TIP TIG TIG 500 FOCUS Operating Manual
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TIP TIG TIG 500 FOCUS Operating Manual

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TIP TIG - TIG 500 FOCUS
Operating Manual
Version 1.1 Revision 0.1

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  • Page 1 TIP TIG - TIG 500 FOCUS Operating Manual Version 1.1 Revision 0.1...
  • 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.

  • Page 3: Table Of Contents

    TIP TIG - TIG 500 FOCUS, 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 Crane transport CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS...
  • Page 4 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.3 Spare part list 10.4 WIRING DIAGRAM Page 4 of 75...

  • 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

    Intended use TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 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.

  • 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 - TIG 500 FOCUS, 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 - TIG 500 FOCUS, 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

    FOCUS-welding. Manual welding isn‘t possible with this welding machine. 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.) WARNING Falling equipment can cause death or serious injury.

  • Page 11: Controls, Connections And Mechanical Components

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS System overview Front of TIP TIG – TIG 500 FOCUS Description Transport eyebolt (Lifting lug) Control Panel Power Source – See 5.5 Control Panel – Power Source Control Panel FOCUS –...
  • Page 12 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL (10) Coolant tank with cap Rear of TIP TIG – TIG 500 FOCUS Description Transport eyebolt (Lifting lug) Button gas test 24 pole connection socket rotary table – optional for connecting a TIP TIG rotary table...
  • Page 13 Output 230 VAC (14) Bracket for shielding gas cylinder (15) Wheels, fixed castors TIP TIG – TIG 500 FOCUS: operating elements in the machine Description Four roll wire drive Clamping levers for setting the contact pressure of the feed rollers Wires pool holder with brake for holding standard wire spools with max.

  • Page 14: Front Connection

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Front connection Description 17 pole connection socket hand control box for connecting the provided hand control box Connection socket hot wire for connecting hot wire power from the welding torch hose package, minus potential Connecting nipple coolant return (red) for connecting coolant return (G3/8"...

  • Page 15: Main Switch With Fuses

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Main switch with fuses Description Main switch Machine on/off Fuse F1 T8 A, 230 VAC Fuse F2 T8 A, 0 VAC Connection socket relays Existing welding equipment can be controlled via the 7-pole panel socket Configuration Example –...

  • Page 16: Control Panel - Power Source

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Control Panel – Power Source CAUTION This welding system is designed and build for FOCUS-welding. Manual welding isn‘t possible with this welding machine. Function 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.
  • Page 17 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Pulse Time t1 Rotary Knob for setting the pulse time t1, while welding current I1 is active during TIG pulses. (Range: 20ms - 1.3sec.) Pulse Time t2 Rotary Knob for setting the pulse time t2, while welding current I2 is active during TIG pulses. (Range: 20ms - 1.3sec.)
  • Page 18 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL (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 75...

  • Page 19: Control Panel - Focus

    - VOLTAGE (left) - HEAT INPUT (right) Software version number displays the version number of the installed TIP TIG software Home Button Touching the screen in the black area labeled "HOME" will select the Home Screen. Settings Button Touching the screen in the black area labeled "SETTINGS"...
  • Page 20 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Gas Test Button Touching the screen in the black area labeled "GAS TEST" will perform a gas test. Offset Settings Button Touching the screen in the black area labeled "OFFSET SETTINGS" selects the Offset Settings Screen.
  • Page 21 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Home Button Touching the screen in the black area labeled "HOME" will select the Home Screen. Settings Button Touching the screen in the black area labeled "SETTINGS" will select the Settings Screen.
  • Page 22 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Settings Button Touching the screen in the black area labeled "SETTINGS" will select the Settings Screen. Gas Test Button Touching the screen in the black area labeled "GAS TEST" will perform a gas test.
  • Page 23 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Settings Button Touching the screen in the black area labeled "SETTINGS" will select the Settings Screen. Gas Test Button Touching the screen in the black area labeled "GAS TEST" will perform a gas test.
  • Page 24 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL OK Button Touching the screen in the area marked "OK" confirms the set value. Input keys (numeric field) Touching the screen in the area of the numeric keypad enters the setting value.
  • Page 25 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL FOCUS – Emergency Stop Reset Screen Function RESET Button Touching the screen in the green area marked "RESET" will reset the EMERGENCY STOP button. Page 25 of 75...
  • Page 26 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL FOCUS – End Switch Screen Function END SWITCH Display displays the end switches (left) and the corresponding status (right): - End switch left (END: LEFT) - End switch right (END: RIGHT) - End switch top (END: UP)

  • Page 27: Installation And Commissioning

    TIP TIG - TIG 500 FOCUS, 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 28: Start-Up - Power Source

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage. Observe the ambient conditions! Keep the cooling air inlet and outlet clear! Observe the minimum distance of 0.5 m from obstacles! Mains Connection The devices are designed to run on the mains voltage shown on the respective rating plates.
  • Page 29 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 6.2.1 Welding torch cooling system CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants).
  • Page 30 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 6.2.2 Connecting the gas cylinder WARNING If gas cylinders topple over, there is a risk of very serious injury and damage. • Place gas cylinders on a solid, level surface in such a way that they remain stable •...

  • Page 31: Start-Up - Wire Feeder

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Start-up – Wire feeder 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 32 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 6.3.1 Inserting/replacing feed rollers Safety WARNING An electric shock can be fatal. Before starting the work described below: • turn the power source mains switch to the „0“ position • disconnect the power source from the mains •...
  • Page 33 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 6.3.3 Inching the wire electrode Safety CAUTION Risk of injury and material damage from the welding current and accidental ignition of an arc. Before starting work, disconnect the ground earth connection between the welding system and the workpiece.
  • Page 34 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Description Adjusting nut Feed roll tensioner for fixing the clamping unit and setting the pressure. Clamping unit Pressure roller Drive roller Wire feed nipple Guide tube Extend and lay out the torch hose package.
  • Page 35 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 6.3.4 Spool brake setting Safety CAUTION Risk of injury and material damage from the welding current and accidental ignition of an arc. Before starting work, disconnect the ground earth connection between the welding system and the workpiece.

  • Page 36: Welding

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL WELDING CAUTION This welding system is designed and build for FOCUS-welding. Manual welding isn‘t possible with this welding machine. Preparation Safety WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the...

  • Page 37: Operating Modes

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Operating modes Safety WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: • these operating instructions 
...
  • Page 38 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 7.2.2 TIG 4-Stroke with HF 1. Stroke Press and hold the torch button. When the gas pre-flow time has elapsed, the arc ignites at 20% of I1 (search arc). 2. Stroke Open torch button. The welding current rises to the set value of I1.
  • Page 39 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 7.2.5 TIG 2-Stroke Liftarc In this mode, the ignitor is switched off. This operating mode can not be used with AC welding (TIG 500AC only), as with AC, the ignitor is also required for welding.

  • Page 40: Welding Current Types (Tig 500Ac Only)

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 2. Stroke Open torch button. The welding current drops to minimum with the time set on the soft-down rotary knob. The arc goes out. The shielding gas flows during the set gas post-flow time.

  • Page 41: Mma Welding

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL MMA welding Safety WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: • these operating instructions 
...

  • Page 42: Tig Welding

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL TIG welding Safety WARNING Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: • these operating instructions 
...
  • Page 43 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL - Frequency - Balance 4. Open the gas cylinder valve 5. Set the shielding gas flow rate 6. Start welding (ignite the arc) Page 43 of 75...

  • Page 44: Troubleshooting, Maintenance And Disposal

    TIP TIG - TIG 500 FOCUS, 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 45 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Troubleshooting-Checklist Main power switch on, no function Mains fuse defective - Change mains fuse Power supply interrupted - Check mains supply - Litz terminated, terminals loose - Exchange mains supply 10s after starting welding under TIG the welding process is stopped, the message H20...
  • Page 46 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Electrode works but TIG has no function Plug from the torch trigger is not - Check, plug in inserted (correctly) Burner button line has interruption - Check control line Burner button is defective...
  • Page 47 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Unstable arc Unsuitable or worn welding torch - Adjust contact tip to wire diameter and -material and equipment replace if necessary - Adjust wire guide to material in use, blow through and replace if necessary Material inclusions in the tungsten...
  • Page 48 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Pore formation Inadequate missing - Check shielding gas setting and replace shielding gas shielding cylinder if necessary - Shield welding site with protective screens (draughts affect the welding result) - Use gas lens for aluminum applications and high-alloy...

  • Page 49: Care, Maintenance And Disposal

    TIP TIG - TIG 500 FOCUS, 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 50: Technical Data

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL TECHNICAL DATA Power Source TIG 500 AC TIG 500 DC Mains connection 3/PE AC 400 V 3/PE AC 400 V 35,5A 35,5A 1-TIG 24,6kVA 24,6kVA 1-TIG 1-Electrode 23,5kVA 23,5kVA 1-Electrode Fuse, lazy...
  • Page 51 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Duty cycle at 40 °C ambient temperature 35% DC 120 A 60% DC 100 A 100% DC 80 A Load cycle 10 min. (60% DC; 6 min. welding, 4 min. pause) Open circuit voltage...

  • Page 52: Appendix

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL APPENDIX 10.1 Installation Guide Step 1: Connecting of the remote pendant - Connect the remote pendant to the 17-pole connection socket [(1) Chapter 5.2] - Reset EMERGENCY STOP button if it is pressed.
  • Page 53 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Step 2: Connecting the cooling adapter - Connect the cooling adapter with the connection socket welding current [(5) Chapter 5.2] After completion and verification, continue to step 3 Page 53 of 75...
  • Page 54 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Step 3: Bridging the internal coolant supply - Connect the cooling water bridge provided with the coolant return connection nipple [(3) Chapter 5.2] and the connecting nipple for the current / water cable [(7) Chapter 5.2]...
  • Page 55 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Step 4: Connection of the welding torch - Connect the supplied welding torch to the still free connections of the front side [Chapter 5.2] After completion and verification, continue to step 5...
  • Page 56 • Set coolant temperature during welding: max. 20°C • Pump pressure: 0,14m /h at 2,8 bar CAUTION TIP TIG Automation GmbH is not responsible for the issue, commissioning and operation of cooling units from third-party manufacturers. Page 56 of 75...
  • Page 57 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL Step 6: Connecting the distribution box - Connect the supplied distribution box with the pre- installed axles to the 37-pin socket [(7) Page Fehler! Textmarke nicht definiert.] on the back. After completion and verification, as well as connection of the gas and electricity supply and attachment of the axles, the welding system can be put into operation.

  • Page 58: Welding Check List

    TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.2 Welding Check List Step 1: Torch - Check welding and shielding gas connections and supply - Check water connections - Check electrode is sharp (~ 42°) - Check torch position (Set electrode to work gap (AEA, see 5.6) to between 1.0 and 1.2mm)
  • Page 59 - AVC has to be used and switched on After completion and verification, continue to step 6 Step 6: Operating conditions - TIP TIG - focus is a precision high-performance welding process and it requires greater care and precision than would be expected for GMAW or GTAW...
  • Page 60 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.3 Spare part list 10.3.1 Four roll wire drive Page 60 of 75...
  • Page 61 TIP TIG - TIG 500 FOCUS, 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...
  • Page 62 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4 WIRING DIAGRAM 10.4.1 Internal wire feeder 10.4.1.1 Welding inverter Page 62 of 75...
  • Page 63 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.1.2 DC power supply -REC +SCHWEISSMASCHINE-230V 24V_DC / 8.1 +SCHWEISSMASCHINE-0V 0V_DC / 8.1 -REC.1 48V_DC / 8.2 10.4.1.3 PLC structure Rext Rext 1° 5° 1° 5° 1° 5° 1° 5° +Uin -Uin 2°...
  • Page 64 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.1.4 PLC overview EtherCAT Page 64 of 75...
  • Page 65 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.1.5 Control Panel BECKHOFF EtherNet 192.168.10.100 / 255.255.255.0 COM1 X104 LAN2 LAN1 Power-Supply X107 X105 X103 X102 X101 LAN2 0V_DC 24V_DC Datum 03.09.2018 TIP TIG Automation Control Panel 10.4.1.6 Remote pendant Bearb.
  • Page 66 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.1.7 Distribution box (with AVC-Axis and X-Axis) -AVC -X-AXIS -MTR -MTR_X -END_SWITCH_M2_1 -END_SWITCH_M1_1 -END_SWITCH_M2_2 -END_SWITCH_M1_2 -DISTRIBUTION BOX -CBL3 -PT2,5-3PE -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L...
  • Page 67 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.1.8 Cable to distribution box Datum 08.11.2018 TIP TIG Automation Cable DB TIG 500 COMPACT Bearb. Jürgen GmbH Gepr 1701 TIG 500 focus Name Urspr Ersatz von Ersetzt durch Page 67 of 75...
  • Page 68 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.2 External wire feeder 10.4.2.1 Welding inverter Page 68 of 75...
  • Page 69 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.2.2 DC power supply -REC +SCHWEISSMASCHINE-230V 24V_DC / 8.1 +SCHWEISSMASCHINE-0V 0V_DC / 8.1 -REC.1 48V_DC / 8.2 10.4.2.3 PLC structure Rext Rext 1° 5° 1° 5° 1° 5° 1° 5° +Uin -Uin 2°...
  • Page 70 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.2.4 PLC overview EtherCAT Page 70 of 75...
  • Page 71 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.2.5 Control Panel BECKHOFF EtherNet 192.168.10.100 / 255.255.255.0 COM1 X104 LAN2 LAN1 Power-Supply X107 X105 X103 X102 X101 LAN2 0V_DC 24V_DC Datum 03.09.2018 TIP TIG Automation Control Panel 10.4.2.6 Remote pendant Bearb.
  • Page 72 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.2.7 Distribution box (with AVC-Axis) -AVC -MTR -END_SWITCH_M2_1 -END_SWITCH_M2_2 -DISTRIBUTION BOX -CBL3 -CBL17 -PT2,5-3PV -PT2,5-3PV -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L -PIT2,5-3L 08.11.2018 TIP TIG Automation GmbH Distribution Box FOCUS_TIPTIG_EXTERN Jürgen TIP TIG focus 1701...
  • Page 73 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.2.8 Cable to distribution box Datum 08.11.2018 TIG 500 COMPACT TIP TIG Automation Cable DB Bearb. Jürgen GmbH Gepr 1701 TIG 500 focus Blatt Name Urspr Ersatz von Ersetzt durch Blatt Page 73 of 75...
  • Page 74 TIP TIG - TIG 500 FOCUS, OPERATING MANUAL 10.4.2.9 External wire feeder -TIPTIG_EXTERN 69 K 0,33 -CBL4 WIRE FEED MOTOR MTR1 HF-Filter OSCILLATION MOTOR MTR2 HF-Filter GNYE 10.4.2.10 Cable to wire feeder Datum 03.09.2018 TIP TIG Automation GmbH TIP TIG extern Bearb.
  • Page 75 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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