TIG Welding | CK Worldwide
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Instruction Manual for CK WORLDWIDE models including: CK9, CK9 Gas Cooled Superflex TIG Torch, Gas Cooled Superflex TIG Torch, Cooled Superflex TIG Torch, Superflex TIG Torch, TIG Torch, Torch
CK9 125A Gas Cooled Superflex TIG Torch - Rigid, Flex, 4m, 8m
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DocumentDocumentTORCH MANUAL for CK9,CK20, CK25 2 Series Standard FORM TM-2 APRIL 2019 Toll Free: (800) 426.0877 www.CKWORLDWIDE.com Congratulations on your purchase of a CK Worldwide TIG Torch! CK Worldwide's premium quality TIG torches perform with a reliability and efficiency you can always depend on. CK equipment and technical support is available online at www.CKWORLDWIDE.com or by calling (800) 426-0877 between 7:00AM and 3:30PM, Monday through Friday. Phone: 1.800.426.0877 Fax: 1.800.327.5083 CK Worldwide, Inc. PO Box 1636 Auburn, WA 98071 USA www.CKWORLDWIDE.com FIND US ON: IN THIS MANUAL Torch Specifications...................................................................... 3 Warranty ....................................................................................... 3 SAFETY INFORMATION Safety Information ....................................................................45 TECHNICAL INFORMATION Torch Connection Diagrams.......................................................... 6 Machine Connection Diagrams / Quick Disconnects .................... 7 ORDERING INFORMATION CK9 125 Amp ........................................................................... 8 9 CK20 and CK25 250 Amp .....................................................10 11 2 SERIES CONSUMABLES / GAS SAVERTM KITS 2 Series Standard Parts ...............................................................12 2 Series Gas SaverTM Parts 13 ............................................................ Gas SaverTM Kits ........................................................................... 14 TORCH ACCESSORIES Remote Amperage Controls, Leather Hose Covers, Tungsten Sharpener.................................................................... 15 ADDITIONAL INFORMATION Troubleshooting Guide ................................................................ 16 Product demonstrations, welding tips and more. TWITTER: @CKWWInc INSTAGRAM: @ckworldwide TS PEE C ICF IHC A T NIIO NCSAF OLR T IGGUW EIL D DI NEG TINHETISGTW ANEDLDARINDG Need technical information? Call or email to request a copy of our Technical Guide (Form 116) THE MAS TCEHROCICREAwFOwPTwhFSo.CnMKeM:WA1DOE(ER8LI0NND0W)T4HFIOD2ER6MEU1-.1c06.SMo8A.Ym7A207.17 The information in this manual represents the best judgement of CK Worldwide, Inc. and is intended for use by experienced personnel. Never operate any equipment without carefully reading, understanding, and following all of the related safety rules and practices. CK Worldwide makes no claims, expressed or implied, as to the viability of this information for any application or use. The individual user is solely responsible for any and all uses of the information contained herein, since CK Worldwide has no means to confirm the correct use of, or control any of the variables to the use of any and all information herein. 2 TOLL FREE: (800) 426.0877 | www.CKWORLDWIDE.com IN THIS MANUAL you will find technical and ordering information for CK9, CK20, and CK25 TIG torches, hoses, and accessories. TORCH SPECIFICATIONS CK9 CK20/CK25* 5/16"-24 3/8"-24 MAX-FLOTM *CK25 (Pencil) uses same thread pattern as the CK20 5/16"-24 1/4"-28 INSTALLATION: Before using this torch, tighten regulator, hose and power cable fittings with proper wrenches. Using small pliers, securely tighten all knurled hose fittings (Slide the torch handle back for access to the torch connections). Purge the regulator and TIG torch with inert gas at 20 cubic feet per hour. Following these steps will ensure contamination free welds. Repeat this procedure whenever torch or regulator fittings have been detached. Improved Cooling Capacity Fail SafeTM Hose Connections 4X Cooling Surface Area Competitor's Torch WARRANTY: CK Worldwide, Inc. warrants products manufactured by CK Worldwide, Inc. to be free of defects in materials and workmanship. CK Worldwide, Inc. limits this warranty to replacement of the product or parts thereof and excludes liability for injury, property damage or economic loss attributable to product use or misuse. In any event, CK Worldwide, Inc. will only be responsible for its products when used with accessory items manufactured by CK Worldwide, Inc. CALIFORNIA PROPOSITION 65 WARNING: This product contains or produces a chemical known to the state of California to cause cancer and birth defects or other reproductive harm) (California Health and Safety Code Section 25249.5 et seq.) WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer (California Health and Safety Code Section 25249.5 et seq.) PHONE: (253) 854.5820 | FAX: (253) 939.1746 INFORMATION SOURCES California Health and Safety Code, Section 25249.4 through 25249.13. The California Office of Environmental Health Hazard Assessment, 301 Capitol Mall, Sacramento, CA 95814; Telephone 916-445-6900. California Proposition 65 Website: www.oehha.ca.gov/prop65.html. American National Standards Institute (ANSI). Product Safety Signs And Labels (ANSI Z535.4), available from ANSI, 25 West 43rd Street, New York, NY 10036; Telephone 212-642-4900; Website www.ansi.org. 3 SAFETY INFORMATION Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations. Read and understand this instruction manual carefully before the installation and operation of this equipment. ELECTRIC SHOCK: It can kill FUMES AND GASES ARE DANGEROUS ARC RAYS: Harmful to people's eyes and skin ELECTRIC SHOCK: It can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and internal machine circuits are also live when power is on. Incorrectly installed or improperly grounded equipment is dangerous. · Connect the primary input cable according to American standards and regulations. ANSI Z49.1. · Avoid all contact with live electrical parts of the welding circuit, electrodes and wires with bare hands. The operator must wear dry welding gloves while he/she performs the welding task. · The operator should keep the work piece insulated from himself/herself. · Keep cords dry, free of oil and grease, and protected from hot metal and sparks. · Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged, bare wiring is dangerous and can kill. · Do not use damaged, under-sized, or badly joined cables. · Do not drape cables over your body. FUMES AND GASES ARE DANGEROUS: Smoke and gas generated while welding or cutting can be harmful to people's health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. · Do not breathe the smoke and gas generated while welding or cutting, keep your head out of the fumes. · Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and gases. · In confined or heavy fume environments always wear an approved air-supplied respirator. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be certain the air in your work environment is safe to breathe. · Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. · Materials such as galvanized, lead, or cadmium plated steel, contain elements that can give off toxic fumes when welded. Do not weld these materials unless the area is very well ventilated, and or wearing an air supplied respirator. ARC RAYS: Harmful to people's eyes and skin. Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin. · Always wear a welding helmet with correct shade of filter lens and suitable protective clothing including welding gloves while the welding operation is performed. · Measures should be taken to protect people in or near the surrounding working area. Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. HOT PARTS: Items being welded generate and hold high heat and can cause severe burns. Do not touch hot parts with bare hands. Allow a cooling period before working on the welding gun. Use insulated welding gloves and clothing to handle hot parts and prevent burns. 4 TOLL FREE: (800) 426.0877 | www.CKWORLDWIDE.com FIRE HAZARD: Welding on closed containers, such as tanks, drums, or pipes, can cause them to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. · Welding sparks may cause fire, therefore remove any flammable materials away from the working area, at least 40 feet (12m) from the welding arc. Cover flammable materials and containers with approved covers if unable to be moved from the welding area. · Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to the required Safety Standards to insure that flammable or toxic vapors and substances are totally removed, these can cause an explosion even though the vessel has been "cleaned". Vent hollow castings or containers before heating, cutting or welding. They may explode. · Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors such as gasoline. · Have a fire extinguisher nearby and know how to use it. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. GAS CYLINDERS: Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders are normally part of the welding process, be sure to treat them carefully. CYLINDERS can explode if damaged. · Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. · Insure cylinders are held secure and upright to prevent tipping or falling over. · Never allow the welding electrode or earth clamp to touch the gas cylinder, do not drape welding cables over the cylinder. · Never weld on a pressurized gas cylinder, it will explode and kill you. · Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator. GAS BUILD UP: The build up of gas can cause a toxic environment by depleting the air's oxygen content and potentially resulting in injury or death. · Shut off shielding gas supply when not in use. · Always ventilate confined spaces or use approved air-supplied respirator. ELECTRONIC MAGNETIC FIELDS: MAGNETIC FIELDS can affect implanted medical devices. · Wearers of pacemakers and other implanted medical devices should keep away. · Implanted medical device wearers should consult their doctor and the device manufacturer before going near any electric welding, cutting or heating operation. NOISE CAN DAMAGE HEARING: Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. FIRE HAZARD GAS CYLINDERS Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode GAS BUILD UP ELECTRONIC MAGNETIC FIELDS can affect implanted medical devices PHONE: (253) 854.5820 | FAX: (253) 939.1746 NOISE CAN DAMAGE HEARING 5 CONNECTION DIAGRAMS GAS-COOLED 2 PIECE 1 PIECE 1 PIECE GAS-THRU LUG GAS IN WATER-COOLED STANDARD DINSE GAS IN DINSE GAS IN GAS-THRU DINSE WATER RETURN WATER IN GAS IN DINSE GAS IN GAS CONNECT WATER RETURN WATER IN 6 TOLL FREE: (800) 426.0877 | www.CKWORLDWIDE.com MACHINE CONNECTION DIAGRAMS 1 PIECE GAS-COOLED VALVE DINSE GAS IN 2 PIECE GAS-COOLED WATER-COOLED NOTE: 1 quart (1 liter) per minute flow rate. Water in through water line, water out through power cable. DINSE WATER RETURN WATER IN GAS IN WATER-COOLED GAS-THRU VALVE LUG GAS IN GAS IN 1 PIECE GAS-THRU DINSE WATER RETURN WATER IN QUICK DISCONNECTS Adapters for gas-cooled and water-cooled torch setups that have quick-disconnect female adapters on either the machine or water-cooler. QDWAP WATER COOLED 9mm male quick disconnect for water. 9mm Male Spud Female 5/8"-18 LH QDGAP GAS COOLED 9mm male quick disconnect for argon. 9mm Male Spud Female 5/8"-18 RH PHONE: (253) 854.5820 | FAX: (253) 939.1746 7 125 CK9 AMP GAS COOLED 125 amp ACHF or DCSP @ 100% 2 Series Head Accessories CK9 & CK9V | RIGID HEAD STYLE CABLE RIGID 1 Piece 2 Piece CABLE LENGTH 12.5 ft. (3.8m) 25 ft. (7.6m) 12.5 ft. (3.8m) 25 ft. (7.6m) RIGID + VALVE 1 Piece 2 Piece 12.5 ft. (3.8m) 25 ft. (7.6m) 12.5 ft. (3.8m) 25 ft. (7.6m) STANDARD # CK9-12-R RG CK9-25-R RG CK9-12-2 RG CK9-25-2 RG CK9V-12-R RG CK9V-25-R RG CK9V-12-2 RG CK9V-25-2 RG CK9 & CK9V | FLEX HEAD STYLE CABLE FLEX 1 Piece 2 Piece CABLE LENGTH 12.5 ft. (3.8m) 25 ft. (7.6m) 12.5 ft. (3.8m) 25 ft. (7.6m) FLEX + VALVE 1 Piece 2 Piece 12.5 ft. (3.8m) 25 ft. (7.6m) 12.5 ft. (3.8m) 25 ft. (7.6m) STANDARD # CK9-12-R FX CK9-25-R FX CK9-12-2 FX CK9-25-2 FX CK9V-12-R FX CK9V-25-R FX CK9V-12-2 FX CK9V-25-2 FX CK9P & CK9PV | PENCIL HEAD STYLE CABLE RIGID 1 Piece 2 Piece CABLE LENGTH 12.5 ft. (3.8m) 25 ft. (7.6m) 12.5 ft. (3.8m) 25 ft. (7.6m) STANDARD # CK9P-12-R CK9P-25-R CK9P-12-2 CK9P-25-2 RIGID + VALVE 1 Piece 2 Piece 12.5 ft. (3.8m) 25 ft. (7.6m) 12.5 ft. (3.8m) 25 ft. (7.6m) CK9PV-12-R CK9PV-25-R CK9PV-12-2 CK9PV-25-2 SUPER-FLEX # CK9-12-RSF RG CK9-25-RSF RG CK9-12-2SF RG CK9-25-2SF RG CK9V-12-RSF RG CK9V-25-RSF RG CK9V-12-2SF RG CK9V-25-2SF RG SPECIFICATIONS 7-1/2" (19.0cm) 2.75 oz (78gm) SUPER-FLEX # CK9-12-RSF FX CK9-25-RSF FX CK9-12-2SF FX CK9-25-2SF FX CK9V-12-RSF FX CK9V-25-RSF FX CK9V-12-2SF FX CK9V-25-2SF FX SPECIFICATIONS 8" (20.3cm) 3.5 oz (99gm) SUPER-FLEX # CK9P-12-RSF CK9P-25-RSF CK9P-12-2SF CK9P-25-2SF CK9PV-12-RSF CK9PV-25-RSF CK9PV-12-2SF CK9PV-25-2SF SPECIFICATIONS 7-3/4" (19.7cm) 3 oz (85gm) CK9 RG REPLACEMENT TORCH BODIES PART # STYLE CK9 RG RIGID CK9 FX FLEX CK9V RG VALVED RIGID CK9V FX CK9P CK9PV VALVED FLEX PENCIL VALVED PENCIL 8 CK9 FX CK9V RG CK9V FX CK9P TOLL FREE: (800) 426.0877 | www.CKWORLDWIDE.com POWER CABLES/HOSES 1 PIECE STANDARD POWER CABLE 3/8"x 24 RH 1 PIECE SUPER-FLEX POWER CABLE 3/8"x 24 RH 2 PIECE STANDARD POWER CABLE 3/8"x 24 RH 2 PIECE SUPER-FLEX POWER CABLE 3/8"x 24 RH ARGON HOSE WELD LEAD ARGON HOSE WELD LEAD POWER CABLE ADAPTER 15PCA | 105Z57 3/8"x 24 RH 5/8"x 18 RH CK9 3/8"x 24 RH 3/8"x 24 RH 5/8"x18 RH 5/8"x18 RH LENGTH 12-1/2 ft. (3.8m) 25 ft. (7.6m) STANDARD 1 PIECE CABLE 1512PCHF (57Y01R) 1525PCHF (57Y03R) SUPER-FLEX 1 PIECE CABLE 1512PCSF (57Y01RSF) 1525PCSF (57Y03RSF) LENGTH 12-1/2 ft. (3.8m) 25 ft. (7.6m) 2 PIECE CABLES 2 PIECE CABLES 1512PCN (57Y01-2) 1512PCNSF (57Y01-2SF) 1525PCN (57Y03-2) 1525PCNSF (57Y03-2SF) LENGTH 12-1/2 ft. (3.8m) 25 ft. (7.6m) WELD LEAD 1512CN 1525CN LENGTH 12-1/2 ft. (3.8m) 25 ft. (7.6m) ARGON HOSE 212AH (45V09) 225AH (45V10) ARGON HOSE 212AHSF (45V09SF) 225AHSF (45V10SF) HANDLE Part # HS DINSE 25 DINSE CONNECTORS (3/8" 9.5mm) DINSE 35 (1/2" 12.8mm) DINSE 25M (3/8" 9.5mm) DINSE 35M (1/2" 12.8mm) STANDARD GAS-THRU TWECO OR CAM-LOCK GAS IN GAS IN STANDARD DINSE SIZE 3/8" (9mm) 1/2" (12.8mm) ORDER # SL2-25 SL2-35 GAS-THRU DINSE SIZE 3/8" (9mm) 1/2" (12.8mm) ORDER # SL2-25M SL2-35M PHONE: (253) 854.5820 | FAX: (253) 939.1746 GAS IN TWECO / CAM-LOCK DINSE STYLE ORDER # TWECO SL-2 CAM-LOCK SL2-CL 9 250 AMP CK20 WATER COOLED 250 amp ACHF or DCSP @ 100% 2 Series Head Accessories CK20 & CK20V | RIGID HEAD STYLE CABLE RIGID 3 Piece CABLE LENGTH 12.5 ft. (3.8m) 25 ft. (7.6m) STANDARD # CK20-12 CK20-25 RIGID + VALVE 3 Piece 12.5 ft. (3.8m) 25 ft. (7.6m) CK20V-12 CK20V-25 SUPER-FLEX # CK20-12SF CK20-25SF CK20V-12SF CK20V-25SF SPECIFICATIONS 7-1/2" (19.0cm) 3 oz (85gm) CK20 & CK20V | FLEX HEAD STYLE CABLE FLEX 3 Piece CABLE LENGTH 12.5 ft. (3.8m) 25 ft. (7.6m) STANDARD # CK20-12 FX CK20-25 FX FLEX + VALVE 3 Piece 12.5 ft. (3.8m) 25 ft. (7.6m) CK20V-12 FX CK20V-25 FX SUPER-FLEX # CK20-12SF FX CK20-25SF FX CK20V-12SF FX CK20V-25SF FX SPECIFICATIONS 7-1/2" (19.0cm) 3 oz (85gm) CK20P | PENCIL | SAME AS CKM200 HEAD STYLE CABLE CABLE LENGTH STANDARD # SUPER-FLEX # SPECIFICATIONS RIGID 12.5 ft. (3.8m) 3 Piece 25 ft. (7.6m) CK20P-12 CK20P-25 CK20P-12SF 7-1/2" (19.0cm) CK20P-25SF 3 oz (85gm) REPLACEMENT TORCH BODIES PART # STYLE CK20 RG RIGID CK20 FX FLEX CK20V RG VALVED RIGID CK20V FX CK20P CK20PV VALVED FLEX PENCIL VALVED PENCIL CK20 FX CK20V RG CK20V FX CK20P CK20 RG CK25 WATER COOLED 250 amp ACHF or DCSP @ 100% 2 Series Head Accessories CK25 | PENCIL FLEX HEAD STYLE CABLE CABLE LENGTH FLEX 12.5 ft. (3.8m) 3 Piece 25 ft. (7.6m) STANDARD # CK25-12 CK25-25 CKPF200 Torch Body SUPER-FLEX # CK25-12SF CK25-25SF SPECIFICATIONS 11-1/2" (29.2cm) 3 oz (85gm) CK25 Custom lengths available up to 10" (25.4cm), and uses the same thread pattern as the CK20 6" (15.2cm) Neck 230M-C Torch Head 10 TOLL FREE: (800) 426.0877 | www.CKWORLDWIDE.com CK20/CK25 POWER CABLES/HOSES STANDARD POWER CABLE 1/4"x28 RH SUPER-FLEX POWER CABLE 1/4"x28 RH STANDARD TRI-FLEX CABLES POWER CABLE ARGON HOSE 7/8"x14 LH 7/8"x14 LH 5/8"x18 RH LENGTH 12-1/2 ft. (3.8m) 25 ft. (7.6m) STANDARD POWER CABLE 212PC (45V03) 225PC (45V04) SUPER-FLEX POWER CABLE 212PCSF (45V03SF) 225PCSF (45V04SF) LENGTH 12-1/2 ft. (3.8m) 25 ft. (7.6m) TRI-FLEX CABLES 212TF 225TF 3-PIECE ASSEMBLY 212SF 225SF 1/4"x28 RH ARGON HOSE WATER HOSE WATER HOSE 5/8"x18 LH 7/8"x14 LH 5/8"x 18 RH 5/8"x18 LH LENGTH 12-1/2 ft. (3.8m) 25 ft. (7.6m) LENGTH 12-1/2 ft. (3.8m) 25 ft. (7.6m) WATER HOSE 212WH (45V07) 225WH (45V08) ARGON HOSE 212AH (45V09) 225AH (45V10) WATER HOSE 212WHSF (45V07SF) 225WHSF (45V08SF) ARGON HOSE 212AHSF (45V09SF) 225AHSF (45V10SF) POWER CABLE ADAPTER 2PCA | 45V11 7/8"-14 LH 5/8"-18 LH HANDLE Part # HS DINSE 25 DINSE CONNECTORS (3/8" 9.5mm) DINSE 35 (1/2" 12.8mm) DINSE 25M (3/8" 9.5mm) DINSE 35M (1/2" 12.8mm) STANDARD GAS-THRU Water Out Water In GAS IN STANDARD DINSE SIZE 3/8" (9mm) 1/2" (12.8mm) ORDER # SLWHAT-25 SLWHAT-35 GAS IN Water Out Water In GAS-THRU DINSE SIZE 3/8" (9mm) 1/2" (12.8mm) ORDER # SLWHAT-25M SLWHAT-35M PHONE: (253) 854.5820 | FAX: (253) 939.1746 TWECO OR CAM-LOCK Water Out Water In GAS IN TWECO / CAM-LOCK DINSE STYLE ORDER # TWECO SLWHAT-T CAM-LOCK SLWHAT-CL 11 2 SERIES PARTS (13N) TORCH MODELS 9, 20 THREAD PATTERN: 5/16" x 24 CUP COLLET BODY COLLET HEATSHIELD TORCH BACKCAP ALUMINA 2A4 (13N08) 2A5 (13N09) 2A6 (13N10) CERAMIC 2C4 (13N14) 2C5 (13N15) 2C6 (13N16) 2A7 (13N11) 2A8 (13N12) 2A10 (13N13) 2C7 (13N17) 2C8 (13N18) 2C10 (13N19) STANDARD 2CB20 (13N25) 2CB40 (13N26) 2CB116 (13N27) 2CB332 (13N28) 2CB418 (13N29) ALUMINA - LONG 2A3L (A796F70) 2A5L (A796F72) 2A4L (A796F71) 2A6L (A796F73) CERAMIC - LONG 2C3L (796F70) 2C5L (796F72) 2C4L (796F71) 2C6L (796F73) ALUMINA - GAS LENS 2AG4 (53N58) 2AG7 (53N61) 2AG5 (53N59) 2AG8 (53N61S) 2AG6 (53N60) 2AG10 GAS LENS 2GL20 (45V41) 2GL40 (45V42) 2GL116 (45V43) 2GL332 (45V44) 2GL418 (45V45) ALUMINA LONG - GAS LENS 2AG5L (53N59L) 2AG7L (53N61L) 2AG6L (53N60L) STANDARD 2C20 (13N20) 2C40 (13N21) 2C116 (13N22) 2C332 (13N23) 2C418 (13N24) WEDGE 2C040GS 2C332GS 2C116GS 2C418GS STANDARD 2GHS REVERSE 6C20 6C40 6C116 6C332 6C418 STANDARD SEE ABOVE WEDGE SEE ABOVE REVERSE SEE ABOVE STANDARD SEE ABOVE ALUMINA - LARGE DIAMETER 3AG6LD (57N75) 3AG11LD(53N89) 3AG8LD (57N74) 3AG12LD(53N87) 3AG10LD (53N88) LARGE DIAMETER LARGE DIAMETER 2C020LD (13N20L) 2GL0204LD (45V0204S) 2C040LD (13N21L) 2GL116LD (45V116S) 2C116LD (13N22L) 2GL332LD (45V64S) 2C332LD (13N23L) 2GL418LD (995795S) 2C418LD (13N24L) ALUMINA 8A4 (A53N24) 8A5 (A53N25) CERAMIC 8C4 (53N24) 8C5 (53N25) 8A6 (A53N27) 8C6 (53N27) SHORT 6CB20 6CB40 6CB116 6CB332 6CB418 REVERSE SEE ABOVE CERAMIC - LONG 8C4L (53N28) 8C6L (53N26) LARGE DIAMETER 2GHSLD STANDARD SEE ABOVE LONG 200L (41V24) TORCHES USED ON: CK100 CK110 CK130 CK200 CK230 FL2L CKM230 CWH230 CWM230 CK9 CK20 CK25 MEDIUM 200M (41V35) SHORT 200S (41V33) TUNGSTEN ELECTRODE CONVERSION CHART SIZE SUFFIX INCHES MILLIMETERS 20 .020" .5mm 40 .040" 1.0mm 116 1/16" 1.6mm 332 3/32" 2.4mm 418 1/8" 3.2mm 532 5/32" 4.0mm 316 3/16" 4.8mm 14 1/4" 6.4mm 2C332 Size Suffix 12 TOLL FREE: (800) 426.0877 | www.CKWORLDWIDE.com 2 SERIES GAS SAVER PARTS TORCH MODELS 9, 20 THREAD PATTERN: 5/16" x 24 CUP ADAPTER COLLET BODY COLLET HEATSHIELD TORCH BACKCAP ALUMINA 2A4GS 2A7GS 2A5GS 2A8GS 2A6GS WITH SCREEN TAS040GS TAS116GS TAS332GS TAS418GS CLEAR 2P8GS WITHOUT SCREEN TA040GS TA116GS TA332GS TA418GS STANDARD 2CBGS-1 WEDGE 2C040GS 2C116GS 2C332GS 2C418GS ALUMINA 2A18GSLD CLEAR 2P18GSLD LARGE DIAMETER WITH SCREEN TAS040GSLD TAS116GSLD TAS332GSLD TAS418GSLD LARGE DIAMETER 2CBGSLD WEDGE SEE ABOVE STANDARD 2HSGS-1 LONG 200L (41V24) LARGE DIAMETER 2HSGSLD TORCHES USED ON: CK100 CK110 CK130 CK200 CK230 FL2L CKM230 CWH230 CWM230 CK9 CK20 CK25 MEDIUM 200M (41V35) SHORT 200S (41V33) ACCESSORY KITS Pre-packaged kits containing common consumables for our 2 Series torches. 2 SERIES | ORDER #AK-4 2 SERIES GAS SAVER | ORDER #AK-4GS AK-4 ACCESSORY KIT 9, 20 TORCHES: 1/16" (1.6mm), 3/32" (2.4mm), 1/8" (3.2mm) Accessories For 2 Series TIG Torch 3 Collets 3 Tungsten Electrodes ITEM (Quantity 1 Each) Long Backcap 1/16" (1.6mm) Collet 3/32" (2.4mm) Collet 1/8" (3.2mm) Collet 1/16" (1.6mm) Collet Body 3/32" (2.4mm) Collet Body 1/8" (3.2mm) Collet Body #5 (5/16" 8.0mm) Alumina Cup #6 (3/8" 9.6mm) Alumina Cup #8 (1/2" 12.8mm) Alumina Cup 1/16" (1.6mm) x 7" 2% Ceriated Tungsten 3/32" (2.4mm) x 7" 2% Ceriated Tungsten 1/8" (3.2mm) x 7" 2% Ceriated Tungsten 3 Collet Bodies 3 Cups 1 Backcap www.CKWORLDWIDE.com PART # 200L (41V24) 2C116 (13N22) 2C332 (13N23) 2C418 (13N24) 2CB116 (13N27) 2CB332 (13N28) 2CB418 (13N29) 2A5 (13N09) 2A6 (13N10) 2A8 (13N12) T1167GC2 T3327GC2 T187GC2 2 SERIES | ORDER #AK-1 (NOT SHOWN) .040" (1.0mm) 1/16" (1.6mm) accessory kit. See website for details. AK-4GS ACCESSORY KIT 9, 20 TORCHES: 1/16" (1.6mm), 3/32" (2.4mm), 1/8" (3.2mm) Accessories For 2 Series TIG Torch 3 Collets 1 Collet Body 3 Adapters 1 Heat Shield 3 Tungsten Electrodes 3 Cups 1 Backcap www.CKWORLDWIDE.com ITEM (Quantity 1 Each) Long Backcap 1/16" (1.6mm) Collet 3/32" (2.4mm) Collet 1/8" (3.2mm) Collet 1/16" (1.6mm) Tungsten Adapter 3/32" (2.4mm) Tungsten Adapter 1/8" (3.2mm) Tungsten Adapter Collet Body Heatshield #4 (1/4" 6.4mm) Alumina Cup #6 (3/8" 9.6mm) Alumina Cup #8 (1/2" 12.8mm) Pryex Cup 1/16" (1.6mm) x 7" 2% Ceriated Tungsten 3/32" (2.4mm) x 7" 2% Ceriated Tungsten 1/8" (3.2mm) x 7" 2% Ceriated Tungsten PART # 200L (41V24) 2C116GS 2C332GS 2C418GS TAS116GS TAS332GS TAS418GS 2CBGS-1 2HSGS-1 2A4GS 2A6GS 2P8GS T1167GC2 T3327GC2 T187GC2 PHONE: (253) 854.5820 | FAX: (253) 939.1746 13 STANDARD GAS SAVERTM KITS Use these conversion kits and save up to 40% of shield gas consumption plus save money on replacement parts. · Provides better gas coverage versus standard collet bodies · Tungsten stick-out can be up to 6 times the electrode diameter · Clear Pyrex or Alumina push on nozzles available · Improves visibility · Less expensive replacement parts than standard gas lenses · Fits most standard silicone rubber insulated torch bodies · Replaceable screen adapter SAVE UP TO 40% of shield gas consumption 2 SERIES | STANDARD | GAS SAVER KITS TORCHES TUNGSTEN CUP TYPE 1/16" (1.6mm) ALUMINA ORDER # D2GS116 CK9, CK20 (2 SERIES) 3/32" (2.4mm) 1/8" (3.2mm) 1/16" (1.6mm) 3/32" (2.4mm) ALUMINA ALUMINA PYREX PYREX D2GS332 D2GS418 D2GS116-P D2GS332-P 1/8" (3.2mm) PYREX D2GS418-P KITS INCLUDE WEDGE COLLET COMPLETE FRONT-END KIT INCLUDES ITEMS BELOW (ONE EACH): Push-on Tungsten Alumina Cup OR Adapter with 2A4GS 2A7GS Screens 2A5GS 2A8GS TAS040GS 2A6GS TAS116GS TAS332GS TAS418GS Collet Body 2CBGS-1 Push-on Pyrex Clear Cup 2P8GS 2 Series Wedge Collet 2C040GS 2C116GS 2C332GS 2C418GS 2 Series Heatshield 2HSGS-1 LARGE DIAMETER GAS SAVERTM KITS With a cup orifice of 1-1/8" (28.5mm) the Large Diameter Gas SaverTM kit provides a large inert atmosphere for the welding of reactive metals such as titanium, molybdenum, nickel-based and aluminum-based alloys as well as non-reactive metals like stainless steel. GREAT FOR TITANIUM! 2 SERIES | LRG. DIAMETER | GAS SAVER KITS TORCHES TUNGSTEN CUP TYPE ORDER # 1/16" (1.6mm) ALUMINA D2GS116LD-A CK9, CK20 (2 SERIES) 3/32" (2.4mm) 1/8" (3.2mm) 1/16" (1.6mm) 3/32" (2.4mm) ALUMINA ALUMINA PYREX PYREX D2GS332LD-A D2GS418LD-A D2GS116LD D2GS332LD 1/8" (3.2mm) PYREX D2GS418LD COMPLETE FRONT-END KIT INCLUDES ITEMS BELOW (ONE EACH): Push-on Alumina Cup OR 2A18GSLD Large Diameter Adapter with Screen TAS040GSLD TAS116GSLD TAS332GSLD TAS418GSLD Push-on Pyrex Clear Cup 2P18GSLD Large Diameter Collet Body 2CBGSLD 2 Series Wedge Collet 2C040GS 2C116GS 2C332GS 2C418GS 2 Series Large Diameter Heatshield 2HSGSLD 14 TOLL FREE: (800) 426.0877 | www.CKWORLDWIDE.com REMOTE AMPERAGE CONTROLS · Available in either Steady-GripTM, rotary, linear slide, or spring loaded wheel configurations · Fits most makes and models of TIG power supplies · Controls contactor on / off, gas solenoids and full range current output · Available with a Velcro strap or built into the torch handle · Contact CK for order numbers Flex-LocTM torch not included. STEADY-GRIPTM Velcro Straps ROTARY Velcro Straps LINEAR SLIDE Built-In Handle (For CK torches) SPRING LOADED WHEEL Velcro Straps LEATHER VELCRO HOSE COVERS ABRASION, HEAT, OIL, FLAME AND UV RESISTANT TORCHES CK9, CK17, CK20 CK18, CK26 LENGTH* 10 ft. (3.0m) 22 ft. (7.0m) 10 ft. (3.0m) 22 ft. (7.0m) WIDTH 3-3/4" (95mm) 3-3/4" (95mm) 4-1/2" (114mm) 4-1/2" (114mm) INSIDE DIAMETER 1" (25mm) 1" (25mm) 1-1/4" (31mm) 1-1/4" (31mm) ORDER# 212HCLV 225HCLV 312HCLV 325HCLV TUNGSTEN ELECTRODE GRINDER · Enclosed electrode grinder · Minimizes grinding dust exposure to both the user and the environment · Standard head for diameters: .040" (1.0mm) 1/16" (1.6mm) 3/32" (2.4mm) 1/8" (3.2mm) · Angles adjustable from 20° 60° · Consistent tip geometry · Eliminate grinding wheel contamination SPECIFICATIONS Voltage .......................120V AC Single Phase................... 60 Hz Power.............................710 W Amp............................... 6.45 A No Load Speed ..... 34,000 RPM Weight .............4.1 lbs. (1,860 grams) Ship Weight ...........10.1 lbs. (4,581 grams) Warranty...................... 2 years 230V available, contact us for more information PHONE: (253) 854.5820 | FAX: (253) 939.1746 15 TROUBLESHOOTING GUIDE PROBLEM Excessive Electrode Consumption Erratic Arc Inclusion of Tungsten or Oxides in Weld Porosity in Weld Deposit Cracking in Welds Inadequate Shielding Arc Blow Short Parts Life CAUSE Inadequate gas flow Improper size electrode for current required Operating of reverse polarity Electrode contamination Excessive heating inside torch Electrode oxidizing during cooling Shield gas incorrect Incorrect voltage (arc too long) Current too low for electrode size Electrode contaminated Joint too narrow Contaminated shield gas, dark stains on the electrode or weld bead indicate contamination Base metal is oxidized, dirty or oily Poor scratch starting technique Excessive current for tungsten size used Accidental contact of electrode with puddle Accidental contact of electrode to filler rod Using excessive electrode extension Inadequate shielding or excessive drafts Wrong gas Heavy surface oxides not being removed Entrapped impurities, hydrogen, air, nitrogen, water vapor Defective gas hose or loose connection Filler material is damp (particularly aluminum) Filler material is oily or dusty Alloy impurities in the base metal such as sulphur, phosphorus, lead and zinc Excessive travel speed with rapid freezing of weld trapping gases before they escape Contaminated gas shield Hot cracking in heavy section or with metals which are hot shorts Crater cracks due to improperly breaking the arc or terminating the weld at the joint edge Post weld cold cracking, due to excessive joint restraint, rapid cooling, or hydrogen embrittlement Centerline cracks in single pass welds Underbead cracking from brittle microstructure Gas flow blockage or leak in hoses or torch Excessive travel speed exposes molten weld to atmospheric contamination Wind or drafts Excessive electrode stickout Excessive turbulence in gas stream Induced magnetic field from DC weld current Arc is unstable due to magnetic influences Short water cooled leads life Cup shattering or breaking in use Short collet life Short torch head life Gas hoses ballooning, bursting or blowing off while hot SOLUTION Increase gas flow Use larger electrode Use larger electrode or change polarity Remove contaminated portion, then prepare again Replace collect, try wedge collet or reverse collet Increase gas post flow time to 1 sec. per 10 amps Change to proper gas (no oxygen or Co2) Maintain short arc length Use smaller electrode or increase current Remove contaminated portion, then prepare again Open joint groove Most common cause is moisture or aspirated air in gas stream. Use welding grade gas only. Find the source of the contamination and eliminate it promptly. Use appropriate chemical cleaners, wire brush or abrasives prior to welding. Many codes do not allow scratch starts. Use copper strike plate. Use high-frequency arc starter. Reduce current or use larger electrode Maintain proper arc length Maintain a distance between electrode and filler metal Reduce electrode extension to recommended limits Increase gas flow, shield arc from wind, or use gas lens Do not use Ar-02 or Ar-Co2 GMA (MIG) gases for TIG welding Use ACHF, adjust balance control for maximum cleaning, or wire brush and clean the weld joint prior to welding. Do not weld on wet material. Remove condensation from line Check hoses and connections for leaks Dry filler metal in oven prior to welding Replace filler metal Change to a different alloy composition which is weldable. These impurities can cause a tendency to crack when hot. Lower the travel speed Replace the shielding gas Preheat, increase weld bead cross-section size, change weld bead contour. Reverse direction and weld back into previous weld at edge. Use remote or foot control to manually down slope current. Preheat prior to welding, use pure to non-contaminated gas. Increase the bead size. Prevent craters or notches. Change the weld joint design. Increase bead size. Decrease root opening, use preheat, prevent craters. Eliminate sources of hydrogen, joint restraint, and use preheat. Locate and eliminate blockage or leak. Use slower travel speed or carefully increase the flow rate to a safe level below creating excessive turbulence. Use trailing shield cup. Set up screens around the weld area Reduce electrode stickout. Use a larger size cup. Change to gas saver parts or gas lens parts. Change to ACHF current. Rearrange the split ground connection. Reduce weld current and use arc length as short as possible. Verify coolant flow direction, return flow must be on the power cable lead. Change cup size or type, change tungsten position, refer to CK Worldwide technical specifications available at www.CKWorldwide.com Ordinary style is split and twists or jams, change to wedge style. Do not operate beyond rated capacity, use water cooled model, do not bend rigid torches. Incorrect flowmeter, TIG flowmeters operate at 35 psi with low flows. MIG flowmeters operate with high flows at 65 psi or more. © 2017/2019 CK Worldwide, Inc. All rights reserved. 2367 Printed 4/2019 Phone: 1.800.426.0877 Fax: 1.800.327.5038 CK Worldwide, Inc., PO Box 1636, Auburn, WA 98071 CONNECT WITH US ON: TRADEMARK NOTICES: Gas Saver,TM Safe-Loc,TM Flex-Loc,TM Super-Flex,TMTrim-Line,TM Max-FloTM, Fail-SafeTM, Steady-GripTM and LaYZrTM are registered trademarks of CK Worldwide, Inc. www.CKWORLDWIDE.com