TIP TIG TIG 500 COMPACT, TIG 500 FOCUS Operating Manual
.
TIP TIG – TIG 500 COMPACT
OPERATING MANUAL
TIP TIG - TIG 500 COMPACT
Operating Manual
Version 1.0 Revision 0
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
INTRODUCTION
Thank you for the trust you have placed in our company and congratulations on buying this highquality TIP TIG product. These instructions will help you familiarize yourself with the product.
Reading the instructions carefully will enable you to learn about the many different features it has to
offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful handling
of the product will repay you with years of safe and reliable operation. These are essential
prerequisites for excellent results.
Page 2 of 58
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
CONTENTS
1.! GENERAL INSTRUCTIONS 5!
2.! INTENDED USE 6!
2.1! Declaration of conformity 6!
2.2! Welding in environments with increased electrical hazards 6!
2.3! Calibration/Validation 6!
3.! SAFETY RULES 7!
3.1! Explanation of safety symbols 7!
3.2! General safety instructions 7!
4.! GENERAL 10!
4.1! Device concept 10!
4.2! Crane transport 10!
5.! CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS 11!
5.1! System overview 11!
5.2! Front connection 14!
5.3! Main switch with fuses 15!
5.4! Connection Socket Automation 15!
5.5! Control Panel – Power Source 17!
5.6! Control Panel – Wire Feeder D24B2M1.6 19!
5.7! Control Panel – Wire Feeder Version 2.0 21!
6.! INSTALLATION AND COMMISSIONING 25!
6.1! Before installation and commissioning 25!
6.2! Start-up – Power Source 26!
6.3! Start-up – Wire feeder 29!
7.! WELDING 34!
7.1! Preparation 34!
7.2! Operating modes 35!
7.3! Welding current types (TIG 500AC only) 38!
7.4! MMA welding 39!
7.5! TIG welding 40!
8.! TROUBLESHOOTING, MAINTENANCE AND DISPOSAL 42!
8.1! Troubleshooting 42!
8.2! Care, maintenance and disposal 47!
9.! TECHNICAL DATA 48!
10.! APPENDIX 50!
10.1! Spare part list 50!
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TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
10.2! Wire Feeder 52!
10.3! Wiring Diagram 56!
Page 4 of 58
1. GENERAL INSTRUCTIONS
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on +43 720 303500 or office@tiptig.com.
A list of authorized sales partners can be found at www.tiptig.com.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of liability
shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result.
For this reason, we do not accept any responsibility or liability for losses, damages or costs arising
from incorrect installation, improper operation or incorrect usage and maintenance or any actions
connected to this in any way.
© TIP TIG Automation GmbH, Baumayrweg 5, 4631 Krenglbach, Austria
The copyright to this document remains the property of the manufacturer. Reprinting, including
extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The
information provided is subject to change, errors excepted.
Page 5 of 58
2. INTENDED USE
WARNING!
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
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WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
A suitable power source (system component) is required in order to operate the wire feed unit!
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
The labelled machine complies with the following EC directives in terms of its design and
construction:
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
• The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
• Do not improperly modify or convert the equipment!
The labelled machine complies with the following EC directives in terms of its design and
construction:
• Low Voltage Directive (LVD)
• Electromagnetic Compatibility Directive (EMC)
• Restriction of Hazardous Substance (RoHS)
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
2.1 Declaration of conformity
The$labelled$machine$complies$with$the$following$EC$directives$and$standards$in$terms$
of$its$design$and$construction:!!
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TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
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2.2 Welding in environments with increased electrical hazards
In$compliance$with$IEC$/$DIN$EN$60974,$VDE$0544$the$machines$can$be$used$in$
environments$with$an$increased$electrical$hazard.$$
2.3 Calibration/Validation
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Page 6 of 58
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
WARNING: This symbol indicates that instructions must be followed to avoid
serious personal injury, loss of life, or damage to this equipment. Protect yourself
and others from possible serious injury or death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual
before operating this equipment. Arc welding can be hazardous. Failure to follow
the instructions in this manual could cause serious personal injury, loss of life, or
damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do
not touch the electrode, work clamp, or connected work pieces when this equipment
is on. Insulate yourself from the electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the
disconnect switch at the fuse box before working on this equipment. Ground this
equipment in accordance with local electrical regulations.
DANGER! Indicates immediate and real danger. If is not avoided, death or serious
injury will result.
WARNING! Indicates a potentially situation. Death or serious injury may result if
appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not avoided,
minor injury and/or damage to property may result.
CAUTION
This equipment must be used by qualified personnel. Be sure that all installation, operation,
maintenance and repair procedures are performed only by qualified person. Read and
understand this manual before operating this equipment. Failure to follow the instructions in this
manual could cause serious personal injury, loss of life, or damage to this equipment. Read and
understand the following explanations of the warning symbols. TIP TIG is not responsible for
damages caused by improper installation, improper care or abnormal operation.
3. SAFETY RULES
3.1 Explanation of safety symbols
NOTE! Indicates a risk of flowed and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information. It does
not indicate a potential damaging or dangerous situation.
If you see any of the symbols depicted in the “Safety rules” chapter, special care is required.
3.2 General safety instructions
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TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode,
and work clamp cables. If any insulation damage exists replace the cable
immediately. Do not place the electrode holder directly on the welding table or any
other surface in contact with the work clamp to avoid the risk of accidental arc
ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current
flowing through any conductor creates electric and magnetic fields (EMF). EMF
fields may interfere with some pacemakers, and welders having a pacemaker shall
consult their physician before operating this equipment.
CE COMPLIANCE: This equipment complies with the European Community
Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in
2006/25/EC Directive and EN 12198 Standard, the equipment is a category 2. It
makes mandatory the adoption of Personal Protective Equipment (PPE) having filter
with a protection degree up to a maximum of 15, as required by EN169 Standard.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and
gases hazardous to health. Avoid breathing these fumes and gases. To avoid these
dangers the operator must use enough ventilation or exhaust to keep fumes and
gases away from the breathing zone.
ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to
protect your eyes from sparks and the rays of the arc when welding or observing.
Use suitable clothing made from durable flame-resistant material to protect you skin
and that of your helpers. Protect other nearby personnel with suitable, nonflammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards
from the welding area and have a fire extinguisher readily available. Welding sparks
and hot materials from the welding process can easily go through small cracks and
openings to adjacent areas. Do not weld on any tanks, drums, containers, or
material until the proper steps have been taken to ensure that no flammable or toxic
vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat.
Hot surfaces and materials in work area can cause serious burns. Use gloves and
pliers when touching or moving materials in the work area.
SAFETY MARK: This equipment is suitable for supplying power for welding
operations carried out in an environment with increased hazard of electric shock.
EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the
help of another person. Lifting may be dangerous for your physical health.
Page 8 of 58
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders
containing the correct shielding gas for the process used and properly operating
regulators designed for the gas and pressure used. Always keep cylinders in an
upright position securely chained to a fixed support. Do not move or transport gas
cylinders with the protection cap removed. Do not allow the electrode, electrode
holder, work clamp or any other electrically live part to touch a gas cylinder. Gas
cylinders must be located away from areas where they may be subjected to
physical damage or the welding process including sparks and heat sources.
CAUTION: The high frequency used for contact-free ignition with TIG (GTAW)
welding, can interfere with the operation of insufficiently shielded computer
equipment, EDP centers and industrial robots, even causing complete system
breakdown. TIG (GTAW) welding may interfere with electronic telephone networks
and with radio and TV reception.
NOISE APPEARES DURING WELDING CAN BE HARMFUL: Welding arc can
cause noise with high level of 85dB for 8-hour week day. Welders operating welding
machines are obligated to wear the proper ear protectors /appendix No. 2 for the
Decree of the Secretary of Labor and Social Policy from 17.06 1998 – Dz.U. No. 79
pos. 513/. According to the Decree the Secretary of Health and Social Welfare from
09.07.1996 /Dz.U. No. 68 pos. 194/, employers are obligated to carry examinations
and measurements of health harmful factors.
The manufacturer reserves the right to make changes and/or improvements in design without
upgrade at the same time the operator’s manual.
Page 9 of 58
4. GENERAL
WARNING
Falling equipment can cause death or serious injury.
• Only use a suitable lifting tackle when transporting devices by crane (e.g. belt with round
slings)
• The lifting tackle must be undamaged and in perfect condition
• Do not transport any other loads by the handle apart from the wirefeeder itself
• Do not hang from the wirefeeder as it is being transported
4.1 Device concept
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
The TIP TIG COMPACT welding system is a
completely digitised, microprocessor
controlled inverter power source with an
included wire feeder and is suitable for wire
spools with max. diameter of 300 mm (11.81
in.).
The power source is generator-compatible. It
is exceptionally sturdy in day-to-day
operation thanks to the protected control
elements and its powder-coated housing.
The function of a TIG pulse arc with a wide
frequency range is available.
The 4-roller drive has good wire-feeding
properties. The wire feeder is also suitable
for long hose packages.
4.2 Crane transport
The TIP TIG FOCUS can be transported by crane at the lifting eyes.
The maximum load-bearing capacity of the lifting eyes is 150 kg (330.69 lbs.)
Before transporting by crane:
- feed out the wire electrode, remove the wire spool
- disconnect the torch hose package and interconnecting hose package from the wire feeder
- if present, unplug the coolant connections
Page 10 of 58
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
No.
Description
(1)
Transport eyebolt (Lifting lug)
(2)
Control Panel Power Source – See 5.5 Control Panel – Power Source
(3)
Control Panel wire Feeder – See 5.7 Control Panel – Wire Feeder Version 2.0
(4)
Front connection – See 5.2 Front connection
(5)
Wire electrode connection – for connecting the welding torch wire feed
(6)
Transport handle
(7)
Hotwire indicator lamps
Temperature fault indicator (down)
is lit in the case of overheating. It extinguishes after a few minutes when the unit has
cooled down.
Hotwire-on indicator (top)
(1) is lit when there is live operating voltage and the hot wire unit is ready for service,
(2) blinks in case of a fault.
(8)
Connection socket, welding current „+“
for connecting the workpiece lead
(9)
Cooling air inlet
5. CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS
5.1 System overview
Front of TIP TIG – TIG 500 COMPACT
Page 11 of 58
(10)
Coolant tank with cap
Rear of TIP TIG – TIG 500 COMPACT
No.
Description
(1)
Transport eyebolt (Lifting lug)
(2)
Button gas test
(3)
24 pole connection socket automation – See 5.4 Connection Socket Automation
(4)
Connecting nipple shielding gas
for connecting the shielding gas (G1/4" RH) on the pressure regulator
(5)
Main switch with fuses – See 5.3 Main switch with fuses
(6)
Mains connection cable with plug
(7)
Securing elements for shielding gas cylinder (strap / chain)
(8)
Cooling air outlet
(9)
Hotwire amperage adjustment
for adjusting the amperage setting of the hotwire unit. Adjustment with a flat screw driver.
Adjustment range: 60 – 100 A (Presetting 80 A)
(10)
Connecting socket
Output 230 VAC
(11)
Bracket for shielding gas cylinder
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
Page 12 of 58
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
(12)
Wheels, fixed castors
No.
Description
(1)
Four roll wire drive
(2)
Clamping levers
for setting the contact pressure of the feed rollers
(3)
Wires pool holder with brake
for holding standard wire spools with max. diameter of 300 mm (11.81 in.) and max.
weight of 15 kg (33.1 lb.)
TIP TIG – TIG 500 COMPACT: operating elements in the machine
Page 13 of 58
5.2 Front connection
No.
Description
(1)
Connection socket control lead (7-pole)
for connecting control lead from the welding torch hose package
(2)
Connection socket hot wire
for connecting hot wire power from the welding torch hose package, minus potential
(3)
Connecting nipple coolant return (red)
for connecting coolant return (G3/8" LH) from the welding torch hose package
(4)
Connecting nipple shielding gas
for connecting shielding gas (G1/4" RH) from the welding torch hose package
(5)
Connecting socket, welding current „-“
for connecting TIG welding torch / electrode holder
(6)
Wire electrode connection – for connecting the welding torch wire feed
(7)
Connecting nipple current / coolant supply (blue)
for connecting current / coolant supply (G3/8" RH) from the welding torch hose package
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
Page 14 of 58
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
No.
Description
(1)
Main switch
Machine on/off
(2)
Fuse F1
T8 A, 230 VAC
(3)
Fuse F2
T8 A, 0 VAC
No.
Configuration
No.
Configuration
A
Current 1
N
Gas on
B
Current 2
P
Gas on
C
Pulse time t1
Q
Arc start
D
Pulse time t2
R
Arc start
E
Soft-start time
S
Ground
F
Soft-down time
T
Uist
G
Spot time
U
GND
H
External mode
V
List J Ground 0V
W
TIPTIG RC 8-2
K
10V
X
TIPTIG RC 8-1
L
I>0 (contact)
Y
NC M I>0 (contact)
Z
NC
5.3 Main switch with fuses
5.4 Connection Socket Automation
With this 24 pol. installation socket, the power source can be commanded with an external control.
Which of these setpoints can be set externally depends on H „External mode“ circuit by means of a
resistor Rx against 10V.
Thus, a very simple and comfortable mode selection is possible.
Page 15 of 58
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
Mode
Name
Rx
Comment
0
Internal
open
everything internally
1
Pulse 1
1k 1%
I1, I2 internal; t1, t2 external
2
Pulse 2
4k 1%
I1, I2 external; t1, t2 external
3
Footmode
10k 1%
I1 external % from I1 internal
4
Remote 1
22k 1%
I1, I2 external
5
Remote 2
47k 1%
I1 external
6
Remote 3
100k 1%
I1, I2 external; Upslope, Downslope external
7
Spottime
150k 1%
Spottime external
8
Upslope external
220k 1%
Upslope external
9
Pulse 1 +
Footmode
470k 1%
I1, I2 internal; t1, t2 external
I1 external % from I1 internal
The remote control and automation interface provides the following functions:
Mode 1 – Internal Pulsing
The current setting I1 and I2 takes place on the control panel.
The pulse times t1 and t2 can be set externally.
Mode 2 – External Pulsing
The current settings I1 and I2 as well as the pulse times t1 and t2 can be set externally.
Mode 3 – Limitation of welding current
In this mode, generally only 2-Stroke operation is selected.
Externally, the current setpoint can be varied between the minimum and the internal current
setpoint I1.
Mode 4 – Mode 6
In these operating modes, an externally connected potentiometer assumes the function of the
internal I1 setpoint specification on the control panel.
Mode 7 – Spottime function
In the operating mode Spottime, the spot time can be set with an externally connected
potentiometer
Page 16 of 58
5.5 Control Panel – Power Source
No.
Function
(1)
Welding data display (3-digit)
displays the current value of the welding current as well as error messages:
- In normal operation, the welding current is displayed.
- If a fault occurs in the cooling system, the welding process is switched off and the
message "H2O" flashes together with (2) Overheat Indicator
- In the event of a mains or inverter fault as well as overheating, the display flashes "- - -"
and the welding process is switched off.
(2)
Overheat Indicator
lights up when the power source has overheated and turned off (for example, due to the
duty cycle being exceeded). It extinguishes when the unit is cooled down and is ready
for welding.
If there is a lack of water, the display flashes.
(3)
Inverter Fault Indicator
lights up if there is a mains under voltage or a defect in the welding inverter.
(4)
Welding Current I1 Indicator
lights up when welding current I1 is active. With TIG pulses, this corresponds to the
pulse current phase.
(5)
Welding Current I2 Indicator
lights up when welding current I2 is active. With TIG pulses, this corresponds to the
basic current phase.
(6)
Pulse Time t1 Rotary Knob
for setting the pulse time t1, while welding current I1 is active during TIG pulses. (Range:
20ms - 1.3sec.)
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
Page 17 of 58
TIP TIG - TIG 500 COMPACT, OPERATING MANUAL
(7)
Pulse Time t2 Rotary Knob
for setting the pulse time t2, while welding current I2 is active during TIG pulses. (Range:
20ms - 1.3sec.)
(8)
Soft Start (Upslope) Rotary Knob
for setting the soft-start time, in which the welding current is increased to the set value.
(Range: 5ms - 2sec.). In 2-stroke mode, the welding current starts in the minimum, in 4cycle mode with the starting current (20% of the welding current I1)
(9)
Welding Current I1 Rotary Knob
for adjusting the welding current I1:
- Setting range TIG: 4A - 500A
- Setting range MMA: 15A - 400A
(10)
Welding Current I1 Rotary Knob
for adjusting the welding current I2 (range: 0% - 100%). In 2-stroke operation, the
welding current starts in the minimum, in 4-stroke operation with the starting current
(20% of the welding current I1). The maximum adjustable welding current I2 always
corresponds to the set value of I1. This welding current is used as a base current during
pulsing.
(11)
Soft Down (Downslope) Rotary Knob
for setting the soft-down time (range: 5ms - 10sec.) at which the welding current is
reduced from the set value to min.
(12)
Gas Post-Flow Time Rotary Knob
for adjusting the gas post-flow time during TIG welding (range: 5sec - 35sec.). If started
but not welded, the gas post-flow time does not expire.
(13)
Operating Mode Rotary Knob
for setting the operating mode, see 7.2 Operating modes:
- MMA
- TIG 4-Stroke
- TIG 2-Stroke
- TIG Liftarc 4-Stroke
- TIG Liftarc 2-Stroke
- TIG Pulse 4-Stroke
- TIG Pulse 2-Stroke
(14)
Frequency Rotary Knob (AC only)
for adjusting the frequency of the AC arc (range: 40Hz - 200Hz)
(15)
Balance Rotary Knob (AC only)
for adjusting the balance of the AC arc (range: 80:20 - 20:80). As a result, either a deep
penetration or a high cleaning effect can be set.
(16)
Welding Current Type / S-Test Rotary Knob (AC only)
for setting the welding current type, see 7.3 Welding current types (TIG 500AC only):
- DC welding with pulse start
- DC welding
- AC welding sinus (soft)
- AC welding rectangle (hard)
- S-Test
(17)
S-Test indicator (AC only)
lights up when the Current Type / S-Test Rotary Knob is set to S-Test mode and the
inverter is operating correctly, see 7.1.1 S-Test (AC only)
Page 18 of 58
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