LTEC INSTROCTIONS WELDING & CUTTING SYSTEMS TIiG 180 ac pe 3 310 120 / 12.91 CONTENTS PAGE Technical Data 2 Safety Precautions 3 Technical Description = Installation and Welding 4 Maintenance 9 Trouble-Shooting 10 Pictures and Spare Parts List 13 Option 17 Wiring Diagrams L-TEC Deutschiand GmbH, Kottinger Weg 118, 0.5248 Wissen, Tol.: 02742/7540, Telefax: 027 42/76.279, Telex: 875416LTEC INSTRUCTIONS WELDING & CUTTING SYSTEMS TIG 180 ac DG 2 TECHNICAL DATA Input voltage { Ww) 220-380 415 S00 Permenent power ¢kVAD 4.5 °° 4.5 4.5 °° 4.5 M | Permanent current (A) 20.7 12.0 11.0 4 a 1 | Max. current «ay 34.5 20.0 18.3 15.2 N 8 | Power factor cos ¥ 0.74 0.74 0.74 0.74 Frequency (Hz) 50 50 50 50 Fuses, slow blow (A) 32 20 20 16 Current range, stepless Ww | adjustable 5 - 180 (A) 15 - to (Ad E tL | Welding voltage 10 - 17 Ww) D I | Max. current at 100 % ED 106 (A) N at 60 % ED 140 (A) 6 at 35 % ED 180 (A) Open circuit voltage 90 WwW) 42 Ww) c © | Dimensions Lenght x Width x Height 315 x 340 x 540 (mm) N $ | Weight 5S (kg) T R | Type of protection IP 24 u c | Cooling F T 1 | Insulation class F a N L-TEC Deutschland GmbH, Kétinger Weg 118, D-5248 Wissen, Tel.: 02742/75-0, Telefax: 02742/75-279, Telex: 875416LTEC INSTRUCTIONS TIG 160 ac pc 3 SAFETY PRECAUTIONS Please consider the following important recommendations and in- structions: + Disconnect power supply from mains before commencement of installation or repair work. 2. Make sure that mains plug and socket are properly grounded. 3. Work return lead and clamp must be sufficient for maximum current. 4. Protect yourself by means of suitable protective clothing. 5. Protect your hands by means of suitable protective gloves. 6. Protect your face and especially your eyes by means of a suitable helmet with good protection glass against the intensive ultraviolet rays. 7. Provide sufficient air circulation without disturbing shielding gas. 8. Switch off the mains plug before starting reparations or changes at the welding torch. 9. Never put a torch or an electrode holder on the gas cylinder. NICAL DESCRIFTION The welding machine TIG 180 AC DC has been developed for TIG welding as well as for manual Stick DC welding. The stepless setting of the welding current is made through a triac board on the primary side, which consists of anti-paralell connected thyristors. The AC transformer with series connected recti- fiers enables according to the position =/ ~~ of the switch on the front plate the DC ~ or AC welding. However, the manual stick welding in the AC sector is only in part possible. This power supply complies with VDE standard 0542, 5 8 K (confined space welding specification). L-TEC Deutschland @mbH, Postfach, 0-5248 Wissen, Tel: 02742/750, Telex 875416LTEC OPERATING INSTRUCTIONS TIG 180 ac De 4 RRR ERR RRR REE * * * In the last page of this operating instructions is + * located a picture of the unit marked with symbols. * * Please unfold and refer to this page in conjunc— * * tion with these instructions. * * * See eee eee eee eee INSTALLATION AND WELDING ATTENTION: Never start the power supply with the side Panels removed. Firstly this would violate safety regulations and secondly it would prevent efficient fan cooling of the elec~ trical components. Mains Connection PAY ATTENTION to the voltage printed on the label fixed to the mains cable. The mains plug must comply to country regulations and should be connected by an expert. Check mains voltage and fuses before machine is switched on. Gas Connection At the rear of the unit is the necessary union for the gas hose. Connect the gas hose with the regulator between the cylin— der valve and the union. Open the gas cylinder valve slowly and adjust the gas flow to 6-12 1/min according to the application. The machine is equipped with a TIG-torch and 4 metre gas hose. Accessories and technical data refer to operating instructions. L-TEC Deutschiand GmbH, Postfach, D-5248 Wissen, Tel: 02742/750, Telex 875416LETEC WELDING & CUTTING SYSTEMS TIG 180 ac pc Down-slope OPERATING _ | | control cable of the torch is fastened to socket C. =? when the DIP-switch Si is switched = ‘energency off (see page 6), When the L-TEC Deutschland GmbH, Kéttinger Weg 118, 0.5248 Wissen, Tel.: 027 42/76.0, Telefax: 02742/75-279, Telex: 875416 [__—— The ges pre-tdon ti energency off is without function ‘an be presat fron 0-5 sec, at trigner R, and the hot-start tan be preset at trioaer Ro. 11 other trinsers of this control unit aF® for adjusting of the board and aust not changed.LTEC INSTRUCTIONS WELDING & CUTTING SYSTEMS TIS aso ac pc & 4. Connection of remote control /ermeryency off. The S pol. socket # is the connection for remote controls with 47 k 169. pot. Manual remote controls and remote controls with foot pedals FC 4 or FC 47 k can be used. Please note when using remote controls with foot pedals that switch D has to be in position for two-stroke mode. Emergency off when contact, open (see page 5 *-?) Fernregler 7 5 zit Z i Wk log. i 1 Connection of ground and electrode cable a) The ground cable is connected to socket & b) When stick welding the electrode cable must be con— nected to either socket A (+) or EX (-) according to the electrode vendor’s recommendation. L-TEC Deutschland GmbH, Kottinger Weg 118, 0-5248 Wissen, Tel.: 027 42/75-0, Telefax: 027 42/75-279, Telex: 875.416LTEC INSTRUCTIONS WELDING & CUTTING SYSTEMS TIG 180 ac De 6a & Switching On RRR RRR Switch J is a combined safety switch for ON/OFF and AC — DC range - but not a main switch. Therefore the power supply has to be connected by means of a main switch in accordance with the local safety regulations and must at least correspond with the nominal current of the power sup ply at nominal voltage. ARR RRR RE RRA RR HERRERO The switch has following positions: Meaning ° QFF. Power supply is completely discon nected from mains. = TIG- and Stick welding with DC ~ with negative polarity at the torch ~1 TIG-AC welding with larger negative @C_portion of welding at the electrode and larger penetration effect ~2 TIG AC welding with larger positive AC portion of welding at the electrode and larger cleaning effect. ATTENTION: To get a good formation of a ball at the tip of the tungsten electrode (especially for thorium electrodes), position 27 should be used when starting to weld. Beside the main switch a dual Lamp is located. The green lamp shows that unit is ready for operation, the white amp shows unit in operation. L-TEC Deutschiand GmbH, Postfach, D-5248 Wissen, Tel.: 02742/75-0, Telefax: 02742/75278, Telex: 875416LTEC OPERATING INSTRUCTIONS TIG 180 #4 7 Symbol, 2nd ara 4th c pc Program Selection Meaning Manual stick electrode welding TiG-welding with remote control or two-stroke Current up-slope time can be adjusted mode. at potentiometer F. TiG-welding with two-stroke mode and adjust— able current up- and down-slope. Current down-slope can be adjusted at poten- tiometer G. Welding current is switched off automatically after gas post flow. torch trigger during down-slope is depressed again current up-slope comes again to preset welding current. This type of welding is suitable especially for mechanised or automatic welding. 4-stroke mode welding Depress and hold torch trigger Release torch trigger Drepress torch trigger Release torch trigger Program selector-switch D> has following positions: If the gas pre-flow, high frequency, base current current up-slope to the preset welding current (depending on setting of pat. >) current down-slope to base current (depending on setting of pot. G) end of welding and gas post-flow L-TEC Deutschland GmbH, Postfach, 0-5248 Wissen, Tel: 02742/75-0, Telex 875416LTEC INSTRUCTIONS WELDING £ CUTTING SYSTEMS TIG 180 ac pc a 8. Current adjustment, For TIG~ as well as for manual Stick welding current can be stepless adjusted at the dual-scale (AC-DC) of poten- tiometer E. 9. Adjustment of ignitiation current during DC welding At potentiometer Hi DC arc start current can be adjusted. After stabilization control switches automatically to pre- selected welding current. 10, Capacity of tungsten electrodes AC-welding Electrode pe- Pure tungsten | Tungsten electrodes diameter welding electrodes with 2% thorium mm) (A) “ay ay 1.0 15 - 80 10 - 60 15 - 90 1.66 7o - 150 50 - 100 70 - 150 24 150 - 250 100 - 160 90 - 220 Pure tungsten electrodes (99,7 % minimum) are suitable for @C-welding. The formation of a ball at the tip af the tungsten electrode is the condition for a uniform weld seam. For DC-welding tungsten electrodes with 2 % thorium are generally used. (DIN 32 528) For higher current values, quality of the weld seam and capacity of the torch can be improved by the use of gas lenses. (Refer to the torch instructions for further details). MAKE SURE THAT ELECTRODE NEVER TOUCHES THE WELDING Pact L-TEC Deutschland GmbH, Kottinger Weg 118, 0-5248 Wissen, Tel.: 027 42/75-0, Telefax: 02742/75-279, Telex: 875.416LTEC OPERATING INSTRUCTIONS TIS 180 ac Dc 10.4 te Hints for electrode care Always keep the electrode clean. The electrodes are care- fully cleaned by the manufacturer. Dirty electrodes conta— minate the weld seam and reduce the welding quality. Never break electrodes off. Mark the electrode where it should be shortened and cut with pliers. Always keep the electrode properly shaped. For DC-welding the tip should be ground at an included angle of 40° and for AC-welding of 90°. The electrode must remain bright and silvery. Changed colour (blue to black) shows that there is not enough gas post flow. Normally the tungsten electrode has a length of 175 mm. This length should be sufficient for 30 working hours. Excessive consumption indicates that the unit should be checked for any malfunction. MAINTENEaNCE Power Supply. Under regular conditions no formalized maintenance is neces: sary for the machine. Nevertheless on a "good housekeeping basis it is recommended to clean the power supply every three months using dry compressed air. ATTENTIO} First disconnect machine from mains. Remove both side panels. Electrical Control Use extreme care in cleaning the printed circuit boards. Do not blow with air yet L-TEC Deutschland GmbH, Postfach, 0-5248 Wissen, Tel: 02742/750, Telex 875416LTEC OPERATING INSTRUCTIONS TIG 180 ac De to TROUBLE SHOOTING All L—TEC equipment is subjected to a thorough quality control check and final inspection. Nevertheless, if there is a malfunction, please check the power supply according to the following chart or contact your service man. External inspections and general recommendation - Is the correct and appropriate main voltage available? - Does the pilot Lamp light when main switch J is switched on? - Is the ground cable connected to socket and carefully locked? - Is the necessary secondary DC-voltage of 90 V between the sockets @ and E present when switch Dis at position gm 7 TIS Welding Check that selector switch D is in position & that control cable plug is well locked in socket ©, and remote control is locked to socket I that correct shielding gas e.g. 99,9 % Argon is used that ground cable is connected to socket © and well locked 1_Recommendations for Trouble Shooting Measure open circuit voltage behind HF choke at the two sockets © and B. (High frequency could damage the measuring instru- ment if measuring is taken at any other position). (The item no’s relate to the pictures on the following pages (from page 13). L-TEC Deutschland GmbH, Postfach, 0-5248 Wissen, Tel: 02742/7540, Telex 875416LTEC OPERATING INSTRUCTIONS TIG 180 ac DCG wn SYMPTOMS POSSIBLE CAUSE REMEDIAL ACTION Main switch Gitem 8) is "ON" but green pilot lamp (item 9) does not Light up Mains fuse is defec— tive. Fuse (item 13) is defective Replace fuse. Replace (4 A slow blow fuse) No function when torch switch is preset Torch switch or con— trol cable of the torch is defective Selector switch (item 3) is not in position Control unit (item 12) defective Check or replace Correct to right Position Replace No gas flow Solenoid valve (item 32) no reference voltage or it is sticking Check 42 V AC vol- tage or replace No high frequency during TIG welding No reference of trigger voltage at HF-unit (item 25) HF-unit defective Control unit (item 12) defective Check clamp TO Taz Replace Replace Only basic current No reference voltage at transformer (item 20) Check transformer Qnly max. current No reference voltage from shunt (item 21) Triac (item 23) is defective Control unit (item 12) is defective Check shunt con- nections Replace Replace L-TEC Deutschland GmbH, Postfach, 0-5248 Wissen, Tel: 02742/750, Telex 875416LTEC OPERATING INSTRUCTIONS TIG 180 Ac 12 SYMPTOMS POSSIBLE Cause REMEDIAL ACTION No open circuit valtage at posi- tion ~ of main switch (item 8) max. Triac (item 23) is defective Contactor (item 15) does not operate Replace Check 42 V is defective Control unit consis- ting of control trans— former (item 14), resistor titem 22) and contactor (item 15) defective Rectifier (item 34) is defective az Control unit Replace (item 12) defective No open circuit Triac (item 23) Replace voltage at posi- is defective tion = of main switch (item 8), Contactor (item 15) Check 42 V max. 100 V does not operate Control unit (item 12) Replace Check compo nents and replace Replace L-TEC Deutschland GmbH, Postfach, 0-5248 Wissen, Tel: 02742/750, Telex 875416LTEC OPERATING INSTRUCTIONS TIG 180 ac pc SPARE FaARTsS— crst 1° Item Description 1 Socket 2 Central connection 3 Switch 3.1 Knob 4 Potentiometer 10k, 4.1 Knob 5 Potentiometer 10k, 5.1 Knob & Handle isol. 7 Torch HW=17, 4 m ZA 8 Switch 9 Socket lamp 9.1 Bulb 60 V 10 Ground cable AW Lin. 0.15 47a 13 SYMBOL IN WIRING DIAGRAM ai HiH2 L-TEC Deutschland GmbH, Postfach, D-5248 Wissen, Tel: 02742/75-0, Telex 875416OPERATING INSTRUCTIONS TIG 180 ac Dc 14 Ttem Description Part-No. SYMBOL IN WIRING DIAGRAM 12 Control unit TIG 180 compl. 1 170 157 13 Fuse 6A, 5x30 1 440 036 Fi 13.1 Screw cap 1 440 017 13.2 Fuseholder 1 405 436 14 Control transformer 1 442 189 T2 15 Contactor 42V, 16a, SH/1S/16 1 440 578 Ki 16 Control module 1 270 481 AL L-TEC Deutschland GmbH, Postfach, D-5248 Wissen, Tel: 02742/750, Telex 875416LTEC INSTRECTIONS | 7 TIG 16860 ac pC Item Description Part-No. SYMBOL IN WIRING DIAGRAM 20 Ring core transformer 1 440 Bat TS 21 Shunt 180A, 60mv 1 492 197 R2 22 Resistor &,2/3.5A 1440 261 Ri 23 Triac 886 45 C100 1440 993 va 24 @rc starting support 1 441 503 vs 25 HF-box SIG 2.3 &kV 1 170 097 HE 26 HF-choke 1 130 093 La L-TEC Deutschland GmbH, Postfach, 0-5248 Wissen, Tel: 02742/750, Telex 875416LTEC INSTRUCTIONS TIG 180 AC DC 16 Item Description Part-No. 30 Castor 140 mm 1 431 626 30.1 Quick fastening 1 431 624 aM Fan 1 441 550 32 Solenoid valve 42 V 1 440 327 33 HF-chake 200A / 850pH 1 130 037 34 Rectifier B125/100 48/80 1 442 193 35 Transformer 1 120 236 SYMBOL IN WIRING DIAGRAM M1 vu L2 v2 Th L-TEC Deutschland GmbH, Postfach, D-5248 Wissen, Tel: 02742/75-0, Telex 875416LTEC OPERATING WELDING & cUTNG SYST INSTRUCTIONS TIG 180 ac pc 17 OFPTION Faig- 2 MANUAL CONTROL PART-NO. 1090 124, 8m 1090 125, 16m 1 090 126, 25m Faig- 2 REMOTE CONTROL FC-4 PART-NO. 1 090 130 Faig- = DOWN SLOPE SWITCH PART-NO. 1 090 129, 8m L-TEC Deutschland GmbH, Kéttinger Weg 118, 0-5248 Wissen, Tel: 02742/75-0, Telelax: 02742/75-2 79, Telex: 875416LTEC ANLETTUNG : WELDING & CUTTING SYSTEMS control unit/Einschub 1170 126 contro! module / Platine 1 270 482 wicing diagram /Schaltplan 1 910669 wiring diagron/Schaltplan 1: 910 652 e ¢ : er XE KEI KEG ABZ KW XBT ARE a KER 152 \ ¥ | PLATINE i vansieurnuyg 277%", [rseted made I | Seraitplan 1 9706) 300/015 v~ s0He Klenmbret? x6 300V 45 yn contacts |edbhtranal cones = Bavathontonce \[urhwcr cree ® i soy assy teil dled ea alee [oD ae eed a aed an 4 oat ies dxf ol; Ln. = Cl Viki 5 a “ Base WIC te 48 + Achtungl. dur + chiige Phaseniire bridge ia? HE-Gardt ahten. lo an Stutter 419 Verwengungaper Ta. Abw }Ober*s.] HonMater iat in Altenticn. Phase position at #F unit Too enna vs important, To te switch Q19 ~ tae ee = ~ i Bar '5 oy rs Schatter aut Steitung Wechse 1 Tee TIG 180 AC DC (380/415V) Steen eae esate rate sal eee free fel (ZA) from satal-no: 163632 Switch is drawn to cosit n @ terrae DEUTEGMAND GMH Sere eee eae LE KOTTNGER WEG "2 1910 683 orrers BL Sneime Ocs2aWissen oy "EC Deutschland GmbH, Kattinger Weg 118, -5248 Wissen, Tel.: 02742/75-0, Telefax: 02742/75.279, Telex: 875416control unit/Einschub 1170 126 control module / Platine 1270 482 wiring diagram/Schaltplan 1 910 669 wiring diagr n / Schaltplan 1910 652 ‘ \ en Meee 156 x87 ey “HEL XSI RUS X32 XBY X31 KIS KAZ ASR HEL HHS KH US Y5U AES Ho elie 1270081! [cnn matie | | Seraitoan 1 91040, BEDIENUNGS- ANLEITUNG es WOV~ sone Nonnorett X6 zz0y_300v (main contacts |laktitianal contests oum—D thontakce || mitsontarte® 20V_ 360 Yel A776 el el Pa alo ~! * x xIx[x fy | ~2 Xpet_efxti tet * ° Trill +e ibd aiettes ne = Achtung! Auf richtige Phasentage e* HF-Gerat achten, To an Schalter 219 Verwendungsber Teal ABW T Z Attention! Phase position at-HF-unit [Abmessung [7 /s important. To te smitch Q19 coy saa Schalter out Stellung Wechsel 1 Teepe TIG- 180 AC DC (220/380v) wb Fah oie TENE gezerchnet / Taare po (ZA) from serial-ro.: 163432 Switch 1s orawn Lo posit o.ternate TSCHLANO GMBH poe Cat ieerrecer ETEC ficitnet 1910 686 en waiecscrme sms — D~5248 WISSEN L-TEC Deutschland GmbH, Kottinger Weg 118, 0-5248 Wissen, Tel.: 02742/76-0, Telefax: 027 42/75-279, Telex: 875416LTEC ERE i‘ WELDING & CUTTING SYSTEMS contrat unit/Einschub 1170 126 control modile / Platine 1 270 482 wiring diagram/Schaltplan 1 910669 wiring diagr m / Schaltpian 1910 652 \ aa eee 156 157 wey x42 X64 ¢ e ¢ % Aas 133 x53 X82 Tea rey rs SU 15S Ho (maa sad ¥ J 7 @ @ +) Gu Spa Teas a @ G ») Gi | é | PLATINE | «so70 ugh! [aveteveneng “12778 |ont=ot mace ov~ Ea oO 3807 500 sone _ mm Kiemabselt Xb Pair att ws conaal ain Witsmontaxte ® aeay soo elle altel fg a-n—D xxx] [>| x L het ruatige Phosentage HF Gerdt achten, fo an Schalter 219 [Verwendungaber Tal abe] Attention! Phase position at HF-unit a Js important, To t switch B19 r v5 Schaiter out Stellung Wechsel # gezerchnet ! i lee TIG 180 AC DC (360/500) (ZA) Switch is chawn to position alternate eee peont LTEC KOrTMGER WEG Me" 1910 687 Bile D-5248 WiSSEN if senaerang LTEC Deutschland GmbH, Kéttinger Weg 118, 0:5248 Wissen, Tel.i 027 42/75-0, Telefax: 027 42/75:279, Telex: 875416