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PTA-3500
PROCESS MANUAL
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IMPORTANT!
BEFORE ATTEMPTING TO OPERATE
THE WELDTECH PTA-3500,
BE SURE TO READ AND UNDERSTAND
THE ENTIRE SAFETY SECTION
THAT FOLLOWS.
IMPORTANT!
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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
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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:
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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.
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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
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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
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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.
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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.
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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.
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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
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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
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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
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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.
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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
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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.
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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.
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4.5 Connecting Input Power for 3500 Models
A. Connecting Three- Phase Input Power
Installation must meet all National and
Local Codes - have only quali- fied
persons make this installation.
Disconnect and lockout/tagout in- put
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 dis- connect switch shown).
Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.
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1 '\.,
8
3
Installation must meet all National and
Local Codes - have only quali- fied
persons make this installation.
Disconnect and lockout/tagout in- put
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.
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
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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
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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.
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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-
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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.
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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
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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
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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.
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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
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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
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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.
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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.
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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.
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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.
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8. Troubleshooting
8.1 INTRODUCTION
If a system component malfunctions, this trouble- shooting 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 ar- ranged 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 in- crease 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.
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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.
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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 con- nections at the hopper, console and torch.
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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
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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
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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
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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)
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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
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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
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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
8. Press ‘Enter’ Button
9. Input desired value(s)
10. Press ‘Enter’ Button
---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
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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.
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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
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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
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