Snap-On FLEX-TIG User manual

THE FLEX-TIG
ENABLES THE OPERATOR TO PERFORM HIGH
QUALITY TUNGSTEN-INERT GAS (T.I.G.) WELDING
ON STEEL, STAINLESS STEEL, CHROME-MOLY, COP-
PER AND CAST IRON.
THIS T.I.G. WELDING PACKAGE WILL NOT WELD ALUMINUM.
OWNERS MANUAL
FLEX-TIG
FOR TECH. SERVICE, CALL TOLL-FREE 1-800-232-9353
FORM WC5229 Rev. 1/99
INSTALLATION
OPERATION
REPLACEMENT PARTS

INTRODUCTION ........................................................................... 1
CONTENTS ................................................................................... 1
SPECIFICATIONS ......................................................................... 2
INSTALLATION ............................................................................. 2
OPERATION ................................................................................. 4
SCHEMATIC DIAGRAM ................................................................ 4
PARTS BREAKDOWN.................................................................. 5
MANUFACTURER’S LIMITED WARRANTY
This equipment is warranted against defects in materi-
als and workmanship for a period of 90 DAYS from the date
of purchase.
Should it become defective for such reason, the Manu-
facturer will repair it without charge, if it is returned to the
Manufacturer’s factory, freight prepaid. This warranty
does not cover: (1) failure due to normal wear and tear; (2)
consumable parts, such as, but not limited to, collets, collet
bodies, gas cups and heat shields; (3) damage by acci-
dent, force majeure, improper use, neglect, unauthorized
repair or alteration; (4) anyone other than the original
purchaser.
THIS LIMITED WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED. THE
MANUFACTURER SHALL NOT BE LIABLE FOR ANY
INJURY TO PERSONS, INCLUDING DEATH; OR LOSS
OR DAMAGE TO ANY PROPERTY, DIRECT OR CON-
SEQUENTIAL, INCLUDING, BUT NOT LIMITED TO,
LOSS OF USE, ARISING OUT OF THE USE, OR THE
INABILITY TO USE, THE PRODUCT. THE USER AS-
SUMES ALL RISK AND LIABILITY WHATSOEVER IN
CONNECTION WITH THE USE OF THE PRODUCT,
AND BEFORE DOING SO, SHALL DETERMINE ITS
SUITABILITY FOR HIS INTENDED USE, AND SHALL
ASCERTAIN THE PROPER METHOD OF USING IT.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, OR THE
EXCLUSIONS OR LIMITATIONS OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES. SO THE ABOVE LIMI-
TATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY HAVE OTHER RIGHTS WHICH
MAY VARY FROM STATE TO STATE.
TABLE OF CONTENTS
Snap-on Tools Corporation Kenosha, WI 53141-1410

Snap-on Tools Corporation Kenosha, WI 53141-1410 1
INTRODUCTION
The TIG Welding process is
used to produce the highest qual-
ity, porosity-free welds. The FLEX-
TIG adds this capability to your
MUSCLE MIG Welder. The FLEX-TIG
enables the operator to perform
high quality Tungsten-Inert Gas
(T.I.G.) welding on steel, stain-
less steel, chrome-moly, copper and
cast iron.
With Direct Current-Straight
polarity (DCSP), the FLEX-TIG will
perform on the (4) TIG settings, as
well as all (8) MIG settings (see
welder output chart and warning on
page 4). The (4) TIG settings are
"Special" TIG voltages for use on
materials ranging from 18 gauge
thru 3/32". The higher MIG voltages
are for use on material from 3/32"
thru 1/4".
The FLEX-TIG consists of a 200
amp gas cooled torch with built-in
gas control valve, remote On/Off
switch, 12 1/2 or 25 foot cable
assembly and the required consum-
able parts.
NOTE: THIS T.I.G. WELDING PACKAGE
WILL NOT WELD ALUMINUM.
CONTENTS
1- TIG Torch with built-in valve
1- Locking Electric Switch with
cord
(installed on torch)
1- Power Cable with Connector
(installed on torch)
1- Gas Hose with fitting
(installed on torch)
3- 3C116 Collet - for 1/16" tung-
sten
3- 3C332 Collet - for 3/32" tung-
sten
2- 3CB116 Collet Body - for 1/16"
tungsten
2- 3CB332 Collet Body - for 3/32"
tungsten
2- 3C6 Gas Cup - 3/8" orifice
6- 3C7 Gas Cup - 7/16" orifice
2- 3C8 Gas Cup - 1/2" orifice
1- 300L Long Backcap
3- 1/16" X 3" Tungsten Electrode
3- 3/32" X 3" Tungsten Electrode

2Snap-on Tools Corporation Kenosha, WI 53141-1410
TORCH HEAD ASSEMBLY
1. Select the size tungsten elec-
trode to be used.
2. Make sure teflon heatshield is
in place.
3. Locate the matching size Collet
and Collet body.
4. Drop the Collet, slit-end down,
into the Collet body.
5. Screw assembly into torch head,
Heatshield side, and tighten
firmly.
6. Install a Gas cup, screw into
place seating cup against teflon
heatshield.
7. Insert tungsten electrode,
prepped end first, thru torch
head, Collet and center hole of
Collet body.
8. Allow tungsten electrode to ex-
tend pass the cup 1/8".
9. Screw Backcap into torch head,
tighten firmly.
SPECIFICATIONS
PART NUMBER: FLEX-TIG 12
FLEX-TIG 25
TORCH RATING: 200 Amps, DCSP
DUTY CYCLE: 100%
(reduce duty cycle when operating
over 200 amps.)
COOLING METHOD: Gas (100% Argon)
SHIELDING GAS CONTROL METHOD:
Gas Valve on Torch
WELD CURRENT ON-OFF CONTROL:
Locking Switch on Torch
FIG. 1. TUNGSTEN PREPARATION
STABLE ARC
STRAIGHT GROUND
IDEAL VIEW
FLAT (the Dia. of this
flat governs Amperage
Capacity)
FIG. 2. TORCH HEAD ASSEMBLY
GAS CUP COLLET BODY
COLLET
HEAT-
SHIELD
TORCH
HEAD
TUNGSTEN
ELECTRODE BACKCAP
INSTALLATION
TUNGSTEN PREPARATION
NOTE
Before using the FLEX-TIG the
tungsten electrode must be
prepped.
1. Referring to Figure 1, grind the
electrode following the IDEAL
VIEW.
WRONG VIEW
ARC WANDER
RADIAL GROUND
POINT

Snap-on Tools Corporation Kenosha, WI 53141-1410 3
4. Plug the TIG torch switch cord
into the Control receptacle
(OUTPUT).
5. Attach the gas regulator/flow-
meter to a cylinder of 100% pure
Argon gas.
6. Attach the TIG torch gas hose
directly to the gas regulator/
flowmeter.
7. Turn on the gas cylinder and open
the TIG torch gas valve to purge
the system of impurities in the
gas line. Purge for one minute to
ensure porosity free welds.
INSTALLATION (Cont.)
FLEX-TIG INSTALLATION
1. Disconnect the Feeder control
cable assembly from the front of
the power source.
2. Plug the TIG torch power cable
into "WORK" (-) terminal.
3. Plug the Work cable into "TORCH"
(+) terminal. With the TIG torch
and Work cable connected in this
manner, straight polarity(DCSP)
current is available as required
for TIG welding.
SWITCH CORD
TO WELDER
CONTROL
RECEPTACLE
TIG
TORCH
GAS HOSE
TO REGULATOR/
FLOWMETER
100%
ARGON
GAS
CONTROL
RECEPTACLE
(OUTPUT)
POWER CABLE TO
WORK (-) TERMINAL
(WORK CABLE PLUGS INTO
POSITIVE (+) TERMINAL)
LOCKING
SWITCH
FIG. 3. FLEX-TIG TYPICAL INSTALLATION PROCEDURES
YOU ARE NOW READY TO TIG WELD!
GAS
VALVE

4Snap-on Tools Corporation Kenosha, WI 53141-1410
OPERATION
1. Open the TIG torch gas valve.
2. Set the flowmeter @ a 20 CFH flow
rate.
3. Turn "On" the MIG welding ma-
chine.
4. Set the welder MIG/TIG Voltage
control switch to the desire
setting. See "Welder Output
Chart" and Warning that follows.
WELDER OUTPUT CHART - FOR TIG WELDING
HEAT SETTING OUTPUT(Approx.)
TIG 1 50 AMPS
2 90 AMPS
3 105 AMPS
4 150 AMPS
MIG 1 160 AMPS
2 175 AMPS
3 190 AMPS
WARNING
THE FLEX-TIG IS RATED UP TO 200
AMPS, @ A 100 % DUTY CYCLE.
OPERATION ABOVE MIG VOLTAGE
SETTING #3 COULD RESULT IN
PERMANENT DAMAGE TO THE
TORCH HEAD AND CABLES.
5. Depress the TIG torch switch and
lock "On", scratch or touch
tungsten to the work and draw
back to establish an arc.
CAUTION
Continual sticking of the
tungsten electrode to the
work surface can cause severe
damage to the MIG welding
machine.
6. Once arc is established, hold
and maintain a steady arc until
base material becomes fluid.
Then continue welding while
maintaining a consistent arc
length and travel speed.
DIRECTION OF TRAVEL
WORK
FIG. 4. TIG WELDING ILLUSTRATION
14 PIN
PLUG
ON/OFF
SWITCH
RED
BLACK
A
B
FIGURE 5. SCHEMATIC DIAGRAM
COM.
N.O.

Snap-on Tools Corporation Kenosha, WI 53141-1410 5
{
REPLACEMENT PARTS - TIG TORCH ASSEMBLY
3C6
3C7
3C8
3CB116
3CB332
3C116
3C332
300HS
CK210V
300S
300L
SW2
312AH
325AH
SC12-300
SC25-300
SN-170A
SN-169A
SN-6204B
SN-168A
PART
NO. DESCRIPTION
210HE HANDLE (only)
300HS HEATSHIELD
300L LONG BACKCAP (with "o" ring)
300S SHORT BACKCAP (with "o" ring)
312AH GAS HOSE (only) - with fittings, 12 1/2'
325AH GAS HOSE (only) - with fittings, 25'
3C116 COLLET, 1/16"
3C332 COLLET, 3/32"
3C6 CUP, 3/8" ORIFICE
3C7 CUP, 7/16" ORIFICE
3C8 CUP, 1/2" ORIFICE
3CB116 COLLET BODY, 1/16"
3CB332 COLLET BODY, 3/32"
3HF FITTING, GAS HOSE
412CN-200A POWER CABLE (only) - with fittings, 12 1/2'
210HE
SN-6191B
3HF SN-520
412CN-200A
425CN-200A
412PC-200A
425PC-200A
VK
PART
NO. DESCRIPTION
425CN-200A POWER CABLE (only) - with fittings, 25'
412PC-200A POWER CABLE AND HOSE ASSEMBLY, 12 1/2'
425PC-200A POWER CABLE AND HOSE ASSEMBLY, 25'
CK210V TORCH BODY (only)
- with valve assembly & heatshield
SC12-300 CONTROL WIRE (only) - with fittings, 12 1/2'
SC25-300 CONTROL WIRE (only) - with fittings, 25'
SN-168A CABLE TERMINAL (only)
SN-169A TERMINAL INSULATOR (only)
SN-170A CABLE TERMINAL ASSEMBLY (only)
SN-520 HOSE NUT
SN-6191B PLUG, 14 PIN (MALE PINS)
SN-6204B CLAMP, AMPHENOL
SW2 LOCKING ELECTRIC SWITCH (only)
VK VALVE (with "o" rings)

6Snap-on Tools Corporation Kenosha, WI 53141-1410
NOTES: