Related Manuals for Fronius TransTig 1600
Summary of Contents for Fronius TransTig 1600
- Page 1 TransTig 1600 Operating Instructions TransTig 1700 Spare Parts List TIG power source 42,0426,0023,EN 003-08112013 42,0426,0023,EN 012006...
- Page 3 Read the manual carefully and you will soon be familiar with all the many great features of your new Fronius product. This really is the best way to get the most out of all the advantages that your machine has to offer.
- Page 5 Safety rules DANGER! “DANGER!” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.
- Page 6 General remarks Any malfunctions which might impair machine safety must be eliminated (continued) immediately - meaning before the equipment is next switched on. It’s your safety that’s at stake! Utilisation for The machine may only be used for jobs as defined by the “Intended purpose”. intended purpose The machine may ONLY be used for the welding processes stated on the only...
- Page 7 Obligations of Before starting work, all persons to be entrusted with carrying out work with personnel (or on) the machine shall undertake to observe the basic regulations on workplace safety and accident prevention to read this operating manual particulary the sections on “Safety rules” and to sign to confirm that they have understood these and will comply with them.
- Page 8 Protection for “Protective clothing” also includes: yourself and protecting your eyes and face from UV rays, heat and flying sparks with other persons an appropriate safety shield containing appropriate regulation filter glass (continued) wearing a pair of appropriate regulation goggles (with sideguards) behind the safety shield wearing stout footwear that will also insulate even in wet conditions protecting your hands by wearing appropriate gloves (electrically insula-...
- Page 9 Hazards from The harmfulness of the welding fumes will depend on e.g. the following noxious gases components: and vapours the metals used in and for the workpiece (continued) the electrodes coatings cleaning and degreasing agents and the like For this reason, pay attention to the relevant Materials Safety Data Sheets and the information given by the manufacturer regarding the components listed above.
- Page 10 Hazards from Do not loop any cables or other leads around your body or any part of your mains and weld- body. ing current (continued) Never immerse the welding electrode (rod electrode, tungsten electrode, welding wire, ...) in liquid in order to cool it, and never touch it when the power source is ON.
- Page 11 Stray welding When using current supply distributors, twin head wire feeder fixtures etc., currents please note the following: The electrode on the unused welding torch/ (continued) welding tongs is also current carrying. Please ensure that there is sufficient insulating storage for the unused welding torch/tongs. In the case of automated MIG/MAG applications, ensure that only insulated filler wire is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.
- Page 12 EMI Precautions Electromagnetic fields may cause as yet unknown damage to health. Effects on the health of persons in the vicinity, e.g. users of heart pace- makers and hearing aids Users of heart pacemakers must take medical advice before going anywhere near welding equipment or welding workplaces Keep as much space as possible between welding cables and head/ body of welder for safety reasons...
- Page 13 Particular danger Risk of scalding from accidental discharge of hot coolant. Before unplugging spots the connectors for coolant forward flow and return flow, switch off the coo- (continued) ling unit. Observe the information on the coolant safety data sheet when handling coolant.
- Page 14 Danger from Shielding-gas cylinders contain pressurized gas and may explode if they are shielding-gas damaged. As shielding-gas cylinders are an integral part of the overall cylinders welding outfit, they also have to be treated with great care. Protect shielding-gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
- Page 15 Safety precauti- Before transportation, completely drain any coolant and dismantle the ons at the instal- following components: lation site and Wire feed when being Wire wound coil transported Gas bottle (continued) Before commissioning and after transportation, a visual check for damage must be carried out.
- Page 16 Preventive and With parts sourced from other suppliers, there is no certainty that these corrective main- parts will have been designed and manufactured to cope with the stressing tenance and safety requirements that will be made of them. Use only original spares and wearing parts (this also applies to standard parts).
- Page 17 Data security The user is responsible for the data security of changes made to factory settings. The manufacturer is not liable, if personal settings are deleted. Copyright Copyright to this instruction manual remains the property of the manufacturer. The text and illustrations are all technically correct at the time of going to print.
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Page 19: Table Of Contents
Connection points on front of machine ..................... 6 Assembling a gas-cooled TIG torch ......................7 Design with central burner connection GWZ .................... 7 Design with Fronius central welding torch connection F ................7 Commissioning - General details ........................8 Mains connection ............................. 8 Setting-up instructions .......................... -
Page 20: General Details
Designed as a primary transistor-switched welding machine, the welding rectifier principle TRANSTIG 1600 / 1700 (DC) represents a further deve-lopment of the transistor cont- rolled welding machine. It is especially suitable for TIG-manual-, and MANUAL ELEC- TRODE WELDING in the DC area. The machine’s compact dimensions, low weight and modest power requirements are important advantages, both in the production and repair fields.UP/DOWN control (continuous welding-current regulation via torch trigger) is also... -
Page 21: Control Panel
Control panel TT 1700 WARNING! Operating the equipment incorrectly can cause serious injury and control panel damage. Do not use the functions described here until you have read and completely understood all of the following documents: these Operating Instructions all “Operating Instructions” for the system components, especially the “Safety rules”... - Page 22 Description of e) Manual electrode welding functions LED indicator (5) lights up and the digital voltmeter indicates the open-circuit (continued) voltage. The welding characteristics are governed by the values for ARC FORCE and HOT-START which are fixed in the machine itself. It is possible to influence these parameters from outside via the TPmc remote control unit and the inert menue at function selector switch position LED indicator for manual electrode welding...
- Page 23 Description of (14) LED indicator "HOLD" functions Permits subsequent checking of the welding parameters (continued) Lights up after actual values have been stored (end of welding) The mean of the welding current and voltage values measured before the end of a welding operation is indicated by the digital displays (2) and (3) The function works in the operating mode for r.c.
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Page 24: Connections, Switches And System Add-Ons
Connections, switches and system add-ons Connection points on front of machine Fig. 3 Design with central welding torch connec- Fig. 4 Design with central welding torch connec- tion GWZ tion F TIG TORCH CONNECTION for connecting the GAS + CURRENT supply for the welding torch (+) SOCKET with bayonet coupling as the earth cable connection point with TIG welding;... -
Page 25: Assembling A Gas-Cooled Tig Torch
Important! Please see your torch’s instruction manual for technical details on the torch and for information on torch assembly, care and maintenance. Control plug Control lead Gas and current connection Hose sleeve Fig. 7 Design with Fronius central welding torch connection F: Torch connection gas-cooled... -
Page 26: Commissioning - General Details
WARNING! Electrical work like fitting or changing the power plug, may only be carried out by a qualified electrician! The Transtig 1600 / 1700 may be operated as standard on a mains voltage of 230V (+/- 15% tolerance range). 195V... -
Page 27: Tig Operating Modes
TIG operating modes General remarks Warning! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understood all of the following documents: these Operating Instructions all “Operating Instructions” for the system components, especially the “Safety rules”... -
Page 28: Special 2-Step Mode
Special 2-step Activated from TIG torch trigger mode Mainly used for tack welding In the "PRESETTINGS LEVEL___" (see "Working with the program levels"), TIG parameters, StS must be set to ON Functional sequence 1. Pull back and hold trigger Gas pre-flow time elapses Arc ignites at the pre-set start arc value I (with HF ignition: HF cuts out automatical- ly after the ignition cycle) -
Page 29: 4-Step Mode - Without Intermediate Lowering
4-step mode - In the manual or automatic welding modes, for flawless welding joints without interme- Pre-settable parameters such as gas pre-flow, start arc, upslope time, main current, diate lowering downslope time, crater-fill cur-rent and gas post-flow time In the "PRESETTINGS LEVEL ___" program level (see section headed “Working with the program-levels”) (TIG parameters), SFS must be set to OFF Functional sequence 1. -
Page 30: 4-Step Mode - With Intermediate Lowering
4-step mode - Activated from TIG torch trigger with double-pushbutton function with intermediate Intermediate lowering to the reduced current I Welding current can be lowered lowering from the main current to the reduced current I and back, without interrupting the weld-ing sequence In the "PRESETTINGS LEVEL___"... -
Page 31: Special 4-Step Mode - Variant I
Special 4-step Enables the 4-step mode to be activated from TIG torch triggers without the double- mode - Variant I pushbutton function ZIntermediate lowering to the reduced current I (for details of how to set this, see "Working with the program-levels") Welding current can be lowered from the main current to the reduced current I and back, without interrupting the welding sequence In the "PRESETTINGS LEVEL___"... - Page 32 Special 4-step Enables the 4-step mode to be activated from TIG torch triggers with the double- mode - Variant II / push button function III / IV / V In the "PRESETTINGS LEVEL___" (see "Working with the program-levels"), TIG parameters, SFS must be set to "2"...
- Page 33 Special 4-step Pull back torch trigger and hold it down mode - Variant II / Release the torch trigger III / IV / V Push trigger forward and hold it (continued) Release the torch trigger Pull back torch trigger and hold it down Diagram showing intermediate lowering Fig.
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Page 34: Working With The Program Levels
Diameter of tungsten electrode (from 0-3,2mm) Program - For storing the parameters, once these have been set, by pressing the torch trigger Factory - For activating the parameters pre-set by Fronius, by pressing the torch trigger Parameters for electrode operating mode... -
Page 35: Level Codelock P2
Level codelock P2 The Transtig 1600 machine comes with an electronic codelock. The codelock is not activated when the machines leave the factory. Whenever you change the numerical combination, keep a written note of it! Only a 3-digit code may be used. (On new machi- nes, the code number is set to “321”) -
Page 36: Tig Welding With High-Frequency Ignition (Hf)
(insulated) that the electrode holder and the coated electrode cannot touch any electrically conductive or earthed parts. Fig. 18 Transtig 1600 / 1700 TIG welding machine consisting of: power source with control unit, manual torch, earth cable (gas cylinder with pressure regulator without figure) Start up Fit the torch with a tungsten electrode and a gas nozzle (see the instruction manual for the torch concerned). - Page 37 Start up a) Fit gas nozzle b) Contact-free HF ignition c) Arc is ignited (continued) Fig. 19 Ignition with HF ignition Ignition monitoring If, after fruitless attempts to ignite an arc or after an arc-interrupt, the welder forgets to stop the control sequence (2-step or 4-step) by means of the torch trigger, the shielding gas will continue to flow, leading to considerable wastage of gas.
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Page 38: Tig Welding With Contact Ignition (Without Hf)
TIG welding with contact ignition (without HF) Safety WARNING! At TIG welding, the manual electrode cable will always be live when: the mains master switch (1) is ON the operating mode is in the position and when the “start welding” signal has been given from the torch trigger. WARNING! Make sure, when the manual electrode cable is not in use, that it is either disconnected from the machine or else fastened to the machine in such a way (insulated) that the electrode holder and the coated electrode... -
Page 39: Manual Electrode Welding
“Safety rules” Fig. 21 The Transtig 1600 / 1700 as a manual electrode welding machine, consisting of: power source with control unit, Tpmc manual remote control unit (may be used optionally) and welding cables Start up Plug the welding cable into the appropriate current socket (see symbols) and secure it by turning it clockwise. -
Page 40: Remote Control Operation
Remote control operation General Remote control units are intended for use in situations where the welding parameters must be set directly from the welding workplace. The remote control unit is connected electrically to the power source by means of special cables 5 or 10 m in length. The following types of remote control unit are available: Manual electrode and TIG remote control unit ..... - Page 41 TR 50mc remote With the TR 50mc remote control pulsing unit two operational modes are possible: control pulsing Regulation of impulse current I by TR 50mc remote control unit. unit Adjustment of impulse current I by means of the TR 52mc remote control pedal (contiued) unit.
- Page 42 Important! If you wish to be able to switch from main current to crater-fill current while in pulsed-arc mode (without interrupting welding), use: 4-step mode and a FRONIUS TIG torch with double control-switch function, or: special 4-step mode and a non-Fronius TIG torch Please see chapter "Description of controls"...
- Page 43 TR 50mc remote Operating mode: control pulsing Regulation of pulse current I using TR 52mc remote-control pedal unit unit It is particularly advantageous with manual TIG welding in cases where it is necessary to (continued) alter the welding pulse current during the welding operation. (Where the welder is dea- ling with materials of different strengths, for example).
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Page 44: Tr 52Mc Remote Control Pedal Unit
TR 52mc remote Due to the fact that workpieces are often awkwardly shaped, it is often necessary to alter control pedal unit the amperage in the course of the welding operation. (e.g. repairing the edges of tools, improvements to cutting dies). The TR52mc pedal remote-control unit is designrd to be used for jobs such as these. -
Page 45: Tr 51Mc Remote Control Spot-Welding Unit
TR 51mc remote Standard welding of thin sheet metal constructions in such a way that they do not rust is control spot- often not possible due to severe warping of the material. This is where spot welding welding unit comes into its own. Similarly, problem welds, such as joins which are only accessible from a single side, can easily be dealt with using the TIG spot-welding process. -
Page 46: Tpmc Remote Control Unit
TPmc remote This workplace remote control unit is intended for use in particular with manual electrode control unit and TIG welding. Fig. 30 TPmc remote control unit (34) Welding current dial for continuous adjustment of the welding current (35) Arc force control dial influences the short circuit amperage at the moment of drop transfer (from electrode to workpiece) At scale setting "0"... - Page 47 TPmc remote With fine-globule electrodes (titanium) the above will not be observed, as metal transfer control unit occurs without a short circuit being produced. (continued) ARC FORCE CONTROL DIAL Fig. 31 Effect of arc force control dial (35) on constant-current characteristic at the moment of short circuiting.
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Page 48: Troubleshooting
Troubleshooting Safety WARNING! An electric shock can be fatal. Before opening up the machine Switch the mains switch to the “O” position Unplug the machine from the mains Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again Using a suitable measuring instrument, check to make sure that electrical- ly charged components (e.g. - Page 49 2. No reaction when torch trigger is actuated Mains switch is ON, relevant operating status LED and digital displays are lit up, but LED displays (9), (10), (12) do not light up when trigger is pulled back Cause: Torch control plug is not plugged in, or the plug-in connection is faulty Remedy: Plug in the control plug and secure it, check connection, replace if neces- sary...
- Page 50 Troubleshooting Cause: Welding torch is faulty (continued) Remedy: Replace the torch Cause: Gas solenoid valve is defective Remedy: Call after-sales service 7. No gas post-flow Tungsten electrode discolours after end of welding Cause: Gas pre-flow time is set too short Remedy: Using internal program parameters, increase the gas post-flow time (depends on welding amperage)
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Page 51: Care, Maintenance And Disposal
Care, maintenance and disposal General remarks Under normal operating conditions the power source requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding machine remains in a usable condition for many years. WARNING! An electric shock can be fatal. -
Page 52: Technical Data
Technical data TransTig 1600 / TransTig 1600 TransTig 1700 TransTig 1700 1 x 230 V 1 x 230 V Mains voltage tolerance +/- 15 % +/- 15 % Mains voltage Power frequency 50 / 60 Hz 50 / 60 Hz... -
Page 53: Circuit Diagram
Ersatzteilliste Schaltplan Spare Parts List Circuit Diagram Liste de pièces de rechange Schéma de connexions Lista parti di ricambio Schema Lista de repuestos Esquema de cableado Lista de peças sobresselentes Esquema de conexões Onderdelenlijst Bedradingsschema Reservdelsliste Koblingsplan Seznam náhradních dílů Schéma zapojení... - Page 54 43,0003,0031 43,0003,0031 42,0405,0056 42,0405,0056 42,0404,0024 42,0407,0273 42,0404,0024 42,0407,0273 4,001,603 4,100,423 TransTig 1600 / 1700 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_wi_00156 012004...
- Page 55 Carriage Easy- LT 4,045,917 42,0402,0215 42,0300,1583 42,0300,2619 BP2,0200,9218 42,0406,0293 44,0001,0042 44,0001,0105 Carriage Easy- LT Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_so_00701 012003...
- Page 58 FRONIUS INTERNATIONAL GMBH Buxbaumstraße 2, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations. ud_fr_st_so_00082 012008...
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