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Summary of Contents for TEAM WELDER TIG 180 DC
- Page 1 Operating instructions Welding machine TIG 180 DC 299-020100-TWD01 18.03.2016...
- Page 2 General information CAUTION Read the operating instructions! The operating instructions provide an introduction to the safe use of the products. • Read the operating instructions for all system components. • Observe the applicable accident prevention regulations. • Observe all country-specific statutory provisions. •...
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 General ............................7 Transport and installation ......................11 2.4.1 Ambient conditions ....................... - Page 4 Machine faults (error messages) ....................47 Resetting welding parameters to the factory settings ..............48 Display machine control software version ..................48 Dynamic power adjustment ......................48 8 Technical data............................49 TIG 180 DC ..........................49 9 Accessories ............................50 Internet ............................50 299-020100-TWD01 18.03.2016...
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Page 5: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 6: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine enter the menu ENTER Navigating in the menu NAVIGATION Exit the menu EXIT... -
Page 7: General
Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •... - Page 8 Safety instructions General WARNING Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- Page 9 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
- Page 10 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes - See 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 11: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 12: Ambient Conditions
Safety instructions Transport and installation 2.4.1 Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 13: Intended Use
Intended use Documents which also apply Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! •... -
Page 14: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Carrying strap - See 5.4.1 chapter Machine control- See 4.3 chapter Connection socket, "+" welding current • TIG: Connection for workpiece lead •... -
Page 15: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Main switch, machine on/off Cooling air inlet Mains connection cable - See 5.5 chapter G¼” connecting nipple Shielding gas connection on the pressure regulator. Connection socket, 19-pole Remote control connection 299-020100-TWD01 18.03.2016... -
Page 16: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-3 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values- See 4.3.1 chapter Welding procedure/power-saving mode push-button ---- MMA welding -- TIG welding (non-latched operating mode) TIG welding (latched operating mode) Signal light green: HF start (contactless) switched on (ex works) -
Page 17: Welding Data Display
Machine description – quick overview Machine control – Operating elements Item Symbol Description Excess temperature signal light In case of excess temperature, temperature monitors de-activate the power unit, and the excess temperature control lamp comes on. Once the machine has cooled down, welding can continue without any further measures. -
Page 18: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 19: Workpiece Lead, General
Design and function Workpiece lead, general Workpiece lead, general CAUTION Risk of burns due to incorrect connection of the workpiece lead! Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents. Stray welding currents may cause fires and injuries! •... -
Page 20: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •... -
Page 21: Tig Welding
Design and function TIG welding TIG welding 5.6.1 Welding torch and workpiece line connection Prepare welding torch according to the welding task in hand (see operating instructions for the torch). Figure 5-3 Item Symbol Description Welding torch Welding torch hose package Connection socket, "-"... -
Page 22: 5-Pole Control Lead
Design and function TIG welding 5.6.2 5-pole control lead 5.6.3 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. •... -
Page 23: Connecting The Shielding Gas Supply
Design and function TIG welding 5.6.3.1 Connecting the shielding gas supply • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. Figure 5-4 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve •... -
Page 24: Setting The Shielding Gas Quantity
Design and function TIG welding 5.6.3.2 Setting the shielding gas quantity CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact. -
Page 25: Welding Task Selection
Design and function TIG welding 5.6.4 Welding task selection Operating Action Result element Select welding procedure MMA welding TIG welding (non-latched operating mode) TIG welding (latched operating mode) Signal light green: HF start (contactless) switched on Signal light red: Lift arc start (contact ignition) switched on Welding current setting range Secondary current AMP% selection Secondary current setting... -
Page 26: Arc Ignition
Design and function TIG welding 5.6.5 Arc ignition The HF ignition ignition type is activated ex works. To switch the ignition type, access the machine control advanced menu- See 5.6.11 chapter. 5.6.5.1 HF ignition Figure 5-6 The arc is started without contact from high-voltage ignition pulses. a) Position the welding torch in welding position over the workpiece (distance between the electrode tip and workpiece should be approx. -
Page 27: Function Sequences/Operating Modes
Design and function TIG welding 5.6.7 Function sequences/operating modes Using the welding parameter push-button and welding parameter setting rotary knob the sequence parameters are set. Figure 5-8 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. -
Page 28: Tig Non-Latched Operation
Design and function TIG welding 5.6.7.2 TIG non-latched operation When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The up- and down-slopes are switched off. Figure 5-9 1st cycle: • Press and hold torch trigger 1. •... -
Page 29: Tig Latched Operation
Design and function TIG welding 5.6.7.3 TIG latched operation Figure 5-10 Step 1 • Press torch trigger 1, the gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece, the arc ignites. • Welding current flows and immediately assumes the ignition current value set (search arc at minimum setting). -
Page 30: Welding Torch (Operating Variants)
Design and function TIG welding 5.6.8 Welding torch (operating variants) Welding torches in different operating versions can be connected. The torch trigger (BRT) functions and operating elements can be customised in different modes. Explanation of operating element symbols: Symbol Description Press torch trigger Tap torch trigger Tap torch trigger and then press... -
Page 31: Torch Mode And Up/Down Speed Setting
Design and function TIG welding 5.6.9 Torch mode and up/down speed setting The user has the modes 1 to 3 and modes 11 to 13 available. Modes 11 to 13 include the same function options as 1 to 3, but without tapping function for the secondary current. The function options in the individual modes can be found in the tables for the corresponding torch types. -
Page 32: Standard Tig Torch (5-Pole)
Design and function TIG welding 5.6.9.1 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function) Functions mode Operating elements Welding current On/Off (factory-set) Secondary current (Latched mode) Standard torch with two torch triggers:... - Page 33 Design and function TIG welding Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions mode Operating elements Welding current On/Off Secondary current (factory-set) Secondary current (tapping mode) / (latched mode)
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Page 34: 5.6.10 Average Value Pulse Welding
Design and function TIG welding 5.6.10 Average value pulse welding Average value pulse welding means that two currents are switched periodically, a current average value (AMP), a pulse current (Ipuls), a balance ( ) and a frequency ( ) having been defined first. The predefined ampere current average value is decisive, the pulse current (Ipuls) is defined by the parameter as a percentage of the current average value (AMP). - Page 35 Design and function TIG welding Figure 5-13 Display Setting/selection Pulse welding (average value pulses) ------- Function switched on ------- Function switched off (ex works) Pulse frequency Setting range: 0.2 Hz to 2.0 kHz, ex works: 2.8 Hz For parameter setting, - See 5.6.11 chapter. 299-020100-TWD01 18.03.2016...
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Page 36: Expert Menu (Tig)
Design and function TIG welding 5.6.11 Expert menu (TIG) To change the advanced setting parameters, hold down the "Welding parameters" button for 2 seconds after selecting the welding process. The following diagram shows the setting options. ENTER EXIT NAVIGATION Figure 5-14 Display Setting/selection Switch ignition mode... -
Page 37: Mma Welding
Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 38: Welding Task Selection
Design and function MMA welding 5.7.2 Welding task selection Operating Action Result element Select welding process MMA welding Set welding current This completes the basic settings and you can now start welding. The optimum values for hot start current, hot start time and arcforcing are predefined ex works, but can be adjusted when necessary- See 5.7.7 chapter. -
Page 39: Antistick
Design and function MMA welding 5.7.5 Antistick Anti-stick prevents the electrode from annealing. If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating. Check the welding current setting and correct according to the welding task! 5.7.6 Average value pulse welding... - Page 40 Design and function MMA welding Figure 5-18 Display Setting/selection Pulse welding (average value pulses) ------- Function switched on ------- Function switched off (ex works) Pulse frequency Setting range 0.2 Hz to 500 Hz, 1.2 Hz ex works. For parameter setting, - See 5.7.7 chapter. 299-020100-TWD01 18.03.2016...
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Page 41: Expert Menu (Mma)
Design and function MMA welding 5.7.7 Expert menu (MMA) To change the advanced setting parameters, hold down the "Welding parameters" button for 2 seconds after selecting the welding process. The following diagram shows the setting options. ENTER NAVIGATION EXIT Figure 5-19 Display Setting/selection Hotstart current... -
Page 42: Remote Control
Design and function Remote control Remote control The remote controls are operated on the 19-pole remote control connection socket (analogue). 5.8.1 TW-RT1 19POL Functions • Infinitely adjustable welding current (0% to 100%) depending on the preselected main current on the welding machine. 5.8.2 Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button - See 5.9 chapter for a... - Page 43 Design and function Machine configuration menu ENTER EXIT NAVIGATION Figure 5-20 Display Setting/selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on. Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (factory setting 1) Up-/Down speed Increase value...
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Page 44: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. •... -
Page 45: Annual Test (Inspection And Testing During Operation)
Maintenance, care and disposal Disposing of equipment 6.2.3 Annual test (inspection and testing during operation) The welding machine may only be tested by competent, capable personsl. A capable person is one who, because of his training, knowledge and experience, is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures. -
Page 46: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. -
Page 47: Machine Faults (Error Messages)
Rectifying faults Machine faults (error messages) Machine faults (error messages) A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down. -
Page 48: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. RESET Figure 7-1 Display Setting/selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on. Initialising Keep the push-button pressed until "InI"... -
Page 49: Technical Data
Technical data TIG 180 DC Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! TIG 180 DC Setting range for welding current 5 A–180 A 5 A–150 A Setting range for welding voltage 10.2 V–17.2 V 20.2 V–26.0 V... -
Page 50: Accessories
Accessories Internet Accessories Internet For the accessories available for your product go to www.teamwelder.com. Figure 9-1 299-020100-TWD01 18.03.2016...
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