REHM TIGER 180 AC/DC ULTRA Operating Instructions Manual Download

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Circuit diagram

Legend to the circuit diagram

Identifier

Name

Main board

Operating unit

CAN-module

Power supply

AC control

HF ignition device

HF interference suppression

Operation film

Water cooling device

PFC switch

Primary switch

Secondary rectifier

AC switch

Primary rectifier

Gas valve

Fan

Main switch

Power transformer

Ignition transformer

PFC choke

Torch & remote control socket

iSystem socket

Summary of Contents for TIGER 180 AC/DC ULTRA

Page 1: ...GB OPERATING INSTRUCTIONS TIG inert gas welding units TIGER 180 DC AC DC ULTRA HIGH TIGER 230 DC AC DC ULTRA HIGH ...

Page 2: ... 20 e mail rehm rehm online de Internet http www rehm online de Doc No 730 2300 Date of issue 28 04 2016 Rehm GmbH u Co KG Uhingen Germany 2016 The content of this description is the property of Rehm GmbH u Co KG The copying and distribution of this document use and communication of its contents are strictly prohibited unless expressly authorized Offenders are liable to damages All rights reserved...

Page 3: ...ing parameters 19 4 6 1 Setting the welding parameters 19 4 6 2 Gas pre flow time 19 4 6 3 Ignition energy Iz 19 4 6 4 Starting current Is 20 4 6 5 Current slope up time tu 20 4 6 6 Welding current I1 20 4 6 7 I1 Pulse time t1 20 4 6 8 Welding current I2 22 4 6 9 I2 Pulse time t2 22 4 6 10 Current slope down time td 22 4 6 11 End crater current le 23 4 6 12 Gas post flow time 23 4 6 13 TIG spot we...

Page 4: ...on 38 5 2 Working under increased electrical hazard 38 5 3 Placement and transportation of the welding unit 39 5 4 Connecting the welding unit 39 5 5 Cooling the welding unit 39 5 6 Guidelines for working with welding current sources 40 5 7 Connecting the welding leads and the torch 40 5 8 Connection of external components 40 6 Operation 41 6 1 Safety information 41 6 2 Electrical hazard 41 6 3 In...

Page 5: ...welding systems are manufactured using only parts that comply with strict REHM quality demands The TIGER welding machines were designed and developed according to the generally recognized safety regulations All of the relevant statutory provisions have been complied with and certified with the declaration of conformity and the CE mark REHM welding systems are manufactured in Germany and carry the ...

Page 6: ...Introduction 6 1 2 General description Fig 1 TIGER Fig 2 TIGER with integrated Water cooling ...

Page 7: ...elding machines may be used only for TIG or electrode welding as intended REHM welding devices are designed for welding various different metallic materials such as unalloyed and alloyed steels stainless steels copper titanium and aluminium Also observe the special rules that apply to your applications REHM welding machines are designed for use in hand held and machine guided operation REHM weldin...

Page 8: ...use is considered unintended use The consequences of unintended use rests with the operator 1 3 Symbols used Enumerations proceeded by a bullet point General enumerations Enumerations proceeded by a square Work or maintenance steps that must be performed in the order listed Section 2 2 Warning symbols on the system Cross reference Here to Section 2 2 Warning symbols on the system warning symbols o...

Page 9: ...eded Warning of a potentially dangerous situation Death or serious injury may result if the warning is not heeded Caution warns of a potentially harmful situation Slight or minor injuries or property damage may result if the warning is not heeded Important Notice of a potentially harmful situation The product or an object in the vicinity may be damaged if the warning is not heeded Materials that a...

Page 10: ... welding and cutting contained therein or the corresponding national regulations must be observed Also observe the safety information signs on the factory floor of the operator REHM welding machines are except when this is expressly stated in writing by REHM only for sale to commercial industrial users and are only intended to be used by these TIGER TIG inert gas welding systems may only be used a...

Page 11: ... trained and instructed in the use and maintenance of welding equipment Only qualified assigned and trained personnel may work on and with the system These operating instructions contain important information on how this unit can be operated safely properly and economically A copy of the operating instructions must be constantly at hand in a suitable place at the site of use of the system Before u...

Page 12: ...3 Unit description TIGER without water cooling Front view Rear view 1 2 3 4 5 6 7 8 9 10 11 12 13 TIGER with integrated water cooling Front view Rear view 1 2 3 4 14 15 5 6 7 16 17 8 9 10 11 12 13 18 Fig 3 Unit description ...

Page 13: ...Torch remote control jack 6 Current socket positive TIG workpiece Electrode Workpiece or electrode holder 7 Cooling air inlet 8 Drawer storage for electrodes gas nozzles etc 9 Main switch On Off 10 Power cable 11 Shield gas feed connection shield gas cylinder 12 Remote control socket Optional 13 Cooling air outlet 14 Coolant inlet to coolant filling 15 Coolant level window 16 Connection coolant re...

Page 14: ...Function description 14 4 Function description 4 1 Overview of the operating panel Ultra AC DC Ultra DC High AC DC High DC Fig 4 Overview of the operating panel ...

Page 15: ...perating and temperature displays 2 Remote control display 3 Special parameter button 4 Welding parameters Gas pre flow time Iz Ignition power Is Starting current tu Slope up time I1 Welding current I1 t1 I1 Pulse time t1 I2 Welding current I2 t2 I2 Pulse time t2 tp Spot time td Slope down time Ie End crater current Gas post flow time AC balance AC frequency 5 Digital display 3 digit ...

Page 16: ...ton process TIG welding Electrode welding Electrode booster function 10 Operating mode button 2 cycle 4 cycle Spot 11 Ignition button HF on HF off 12 Units A Amp V Volt S Second Percent Hz Hertz kHz Kilohertz 13 Save program 14 Load program 15 Polarity button DC negative pole DC Alternating current AC DC positive pole DC Dual Wave 16 Pulse button without pulse convectional pulse high frequency pul...

Page 17: ...hed off at the mains switch When the unit is switched back on the parameters used during the last welding process are set An arc must be struck for any changes to the parameters to be saved when the unit is switched off Only the current parameters are shown for example if the TIG parameters when electrode welding are 2 4 cycle HF on off etc is suppressed This also applies to the parameters for fre...

Page 18: ...ir and stabilizing the arc It also forms slag which protects and forms the weld seam Electrode welding can be used to weld almost all metals Electrode welding is a common easily handled welding process When setting up for electrode welding care must be taken that no TIG torch is fitted If this is not the case the digital display shows the error number E021 see Section 7 3 4 5 3 Electrode BOOSTER f...

Page 19: ...e period of time after activating the torch trigger of torch 1 to start the welding process and the opening of the protective gas valve before the arc is ignited Then the arc is ignited in the protective gas mantle whereby the electrode and the workpiece is protected from burning out If the welding process is restarted during the gas post flow time then the gas pre flow time is automatically set t...

Page 20: ...lding the current slope up time begins immediately after the arc is ignited During 4 cycle welding the slope up time begins with the release of the torch trigger 1 with the start of current flow 4 6 6 Welding current I1 The settings for the welding current I1 4 is performed as described in Section 4 6 1 The setting range for welding current I1 depends on the selected mode and type of machine 4 6 7...

Page 21: ...G pulse welding enables the weld pool to be controlled better than with constant welding current High frequency puling with a pulse frequency of 10 Hz to 17 5 Hz The flow of the welding current is the same as conventional pulsing However the periods during which current I1 and I2 are active are always the same As this period is very small a description with pulse frequency is expedient and customa...

Page 22: ...ycle modes without pulsing The current I2 is set either by activating the setting option I2 or also very quickly and easily by actuating torch trigger 2 before the welding process When the torch trigger 2 is held down the current value I2 is shown in the digital display and can be altered by turning the push and rotate knob 4 6 9 I2 Pulse time t2 The setting is performed according to I1 pulse time...

Page 23: ...d seam at edges or for heat accumulation 4 6 12 Gas post flow time The setting for the gas post flow time 4 is performed as described in Section 4 6 1 The gas post flow time is the time after the arc extinguishes before the protective gas valve closes The post flow of protective gas protects the workpiece and the tungsten needle from attack by oxygen in the atmosphere until they have cooled down T...

Page 24: ... extends from 30 Hz to 300 Hz For example at a frequency of 200 Hz the polarity reversal at the output socket from plus to minus and back occurs every 5ms 0 005 seconds The welding current drops to zero with every polarity reversal ignites again in the opposite direction and increases to the set welding current The sinus form used in this processor controlled process results in a significant noise...

Page 25: ...ng the torch to be guided for a longer period without fatigue Sequence of the 4 cycle operating mode 1st cycle operate the torch trigger The protective gas solenoid valve opens After the set gas pre flow time has expired the arc is ignited The welding current is at the value set for the starting current 2nd cycle Release the torch trigger The welding current automatically reaches the preset values...

Page 26: ...ve gas solenoid valve opens After the set gas pre flow time has expired the arc is ignited The welding current automatically adjusts to the selected slope up time starting from the set starting current and rising to the preselected value for I1 2nd cycle Release the torch trigger The current reduces to the set end crater value at the preselected current slope down time and then automatically switc...

Page 27: ...t Punkten Brennertaster 1 Gasventil Schweißstrom Fig 10 TIG spot welding 1st cycle Operate the torch trigger The set gas pre flow time expires the gas valve opens After the gas pre flow time has expired the arc is ignited The welding current automatically adjusts to the starting current After expiration of the current slope up time the welding current reaches the preselected value I1 The set spot ...

Page 28: ...rational when set to RF On To ignite the arc the electrode is kept approx 3 5 mm above the workpiece By actuating the torch trigger the path is ionized by a high voltage pulse and arcing occurs Contactless ignition enables the prevention of tungsten inclusions in the welded seam When welding the HF ignition is automatically switched off after ignition 4 8 2 Welding without HF ignition When welding...

Page 29: ...nd negative polarity When TIG welding the torch is normally connected to the left output socket The use of alternating current enables the welding of aluminium and aluminium alloys 4 10 3 DC positive positive pole In TIG welding with direct current positive pole the plus pole is applied to the left output socket for the TIG torch In DC TIG welding the positive electrode is subject to a very high t...

Page 30: ...er current ignition energy etc for use by multiple people can be saved for each person and quickly duplicated One special feature of the TIGER welding system is the rapid loading and storing of 2 programs P1 6 and P2 7 4 11 1 Fast setting P1 and P2 Quick choice buttons The push buttons P1 6 and P2 7 enable the user to quickly load and save programs To load program 1 or program 2 briefly press butt...

Page 31: ...iefly pushing the Save 13 push button illuminates the indicator LED Pxx for saving the program Select the desired program number using the push and rotate knob 8 The program number is shown in the digital display 5 If a program number has already been assigned a P always appears before the number for example P34 A free program number is indicated with a before the number for example 35 or two dash...

Page 32: ...circuit voltage is connected to the torch or electrode holder Control lamp TEMPERATUR LED illuminates yellow 1 If the temperature limit is reached the LED illuminates yellow The power section is switched off and there is no output voltage as long as this LED remains yellow With TIG welding the gas post flow time runs when the power section is switched off Once the unit has cooled the LED goes out ...

Page 33: ...ess the Special Parameter push button 3 The desired special parameter SP1 to SP7 and CLr can be selected and activated by turning and pressing the push and rotate knob 8 The digital display flashes 5 The selected special parameter can be adjusted by again turning the push and rotate knob and accepted by pressing the push and rotate knob 8 To exit the special parameters press the Special Parameters...

Page 34: ...e cold wire unit APUS 20 C Special parameter SP3 AC waveform Setting of an AC waveform in the polarity Alternating Current AC 0 AC waveform Sinus Noise optimised 1 AC waveform Triangle Improved penetration compared with the Sinus waveform 2 AC waveform Rectangle Greatest possible arc stability and high penetration Special parameter SP4 I1 I2 switching 0 static operation BT2 0 I1 BT2 1 I2 1 Push to...

Page 35: ... torch is set to 1 Special parameter factory setting CLr When CLr is selected the digital display flashes All parameters are reset to the factory settings Programs 1 to 99 and the special parameters remain Welding parameters Factory settings Gas pre flow time 0 1 s Ignition current 50 Starting current 50 Slope up time 0 1 s Current I1 100 A Current I2 80 A Pulse time t1 0 3 s Pulse time t2 0 3 s S...

Page 36: ...ivation is possible from every welding parameter for example if gas post flow is selected 4 15 2 Setting the welding current I1 and I2 with the up down torch To do this the special parameter SP2 must be set to 1 see Section 4 14 Special parameters Using the up down torch the current I1 I2 can be controlled up or down before and during welding work The set value is shown in the digital display 5 Tu...

Page 37: ...HM participants 7531051 The foot activated remote controller TIGER 180 230 see Section 10 Accessories can be used to match the welding current to the welding task during the welding work using the foot pedal In doing so the current set at the machine is the current that is adjusted by actuating the pedal The foot actuated controller is connected to the remote operating socket on the front side of ...

Page 38: ...ctrical hazard IEC 874 EN 60974 1 TRBS 2131 and BGR 500 KAP 2 26 REHM TIG welding systems meet the regulations for working under increased electrical hazard in accordance with IEC 874 EN 60974 1 TRBS 2131 and BGR 500 KAP 2 26 For AC welding a safety unit is built into the electronic control When AC welding this ensures that the arc is always only ignited with DC voltage and the change to AC curren...

Page 39: ...not use the welding unit in the open in the rain or snow 5 4 Connecting the welding unit Only connect the REHM welding current source to the power supply in accordance with the applicable VDE regulations and also observe the regulations of the respective professional associations When connecting the unit observe the instructions concerning the power supply voltage and local mains fuse Automatic ci...

Page 40: ...lding unit via a quick coupling The torch trigger connector is inserted into the 19 pole socket Important To prevent unnecessary energy loss during welding ensure that all welding line connections are tightened and well insulated 5 8 Connection of external components The connection of external components is achieved via the standard 19 pole remote control socket on the front side of the TIGER REHM...

Page 41: ...nance works on the welding unit and their accessories may only be performed in agreement with the applicable VDE regulations and the regulations of the respective professional association Never make contact with live metal parts with the naked skin or wet clothing When welding always wear gloves and a welder s hood with an approved protective filter Ensure that everything that you must come into c...

Page 42: ...tective gas bottles from falling over Never transport protective gas bottles without a protective cap During welding work noise levels of over 70 dBA can occur depending on the process and the environment this can cause permanent hearing damage Persons who remain in the working area must if necessary wear suitable hearing protection 6 4 Fire protection Hot slag or sparks can start a fire if they c...

Page 43: ...duce the effectiveness and increase the risk of electrical shock and vagrant currents 6 8 Practical instructions for use The practical instructions for use listed below can only provide an overview of the uses for REHM TIG welding systems In the event of questions concerning special welding tasks materials protective gases or welding fixtures refer to topic specific publications or specialist reco...

Page 44: ...n Helium argon helium mixture or argon hydrogen mixture is used for special applications Igniting the arc becomes more difficult and the thermal input increases with an increasing portion of helium The quantity of protective gas required depends on the electrode diameter size of the gas nozzle welding current strength and the movement of air depending on the working place With a workpiece of 4 mm ...

Page 45: ...R systems as standard for contactless ignition of the welding arc The high voltage causes the path between the tungsten electrode and the workpiece to become so electrically ionised that the welding arc can jump the gap A higher oxide content in the electrode and a closer distance to the workpiece positively influence the ignition response With DC and AC welding the arc can be ignited by the insta...

Page 46: ...gital display instrument has no display and no LEDs illuminate Cause Remedy Mains power supply is missing possible mains fuse Check the mains voltage Mains cable of plug is defective Check Current slope up time current slope down time are at 0 0 and cannot be altered Cause Remedy Remote foot control is plugged in Times are controlled by the remote controller Unplug the remote controller Current sl...

Page 47: ...high voltage pulse Cause Remedy HF ignition is set to off Switch on the HF ignition No protective gas present Check Grounding cable poorly connected Check Electrode dirty Grind Electrode not suitable Change electrode Gas pre flow time too long Reduce gas pre flow time or wait until time expires High voltage flashover in the torch Change the torch Connection between the torch and the Connect correc...

Page 48: ...ease the negative share using balance Connection between the torch and the grounding cable reversed Connect correctly Electrode welding is set Set TIG welding System does not pulse Cause Remedy Pulse is not switched on Set pulse time T1 and or T2 Values for T1 and T2 are equal Change the values Arc breaks away on ignition Cause Remedy Ignition energy set too low Set the ignition energy or use thin...

Page 49: ...it is present on the welding socket when switching on Internal short circuit Eliminate the short circuit on the welding socket Service call 33 Reversing pole current or reversing pole power is too high Welding circuit inductance too high Change the torch and grounding cable run No loops and windings 34 Remote control connected to the torch socket Connected torch is not detected Use a Rehm torch De...

Page 50: ...on again B Fault message will go out automatically when the fault is eliminated C Fault message will go out when the fault is eliminated and the push and rotate knob 23 is actuated If the fault is still present the fault message will reappear in the digital display 22 after 2 seconds ...

Page 51: ...ly lines must be shut off and vented free of pressure The warning notices listed in Section 2 Safety must be observed The welding system and its components must be maintained in accordance with the requirements of the operating and maintenance instructions Insufficient or improper maintenance or repair may result in operating faults Periodic maintenance of the system is therefore essential No cons...

Page 52: ...t is used in a dusty environment the inside of the unit must be cleaned at regular intervals by blowing out or vacuuming The frequency of this cleaning depends on the respective conditions of use Only use clean dry air to blow out the unit or use a vacuum cleaner If maintenance or repair work is performed on this unit by persons who have not been trained and authorised to carry out the work by REH...

Page 53: ...cuit voltage 77 V 82 V 91 V 89 V Setting range I2 TIG 4 A 180 A 4 A 230 A 4 A 180 A 4 A 230 A Electrode 20 A 140 A 20 A 150 A 20 A 140 A 20 A 150 A Electrode booster 20 A 150 A 20 A 180 A 20 A 150 A 20 A 180 A Duty cycle ED at 40 C TIG 35 ED 225 A 225 A 40 ED 180 A 180 A 60 ED 160 A 180 A 160 A 180 A 100 ED 140 A 160 A 140 A 160 A Electrode 40 ED 180 A 180 A 60 ED 140 A 160 A 140 A 160 A 100 ED 13...

Page 54: ...x160x320 mm 480x160x320 mm 480x160x320 mm with water cooling 480x215x530 mm 480x215x530 mm 480x215x530 mm 480x215x530 mm Weight without coolant without water cooling 7 1 kg 7 5 kg 7 3 kg 7 9 kg with water cooling 15 6 kg 16 0 kg 15 8 kg 16 4 kg Standards 60974 1 60974 2 60974 9 60974 10 CE 60974 1 60974 2 60974 9 60974 10 CE 60974 1 60974 2 60974 9 60974 10 CE 60974 1 60974 2 60974 9 60974 10 CE W...

Page 55: ...up to an angle of 60 from the vertical The unit should be placed and operated outdoors in accordance with the protection class The device is not to be operated transported and stored in rain or snow 3 Insulation class Class of insulation materials used and their maximum continuous temperature F maximum permissible permanent temperature 155 4 Noise emission Idle and operating with a standard load a...

Page 56: ... 4m UD GRIP LITTLE HighFlex Leder 7631803 R TIG 150 19 8m UD GRIP LITTLE HighFlex Leder TIG torch with 19 pin connector for TIGER 180 230 Gas cooled to max 240A DC 7633400 R TIG 210 19 4m UD HighFlex Leder 7633401 R TIG 210 19 8m UD HighFlex Leder 7633133 AE 210 19 4m UD HighFlex Leder 7633134 AE 210 19 8m UD HighFlex Leder 7631850 R SR 26 19 4m UD HighFlex Leder 7631851 R SR 26 19 8m UD HighFlex ...

Page 57: ...r TIGER 180 230 Fitting cases 2600366 Fitting case for set plastic unequipped 2600355 Aluminium transport box 850x350x350mm LxWxH Coolant 1680075 Coolant RCL 5 litre 1680077 Coolant RCL 25 litre Adapter for accessories 3600615 Torch duo cable 19 pin 3600650 Torch adapter cable INVERTIG PRO to TIGER 180 230 3600628 Torch adapter cable TIGER 170 210 to TIGER 180 230 water cooled 3600629 Torch adapte...

Page 58: ...Circuit diagram 58 11 Circuit diagrams Circuit diagram TIGER 230 AC DC ...

Page 59: ...Circuit diagram 59 Circuit diagram TIGER 230 AC ...

Page 60: ...Circuit diagram 60 Circuit diagram TIGER 180 AC DC ...

Page 61: ...Circuit diagram 61 Circuit diagram TIGER 180 DC ...

Page 62: ...trol A6 HF ignition device A7 HF interference suppression A8 Operation film A9 Water cooling device B1 PFC switch B2 Primary switch B3 Secondary rectifier B4 AC switch B5 Primary rectifier G1 Gas valve M1 Fan M2 Fan S1 Main switch T1 Power transformer T2 Ignition transformer T3 PFC choke X1 Torch remote control socket X2 iSystem socket ...

Page 63: ...Circuit diagram 63 Circuit diagram TIGER water cooling unit ...

Page 64: ...lding 45 F Function description 14 G Gap bridging 21 I Ignition 45 Increased electrical hazard 38 Instructions for use 43 K Keeping of the operating instructions 11 L List of contents 3 M Maintenance intervals 51 Maintenance work 41 51 Manufacturer 2 O Occupational safety 10 Operating mode 25 Operation Checks before switching on 43 Out of position welding 21 ...

Page 65: ...er 2 Protective gas consumption 23 Protective gases 44 Pulsing 21 Purpose of the document 11 R Rod electrodes 45 S Safety Hazards of non compliance 10 Safety symbols 5 Special parameters 33 T Technical data 53 TIG welding torch 44 Tungsten Electrodes 43 Typographic distinctions 8 U Unit description 12 ...

Page 66: ...quirements of this directive and comply with the safety requirements for arc welding devices in accordance with the following product standards EN 60 974 1 2013 06 Arc welding equipment Part 1 Welding power source EN 60 974 2 2013 11 Arc welding equipment Part 2 Liquid cooling systems EN 60 974 3 2014 09 Arc welding equipment Part 3 Arc striking and stabilizing devices EN 60974 10 2008 09 Arc weld...

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Page 68: ...als Welding smoke extraction fans Welding rotary tables and positioners Technical welding consultation Torch repair Machine Service Please contact your local distributor REHM WELDING TECHNOLOGY German Engineering and Production at its best Development construction and production all under one roof in our factory in Uhingen Thanks to this central organisation and our forward thinking policies new d...

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