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REHM TIGER 180 AC/DC HIGH Operating Instructions Manual

Tig inert gas welding units
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OPERATING INSTRUCTIONS
TIG inert gas welding units
TIGER 180 DC / AC/DC ULTRA/HIGH
TIGER 230 DC / AC/DC ULTRA/HIGH

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Summary of Contents for REHM TIGER 180 AC/DC HIGH

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

  • Page 2: Product Identification

    Date of issue: 28.04.2016  Rehm GmbH u. Co. KG, Uhingen, Germany 2016 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 Selection of programs P1 and P2 with Up/Down torch 4.15.4 Anti-stick function 4.16 Foot-actuated remote controller TIGER 180/230 4.17 REHM TIG torch Commissioning Safety information Working under increased electrical hazard Placement and transportation of the welding unit. Connecting the welding unit...

  • Page 5: Introduction

    Introduction 1.1 Foreword Dear Customer, You have purchased a REHM inert gas welding system and in doing so have acquired a noteworthy branded appliance. We thank you for the trust you have placed in our quality products. Only the highest quality components are used in the development and manufacture of REHM TIGER welding systems.

  • Page 6: General Description

    Introduction 1.2 General description Fig. 1: TIGER Fig. 2: TIGER with integrated Water cooling...

  • Page 7: 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 these. The machines may only be operated by persons who trained in the use and maintenance of welding equipment.

  • Page 8: 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 8.4 Proper disposal.

  • Page 9: 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 10: Notes And Requirements

    REHM welding machines are, except when this is expressly stated in Applications writing by REHM, only for sale to commercial / industrial users and are only intended to be used by these. TIGER TIG inert gas welding systems may only be used ...
  • Page 11 For TIGER 230 AC/DC and TIGER 230 DC The unit complies with IEC61000-3-12. 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 personnel assigned and trained personnel may work on and with the system.

  • Page 12: Unit Description

    Unit description Unit description TIGER without water cooling Front view Rear view TIGER with integrated water cooling Front view Rear view Fig 3: Unit description...
  • Page 13 Unit description Symbol Function / description Control panel - See "Description of controls" Control panel push and rotate knob 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 14: Function Description

    Function description Function description 4.1 Overview of the operating panel Ultra AC/DC Ultra DC High AC/DC High DC Fig. 4: Overview of the operating panel...

  • Page 15: Description Of The Controls

    Function description 4.2 Description of the controls Fig. 5: Controls Ultra Ultra High High Symbol Description / function AC/DC AC/DC     Operating and temperature displays     Remote control display     Special parameter button Welding parameters ...
  • Page 16 Function description Ultra Ultra High High Symbol Description / function AC/DC AC/DC     Program 1 - Quick Choice button     Program 2 - Quick Choice button     Push and rotate knob (R pilot) Button process ...

  • Page 17: Switch On

    Function description 4.3 Switch on The TIGER welding system is started with the mains switch. All LEDs illuminate for approximately 1 second. Next the software version and the machine type are displayed in the digital display for approximately 3 seconds. After 3 seconds expires all of the settings from the last welding process are run through in sequence and the set values displayed.

  • Page 18: Push Button Welding Process

    Function description 4.5 Push button welding process The selection of the desired welding process TIG welding, electrode welding and electrode BOOSTER is made with the push button [9], whereby the LEDs indicate the selected welding process by illuminating. 4.5.1 TIG welding The setting of the welding parameters for TIG welding is performed as described in Section 4.5.

  • Page 19: The Welding Parameters

    Function description 4.6 The welding parameters The press and rotate switch [8] is used to select the welding parameters [4] shown in the welding curve for TIG welding with AC current. Using both the LEDs and the 3 digit digital display [5], the setting options are always selected and set using the same principle /see section 4.6.1) 4.6.1 Setting the welding parameters...

  • Page 20: Starting Current I

    Function description 4.6.4 Starting current I The settings for the starting current I [4] is performed as described in Section 4.6.1. The starting current is the welding current that is first set after the ignition process. The setting can be infinitely adjusted between 10% and 200% of the selected current I (but a maximum of Imax), for example: Starting current 40% and welding current I...
  • Page 21 Function description During welding the pulse can be switched off and switched back on by actuating the torch trigger 2. If torch trigger 2 is actuated during pulsing welding current the pulses are switched off and welding continues with welding current I .

  • Page 22: Welding Current

    Function description 4.6.8 Welding current I The settings for the welding current I [4] is performed as described in Section 4.6.1. The use of welding current I only makes sense with TIG welding and therefore is only displayed when TIG welding. Welding current I is used for pulsing (see Section 4.6.7) and for twin-current control: Twin-current control:...

  • Page 23: End Crater Current L

    Function description Torch trigger 1 Gas valve Welding current Fig. 7: Process for manual pulsing 4.6.11 End crater current l The setting of the end crater current l [4] is performed as described in Section 4.6.1. The end crater current is the welding current to which the welding current is reduced when the welding process is ended.

  • Page 24: Ac Balance ( )

    AC welding. The REHM patented automatic frequency control can be selected as a special feature for TIG AC current welding. To activate, the setting for the frequency is switched to "On", which switches on under 30 Hz.

  • Page 25: Push And Rotate Knob (R-Pilot)

    Function description 4.6.17 Push and rotate knob (R-Pilot) The push and rotate knob [8] is centrally located and can be operated by a right handed or left handed operator. The special receptacle provides very good protection against mechanical stress. The push and rotate knob has no end stop so over rotation is not possible.

  • Page 26: Cycle Operating Mode

    Function description Peculiarities: to the 2nd cycle Actuating the torch trigger a second time during slope-up of the current extinguishes the arc and the protective gas continues to flow according to the selected gas post-flow time. to the 3rd Cycle The arc can be switched off during the slope-down period.

  • Page 27: Tig Spot Welding

    Function description 4.7.3 TIG spot welding The spot welding mode is recommended for welding with a fixed spot welding time from 0.01 seconds. The stationary welding process runs with a fixed spot welding time, unless the trigger is released prematurely during the welding. The program runs to the end after expiry of the set spot welding time or after releasing the torch trigger during the welding.

  • Page 28: High-Frequency (Hf) Ignition

    LED display shows whether the high frequency is on or off. 4.8.1 Welding with HF ignition REHM TIG welding machines are equipped with RF igniter. HF ignition 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 29: Polarity

    4.10.4 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: Load And Save Programs

    Function description Fig.11: Welding current process with the dual-wave method 4.11 Load and save programs Loading and saving of 100 programs is performed using the push buttons Load [14] for loading and the Save [13] for saving. The programs can be stored and loaded under an arbitrary number.

  • Page 31: Load Program

    Function description 4.11.2 Load program Programs ate loaded using the Load [14] push button.  Briefly pushing the Load [14] push button illuminates the indicator LED “Pxx” for loading the program.  Select the desired program number using the push and rotate knob [8] (for example “P34”).

  • Page 32: Control Lamps

    Function description 4.13 Control lamps Control lamp REMOTE CONTROL ACTIVE [2] The LED illuminates when the remote control element is connected and active. Control lamp OPERATION (LED illuminates green) [1] The LED illuminates green If open-circuit voltage is connected to the torch or electrode holder. Control lamp TEMPERATUR (LED illuminates yellow) [1] If the temperature limit is reached the LED illuminates yellow.

  • Page 33: Special Parameters

    Function description 4.14 Special parameters Special parameters enable the user to make individual settings. 4.14.1 Overview of special parameters Fig. 12: Overview of special parameters 4.14.2 Setting special parameters  Press the Special Parameter push button [3].  The desired special parameter (SP1 to SP7 and CLr) can be selected and activated by turning and pressing the push and rotate knob [8].

  • Page 34: Explanation Of Special Parameters

    Function description 4.14.3 Explanation of special parameters Special parameter SP1 – Torch potentiometer  This special parameter is foreseen for use with a torch with a potentiometer. Torch potentiometer is inactive, this means that the potentiometer on the torch is not evaluated. Torch potentiometer is active, this means that the potentiometer on the torch is evaluated.
  • Page 35 Function description Special parameter SP6 – Voltage indicator  Voltage indicator off Average voltage is shown at the end of every weld. The actual voltage is shown when welding (the value is updated every 2 seconds) and at the end of every weld. Voltage detection range: Detection range Special parameter SO7 –...

  • Page 36: Other Functions

    Function description 4.15 Other functions 4.15.1 Torch functions for fast setting of the welding currents I Setting the welding current I (before starting to weld) Briefly (<0.5 seconds) actuating the torch trigger 1 selects the setting options for – the LED current I the welding current I [4] flashes.

  • Page 37: Selection Of Programs P1 And P2 With Up/Down Torch

    TIGER. CAUTION: When TIG torches with remote control capability of any type that are not explicitly recommended by REHM are used all warranty claims are void.

  • Page 38: 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 39: Placement And Transportation Of The Welding Unit

    5.5 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 40: Guidelines For Working With Welding Current Sources

    5.8 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. REHM accessories are available for this purpose as described in Section 10. Only external components listed in this guide may be used. If external components other than those listed are used, the manufacturer’s warranty is...

  • Page 41: Operation

    Instruction, 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. Working with and maintaining electric welding units is always associated with possible hazards.

  • Page 42: Instructions For Your Personal Safety

    Operation 6.3 Instructions for your personal safety The effects of radiation from the electrical arc and the hot metal can result in serious injury to unprotected skin and eyes.  Only use a welder’s hood in perfect condition or automatic welding masks with an approved filter and leather gloves to protect eyes and skin from sparks and radiation from the arc (see TRBS 2131 and BGR 500 KAP.

  • Page 43: Checks Before Switching On

    6.8 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 44 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 45 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 46: Faults Tig Welding Unit

     Section 2 Before restarting the system must be released by qualified personnel. 7.2 Table of faults REHM control panel is not working The digital display instrument has no display and no LEDs illuminate. Cause: Remedy:...
  • Page 47 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 48 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 welding Increase the negative share using balance Connection between the torch and the grounding cable reversed...

  • Page 49: Error Messages

    No loops current or and windings. reversing pole power is too high  Connected torch is not  Use a Rehm torch  - Remote control  Defective torch. detected. connected to the torch socket ...
  • Page 50 Fault Acknowledge legend Fault message can be reset by switching off and back on again. Fault message will go out automatically when the fault is eliminated Fault message will go out when the fault is eliminated and the push and rotate knob [23] is actuated. If the fault is still present the fault message will reappear in the digital display [22] after 2 seconds.

  • Page 51: 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 and claims against REHM for warranty or liability become void.

  • Page 52: Cleaning The Inside Of The Unit

    8.3 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 53: Technical Data

    Technical data 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 54 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 55 Technical data Mains voltage The unit may only be operated and connected with a grounded mains (grounded neutral and protective conductor). Protection type Protection type IP23 S Protection of the unit against ingress of solid foreign bodies  larger than 12 mm Protection of the unit against spray water up to an angle of 60°...

  • Page 56: Accessories

    Accessories 10 Accessories REHM-part number Name Ground cable 7810101 Ground cable 25 mm² 4 m 13 mm 400A clamp Electrode cable 7810201 Electrode cable 25 mm² 5m 13mm with 260A mount Pressure reducer Pressure reducer with content and work pressure gauge, 200 bar,...
  • Page 57 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 7531051 Remote foot-actuated controller TIGER 180/230...

  • Page 58: Circuit Diagrams

    Circuit diagram 11 Circuit diagrams Circuit diagram TIGER 230 AC/DC...
  • Page 59 Circuit diagram Circuit diagram TIGER 230 AC...
  • Page 60 Circuit diagram Circuit diagram TIGER 180 AC/DC...
  • Page 61 Circuit diagram Circuit diagram TIGER 180 DC...
  • Page 62 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 63 Circuit diagram Circuit diagram TIGER water cooling unit...

  • Page 64: Index

    Index 12 INDEX AC welding ..................................45 Accessories ................................... 56 Applications ................................... 10 Circuit diagrams ................................58 Connecting the grounding cable ............................ 43 Connecting the welding unit ............................39 DC welding ..................................45 Function description ..............................14 Gap bridging .................................. 21 Ignition ...................................
  • Page 65 Index Placement and transportation ............................39 Product ID Machine name ................................2 Product identification Type number ................................2 Protective gas consumption............................23 Protective gases ................................44 Pulsing ................................... 21 Purpose of the document .............................. 11 Rod electrodes ................................45 Safety Hazards of non-compliance ............................
  • Page 66 EC. Directive 2006/42/EC article 1, paragraph 2 the above mentioned products fall exclusively within the scope of the directive 2006/95/EC relating to electrical equipment designed for use within certain voltage limits. This declaration is given for the manufacturer: REHM GmbH u. Co. KG Schweißtechnik Ottostr. 2 73066 Uhingen Uhingen, 28.04.2016 submitted by R.
  • Page 68 REHM – Setting the pace in welding and cutting REHM WELDING TECHNOLOGY – The REHM range German Engineering and Production at its best  REHM MIG/MAG inert gas welding units Development, construction and production – all under one SYNERGIC.PRO² gas- and water-cooled to 450 A roof –...

This manual is also suitable for:

Tiger 180 dc ultraTiger 180 dc highTiger 230 dc ultraTiger 230 ac/dc ultraTiger 230 dc highTiger 230 ac/dc high

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