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TIP TIG TIG 500 COMPACT, Operating Manual

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TIP TIG TIG 500 COMPACT Operating Manual Download Page 58

 

 

 
 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 

Summary of Contents for TIG 500 COMPACT

Page 1: ...TIP TIG TIG 500 COMPACT Operating Manual Version 1 0 Revision 0 TIP TIG TIG 500 COMPACT OPERATING MANUAL...

Page 2: ...iarize 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 Pl...

Page 3: ...2 Front connection 14 5 3 Main switch with fuses 15 5 4 Connection Socket Automation 15 5 5 Control Panel Power Source 17 5 6 Control Panel Wire Feeder D24B2M1 6 19 5 7 Control Panel Wire Feeder Vers...

Page 4: ...TIP TIG TIG 500 COMPACT OPERATING MANUAL Page 4 of 58 10 2 Wire Feeder 52 10 3 Wiring Diagram 56...

Page 5: ...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 lo...

Page 6: ...for Arc Welding Equipment Inspection and Testing during Operation and or prohibited modifications which have not been explicitly authorised by EWM this declaration shall be voided An original document...

Page 7: ...r 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 swi...

Page 8: ...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 suitabl...

Page 9: ...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...

Page 10: ...e wire feeder is also suitable for long hose packages 4 2 Crane transport The TIP TIG FOCUS can be transported by crane at the lifting eyes The maximum load bearing capacity of the lifting eyes is 150...

Page 11: ...sion 2 0 4 Front connection See 5 2 Front connection 5 Wire electrode connection for connecting the welding torch wire feed 6 Transport handle 7 Hotwire indicator lamps Temperature fault indicator dow...

Page 12: ...g gas for connecting the shielding gas G1 4 RH on the pressure regulator 5 Main switch with fuses See 5 3 Main switch with fuses 6 Mains connection cable with plug 7 Securing elements for shielding ga...

Page 13: ...G 500 COMPACT operating elements in the machine No Description 1 Four roll wire drive 2 Clamping levers for setting the contact pressure of the feed rollers 3 Wires pool holder with brake for holding...

Page 14: ...3 Connecting nipple coolant return red for connecting coolant return G3 8 LH from the welding torch hose package 4 Connecting nipple shielding gas for connecting shielding gas G1 4 RH from the welding...

Page 15: ...ol 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...

Page 16: ...2 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 T...

Page 17: ...tor 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 l...

Page 18: ...own 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...

Page 19: ...ion button for selecting the parameters listed below 5 3 Adjusting button for negative adjustment of the selected parameter 5 4 Adjusting button for positive adjustment of the selected parameter 5 5 P...

Page 20: ...y Control The value is as shown as factor For all applications use 230 17 Hz Start Delay The value is as shown as factor optional Useful for track weld Wire Retract The value is as shown as factor opt...

Page 21: ...n switching menu up down 2 Parameter range indicator shows min and max value of the selected parameter 3 Menu parameter indicator shows which parameter is selected Wire speed Frequency Weld amps 4 Par...

Page 22: ...knob to adjust the selected parameter parameter positive adjustment rotate clockwise parameter negative adjustment rotate counter clockwise 12 I Mode button for selecting the desired mode 5 13 II Sett...

Page 23: ...offset Automation on off Remote control on off Up Down Wire Amps Language EN DE CN Invert colors on off 3 A Menu parameter up button switching menu line up 4 B Menu parameter down button switching men...

Page 24: ...xample Factor 100 6 74 m min or 265 35 IPM For more information please go to Appendix 9 2 2 or visit https www tiptig com english support Modes 2 Step 2 Stroke mode mostly used for tack welding 4 Step...

Page 25: ...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 o...

Page 26: ...t 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...

Page 27: ...itial 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 thi...

Page 28: ...unding earthing cable in and latch it 3 Use the other end of the grounding earthing cable to establish a connection to the workpiece 6 2 4 Connecting the welding torch 1 Move the mains switch to the O...

Page 29: ...n 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...

Page 30: ...to 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 th...

Page 31: ...rting 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 e...

Page 32: ...rs 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 a...

Page 33: ...ON 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 workpiec...

Page 34: ...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 weldi...

Page 35: ...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 t...

Page 36: ...ding 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 shieldin...

Page 37: ...ke 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...

Page 38: ...de 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...

Page 39: ...a display 3 Start welding WARNING Operating the equipment incorrectly can cause serious injury and damage Do not use the functions described until you have thoroughly read and understood the following...

Page 40: ...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...

Page 41: ...TIP TIG TIG 500 COMPACT OPERATING MANUAL Page 41 of 58 Frequency Balance 4 Open the gas cylinder valve 5 Set the shielding gas flow rate 6 Start welding ignite the arc...

Page 42: ...s for the system components especially the safety rules WARNING An electric shock can be fatal Before starting the work described below turn the power source mains switch to the 0 position disconnect...

Page 43: ...h 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...

Page 44: ...oy 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 ri...

Page 45: ...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 necess...

Page 46: ...g 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 Unsuitable or worn welding torch...

Page 47: ...cordance 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 tra...

Page 48: ...tting 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 1...

Page 49: ...d generator rating 3 4 kVA cosj efficiency 0 99 86 Insulation class protection classification H IP 23 Ambient temperature 25 C to 40 C Machine cooling Fan Hot wire current welding lead 25 mm2 Welding...

Page 50: ...TIP TIG TIG 500 COMPACT OPERATING MANUAL Page 50 of 58 10 APPENDIX 10 1 Spare part list 10 1 1 Four roll wire drive...

Page 51: ...9 Motor fixation screws 88807214 10 Drive Gear 88807216 11 Flat washer 88807218 12 Machine screw 88807220 13 Pressure adjustment unit 88807222 14 Tapered pin 88807224 15 Quick change carrier gear 8880...

Page 52: ...95 37 50 20 1 27 50 00 25 1 59 62 50 30 1 91 75 00 35 2 22 87 50 40 2 54 100 00 45 2 86 112 50 50 3 18 125 00 55 3 49 137 50 60 3 81 150 00 65 4 13 162 50 70 4 45 175 00 75 4 76 187 50 80 5 08 200 00...

Page 53: ...80 11 43 450 00 185 11 75 462 50 190 12 07 475 00 195 12 38 487 50 200 12 70 500 00 205 13 02 512 50 210 13 34 525 00 215 13 65 537 50 220 13 97 550 00 225 14 29 562 50 230 14 61 575 00 235 14 92 587...

Page 54: ...48 58 43 25 1 81 71 36 30 2 14 84 29 35 2 47 97 22 40 2 80 110 16 45 3 13 123 09 50 3 46 136 02 55 3 78 148 96 60 4 11 161 89 65 4 44 174 82 70 4 77 187 76 75 5 10 200 69 80 5 43 213 62 85 5 75 226 56...

Page 55: ...0 472 28 185 12 32 485 22 190 12 65 498 15 195 12 98 511 08 200 13 31 524 02 205 13 64 536 95 210 13 97 549 88 215 14 30 562 82 220 14 62 575 75 225 14 95 588 68 230 15 28 601 61 235 15 61 614 55 240...

Page 56: ...Torch connection X5 Socket 230V 6A A2 TIG 500AC A3 Interference filter INV41EMV A4 INV CB 45 500A A5 HF Ignition SIG 8 32 A6 Hot wire inverter INV160 F1 Fuse F2 Fuse F3 Fuse F4 Fuse F5 Fuse T1 Control...

Page 57: ...11 2018 TIP TIG Automation GmbH 1 2 Name 5 TIPTIG CONTROL BOARD NEW L4 69 K x1 x2 0 33 Oscillator motor Wire feed motor X1 1S ENABLE DRIVE X2 3S INPUTS X1 3S OUTPUTS X4 3S ENCODER X3 3S ANALOG I Os X...

Page 58: ...TIP TIG Automation GmbH Baumayrweg 5 4631 Krenglbach Austria Tel 43 720 303500 Fax 43 720 303500 99 E Mail office tiptig com www tiptig com...

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