tiptig operating manual tig 500 compact en v1.0 final · wire feeder to feed welding consumables...

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TIP TIG - TIG 500 COMPACT

Operating Manual Version 1.0 Revision 0

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TIP TIG - TIG 500 COMPACT, OPERATING MANUAL

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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 Automation 15

5.5 Control Panel – Power Source 17

5.6 Control Panel – Wire Feeder D24B2M1.6 19

5.7 Control Panel – Wire Feeder Version 2.0 21

6. INSTALLATION AND COMMISSIONING 25

6.1 Before installation and commissioning 25

6.2 Start-up – Power Source 26

6.3 Start-up – Wire feeder 29

7. WELDING 34

7.1 Preparation 34

7.2 Operating modes 35

7.3 Welding current types (TIG 500AC only) 38

7.4 MMA welding 39

7.5 TIG welding 40

8. TROUBLESHOOTING, MAINTENANCE AND DISPOSAL 42

8.1 Troubleshooting 42

8.2 Care, maintenance and disposal 47

9. TECHNICAL DATA 48

10. APPENDIX 50

10.1 Spare part list 50


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10.2 Wire Feeder 52

10.3 Wiring Diagram 56


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1. GENERAL INSTRUCTIONS

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.

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.


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2. INTENDED USE

2.1 Declaration of conformity

ThelabelledmachinecomplieswiththefollowingECdirectivesandstandardsintermsofitsdesignandconstruction:

• 2014/35/EULowVoltageDirective(LVD)• 2014/30/EUElectromagneticCompatibilityDirective(EMC)• 2011/65/EURestrictionofHazardousSubstance(RoHS)

Standards

• IEC60974-1:2012Arcweldingequipment-Part1:Weldingpowersources• IEC60974-3:2013Arcweldingequipment-Part3:Arcstrikingstabilizing

devices• IEC60974-10:2014Arcweldingequipment–Part10:Electromagnetic

compatibilityrequirements

August1,2018

______________________________ ______________________________JürgenPlasch,CEO DateofDeclaration

In caseofunauthorized changes, improper repairs, and/orprohibitedmodificationswhichhavenotbeenexplicitlyauthorizedbyTIPTIGAutomationGmbH,thisdeclarationshallbevoided.

2.2 Welding in environments with increased electrical hazards

IncompliancewithIEC/DINEN60974,VDE0544themachinescanbeusedinenvironmentswithanincreasedelectricalhazard.

2.3 Calibration/Validation

We hereby confirm that this machine has been tested using calibrated measuring equipment, asstipulated in IEC/EN60974, ISO/EN17662,EN50504,andcomplieswiththeadmissible tolerances.Recommendedcalibrationinterval:12months

2

Konformitätserklärung

TIP TIG Automation GmbH

Erklärt, dass die Schweißautomatisation:

TIP TIG - Automation

den folgenden Richtlinien entspricht:

2014/35/EU, 2014/30/EU

und in Übereinstimmung mit den folgenden

Normen hergestellt wurde:

EN 60974-1:2012, EN 60974-3:2014,

EN 60974-10:2014

14.02.2018

Jürgen Plasch TIP TIG Automation GmbH., Baumayrweg 5, 4631 Krenglbach, Austria

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!

• Theequipmentmustonlybeusedinlinewithitsdesignatedpurposeandbytrainedorexpertpersonnel!

• Donotimproperlymodifyorconverttheequipment!

Intended use Applications

8 099-000180-EW501 27.06.2017

3 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!

3.1 Applications Wire feeder to feed welding consumables for MMA welding.

3.1.1 Use and operation solely with the following machines

A suitable power source (system component) is required in order to operate the wire feed unit!

This machine can be combined with any TIG welding machine.

3.2 Documents which also apply 3.2.1 Warranty

For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com!

3.2.2 Declaration of Conformity

The labelled machine complies with the following EC directives in terms of its design and construction: • Low Voltage Directive (LVD) • Electromagnetic Compatibility Directive (EMC) • Restriction of Hazardous Substance (RoHS)

In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product.

3.2.3 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.

3.2.4 Service documents (spare parts and circuit diagrams)

WARNING

Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. • Appoint only skilled persons for repair work (trained service personnel)!

Original copies of the circuit diagrams are enclosed with the unit. Spare parts can be obtained from the relevant authorised dealer.

3.2.5 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

Intended use Applications

8 099-000180-EW501 27.06.2017

3 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!

3.1 Applications Wire feeder to feed welding consumables for MMA welding.

3.1.1 Use and operation solely with the following machines

A suitable power source (system component) is required in order to operate the wire feed unit!

This machine can be combined with any TIG welding machine.

3.2 Documents which also apply 3.2.1 Warranty

For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com!

3.2.2 Declaration of Conformity

The labelled machine complies with the following EC directives in terms of its design and construction: • Low Voltage Directive (LVD) • Electromagnetic Compatibility Directive (EMC) • Restriction of Hazardous Substance (RoHS)

In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product.

3.2.3 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.

3.2.4 Service documents (spare parts and circuit diagrams)

WARNING

Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. • Appoint only skilled persons for repair work (trained service personnel)!

Original copies of the circuit diagrams are enclosed with the unit. Spare parts can be obtained from the relevant authorised dealer.

3.2.5 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

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

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.

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.

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.


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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 COMPACT welding system is a completely digitised, microprocessor controlled inverter power source with an included wire feeder and is suitable for wire spools with max. diameter of 300 mm (11.81 in.).

The power source is generator-compatible. It is exceptionally sturdy in day-to-day operation thanks to the protected control elements and its powder-coated housing.

The function of a TIG pulse arc with a wide frequency range is available.

The 4-roller drive has good wire-feeding properties. The wire feeder is also suitable for long hose packages.

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.)

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

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


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5. CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS

5.1 System overview

Front of TIP TIG – TIG 500 COMPACT

No. Description

(1) Transport eyebolt (Lifting lug)

(2) Control Panel Power Source – See 5.5 Control Panel – Power Source

(3) Control Panel wire Feeder – See 5.7 Control Panel – Wire Feeder Version 2.0

(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 COMPACT

No. Description

(1) Transport eyebolt (Lifting lug)

(2) Button gas test

(3) 24 pole connection socket automation – See 5.4 Connection Socket Automation

(4) Connecting nipple shielding gas for connecting the shielding gas (G1/4" RH) on the pressure regulator

(5) Main switch with fuses – See 5.3 Main switch with fuses

(6) Mains connection cable with plug

(7) Securing elements for shielding gas cylinder (strap / chain)

(8) Cooling air outlet

(9) 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)

(10) Connecting socket Output 230 VAC

(11) Bracket for shielding gas cylinder


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(12) Wheels, fixed castors

TIP TIG – TIG 500 COMPACT: 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) Connection socket control lead (7-pole) for connecting control lead from the welding torch hose package

(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 Automation

With this 24 pol. installation socket, the power source can be commanded with an external control.

No. Configuration No. Configuration

A Current 1 N Gas on

B Current 2 P Gas on

C Pulse time t1 Q Arc start

D Pulse time t2 R Arc start

E Soft-start time S Ground

F Soft-down time T Uist

G Spot time U GND

H External mode V List

J Ground 0V W TIPTIG RC 8-2

K 10V X TIPTIG RC 8-1

L I>0 (contact) Y NC

M I>0 (contact) Z NC

Which of these setpoints can be set externally depends on H „External mode“ circuit by means of a resistor Rx against 10V.

Thus, a very simple and comfortable mode selection is possible.


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The remote control and automation interface provides the following functions:

Mode Name Rx Comment

0 Internal open everything internally

1 Pulse 1 1k 1% I1, I2 internal; t1, t2 external

2 Pulse 2 4k 1% I1, I2 external; t1, t2 external

3 Footmode 10k 1% I1 external % from I1 internal

4 Remote 1 22k 1% I1, I2 external

5 Remote 2 47k 1% I1 external

6 Remote 3 100k 1% I1, I2 external; Upslope, Downslope external

7 Spottime 150k 1% Spottime external

8 Upslope external 220k 1% Upslope external

9 Pulse 1 + Footmode

470k 1% I1, I2 internal; t1, t2 external I1 external % from I1 internal

Mode 1 – Internal Pulsing

The current setting I1 and I2 takes place on the control panel.

The pulse times t1 and t2 can be set externally.

Mode 2 – External Pulsing

The current settings I1 and I2 as well as the pulse times t1 and t2 can be set externally.

Mode 3 – Limitation of welding current

In this mode, generally only 2-Stroke operation is selected.

Externally, the current setpoint can be varied between the minimum and the internal current setpoint I1.

Mode 4 – Mode 6

In these operating modes, an externally connected potentiometer assumes the function of the internal I1 setpoint specification on the control panel.

Mode 7 – Spottime function

In the operating mode Spottime, the spot time can be set with an externally connected potentiometer


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5.5 Control Panel – Power Source

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.

(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.)


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(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

(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 – Wire Feeder D24B2M1.6

No. Function

(1) Display shows the current figure of the selected parameter

(2) Parameter selection button for selecting the parameters listed below (5)

(3) Adjusting button - for negative adjustment of the selected parameter (5)

(4) Adjusting button + for positive adjustment of the selected parameter (5)

(5) Parameter indicator shows which parameter is selected: - Wire Feeding Speed - Frequency Control - Start Delay - Wire Retract - Spot Time

(6) Mode button for selecting the desired mode (7)

(1)

(2) (3)

(4)

(5)

(7)

(6)


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(7) Mode indicator shows which mode is selected: - 4-Stroke - 2-Stroke - Lead Voltage 0-10 V - Spot Function - Program Load - Program Save

Display values

Wire Feeding Speed Display value multiplied by 0,0635 is the wire feed speed in m/min or display value multiplied by 2,5 is the wire feed speed in IPM (WIRE FEED SPEED = 0,0635*Display value)

Example: Factor 100 = 6,35 m/min or 250 IPM

For more information please go to Appendix 9.2.1 or visit https://www.tiptig.com/english/support/

Frequency Control The value is as shown as factor

For all applications use 230 = 17 Hz

Start Delay The value is as shown as factor (optional)

Useful for track weld

Wire Retract The value is as shown as factor (optional)

Is an option – normally not used

Spot Time The value is as shown as factor (optional)

Only for spot weld

To use spot time it's needed to adjust the mode spot function

Modes

4-Stroke Generally select 4-Stroke mode for hand welding

2-Stroke 2-Stroke mode mostly used for tack welding

Lead Voltage 0-10 V optional

Spot Function optional

Program Load optional

Program Save optional

CAUTION

The wire feed speed may have a variation of ± 10%. It depends on the settings of the feed roll tensioner (see 5.5 (2)) and the quality of the wire.


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5.7 Control Panel – Wire Feeder Version 2.0

Display – Parameters and Modes

No. Function

(1) Menu (parameter) forecast up/down shows which parameter will be selected when switching menu up/down

(2) Parameter range indicator shows min. and max. value of the selected parameter

(3) Menu (parameter) indicator shows which parameter is selected: - Wire speed - Frequency - Weld amps

(4) Parameter shows the current value and unit of the selected parameter

(5) Mode indicator shows which mode is selected: - 2-Step - 4-Step

(6) A – Menu (parameter) up button switching menu up

(1)

(7)

(3) (4) (2)

(9)

(5)

(14)

(16)

(6)

(8)

(10) (12) (13) (11)

(1)

(15)


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(7) Software update port to update provided TIP TIG software

(8) C – Button not assigned button is not assigned in this software version

(9) B – Menu (parameter) down button switching menu down

(10) D – Button not assigned button is not assigned in this software version

(11) Rotary knob to adjust the selected parameter (parameter positive adjustment – rotate clockwise / parameter negative adjustment – rotate counter-clockwise)

(12) I – Mode button for selecting the desired mode (5)

(13) II – Settings button press and hold for 3 seconds to enter settings menu

(14) HOT WIRE button on/off for switching hot wire on/off

(15) Hot wire indicator shows if hotwire is switched on (green) or off (no light)

(16) OIO – Wire inching button potential- and oscillation-free inching of the wire through the hose package to the welding torch


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Display – Settings menu

No. Function

(1) Software version indicates the installed software version number

(2) Settings menu highlights the selected parameter and its value - Weld amps (on/off) - Weld amps max - Weld amps offset - Automation (on/off) - Remote control (on/off) - Up/Down (Wire/Amps) - Language (EN/DE/CN) - Invert colors (on/off)

(3) A – Menu (parameter) up button switching menu line up

(4) B – Menu (parameter) down button switching menu line down

(5) Rotary knob to adjust the selected parameter value (parameter value positive adjustment – rotate clockwise / parameter value negative adjustment – rotate counter-clockwise)

(6) II – Settings button press and hold for 1 second to exit settings menu

(2) (1)

(4)

(3)

(6) (5)


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Display values

WIRE SPEED Display value multiplied by 0,0657+0,17 is the wire feed speed in m/min! (WIRE FEED SPEED = 0,0657*Display value+0,17)

Example: Factor 100 = 6,74 m/min or 265,35 IPM

For more information please go to Appendix 9.2.2 or visit https://www.tiptig.com/english/support/

Modes

2-Step 2-Stroke mode mostly used for tack welding

4-Step Generally select 4-Stroke mode for hand welding

CAUTION

The wire feed speed may have a variation of ± 10%. It depends on the settings of the feed roll tensioner (see 5.5 (2)) and the quality of the wire.


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6. INSTALLATION AND COMMISSIONING

6.1 Before installation and commissioning

Safety

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

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


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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

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.

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.


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6.2.1 Welding torch cooling system

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.

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! �


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6.2.2 Connecting the gas cylinder

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.

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.


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6.3 Start-up – Wire feeder

Safety

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).

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:



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6.3.1 Inserting/replacing feed rollers

Safety

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

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.

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

WARNING


• 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.


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6.3.3 Inching the wire electrode

Safety

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 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.

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

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.

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.


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7. WELDING

7.1 Preparation

Safety

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.

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.

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.

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 safety rules


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7.2 Operating modes

Safety

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

WARNING



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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


4. Stroke



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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


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


4. Stroke


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


7.3 Welding current types (TIG 500AC only)

Safety

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.

WARNING



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7.4 MMA welding

Safety

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

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

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 safety 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 injury 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

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.).


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7.5 TIG welding

Safety

Preparation

1. Plug in the mains plug

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

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 safety 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 injury 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

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.).


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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

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.

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:


WARNING


• 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 injury or damage. The housing screws provide a suitable ground conductor connection 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


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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 reduction device has triggered. Rotary knob is in position S-test

- Turn the rotary knob to the desired welding current mode, switch off the device, wait until the display completely extinguishes, then switch on the device again.

Display flashes, green LED for S-test does not light up

The danger reduction device has failed

- Switch off the device, wait until the display turns off 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 inserted (correctly)

- Check, plug in

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 source is missing

- Check 230V, check fuses F1, F2 and F3 (F3 on the 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 equipment

- Adjust contact tip to wire diameter and -material andreplaceifnecessary

- Adjust wire guide to material in use, blow through andreplaceifnecessary

Material inclusions in the tungsten electrode due to contact with filler material or workpiece

-Regrind or replace the tungsten electrode

Incompatible parameter settings - Check settings and correct if necessary


- Adjust contact tip (cold wire/hot wire) to wire diameter, 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 chapter 6.3.4 Spool brake setting

- Check settings and correct if necessary

Setting pressure units > see chapter 6.3.3 Inching the wire electrode

- Check settings and correct if necessary

Worn wire rolls - Check and replace if necessary

Wire feed motor without supply voltage

- Check and replace fuse if necessary

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 workpiece (metal vapor on the gas nozzle)

- Replace gas nozzle


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Pore formation

Inadequate or missing gas shielding

-Check shielding gas setting and replace shielding gas cylinder if necessary

- Shield welding site with protective screens (draughts affect the welding result)

- Use gas lens for aluminum applications and high-alloy steels


-Check size of gas nozzle and replace if necessary

Condensation (hydrogen) in the gas tube

- Replace hose package

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

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.

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-cooledsystemcomponents• wirefeedunitdrivemotor


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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

Harmonized standards used see declaration of conformity (machine documentation)

see declaration of conformity (machine 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

Harmonized standards used see declaration of conformity (machine documentation)


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10. APPENDIX

10.1 Spare part list

10.1.1 Four roll wire drive


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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

(17)

(18)

Quick change feed roll (0.8 / 1.0)





Quick change feed roll (1.0 & 1.0)

88807158

88807160

88807162

88807170

88807172

88807174

(19) Machine screw 88807232

(20) Wire guide set blue 88807234


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10.2 Wire Feeder

10.2.1 Control Panel – D24B2M1.6 Display value m/min IPM

5 0,32 12,50

10 0,64 25,00

15 0,95 37,50

20 1,27 50,00

25 1,59 62,50

30 1,91 75,00

35 2,22 87,50

40 2,54 100,00

45 2,86 112,50

50 3,18 125,00

55 3,49 137,50

60 3,81 150,00

65 4,13 162,50

70 4,45 175,00

75 4,76 187,50

80 5,08 200,00

85 5,40 212,50

90 5,72 225,00

95 6,03 237,50

100 6,35 250,00

105 6,67 262,50

110 6,99 275,00

115 7,30 287,50

120 7,62 300,00

125 7,94 312,50

130 8,26 325,00


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135 8,57 337,50

140 8,89 350,00

145 9,21 362,50

150 9,53 375,00

155 9,84 387,50

160 10,16 400,00

165 10,48 412,50

170 10,80 425,00

175 11,11 437,50

180 11,43 450,00

185 11,75 462,50

190 12,07 475,00

195 12,38 487,50

200 12,70 500,00

205 13,02 512,50

210 13,34 525,00

215 13,65 537,50

220 13,97 550,00

225 14,29 562,50

230 14,61 575,00

235 14,92 587,50

240 15,24 600,00

245 15,56 612,50

250 15,88 625,00

255 16,19 637,50

CAUTION

The actual wire feed speed can vary by ± 10%. The reason for this may be the setting of the wire feed and the quality of the wire.


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10.2.2 Control Panel – Version 2.0 Display value m/min IPM

5 0,50 19,63

10 0,83 32,56

15 1,16 45,49

20 1,48 58,43

25 1,81 71,36

30 2,14 84,29

35 2,47 97,22

40 2,80 110,16

45 3,13 123,09

50 3,46 136,02

55 3,78 148,96

60 4,11 161,89

65 4,44 174,82

70 4,77 187,76

75 5,10 200,69

80 5,43 213,62

85 5,75 226,56

90 6,08 239,49

95 6,41 252,42

100 6,74 265,35

105 7,07 278,29

110 7,40 291,22

115 7,73 304,15

120 8,05 317,09

125 8,38 330,02

130 8,71 342,95

135 9,04 355,89


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140 9,37 368,82

145 9,70 381,75

150 10,03 394,69

155 10,35 407,62

160 10,68 420,55

165 11,01 433,48

170 11,34 446,42

175 11,67 459,35

180 12,00 472,28

185 12,32 485,22

190 12,65 498,15

195 12,98 511,08

200 13,31 524,02

205 13,64 536,95

210 13,97 549,88

215 14,30 562,82

220 14,62 575,75

225 14,95 588,68

230 15,28 601,61

235 15,61 614,55

240 15,94 627,48

245 16,27 640,41

250 16,60 653,35

255 16,92 666,28

CAUTION

The actual wire feed speed can vary by ± 10%. The reason for this may be the setting of the wire feed and the quality of the wire.


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10.3 Wiring Diagram

BlattBlatt

Bearb.

UrsprFOCUS_TIPTIG_Intern

Jürgen+

Datum

Datum

Ersetzt durch

TIG 500 COMPACT

OHNE STEUERUNGTIG 500 com

pact AC

1

Änderung

07

6

GeprErsatz von

89

3

2

+CC1/1

4

30.11.2018TIP TIG Autom

ationGm

bH1

2

=

Name

5

L1L2

L3PE

INV41EMV

INV 41 PrimINV 41 Prim

INV 41 SekACL 500-W

R

ACL 500-ADPINV 41 Cont

X1

460V

400V

230V

0V

32V

0V42V

24V

0V

X6X3

StartHF

GasI>

0

++

-- -

SIG 8.31

INV 160Inverter

Brenner/ElektrodeTorch / electrode

Werkstück

Workpiece

gnw

sor

X5X4

INV CB 45Control Board

LB Start / current on

LB Start / current on

Gas ein / gas on

Gas ein / gas on

Meldung I>

0 / arc on

Meldung I>

0 / arc on

10V - extern / 10V remote control

Ground 0V

Mode Extern / rem

ote control

Punkt Zeit / spot time

Soft Down

Soft Start

Pulsen t2 / pulsing time 2

Pulsen t1 / pulsing time 1

Strom 2 / current 2

Strom 1 / current 1

X1...Power term

inalX2...Actuator and sensor term

inalX3...Rem

ote controlX4...Torch connectionX5...Socket 230V/6AA2...TIG 500ACA3...Interference filter INV41EM

VA4...INV CB 45 500AA5...HF-Ignition SIG 8.32A6...Hot w

ire inverter INV160F1...FuseF2...FuseF3...FuseF4...FuseF5...FuseT1...Control transform

er

R3...HF blocking chockeC1...Supression CapacitorR5...Poti 10kRL2...HF-FilterL3...HF-FilterM

1...Waterpum

p 230VM

2...FanM

3...FanB1...Pressure sw

itch water

K1...Solenoid valve gasS1...Torch triggerS2...Torch triggerS3...Gas test

X1

12

34

56

Q1

L1L2

L3PE

A3

L1L2

L3PE

PEL3L2L1

A2

16 pol.20 pol.

24 pol.

26 pol.

A44 3 2 156

T1

12

T8A

F1

12

T8A

F2

12

T8A

F3

12

X5

PE 3 12

T10A

F4

12

T1A

F5

24V DC

20 pol.

14 pol.

32

16

54

37

82

1

3456 2 1789101112131415

ABCD

X3

EFGHJKLMNPQRSTUVWXYZ1234

X4

5

110

29

38

L2

110

29

38

L3

A5A6

D0D8

T0T70

K1

S3

0V230V

T0T70R3

C1

230V0V

START

STOP

R5I-Soll HD

43

21

12

3

B1

M2

M3

M1

MTR

1

X2

6PE

-CBL1

OGOGWH

BU GY BK

I-IST/

1.9GND

/1.9 U-IST

/1.9

230V/

1.2

0V/

1.2

0V_32V/

32V/

0V_42V/1.4

42V/1.4

U-IST/

1.2

GND/

1.2

I-IST/

1.2

X3-W/

X3-X/

42V/

1.3

0V_42V/

1.3

0V/

1.1230V

/1.1

230V/1.5

0V/1.5

START_HD/

STOP_HD/

0V/

1.2230V/

1.2

UP/

EXT-START/

DOWN

/

+15V-EXT/

+CC1/1.5


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BlattBlatt

Bearb.

+OHNE STEUERUNG/1

UrsprFOCUS_TIPTIG_Intern

Jürgen+

Datum

Datum

Ersetzt durch

TIG 500 COMPACT

CC1neue Steuerung

1

Änderung

07

6

GeprErsatz von

89

3

2

4

27.11.2018TIP TIG Autom

ationGm

bH1

2

=

Name

5

TIPTIG CONTROL BOARDNEW

-L4

69 Kx1 x2

0,33

Oscillator motor

Wire feed m

otor

X1-1SENABLE DRIVE

X2-3SINPUTS

X1-3SOUTPUTS

X4-3SENCODER

X3-3SANALOG I/Os

X2-1S

An.-OUT 0-10V

An.-GND

An.-IN 0-10V

An.-GND 0-10V

4 Roll Drive

-A2

43

21

34

56

2

+-

-M2

M

+-

-M1

MPE

1

4 3 2 156

65

43

78

21

87

65

910

43

21

43

21

PE

1

+15V-EXTEXT-START

UPDOW

N

START_HDSTOP_HD

32V/

0V_32V/

X3-W/

X3-X/

PE

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