TIP TIG - ORBITAL Operating Manual · TIP TIG - ORBITAL, OPERATING MANUAL Page 2 of 82 INTRODUCTION...

.

TIP TIG - ORBITAL

Operating Manual Version 1.0 Revision 0

TIP

TIG

– O

RB

ITA

L O

PE

RA

TIN

G M

AN

UA

L

TIP TIG - ORBITAL, OPERATING MANUAL

Page 2 of 82

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.


Page 3 of 82

CONTENTSCHECKFELIX

1. GENERAL INSTRUCTIONS 5

2. INTENDED USE 6

2.1 Declaration of conformity 7

2.2 Welding in environments with increased electrical hazards 7

2.3 Calibration/Validation 7

3. SAFETY RULES 8

3.1 Explanation of safety symbols 8

3.2 General safety instructions 8

4. GENERAL 11

4.1 Device concept 11

4.2 Device versions 11

4.3 Scope of supply 11

4.4 Crane transport 12

5. CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS 13

5.1 Weld head 13

5.2 Ring rail 16

5.3 Control cabinet with Control Panel 17

5.4 Power Source 21

5.5 Connection Socket Automation 23

5.6 Control Panel – Power Source 25

5.7 Wire Feeder 27

5.8 Cooling unit 31

5.9 Remote control 32

5.10 Control Panel – ORBITAL 33

6. INSTALLATION AND COMMISSIONING 52

6.1 Before installation and commissioning 52

6.2 Fitting the ring rail to the workpiece/pipe 53

6.3 Coupling the weld head to the ring rail 55

6.4 Connecting the Control Cabinet 56

6.5 Start-up – Power Source 58

6.6 Start-up – Wire feeder 60

7. WELDING 65

7.1 Preparation 65

7.2 Operating modes 66

7.3 Welding current types (TIG 500AC only) 69

7.4 TIG welding 70


Page 4 of 82

7.5 Start Welding 72

8. TROUBLESHOOTING, MAINTENANCE AND DISPOSAL 73

8.1 Troubleshooting 73

8.2 Care, maintenance and disposal 77

9. TECHNICAL DATA 78

10. APPENDIX 81

10.1 Wiring Diagram 81


Page 5 of 82

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.


Page 6 of 82

2. INTENDED USE

WARNING! Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate. Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage!

• The equipment must only be used in line with its designated purpose and by trained or expert personnel!

• Do not improperly modify or convert the equipment!


Page 7 of 82

2.1 Declaration of conformity

ThelabelledmachinecomplieswiththefollowingECdirectivesandstandardsinterms

ofitsdesignandconstruction:

• 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

• ENISO12100-1:2003+A1:2009

• ENISO12100-2:2003+A1:2009

• EN60201-1:2006(forelectricmachines)

• ENISO13857:2008

• EN13732-1:2006

• ENISO14121-1:2007

August 1, 2019

______________________________ ______________________________Jürgen Plasch, CEO Date of Declaration

In case of unauthorized changes, improper repairs, and/or prohibited modifications which have not been explicitly authorized by TIP TIG Automation GmbH, this declaration shall be voided.

2.2 Welding in environments with increased electrical hazards

In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.

2.3 Calibration/Validation

We hereby confirm that this machine has been tested using calibrated measuring equipment, as stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances. Recommended calibration interval: 12 months

Intended use

•

•

•••

–

•

Intended use

•

•

•••

–

•


Page 8 of 82

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.


Page 9 of 82

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.


Page 10 of 82

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.


Page 11 of 82

4. GENERAL

4.1 Device concept

TIP TIG - ORBITAL is a complete welding system intended for the welding of tubes, pipes and fittings. The complete system consists of the orbital weld head, TIG 500i power supply, TIPTIG wire feeder, remote pendant, control cabinet, adapter cables and the TIPTIG-Automation-Torch.

The standard version of the TIP TIG - ORBITAL provides GTAW current with pulsation controls, high frequency arc starting, purge gas controls, hot wire feed, Arc Voltage Control, Torch Weave/Steering (Oscillation) and automatic timing functions. The TIP TIG - ORBITAL includes an Operators Pendant and comes ready to weld. Users need only to supply input AC power, regulated gas source with flow meter and welding wire.

The TIP TIG - ORBITAL family of options also includes PC or Laptop operation for Remote Welding and a variety of quality assurance options such as project and function data acquisition.

4.2 Device versions

- Ring rails for 6in – 48in pipes

- Straight rails

4.3 Scope of supply

The scope of supply comprises:

- Weld head

- Power Source

- Wire Feeder

- Ring rails and/or straight rails

- Cooling unit

- Control Cabinet with Control Panel

- Remote pendant

CAUTION

This welding system is designed and build for ORBITAL-welding. Manual welding isn‘t possible

with this welding machine.


Page 12 of 82

4.4 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 250 kg (551,2 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


Page 13 of 82

5. CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS

5.1 Weld head

Front of weld head

No. Description

(1) Transport handle

(2) Welding torch mount – for clamping the the welding torch

(3) Adjustable ring rail guide


Page 14 of 82

Rear of weld head

No. Description

(1) Coupling lever lock – for locking the coupling lever

(2) Coupling lever – for coupling the pinion gear drive with the ring gear


(4) Control cabinet connection – for connecting the welding unit with the control cabinet

(5) 1st Guide lever lock – for locking the guide lever

(6) 2nd Guide lever lock – for locking the guide lever

(7) Guide lever – for coupling the welding unit to the ring rail through the ring rail guides


Page 15 of 82

Weld head with mounted welding torch

No. Description

(1) Welding torch handle

(2) Wire feed adjustment screw – for vertical fine adjustment of wire feed device

(3) Wire feed adjustment screw – for horizontal fine adjustment of wire feed device


Page 16 of 82

5.2 Ring rail

Front of ring rail

No. Description

(1) Spacers – for fixing the ring rail to the workpiece/pipe

(2) Rail segment no. 1 – pre contoured rail segment

(3) Rail segment no. 2 – pre contoured rail segment

(4) Quick clamps – for speedy assembly of the rail segments (Allen key 6mm)

(5) Ring gear


Page 17 of 82

5.3 Control cabinet with Control Panel

Right side of control cabinet

No. Description

(1) Data login and update port – RJ45 Socket

(2) Remote control – see 5.9 Remote control

(3) Lock for the control cabinet door

(4) Control Panel – see 5.10 Control Panel – ORBITAL


Page 18 of 82

Left side of control cabinet

No. Description

(1) Emergency button

(2) Main power switch – system on/off

(3) Cooling air inlet


Page 19 of 82

Front connection of control cabinet

No. Description

(1) Connection socket (17-pole) – Remote Control for connecting the remote control

(2) Connection socket (32-pole) – Weld head for connecting the weld head


Page 20 of 82

Rear connection of control cabinet

No. Description

(1) Connector plug (17/24-pole) – Power source for connecting the power source

(2) Connection socket (7-pole) – Wire feeder for connecting the wire feeder

(3) Connector plug (7-pole) – Straight rail (option) for connecting straight rail end switches

(4) Connector plug (4-pole) – Mains connection 120/230 VAC main power connection


Page 21 of 82

5.4 Power Source

Front of power source

No. Description

(1) Control Panel Power Source – See 5.6 Control Panel – Power Source

(2) Connection socket control lead (7-pole) for connecting control lead from the welding torch hose package

(3) Connection socket hot wire for connecting hot wire power from the welding torch hose package, minus potential

(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


(7) Cooling air inlet

(8) Hotwire indicator lamps

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.

Temperature fault indicator (down) is lit in the case of overheating. It extinguishes after a few minutes when the unit has cooled down.


Page 22 of 82

(9) Connection socket, welding current „+“ for connecting the workpiece lead

(10) Coolant tank with cap

(11) Coolant level indicator

Rear of power source

No. Description

(1) Button gas test

(2) 24 pole connection socket automation – See 5.5 Connection Socket Automation

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

(4) Main switch Machine on/off

(5) Fuses

Fuse F1 (top) T8 A, 230 VAC

Fuse F2 (down) T8 A, 0 VAC

(6) Mains connection cable with plug

(7) Cooling air outlet


Page 23 of 82

(8) 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)

(9) Connecting socket Output 230 VAC

5.5 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.


Page 24 of 82

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


Page 25 of 82

5.6 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.)


Page 26 of 82

(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)


Page 27 of 82

5.7 Wire Feeder

Front of wire feeder

No. Description

(1) Carrying handle

(2) Connection socket hot wire for connecting hot wire power from the welding torch hose package, minus potential

(3) Connecting nipple shielding gas for connecting shielding gas (G1/4" RH) from the welding torch hose package

(4) Connecting nipple coolant return (red) for connecting coolant return (G3/8" LH) from the welding torch hose package

(5) Connecting nipple current / coolant supply (blue) for connecting current / coolant supply (G3/8" RH) from the welding torch hose package

(6) Wire electrode connection – for connecting the welding torch wire feed


Page 28 of 82

Rear of wire feeder

No. Description

(1) Carrying handle

(2) Connector plug hot wire and workpiece for connecting hot wire power from the interconnection hose package, plus potential, workpiece connection

(3) Connecting nipple coolant supply (blue) for connecting coolant supply (G3/8" RH) from the interconnection hose package

(4) Connector plug welding current for connecting welding current, minus potential from the interconnection hose package

(5) Cooling air outlet

(6) Connecting nipple shielding gas for connecting shielding gas (G1/4" RH) from the interconnection hose package

(7) Connector plug (17-pole) – Automation for connecting TIP TIG Control Cabinet

(8) Connecting nipple coolant return (red) for connecting coolant return (G3/8" LH) from the interconnection hose package


Page 29 of 82

Side of wire feeder

No. Description

(1) Protective cap Cover for the wire feed mechanism and other operating elements

(2) Lock for the protective cap


Page 30 of 82

Wire feeder: 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.)


Page 31 of 82

5.8 Cooling unit

Front of cooling unit

No. Description

(1) Coolant tank with cap

(2) Quick coupling coolant supply (blue)

(3) Quick coupling coolant return (red)

(4) SET button by pressing the SET button, the set temperature of the cooling liquid is displayed. The set temperature can be adjusted by pressing the UP and DOWN buttons.

(5) UP and DOWN buttons

(6) Display (7-seg display) indicates the actual temperature of the cooling liquid

CAUTION

The thermostat may only be adjusted by trained operating personnel and within the approved

limits.


Page 32 of 82

5.9 Remote control

Front of remote control

No. Description

(1) EMERGENCY STOP button Pressing the EMERGENCY STOP button on the supplied remote control puts the system in EMERGENCY STOP mode. All axis movements are slowed down by a safety stop. Pulling the red cap back at its initial position will reset the EMERGENCY STOP button.

(2) START/STOP button (2 cycle mode) - 1st cycle: press the button and the weld process will start - 2nd cycle: press the button again and the weld process will stop

(3) WIRE FEED IN button < 3 sec. the wire will feed about 3mm > 3 sec. the wire will feed endless

(4) TORCH MOTION joystick - UP: vertical hight adjustment up - DOWN: vertical hight adjustment down - LEFT: horizontal fine adjustment left - RIGHT: horizontal fine adjustment right

(5) TRAVEL AXIS “negative/counterclockwise movement” button

(6) TRAVEL AXIS “positive/clockwise movement” button

(7) Remote control handle


Page 33 of 82

5.10 Control Panel – ORBITAL

5.10.1 ORBITAL – Start Screen

No. Function

(1) MOTOR TERMINALS Display displays the status of the motor terminals: - OK: All terminals are working properly - ERROR: See 8.1 Troubleshooting

(2) SURGE PROTECTION Display displays the status of the surge protection: - OK: Surge protection is working properly - ERROR: See 8.1 Troubleshooting

(3) CHANGE USER LEVEL Button to enter change user level screen – see 5.10.2 ORBITAL – Change User Level Screen

(4) USER LEVEL Display displays the current user level: - User Level 1: minimum required level to enter the offset settings (OFFSET SETTINGS) - User level 7: minimum required level to enter main menu (ENTER)

(5) LANGUAGE Setting Buttons to set the graphical user interface (GUI) language: - DE: German - EN: English

(6) Software version number displays the version number of the installed TIP TIG software


Page 34 of 82

(A) ENTER Button Touching the screen in the green area labeled "ENTER" selects the Main Menu Screen – see 5.10.5 ORBITAL – Orbital Welding – Main Menu Screen

(B) OFFSET SETTINGS Button Touching the screen in the grey area labeled "OFFSET SETTINGS" selects the Offset Settings Screen – see 5.10.3 ORBITAL – Offset Settings Screen

5.10.2 ORBITAL – Change User Level Screen

No. Function

(1) User Level Drop-Down List to select a user level from the following options: - User Level 1: minimum required level to enter the offset settings (OFFSET SETTINGS) - User level 7: minimum required level to enter main menu (ENTER)

(2) Password Input Field to enter the required password for each user level

(3) Input Panel for entering the required password


Page 35 of 82

5.10.3 ORBITAL – Offset Settings Screen

No. Function

(1) OFFSET SETTINGS Parameters Edit offset settings by touching the screen in the area outlined in gray: - WELDING VOLTAGE - WELDING CURRENT

(2) AVC SETTINGS Parameters Edit settings by touching the screen in the area outlined in green: - STANDARD DEVIATION SETTING RANGE

(3) END SWITCH! Selection Fields Select End Switch inversion by touching the screen in the area marked as “ON/OFF”. Selected area turns green for “ON” (inversion) and red for “OFF” (normal). - END UP/DOWN - END LEFT/RIGHT

(4) CHANGE PASSWORD Field Change password for the user levels by touching the area outline in gray.

(A) EXIT Button Touching the screen in the red area labeled "EXIT" exits the Offset Settings Screen.


Page 36 of 82

5.10.4 ORBITAL – Rail System Selection Screen

No. Function

(1) ORBITAL WELDING Touching the screen in the area with the ring icon outlined in gray selects orbital welding and enters the Orbital Welding Main Menu Screen – see 5.10.5 ORBITAL – Orbital Welding – Main Menu Screen

(2) STRAIGHT LINE WELDING Touching the screen in the area with the rail icon outlined in gray selects straight line welding and enters the Straight Line Welding Main Menu Screen – see 5.10.14 ORBITAL – Straight Line Welding – Main Menu Screen

(A) EXIT Button Touching the screen in the red area labeled "EXIT" exits the Rail System Selection Screen.


Page 37 of 82

5.10.5 ORBITAL – Orbital Welding – Main Menu Screen

No. Function

(1) ACTUAL WELD PARAMETERS displays the value of the actual weld parameters: - WELD AMPS: edit the set value by touching the screen in the area labeled “-/+” - WIRE SPEED: edit the set value by touching the screen in the area labeled “-/+” - WIRE SPEED

(2) PROGRAM / EDIT highlights the selected program in green. Edit the program parameters by touching the area next to the program labeled “>”.

(3) TORCH POSITION displays the torch position relative to the rail (pipe) and relative to the weld head: - POSITION: position of the torch (weld head) relative to the pipe (rail) - X/Y: position of the torch relative to the weld head - ZERO: Zeroing of the torch position - HOMING: Homing of the torch (weld head) to the zero position

(4) SPEED PARAMETERS displays the value of the actual speed parameters and pipe dimension: - WELD SPEED: in IPM and m/min - PIPE DIMENSIONS: edit pipe dimensions and enter Pipe Dimensions Screen by touching the display in the area outlinerd in grey.

(5) ENERGY PARAMETERS displays the value of the actual energy parameters: - VOLTAGE - HEAT INPUT

(6) WELDING FUNCTIONS - 360° WELDING: Select 360° settings enabled/disabled by touching the screen in the


Page 38 of 82

area labeled as “ON/OFF”. Area turns green for “ON” (360° Settings enabled) and red for “OFF” (360° settings disabled). Enter 360° Welding Screen by touching the screen in the area labaled as “360° SETTINGS”. - REPAIR: enter Repair Screenn by touching the screen in the orange area labeled “>” - GAS TEST: touching the screen in the magenta area labeled ">" performs a gas test. - TEST MODE: enter Test Mode by touching the screen in the grey outlined area labeled “>”

(A) EXIT Button Touching the screen in the red area labeled "EXIT" exits the Main Menu Screen and selects the Start Screen – see 5.10.1 ORBITAL – Start Screen

(B) SETTINGS Button Touching the screen in the green area labeled "SETTINGS" selects the Settings Screen – see 5.10.8 ORBITAL – Orbital Welding – Settings Screen

(C) RING SETTINGS Button Touching the screen in the blue area labeled "RING SETTINGS" selects the Ring Settings Screen – see 5.10.7 ORBITAL – Orbital Welding – Ring Settings Screen

5.10.6 ORBITAL – Orbital Welding – Main Menu Screen – Test Mode

No. Function

(1) MEST MODE for testing the actual parameters without arc, without wire and AVC = OFF


Page 39 of 82

5.10.7 ORBITAL – Orbital Welding – Ring Settings Screen

No. Function

(1) RING SETTINGS Selection Fields Select ring diameter activation/deactiviation by touching the screen in the area marked as “ON/OFF” next to your mounted ring diameter (400, 610, 810, 1010). Selected area turns green for “ON” and red for “OFF”.

(A) SAVE Button Touching the screen in the green area labeled "SAVE" saves the settings and exits the Ring Settings Screen.


Page 40 of 82

5.10.8 ORBITAL – Orbital Welding – Settings Screen

No. Function

(1) WELDING SETTINGS Display displays the welding settings (left) and the corresponding value as well as the range (min - max.) (right). The set value can be adjusted by touching the screen in the area outlined in green: - EVENT 1: AEA (automatic torch height adjustment) - EVENT 2: PRE-GAS (gas pre-flow time) - EVENT 3: UPSLOPE (arc upslope time) - EVENT 4: WIRE DELAY (wire delay) - EVENT 5: TRAVEL DELAY (welding delay) - EVENT 6: DOWNSLOPE (arc downslope time) - EVENT 7: WIRE TRAILING (wire feed downslope time) - EVENT 8: TORCH LIFT (burner lift at the end of the welding process)

(2) TRACTOR SETTINGS Display displays the tractor settings: - AVC: Select AVC by touching the screen in the area labeled as “ON/OFF”. Area turns green for “ON” (AVC on) and red for “OFF” (AVC off). Enter AVC Settings Screen by touching the screen in the area labaled as “AVC SETTINGS”. - SECTOR SETTINGS: enter Sector Settings Screen by touching the screen in the area labeled “>” - TRACTOR MOVEMENT IN PROCESS: Select tractor movement by touching the screen in the area labeled as “CW” for clockwise movement and “CCW” for counterclockwise movement. Selected area turns green.

(A) SAVE Button Touching the screen in the green area labeled "SAVE" saves the settings and exits the Settings Screen.


Page 41 of 82

5.10.9 ORBITAL – AVC Settings Screen

No. Function

(1) AVC SETTINGS Display displays the AVC setting (left) and the corresponding value (right). The value can be changed by touching the screen in the areas outlined in green: - AVC START DELAY (AVC start delay) - AVC RESPONSE TIME (FAST / MED / SLOW) (AVC response speed) - UP/DOWN AVC STEP (burner adjustment per joystick push)

(A) SAVE Button Touching the screen in the green area labeled "SAVE" saves the settings and exits the AVC Settings Screen.


Page 42 of 82

5.10.10 ORBITAL – Orbital Welding – Sector Settings Screen

No. Function

(1) AVC SETTINGS Display displays the sectors (left) and the corresponding value (right). The value can be changed by touching the screen in the areas outlined in gray.

(A) SAVE Button Touching the screen in the green area labeled "SAVE" saves the settings and exits the Sector Settings Screen.


Page 43 of 82

5.10.11 ORBITAL – Orbital Welding – Program Screen

No. Function

(1) WELDING PARAMETERS Display displays the welding settings for the corresponding sector. The values for the parameters can be changed by touching the screen. - WELD AMPS - WIRE SPEED - TRAVEL SPEED

(2) OSC Display displays the OSC settings (left) and the corresponding value (right). The value can be changed by touching the screen in the areas outlined in gray. - OSC-WITH - OSC-SPEED - IN DWELL - OUT DWELL

(A) SAVE Button Touching the screen in the green area labeled "SAVE" saves the settings and exits the Program Screen.


Page 44 of 82

5.10.12 ORBITAL – Orbital Welding – 360° Settings Screen

No. Function

(1) 360° SETTINGS Display displays the 360° settings (left) and the corresponding value (right). The value can be changed by touching the screen in the areas outlined in green. - OVERLAP - POST FLOW - RETURN TO HOME

(A) SAVE Button Touching the screen in the green area labeled "SAVE" saves the settings and exits the 360° Settings Screen.


Page 45 of 82

5.10.13 ORBITAL – Orbital Welding – Repair Screen

No. Function

(1) WELDING PARAMETERS Display displays the welding parameters (left) and the corresponding value (right). The value can be changed by touching the screen in the areas outlined in gray. - WELD AMPS - WIRE SPEED - TRAVEL SPEED

(2) OSC Display displays the OSC settings (left) and the corresponding value (right). The value can be changed by touching the screen in the areas outlined in gray. - OSC-WIDTH - OSC-SPEED - IN DWELL - OUT DWELL

(A) EXIT Button Touching the screen in the red area labeled "EXIT" exits the Repair Screen.


Page 46 of 82

5.10.14 ORBITAL – Straight Line Welding – Main Menu Screen

No. Function

(1) WELDING PARAMETERS displays the value of the actual weld parameters: - WELD AMPS: edit the set value by touching the screen in the area labeled “-/+” - WIRE SPEED: edit the set value by touching the screen in the area labeled “-/+” - TEST MODE: enter Test Mode by touching the screen in the grey outlined area labeled “>”

(2) MOTION PARAMETERS displays the value of the actual motion parameters and tractor movement: - WELD SPEED: in IPM and m/min - TRACTOR MOVEMENT IN PROCESS: Select tractor movement by touching the screen in the area labeled as “<<<” for movement to the left and “>>>” for movement to the right. Selected area turns green.

(3) OSC Display displays the OSC settings (left) and the corresponding value (right). The value can be changed by touching the screen in the areas outlined in gray. - OSC-WIDTH - OSC-SPEED - IN DWELL - OUT DWELL

(4) ENERGY PARAMETERS displays the value of the actual energy parameters: - VOLTAGE - HEAT INPUT


Page 47 of 82

(5) TORCH POSITION displays the torch position relative to the rail (straight rail) and relative to the weld head: - POSITION: position of the torch (weld head) relative to the rail (straight rail) - X/Y: position of the torch relative to the weld head - ZERO: Zeroing of the torch position - HOMING: Homing of the torch (weld head) to the zero position

(A) EXIT Button Touching the screen in the red area labeled "EXIT" exits the Main Menu Screen – Straight Line Welding and selects the Start Screen – see 5.10.1 ORBITAL – Start Screen

(B) SETTINGS Button Touching the screen in the green area labeled "SETTINGS" selects the Settings Screen – see 5.10.16 ORBITAL – Straight Line Welding – Settings Screen

(C) GAS TEST Button Touching the screen in the magenta area labeled ">" performs a gas test.

5.10.15 ORBITAL – Straight Line Welding – Main Menu Screen – Test Mode

No. Function

(1) MEST MODE for testing the actual parameters without arc, without wire and AVC = OFF


Page 48 of 82

5.10.16 ORBITAL – Straight Line Welding – Settings Screen

No. Function

(1) WELDING SETTINGS Display displays the welding settings (left) and the corresponding value as well as the range (min - max.) (right). The set value can be adjusted by touching the screen in the area outlined in green: - EVENT 1: AEA (automatic torch height adjustment) - EVENT 2: PRE-GAS (gas pre-flow time) - EVENT 3: UPSLOPE (arc upslope time) - EVENT 4: WIRE DELAY (wire delay) - EVENT 5: TRAVEL DELAY (welding delay) - EVENT 6: DOWNSLOPE (arc downslope time) - EVENT 7: WIRE TRAILING (wire feed downslope time) - EVENT 8: TORCH LIFT (burner lift at the end of the welding process)

(2) TRACTOR SETTINGS Display displays the tractor settings: - AVC: Select AVC by touching the screen in the area labeled as “ON/OFF”. Area turns green for “ON” (AVC on) and red for “OFF” (AVC off). Enter AVC Settings Screen by touching the screen in the area labaled as “AVC SETTINGS”.

(A) SAVE Button Touching the screen in the green area labeled "SAVE" saves the settings and exits the Settings Screen – Straight Line Welding.


Page 49 of 82

5.10.17 ORBITAL – Emergency Stop Screen

No. Function

(1) EMERGENCY STOP Display Pressing the EMERGENCY STOP button on the supplied manual control box puts the system in EMERGENCY STOP mode. All axis movements are slowed down by a safety stop. The arc and wire feed are switched off in a controlled manner.

(A) RESET Button Touching the screen in the green area labeled "RESET" resets the emergency stop mode and exits the Emerengy Stop Screen.


Page 50 of 82

5.10.18 ORBITAL – Surge Protection Screen

- Change surge or call the supplier

- See 8.1 Troubleshooting


Page 51 of 82

5.10.19 ORBITAL – End Switch Screen

No. Function

(1) END SWITCH Display displays the end switches (left) and the corresponding status (right): END: UP (End switch top) END: DOWN (End switch down) END: LEFT (End switch left) END: RIGHT (End switch right)


Page 52 of 82

6. INSTALLATION AND COMMISSIONING

General information

The standard configuration consists of the following system components:

- Weld head

- Wire feeder

- Power source

- Control cabinet

- Remote pendant

- Welding torch

NOTE! TIP TIG – Orbital is shipped from the factory completely assembled and lubricated.

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)!

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


Page 53 of 82

In operation

Temperature range of the ambient air:

- -25 °C to +45 °C

Relative air humidity:

- Up to 50% at 45 °C

- Up to 90% at 30 °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 30 °C

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!

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 Fitting the ring rail to the workpiece/pipe

General information

The ring rail is fitted to the workpiece using spacer plates and spacers.


Page 54 of 82

Fitting the ring rail to the workpiece/pipe

NOTE! Spacer plates are provided with the ring rail.

1) Rough distance adjustment with spacer plates

2) Fine distance adjustment with the build in thread/spacers

3) Tighten the quick clamps with an allen key 6mm

CAUTION

• Make sure that the distance is set correctly

• Make sure that the ring isn’t too lose or too tight

• Make sure that the ring can‘t move on the workpiece/pipe

If this is not avoided, it could result in minor or moderate injury and may damage the equipment.


Page 55 of 82

6.3 Coupling the weld head to the ring rail

Coupling the weld head to the ring rail

1) Mount the weld head to the ring rail.


Page 56 of 82

2) Close the guide lever to fix the weld ehad on the ring rail.

3) Secure the lever.


5) Close the coupling lever to connect the gear with the toothwork.


7) Connect the cut-off unit to the control cabinet with the provided motor cable.

6.4 Connecting the Control Cabinet

Connecting the Control Cabinet

CAUTION

Heavy object

Can cause muscle strain or back injury. Use lifting aids and proper lifting techniques when

moving.

WARNING

Make sure that the two safety installations will be always locked.

If this not avoided, could result in death or serious injury and my damage the equipment.


Page 57 of 82

1) Connect the power source

2) Connect the wire feeder

3) Connect straight rail end switches (option)

4) Connect to mains (110 – 240 VAC, 50/60Hz)

5) Connect the provided remote pendant

6) Connect the provided motor cable

7) Switch on


Page 58 of 82

6.5 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 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.

6.5.1 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:

WARNING

An 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 0-position

• the device is unplugged from the mains

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!


Page 59 of 82

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.

6.5.2 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

6.5.3 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

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.


Page 60 of 82

6.5.4 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.

6.6 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:

• this document



Page 61 of 82

6.6.1 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).

6.6.2 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





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.


Page 62 of 82

6.6.3 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 earthedparts, such as

the housing, etc.


Page 63 of 82

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.


Page 64 of 82

6.6.4 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 earthedparts, such as

the housing, etc.


Page 65 of 82

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.

CAUTION

This welding system is designed and build for ORBITAL-welding. Manual welding isn‘t possible

with this welding machine.

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


Page 66 of 82

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



documents:




Page 67 of 82

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



Page 68 of 82

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.


Page 69 of 82

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



documents:




Page 70 of 82

7.4 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)

WARNING



documents:



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 0-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.).


Page 71 of 82

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 - Frequency - Balance

4. Open the gas cylinder valve

5. Set the shielding gas flow rate

6. Start welding (ignite the arc)


Page 72 of 82

7.5 Start Welding

Welding

1) Make sure that everything is connected and running

2) Press the TRACKTOR “positive/clockwise movement” button or TRACKTOR “negative/counterclockwise movement” button on the remote rontrol to move the weld head on the ring rail

3) Press the joystick on the remote rontrol to move the welding torch on the weld head

4) Press the WIRE FEED IN button until the wire is in the right position

5) Press the START button on the remote control to start the welding process


Page 73 of 82

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:

• this document


WARNING





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


Page 74 of 82

Troubleshooting-Checklist

Motor Terminal Error

Start Screen shows an Error for the Motor Terminals

- Contact the supplier

Surge Protection Error

Start Screen shows an Error for the Surge Protection

- Change surge

- Contact the supplier

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


Page 75 of 82

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

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


Page 76 of 82

Unstable arc

Unsuitable or worn welding torch equipment

- Adjust contact tip to wire diameter and -material and replace if necessary

- Adjust wire guide to material in use, blow through and replace if necessary

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 6.6.4 Spool brake setting

- Check settings and correct if necessary

Setting pressure units > see chapter 6.6.3 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

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


Page 77 of 82

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


WARNING


• turn the power source mains switch to the "0" position



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


Page 78 of 82

9. TECHNICAL DATA

Power Source / Hot wire

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)

Hot wire

Hot wire current setting range 60 A to120 A

Max. hot wire voltage 10,5 V


Page 79 of 82

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%)

Wire feeder

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



Page 80 of 82

Cooling Unit

Refrigerant / Weight R513a / 0,25 kg

Pressures

PT ref.

PT wat.

PS HP

PS LP

PS wat.

9 bar

0 – 6 bar

22 bar

18 bar

0 – 6 bar

Temperature range +5 °C to +42 °C

Mains voltage 230 V/N/PE

Frequency 50 Hz

Operating current 6 A

Start-up current 10 A

Protection classification IP 33

Tank capacity 6 Liter

Weight 55 kg 121,25 lb.

Control Cabinet

Mains voltage 100 – 250 VAC

Frequency 50/60 Hz

Mains fuse 16 A

Operating voltage 24 and 48 VDC

Insulation class / protection classification F/IP 23

Ambient temperature –25 °C to +45 °C

Safety identification EAC/S/CE



Page 81 of 82

10. APPENDIX

10.1 Wiring Diagram

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.

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

Date post:	01-Nov-2020
Category:	Documents
Upload:	others
View:	3 times
Download:	0 times

TIP TIG - ORBITAL Operating Manual · TIP TIG - ORBITAL, OPERATING MANUAL Page 2 of 82 INTRODUCTION...

Documents