REHM TIGER DIGITAL 230 AC/DC ULTRA Operating Instructions Manual
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REHM TIGER DIGITAL 230 AC/DC ULTRA Operating Instructions Manual

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OPERATING INSTRUCTIONS
TIG inert gas welding equipment
TIGER DIGITAL 230 DC / AC/DC ULTRA/HIGH
TIGER DIGITAL 180 DC / AC/DC ULTRA/HIGH

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Summary of Contents for REHM TIGER DIGITAL 230 AC/DC ULTRA

  • Page 1 OPERATING INSTRUCTIONS TIG inert gas welding equipment TIGER DIGITAL 230 DC / AC/DC ULTRA/HIGH TIGER DIGITAL 180 DC / AC/DC ULTRA/HIGH...

  • Page 2: Product Identification

    Date of issue: 16/08/2017  Rehm GmbH u. Co. KG, Uhingen, Germany 2017 The content of this description is the property of Rehm GmbH u. Co. KG The copying and distribution of this document, use and communication of its contents are strictly prohibited unless expressly authorized.

  • Page 3: Table Of Contents

    List of contents List of contents Product identification Introduction Foreword General description 1.2.1 Principle of the TIG inert gas welding process 1.2.2 Scope of application of TIG welding equipment 1.2.3 Intended use Symbols used Safety information Warning symbols in these operating instructions Warning symbols on the system Notes and requirements Unit description...
  • Page 4 Setup / special parameters Error memory Indicating symbol Accessories 11.1 Foot-actuated remote controller TIGER DIGITAL 180/230 11.2 REHM TIG torch 11.3 Optional water cooling unit Commissioning 12.1 Safety information 12.2 Working under increased electrical hazard (IEC 874, EN 60974-1, TRBS 2131 and BGR 500 KAP.
  • Page 5 List of contents Maintenance work 15.1 Safety information 15.2 Maintenance table 15.3 Cleaning the inside of the unit 15.4 Proper disposal Technical data Accessories Circuit diagrams INDEX...

  • Page 6: Introduction

    We thank you for the confidence you have placed in our quality products. Only components of the highest quality are used in TIGER DIGITAL equipment. To enable a long service life even under the toughest conditions all REHM equipment is manufactured using only parts that comply with our strict quality demands.

  • Page 7: General Description

    Introduction 1.2 General description Fig.1 TIGER DIGITAL (in the background with a water cooling unit)

  • Page 8: Principle Of The Tig Inert Gas Welding Process

    REHM welding machines are, except when this is expressly stated in writing by REHM, only for sale to commercial / industrial users and are only intended to be used by commercial / industrial users. The machines may only be operated by persons who trained in the use and maintenance of welding equipment.

  • Page 9: Symbols Used

    Introduction Welding power sources may not be used to defrost pipes. Intended use also includes compliance with the prescribed assembly, disassembly and reassembly, commissioning, use, maintenance and disposal measures. Please make particular note of the information in Section 2 Safety information and Section 15.4 Proper disposal.

  • Page 10: Safety Information

    Safety information Safety information 2.1 Warning symbols in these operating instructions Warnings and This or a symbol that more accurately specifies the risk can be found in symbols all of the safety instructions given in these operating instructions where there is danger to life and limb. One of the signal words below (Danger!, Warning!, Caution!) is used to indicate the severity of the risk: …warning of immediate danger.

  • Page 11: Notes And Requirements

    REHM welding machines are, except when this is expressly stated in writing by Applications REHM, only for sale to commercial / industrial users and are only intended to be used by commercial / industrial users. TIGER DIGITAL TIG inert gas welding systems may only be used ...
  • Page 12 This is the responsibility of the operator or the user of the unit. Qualification of the REHM welding equipment should be operated only by persons who are trained and instructed in the use and maintenance of welding equipment. Only qualified, operating assigned and trained personnel may work on and with the system.

  • Page 13: Unit Description

    Unit description Unit description TIGER DIGITAL without water cooling TIGER DIGITAL with optional water cooling unit Fig.2 Unit description...
  • Page 14 Unit description Symbol Function / description Control panel - See "Description of controls" Control panel push and rotary encoder Shielding gas connection - TIG welding torch Current socket "negative" TIG: TIG welding torch Electrode: Workpiece or electrode holder Torch / remote control jack Current socket "positive"...

  • Page 15: Function Description

    Function description Function description 4.1 Overview of the operating panel Fig.3 TIGER Digital operating panel...

  • Page 16: Operation Description

    Function description 4.2 Operation description 4.2.1 Controls Controls Function Quick program buttons P1-P4 Fig.4 Quick program buttons Main screen Operation via rotary encoder with push- knob and buttons for menu selection in the 4 corners of the screen Fig.5 Main screen Function buttons (from left to right) Butto Submenu...

  • Page 17: Operating Functions

    Function description 4.2.2 Operating functions Fig.9 Screen functions Ultra Ultra High High Symbols Description / function AC/DC AC/DC Corner menu welding processes TIG welding     Electrode welding     Electrode booster function    ...
  • Page 18 Function description Ultra Ultra High High Symbols Description / function AC/DC AC/DC     Pulse off     Conventional pulsing ─ ─   High-frequency pulse (hyper pulse) Corner menu polarity ─ ─   Alternating current (AC) ─...
  • Page 19 Function description Ultra Ultra High High Symbols Description / function AC/DC AC/DC Welding current I2 and pulse time t2     alternative t1/t2 hyperpulse frequency     Slope-down time     End-crater current ─ ─...
  • Page 20 Function description Ultra Ultra High High Symbols Description / function AC/DC AC/DC     BF10 Sub menu buttons Back button “Home” and “Back”     BF11 ─ ─   Function Assist see Chap. 7.2 BF12 Function program (Jobs) ─...

  • Page 21: Switch On

    4.3 Switch on The TIGER DIGITAL welding system is started with the mains switch. The screen shows the Rehm logo and the unit type for approximately 10 seconds. The display then switches to the main screen [Fig.5 Main screen. The last active welding parameters are set.

  • Page 22: Corner Menu Functions

    Electrode welding BOOSTER. Turning and pressing the rotary encoder [Fig.8] selects and confirms the process. Pressing the button [Fig.6] "Back" or "Rehm" returns to the main screen [Fig.5]. The setting of the welding parameters for TIG welding is performed as described in Section 6, Parameter settings.

  • Page 23: Corner Menu Operating Mode (Top Right)

    Function description 5.2 Corner menu operating mode (top right) The menu Operating modes [BF3] is activated by pressing the button at the top right of the keypad Fig.8. This allows the selection of the operating modes 1. 2 cycle with HF ignition (see Section 5.3) 2.

  • Page 24: Cycle Operating Mode

    Function description 5.2.2 4 cycle operating mode In the 4 cycle operating mode the need to permanently actuate the trigger is omitted, enabling the torch to be guided for a longer period without fatigue. Sequence of the 4 cycle operating mode: 1.

  • Page 25: Tig Interval

    Function description The lower heat input into the materials being welded enables TIG welding with low distortion and only slight discolouration. 2-Takt-Punkten Brennertaster 1 Gasventil Schweißstrom Fig.12 TIG spot welding  1. cycle Operate the torch trigger The set gas pre-flow time expires, the gas valve opens. After the gas pre-flow time has expired the arc is ignited.

  • Page 26: High-Frequency (Hf) Ignition

    HF ignition. 5.3.1 Welding with HF ignition REHM TIG welding machines are equipped with RF igniter. HF ignition is automatically switched off in the "electrode" setting. HF ignition makes contact-free ignition of the arc between the electrode and workpiece through pre-ionization of the air gap for DC and AC welding possible, whereby tungsten inclusions and therefore welding defects are prevented.

  • Page 27: Welding Without Hf Ignition

    Function description even enables AC welding without HF ignition, as is already known for DC welding (see Section 5.3.2). The RF igniter is operational when set to RF On " ". To ignite the arc, the electrode is kept approx. 3-5 mm above the workpiece. By actuating the torch trigger the path is ionized by a high-voltage pulse and arcing occurs.

  • Page 28: Corner Menu Welding Process (Bottom Right)

    Function description 5.4 Corner menu welding process (bottom right) The corner menu welding process [BF4] is used to select:  Time pulses  Hyper-Pulsen®  Pulse off 5.4.1 Time pulses Pulses with pulse times from 0.5 to 5.0 seconds The setting of the I1-pulse time t1 and the I2-pulse time t2 determines the duration that current I1 or current I2 remains active until switching to the other current.

  • Page 29: Corner Menu Polarity (Bottom Left)

    5.5.2 Dual Wave (=/~) The Dual Wave process from REHM is a combination of AC and DC welding. When welding this is automatically set by the processor controller at 0.2 seconds DC and then 0.3 seconds AC. The selected values for the welding current I...

  • Page 30: Dc Negative Pole

    Function description In DC TIG welding the positive electrode is subject to a very high thermal load, which can result in the electrode melting and damage even at low current. When electrode welding with plus pole the electrode holder is also connected to the left output socket.

  • Page 31: Parameter Settings

    Function description Parameter settings The selection and processing of the welding parameters is carried out for the most part directly in the illustrated welding wave using the push and rotate encoder [Fig.8]. The representation and setting options depend on the device type and the preselected welding process.

  • Page 32: Starting Current

    Function description 6.1.3 Starting current The starting current is the welding current that is first set after the ignition process. The setting is infinitely variable between 10% and 200% of the selected welding and pulse current I The value range is limited by the maximum unit flow. Example: Start current 40% and welding current I 100A...

  • Page 33: Automatic Pulsing

    Function description The current I is set either by activating the setting option I , or also very quickly and easily by actuating torch trigger 2 before the welding process. When the torch trigger 2 is held down the current value I is shown in the digital display and can be altered by turning the rotary encode.

  • Page 34: Manual Pulsing

    Function description Example: Pulse frequency = 50 Hz Total pulse time = I -pulse time t -pulse time t 1 / Hz = 20 ms = 0.02 s -pulse time t = 0.5 * total pulse time = 0.01s -pulse time t = 0.5 * total pulse time = 0.01s This means that the current when welding has the value current I for 0.01 s (=...

  • Page 35: Gas Post Flow Time

    Function description Example: End crater current 40% and welding current I 100A results in an end crater current of 40A. Selecting the appropriate end crater current enables:  Prevention of notches and end crater cracks at the end of the weld seam due to rapid cooling of the weld pool ...

  • Page 36: Ac Settings Menu

    The adjustable frequency when AC welding, results in a considerable noise reduction and improvements in the alternating current welding. The REHM patented automatic frequency control can be selected as a special feature for TIG AC current welding. The frequency is set to "Auto" for activation.

  • Page 37: Menu Spot Welding And Interval

    During this time the unit welds in the AC mode set above DC time: Her in DC mode. The Dual Wave process from REHM is a combination of AC and DC welding. The selected values for the welding current I or I , the frequency and the balance are taken into account for purely DC or AC welding.

  • Page 38: Setting Options (From Left To Right)

    Function description 6.4.1 Setting options (from left to right) Function Setting Ultra Ultra High High AC/DC AC/DC ─ ─   Hotstart In % over welding current current ─ ─   Hotstart time 0.1 to 10s 20A … Imax ...

  • Page 39: Anti-Stick-Automatic

    Function description 6.4.5 Anti-stick-automatic If a permanent short-circuit is present during electrode welding, then after 0.3s the ant-stick function initiates and limits the current to approximately 20A. This prevents the electrode from glowing and the permanent short circuit can be solved easily by pulling out.

  • Page 40: Submenus

    1. One level back by acknowledging a setting 2. One level back by pressing the "Back" button 3. Completely back to the main screen with the button "Main menu" (Rehm or Home). Language menu The available languages are displayed as flags in a selection list.
  • Page 41 Function description Corner menu Assist Indicates that you are in Assist Corner menu Display and recommendations for the welding task other than the TIG or electrode settings:  Number of positions  Type of gas  Gas flow rate  Gas nozzle size ...

  • Page 42: Save And Load Programs

    Function description Workpiece view Select the workpiece with the rotary encoder, confirm by pressing and set the material thickness. Displays: - Material thickness - Grinding angle (only with butt seam) Workpiece - A dimension (only for fillet welds) - Required number of layers Alerts: An alert is given for inapplicable settings.

  • Page 43: Manage Parameter Lists (Folders)

    Function description The individual welding unit base settings such as the start and end crater current, ignition energy, etc., for use by multiple people can be saved for each person and quickly duplicated. 7.3.3 Manage parameter lists (folders) Initially, the overview of the existing program lists appears in the program submenu, as shown in Fig.25.
  • Page 44 Function description Fig.25 Submenu program lists The following is a representative example of how to create a program list. Fig.26 Example creation of a P list...

  • Page 45: Optional Water Cooling Unit

    Function description 7.4 Optional water cooling unit The TIGER DIGITAL can be equipped with the REHM water cooling unit as an option. The TIGER DIGITAL is connected to the water cooling unit with a plug-in connection cable with 9-pin plug (see fig. 27)

  • Page 46: Setup / Special Parameters

    Function description Setup / special parameters Up/Down Idle Adjustment possibilities from the torch using the UP / DOWN buttons when not welding:  Switch off UP/Down function (inactive)  AC waveform  AC frequency  AC balance  AC time DualWave ...
  • Page 47 Function description Current I and I Setting the welding current I and I with an up/down torch: 1. Enable UP/Down torch The currents I can be controlled up or down before and during welding work. 2. I can be adjusted using Up/Down 3.
  • Page 48 Function description Current display Voltage indicator off Display of the average voltage after welding has stopped. Display of the average voltage - during welding - at the end of welding The average value is updated every 2 seconds. Voltage detection range: Water cooling unit Pump and fan are off mode...
  • Page 49 Function description Factory settings All settings (parameters) are reset to the factory settings. This does not affect: Special parameters and programs. Welding parameters Factory settings Gas pre-flow time 0.1 s Ignition current Starting current Slope-up time 0.1 s Current I 100 A.

  • Page 50: Error Memory

    Function description Error memory Error message display  Number of errors  Error text  Welding time  Operating time 10 Indicating symbol The REMOTE CONTROL AKTIVE symbol [BF17]appears on the right of the status line [BF9] and indicates the remote controller as active.

  • Page 51: Accessories

    11.3 Optional water cooling unit Part No.: 753 2316 The REHM water cooling unit (see Section 7.4) is adapted to the TIGER DIGITAL with respect to the performance data and the design and allows the use of water-cooled TIG torches. The water cooling unit, together with the TIGER DIGITAL, forms a single unit.

  • Page 52: Commissioning

    Warning! REHM welding equipment should be operated only by persons who are trained and instructed in the use, maintenance and the safety regulations concerning welding systems. When welding always wear protective clothing and take care to avoid other persons who may be in the vicinity being endangered by the UV radiation emitted by the welding arc.

  • Page 53: Placement And Transportation Of The Welding Unit

    12.5 Cooling the welding unit Place the REHM welding unit so that the air entry and exit ports are not obstructed. The power section can only achieve the specified duty cycle with sufficient ventilation (see “Technical data”). Ensure that no grinding chips, dust or...

  • Page 54: Guidelines For Working With Welding Current Sources

    12.8 Connection of external components The connection of external components is achieved via the standard 19 pole remote control socket on the front side of the TIGER DIGITAL. REHM accessories are available for this purpose as described in Section 17.

  • Page 55: Operation

    Carefully read the operating instructions, in particular the  Section 2, before commissioning and before beginning work with this welding current source. Warning! REHM welding equipment should be operated only by persons who are trained and instructed in the use, maintenance and the safety regulations concerning welding systems.

  • Page 56: Fire Protection

    Operation  Notify persons in the vicinity of the danger of arc radiation as well as hot metal sputter and parts and protect against these with non-flammable screens.  Pressurised gas bottles are also a potential hazard. Therefore strictly comply with the safety instructions of the respective professional association and the supplier.

  • Page 57: Checks Before Switching On

    13.8 Practical instructions for use The practical instructions for use listed below can only provide an overview of the uses for REHM TIG welding systems. In the event of questions concerning special welding tasks, materials, protective gases or welding fixtures refer to topic-specific publications or specialist recommendations for manufacturers.
  • Page 58 When welding with DC the electrode is ground to a point. With the REHM TIG welding system it is also possible to work in the AC range with balance adjustments in the negative range using a pointed electrode. This offers the advantage that the arc is even more concentrated and effective.
  • Page 59 During the negative half-wave the electrode cools down and the aluminium is heated. As only a short plus pulse is required to break the aluminium oxide skin, the REHM TIG system can be worked with a high negative share.

  • Page 60: Faults Tig Welding Unit

     Section 2 Before restarting the system must be released by qualified personnel. 14.2 Table of faults REHM control panel is not working The digital display instrument has no display and no LEDs illuminate. Cause: Remedy:...
  • Page 61 Fault When switched on the system has different parameters than those when it was switched off Cause: Remedy: Values are only saved Execute welding process after a successful welding process. No protective gas flows Cause: Remedy: Bottle is empty or the gas hose is kinked. Check Pressure reduced is defective.
  • Page 62 Fault Arc has a strange colour Cause: Remedy: No or too little protective gas Check Electrode dirty Grind Electrode burns off Cause: Remedy: No protective gas Check Current load too high Use a thicker electrode Pulse share too high with AC current Increase the negative share using welding balance...

  • Page 63: Error Messages

    No loops and windings. reversing pole power is too high  - Remote control Connected torch is not Use a Rehm torch connected to the detected. Defective torch. torch socket  - Coolant Temperature of the coolant >...
  • Page 64 Fault Acknowledge legend A Fault message can be reset by switching off and back on again. Fault message will go out automatically when the fault is eliminated C Fault message will go out when the fault is eliminated and the push and rotatory encoder [Fig.8] is actuated.

  • Page 65: Maintenance Work

    REHM original spare parts. If maintenance or repair work is performed on this unit by persons who have not been trained and authorised to carry out the work by REHM, then claims against REHM become void. Before beginning cleaning work the unit must be switched off and disconnected from the mains supply.

  • Page 66: Cleaning The Inside Of The Unit

    15.3 Cleaning the inside of the unit If the REHM welding unit is used in a dusty environment the inside of the unit must be cleaned at regular intervals by blowing out or vacuuming. The frequency of this cleaning depends on the respective conditions of use. Only use clean, dry air to blow out the unit or use a vacuum cleaner.

  • Page 67: Technical Data

    Technical data 16 Technical data 180 DC 230 DC 180 AC/DC 230 AC/DC Mains voltage U1 * 1 x 230 V 1 x 230 V 1 x 230 V 1 x 230 V Mains voltage tolerance without water cooling -15% / +10% 90V...
  • Page 68 Technical data...
  • Page 69 Technical data 180 DC 230 DC 180 AC/DC 230 AC/DC Protection class without water cooling * with water cooling Insulation class * EMV emissions class Cooling type Overvoltage category Torch cooling without water cooling with water cooling Water Water Water Water Noise emission * <...
  • Page 70 Technical data Mains voltage The unit may only be operated and connected with a grounded mains (grounded neutral and protective conductor). Open-circuit voltage Measured open-circuit voltages, which are below the permissible tolerance according to EN60974-4 for voltages, less than the open-circuit voltage specified on the type plate, pose no danger and do not change the welding properties.

  • Page 71: Accessories

    Accessories 17 Accessories REHM-part number Name Ground cable 7810101 Ground cable 25 mm² 4 m 13 mm 400A clamp Electrode cable Electrode cable 25 mm² 5m 13mm with 260A 7810201 mount Pressure reducer Pressure reducer with content and work pressure...
  • Page 72 Accessories REHM-part number Name Torch wear parts sets 7700435 Wear parts set R SR 17/26 7700440 Wear parts set R SR 20 7700426 Wear parts set R TIG 200 7700425 Wear parts set R TIG 150/260W Remote control Foot-actuated remote controller TIGER DIGITAL...

  • Page 73: Circuit Diagrams

    Circuit diagram 18 Circuit diagrams Circuit diagram TIGER DIGITAL 230 AC/DC...
  • Page 74 Circuit diagram Circuit diagram TIGER DIGITAL 230 DC...
  • Page 75 Circuit diagram Circuit diagram TIGER DIGITAL 180 AC/DC...
  • Page 76 Circuit diagram Circuit diagram TIGER DIGITAL 180 DC...
  • Page 77 Circuit diagram Legend to the circuit diagram Identifier Name Main board Operating unit CAN-module Power supply AC control HF ignition device HF interference suppression Operation film Water cooling device PFC switch Primary switch Secondary rectifier AC switch Primary rectifier Gas valve Main switch Power transformer Ignition transformer...
  • Page 78 Circuit diagram Circuit diagram TIGER DIGITAL water cooling unit...

  • Page 79: Index

    Index 19 INDEX " "Automatic ..................................36 "Cleaning ..................................67 "Commissioning" ................................52 "Connecting ................................53, 57 "DVS" .................................... 59 "Faults" ..................................60 "Health ................................... 11 "High ....................................26 "Increased ..................................52 "Index" ................................... 80 "Instructions ................................... 57 "Intended ..................................9 "Lift-Arc"..................................
  • Page 80 Index Operating mode ................................23 Operation checks before switching on" ............................. 57 Out of position welding" ............................28, 33 Product identification Machine name ................................2 Type number ................................2 Protective gas consumption" ............................35 Pulsing" ..................................33 Purpose of the document .............................. 12 Rod electrodes ................................
  • Page 82 EC declaration of conformity For the following named products TIG - protective gas - welding machine TIGER DIGITAL 230 AC/DC ULTRA TIGER DIGITAL 180 AC/DC ULTRA TIGER DIGITAL 230 DC ULTRA TIGER DIGITAL 180 DC ULTRA TIGER DIGITAL 230 AC/DC HIGH...
  • Page 83 REHM – The benchmark for modern welding and cutting Development, design and production – all under one roof – THE REHM product range at our plant in Uhingen. Thanks to this central organisation  REHM TIG/MAG inert gas-welding equipment and our forward-looking commitment, new insights can be SYNERGIC.PRO²...

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