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TIP TIG TIG 500 FOCUS - User Manual

TIP TIG TIG 500 FOCUS
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TIP TIG - TIG 500 FOCUS
Operating Manual
Version 1.1 Revision 0.1
TIP TIG TIG 500 FOCUS
OPERATING MANUAL
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Summary

INTRODUCTION

GENERAL INSTRUCTIONS

INTENDED USE

Declaration of conformity

Confirms compliance with EC directives and standards for design and construction.

Welding in environments with increased electrical hazards

Details the machine's suitability for environments with higher electrical risks.

Calibration;Validation

Confirms machine testing with calibrated measuring equipment against standards.

SAFETY RULES

Explanation of safety symbols

Defines danger, warning, caution, and note symbols for safe operation.

General safety instructions

Provides essential safety guidelines for operation, maintenance, and repair.

GENERAL

Device concept

Explains the TIP TIG FOCUS as a digitized, microprocessor-controlled welding system.

Crane transport

Details safe lifting procedures and load-bearing capacity for crane transport.

CONTROLS, CONNECTIONS AND MECHANICAL COMPONENTS

System overview

Identifies and describes the main components on the front and rear of the machine.

Front connection

Details the various connection sockets and nipples on the front panel.

Main switch with fuses

Describes the main power switch and associated fuses.

Connection socket relays

Explains the functionality of the 7-pole connection socket for external equipment.

Control Panel - Power Source

Details the indicators and rotary knobs on the power source control panel.

Control Panel - FOCUS

Explains the touch screen interface for welding parameters and settings.

INSTALLATION AND COMMISSIONING

Before installation and commissioning

Covers safety, ambient conditions, and general preparation requirements.

Start-up - Power Source

Provides instructions for commissioning the power source for TIG welding.

Welding torch cooling system

Details coolant types, adding coolant, and frost protection for the torch.

Connecting the gas cylinder

Step-by-step guide for safely connecting the gas cylinder and regulator.

Establishing a ground (earth) connection to the workpiece

Instructions for creating a proper ground connection for safety and operation.

Connecting the welding torch

Guides on connecting the TIG welding torch and its control cable.

Start-up - Wire feeder

Outlines prerequisites and general steps for commissioning the wire feeder unit.

Inserting;replacing feed rollers

Instructions for fitting the correct feed rollers for optimal wire feeding.

Inserting the wire spool

Details the process of mounting a wire spool onto the wire feeder.

Inching the wire electrode

Explains how to feed the wire electrode using the inching function.

Spool brake setting

Describes how to adjust the spool brake for proper wire tension control.

WELDING

Preparation

Covers essential pre-welding checks and safety procedures.

S-Test (AC only)

Procedure for testing the hazard reduction device before welding.

Forced switch-off

Explains the automatic shutdown sequence for non-ignition or process interruption.

Operating modes

Details various welding modes like MMA, TIG 2/4-Stroke, Liftarc, and Pulse.

Welding current types (TIG 500 AC only)

Describes different AC and DC welding current types and their characteristics.

MMA welding

Instructions for setting up and performing MMA welding.

TIG welding

Instructions for setting up and performing TIG welding modes and parameters.

TROUBLESHOOTING, MAINTENANCE AND DISPOSAL

Troubleshooting

Provides a checklist and common solutions for operational issues and faults.

Care, maintenance and disposal

Guidance on routine care, periodic maintenance, and proper disposal of the equipment.

TECHNICAL DATA

APPENDIX

Installation Guide

Step-by-step guide for connecting the remote pendant and system components.

Welding Check List

A comprehensive checklist for torch, purge, parameters, gas, AVC, and joint preparation.

Spare part list

Lists spare parts for the four-roll wire drive with item numbers.

Wiring Diagrams

Includes diagrams for internal/external wire feeders, PLC structures, and control panels.

TIP TIG TIG 500 FOCUS Specifications

General IconGeneral
Input Voltage3 x 400 V
Welding Current Range5 - 500 A
Duty Cycle100% at 400 A
CoolingWater-cooled
Rated Duty Cycle (at 500 A)60%
Input Frequency50/60 Hz
Current Range (TIG)5 - 500 A
Protection ClassIP23
Cooling MethodWater-cooled
Welding ProcessTIG (GTAW)