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TIP TIG - TIG 500 FOCUS
Operating Manual
Version 1.1 Revision 0.2
TIG 500 FOCUS 500 TIG – –
OPERATING MANUAL MANUAL OPERATING TIP TIG TIG TIP TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
INTRODUCTION
Thank you for the trust you have placed in our company and congratulations on buying this high- quality TIP TIG product. These instructions will help you familiarize yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful handling of the product will repay you with years of safe and reliable operation. These are essential prerequisites for excellent results.
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CONTENTS
1. GENERAL INSTRUCTIONS 5
2. INTENDED USE 6 2.1 Declaration of conformity 6 2.2 Welding in environments with increased electrical hazards 6 2.3 Calibration/Validation 6
3. SAFETY RULES 7 3.1 Explanation of safety symbols 7 3.2 General safety instructions 7
4. GENERAL 10 4.1 Device concept 10 4.2 Crane transport 10
5. CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS 11 5.1 System overview 11 5.2 Front connection 14 5.3 Main switch with fuses 15 5.4 Connection socket relays 15 5.5 Control Panel – Power Source 16 5.6 Control Panel – FOCUS 19
6. INSTALLATION AND COMMISSIONING 27 6.1 Before installation and commissioning 27 6.2 Start-up – Power Source 28 6.3 Start-up – Wire feeder 31
7. WELDING 36 7.1 Preparation 36 7.2 Operating modes 37 7.3 Welding current types (TIG 500AC only) 40 7.4 MMA welding 41 7.5 TIG welding 42
8. TROUBLESHOOTING, MAINTENANCE AND DISPOSAL 44 8.1 Troubleshooting 44 8.2 Care, maintenance and disposal 49
9. TECHNICAL DATA 50
10. APPENDIX 52 10.1 Installation Guide 52 10.2 Welding Check List 58
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10.3 Spare part list 60 10.4 WIRING DIAGRAM 62
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1. GENERAL INSTRUCTIONS
CAUTION
Read the operating instructions! The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components! • Observe accident prevention regulations! • Observe all local regulations! • Confirm with a signature where appropriate.
In the event of queries on installation, commissioning, operation or special conditions at the installation site, or on usage, please contact your sales partner or our customer service department on +43 720 303500 or [email protected]. A list of authorized sales partners can be found at www.tiptig.com.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the user on commissioning the equipment. The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation, operation, usage and maintenance of the equipment. An incorrectly performed installation can result in material damage and injure persons as a result. For this reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation, improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© TIP TIG Automation GmbH, Baumayrweg 5, 4631 Krenglbach, Austria The copyright to this document remains the property of the manufacturer. Reprinting, including extracts, only permitted with written approval. The content of this document has been prepared and reviewed with all reasonable care. The information provided is subject to change, errors excepted.
Page 5 of 75 Intended use
TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
2. INTENDED USE
• WARNING! Hazards• due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate. Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with its designated purpose and by trained or expert personnel! • Do not improperly modify or convert the equipment!
2.1 Declaration of conformity
The labelled machine complies with the following EC directives and standards in terms Intended of its design and construction: use • • • • 2014/35/EU Low Voltage Directive (LVD)
• 2014/30/EU Electromagnetic Compatibility Directive (E– MC) • 2011/65/EU Restriction of Hazardous Substance (RoHS)
• Standards • • IEC 60974-1: 2012 Arc welding equipment - Part 1: Welding power sources • IEC 60974-3: 2013 Arc welding equipment - Part 3: Arc striking stabilizing devices • IEC 60974-10: 2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
•
August 1, 2018
______Jürgen Plasch, CEO• Date of Declaration • • In case of unauthorized changes, improper repairs, and/or prohibited modifications which have not been explicitly –authorized by TIP TIG Automation GmbH, this declaration shall be voided.
2.2 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.
2.3 Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances. Recommended calibration interval: 12 months •
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3. SAFETY RULES
3.1 Explanation of safety symbols
DANGER! Indicates immediate and real danger. If is not avoided, death or serious injury will result.
WARNING! Indicates a potentially situation. Death or serious injury may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flowed and possible damage to the equipment. IMPORTANT! Indicates tips for correct operation and other particularly useful information. It does not indicate a potential damaging or dangerous situation. If you see any of the symbols depicted in the “Safety rules” chapter, special care is required.
3.2 General safety instructions
CAUTION
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair procedures are performed only by qualified person. Read and understand this manual before operating this equipment. Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment. Read and understand the following explanations of the warning symbols. TIP TIG is not responsible for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury, loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from the electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the fuse box before working on this equipment. Ground this equipment in accordance with local electrical regulations.
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ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder directly on the welding table or any other surface in contact with the work clamp to avoid the risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers, and welders having a pacemaker shall consult their physician before operating this equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal Protective Equipment (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169 Standard.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel with suitable, non- flammable screening and warn them not to watch the arc nor expose themselves to the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding process can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks, drums, containers, or material until the proper steps have been taken to ensure that no flammable or toxic vapors will be present. Never operate this equipment when flammable gases, vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and materials in work area can cause serious burns. Use gloves and pliers when touching or moving materials in the work area.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an environment with increased hazard of electric shock.
EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the help of another person. Lifting may be dangerous for your physical health.
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CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located away from areas where they may be subjected to physical damage or the welding process including sparks and heat sources.
CAUTION: The high frequency used for contact-free ignition with TIG (GTAW) welding, can interfere with the operation of insufficiently shielded computer equipment, EDP centers and industrial robots, even causing complete system breakdown. TIG (GTAW) welding may interfere with electronic telephone networks and with radio and TV reception.
NOISE APPEARES DURING WELDING CAN BE HARMFUL: Welding arc can cause noise with high level of 85dB for 8-hour week day. Welders operating welding machines are obligated to wear the proper ear protectors /appendix No. 2 for the Decree of the Secretary of Labor and Social Policy from 17.06 1998 – Dz.U. No. 79 pos. 513/. According to the Decree the Secretary of Health and Social Welfare from 09.07.1996 /Dz.U. No. 68 pos. 194/, employers are obligated to carry examinations and measurements of health harmful factors.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time the operator’s manual.
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4. GENERAL
4.1 Device concept The TIP TIG FOCUS welding system is a fully digitized and microprocessor-controlled welding system specially developed for TIG keyhole welding. Thanks to its extremely focused arc, this novel joining process enables a very high energy density in the weld pool and highest welding speeds. Reworking and preparatory work can be significantly reduced.
CAUTION This welding system is designed and build for FOCUS-welding. Manual welding isn‘t possible with this welding machine.
4.2 Crane transport The TIP TIG FOCUS can be transported by crane at the lifting eyes. The maximum load-bearing capacity of the lifting eyes is 150 kg (330.69 lbs.)
WARNING Falling equipment can cause death or serious injury.
• Only use a suitable lifting tackle when transporting devices by crane (e.g. belt with round slings) • The lifting tackle must be undamaged and in perfect condition • Do not transport any other loads by the handle apart from the wirefeeder itself • Do not hang from the wirefeeder as it is being transported
Before transporting by crane: - feed out the wire electrode, remove the wire spool - disconnect the torch hose package and interconnecting hose package from the wire feeder - if present, unplug the coolant connections
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5. CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS
5.1 System overview
Front of TIP TIG – TIG 500 FOCUS
No. Description
(1) Transport eyebolt (Lifting lug)
(2) Control Panel Power Source – See 5.5 Control Panel – Power Source
(3) Control Panel FOCUS – See 5.6 Control Panel – FOCUS
(4) Front connection – See 5.2 Front connection
(5) Wire electrode connection – for connecting the welding torch wire feed
(6) Transport handle
(7) Hotwire indicator lamps Temperature fault indicator (down) is lit in the case of overheating. It extinguishes after a few minutes when the unit has cooled down. Hotwire-on indicator (top) (1) is lit when there is live operating voltage and the hot wire unit is ready for service, (2) blinks in case of a fault.
(8) Connection socket, welding current „+“ for connecting the workpiece lead
(9) Cooling air inlet
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(10) Coolant tank with cap
Rear of TIP TIG – TIG 500 FOCUS
No. Description
(1) Transport eyebolt (Lifting lug)
(2) Button gas test
(3) 24 pole connection socket rotary table – optional for connecting a TIP TIG rotary table
(4) RJ-45 female connector for connecting a network cable
(5) Connecting nipple shielding gas for connecting the shielding gas (G1/4" RH) on the pressure regulator
(6) 7 pole connection socket relays – See 5.4 Connection socket for connecting existing welding equipment such as longitudinal seam welding devices, rotary tables, welding machine carrier, etc.
(7) 37 pole connection socket distributor box for connecting the provided distributor box
(8) Main switch with fuses – See 5.3 Main switch with fuses
(9) Mains connection cable with plug
(10) Securing elements for shielding gas cylinder (strap / chain)
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(11) Cooling air outlet
(12) Hotwire amperage adjustment for adjusting the amperage setting of the hotwire unit. Adjustment with a flat screw driver. Adjustment range: 60 – 100 A (Presetting 80 A)
(13) Connecting socket Output 230 VAC
(14) Bracket for shielding gas cylinder
(15) Wheels, fixed castors
TIP TIG – TIG 500 FOCUS: operating elements in the machine
No. Description
(1) Four roll wire drive
(2) Clamping levers for setting the contact pressure of the feed rollers
(3) Wires pool holder with brake for holding standard wire spools with max. diameter of 300 mm (11.81 in.) and max. weight of 15 kg (33.1 lb.)
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5.2 Front connection
No. Description
(1) 17 pole connection socket hand control box for connecting the provided hand control box
(2) Connection socket hot wire for connecting hot wire power from the welding torch hose package, minus potential
(3) Connecting nipple coolant return (red) for connecting coolant return (G3/8" LH) from the welding torch hose package
(4) Connecting nipple shielding gas for connecting shielding gas (G1/4" RH) from the welding torch hose package
(5) Connecting socket, welding current „-“ for connecting TIG welding torch / electrode holder
(6) Wire electrode connection – for connecting the welding torch wire feed
(7) Connecting nipple current / coolant supply (blue) for connecting current / coolant supply (G3/8" RH) from the welding torch hose package
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5.3 Main switch with fuses No. Description
(1) Main switch Machine on/off
(2) Fuse F1 T8 A, 230 VAC
(3) Fuse F2 T8 A, 0 VAC
5.4 Connection socket relays Existing welding equipment can be controlled via the 7-pole panel socket
No. Configuration No. Example – Longitudinal seam welding device
1 Relays 1_1 1 Forward
2 Relays 1_2 2 Forward
3 Relays 2_1 3 Backward
4 Relays 2_2 4 Backward
5 Not assigned 5 Not assigned
6 Not assigned 6 Not assigned
7 Ground 7 Ground
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5.5 Control Panel – Power Source
CAUTION This welding system is designed and build for FOCUS-welding. Manual welding isn‘t possible with this welding machine.
No. Function
(1) Welding data display (3-digit) displays the current value of the welding current as well as error messages: - In normal operation, the welding current is displayed. - If a fault occurs in the cooling system, the welding process is switched off and the message "H2O" flashes together with (2) Overheat Indicator - In the event of a mains or inverter fault as well as overheating, the display flashes "- - -" and the welding process is switched off.
(2) Overheat Indicator lights up when the power source has overheated and turned off (for example, due to the duty cycle being exceeded). It extinguishes when the unit is cooled down and is ready for welding. If there is a lack of water, the display flashes.
(3) Inverter Fault Indicator lights up if there is a mains under voltage or a defect in the welding inverter.
(4) Welding Current I1 Indicator lights up when welding current I1 is active. With TIG pulses, this corresponds to the pulse current phase.
(5) Welding Current I2 Indicator lights up when welding current I2 is active. With TIG pulses, this corresponds to the basic current phase.
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(6) Pulse Time t1 Rotary Knob for setting the pulse time t1, while welding current I1 is active during TIG pulses. (Range: 20ms - 1.3sec.)
(7) Pulse Time t2 Rotary Knob for setting the pulse time t2, while welding current I2 is active during TIG pulses. (Range: 20ms - 1.3sec.)
(8) Soft Start (Upslope) Rotary Knob for setting the soft-start time, in which the welding current is increased to the set value. (Range: 5ms - 2sec.). In 2-stroke mode, the welding current starts in the minimum, in 4- cycle mode with the starting current (20% of the welding current I1)
(9) Welding Current I1 Rotary Knob for adjusting the welding current I1: - Setting range TIG: 4A - 500A - Setting range MMA: 15A - 400A
(10) Welding Current I1 Rotary Knob for adjusting the welding current I2 (range: 0% - 100%). In 2-stroke operation, the welding current starts in the minimum, in 4-stroke operation with the starting current (20% of the welding current I1). The maximum adjustable welding current I2 always corresponds to the set value of I1. This welding current is used as a base current during pulsing.
(11) Soft Down (Downslope) Rotary Knob for setting the soft-down time (range: 5ms - 10sec.) at which the welding current is reduced from the set value to min.
(12) Gas Post-Flow Time Rotary Knob for adjusting the gas post-flow time during TIG welding (range: 5sec - 35sec.). If started but not welded, the gas post-flow time does not expire.
(13) Operating Mode Rotary Knob for setting the operating mode, see 7.2 Operating modes: - MMA - TIG 4-Stroke - TIG 2-Stroke - TIG Liftarc 4-Stroke - TIG Liftarc 2-Stroke - TIG Pulse 4-Stroke - TIG Pulse 2-Stroke
(14) Frequency Rotary Knob (AC only) for adjusting the frequency of the AC arc (range: 40Hz - 200Hz)
(15) Balance Rotary Knob (AC only) for adjusting the balance of the AC arc (range: 80:20 - 20:80). As a result, either a deep penetration or a high cleaning effect can be set.
(16) Welding Current Type / S-Test Rotary Knob (AC only) for setting the welding current type, see 7.3 Welding current types (TIG 500AC only): - DC welding with pulse start - DC welding - AC welding sinus (soft) - AC welding rectangle (hard) - S-Test
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(17) S-Test indicator (AC only) lights up when the Current Type / S-Test Rotary Knob is set to S-Test mode and the inverter is operating correctly, see 7.1.1 S-Test (AC only)
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5.6 Control Panel – FOCUS
FOCUS – Home Screen
No. Function
(1) WELDING PARAMETERS Display displays the welding parameter (left) and the corresponding value (right). The value can be changed by touching the screen in the framed area: - WELD AMPS - WIRE SPEED - TEST MODE
(2) MOTION PARAMETERS Display displays the motion parameter (left) and the corresponding value (right). The value can be changed by touching the screen in the framed area: - WELD SPEED - ROTATING DIRECTION
(3) ENERGY PARAMETER Display displays the energy parameter and its value: - VOLTAGE (left) - HEAT INPUT (right)
(4) Software version number displays the version number of the installed TIP TIG software
(A) Home Button Touching the screen in the black area labeled "HOME" will select the Home Screen.
(B) Settings Button Touching the screen in the black area labeled "SETTINGS" will select the Settings Screen.
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(C) Gas Test Button Touching the screen in the black area labeled "GAS TEST" will perform a gas test.
(D) Offset Settings Button Touching the screen in the black area labeled "OFFSET SETTINGS" selects the Offset Settings Screen.
FOCUS – Settings Screen
No. Function
(1) WELDING SETTINGS Display displays the welding settings (left) and the corresponding value as well as the range (min - max.) (right). The value can be changed by touching the screen in the framed area: - EVENT 1: AEA (automatic torch height adjustment) - EVENT 2: PRE-GAS (gas pre-flow time) - EVENT 3: UPSLOPE (arc upslope time) - EVENT 4: WIRE DELAY (wire delay) - EVENT 5: TRAVEL DELAY (welding delay) - EVENT 6: DOWNSLOPE (arc downslope time) - EVENT 7: DOWNSLOPE - WIRE (wire feed downslope time) - EVENT 8: TORCH LIFT (burner lift at the end of the welding process)
(2) AVC SETTINGS Display indicates the ACV setting ON / OFF.
(3) SETTINGS (AVC Settings) Button Touching the screen in the framed area labeled "SETTINGS" selects the AVC Settings Screen.
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(A) Home Button Touching the screen in the black area labeled "HOME" will select the Home Screen.
(B) Settings Button Touching the screen in the black area labeled "SETTINGS" will select the Settings Screen.
(C) Gas Test Button Touching the screen in the black area labeled "GAS TEST" will perform a gas test.
(D) Offset Settings Button Touching the screen in the black area labeled "OFFSET SETTINGS" selects the Offset Settings Screen.
FOCUS – AVC Settings Screen
No. Function
(1) AVC SETTINGS Display displays the AVC setting (left) and the corresponding value (right). The value can be changed by touching the screen in the framed area: - AVC START DELAY (AVC start delay) - UP / DOWN SPEED (FAST / MED / SLOW) (AVC response speed) - AVC RANGE (burner adjustment per joystick push)
(A) Home Button Touching the screen in the black area labeled "HOME" will select the Home Screen.
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(B) Settings Button Touching the screen in the black area labeled "SETTINGS" will select the Settings Screen.
(C) Gas Test Button Touching the screen in the black area labeled "GAS TEST" will perform a gas test.
(D) Offset Settings Button Touching the screen in the black area labeled "OFFSET SETTINGS" selects the Offset Settings Screen.
FOCUS – Settings Screen
No. Function
(1) OFFSET SETTINGS Display displays the offset setting (left) and the corresponding value as well as the range (min - max.) (right). The value can be changed by touching the screen in the framed area: - WELDING VOLTAGE - WELDING CURRENT
(2) AVC SETTINGS Display displays the AVC setting (left) and the corresponding value (right). The value can be changed by touching the screen in the framed area: - STANDARD DEVIATION / SETTING RANGE
(3) Settings Overview displays the calibrated and validated settings for the particular system.
(A) Home Button Touching the screen in the black area labeled "HOME" will select the Home Screen.
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(B) Settings Button Touching the screen in the black area labeled "SETTINGS" will select the Settings Screen.
(C) Gas Test Button Touching the screen in the black area labeled "GAS TEST" will perform a gas test.
(D) Offset Settings Button Touching the screen in the black area labeled "OFFSET SETTINGS" selects the Offset Settings Screen.
FOCUS – Input Screen
No. Function
(1) Setting Value Display displays the value to be set. The value can be set by touching the input keys (7).
(2) Range (Min. / Max.) Display displays the range in which the value can be set in the values Min. (left) and Max. (right).
(3) BACK Button Touching the screen in the area labeled "BACK" will undo the previously executed command.
(4) CL Button Touching the screen in the area labeled "CL" clears the setting.
(5) ESC Button Touching the screen in the area labeled "ESC" exits the input screen.
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(6) OK Button Touching the screen in the area marked "OK" confirms the set value.
(7) Input keys (numeric field) Touching the screen in the area of the numeric keypad enters the setting value.
FOCUS – Emergency Stop Screen
No. Function
(1) EMERGENCY STOP Pressing the EMERGENCY STOP button on the supplied manual control box puts the system in EMERGENCY STOP mode. All axis movements are slowed down by a safety stop. The arc and wire feed are switched off in a controlled manner.
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FOCUS – Emergency Stop Reset Screen
No. Function
(1) RESET Button Touching the screen in the green area marked "RESET" will reset the EMERGENCY STOP button.
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FOCUS – End Switch Screen
No. Function
(1) END SWITCH Display displays the end switches (left) and the corresponding status (right): - End switch left (END: LEFT) - End switch right (END: RIGHT) - End switch top (END: UP) - End switch down (END: DOWN)
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6. INSTALLATION AND COMMISSIONING
6.1 Before installation and commissioning
Safety
WARNING Incorrect operation or shoddy workmanship can cause serious injury or damage. All work described in this document must only be carried out by trained and qualified personnel. All functions described in this document must only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
• this document • all the operating instructions for the system components, especially the safe ty rules
Utilization for intended purpose The power source is intended exclusively for TIG and MMA welding. Utilization for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose. The manufacturer shall not be liable for any damage resulting from such improper use. Proper use also includes: - following all the information in the operating instructions - carrying out all the specified inspection and servicing work
Ambient conditions The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! - The operator must ensure that the ground is non-slip and level and provide sufficient lighting for the place of work. - Safe operation of the machine must be guaranteed at all times. Unusually high quantities of dust, acid, corrosive gases or substances may damage the equipment. - Avoid high volumes of smoke, vapor, oil vapor and grinding dust! - Avoid ambient air containing salt (sea air)! In operation Temperature range of the ambient air: - -25 °C to +40 °C Relative air humidity: - Up to 50% at 40 °C - Up to 90% at 20 °C Transport and storage Storage in an enclosed space, temperature range of the ambient air: - -30 °C to +70 °C Relative air humidity: - Up to 90% at 20 °C
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Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage. - Observe the ambient conditions! - Keep the cooling air inlet and outlet clear! - Observe the minimum distance of 0.5 m from obstacles!
Mains Connection The devices are designed to run on the mains voltage shown on the respective rating plates. If your version of the device does not come with mains cables and plugs ready-fitted, these must be fitted in accordance with national regulations and standards. For details of fuse protection of the mains lead, please see the Technical Data.
NOTE! Inadequately dimensioned electrical installations can cause serious damage. The incoming mains lead and its fuse must be dimensioned to suit the local power supply. The technical data shown on the rating plate applies.
Generator-powered operation The power source is generator-compatible, provided that the maximum apparent power delivered by the generator is at least 10 kVA.
NOTE! The voltage delivered by the generator must never exceed the upper or lower limits of the mains voltage tolerance range. Details of the mains voltage tolerance are given in the "Technical data" section.
6.2 Start-up – Power Source
Safety
WARNING A electric shock can be fatal. If the machine is plugged into the mains supply during installation, there is a high risk of very serious injury and damage. Do not carry out any work on the device unless: • the mains switch is in the „O“ position, • the device is unplugged from the mains.
General This section describes how to commission the power source: - for the main TIG welding application, - with reference to a standard configuration for a TIG welding device. The standard configuration consists of the following system components: - power source - TIG manual welding torch - pressure regulator - gas cylinder - gas cylinder holder The steps set out below provide an overview of how to commission the power source. For detailed information about the individual steps, please refer to the operating instructions for the system components.
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6.2.1 Welding torch cooling system
CAUTION
Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void!
• Only use the coolant described in this manual (overview of coolants). • Do not mix different coolants. • When changing the coolant, the entire volume of liquid must be changed.
Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components.
• The coolant must be checked for adequate frost protection with a frost protection tester. • Replace coolant as necessary if frost protection is inadequate!
NOTE! The disposal of coolant must be carried out according to official regulations and observing the relevant safety data sheets. Coolant must not be disposed of together with household waste. Coolant must not be discharged into the sewerage system. Recommended cleaning agent: water, if necessary with cleaning agent added.
List of coolants The following coolants may be used:
Coolant Temperature range
KF 23E (Standard) -10 °C to +40 °C
KF 37E -20 °C to +10 °C
Adding coolant The unit is supplied ex works with a minimum level of coolant. - Unscrew and remove the coolant tank sealing cover. - Top up coolant, close sealing cover again.
NOTE! After the initial filling, wait for at least one minute when the machine is switched on so that the hose package is filled with coolant completely and without bubbles. With frequent changes of torch and during the initial filling process, the cooling unit tank should be topped up as necessary.
NOTE! If there is less coolant in the coolant tank than the minimum required, you may need to vent the coolant circuit. In this case the welding machine will automatically shut down the coolant pump and signal an error, Rectifying faults.
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6.2.2 Connecting the gas cylinder
WARNING If gas cylinders topple over, there is a risk of very serious injury and damage.
• Place gas cylinders on a solid, level surface in such a way that they remain stable • Secure gas cylinders to prevent them from toppling over: fix the safety strap at the same height as the top part of the cylinder • Never fix the safety strap around the neck of the cylinder
Follow the gas cylinder manufacturer's safety instructions.
1. Secure the gas cylinder 2. Take the protective cap off the gas cylinder 3. Briefly open the gas cylinder valve to remove any dust or dirt 4. Check the seal on the pressure regulator 5. Screw the pressure regulator onto the gas cylinder and tighten it When using a TIG welding torch with an integral gas connector: 6. Use the gas hose to connect the pressure regulator to the shielding gas connection on the rear of the power source 7. Tighten the union nut on the gas hose When using a TIG welding torch with no integral gas connector: 6. Connect the TIG welding torch gas hose to the pressure regulator
6.2.3 Establishing a ground (earth) connection to the workpiece 1. Move the mains switch to the O position 2. Plug the grounding (earthing) cable in and latch it 3. Use the other end of the grounding (earthing) cable to establish a connection to the workpiece
6.2.4 Connecting the welding torch 1. Move the mains switch to the O position 2. Plug in the TIG welding torch cable and latch it by turning it clockwise 3. Plug the welding torch control plug into the torch control connection and latch it 4. Equip the welding torch in accordance with the welding torch operating instructions Only when using a water-cooled torch: 5. Plug in the welding torch water connections to the water flow (blue) and return (red) connections.
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6.3 Start-up – Wire feeder
Safety
WARNING Incorrect operation or shoddy workmanship can cause serious injury or damage. All work described in this document must only be carried out by trained and qualified personnel. All functions described in this document must only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents:
• this document • all the operating instructions for the system components, especially the safety rules
Prerequisites When commissioning the wire-feed unit, the following requirements must be met: - Wire-feed unit connected to the power source using the interconnection hose package - Welding torch connected to wire-feed unit - Feed rollers inserted in the wire-feed unit - Wire spool or basket-type spool and adapter inserted in the wire-feed unit - Wire electrode threaded in - Feed roller contact pressure set - Brake adjusted - All covers closed, all side panels in place, all protection devices intact and in their proper place
General The wire-feed unit is started by pressing the torch trigger (for manual applications) or by means of a welding start-up signal (for automatic applications).
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6.3.1 Inserting/replacing feed rollers
Safety
WARNING An electric shock can be fatal. Before starting the work described below:
• turn the power source mains switch to the „0“ position • disconnect the power source from the mains • ensure that the power source remains disconnected from the mains until all work has been completed
General information In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.
NOTE! Only use feed rollers that match the wire electrode.
Inserting/replacing feed rollers - Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller. - Fix the drive rollers in place with the built-in lock system (no tools needed).
6.3.2 Inserting the wire spool
Safety
WARNING An electric shock can be fatal. Before starting the work described below:
• turn the power source mains switch to the „0“ position • disconnect the power source from the mains • ensure that the power source remains disconnected from the mains until all work has been completed
CAUTION Risk of injury from springiness of spooled wire electrode. When inserting the wire spool/basket- type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back.
CAUTION Risk of injury from falling wire spool/basket-type spool. Ensure that the wire spool/basket-type spool and basket-type spool adapter are always seated securely on the wire spool holder.
Inserting the wire spool Standard D300 wire spool holder can be used. Adapters are required when using standardized basket coils (DIN 8559). - Loosen knurled nut from spool holder. - Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore. - Fasten wire spool using knurled nut.
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6.3.3 Inching the wire electrode
Safety
CAUTION Risk of injury and material damage from the welding current and accidental ignition of an arc. Before starting work, disconnect the ground earth connection between the welding system and the workpiece.
CAUTION Risk of damage to the welding torch from sharp end of wire electrode. Deburr the end of the wire electrode well before feeding in.
CAUTION Risk of injury from springiness of spooled wire electrode. When inserting the wire electrode into the 4-roller drive, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back.
General Information Incorrect contact pressure will cause extensive wear of the wire feed rollers! - With the adjusting nuts of the pressure units set the contact pressure so that the wire electrode is conveyed but will still slip through if the wire spool jams. - Set the contact pressure of the front rollers (in wire feed direction) to a higher value!
Inching the wire electrode
CAUTION Risk of injury and damage from wire electrode emerging. While working:
• hold the welding torch with the point directed away from the face and body • wear suitable protective goggles • do not point the welding torch at people • make sure that the wire electrode does not touch any conductive or earthed parts, such as the housing, etc.
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No. Description
(1) Adjusting nut
(2) Feed roll tensioner for fixing the clamping unit and setting the pressure.
(3) Clamping unit
(4) Pressure roller
(5) Drive roller
(6) Wire feed nipple
(7) Guide tube
- Extend and lay out the torch hose package. - Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards). - Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe. - Press the clamping element with the pressure roller back downwards and fold the wire units back up again (wire electrode should be in the groove on the drive roller). - Set the contact pressure with the adjusting nuts of the pressure unit. - Press the wire inching button until the wire electrode projects out of the welding torch.
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6.3.4 Spool brake setting
Safety
CAUTION Risk of injury and material damage from the welding current and accidental ignition of an arc. Before starting work, disconnect the ground earth connection between the welding system and the workpiece.
CAUTION Risk of injury and damage from wire electrode emerging. While working:
• hold the welding torch with the point directed away from the face and body • wear suitable protective goggles • do not point the welding torch at people • make sure that the wire electrode does not touch any conductive or earthed parts, such as the housing, etc.
General Information After releasing the torch trigger the wire spool must stop unreeling. If it continues unreeling, readjust the brake.
Setting the brake - Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect.
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7. WELDING
CAUTION This welding system is designed and build for FOCUS-welding. Manual welding isn‘t possible with this welding machine.
7.1 Preparation
Safety
WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: • these operating instructions • all the operating instructions for the system components, especially the safe- ty rules
7.1.1 S-Test (AC only)
According to DIN EN 60974-1, a welding unit with a hazard reduction device (in this unit a changeover device from AC to DC according to DIN EN 60974-1, clause 13.2.2) must offer the possibility to test the device without tools. When the rotary knob is turned to the Test position, the unit will cycle for max 0.3s at idle. This fault must be detected, the system switches off, the green LED no longer lights up, 3 horizontal bars are flashing in the display, the LED inverter fault lights up. Turn the rotary knob back to the required welding mode, open the main switch and wait until the display on the front does not light up. Then the switch can be closed again, the device is ready for operation.
WARNING Perform this test daily before starting welding. If the green LED does not go out and the welding unit does not switch off, the device should be shut down immediately.
7.1.2 Forced switch-off
If, after pressing the torch key in 2-stroke and 4-stroke welding operation, it does not ignite within 5 seconds, then the forced shutdown takes place. If the sequence is stopped by the torch button before the current flows, it will be stopped directly without gas post flow.
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7.2 Operating modes
Safety
WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: • these operating instructions • all the operating instructions for the system components, especially the safe- ty rules
7.2.1 MMA
There is no activation of ignition device, gas valve or water pump. The output voltage is applied to the socket of the welding machine, regardless of the status of the torch trigger.
Hot-Start Function During the hot start, a current increase of 30% occurs with the set welding current I1. After detecting "I <0", the hotstart time of 600ms expires, after which it switches back to the set welding current. Advantages - Improvement of the ignition properties, even with electrodes with poor ignition properties - Better melting of the basic material in the starting phase, thus fewer cold spots - Extensive avoidance of slag inclusions
Arc-Force Function If the arc voltage drops below a certain minimum value during welding, the welding current is increased by 50%. However, the value is limited to the electrode maximum. When the minimum voltage is reached again, the system switches back to the set current setpoint.
Anti-Stick Function If the INVCB_45 detects a short circuit in the welding process, it switches to the minimum current after 0.5 seconds to prevent the electrode from glowing. After elimination of the short circuit, the commanded setpoint is output again
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7.2.2 TIG 4-Stroke with HF
1. Stroke Press and hold the torch button. When the gas pre-flow time has elapsed, the arc ignites at 20% of I1 (search arc).
2. Stroke Open torch button. The welding current rises to the set value of I1.
3. Stroke Press and hold the torch button. The welding current decreases to the minimum current during the set time.
4. Stroke Open torch button. The arc goes out. The shielding gas flows during the set gas post-flow time.
7.2.3 TIG 2-Stroke with HF
1. Stroke Press and hold the torch button. After expiration of the gas pre-flow time the arc ignites. The welding current increases to the value I1 with the time set on the soft start rotary knob. The welding current I1 can be adjusted continuously on the knob I1.
2. Stroke Open torch button. The welding current drops to minimum with the time set on the soft-down rotary knob. The arc goes out. The shielding gas flows during the set gas post-flow time.
7.2.4 TIG 4-Stroke Liftarc
In this mode, the ignitor is switched off. This operating mode cannot be used with AC welding (TIG 500AC only) as the ignitor is also required for welding.
1. Stroke The TIG electrode must touch the workpiece. Press and hold the torch button. After the gas pre-flow time has elapsed and the TIG electrode has been lifted off, the arc ignites at 20% of I1 (search arc).
2. Stroke Open torch button. The welding current rises to the set value of I1.
3. Stroke Press and hold the torch button. The welding current decreases to the minimum current during the set time.
4. Stroke Open torch button. The arc goes out. The shielding gas flows during the set gas post-flow time.
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7.2.5 TIG 2-Stroke Liftarc
In this mode, the ignitor is switched off. This operating mode can not be used with AC welding (TIG 500AC only), as with AC, the ignitor is also required for welding.
1. Stroke The tungsten electrode must touch the workpiece. Press and hold the torch button. After expiration of the gas pre-flow time and lifting of the TIG electrode, the arc ignites. The welding current increases to the value I1 with the time set on the soft start rotary knob. The welding current I1 can be adjusted continuously on the rotary knob I1.
2. Stroke Open torch button. The welding current drops to minimum with the time set on the soft-down rotary knob. The arc goes out. The shielding gas flows during the set gas post-flow time.
7.2.6 TIG 4-Stroke Pulse with HF
1. Stroke Press and hold the torch button. When the gas pre-flow time has elapsed, the arc ignites at 20% of I1 (search arc).
2. Stroke Open torch button. The welding current rises to the set value of I1. The arc is pulsing. The welding current 1 can be adjusted continuously on the rotary knob I1. The welding current 2 can be adjusted continuously on the rotary knob I2, as a percentage of I1. The rotary knob t1 is used to select the pulse time for I1 and the rotary knob t2 for the pulse time for I2. The pulse times are adjustable from 20 ms to 1.3 s.
3. Stroke Press and hold the torch button. The welding current decreases to the minimum current during the set time.
4. Stroke Open torch button. The arc goes out. The shielding gas flows during the set gas post-flow time.
7.2.7 TIG 2-Stroke Pulse with HF
1. Stroke Press and hold the torch button. After expiration of the gas pre-flow time the arc ignites. The welding current increases to the value I1 with the time set on the soft-start rotary knob. The welding current I1 can be adjusted continuously on the rotary knob I1. The welding current 2 can be adjusted continuously on the rotary knob I2, as a percentage of I1. The rotary knob t1 is used to select the pulse time for I1 and the rotary knob t2 for the pulse time for I2.
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2. Stroke Open torch button. The welding current drops to minimum with the time set on the soft-down rotary knob. The arc goes out. The shielding gas flows during the set gas post-flow time.
7.3 Welding current types (TIG 500AC only)
Safety
WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: • these operating instructions • all the operating instructions for the system components, especially the safe- ty rules
7.3.1 DC welding with pulse start
With this type of current, the arc is ignited with plus at the burner. Immediately after the ignition of the arc it is switched to minus. This makes it easier to ignite even under difficult conditions (mixed gases).
7.3.2 DC welding
This mode corresponds to the known DC welding.
7.3.3 AC welding sinus (soft)
The arc shape is a bit softer, the arc noise a bit quieter. The frequency is adjustable from 20 to 250 Hz, the balance from 80:20 to 20:80. The ignitor is permanently active for AC welding.
7.3.4 AC welding rectangle (hard)
The arc shape is a bit harder and more stable. The frequency is adjustable from 20 to 250 Hz, the balance from 80:20 to 20:80. The ignitor is permanently active for AC welding.
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7.4 MMA welding
Safety
WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:
• these operating instructions • all the operating instructions for the system components, especially the safe- ty rules
WARNING An electric shock can be fatal. If the power source is connected to the mains electricity supply during installation, there is a high risk of very serious in- jury and damage. Before carrying out any work on the device make sure that:
• the power source mains switch is in the "O" position • the power source is unplugged from the mains
Preparation 1. Switch off cooling units 2. Move the mains switch to the O position 3. Disconnect the mains plug 4. Disconnect the TIG welding torch 5. Plug the grounding (earthing) cable in and latch it into place 6. Use the other end of the grounding (earthing) cable to establish a connection to the workpiece 7. Plug in the electrode cable and twist it clockwise to latch it into place 8. Plug in the mains plug
CAUTION Risk of injury and damage from electric shock. As soon as the mains switch is in the "I" position, the rod electrode in the electrode holder is live. Make sure that the rod electrode does not touch any persons or electrically conducting or earthed parts (e.g. the housing etc.).
9. Move the mains switch to the I position
Manual metal arc welding 1. Select operating mode with the rotary knob: - Operating mode MMA 2. Set the desired welding current I1 using the rotary knob - The value for the welding current is displayed in the welding data display. 3. Start welding
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7.5 TIG welding
Safety
WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:
• these operating instructions • all the operating instructions for the system components, especially the safe- ty rules
WARNING An electric shock can be fatal. If the power source is connected to the mains electricity supply during installation, there is a high risk of very serious in- jury and damage. Before carrying out any work on the device make sure that:
• the power source mains switch is in the "O" position • the power source is unplugged from the mains
Preparation 1. Plug in the mains plug
CAUTION Risk of injury and damage from electric shock. As soon as the mains switch is in the "I" position, the tungsten electrode of the welding torch is live. Make sure that the tungsten electrode does not touch any persons or electrically conducting or earthed parts (e.g. the housing etc.).
2. Move the mains switch to the I position
TIG welding 1. Select operating mode with the rotary knob: - TIG 4-Stroke - TIG 2-Stroke - TIG Liftarc 4-Stroke - TIG Liftarc 2-Stroke - TIG Pulse 4-Stroke - TIG Pulse 2-Stroke 2. Select the welding current type using the rotary knob: - DC welding with pulse start - DC welding - AC welding sinus (soft) - AC welding rectangle (hard) 3. Use the rotary knobs to set the parameters to the desired values: - Pulse time t1 - Pulse time t2 - Soft Start (Upslope) - Welding current I1 - Welding current I2 - Soft Down (Downslope) - Gas post-flow time
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- Frequency - Balance 4. Open the gas cylinder valve 5. Set the shielding gas flow rate 6. Start welding (ignite the arc)
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8. TROUBLESHOOTING, MAINTENANCE AND DISPOSAL
8.1 Troubleshooting
Safety
WARNING Work that is carried out incorrectly can cause serious injury or damage. All the work described below must only be carried out by trained and qualified personnel. Do not carry out any of the work described below until you have fully read and understood the following documents:
• this document • all the operating instructions for the system components, especially the safety rules
WARNING An electric shock can be fatal. Before starting the work described below:
• turn the power source mains switch to the "0" position • disconnect the power source from the mains • ensure that the power source remains disconnected from the mains until all work has been completed
After opening the device, use a suitable measuring instrument to check that electrically charged components (e.g. capacitors) have been discharged.
WARNING An inadequate ground conductor connection can cause serious inju- ry or damage. The housing screws provide a suitable ground conductor connec- tion for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
CAUTION Risk of scalding by hot system components. Before starting work, allow all hot system components to cool down to room temperature (+25 °C, +77 °F). For example:
• coolant • water-cooled system components • wire-feed unit drive motor
General All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following checklist. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorized dealer.
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Troubleshooting-Checklist Main power switch on, no function
Mains fuse defective - Change mains fuse
Power supply interrupted - Check mains supply - Litz terminated, terminals loose - Exchange mains supply
10s after starting welding under TIG the welding process is stopped, the message H20 flashes
Malfunction in the cooling circuit - Check coolant level - Check pump - Check fuses F1, F2 and F3 (F3 on the control transformer) - Remove kinks in the hose system
Display flashes, green LED for S-test does not light up
The test device of the hazard - Turn the rotary knob to the desired welding current reduction device has triggered. mode, switch off the device, wait until the display Rotary knob is in position S-test completely extinguishes, then switch on the device again.
Display flashes, green LED for S-test does not light up
The danger reduction device has - Switch off the device, wait until the display turns off failed completely, then switch on the device again. - If the display flashes again and the green S-Test LED is off, stop the unit immediately and notify the service
Display flashes, yellow LED lights up
Device was overloaded - Leave the appliance switched on and wait until it has cooled down
When switched on, the mains fuse triggers
Power module defective - Notify service
It can be welded under TIG DC, but HF does not fire
Wrong mode of operation - Select operating mode TIG with HF
Ignitor defective - Replace ignitor
Power supply for ignitor interrupted - Check power supply 230V - Check fuses F1, F2 and F3 (F3 on the control transformer)
Trigger voltage is missing - Check trigger inputs
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Electrode works but TIG has no function
Plug from the torch trigger is not - Check, plug in inserted (correctly)
Burner button line has interruption - Check control line
Burner button is defective - Replace the button or replace the burner
Device overheats but fans do not start
Fan is blocked - Remove blockage
Supply voltage 24V missing - Check wiring
Power supply 24V is defective - Notify service
At the input of the AC switch (DC link), the open circuit voltage can be measured, not at the output of the AC switch. (Attention, the ignition voltage may destroy the meter! Only check in position MMA)
Defect in the inverter - Check ribbon cables - Notify service
Hot wire power source does not bring power
Too little power set - Turn the trimmer on the back to the right
Start does not take place - Check wiring
Green LED on the front does not light up
Power supply for hot wire power - Check 230V, check fuses F1, F2 and F3 (F3 on the source is missing control transformer)
Hot-wire power source defective - Notify service
Yellow LED on the front lights up
Hot wire power source overloaded - Allow the hot wire power source to cool down
Welding torch overheated
Loose welding current connections - Tighten power connections on the torch and/or on the workpiece - Tighten contact tip correctly
Overload - Check and correct welding current setting - Use a more powerful welding torch
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Unstable arc
Unsuitable or worn welding torch - Adjust contact tip to wire diameter and -material and equipment replace if necessary - Adjust wire guide to material in use, blow through and replace if necessary
Material inclusions in the tungsten - Regrind or replace the tungsten electrode electrode due to contact with filler material or workpiece
Incompatible parameter settings - Check settings and correct if necessary
Unsuitable or worn welding torch - Adjust contact tip (cold wire/hot wire) to wire diameter, equipment blow through and replace if necessary - Adjust wire guide to material in use, blow through and replace if necessary
Contact tip blocked - Clean, spray with anti-spatter spray and replace if necessary
Setting the spool brake > see - Check settings and correct if necessary chapter 6.3.4 Spool brake setting
Setting pressure units > see - Check settings and correct if necessary chapter 6.3.3 Inching the wire electrode
Worn wire rolls - Check and replace if necessary
Wire feed motor without supply - Check and replace fuse if necessary voltage
Kinked hose packages - Extend and lay out the torch hose package
Incompatible parameter settings - Check settings and correct if necessary
Arc between gas nozzle and - Replace gas nozzle workpiece (metal vapor on the gas nozzle)
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Pore formation
Inadequate or missing gas - Check shielding gas setting and replace shielding gas shielding cylinder if necessary - Shield welding site with protective screens (draughts affect the welding result) - Use gas lens for aluminum applications and high-alloy steels
Unsuitable or worn welding torch - Check size of gas nozzle and replace if necessary equipment
Condensation (hydrogen) in the gas - Replace hose package tube
Workpieces dirty - Clean workpieces
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8.2 Care, maintenance and disposal
General Under normal operating conditions, the device requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.
Safety
WARNING Work that is carried out incorrectly can cause serious injury or damage. All the work described below must only be carried out by trained and qualified personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: • this document • all the operating instructions for the system components, especially the safety rules
WARNING An electric shock can be fatal. Before starting the work described below: • turn the power source mains switch to the "0" position • disconnect the power source from the mains • ensure that the power source remains disconnected from the mains until all work has been completed
After opening the device, use a suitable measuring instrument to check that electrically charged components (e.g. capacitors) have been discharged.
CAUTION Risk of scalding by hot system components. Before starting work, allow all hot system components to cool down to room temperature (+25 °C, +77 °F). For example: • coolant • water-cooled system components • wire feed unit drive motor
Every start-up - Check all hose package and the ground earth connection for damage. Replace any damaged components. - Check feed rollers and inner liners for signs of damage. Replace any damaged components. - Check contact pressure of feed rollers and adjust if necessary.
Every 6 months
NOTE! Risk of damage to electronic components. Do not bring the air nozzle too close to electronic components. - Open covers, remove device side panels and clean inside of device with dry reduced compressed air. After cleaning, restore device to its original state.
Disposal Dispose of in accordance with the applicable national and local regulations.
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9. TECHNICAL DATA
Power Source
TIG 500 AC TIG 500 DC
Mains connection 3/PE AC 400 V 3/PE AC 400 V
I 1-TIG 35,5A 35,5A
S1-TIG 24,6kVA 24,6kVA
I 1-Electrode 34A 34A
S1-Electrode 23,5kVA 23,5kVA
Fuse, lazy 32A 32A
U 0 71V 71V
Setting range I2 TIG 4-500Apeak 4-500A
Setting range I2 Electrode 15-400Apeak 15-400A
Max ED TIG 40% 40%
Max ED Electrode 40% 40%
Setting range Balance 20-80% 20-80%
Setting range Frequency 20-250Hz 20-250Hz
Dimensions L/W/H 1100 x 1230 x 545 mm 1100 x 1230 x 545 mm
Weight 147 kg. 139 kg
EMC class A A
Safety identification EAC/S/CE EAC/S/CE
see declaration of see declaration of Harmonized standards used conformity (machine conformity (machine documentation) documentation)
Wire feeder / Hot wire
Hot wire current setting range 60 A to120 A
Max. hot wire voltage 10,5 V
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Duty cycle at 40 °C ambient temperature
35% DC 120 A
60% DC 100 A
100% DC 80 A
Load cycle 10 min. (60% DC; 6 min. welding, 4 min. pause)
Open circuit voltage 82 V
Reduced open circuit voltage 10,5 V
Frequency 50/60 Hz
Mains fuse T8 A 120/230 VAC
Feeder fuse T8 A 32 VAC
Max. connected load 2.6 kVA
Recommended generator rating 3.4 kVA cosj / efficiency 0.99 (86%)
Insulation class / protection classification H/IP 23
Ambient temperature –25 °C to +40 °C
Machine cooling Fan
Hot wire current welding lead 25 mm2
Welding current welding lead 95 mm2
Wire feed speed 0.15 m/min. to 17 m/min. 5.6 IPM to 670 IPM
Standard WF roller equipment 0.8 + 1.0 mm (for steel wire)
Drive 4 rolls (37 mm)
Torch connector Decentral
Forward/backward motion frequency 17 – 20 Hz
EMC class A
Safety identification EAC/S/CE
see declaration of conformity (machine Harmonized standards used documentation)
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10. APPENDIX
10.1 Installation Guide Step 1: Connecting of the remote pendant
- Connect the remote pendant to the 17-pole connection socket [(1) Chapter 5.2]
- Reset EMERGENCY STOP button if it is pressed.
After completion and verification, continue to step 2
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Step 2: Connecting the cooling adapter
- Connect the cooling adapter with the connection socket welding current [(5) Chapter 5.2]
After completion and verification, continue to step 3
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Step 3: Bridging the internal coolant supply
- Connect the cooling water bridge provided with the coolant return connection nipple [(3) Chapter 5.2] and the connecting nipple for the current / water cable [(7) Chapter 5.2]
After completion and verification, continue to step 4
Page 54 of 75 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
Step 4: Connection of the welding torch
- Connect the supplied welding torch to the still free connections of the front side [Chapter 5.2]
After completion and verification, continue to step 5
Page 55 of 75 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
Step 5: Connecting the external cooling unit
- Connect the yellow marked connections to the external cooling unit.
After completion and verification, proceed to step 6
WARNING The external cooling unit must have the following technical data:
• Actual cooling capacity: min. 810 W • Temperature range: +5°C to +42°C • Set coolant temperature during welding: max. 20°C • Pump pressure: 0,14m3/h at 2,8 bar
CAUTION TIP TIG Automation GmbH is not responsible for the issue, commissioning and operation of cooling units from third-party manufacturers.
Page 56 of 75 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
Step 6: Connecting the distribution box
- Connect the supplied distribution box with the pre- installed axles to the 37-pin socket [(7) Page 12] on the back.
After completion and verification, as well as connection of the gas and electricity supply and attachment of the axles, the welding system can be put into operation.
Page 57 of 75 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
10.2 Welding Check List Step 1: Torch
- Check welding and shielding gas connections and supply - Check water connections - Check electrode is sharp (~ 42°)
- Check torch position (Set electrode to work gap (AEA, see 5.6) to between 1.0 and 1.2mm) After completion and verification, continue to step 2
Step 2: Back purge (100% Ar)
- Ensure purge is correctly positioned - Check integrity of the purge - Check flow rate (5 - 6 liters per minute)
After completion and verification, continue to step 3
Step 3: Welding parameters (see 5.6)
- Welding current (WELD AMPS) - Wire feed speed (WIRE SPEED) - Welding speed (WELD SPEED) - Welding direction (ROTATING DIRECTION) - AEA (1.0 – 1.2 mm) - UPSLOPE - DOWNSLOPE
After completion and verification, continue to step 4
Step 4: Gas (95% Ar, 5% H2)
- Ensure gas mixtures are correct and directed appropriately - Set flow rates to 17 liters per min
After completion and verification, continue to step 5
Page 58 of 75 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
Step 5: AVC
- AVC has to be used and switched on
After completion and verification, continue to step 6
Step 6: Operating conditions
- TIP TIG - focus is a precision high-performance welding process and it requires greater care and precision than would be expected for GMAW or GTAW - The two fundamental issues for TIP TIG - focus implementations are consistency and cleanliness - Consistency applies to all the parameters that affect the keyholing process and particularly those relating to the electrode and the joint fit-up. Cleanliness applies to both the condition of the material being welded, and to the quality of the shielding gas environment
After completion and verification, continue to step 7
Step 7: Joint preparation
- It is most important to minimize gap variation and mismatch. The process can be set up to operate with a variable fit-up but this invariably requires significant compromises and reduces the resultant joint quality and appearance. For example, a rapidly varying gap would require an automated adjustment of the wire feed rate for a consistent bead profile. Such problems are best avoided by intervention earlier in the production process - Zero joint gap is expected because this minimizes filler consumption and avoids any confusion between full and partial penetration
After completion and verification, continue to step 8
Step 8: Contamination from the plate
- The most likely source of contamination and resultant electrode damage is the plate itself - Obvious sources are oil, grease, paint or water on the plate surfaces or edges. Care should be taken to ensure these do not enter the weld zone, as the decomposition products will attack the tungsten electrode. Electrode damage is cumulative, and so the degradation caused by even a single patch of contaminant continues after the contamination has been removed - Oxidized surfaces may also cause problems by reducing surface tension. In addition, if the oxide is thick it may introduce moisture into the welding atmosphere. Such material must be cleaned and all oxide removed before welding, or welded with an alternative, non-keyholing process
Thank you for your attention
Page 59 of 75 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
10.3 Spare part list
10.3.1 Four roll wire drive
Page 60 of 75 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
Pos. Description Item-No.
(1) Feed plate front 88807200
(2) Feed plate rear 88807202
(3) Feed roll shaft 88807204
(4) Hex-nut M6 88807206
(5) Pressure arm assembly left SFT4 88807208
(6) Pressure arm assembly right SFT4 88807208
(7) Torsion spring 88807210
(8) Motor-New Wire Drive 88807212
(9) Motor fixation screws 88807214
(10) Drive Gear 88807216
(11) Flat washer 88807218
(12) Machine screw 88807220
(13) Pressure adjustment unit 88807222
(14) Tapered pin 88807224
(15) Quick change carrier gear 88807226
(16) Circlip 88807228
Quick change feed roll (0.8 / 1.0) 88807158 Quick change feed roll (1.0 / 1.2) 88807160 (17) Quick change feed roll (1.2 / 1.6) 88807162 (18) Quick change feed roll (0.8 / 0.8) 88807170 Quick change feed roll (0.9 / 0.9) 88807172 Quick change feed roll (1.0 & 1.0) 88807174
(19) Machine screw 88807232
(20) Wire guide set blue 88807234
Page 61 of 75 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL
10.4 WIRING DIAGRAM
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10.4.2 External wire feeder
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TIP TIG Automation GmbH Baumayrweg 5, 4631 Krenglbach, Austria Tel: +43 720 303500, Fax: +43 720 303500 99 E-Mail: [email protected] www.tiptig.com