Operation Manual

11
A5 TIG Orbital System 75© Kemppi Oy 2016 1615
OPERATING MANUAL
3. OPERATION
3.1 Rotor gear
Weld head contains a rotor gear that drives the electrode
around the tube. Rotor gear is U-shaped to allow
easy placement of the weld head on and o the tube.
Electrode is fastened on the rotor gear with an easily
replaceable electrode holder. The holder prevents the
rotor gear from damage.
Electrodes and holders are available in the following
diameters:
• 1 mm (.040”)
• 1.6 mm (.062”), default
• 2.4 mm (.094”)
3.2 Tungsten electrode
ø 1.0 /1.6 / 2.4 mm
20 – 30°
14 – 75 mm
0.25 – 1.0 mm
Electrode diameter, tip geometry, and arc gap are
important factors in repetitive precision welding. Inserted
into the holder and carefully bottomed, the electrode
forms exactly the correct arc gap. The electrode must be
exactly the correct length with a maximum tolerance of
0.1 mm. Pre-grinded and cut-to-length electrodes are
available.
3.2.1 Tungsten electrode diameter and length
You can use multiple tungsten electrode sizes in each
weld head by changing the tungsten electrode holder.
Tungsten electrodes and tungsten electrode holders are
available in the following sizes:
• 1.0 mm
• 1.6 mm
• 2.4 mm
Order the tungsten electrodes or cut them to a precise
length yourself. When the tungsten is inserted into the
holder and bottomed, it will create the desired tip-to-
work distance without the need for adjustment.
To determine the correct tungsten length, use the
75 series controller’s Tungsten Length Calculator. If the
controller is not available, use the following formula to
calculate cut-length or visit Kemppi Automation website.
Model Tungsten length
7530 54.6 mm – radius of tube – arc gap
7540 66.8 mm – radius of tube – arc gap
The electrode must be precisely the correct length with a
maximum tolerance of 0.1 mm. Correct electrode length
depends on the weld head size, electrode diameter, and
tube diameter. See correct tungsten electrode lengths
under Ordering Information.