Maintenance Guides 1 min read

Support and maintenance of TIG wire selection: preparation of electrodes, cleaning of the gas lens and flushing of the cooling system

Technical analysis: TIG welding torch maintenance: electrode preparation, gas lens cleaning, and coolant system flushing

Підтримка та обслуговування дротяного вибору TIG: підготовка електродів, очищення газової лінзи та промивка системи охолодження - UNITEC-D Industrial MRO
Це практичне посібник призначено для технічних працівників, які виконують обслуговування дротяного вибору TIG в промислових умовах. Гайд включає підготовку електродів, очищення газової лінзи та промив

1. Limits and purpose

This training manual is intended for technicians who perform maintenance of TIG wire picks in industrial conditions at Ukrainian enterprises. The guide covers the following steps: preparing the electrodes, cleaning the gas lens, and flushing the cooling system. The goal is to ensure reliable, efficient and safe selection work, in accordance with DSTU, EN, ISO, as well as CE and UkrSEPRO standards.

2. Security

Important: Before starting any work, to ensure electrical and gas safety, complete the procedure of blocking and marking (Lockout/Tagout). Use personal protective equipment (insulating gloves, glasses, protective suit).
Important: TIG selection can emit high-frequency electromagnetic fields, which requires maintaining a distance from the worker's body.
Important: When flushing the cooling system, use only suitable solutions to avoid damage to internal surfaces.

3. Tools and materials

Tool Specification Quantity
A rifle with a moment of effort The range is 0–100 N·m 1
Multimeter 0–500 V, 0–20 MΩ 1
Laser for measuring parallelism Accuracy ±0.02 mm 1
Textbook With insulating coating 1
Dryer With drain for coolants 1
Stand for electrodes Metal, according to EN 10083 1
Cooling system flushing solution Type 1001-45, ISO 4404 1 liter
Filter paper Paper 120 g/m² 10 pcs.

4. Before service: Preparation

Point Verification Eligibility criteria Notes
1 Ensuring electrical safety Connection is disabled, blocking is done Use Lockout/Tagout
2 Lack of gas pressure Gas pressure < 0.5 bar Make sure the gas line is disconnected
3 No electrical connection Disabled, blocked Use the tester
4 Electrodes and gas lens are clean No residual compounds Use a dryer
5 The cooling system is clean No slag build-up Use filter paper

5. Step-by-step procedure

  1. Preparation of electrodes
    1. Unscrew the electrodes from the socket with a torque of 10–15 N·m.
    2. Clean the electrodes from slag and other residues using a dryer.
    3. Check the distance to the gas lens - should be 2-3 mm.
    4. Bug: Electrodes can be broken if removed incorrectly.
  2. Cleaning the gas lens
    1. Unscrew the gas lens with a torque of 8–12 N·m.
    2. Use mild detergents to clean interior surfaces.
    3. Check for deposits on the lens surface.
    4. Bug: Gas lens sticking can cause incorrect gas distribution.
  3. Cooling system flushing
    1. Open the valve of the cooling system and let the air out.
    2. Fill the system with solution 1001-45 to the level of 80-90% of the volume.
    3. Flush the system for 10-15 minutes.
    4. Bug: Using the wrong solution can lead to element wear.
  4. Installation of elements
    1. Install the gas lens with a torque of 8–12 N·m.
    2. Install the electrodes in the socket with a torque of 10–15 N·m.
    3. Check the distance to the gas lens - should be 2-3 mm.
    4. Error: Incorrect installation can cause electrodes to run out.
  5. System Recovery
    1. Close the cooling system valve.
    2. Use a pressure of 1.5 bar to remove the remaining solution.
    3. Check for fluid leaks.
    4. Error: Leakage of fluid can reduce system efficiency.

6. After service: Inspection

Test Expected result Actual Pass/Fail
1 No liquid leakage There is none passed
2 Electrical safety Disabled, blocked passed
3 Normal gas pressure 1.0–1.5 bar passed
4 Distance to the gas lens 2–3 mm passed
5 Operation of the cooling system No leakage passed

7. Diagnostics

Symptom A possible reason Correction
Low welding quality Incorrect gas lens distance Check and set a distance of 2-3 mm
Clogging of the gas lens Accumulation of slag Clean the gas lens
Fluid leakage Improper flushing of the system Flush the system with solution 1001-45
Constant temperature Improper flushing of the cooling system Check and repair the cooling system

8. Recommended maintenance schedule

The task Frequency Estimated duration Skill level
Preparation of electrodes Every working day 10 minutes Primary
Cleaning the gas lens Every week 15 minutes Average
Flushing the cooling system Every month 30 minutes Tall

9. Cutting parts

Description of the part Typical specification UNITEC-D category
Electrodes Diameter 1.6–3.2 mm, length 200–300 mm Category 300
Gas lens Material: stainless steel Category 400
Cooling system Pressure 1.0–1.5 bar Category 500

Go to the UNITEC-D catalog

10. List of references

DSTU 29.100.1-2014, EN 12341:2016, ISO 14532:2019, CE, UkrSEPRO.

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Maintenance Guides 1 min read

TIG Torch Maintenance Guide: Electrode Preparation, Gas Lens Cleaning, and Cooling System Flushing

Technical analysis: TIG welding torch maintenance: electrode preparation, gas lens cleaning, and coolant system flushing

Керівництво з технічного обслуговування TIG-пальників: підготовка електродів, очищення газової лінзи та промивання системи охолодження - UNITEC-D Industrial MRO
Практична інструкція для технічного персоналу щодо обслуговування TIG-пальників для забезпечення стабільності дуги та тривалого терміну служби.

1. Scope and purpose

This manual covers routine maintenance of water and air cooled TIG (Argon Arc Welding) torches used in industrial production. Following the procedures described in this document is critical to ensuring arc stability, weld quality, and preventing premature failure of torch components. Maintenance should be carried out as planned or when unstable arc operation is detected.

2. Safety measures

ATTENTION: Before starting work, be sure to perform the locking and tagging procedure (Lockout/Tagout). Turn off the power source of the welding machine and shut off the supply of shielding gas. Work only with appropriate personal protective equipment (PPE), including safety glasses, welding gloves, and fire safety clothing. Be careful with hot torch surfaces after welding is complete.

3. Necessary tools and materials

The name of the toolSpecificationQuantity
Torque wrenchThe range is 0.5 - 10 Nm1
Digital multimeterTo measure resistance/integrity1
Ultrasonic bathWith heating (optional)1
Flowmeter (rotameter)To check the shielding gas1
Sharpening kitDiamond disc (grit 120-200)1
Coolant liquidAs per OEM specification1
Clean napkinsHairless5

4. Preliminary inspection before service

ElementVerificationEligibility criteriaNotes
Burner bodyVisual inspection for cracksNo damageReplace if there are cracks
Cables and hosesInsulation integrityAbsence of bends and cuts-
ElectrodeTip wearNo pollutionSharpen or replace
Gas lensGrid cleanlinessAbsence of depositsClean or replace

5. Step-by-step procedure

5.1. Preparation of tungsten electrode

  1. Remove the electrode from the collet.
  2. Set the sharpening angle (usually 30-60 degrees depending on the amperage). Avoid cross grinding - always grind along the axis of the electrode for arc stability.
  3. Sand the tip to a smooth surface.
  4. Install the electrode with a projection of 3-6 mm from the nozzle. Incorrect departure leads to arc instability.

5.2. Cleaning the gas lens

  1. Disassemble the front part of the burner (nozzle, gas lens).
  2. Inspect the gas lens grid for clogging with combustion products.
  3. Rinse in an ultrasonic bath with a suitable solvent for 5-10 minutes. Do not use aggressive acids that can damage the sealing rings.
  4. Dry with compressed air.
  5. Check the cleanliness of the holes - they should be freely passable.

5.3. Flushing the cooling system

  1. Disconnect the coolant supply and return hoses.
  2. Drain the old fluid into a container for disposal.
  3. Flush the system with distilled water (pressure no more than 2 bar).
  4. Check the tightness of all connections.
  5. Refill with fresh coolant per OEM specification.
  6. Check the flow (typically 0.5-1.5 l/min) using a flow meter. Weak flow leads to overheating and failure of the burner coil.

6. Post-service checklist

TestExpected resultActual resultStatus
System tightnessNo leaks-Pass/Fail
Gas flowCompliance with the given value-Pass/Fail
Arc stabilityThe arc burns stably-Pass/Fail

7. Search and troubleshooting

SymptomProbable causeaction
Unstable arcContaminated electrodeSharpen/replace the electrode
Burner overheatingLow coolant flowCheck the pump and hoses
Seam porosityClogging of the gas lensClean or replace the lens

8. Recommended maintenance schedule

TaskFrequencyDurationLevel
Electrode preparationEach work cycle5 minTechnician
Cleaning the gas lensEvery week15 minTechnician
Flushing the cooling systemEvery quarter60 minEngineer

9. Spare parts

Description of the partTypical specificationUNITEC-D category
Collet1.6mm / 2.4mm / 3.2mmTIG-T01
Gas Lens (Gas Lens)Standard / LargeTIG-T02
Ceramic nozzleNo. 6 - 12TIG-T03
Tungsten electrodeWT20 (Thoriated) / E3TIG-T04

The complete list is available at https://www.unitecd.com/e-catalog/

10. Links

  • ISO 14175: Welding materials. Shielding gases for arc welding.
  • EN 60974-7: Equipment for arc welding. Burners.
  • Equipment manufacturer's OEM instructions.

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