Operating instructions
Welding machine
Smootharc Elite TIG 230 AC/DC
099-000143-BOC01
16.11.2009
General instructions
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 accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on +61 (02) 8874 4721.
A list of authorised sales partners can be found at www.boc.com.au or www.boc.co.nz
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other
form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the
user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are
observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© 2009
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.
Dear Customer
Premium quality with a three-year warranty - Five year warranty on transformers and rectifiers
Congratulations on purchasing a BOC SMOOTHARC ELITE machine. You have chosen a quality product from
EWM Hightec Welding – Germany’s leading manufacturer and technology expert of arc welding machines.
These machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore, we are
happy to provide you with a full 3-year warranty (five year warranty on transformers and rectifiers) according to
the operating instructions.
In all their high-tech components, these welding machines embody future-oriented advanced technology at the
utmost level of quality. Each of these products is carefully checked; EWM guarantee that the material and
processing of these products is faultless.
These operating instructions contain everything about commissioning the machine, notes regarding safety,
maintenance and care, technical data as well as information regarding the warranty.
Please heed all these notes to ensure many years of safe operation of the machine.
Thank you for the trust that you have placed in us. We look forward to a long-term partnership
with you.
Yours sincerely
Bruce Currie
Marketing Director - South Pacific
BOC Limited
Contents
Notes on the use of these operating instructions
1
Contents
1 Contents ..................................................................................................................................................4
2 Safety instructions .................................................................................................................................6
2.1 Notes on the use of these operating instructions...........................................................................6
2.2 General...........................................................................................................................................8
2.3 Transport and installation.............................................................................................................11
2.4 Ambient conditions.......................................................................................................................12
2.4.1
In operation...................................................................................................................12
2.4.2
Transport and storage ..................................................................................................12
3 Intended use .........................................................................................................................................13
3.1 Applications..................................................................................................................................13
3.2 Documents which also apply........................................................................................................13
3.2.1
Warranty .......................................................................................................................13
3.2.2
Declaration of Conformity .............................................................................................13
3.2.3
Welding in environments with increased electrical hazards .........................................13
3.2.4
Service documents (spare parts and circuit diagrams) ................................................13
4 Machine description – quick overview...............................................................................................14
4.1 Smootharc TIG 230 AC/DC..........................................................................................................14
4.1.1
Front view .....................................................................................................................14
4.1.2
Rear view......................................................................................................................15
4.2 Machine control – Operating elements ........................................................................................16
4.2.1
Function sequence .......................................................................................................18
5 Design and function.............................................................................................................................20
5.1 General.........................................................................................................................................20
5.2 Installation ....................................................................................................................................21
5.3 Machine cooling ...........................................................................................................................21
5.4 Workpiece lead, general ..............................................................................................................21
5.5 Mains connection .........................................................................................................................22
5.5.1
Mains configuration.......................................................................................................22
5.6 TIG welding ..................................................................................................................................23
5.6.1
Connecting the welding torch and workpiece lead .......................................................23
5.6.2
Torch connection options and pin assignments ...........................................................24
5.6.3
Shielding gas supply (shielding gas cylinder for welding machine)..............................24
5.6.3.1 Connecting the shielding gas supply.............................................................25
5.6.3.2 Setting the shielding gas quantity .................................................................26
5.7 Select welding task ......................................................................................................................27
5.7.1
Save welding tasks (JOBs)...........................................................................................28
5.7.1.1 Displaying and changing the JOB number....................................................28
5.7.2
Welding data display.....................................................................................................29
5.7.2.1 Welding parameter setting ............................................................................29
5.8 TIG welding ..................................................................................................................................30
5.8.1
Arc ignition ....................................................................................................................30
5.8.1.1 HF ignition .....................................................................................................30
5.8.1.2 Liftarc ignition ................................................................................................30
5.8.2
Optimising the ignition characteristics for pure tungsten electrodes ............................31
5.8.2.1 Manual, standard operation (JOB 0) .............................................................31
5.8.2.2 JOB operation (JOB 1 to 7) ...........................................................................31
5.8.3
Automatic cut-out..........................................................................................................31
5.8.4
Function sequences/operating modes..........................................................................32
5.8.4.1 Explanation of symbols .................................................................................32
5.8.4.2 SpotArc..........................................................................................................35
5.8.5
Pulses, function sequences ..........................................................................................37
5.8.5.1 TIG pulses – non-latched operation ..............................................................37
5.8.5.2 TIG pulses - latched operation ......................................................................37
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Contents
Notes on the use of these operating instructions
5.8.6
6
7
8
9
Pulse variants ...............................................................................................................38
5.8.6.1 Pulses (thermal pulses) ................................................................................ 38
5.8.6.2 Automated pulses .........................................................................................39
5.8.6.3 AC pulses...................................................................................................... 39
5.8.6.4 AC special ..................................................................................................... 39
5.8.7
TIG activArc welding..................................................................................................... 40
5.8.8
Welding torch (operating variants) ............................................................................... 41
5.8.9
Torch mode and up/down speed setting ...................................................................... 42
5.8.9.1 Standard TIG torch (5-pole) .......................................................................... 43
5.8.9.2 TIG up/down torch (8-pole) ........................................................................... 45
5.8.9.3 Potentiometer torch (8-pole) ......................................................................... 47
5.8.9.4 RETOX TIG torch (12-pole) .......................................................................... 48
5.9 MMA welding ............................................................................................................................... 49
5.9.1
Connecting the electrode holder and workpiece lead .................................................. 49
5.9.2
Select welding task....................................................................................................... 50
5.9.3
Hotstart ......................................................................................................................... 50
5.9.3.1 Hotstart current ............................................................................................. 50
5.9.3.2 Hotstart time.................................................................................................. 50
5.9.4
Antistick ........................................................................................................................ 50
5.10 Remote control............................................................................................................................. 51
5.10.1 Manual remote control RT 1.........................................................................................51
5.10.2 Foot-operated remote control RTF 1............................................................................ 51
5.10.3 Manual remote control RTP 1 ......................................................................................51
5.10.4 Manual remote control RTP 2 ......................................................................................51
5.10.5 RTP 3 manual remote control ...................................................................................... 51
5.11 Interfaces for automation ............................................................................................................. 52
5.11.1 Remote control connection socket, 19-pole ................................................................. 52
5.12 Advanced settings........................................................................................................................ 53
5.12.1 Testing the machine fan ...............................................................................................53
5.12.2 Limiting the mains current (10A) .................................................................................. 54
5.12.3 Protecting welding parameters from unauthorised access .......................................... 55
5.12.3.1 Changing the three-digit machine code ........................................................ 56
5.12.4 Setting the welding current (absolute/percentage)....................................................... 57
5.12.5 Selecting the welding current polarity during the ignition phase .................................. 58
Maintenance, care and disposal......................................................................................................... 59
6.1 General ........................................................................................................................................ 59
6.2 Maintenance work, intervals ........................................................................................................ 59
6.2.1
Daily maintenance tasks .............................................................................................. 59
6.2.2
Monthly maintenance tasks.......................................................................................... 59
6.2.3
Annual test (inspection and testing during operation) .................................................. 59
6.3 Repair Work ................................................................................................................................. 60
6.4 Meeting the requirements of RoHS ............................................................................................. 60
Rectifying faults ................................................................................................................................... 61
7.1 Machine faults (error messages) ................................................................................................. 61
7.2 Resetting welding parameters to the factory settings.................................................................. 62
7.2.1
Display machine control software version .................................................................... 63
Technical data ...................................................................................................................................... 64
8.1 Smootharc TIG 230 AC/DC ......................................................................................................... 64
Accessories, options ........................................................................................................................... 65
9.1 TIG welding torch......................................................................................................................... 65
9.2 Electrode holder / workpiece lead................................................................................................ 65
9.3 Remote controls and accessories................................................................................................ 65
9.4 Transport vehicle ......................................................................................................................... 65
9.5 Options......................................................................................................................................... 65
9.6 Welding torch cooling system ...................................................................................................... 65
9.7 General accessories .................................................................................................................... 65
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5
Safety instructions
Notes on the use of these operating instructions
2
Safety instructions
2.1
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.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
• Notes are highlighted using a "hand" symbol at the edge of the page.
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Safety instructions
Notes on the use of these operating instructions
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
Symbol
Description
Press
Do not press
Turn
Switch
0
0
1
Switch off machine
1
Switch on machine
ENTER (enter the menu)
NAVIGATION (Navigating in the menu)
EXIT (Exit the menu)
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use
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7
Safety instructions
General
2.2
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.
• Observe the maintenance instructions! (see Maintenance and Testing chapter)
• Unwind welding lines completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if
necessary).
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.
• Appoint only skilled persons for repair work (trained service personnel)!
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks
and burns on contact. Even low voltages can cause you to get a shock and lead to
accidents.
• Do not touch any live parts in or on the machine!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
WARNING
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant
regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using safety
curtains!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
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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!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before starting
welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
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Safety instructions
General
CAUTION
Obligations of the operator!
In the European Economic Area (EEA), the relevant national version of the basic
guidelines must be followed and observed!
• National version of the basic guidelines (89/391/EEC) as well as the relevant individual
guidelines.
• Please note that under no circumstances should any equipment or parts be altered or
changed in any way from the standard specification without written permission given by
BOC. To do so, will void the Equipment Warranty.
• Further information can be obtained from Welding Institute of Australia (WTIA) Technical
Note No.7 ´Health and Safety Welding` Published by WTIA, PO Box 6165 Silverwater NSW
2128 Phone (02) 9748 4443.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Electromagnetic interference!
The machines are intended to be used in industrial areas, according to IEC 60974-10. If
they are used in residential areas, for example, problems may occur with ensuring
electromagnetic compatibility.
• Check whether interference is caused to other machines!
10
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Safety instructions
Transport and installation
2.3
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!
• Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
• Avoid heating the shielding gas cylinder!
CAUTION
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10°
(according to IEC 60974-1, -3, -10).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
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11
Safety instructions
Ambient conditions
2.4
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.
• Safe operation of the machine must be guaranteed at all times.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
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!
2.4.1
In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.4.2
Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C
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Intended use
Applications
3
Intended use
This machine has been manufactured according to the latest developments in technology and current
regulations and standards. It must only be operated in line with the instructions on correct usage.
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!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
3.1
Applications
These welding machines are only suitable for:
• MMA direct current welding for rutile and basic electrodes.
• TIG direct current and alternating current welding with HF ignition or liftarc.
• TIG DC: Unalloyed, low-alloy and high-alloy steels, copper, nickel-based alloys and special metals.
• TIG AC/DC: Aluminium and aluminium alloys.
3.2
Documents which also apply
3.2.1
Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.2.2
Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.2.3
Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.2.4
Service documents (spare parts and circuit diagrams)
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.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
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13
Machine description – quick overview
Smootharc TIG 230 AC/DC
4
Machine description – quick overview
4.1
Smootharc TIG 230 AC/DC
4.1.1
Front view
1
2
3
4
5
6
Figure 4-1
Item
1
2
3
14
Symbol Description 0
Machine control
See Machine control – operating elements chapter
Connection socket, "+" welding current
• TIG: Connection for workpiece lead
• MMA: Electrode holder or workpiece lead connection
Connection socket, 5-pole/8-pole/12-pole
5-pole:
Standard TIG torch control lead
8-pole:
TIG Up/Down or potentiometer torch control lead
12-pole:
Control lead for TIG up/down torch with display (option)
4
G¼” connecting nipple, “-” welding current
Shielding gas connection (with yellow insulating cap) for TIG welding torch
5
Connection socket, "-" welding current
• TIG: TIG welding torch connection
• MMA: Electrode holder or workpiece lead connection
6
Cooling air inlet
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Machine description – quick overview
Smootharc TIG 230 AC/DC
4.1.2
Rear view
2
1
3
5
4
7
8
6
9
10
11
Figure 4-2
Item
Symbol Description 0
Carrying strap
1
Carrying handle
2
3
HF
HF
4
8-pole connection socket
Cooling unit control lead
5
Connection socket, 19-pole
Remote control connection
Main switch, machine on/off
6
7
4-pole connection socket
Cooling unit voltage supply
8
G¼” connecting nipple
Shielding gas connection on the pressure reducer
9
Cooling air outlet
10
Mains connection cable
11
Machine feet
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Ignition type changeover switch
HF= HF ignition
HF = Liftarc (contact ignition)
15
Machine description – quick overview
Machine control – Operating elements
4.2
Machine control – Operating elements
T 2.30
S
Puls
10
S
AMP
Automatic
VOLT
sec
JOB
AC
special
5
sec
11
1
2
3
DC +
sec
12
AMP
DC sec
sec
AC
AMP%
AC
AMP%
AMP%
9
AC
AMP
4
sec
%
2,4
125
150
100
mm
Hz
JOB
sec
+10
0
-10
3,2
1,6
75
6
175
50
JOB 0
+20
7
Hz
200
8
+30
mm
-20
%
-30
1,0
4>
Figure 4-3
Item
Symbol Description 0
Welding process button
MMA welding
1
TIG welding
Operating mode button
spotArc (spot time setting range 0.01 sec. to 20.0 sec.)
2
Non-latched
Latched
3
Puls
Automatic
sec
AC
special
16
TIG pulse welding
TIG automated pulses (frequency and balance)
sec
TIG pulses
TIG AC special
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Machine description – quick overview
Machine control – Operating elements
Item
Symbol Description 0
Welding current polarity button
Direct current welding with positive polarity on the electrode holder in
relation to the workpiece (pole reversal switch, MMA only).
DC welding with negative polarity on the torch (or stick electrode holder)
in relation to the workpiece.
Alternating current welding with rectangular current output wave form.
Maximum power loading and safe welding.
Alternating current welding with trapezoidal current output wave form.
The all-rounder for most applications.
Alternating current welding with sinusoidal current output wave form.
Low noise level.
Switch display/JOB number button
Welding current display
Welding voltage display
Display and select JOB number
4
5
125
6
150
100
75
175
50
7
+10
200
Hz
0
-10
+20
-20
+30
8
-30
%
2,4
1,6
1,0
3,2
mm
Alternating current frequency (TIG AC) rotary dial
50 Hz to 200 Hz
Alternating current balance (TIG AC) rotary dial
Max. setting range: - 30% to + 30%
Tungsten electrode diameter/Ignition optimisation rotary dial
Infinitely adjustable from 1 mm to 4 mm or greater
4>
9
Welding parameter setting rotary transducer
Setting flows, times and parameters.
10
Display, 3-digit
11
Error/status indicators
Collective interference signal light (see Operating problems chapter)
Water deficiency signal light (welding torch cooling)
Excess temperature signal light
S
S
12
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safety sign signal light
Function sequence (see next chapter)
17
Machine description – quick overview
Machine control – Operating elements
4.2.1
Function sequence
5
sec
sec
6
4
sec
3
AMP
8
9
sec
AMP%
1
AMP%
2
7
15
sec
AMP%
11
10
AMP
Hz
JOB
14
mm
sec
%
13
12
Figure 4-4
Item
Symbol Description 0
1
18
2
sec
3
AMP%
4
sec
5
sec
6
AMP
7
sec
8
AMP%
9
sec
10
AMP%
11
sec
Select welding parameters button
This button is used to select the welding parameters depending on the welding process
and operating mode used.
Gas pre-flow time (TIG)
Absolute setting range 0.1 s to 5.0 s (0.1 s increments).
Hotstart current (MMA)
Ignition current (TIG)
Percentage of the main current. Setting
Percentage of the main current. Setting
range 1 % to 200 % (1 % increments).
range 1 % to 200 % (1 % increments).
Up-slope time (TIG)
Hotstart time (MMA)
Setting ranges: 0.00 s to 20.0 s
Setting ranges: 0.00 s to 5.0 s
(0.1 s increments).
(0.1 s increments).
The up-slope time can be set separately
for non-latched and latched.
Pulse time
Pulse time setting range: 0.01 s to 9.99 s (0.01 s increments)
TIG pulses
TIG AC Special
The pulse time applies to the main current The pulse time applies to the AC phase for
phase (AMP) for pulses.
AC special.
Main current (TIG) / pulse current
Main current (MMA)
I min to I max (1 A increments)
I min to I max (1 A increments)
Pulse break time
Pulse break setting range: 0.01 s to 9.99 s (0.01 s increments)
TIG pulses
TIG AC Special
The pulse break time applies to the
The pulse break time applies to the
secondary current phase (AMP%)
DC phase with AC special.
Secondary current (TIG) / pulse pause current
Setting range 1 % to 100 % (1 % increments). Percentage of the main current.
Down-slope time (TIG)
0.00 s to 20.0 s (0.1 s increments).
The down-slope time can be set separately for non-latched and latched.
End-crater current (TIG)
Setting range 1 % to 100 % (1 % increments). Percentage of the main current.
Gas post-flow time (TIG)
Setting ranges: 0.1 s to 20.0 s (0.1 s increments).
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Machine description – quick overview
Machine control – Operating elements
Item
Symbol Description 0
12
13
14
15
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Tungsten electrode diameter / Ignition optimisation (TIG)
Infinitely adjustable from 1 mm to 4 mm or greater (0,1 mm increments)
Alternating current balance (TIG AC)
Max. setting range: -30 % to +30 % (1% increments).
Optimisation of cleaning effect and fusion penetration characteristics.
Alternating current frequency (TIG AC)
50 Hz to 200 Hz (1 Hz increments) Constriction and stabilisation of the arc:
At a higher frequency, the cleaning effect is increased. Particularly thin panels (welding
with a low current), anodised sheet aluminium or highly contaminated articles for
welding can be welded and cleaned perfectly at a higher frequency.
activArc TIG welding process
• Switch activArc on or off
• Correct the activArc characteristic (setting range: 0 to 100)
19
Design and function
General
5
Design and function
5.1
General
DANGER
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!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
CAUTION
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up and can
cause burns, if touched!
• Check the welding current connections every day and lock by turning in clockwise direction, if
necessary.
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and an
electrode holder remain connected to the machine, the open-circuit/welding voltage is
applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.
CAUTION
Using protective dust caps!
Protective dust caps protect the connection sockets and therefore the machine against
dirt and damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!
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Design and function
Installation
5.2
Installation
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.
• Safe operation of the machine must be guaranteed at all times.
5.3
Machine cooling
To obtain an optimal duty cycle from the power components, the following precautions should be
observed:
• Ensure that the working area is adequately ventilated.
• Do not obstruct the air inlets and outlets of the machine.
• Do not allow metal parts, dust or other objects to get into the machine.
5.4
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!
• Clean the connections!
• Fix the workpiece lead securely!
• Do not use structural parts of the workpiece as a return lead for the welding current!
• Take care to ensure faultless power connections!
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Design and function
Mains connection
5.5
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 (any phase sequence for three-phase
machines)!
• Mains plug, socket and lead must be checked regularly by an electrician!
5.5.1
Mains configuration
NOTE
The machine may be connected and operated on all TN or TT networks with a neutral
conductor and a protective conductor.
L1
N
PE
Figure 5-1
Legend
Item
L1
N
PE
Designation
Outer conductor
Neutral conductor
Protective conductor
Colour code
brown
blue
green-yellow
CAUTION
Operating voltage - mains voltage!
The operating voltage shown on the rating plate must be consistent with the mains
voltage, in order to avoid damage to the machine!
• For mains fuse protection, please refer to the “Technical data” chapter!
•
22
Insert mains plug of the switched-off machine into the appropriate socket.
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Design and function
TIG welding
5.6
TIG welding
5.6.1
Connecting the welding torch and workpiece lead
NOTE
Prepare welding torch according to the welding task in hand (see operating instructions
for the torch).
4
3
2
1
Figure 5-2
Item
Symbol Description 0
1
Connection socket, "-" welding current
Welding current lead connection for TIG welding torch
G¼" connecting nipple
TIG welding torch shielding gas connection
2
Connection socket, 5-pole/8-pole
5-pole: Standard TIG torch control lead
8-pole: TIG Up/Down or potentiometer torch control lead
Connection socket for "+" welding current
Workpiece lead connection
3
4
•
Insert the welding current plug on the welding torch into the welding current connection socket and
lock by turning to the right.
• Remove yellow protective cap on G¼ connecting nipple.
• Screw welding torch shielding gas connection tightly onto the G¼" connection nipple.
• Insert the welding torch control lead plug into the connection socket for the welding torch control lead
(5-pole with standard torch, 8-pole with up/down or potentiometer torch and 12-pole with up/down
torch with LED display) and tighten.
• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by
turning to the right.
If fitted:
• Lock connecting nipples of the cooling water tubes into the corresponding rapid-action closure
couplings:
Return line red to rapid-action closure coupling, red (coolant return) and
supply line blue to rapid-action closure coupling, blue (coolant supply).
NOTE
Please note the relevant documentation of the accessory components.
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Design and function
TIG welding
5.6.2
Torch connection options and pin assignments
BT1
5
BT1
A
BT2
B
-
C
0V
4
BT2
+
D
3
E
Uref 10V
IH-Down
Up
2
1
Poti UD/ein
I1
BT
F
Down
Up
+
-
G
H
I2
5-pole control lead
8-pole control lead
12-pole control lead
Figure 5-3
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.
• Observe the instructions from the gas manufacturer and in any relevant regulations
concerning the use of compressed air!
• Place shielding gas cylinders in the holders provided for them and secure with fixing
devices.
• Avoid heating the shielding gas cylinder!
CAUTION
Faults in the shielding gas supply.
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch
is a fundamental requirement for optimum welding results. In addition, a blocked
shielding gas supply may result in the welding torch being destroyed.
• Always re-fit the yellow protective cap when not using the shielding gas connection.
• All shielding gas connections must be gas tight.
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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.
4
1
2
3
Figure 5-4
Item
Symbol Description 0
1
Pressure reducer
2
Shielding gas cylinder
3
Output side of the pressure reducer
4
Cylinder valve
•
Tighten the pressure reducer screw connection on the gas bottle valve to be gas-tight.
NOTE
Before connecting the pressure reducer to the gas cylinder, open the cylinder valve
briefly to expel any dirt.
•
Screw gas hose connection crown nut onto the output side of the pressure reducer.
1
Figure 5-5
Item
Symbol Description 0
Connecting nipple G¼, shielding gas connection
1
•
Connect crown nut of the shielding gas line to the G¼“ connecting nipple.
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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.
• Keep the welding torch electrically insulated from persons, animals or equipment during the
setting procedure.
•
Press the torch trigger and set the shielding gas quantity with the flow gauge of the pressure reducer.
NOTE
Rule of thumb for the gas flow rate:
Diameter of gas nozzle in mm corresponds to gas flow in l/min.
Example: 7mm gas nozzle corresponds to 7l/min gas flow.
Incorrect shielding gas setting!
If the shielding gas setting is too low or too high, this can introduce air to the weld pool
and may cause pores to form.
• Adjust the shielding gas quantity to suit the welding task!
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Design and function
Select welding task
5.7
Select welding task
Operating
element
Action
Result
Select and display welding process
MMA welding
TIG welding
Select and display welding current polarity
Direct current welding with positive polarity at the electrode
holder (MMA).
DC welding with negative polarity at the torch (or electrode
holder) with respect to the workpiece.
AC welding with rectangular current output wave form.
Maximum power loading and safe welding (TIG).
AC welding with trapezoidal current output wave form.
The all-rounder for most applications (TIG).
AC welding with sinusoidal current output wave form.
Low noise levels (TIG).
Select and display operating mode
spotArc (spot time setting range 0.01 sec. to 20.0 sec.)
Non-latched
Latched
Puls
Automatic
sec
AC
special
2,4
Set tungsten electrode diameter for optimisation of ignition
3,2
1,6
Select and display pulse procedure
TIG automated pulses (frequency and balance)
sec
TIG pulses
TIG AC special
mm
1,0
4>
+10
0
Set alternating current balance (TIG AC)
-10
+20
-20
+30
%
-30
125
150
100
75
Alternating current frequency (TIG AC)
175
50
Hz
200
Select welding parameter in the function sequence
Set welding parameters
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Design and function
Select welding task
5.7.1
Save welding tasks (JOBs)
All user settings are saved immediately after being modified or changed. No special save command or
user input is needed.
The last welding parameters that were used are available even after switching off and on again.
There are altogether 8 JOBs that can be used to save the respective parameters for different frequently
occurring welding tasks. JOB 0 is set by default on delivery and every time the machine control is reset.
The control display shows the currently selected JOB number for approx. 2 seconds after the machine is
switched on. You change JOBs by pressing the "Switch display/JOB number" button until the respective
signal lamp lights. You can choose between 8 JOBs (JOB 0 to 7) with the welding parameter rotary dial.
The parameters for the currently selected JOB can now be set according to the welding task.
You cannot switch JOB numbers during welding.
NOTE
Note the differences between JOB 0 and JOBs 1 to 7:
The parameter values for AC frequency, AC balance and Tungsten electrode
diameter/optimisation of ignition are set with the respective rotary dials in JOB 0. In JOBs 1 to 7,
this setting takes place in the function sequence (signal lights with the same names show the
selection).
5.7.1.1
Displaying and changing the JOB number
Operating
Action
Result
element
Select JOB display
nx
Change the JOB number
1x
28
If the display switchover is pressed or if there is no keyboard input for 5
seconds, the new JOB will be active
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Design and function
Select welding task
5.7.2
Welding data display
The following welding parameters can be displayed before (nominal values) or during (actual values)
welding.
Parameter
Before welding
During welding
(nominal values)
(actual values)
Welding current
;
;
Welding voltage
;
JOB number
;
Parameter times
;
Frequency, balance
;
Parameter currents
;
† not possible
; possible
5.7.2.1 Welding parameter setting
The parameters that can be set in the function sequence of the machine control depend on the selected
welding task. This means that if for example you have not selected a pulse variant, then you cannot set
any pulse times in the function sequence.
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Design and function
TIG welding
5.8
TIG welding
5.8.1 Arc ignition
5.8.1.1 HF ignition
Figure 5-6
5.8.1.2
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. 2-3mm).
b) Press the torch trigger (high voltage ignition pulses ignite the arc).
c) Ignition current flows, and the welding process is continued depending on the operating mode
selected.
End the welding process: Release or press the torch trigger depending on the operating mode
selected.
Liftarc ignition
a)
b)
c)
Figure 5-7
The arc is ignited on contact with the workpiece:
a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch
trigger (liftarc current flowing, regardless of the main current set).
b) Incline the torch over the torch gas nozzle to produce a gap of approx. 2-3 mm between the electrode
tip and the workpiece. The arc ignites and the welding current is increased, depending on the
operating mode set, to the ignition or main current set.
c) Lift off the torch and swivel to the normal position.
Ending the welding process: Release or press the torch trigger depending on the operating mode
selected.
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Design and function
TIG welding
5.8.2 Optimising the ignition characteristics for pure tungsten electrodes
5.8.2.1
The best ignition and stabilisation of the arc (DC, AC) and optimum spherical cup formation in the
tungsten electrode depend on the electrode diameter being used.
The set value should correspond to the diameter of the tungsten electrode. The value can of course be
adjusted in line with different requirements.
Manual, standard operation (JOB 0)
Result
Operating
Action
element
2,4
1,6
5.8.2.2
Set diameter of tungsten electrode
• Increase parameter value > more ignition power
• Reduce parameter value > less ignition power
3,2
1,0
4>
mm
JOB operation (JOB 1 to 7)
Operating
Action
element
xx
5.8.3
Result
Select ignition characteristics parameter
Press until
signal light comes on
Set diameter of tungsten electrode
• Increase parameter value: more ignition power
• Reduce parameter value: less ignition power
Automatic cut-out
NOTE
The automatic cut-out function will be triggered by two conditions during the welding
process:
During the ignition phase (ignition fault)
• If there is no welding current within 3s after starting the welding.
During the welding phase (arc interruption)
• If the arc is interrupted for longer than 3s.
In both cases, the welding machine ends the ignition or welding process immediately.
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Design and function
TIG welding
5.8.4
Function sequences/operating modes
The parameters for the function sequence are set using the “Select welding parameters” button and the
“Welding parameter setting” rotary dial.
T 2.30
Pos. Description
S
1
“Select welding parameters” button
sec
2
“Welding parameter setting” rotary dial
Puls
AMP
Automatic
VOLT
AC
JOB
S
special
sec
DC +
sec
AMP
DC sec
sec
AC
AMP%
AMP%
AC
2
AMP%
AC
1
AMP
Hz
JOB
sec
150
100
mm
sec
%
2,4
125
0
+10
-10
1,6
75
175
50
JOB 0
Hz
+20
200
+30
3,2
mm
-20
%
-30
1,0
4>
Figure 5-8
5.8.4.1 Explanation of symbols
Symbol Meaning
Press torch trigger 1
Release torch trigger 1
I
Current
t
Time
Gas pre-flows
Istart
Ignition current
tUp
Up-slope time
tP
Spot time
AMP
AMP%
Main current (minimum to maximum current)
Secondary current (0% to 100% of AMP)
t1
Pulse time
t2
Pulse pause time
tDown
Down-slope time
Iend
End-crater current
Gas post-flows
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Design and function
TIG welding
Non-latched mode
NOTE
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.
1.
2.
AMP
I
AMP%
Istart
Iend
tUp
tDown
t
Figure 5-9
1st cycle:
• Press and hold torch trigger 1.
• The gas pre-flow time elapses.
• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.
• The welding current flows and immediately assumes the value set for the ignition current Istart.
• HF is switched off.
• The welding current increases with the adjusted up-slope time to the main current AMP.
Switching from main current AMP to secondary current AMP%:
Press torch trigger 2 or Tap torch trigger 1 *
2nd cycle:
• Release torch trigger 1.
• The main current falls in the set down-slope time to the
end-crater current Iend (minimum current).
If the 1st torch trigger is pressed during the down-slope time, the welding current returns to the
main current AMP set.
• The main current reaches the end-crater current Iend, the arc extinguishes.
• The set gas post-flow time elapses.
*
Tapping function:
Tap briefly on the torch trigger to initiate a function change, e.g. changeover from main to
secondary current (for more in-depth information, see chapter "Setting the torch mode and
up/down speed").
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Design and function
TIG welding
Latched mode
NOTE
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.
1.
2.
3.
4.
AMP
I
AMP%
Istart
Iend
tUp
tDown
t
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). HF is switched off.
Step 2
• Release torch trigger 1.
• The welding current increases with the set up-slope time to the main current AMP.
Switching from main current AMP to secondary current AMP%:
Press torch trigger 2 or Tap torch trigger 1 *
Step 3
• Press torch trigger 1.
• The main current drops with the set down-slope time to the end-crater current Iend (minimum current).
Step 4
• Release torch trigger 1, the arc extinguishes.
• The set gas post-flow time begins.
Immediate termination of the welding process in the downslope by releasing torch trigger 1.
*
34
Tapping function:
Tap briefly on the torch trigger to initiate a function change, e.g. changeover from main to
secondary current (for more in-depth information, see chapter "Setting the torch mode and
up/down speed").
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Design and function
TIG welding
5.8.4.2
SpotArc
The TIG SpotArc function is activated with the pulse variant automated frequencies by default, because
this combination produces the most effective results. The user can of course combine the function with
other pulse variants depending on the selected welding process.
NOTE
The up-slope and down-slope times should be set to “0 s” to achieve an effective result.
Selecting and setting TIG spotArc
Operating
Action Result
element
Signal light
comes on
The spot time can be set for approx. 4 s using the "Welding parameter
setting" rotary dial (spot time setting range 0.01 s to 20.0 s)
Set spot time "tP"
Puls
Automatic
sec
AC
special
The TIG spotArc process is switched on with the pulse variant "TIG
automated pulses" by default. The user can select other pulse variants:
TIG automated pulses (frequency and balance)
sec
TIG pulses
TIG AC special
For combinations that can be selected refer to the "spotArc/pulse variants
table"
Figure 5-11
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Design and function
TIG welding
Sequence:
• Press and hold torch trigger 1.
• The gas pre-flow time elapses.
• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.
• The welding current flows and immediately assumes the value set for the ignition current Istart.
• HF is switched off.
• The welding current increases in the adjusted up-slope time to the main current AMP.
NOTE
The process ends when the set SpotArc time elapses or if the torch trigger is released
prematurely.
spotArc/pulse variants table:
Process
Pulse variants
TIG DC
sec
(lights up in green)
Automated pulses (factory setting)
Pulses (thermal pulses)
No pulses
TIG AC
sec
(lights up in green)
Pulses (thermal pulses)
AC special
No pulses
36
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Design and function
TIG welding
5.8.5
Pulses, function sequences
NOTE
The function sequences in pulses basically behave in the same way as in standard
welding, but during the main current phase there is a continual switching back and forth
between the pulse and pause currents at the relevant times.
5.8.5.1 TIG pulses – non-latched operation
1.
2.
AMP
I
AMP%
Istart
Iend
tUp
t
tDown
Figure 5-12
5.8.5.2 TIG pulses - latched operation
1.
2.
3.
4.
AMP
I
AMP%
Istart
Iend
tUp
tDown
t
Figure 5-13
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Design and function
TIG welding
5.8.6
Pulse variants
NOTE
The machines have an integrated pulse device.
With pulses, the machine switches back and forth between the pulse current (main
current) and pause current (secondary current).
5.8.6.1
Pulses (thermal pulses)
I
AMP
AMP%
t1
t2
t
Figure 5-14
Operating
element
Puls
Automatic
sec
Action
Result
Select TIG pulses function
sec Signal light lights up in green
AC
special
Select pulse time "t1"
LED "Pulse time" comes on (see chapter "Function sequence")
Set pulse time "t1"
Select break time "t2"
LED "Pulse break time" comes on (see chapter "Function sequence")
Set break time "t2"
38
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Design and function
TIG welding
5.8.6.2
Automated pulses
The automated pulses are used with tacking and spot welding of workpieces in particular.
An oscillation in the molten pool is produced by the current-dependent pulse frequency and balance,
which positively influences the ability to bridge the air gap. The pulse parameters required are
automatically specified by the machine control.
Operating
Action
Result
element
Puls
Select TIG automated pulses
Automatic
Press the "TIG pulses" button until the
sec
TIG automated pulses signal light
comes on
AC
special
5.8.6.3
AC pulses
(AC pulse, max. 50Hz)
Setting:
+
AMP
AMP
AMP%
t
tpause
5.8.6.4
AMP
AMP%
tpuls
tpause
= pulse current
= pulse pause current / basic current
= pulse time
= pulse pause time
tpuls
AC special
Application: e.g. for welding thick metal sheets onto thin metal sheets.
Operating
Action
Result
element
Puls
Select TIG AC special
Automatic
Press the "TIG pulses" button until the
sec
signal light comes on
AC
special
AMP
AMP
AMP%
tpulse
tbreak
AMP
=
=
=
=
AC current phase pulse current
DC phase pulse pause current
Pulse time; AC phase time
Pulse break time; DC phase time
t
AMP%
tpause
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tpuls
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Design and function
TIG welding
5.8.7
TIG activArc welding
The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power
supplied is kept virtually constant in the event of changes in the distance between the welding torch and
the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance
between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice
versa. This helps prevents the tungsten electrode sticking in the molten pool and the tungsten inclusions
are reduced. This is particularly useful in tacking and in spot welding.
Operating
Action
Result
Display
element
Select activArc parameter
xx
Press until
LED flashes
• Switch parameter on
•
Switch parameter off
Parameter setting
The activArc parameter (control) can be adjusted specifically for the welding task (panel thickness).
• Preset with: TIG activArc welding
• Enter the menu (ENTER) Keep the runtime parameter button pressed for 3 s.
• Leave the menu (EXIT) Keep the runtime parameter button pressed for 3 s.
Figure 5-15
Display
40
Setting/selection
activArc parameter
Setting: 0 to 100 (factory setting 50)
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Design and function
TIG welding
5.8.8
Welding torch (operating variants)
Different torch versions can be used with this machine.
Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be
modified individually via torch modes.
Explanation of symbols for operating elements:
Symbol
Description
BRT 1
Press torch trigger
*
BRT 1
Tap torch trigger *
BRT 2
Tap * and press torch trigger
Tapping function:
Tap briefly on the torch trigger to initiate a function change, e.g. changeover from main to
secondary current (for more in-depth information, see chapter "Setting the torch mode and
up/down speed").
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Design and function
TIG welding
5.8.9
Torch mode and up/down speed setting
The user has the modes 1 to 4 and modes 11 to 14 available. Modes 11 to 14 include the same function
options as 1 to 4, 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.
The welding process can of course be switched on and off in all modes using torch trigger 1 (TT 1).
AMP
VOLT
JOB
Figure 5-16
Display
Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Torch configuration menu
Set welding torch functions
Torch mode setting
Modes 1-4: with tapping function*, modes 11-14: without tapping function*
Up-/Down speed (not available in modes 4 and 14)
Increase value = rapid current change
Reduce value = slow current change
Exit the menu
Exit
*
Tapping function:
Tap briefly on the torch trigger to initiate a function change, e.g. changeover from main to
secondary current (for more in-depth information, see chapter "Setting the torch mode and
up/down speed").
NOTE
Only the modes listed are suitable for the corresponding torch types.
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TIG welding
5.8.9.1 Standard TIG torch (5-pole)
Standard torch with one torch trigger:
Diagram
Operating
Explanation of symbols
elements
BRT1
Functions
= Torch trigger 1 (welding current on/off;
secondary current via tapping function)
mode
Operating
elements
BRT 1
Welding current On/Off
1
(factory-set)
BRT 1
Secondary current (Latched mode)
Standard torch with two torch triggers:
Explanation of symbols
Diagram
Operating
elements
BRT1
BRT2
Functions
= torch trigger 1
= torch trigger 2
mode
Operating
elements
BRT 1
Welding current On/Off
Secondary current
1
(factory-set)
BRT 2
BRT 1
Secondary current (tapping mode) / (Latched mode)
BRT 1
Welding current On/Off
BRT 1
Secondary current (tapping mode) / (Latched mode)
3
BRT 2
Up function
BRT 2
Down function
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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
BRT 1
Welding current On/Off
Secondary current
1
(factory-set)
BRT 2
BRT 1
Secondary current (tapping mode) / (Latched mode)
BRT 1
+
BRT 2
Welding current On/Off
Secondary current (tapping mode)
2
BRT 1
+
BRT 2
BRT 1
Up function
Down function
BRT 2
BRT 1
Welding current On/Off
BRT 1
Secondary current (tapping mode) / (Latched mode)
3
Up function
Down function
44
BRT 2
BRT 2
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Design and function
TIG welding
5.8.9.2 TIG up/down torch (8-pole)
Up/down torch with one torch trigger
Diagram
Operating
elements
Explanation of symbols
TT 1 = torch trigger 1
Functions
Mode
Operating
elements
BRT 1
Welding current on/off
BRT 1
Secondary current (tapping mode) / (Latched mode)
Increase welding current, infinite adjustment (up function)
1
(factoryset)
Reduce welding current, infinite adjustment (down function)
Up
Down
BRT 1
Welding current on/off
2
BRT 1
Secondary current (tapping mode)
BRT 1
Welding current on/off
BRT 1
Secondary current (tapping mode) / (Latched mode)
4
Increase welding current by an increment (see chapter "Setting the first
increment in modes 4 and 14")
Reduce welding current by an increment (see chapter "Setting the first
increment in modes 4 and 14")
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Up
Down
45
Design and function
TIG welding
Up/down torch with two torch triggers
Diagram
Operating
elements
Explanation of symbols
TT 1 = torch trigger 1 (left)
TT 2 = torch trigger 2 (right)
Functions
Mode
Operating
elements
BRT 1
Welding current on/off
BRT 2
Secondary current
Secondary current (tapping mode) / (Latched mode)
1
(factoryset)
BRT 1
Up
Increase welding current, infinite adjustment (up function)
Reduce welding current, infinite adjustment (down function)
Down
BRT 1
Welding current on/off
BRT 2
Secondary current
2
BRT 1
Secondary current (tapping mode)
BRT 1
Welding current on/off
BRT 2
Secondary current
BRT 1
Secondary current (tapping mode)
4
Increase welding current by an increment (see chapter "Setting the
first increment in modes 4 and 14")
Up
Reduce welding current by an increment (see chapter "Setting the
first increment in modes 4 and 14")
Down
BRT 2
Gas test
4
> 3s
46
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Design and function
TIG welding
5.8.9.3 Potentiometer torch (8-pole)
The welding machine needs to be configured for operation with a potentiometer torch (see chap.
"Configuring TIG potentiometer torch")
Potentiometer torch with one torch trigger:
Diagram
Operating
Explanation of symbols
elements
BRT 1 = torch trigger 1
Functions
Mode
Operating
elements
BRT 1
Welding current On/Off
BRT 1
Secondary current (tapping mode) / (Latched mode)
3
Increase welding current, infinite adjustment
Reduce welding current, infinite adjustment
Potentiometer torch with two torch triggers:
Diagram
Operating
Explanation of symbols
elements
BRT 1 = torch trigger 1
BRT 2 = torch trigger 2
Functions
Mode
Operating
elements
BRT 1
Welding current On/Off
BRT 2
Secondary current
BRT 1
Secondary current (tapping mode) / (Latched mode)
3
Increase welding current, infinite adjustment
Reduce welding current, infinite adjustment
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Design and function
TIG welding
5.8.9.4 RETOX TIG torch (12-pole)
NOTE
For operation with this welding torch, the welding machine must be equipped with the
retrofit option "ON 12POL RETOX TIG" (12-pole torch connection socket)!
Diagram
Operating elements
888
BRT 3
Explanation of symbols
TT= torch trigger
BRT 1
BRT 2
BRT 4
Functions
Mode
Welding current on/off
Secondary current
Secondary current (tapping function)
Increase welding current (up function)
TT 1
TT 2
1
TT 1 (tapping)
(ex works)
TT 3
Reduce welding current (down function)
TT 4
Welding current on/off
TT 1
Secondary current
TT 2
Secondary current (tapping function)
2
TT 3
Decrease JOB number
TT 4
Secondary current
TT 1
3
TT 2
Secondary current (tapping function)
TT 1 (tapping)
Welding current on/off
TT 1
Secondary current
TT 2
Secondary current (tapping function)
TT 1 (tapping)
Increase welding current (up function)
Reduce welding current (down function)
48
TT 1 (tapping)
Increase JOB number
Welding current on/off
*
Operating
elements
4
TT 3
TT 4
Switchover between Up-Down and JOB changeover
TT 2 (tapping)
Increase JOB number
TT 3
TT 4
Decrease JOB number
Tapping function:
Tap briefly on the torch trigger to initiate a function change, e.g. changeover from main to
secondary current (for more in-depth information, see chapter "Setting the torch mode and
up/down speed").
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Design and function
MMA welding
5.9
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
• Always put the electrode holder down on an insulated surface.
CAUTION
Shielding gas connection!
During MMA welding open circuit voltage is applied at the shielding gas connection
(G¼" connecting nipple).
• Place yellow insulating cap on the G¼" connection nipple (protects against electrical voltage
and dirt).
5.9.1
Connecting the electrode holder and workpiece lead
2
3
1
Figure 5-17
Item
Symbol Description 0
Connection socket, “-” welding current
Workpiece lead or electrode holder connection
Connection socket for "+" welding current
Electrode holder or workpiece lead connection
1
2
•
•
Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and
lock by turning to the right.
Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and
lock by turning to the right.
NOTE
Polarity depends on the instructions from the electrode manufacturer given on the
electrode packaging.
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Design and function
MMA welding
5.9.2 Select welding task
Operating
element
Action
Result
Select MMA welding process
The
signal light lights up in green
Set welding current
5.9.3 Hotstart
The hotstart device improves the ignition of the stick electrodes using an increased ignition current.
a) =
b) =
I=
t=
5.9.3.1
Hotstart time
Hotstart current
Welding current
Time
Hotstart current
Operating
element
Action
Result
Displays
Select hotstart current welding parameter
5.9.3.2
xx
Press until hotstart current signal light AMP% comes on
Set hotstart current
The factory setting is a value as a percentage of the
selected main current. To set an absolute value for the
hotstart current, see chapter "Advanced settings".
Action
Result
Hotstart time
Operating
element
Displays
Select hotstart time welding parameter
Press until hotstart time light sec comes on
Set hotstart time
5.9.4 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!
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Design and function
Remote control
5.10 Remote control
NOTE
The remote control is operated on the 19-pole remote control connection socket.
• If required, extension cables are available in different lengths (see chapter Accessories).
• Plug the remote control unit into the remote control connection socket on the welding
machine or wire feed unit and lock it only when the machine is switched off.
• The remote control is detected automatically when the welding machine is switched on.
5.10.1 Manual remote control RT 1
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
5.10.2 Foot-operated remote control RTF 1
Functions
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Start/stop welding operation (TIG)
ActivArc welding is not possible in combination with the RTF 1 foot-operated remote control.
5.10.3 Manual remote control RTP 1
Functions
• TIG/MMA
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Pulse/spot/normal
• Pulse, spot and break times are infinitely adjustable.
5.10.4 Manual remote control RTP 2
Functions
• TIG/MMA.
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Pulse/spot/normal
• Frequency and spot times infinitely adjustable.
• Coarse adjustment of the cycle frequency.
• Pulse/pause ratio (balance) adjustable from 10% to 90%.
5.10.5 RTP 3 manual remote control
Functions
• TIG / MMA.
• Infinitely adjustable welding current (0% to 100%) depending on the preselected
main current on the welding machine.
• Pulse / SpotArc spots / normal
• Frequency and spot time infinitely adjustable.
• Coarse adjustment of the pulse frequency.
• Pulse/pause ratio (balance) adjustable from 10% to 90%.
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Design and function
Interfaces for automation
5.11 Interfaces for automation
5.11.1 Remote control connection socket, 19-pole
CAUTION
Damage to the machine due to improper connection!
Unsuitable control leads or incorrect connection of input and output signals can cause
damage to the machine.
• Only use shielded control leads!
• If the machine is to be operated with control voltages connection via suitable isolation
amplifiers is required!
• To control the main or secondary current via control voltages, the relevant inputs must be
enabled (see specification for activation of control voltage).
A
B
L
10V
F
C
D
1
2
2
I>0
3
4
0-10V
10-100K
5
E
10-100K
0-10V
T
A
B
C
D
T
S
F
U
V
R
E
L
N
P
G
0V
M
J
U
K
J
H
+15V (max. 75mA)
K
-15V (max. 25mA)
V
R
6
6
7
8
9
START / STOP
AMP / AMP%
(PULS)
S
H
10
M
N
11
P
G
Figure 5-18
52
Item
1
2
3
4
Pin
A
B/L
F
C
Signal shape
Output
Output
Output
Input
5
D
Input
6
7
8
9
10
11
J/U
K
V
R
H
M/N
Output
Output
Output
Input
Input
Input
Designation
Connection for cable screen (PE)
Current flowing signal I>0, galvanically isolated (max. +- 15V/100mA)
Reference voltage for potentiometer 10V (max. 10mA)
Control voltage specification for main current, 0–10V (0V = Imin/10V =
Imax)
Control voltage specification for secondary current, 0–10V (0V =
Imin/10V = Imax)
Reference potential 0V
Power supply +15V, max. 75mA
Power supply -15V, max. 25mA
Start/Stop welding current
Switching between main and secondary welding currents (pulses)
Activation of control voltage specification
Signals M and N must be set to reference potential 0V to activate the
external control voltage specification for main and secondary current.
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Design and function
Advanced settings
5.12 Advanced settings
5.12.1 Testing the machine fan
The machine fan can be switched on at the machine controls so that you can check that it is working
correctly.
AMP
VOLT
JOB
Figure 5-19
Display
Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Service menu
Service settings
Exit the menu
Exit
Machine fan test
Machine fan is switched off
Machine fan test
Machine fan is switched on
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Design and function
Advanced settings
5.12.2 Limiting the mains current (10A)
If the plug socket has a 10A mains fuse in order to comply with national regulations, it may be necessary
to reduce the mains current of the welding machine to 10A in order to avoid triggering the fuse. This
restricts the welding machine's power input. The maximum welding performance cannot be achieved
when the current is limited to 10A.
AMP
VOLT
JOB
Figure 5-20
Display
Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Service menu
Service settings
Exit the menu
Exit
Mains current limit
Mains current limited to 16A
Mains current limit
Mains current limited to 10A
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Design and function
Advanced settings
5.12.3 Protecting welding parameters from unauthorised access
To protect against unauthorised or unintentional changes to the welding parameters, you can lock the
machine controls with a software key (3-digit machine code).
If the access lock is active, only the following parameters can be changed:
• Welding current (within a previously defined range).
• Switch display.
• Switch welding parameters (JOBs)
AMP
VOLT
JOB
Figure 5-21
Display
Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Exit the menu
Exit
Error
Error message after entering an incorrect machine code
Machine code
Querying the three-digit machine code (000 to 999), user input
Switch off
Switching off machine function
Switch on
Switching on machine function
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Design and function
Advanced settings
5.12.3.1 Changing the three-digit machine code
In this menu you can change the 3-digit machine code.
After entering and confirming the old code, you can enter a new code.
The correct machine code is necessary for activating and deactivating the access lock!
AMP
VOLT
JOB
Figure 5-22
Display
Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Machine code
Confirming the old machine code/entering the new machine code
Machine code
Querying the three-digit machine code (000 to 999), user input
Error
Error message after entering an incorrect machine code
New machine code
• Machine code entered correctly
• Prompt for entering the new machine code
Exit the menu
Exit
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Design and function
Advanced settings
5.12.4 Setting the welding current (absolute/percentage)
The welding currents for start current, secondary current, end current and hotstart current can be set as
percentages (factory setting) or absolute values.
If absolute current display is set, the "AMP" signal light for the main current is lit in addition to the
respective "AMP%" signal light. However, in percentage display mode, only the respective "AMP%" signal
light is lit.
AMP
VOLT
JOB
Figure 5-23
Display
Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Settings
Settings for machine functions and parameter displays
Welding current display, percentage
Representation of the welding current as a percentage in relation to the main current
setting (AMP). Example: Main current setting to 120A and secondary current to 50%
results in an absolute secondary current of 60A.
Welding current display, absolute
Absolute representation of all welding currents in amperes
Exit the menu
Exit
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Design and function
Advanced settings
5.12.5 Selecting the welding current polarity during the ignition phase
Selection of welding current polarity during ignition phase, until the arc stabilises. It always switches over
to DC- polarity after a few milliseconds.
AMP
VOLT
JOB
Figure 5-24
Display
Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Settings
Settings for machine functions and parameter displays
Negative welding current polarity during the ignition phase
Positive welding current polarity during the ignition phase
Exit the menu
Exit
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Maintenance, care and disposal
General
6
Maintenance, care and disposal
DANGER
Risk of injury from electric shock!
Cleaning machines that are not disconnected from the mains can lead to serious injuries!
• Disconnect the machine completely from the mains.
• Remove the mains plug!
• Wait for 4 minutes until the capacitors have discharged!
6.1
General
When used in the specified environmental conditions and under normal operating conditions, this
machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding
machine. Among these are regular cleaning and checking as described below, depending on the pollution
level of the environment and the length of time the unit is in use.
6.2
Maintenance work, intervals
6.2.1
Daily maintenance tasks
•
•
•
•
6.2.2
Monthly maintenance tasks
•
•
•
6.2.3
Mains supply lead and its strain relief
Welding current cables (check that they are fitted correctly and secured)
Operating, message, safety and adjustment devices
Other, general condition
Casing damage (front, rear and side walls)
Transport elements (strap, lifting lugs, handle)
Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
Annual test (inspection and testing during operation)
NOTE
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.
The former term of repetition test has been replaced due to a change in the corresponding standard with
“Inspection and testing during operation”.
In addition to the regulations on the test given here, the relevant local laws and regulations must also be
observed.
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
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Maintenance, care and disposal
Repair Work
6.3
Repair Work
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.
• Appoint only skilled persons for repair work (trained service personnel)!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
6.4
Meeting the requirements of RoHS
We, EWM HIGHTEC Welding GmbH Mündersbach, hereby confirm that all products supplied by us which
are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
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Rectifying faults
Machine faults (error messages)
7
Rectifying faults
All machines are subject to rigorous production checks and final checks. If despite this, anything fails to
work at any time, please check the machine using the following chart. If none of the fault rectification
procedures described leads to the correct functioning of the machine, please inform your authorised
dealer.
7.1
Machine faults (error messages)
NOTE
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.
• Document machine errors and inform service staff as necessary.
Error message
Possible cause
Remedy
E1
Water fault
Ensure that sufficient water pressure can be built
up. (e.g. top up water)
Only occurs if a water cooling
unit is connected.
E2
Temperature error
Allow machine to cool down.
E3
Electronics error
Switch machine off and on again.
If the fault persists, inform the service
department.
E4
see "E3"
see "E3"
E5
see "E3"
see "E3"
E6
Balancing error in voltage
Switch machine off, place the torch on an
recording.
insulated surface and switch on again.
If the fault persists, inform the service
department.
E7
Balancing error in current
Switch machine off, place the torch on an
recording.
insulated surface and switch on again.
If the fault persists, inform the service
department.
E8
Error in one of the electronics
Allow machine to cool down. If the error message
supply voltages or excess
persists, switch the machine off and back on
again.
temperature of the welding
transformer.
If the fault persists, inform the service
department.
E9
Low voltage
Switch off the machine and check the mains
voltage.
E10
Secondary overvoltage
Switch machine off and on again.
If the fault persists, inform the service
department.
E11
Overvoltage
Switch off the machine and check the mains
voltage.
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Rectifying faults
Resetting welding parameters to the factory settings
7.2
Resetting welding parameters to the factory settings
NOTE
All customised welding parameters that are stored will be replaced by the factory
settings.
AMP
VOLT
JOB
Figure 7-1
Display
62
Setting/selection
Input confirmation
User entries are applied, release button(s).
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Rectifying faults
Resetting welding parameters to the factory settings
7.2.1
Display machine control software version
NOTE
The query of the software versions only serves to inform the authorised service staff!
AMP
VOLT
JOB
Figure 7-2
Display
Setting/selection
Lock JOB menu
Protect welding parameters from unauthorised access
Service menu
Service settings
Exit the menu
Exit
Software version of the machine control
Version display (example 014 = version 14)
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Technical data
Smootharc TIG 230 AC/DC
8
Technical data
8.1
Smootharc TIG 230 AC/DC
NOTE
Performance specifications and guarantee only in connection with original spare and
replacement parts!
Setting range
Welding current
DC
AC
Welding voltage
Duty cycle (DC) at 25°C
40% DC
45% DC
60% DC
100% DC
Duty cycle (DC) at 40°C
35% DC
60% DC
100% DC
Load alternation
Open circuit voltage (DC)
Mains voltage (tolerances)
Frequency
Mains fuse
Mains connection lead
Max. connected load
Recommended generator rating
cosϕ
Insulation class/protection classification
Ambient temperatures
Machine cooling
Torch cooling
Workpiece lead
Dimensions L x W x H
Weight
Constructed to standards
64
TIG
MMA
3 A-230 A
5 A-230 A
10.1V-19.2V
5 A-180 A
5 A-180 A
20.2V-27.2V
230A
180A
150A
180A
160A
140A
230A
160A
130A
180A
140A
110A
10 min. (60% DC ∧ 6 min. welding, 4 min. pause)
45V
1 x 230V (-40% to +15%)
50/60Hz
1 x 16A (safety fuse, slow-blow)
H07RN-F3G2.5
5.2kVA
5.8kVA
7.8kVA
1.0
F/IP 23
-20 °C to +40 °C
Fan
Gas
35mm2
575 x 205 x 415mm
17kg
IEC 60974-1, -3, -10
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Accessories, options
TIG welding torch
9
Accessories, options
9.1
TIG welding torch
Type
TIG 200 GD 4M 8P 2T UD
TIG 200 GD 4M 12P RETOX
HFL
9.2
RA5 19POL 5M
RA10 19POL 10M
RA20 19POL 20M
RV5M19 19POLE 5M
Item no.
090-008097-00000
090-008098-00000
090-008099-00000
090-008211-00000
094-006680-00000
Designation
Transport vehicle
Transport vehicle, long wheelbase
Item no.
090-008198-00000
090-008270-00000
Designation
Optional retrofit 12-pole connection socket, torch
Retrofit option, dirt filter for air inlet
Item no.
092-002519-00000
092-002551-00000
092-001470-00005
092-001470-00010
092-001470-00020
092-000857-00000
Designation
Air cooling unit
Coolant (-10 °C), 9.3 l
Coolant (-10°C), 200 litres
Coolant (-20 °C), 9.3 l
Coolant (-20 °C), 200 l
Frost protection tester
Item no.
090-008593-00102
094-000530-00000
094-000530-00001
094-006256-00000
094-006256-00001
094-014499-00000
Designation
Earth contact coupling/CEE16A plug
Gas hose
8 to 5-pole adapter
Threaded adapter, G1/4 to G1/8
Item no.
092-000812-00000
094-000010-00001
092-000940-00000
094-001650-00000
General accessories
Type
ADAP SCHUKO/16ACEE
G1 2M G1/4 R 2M
ADAP 8-5 POL
ADAP1 G1/4-G1/8
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Designation
Remote control current
Remote control spots/pulses
Remote control spots/pulses
spotArc remote control for spots/pulses
Foot-operated remote control current with
connection cable
Remote control e.g. connection cable
Remote control e.g. connection cable
Remote control e.g. connection cable
Extension cable
Welding torch cooling system
Type
COOL40 U31
KF 23E-10
KF 23E-200
KF 37E-10
KF 37E-200
TYP 1
9.7
Item no.
092-000052-00000
092-000008-00000
Options
Type
ON 12POL TIG
ON FILTER TIG 40
9.6
Designation
Electrode holder
Workpiece lead, clamp
Transport vehicle
Type
TROLLY 35-2
TROLLY 38-2 E
9.5
094-011554-00004
Remote controls and accessories
Type
RT1
RTP1
RTP2
RTP3
RTF1 19POLE 5M
9.4
Item no.
094-010981-00200
Electrode holder / workpiece lead
Type
EH35QMM 4M
WK35QMM 4M KL
9.3
Designation
TIG welding torch, 4m, gas-cooled, double
pressure, U/D
TIG welding torch, 4m, gas-cooled, RETOX, flex.,
leather
65