Castolin Eutectic CastoTIG Operating Manual / Spare Parts List
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Castolin Eutectic CastoTIG Operating Manual / Spare Parts List

1702/2202 ac/dc - 2201 dc
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CastoTIG
1702/2202 AC/DC - 2201 DC
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OPERATING MANUAL / SPARE PARTS LIST
© by Eutectic+Castolin - 304911 - 01/2003

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Summary of Contents for Castolin Eutectic CastoTIG

  • Page 1 CastoTIG 1702/2202 AC/DC - 2201 DC OPERATING MANUAL / SPARE PARTS LIST © by Eutectic+Castolin - 304911 - 01/2003...
  • Page 3 Dear Castolin customer Introduction These directions are intended to familiarise you with the operation and maintenance of the equipment. It is in your interests to read these directions carefully and to conscientiously apply the instructions given here. If you do this, you will avoid faults and operating errors. The reward will be a piece of equipment, which is always ready for use and which will serve you well for many years.

  • Page 5: Safety Rules

    Safety rules Danger! “Danger!” indicates an imminently hazardous situation which, if not avo- ided, 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 must not be removed (continued) must not be covered, pasted or painted over For information about where the safety instructions and danger warnings are located on the machine, please see the section of your machine’s instruction manual headed “General remarks”. Any malfunctions which might impair machine safety must be eliminated immediately - meaning before the equipment is next switched on.
  • Page 7 Obligations of The owner/operator undertakes to ensure that the only persons allowed to owner/operator work with the machine are persons who are familiar with the basic regulations on workplace safety and accident prevention and who have been instructed in how to operate the machine have read and understood the sections on “safety rules”...
  • 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 Flying sparks can cause fires and explosions! flying sparks Never perform welding anywhere near combustible materials. Combustible materials must be at least 11 meters (35 feet) away from the arc, or else must be covered over with approved coverings. Have a suitable, approved fire extinguisher at the ready.
  • Page 10 Hazards from If the machine is run on a mains network without a PE conductor and mains and weld- plugged into a power outlet socket without a protective-conductor contact, ing current this counts as gross negligence and the manufacturer shall not be liable for (continued) any resulting damage.
  • Page 11 EMC precautions It is the responsibility of the owner/operator to ensure that no electromagnetic interference is caused to electrical and electronic equipment. If electromagnetic interference is found to be occurring, the owner/operator is obliged to take all necessary measures to prevent this interference. Examine and evaluate any possible electromagnetic problems that may occur on equipment in the vicinity, and the degree of immunity of this equipment, in accordance with national and international regulations:...
  • Page 12 Particular danger While the machine is in use: spots ensure that all the covers are closed and that all the sideguards are (continued) properly mounted ..and that all covers and sideguards are kept closed. When the welding wire emerges from the torch, there is a high risk of injury (the wire may pierce the welder’s hand, injure his face and eyes ...).
  • Page 13 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 14 Safety precauti- Before transportation, completely drain any coolant and dismantle the follo- ons at the instal- wing 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 15 Preventive and When ordering spare parts, please state the exact designation and the corrective main- relevant part number, as given in the spare parts list. Please also quote the tenance serial number of your machine. (continued) Safety inspection The owner/operator is obliged to have a safety inspection performed on the machine at least once every 12 months.
  • Page 16 ud_ca_st_sv_00676 032003...

  • Page 17: Table Of Contents

    Safety ..............................30 Tooling up ............................... 30 Selecting the operating mode ........................ 30 Selecting the process (CastoTIG 1702 /2202 AC/DC) ................31 Cap-shaping (CastoTIG 1702 /2202 AC/DC) ..................31 Setting the parameters ........................... 31 Setting the shielding-gas flow rate ......................31 Arc ignition - generalremarks .........................
  • Page 18 Exiting and saving ..........................48 Available set-up parameters ........................48 Special function ............................49 Indicating the software version ....................... 49 Troubleshooting ............................49 General remarks ............................ 49 Displayed service codes ........................49 CastoTIG 1702 /2202 AC/DC, CastoTIG 2201 DC power source ............51...
  • Page 19 Every 6 months ............................53 Disposal ..............................53 Technical data ............................. 54 Special voltages ............................. 54 CastoTIG 1702 AC/DC / 2202 AC/DC ....................54 CastoTIG 2201 DC ..........................55 Terms and abbreviations used ........................56 General remarks ............................ 56 Terms and abbreviations ........................56...

  • Page 20: General Remarks

    General remarks Basic system The CastoTIG 1702 AC/DC, CastoTIG 2202 AC/DC and CastoTIG 2201 DC belong to a principle new generation of TIG power sources. Among their outstanding features are superlative precision in the welding process, exact replicability of all results, and superb welding properties.

  • Page 21: Minimum Equipment Needed For Welding

    Gas connection (for supplying the machine with shielding gas), with pressure regulator Filler metal (depending on the application) TIG-DC welding CastoTIG 1702/2202 AC/DC or CastoTIG 2201 DC power source Grounding (earthing) cable TIG welding torch with rocker switch Gas connection (for supplying the machine with shielding gas)

  • Page 22: System Components

    System components General remarks The CastoTIG 1702 AC/DC, CastoTIG 2202 AC/DC and CastoTIG 2201 DC power sources can be run with numerous different system add-ons and options. Overview Trolley, and gas- cylinder holders TIG welding torch: Standard / Up/Down Power source...

  • Page 23: Control Panel

    The illustration below shows an overview of the main settings needed for day-to-day working, based on the example of the CastoTIG 1702/2202 AC/DC and CastoTIG 2201 DC control panel. You will find a detailed description of these settings in the following section (“Control panel”).

  • Page 24: General Remarks

    General remarks In this section, the control panels of the CastoTIG 1702/2202 AC/DC and CastoTIG 2201 DC power sources will be dealt with separately. CastoTIG 1702/ Warning! Operating the equipment incorrectly can cause serious injury and 2202 AC/DC damage. Do not use the functions described here until you have read and com-...
  • Page 25 2-step and 4-step operating modes. Main current I ...... CastoTIG 1702 AC/DC: 3 to 170 A CastoTIG 2202 AC/DC: 3 to 220 A Important! On welding torches with Up/Down functionality, the entire setting range is available for selection while the machine is idling. During welding, the main current can be corrected by +/-20 A.
  • Page 26 2-step and 4-step operating modes. Main current I ...... CastoTIG 1702 AC/DC: 3 to 170 A CastoTIG 2202 AC/DC: 3 to 220 A Important! On welding torches with Up/Down functionality, the entire setting range is available for selection while the machine is idling. During welding, the main current can be corrected by +/-20 A.
  • Page 27 CastoTIG 1702/ (10) Welding current display ... for indicating the welding current for the parameters: 2202 AC/DC control panel (starting current) (continued) (main current) (reduced current) (final current) Before the start of welding, the left-hand display shows the command value. For I...
  • Page 28 CastoTIG 1702/ (14) Gas-test button ... for setting the required gas-flow rate on the pressure regulator. 2202 AC/DC After you press this button, gas will flow out for 30 s. Press the button again to stop control panel the gas test-flow before the 30 seconds are up.

  • Page 29: Castotig 2201 Dc Control Panel

    (13) (14) Fig.4 CastoTIG 2201 DC control panel On the CastoTIG 2201 DC power source, the TIG-DC and rod electrode DC welding processes are available. The following processes and functions are not available and cannot be retro-fitted: TIG-AC welding rod-electrode AC welding...
  • Page 30 2-step and 4-step operating modes. Main current I ...... CastoTIG 2201 DC: 3 to 220 A Important! On welding torches with Up/Down functionality, the entire setting range is available for selection while the machine is idling. During welding, the main current can be corrected by +/-20 A.
  • Page 31 Available parameters where the “Rod electrode (MMA) welding” mode (5) has been selected: Main current I ...... CastoTIG 2201 DC: 10 to 180 A (10) Welding current display ... for indicating the welding current for the parameters: (starting current) (main current) Important! On welding torches with Up/Down functionality, the entire setting range is available for selection while the machine is idling.
  • Page 32 CastoTIG 2201 (11) Welding voltage display ... for indicating the actual welding-voltage value on the DC control panel right-hand display. (continued) Where one of the TIG-welding modes has been selected, the right-hand display reads “0.0” before the start of welding. Where the “Rod electrode (MMA) welding”...

  • Page 33: Connections, Switches And System Add-Ons

    (17) (16) (21) Fig.5 Connections and switches on CastoTIG 2202 AC/DC power source (16) - welding torch current socket ... for connecting the welding cable of the TIG welding torch connecting the electrode (or grounding/earthing) cable in rod electrode (MMA)

  • Page 34: Castotig 2201 Dc

    (23) (17) (16) (21) Fig.5b Connections and switches on CastoTIG 2201 DC power source (as example) (16) - “minus“ current socket with bayonet latch ... for connecting the welding cable of the TIG welding torch connecting the electrode (or grounding/earthing) cable in rod electrode (MMA)

  • Page 35: Before Putting The Power Source Into Service

    The technical data shown on the rating plate shall apply. Generator- The CastoTIG 1702 / 2202 AC/DC and CastoTIG 2201 DC power sources are suitable powered operati- for being run on generator power, provided that the maximum apparent power delivered by the generator is at least 10 kVA.

  • Page 36: Putting The Machine Into Service

    Putting the machine into service General remarks Warning! An electric shock can be fatal. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage. Only carry out any work on the machine if the mains switch is in the "OFF"...

  • Page 37: Establishing A Connection To The Workpiece

    Connecting up When using a TIG welding torch with an integral gas connector: the gas cylinder On the rear of the power source, connect the pressure regulator to the Shielding (continued) gas connection socket (22) by means of the gas hose Tighten the swivel nut Establishing a Shift the mains switch into the “0FF”...

  • Page 38: 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 com- pletely understood all of the following documents: these Operating Instructions all "Operating Instructions" for the system components, especially the "Safety rules"...

  • Page 39: 2-Step

    2-step Select 2-step mode (2) Spot-welding status indicator: If the spot-welding status indicator is lit up, set the set-up parameter SPt to “OFF” (see: “The Set-up menu: Level 1”) Important! When 2-step mode has been selected, the spot-welding status indicator on the control panel must not be lit up.

  • Page 40: Spot Welding

    Spot welding For information on setting the “Spot-welding time” set-up parameter (SPt), see the section headed “The Set-up menu: Level 1”. If a value has been set for the “SPt” set-up parameter, the operating mode “2-step mode” (2) will have the function of the spot-welding mode. Spot-welding status indicator: Remains lit up as long as a value has been speci- fied for the spot-welding time.

  • Page 41: 4-Step

    4-step Select 4-step mode (3) Important! The set-up parameter SFS must be set to “OFF” (see: “The Set-up menu: Level 2”). The factory setting (i.e. in which the power source is delivered) is: Parameter SFS = “OFF”. Welding start-up with starting current I : Push forward and hold the torch trigger Welding with main current I : Release the torch trigger...

  • Page 42: 4-Step With Intermediate Lowering

    4-step with In the variant of the 4-step mode illustrated below, an “intermediate lowering” of the intermediate welding current takes place. This is initiated by pull back and holding the trigger. lowering Select the 4-step operating mode (3) Important! The set-up parameter SFS must be set to “OFF” (see: “The Set-up menu: Level 2”).

  • Page 43: Special 4-Step: Variant 1

    Special 4-step: In the variant of the “Special 4-step” mode illustrated below, intermediate lowering to the Variant 1 pre-set reduced current I is effected by briefly pushing forward the torch trigger. When the torch trigger is briefly pushed forward a second time, the amperage returns to the Main current I Select the 4-step operating mode (3) Set the “SFS”...

  • Page 44: Welding Torch With Standard Functionality

    Welding torch Warning! Operating the equipment incorrectly can cause serious injury and with standard damage. Do not use the functions described here until you have read and functionality completely understood the whole of the “Operating Instructions” manual. (24) (24) Cap-shaping: Briefly pull back To start welding: Push the torch trigger forward and hold the torch...

  • Page 45: Welding Torch With Up / Down Functionality

    To increase the parameter: Push the parameter settings button forward To decrease the parameter: Pull the parameter settings button back Cap-shaping (only on CastoTIG 1702 / 2202 AC/DC)... Briefly pul back the torch trigger (26) Before starting welding, activate the cap-shaping function by briefly pulling back the torch trigger (26).

  • Page 46: Tig Welding

    Shift the mains switch (20) into the “ON” position Press the “Mode” button (1) to select either: 2-step mode (2) or 4-step mode (3) Note! Do not use any pure tungsten electrodes (colour- coded green) on the CastoTIG 2201 DC power source.

  • Page 47: Selecting The Process (Castotig 1702 /2202 Ac/Dc)

    For an optimised ignition sequence where the TIG-AC welding process has been se- generalremarks lected, the CastoTIG 1702 / 2202 AC/DC power source takes account of the diameter of the electrode. It also takes account of the electrode’s actual temperature, computed with...

  • Page 48: Hf Ignition

    HF ignition For details of how to adjust the set-up parameter “HFt”, please refer to the section headed “The set-up menu: Level 2” - sub-section “TIG set-up parameters”. Use the HFt parameter to set the time interval of the HF impulses to 0.01 s. The factory setting (i.e.

  • Page 49: Touchdown Ignition

    Touchdown To ignite the arc, proceed as follows: ignition Press the “Mode” button (1) to select: ”Contact ignition” mode (4) Place the gas nozzle down on the ignition location in such a way that there is a gap of approx. 2 to 3 mm (0.08 to 0.12’’) between the tungsten electrode and the workpiece .

  • Page 50: Ignition Time-Out Function

    Ignition time-out For details of how to adjust the set-up parameter Ignition Time-Out (Ito), please refer to function the section headed “The set-up menu: Level 2” - sub-section “TIG set-up parameters”. If no arc ignites before the end of the period specified in the set-up menu, the power source cuts out automatically and the error message “no|IGn”...

  • Page 51: Rod Electrode (Mma) Welding

    Shift the mains switch (20) into the “OFF” position Dismount the TIG welding torch Important! The CastoTIG 2201 DC power source has no switchover facility between the rod electrode DC- and rod electrode DC+ welding processes. To change over from the rod electrode DC- welding process to the rod electrode DC+ welding process on the CastoTIG 2201 DC power source, reconnect the electrode holder and the earthing (grounding) cable to the opposite welding sockets (i.e.

  • Page 52: Setting The Parameters

    Selecting the Press the “Mode” button (1) to select: operating mode “Rod-electrode (MMA) welding” mode (continued) Press the “Process” button (6) to select: Selecting the process (Casto- TIG 1702/2202 DC+ welding or AC/DC) DC- welding or AC welding Setting the A list of all the available parameters may be found in the section headed: “The control parameters panel”.

  • Page 53: Dynamic (Arc Force) Function

    Hot-Start func- Legend I (A) tion Hti ..Hot-current time, 0-2 s, factory (continued) setting: 0.5 s HCU .. Hot-start current, 0-100%, factory setting: 50 % ..Main current = Pre-set welding current Mode of functioning During the pre-set hot-current time (Hti), the welding current is increased to a certain value.

  • Page 54: Further Explanations Of The "Eln" Characteristic-Selection Function

    “Eln” characteri- “con” (constant welding current) parameter stic-selection If the “con” parameter is set, the welding current will be kept constant, irrespective function of the welding voltage. This results in a vertical characteristic . (continued) The “con” parameter is especially suitable for rutile electrodes and basic electrodes, as well as for gouging.

  • Page 55: Anti-Stick Function

    Further explana- Depending on what welding current (I) has been set, the point of intersection (operating tions of the “Eln” point) of characteristics will be displaced along the load line . The opera- characteristic- ting point provides information on the actual welding voltage and the actual welding selection func- current.

  • Page 56: The Set-Up Menu

    The picture below shows an overview of the set-up settings, taking the control panel of the CastoTIG 1702 / 2202 AC/DC as an example. A detailed description of these settings will be found in the following sections: “The set-up menu: Level 1” and “The set-up menu: Level 2”.

  • Page 57: The Set-Up Menu: Level 1

    The set-up menu: Level 1 General remarks The set-up menu makes it easy for you to adapt the parameters to many very different types of welding task. “Set-up menu: Level 1” contains all the set-up parameters that have an immediate effect upon the welding process.

  • Page 58: Available Set-Up Parameters

    Available set-up GPr ..Gas pre-flow time ... 0.0 to 9.9 s parameters Factory setting: 0.4 s Gas-Low ... Gas post-flow at minimum welding amperage (minimum gas post-flow time) ... 0 to 25 s; factory setting: 5 s G-H ..Gas-High ... Increase in the gas post-flow time at maximum welding amperage ...

  • Page 59: Level 1: Ac / Polarity Reversal Set-Up Parameters

    Level 1: AC / polarity reversal set-up parameters General remarks The AC / polarity reversal set-up parameters are only available on the CastoTIG 1702 / 2202 AC/DC power sources. Press the “Process” button (6) to select the AC welding process Accessing While pressing and holding the Set button (13), press the “Process”...

  • Page 60: Selecting And Altering The Set-Up Parameter

    Selecting and Select the desired set-up parameter with the parameter selection buttons (8) and (9). altering the set- Alter the value of the set-up parameter with the adjusting dial (7) up parameter Saving and Press the Set button (13) exiting Available set-up ACF ..

  • Page 61: Available Set-Up Parameters

    HCU ... Hot-start current ... 0 to 100 %, factory setting: 50 % Available set-up parameters Hti ..Hot-current time ... 0 to 2.0 s, factory setting: 0.5 s dYn ..dynamic ... arc-force dynamic correction ... 0 to 100, factory setting: 20 FAC ..

  • Page 62: Accessing

    Accessing Once the set-up parameter “2nd” has been selected: While pressing and holding the Set button (13), press the “Mode” button (1) The first set-up parameter of Level 2 is displayed (e.g. “SFS”) Important! The first parameter to be displayed is always the one that was the last to be selected the last time the set-up menu was accessed.

  • Page 63: Level 2: Ac / Polarity Reversal Set-Up Parameters

    Level 2: AC / polarity reversal set-up parameters Select “Parameter Press the “Process” button (6) to select the AC welding process 2nd” While pressing and holding the Set button (13), press the “Process” button (6) The first set-up parameter is displayed (e.g. “ACF”) Important! The first parameter to be displayed is always the one that was the last to be selected the last time the set-up menu was accessed.

  • Page 64: Level 2: Rod-Electrode Set-Up Parameters

    Level 2: Rod-electrode set-up parameters Press the “Mode” button (1) to select the “Rod-electrode (MMA) welding” mode (5) Select “Parame- ter 2nd” While pressing and holding the Set button (13), press the “Mode” button (1) The first set-up parameter is displayed (e.g. “HCU”) Important! The first parameter to be displayed is always the one that was the last to be selected the last time the set-up menu was accessed.

  • Page 65: Special Function

    Special function Indicating the software version Indicating the software version: While pressing and holding the Set button (13), press the parameter selection button (8). The software version now appears on the displays. To exit, press the Set button (13) again. Troubleshooting General remarks The power sources are equipped with an intelligent safety system.
  • Page 66 Displayed service tS1 | xxx, tS2 | xxx, tS3 | xxx codes (continued) Cause: Over-temperature in the secondary circuit of the power source Remedy: Allow the power source to cool down tSt | xxx Cause: Over-temperature in the control circuit Remedy: Allow the power source to cool down Err | 051...

  • Page 67: Castotig 1702 /2202 Ac/Dc, Castotig 2201 Dc Power Source

    Initialise “Robot ready” signal, initialise “Source error reset” signal (N.B. “Source error reset” only available in conjunction with Automatic interface AUT 2) CastoTIG 1702 / Power source does not function 2202 AC/DC, Mains switch is ON, but indicators are not lit up...
  • Page 68 CastoTIG 1702 / Cause: The gas hose is not mounted, or is damaged 2202 AC/DC, Remedy: Mount / change the gas hose CastoTIG 2201 Cause: The welding torch is defective Remedy: Change the welding torch (continued) Cause: The gas solenoid valve is defective...

  • Page 69: 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 indispensable to follow some important points to ensure the operationality of the welding machine for many years. Warning! An electric shock can be fatal.

  • Page 70: Technical Data

    Note! Inadequately dimensioned electrical installations can lead to serious damage. The mains supply lead, and its fuse protection, must be dimensioned accordingly. The technical data shown on the rating plate shall apply. CastoTIG 1702 1702 AC/DC 2202 AC/DC AC/DC / 2202 AC/...

  • Page 71: Castotig 2201 Dc

    CastoTIG 2201 2201 DC Mains voltage 230 V Mains voltage tolerance -20% / +15% Mains fuse protection (slow-blow) 16 A Primary contin. power (100% d.c.) 2.7 kVA Cos phi 0.99 Welding current range 3 - 220 A Rod electrode (MMA)

  • Page 72: Terms And Abbreviations Used

    Terms and abbreviations used General remarks The terms and abbreviations listed here are used in connection with functions that are either included in the standard scope of supply or that are available as optional extras. Terms and abbre- Arc ..Arc-break watchdog viations ASt ..

  • Page 73: Spare Parts List

    Schaltplan Circuit diagram Schema de connexions Schemi elettrici Esquema de conexiones Ersatzteilliste Spare parts list Liste de pièces de rechange Lista delle parti di ricambio Lista de repuestos...
  • Page 74 301160 304939 304934 304938 - CT2201 304927 304947 CastoTig 1702 / 2201 / 2202 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_ca_st_wi_00704 012003...
  • Page 75 304941 304930 304926 304924 304944 - 26pol. 304984 CastoTig 1702 / 2201 / 2202 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_ca_st_wi_00704 012003...
  • Page 76 CastoTIG 2201 DC...
  • Page 77 CastoTIG 1702 AC/DC...
  • Page 78 CastoTIG 2202 AC/DC...
  • Page 79 Fax (+32) 02 376 28 16 Fax (+34) 91 6 62 65 01 Österreich Schweiz/Suisse Sverige Italia Castolin Ges.m.b.H. Castolin Eutectic International Castolin Scandinavia AB VIRTECO Brunner Straße 69 S.A. - Zweigniederlassung Transportgatan 37 Divisione della SALTECO S.p.A. 1235 Wien...

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