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TransTig 170 / 210

Fronius TransTig 170 / 210 Operating Instruction [EN]

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TransTig 170 TransTig 210
Operating instructions
EN-US
42,0426,0308,EA 010-10022022
Table of contents
Safety Instructions 6
EN-US
General information 17
General 19
Operating controls and connections 23
Control Panel 25
Connections, Switches, and Mechanical Components 30
Operating Controls, Connections, and Mechanical Components 30
Installation and Startup 31
Minimum equipment for welding operations 33
Before installation and initial operation 34
3
Connecting the Mains Cable 36
Commissioning 37
Welding Mode 41
TIG Operating Modes 43
TIG welding 47
Safety 47 Preparation 47 TIG welding 48 Welding parameters 49
Igniting the arc 51
Igniting the arc using high frequency(HF ignition) 51 Contact Ignition for Welding Torch with Torch Trigger 52 Contact Ignition for Welding Torch without Torch Trigger 54 Igniting the arc using high-frequency contact(Touch-HF) 55 Overloading of the Tungsten Electrode 55 End of Welding 55
Special functions 56
Arc Break Monitoring Function 56 Ignition Time-Out Function 56 TIG pulsing 56 Tacking Function 57
Manual Metal Arc Welding 59
Setup Settings 65
The Setup Menu 67
TIG Setup Menu 69
Rod Electrode Setup Menu 79
Parameters in the Rod Electrode Setup Menu 79
Troubleshooting and Maintenance 83
Troubleshooting 85
4
Service, maintenance and disposal 90
Appendix 93
Average consumption values during welding 95
Technical data 96
Special Voltage 96 TT170 /EF, TT170 /np 96 TT 170 MV/B, TT 170 MV/np 98 TT 210 EF, TT 210 np 100 TT 210 MV/B, TT 210 MV/np 102 Explanation of Footnotes 103 Overview with critical raw materials, year of production of the device 104
EN-US
5
Safety Instructions
Explanation of Safety Instruc­tions
DANGER!
Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
▶
WARNING!
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are not
▶
taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and according to
recognized safety standards. If used incorrectly or misused, however, it can cause
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the device must
- Be suitably qualified
- Have knowledge of welding
- Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- Be kept in a legible state
- Not be damaged/marked
- Not be removed
- Not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section headed "General" in the Operating Instructions for the device. Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
6
The device is intended exclusively for the welding process specified on the rating plate. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose." The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
- Thawing pipes
- Charging batteries
- Starting motors
The device is designed for operation in industry and business. The manufacture shall not be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
EN-US
Environmental Conditions
Obligations of the Operating Com­pany
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.
Temperature range of the ambient air:
- During operation: -10°C to +40°C (14°F to 104°F)
- During transport and storage: -20°C to +55°C (-4°F to 131°F)
Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc. Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section "Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of Personnel
Grid Connection Devices with a high output can influence the energy quality of the grid due to their cur-
All persons who are assigned to work with the device must do the following before begin­ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and con­firm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can oc­cur in one's absence.
rent consumption.
7
This may affect a number of device types in terms of:
- connection restrictions
-
criteria regarding maximum permissible grid impedance
-
criteria regarding the minimum required short-circuit power
*)
both at the interface with the public grid
*)
*)
See technical data
In this case, the operator or the person using the device should check whether or not the device is allowed to be connected, where appropriate through discussion with the power supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Residual current circuit breaker
Personal Protec­tion and Protec­tion of Others
Local regulations and national guidelines may mean that a residual current circuit break­er is required when connecting a device to the public grid. The residual current circuit breaker recommended for the device by the manufacturer can be found in the technical data.
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Hazardous electromagnetic fields that pose a risk of death for individuals with pace­makers
- Electrical risks from grid current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks with a face guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection behind the face guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation and thermal protection)
- Wearing ear protection to reduce noise exposure and protect against injury
Keep persons, especially children, away during the operation of the devices and during the welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying sparks, welding fumes hazardous to health, noise exposure, possible hazard due to grid current or welding current, etc.)
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
8
Data on noise emission values
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation in relation to the maximum permitted operating point at standard loading in accordance with EN 60974-1.
A workplace-specific emission value for welding (and cutting) cannot be specified be­cause this value depends on the welding process and the environmental conditions. It is influenced by a wide range of parameters, such as the welding process itself (MIG/MAG, TIG welding), the selected current type (direct current, alternating current), the power range, the type of weld metal, the resonance properties of the workpiece, the workplace environment, and many other factors.
EN-US
Danger from tox­ic gases and va­pors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph 118 from the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system. If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in.
- Extract them from the work area using appropriate equipment.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
- The welding process used
Danger from Fly­ing Sparks
Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.
Recommendations for exposure scenarios, risk management measures and identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or pro­tected with a certified cover.
9
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums, or pipes if these have not been prepared in accordance with corresponding na­tional and international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/were stored. Residues pose a risk of explosion.
Risks from grid current and weld­ing current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers, as well as all pieces of metal that are in contact with the welding wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimen­sioned. Replace loose connections and scorched, damaged, or inadequately dimen­sioned cables and leads immediately. Before every use, check power connections for secure fit by hand. In the case of power cables with bayonet connectors, turn the power cable by at least 180° around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
- Never immerse it in liquids to cool it
- Never touch it when the power source is switched on.
The open circuit voltage of a welding system may double, for example, between the elec­trodes of two welding systems. Touching the potentials of both electrodes at the same time may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure that the ground conductor is functioning properly.
Protection class I devices require a grid with a ground conductor and a connector system with ground conductor contact for proper operation.
Operation of the device on a grid without a ground conductor and on a socket without a ground conductor contact is only permitted if all national regulations for protective separ­ation are observed. Otherwise, this is considered gross negligence. The manufacturer accepts no liability for any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if neces­sary.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
10
Secure the device to prevent the grid plug from being connected and switched on again by applying a clearly legible and understandable warning sign.
Stray welding currents
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply.
If work is needed on voltage-carrying parts, bring in a second person who will switch off the main switch at the correct time.
If the following instructions are not observed, stray welding currents may occur, which pose a risk of the following:
- Fire
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to the device and other electrical equipment
Ensure that the workpiece clamp is securely connected to the workpiece.
Secure the workpiece clamp as close to the spot to be welded as possible.
Position the device with sufficient insulation against electrically conductive environments, e.g., insulation against electrically conductive floors or electrically conductive mounts.
Observe the following when using power distribution boards, twin-head mounts, etc.: Even the electrode of the welding torch/electrode holder not in use carries electric poten­tial. Ensure that there is sufficient insulation when the unused welding torch/electrode holder is stored.
EN-US
In automated MIG/MAG applications, only guide the wire electrode from the welding wire drum, large spool, or wirespool to the wirefeeder with insulation.
EMC Device Clas­sifications
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage grid.
EMC device classification as per the rating plate or technical data.
sions, it may affect the application area for which it was designed (e.g., when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). If this is the case, then the operating company is obliged to take appropriate action to rectify the situation.
Test and assess the immunity of equipment in the vicinity of the device in accordance with national and international provisions. Examples of interference-prone equipment that could be affected by the device:
- Safety devices
- Grid power lines, signal lines, and data transfer lines
- IT and telecommunications equipment
- Devices for measuring and calibrating
11
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
- If necessary, establish grounding using suitable capacitors.
5. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
EMF measures Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, e.g., those with pacemakers and hearing aids
- Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the welding process
- Keep distances between welding power-leads and the head/torso of the welder as great as possible for safety reasons
- Do not carry welding power-leads and hosepacks over your shoulder or wrap them around your body or body parts
Particular hazard areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- Fans
- Gears
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side parts must only be opened/removed during maintenance and repair work.
During operation
- Ensure that all covers are closed, and all side parts have been mounted properly.
- Keep all covers and side parts closed.
The protrusion of welding wire from the welding torch represents a high risk of injury (cuts to the hand, facial and eye injuries, etc.)
Therefore always hold the welding torch away from the body (devices with wirefeeder) and use suitable protective goggles.
Do not touch the workpiece during or after welding—burning hazard.
Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective equipment when reworking workpieces and ensure that other persons are sufficiently protected.
12
Leave the welding torch and other parts with a high operating temperature to cool before working on them.
Special regulations apply in areas at risk of fire or explosion –follow the appropriate national and international regulations.
Power sources for work in areas with increased electrical hazard (e.g. boilers) must be labeled with the symbol (Safety). However, the power source may not be located in such areas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting connections for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data sheet. The coolant safety data sheet can be obtained from your service center or via the manufac­turer's website.
In the event of crane attachment of the wirefeeder during welding, always use a suitable, insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by hand. The carrier belt is not suitable for transport by crane, counterbalanced lift truck or other mechanical lifting tools.
All lifting equipment (belts, buckles, chains, etc.), which is used in association with the device or its components, must be checked regularly (e.g. for mechanical damage, cor­rosion, or changes due to other environmental influences). The test interval and scope must at least comply with the respective valid national stand­ards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is used for the shielding gas connection. Use suitable Teflon tape to seal the thread of the shielding gas connection adapter on the device side before installation.
EN-US
Requirement for the shielding gas
Danger from Shielding Gas Cylinders
Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality. Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding gas cylinders are an integral part of the welding equipment, so they must be handled very carefully.
Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with instruc­tions so they cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the correct matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylin­ders and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
13
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connec­ted.
Follow the manufacturer's instructions and applicable national and international provi­sions for shielding gas cylinders and accessories.
Danger Posed by Shielding Gas Leak
Safety Measures at the Setup Loc­ation and During Transport
Risk of asphyxiation due to uncontrolled shielding gas leak
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.
- Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour.
- Please observe the safety and maintenance information for the shielding gas cylin­der or the main gas supply.
- When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
- Always check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before each start-up.
A toppling device can be deadly! Set up the device securely on an even, solid surface
- The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the work­place is always clean and organized.
Only set up and operate the device in accordance with the protection class shown on the rating plate.
Safety Measures in Normal Opera­tion
When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before transport or lifting.
Before transporting the device, completely drain the coolant and dismantle the following components:
- wirefeeder
- wirespool
- shielding gas cylinder
It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before commissioning. Have any damage repaired by trained ser­vice technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a danger of:
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
14
Safety devices that are not fully functional must be repaired before the device is switched on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting by crane.
Only the original coolant from the manufacturer is suitable for use in our devices due to its properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit circuit.
If there is damage due to use of other system components or other coolants, the manu­facturer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in certain conditions. Only transport the coolant in closed original containers and keep away from sources of ignition.
Properly dispose of used coolant according to national and international regulations. The coolant safety data sheet can be obtained from your service center or via the manufac­turer’s website.
EN-US
When the system is cool, always check the coolant level before starting welding.
Maintenance and repair
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manu­facturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing parts. Only use original housing screws in the correct number and tightened to the specified torque.
least every 12 months.
The manufacturer recommends calibrating power sources within the same 12-month in­terval.
A safety inspection by a certified electrician is recommended:
- After changes
- After alterations
- After repair, care, and maintenance
- At least every 12 months
15
For the safety inspection, follow the appropriate national and international standards and guidelines.
You can obtain more information about the safety inspection and calibration from your service center. The service center will provide the necessary documents upon request.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as nation­al law, electrical equipment that has reached the end of its life must be collected separ­ately and returned to an approved recycling facility. Any device that you no longer require must be returned to your dealer, or you must locate the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse af­fects on the environment and your health!
Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directive (e.g., relevant product standards of the EN 60974 series).
Fronius International GmbH declares that the device complies with Directive 2014/53/EU. The full text of the EU Declaration of Conformity is available on the follow­ing website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant stand­ards for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings. The
manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for im­provement, or can point out any mistakes that you have found in the Operating Instruc­tions, we will be most grateful for your comments.
16
General information
17
18
General
Device Concept The TransTig 170 and TransTig 210 TIG
power sources are microprocessor-con­trolled inverter power sources.
A modular design and easy ability to ex­tend the system guarantee a high degree of flexibility. The power sources are generator-compat­ible and are equipped with protected oper­ating elements and a robust plastic hous­ing.
As a result of the simple operating concept, key functions can be quickly viewed and adjusted.
The power source can also be operated via the standard TIG Multi Connector with vari­ous remote controls or an Up/Down torch.
EN-US
Operating Prin­ciple
The TIG pulsed arc function means that the power source offers a wide frequency range.
Additionally, the power source offers "Power Factor Correction", meaning the current consumption of the power source adapts to the sinusoidal grid voltage. This results in advantages such as:
- Low primary current
- Low conductivity losses
- Late tripping of the power circuit breaker
- Improved stability during voltage fluctuations
- Compatibility with long grid leads
- Consistent input voltage range with multivoltage devices
The central control unit of the power source controls the entire welding process. During the welding process, actual values are continually measured and any changes are immediately responded to. Control algorithms ensure that the desired status is main­tained.
This results in:
- A precise welding process,
- A high degree of reproducibility on all results
- Excellent weld properties.
Applications The power source can be used in repair and maintenance for production and manufac-
turing tasks.
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Remote control operating mode
The TransTig 170 and TransTig 210 power sources can be operated using the following remote controls:
- RC Bar 1P
- RC Panel MMA
- RC Pedal TIG
- RC Panel Basic TIG
Warning notices on the device
Warning notices and safety symbols can be found on power sources with the CSA test mark for use in the North American region (USA and Canada). These warning notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and property damage.
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* MV power sources: 1 ~ 120 - 230 V
Safety symbols on the rating plate:
Welding is dangerous. The following basic requirements must be met:
- Adequate welding qualifications
- Appropriate protective equipment
- Exclusion of unauthorized persons
Do not use the functions described here until you have fully read and understood the fol­lowing documents:
- These Operating Instructions
- All system component Operating Instructions, especially the safety rules
EN-US
21
22
Operating controls and connections
23
24
Control Panel
(1) (2) (3) (4) (5) (6) (7)
(12) (11) (10)
(8)
(9)
EN-US
General
Safety
Control panel
NOTE!
Because of software updates, certain functions may be available for your device but not described in these Operating Instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your device. However, the function of these operating elements is identical.
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equipment
▶
and all system components.
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Item Name
(1) Special indicators
HF ignition indicator (high frequency ignition)
Illuminates when the "IGn" setup parameter has been set to "on"
Tacking indicator
Illuminates when the "tAC" setup parameter has been set to a period of time
Pulsing indicator
Illuminates when the "F-P" setup parameter has been set to a pulse frequency
Spot welding indicator
Illuminates when the "SPt" setup parameter has been set to a spot welding time
(2) Special indicators
Remote control indicator
Illuminates when a foot-operated remote control is connected
Electrode overloaded indicator
Illuminates when the tungsten electrode is overloaded Further information related to the "electrode overloaded" indicator can be found in the "TIG welding" section of the "Welding mode" chapter
CEL indicator
Illuminates when the "CEL" setup parameter has been set to "on"
26
Trigger indicator
Illuminates when the "tri" setup parameter has been set to "off"
(3) Welding current display
To display the welding current for the parameters:
- Starting current I
- Welding current I
- Lowering current I
- Final current I
Before the start of welding, the left digital display shows the set value. For IS, I2,
and IE, the right digital display also indicates the % amount of the welding current
I1.
After the start of welding, the left digital display shows the current actual value of the welding current. The relevant parameters in the welding process are shown by the illuminated segment in the welding parameter overview (10)
(4) Left digital display
(5) HOLD indicator
At the end of welding, the current actual values for the welding current and weld­ing voltage are saved - the "hold" indicator illuminates. The "hold" indicator relates to the last main current I1 to be reached. Any further
interaction with the power source will cause the "hold" indicator to go out. IMPORTANT! No hold values are output if the main current phase has never been reached.
S
1
2
E
EN-US
(6) Right digital display
(7) Welding voltage indicator
Illuminates when parameter "I1" is selected.
During welding, the current actual value of the welding voltage is shown on the right digital display. Before welding, the right digital display shows:
- 0.0 for selected TIG welding operating modes
- Current value of the open circuit voltage if the setup parameter "tri" is set to "off" or if the manual metal arc welding mode is selected (after a delay of 3 seconds; 93 V is approximately the average value of the pulsed open circuit voltage)
(8) Unit indicators
s indicator
Illuminates if the parameters "tup" and "tdown" have been selected, as well as the following setup parameters: GPr | GPo | SPt | tAC | t-S | t-E | Hti | Ito | ArC | St1 | St2 | SPb
Hz indicator
Illuminates: When a value for the pulse frequency has been set for the "F-P" setup parameter If the "F-P" setup parameter is selected.
27
% indicator
I
S
t
up
I
1
t
down
I
E
I
2
Illuminates when parameters "IS", "I2" and "IE" have been selected, as well as the
setup parameters "dcY", "I‑G", and "HCU"
mm indicator
Illuminates when the "ELd" setup parameter is set
(9) "Mode" button
For selecting the operating mode
2-step mode
4-step mode
Manual metal arc welding When an operating mode is selected, the corresponding LED lights up. If the "Trigger" parameter is set to "oFF" in the Setup menu or a foot-operated remote control is connected, the 2T and 4T LEDs light up at the same time.
(10) Welding parameter overview
The welding parameter overview contains the most important welding paramet­ers for the welding operation. The welding parameter sequence is depicted by a "washing line" structure. Navigation within the welding parameter overview is car­ried out by turning the selection dial.
The welding parameter overview contains the following welding parameters:
Starting current I
For TIG welding
UpSlope t
28
Period of time it takes to rise from the starting current IS to the specified main current I
during TIG welding
up
S
1
t-u for the UpSlope is displayed on the left digital display. IMPORTANT! The UpSlope tup is saved separately for the following operating modes:
- 2-step mode
- 4-step mode
- When the "Trigger" setup parameter is set to "oFF"
- When a foot-operated remote control has been connected
Main current (welding current) I
1
- For TIG welding
- For manual metal arc welding
EN-US
Lowering current I
2
For TIG 4-step mode
DownSlope t
down
Period of time it takes to fall from the specified main current I1 to the final current IE dur-
ing TIG welding t-d for the DownSlope is displayed on the left digital display. IMPORTANT! The DownSlope t
is saved separately for the following operating
down
modes:
- 2-step mode
- 4-step mode
- When the "Trigger" setup parameter is set to "oFF"
Final current I
E
For TIG welding
Pulses *) Pulse frequency for TIG welding
Tacking *) Duration of the pulsed welding current *) The pulsing and tacking parameters are only displayed if the setup parameter "Ptd ­pulse TAC display" is set to "on".
(11) Selection dial with rotary/push button function
For selecting elements, setting values, and scrolling through lists
(12) Gas-test button
For setting the required shielding gas volume on the pressure regulator When the gas-test button is pressed, shielding gas will flow for 30 s. Press the button again or start welding to stop the gas flow prematurely.
29
Connections, Switches, and Mechanical Compon-
(1)
(2)
(3)
(4)
(7) (8)
(9)
(5)
(6)
(10)
MV
TT170/210
TT 170/210
*
*
ents
Operating Con­trols, Connec­tions, and Mech­anical Compon­ents
(1) Control panel
(2) (-) Current socket with integrated gas connection
For connecting: the TIG welding torch the electrode cable during manual metal arc welding
(3) TMC connection (TIG Multi Connector)
For connecting the control plug of the TIG welding torch For connecting foot remote controls For connecting remote controls for manual metal arc welding
(4) (+) Current socket with bayonet latch
Connect the grounding cable here
(5) Carry strap
(6) Cable strap
To hold the mains cable and the welding power-leads
IMPORTANT! Do not use the cable strap to transport the device!
(7) Mains switch
(8) Mains cable with strain relief
For MV devices: mains cable to plug in (see "Connecting the Mains Cable" on page 36)
(9) Air filter
(10) Shielding gas connection socket
30
Installation and Startup
31
32
Minimum equipment for welding operations
General Depending on the welding process, a minimum level of equipment is required to work
with the power source. The following describes the welding processes and the corresponding minimum equip­ment for welding operations.
TIG DC Welding - Power source
- Grounding cable
- TIG welding torch with or without rocker switch
- Gas connection (shielding gas supply)
- Filler metal depending on application
EN-US
Manual Metal Arc Welding
- Power source
- Grounding cable
- Electrode holder
- Rod electrodes, depending on application
33
Before installation and initial operation
Safety
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶ ▶
▶
Intended Use The power source is intended exclusively for TIG welding and manual metal arc welding.
Any other use does not constitute proper use. The manufacturer accepts no responsibility for any damage resulting from improper use.
Intended use also means
- Following all the instructions in these Operating Instructions
- Carrying out all the specified inspection and servicing work
Setup Regula­tions
The device has been tested according to degree of protection IP 23. This means:
- Protection against penetration by solid foreign bodies with diameters > 12.5 mm
- Protection against spraywater at any angle up to 60° from the vertical
WARNING!
All the work and functions described in this document must only be carried out by technically trained and qualified personnel. Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
(0.49 in.)
The device can be set up and operated outdoors in accordance with degree of protection IP 23. Direct moisture (e.g., from rain) must be avoided.
WARNING!
Toppling or falling devices can be deadly.
Place devices on a solid, level surface so that they remain stable.
▶
The ventilation channel is a very important safety device. When selecting the setup loca­tion, ensure that the cooling air can enter or exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g. from grinding work) must not be al­lowed to be sucked directly into the device.
Grid Connection The devices are designed for the grid voltage stated on the rating plate. If the mains
cable or mains plug has not been attached to your version of the appliance, these must be installed according to national standards. Fuse protection for the grid lead can be found in the technical data.
34
CAUTION!
Generator­Powered Opera­tion
Danger due inadequately dimensioned electrical installations.
This can lead to serious damage
The grid lead and its fuse protection should be designed to suit the existing power
▶
supply. The technical data on the rating plate should be followed.
The power source is generator-compatible.
The maximum apparent power S
of the power source is required for dimensioning
1max
the necessary generator output.
The maximum apparent power S S
= I
1max
I
and U1 according to the device rating plate and technical data
1max
1max
x U
1
The generator apparent power S
of the power source is calculated as follows:
1max
needed is calculated using the following rule of
GEN
thumb: S
GEN
= S
1max
x 1.35
A smaller generator can be used when not welding at full power.
EN-US
IMPORTANT! The generator apparent power S
apparent power S
of the power source!
1max
must not be less than the maximum
GEN
When single phase devices are being operated with a 3-phase generator, note that the stated apparent power of the generator is often just the total that can be present across all three phases of the generator. If necessary, obtain further information about the single-phase power of the generator from the generator manufacturer.
NOTE!
The voltage delivered by the generator must never fall outside of the mains voltage tolerance range.
The mains voltage tolerance is specified in the "Technical Data" section.
35
Connecting the Mains Cable
1
General If a power source is delivered without a mains cable installed, a mains cable correspond-
ing to the power source's connection voltage must be connected before commissioning. The mains cable is included in the scope of supply for the power source.
Safety
Connecting the Mains Cable
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equipment
▶
and all system components.
To connect the mains cable:
1
- Plug in the mains cable
- Turn the mains cable 45° to the right until it audibly locks into place
36
IMPORTANT! If the power source is equipped with a mains cable but no mains plug, connection to the public grid must only be carried out in accordance with national guidelines and only by trained and qualified personnel.
Commissioning
EN-US
Safety
Danger from electrical current.
This can result in serious personal injury and damage to property.
▶ ▶
▶
Danger of electrical current due to electrically conductive dust in the device.
This can result in severe personal injury and damage to property.
▶
General Commissioning of the power source is described in relation to a standard configuration
for the main usage scenario of TIG welding.
The standard configuration consists of the following system components:
- Power source
- TIG manual welding torch
- Gas pressure regulator
- Gas cylinder
WARNING!
Before starting work, switch off all devices and components involved, and discon­nect them from the grid. Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electric­ally charged components (such as capacitors) have been discharged.
WARNING!
Only operate the device if an air filter is fitted. The air filter is a very important safety device for achieving IP 23 protection.
Connecting the Gas Cylinder
WARNING!
Danger of falling gas cylinders.
This can result in serious personal injury and damage to property.
Securely set up the gas cylinders on a level and stable surface. Secure gas cylin-
▶
ders to prevent them from falling over. Please observe the gas cylinder manufacturer's safety rules.
▶
37
1
max. 5 bar (72 psi)
TT 170 TT 210
TT 170 MV TT 210 MV
+
-
2
Connecting the welding torch to the power source
NOTE!
Do not use pure tungsten electrodes for TransTig power sources (color code: green).
Fit parts to the welding torch according to the Operating Instructions for the welding
1
torch
2
3
38
Establishing a
+
Ground Earth Connection with the Workpiece
1
EN-US
Measuring the welding circuit resistance "r"
IMPORTANT! For optimum welding results, determine the welding circuit resistance " r "
before starting welding.
The welding circuit resistance " r " must also be determined if one of the following com­ponents of the welding system is changed:
- Torch hosepack
- Welding torch
- Grounding cable
For more information on determining the welding circuit resistance, refer to the 2nd TIG menu (see page72).
39
40
Welding Mode
41
42
TIG Operating Modes
EN-US
Safety
WARNING!
Danger due to incorrect operation.
This can result in severe personal injury and damage to property.
Do not use the functions described here until you have fully read and understood the
▶
Operating Instructions. Do not use the functions described here until you have fully read and understood all
▶
of the Operating Instructions of the system components, especially the safety rules.
Follow the guidelines referring to setting, setting range, and units of measurement for the available parameters in the "Setup Menu" section.
43
Symbols and ex­planations
Pull back and hold the torch trigger | Release the torch trigger | Briefly pull back the torch trigger (< 0.5 s)
Push the torch trigger forward and hold | Release the torch trigger
I
S
Starting-current phase: the temperature is raised gently at low welding current, so that the filler metal can be positioned correctly
t
S
t
up
I
1
Starting current duration
UpSlope phase: steady rise of the starting current to the main current (welding current) I
1
Main current phase (welding current phase): uniform thermal input into the parent material, whose temperature is raised by the advancing heat
I
2
Lowering current phase: intermediate lowering of the welding current to avoid local overheating of the parent material
t
down
DownSlope phase: steady lowering of the welding current until it reaches the final current
I
E
Final current phase: to avoid local overheating of the parent material caused by heat accumulation at the end of welding. This prevents possible sagging of the weld seam.
t
E
Final current duration
SPt Spot welding time
GPr Gas pre-flow time
44
GPo Gas post-flow time
2-Step Mode - Welding: Pull back the torch trigger and hold it in this position
I
t
I
1
GPo
GPr t
down
t
up
I
t
I
1
GPr
I
S
t
down
t
up
I
E
I-2
GPo
I
1
*)
- End of welding: Release the torch trigger
2-step mode
The Setup menu can be used to set a starting current time (t-S) and a final current time (t-E) for 2-step mode.
EN-US
4-Step Mode - Start of welding with starting current IS: pull back the torch trigger and hold it in this
position
- Welding with main current I1: release the torch trigger
- Lowering to final current IE: pull back the torch trigger and hold it in this position
- End of welding: release the torch trigger
4-step mode
*) Intermediate lowering
With intermediate lowering, the welding current is lowered to the set lowering current I-2 during the main current phase.
- To activate intermediate lowering, push the torch trigger forward and hold it in this
- Release the torch trigger to resume the main current
position
45
Spot Welding If a value has been set for the setup parameter SPt, then 2-step mode operating mode is
I
t
I
1
GPr
t
up
t
down
SPt
GPo
I
S
t
E
I
E
t
S
the same as spot welding operating mode. The spot welding special display illuminates on the control panel.
- Welding: Briefly pull back the torch trigger The duration of welding corresponds to the value that was entered for the setup parameter SPt.
- Premature ending of the welding process: Pull back the torch trigger again
When using a foot remote control, the spot welding time begins when the foot remote control is pressed. Foot remote controls cannot be used to adjust the power.
46
TIG welding
TT 170 TT 210
TT 170 MV TT 210 MV
EN-US
Safety
Preparation
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equipment
▶
and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and discon-
▶
nect them from the grid. Secure all devices and components involved so they cannot be switched back on.
▶
After opening the device, use a suitable measuring instrument to check that electric-
▶
ally charged components (such as capacitors) have been discharged.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
When the power switch is switched to position - I -, the tungsten electrode of the
▶
welding torch is live. Ensure that the tungsten electrode is not touching any people or electrically conduct-
▶
ive or grounded parts (housing, etc.).
1
47
TIG welding
Select the desired TIG operating mode by pressing the operating mode button:
1
Press the selection dial
2
In the welding parameter overview, the assigned welding parameters illuminate to around 50%. The segment of the currently selected welding parameter illumin­ates fully.
Turn the selection dial and select the welding parameter to be set (so that the seg-
3
ment assigned to the welding parameter in the welding parameter overview illumin­ates)
Press the selection dial
4
Turn selection dial and adjust the value of the selected welding parameter
5
Press selection dial to confirm the value of the welding parameter
6
Adjust other parameters in the Setup menu if necessary
7
(Details in the "Setup settings" chapter from page 69)
Open the gas cylinder valve
8
48
Adjust quantity of shielding gas:
I
S
t
up
I
1
t
down
I
E
I
2
9
Welding paramet­ers
Press the gas-test button
The gas pre-flow test lasts for 30 seconds at the most. Press the button again to stop the gas flow prematurely.
Turn the adjusting screw on the bottom of the gas pressure regulator until the mano­meter displays the desired quantity of gas
NOTE!
All parameter set values that are set using the selection dial are saved until their next alteration.
This applies even if the power source is switched off and on again.
Commence the welding process (ignite arc)
10
EN-US
I
S
t
up
I
1
Starting current
1 - 200% of the main current I
Factory setting 35%
UpSlope
off / 0.01 - 9.9 s Factory setting: 0.5 s IMPORTANT! The UpSlope tup is saved separately for the following operating
modes:
- 2-step mode
- 4-step mode
- When the "Trigger" setup parameter is set to "oFF"
- When a foot-operated remote control has been connected
Main current
10 – 170 A ... TT 170 10 – 210 A ... TT 210 Factory setting: 100 A
1
49
I
2
Lowering current (only in 4-step mode)
1 - 200% (of the main current I1)
Factory setting: 50%
t
down
I
E
DownSlope
off / 0.01 - 9.9 s Factory setting: 1.0 s IMPORTANT! The DownSlope t
is saved separately for the following operat-
down
ing modes:
- 2-step mode
- 4-step mode
- When the "Trigger" setup parameter is set to "oFF"
Final current
1 - 100% (of the main current I1)
Factory setting: 30%
Pulses *
F-P (pulse frequency) off / 0.2 - 990 Hz Factory setting: off
Tacking *
Duration of the pulsed welding current off / 0.1 - 9.9 s / on Factory setting: off
* The pulsing and tacking parameters are only displayed if the setup parameter
"Ptd - pulse TAC display" is set to "on".
50
Igniting the arc
EN-US
Igniting the arc using high fre­quency (HF ignition)
CAUTION!
Risk of injury due to an electric shock
Although Fronius devices comply with all relevant standards, the high frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances.
Use prescribed protective clothing, especially gloves!
▶
Only use suitable, completely intact and undamaged TIG hosepacks!
▶
Do not work in damp or wet environments!
▶
Take special care when working on scaffolds, work platforms, in forced positions, in
▶
tight, difficult to access or exposed places!
HF ignition is activated when the setup parameter "IGn" is set to "on". The HF ignition special indicator illuminates on the control panel.
Unlike with contact ignition, there is no risk of contaminating the tungsten electrode and workpiece during HF ignition.
Procedure for HF ignition:
Position the gas nozzle at the ignition
1
point so that there is a distance of ap­proximately 2 to 3 mm (5/64 - 1/8 in.) between the tungsten electrode and the workpiece. Distance exists.
51
Increase the tilt angle of the welding
2
torch and press the torch trigger ac­cording to the selected operating mode
The arc ignites without coming into contact with the workpiece.
Tilt the welding torch to the normal po-
3
sition
Carry out welding
4
Contact Ignition for Welding Torch with Torch Trig­ger
When the setup parameter IGn is set to OFF, the HF ignition is deactivated. The arc ig­nites when the workpiece makes contact with the tungsten electrode.
Procedure for igniting the arc using contact ignition for welding torches with torch trigger:
Position the gas nozzle at the ignition
1
point so that there is a distance of ap­proximately 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece
52
Press the torch trigger
2
Shielding gas flows
Slowly straighten the welding torch un-
3
til the tungsten electrode touches the workpiece
Lift the welding torch and swivel into
4
normal position
The arc ignites.
Carry out welding
5
EN-US
53
Contact Ignition for Welding Torch without Torch Trigger
When the setup parameter "IGn" is set to "oFF", the HF ignition is deactivated. The arc ignites when the workpiece makes contact with the tungsten electrode.
The setup parameter "Tri" must be set to "oFF".
Procedure for igniting the arc using contact ignition for welding torches without torch trig­ger:
Position the gas nozzle at the ignition
1
point so that there is a distance of ap­proximately 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece
Actuate gas cut-off valve
2
Shielding gas flows
Gradually tilt the welding torch up until
3
the tungsten electrode touches the workpiece
Raise the welding torch and rotate it
4
into its normal position
The arc ignites.
Carry out welding
5
54
Igniting the arc using high-fre­quency contact (Touch-HF)
CAUTION!
Risk of injury due to an electric shock
Although Fronius devices comply with all relevant standards, the high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances.
Use prescribed protective clothing, especially gloves!
▶
Only use suitable, completely intact and undamaged TIG hosepacks!
▶
Do not work in damp or wet environments!
▶
Take special care when working on scaffolds, work platforms, in forced positions, in
▶
tight, difficult to access or exposed places!
The welding process is initiated by briefly touching the workpiece with the tungsten elec­trode. The high-frequency ignition is performed after the set HF ignition delay time has elapsed.
EN-US
Overloading of the Tungsten Electrode
End of Welding
If the tungsten electrode is overloaded, the "electrode overloaded" display illuminates on the control panel.
Possible causes of an overloaded tungsten electrode:
- Diameter of the tungsten electrode is too small
- Main current I1 value is set too high
Remedy:
- Use tungsten electrode with larger diameter (in this case, the "ELd" setup parameter value must also be adjusted to the new electrode diameter)
- Reduce the main current
IMPORTANT! The "electrode overloaded" display is tailored for use with ceriated tung­sten electrodes. For all other electrodes, the "electrode overloaded" indicator can be used as a guide.
Depending on the set operating mode, end welding by releasing the torch trigger
1
Wait for the set gas post-flow and hold the welding torch in position over the end of
2
the weld seam.
It is also possible to end welding with the TIG Comfort Stop (CSS) function on welding torches with or without a torch trigger. This function can be adjusted in the TIG - 2nd level Setup menu (see page 72).
55
Special functions
Arc Break Monit­oring Function
Ignition Time-Out Function
If the arc breaks and no current flow takes place during the time set in the Setup menu, the power source automatically switches off. The control panel displays the service code "no | Arc".
Press any button on the control panel or the torch trigger to restart the welding process.
The "2nd Level Setup Menu" section describes how to set the arc break monitoring (Arc) setup parameters.
The power source has an ignition time-out function.
If the torch trigger is pressed, gas pre-flow begins immediately. Then the ignition proced­ure is initiated. If no arc emerges during the period of time set in the Setup menu, the power source automatically switches off. The control panel displays the service code "no | IGn".
Press any button on the control panel or the torch trigger to launch a further attempt.
The "2nd Level Setup Menu" section describes how to set the "ignition time-out function" (Ito) parameter.
TIG pulsing The welding current set at the start of welding may not always be optimum for the entire
welding process:
- If the amperage is too low, the parent material will not be sufficiently melted
- If overheating occurs, there is a danger that the liquid weld pool may drip
The TIG pulsing function is able to help with this (TIG welding with a pulsing welding cur­rent): A low base current I-G rises steeply to a significantly higher pulse current I1 and falls again, after the set time dcY (duty cycle), to the base current I-G. During TIG pulsing, small sections of the welding point are quickly melted and then al­lowed to quickly solidify again. During manual applications, the welding wire is applied in the maximum current phase during TIG pulsing (only possible in the low frequency range from 0.25 - 5 Hz). Higher pulse frequencies are mostly used in automated applications and mainly serve to stabil­ize the arc.
TIG pulsing is used to weld steel pipes when welding out-of-position or to weld thin sheet metal.
56
TIG pulsing in operation:
1/F-P
I
1
I-G
I
t
t
up
t
down
I
S
I
E
dcY
tAC
I
1
I
t
t
up
t
down
I
S
I
E
TIG pulsing - welding current progression curve
Key:
EN-US
I
S
I
E
t
up
t
Down
Starting current
Final current
UpSlope
DownSlope
F-P Pulse frequency *) dcY Duty cycle I-G Base current I
1
*) (1/F-P = Time between two impulses)
Tacking Function There is a tacking function on the power source.
When a period of time is set for the setup parameter tAC (tacking), the tacking function is assigned to the 2-step and 4-step modes. The process of the operating modes remains unchanged. During this time, a pulsed welding current is available, which optimizes the merging of the weld pool when tacking two components.
Tacking function in operation:
Main current
Tacking function - welding current progression curve
Key:
57
tAC Duration of pulsed welding current for tacking process I
S
I
E
t
up
t
Down
I
1
Starting current
Final current
UpSlope
DownSlope
Main current
IMPORTANT! When using a pulsed welding current:
- The power source automatically regulates the pulse parameters in relation to the set main current I1.
- No pulse parameters have to be set.
The pulsed welding current starts
- After the starting-current phase IS has finished
- With the UpSlope phase t
up
Depending on the set tAC time, the pulsed welding current can be stopped up to and in­cluding the final current phase IE (tAC setup parameter to "On").
After the tAC time has passed, further welding is carried out at a constant welding cur­rent. Set pulse parameters are available if applicable.
IMPORTANT! To set a defined tacking time, the setup parameter tAC can be combined with the setup parameter SPt (spot welding time).
58
Manual Metal Arc Welding
EN-US
Safety
Preparation
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equipment
▶
and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and discon-
▶
nect them from the grid. Secure all devices and components involved so they cannot be switched back on.
▶
After opening the device, use a suitable measuring instrument to check that electric-
▶
ally charged components (such as capacitors) have been discharged.
Set the power switch to - O -
1
Unplug mains plug
2
Remove TIG welding torch
3
Insert grounding cable and lock:
4
- For manual metal arc DC- welding in the (+) current socket
- For manual metal arc DC+ welding in the (-) current socket
Connect the other end of the grounding cable to the workpiece
5
Insert electrode cable and lock by turning to the right:
6
- For manual metal arc DC- welding in the (-) current socket
- For manual metal arc DC+ welding in the (+) current socket
Insert mains plug
7
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
When the power switch is switched to position - I -, the rod electrode in the electrode
▶
holder is live. Ensure that the rod electrode is not touching any people or electrically conductive or
▶
grounded parts (housing, etc.).
Set the power switch to - I -
8
All displays on the control panel briefly illuminate.
59
Manual metal arc welding
Select the manual metal arc welding operating mode by pressing the operating
1
mode button:
IMPORTANT! If the manual metal arc welding operating mode is selected, the weld­ing voltage is only available after a delay of 3 seconds.
Turn selection dial to set the welding current
2
The set value is immediately applied.
Adjust other parameters in the Setup menu if necessary
3
(Details in the "Setup settings" chapter from page 79)
NOTE!
All parameter set values that are set using the selection dial are saved until their next alteration.
This applies even if the power source is switched off and on again.
Initiate welding process
4
Manual Metal Arc Welding with Cel
IMPORTANT! To weld with Cel electrodes, the setup parameter CEL must be set to "on"
(also see page 79)!
Electrodes
Pulse Welding Pulse welding is welding with a pulsing welding current. It is used to weld steel pipes out-
of-position or to weld thin sheet metal.
In these applications, the welding current set at the start of welding is not always optim­um for the entire welding process:
- If the amperage is too low, the parent material will not be melted enough
- If overheating occurs, there is a danger that the liquid weld pool may drip
Adjustment range: off, 0.2 - 990 Hz
60
Operating principle:
- A low base current I-G rises steeply to the significantly higher pulse current I-P and drops back to the base current I-G after the Duty cycle dcY time.
- During pulse welding, small sections of the welding location melt quickly and then rapidly re-solidify.
NOTE!
I-P
I-G
I
t
SoftStart / HotStart
dcY
1/F-P
The power source regulates the duty cycle parameter "dcY" and the base current "I-G" according to the set pulse frequency.
Pulse welding - welding current progression curve
Adjustable parameters:
F-P Pulse frequency (1/F-P = Time between two pulses)
- SoftStart / HotStart
EN-US
Fixed parameters:
I-G Base current dcY Duty cycle
Using pulse welding:
Select manual metal arc welding operating mode
1
Set the parameter "F-P" in the Setup menu to a value between 0.2 and 990 Hz
2
The pulsing special display illuminates on the control panel of the power source.
61
Starting current
I (A)
t (s)
0,5 1 1,5
Hti
I
1
HCU
100
150
I (A)
t (s)
90A
30A
(1)
(3)
(2)
> 100% (HotStart)
Advantages
- Improved ignition properties, even when using electrodes with poor ignition proper­ties
- Better fusion of parent material in the start phase, therefore less neutralization
- Slag inclusions largely avoided
Key:
Hti
Hot current time, 0-2 s, Factory setting 0.5 s
HCU
HotStart current, 0-200%, Factory setting 150%
I
1
Main current = set welding current
Example of a starting current > 100% (HotStart)
Operation
During the set hot current time (Hti) the welding current I1 rises to the HotStart current HCU.
Starting current < 100% (SoftStart)
The setting of the available parameters is described in the "Setup Menu" section on page
79.
A starting current of < 100% (SoftStart) is suitable for basic electrodes. Ignition is carried out with a low welding current. As soon as the arc is stable, the welding current contin­ues to increase until it reaches the welding current command value that was set.
Advantages:
- Improvement of ignition properties with electrodes that ignite at a low welding current
- Slag inclusions largely avoided
- Reduction of welding spatter
(1) HCU starting current (2) Hti starting current time (3) Main current I
1
The starting current and starting current time are set in the Setup menu from page
79.
Example of a starting current < 100% (SoftStart)
62
Anti-Stick Func­tion
As the arc becomes shorter, the welding voltage may also fall so that the rod electrode is more likely to stick to the workpiece. This can also cause the rod electrode to anneal.
Activating the anti-stick function will prevent this annealing. If the rod electrode starts to stick to the workpiece, the power source switches off the welding current immediately. The welding process can be resumed without problems once the rod electrode has been detached from the workpiece.
The anti-stick function can be activated or deactivated in the Setup menu, see page 79.
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63
64
Setup Settings
65
66
The Setup Menu
I
S
I
E
2
1
General The power source Setup menu provides easy access to expert knowledge and additional
functions. The Setup menu makes it possible to easily adjust the parameters for various tasks.
Located in the Setup menu are:
- Setup parameters with a direct effect on the welding process
- Setup parameters for pre-setting the welding system
Accessing the Setup Menu
EN-US
Press and hold the operating mode button
1
Press the gas-test button
2
The corresponding Setup menu will be displayed for the set operating mode.
To exit the Setup menu, press the operating mode button
3
67
Adjusting Para­meters
The parameters in the Setup menu are adjusted as follows:
Turn the selection dial and select the desired setup parameter
1
Press selection dial to adjust the value for the setup parameter
2
The parameter is displayed on the left digital display. The currently set value for the parameter is displayed on the right digital display.
Turn selection dial and adjust the value of the setup parameter
3
Press selection dial to confirm the value of the setup parameter
4
Overview The following sections describe the Setup menu:
- TIG Setup menu
- Rod electrode Setup menu
68
TIG Setup Menu
EN-US
Parameters in the TIG Setup menu
The following parameters are available through the TIG Setup menu:
Electrode diameter
0.0 - 3.2 mm Factory setting: 2.4 mm
Spot welding time/interval welding time
off / 0.05 - 25 s Factory setting: off
If a value has been set for the setup parameter SPt, this means that 2-step mode corres­ponds to the spot welding mode.
The spot welding special display illuminates on the control panel if a value for the spot welding time has been entered.
Interval pause time
This parameter is only available in 2-step mode and when the "SPt" parameter is activ­ated.
off / 0.5 - 25 s Factory setting: off
Tacking
Tacking function - duration of the pulsed welding current at the start of the tacking pro­cess
off / 0.1 - 9.9 s / on Factory setting: off
on The pulsed welding current remains present until the end of the tacking process
0.1 - 9.9 s The set time begins with the UpSlope phase. After the set time has passed, further weld­ing is carried out at a constant welding current. Set pulse parameters are available if ap­plicable.
69
off Tacking function is switched off
The tacking special display illuminates on the control panel if a value has been set.
Pulse frequency
off / 0.2 - 990 Hz Factory setting: off
The set pulse frequency is also applied for the lowering current.
The pulsing special display illuminates on the control panel if a value for the pulse fre­quency has been entered.
Duty cycle
Relationship between pulse duration and base current duration at the set pulse fre­quency
10 - 90% Factory setting: 50%
Base current
0 - 100% (of the main current I1) Factory setting:50%
Starting current time
The starting current time indicates the duration of the starting-current phase.
off / 0.01 - 9.9 s Factory setting: off
IMPORTANT! The starting current time is only valid for 2-step mode, spot welding, and operation using a foot-operated remote control. In 4-step mode, the duration of the starting-current phase is determined by the torch trig-
ger.
70
Final current time
The final current time indicates the duration of the final current phase.
off / 0.01 - 9.9 s Factory setting: off
IMPORTANT! The final current time is only valid for 2-step mode and spot welding. In 4­step mode, the duration of the final current phase is determined by the torch trigger (sec­tion "TIG Operating Modes").
Gas pre-flow time
Duration of the gas pre-flow
0 - 9.9 s Factory setting: 0.4 s
Gas post-flow time
Duration of the gas post-flow
0.2 - 25 s / Aut Factory setting: Aut
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Gas purging
off / 0.1 - 9.9 minutes Factory setting: off
Shielding gas pre-purging starts once a value has been set for GPU.
For safety reasons, it is necessary to re-enter a value for GPU in order to re-start shield­ing gas pre-purging.
IMPORTANT! Shielding gas pre-purging is mainly required if condensate has built up after longer periods of downtime in the cold. Long hosepacks in particular may be af­fected by this.
Reset welding system
No / YES / ALL Factory setting: No
YES: Only the currently active welding mode is reset (2T / 4T / trigger = oFF / STICK / STICK CEL / foot-operated remote control)
ALL: All operating modes are reset.
71
Left display Right display
TIG - 2nd level Setup menu
For setting the following parameters:
- r (welding circuit resistance)
- Slope Time 1 (only in 4-step mode)
- Slope Time 2 (only in 4-step mode)
- Trigger
- HF ignition
- Pulse TAC display
- Ignition time out
- Arc break monitoring
- TIG Comfort Stop - Comfort Stop sensitivity
- Break voltage
- Main current changeover
2nd level Setup menu
For viewing "system active time", "system on time", "fuse", and "software version" para­meters
For setting the "time shut down" parameter
Parameters in the TIG - 2nd level Setup menu
The following parameters are available through the second level of the TIG Setup menu:
Welding circuit resistance
For displaying the total resistance of the torch hosepack, welding torch, workpiece, and grounding cable
IMPORTANT! The ground earth connection and contact of the tungsten electrode must be made on a cleaned workpiece surface.
Establish a ground earth connection
1
Select "r" and press the selection dial
2
The last measured value is displayed on the right display.
Place the tungsten electrode flush against the workpiece surface
3
Press the torch trigger or gas-test button
4
The value for "r" is determined, the right display shows "run". The current value for "r" is then displayed in MOhm on the right display.
72
If an error occurs while determining the welding circuit resistance, "r" is displayed on the left display and "Err" is displayed on the right display. Pressing the torch trigger or the gas-test button restarts the determination of the welding circuit resistance.
In the event of an error:
- Inspect torch hosepack, welding torch, and grounding cable for damage
- Check connections and contacts
- Check the cleanliness of the workpiece surface
Slope Time 1 (only available in 4-step mode) Ramping time from the main current I1 to the lowering current I
2
off / 0.01 - 9.9 s Factory setting: 0.5 s
Slope Time 2 (only available in 4-step mode) Ramping time from the lowering current I2 back up to the main current I
1
off / 0.01 - 9.9 s Factory setting: 0.5 s
EN-US
Trigger
Torch trigger operating mode
off / on Factory setting: on
off Operating welding torch without torch trigger High frequency ignition is deactivated.
on TIG 2-step or 4-step mode
HF ignition
off / tHF / EHF / on Factory setting: on
off No HF ignition at the start of welding - welding started by contact ignition
tHF The welding process is initiated by briefly touching the workpiece with the tungsten elec­trode. The high-frequency ignition is performed after the set HF ignition delay time has elapsed.
EHF Start with external ignition aid, e.g. plasma welding
on HF ignition is activated
73
The HF ignition special indicator illuminates on the control panel when the "HF ignition" parameter is set to "on".
CAUTION!
Risk of injury due to an electric shock
Although Fronius devices comply with all relevant standards, the high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances.
Use prescribed protective clothing, especially gloves!
▶
Only use suitable, completely intact and undamaged TIG hosepacks!
▶
Do not work in damp or wet environments!
▶
Take special care when working on scaffolds, work platforms, in forced positions, in
▶
tight, difficult to access or exposed places!
HF ignition delay time
Time after touching the workpiece with the tungsten electrode after which the high-fre­quency ignition takes place.
0.1 - 5.0 s Factory setting: 1.0 s
Pulse TAC display
off / on Factory setting: on
This menu item can be used to hide the pulsing and tacking parameters on the control panel in the welding parameter overview.
Ignition time out
Period of time until the safety cut-out following failed ignition
0.1 - 9.9 s Factory setting: 5 s
74
Arc break monitoring
Period of time until the safety cut-out following an arc break
0.1 - 9.9 s Factory setting: 1.0 s
IMPORTANT! Arc break monitoring is a safety function and cannot be deactivated.
1
2
3
4 5
A description of the arc break monitoring function can be found in the "TIG welding" sec­tion on page 56.
TIG Comfort Stop Sensibility - comfort stop sensitivity
The parameter is only available if the "Trigger" parameter is set to "off".
oFF / 0.6 - 3.5 V Factory setting: 1.5 V
At the end of the welding process, an automatic shutdown of the welding current follows a significant increase of the arc length. This prevents the arc from having to be unneces­sarily lengthened when lifting the TIG welding torch.
Process:
EN-US
Welding
1
Briefly lift the welding torch at the end of welding
2
The arc lengthens significantly.
Lower the welding torch
3
- The arc shortens significantly
- The TIG Comfort Stop function has triggered
Maintain height of the welding torch
4
- The welding current continuously ramps down (DownSlope).
- The arc goes out.
IMPORTANT! The DownSlope is fixed and cannot be adjusted.
Lift the welding torch from the workpiece
5
Break voltage
For setting a voltage value at which the welding process may be ended by slightly raising
75
the TIG welding torch. The higher the break voltage value, the higher the arc can be raised.
The break voltage values for 2-step mode, 4-step mode, and operation with a foot-oper­ated remote control are all stored together. If the "tri" parameter (trigger - torch trigger operating mode) is set to "oFF", the values are stored separately.
10 - 45 V Factory setting: 35 V (for 2-step and 4-step mode and operation with a foot-operated re­mote control) Factory setting: 25 V (for trigger = oFF operation)
Main current changeover
on / off Factory setting: on
on After welding has started, an automatic selection of the main current I1 takes place.
The main current I1 can be adjusted immediately.
Parameters in the 2nd level Setup menu
off During welding, the last selected parameter remains selected. The last selected parameter can be adjusted immediately. No automatic selection of the main current I1 takes place.
The following parameters are available through the second level of the Setup menu:
System active time
To display the welding duration (the time during which welding has taken place)
The complete welding duration is divided across several displays and can be viewed by turning the selection dial. Displayed in h / min. / sec.
76
System on time
For displaying the operating duration (count begins as soon as the device is switched on)
The complete operating duration is divided across several displays and can be accessed by turning the selection dial. Displayed in h / min. / sec.
Fuse
To display/set the fuse being used
At 230 V: 10, 13, 16 A / off * at 120 V: 15, 16, 20 A * / off *
* Only on the TT 170 MV / TT 210 MV
Factory setting: 16 A at a grid voltage of 230 V 16 A at a grid voltage of 120 V
If a fuse is set on the power source, the power source will limit the current drawn from the grid, which prevents an immediate tripping of the power circuit breaker.
Max. welding current depending on the selected fuse
Duty cycle = 40%
Device Mains voltage Fuse Max. TIG welding
current
10 A 170 A 125 A
13 A 170 A 150 A
16 A 170 A 150 A
TT 170
oFF * 170 A 150 A
230 V
Max. electrode welding current
EN-US
TT 170 MV
16 A 140 A 95 A
20 A * 140 A 100 A
oFF * 140 A 100 A
13 A 200 A 150 A
16 A 210 A 150 A
TT 210
oFF * 210 A 150 A
TT 210 MV
16 A 140 A 95 A
20 A * 170 A 120 A
oFF * 170 A 120 A
* Only on the TT 170 MV / TT 210 MV ** Depending on the trigger characteristics of the power circuit breaker used, the full
duty cycle of 40% may not be reached with a 120 V grid (for example, USA cir­cuit breaker type CH 15% D.C.).
120 V **
230 V
120 V **
15 A 130 A 85 A
10 A 180 A 125 A
15 A 130 A 85 A
Software version
The complete version number of the current software is divided across several displays and can be viewed by turning the selection dial.
77
Automatic shutdown
off / 5 - 60 minutes Factory setting: off
If the device is not used or operated within a set period of time, it automatically switches into Standby mode. Pressing a button on the control panel switches off Standby mode - the device is now ready for welding.
78
Rod Electrode Setup Menu
EN-US
Parameters in the Rod Electrode Setup Menu
The following parameters are available through the rod electrode setup menu:
HotStart current
1 - 200% Factory setting: 130%
Starting current duration
0.1 - 2.0 s Factory setting: 0.5 s
Start ramp
To activate/deactivate the start ramp for the manual metal arc welding ignition process
on / off Factory setting: on (activated)
Pulse frequency
for pulse welding with rod electrodes
off / 0.2 - 990 Hz Factory setting: off
The set pulse frequency is also applied for the lowering current.
The pulsing special indicator illuminates on the control panel if a value for the pulse fre­quency has been entered.
Anti-stick
on / off Factory setting: on
As the arc becomes shorter, the welding voltage may also fall so that the rod electrode is more likely to stick to the workpiece. This may also cause the rod electrode to burn out.
79
Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode begins to stick, the power source immediately switches the welding current off. The weld­ing process can be resumed without problems once the rod electrode has been de­tached from the workpiece.
CEL mode
on / off Factory setting: off
To weld with Cel electrodes, the parameter must be set to "on".
Dynamic correction
To optimize the welding result
0 - 100 Factory setting: 20
0 Softer and low-spatter arc
100 Harder and more stable arc
At the moment of droplet transfer or in event of a short circuit, a short-term increase in the amperage will occur. To maintain a stable arc, the welding current temporarily rises. If the rod electrode is at risk of sinking into the weld pool, this action prevents the weld pool from solidifying, as well as reducing the duration of the arc's short circuit. The risk of the rod electrode sticking is therefore largely ruled out.
Break voltage
Limitation of the welding voltage
25 - 90 V Factory setting: 45 V
In principle, the arc length depends on the welding voltage. To end the welding process, a significant lifting of the rod electrode is usually required. The "Uco" parameter allows the welding voltage to be limited to a value, which permits the welding process to be ended by only slightly lifting the rod electrode.
IMPORTANT! If the welding process regularly comes to an unintentional end, set the break voltage parameter to a higher value.
80
Reset welding system
No / YES / ALL Factory setting: No
YES: Only the currently active welding mode is reset (2T / 4T / trigger = oFF / STICK / STICK CEL / foot-operated remote control)
ALL: All operating modes are reset.
2nd level Setup menu
For viewing "system active time", "system on time", "fuse" and "software version" para­meters
For setting the "time shut down" parameter
For more details about the 2nd level Setup menu, see page 76.
EN-US
81
82
Troubleshooting and Maintenance
83
84
Troubleshooting
General The power source is equipped with an intelligent safety system, which completely neg-
ates the need for fuses. After correcting a possible error, the power source can be prop­erly operated again without having to change any fuses.
EN-US
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel. Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equipment
▶
and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and discon-
▶
nect them from the grid. Secure all devices and components involved so they cannot be switched back on.
▶
After opening the device, use a suitable measuring instrument to check that electric-
▶
ally charged components (such as capacitors) have been discharged.
WARNING!
Displayed Faults
Danger due to insufficient ground conductor connection.
This can result in serious personal injury and damage to property.
The housing screws provide a suitable ground conductor connection for grounding
▶
the housing. The housing screws must not under any circumstances be replaced by other screws
▶
without a reliable ground conductor connection.
High temperature
"hot" is shown in the display
Cause:
Remedy:
Operating temperature is too high
Leave the device to cool (Do not switch off the device - the fan will cool the device)
85
Service mes­sages
If "Err" is displayed on the left display and an error code is displayed on the right display, this is an internal service code for the power source.
Example:
There can be multiple error codes. These appear by turning the adjustment wheel.
Take note of all displayed error codes as well as the serial number and configuration of the power source, and then contact the service center with a detailed error description.
Err | 1-3 / 11 / 15 / 21 / 33-35 / 37-40 / 42-44 / 46-52
Cause:
Remedy:
Power module error
Contact the service team
Err | 4
Cause:
Open circuit voltage has not been reached: Electrode is in contact with the component/hardware defect
Remedy:
Remove the electrode support from the component. If the service code con­tinues to be displayed, contact service team
Err | 5 / 6 / 12 / 14
Cause:
Remedy:
System start failure
Turn device off and on again. If this happens multiple times, inform service team
Err | 10
Cause:
Remedy:
Overvoltage at the current socket (> 113 VDC)
Contact the service team
Err | 16 / 17 / 18
Cause:
Remedy:
Memory error
Contact service team
;
Err 16: press selection dial to acknowledge service message
NOTE!
For standard device variants, acknowledging the service message does not have an effect on the power source's range of functions.
For all other device variants (TIG, etc.), the power source only offers a restricted range of functions after acknowledgment. Inform the service team to re-establish the full range of functions.
86
Err | 19
Cause:
Remedy:
Overtemperature or undertemperature
Operate device at permitted ambient temperature. For more information about environmental conditions see "Environmental Conditions" in the "Safety Rules" section
Err | 20
Cause:
Remedy:
Err | 22
Cause:
Remedy:
Err | 37
Cause:
Remedy:
Err | 36 / 41 / 45
Cause:
Remedy:
Err | 65-75
Cause:
Remedy:
Improper use of the device
Only use the device in accordance with the intended purpose
Welding current set too high
Ensure that the power source is being operated at the correct grid voltage; ensure the correct fuse is set; set a lower welding current
Grid voltage exceeds admissible limits
Immediately pull out the mains plug and ensure that the power source is be­ing operated at the correct grid voltage
Grid voltage is outside of the tolerance or grid output is insufficient for the connected device(s)
Ensure that the power source is being operated at the correct grid voltage; ensure the correct fuse is set;
Error in communicating with the display
Turn device off and on again / inform service team if this happens multiple times
EN-US
No Function
r | Err
Cause:
Remedy:
Device cannot be switched on
Cause:
Remedy:
No welding current
The power source is switched on, display for selected process illuminates
Cause:
Remedy:
Cause:
Remedy:
Error while determining the welding circuit resistance
Inspect torch hosepack, welding torch, and grounding cable for damage; check connections and contacts; check the cleanliness of the workpiece surface.
For more information on determining the welding circuit resistance, refer to the 2nd TIG menu (see page 72).
Defective power switch
Inform service team
Welding power-lead connections interrupted
Correctly establish welding power-lead connections
Poor grounding or no grounding at all
Establish a connection with the workpiece
Cause:
Remedy:
Power cable in the welding torch or electrode holder interrupted
Replace welding torch or electrode holder
87
No welding current
Switch on device, display illuminates for selected process, overtemperature display illu­minates
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Duty cycle exceeded - device overloaded - fan running
Observe duty cycle
Thermal automatic circuit breaker has shut down the device
Wait for device to cool down (do not switch off the device - the fan will cool the device); the power source will switch on again automatically after a short time
Fan in the power source is faulty
Inform service team
Cooling air supply is insufficient
Ensure there is a sufficient air supply
Air filter is dirty
Clean air filter
Power module error
Switch the device off and then on again If this error persists, inform service team
Inadequate func­tion
Poor ignition properties during manual metal arc welding
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Arc occasionally breaks during the welding process
Cause:
Remedy:
Cause:
Remedy:
Rod electrode tends to stick to the workpiece
Cause:
Remedy:
The wrong process has been selected
Select "manual metal arc welding" or "manual metal arc welding with Cel electrodes" process
Starting current too low; electrode remains stuck during ignition process
Raise starting current with HotStart function
Starting current too high; electrode burns too quickly during ignition process or spatters strongly
Reduce starting current with SoftStart function
Break voltage (Uco) is set too low
Raise the break voltage (Uco) in the Setup menu
Voltage of the electrode too high (e.g. grooved electrode)
Use alternative electrode if possible or use power source with higher weld­ing power
Value for dynamic parameter (manual metal arc welding) set too low
Set a higher value for dynamic parameter
88
Poor-quality weld property
(strong spattering)
Cause:
Remedy:
Incorrect polarity of the electrode
Reverse the polarity of the electrode (observe manufacturer guidelines)
EN-US
Cause:
Remedy:
Cause:
Remedy:
Tungsten electrode melts
Tungsten inclusions in the parent material during the ignition phase
Cause:
Remedy:
Cause:
Remedy:
Poor ground earth connection
Attach earthing clamps directly to the workpiece
Non-viable setup setting for the selected process
Optimize the setting for the selected process in the Setup menu
Incorrect polarity of the tungsten electrode
Connect TIG welding torch to the (-) current socket
Incorrect shielding gas, no shielding gas
Use inert shielding gas (argon)
89
Service, maintenance and disposal
General The power source only requires minimal care and maintenance under normal operating
conditions. However, several points must be observed in order for the power source to remain operational for years to come.
Safety
Danger from electrical current.
This can result in serious personal injury and damage to property.
▶ ▶
▶
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶ ▶
▶
At every start-up - Check mains plug and mains cable, as well as the welding torch, interconnecting
- Check if the all-round clearance of the device is 0.5 m (1 ft. 8 in.) so that cooling air
WARNING!
Before starting work, switch off all devices and components involved, and discon­nect them from the grid. Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electric­ally charged components (such as capacitors) have been discharged.
WARNING!
All the work and functions described in this document must only be carried out by technically trained and qualified personnel. Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
hosepack, and ground earth connection for damage
can circulate unimpeded
90
NOTE!
Air inlet and outlet openings must not be blocked or even partially covered.
Maintenance every two months
Clean air filter:
1
Disposal Materials should be disposed of according to valid local and national regulations.
EN-US
91
92
Appendix
93
94
Average consumption values during welding
EN-US
Average shield­ing gas con­sumption during TIG welding
Gas nozzle size 4 5 6 7 8 10
Average con­sumption
6 l/min 8 l/min 10 l/min 12 l/min 12 l/min 15 l/min
95
Technical data
Special Voltage For devices designed for special voltages, the technical data on the rating plate applies.
TT170 /EF, TT170 /np
Grid voltage U
1
Max. effective primary current (I
Max. primary current (I
) 15.0 A
1max
) 11.3 A
1eff
1 x 230 V
Mains voltage tolerance - 30% / +15%
Grid frequency 50 / 60 Hz
Mains fuse protection 16 A slow-blow
Grid connection
1)
Z
at PCC3) = 356 MOhm
max
Primary continuous power (100% D.C. 2) ) 2.7 kVA
Max. apparent power S
1max
3.5 kVA
Cos phi 0.99
Welding current range
TIG 3 - 170 A
Rod electrode 10 - 150 A
Welding current at 10 min / 40 °C (104 °F), U1 = 230 V
TIG
40% D.C. 2) / 170 A
Rod electrode
60% D.C.2) / 155 A
100% D.C.2) / 140 A
40% D.C. 2) / 150 A
60% D.C. 2) / 120 A
100% D.C.
2)
/ 110 A
Open circuit voltage (pulsed)
TIG 35 V
Rod electrode 101 V
Working voltage
TIG 10.1 - 16.8 V
Rod electrode 20.4 - 26.0 V
Striking voltage U
p
9.0 kV
The arc ignition device is suitable for
manual operation
Degree of protection IP 23
Type of cooling AF
Insulation class A
96
EMC device class (according to EN/IEC 60974-10)
A
Overvoltage category III
Pollution degree according to IEC60664 3
Ambient temperature -10 °C - +40 °C / +14 °F - +104 °F
Storage temperature -25 °C - +55 °C / -13 °F - +131 °F
Dimensions l x w x h 435 x 160 x 310 mm / 17.1 x 6.3 x 12.2 in.
Weight 9.8 kg / 21.61 lb.
Marks of conformity CE
Safety symbol S
Max. shielding gas pressure 5 bar / 73 psi
Noise emissions (LWA) 68.0 dB (A)
Idle state power consumption at 230 V 15 W
Power source efficiency at 150 A / 26 V 88 %
EN-US
97
TT 170 MV/B, TT 170 MV/np
Grid voltage 1 x 120 V / 1 x 230 V
Max. effective primary current (I
)
1eff
1 x 120 V 14.5 A
1 x 230 V 11.3 A
Max. primary current (I
)
1max
1 x 120 V 22.7 A
1 x 230 V 15.0 A
Mains voltage tolerance
1 x 120 V - 20% / +15%
1 x 230 V - 30% / +15%
Grid frequency 50 / 60 Hz
Mains fuse protection
1 x 120 V 20 A slow-blow
1 x 230 V 16 A slow-blow
Grid connection
1)
Z
at PCC 3) = 356 mOhm
max
Primary continuous power (100% D.C. 2) )
1 x 120 V
1 x 230 V
Max. apparent power S
1max
1.8 kVA
2.7 kVA
1 x 120 V 2.8 kVA
1 x 230 V 3.5 kVA
Cos phi 0.99
Welding current range
TIG / 1 x 120 V 3 - 140 A
TIG / 1 x 230 V 3 - 170 A
Rod electrode / 1 x 120 V 10 - 100 A
Rod electrode / 1 x 230 V 10 - 150 A
Welding current at 10 min / 40 °C (104 °F)
TIG / 1 x 120 V
TIG / 1 x 230 V
Rod electrode / 1 x 120 V
40% D.C. 2) / 140 A
60% D.C. 2) / 120 A
100% D.C 2) / 100 A
40% D.C. 2) / 170 A
60% D.C.2) / 155 A
100% D.C.2) / 140 A
40% D.C. 2) / 100 A
60% D.C. 2) / 90 A
98
Rod electrode / 1 x 230 V
100% D.C. 2) / 80 A
40% D.C. 2) / 150 A
60% D.C. 2) / 120 A
100% D.C. 2) / 110 A
Open circuit voltage (pulsed)
TIG 35 V
Rod electrode 101 V
Working voltage
TIG / 1 x 120 V 10.1 - 15.6 V
TIG / 1 x 230 V 10.5 - 16.8 V
Rod electrode / 1 x 120 V 20.4 - 24.0 V
Rod electrode / 1 x 230 V 20.4 - 26.0 V
Striking voltage U
p
9 kV
The arc ignition device is suitable for
manual operation
Degree of protection IP 23
Type of cooling AF
Insulation class A
EMC device class (according to EN/IEC 60974-10)
EN-US
A
Overvoltage category III
Pollution degree according to IEC60664 3
Ambient temperature -10 °C - +40 °C / +14 °F - +104 °F
Storage temperature -25 °C - +55 °C / -13 °F - +131 °F
Dimensions l x w x h 435 x 160 x 310 mm / 17.1 x 6.3 x 12.2 in.
Weight 9.8 kg / 21.61 lb.
Marks of conformity CE, CSA
Safety symbol S
Max. shielding gas pressure 5 bar / 73 psi
Noise emissions (LWA) 68.0 dB (A)
Idle state power consumption at 230 V 15 W
Power source efficiency at 150 A / 26 V 88 %
99
TT 210 EF, TT 210 np
Grid voltage U
1
Max. effective primary current (I
1 x 230 V
) 13.5 A
1eff
Max. primary current (I
) 20.0 A
1max
Mains voltage tolerance - 30% / +15%
Grid frequency 50 / 60 Hz
Mains fuse protection 16 A slow-blow
Grid connection
1)
Z
at PCC3)= 261 MOhm
max
Primary continuous power (100% D.C. 2) ) 3.2 kVA
Max. apparent power S
1max
4.6 kVA
Cos phi 0.99
Welding current range
TIG 3 - 210 A
Rod electrode 10 - 180 A
Welding current at 10 min / 40 °C (104 °F), U1 = 230 V
TIG
40% D.C. 2) / 210 A
60% D.C. 2) / 185 A
100% D.C.
2)
/ 160 A
Rod electrode
40% D.C. 2) / 180 A
60% D.C. 2) / 150 A
100% D.C.
2)
/ 120 A
Open circuit voltage (pulsed)
TIG 35 V
Rod electrode 101 V
Working voltage
TIG 10.1 - 18.4 V
Rod electrode 20.4 - 27.2 V
Striking voltage U
p
9.0 kV
The arc ignition device is suitable for
manual operation
Degree of protection IP 23
Type of cooling AF
Insulation class A
EMC device class (according to EN/IEC 60974-10)
A
100
Overvoltage category III
Pollution degree according to IEC60664 3
Ambient temperature -10 °C - +40 °C / +14 °F - +104 °F
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