TIPTIG Hot Wire Unit Technical Manual Download Page 1

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TIP TIG TECHNICAL MANUAL

V4.5

www.tiptigusa.com

155 E 9

Ave Suite A, Runnemede, NJ 08078

Summary of Contents for Hot Wire Unit

Page 1: ...TIP TIG TECHNICAL MANUAL V4 5 www tiptigusa com 155 E 9th Ave Suite A Runnemede NJ 08078...

Page 2: ...ead through the Technical Manual thoroughly before installing and starting to use the TIPTIG Hot Wire Unit It will help you to familiarize yourself with your new product as rapidly as possible and to...

Page 3: ...Selection and Angles 13 14 III VII Teflon Guide inside the feeder 15 III VIII Loading wire for the first time 16 19 SECTION IV Introduction Tips Warnings IV I Introduction 20 IV II Tips II Function o...

Page 4: ...traight Fixed Addition 47 SECTION XIV TIP TIG FEEDER PC BOARD DIAGRAM 48 SECTION XV TIP TIG HOTWIRE CASE DIAGRAM 49 51 SECTION XVI Miller Maxstar TIP TIG Setup 52 SECTION XVII Miller Dynasty TIP TIG S...

Page 5: ...grounding of the work piece is required ground it directly the output is on The input power circuit and machine internal with a separate cable circuits are also live when power is on In semiautomatic...

Page 6: ...ications Manual for the Revised NIOSH H F RADIATION can cause interference Lifting Equation publication No 94 110 when manually heavy parts High frequency H F can interference with radio or equipment...

Page 7: ...lized 4 Keep head an trunk as far away from the equipment in the electric and magnetic fields EMF Welding current creates an EMF field welding circuit as possible around the welding circuit and weldin...

Page 8: ...e instructions given may pose risk of injury or even danger of life Prohibition sign The prohibition sign often shows the action or object which is prohibited The text accompanying this symbol details...

Page 9: ...Ing Siegfried Plasch Only personnel that have trained for use and servicing of welding equipment may operate this machine The operator for this equipment must carefully read and fully understand all...

Page 10: ...ded Make sure that the welding ground is connected close by the welding area to the work piece Poor Welding ground connections or poor grounding taken from parts of the building or remote points decre...

Page 11: ...is damaged Pull the plug In the event of repairs and maintenance work or when the equipment is not in use always disconnect the mains power supply plug from wall socket WARNING Work on the electrical...

Page 12: ...ust be fuse protected to a maximum of 16A Recommendation To protect you against electric shock the circuit should be protected by an GFI circuit breaker ground fault circuit breaker The TIPTIG Hot Wir...

Page 13: ...VAC socket Connection step 3 Put the wire spool in the spool holder and secure the spool with the plastic nut an secure the plastic nut with the plastic screw Feed the wire by hand through the 4 feed...

Page 14: ...Process If AC Welding DO NOT USE HOTWIRE Power Off Hotwire When first Powered On The LED Indicator light will flash several times then become solid The Hot Wire Unit is activated The Hot Wire Amp Ran...

Page 15: ...y with a minimum of 350 amps with HF start and trigger hold function because the TIP TIG process doesn t use a foot petal The TIP TIG process can be operated in all welding positions both manually or...

Page 16: ...ferred over the Wire Steel Reels Wire Steel Reels may Bend or Break Causing Wire Feed Problems With TIP TIG the Wire Cast and Helix are Important for good Feedability Use standard 30LB to 40LB Wire Sp...

Page 17: ...or pulsing amperage loads It has the ability to resist thermal shock which provides the user with excellent ignition with a lower burn off rate Tungsten Electrodes Sizes to Amperage Ranges 3 32 093 2...

Page 18: ...weld duty cycle attained For manual TIP TIG welds you want an included angle of 25 degree with a flat on the tungsten tip This provides a wider arc plasma suited for most TIG welds For better penetra...

Page 19: ...e main connection terminal as shown below Teflon Inlet Guide Tube is 4 Long The purpose of the Teflon Inlet Guide Tube is to keep the wire centered from the action of the wire feeder s forward and bac...

Page 20: ...ble The number shown on the front side of the drive wheel indicates the correct wire size used Available Drive Roll Sizes 8 1 0 1 0 1 2 1 2 1 6 Drive Rolls labeled both Metric Standard Wire Hand Tight...

Page 21: ...en installing the upper drive wheels make sure the metal tension spring is against the bracket before installing the drive wheel Set the Drive wheel Tension to 3 for most wire types 17 Loading the Wir...

Page 22: ...Make sure the Inlet Guide and the Outlet Guide are as close to the drive rolls as possible This will greatly reduce any wire feed issues INCORRECT CORRECT Loading the Wire 18...

Page 23: ...100 4 Use a file to round off wire before inserting in into the TIP TIG 5 Run the wire until it is about 12 inches past the handle 6 Install liner and guide blocks Make all settings as shown below 7...

Page 24: ...e is shown as factor start delay Useful for tack weld Display value The value is shown as a factor wire retract delay Is an option normally not used Display value The value is shown as factor spot tim...

Page 25: ...IPTIG Hotwire 18 Water Cooled Torch Up Function Arc On and Off Down Function Wire On and Off To Start the Weld process Step 1 Press Up Button to Start Arc Step 2 Press Down Button to Start Wire To Sto...

Page 26: ...H 5 Water Inlet Connection G3 8 LH 6 Hotwire Terminal 25 Connecting the Torch to the Feeder can only go ONE WAY See Pictures Below 1 2 3 4 5 6 TIP TIG TORCH 1 Torch Connection 2 5 Pin Male Bajonet Con...

Page 27: ...tion TIP TIG Interconnect Cable 2 Way Adapter Hotwire Lead TIG Lead NOTE Cable Ends will be labeled with RED and indicators to match the location on the Power Supply Coolant Miller Plug Gas Line TIPS...

Page 28: ...press Oscillation frequency F press Start delay F press Wire retract time F press Spot time F press To change values 4 Stroke Regular Welding F press 2 Stroke Tack Welding F press Lead Voltage 0 10v...

Page 29: ...FRONT VIEW 1 3 13 4 5 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 2 6 25 SECTION V...

Page 30: ...LEFT RIGHT SIDE 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 39 41 42 37 40 45 44 43 26 SECTION V II...

Page 31: ...22 1 pc TIP TIG Steering roller without brake 88800556 23 1 pc TIP TIG Plastic wire cover black 77700044 24 1 pc TIP TIG Plastic handle 77700690 25 1 pc TIP TIG Wire spool holder 88800620 26 1 pc TIP...

Page 32: ...CONNECTION TIPTIG TO TIPTIG HOT WIRE MODUL CONNECTION TIPTIG HOT WIRE MODUL TO WELDING UNIT VIEW CONNECTION INSIDE HOT WIRE MODULE 1 2 3 4 5 6 7 8 9 10 11 12 13 28 SECTION V V...

Page 33: ...54 6 1 pc TIP TIG Built in plug BE 50 70 77700050 7 1 pc TIP TIG Female socket 6 PE screw termination Series 693 88800453 8 1 pc TIP TIG Male x Male connector with inner cone for water G3 8 LH 8880043...

Page 34: ...Wire Feed Diagram 30 SECTION V VII 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 35: ...31 15 10 16 17 25 1 18 24 19 20 21 22 23 Wire Feed Diagram SECTION V VII...

Page 36: ...874018 13 TIPTIG Screw 7 88874034 14 TIPTIG Guard safety kit 88874004 15 TIPTIG Axle pressure roll 88874014 16 TIPTIG Pin gear adaptor feed 88874027 17 TIPTIG U Drive roll 0 8 1 0mm 88807058 17 TIPTIG...

Page 37: ...a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is s...

Page 38: ...3 4 77700578 6L 3 8 77700571 6XXL 3 8 77700585 8L 1 2 77700572 8XXL 1 2 77700586 10L 5 8 77700573 10XXL 5 8 77700587 12L 3 4 77700574 12XXL 3 4 77700588 Back Caps Small 77700240 Med 77700241 Large 77...

Page 39: ...4 5L 5 16 54N17L 6L 3 8 54N16L 7 7 16 54N15L 8 1 2 54N14L Back Caps Small 77700240 Med 77700241 Large 77700242 Tip Holder 39 Deg Fillet 77700686 42 Deg Butt 77700685 Liner Bronze Liner 77700566 Insula...

Page 40: ...00605 Nozzles 6 3 8 77700530 8 1 2 77700532 10 5 8 77700533 12 3 4 77700534 Back Caps Small 99903008 Med 99903009 Large 99903010 Tip Holder 39 Deg Fillet 77700686 42 Deg Butt 77700685 Liner Bronze Lin...

Page 41: ...zles 7 7 16 54N15 8 1 2 54N14 5L 5 16 54N17L 6L 3 8 54N16L 7 7 16 54N15L 8 1 2 54N14L Back Caps Small 99903008 Med 99903009 Large 99903010 Tip Holder 39 Deg Fillet 77700686 42 Deg Butt 77700685 Liner...

Page 42: ...r Step 2 Install the Ring for Universal Tip Holder Step 3 Install the Nozzle Insulator 1 2 3 Step 4 Install the Gas Lens by hand then tighten slightly with pliers as shown 4 WP18 SC and WP20 SC Torch...

Page 43: ...Step 5 Install the Gas Nozzle Step 6 Install the Collet Step 7 Install the Tungsten 7 6 5 Step 8 Install the Back Cap and tighten to secure the tungsten in place 39 SECTION IX...

Page 44: ...ct Tip 035 045 Liner Fiberglass Sleeve Assembly Holder Block 42 RED Deg Tip Holder for PIPE Applications Adjustment Shaft Also Available in 39 BLUE Deg Tip Holder for PLATE Applications 7 5 Liner Asse...

Page 45: ...sembly to the Universal Tip Holder Loosen the Set Screw inside the Tip Holder Install the Tip Assembly into the Tip Holder and tighten 41 SECTION IX Install the weld repellant tape as shown Install th...

Page 46: ...crew 9 10 Step 11 Push in Liner Assembly to Hull Adapter on torch Step 12 Connect Adjustment Shaft to Assembly Holder Block and tighten screws 11 12 Adjustment Screws Radius of Tip Assembly needs to h...

Page 47: ...Part Number 77701000 A TIPTIG Hotwire Spare box TW18 SC JUMBO For Reordering Parts see Individual Parts Breakdown on next slide SECTION X 43...

Page 48: ...700242 Two Large Back Caps PN 77700569 One Inlet Guide Tube w Guide Bearing PN 77700603 Three 035 Liner Complete PN 77700604 Three 045 Liner Complete PN 88807060 Four 1 0 1 2mm Drive Rolls PN 77700538...

Page 49: ...77700530 8 1 2 77700532 10 5 8 77700533 12 3 4 77700534 Back Caps TIP TIG AUT Torch Cap A 77700415 TIP TIG AUTO Electrode Case 77700420 Tip Holder 39 Deg 77700686 42 Deg 77700685 Liner Bronze Liner 77...

Page 50: ...ngsten Size into the electrode case 3 NOTE Inner Collets NOT USED on Handheld torch Insert the Tungsten into the Electrode Case adjust stick out and tighten Electrode Case 4 Install the ring insulator...

Page 51: ...IP TIG AUTO Electrode Case 77700420 TIP TIG AUT 410 S Collet 2 4mm 77700432 TIP TIG AUT 410 S Collet 3 2mm 77700433 TIP TIG AUT 410 S Collet 4 0mm 77700434 Tip Holder 39 Deg 77700686 42 Deg 77700685 L...

Page 52: ...48 SECTION XIV TIP TIG FEEDER PC BOARD DIAGRAM...

Page 53: ...49 SECTION XV TIP TIG HOTWIRE DIAGRAM...

Page 54: ...50 SECTION XV...

Page 55: ...51 SECTION XV...

Page 56: ...52 SECTION XVI...

Page 57: ...53 SECTION XVII...

Page 58: ...Argon used with a regular at 30 40 CF for most welding ADVANCED SETTINGS PULSER Not Recommended SEQUENCER The TIP TIG Process does not require a foot pedal The Sequencer settings is where you can con...

Page 59: ...DO NOT PLUG THE TIP TIG INTO THE BACK OF YOUR POWERSUPPLY AS THE HF INTERFERS WITH THE TIP TIG EQUIPMENT USE A SEPARATE 115V OUTLET 55...

Page 60: ...election 125 150 150 175 175 200 200 225 225 250 250 275 275 300 300 325 325 350 350 375 375 420 Amps A Wire speed Factor Wire 0 035 Materials All except Aluminium Hotwire current 80A 3 32 1 8 5 32 25...

Page 61: ...as needed Wire Spool Hub Check wire spool hub tension Too much tension will cause wire to slip causing feed issues Adjust the tension so the spool stops the instant the wire is turned off Preventative...

Page 62: ...hull device on should be just below the WP18 torch body Wire to tip size not matched properly Try then next larger size tip Worn or defective bronze liner Replace Liner in torch defective Replace Tens...

Page 63: ...d make sure switch on front panel is on Check high temp over heat light If on check to see if power supply is on Check 115V input on transformer Check to make sure ground cable is plugged into power s...

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