Kemppi TTC 130, TTC 160, TTC 130F, TTC 160S, TTC 220 Operation Instructions Manual

Operation instructions  english
Gebrauchsanweisung  deutsch
Gebruiksaanwijzing  nederlands
Manuel dutilisation  français

TTC 130
TTC 130F
TTC 160
TTC 160S

RTC 20

RTC 10

1927570E
TTC 220
TTC 200W
TTC 250W
TTC 250WS

CONTENTS

1. PREFACE ........................................................................................................................ 3

1.1. Introduction .......................................................................................................................3

1.2. Product introduction ..........................................................................................................3

TTC 130, TTC 130F, TTC 160S, TTC 200W, TTC 250WS .............................................. 3

1.3. Operation safety................................................................................................................4

1.2.1. Selection table for consumable parts

1.2.2. Selection table for consumable partsTTC 160, TTC 220, TTC 250W ............................. 4

2. INSTALLATION ...............................................................................................................5

2.1. Connecting TTC-torch.......................................................................................................5

2.2. Switch and regulator operations........................................................................................5

2.3. Adjustment of torch body and grips...................................................................................6

2.4. Choice of electrode size and ow amount of shielding gas...............................................7

2.5. Sharpening of electrode.................................................................................................... 7

2.6. Projection of electrode ......................................................................................................9

2.4.1. Electrode choice according to base material to be welded ............................................. 7

2.5.1. D.C. welding ....................................................................................................................7

2.5.2. A.C. welding .................................................................................................................... 8

3. MAINTENANCE ..............................................................................................................9

4. OPERATION DISTURBANCES ....................................................................................10

4.1. The most usual operation disturbances ..........................................................................10

5. ORDERING NUMBERS ................................................................................................10

6. TECHNICAL DATA ........................................................................................................ 11

2 – TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W,
TTC 250W, TTC 250WS/0109

© COPYRIGHT KEMPPI OY

1. PREFACE

1.1. INTRODUCTION

Congratulations on having purchased this product. Properly installed Kemppi products should
prove to be productive machines requiring maintenance at only regular intervals. This manual
is arranged to give you a good understanding of the equipment and its safe operation. It also
contains maintenance information and technical specications. Read this manual from front to
back before installing, operating or maintaining the equipment for the rst time. For further
information on Kemppi products please contact us or your nearest Kemppi distributor.

The specications and designs presented in this manual are subject to change without prior
notice.

In this document, for danger to life or injury the following symbol is used:

Read the warning texts carefully and follow the instructions. Please also study the Operation
safety instructions and respect them when installing, operating and servicing the machine.

1.2. PRODUCT INTRODUCTION

TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W, TTC 250W and TTC 250WS
are TIG welding torches designed for demanding use. They are suitable to be used with the
Mastertig MLS welding machines.

1.2.1. Selection table for consumable parts
TTC 130, TTC 130F, TTC 160S, TTC 200W, TTC 250WS

Normal gas nozzle equipment

Welding current Size 9878013
DC [A] AC [A] Ø [mm (in)]
WC20 9873531 3 9878018
5…80 5…50 1,0 (.040) WZ8 9873520 7990635 7990640 7990660 4 7990760 9878019

5 7990761 9878020

WC20 9873532 4 7990760 9878019
70…150 30…100 1,6 (1/16) WZ8 9873521 7990636 7990641 7990661 5 7990761 9878020

6 7990762 9878021

WC20 9873533
130…250 80…150 2,4 (3/32) WZ8 9873522 7990637 7990642 7990662 6 7990762 9878021
7 7990763 -

Gas lens equipment

Welding current Size 9878013
DC [A AC [A] Ø [mm (in)]
WC20 9873531
5…80 5…50 1,0 (.040) WZ8 9873520 7990635 7990640 7990700 4 7990779
5 7990780
WC20 9873532 4 7990779
70…150 30…100 1,6 (1/16) WZ8 9873521 7990636 7990641 7990701 5 7990780
6 7990781
WC20 9873533
130…250 80…150 2,4 (3/32) WZ8 9873522 7990637 7990642 7990702 6 7990781
7 7990782

XXXX Delivery only ex works. By deliveries ex works you have to pay the real delivery costs.

Data in table are given only as a guide.

© COPYRIGHT KEMPPI OY

TTC 250WS/0109

TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W, TTC 250W, – 3

1.2.2. Selection table for consumable parts TTC 160, TTC 220, TTC 250W

Normal gas nozzle equipment

Welding current Size 9580266
DC [A] AC [A] Ø [mm (in)]
WC20 9873531
5…80 5…50 1,0 (.040) WZ8 9873520 9876866 7990680 4 7990766
5 7990770
WC20 9873532 4 7990766
70…150 30…100 1,6 (1/16) WZ8 9873521 9876867 7990681 5 7990770
6 7990771
WC20 9873533
130…250 80…150 2,4 (3/32) WZ8 9873522 9876868 7990682 6 7990771
7 7990772
WC20 9873534 7 7990772
220…350 120…210 3,2 (1/8) WZ8 9873523 9876869 7990683 8 7990773
10 7990775
WC20 9873535 8 7990773
330…500 180…280 4,0 (5/32) WZ8 9873524 9876870 7990684 10 7990775
W 9873505 12 7990776

Gas lens equipment

9876860+9580266
Welding current Size
DC [A] AC [A] Ø [mm (in)]
WC20 9873531
5…80 5…50 1,0 (.040) WZ8 9873520 9876866 7990710 5 7990783
WC20 9873532
70…150 30…100 1,6 (1/16) WZ8 9873521 9876867 7990711 5 7990783
6 7990784
WC20 9873533
130…250 80…150 2,4 (3/32) WZ8 9873522 9876868 7990712 6 7990784
7 7990785
WC20 9873534 7 7990785
220…350 120…210 3,2 (1/8) WZ8 9873523 9876869 7990713 8 7990786
11 7990787
WC20 9873535
330…500 180…280 4,0 (5/32) WZ8 9873524 9876870 7990714 8 7990786
W 9873505 11 7990787
Data in table are given only as a guide.

1.3. OPERATION SAFETY

Please study these Operation safety instructions and respect them when installing, operating and
servicing the machine.

Welding arc and spatters

Welding arc hurts unprotected eyes. Be careful also with reecting arc ash. Welding arc and
spatter burn unprotected skin. Use safety gloves and protective clothing.

Danger for re or explosion

Pay attention to re safety regulations. Remove ammable or explosive materials from welding
place. Always reserve sufcient re-ghting equipment on welding place. Be prepared for

4 – TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W,
TTC 250W, TTC 250WS/0109

© COPYRIGHT KEMPPI OY

hazards in special welding jobs, eg. for the danger of re or explosion when welding container
type work pieces. Note! Fire can break out from sparks even several hours after the welding
work has been nished!

Mains voltage

Never take welding machine inside a work piece (eg. container or truck). Do not place welding
machine on a wet surface. Always check cables before operating the machine. Change defected
cables without delay. Defected cables may cause an injury or set out a re. Connection cable
must not be compressed, it must not touch sharp edges or hot work pieces.

Welding power circuit

Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work
on a wet surface or use defected cables. Do not put TIG-torch or welding cables on welding
machine or on other electric equipment. Do not press TIG-torch switch, if the gun is not directed
towards a work piece.

Welding fumes

Take care that there is sufcient ventilation during welding. Take special safety precautions
when welding metals which contain lead, cadmium, zinc, mercury or beryllium.

2. INSTALLATION

2.1. CONNECTING TTC-TORCH

Connect torch (and extension parts) according to welding machine’s operation instructions.

Tighten adaptors of torch carefully in order to avoid heating of adaptors, contact disturbances,
mechanical damage and water or gas leakage.

Check by connection of liquid hoses that there are no dirt, metal powder or other
wastes. Wastes may cause blocking in liquid circulation, throughburning of torch
or stopping or breaking of pump.

Connect liquid hoses of torch according to operation instruction of the cooling liquid circulation
unit. (They are fastened to pipe chassis.) Fix liquid hoses (torch – cooling liquid circulation unit)
in such a way that those having red code always are connected to corresponding red counter
connectors and the blue ones respectively to blue counter connectors.

If connections cross, cooling liquid is circulating in wrong direction in torch, and
torch handle and neck body might be considerably heatened.

2.2. SWITCH AND REGULATOR OPERATIONS

The TTC torches are equipped with ON/OFF switch. Operation of switch in 2-functions,
4-functions and Minilog positions is described in operation instructions of the welding machine.

TTC torches can be equipped with RTC 10 or RTC 20 torch regulators which are available as
assessory. Regulators can be assembled in place of the original start-switch.

© COPYRIGHT KEMPPI OY

TTC 250WS/0109

TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W, TTC 250W, – 5

RTC 10 (code 6185477)

Besides the start-switch there is a potentiometer for controlling the welding current.

S = start

U (clockwise) = welding current
will slope-up

D (anticlockwise) = welding current
will slope-down

RTC 20 (code 6185478)

Besides the start-switch there is a seesaw switch for controlling the welding current.

S = start

U = welding current
will slope-up

D = welding current
will slope-down

Assembly instruction is delivered with the regulators.

2.3. ADJUSTMENT OF TORCH BODY AND GRIPS

You can draw the torch neck outwards from inside the handle in approx. 30 mm length in order
to grow reach or to minimize heat radiation to welder’s hand. You can also twist the torch
body 360° in regard of the handle. Twisting of neck makes the length adjustment easier. Before
starting to weld make sure that the parts being exposed to voltage at the back end of the neck
body are not visible.

You can without tools move or twist grips on the lower surface of the handle into such position
you like that you can get a steady hold on the torch. You can also easily remove one or both of
the grips through the front end of the handle.

6 – TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W,
TTC 250W, TTC 250WS/0109

© COPYRIGHT KEMPPI OY

2.4. CHOICE OF ELECTRODE SIZE AND FLOW AMOUNT
OF SHIELDING GAS

Electrode size and shielding gas ow are dened by welding current level. The most usual
shielding gas for TIG welding is argon.

The table below is given only as a guide.

Welding current Electrode Gas nozzle Gas ow rate
DC­(AC)
A Ø mm Number Ø mm l/min
5…80 1,0 4/5 6,5/8,0 5…6
(5…50)
70…150 1,6 4/5/6 6,5/8,0/9,5 6…7
(30…100)
130…250 2,4 6/7 9,5/11,0 7…8
(80…150)
220…350 3,2 7/8/10 11,0/12,5/16,0 8…10
(120…210)
330…500 4,0 10/11/12 16,0/17,5/19,0 10…12
(180…280)

2.4.1. Electrode choice according to base material to be welded

Electrode Welding current Base material
Type Symbol colour Fe Ss Al Ti
WC20 grey AC
DC­WZ8 white AC
DC­W green AC
DC-

Delivery length of electrodes is 175 mm.

Data in table are given only as a guide.

2.5. SHARPENING OF ELECTRODE

2.5.1. D.C. welding

In D.C. welding the tip of electrode is sharpened into cone shape in order to get a steady arc and
to concentrate heat energy on welding point. Size of sharpening angle has an effect on width of
welding run and depth of penetration. Ratio of sharpening length to electrode diameter:

© COPYRIGHT KEMPPI OY

I = 1...5 x d

TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W, TTC 250W, – 7

TTC 250WS/0109

Suitable sharpening length depends on welding current which is used most often.

Low currents

Mean currents

High currents

Always make sharpening grinding lengthwise of electrode.

2.5.2. A.C. welding

In A.C. welding the temperature of electrode tip rises a little more higher than melting point of
tungsten and brings about formation of ball-shaped curved surface. On basis of tip formation
and arc behaviour you can determine suitability of welding current for used electrode size and
material.

A Low welding current or big electrode size. Arc will be unsteady and is not directed

on welding object.

B Suitable current.

C Too high current or too small electrode diameter.

You can speed up the tip formation by electrode change e.g. with following:

- Adjust welding current a little higher than usually.

- Burn arc to waste piece by keeping the torch in vertical position.

- Arc is extinguished immediately after the electrode tip has become round.

- Current is reduced to be suitable for work and welding is started.

You can grind the electrode partly at its tip at which the tip will be better ball-shaped and
the arc more steady.

8 – TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W,
TTC 250W, TTC 250WS/0109

© COPYRIGHT KEMPPI OY

2.6. PROJECTION OF ELECTRODE

Suitable distance of electrode tip from front edge of gas nozzle depends among others on electrode
diameter and current type.

Formation of weld preparation has a considerable effect on suitable electrode projection. E.g. when
you are welding the external angle, you should use a clearly smaller projection than in llet weld.

Tighten the electrode with reasonable force. Too strong a tightening may damage tightening parts
of electrode.

3. MAINTENANCE

Due to high temperatures and wear the welding end of TIG torch requires most maintenance, but
also condition of other parts should be checked regularly.

Welding end

Check that…

- All insulations of welding end are undamaged and at their place.

- Gas nozzle is undamaged and suitable for work.

- Flow of shielding gas is free and even.

- Electrode is undamaged. Use electrode size and tip sharpening angle which is suitable for
welding case. Make sharpening grinding lengthwise of electrode.

- Fastening parts of electrode are undamaged and electrode is fastened tightly at its place.

Torch cable

Check that…

- Insulations of handle and torch cable are undamaged.

- There are no sharp bends in torch cable.

Replace damaged parts immediately by new ones.

Frequent bending of neck body of torch may cause damage of gas
or liquid channels.
Length adjustment of neck body doesn’t work on bent neck.

© COPYRIGHT KEMPPI OY

TTC 250WS/0109

TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W, TTC 250W, – 9

4. OPERATION DISTURBANCES

4.1. THE MOST USUAL OPERATION DISTURBANCES ARE
AS FOLLOWS:

Arc is not ignited:

- Cable is loose or there is a bad connection.

- Electrode of torch is highly oxidized (grey). Sharpen again lengthwise. Check that
post gas time is long enough. Check ignition by using pre-gas e.g. by 4-function
operation of torch.

- There are impurities in shielding gas (moisture, air).

- Protective hose or another insulation of torch is broken and ignition spark is “esca­ping” from elsewhere than from electrode of torch.

- Torch is wet.

- At low current is used too big or blunt electrode.

Gas shielding is bad (weld pool “is boiling”, electrode will be oxidized)

- There are impurities in shielding gas (moisture, air).

- There are impurities in base material (rust, base coat, grease).

- On gas nozzle or housing of tightening bushing has stuck “spatter”.

- Net of gas lens is damaged.

- There is too much draught at welding place.

- Note! With gas lens equipment you get a more balanced gas ow than with normal
gas nozzle equipment.

5. ORDERING NUMBERS

TTC 130 TTC 130F TTC 160 TTC 160S

4m 627013004 627013104 627016004 627016204

8m 627013008 627013108 627016008 627016208

16m 627013016 627013116 627016016 627016216

TTC 220 TTC 200W TTC 250W TTC 250WS

4m 627022004 627020504 627025504 627025704

8m 627022008 627020508 627025508 627025708

16m 627022016 627020516 627025516 627025716

10 – TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W,
TTC 250W, TTC 250WS/0109

© COPYRIGHT KEMPPI OY

6. TECHNICAL DATA

6.1. TECHNICAL DATA

TTC 130 TTC 130F TTC 160 TTC 160S

Loading capacity
DC- 40% ED 130A 130A 160A 160A
100% ED - - - - - - - - - - - -

Electrode sizes to be used ø 1,0…2,4 ø 1,0…2,4 ø 1,0…2,4 ø 1,0… 2,4

Voltage class L L L L

Cooling Air Air Air Air

Connection to TIG-unit
Gas/current R R R R
Water - - - - - - - - - - - -

TTC 220 TTC 200W TTC 250W TTC 250WS

Loading capacity
DC- 40% ED 220A - - - - - - - - ­ 100% ED - - - 200A 250A 200A

Electrode sizes to be used ø 1,0…3,2 ø 1,0…2,4 ø 1,0…4,0 ø 1,0…4,0

Voltage class L L L L

Cooling Air Liquid Liquid Liquid

- min. 1 l/min - min. 1 l/min - min. 1 l/min
In inlet: In inlet: In inlet:

- max. 50 °C - max. 50 °C - max. 50 °C

- min. 1 bar - min. 1 bar - min. 1 bar

- max. 5 bar - max. 5 bar - max. 5 bar

Connection to TIG-unit
Gas/current R R R R
Water - - - Snap connectors Snap connectors Snap connectors

The torch meets the construction and safety requirements according to norm EN 50 078.

CE-marking: CE EN50078

Make sure that the torch being in your use is designed for max. welding current needed by you.

© COPYRIGHT KEMPPI OY

TTC 250WS/0109

TTC 130, TTC 130F, TTC 160, TTC 160S, TTC 220, TTC 200W, TTC 250W, – 11

KEMPPI OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
www.kemppi.com

KEMPPIKONEET OY
PL 13
FIN – 15801 LAHTI
FINLAND
Tel [phone]
Telefax [phone]
e-mail: myynti.@kemppi.com

KEMPPI SVERIGE AB
Box 717
S – 194 27 UPPLANDS VÄSBY
SVERIGE
Tel [phone]
Telefax (08) 59 082 394
e-mail: [e-mail]

KEMPPI NORGE A/S
PB 2151 Postterminalen
N – 3103 TØNSBERG
NORGE
Tel [phone]
Telefax 33 35 80 90
e-mail: [e-mail]

KEMPPI A/S
Literbuen 11
DK – 2740 SKOVLUNDE
DANMARK
Tel [phone]
Telefax 44 941 536
e-mail:[e-mail]

KEMPPI BENELUX B.V.
Postbus 5603
NL – 4801 EA BREDA
NEDERLAND
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI (U.K) Ltd.
4-6 Sergeants Way
Elms Industrial Estate
BEDFORD, MK 41 OEH
ENGLAND
Tel [phone]
Telefax [phone]
e-mail: [e-mail]

KEMPPI FRANCE S.A.
S.A. au capital de 5 000 000 F.
65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
Tel [phone]
Telefax (01) 30 90 04 45
e-mail: [e-mail]

KEMPPI GmbH
Otto – Hahn – Straße 14
D – 35510 BUTZBACH
DEUTSCHLAND
Tel [phone]
Telefax (06033) 72 528
e-mail:[e-mail]

KEMPPI OY
Oddzial w Polsce
Ul. Pilsudskiego 2
05091 ZA¸BKI
Poland
Mobile phone [phone]
e-mail: [e-mail]

KEMPPI SWITZERLAND SA
Chemin de la Colice 4
CH-1023 Crisser/ Lausanne
SUISSE
Tel. [phone]
Telefax [phone]
mobile [phone]
e-mail: [e-mail]
Manager Felix Baumgartner

KEMPPI WELDING
MACHINES AUSTRALIA PTY LTD
P.O. Box 404 (2/58 Lancaster Street)
Ingleburn NSW 2565, Australia
Tel. [phone]
Telefax [phone]
mobile (Kent E.) [phone]
e-mail: [e-mail]
Manager Kent Eimbrodt

www.kemppi.com

Ver. 2