Dear Customer

This instruction manual will help you get to know your new machine. Read the manual
carefully and you will soon be familiar with all the many great features of your new
product. Meanwhile, please remember well safety rules and operate as instruction.

If you treat your product carefully, this definitely helps to prolong its enduring quality and
reliability things which are both essential prerequisites for getting outstanding results.

Production specification may change without advance notice.

The model you purchase is for:
 WTS 40
Please find corresponding models from the "Contents".

Important:
Please take special note of safety rules and operate as instruction in case of damage
and serious injury.

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Safety Rules

Basic requirements for safe operation

◆Please strictly use the manual for installing and debugging !

◆Electrical connection must be performed after the power switch is off!
◆Operation process should be carried out according to relevant safety operation
procedure!
◆Irrelevant personnel please do not enter welding site! Be sure to wear right
clothes and protective gears!
◆Construction of input power supply, selection of the site, usage, storage and
configuration of high pressure gas, storage of welded work piece, and waste
disposal should be done according to relevant standards！
◆In order to ensure safety, please carefully read and fully understand this
manual. Operation has to be done by professional workers！
◆The equipment shall not be used for work other than welding！
◆Please do not use cable with insufficient capacity or damaged insulation
sheath！
◆Regular maintenance is very necessary. Damaged parts have to be repaired
before use again！

◆Turn off all input power if not use！

Warning: Shock hazard

◆Please do not touch the electrified parts. During welding, temperature of

electrode, nozzle, welding torch and workpiece is very high. Please do not
touch them directly with your skin or wet cloth. To protect your hands, wear dry
gloves.

◆Use dry insulation to insulate you from workpiece and ground. Size of insulation
material should be big enough.

◆Ensure that the working cable is in good contact with the workpiece to be
welded, and as close as possible to the solder joint of the workpiece.

◆In safe operation mode, check whether electrode, ground clamp, welding cable
and welder are in good condition, replace if damaged.

◆Workpiece and welded metal need to be grounded well.

◆Electrodes cannot be thrown into water for cooling.

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 ◆Electrodes cannot be thrown into water for cooling.

Warning: Welding arc, spatter and welding slag are harmful to health

◆When welding, please wear good protective glasses. Arc can cause inflammation of
eyes, splash and welding slag can burn eyes.

◆Please wear protective clothing made of flame retardant material so as to avoid arc,
splash and welding slag burn, or scald skin.

◆Use incombustible screen to protect people around from arc rays.

Warning: Smoke is harmful to health

◆Smoke during welding is harmful to health. Please try to avoid breathing in these
smoke.

◆Inhalation of protective gas for welding is harmful to human health. So, welding site
must be well ventilated.

Warning: Fire risk

◆Combustible materials cannot be put at welding site. Spatter and hot welding seam
can cause fire.Please prepare fire extinguisher nearby.

◆Welding cable and base metal must be well connected. Otherwise heating might
cause fire.

◆Fire extinguisher should be prepared.

Warning: Cylinder will explode if damaged.

◆Only good compressed gas cylinder can be used. Its regulating valve, gas tubes,
filter should be well and suitable.

◆Cylinders must stand upright and should be fixed well.

Gas cylinder installation

◆Sufficient space is necessary so as to avoid collision.

◆Maintain safe distance from welding site or other heat source and fire source.
◆Do not touch gas cylinders with electrodes, electrode clips or other charged parts.
◆When opening valve, head and face should not face to valve outlet.
◆Please do not remove protective cap and handle of gas valve unless the cylinder is

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in use or ready to use.

Warning: Noise over 70 db will permanent damage to hearing

◆Please wear appropriate earmuffs.

◆Ensure that the noise does not cause inconvenience to other people passing
through the working area.

Warning: Electromagnetic interference must be reduced to a level that no longer

constitutes interference

◆Reduce factors that cause interference.

◆Wires should be as short as possible and should be close to or near the ground.

◆Protecting surrounding wires and equipment can reduce impact of radiation.

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 Contents
1.WTS40 Introduction................................................................................................................................................6
1.1 Summary....................................................................................................................................................6
1.2 Main structure............................................................................................................................................7
1.3 technical parameter............................................................................................................................... 12
2.Installation and adjustment of equipment........................................................................................................ 13
2.1Installation environment......................................................................................................................... 13
2.2Installation and adjustment of torch head parts................................................................................. 13
3.Operation guide.................................................................................................................................................... 14
3.1Welding preparation................................................................................................................................14
3.2 Adjust welding torch...............................................................................................................................14
3.3 Welding operation.................................................................................................................................. 15
4.Maintenance..........................................................................................................................................................16
4.1 Maintenance cautions............................................................................................................................16
4.2 Clean and maintenance........................................................................................................................ 16
5.Equipment List...................................................................................................................................................... 17

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1.WTS40 Introduction

1.1 Summary

This welding head is designed for all position TIG tube-sheet automatic welding. It is mainly used in
power station, air conditioning, various heat exchangers, nuclear power, chemical industry and other
industries.

This machine head is specially designed for thin-walled tube Self Fusing tubesheet welds. It can weld
various types of tube / tube-sheet joints of stainless steel, titanium alloy, carbon steel, etc. This machine
head can be welded tube plate form is mainly flat end connection, no filler wire welding, pipe diameter
range of Φ 16 ~ Φ 38mm.
This machine head is 3kg in total, which is convenient to use. The welding process can be completed
automatically by pressing the start button. There is no requirement for welder's skill.
This machine head adopts flexible expanding core positioning and special tightening technology, which
can make the head firmly positioned on the tube plate, accurate positioning, safe and reliable.
This machine head adopts standard air drag cover, closed welding, good weld protection effect, can
weld titanium alloy workpiece.
The machine head is driven by Swiss imported DC servo motor, speed closed-loop control, no winding
of water and electricity, and continuous rotation can be realized.
The welding gun and positioning system of the machine head adopts circulating water cooling to improve
the welding efficiency and prevent the welding gun from overheating during continuous operation for a
long time, which will affect the welding operation.
This machine head and WZM-400 inverter type pulsed TIG welding machine power supply can be used
together to form a complete self melting tube sheet automatic welding machine system, realizing all
position TIG tube-sheet welding, achieving ideal welding effect and high repeatability.

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1.2 Main structure

B1 B2

B3

B4

WTS40mainly include following parts.

B1：Core rod tension positioning part；

B2：Rotating torch body part；
B3：Shell part；
B4：Cable and button part.
● Core rod tension positioning part

1 2 3

4 5
6

The Core rod tension positioning part includes: mandrel pull rod 1, elastic chuck 2, ceramic spacer
sleeve 3, front cone sleeve 4, rear cone sleeve 5, handle 6 and other parts.
In the positioning part, the handle 6 is pulled 180 ° to make the mandrel pull rod 1 stretch through a
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group of springs, and the distance between the front cone sleeve 4 and the rear cone sleeve 5 is
adjusted to make the elastic collet 2 expand and shrink, so as to realize the positioning function.
During welding, the elastic chuck is expanded in the welded pipe, which plays the role of radial
positioning and makes the machine head always close to the tube plate axially without human
intervention. After welding, loosen the elastic chuck and pull out the welding torch.
In addition, the elastic chuck is customized according to the customer's workpiece, and its outer
diameter is 0.5mm smaller than the corresponding pipe inner hole. Customers need to select the
corresponding elastic chuck according to their own workpiece conditions.

● Rotating torch body part

1 2 3

The rotary torch body includes: air hood 1, rotary table 2, gear mandrel 3, tungsten pole clamp 4,
intermediate transmission gear 5, rotary driving gear 6, rotary motor 7 and other parts. This part mainly
includes three parts: rotary drive part, torch body part and water electric circuit system.
1.Rotary drive part
The rotary torch body is driven by a rotating motor 7 (ESCAP DC servo motor reducer) to drive the rotary
driving gear 6-intermediate transmission gear 5-gear spindle 3 to rotate, and then it is transmitted to the
rotary table 2 through the gear mandrel. The tungsten electrode clamp 4 installed with tungsten
electrode is installed on the rotary table 2 and rotates together with the gear spindle 3.
2.Torch body part

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 Tungsten
electrode clamp

Hexagon socket head cap

screw

To weld pipes with different diameters, as shown in the figure above, the distance between tungsten
electrode and the center of rotary table can be adjusted by loosening the hexagon socket head screw on
the tungsten electrode clamp and moving the tungsten electrode clamp, that is, the size of welding pipe
diameter. There are two kinds of tungsten electrode clamp: 0 °tungsten electrode clamp and 7 ° tungsten
electrode clamp. The welding range of the head equipped with 0 °tungsten electrode clamp is: Φ25
~Φ38mm; the welding range of machine head with 7 °tungsten electrode clamp is: Φ16 ~ Φ28mm.

In addition, there is a gas hood at the end of the rotary gun body, as shown in the figure above, which
can make the gas protection more effective in the welding process; at the same time, the plane of the
gas cover is against the workpiece tube plate to play the role of axial positioning.
The standard gas cover of the equipment is Φ25mm protective gas cover, and the welding range is: Φ16
~ Φ28mm. When the workpiece is Φ28 ~ Φ38mm, the protective gas hood with the model of Φ 38
should be replaced.
3.Water electric circuit system

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 Spindle porosity

Conductive ring

The water cooling system of the machine head is cooled to the turntable through the gear mandrel, and
the tungsten electrode is connected with the turntable through the tungsten electrode clamp, so as to
realize the welding torch cooling.
The main cable of the machine head is fixed on the conductive ring under the flange. There are three
adjustable springs on the flange to tighten the conductive ring, so that the end face of the conductive ring
is always close to the end face of the rotary mandrel. Moreover, the surface of the conductive ring is
coated with silver, which has better conductivity. The tungsten electrode rotates and conducts electricity
together through the gear mandrel.
The protective gas of the machine head passes through the hole of the mandrel, and then passes
through the hole of the spindle into the rotary table, and then sprays to the welding area through a circle
of small holes on the turntable, so as to play a protective role.
● Cable and key
The water, electricity and gas pipe joints of the cable assembly are shown as follows：

Cable assembly composition：

1：Fast plug; (power negative)
1
2：24 Core aviation plug (nose control signal plug)
2
3：5-core aviation plug (button plug of remote control box)
3
4 4：Protective gas pipe connector (black)
5 5：Return pipe connector (red)
6 6：Water inlet pipe joint (blue)

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Head button pattern and function description:

Head key pattern and function description table

pattern Function description

Emergency stop button

Stop everything in case of emergency

Welding start button

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1.3 technical parameter

Figure 1.3.1 outline dimension drawing of machine head

name technical parameter

Equipment model WTS40

Weldable material Stainless steel, titanium alloy, carbon steel, etc

Main tube sheet connection form In line

Diameter of weldable pipe Φ16～Φ38 mm

Tungsten electrode diameter Φ2.4

Rotation speed of welding torch 0.5~10 rpm

7° Weldable range：Φ16～Φ28 mm
Tilt angle of tungsten electrode
0° Weldable range：Φ25～Φ38 mm

Welding shielding gas argon

Cooling mode water-cooling

Cooling water flow ≥500ml/min

weight 3kg

Dimensions 317×86×160 mm

Rated welding current 100A Rated load duration：70％

Main distribution power supply WZM-400Inverter pulsed argon arc welding machine

Table 1.3.1 head technical parameters

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2.Installation and adjustment of equipment

2.1Installation environment
1. It should be placed in the room without direct sunlight, rain proof, low humidity and little dust. The
ambient air temperature range is - 10 ℃~ + 40 ℃. The cooling liquid in the welding power supply tank
must use antifreeze.
2. There should be no wind in the welding station, if any, it should be covered.

2.2Installation and adjustment of torch head parts

● Installation of elastic chuck and ceramic spacer sleeve

Front cone Elastic chuck Rear cone sleeve Ceramic spacer sleeve

● Tungsten electrode installation and pipe diameter adjustment

Tungsten electrode clamp

Hexagon socket head

cap screw

Put the tungsten electrode directly into the tungsten electrode clamp and tighten the screw on the clamp
to complete the installation of the tungsten electrode.
To weld pipes with different diameters, as shown in the figure above, the distance between tungsten
electrode and the center of rotary table can be adjusted by loosening the hexagon socket head screw on
the tungsten electrode clamp and moving the tungsten electrode clamp, that is, the size of welding pipe
diameter.

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3.Operation guide

3.1Welding preparation
● Essential tools
A．Hexagon wrench s = 2; s = 2.5 each；
● Prepare and install the following parts or welding materials
A．Prepare and install the positioner (elastic chuck) to match the inner hole of the pipe；
B．Preparation and installation of tungsten electrode with proper diameter (Φ 2.4)
● Prepare other materials
A．Provide 99.99% pure argon gas source or cylinder;
B．Check whether the liquid in the water tank of the matched welding power supply is sufficient, and fill
the insufficient with proper amount of cooling liquid;
☞ Note: the coolant in the water tank must use antifreeze.
● Connection preparation
A. Connect the control line, water pipe joint and gas pipe joint between the head cable and the power
supply;
B. Connect the welding cable；
C. Connect the gas pipe between the argon cylinder and the power supply；
D. Connect the remote control box cable；
E. Install the grounding clamp；
F. Connect the power inlet wire.
☞ Attention: when connecting the water pipe, the air in the water pump must be discharged, so as to
avoid the normal implementation of water circulation. The specific operation is as follows: connect the
outlet pipe and return pipe to the corresponding interface of the welding machine, press the water
inspection button, and the water pump will start until there is no water shortage alarm in the welding
machine. Press the water inspection button again to close the water inspection.

3.2 Adjust welding torch

A．According to the welding process requirements, grind the tungsten electrode angle, insert it into the
tungsten electrode clamp, and adjust the tungsten electrode extension length (generally, the tungsten
electrode tip is 0.5 ~ 1.5mm from the workpiece, and the inclination angle is 0 ° or 7 °).
B. Loosen the hexagon socket head screw that fastens the tungsten electrode clamp, and adjust the
radial position of tungsten electrode.
C. Install the protective gas hood (the hood should be selected according to the diameter of the welded
pipe).
D. According to the diameter of the workpiece, choose the appropriate positioner to install on the
mandrel rod.
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E. Insert the mandrel positioning device into the welded pipe, press the end face of the gas hood against
the tube plate, pull the handle 180 ° to tighten the elastic chuck, and fix the axial and radial positions of
the head.
F. After setting the parameters of welding power supply, welding can be started.

3.3 Welding operation

1.Power on
Turn on the power, operate the remote control box, check whether the rotation function is normal (for the
operation method of the remote control box, refer to the power supply manual), and check whether the
coolant flow is at the normal value.
☞ Note: before starting the machine, check whether there is coolant in the water tank. Make sure that
the coolant in the water tank is not less than 3 / 4 of the volume of the water tank. Press the water
inspection button to check whether the water channel is blocked or leaking.
2.Press the gas detection button on the remote control box to adjust the argon flow as required. After the
adjustment, press the gas detection button again to turn off the gas detection;
3.Input welding parameters on the touch screen.
4.Before starting welding for the first time, simulation welding must be carried out to observe whether the
welding condition is good and whether the shielding gas is normal.
5.Adjust the start welding point (usually at 1 o'clock position), and press the start welding

button ,Start welding

☞ Note: before welding, check whether the program number displayed on the display screen of the front
panel of the welding power supply is the program number to be used. To change the program number,

use the "function key" on the remote control box before welding”,With "arc length control

key" ,to Select program number

6.If it is necessary to stop the welding process, usually press the attenuation button. If it is necessary to
stop immediately under special circumstances, press the emergency stop button. In addition, the "start"
and "emergency stop" buttons on the head can also be used to start or stop welding.
7.After welding, pull out the welding gun to complete the welding of a pipe orifice.
8. After the whole welding work is finished, turn off the power supply and argon cylinder.

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4.Maintenance

4.1 Maintenance cautions

1.Only professional personnel can check the machine. If problem cannot be solved, please contact us or
our distributors.
2.When you need to replace parts, please use original accessories.
3.When ordering accessories, please write welder model, product serial number and quantity. It’s better
to describe required parts in detail.
4.Repair must be done by professionals. If nonprofessionals repair or maintain the machine, they must
follow the cautions above strictly.

4.2 Clean and maintenance

Under normal circumstance, the welding head can be used without concern, and only needs minimal
maintenance. But some cautions including regular clean and inspection should be obeyed to ensure the
head is working properly during use. Of course, maintenance frequency depends on amount of
pollutants in working environment and operation time of head.
Cleaning, inspection and repair of welding head must be done by professionals.
If fault occurs due to wrong operation which is not in accordance with following requirement,
please do not use the head again until problem is solved.
● Clean
Before cleaning, please make sure welding power source is disconnected from power grid.
Please be sure to disconnect power!
Unplug connection plugs of welding head and welding power source !
（Cutting or removing fuse cannot guarantee 100% insulation）
◆ If dust is too much, use dry compressed air to clean.
◆ Outer surface of welding head should be wiped with dry cloth.
◆ Dirt on electrodes, torch and other parts can be cleared with sandpaper.
● Maintenance
◆ Cooling system
Check head cooling system regularly to ensure that there is no leakage under 0.3MPa pressure. Check
water flow of water cooling system once a month. Normal flow rate must not be lower than 450 ml/min. It
is recommended to replace coolant once every quarter. Coolant must use antifreeze. Do not add tap
water or dirty coolant. Otherwise, welding head might not be able to normally work, or even damaged.
◆ Rotating system
Rotating system should ensure smooth operation and no abnormal sound when rotating.Regularly clean
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dirt generated by wearing between two bearings and gears inside of the head. Regularly add suitable
amount of molybdenum disulfide grease. Time is once a year.

◆Welding gun and welding cable assembly

Keep tungsten electrode, tungsten electrode clamp and turntable clean; ensure that the gun head is
airtight and watertight.
The cable joint and conductive ring are fixed without looseness.
Check that the insulation coating inside the machine is not damaged.

5.Equipment List

Please check immediately after receiving the goods:

1.According to the packing list, check whether the packing box contains the following parts (including the
items listed in the packing list) item by item:

Name Unit Quantity Remark

WTS40 Tube-sheet welding head pc 1

Tools set 1

Manual pc 1

Product certificate pc 1

Product warranty pc 1

Packing List pc 1

2.Check the name plate of welding head (directly above the equipment) to confirm whether it is the
ordered product.
3.Appearance inspection: check whether all parts of the machine head are in good condition; whether
there are other losses during transportation.
Remark ： Due to continuous technology improvement, equipment appearance, color, and parameters
may change. This manual is not taken as acceptance standard.

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