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Manual Orbital v1.0
Manual Orbital v1.0
Operating Manual
Version 1.0 Revision 0
OPERATING MANUAL
TIP TIG – ORBITAL
TIP TIG - ORBITAL, OPERATING MANUAL
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.
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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
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
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9. TECHNICAL DATA 78
10. APPENDIX 81
10.1 Wiring Diagram 81
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1. GENERAL INSTRUCTIONS
CAUTION
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.
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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!
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The labelled machine complies with the following EC directives and standards in terms
of its design and construction:
•
•
• •
2014/35/EU Low Voltage Directive (LVD)
• 2014/30/EU Electromagnetic Compatibility Directive (EMC)
–
• 2011/65/EU Restriction of Hazardous Substance (RoHS)
Standards
Intended use
• IEC 60974-1: 2012 Arc welding equipment - Part 1: Welding power sources
• IEC 60974-3: 2013 Arc welding equipment - Part 3: Arc striking stabilizing
devices
• IEC 60974-10: 2014 Arc welding equipment – Part 10: Electromagnetic
compatibility requirements
•
• EN ISO 12100-1:2003 + A1:2009
•
• • EN ISO 12100-2:2003 + A1:2009
• EN 60201-1:2006 (for electric machines)
• EN ISO 13857:2008
• EN 13732-1:2006
• EN ISO 14121-1:2007
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.
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
•
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3. SAFETY RULES
DANGER! Indicates immediate and real danger. If is not avoided, death or serious
injury will result.
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.
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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.
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.
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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.
The manufacturer reserves the right to make changes and/or improvements in design without
upgrade at the same time the operator’s manual.
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4. GENERAL
CAUTION
This welding system is designed and build for ORBITAL-welding. Manual welding isn‘t possible
with this welding machine.
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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
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No. Description
(2) Welding torch mount – for clamping the the welding torch
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No. Description
(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
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No. Description
(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
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No. Description
(4) Quick clamps – for speedy assembly of the rail segments (Allen key 6mm)
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No. Description
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No. Description
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No. Description
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No. Description
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No. Description
(1) Control Panel Power Source – See 5.6 Control Panel – Power Source
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No. Description
(2) 24 pole connection socket automation – See 5.5 Connection Socket Automation
(5) Fuses
Fuse F1 (top)
T8 A, 230 VAC
Fuse F2 (down)
T8 A, 0 VAC
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A Current 1 N Gas on
B Current 2 P Gas on
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.
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The remote control and automation interface provides the following functions:
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.
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No. Function
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No. Description
(6) Wire electrode connection – for connecting the welding torch wire feed
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No. Description
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No. Description
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No. Description
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No. Description
CAUTION
The thermostat may only be adjusted by trained operating personnel and within the approved
limits.
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No. Description
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No. Function
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No. Function
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No. Function
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No. Function
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No. Function
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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
“>”
No. Function
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No. Function
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No. Function
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No. Function
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No. Function
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No. Function
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No. Function
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No. Function
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No. Function
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5.10.15 ORBITAL – Straight Line Welding – Main Menu Screen – Test Mode
No. Function
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No. Function
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No. Function
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No. Function
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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.
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
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)!
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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.
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.
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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.
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CAUTION
Heavy object
Can cause muscle strain or back injury. Use lifting aids and proper lifting techniques when
moving.
2) Close the guide lever to fix the weld ehad on the ring rail.
3) Secure the lever.
4) Secure the lever.
5) Close the coupling lever to connect the gear with the toothwork.
6) Secure the lever.
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.
7) Connect the cut-off unit to the control cabinet with the provided motor cable.
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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
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.
CAUTION
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage and
renders the manufacturer's warranty void!
• The coolant must be checked for adequate frost protection with a frost protection tester.
• Replace coolant as necessary if frost protection is inadequate!
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:
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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.
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
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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
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).
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Safety
WARNING
An electric shock can be fatal. Before starting the work described below:
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.
Safety
WARNING
An electric shock can be fatal. Before starting the work described below:
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.
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.
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Safety
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.
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!
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 earthed
parts, such as
the housing, etc.
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No. Description
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Safety
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 earthed
parts, such as
the housing, etc.
General Information
After releasing the torch trigger the wire spool must stop unreeling. If it continues unreeling, readjust
the brake.
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7. WELDING
CAUTION
This welding system is designed and build for ORBITAL-welding. Manual welding isn‘t possible
with this welding machine.
7.1 Preparation
Safety
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 safe- ty rules
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.
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.
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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 safe- ty rules
7.2.1 MMA
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
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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.
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.
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
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.
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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
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.
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
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.
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.
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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.
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 safe- ty rules
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
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.
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.
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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:
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 in- jury and damage. Before
carrying out any work on the device make sure that:
Preparation
1. Plug in the mains plug
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.).
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)
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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)
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8.1 Troubleshooting
Safety
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
• all the operating instructions for the system components, especially the safety rules
WARNING
An electric shock can be fatal. Before starting the work described below:
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 inju- ry or damage. The
housing screws provide a suitable ground conductor connec- tion 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
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.
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Troubleshooting-Checklist
Motor Terminal Error
10s after starting welding under TIG the welding process is stopped, the message H20
flashes
The test device of the hazard - Turn the rotary knob to the desired welding current
reduction device has triggered. mode, switch off the device, wait until the display
Rotary knob is in position S-test completely extinguishes, then switch on the device again.
The danger reduction device has - Switch off the device, wait until the display turns off
failed 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
Device was overloaded - Leave the appliance switched on and wait until it has
cooled down
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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)
Too little power set - Turn the trimmer on the back to the right
Power supply for hot wire power - Check 230V, check fuses F1, F2 and F3 (F3 on the
source is missing control transformer)
Hot wire power source overloaded - Allow the hot wire power source to cool down
Loose welding current connections - Tighten power connections on the torch and/or on the
workpiece
- Tighten contact tip correctly
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Unstable arc
Unsuitable or worn welding torch - Adjust contact tip to wire diameter and -material and
equipment replace if necessary
- Adjust wire guide to material in use, blow through and
replace if necessary
Unsuitable or worn welding torch - Adjust contact tip (cold wire/hot wire) to wire diameter,
equipment 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 - Check settings and correct if necessary
chapter 6.6.4 Spool brake setting
Setting pressure units > see chapter - Check settings and correct if necessary
6.6.3 Inching the wire electrode
Wire feed motor without supply - Check and replace fuse if necessary
voltage
Kinked hose packages - Extend and lay out the torch hose package
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
Unsuitable or worn welding torch - Check size of gas nozzle and replace if necessary
equipment
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Safety
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
• all the operating instructions 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 the power source from the mains
• ensure that the power source remains disconnected from the mains until all work has
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-cooled system components
• wire feed unit drive motor
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.
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9. TECHNICAL DATA
U0 71V 71V
EMC class A A
Hot wire
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35% DC 120 A
60% DC 100 A
100% DC 80 A
Frequency 50/60 Hz
Wire feeder
EMC class A
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Cooling Unit
Pressures
PT ref. 9 bar
PT wat. 0 – 6 bar
PS HP 22 bar
PS LP 18 bar
PS wat. 0 – 6 bar
Frequency 50 Hz
Operating current 6A
Start-up current 10 A
Protection classification IP 33
55 kg
Weight
121,25 lb.
Control Cabinet
Frequency 50/60 Hz
Mains fuse 16 A
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10. APPENDIX
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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