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OPERATING INSTRUCTIONS TIG inert gas welding equipment INVERTIG i 260-450 DC and AC/DC HIGH REHM SCHWEISSTECHNIK...
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Fax: +49 (0) 7161 3007-20 E-mail: rehm@rehm-online.de Internet: www.rehm-online.de Document No.: 7303173 Date of issue: 07.2023 REHM GmbH u. Co. KG Schweißtechnik, Uhingen, Germany 2023 content this description sole property REHM GmbH u. Co. KG Schweißtechnik The copying and distribution of this document, its use, and the communication of its contents are strictly prohibited unless expressly authorized.
List of contents List of contents INTRODUCTION ..........................6 Foreword ............................6 General description ........................7 1.2.1 The principle of the TIG inert gas welding process ................8 1.2.2 Intended use ............................ 8 Symbols used ..........................8 SAFETY INSTRUCTIONS ......................10 Warning symbols in these operating instructions ..............10 Warning symbols on the system ....................10 Notes and requirements ......................11...
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List of contents 5.4.2 Automatic pulse ..........................42 5.4.3 Balling ............................42 Quick Choice buttons ......................... 43 Submenu ............................43 Current curve functions......................43 5.7.1 Parameter settings ........................43 5.7.2 Setting the TIG welding parameters ....................43 5.7.3 Explanation of welding parameters ....................45 5.8.
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List of contents FAULTS ............................75 11.1 Safety instructions ........................75 11.2 Table of faults ..........................75 11.3 Error messages ..........................77 MAINTENANCE AND REPAIR .....................78 12.1 Safety instructions ........................78 12.2 Maintenance table ........................79 12.3 Cleaning the inside of the unit ....................79 12.4 Cooling water check ........................80 12.5 Proper disposal ..........................80 CIRCUIT DIAGRAMS ........................81...
Only components of the highest quality are used in INVERTIG i 260-450 welding systems. To allow long service life even under the toughest conditions, all REHM equipment is manufactured using only parts that comply with our strict quality demands. INVERTIG i 260-450 welding systems have been developed and designed according to the generally accepted rules for technology and safe operation.
Use under special requirements may necessitate the observance of particular regulations. If in doubt, ask your responsible safety officer or contact the REHM customer service department. The special instructions listed in the supplier documentation for intended use must be observed.
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Introduction Section 2.2, Warning symbols on the system Cross reference: here to Section 2.2, Warning symbols on the system Bold text is used for emphasis Note! ... indicates practical tips and other particularly useful information. Safety The safety symbols used in this manual: Section 2.1 symbols...
Safety information Safety instructions Warning symbols in these operating instructions This or a symbol that more accurately specifies the risk can be found in all of the safety instructions given in these operating instructions where there is Warnings and danger to life and limb. symbols One of the signal words below (Danger!, Warning!, Caution!) is used to indicate the severity of the risk:...
Also observe the safety information signs on the factory floor of the operator. 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 commercial/industrial users.
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Safety information This Class A equipment is not intended for use in residential areas in which power is supplied from a public low-voltage supply network. Such environments could entail difficulties ensuring electromagnetic compatibility because of interference from wires and radiation. The welding equipment does not comply with IEC 61000- 3-12:2011.
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Before using the system be sure to read the information compiled in these operating instructions. These include important instructions on use of the equipment that enable the full technical advantages of the REHM equipment to be exploited. See also the information on repair and maintenance, operating safety and functional reliability.
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Safety information Free of unusual amounts of dust, acids, corrosive gases or substances, etc., unless they are produced during welding. Altitude above sea level: Up to 2000m (6500 ft) High-power units can affect the mains voltage due to their high power Requirements of consumption.
Commissioning Unit description Figure 2: INVERTIG i 350 AC/DC Front view (Figure does not illustrate standard equipment)
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Commissioning Figure 3: INVERTIG i 350 AC/DC Front view (Figure does not illustrate standard equipment)
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Commissioning Figure 4: INVERTIG i 260-450 Rear view (Figure does not illustrate standard equipment)
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Commissioning Symbol Function/description Control panel – See "Description of controls" Control panel push and rotary encoder Main switch for switching on/off the welding power source Inert gas connection for TIG welding torch Second inert gas connection for TIG welding torch/backing (option) Torch connection;...
Commissioning Control panel description 4.2.1 Operating elements Operating elements Function Main screen Operation via rotary encoder with push- knob and buttons for menu selection in the 4 corners of the screen Fig. 6 Main screen Function buttons (from left to right) Quick Choice Quick Choice Submenu...
Commissioning 4.2.2 Operating elements Figure 10: Screen functions Symbols Description/functions Corner menu welding processes E-Hand Corner menu operating modes (press once) Not all are available for every ignition type Two-cycle Four-cycle Spot Two-cycle interval Four-cycle interval Ignition type corner menu (press BF2/2 twice) HF on (ignition with high frequency)
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Commissioning Symbols Description/functions Corner menu polarity Direct current negative Direct current positive Alternating current Alternating current/direct current negative DUAL.WAVE Corner menu welding process Pulse off Time pulses HYPER.PULS Current curve functions Gas pre-flow time 0.1s – 10.0s Ignition energy 10% – 100% Starting current 1% –...
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Commissioning BF19 “Pulsing Access to Pulse menu AC current form Auto Sine BF20 Triangle Rectangle Hard sine AC frequency Auto BF21 30 Hz – 300 Hz BF22 AC balance -5.0 – +5.0 BF23 DUAL.WAVE AC time 0.1s – 10.0s BF24 DUAL.WAVE DC time 0.1s –...
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Commissioning Symbols Description/functions BF32 Submenu buttons BF33 Job memory function (programs) Quick-storage keys BF34 Short button press: Load job – Long button press: Save job BF37 BF38 Setup (Settings) (Various submenus can be called up) BF39 Language BF40 “Home” and “Back” return button BF41 Fault message Links in the characteristic curve...
INVERTIG i 260-450 welding systems are started with the main switch. The screen shows the Rehm logo and the unit type for approximately 10 seconds. The display then switches to the main screen [Fig. 6 Main screen]. The last active welding parameters are set.
• Turning and pressing the rotary encoder [Fig. 9] selects and confirms the process. Pressing the “Back” or “Rehm” button [BF40] returns to the main screen [Fig. 6]. 5.1.1 TIG For TIG welding, connect the torch to the socket provided. Plug the control plug into the socket and lock it.
Commissioning Operating mode corner menu (top right) The Operating modes menu [BF2] is activated by pressing the button at the top right of the keypad Fig. 9. This allows the selection of the following operating modes: 1. Two-cycle 2. Four-cycle 3.
Commissioning 5.2.1 Two-cycle operating mode with HF ignition Two-cycle operating mode procedure: First cycle – press the torch trigger The inert gas solenoid valve opens After the set gas pre-flow time has expired, the arc is ignited with high- ...
Commissioning 5.2.2 Four-cycle operating mode with HF ignition Four-cycle operating mode procedure: First cycle – press the torch trigger The inert gas solenoid valve opens After the gas pre-flow time has expired, the arc is ignited with high ...
Commissioning 5.2.3 Spot operating mode with HF ignition Procedure for Spot operating mode with HF ignition: First cycle – press the torch trigger The inert gas solenoid valve opens After the set gas pre-flow time has expired, the arc is ignited with high- ...
Commissioning 5.2.4 HYPER.SPOT operating mode with HF ignition Procedure for the HYPER.SPOT operating mode with HF ignition: First cycle – press the torch trigger The inert gas solenoid valve opens After the set gas pre-flow time has expired, the arc is ignited with high- ...
Commissioning 5.2.5 Two-cycle interval operating mode with HF ignition Procedure for two-cycle interval operating mode with HF ignition: First cycle – press the torch trigger The inert gas solenoid valve opens After the set gas pre-flow time has expired, the arc is ignited with high- ...
Commissioning 5.2.6 Four-cycle interval operating mode with HF ignition Procedure for four-cycle interval operating mode with HF ignition: First cycle – press the torch trigger The inert gas solenoid valve opens After the set gas pre-flow time has expired, the arc is ignited with high- ...
Commissioning 5.2.7 Two-cycle operating mode with LiftArc ignition Procedure for two-cycle operating mode with LiftArc ignition: First cycle – press the torch trigger The inert gas solenoid valve opens Attach the electrode to the workpiece When the gas pre-flow time expires, the power unit is switched on ...
Commissioning 5.2.8 Four-cycle operating mode with LiftArc ignition Procedure for four-cycle operating mode with LiftArc ignition: First cycle – press the torch trigger The inert gas solenoid valve opens Attach the electrode to the workpiece When the gas pre-flow time expires, the power unit is switched on ...
Commissioning 5.2.9 Spot operating mode with LiftArc ignition Procedure for Spot operating mode with LiftArc ignition: First cycle – press the torch trigger The inert gas solenoid valve opens Attach the electrode to the workpiece When the gas pre-flow time expires, the power unit is switched on ...
Commissioning 5.2.10 HYPER.SPOT operating mode with LiftArc ignition Procedure for Spot operating mode with LiftArc ignition: First cycle – press the torch trigger The inert gas solenoid valve opens Attach the electrode to the workpiece When the gas pre-flow time expires, the power unit is switched on ...
Commissioning 5.2.11 Touch-HF operating mode Two-cycle operating mode with HF ignition The Touch-HF ignition type is specifically designed to ignite the arc without the torch trigger being actuated. This is especially advantageous when the arc must be positioned with great precision for intricate components. #) Only with the Ultra version.
Commissioning 5.2.12 Touch-HF operating mode Spot with HF ignition Process release for Touch-HF Setup: “‘Touch-HF’ ignition mode” Individual For release, press the torch trigger briefly and release it; release for 30s; release before each welding operation; observe the information on the operating interface. Continuous For release, press the torch trigger briefly and release it;...
Commissioning 5.2.13 Touch-HF HYPER.SPOT operating mode with HF ignition Process release for Touch-HF Setup: “‘Touch-HF’ ignition mode” Individual For release, press the torch trigger briefly and release it; release for 30s; release before each welding operation; observe the information on the operating interface. Continuous For release, press the torch trigger briefly and release it;...
5.3.4 DUAL.WAVE (DC-/AC) 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 I1 or I2, frequency, and balance are taken into account for purely DC or AC welding.
Commissioning Welding process corner menu Five additional welding processes are available for the TIG welding process. These differ fundamentally in the material transition of the filler material, the heat input and the arc length. Depending on welding system equipment and filler material, various processes are available.
1. One level back by acknowledging a setting 2. One level back by pressing the "Back" button 3. Completely back to the main screen with the button "Main menu" (Rehm). Current curve functions With the welding parameters, the user can individually set the most important parameters for welding, such as gas pre-flow time, creep, etc.
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Commissioning If the parameter field is active, the set value appears as a large display at the top centre of the screen (Fig. 24). In addition, a bar display appears in the status field Figure, which shows the set value in the permissible value range. The welding parameters are described in detail below in a sequence that follows the TIG parameter curve.
Commissioning Figure 28: Figure 29: TIG parameter details, TIG parameter details, time pulses HYPER.PULS 5.7.3 Explanation of welding parameters BF 5 gas pre-flow time The gas pre-flow time is the period of time after activating the torch trigger of torch to start the welding process and the opening of the inert gas valve before the arc is ignited.
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Commissioning The starting current time is the time in which welding is with starting current. Starting current time takes effect only in the 2T, Interval 2T, and Spot operating modes. BF 9 Starting current slope time The current slope-up time is the period in which the welding current increases linearly from the starting current to the preselected welding current I1.
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The sinusoidal shape used in this processor- controlled process results in significant noise reduction and technical welding benefits during AC welding. REHM recommends the automatic frequency control setting. The automatic frequency control automatically adjusts AC frequency to the current.
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Commissioning centre position (0) the negative and positive welding current is equally distributed over time. With an increasing positive value the share of the positive welding current increases (up to +5.0) and the negative share reduces. The cleaning of the weld pool is improved by the positive share.
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Commissioning BF30 Time pulses Time I1 The time pulse t1 value reflects the time in which welding current I1 is applied. BF31 Time pulses Time I2 The time pulse t1 value reflects the time in which welding current I2 is applied.
Commissioning 5.8. Submenus Pressing the [BF32] button calls up the submenu. There, individual settings for the welding unit can be adjusted. The menu structure is organized as follows: Menu Factory Job memory Setup Diagnostics Language Gas test settings Load Edit Save Welding Screen...
Commissioning 5.8.1 Job memory The Jobs submenu allows loading, saving and deleting of up to 500 jobs. The jobs can be saved and loaded under a freely selectable name in a freely selectable folder. Once the unit settings for recurring welding tasks have been determined, they can be quickly recalled and reset on the welding unit.
Commissioning 5.8.1.1 Save job Carry out the required machine setting Pressing the "Submenus" button [BF32] accesses a selection list (drop- down list) for the existing submenu. Select the job memory view by turning and pressing the rotary encoder. ...
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Commissioning Symbol Function Add a space Cursor left Cursor right Delete letter to the left of the cursor Lower-case New line Table 4 Explanation symbols Text input...
Commissioning 5.8.1.2 Load job Pressing the "Submenus" button [BF32] accesses a selection list (drop- down list) for the existing submenu. Select the job memory view by turning and pressing the rotary encoder. Select and open the desired job folder by turning and pressing the rotary encoder.
Commissioning Figure 33: Main view with active job If parameters are changed, the previously selected job is ended. Exception: Operating mode selection 5.8.1.3 Editing jobs and folders Pressing the "Submenus" button [BF32] accesses a selection list (drop- down list) for the existing submenu. ...
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Commissioning Job: Load You can load the selected job by pressing this function JOB: Copy Pressing this function saves the selected job to the clipboard. A copy of the job can then be added to a different folder. JOB: Insert This function is enabled only when a job has previously been copied to the clipboard.
Commissioning 5.8.2 Setup submenu Functions and processes can be defined very conveniently and clearly in the Setup submenu. The required setting is selected by turning the push and rotary encoder [Fig. 9]. The settings are logically structured in various subfolders. Some settings depend on characteristic curve, process, welding system equipment, etc.
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Commissioning Name Setting possibility Description Screen Display: Mirroring X No/Yes Only factory setting Display: Mirroring Y No/Yes Only factory setting Colour scheme Light/Dark Menu back 1s-2:00 min Welding End current: Unit Percent/absolute Folder: Mode Rolling/limiting Starting current: Unit Percent/absolute Up/Down (Idle) Various welding Examples: Starting parameters can be set...
Commissioning 5.8.3 Language menu The available languages are displayed as flags in a selection list. Use the cursor to select a language and confirm by pressing the rotary encoder. language becomes active immediately. selected language illustrated with cross. Figure 36: Language selection submenu...
Commissioning Control lamps Symbol Description Operation/ The symbol OPERATION in black indicates that there is an excess temperature idle voltage at the torch or electrode holder. The symbol is located on the left in the characteristic curve info bar The symbol illuminates red and flashes in the event of excess temperature.
Commissioning Other functions test The "gas test" is used to set the required gas quantity at the pressure reducer. This enables the desired gas flow to be set without voltage. The Gas test function is displayed in the bottom left corner menu as soon as the [BF 32] button is pressed.
142 2535 142 2545 INVERTIG AC/DC 142 2528 142 2533 142 2537 142 2547 Accessories: Torch including component kit and Rehm Quick Connect. More are available upon request. Length 4.0 m 8.0 m Type WIG R TIG-251w 19 UD HF...
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Commissioning Inert gas filter 1/4" mounting between the gas hose and 7501111 pressure reducer...
Setting up the welding unit CAUTION Place the REHM welding unit so that the welder has sufficient space in front of the unit to adjust and operate the controls. Transport the unit only under compliance with the applicable accident prevention regulations.
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Commissioning WARNING CAUTION: For suspended transport (on ropes or chains, for instance), INVERTIG i welding systems may be attached with crane eyelets only. Fastening to the handles or other parts of the system is not permitted. Injury hazard during attachment to a crane! When the device is attached to a crane, the possibility of the device or its attachments falling poses an injury hazard! •...
Cooling the welding unit Place the REHM welding unit so that the air entry and exit ports are not obstructed. The machine can achieve the specified duty cycle only with sufficient ventilation. Ensure that no metal parts, grinding dust, dust or other foreign bodies can enter the unit.
Commissioning Connecting the torch To connect the TIG welding torch, the housing has a socket with the torch connection symbol. If water-cooled torches are used, the cooling water hoses are connected via quick couplings. These are colour-coded (red = return, blue = flow). Important! When a gas-cooled torch is used on a water-cooled system, the water connections must be connected via a hose bridge, or the water cooling must...
Carefully read the operating instructions, especially Section 2, Safety, before commissioning and before beginning work with this welding power 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.
Operation Serious risks during welding Fire and explosion Materials can be ignited by the electric arc, hot slag, secondary flames or thermal radiation. So remove all combustible materials from the area where welding will be performed and keep a fire extinguisher handy as a preventative measure. There is an explosion risk from the combustible materials particularly due to leaking hoses and containers.
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There is a risk of trapping fingers between the feed rollers or the rotating wire coil and parts of the housing. Working under elevated electrical risk All REHM inert gas welding systems are suitable for working under elevated electrical risk and therefore carry the S mark. Increased electrical risk exists where: •...
REHM specialist dealer. REHM INVERTIG i 260-450 welding systems can be used to weld a wide variety Weldable materials of materials, including unalloyed and alloyed steels, stainless steels, and aluminium.
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REHM TIG units. All guidelines state that a specific electrode is exposed to a current that is too high if it drips or takes on a brush-like appearance. You have the choice between lower current or, with AC operation, using a larger minus portion in the balance setting.
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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. This has many advantages: 1.
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REHM TIG systems are particularly suitable as welding current sources for electrode welding due to their fast and precise control dynamics. The current strength and polarity settings are specified by the electrode manufacturer. Positive pole welding is used when welding with basic electrodes.
Section 2 Before restarting, the system must be approved by qualified personnel. 11.2 Table of faults is not workin The screen has no display REHM control panel Cause: Remedy: No mains power supply (possible mains fuse) Check mains voltage...
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Fault No inert gas Cause: Remedy: Bottle empty Check Pressure reducer defective Check Hose kinked Check Machine gas valve defective Service required! Arc sputters and jumps Cause: Remedy: Electrode and workpiece do not reach Use thinner electrodes working temperature Electrode is poorly sharpened Grind electrode Electrode not suitable Change electrode...
Fault Electrode is worn or dirty Grind electrode 11.3 Error messages Error Error Cause Elimination number Mains voltage is below the Switch the unit off and check the 1 000 Mains undervoltage tolerance range mains voltage Mains voltage is above the Switch the unit off and check the 2 000 Mains overvoltage...
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 claims against REHM become void. Before cleaning work begins, the welding unit must be switched off and disconnected from the mains supply.
12.3 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, however, it should be carried out at least twice a year.
Dispose of these agents at appropriate collection points for hazardous substances. 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 become void. 12.5 Proper disposal...
Components 13.1 Components and spare parts Item Name Part Comments Item number + A0 ELKO EMV circuit board 260A-450A 690 0881 + A1 Power supply 260A-450A 690 0874 + A2 Main board 260A-450A 690 0748 + A2.1/A2.2 260A-310A 690 0862 Primary IMS 350A-450A 690 0850...
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Components Item Name Part Comments Item number 470 0450 260A-450A DC & 450AC - B3 Current converter 470 0452 260A-350A AC - B5 Flow monitor 360 0781 - F1 T 1.25A/500V 660 0009 - K1 Relay 420 0168 410 0077 260A-350A AC &...
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Components Figure 40: INVERTIG i housing...
Technical data Technical data Technical data INVERTIG i Power class 260 DC/AC 300 DC/AC 350 DC/AC 450 DC/AC Setting range 5-260 5-300 5-350 5-450 Duty cycle (ED) at Imax. (40°C) Welding current at 100% ED Idle voltage, approximate Power supply 3x400 3x400 3x400...
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Index 17 INDEX and safety Changes to the system Checking cooling water and the cooler Checks before switching on Cleaning the inside of the unit Commissioning Connect ground cable Connecting the ground cable Connecting the welding unit Cooling the welding unit Fault 75, 78 Function description...
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Table of faults Technical data Type number Typographic distinctions Warning symbols on the system Warnings and symbols Presentation Water cooling for MIG/MAG welding torches Weldable materials Working under elevated electrical risk...
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For the following named products TIG welding systems REHM INVERTIG i 260 – 350 DC HIGH REHM INVERTIG i 260 – 350 AC/DC HIGH it is hereby confirmed that they comply with the essential protection requirements which are laid down in...
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E-Mail: rehm@rehm-online.de Rehm GmbH u. Co. KG Schweißtechnik Tel.: +49 (0) 7161 3007-0 Ottostraße 2 I 73066 Uhingen I Germany Fax: +49 (0) 7161 3007-20 Internet: www.rehm-online.de Date of issue 12/2023 | Item-no. 7303173...
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