EWM TIG-SR 300 GD HD User manual

Operating instructions
EN
Welding torch
TIG-SR 300 GD HD
TIG-SR 300F GD HD
099-020967-EW501
Observe additional system documents!
06.06.2023

General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read and observe the operating instructions for all system components, especially the sa-
fety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and re-
pair the machine.
• Technical changes due to further development in machine technology may lead to a dif-
fering welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No
other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed ac-
cepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods
are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this
reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect
installation, improper operation or incorrect usage and maintenance or any actions connected to this in
any way.
© EWM GmbH
Dr. Günter-Henle-Strasse 8
56271 Mündersbach Germany
Tel.: [phone], Fax: -244
Email: inf[email protected]
www.ewm-group.com
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.
Data security
The user is responsible for backing up data of all changes from the factory setting. The user is liable for
erased personal settings. The manufacturer does not assume any liability for this.

Contents
Notes on using these operating instructions
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1 Contents
1Contents ........................................................................................................................................ 3
2For your safety ............................................................................................................................. 4
2.1 Notes on using these operating instructions ........................................................................ 4
2.2 Explanation of icons ............................................................................................................. 5
2.3 Safety instructions ................................................................................................................ 6
2.4 Transport and installation ..................................................................................................... 9
3Intended use ............................................................................................................................... 11
3.1 Applications ........................................................................................................................ 11
3.2 Documents which also apply .............................................................................................. 11
3.2.1 Warranty ............................................................................................................. 11
3.2.2 Declaration of Conformity ................................................................................... 11
3.2.3 Service documents (spare parts) ........................................................................ 11
3.2.4 Part of the complete documentation ................................................................... 12
4Machine description – quick overview ..................................................................................... 13
4.1 Product variants ................................................................................................................. 13
4.2 TIG-SR 300 GD HD ........................................................................................................... 14
5Design and function ................................................................................................................... 15
5.1 General .............................................................................................................................. 15
5.2 Scope of delivery................................................................................................................ 15
5.3 Transport and installation ................................................................................................... 16
5.3.1 Ambient conditions .............................................................................................. 16
5.4 Equipping the welding torch ............................................................................................... 17
5.5 Function specification ......................................................................................................... 18
5.5.1 General ............................................................................................................... 18
5.5.2 TIG torch ............................................................................................................. 18
6Maintenance, care and disposal ............................................................................................... 19
6.1 General .............................................................................................................................. 19
6.1.1 Identifying damage or worn components ............................................................ 19
6.1.2 Maintenance and care before each use .............................................................. 20
6.1.3 Regular maintenance .......................................................................................... 21
6.2 Disposing of equipment ...................................................................................................... 22
7Rectifying faults ......................................................................................................................... 23
7.1 Checklist for rectifying faults............................................................................................... 23
8Technical data ............................................................................................................................ 24
8.1 TIG-SR 300 GD HD ........................................................................................................... 24
9Accessories ................................................................................................................................ 25
9.1 General accessories .......................................................................................................... 25
10 Replaceable parts....................................................................................................................... 26
10.1 TIG-SR 300 GD HD ........................................................................................................... 26
11 Circuit diagram ........................................................................................................................... 29
11.1 TIG-SR 300 GD HD ........................................................................................................... 29
12 Appendix ..................................................................................................................................... 30
12.1 Searching for a dealer ........................................................................................................ 30

For your safety
Notes on using these operating instructions
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2 For your safety
2.1 Notes on using these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning sym-
bol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general warn-
ing symbol.
• The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release / Tap / Tip
Switch off machine
Release
Switch on machine
Press and hold
Incorrect / Invalid
Switch
Correct / Valid
Turn
Input
Numerical value – adjustable
Navigation
Signal light lights up in green
Output
Signal light flashes green
Time representation (e.g.: wait 4 s / ac-
tuate)
Signal light lights up in red
Interruption in the menu display (other
setting options possible)
Signal light flashes red
Tool not required/do not use
Signal light lights up in blue
Tool required/use
Signal light flashes blue

For your safety
Safety instructions
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2.3 Safety instructions
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with the regulations!
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low vol-
tages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
• The device must not be used to defrost pipes!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a techni-
cal specialist may interconnect the sources as per standard IEC 60974-9:2010: Installa-
tion and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or
country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
• Only qualified personnel may connect the machine.
• When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
• Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be com-
bined, which is not permitted.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
• Use hand shield or welding helmet with the appropriate safety level (depends on the appli-
cation).
• Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
• Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!

For your safety
Safety instructions
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WARNING
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
• Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
• Dry welding clothing (shoes, gloves and body protection) to protect against warm environ-
ments with conditions comparable to ambient temperatures of 100 °C or higher and arcing
and work on live components.
• Hearing protection against harming noise.
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!

For your safety
Safety instructions
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CAUTION
Smoke and gases!
Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia-
tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso-
nous phosgene.
• Ensure sufficient fresh air!
• Keep solvent vapours away from the arc beam field!
• Wear suitable respiratory protection if necessary!
• To prevent the formation of phosgene, residues of chlorinated solvents on workpieces must
first be neutralised using appropriate measures.
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
According to IEC 60974-10, welding machines are divided into two classes of
electromagnetic compatibility (the EMC class can be found in the Technical
data) > see 8 chapter:
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas, inclu-
ding residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the
surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding system
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Electromagnetic fields!
The power source can create electrical or electromagnetic fields that may impair the
function of electronic systems such as EDP and CNC devices, telecommunication,
power and signal lines as well as pacemakers and defibrillators.
• Follow the maintenance instructions > see 6.1.2 chapter!
• Unwind the welding leads completely!
• Shield radiation-sensitive equipment or facilities appropriately!
• The function of pacemakers may be impaired (seek medical advice if necessary).

For your safety
Transport and installation
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CAUTION
Obligations of the operator!
The respective national directives and laws must be complied with when operating the
machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the int-
roduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements
for the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode hold-
ers, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the ma-
chine is switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains
network. For some types of machines, connection restrictions or requirements relating to the
maximum possible line impedance or the necessary minimum supply capacity at the interface
with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,
attention is also drawn to the machines' technical data. In this case, it is the responsibility of the
operator, where necessary in consultation with the mains network operator, to ensure that the
machine can be connected.
2.4 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause seri-
ous injuries!
• Observe the instructions from the gas manufacturer and any relevant regulations concern-
ing the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.

For your safety
Transport and installation
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CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10° (ac-
cording to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose pack-
ages ) can present a tripping hazard.
• Lay the supply lines flat on the floor (avoid loops).
• Avoid laying the leads on passage ways.
Risk of injury from heated coolant and its connections!
The coolant used and its connection or connection points can heat up significantly
during operation (water-cooled version). When opening the coolant circuit, escaping
coolant may cause scalding.
• Open the coolant circuit only when the power source or cooling unit is switched off!
• Wear proper protective equipment (protective gloves)!
• Seal open connections of the hose leads with suitable plugs.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant ac-
cessory components.
• Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and stand-
ards applicable for use in industry and trade. It may only be used for the welding proce-
dures indicated at the rating plate. Hazards may arise for persons, animals and material
objects if the equipment is not used correctly. No liability is accepted for any damages
arising from improper usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
3.1 Applications
Welding torch for TIG welding with arc welding machines.
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information regarding
warranty, maintenance and testing at www.ewm-group.com!
3.2.2 Declaration of Conformity
This product corresponds in its design and construction to the EU directives listed in the decla-
ration. The product comes with a relevant declaration of conformity in the original.
The manufacturer recommends carrying out the safety inspection according to national and in-
ternational standards and guidelines every 12 months (from commissioning).
3.2.3 Service documents (spare parts)
WARNING
No improper repairs and modifications!
To prevent injuries and damage to the machine, only competent personnel (authorised
service personnel) are allowed to repair or modify the machine.
Unauthorised manipulations will invalidate the warranty!
• Instruct competent personnel (authorised service personnel) to repair the machine.
Spare parts can be obtained from the relevant authorised dealer.

Intended use
Documents which also apply
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3.2.4 Part of the complete documentation
This document is part of the complete documentation and valid only in combination with all other
parts of these instructions! Read and observe the operating instructions for all system
components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 3-1
Item
Documentation
A.1
Remote control
A.2
Control
A.3
Power source
A.4
Welding torch
A
Complete documentation

Machine description – quick overview
Product variants
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4 Machine description – quick overview
4.1 Product variants
Version
Functions
SR
Silicone rubber
Standard torch for simple welding tasks
GD
Gas-cooled with decentral connection
WD
Water-cooled with decentral connection
HD
Heavy-duty
For heavy-duty use
GDV
Rotary gas valve
To regulate the gas volume
GRIP
GRIP Grip
Ergonomic grip for a high grip safety
KOMBI
Hose package
Euro torch connector with added welding current lead for polarity change.
SC
SuperCool
Higher load capacity thanks to improved design of the hose package.
F
Flexible torch neck
HFL
Highly flexible hose package
U/D
Control Up-/Down
The welding power (welding current) can be infinitely increased or decreased during
the welding process.
2T
Double push-button
5P
5-pole torch connection socket
8P
8-pole torch connection socket
12P
12-pole torch connection socket
RETOX
Control RETOX
U/D functions with an additional display of the set welding current or the selected JOB
number.
RETOX XQ
Control RETOX XQ
TIG function torch for the machine series Tetrix XQ
EZA
Euro torch connector

Machine description – quick overview
TIG-SR 300 GD HD
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4.2 TIG-SR 300 GD HD
Figure 4-1
Item
Symbol
Description 0
1
Back cap
2
Gas nozzle
3
Torch trigger
4
Grip plate
5
Hose package
6
Welding current connection
Decentral
7
Shielding gas hose
Crown nut G ¼“
8
Connector plug, 5-pole
Control lead

Design and function
General
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5 Design and function
5.1 General
WARNING
Risk of burns and electric shock on the welding torch!
Welding torch (torch neck or torch head) and coolant (water-cooled version) heat up
strongly during the welding process. During assembly work, you may come into touch
with electrical voltage or hot components.
• Wear proper protective equipment!
• Switch off the power source or torch cooling and allow the welding torch to cool!
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
• Observe the safety information on the first pages of the operating instructions!
• Commissioning must be carried out by persons who are specifically trained in handling
power sources!
• Connect connection or power cables while the machine is switched off!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant ac-
cessory components.
• Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!
Machine damage due to incompletely assembled welding torch!
Incomplete assembly may destroy the welding torch.
• Always assemble the welding torch completely.
After each opening of the welding torch, using the "gas test" "gas flush" function and increased
flow rates, remove moisture, atmospheric oxygen and any impurities from the welding torch.
Read and observe the documentation to all system and accessory components!
5.2 Scope of delivery
The delivery is checked and packaged carefully before dispatch, however it is not possible to exclude the
possibility of damage during transit.
Receiving inspection
• Check that the delivery is complete using the delivery note!
In the event of damage to the packaging
• Check the delivery for damage (visual inspection)!
In the event of complaints
If the delivery has been damaged during transport:
• Please contact the last haulier immediately!
• Keep the packaging (for possible checking by the haulier or for the return shipment).
Packaging for returns
If possible, please use the original packaging and the original packaging material. If you have any queries
on packaging and protection during transport, please contact your supplier.

Design and function
Transport and installation
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5.3 Transport and installation
CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
5.3.1 Ambient conditions
Equipment damage due to contamination!
Unusually high amounts of dust, acids, corrosive gases or substances can damage the machine
(observe maintenance intervals > see 6.1.3 chapter).
• Avoid large amounts of smoke, steam, oily fumes, grinding dust and corrosive ambient air!
In operation
Temperature range of the ambient air:
• -10 °C to +40 °C (-13 F to 104 F) [1]
Relative humidity:
• up to 50 % at 40 °C (104 F)
• up to 90 % at 20 °C (68 F)
Transport and storage
Storage in a closed area, temperature range of the ambient air:
• -25 °C to +55 °C (-13 F to 131 F) [1]
Relative humidity
• up to 90 % at 20 °C (68 F)
[1] Ambient temperature dependent on coolant! Observe the coolant temperature range of the torch coo-
ling

Design and function
Equipping the welding torch
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5.4 Equipping the welding torch
Figure 5-1
Item
Symbol
Description 0
1
Gas nozzle
2
Collet casing
3
Grip plate
4
Collet
5
Electrode
6
Back cap

Design and function
Function specification
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5.5 Function specification
5.5.1 General
TIG torches are connected to the power source via the hose package. The following components are
guided through the hose package:
• welding current lead
• shielding gas supply
• control cable
In TIG welding, the welding consumable is usually added manually in form of a stick. With fully automatic
machines, the welding consumable is usually added as a wire by a separate wire feeder.
5.5.2 TIG torch
Figure 5-2
Item
Symbol
Description 0
1
Torch trigger
Welding current ON/OFF
2
Torch trigger
Reduce welding current
TIG torches are equipped with a torch trigger. This trigger is used to:
• switch the welding current on and off,
• reduce the current during welding to a secondary current by tapping it.
Tapping function: Swiftly tap the torch trigger to change the function. The set torch mode determines the
operating mode.

Maintenance, care and disposal
General
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6 Maintenance, care and disposal
6.1 General
DANGER
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
for up to four minutes after the mains plug is removed.
1. Switch off machine.
2. Remove the mains plug.
3. Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Improper maintenance, testing and repairs!
Maintenance, testing and repair of the machine may only be carried out by skilled and
qualified personnel (authorised service personnel). A competent person is someone
who, based on training, knowledge and experience, can recognize the hazards and pos-
sible consequential damage that may occur when testing power sources and can take
the necessary safety precautions.
• Follow the maintenance instructions > see 6.1.2 chapter.
• If any of the test requirements below are not met, the unit must not be put back into opera-
tion until it has been repaired and tested again.
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
The welding torch is one of the most stressed components of the welding system. Due to the high thermal
load and contamination, regular maintenance and care not only extends the service life of the system but
also saves costs in the long term through the use of fewer replacement parts and less downtime. Perfect
welding results can only be achieved with a properly maintained welding torch.
For maintenance and care, use only the tools, aids and tightening torques specified in the operating in-
structions.
6.1.1 Identifying damage or worn components
Electrode holder/collet body
• Clinging weld spatter that can no longer be removed.
• Penetration or burn-off; damage to thread
Gas nozzle/extraction nozzle
• Clinging weld spatter, cracks or lack of fusion, damage to thread
Insulator
• Cracks, lack of fusion or burnt-off outer edges
Back cap
• Damage to thread, cracks or lack of fusion
Electrode
• Blunt, lack of fusion, burn-off
Torch neck
• Penetration or burn-off of insulation
• Cracks or lack of fusion of the insulation

Maintenance, care and disposal
General
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Torch connection
• The thread of the crown nut is dirty or damaged.
• For water-cooled welding torches, check the coolant connections for damage.
Grip
• Cracks, penetration
Hose package
• Cracks, penetration
Figure 6-1
To prevent damage and malfunction of the welding torch:
• Never hit hard objects (hammering)!
• Do not use the welding torch for levering or straightening!
• Do not bend the torch neck! Bending flexible torch necks is possible considering the maxi-
mum bending cycles.
• During breaks or after work, place the welding torch in the torch holder provided on the
welding machine or at the workplace!
• Never throw the welding torch!
• Do not pull welding machines / wire feeders with the welding torch!
• Do not wind the hose package around the body and particularly the forearms!
6.1.2 Maintenance and care before each use
• Loosen the gas nozzle, check the replacement parts for damage, replace if necessary and ensure a
tight fit.
• Clean and remove soiling and welding spatter from the welding torch and, particularly, the wear parts;
replace any worn or defective parts, if necessary.
• With water-cooled welding torches, check the coolant connections for tightness and flow. Check the
coolant fill level at the cooling unit.
• Check the grip and hose package for cracks and damage.