TEAMWELDER TIG 180 AC/DC puls Operating Instructions Manual Download

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Operating instructions

Welding machine

TIG 180 AC/DC puls

299-020200-TWD01

14.07.2017

Summary of Contents for TIG 180 AC/DC puls

Page 1: ...Operating instructions EN Welding machine TIG 180 AC DC puls 299 020200 TWD01 14 07 2017 ...

Page 2: ... on 49 2623 9276400 A list of authorised sales partners can be found at www teamwelder 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 whe...

Page 3: ...the length of the carrying strap 19 5 1 5 Welding torch cooling system 20 5 1 5 1 Welding torch cooling unit connection 20 5 1 6 Notes on the installation of welding current leads 21 5 1 6 1 Stray welding currents 22 5 1 7 Mains connection 23 5 1 7 1 Mains configuration 23 5 2 Welding data display 23 5 3 TIG welding 24 5 3 1 Welding torch and workpiece line connection 24 5 3 1 1 Connection assignm...

Page 4: ...9 Machine configuration menu 43 5 9 1 Selecting changing and saving parameters 43 6 Maintenance care and disposal 46 6 1 General 46 6 2 Cleaning 46 6 2 1 Dirt filter 46 6 3 Maintenance work intervals 47 6 3 1 Daily maintenance tasks 47 6 3 2 Monthly maintenance tasks 47 6 3 3 Annual test inspection and testing during operation 48 6 4 Disposing of equipment 48 6 4 1 Manufacturer s declaration to th...

Page 5: ...served to prevent serious and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The hazard is also highlighted using a symbol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading with a general warn...

Page 6: ... off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal light flashes green Exit menu Signal light lights up in red Time representation e g wait 4 s activate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do not...

Page 7: ...fety instructions The illustration shows a general example of a welding system Figure 2 1 Item Documentation A 1 Power source A 2 Remote control A 3 Welding torch A Complete documentation 2 4 Safety instructions WARNING Risk of accidents due to non compliance with the safety instructions Non compliance with the safety instructions can be fatal Carefully read the safety instructions in this manual ...

Page 8: ... cause the welding voltages to be combined which is not permitted Risk of injury due to improper clothing During arc welding radiation heat and voltage are sources of risk that cannot be avoided The user has to be equipped with the complete personal protective equipment at all times The protective equipment has to include Respiratory protection against hazardous substances and mixtures fumes and v...

Page 9: ...or to starting to weld Only further process workpieces after they have cooled down Do not allow them to contact any flammable materials CAUTION Smoke and gases Smoke and gases can lead to breathing difficulties and poisoning In addition solvent vapour chlorinated hydrocarbon may be converted into poisonous phosgene due to the ultraviolet radiation of the arc Ensure that there is sufficient fresh a...

Page 10: ...ied out Recommendations for reducing interference emission Mains connection e g additional mains filter or shielding with a metal tube Maintenance of the arc welding system Welding leads should be as short as possible and run closely together along the ground Potential equalization Earthing of the workpiece In cases where it is not possible to earth the workpiece directly it should be connected by...

Page 11: ...tions concerning the use of compressed air Do not attach any element to the shielding gas cylinder valve Prevent the shielding gas cylinder from heating up CAUTION Risk of accidents due to supply lines During transport attached supply lines mains leads control cables etc can cause risks e g by causing connected machines to tip over and injure persons Disconnect all supply lines before transport Ri...

Page 12: ...4 07 2017 Protective dust caps protect the connection sockets and therefore the machine against dirt and damage The protective dust cap must be fitted if there is no accessory component being operated on that connection The cap must be replaced if faulty or if lost ...

Page 13: ...tive 2006 95 EC EC EMC Directive 2004 108 EC In case of unauthorised changes improper repairs non compliance with specified deadlines for Arc Welding Equipment Inspection and Testing during Operation and or prohibited modifications which have not been explicitly authorised by TEAMWELDER this declaration shall be voided An original document of the specific declaration of conformity is included with...

Page 14: ... torch control cable see 5 3 1 1 chapter 4 Connection socket welding current MMA Electrode holder or workpiece lead connection TIG Connection for workpiece lead 5 Cooling air inlet 6 Connection socket welding current TIG TIG welding torch connection MMA Electrode holder or workpiece lead connection 7 G connecting nipple welding current Shielding gas connection with yellow insulating cap for TIG we...

Page 15: ...d 2 Ignition type changeover switch see 5 3 6 chapter Liftarc contact ignition HF ignition 3 Main switch machine on off 4 Cooling air outlet 5 Machine feet 6 Mains connection cable see 5 1 7 chapter 7 G connecting nipple Shielding gas connection on the pressure regulator 8 5 pole connection socket Cooling unit voltage supply 9 Connection socket 19 pole Remote control connection ...

Page 16: ...d the corresponding values see 5 2 chapter 2 Error status indicators Collective interference signal light Water deficiency signal light welding torch cooling Excess temperature signal light S safety sign signal light 3 AMP Main current signal light Imin to Imax 1 A increments 4 AMP Secondary current TIG 5 Welding parameter setting rotary dial Setting currents times and parameters 6 Select welding ...

Page 17: ...nating current welding alternating current forms see 5 3 4 chapter 10 Pulsed welding push button TIG pulsed welding see 5 3 7 4 chapter MMA pulsed welding see 5 4 5 chapter 11 Operating mode power saving mode push button Non latched Latched Press for 2 s to put the machine into power saving mode To reactivate activate one of the operating elements see 5 8 chapter 12 Welding procedure push button M...

Page 18: ...r lifted using a crane 5 1 1 Ambient conditions T he 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 g...

Page 19: ... these connections and leads can heat up and cause burns when touched Check welding current connections on a daily basis and lock by turning to the right when necessary Clean workpiece connection thoroughly and secure properly Do not use structural parts of the workpiece as welding current return lead 5 1 4 Adjusting the length of the carrying strap To demonstrate adjustment lengthening the strap ...

Page 20: ...bol Description 0 1 8 pole connection socket Cooling unit control lead 2 5 pole connection socket Cooling unit voltage supply 3 Cooling module Insert and lock the 8 pole control lead plug on the cooling unit into the 8 pole connection socket on the welding machine Insert and lock the 5 pole supply plug on the cooling unit into the 5 pole connection socket on the welding machine ...

Page 21: ...urces with HF igniter TIG for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences Always keep leads as short as possible For optimum welding results max 30 m welding lead intermediate hose package torch lead Figure 5 3 Use an individual welding lead to the workpiece for each w...

Page 22: ...o fire Check that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing transport vehicles and crane frames so they are insulated Do not place any other electronic devices such as drills or angle grinders on the power source transport vehicle or crane frames unless they a...

Page 23: ...ctions The network created must be suitable for operating machines according to protection class I 5 1 7 1 Mains configuration The machine may only be connected to a one phase system with two conductors and an earthed neutral conductor Figure 5 7 Legend Item Designation Colour code L Outer conductor brown N Neutral conductor blue PE Protective conductor green yellow Insert mains plug of the switch...

Page 24: ...r welding current Workpiece lead connection Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right Remove yellow protective cap on G connecting nipple Screw welding torch shielding gas connection tightly onto the G connection nipple Plug the welding torch control cable plug into the welding torch control cable connection soc...

Page 25: ...stening elements within the upper half of the shielding gas cylinder The fastening elements must tightly enclose the shielding gas cylinder An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being destroyed Always re fit the yellow...

Page 26: ...e valve to be gas tight Screw gas hose connection crown nut onto the output side of the pressure regulator Install gas hose with G1 4 crown nut at the correct welding machine connection so that it is gas tight 5 3 3 Welding task selection The following welding task selection is an example of use In general the selection process always has the same sequence Signal lights LED will show the selected ...

Page 27: ... the correct durations balance for positive phase cleaning effect balled end size and negative phase penetration depth by setting the AC balance The default zero setting balance setting is 65 referring to the duration of the negative half wave Figure 5 12 5 3 5 Gas test setting the shielding gas volume CAUTION Electric shocks When setting the shielding gas quantity high voltage ignition pulses or ...

Page 28: ...c is ignited on contact with the workpiece a Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger liftarc current flowing regardless of the main current set b Incline the torch over the torch gas nozzle to produce a gap of approx 2 3 mm between the electrode tip and the workpiece The arc ignites and the welding current is increased dependin...

Page 29: ...tton is used to select the welding parameters depending on the welding process and operating mode used 2 Welding parameter setting rotary dial Setting currents times and parameters 5 3 7 1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 I Current t Time Gas pre flows Istart Ignition current tUp Up slope time tP Spot time AMP Main current minimum to maximum curre...

Page 30: ...e main current AMP Switching from main current AMP to secondary current AMP Press torch trigger 2 or Tap torch trigger 1 2nd cycle Release torch trigger 1 The main current falls in the set down slope time to the end crater current Iend minimum current If the 1st torch trigger is pressed during the down slope time the welding current returns to the main current AMP set The main current reaches the ...

Page 31: ...eases with the set up slope time to the main current AMP Switching from main current AMP to secondary current AMP Press torch trigger 2 or Tap torch trigger 1 Step 3 Press torch trigger 1 The main current drops with the set down slope time to the end crater current Iend minimum current Step 4 Release torch trigger 1 the arc extinguishes The set gas post flow time begins Immediate termination of th...

Page 32: ...e value instead to ensure that the average value of the welding current AMP is maintained For average value pulsing the current is the secondary current only activated with the torch trigger Figure 5 18 AMP main current average value e g 100 A Ipuls pulse current x AMP e g 140 x 100 A 140 A IPP pulse pause current Tpuls duration of one pulse cycle 1 e g 1 100 Hz 10 ms balance Selection Figure 5 19...

Page 33: ... 14 are available to the user Modes 11 to 14 feature the same functionality as 1 to 4 but without the tapping function see 5 3 9 1 chapter for the secondary current The functionality of the individual modes can be found in the corresponding torch type tables The torch modes are set using the torch configuration parameters in the machine configuration menu torch mode see 5 9 chapter Only the modes ...

Page 34: ...ailable when using up down torches in modes 4 and 14 By tapping the corresponding torch trigger the welding current can be determined in an adjustable jump range Each tap will cause the welding current to jump up or down by the defined value EXIT 4s Figure 5 20 Display Setting selection Current jump 1 A 10 A ...

Page 35: ...Welding current on off 1 ex works Secondary current latched operation Standard torch with two torch triggers Figure Operating elements Explanation of symbols BRT1 torch trigger 1 BRT2 torch trigger 2 Functions Mode Operating elements Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 3 Secondary current tapping fun...

Page 36: ...h trigger 2 Functions Mode Operating elements Welding current on off 1 ex works Secondary current Secondary current tapping function 1 latched operating mode Welding current on off 2 Secondary current tapping function1 Up function2 Down function2 Welding current on off 3 Secondary current tapping function 1 latched operating mode Up function2 Down function2 1 see 5 3 9 1 chapter 2 see 5 3 9 3 chap...

Page 37: ...ER 3 s EXIT 3 s Figure 5 21 Display Setting selection Gas pre flow time Ignition current Setting range in percent depending on main current Setting range absolute Imin to Imax Upslope time to main current End crater current Setting range in percent depending on main current Setting range absolute Imin to Imax Diameter of tungsten electrode ignition optimisation 1 mm to 4 mm or larger 0 1 mm increm...

Page 38: ...ection nipple protects against electrical voltage and dirt Figure 5 22 Item Symbol Description 0 1 Electrode holder 2 Connection socket welding current Workpiece lead or electrode holder connection 3 Workpiece 4 Connection socket for welding current Electrode holder or workpiece lead connection 5 Connecting nipple G shielding gas connection Polarity depends on the instructions from the electrode m...

Page 39: ...ction improves the arc striking After striking the stick electrode the arc ignites at the increased hot start current and decreases to the set main current once the hot start time has elapsed For parameter setting see 5 4 6 chapter A Hot start current B Hot start time C Main current I Current t Time Figure 5 24 5 4 4 Antistick The Antistick feature prevents the electrode from annealing Should the ...

Page 40: ...lse pause current IPP requires no setting This value is calculated by the machine control so that the welding current average value AMP is maintained at all times Figure 5 26 AMP Main current e g 100 A IPL Pulse current IP1 x AMP e g 170 x 100 A 170 A IPP Pulse pause current Tpuls Duration of one pulse cycle 1 FrE e g 1 1 Hz 1 s bAL Balance For parameter setting see 5 4 6 chapter 5 4 6 Expert menu...

Page 41: ...ted main current on the welding machine 5 6 Interfaces for automation Damage to the machine due to improper connection Unsuitable control leads or incorrect connection of input and output signals can cause damage to the machine Only use shielded control leads If the machine is to be operated with control voltages connection via suitable isolation amplifiers is required To control the main or secon...

Page 42: ... sequence can only be viewed but not changed Welding procedure and welding current polarity cannot be changed The parameters for the access block are configured in the machine configuration menu see 5 9 chapter Enabling the access block Assign the access code for the access block Select parameter and select a number code 0 999 Enable access block Set parameter to function Disabling the access bloc...

Page 43: ...Machine configuration menu Basic machine settings are defined in the machine configuration menu 5 9 1 Selecting changing and saving parameters NAVIGATION ENTER B B A A A B 3 s B A B B B B 3 s B B B B B B B B EXIT B B B B B B B B B B B B B B B B A A A A A A A A A A A A 3 s Figure 5 29 ...

Page 44: ... Example Main current setting to 120A and secondary current to 50 results in an absolute secondary current of 60A Welding current display absolute Absolute representation of all welding currents in amperes TIG antistick see 5 3 8 chapter function active factory setting function inactive Time based power saving mode see 5 8 chapter Time to activation of the power saving mode in case of inactivity S...

Page 45: ...ersion display example 034 version 34 Access control access code Setting 000 to 999 000 ex works Error Error message after entering an incorrect machine code New machine code Machine code entered correctly Prompt for entering the new machine code Machine code Querying the three digit machine code 000 to 999 user input Exit the menu Exit Numerical value adjustable ...

Page 46: ...nder warranty is void In all service matters always consult the dealer who supplied the machine Return deliveries of defective equipment subject to warranty may only be made through your dealer When replacing parts use only original spare parts When ordering spare parts please quote the machine type serial number and item number of the machine as well as the type designation and item number of the...

Page 47: ...re spool Wheels and their securing elements Transport elements strap lifting lugs handle Other general condition Functional test Operating message safety and adjustment devices Functional test Welding current cables check that they are fitted correctly and secured Gas tubes and their switching equipment solenoid valve Gas cylinder securing elements Check correct mounting of the wire spool Check th...

Page 48: ...and Electronic Equipment used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a waste container on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law governing the d...

Page 49: ...ight is illuminated after switching on No welding power Phase failure check mains connection fuses Connection problems Make control lead connections and check that they are fitted correctly Loose welding current connections Tighten power connections on the torch and or on the workpiece Tighten contact tip correctly No arc ignition Incorrect ignition type setting Ignition type Select HF start Depen...

Page 50: ...ttings and correct if necessary 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 aluminium applications and high alloy steels Unsuitable or worn welding torch equipment Check size of gas nozzle and replace if necessary Condens...

Page 51: ...nt Err 4 see Err 3 see Err 3 Err 5 see Err 3 see Err 3 Err 6 Balancing error in voltage recording Switch machine off place the torch on an insulated surface and switch on again If the fault persists inform the service department Err 7 Balancing error in current recording Switch machine off place the torch on an insulated surface and switch on again If the fault persists inform the service departme...

Page 52: ...lding parameters that are stored will be replaced by the factory settings RESET l 0 Figure 7 1 Display Setting selection Input confirmation User entries are applied release button s 7 4 Display machine control software version The query of the software versions only serves to inform the authorised service staff It is available in the machine configuration menu see 5 9 chapter ...

Page 53: ... voltage DC 43 V Mains voltage tolerances 1 x 230 V 40 to 15 Frequency 50 60 Hz Mains fuse 1 x 16 A Mains connection lead H07RN F3G2 5 Max connected load 5 3 kVA 6 0 kVA Recommended generator rating 8 1 kVA cos efficiency 0 99 85 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine cooling torch cooling Fan gas Noise level 70 dB A Workpiece lead 35 mm2 EMC cl...

Page 54: ...Accessories Internet 54 299 020200 TWD01 14 07 2017 9 Accessories 9 1 Internet For the accessories available for your product go to www teamwelder com Figure 9 1 ...

Page 55: ... 20 0 s Secondary current AMP 50 1 200 End current 30 1 200 Diameter of tungsten electrode ignition optimisation 2 4 1 4 mm AC balance 10 30 30 AC frequency 80 50 200 Hz Pulse balance 50 1 99 Pulse frequency 2 8 0 2 5 0 Hz Pulse current 140 1 200 MMA Hot start current 150 1 150 Hot start time 0 1 0 0 5 0 s Pulse balance 30 1 99 Pulse frequency 1 2 0 2 50 Hz Pulse current 142 1 200 Basic parameters...

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