GB OPERATING INSTRUCTIONS TIG inert gas welding equipment TIGER DIGITAL 230 DC / AC/DC ULTRA/HIGH TIGER DIGITAL 180 DC / AC/DC ULTRA/HIGH Operating instructions Operating instructions TIG inert gas welding equipment TIGER DIGITAL 230 AC/DC ULTRA TIGER DIGITAL 230 AC/DC ULTRA TIGER DIGITAL 180 AC/DC ULTRA TIGER DIGITAL 180 AC/DC ULTRA TIGER DIGITAL 230 AC/DC HIGH TIGER DIGITAL 230 DC HIGH TIGER DIGITAL 180 AC/DC HIGH TIGER DIGITAL 180 DC HIGH Rehm GmbH u. Co. KG Ottostr. 2 D-73066 Uhingen Telephone: +49 (0)7161/3007-0 Telefax: +49 (0)7161/3007-20 e-mail: [email protected] Internet: http://www.rehm-online.de Doc. No.: 730 2430 Date of issue: 16/08/2017  Rehm GmbH u. Co. KG, Uhingen, Germany 2017 The content of this description is the property of Rehm GmbH u. Co. KG The copying and distribution of this document, use and communication of its contents are strictly prohibited unless expressly authorized. Offenders are liable to damages. All rights reserved in the event of patent, utility model or design patent. The manufacture based on these documents is not allowed. Subject to change. 2 List of contents List of contents Product identification 2 1 Introduction 6 1.1 Foreword 6 1.2 General description 7 1.2.1 Principle of the TIG inert gas welding process 8 1.2.2 Scope of application of TIG welding equipment 8 1.2.3 Intended use 8 1.3 Symbols used 9 2 Safety information 10 2.1 Warning symbols in these operating instructions 10 2.2 Warning symbols on the system 10 2.3 Notes and requirements 11 3 Unit description 13 4 Function description 15 4.1 Overview of the operating panel 15 4.2 Operation description 16 4.2.1 Controls 16 4.2.2 Operating functions 17 4.3 Switch on 21 4.4 Peculiarities of the operating panel 21 5 Corner menu functions 22 5.1 Corner menu welding processes (top left) 22 5.1.1 Electrode welding 22 5.1.2 Electrode BOOSTER function 22 5.2 Corner menu operating mode (top right) 23 5.2.1 2 cycle operating mode 23 5.2.2 4 cycle operating mode 24 5.2.3 TIG spot welding 24 5.2.4 TIG interval 25 5.3 High-frequency (HF) ignition 26 5.3.1 Welding with HF ignition 26 5.3.2 Welding without HF ignition 27 5.4 Corner menu welding process (bottom right) 28 5.4.1 Time pulses 28 5.4.2 Hyper pulses 28 5.5 Corner menu polarity (bottom left) 29 5.5.1 Alternating current (~) 29 5.5.2 Dual Wave (=/~) 29 5.5.3 DC positive positive pole (+) 29 5.5.4 DC negative pole (-) 30 6 Parameter settings 31 6.1 Setting the TIG welding parameters 31 6.1.1 Gas pre-flow time 31 6.1.2 Ignition power 31 6.1.3 Starting current 32 6.1.4 Slope-up time 32 6.1.5 Welding current I and pulse time t 32 1 1 6.1.6 Welding current I and pulse time t 32 2 2 6.1.7 Automatic pulsing 33 6.1.8 Manual pulsing 34 6.1.9 Slope-down time 34 6.1.10 End crater current l 34 e 6.1.11 Gas post flow time 35 3 List of contents 6.2 AC settings menu 36 6.2.1 AC waveform 36 6.2.2 AC frequency (Hz) 36 6.2.3 AC balance ( ) 36 6.2.4 Further settings for DualWave 36 6.3 Menu spot welding and interval 37 6.3.1 Spot time 37 6.3.2 Pause time 37 6.4 Electrode welding parameters 37 6.4.1 Setting options (from left to right) 38 6.4.2 Hot Start 38 6.4.3 Welding current I1 38 6.4.4 ArcForce 38 6.4.5 Anti-stick-automatic 39 7 Submenus 40 7.1 Language menu 40 7.2 Assist 40 7.3 Save and load programs 42 7.3.1 Quick program buttons P1 … P4 42 7.3.2 Memory programs 5 to 99 42 7.3.3 Manage parameter lists (folders) 43 7.4 Optional water cooling unit 45 8 Setup / special parameters 46 9 Error memory 50 10 Indicating symbol 50 11 Accessories 51 11.1 Foot-actuated remote controller TIGER DIGITAL 180/230 51 11.2 REHM TIG torch 51 11.3 Optional water cooling unit 51 12 Commissioning 52 12.1 Safety information 52 12.2 Working under increased electrical hazard (IEC 874, EN 60974-1, TRBS 2131 and BGR 500 KAP. 2.26) 52 12.3 Placement and transportation of the welding unit. 53 12.4 Connecting the welding unit 53 12.5 Cooling the welding unit 53 12.6 Guidelines for working with welding current sources 54 12.7 Connecting the welding leads and the torch 54 12.8 Connection of external components 54 13 Operation 55 13.1 Safety information 55 13.2 Electrical hazard 55 13.3 Instructions for your personal safety 55 13.4 Fire protection 56 13.5 Ventilation 56 13.6 Checks before switching on 57 13.7 Connecting the grounding cable 57 13.8 Practical instructions for use 57 14 Faults TIG welding unit 60 14.1 Safety information 60 14.2 Table of faults 60 14.3 Error messages 63 4 List of contents 15 Maintenance work 65 15.1 Safety information 65 15.2 Maintenance table 65 15.3 Cleaning the inside of the unit 66 15.4 Proper disposal 66 16 Technical data 67 17 Accessories 71 18 Circuit diagrams 73 19 INDEX 79 5 Introduction 1 Introduction 1.1 Foreword Dear Customer, You have purchased a REHM inert gas welding system, a renowned German brand name. We thank you for the confidence you have placed in our quality products. Only components of the highest quality are used in TIGER DIGITAL equipment. To enable a long service life even under the toughest conditions all REHM equipment is manufactured using only parts that comply with our strict quality demands. The TIGER DIGITAL has been developed and designed according to the generally accepted rules for technology and safe operation. All relevant legal regulations have been observed and complied with. Conformity is declared and is marked with the CE symbol. REHM welding systems are manufactured in Germany and therefore bear the "Made in Germany" quality label. Since REHM strives to immediately take advantage of technical progress, it reserves the right to adapt the design of the welding equipment at any time to the latest technical requirements. 6 Introduction 1.2 General description Fig.1 TIGER DIGITAL (in the background with a water cooling unit) 7 Introduction 1.2.1 Principle of the TIG inert gas welding process In TIG welding the arc burns freely between a tungsten electrode and the workpiece. The inert gas is a noble gas such as argon, helium or a mixture of these. One pole of the power source is connected to the tungsten electrode, the other to the workpiece. The electrode is the current conductor and arc carrier (continuous electrode). The filler material is introduced in the form of a rod or wire by hand or a separate cold wire feed unit. The tungsten electrode, the weld pool and the molten end of the filler material are protected against the ingress of atmospheric oxygen by inert shielding gas that escapes from the protective gas nozzle arranged concentrically around the electrode. 1.2.2 Scope of application of TIG welding equipment TIGER DIGITAL DC welding machines are DC sources. They are suitable for welding all carbon and alloy steels, stainless steels and non-ferrous metals. TIGER DIGITAL AC/DC welding machines are AC and DC sources. They can be used for processing all carbon and alloy steels, stainless steels, non-ferrous metals, aluminium and aluminium alloys. 1.2.3 Intended use TIGER DIGITAL welding machines may be used only for TIG or electrode welding as intended. REHM welding devices are designed for welding various different metallic materials such as unalloyed and alloyed steels, stainless steels, copper, titanium and aluminium. Please also observe the special rules that apply to your applications. REHM welding machines are designed for use in hand-held and machine-guided operation. REHM welding machines are, except when this is expressly stated in writing by REHM, only for sale to commercial / industrial users and are only intended to be used by commercial / industrial users. The machines may only be operated by persons who trained in the use and maintenance of welding equipment. Welding power sources may not be installed in areas with increased electrical risk. This manual contains rules and guidelines for the intended use of your system. Only compliance with these guidelines shall be considered as proper use. Risks and damages incurred due to any other use is the responsibility of the operator. Use under special requirements may necessitate the observance of particular regulations. If in doubt, ask your competent safety officer or contact the REHM customer service department. The special instructions listed in the supplier documentation for intended use must be observed. National regulations also apply without restriction to the operation of the system. 8 Introduction Welding power sources may not be used to defrost pipes. Intended use also includes compliance with the prescribed assembly, disassembly and reassembly, commissioning, use, maintenance and disposal measures. Please make particular note of the information in Section 2 Safety information and Section 15.4 Proper disposal. The system may only be operated under the aforementioned conditions. Any other use is considered unintended use. The consequences of unintended use rests with the operator. 1.3 Symbols used Typographic  Enumerations proceeded by a bullet point: General enumerations  Enumerations proceeded by a square: Work or maintenance steps that must distinctions be performed in the order listed.  Section 2.2, Warning symbols on the system Cross-reference: Here to Section 2.2 Warning symbols on the system, warning symbols on the system Bold text is used for emphasis Note! ... indicates practical tips and other particularly useful information. Safety The safety symbols used in this manual: Section 2.1 symbols 9 Safety information 2 Safety information 2.1 Warning symbols in these operating instructions Warnings and This or a symbol that more accurately specifies the risk can be found in symbols all of the safety instructions given in these operating instructions where there is danger to life and limb. One of the signal words below (Danger!, Warning!, Caution!) is used to indicate the severity of the risk: Danger! …warning of immediate danger. Death or serious injury may result if the warning if not heeded. Warning! ... of a potentially dangerous situation. Death or serious injury may result if the warning is not heeded. Caution! … warns of a potentially harmful situation. Slight or minor injuries or property damage may result if the warning is not heeded. Important! Notice of a potentially harmful situation. The product or an object in the vicinity may be damaged if the warning is not heeded. Materials that are hazardous to health or the environment. Materials/operating materials that must be handled or disposed of in a legally conformant way. 2.2 Warning symbols on the system identify hazards and hazards on the system. Danger! Risk of electrical shock! Non-observance mas result in death or injury. 10