CK WORLDWIDE CK130 MasterTIG Torches Instruction Manual

CK WORLDWIDE CK130 MasterTIG Torches

Congratulations on your purchase of a CK Worldwide TIG Torch!
CK Worldwide’s premium quality TIG torches perform with 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 7:00 AM and 3:30 PM, 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
• Product demonstrations, welding tips, and more.
• TWITTER: @CKWWInc
• INSTAGRAM: @ckworldwide

Need technical information? Call or email to request a copy of our Technical Guide (Form 116)
The information in this manual represents the best judgment 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.

TORCH SPECIFICATIONS

INSTALLATION: Before using this torch, tighten the 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 the torch or regulator fittings have been detached.

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 that 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.)

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.

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. 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 workpiece 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, and 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, and 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 the 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.

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 pieces, and hot equipment can cause fires and burns. Accidental contact of electrodes to metal objects can cause sparks, explosions, 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 ensure 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.
• Ensure 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 the shielding gas supply when not in use.
• Always ventilate confined spaces or use an 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 the noise level is high.

CONNECTION DIAGRAMS

GAS-COOLED

WATER-COOLED

MACHINE CONNECTION DIAGRAMS

QUICK DISCONNECTS

Adapters for gas-cooled and water-cooled torch setups that have quick- disconnect female adapters on either the machine or water-cooler.

GAS COOLED 130 amp ACHF or DCSP @ 100% 2 Series Head Accessories

CK130 & CK130V | RIGID

RIGID

| 1 Piece| 12.5 ft. (3.8m)| CK1312H RG| CK1312HSF RG| 8″ (20.3cm)

3-1/2 oz (99gm)

---|---|---|---|---|---
25 ft. (7.6m)| CK1325H RG| CK1325HSF RG
2 Piece| 12.5 ft. (3.8m)| CK1312N RG| CK1312NSF RG
25 ft. (7.6m)| CK1325N RG| CK1325NSF RG

RIGID

+ VALVE

| 1 Piece| 12.5 ft. (3.8m)| CK1312VH RG| CK1312VHSF RG
25 ft. (7.6m)| CK1325VH RG| CK1325VHSF RG
2 Piece| 12.5 ft. (3.8m)| CK1312VN RG| CK1312VNSF RG
25 ft. (7.6m)| CK1325VN RG| CK1325VNSF RG

CK130 & CK130V | FLEX

FLEX

| 1 Piece| 12.5 ft. (3.8m)| CK1312H FX| CK1312HSF FX| 8″ (20.3cm)

3-1/2 oz (99gm)

---|---|---|---|---|---
25 ft. (7.6m)| CK1325H FX| CK1325HSF FX
2 Piece| 12.5 ft. (3.8m)| CK1312N FX| CK1312NSF FX
25 ft. (7.6m)| CK1325N FX| CK1325NSF FX

FLEX

+ VALVE

| 1 Piece| 12.5 ft. (3.8m)| CK1312VH FX| CK1312VHSF FX
25 ft. (7.6m)| CK1325VH FX| CK1325VHSF FX
2 Piece| 12.5 ft. (3.8m)| CK1312VN FX| CK1312VNSF FX
25 ft. (7.6m)| CK1325VN FX| CK1325VNSF FX

REPLACEMENT TORCH BODIES

CKPF130 | PENCIL FLEX

FLEX|

1 Piece

| 12.5 ft. (3.8m)| CKPF1312H| CKPF1312HSF| 11″ (27.9cm)

3 oz (85gm)

---|---|---|---|---|---
25 ft. (7.6m)| CKPF1325H| CKPF1325HSF

POWER CABLES/HOSES

POWER CABLE ADAPTER

HANDLE Part # HS

DINSE CONNECTORS

FL130 & FL130V | FLEX-LOC

FL130 & FL130V | REPLACEMENT PARTS

POWER CABLES/HOSES

POWER CABLE ADAPTER

HANDLE

DINSE CONNECTORS

POWER CABLES/HOSES

POWER CABLE ADAPTER

HANDLE Part # HS

DINSE CONNECTORS

BARREL MACHINE TORCH

POWER CABLES/HOSES

POWER CABLE ADAPTER

HANDLE

DINSE CONNECTORS

POWER CABLES/HOSES

POWER CABLE ADAPTER

HANDLE Part # HS

DINSE CONNECTORS

SERIES PARTS (13N) TORCH MODELS 9, 20

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

TROUBLESHOOTING GUIDE

Excessive Electrode Consumption

| Inadequate gas flow| Increase gas flow
Improper size electrode for current required| Use larger electrode
Operating of reverse polarity| Use larger electrode or change the polarity
Electrode contamination| Remove the  contaminated portion, then prepare again
Excessive heating inside torch| Replace collect, try wedge collet or reverse collet
Electrode oxidizing during cooling| Increase gas post-flow time to 1 sec. per 10 amps
Shield gas incorrect| Change to proper gas (no oxygen or CO2)

Erratic Arc

| Incorrect voltage (arc too long)| Maintain short arc length
The current too low for the electrode size| Use smaller electrodes or increase the  current
Electrode contaminated| Remove the  contaminated portion, then prepare again
Joint too narrow| Open joint groove
Contaminated shield gas, dark stains on the electrode or weld bead indicate contamination| A 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.
Base metal is oxidized, dirty or oily| Use appropriate chemical cleaners, wire brushes or abrasives prior to welding.

Inclusion of Tungsten or Oxides in Weld

| Poor scratch-starting technique| Many codes do not allow scratch starts. Use copper strike plate. Use a  high-frequency arc starter.
Excessive current for tungsten size used| Reduce current or use larger electrode
Accidental contact of electrode with puddle| Maintain proper arc length
Accidental contact of electrode to filler rod| Maintain a distance between electrode and filler metal
Using excessive electrode extension| Reduce electrode extension to recommended limits
Inadequate shielding or excessive drafts| Increase gas flow, shield arc from wind, or use gas lens
Wrong gas| Do not use Ar-02 or Ar-Co2 GMA (MIG) gases for TIG welding
Heavy surface oxides not being removed| Use ACHF, adjust balance control for maximum cleaning, or wire brush and clean the weld joint prior to welding.

Porosity in Weld Deposit

| Entrapped impurities, hydrogen, air, nitrogen, water vapor| Do not weld on wet material. Remove condensation from line
Defective gas hose or loose connection| Check hoses and connections for leaks
Filler material is damp (particularly aluminum)| Dry filler metal in oven prior to welding
Filler material is oily or dusty| Replace filler metal
Alloy impurities in the base metal such as sulphur, phosphorus, lead and zinc| Change to a different alloy composition which is weldable. These impurities can cause a tendency to crack when hot.
Excessive travel speed with rapid freezing of weld trapping gases before they escape| Lower the travel speed
Contaminated gas shield| Replace the shielding gas

Cracking in Welds

| Hot cracking in heavy section or with metals which are hot shorts| Preheat, increase weld bead cross-section size, and  change weld bead contour.
Crater cracks due to improperly breaking the arc or terminating the weld at the joint edge| Reverse the direction and weld back into the previous weld at the edge. Use remote or foot control to manually down slope current.
Post weld cold cracking, due to excessive joint restraint, rapid cooling, or hydrogen embrittlement| Preheat prior to welding, use pure to non- contaminated gas. Increase the bead size. Prevent craters or notches. Change the weld joint design.
Centerline cracks in single pass welds| Increase bead size. Decrease root opening, use preheat, and prevent craters.
Underbead cracking from brittle microstructure| Eliminate sources of hydrogen, joint restraint, and use preheat.

Inadequate Shielding

| Gas flow blockage or leak in hoses or torch| Locate and eliminate blockage or leak.
Excessive travel speed exposes molten weld to atmospheric contamination| Use a slower travel speed or carefully increase the flow rate to a safe level below creating excessive turbulence. Use a trailing shield cup.
Wind or drafts| Set up screens around the weld area
Excessive electrode stickout| Reduce electrode stickout. Use a larger size cup.
Excessive turbulence in gas stream| Change to gas saver parts or gas lens parts.
Arc Blow| Induced magnetic field from DC weld current| Change to ACHF current. Rearrange the split ground connection.
Arc is unstable due to magnetic influences| Reduce weld current and use arc length as short as possible.

Short Parts Life

| Short water cooled leads life| Verify coolant flow direction, return flow must be on the power cable lead.
Cup shattering or breaking in use| Change cup size or type, change tungsten position, refer to CK Worldwide technical specifications available at www.CKWorldwide.com
Short collet life| Ordinary style is split and twists or jams, change to wedge style.
Short torch head life| Do not operate beyond rated capacity, use water cooled model, and do not bend rigid torches.
Gas hoses ballooning, bursting or blowing off while hot| Incorrect flowmeter, TIG flowmeters operate at 35 psi with low flows. MIG flowmeters operate with high flows at 65 psi or more.

• Phone: 1.800.426.0877 Fax: 1.800.327.5038 CK Worldwide, Inc., PO Box 1636, Auburn, WA 98071
• www.CKWORLDWIDE.com
• TRADEMARK NOTICES: Gas Saver™, Safe-Loc™, Flex-Loc™, Super-Flex™, Trim-Line™,Max-Flo™ , Fail-Safe™, Steady-Grip™ and LaYZr™ are registered trademarks of CK Worldwide, Inc.

References

• CK Worldwide | TIG Torches, Welding Machines, and Accessories | CK Worldwide
• oehha.ca.gov/prop65.html

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