Operation Manual

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A7 TIG Orbital System 150© Kemppi Oy 2016 1615
OPERATING MANUAL
3.2.2 Holder
To install the tungsten electrode and holder, do the
following:
1. Turn the controller power switch ON.
2. Using the +/- Rotation Jog on the weld head
handle, rotate the rotor until you can see the
electrode holder's postiion at the open throat
area of the weld head.
3. Using 3 mm x 6 mm cap screws, install the block
and tungsten electrode into desired position. The
tungsten electrode mount block is a split block.
a. Leave screws loose and push up against the
tungsten intu the holder.
b. Tighten screws, solid side rst, then split side.
The standard position of the tungsten electrode
as viewed from the side along the tube centerline is a 5°
down from 3 o’clock. This is to avoid breaking of tungsten
when installing the weld head on pre-tacked tube. You
can use alternative tapped holes in rotor (8 or 6 o’clock
position) e.g. in case of stripped threads in the rotor.
3.2.3 Geometry guidelines
Diameter
Use the smallest diameter tungsten electrode suitable
for the weld current range for positive arc ignition and
a stable arc. Thicker diameters handle high currents and
have a greater life at the expense of arc starting.
Electrode diameter Tube wall thickness
Up to 1.0 mm 1.0 mm
1.0–2.4 mm 1.6 mm (.062")
2.4–4.0 mm
2.4 mm (0.094”)
Arc gap
The tungsten electrode tip-to-work distance, the arc length
is kept to a minimum and produces a more stable arc and
deeper penetration. For general tube welding, the arc gap
should be adjusted between 0.75 mm (.03") and 1.8 mm
(.07").
Tube wall thickness Recommended arc length
0.5–1.0 mm 0.75 mm
1.0–2.0 mm 1.3 mm
2.0–4.0 mm
1.8 mm
Tip angle and at diameter
The tungsten electrode angles (included angle) between 15° to 30° enable the most automated welding.
Kemppi recommends 20° for autogenous welding in the general current range used with the 150 series
weld heads.
Tungsten electrode tip angle and at diameter
Electrode
Diameter mm
Flat diameter
mm
Included
Angle (deg)
Constant current
Range (amp)
Pulsed current
Range (amp)
1.0 mm 0.25 mm 20° 1
1.6 mm 0.5 mm 20° 8–50 8–100
1.6 mm 0.75 mm 20° 10–70 10–140
2.4 mm 0.75 mm 30° 12–90 12–180
2.4 mm 1.0 mm 30° 15–150 15–250
3.2 mm 1.0 mm 30° 20–200
20–300