the National Fire Protection

Association, 470 Atlantic Avenue, Boston, MA 02210.



10. NFPA Standard 51B, CUTTING AND WELDING

PROCESSES obtainable from the National Fire

Protection Association, 470 Atlantic Avenue, Boston, MA

02210.

11. CGA Pamphlet P-1, SAFE HANDLING OF

COMPRESSED GASES IN CYLINDERS obtainable

from the Compressed Gas Association, 500 Fifth Avenue,

New York, NY 10036.

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING obtainable from the

Canadian Standards Association, Standard Sales, 178

Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply

Association, 1900 Arc Street, Philadelphia, PA 19103.

14. American Welding Society Standard AWSF4.1, “

Recommended Safe Practices for the Preparation for

Welding and Cutting of Containers and Piping that Have

Held Hazardous Substances” obtainable from the

American Welding Society, 550 LeJeune Road, P.O.Box

351040, Miami, FL 33135

15. ANSI Standard Z88.2 “Practice for Respiratory

Protection,” obtainable from the American National

Standards Institute, 1430 Broadway, New York, NY

10018.

16. Chapter 11 of “ Thermal Spraying.” obtainable from the

American Welding Society, 550 NW LeJeune Road,

P.O.Box 351040, Miami, Florida 33135



2. WELDTECH PTA-3500 Overview THE WELDTECH PTA-3500 represents the world’s best

technology in the field of Plasma Transferred-Arc (PTA)

Welding. Through the intensive efforts of Research and

Development - optimal quality wear-resistant surfacing is now

available in a light weight, modular system with hand-held

deposition capability.

The WELDTECH PTA-3500 operates by utilizing a controlled

amount of alloy that is carried by Argon into an Argon/7%

hydrogen shielded, transferred-arc plasma column so as to

apply a metallurgically bonded, wear-resistant coating to the

work piece, accurate control of powder feed rate, current input

(amperage), gas flow rates and traverse course and rate allow

the operator to obtain precise deposit profiles with minimal

dilution of the base metal.

WELDTECH PTA-3500 System

208/575 V



The resulting coating is assured to provide:

• Optimal wear resistance

• Minimal base metal distortion and dilution

• Substantial increase in effective life of parts

• Cost-effective use of alloys

� All of these benefits are incorporated in a system

designed to be flexible. WELDTECH PTA-3500 can be

used in a machine-mounted mode or for hand-held in-situ

work, due to the compact design of the three major

components. In addition, we offer several torches,

including the innovative WT-120 or WT-200 ID torches

for coating bores up to 38 inches in depth and as tight as

� 1.25 inches in diameter. WELDTECH PTA-3500

incorporates the best of all modern welding processes in a

versatile, modern set-up, with consistent performance and

operation control taken into account. The dedicated

system- WELDTECH PTA-3500 equipment sets the

standard of comparison for wear protection industry.

THE WELDTECH PROCESS

The Weld Tech WT-350 Power Source connects directly to

the Weld Tech control console and serves, as its name implies,

as the source off electrical input to the entire system. The

Weld Tech Arc Voltage Controller (AVC), Oscillator, water

cooling system and the gas lines also connect to the Control

Console, which in turn links directly to the torch.

The Control Console acts as the “brain” of the system,

regulating gases and water flow as well as the powder

feed rate, Arc Voltage Control (AVC) and Oscillation

while linking the necessary power to the torch.

As outlined above, these components are able to work as

a dedicated system because of the advanced engineering

of the Control Console. Every one of the necessary

elements for PTAW originates at the control console -

alloy, Argon, Argon/7% Hydrogen, high frequency direct

current reverse polarity (DCRP) and water IN/OUT .

Each can be metered precisely to produce deposits of

highest integrity for long-lasting wear resistance.



3. Equipment Description 3.1 INTRODUCTION

This section provides a general description of each of the

major components of the WELD TECH PTA-3500. Figure 2-1

is a schematic displaying the process by which the

components interact to produce coatings. It should be noted

that the WELD TECH PTA-3500 has been designed to allow

its use in a variety of different applications with any industry

torch.

3.2 POWER SOURCE – WT-3500

The 3500 Power Supply allows for any input voltage hookup

(208–575 V) with no manual linking, providing convenience

in any job setting. Thus, being an ideal solution for dirty or

unreliable power.

The patented high-frequency arc starter for non-contact arc

initiation provides more consistent arc starts and greater

reliability compared to traditional HF arc starters.

Patented wind tunnel technology protects internal electrical

components from airborne contaminates, extending the

product life.

Fan-On-Demand power source cooling system operates only

when needed, reducing noise, energy use and the amount of

contaminates pulled though the machine.

3.3 WELDTECH CONTROL CONSOLE

The Weld Tech control console, the “Brain” of the

WELDTECH PTA-3500, utilizes a programmable controller

and associated solid state circuitry to perform the following

functions:

1. Control the welding current, which is adjustable via Touch

Screen Interface.

2. Control the upslope and downslope of the welding current,

which is adjustable via Touch Screen Interface.

3. Sequence and control the welding cycle.

4. Integrate either of two WT-350 Powder Feeders into the

welding cycle.

5. Control the Fully Integrated Arc Voltage Controller (AVC).

6. Control the Fully Integrated Oscillator.

7. Provide safety interlocks to terminate the weld cycle as a

result of insufficient water or gas flows.

8. House the WT-350 Hopper and gas circuitry and controls

which regulate the supply of powder to the torch.

9. Provide for time adjustment of the post-weld gas flow.

10. Provides several outputs and inputs to fully control /

integrate motion automation systems.

The Control Console allows for the selection of one of three

modes of operation: fully automatic, automatic with manual

control of the powder feed, and manual. In addition, the

console allows for control of the weld current at the console or

remote control of the weld current at an external location. The

handheld pendant is an extension of the Touch Panel and thus

allows remote adjustments of the Amperage, Voltage and

Powder Flow Rate while welding.

3.4 WATER COOLER WELDTECH

The Weld Tech water cooling system serves to provide a

steady supply of cooling water to the various torches. It

consists of a bronze pump, radiator, fan and stainless steel

reservoir. An optional refrigeration system is available upon

request.

The Weld Tech water cooling system has a sufficient cooling

capacity to allow operation of each WELDTECH Torch at its

maximum amperage on a production basis.



3.5 CABLES AND AUXILIARY HARDWARE

All necessary hoses, cables and regulators used to integrate

the WELDTECH PTA-3500 components are included in the

standard system. In addition two dual-stage gas Monitors

are included to regulate the supply of plasma gas and

shielding gas along with an air regulator to set the pressure

for the powder feeder vibrator.

3.6 WELDTECH TORCHES

The WELDTECH PTA-3500 is unique in that it allows for

the selection of any industry torch to cover a broad range of

welding applications.



WT-200 ID TORCH

WT200

The WT200 is designed for high quality deposits of a

variety different MicroFlo Alloys. This can be applied to

the surfaces of inside diameters using the WT200 Torch.

The torch assembly comes equipped with a Torch Holder

and spare Parts Kit. The WT200 Torch can be used on

inside diameters as small as 2.5 inches and can extended

to 22 inches into the I.D. bore. The maximum amperage

rating is 200 amperes with an average deposition rate of

2.0 to 6.0 b/hr.

General Specifications

• Welding current range 10-200 Amps

• Nozzle sizes 1/8in dia.

• Electrode 5/32 inch (4mm) dia.

• Water required 0.5 - 2 gym at 60 psi

• Powder Gas 2.0 – 6.0 SCFH at 50 psi

• Plasma Gas 4.0 - 8.5 SCFH at 50 psi

• Shield Gas 16-30 SCFH at 50psi

• Deposition Rate 2.0 – 4.5 LB/HR

• Lengths Available:

o 30 inches (22 inches usable)

o 42 inches (33 inches usable)

o 1.65 inches

[Diameter]

o 9 pounds

[Weight]

• Maximum operating temperature 750 deg. F with

a refrigerant chiller to maintain a 68 deg.F

maximum Operating temperature.

Start Up Procedure

• With all hoses attached turn on the water supply.

Check for water leaks at the hose fittings.

• Purge all three gases for about five seconds. The

gas flows should be set to the recommended

parameters – POWDER GAS 2.0 SCFH

• Initiate the Pilot Arc. This should become

established within one second. If the Pilot fails

to strike hit the stop button to shut down the

procedure.

• Internal damage may be caused in the torch if the

arc initiation is continued without visible sign of

establishment. Electronic equipment may also

be damage from excessive high frequency

emissions during this operation.

• The Pilot Arc should be set at 30 amperes for

best results. There may be a tendency under



these conditions that the pilot arc may be

difficult to establish. It is recommended that the

electrode and nozzle are checked prior to start up

in these cases.

• When the Pilot has been established a flame will

extend from the nozzle. This is known as a non-

transferred arc.

• When the torch is positioned over the work piece

the transferred arc may be established.

Operating Notes

• Always use a minimum of 5 SCFH Argon center

gas. This may be increased as the power level is

raised.

• The shield gas can be set between 10 and 25

SCFH for most applications.

•

In the event of a powder blockage the powder

tubes may be cleared by clean, dry air. A gas

purge for 20 seconds is also recommended after

reassembly.

•

If the pilot appears reluctant to strike or if an arc

appears to be established inside the nozzle the

pilot should be stopped immediately and the

electrode checked for damage or wear.

•

Continued efforts to establish a pilot arc with a

worn nozzle or electrode may result in damage to

the torch.

Gas Flows

The gas flows are dependent, for the most part, on the

application being hard-faced and the consumable used.

Description of Gases:

• Center Gas. This is normally 99.995% pure

Argon. The gas is directed through the nozzle

and becomes plasma when ionized by the pilot

arc voltage.

• Powder Gas. This transports the powder from

the powder feeder to the torch. This can be

either pure Argon or special gas. The special gas

is normally Helium or a mixture of Argon and

Hydrogen.

• Shield Gas. This is normally Argon/Hydrogen

or Pure Argon and provides blanket coverage

over the weld area to prevent oxidation.

Typical flows for Center Gas

4.0 to 8.0 SCFH 1/8 inch Nozzle

Typical flows for powder Gas

2.0 to 6.0 SCFH

Note - These are starting values only. It is good practice

to observe the powder flow from the torch prior to

welding. The powder should flow evenly from the

nozzle. If there is a tendency for the powder to build up

in the tube (from the feeder), the flow should be

increased. A high gas flow may, however result in

excessive powder overspray, pulsation or turbulence. The

gas flow should be just enough to feed the powder.

Typical flows for Shield Gas

15 to 25 SCFH

Surfacing and operating guidelines

For most applications the torch should be positioned over

the work piece at about 3/8 in. This is known as torch

standoff.

The torch can be positioned using the pilot arc as a guide.

It may also be beneficial to use the oscillation especially

when welding in a recess.

Typical Operation and sequence

1. Preset the travel speed of the work piece

(example 4 inches per minute)

2. Preset the powder feed rate ( example 2 lbs./hr. )

- 2.0 such carrier gas flow

3. Start the transferred arc. A molten pool should

develop on the base material. Powder should

start to flow creating a build up

4. The work piece or torch movement should be

started at this point to initiate the surfacing

action.

5. After the torch or work piece has moved

approximately 1/2 inch the weld bead can be

evaluated to determine what adjustments are

required to achieve a good deposit.

6. At the completion of the deposit the weld stop

sequence should be initiated by down sloping

Parameter development and selection



A good quality deposit is achieved by having a correct

balance between the power required to melt the base

material and consumable.

As the power generated by Plasma is extremely intense

the relative motion of the torch across the work piece is

important. If the motion is too fast for a given power

setting, there will be insufficient heat input to the base

material to ensure a good metallic bond or weld. This

condition is to be avoided at all costs as there is a

possibility of the deposit becoming detached

If the relative motion is too slow the excessive heat will

cause base material dilution and consequent deterioration

of the deposit. This will, in most cases cause a reduction

in hardness and make hard facing alloy performance less

effective.

Center Gas

The center gas should be regulated so that the plasma

column is stable. Insufficient center gas flow will cause

instability in the plasma plume and can also reduce the

effects of electrode cooling. A high center gas flow will

cause excessive penetration and may result in high base

metal dilution Optimum gas flow rates are generally

obtained by experimentation. It is good practice to log all

parameters at the completion of a job.

Powder Gas

The powder gas flow should be a balance between

transporting the powder efficiently and preventing

blockages in the feed tube. Experience will determine

what minimum flows are required to prevent blockages

and also minimize overspray.

Shield Gas

The shield gas flow should be set such that there is no

oxidation on the deposit. Typically, Lower gas flows are

required compared to hard facing on external surfaces as

the internal diameter provides an enclosure for the “gas

shield”.

Note - The overspray may appear excessive compared to

hard facing an external surface this is because the powder

will collect at the low point in the internal diameter rather

than be dispersed on an external surface

The PTA process will yield the best benefits of alloy

performance and deposit consistency when the dilution

rate is controlled between 5 and 10 percent.

Typically, larger applications can be controlled to achieve

5 percent easier than small jobs which will heat up more

readily.

A good deposit will be result of just sufficient power to

fuse the powder to the substrate. The bead will be

preceded by a “silver” band at the leading edge.

For most applications on oscillations width of 0.5 to 0.63

inches will give good results. As the operation proceeds,

the powder feed rate and linear traverse speed can be

adjusted to develop a good profile.

Deposit thickness of from 0.06 inches to 0.14 inches can

easily be achieved in one pass. Multi layers deposits can

also be applied depending on the type of powder and

application requirements.

For production requirements’ it is desirable to achieve the

highest deposition rate possible while maintaining good

deposit quality.

To optimize the deposit rate, the powder feed rate and

amperage can be increased periodically. A limit will be

reached, however, when the weld pool appears to be

difficult to control and there is an indication of excessive

overspray. Excessive powder feed rate will also be

indicated by a “ragged” edge on the bead which un-

melted or un-fused powder.

Excessive power will also cause the weld bead to oxidize.

A good starting point in developing parameters is to select

a powder feed rate of say 2 to 3 lbs./hr. and then adjust

the other parameters to achieve a good bead with the

desired profile.

Powders

The WT200 can feed most of the hard facing powders

such as Iron base, Cobalt, Nickel, Inconel’s, and

composites with Tungsten Carbide.

Some of the Nickel powders may tend to stick to the front

face of the nozzle. This may be caused by “fines” in the

powder or an unsuitable mesh size. This condition can be

minimized by using good quality powder and by using a

constant temperature water chiller to keep the nozzle cool.

The recommended water temperature for this torch should

be maintained at 68 deg. F. This will also prolong the

nozzle life compared to a radiator type cooler.

Composite Powders can be relatively difficult to deposit

compared to other materials but can still be applied if the



nozzle is maintained at or below 68 deg. F. It is also

beneficial to coat the front face of the nozzle with a

ceramic spray to prevent excessive build up.

Cobalt based alloys are ideally suited for WT200 Torch.

Difficulties will only be experienced with low quality

powder or powders with an excessive particle size

distribution of 325 mesh.

In the event of powder blockage the line should be cleared

with clean, dry compressed air. The powder should

examine for uneven particles and “silvers” which can

block the powder ports.

Anode Replacement (4)

The anode and cathode can be replaced with the WT200

Torch intact and held in its machine mount.

1. Unscrew the anode with the tool provided.

2. Replace worn or defective anode with tool above

Note: if anode is too loose it will over heat due

to inadequate heat transfer.

Cathode Replacement (7)

1. Unscrew the anode with the tool provided-

Counter-clockwise.

2. Remove collect nut with the tool provided –

counter-clockwise.

3. Remove defective or worn cathode with a needle

nose plier

4. Replace cathode and slightly tighten it with the

tool provided to lock it in place – cathode should

be flush with anode or slightly recessed.

5. Replace anode with tool provided – Note: if

anode is loose it will overheat due to inadequate

heat transfer.

Cathode Center Adjustment

1. To center cathode, loosen cathode holder

securing Allen screw located on rear torch body

side

2. Grip cathode holder assay at rear of torch firmly

with one hand, while holding the front body

assay with the other hand

3. Move cathode, in-out, and right-left as needed

to center cathode tip with center of anode.

4. once center position is acquired, carefully

tighten cathode holder recurring Allen screw

Torch Disassembly:

1. Remove cable assembly

2. Remove anode with tool provided

3. Remove cathode collect with tool provided

4. Remove cathode

5. Remove front body tube securing screws (3pcs.)

6. Remove front body tube securing screws

insulators (3 pcs.)

7. Hold front body tube assembly in one hand.

With the other hand hold the rear body

assembly, in one motion twisted slightly and

pull parts apart.

8. Once parts become loose, carefully remove

front body tube.

9. Remove cathode rod securing Allen screw

10. Remove cathode holder assembly from front

body/rear body

11. Front insulator and cathode holder assembly

insulator will come loose at this point

12. Remove water inlet power+ connector from

front body assembly (screw counter-clockwise)

13. Remove water inlet power+ connector

insulating sleeve

14. Remove rear body securing screws (3pcs.)

15. Remove rear body securing screw insulators

(3pcs)

16. At this point the remaining parts of the WT200

Torch are now loose and con be easily removed

by hand.

17. Reverse the steps above to reassemble the torch.



4. System Installation

4.1 INTRODUCTION

After an introductory survey of the Process itself, pertinent safety measures and the main equipment components, you are ready to

install the system. This section provides the necessary information and proper procedures to hook up the various components in

preparation to run the system and deposit excellent coatings. Figure 4-1 is a schematic diagram of the system.

4.2 PTA SYSTEM ARRANGEMENT

Before installing the WELDTECH PTA-3500, select an

appropriate location, keeping in mind the following:

1. The PTAW Process is similar to other gas shielded welding

operations such as GTAW in that a high intensity arc is

produced. Protect workers in the area from the arc and

plasma radiation by using appropriate clothing, eye and

head protection, and standard welding screens.

2. Select an area with adequate ventilation or use a fume

eliminator such as the Fume Eliminator.

3. Avoid locations where the equipment will be exposed to

excessive dust, moisture or oil- laden air. A “dirty” area can

increase maintenance of the components and lead to

premature failure. Both the Power Source 350 and the

WELDTECH Water Cooler have a fan built-in to provide

cooling - allow adequate clearance for air flow.

4. DO NOT LOCATE THE SYSTEM NEAR A CHEMICAL

SOLVENT DEGREASING TANK.

A recommended arrangement of the three main components

is to provide a sturdy table or bench or a two-tier mobile

cart with the power supply and Control Console placed side

by side on top with the Weld Tech water cooler located on a

shelf below.

Power

Source

Model 350

Control

Console

PTA-3500

Water

Cooling

System

Model 350

WT-350

Powder Feeder

Process Schematic Including Torch

230/1 or 460/3

V



4.3 WT-3500 Dimensions

4.4 WT-3500 Power Source Electrical Service Guide

Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in

table. If actual input voltage is outside this range, output may not be be available.

NOTICE – INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage.

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12.

Three-Phase

208 230 380 400 460 575

Input Amperes (A) At Rated Output - 300 amps @ 32 volts 33 30 18 17 15 12

Max Recommended Standard Fuse Rating In Amperes 1

Time-Delay Fuses2

Normal Operating Fuses3

40

35

20

20

15

15

Min Input Conductor Size In AWG4 10 10 14 14 14 14

Max Recommended Input Conductor Length In Feet (Meters)

93

113

121

134

177

276

Min Grounding Conductor Size In AWG4 10 10 14 14 14 14

Reference: 2011 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.

2 'Time-Delay" fuses are UL class "RK5u

• See UL 248.



3 "Normal Operating" (general purpose - no intentional delay) fuses are UL class "K5" (up to and including 60 amps), and UL class "H" ( 65 amps and above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

31 0.15(B)(16~ If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12.

Single-Phase

208 230 460 575

Input Amperes (A) At Rated Output - 225 amps @ 29 volts 43 39 19 14

Max Recommended Standard Fuse Rating In Amperes1

Time-Delay Fuses2

Normal Operating Fuses3

50

45

20

15

Min input Conductor Size In AWG4 8 10 14 14

Max Recommended Input Conductor Length In Feet (Meters)

99

79

124

194

Min Grounding Conductor Size In AWG4 10 10 14 14

Reference: 2011 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time- current curves comparable to the recommended fuse.

2 "lime-Delay" fuses are UL class "RK5" . See UL 248.

3 "Normal Operating" (general purpose - no intentional delay) fuses are UL class "K5" (up to and including 60 amps), and UL class "H" ( 65 amps and above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

31 0.15(B)(16~ If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.



4.5 Connecting Input Power for 3500 Models

A. Connecting Three- Phase Input Power

Installation must meet all National and

Local Codes - have only qualified

persons make this installation.

Disconnect and lockout/tagout input

power before connecting input

conductors from unit.

Always connect green or green/ yellow

conductor to supply grounding

terminal first, and never to a line

terminal.

The Auto-Line circuitry in this unit au-

tomatically adapts the power source to

the primary voltage being applied. Check

input voltage available at site. This unit

can be connected to any in-

put power between 208 and 575 VAC

without removing cover to relink the

power source.

For Three-Phase Operation

1 Input Power Cord.

2 Disconnect Device (switch shown in the

OFF position)

3 Green Or Green/Yellow Grounding

Conductor

4 Disconnect Device Grounding

Terminal

5 Input Conductors (L 1, L2 And L3)

6 Disconnect Device Line Terminals Connect

green or green/yellow grounding conductor to

disconnect device grounding terminal first.

Connect input conductors L 1, L2, and L3 to disconnect device line terminals.

7 Over-Current Protection

Select type and size of over-current protection using Section 4-9 (fused disconnect switch shown).

Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.



1 '\.,

8

3

Installation must meet all National and

Local Codes - have only qualified

persons make this installation.

Disconnect and lockout/tagout input

power before connecting input

conductors from unit.

Always connect green or green/ yellow

conductor to supply grounding

terminal first, and never to a line

terminal.

The Auto-line circuitry in this unit au-

tomatically adapts the power source to

the primary voltage being applied. Check

input voltage available at site.This unit

can be connected to any input power

between 208 and 575 VAC without

removing cover to relink the power

source.

Black And White Input Conductor (L1

And L2)

2 Red Input Conductor

3 Green Or Green/Yellow Grounding

Conductor

4 Insulation Sleeving

5 Electrical Tape

Insulate and isolate red conductor as shown.

6 Input Power Cord.

7 Disconnect Device (switch shown in the OFF position)

8 Disconnect Device Grounding

Terminal

9 Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first.

Connect input conductors L1 and L2 to disconnect device line terminals.

10 Over-Current Protection

Select type and size of over-current

protection using Section 4-9 (fused dis-

connect switch shown).

Close and secure door on disconnect

device. Remove lockout/tag out device,

and place switch in the on position.

=GND/PE Earth Ground

1

3



Falling Unit Can Cause Injury.

Use equipment of adequate capacity to lift and support unit.

1 Lifting Eye 2 Lifting Forks

Use lifting eye or lifting forks to move unit. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

If using lifting forks, extend forks beyond opposite side of unit.

3 Line Disconnect Device

Locate unit near correct input power supply.

Special installation may be required where gasoline or volatile liquids are present - see NEC Article 511 or CEC Section 20.

18 in (460mm)

Location And Airflow

or



4.6 INSTALLING THE CONSOLE

Connecting The Console To The Power Supply

The console is shipped with the positive and negative power

cables connected to terminals on the rear panel. Install the

cable with the black insulator on the male connector into the

negative female receptacle on the rear of the power supply.

Insert and rotate approximately 180 degrees COUNTER-

CLOCKWISE to lock it. Install the cable with the red

insulator on the male connector into the positive female

receptacle and rotate 180 degrees CLOCKW1SE to lock.

DANGER

NEVER ATTEMPT TO CONNECT THE OUTPUT

CABLES WITH THE PRIMARY CORD OF THE

POWER SOURCE PLUGGED INTO THE POWER

LINE.

THE RED-POSITIVE AND BLACK-NEGATIVE

CONNECTORS MUST NEVER BE INSTALLED IN

THE WRONG POLARITY RECEPTACLE. DOUBLE

CHECK YOUR HOOK-UP.

Installing The Control Cable:

The long control / logic cable connects from the back of the

Power Source to the back of the Control Console.

To install the control cable perform the following procedure:

1. Install the control cable to the female connector located at

the back of the Control Console by lining up the pins,

inserting fully and rotating the nut on the outer circumference

of the male connector into a locked position.

Installing The Ground Cable

The system is supplied with a black, size 1/0 copper ground

cable which connects from the back of the Control Console to

the work piece.

To install the ground cable, perform the following procedure:

1. Place the male connector into the female receptacle

located on the back of the Control Console, insert

fully and tighten by rotating COUNTER-

CLOCKWISE approximately 180 degrees.



2. Clamp the opposite end of the ground cable to the

work piece, metal fixture or work handling

equipment.

WARNING CONNECTION OF THE GROUND CABLE TO

THE WORKPIECE MUST BE TIGHT AND MUST

PROVIDE A CONDUCTIVE PATH TO ENSURE PROPER

OPERATION OF THE SYSTEM.

WT-3500 Powder Feeders

The WT-3500 comes with either a Mechanical or Fluidized

Bed Powder Feeder. The desired Powder Feeder is shipped

fully assembled with its gas connections in place. Description

and operation of the unit is covered in Section 6.

4.7 GAS SUPPLY HOOK-UP

Operation of the System requires the hookup of three gases:

Argon, Argon + 7% Hydrogen and Compressed Air. All

necessary hardware is included with the system. Both the

Argon and Argon-Hydrogen must be available in high

pressure cylinders in a high purity (99.997%), welding quality

grade. The requirement for compressed air can be satisfied

from a clean plant air supply. To install the Gas Regulators

and Gas Hoses, follows these steps:

1. Connect the Argon Regulator (right-hand thread) to

the Argon tank and the Argon- Hydrogen Regulator

(left-hand thread) to the Argon-Hydrogen (mixed

gas) tank and secure wrench-tight.

2. Position the two tanks of compressed gas in close

proximity to each other. Secure to a wall or post with

a safety chain. Connect the twin gas hose assembly.

Note that the RED hose has a left-hand thread and

connects to the Argon-Hydrogen gas tank, while the

GREEN hose has a right-hand thread and connects to

the Argon gas tank. Connect the opposite end of the

twin gas hose assembly to bulkhead fittings located at

the back of the Control Console. Connect the

GREEN, right-hand fitting to the “Ar In” port and the

RED, left-hand fitting to the “ArH2”port.

4.8 INSTALLING THE WELDTECH WATER COOLER

There are three connections on the WELDTECH Water

Cooler: water-in, water-out and a power cord.

1. A set of water hoses which connect from the Water

Cooler to the Control Console are installed on the

Water Cooler. To connect the water hoses to the

Control Console, begin by connecting the end of the

WATER IN (left-hand thread) hose to the male

fitting on the back panel of the Console. Connect the

end of the WATER OUT (right-hand thread) hose to

the male fitting on the back of the Console.

2. Power for the Weld Tech water cooling system is

supplied via the cord connected to the unit. The pump

is turned on and water flows when the cord is

plugged in.

WARNING!

DO NOT ENERGIZE THE WATER COOLER

UNTIL ALL COMPONENTS OF THE

SYSTEM, INCLUDING THE TORCH AND

TORCH CABLES, HAVE BEEN INSTALLED.

3. The Water Cooler has a eight gallon reservoir.

Remove the plastic plug located on the top of the

reservoir and fill with Glycol/Water Mixture using a

funnel.

4.9 TORCH AND TORCH CABLE INSTALLATION

At this point in the installation, the Power Supply, Control

Console and Water Cooler have been fully integrated. The

final step is to install the Torch Cable and Torch. All

connections will be made at the front panel of the Console.

The torch is connected to the Torch Cable at the factory.

Removal and servicing of each torch and its appropriate cable

is covered in a separate section of the manual. The Torch

Cable is composed of a braided wire in a protective water

hose. The cables thus carry both the DC current and the torch

cooling water.

The number of cable connections to be completed will depend

on the torch being installed.

To install the Torch and Torch Cable Assembly, perform the

following procedure:

1. Connect the negative torch cable (right-hand thread)

to the negative post and the positive torch cable (left-



hand thread) to the positive post located at the lower

right corner on the front of the Control Console.

Before connecting the fittings, pull back the

protective black boot on each power cable and re-

position after the fittings are tightened.

2. Connect the 1/4 inch diameter clear plastic gas hoses

as follows:

a. Connect the hose identified with a YELLOW band

to the male post on the console marked “Ar”.

b. Connect the hose identified with a RED band to

the male post on the console marked “ArH2”.

WARNING!

BEFORE PROCEEDING TO THE “OPERAT1NG

INSTRUCTIONS” SECTION OF THIS MANUAL,

REVIEW SECTION 4 TO ENSURE THAT ALL

SYSTEM CONNECTIONS HAVE BEEN MADE

CORRECTLY.



5. Operating Instructions

5.1 INTRODUCTION TO OPERATING PROCEDURES

Now that the System has been installed, begin the step-by-step

procedure of presetting parameters, initiating the pilot arc,

transferring an arc and applying a weld deposit.

An actual coating job will, of course, depend on many factors,

including:

Work piece: Size, shape, base metal alloy, area to be coated,

need for preheat, post heat, etc.

Alloy: Alloy type required.

Weld Deposit: Thickness, width, number of passes.

A further aspect, usually determined by the nature of the part

to be coated, is the selection of the torch to be used. This

section includes start-up procedures for the WT 120 and WT

200 Torches.

5.2 OPERATING SEQUENCE

WARNING

BEFORE OPERATING THE SYSTEM, REVIEW THE

RECOMMENDED SAFETY PROCEDURES DISCUSSED

IN SECTION 1 OF THIS MANUAL.

1. Open the Argon and Argon/Hydrogen gas cylinders and set

the pressure regulators to a static pressure of 60 psi each.

2. Open the top of the WT-3500 Hopper and fill to

approximately two-thirds of capacity with the desired powder,

then reseal.

3. To activate the Water Cooler unit, plug the line cord into an

appropriate outlet. Both the fan and pump should be turned on

and water should then flow through the torch.

4. Plug in the primary power cord of the controller into the

back of the power source. **IMPORTANT to note that the

controller will not function unless it is plugged into the power

source prior to the power source being turned on.**

5. Plug in the primary cord on the Power Source and turn the

switch (located on the back panel of the Power Source) to the

ON position. Check the amperage and voltage readings from

the digital meter located on the front of the Power Source. The

voltage and amperage should register AUTO.

6. To preset the gas and powder rates, touch the MANUAL

button on the Console Touchscreen.

A. Select the GAS button and adjust the gas

flows by the flow meter values as follows:

(Read at the center of the flow meter ball.)

Carrier Gas Flow 5.0-8.0 SCFH

Argon Gas Flow 5.0 SCFH

Argon/Hydrogen Gas Flow 15-20 SCFH

To shut-off the gas flow, again touch the

GAS button on the touchscreen display.

B. Activate powder flow by touching the

POWDER button on the touchscreen display

and begin adjusting the Powder flow rate by

touching the up / down arrows next to the

Powder Rate Display until you have reached

the desired rate. To deactivate powder flow,

touch the POWDER button on the

touchscreen display.

7. To measure the powder feed rate, use the following

procedure:

A. Record the weight (in grams) of a clean container.

B. Repeat procedure Number 6 above through Step D

and feed powder into the container for precisely 30

seconds



FIGURE 5-2 Powder Feed Rate Conversion table

C. Weigh the container and powder and subtract the weight of

the container.

D. Multiply the weight of powder collected by 0.264 or

consult Fig. 5-2. The value obtained is the POWDER FEED

RATE in pounds per hour.

8. Change the Mode to SEMI AUTOMATIC.

9. Set the desired Amperage by touching the AMP Setting

indicator on the touchscreen display and entering the desired

setting. Incremental adjustments may be made by touching the

up and down arrows next to the AMP Setting Indicator

respectively.

10. Set the desired Voltage.

11. Turn the optional Automatic Voltage Control (AVC) on

by touching the AVC button on the display.

12. Turn the optional Oscillator on by touching the Oscillator

button within the oscillator settings screen.

13. You are now ready to establish an arc. Before

proceeding, be sure that adequate hand and eye protection is

being used. Review Section 1 covering SAFETY as required.

***The PTA-3500 is capable of storing up to 50 programs for

various weld parameters. Please see Appendix A for further

instruction.***

14. Observe the appearance of the weld bead and adjust the

amperage and/or the powder feed rate as necessary to achieve

a well-fused, well-bonded deposit.

15. To shut down the system, depress the POWDER

BUTTON and then the PILOT / TORCH button on either the

handheld pendant or Touchscreen panel IN THAT ORDER.

16. To shut down the entire system, place the circuit breaker

switch on the back of the Power Source to the OFF position.

Unplug the Water Cooler line cord. Close the gas cylinder

main valves and back out the regulators.

GRAMS GRAMS OUNCES OUNCES

MINUTE 30 SEC MINUTE 30 SEC

1,0 7.5 3.8 0.26 0.13

1.2 9 4.5 0.32 0.16

1.4 11.5 5.8 0.37 0.19

1.6 12 6 0.42 0.21

1.8 13.5 6.8 0.48 0.24

2 15 7.5 0.53 0.26

2.2 17 8.5 0.59 0.29

2.4 18 9 0.64 0.32

2.6 20 10 0.69 0.34

2.8 21 10.5 0.75 0.37

3 23 11.5 0.8 0.4

3.2 24 12 0.85 0.42

3.4 26 13 0.91 0.45

3.6 27 13.5 0.96 0.48

3.8 29 14.5 1 0.5

4 30 15 1.1 0.55

4.5 34 17 1.2 0.6

50 38 19 1.3 0.65

5.5 42 21 1.5 0.75

6 46 23 1.6 0.8

6.5 49 24.5 1.7 0.85

7 53 26.5 1.9 0.95

8 61 30.5 2.1 1.05

9 68 34 2.4 1.2

10 75 37.5 2.7 1.35

11 83 41.5 2.9 1.45

12 91 45.5 3.2 1.6

13 98 49 3.5 1.75

14 106 53 3.7 1.85

POUNDS

HOUR



6. Process Parameters

The WELDTECH PTA-3500 is designed to provide high

quality weld deposits on a wide variety of base metals,

including carbon steels, alloy steels, stainless steels, tool

steels, selected nickel- and cobalt-base alloys and selected cast

irons. The process is not recommended for use on copper,

aluminum or titanium base metals. Proper choice of the

coating alloy and careful control of the process parameters

will ensure consistent, high quality results.

Coating alloy selection will depend upon the service

requirements of the application. In some cases, previous

experience or the existence of coating specifications will

dictate the coating alloy selection. In cases where the coating

alloy has not been defined, direct consultation with a Sales

Engineer. In order to optimize process parameters for each

application, a “test coating” on actual or simulated parts is

generally required. The starting point parameters should be

employed for initial testing and adjusted as necessary

thereafter. This section of the Process Manual explains the key

process variables and how they affect the actual weld deposit.

A thorough review of this information will help to minimize

the set-up time required to achieve high quality weld deposits

and will ensure that the System is being utilized to its fullest

capabilities.

6.1 WORKPIECE

As with any welding process, the base metal chemistry and

surface treatment history of a part to be coated will

influence the specific parameters to be used with the System

The following table presents the common base metal alloys

used in industry with regard to their weldability and preheat

conditions.

ALLOY TYPE WELDABILITY

RATING COMMENTS

Low Carbon &

Mild Steel

C = 0.15 — 0.30

Good to Excellent No special preheat or post

heat required.

Medium Carbon

Steel

C 0.3 — 0.5

Fair Preheat 200-500° F; post

heat may be required.

High Carbon

Steel

C 0.5 — 1.0

Poor

Heat treat to reduce hard-

ness and stresses prior to

welding it possible.

Preheat: 600° F + Post

heat required.

High Strength

Low Alloy

(HSLA Steels)

Good

Preheat may be required.

Select to avoid martensite

transformation; use

carbon equivalent formula

as a guide. Post heat

rarely required.

Chrome-Moly

Steels Fair

Preheat 200-500° F

minimum. Post heat:

Stress

relieving, annealing or

nor malizin and

tempering may

be required.

Martensitic

Stainless Steels Fair-Good

Preheat 400-600° F, but

less than the martensite

transformation

temperature

range.

Post heat: If C = 0.1 —

0.2,

slow cool. If C = 0.2+,

heat treatment is

recommended.

Ferritic

Stainless Steels Good

Preheat: None to 450° F

Post heat: 1300-1550° F

but

cool rapidly from

1000.700° F range.

Austenilic

Stainless Steels Good

Preheat not required,

except to control

distortion.

Post heat not required.



Tool Steels Poor

Preheat is

MANDATORY

Weld procedure

dependent

upon alloy type.

Nickel- and

Cobalt-Base Alloys Good

Preheat: Not required

except to control

distortion

and cracking. Keep heat

input to minimum. Post

heat: Not required.

Gray Cast iron Poor

Preheat: 800-1200° F

post heat: Slow cool

FIGURE 6-1 BASE METAL TREATMENT

6.2 PREHEATING

The previous section provides information detailing

preheating requirements as dictated by the base metal alloy

composition. Additional factors affecting the preheat

temperature are: the coating alloy composition and hardness;

coating alloy thickness; base metal section size; and the need

to control warpage. In general, the preheat temperatures

recommended should be considered as minimum values with

increases dependent upon the effect of temperature increases

on the coating alloy and the base metal (specifically, the risk

of distortion).

6.3 DILUTION

The WELDTECH process can be expected to provide dilution

levels of less than 10%, except when coating thicknesses are

less than 0.030 inch or when the base metal is a cast iron. For

applications where the level of dilution must be less than 5%,

a two-pass application is recommended. In general, dilution

can be controlled through proper base metal preparation (no

sharp corners or edges), sufficient powder feed rate to absorb

the arc energy, proper amperage control and fixturing, to

control heat transfer.

6.4 WELD BEAD CONFIGURATION

The weld alloy can be applied in a “stringer” bead with no

side-to-side motion of the torch or in a “weave” bead. The

weave motion of the torch is created by using an oscillator,

which is an optional component for the System.

6.5 STRINGER BEAD PATTERN

Stringer beads can be used to coat both small and large areas.

However, their use is generally limited to applications where

the area to be coated is less than 1/4 inch wide. A single

stringer bead will produce a bead width from 1/16 to 3/16

inch. By applying a second stringer bead directly on top of the

first bead, the width will increase to approximately 1/4 inch.

Stringer beads can also be used to coat larger areas such as the

outside or inside diameters of a shaft. The use of stringer

beads for large areas has advantages and disadvantages:

The advantages are that fusion to the base metal and between

overlapping weld beads is sound and dilution is minimized

because the transferred arc remains concentrated in the center

of the weld bead. Heat input to the part is significantly less

than when using a weave bead pattern.

The disadvantages are that the weld profile is not as flat as can

be achieved using a weave pattern (which can translate to

increased finishing time). The surface of the coating is more

oxidized due to the shorter shielding time under the protective

shield envelope.

Also, it should be noted that the use of stringer beads for both

small and large areas requires more precise positioning of the

torch relative to the area to be coated.

6.6 WEAVE BEAD PATTERN

A weave pattern is most commonly used when the coating

area exceeds the 1/4 inch width limit of the stringer bead

pattern. For most applications on large surfaces, the weave

width is typically 1/2 to 1 inch. This range is used because it

produces a relatively flat bead profile. The required rotational

and translational speeds necessary to generate a weave bead

profile are readily achievable with conventional welding

turntables and side beams. The use of wider weave patterns

tends to produce concave weld bead profiles which are thinner

in the center. The result is that thicker coatings must be

applied to insure that the coated part will finish to the required

dimensions.

When large areas are to be coated and the weld beads must

overlap, the typical rule-of-thumb is that each bead should

overlap the previous bead 1/4 to 1/3 of its width. This practice

will produce the flattest profile. Most commercially available



oscillation equipment will provide for the use of end dwells,

which allow the operator to control the torch motion by

momentarily stopping for a predetermined time at the end of

each weave. The use of end dwells is recommended in almost

all cases to insure that fusion to the base metal and prior

deposits is complete. The rate of oscillation (number of times

the torch changes direction per unit time) will affect the bead

profile. The rate of oscillation should be no higher than is

necessary to achieve complete coverage of the coating area.

Increasing the rate of oscillation excessively can result in poor

fusion to the base metal and poor coating thickness control. It

is important to note that the time required to coat an area to a

given thickness depends upon the deposition capacity of the

torch and is independent of the width of the weld bead.

6.7 PART PREPARATION AND FIXTURING

Part Preparation

Undercut machining followed by degreasing with a non-

chlorinated solvent is the recommended method of preparing a

surface for coating with the System. In cases where machining

is not feasible, the part must be cleaned of surface slag,

corrosive products or entrapped oil. Abrasive blasting using

steel shot may be used for removing surface slag and debris; it

should be followed by a degreasing operation.

On new castings, the casting “skin” and any foreign material

must be removed. For castings that have been in service and

are impregnated with oil, heating uniformly to 700° F for 30

minutes or at 1000° F for shorter periods of time is

recommended to burn off the oil. Heat can be applied using an

oxyfuel gas torch or, preferably, circulating air furnace.

Fixturing

Mechanical fixtures are generally used to perform one or more

functions:

1. Hold complex shapes

2. To prevent distortion of the part during welding and/or

3. To prevent melting of small parts or parts with thin cross-

sections.

Parts with relatively narrow cross-sections (less than 2 inches)

which are coated on one face, such as an exhauster fan blade,

will distort during welding unless proper fixturing is

employed. Distortion occurs because the solidifying weld

metal creates compressive stresses while the opposite face of

the part is in tension due to thermal expansion. The result is

that the part warps. This type of distortion can be mitigated by

preventing the base metal from moving by using mechanical

constraints (often called “strong backing”). In some instances,

prebending of the part to produce a concave shape prior to

welding can be used to offset the distortion which occurs

during welding. The simplest method of minimizing distortion

caused by welding is to preheat the part and use mechanical

fixtures. Parts which have thin sections (less than 1/4 inch) or

are small in mass, will require fixturing to aid in the

dissipation of heat delivered to the part during welding. Most

fixtures of this type are made of copper and, in production

applications, should be water cooled. Two excellent examples

of applications requiring copper fixtures to dissipate heat are

automotive valve seats and agricultural knife blades.

6.8 KEY WELDING VARIABLES

1. Amperage: The proper amperage setting is dependent

upon powder alloy, base metal chemistry, powder

feed rate and part preheat temperature. Other factors

affecting the amperage setting are the nature of the

plasma and shielding gases and their flows. The

System uses Argon as the plasma gas and Argon +

7% Hydrogen as the shielding gas. The

recommended amperage setting is the lowest value

which will produce a completely fused, porosity-free

deposit. As a rule, amperage levels should be lowered

as the preheat

temperature increases, as the part size decreases and

as the powder feed rate decreases.

2. Powder Feed Rate: For the machine-mount torches,

the powder feed rate is optimal in the 3 to 5 pound

per hour range. The optimum feed rate will be in the

1 to 2.5 pound per hour range. For the higher

capacity machine- mount torches, higher powder feed

rates are possible but the trade-off is higher dilution

levels as well as a sacrifice in the flatness of the weld

bead profile.

3. Upslope/Downslope: The System provides the

operator with control over the current

upslope/downslope time. Both will generally be set at

values of less than 10 seconds. For most applications,

the upslope value is less critical than the downslope

value. The current downslope time should be



adjusted in order to prevent a crater defect. Crater

detects are caused by a too rapid reduction in current.

4. Traverse Rates:

Rotation --- When coating cylindrical parts such as

shafts, a rule-of-thumb is that the rotation speed to

deposit a one-inch wide bead with a 0.100 inch

thickness will be 1/diameter of the part in inches in

RPMs. For example, a 4-inch diameter shaft should

be rotated at 1/4 RPM as a starting point, if the bead

width is to be less than one inch wide, then

INCREASE the rotation speed proportionately.

Weld Travel --- Weld travel rates are difficult to

preset with a high degree of confidence because

many variables are involve. Testing is generally

required. However, a starting point for stringer beads

is to establish a traverse speed of 5 to 7 inches per

minute. For weave beads of one- inch width, use 2 to

3 inches per minute as a starting point.

5. Powder Alloy Selection: WELDTECH PTA-3500

users are encouraged to consult Field Engineers to

assist in the selection of the appropriate alloy. Since

the WELDTECH process is used to apply wear

protective coatings rather than as a joining process,

the coating alloy will, in most cases, differ in

composition from the base metal. Thermal expansion

and thermal conductivity mismatches should be of

concern in many applications. As a result, other

factors such as fixturing, preheating, amperage and

powder rate control take on an added importance.

6. Torch Selection: Torch selection for a machine

mount unit is predicated on the part geometry. Use

the largest torch that will access the weld areas.

6.9 WELDING PARAMETERS

Introduction

The WELDTECH PTA-3500 is unique in the simplicity and

consistency of its operating parameters. For each torch the

same plasma shielding and carrier gas flows can be used

regardless of the alloy being used. In the Weld Parameter

Table that follows, these values are listed for each torch along

with the amperage, voltage and powder feed range.

Since final parameters are dependent upon the base metal

alloy type, geometry and preheat temperature, it will be

necessary to develop specific settings for each application. As

an example, included is a “Parameter and Performance

Record” which illustrates the specific information which we

recommend that you record and retain. This information will

minimize the time required to finalize parameters for each new

application of the System.



TORCH

PLASMA

GAS FLOW

SCFH

SHIELDING

GAS FLOW

SCFH

CARRIER

GAS

FLOW

AMPERAGE

RANGE

VOLTAGE

RANGE

FEED RATE

RANGE

LB/HR

WT120 5 10—15 5.0 20-120 20-30 1.0-4.0

WT200 5 15—20 5.0 40-200 20-30 1.0-5.0

FIGURE 6—2 Weld Parameter Table

ALL gas pressures are 60 PSI.

* * Increased powder teed rates may be achieved with higher Powder Rate settings and a corresponding increase in amperage.



7. Equipment Maintenance

7.1 TORCH DESIGN AND SERVICING

Proper care and maintenance of your WELDTECH Torch will

guarantee reliable extended service. This section covers in

detail the servicing of each of the torches available with the

System Cathode and anode replacement is covered initially,

followed by step- by-step instructions on the disassembly

procedure for each torch. The cathode (electrode) is the torch

component which experiences the most wear during service.

During normal service, the sharp, conical tip will erode and

gradually become blunt. This condition will result in a loss of

concentricity between the cathode and anode, causing the

plasma arc column to become distorted. Eventually, the

cathode will wear to the point that pilot arc starting will be

prevented.

To prevent problems, periodically check the cathode for

excessive wear and sharpen to the correct angle when needed.

It is generally recommended that the cathode be sharpened

after approximately eight (8) hours of operation.

The anode will also experience wear under normal operating

conditions in the conical throat area and at the forward edge of

the throat bore. When this outer edge becomes rounded,

concentricity between the anode and cathode is lost resulting

in poor powder melting and, eventually, difficulty in starting

the arc. When excessive wear of the anode occurs, it should be

replaced. It is generally recommended that the anode be

checked after approximately twenty (20) hours of operation.

WARNING!

NEVER ATTEMPT TO SERVICE A WELDTECH TORCH WITH PRIMARY POWER “ON” IN THE

POWER SOURCE OR WITH THE WATER COOLER “ON.”

ROUTINE MAINTENANCE OF COMPONENTS

The WELDTECH PTA-3500 has been designed in modular

form for both transportability and serviceability. Although the

components are rugged in design, a program of periodic

maintenance will ensure their reliable operation.

7.2 POWER SOURCE 3500

WARNING

WHEN SERVICING THE POWER SOURCE 3500, BE

SURE THAT THE PRIMARY POWER TO HE UNIT IS

OFF. DO NOT ATTEMPT TO CLEAN THE UNIT BY

BLOWNG INTO THE VENTS WITH COMPRESSED

GAS.

Under normal service conditions, cleaning on a monthly basis

should be sufficient. However, where the service environment

is extremely dusty or where humidity levels are high, cleaning

should be done on a WEEKLY basis.

7.3 CONTROL CONSOLE

Periodic maintenance of the Control Console has been divided

into a Console Section and a Powder Feeder Section.

Console

Periodic maintenance of the Console is limited to removal of

accumulated dust from its exterior. Do not place heavy objects

on the Console or use its top as a workbench. Check all hose

and cable connections to the Console for leaks on a regular

basis and retighten as needed.



WARNING!

NO REASON EXISTS FOR REMOVING THE COVER

FROM THE CONTROL CONSOLE. UNAUTHORIZED

REMOVAL OF THE COVER BY SOMEONE OTHER

THAN A FACTORY TRAINED, WELDTECH

APPROVED TECHNICIAN WILL VOID THE

WARRANTY.

7.4 WELDTECH WATER COOLER

Periodic maintenance of the WELDTECH Water Cooler

includes the following:

1. Check the water level in the reservoir on a WEEKLY

basis and maintain it at a minimum of two-thirds full.

The most common causes of loss of cooling water are

leaks at the hose connection points and frequent

removal and reconnection of the torch.

WARNING!

NEVER ATTEMPT TO OPERATE THE SYSTEM

WITH WATER LEAKS AT HOSE OR CABLE

CONNECTIONS OR WITHIN THE TORCH.

2. Check the in-line filter at the pump on a weekly basis

and clean or replace as needed.

WARNING!

A DIRTY OR CLOGGED FILTER WILL

RESTRICT WATER FLOW TO THE TORCH AND

CAN CAUSE THE SYSTEM TO SHUT DOWN

DUE TO INSUFFICIENT WATER FLOW.

3. The radiator in the main cooler housing should be

cleaned of accumulated dust approximately every

two months. Remove the six screws that hold the

cover to the base and blow off with tow pressure

compressed air. Reattach the cover.

WARNING!

ALWAYS DISCONNECT THE WATER

COOLER LINE CORD WHEN PERFORMING

ROUTINE

MAINTENANCE.

7.5 TORCH AND POWER CABLES

The various cables and hoses that complete the system are

critical to its proper operation. They are susceptible to wear

caused by frequent flexing, abrasion from handling and

deterioration due to exposure to heat and ultraviolet radiation.

On a WEEKLY basis, examine all hoses and cables for

evidence of excessive wear and deterioration. Leaks of any

kind should be repaired immediately. Check connections at all

fittings to ensure tightness.

WARNING!

DO NOT ATTEMPT TO TIGHTEN CONNECTIONS ON

POWER CABLES WITH THE SYSTEM CONNECTED

TO PRIMARY POWER. DO NOT ATTEMPT TO

TIGHTEN GAS FITTINGS WITH THE HIGH

PRESSURE GAS CYLINDER REGULATORS OPEN.



8. Troubleshooting

8.1 INTRODUCTION

If a system component malfunctions, this troubleshooting guide is designed to help you to correct the problem. However, the first step should always be a thorough check of all power and gas connections to the component that appears to be inoperative. The troubleshooting guide is arranged in order of the most probable cause of trouble. Problems which will require extensive checking have been arranged lower in the troubleshooting chart to save time.

When the malfunction has been traced to either the Control Console or the Power Source, the recommended course of action is to contact: Weld Tech Monday thru Friday 8AM – 5PM EST Phone:+1 803-802-7966

REMOVAL OF THE OUTER COVER OF THE CONTROL CONSOLE OR POWER SUPPLY MUST NOT BE ATTEMPTED EXCEPT BY TRAINED INDIVIDUALS.

This section concludes with a general guide to solving the typical problems that might be en- countered with the weld deposit.

8.2 TROUBLESHOOTING WELD DEPOSITS:

The following lists are an introduction to the solution of some problems that might be experienced with the weld deposit.

8.2.1 CRACKING

Cause Solution

Deposit too thick Apply thinner beads. Build-up in multiple layers. Apply “buttering” or build –up pass using a lower hardness alloy.

Thermal stresses in coating too high

Increase preheat temperature

Base metal undergoes

phase change during

cooling

Furnace or slow cool after welding

Poor coating fusion to base metal

Increase preheat or increase amperage or decrease powder feed rate.

Base metal hardness too

high

Anneal or temper base metal before welding.

8.2.2 EXCESSIVE POROSITY IN COATING

Cause Solution

Powder rate too high for amperage setting

Contaminated base metal

Insufficient shielding gas flow

Reduce powder feed rate or increase amperage.

Review Section 6.7.

Check shielding gas

flowmeter setting and

correct to

recommended

parameters.

Shielding gas leak at cup or gas connections

Check cup O-Ring and all shielding gas hose connections.

Powder rate too low Increase powder rate or decrease amperage

Incorrect plasma or shielding gas purity

Use high purity (99.997), welding quality grade gases

8.2.3 IMPROPER BEAD FORMATION

A. Center of Bead Thinner than Edges

Cause Solution

Oscillation span too wide

Reduce width of oscillation.

End dwell times too long

Reduce end dwell times.

Rate of oscillation too high

Reduce oscillation rate.

B. Insufficient Coating Coverage - Low Areas or Holes

Cause Solution

Amperage too low Increase amperage

Too rapid reduction of current at shut-down

Increase downslope duration.

Pulsating powder feed See "Inconsistent Powder Feed" Section 8.8.

Torch travel speed too

high

Reduce travel speed.

C. Irregular Profile of Overlapping Weld Beads

Deposit too thick (per

pass)

Reduce powder feed rate

Incorrect bead overlap Increase or decrease overlap of previous bead, as necessary.



8.2.4 EXCESSIVE BASE METAL DILUTION

Cause Solution

Amperage too high Reduce amperage

Oscillation end dwell set too long

Reduce end dwell duration.

Heat input too High Review Process Parameters (Section 6)

Powder feed rate too low

Increase powder feed rate

8.2.5 INCOMPLETE FUSION OF WELD DEPOSIT TO BASE METAL

Cause Solution

Excessive bead thickness

Reduce powder feed rate.

Unweldable base metal

Select alternative coating process or change base metal alloy.

8.3 POWER PROBLEMS

Cause Solution

No Display on Control

Check Power Cable is plugged in and control is receiving 110VAC.

Check Fuse located on the back of the Control.

No Display on Power Source

See section 4.5

8.4 ARC STARTING PROBLEMS

This section is subdivided into three parts in order of occurrence - no high frequency (HF) in torch, no pilot arc ignition with HF in torch and no transfer of the arc to the workpiece.

8.4.1 No High Frequency in Torch

Cause Solution

Plasma and/or shielding gas pressure too low

Check for gas fault light and adjust regulators to supply 60 psi.

Check for leaks at each fitting.

Excess space between anode and cathode

Check anode and cathode for wear. Replace as required and realign cathode tip flush with the face of the anode

Defective torch power Identify the defective

cable cable by checking conductivity of its internal braided copper wire with an ohmmeter and replace

Short between (+) and ( - ) torch power cables

Check torch power cables from connection points at the torch back to theControl Console. Look for signs of an electrical discharge. Separate cables by repositioning

Short inside torch assembly

Check for powder build up inside the anode and clean thoroughly. Remove the torch, disassemble and check all components for wear or cracks, especially insulators. Replace defective parts and reassemble.

8.4.2 High Frequency in the Torch. But No Pilot Arc

Cause Solution

Plasma gas flow too high

Reset plasma gas flow to recommended setting

Plasma and shielding gas connections reversed

Check gas connections at hook-up points at torch and console and correct.

Excessive wear/oxidation of the anode and/or cathode

Remove anode and cathode. Repaint cathode if worn. Clean anode bore or replace if wear is excessive.

Excessive spacing between anode and cathode

Reposition cathode

Cathode misshapen or misaligned

Repoint and reposition cathode.

Poor conductivity in torch power cables

Check resistance of ( + ) and (-) torch power cables with an ohmmeter. Replace cables if defective.

8.4.3 Pilot Arc Ignites, No Transfer of Main Arc

Cause Solution

Poor ground connection

Re-position clamp; clean contact area on work piece.



8.5 POWDER FEED PROBLEMS

A. No Powder Feed

Cause Solution

Clogged powder feed line between torch and console

Disconnect (BLACK) powder feed line at front of console and clear by purging with clean, dry gas.

Clogged pick-up tube Disconnect hopper gas connection and remove powder. Purge hopper and pick-up tube with clean, dry gas.

Debris in powder Remove powder and sieve through a 60 mesh screen.

No carrier gas flow Correct flow meter setting.

B. Intermittent or Inconsistent Powder Feed

Cause Solution

Powder holes in anode are clogged

Remove anode and clear the powder holes.

Build-up on face of anode

Remove anode and clear the two powder holes. Check cathode for concentricity.

Carrier gas flow set too high

Readjust to correct setting.

Gas leaks in hopper or powder feed lines

Check all O-Rings on hopper connections and replace as needed. Leak- check all gas line connections at the hopper, console and torch.



9. Warranty and Service Information

9.1 WARRANTY

The hardware components of the WELDTECH PTA-3500,

including the Power Source 3500, Control Console, Water

Cooler, Torches and torch cables, are warranted only to the

original purchaser to be free from defects in material or

workmanship under normal use and service. The obligation of

Weld Tech Corporation under this warranty is limited to the

repair without charge, F.O.B. its factory or authorized service

center, or the replacement without charge, F.O.B. its factory or

authorized service center, of any of the hardware components

thereof which shall, within THREE YEARS from the date of

sale of the system or components thereof to the original

purchaser, be returned to Weld Tech, or authorized service

center, with transportation charges prepaid; and which on

examination shall disclose to Weld Tech’s satisfaction to have

been thus defective. Excluded from this warranty are the

following:

1. Torch Components:

A. Anodes

B. Cathodes

C. Shielding Cups

D. Ceramic Insulators

E. Torch Body

F. Power & Welding Cables

G. Filters

H. Fuses & Lamps

2. Foot Switch

3. Remote Pendant

4. Primary Power and Welding Current Cables

5. Gas Hoses and Fittings

There are no warranties express or implied, oral or written, in

fact, by operation of law or otherwise except as herein

expressly stated. In no event shall Weld Tech Corporation be

liable for any direct, indirect, special or consequential

damages such as loss of anticipated profits or other economic

loss in connection with or arising out of the existence,

furnishing, functioning or the customer’s use of any item of

equipment or services provided; Weld Tech Corporation’s

liability in connection with the sale being expressly limited to

the repair or replacement of defective parts.

THIS WARRANTY IS VOID IF THE CONTROL

CONSOLE IS OPENED OR IF UNAUTHORIZED

REPAIRS HAVE BEEN ATTEMPTED.

9.2 WARRANTY REPAIRS

To obtain warranty repairs, first contact Weld Tech to obtain a

“return goods authorization number.” Then ship your

equipment prepaid (no collect shipments accepted) to the

designated repair center. Be sure to enclose your name,

address and telephone number and return goods authorization

number. The equipment will be returned prepaid.

9.3 NON-WARRANTY REPAIR

Contact the Weld Tech to obtain a repair authorization

number. Then ship your equipment prepaid (no collect

shipments accepted) to the designated repair center. Be sure to

enclose your name, address, telephone number, repair

authorization number and your purchase order for the repair.

The equipment will be returned prepaid.

NOTE: Office hours of Weld Tech are 8:00 AM to 5:00 PM

Eastern Time, Monday through Friday.

9.4 ON-SITE REPAIR (Continental U.S. Only)

On-site Repair Service is available by contacting the Weld

Tech local representative. A Service Engineer will travel to

customer location to arrive within two working days* (under

normal travel conditions) of receipt of Purchase Order from

customer for charges per the following schedule:

1. All travel costs and expenses incurred from USA or

representative office to customer’s location will be itemized

and invoiced.

2. All parts used for repair (unless covered by warranty) will

be invoiced.

3a. A labor charge per day at customer’s location will be

invoiced. Please note that travel time will be calculated and

included in the per diem fee.

3b. The minimum on-site repair service charge is two days’

labor charge plus travel, food, lodging and parts.

*If unforeseen circumstances prevent achievement of this

schedule, customer will be advised prior to placing order for

service



10. EQUIPMENT SPECIFICATIONS

WT3500 - POWER SUPPLY

TYPE DC INVERTER POWER SOURCE

IGNITION TYPE HF (HIGH FREQUENCY) IGNITION

CURRENT RANGE 10-350 AMPS

WELDING CURRENT @ 100% DUTY CYCLE 250 AMPS

WELDING CURRENT @ 60% DUTY CYCLE 300 AMPS

DISPLAY SHOWS TRUE AMPERAGE AND VOLTAGE DURING LIVE WELD

DIMENSIONS (L X W X H) 13.75 X 22 X 24.75

WEIGHT 135 LBS.

**ALLOWS FOR ANY INPUT VOLTAGE (208-575V) WITH NO MANUAL LINKING

**PATENTED WIND TUNNEL TECHNOLOGYTM COOLS ELECTRICAL COMPONENTS AND PC BOARDS WHILE PROTECTING

THEM FROM DIRT, DEBRIS AND DUST BY UTILIZING AN INTERNAL AIRFLOW SYSTEM GREATLY IMPROVING RELIABILITY

**POWER SOURCE MAINTAINS CONSTANT POWER OUTPUT REGARDLESS OF INPUT POWER FLUCTUATIONS +/- 10%

**INTERNAL FAN ONLY OPERATES WHEN NECESSARY, THUS REDUCING POWER CONSUMPTION, NOISE AND

CONTAMINANTS.

WT3500 - CONTROLLER

CONTROL METHOD

DIGITAL

TOUCH SCREEN DISPLAY

COLOR CODED USER FRIENDLY BUTTONS

HOME SCREEN DISPLAYS SET AND TRUE AMPERAGE, VOLTAGE,

POWDER RATE AND NAME OF CURRENT WELD PROGRAM AT ALL

TIMES

INTERNAL CONTROL WARNINGS

SYSTEM LOCKS DOWN AND WILL NOT PILOT WITH APPROPRIATE

GAS AND / OR WATER FLOW

SYSTEM MAINTAINS A LOG OF ALL GAS / WATER FLOW FAULTS

WITH TIME AND DATE OF OCCURRENCE



PROGRAM MODES MANUAL / SEMI-AUTOMATIC / AUTOMATIC

FLOW METER CONTROL (GAS) ANALOG (PLASMA, SHIELDING, CARRIER GAS)

MOTOR CONTROL

POWDER FEEDER (OPTIONAL CONTROLLER FOR FLUIDIZED BED

POWDER FEEDER)

OSCILLATOR

Z-AXIS ARC VOLTAGE CONTROLLER (AVC)

OPTIONAL CONTROLLER FOR POSITIONER OR GANTRY SYSTEM

STORABLE PROGRAMS 200

PROGRAMMABLE PARAMETERS

17

WELD CURRENT

VOLTAGE

POWDER RATE

UP SLOPE

DOWN SLOPE

PRE-FLOW

POST-FLOW

ARC VOLTAGE CONTROLLER (AVC) ON/OFF

OSCILLATOR WIDTH

OSCILLATOR LEFT SPEED

OSCILLATOR RIGHT SPEED

OSCILLATOR LEFT DWELL

OSCILLATOR RIGHT DWELL

OSCILLATOR ON DELAY

OSCILLATOR OFF DELAY

RELAY ON DELAY (FOR POSITIONER)

RELAY OFF DELAY (FOR POSITIONER



DIMENSIONS 11.5 X 24 X 25

WEIGHT 60 LBS

3500RP - REMOTE PENDANT

NUMBER OF FUNCTIONS 29

CONTROLS EMERGENCY STOP

TORCH (ON/OFF)

GAS (ON/OFF)

POWDER (ON/OFF)

WELD CURRENT (UP/DWN)

ARC VOLTAGE CONTROL [AVC] (UP/DWN)

POWDER RATE (UP/DWN)

OSCILLATOR SETUP (ON/OFF)

OSCILLATOR CENTER POTENTIOMETER

OSCILLATOR WIDTH (INCREASE/DECREASE)

OSCILLATOR LEFT SPEED (UP/DWN)

OSCILLATOR RIGHT SPEED (UP/DWN)

OSCILLATOR LEFT DWELL (INCREASE/DECREASE)

OSCILLATOR RIGHT DWELL (INCREASE/DECREASE)



3500SD - POWDER FEEDER

TYPE STEPPER DRIVEN METERING WHEEL WITH PRESSURE

EQUILIBRIUM SYSTEM

FEEDING RATE 3-120G/MIN

CAPACITY 25 LBS (11.34KG) – CUSTOM SIZES AVAILABLE

TYPICAL PARTICLE SIZES IN US MESH # /

MICROMETERS

WEIGHT %

80 / 180 MICROMETERS 0

100 / 150 MICROMETERS 5 MAX

-100 +270 / 150-53 MICROMETERS BALANCE

-270 +328 / 53-45 MICROMETERS 5 MAX

-325 / 45 MICROMETERS 1 MAX

3500AVC – ARC VOLTAGE CONTROLLER

MOTOR TYPE STEPPER MOTOR

METHOD ACME SCREW

TRAVEL 6 INCHES

TRAVEL SPEED (MAX) 300MM/SEC

TASK VERTICAL TORCH POSITIONER WHEN SYSTEM IS IDLE

AVC ACTUATOR WHEN SYSTEM IS RUNNING



3500OSC – OSCILLATOR

MOTOR TYPE STEPPER MOTOR WITH ENCODER FEEDBACK

METHOD PRECISION BALL SCREW

TRAVEL 4.5 INCHES

GENERAL

WARRANTY 3 YEARS ON POWER SOURCE AND CONTROLLER

SHIPPING 2-3 WEEKS

AVAILABILITY IN-STOCK

TRAINING FREE

HIGHLIGHTS

**FULLY AUTOMATIC FUNCTION ALLOWS FOR SINGLE BUTTON TO TURN SYSTEM ON AND OFF WITHOUT ANY

SEQUENCE BEING FOLLOWED. THE SYSTEM AUTOMATICALLY BEGINS PRE-FLOW, PILOTS, TRANSFERS, ACTIVATES THE

AVC, ACTIVATES THE OSCILLATOR, ACTIVATES WORK HANDLING SYSTEM, ACTIVATES THE POWDER FEEDER AND

BEGINS FOLLOWING ALL STORED PARAMETERS. DEPRESS THE BUTTON AGAIN AND THE SYSTEM SHUTS DOWN IN THE

SAME FASHION.

**ERROR PREVENTION BY CONSTANT MONITORING AND MEASURING OF COOLANT AND GAS FLOW PRIOR TO AND

DURING SYSTEM START

**SHORTCUTS TO OTHER NEEDED PARAMETERS SUCH AS THE OSCILLATOR MAY BE REACHED WITH ONE CLICK OR

CHANGED WITH THE REMOTE PENDANT

**THE AVC (ARC VOLTAGE CONTROLLER) AUTOMATICALLY REDUCES OR INCREASES THE ARC LENGTH DUE TO

SURFACE IRREGULARITIES TO MAINTAIN A STEADY COAT AS WELL AS PREVENT THE TORCH HEAD FROM CRASHING

WITHOUT ANY ADDITIONAL WIRES OR CONTROLLERS.

**ADJUSTABLE AVC SENSITIVITY

**ANY INDUSTRY TORCH MAY BE USED WITH THE WT3500 SYSTEM



APPENDIX ‘A’ PTA 3500 PROGRAMMING

STEPS TO ENTER / CREATE NEW WELD PROGRAM

1. Press ‘Settings’ Button

2. Press ‘Parameters’ Button

3. Select ‘WeldProgram(#)’ By Pressing the Header

4. Press ‘Enter’ Button

5. Press ‘Load Program’ Button

6. Select 'Parameters Area' By Pressing in the middle of the screen

7. Use 'up' and 'down' arrows to select desired Parameter OR Press 'Copy

Present to Program’ Button and proceed to Step 12


9. Input desired value(s)


---Repeat Steps 7-10 until all desired Parameters are entered---

11. Press ‘Copy program to Present’ Button to load your new Program

Settings

12. Press ‘Back’ Button

13. Press ‘Back’ Button

Settings

Parameters

Load

Program

Copy Present to Program

Copy Program to Present

Back

Back



GLOSSARY

Automatic Welding - The equipment turns on Gas a set time (Pre Flow) before torch and off a set time (Post Flow) after

the torch is off. The equipment also turns on the Powder 70% into up slope and turns off powder 20% into down

slope.

Amperage - The measurement of the amount of electricity flowing past a given point in a conductor per second. Current is

another name for amperage.

Arc - The physical gap between the end of the electrode and the base metal. The physical gap causes heat due to

resistance of current flow and arc rays.

Direct Current (DC) - Flows in one direction and does not reverse its direction of flow as does alternating current.

Duty Cycle - The number of minutes out of a 10-minute time period an arc welding machine can be operated at maximum

rated output.

Ground Connection - A safety connection from a welding machine frame to the earth. See Workpiece Connection for the

difference between work connection and ground connection.

Hertz - Hertz is often referred to as "cycles per second". In the United States, the frequency or directional change of

alternating current is usually 60 hertz.

High Frequency - Covers the entire frequency spectrum above 50,000 Hz.

PTA - Plasma Transferred-Arc

RMS (Root Mean Square) - The "effective" values of measured AC voltage or amperage. RMS equals 0.707 times the

maximum, or peak value.

Semiautomatic Welding - The equipment turns on Gas a set time (Pre Flow) before torch and off a set time (Post Flow)

after the torch is off.

Shielding Gas - Protective gas used to prevent atmospheric contamination of the weld pool.

Spatter - The metal particles blown away from the welding arc. These particles do not become part of the completed

weld.

Three Phase Circuit - An electrical circuit delivering three cycles within a 360 degree time span, and the cycles are 120

electrical degrees apart.

Torch - A device used in the process to control the position of the electrode, to transfer current to the arc, and to direct the

flow of the shielding gas.

Tungsten - Rare metallic element with extremely high melting point (3410 deg Celsius).

Voltage - The pressure or force that pushes the electrons through a conductor. Voltage does not flow, but causes amperage

or current to flow. Voltage is sometimes termed electromotive force (EMF) or difference in potential.

Weld Metal - The electrode and base metal that was melted while welding was taking place. This forms the welding bead.



INDEX

Administration, 4

alloy, 4, 12, 13, 18, 30, 32, 33, 34, 35

alloys, 4, 13, 19, 32

Aluminum, 4

arc, 4, 6, 7, 9, 10, 12, 14, 16, 17, 21, 30, 31, 33, 37, 47

Argon, 12, 13, 17, 28, 30, 34

AVC, 13, 14, 31, 44, 45, 46, 47

beryllium, 7

Borates, 4

Boron Oxide, 4

brass, 8

breakers, 5

cables, 5, 6, 10, 15, 27, 28, 38, 42

cadmium, 7

Carbon Monoxide, 4

carrier, 6, 17, 35

CAUTION, 4

Chromate Salts, 4

Chromic, 4

Chromium, 4

Chromous, 4

circuit, 5, 6, 8, 31

circulator, 5

clamps, 8

clothing, 5, 6, 7, 9, 21

Cobalt, 4, 18, 19, 33

codes, 4

Coil, 8

compression, 9

conducting, 5

conductors, 5

Conductors, 5

connection, 5, 9, 38, 42

connections, 5, 8, 9, 10, 28, 37, 38

connectors, 5

Console, 13, 14, 21, 27, 28, 29, 30, 37, 42

continuity, 5

control, 5, 12, 13, 14, 18, 27, 32, 33, 34, 35

Control, 7, 13, 14, 21, 27, 28, 29, 31, 37, 42, 43, 44, 45

copper, 8, 27, 32, 34

Copper, 4

current, 5, 12, 13, 14, 16, 28, 34, 43

currents, 5, 6

cylinder, 8, 9, 10, 31

cylinders, 7, 8, 9, 28, 30

Cylinders, 8

devices, 5, 6, 8

DILUTION, 33

Electrical Code, 4, 5

electrode, 5, 7, 17, 18, 37

electronic, 6

equipment, 4, 5, 6, 8, 9, 10, 13, 16, 21, 28, 34, 42

Equipment, 5, 7, 9, 14, 37

Failure, 4

feeder, 6, 15, 17, 44, 47

Ferrovanadium, 4

ferrules, 8

flammable, 5, 9, 10

fuel, 5, 9

Fume, 4, 7, 21

fumes, 4, 7

gas, 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 21, 28,

29, 30, 31, 34, 35, 36, 43, 47

gases, 4, 7, 8, 9, 13, 16, 28, 34

gauge, 8, 9

gloves, 6, 7

goggles, 6, 7

grease, 5, 9

ground, 5, 8, 27, 28

Health, 4, 5

hose, 8, 9, 16, 28, 29, 37, 38

hoses, 8, 15, 16, 28, 29, 38

Hydrogen, 13, 17, 28, 30, 34

IMPORTANT, 1, 4, 30

industrial, 4

inspection, 4, 6

installation, 4, 6, 28

installing, 5, 21

Iron, 4, 18

Iron Oxide, 4

Lead, 4, 7

Lead compounds, 4

Magnesium Oxide, 4

Magnetic, 6

maintenance, 4, 21, 37, 38

Manganese, 4

mercury, 7

metal, 5, 7, 10, 12, 13, 18, 28, 30, 32, 33, 34, 35

Molybdenum, 4

National, 4, 5, 10, 11

Nickel, 4, 18, 33

Nitrogen Oxides, 4

Occupational, 4

oil, 5, 9, 21, 34

operating, 4, 6, 16, 17, 35, 37

operation, 4, 5, 6, 7, 10, 13, 14, 16, 18, 28, 34, 37, 38, 42



Oscillation, 13

oxygen, 6, 7, 9

Ozone, 4

phase, 5

plasma, 12, 15, 17, 18, 21, 34, 35, 37

Plasma, 4, 12, 16, 18, 44, 49

powder, 6, 12, 13, 14, 15, 17, 18, 19, 30, 31, 33, 34, 35,

36, 37, 43, 44, 47

power, 5, 6, 13, 14, 17, 18, 19, 21, 27, 28, 29, 30, 43

practices, 4

PREHEATING, 33

pressure, 7, 8, 9, 10, 15, 28, 30, 38

pressurization, 9

pressurized, 8, 9

procedures, 4, 21, 30

protection, 5, 6, 7, 8, 9, 13, 21, 31

PTA, 0, 1, 4, 12, 13, 14, 15, 18, 21, 31, 32, 35, 37, 42, 48

radiation, 4, 6, 21, 38

receptacle, 5, 27

References, 4

regulations, 4

regulator, 7, 8, 9, 15

Regulator, 7, 28

regulators, 8, 9, 15, 30, 31

requirements, 4, 5, 18, 32, 33

safe, 4, 7, 9, 10

safety, 4, 6, 8, 14, 21, 28

Safety, 4, 5

service, 4, 6, 8, 9, 32, 34, 37, 42

Shield Gas, 16, 17, 18

shielding, 7, 15, 33, 34, 35

Silicon, 4

source, 5, 6, 7, 9, 13, 14, 30, 43

standards, 4, 10

Standards, 4, 5, 10, 11

STRINGER, 33

substances, 4

switch, 6, 30, 31

switchbox, 5

Terminals, 5

Tin, 4

torch, 13, 14, 15, 16, 17, 18, 19, 28, 30, 33, 34, 35, 37,

38, 42, 46, 47

Tungsten, 4, 18

voltage, 5, 14, 17, 30, 35, 43, 47

WARNING, 4, 5, 6, 7, 9, 28, 29, 30, 37, 38

Weld Tech, 0, 4, 13, 14, 21, 28, 42

WELD TECH, 4

welding, 4, 5, 6, 7, 8, 9, 10, 13, 14, 15, 17, 21, 28, 32,

33, 34

Welding, 4, 5, 6, 10, 11, 12, 16, 42, 43

WORKPIECE, 28, 32

worktable, 5

WT200, 16, 18, 19, 36

zinc, 7

Zinc, 4

WEBSITE:

HTTP://WWW.WELDTECHINTL.COM

PHONE:

+1 803-802-7966

ADDRESS:

3581 CENTRE CIRCLE STE 102

FORT MILL SC 29715

MARCH 31, 2015