SAFETY INSTALLATION OPERATOR CONTROL CARE AND MAINTENANCE SERVICE

HIGH SPEED EDITION HOT WIRE UNIT TECHNICAL MANUAL

WB Alloy Welding Products Ltd WB Alloy Welding Products Ltd WB Alloy Welding Products Ltd Head Office North Scottish Depot South England Depot Dalsetter House Unit 8, Altens Trade Centre Unit 2F, Westbridge Ind Est Pixon Lane 37 Dalsetter Avenue Harness Circle Tavistock, Devon Glasgow Aberdeen PL198DE T: 0141 940 4730 AB123LY T: 01822 618287 E: [email protected] T: 01224 870052 E: [email protected] E: [email protected] Preface

We are very pleased that you have chosen to place your trust in our product. We place great value in ensuring that you draw great pleasure, benefit and work enhancement from your use of the TIPTIG Hot Wire Unit.

For that reason, we would like you to read through the Technical Manual thoroughly before installing and starting to use the TIPTIG Hot Wire Unit. It will help you to familiarize yourself with your new product as rapidly as possible and to use it more efficiently.

This Technical Manual details the TIPTIG Hot Wire Unit, providing you with assistance and support in installing it and getting started, as well as demonstrating how to use it safely and effectively The Manual is structured as follows:

Section I presents the basic concept underlying the TIPTIG Hot Wire Unit and sets out some important safety instructions to ensure safe use of the equipment.

Section II SAFETY Instructions

Section III details how to use the equipment

Section IV Tippings

Section V Pictures/Spare parts

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit TABLE OF CONTENTS

Describtion Page SECTION 1 ! SAFETY PRECAUTIONS - READ BEFORE USING I-I Symbol Usage 1 I-II Arc Welding Hazards 1 I-III Additional Symbols For Installation,Operation,And Mantenance 2 I-IV California Safety Standards 3 I-V Principal Safety Standards 3 I-VI EMF Information 3

SECTION II ! Labels+symbols,Safety instruction especially TIPTIG II-I Labelling+Symbols 4 II-II Safety instructions (CE) 5 II-III Safety instructions (CE) 6 II-IV Safety instructions (CE) 7

SECTION III ! Installation-Getting Started III-I Installation/Getting Started 8 III-II Getting Started 9 III-III Getting Started 10

SECTION IV ! Introduction-Tippings-Warnings IV-I Introduction 11 IV-II Tips I Selection wire diameters for all materials 12 IV-III Tips II Selection intake nozzels,feed rolls 13 IV-IV Tips III Function torch buttons, Distance wire to tungsten 14 IV-V Tips IV Function 4 STEP (STROKE) Mode 15 IV-VI Tips V Operating Micro Processor Control 16 IV-VII Tips VI Micro Processor Control 17

SECTION V ! Pictures/Spare parts numbers V-I TIPTIG Picture front 18 V-II TIPTIG Picture left+right side 19 V-III TIPTIG+TIPTIG Hot Wire Unit Spare part list 20 V-IV TIPTIG Picture 4-rolls wire feeder 21 V-V TIPTIG Spare part list wire feeder 22 V-VI TIPTIG Picture inside connection Hot Wire Modul 23 V-VII TIPTIG Spare list inside connection Hot Wire Modul 24 V-VIII TIPTIG Explosion view 4-rolls feeder 25 V-IX TIPTIG Spare part list 4-rolls feeder 26

SECTION VI ! Warranty VI-I Warranty 27 Page 1 SECTION I - SAFETY PRECAUTIONS -READ BEFORE USING

Protect yourself and others from injury-read and follow these precautions

I - I Symbol Usage

Instead of the examination mark, the danger sign often shows the source of the danger in question.The yellow highlighted text contains details of how to prevent personal injury or substantial damage to property Failure to comply with the instructions given may pose risk This group of symbols means Warning! Watch Out! of injury '-or even danger of life! ELECTRIC SHOCK,MOVING PARTS,and HOT PARTS hazards. Consult symbols and related instructions below for necessary NOTICE- Indicates statements not related to personal injury actions to avoid the hazards

I - II Arc Welding Hazards

The symbols shown below are used throughout this manual to ! Properly install and ground this equipment according to ist call attention to and identify possible hazards.When you see the Owner's Manual and national,state,and local codes. symbol,watch out,and follow the related instructions to avoid the ! Always verify the supply ground-check and be sure that input hazard.The safety information given below is only a summary of power cord ground wire is properly connected to ground terminal he more complete safety information found in the Safety in disconnected box or that cord plug is connected to a properly Standards listed in Section 1-V.Read and follow all Safety grounded receptable outlet. Standards ! When making input connections,attach proper grounding conduc- tor first-double-check connections. Only qualified persons should install,operate,maintain,and ! Keep cords dry,free of oil and grease,and proteced from hot repair this unit metal and sparks. ! Frequently inspect input power cord for damage or bare wiring- During operation,keep everybody,especially children,away. replace cord immeddiately if damaged-bare wiring can kill. ! Turn off all equipment when not in use. ELECTRIC SHOCK can kill. ! Do not use worn,damaged,undersized,or poorly spliced cables. Touching live electrical parts can cause fatal shocks or severe ! Do not drape cables over your body. burns.The electrode and work circuit is electrically live whenever ! If earth grounding of the workpiece is required,ground it directly the output is on.The input power circuit and machine internal with a seperate cable. circuits are also live when power is on.In semiautomatic or ! Use only well-maintained equipment.repair or replace damaged automatic wire welding,the wire,wire reel,drive roll housing and parts at once.Maintain accordinmg to manual. all metal parts touching the welding wire are electrically live. ! Wear a safety harness if working above floor level. Incorrectly installed or improperly grounded equipment is a ! Keep all panels and covers securely in place. hazard. ! Clamp work cable with good metal-to-metal contact to workpiece ! Don't touch live electrical parts. or worktable as near the weld as practical. ! Wear dry,hole-free insulating gloves,and body protection ! Insulate work clamp when not connected to workpice to prevent ! Insulate yourself from work and ground using dry insulating mats or contact with any metal object. covers big enough to prevent any physical contact with the of ground. ! Do not use AC output in damp areas,if move,movement is confined,or SIGNIFICANT DC VOLTAGE exists in Inverter welding if there is a danger of falling. power sources AFTER removal of inputpower! ! Use AC output ONLY if required for the welding process. ! Turn OFF inverter,diconnect input power,and discharge input ! If AC output is required,ude remote output control is present on unit. capacitors according to instructions in Maintenance Section ! Additional safety precautions are required when any of the following before touching any parts. electrically hazardous conditions are present:in damp locations or while wearing wet clothing:on metal structures such as floors,gratings,or HOT PARTS can burn. scaffolds;when in cramped positions such as sitting,kneeling,or lying, ! Do not touch hot parts bare handle. or when there is a high risk of unavoidable or accidental contact with ! Allow cooling period before working on equip- the workpiece or ground. ment. ! Disconnected input power or stop engine berfore installing or servicing ! To handle hot parts,use proper tools and/or this equipment.Lockout/tagout input power according to wear heavy,insulated welding gloves and OSHA 29 CFR 1910.147 (see Safety Standars). clothing to prevent burns. Page 2

I - III Additional Symbols For Installation,Operation,And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can injure. ! Do not install or place unit on,over,or near combustible ! Keep away from moving parts such as fan surfaces ! Keep all doors,panels,covers and guards closed ! Do not install unit near flammables. and securely in place ! Have only qualified persons remove doors,panels,covers,or ! Do not overload building wring,-be sure power supply system is guards for maintenance and troubleshooting as necessary. properly sized,rated,and protected to hanlde this unit ! Reinstall doors,panels,covers or guards when maintenance is finished and before reconnecting input power. FALLING EQUIPMENT can injure. ! Use lifting eye to lift unit only,NOT running gear,gas READ INSTRUCTIONS cylinders,or any other accessories. ! Read and follow all labels and the Owner's ! Use equipment of adequate capacity to lift and support unit. Manual carefully before installing,operating or servicing unit.Read the safety information at the beginning of the manual and in each section ! If using lift forks to move unit,be sure forks are lomg enough to extend ! Use only genuine replacement parts from the manufacturer. beyond opposie side of unit. ! Perform maintenance and service according to the Owner's ! Keep equipment (cables and cords)away from moving vehicles when Manuals,industry standards,and national,state,and local codes working from an aerial location ! Follow the guideline in the Applications Manual for the Revised NIOSH H.F.RADIATION can cause interference. Lifting Equation (publication No.94-110) when manually heavy parts ! High-frequency (H.F) can interference with radio or equipment. navigation,safety services,computers,and communications equipment. OVERUSE can cause OVERHEATIING ! Have only qualified persons familiar with ! Allow cooling period,follow rated duty cycle electronic equipment perform this installation ! Reduce current or reduce duty cycle before starting to ! The user is responsible for having a qualified electrician promptly weld again correct any interference problem resulting from the installation ! Do not block or filter airflow to unit. ! If notified by the FCC about interference,stop using the equipment at once. FLYING SPARKS can injure. ! Have the installation regularly checked and maintained. ! Wear a face shield to protect eyes and face ! Keep high-frequency source doors and panels tightly shut,keep ! Shape tungsten electrode only on grinder with proper sparks gaps at correct setting,and use grounding and shielding guards in a safe location wearing proper face,hand,and to minimize the possibilty of interference. body protection. ! Sparks can cause fires-keep flammables away.

STATIC (ESD) can damage PC boards ! Put on grounded wrist strap BEFORE handling boards or parts. ! Use proper static-proof bags and boxes to store,move,or ship PC boards.

MOVING PARTS can injure. ! Keep away from moving parts ! Keep away from pinch points such as drive rolls.

WELDING WIRE can injure. ! Do not press gun trigger(button) until instructed to do so. ! Do not point gun toward any part of body,other people, or any metal threading welding wire Page 3

I - IV CALIFORNIA PROPOSITION 65 WARNINGS

Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and ,in some cases,cancer, (California Health & Safety Section 25249.5 et.seq.)

I - V Principal Safety Standards

Safety in Welding,Cutting,and Allied Processes ANSI StandardZ49.1 from Global Engineering Documents (www.global.ihs.com)

Safety in Welding,Cutting,and Allied Processes CSA Standard W 117.2 from Canadian Standards Association (www.csa-international.com)

OSHA,Occupational Safety and Health Standards for General Industry Title 29,Code of federal Regulations(CFR) Part 1910,Subpart Q and Part 1926,SubpartI from Givernment Printing Office (www.osha.gov)

I - VI EMF Information

Electric current flowing through any conductor causes localized 4. Keep head an trunk as far away from the equipment in the electric and magnetic fields(EMF).Welding current creates an EMF field welding circuit as possible. around the welding circuit and welding equipment.EMF fields may 5. Connect work clamp to workpiece as close to the weld as interfere with some medical implants, e.g peacemakers. possible. Protective measures for persons wearing medical implants have to 6. Do not work next to,sit or lean on the welding power source. be taken.for example,access restrictions for passers-by or individual 7. Do not weld whilst carrying the welding power source or wire risk assessment for welders.All welders should use the following feeder. procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them,or using a cable cover. 2. Do not place your body between welding cables.Arrange cables to one side and away from the operator 3. Do not coil or drape cables around your body Page 4 Labelling and symbols

Symbols used in the Manual

This Technical manual uses a range of symbol and pictograms. You will need to familiarize yourself closely with their meanings. The symbols will help you to understand the information presented more rapidly and point out of potentially important information, hints and tips. Pay attention to the instructions and information presented adjacent to these symbols with particular care

Danger sign Instead of the examination mark, the danger sign often shows the source of the danger in question. The yellow highlighted text contains details of how to prevent personal injury or substantial damage to property. Failure to comply with the instructions given may pose risk of injury -or even danger of life!

Prohibition sign The prohibition sign often shows the action or object which is prohibited. The text accompanying this symbol details things to be avoided in order to prevent personal injury or damage to property.

Essential action sign The action required (such as wearing protective equipment) is detailed in in place of exclamation mark. Identifies essential action to be taken in order to prevent injury.

Caution sign The text accompanying this symbol details action to be taken in order to prevent damage.

Information sign Note, information or tip as a help in enhancing use of the equipment

Hand book sign Read the instructions-For your own safety and to avoid risk, be sure to read and follow the instructions set out in this Technical Manual

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 5 SAFETY INSTRUCTIONS

General safety instructions

The recognised technical rules and applicable standards and regulations were followed and applied in the development and manufacture of the TIPTIG High Speed Hot Wire Unit The TIPTIG High Speed Hot Wire Unit is designed and manufactured such that, if used in accordance with it's designed purpose, any potential danger is largely avoided. Ing.Siegfried Plasch nonetheless feels obliged to detail the following safety precautions which you should undertake in order to avoid any residual risk

Follow the operating Caution! When using TIPTIG Hot Wire Unit, the following fundamental instructions! safety precautions must be taken in order to protect against electric shock, potential injury and fire risk. Read and follow the instructions for use,cleaning,care and maintenance given in this Technical Manual before beginning work. Keep the Technical Manual within easy reach of the machine operator and pass it on to new operators as and when appropriate

The TIPTIG High Speed Hot Wire Unit is only for commercial and industrial use. Any other use of this machine must be authorised in writing by the manufacturer-Ing.Siegfried Plasch.Only personnel that have trained for use and servicing of welding equipment may operate this machine The operator for this equipment must carefully read and fully understand all the information contained within before the unit can be put into operation! The information contained in this manual has been given the manufacturer's best knowledge. However, the manufacturer can't be held liable for the use of this information Ing.Siegfried Plasch reserves the right to make any changes to this machine and/or operations manual without prior notice.

Check function! Before beginning work, check that the guards and the TIPTIG Hot Wire Unit itself are in good working order. Check the torch and machine for damage and make sure that all parts in good working order!

Look out for damage! All parts must be correctly fitted and all conditions to met ensure trouble-free operation of the machine. If the machine is damaged in any way, it must no longer be used. In such cases, ensure that the machine is professionally repaired. Identify the defect and mark the machine clearly so that it is not used until such time as the repair has been carried out.

Maintain good order! Maintain good order in your work area! Disorder in a work area can cause accidents. Secure your workplace when leaving it.

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 6 SAFETY INSTRUCTIONS

Installation and servicing of the TIPTIG Hot Wire unit welding machines and components may only be performed in accordance with the national rules and regulations of the respective organisation operators safety. Never come into contact with any metal parts that are under stress or use with bare hands or wet clothing. During welding operation always wear safety gloves, welding helmet with correct filter! Be especially careful that anything, such as clothing that comes in contact with the work area including the welding torch, welding ground clamp and welding machine are always dry. Never work in wet clothing! When working with metal in the work area or in areas with high voltage always be sure that all metal parts are isolated. Always use dry gloves and wear rubber soled shoes! Also, make sure that you are standing on a dry, isolated underlay! Do not use any worn or damages welding cable! Make sure that any welding cables are not overloaded! Turn off the TIPTIG Hot Wire Unit and the welding machines if it is not in use for long periods of time! Do not leave the welding cable coiled up and do not wrap it around any parts of the equipment casing! When leaving the TIPTIG Hot Wire Unit and the welding unit, make sure that it has been turned off and never leave it running unattended! Make sure that the welding ground is connected close by the welding area to the work piece! Poor Welding ground connections, or poor grounding taken from parts of the building or remote points decrease efficiency. Furthermore the risk of electrical damage to equipment will increase! Make sure that welding voltage can not come into contact with any chains or steel ropes from equipment such as powered lifts and cranes!

Wear suitable workwear Damaging effect of the rays generated by the electrical arc and from any and personal safety gear! hot metals can lead to severe burns to unprotected skin and eyes. To protect your eyes and body from damaging sparks and rays always use welding helmets with the proper certified filter lens. Also, wear the proper protective clothing etc., even if you are only observing the welding process Any person in the vicinity of the work area must be advised not to look directly into the arc and that metal sparks could be sent through the air. Protect your skin and hair with leather gloves and a welding helmet/mask from the rays and metal sparks emitted. Protect the personnel in the surrounding work area from the welding rays and hot sparks with approved anti-flame retardant gear. Gas tanks under pressure are a potential danger. Follow all safety measures as suggested by gas suppliers and the safety procedures imposed by safety inspectors! Make sure that gas tanks are in a safe place and cannot fall over!

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 7 SAFETY INSTRUCTIONS

Do not use the welding equipment close to flammable liquids or gases!

Danger from electrical energy! There is electrical equipment inside the TIPTIG Hot Wire Unit. Check the machine for external damage before beginning work. Check especially if wires and cables are damaged.

Do not continue working with the equipment if it is damaged. Pull the plug! In the event of repairs and maintenance work, or when the equipment is not in use, always disconnect the mains power supply plug from wall socket

WARNING! Work on the electrical equipment may only be carried out by a qualified electrician. Only original spares may be used. Failure to comply with this requirement may result in users suffering accidents

Use only original parts! WARNING! Use only spares as specified in this Manual. The use of non- approved parts may pose a risk of injury to you.

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 8 Installation/Getting started

Make sure the correct power The TIPTIG Hot Wire Unit must be connected to a socket outlet fitted supply is connected! with a properly installed ground contact. Before connecting the TIPTIG Hot Wire Unit, make sure the mains power cable and the plug are undamaged. Make sure the mains voltage matches the specifications on the rating plate. The TIPTIG Hot Wire Unit may only be connected to a voltage of 115/120VAC /50/60Hz. The power circuit must be fuse-protected to a maximum of 16A.

Recommendation: To protect you against electric shock, the circuit should be protected by an FI circuit-breaker(ground fault circuit-breaker)

The TIPTIG Hot Wire Unit can now be operated as detailed in the "Operator control" section

Using in tanks and Don't take the TIPTIG Hot Wire Unit into a tank or container container structures! structure! It's possible to take only the TIPTIG Feeder into any tank and container structure! You have only to separate the TIPTIG Feeder from the TIPTIG Trolley! In this case the operating supply voltage is only 32 VAC!

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 9 Getting Started

Getting start step 1 Connect the TIPTIG Hot Wire Unit interconnectiing cable to welding machine ! see page

Connection step 2 Put the TIPTIG Hot Wire Unit main cable plug to the socket Only 115/120 VAC socket

Connection step 3 Put the wire spool in the spool holder!Secure the spool with the plastic nut an secure the plastic nut with the plastic screw!

Feed the wire by hand through the 4 rolls feeder and through out the central torch connector:-about 2 inches

Connect the TIPTIG torch to the TIPTIG feeder

Check that all connections are tight!

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Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 10 Getting Started

Press the main switch as shown below to input the voltage

If the red light is flashing the TIPTIG Hot Wire Unit is ready

At the TIPTIG control panel you can see led flashing F 60

This show you the voltage frequency in Hz

After 5 seconds the TIPTIG control panel show you the last parameter which you have used

TIPTIG is ready to work°

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Press the ON/OFF rocket switch as shown in the picture to ON! If the green light is flashing-the Hot Wire Unit is activated Setup 80A at the panel

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SETUP 80 AMPS HOT WIRE CURRENT FOR ALL JOBS

SWITCH OFF THE HOT WIRE UNIT FOR ALUMNIUM!

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit PagePage 1110 Introduction

TIPTIG TIPTIG Hot Wire Unit can be use for TIG/PLASMA/LASER techniques TIPTIG Hot Wire Unit is suitable for Hot and Cold Wire Welding All filler diameters can be used (0.030in-0.063in) For Aluminium it's recommended 0.045in (0.063in) Use the welding machines with the water cooler running ! To do without working water cooler you will destroy the torch!

Display value The display value:- multiplied by 2.5 is the result in inches! feeding speed Example: Factor 100 = 250inches/min (6.4m/min)!

Display value The value is as shown as factor! frequency For all applications use 230!!

Display value The value is shown as factor! start delay Useful for tack weld !

Display value The value is shown as a factor! wire retract delay Is an option -normally not used!

Display value The value is shown as factor! spot time Only for spot weld! To use spot time it's needed to adjust the mode spot function

Mode 4 -step Generally select 4- stroke mode for hand welding > see page 8

Mode 2 -step 2- stroke mode mostly used for tack welding

UP/DOWN Function If a remote control or an UP/DOWN torch is used, it's possible to Wire Feed Speed adjust wire speed+- 33% from the setup of wire feed value

Option UP/DOWN Function If a remote control or an UP/DOWN torch is used, it's possible to AMPS adjust amps + -! This option belongs to the feature of the welding machine!

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 12 Tips I

Aluminium material Solid wire Ø 0.039 in should be used for plate thickness 0.03 - 0.1in AlMg3,AlMg 5,AlMg 4,5Mn Solid wire Ø 0.045 in should be used for plate thickness 0.1 - 1.5 in (ER 5064,ER 5356,ER 5183) Solid wire Ø 0.063 in should be used for plate thickness >1.5 in

Aluminium material Solid wire Ø 0.045 in should be used for plate thickness 0.03 - 1.5in Al99.5,AlSi5,AlSi12 Solid wire Ø 0.063 in should be used for plate thickness >1.5 in (ER 1100,ER4043,ER 4047) Special prepared torch and parts are needed!

Carbon steel, High alloys Solid wire Ø 0.031 in should be used for plate thickness 0.03 - 0.5in Copper alloys, Solid wire Ø 0.039 in should be used for plate thickness 0.5 - 1.5in Nickel basic alloys Solid wire Ø 0.045 in should be used for plate thickness >1.5 in

Titanium Solid wire Ø 0.045 in should be used for plate thickness 0.03 - 1.5 in Solid wire Ø 0.063 in should be used for plate thickness >0.5 in Special prepared torch and parts are needed!

Zinc coated material Solid wire Ø 0.031 in should be used for plate thickness 0.03 - 0.5in Solid wire Ø 0.039 in should be used for plate thickness 0.5 - 1.5in Solid wire Ø 0.045 in should be used for plate thickness >1.5 in

Pipe weld Solid wire Ø 0.031 in should be used for plate thickness 0.03 - 0.5in Solid wire Ø 0.039 in should be used for plate thickness 0.5 - 1.5in Solid wire Ø 0.045 in should be used for plate thickness >1.5 in When welding pipe(s) you should use a torch angle of approx. 70-80°. In order to achieve a faultless root weld, weave the torch In general, you have to maintain a short arc length This way the arc pressure is utilised to ensure proper bonding of the root weldment. Even when welding the cap layer weave the torch slightly. This technique avoids undercut

Trial weld Before starting welding take a look at parameter list and do a trial weld at a test piece

Distance wire to weld Take care that the wire is always in contact with the weld pool pool A minimum feeling of the dynamic movement at the torch is okay! For corner and butt welds use this movement for control the distance to the material

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 13 Tips II

WIRE INTAKE NOZZLES FEED ROLLS wire Ø in wire Ø in wire Ø in wire Ø in 0.031 + 0.035 0.039 0.045 0.063

IMPORTANT Nozzle and feed rolls must shown the same colour!

If feed rolls are fixed the colour show you the wire diamter which you use!

If you use U-rolls you have to setup four rolls

If you use V-rolls you have to setup two rolls at the bottom and two flat rolls two flat rolls at the top

If you use V-knurled rolls (special for bad wire quality) you have to use two rolls at the bottom and two flat knurled rolls at the top

FEED ROLLS PRESSURE SETUP Setup 3 to 3.5 at the pressure device scala for mostly wires!!

Setup 2 to 2.5 at the pressure device scala for alumnium wires!!

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 14 Tips III

Torch Button Function of the torch button

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SETUP Before you start to weld -check the distance from wire to tungsten Ensure wire runs over the center of the tungsten.

1! Tungsten stick out belongs to the application 7 to 15mm is normally range

2! Distance tungsten to wire for all materials except aluminium 0.05 to 0.1inch For all materials except alumnium use 0.05 to 0.1inch (1.5 to 2.5mm) For alumnium 0.07 to 0.12inch (2.0 to 3.0mm)

3! Wire stickout: 0.6 to 0.8inch normally range

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 15 Tips IV

4-STEP MODE Function of the 4-Step mode !"!" !"!" This is the most commonly used function

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FIRST STEP # START WELDING MACHINE Press and hold button 1 # start current is activated Release button 1! main current is activated, weld pool starts to form

SECOND STEP # START TIPTIG Press and release button 2# TIPTIG start to feed

THIRD STEP # STOP TIPTIG Press and release button 2# TIPTIG stop feeding

FOURTH STEP # STOP WELDING MACHINE Press and hold button 1# down slope current starts #crater fill current Release button 1# gas post flow is activated#stop welding machine

OPTION STOP TIPTIG + WELDING MACHINE IN ONE STEP Press and hold button 1+button 2 together # TIPTIG stops feeding# down slope current starts #crater fill current is activated Release button 1+2 # gas post flow activated#stops welding machine

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 16 Tips V

Operating microprocessor Function of the microprocessor control control How to adjust parameter

To choose parameter Wire feed speed ! press Oscillation frequency ! press Start delay ! press !! Wire retract time ! press Spot time ! press

To change values Wire feed speed ! press Oscillation frequency ! press Start delay ! press Wire retract time ! press "! !! Spot time ! press

To choose Mode function 4-STEP "#"# ! press 2-STEP "# ! press Spot function ! press MODE Program load ! press Program save ! press

Create a program Adjust wire feed speed ! press Oscillation frequency 230! ! press Start delay ! press "! !! Wire retract ! press

Choose program save ! press MODE

Choose program number ! press 1-20 program numbers "! !! Save a program Save your program number ! press !!

Load a program Choose program load ! press MODE

Choose program number ! press "! !! Confirm program number ! press !!

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 17 Micro Processor Control

Micro-Processor Control

"##! !! "! !! , O WIRE FEEDER SPEED (Factor) O FREQUENCY CONTROL (Factor) O START DELAY (Factor) O WIRE RETRACT (Factor) O SPOT TIME (Factor)

Mode

O 4-STEP !"!" O 2-STEP !" O O Spot Function O Load Program O Save Program

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 18 FRONT VIEW

1 2 3 4 13 5 14 6 15 7 16 8 17 9 18 19 10

11 12

20 21

22

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 19 VIEW LEFT+RIGHT SIDE

23

24

37 25 38 26 39 27 28 40 29 30 41 31

42 32 33 34 35 36

43

44

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Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 20 PART LIST TIPTIG HIGH SPEED HOT WIRE MODUL

Pos Describtion Article no 1 1 pc TIP TIG Micro processor control hand version 77700103 2 1 pc TIP TIG Front plate new design 88800410 3 1 pc TIP TIG Case housing 88800690 4 1 pc TIP TIG Female socket 5-pin,bajonet connector 88800457 5 1 pc TIP TIG Male x Male connector with inner cone for gas G1/4" RH 88800429 6 1 pc TIP TIG Plastic blind nipple 77700190 7 1 pc TIP TIG Built in plug BEM 25 88800426 8 1 pc TIP TIG Male x Male connector with inner cone G3/8" LH 88800431 9 1 pc TIP TIG Water/current connection G3/8" right hand complete 77700162 10 1 pc TIP TIG Rocker switch without flash-IP 65 88800501 11 1 pc TIP TIG Poti knob for hot wire unit 88800510 11a 1 pc TIP TIG Poti for hot wire unit 88800511 12 1 pc TIP TIG Front plate hot wire modul 88800862 13 1 pc TIP TIG Plastic mask 77700046 14 1 pc TIP TIG Torch central brass connector 77700048 15 1 pc TIP TIG Door knob 77700049 16 1 pc TIP TIG Basic plate 88800601 17 1 pc TIP TIG Label sticker Hot Wire Modul 88800480 18 1 pc TIP TIG LED holder 88800502 18a 1 pc TIP TIG LED yellow 88800504 19 1 pc TIP TIG LED holder 88800502 19a 1 pc TIP TIG LED green 88800503 20 1 pc TIP TIG Plate for wheels 88800552 21 1 pc TIP TIG Steering roller with brake 88800555 22 1 pc TIP TIG Steering roller without brake 88800556 23 1 pc TIP TIG Plastic wire cover black 77700044 23a 1 pc TIPTIG Spool holder complete 77700043 24 1 pc TIP TIG Plastic handle 77700690 25 1 pc TIP TIG Wire spool holder 88800620 26 1 pc TIP TIG Male x Male connector with inner cone for water G3/8" LH 88800431 27 1 pc TIP TIG Built in plug BEM 25 88800426 28 1 pc TIP TIG Built-in socket SE 50/70 88800428 29 1 pc TIP TIG Male x Male connector with inner cone for water G3/8" RH 88800430 30 1 pc TIP TIG Rocker switch with red flash-IP 65 88800500 31 1 pc TIP TIG Fuse holder IP 67 88800506 31a 1 pc TIP TIG Slow-blow fuse 8A 88800507 32 1 pc TIP TIG Plastic blind nipple 88800508 33 1 pc TIP TIG Male x Male connector with inner cone for gas G1/4" RH 88800429 34 1 pc TIP TIG Male socket 6+PE, screw termination (Serie 693) 88800452 35 1 pc TIP TIG Case plate back hot wire modul 88800860 36 2 pc TIP TIG Trestle roller 88800558 37 2 pc TIP TIG Sticker 88800560 38 1 pc TIP TIG Case plate right 88800635 39 4 pc TIP TIG Rubber feet 88800760 40 2 pc TIP TIG Grounidng clip Hot Wire Modul 88800866 41 1 pc TIP TIG Case housing Hot Wire Modul 88800868 42 1 pc TIP TIG Rigt side cover plate Hot Wire Modul 88800870 43 1 pc TIP TIG Screw wire cover 77700045 44 1 pc TIP TIG Door 88800632 45 2 Stk TIP TIG Plastic hinge 88800755

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 21 VIEW 4-ROLLS WIRE FEEDER

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Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 22 PART LIST VIEW 4-ROLLS WIRE FEEDER

Pos Describtion Article no 1 1 pc TIP TIG Safety cover plate 88800646 2 1 pc TIP TIG Brass out going guide 77700570 3 1 pc TIP TIG Connection guide teflon with brass nozzle 77700569 4 1 pc TIP TIG Stainless holder plate for brass central connector 99900076 5 1 pc TIP TIG Plastic bullet crossbow 77700669

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 23 VIEW CONNECTION INSIDE HOT WIRE MODUL

1 2 3 CONNECTION TIPTIG TO TIPTIG HOT WIRE MODUL 4 5 6

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8 CONNECTION TIPTIG HOT WIRE MODUL TO 9 WELDING UNIT 10 11 12

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Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 24 PART LIST VIEW CONNECTION INSIDE

Pos Describtion Article no 1 1 pc TIP TIG Male socket 6+PE, screw termination (Serie 693) 88800452 2 1 pc TIP TIG Male x Male connector with inner cone for water G3/8" LH 88800431 3 1 pc TIP TIG Male x Male connector with inner cone for water G3/8" RH 88800430 4 1 pc TIP TIG Male x Male connector with inner cone for gas G1/4" RH 88800429 5 1 pc TIP TIG Built in plug SEM 25 88800454 6 1 pc TIP TIG Built in plug BE 50/70 77700050 7 1 pc TIP TIG Female socket 6+PE, screw termination (Serie 693) 88800453 8 1 pc TIP TIG Male x Male connector with inner cone for water G3/8" LH 88800431 9 1 pc TIP TIG Male x Male connector with inner cone for water G3/8" RH 88800430 10 1 pc TIP TIG Male x Male connector with inner cone for gas G1/4" RH 88800429 11 1 pc TIP TIG Built in plug BEM 25 88800426 12 1 pc TIP TIG Built-in socket SE 50/70 88800428 13 1 pc TIP TIG Male socket 3+PE, screw termination (Serie 693) 88800458

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 25 Explosion view 4-rolls wire feed unit

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 26 PART LIST 4-ROLLS WIRE FEEDER

Description Pos Qty. Item No. TIP TIG Feed plate 1 88807002 TIP TIG Guard Safety kit 2 88807004 TIP TIG Insulation Mounting Kit 3 88807005 TIP TIG Pressure Arm Right 4 88807010 TIP TIG Pressure Arm Left 4 88807011 TIP TIG Inlet Guide with brass (front side) 5 88807023 TIP TIG Inlet Guide with Liner white 6 88807024 TIP TIG Pressure Device Axis 7 88874007 TIP TIG Inner Body 8 88874008 TIP TIG Cover 9 88874009 TIP TIG Copper Body 10 88874010 TIP TIG Spring Inner Body 11 88874011 TIP TIG Spring pressure arm Auto-Lift 12 88874012 TIP TIG Intermediate Guide 13 88874013 TIP TIG Axle pressure roll 14 88874014 TIP TIG Axle Shaft gear adaptor-feed roll 15 88874015 TIP TIG Circlip 16 88874016 TIP TIG Knurled Screw Pressur Arm 17 88874017 TIP TIG Knurled Screw Rolls 18 88874018 TIP TIG Screw Feed Plate 19 88874019 TIP TIG Screw Safety Plate 20 88874020 TIP TIG Screw 5 21 88874021 TIP TIG Screw 6 22 88874022 TIP TIG Locating Pin pressure Arm 23 88874023 TIP TIG Space Tube pressure arm Auto-Lift 24 88874024 TIP TIG Locating Pin pressure device 25 88874025 TIP TIG Pressure arm Pin 26 88874026 TIP TIG Gear Pin 27 88874027 TIP TIG U-drive roll 0,8-1,0mm 28 88807058 TIP TIG U-drive roll 1,0-1,2mm 28 88807060 TIP TIG U-drive roll 1,2-1,6mm 28 88807062 TIP TIG Gear Adaptor feed 29 88874029 TIP TIG Main Gear Drive 30 88874030 TIP TIG Distance Ring I. 31 88874031 TIP TIG Gauge 32 88874032 TIP TIG Distance Ring II. 33 88874033 TIP TIG Screw 7 34 88874034 TIP TIG Insulation Washer 35 88874035 TIP TIG Washer 2 36 88874036 TIP TIG Washer 1 37 88874037 TIP TIG Screw 9 41 88874052 TIP TIG Washer 5 37A 88874051 TIP TIG Pressure Device Complet 88874002

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit Page 27 WARRANTY

1.Warranty Obligation and Duration of Warranty Ing.Plasch guarantees the customer that its product is free from any defects and workmanship for a period of 12 months from date of commercial purchase.

2. Replacement Parts Not all components can last forever. Parts that endure wear and tear do need to be replaced. These replacement parts are "wear and tear" parts and are excluded from the warranty obligation of the manufacturer. Which components are considered replacement parts are listed by the manufacturer and included the following: Liner,Torch consumables,Feed roller,Wire inlet nozzles etc.

3. Loss of Right to Warranty The tips and information in this operating manual are to be followed. Disregard of the safety information herein as well as wrongful operations or misuse of the equipment (e.g. overloading, using wrong voltage or transformers, or using incompatible components or materials) as well as damage due to foreign forces such as falling or dropping of equipment and shock occurrence are not valid warranty claims; and result in the loss of any warranty remaining. This also extends to dismantling of the product as well as spare parts, replacement parts or any components used that are not from Ing.Plasch. Repair work may only be carried out by Iing.Plasch or by someone authorized by Ing.Plasch. Any technical changes made by any other party is strictly not allowed. Not complying with any of the above mentioned situations will result in loss of any and all warranty on this product.

4.Warrant Costs The customer is bearing the costs of transportation to and from a TIP TIG service point or the facilites from Ing.Plasch

5.Notice of warranty issue The customer must notify Ing.Plasch in written form about a warranty claim within the warranty period. Ing.Plasch must confirm the warranty in written form.

6.Warranty additonal The warranty is waved in case Ing.Plasch finds out that the unit was mistreated or used in manner the design was not intended for. Ing.Plasch can decide if the unit is being repaired or exchanged against a another unit. In case of a valid warranty claim a defective part will be credited if the old part is returned to Ing.Plasch Ing.Plasch will not provide a spare unit for the duration of the repairs for free of charge. Ing.Plasch will not warranty for repairs which have been performed without consent by Ing.Plasch Warranty is limited to cost of repair only. This written guarantee is the only guarantee issued by Ing.Plasch Manufacturer's warranty of this unit is for limited time. Any deviatiation or other agreeements made on the scope of warranty must be authorized in writing.

Technical Manual TIPTIG HIGH SPEED Hot Wire Unit