TIP TIG ALLINONE Operating Manual
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TIP TIG ALLINONE Operating Manual

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TIP TIG - ALLINONE
Operating Manual
Version 1.5 Revision 0

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Summary of Contents for TIP TIG ALLINONE

  • Page 1 TIP TIG - ALLINONE Operating Manual Version 1.5 Revision 0...
  • Page 2 Thank you for the trust you have placed in our company and congratulations on buying this high- quality 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.

  • Page 3: Table Of Contents

    TIP TIG - ALLINONE, OPERATING MANUAL CONTENTS GENERAL INSTRUCTIONS INTENDED USE Declaration of conformity Welding in environments with increased electrical hazards Calibration/Validation SAFETY RULES Explanation of safety symbols General safety instructions GENERAL Device concept Power sources Crane transport CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS...
  • Page 4 TIP TIG - ALLINONE, OPERATING MANUAL 10.2 Wire Feed Speed 10.3 Wiring diagram Page 4 of 57...

  • Page 5: General Instructions

    © 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.

  • Page 6: Intended Use

    In case of unauthorised changes, improper repairs, and/or prohibited modifications which have not In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc been explicitly authorised by TIP TIG Automation GmbH, this declaration shall be voided. Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided.

  • Page 7: Safety Rules

    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.
  • Page 8 TIP TIG - ALLINONE, 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.
  • Page 9 TIP TIG - ALLINONE, 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.

  • Page 10: General

    Power sources The TIP TIG – AllinOne wire feeder can be used with many power sources available on the market – See Table 3-1: Power supply compatibility. Preferably TIP TIG – AllinOne is used in combination with the specially designed power source TIP TIG – TIG 350, 350 AC, 500, 500 AC.

  • Page 11: Crane Transport

    TIP TIG - ALLINONE, OPERATING MANUAL Crane transport The TIP TIG – AllinOne wire feeder can be transported by crane using its handles. The maximum load-bearing capacity of the handles is 35 kg (77.16 lb.) WARNING Falling equipment can cause death or serious injury.

  • Page 12: Controls, Connections And Mechanical Components

    TIP TIG - ALLINONE, OPERATING MANUAL CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS System overview Front of TIP TIG – AllinOne wire feeder Description Carrying handle Control panel – See 5.7 Control panel Hotwire indicator lamps Temperature fault indicator (left) is lit in the case of overheating. It extinguishes after a few minutes when the unit has cooled down.
  • Page 13 TIP TIG - ALLINONE, OPERATING MANUAL Rear of TIP TIG – AllinOne wire feeder Description Main power switch with fuses – See 5.4 Main power switch with fuses Cooling air outlet Rear connection – See 5.3 Rear connection Protective cap Cover for the wire feed mechanism and other operating elements.
  • Page 14 TIP TIG - ALLINONE, OPERATING MANUAL TIP TIG – AllinOne wire feeder: operating elements in the machine Description Four roll wire drive Clamping levers for setting the contact pressure of the feed rollers Hotwire amperage adjustment – See 5.5 Hotwire amperage adjustment...

  • Page 15: Front Connection

    TIP TIG - ALLINONE, OPERATING MANUAL Front connection Description Connection socket control lead (7-pole) for connecting control lead from the welding torch hose package Connecting nipple current / coolant supply (blue) for connecting current / coolant supply (G3/8" RH) from the welding torch hose package Connecting nipple shielding gas for connecting shielding gas (G1/4"...

  • Page 16: Rear Connection

    TIP TIG - ALLINONE, OPERATING MANUAL Rear connection Description Connector plug (7-pole) – option for connecting TIP TIG Automation 0-10V (AUTOMATION ONLY) Connection socket (7-pole) Communication Connection for the welding machine Connector plug (4-pole) – Mains connection 120/230 VAC main power connection Connecting nipple shielding gas for connecting shielding gas (G1/4"...

  • Page 17: Main Power Switch With Fuses

    TIP TIG - ALLINONE, OPERATING MANUAL Main power switch with fuses Description Main power switch machine on/off Mains fuse T8 A, 120/230 VAC Feeder fuse T8 A, 32 VAC Hotwire amperage adjustment Description Adjustment screw adjust the setting with a flat screw...

  • Page 18: Control Panel - D24B2M1.6

    TIP TIG - ALLINONE, OPERATING MANUAL Control panel – D24B2M1.6 Function Display shows the current figure of the selected parameter Parameter selection button for selecting the parameters listed below (5) Adjusting button - for negative adjustment of the selected parameter (5)
  • Page 19 TIP TIG - ALLINONE, OPERATING MANUAL Mode indicator shows which mode is selected: - 4-Stroke - 2-Stroke - Lead Voltage 0-10 V - Spot Function - Program Load - Program Save Display values Wire Feeding Speed Display value multiplied by 0,0635 is the wire feed speed in m/min...

  • Page 20: Control Panel - Version

    TIP TIG - ALLINONE, OPERATING MANUAL Control panel – Version 2.0 Display – Parameters and Modes (14) (15) (16) (10) (11) (12) (13) Function Menu (parameter) forecast up/down shows which parameter will be selected when switching menu up/down Parameter range indicator shows min.
  • Page 21 TIP TIG - ALLINONE, OPERATING MANUAL Software update port to update provided TIP TIG software C – Button not assigned button is not assigned in this software version B – Menu (parameter) down button switching menu down (10) D – Button not assigned...
  • Page 22 TIP TIG - ALLINONE, OPERATING MANUAL Display – Settings menu Function Software version indicates the installed software version number Settings menu highlights the selected parameter and its value - Weld amps (on/off) - Weld amps max - Weld amps offset...
  • Page 23 TIP TIG - ALLINONE, OPERATING MANUAL Display values WIRE SPEED Display value multiplied by 0,0657+0,17 is the wire feed speed in m/min! (WIRE FEED SPEED = 0,0657*Display value+0,17) Example: Factor 100 = 6,74 m/min or 265,35 IPM For more information please go to Appendix 9.2.2 or visit https://www.tiptig.com/english/support/...

  • Page 24: Installation And Commissioning

    TIP TIG - ALLINONE, OPERATING MANUAL INSTALLATION AND COMMISSIONING Before installation and commissioning Safety WARNING Incorrect operation or shoddy workmanship can cause serious injury or damage. All work described in this document must only be carried out by trained and qualified personnel. All functions described in this document must only be used by trained and qualified personnel.

  • Page 25: Connecting The Interconnection Hose Package, Welding Torches And Workpiece Lead

    TIP TIG - ALLINONE, OPERATING MANUAL Connecting the interconnection hose package, welding torches and workpiece lead Safety WARNING An electric shock can be fatal. Before starting the work described below: • turn the power source mains switch to the „0“ position •...
  • Page 26 TIP TIG - ALLINONE, OPERATING MANUAL Connecting nipple coolant supply (blue) – option for connecting coolant supply (G3/8" RH) from the interconnection hose package Connecting nipple coolant return (red) – option for connecting coolant return (G3/8" LH) from the interconnection hose package...
  • Page 27 TIP TIG - ALLINONE, OPERATING MANUAL 6.2.2 Connecting the workpiece lead NOTE! The item described in the following is part of the machine’s scope of delivery. Description Workpiece Connector plug hot wire and workpiece for connecting hot wire power, plus potential, workpiece connection Push the cable socket for the hot wire current onto the connector plug (TIG hot wire) and lock by turning to the right.
  • Page 28 TIP TIG - ALLINONE, OPERATING MANUAL 6.2.3 Connecting a welding torch CAUTION Risk of injury and damage from loose connections. All cables, lines and hose package must be properly secured, undamaged, insulated and adequately dimensioned at all times. Prepare welding torch according to the welding task in hand (see operating instructions for the torch).

  • Page 29: Inserting/Replacing Feed Rollers

    TIP TIG - ALLINONE, OPERATING MANUAL Extend and lay out the torch hose package. Insert the wire feed plug of the welding torch into the wire electrode connector and lock by turning to the right. Push the cable plug for the welding current (TIG) onto the connection socket (TIG hot wire) and lock by turning to the right.

  • Page 30: Inching The Wire Electrode

    TIP TIG - ALLINONE, OPERATING MANUAL CAUTION Risk of injury from springiness of spooled wire electrode. When inserting the wire spool/basket- type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back.
  • Page 31 TIP TIG - ALLINONE, OPERATING MANUAL Inching the wire electrode CAUTION Risk of injury and damage from wire electrode emerging. While working: • hold the welding torch with the point directed away from the face and body • wear suitable protective goggles •...

  • Page 32: Spool Brake Setting

    TIP TIG - ALLINONE, OPERATING MANUAL Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and teflon core using guide pipe.

  • Page 33: Start-Up

    TIP TIG - ALLINONE, OPERATING MANUAL START-UP Safety WARNING Incorrect operation or shoddy workmanship can cause serious injury or damage. All work described in this document must only be carried out by trained and qualified personnel. All functions described in this document must only be used by trained and qualified personnel.

  • Page 34: Troubleshooting, Maintenance And Disposal

    TIP TIG - ALLINONE, OPERATING MANUAL TROUBLESHOOTING, MAINTENANCE AND DISPOSAL Troubleshooting Safety WARNING Work that is carried out incorrectly can cause serious injury or damage. All the work described below must only be carried out by trained and qualified personnel. Do not carry...
  • Page 35 TIP TIG - ALLINONE, OPERATING MANUAL Troubleshooting-Checklist PC Board will not power / Display Blank - Check 120/230V AC Input Power Supply from power cord plug end - Check fuses on the rear panel - Check 120/230V AV at transformer with meter - Check 32V AC at transformer with meter - Remove front panel PC Board.
  • Page 36 TIP TIG - ALLINONE, OPERATING MANUAL - Check fuse on the PC Board If all of the above checks show volatage, PC Board is faulty and needs to be replaced. Feeder Motor will not operate when button pressed on - Check to make sure PC Board has voltage - Check fuses on the rear panel - Check plug X2-1S for DC voltage.
  • Page 37 TIP TIG - ALLINONE, OPERATING MANUAL If voltage is present, oscillator motor is faulty If voltage is not present, bad PC Board If all of the above checks show voltage, Oscillator Motor is faulty and needs to be replaced. No Hotwire Input Power - Check to make sure Main power switch on rear panel is on.
  • Page 38 TIP TIG - ALLINONE, OPERATING MANUAL - Connect “Connector plug hot wire and workpiece” (See 5.3) and “Connection socket hot wire” (See 5.2) with the Hotwire test cable and put a meter clamp around the test cable. Press wire feed button on torch.
  • Page 39 TIP TIG - ALLINONE, OPERATING MANUAL If all of the above checks show no amperage, Hotwire is faulty and needs to be replaced. Page 39 of 57...
  • Page 40 TIP TIG - ALLINONE, OPERATING MANUAL Coolant error / no coolant flowing Insufficient collant fow - Check coolant level and refill if necessary - Eliminate kinks in conduit system (hose package) - Reset automatic cutout of the coolant pump by activating...
  • Page 41 TIP TIG - ALLINONE, OPERATING MANUAL Setting pressure units > see chapter - Check settings and correct if necessary 6.5 Inching the wire electrode Worn wire rolls - Check and replace if necessary Wire feed motor without supply - Check and replace fuse if necessary...

  • Page 42: Care, Maintenance And Disposal

    TIP TIG - ALLINONE, OPERATING MANUAL Care, maintenance and disposal General Under normal operating conditions, the device requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.

  • Page 43: Technical Data

    TIP TIG - ALLINONE, OPERATING MANUAL TECHNICAL DATA Hot wire current setting range 60 A to120 A Max. hot wire voltage 10,5 V Duty cycle at 40 °C ambient temperature 35% DC 120 A 60% DC 100 A 100% DC...
  • Page 44 TIP TIG - ALLINONE, OPERATING MANUAL 600 x 352 x 525 mm Dimensions L/W/H 23.62 x 13.85 x 20.66 in 34 kg Weight 74 lb. EMC class Safety identification EAC/S/CE see declaration of conformity (machine Harmonized standards used documentation) Page 44 of 57...

  • Page 45: Appendix

    TIP TIG - ALLINONE, OPERATING MANUAL APPENDIX 10.1 Spare part list 10.1.1 Front of TIPTIG (Page 12) Pos. Description Item-No. (in pic) Wire electrode connection (complete with plastic cover) 77700051 for connecting the welding torch wire feed 10.1.2 Front connection (Page 15) Description Item-No.
  • Page 46 Rear connection (Page 16) Description Item-No. (in pic). Connector plug (7-pole) – option 95500205 for connecting TIP TIG Automation 0-10V (AUTOMATION ONLY) Connection socket (7-pole) 95500210 Communication Connection for the welding machine Connector plug (4-pole) – Mains connection 95500215 120/230 VAC main power connection...
  • Page 47 TIP TIG - ALLINONE, OPERATING MANUAL 10.1.4 Main power switch (Page 17) Pos. Description Item-No. (in pic) Main power switch 95500260 ON/OFF 10.1.5 Control Panel (Page 12) Pos. Description Item-No. (in pic) Control Panel 20000005 Front Panel + PC Board 10.1.6...
  • Page 48 TIP TIG - ALLINONE, OPERATING MANUAL 10.1.8 Four roll wire drive Page 48 of 57...
  • Page 49 TIP TIG - ALLINONE, OPERATING MANUAL Pos. Description Item-No. Feed plate front 88807200 Feed plate rear 88807202 Feed roll shaft 88807204 Hex-nut M6 88807206 Pressure arm assembly left SFT4 88807208 Pressure arm assembly right SFT4 88807208 Torsion spring 88807210 Motor-New Wire Drive...
  • Page 50 TIP TIG - ALLINONE, OPERATING MANUAL 10.1.9 Power transformer and Filters Pos. Description Item-No. (in pic) Power transformer 11000155 230V/115V/32V-160VA Filter 11000101 DGF3 Filter 77700092 Schurter 10A 10.1.10 Setup Kit Pos. Description Item-No. (in pic) Setup Kit 99909995 for alignment of wire feeding system...
  • Page 51 10.2 Wire Feed Speed 10.2.1 Control panel – D24B2M1.6 Display Value m/min 0,32 12,50 0,64 25,00 0,95 37,50 1,27 50,00 1,59 62,50 1,91 75,00 2,22 87,50 2,54 100,00 2,86 112,50 3,18 125,00 3,49 137,50 3,81 150,00 4,13 162,50 4,45 175,00 4,76 187,50 5,08...
  • Page 52 TIP TIG - ALLINONE, OPERATING MANUAL 8,26 325,00 8,57 337,50 8,89 350,00 9,21 362,50 9,53 375,00 9,84 387,50 10,16 400,00 10,48 412,50 10,80 425,00 11,11 437,50 11,43 450,00 11,75 462,50 12,07 475,00 12,38 487,50 12,70 500,00 13,02 512,50 13,34 525,00...
  • Page 53 TIP TIG - ALLINONE, OPERATING MANUAL 10.2.2 Control panel – Version 2.0 Display Value m/min 0,50 19,63 0,83 32,56 1,16 45,49 1,48 58,43 1,81 71,36 2,14 84,29 2,47 97,22 2,80 110,16 3,13 123,09 3,46 136,02 3,78 148,96 4,11 161,89 4,44...
  • Page 54 TIP TIG - ALLINONE, OPERATING MANUAL 9,37 368,82 9,70 381,75 10,03 394,69 10,35 407,62 10,68 420,55 11,01 433,48 11,34 446,42 11,67 459,35 12,00 472,28 12,32 485,22 12,65 498,15 12,98 511,08 13,31 524,02 13,64 536,95 13,97 549,88 14,30 562,82 14,62 575,75...
  • Page 55 TIP TIG - ALLINONE, OPERATING MANUAL 10.3 Wiring diagram 10.3.1 Control panel – D24B2M1.6 HF-Filter HF-Filter HF-Filter RC7-1 RC6-1 RC7-2 RC6-2 RC7-3 RC5-1 RC5-2 RC8-1 RC8-2 RC3-1 RC3-2 RC3-3 RC3-4 RC3-5 Page 55 of 57...
  • Page 56 TIP TIG - ALLINONE, OPERATING MANUAL 10.3.2 Control panel – Version 2.0 HF-Filter TORCH UP/DOWN TORCH Page 56 of 57...
  • Page 57 TIP TIG Automation GmbH Baumayrweg 5, 4631 Krenglbach, Austria Tel: +43 720 303500, Fax: +43 720 303500 99 E-Mail: office@tiptig.com www.tiptig.com...

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