Kemppi TTC-TIG torches User Manual

130, 130F, 160, 160S

TTC

220, 200W, 250W, 250WS

Operating manual • English

Käyttöohje • Suomi

Bruksanvisning • Svenska

Bruksanvisning • Norsk

Brugsanvisning • Dansk

Gebrauchsanweisung • Deutsch

EN

FI

SV

NO

DA

DE

Gebruiksaanwijzing • Nederlands

Manuel d’utilisation • Français

Инструкции по эксплуатации • По-русски

NL

FR

RU

TTC / © Kemppi Oy / 1130

OPERATING MANUAL

English

CONTENTS

TTC / © Kemppi Oy / 1130

EN

1. PREFACE

1.1 General

1.2 Product introduction

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

1.2.2 Selection table for consumable parts TTC 160, TTC 220, TTC 250W ............................ 5

................................................................................................................................ 3

....................................................................................................................................... 3

............................................................................................................ 3

.................................................... 4

1.3 Operation safety ..................................................................................................................... 6

2. INSTALLATION ................................................................................................................. 6

2.1 Connecting TTC-torch .......................................................................................................... 6

2.2 Switch and regulator operations ...................................................................................... 6

2.3 Adjustment of torch body and grips ............................................................................... 7

2.4 Choice of electrode size and ow amount of shielding gas .................................. 8

2.4.1 Electrode choice according to base material to be welded ......................................... 8

2.5 Sharpening of electrode ...................................................................................................... 9

2.5.1 D.C. welding ..................................................................................................................... 9

2.5.2 A.C. welding ..................................................................................................................... 9

2.6 Projection of electrode .......................................................................................................10

3. MAINTENANCE ..............................................................................................................10

4. OPERATION DISTURBANCES ............................................................................11

4.1 The most usual operation disturbances are as follows: .........................................11

5. ORDERING NUMBERS .............................................................................................11

6. TECHNICAL DATA ........................................................................................................12

2

1. PREFACE

1.1 GENERAL

Congratulations on having purchased this product. Used correctly, Kemppi products can
signicantly increase the productivity of your welding, and provide years of economical
service.

This operating manual contains important information on the use, maintenance and safety of
your Kemppi product. The technical specications of the equipment can be found at the end
of the manual.

Please read the manual carefully before using the equipment for the rst time. For your
own safety and that of your working environment, pay particular attention to the safety
instructions in the manual.

For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi
dealer, or visit the Kemppi web site at www.kemppi.com.

The specications presented in this manual are subject to change without prior notice.

Important notes

Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with the ’NOTE!’ notation. Read these sections carefully and follow
their instructions.

Disclaimer

While every eort has been made to ensure that the information contained in this guide
is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi
reserves the right to change the specication of the product described at any time without
prior notice. Do not copy, record, reproduce or transmit the contents of this guide without
prior permission from Kemppi.

TTC / © Kemppi Oy / 1130

EN

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.

3

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

Normal gas nozzle equipment

Welding current

9878013

TTC / © Kemppi Oy / 1130

EN

DC (A) AC (A)

Size

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

9878013

DC (A) AC (A)

Size

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

*) 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.

4

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

Normal gas nozzle equipment

Welding current

DC (A) AC (A)

ø mm (in)

WC20 9873531

5 – 80 5 – 50 1,0 (.040) WZ8 9873520 9876866 7990680 4 7990766

WC20 9873532 4 7990766

70 – 150 30 – 100 1,6 (1/16) WZ8 9873521 9876867 7990681 5 7990770

WC20 9873533

130 – 250 80 – 150 2,4 (3/32) WZ8 9873522 9876868 7990682 6 7990771

WC20 9873534 7 7990772

220 – 350 120 – 210 3,2 (1/8) WZ8 9873523 9876869 7990683 8 7990773

WC20 9873535 8 7990773

330 – 500 180 – 280 4,0 (5/32) WZ8 9873524 9876870 7990684 10 7990775

W 9873505 12 7990776

9580266

Size

TTC / © Kemppi Oy / 1130

5 7990770

6 7990771

7 7990772

10 7990775

EN

Gas lens equipment

Welding current

9876860 + 9580266

DC (A) AC (A)

Size

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.

5

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

TTC / © Kemppi Oy / 1130

welding place. Always reserve sucient re-ghting equipment on welding place. Be
prepared for 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.

EN

Welding fumes

Take care that there is su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.

NOTE! 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.

NOTE! 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.

6

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.

TTC / © Kemppi Oy / 1130

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.

EN

7

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.

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.

TTC / © Kemppi Oy / 1130

EN

Welding current
DC­(AC)

A Ø mm Number Ø mm l/min
5 – 80

(5 – 50)
70 – 150

(30 – 100)
130 – 250

(80 – 150)
220 – 350

(120 – 210)
330 – 500

(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

WZ8

W

Electrode Gas nozzle

1,0 4/5 6,5/8,0 5 – 6

1,6 4/5/6 6,5/8,0/9,5 6 – 7

2,4 6/7 9,5/11,0 7 – 8

3,2 7/8/10 11,0/12,5/16,0 8 – 10

4,0 10/11/12 16,0/17,5/19,0 10 – 12

grey

white

green

AC
DC-

AC
DC-

AC
DC-

• • •

Gas flow rate

•

•

Delivery length of electrodes is 175 mm.
Data in table are given only as a guide.

8

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 eect
on width of welding run and depth of penetration. Ratio of sharpening length to electrode
diameter:

I = 1 – 5 x d
Suitable sharpening length depends on welding current which is used most often.

Low currents

Mean currents

TTC / © Kemppi Oy / 1130

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.

High currents

EN

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.

9

TTC / © Kemppi Oy / 1130

EN

2.6 PROJECTION OF ELECTRODE

d

I

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 eect 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.

NOTE! 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.

10

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.

TTC / © Kemppi Oy / 1130

5. ORDERING NUMBERS

4 m 8 m 16 m

TTC 130

TTC 130F

TTC 160

TTC 160S

TTC 220

TTC 200W

TTC 250W

TTC 250WS

627013004 627013008 627013016

627013104 627016008 627013116

627016004 627066008 627016016

627016204 627016208 627016216

627022004 627022008 627022016

627020504 627020508 627020516

627025504 627025508 627025516

627025704 627025708 627025716

EN

11

6. TECHNICAL DATA

TTC / © Kemppi Oy / 1130

EN

TTC 130

TTC 130F

TTC 160

TTC 160S

TTC 220

TTC
200W

TTC
250W

TTC
250WS

Loading capacity
DC-

Electrode sizes
to be used

Voltage
class

Cooling Connection to TIG-unit

40% ED 100% ED

130A

130A

160A

160A

220A

– 200A ø 1,0 – 3,2 L Liquid

– 250A ø 1,0 – 2,4 L Liquid

– 200A ø 1,0 – 4,0 L Liquid

-

-

-

-

-

ø 1,0 – 2,4 L Air R¼ -

ø 1,0 – 2,4 L Air R¼ -

ø 1,0 – 2,4 L Air R¼ -

ø 1,0 – 2,4 L Air R¼ -

ø 1,0 – 4,0 L Air R¼ -

- min. 1 l/min
In inlet:

- max. 50 °C

- min. 1 bar

- max. 5 bar

- min. 1 l/min
In inlet:

- max. 50 °C

- min. 1 bar

- max. 5 bar

- min. 1 l/min
In inlet:

- max. 50 °C

- min. 1 bar

- max. 5 bar

Gas/

Water

current

R¼ Snap

connectors

R¼ Snap

connectors

R¼ Snap

connectors

The torch meets the construction and safety requirements according to norm
IEC / EN 60974-7.

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

12

TTC / © Kemppi Oy / 1130

EN

13

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1130