Operation Manual

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A7 TIG Orbital System 150© 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”)
• 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. The
electrode must be exactly the correct length with a
maximum tolerance of 0.1 mm.
Inserted into the holder and carefully bottomed, the
electrode forms exactly the correct arc gap. Pre-grinded
and cut-to-length electrodes are available.
3.2.1 Diameter and length
You can use multiple tungsten electrode sizes in each
weld head by changing the tungsten electrode holder.
Order the tungsten electrodes or cut them to a precise
length by 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.
Weld head Rotor gear
radius
15010 28.7 mm
15020 42.0 mm
15030 54.6 mm
15040 66.8 mm
15060 100.6 mm
The electrode must be precisely the correct length with
a maximum tolerance of 0.1 mm. Its correct length
depends on the weld head size, electrode diameter and
tube diameter.
To determine correct electrode length, use the
150 series controller Tungsten Length Calculator. If the
controller is not available, calculate cut-length by using the
formula below or a calculator on the Kemppi website.
Length calculation formula:
Length = rotor gear radius – tube radius – arc gap