Safety
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
WARNING!
Danger from electric current due to defective system components and incorrect operation.
This can result in serious personal injury and damage to property.
All cables, leads, and hosepacks must always be securely connected, undamaged, and correctly insulated.
Only use adequately dimensioned cables, leads, and hosepacks.
WARNING!
Risk of coolant escaping.
This can result in serious personal injury and damage to property.
When disconnecting a welding torch from the cooling unit or other system components, always seal the coolant hoses using the plastic seal attached to the torch.
WARNING!
Danger due to hot system components and/or equipment.
This can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.).
Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.) if cooling down is not possible.
WARNING!
Danger from contact with toxic welding fumes.
Serious personal injuries may result.
Always extract welding fumes.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least 20 m³ (169,070.1 US gi) per hour at all times.
In case of doubt, the concentration of noxious substances at the work station should be assessed by a safety engineer.
CAUTION!
Danger from operation without coolant.
This can result in damage to property.
Never operate water-cooled welding torches without coolant.
During welding, ensure that the coolant is circulating correctly – this will be the case for Fronius cooling units if a regular return flow of coolant can be seen in the coolant container of the cooling unit.
The manufacturer will not be liable for any damages due to non-observance of the above mentioned points. All claims against the warranty are void.
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
WARNING!
Danger from electric current due to defective system components and incorrect operation.
This can result in serious personal injury and damage to property.
All cables, leads, and hosepacks must always be securely connected, undamaged, and correctly insulated.
Only use adequately dimensioned cables, leads, and hosepacks.
WARNING!
Risk of coolant escaping.
This can result in serious personal injury and damage to property.
When disconnecting a welding torch from the cooling unit or other system components, always seal the coolant hoses using the plastic seal attached to the torch.
WARNING!
Danger due to hot system components and/or equipment.
This can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to cool to +25°C/+77°F (e.g., coolant, water-cooled system components, wirefeeder drive motor, etc.).
Wear suitable protective equipment (e.g., heat-resistant gloves, safety goggles, etc.) if cooling down is not possible.
WARNING!
Danger from contact with toxic welding fumes.
Serious personal injuries may result.
Always extract welding fumes.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least 20 m³ (169,070.1 US gi) per hour at all times.
In case of doubt, the concentration of noxious substances at the work station should be assessed by a safety engineer.
CAUTION!
Danger from operation without coolant.
This can result in damage to property.
Never operate water-cooled welding torches without coolant.
During welding, ensure that the coolant is circulating correctly – this will be the case for Fronius cooling units if a regular return flow of coolant can be seen in the coolant container of the cooling unit.
The manufacturer will not be liable for any damages due to non-observance of the above mentioned points. All claims against the warranty are void.
Intended use
The TIG manual welding torch is intended solely for TIG welding and TIG brazing in manual applications.
Any other use is deemed to be "not in accordance with the intended purpose.”
- Following all the instructions in the Operating Instructions
- Carrying out all the specified inspection and maintenance work.
Functions of the Up/Down torch
Operating elements of the Up/Down-torch
| (1) | Start key The key initiates the following functions:
|
| (2) | Up/Down key To change the welding power |
| (3) | LED button To illuminate the welding area:
|
Operating elements of the Up/Down-torch
| (1) | Start key The key initiates the following functions:
|
| (2) | Up/Down key To change the welding power |
| (3) | LED button To illuminate the welding area:
|
Functional description of the Up/Down-torch
Changing the welding power:
1
Intermediate lowering:
1
Push the button forwards and hold until intermediate lowering is complete
Functions of the JobMaster welding torch
Operating elements and displays of the JobMaster welding torch
| (1) | Start key The key initiates the following functions:
|
| (2) | Display For ergonomic reading of essential welding parameters on the welding torch itself |
| (3) | Up/Down key To change welding parameters |
| (4) | Arrow keys To select welding parameters |
| (5) | LED button To illuminate the welding area:
|
Operating elements and displays of the JobMaster welding torch
| (1) | Start key The key initiates the following functions:
|
| (2) | Display For ergonomic reading of essential welding parameters on the welding torch itself |
| (3) | Up/Down key To change welding parameters |
| (4) | Arrow keys To select welding parameters |
| (5) | LED button To illuminate the welding area:
|
Functional description of the JobMaster-welding torch
Change welding parameters:
1
Select desired welding parameter
2
Change welding parameter
Intermediate lowering:
1
Activate intermediate lowering
Push the button forwards and hold until intermediate lowering is complete
Replacing the user interface
Replacing the user interface
1
2
3
Replacing the user interface
1
2
3
Mounting the Wearing Parts
Fitting an A-type wearing part with gas nozzle (push-on type)
CAUTION!
Risk of damage due to excessive tightening torque on the fixing sleeve (1) or gas lens (2).
Damage to the thread may result.
Only tighten the fixing sleeve (1) or gas lens (2) a little.
| * | Replaceable rubber sealing sleeve only for TTB 220 G/A |
| ** | A gas lens (2) may be used instead of the fixing sleeve (1) depending on the type of welding torch |
1
2
CAUTION!
Risk of damage due to excessive tightening torque on the torch cap.
Damage to the thread may result.
Only tighten the torch cap enough so that the tungsten electrode can no longer be moved by hand.
3
4
Screw down the torch cap
Fitting an A-type wearing part with gas nozzle (push-on type)
CAUTION!
Risk of damage due to excessive tightening torque on the fixing sleeve (1) or gas lens (2).
Damage to the thread may result.
Only tighten the fixing sleeve (1) or gas lens (2) a little.
| * | Replaceable rubber sealing sleeve only for TTB 220 G/A |
| ** | A gas lens (2) may be used instead of the fixing sleeve (1) depending on the type of welding torch |
1
2
CAUTION!
Risk of damage due to excessive tightening torque on the torch cap.
Damage to the thread may result.
Only tighten the torch cap enough so that the tungsten electrode can no longer be moved by hand.
3
4
Screw down the torch cap
Fitting a P-type wearing part with gas nozzle (screw type)
CAUTION!
Risk of damage due to excessive tightening torque on the fixing sleeve (1) or gas lens (2).
Damage to the thread may result.
Only tighten the fixing sleeve (1) or gas lens (2) a little.
| * | Replaceable rubber sealing sleeve only for TTB 220 G/P |
| ** | A gas lens (2) may be used instead of the fixing sleeve (1) depending on the type of welding torch |
1
2
CAUTION!
Risk of damage due to excessive tightening torque on the torch cap.
Damage to the thread may result.
Only tighten the torch cap enough so that the tungsten electrode can no longer be moved by hand.
3
4
Screw down the torch cap
Removing and fitting P / TFC wearing part (with screw-type gas nozzle)
Definition of terms: TFC = Tungsten Fast Clamp
CAUTION!
Danger from tungsten electrode when dismantling clamping unit and collet.
The torch body may be damaged.
Always remove the tungsten electrode before dismantling the clamping unit and collet.
Removing wearing parts:
1
Remove the tungsten electrode
2
Remove the clamping unit
3
Remove the collet
4
Fitting wearing parts:
1
CAUTION!
Danger from tungsten electrode when fitting clamping unit and collet.
The torch body may be damaged.
Fit the clamping unit and collet and only then fit the tungsten electrode.
2
Fit the collet
3
Fit the clamping unit
4
5
Fit the tungsten electrode
6
7
Fitting the torch body and connecting the welding torch
Fitting the torch body
NOTE!
Risk due to damaged O-ring on the torch body.
A damaged O-ring on the torch body can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the torch body is undamaged.
1* Grease the O-ring on the torch body
2
3
Push the torch body locking device fully back and at the same time turn the torch body 180°
4
CAUTION!
Danger due to incorrectly fitted torch body.
This can result in damage to property.
Ensure that the locking device is fully forward after fitting the torch body - only then is the torch body properly fitted and locked.
Fitting the torch body
NOTE!
Risk due to damaged O-ring on the torch body.
A damaged O-ring on the torch body can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the torch body is undamaged.
1* Grease the O-ring on the torch body
2
3
Push the torch body locking device fully back and at the same time turn the torch body 180°
4
CAUTION!
Danger due to incorrectly fitted torch body.
This can result in damage to property.
Ensure that the locking device is fully forward after fitting the torch body - only then is the torch body properly fitted and locked.
Rotating the torch body
1
Connecting the welding torch
NOTE!
Risk due to damaged O-ring on the welding torch connection.
A damaged O-ring on the welding torch connection can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the welding torch connection is undamaged.
1
* only with water-cooled welding system
Connecting the extension hosepack
Connecting the water-cooled extension hosepack
The extension hosepack comes with a protective bag in which the interface connecting the extension hosepack to the torch hosepack is placed.
NOTE!
When carrying out the work described below, ensure that the cables and hoses are not kinked, pinched, abraded or otherwise damaged.
NOTE!
Risk due to damaged O-ring on the welding torch connection.
A damaged O-ring on the welding torch connection can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the welding torch connection is undamaged.
1
Connect the welding torch to the interconnecting hosepack
Fit protective bag, lay coolant hoses:
2Position the protective bag as follows:
left = power source end (A)
right = welding torch end (B)
- the Fronius logo must be visible
- the loops of the protective bag must be at the top
left = power source end (A)
right = welding torch end (B)
3Open the protective bag:
- Push both zip pulls to the right as far as they will go
- Pull the bottom end of the tape out of the zip pulls
4Place the interface connecting the extension hosepack and the torch hosepack in the inside pocket of the protective bag
5
- * = Velcro strips on the inside pocket (inside pocket not shown)
- Secure the interface in the inside pocket with 2 Velcro strips
6
- Route the coolant hose from the extension hosepack (A) to the interface as shown
- Wrap the coolant hose from the torch hosepack (B) around the torch hosepack 3 times and route to the interface
- Connect the coolant hoses
7
- Route the second coolant hose from the extension hosepack (A) behind the torch hosepack (B) to the interface as shown
- Wrap the second coolant hose from the torch hosepack (B) around the extension hosepack (A) 3 times as shown and route back to the interface
- Connect the coolant hoses
8
- Align the coolant connections with each other and in the center of the insulating tube (1)
9
- * = Inside pocket
- Attach the two Velcro strips supplied to the inside pocket
10
- * = Inside pocket
- Assemble the TIG Multi Connector and position it next to the inside pocket
11Close the protective bag
12Connect the interconnecting hosepack to the power source
- The interconnecting hosepack is connected in the same way as the welding torch - see section Connecting the welding torch from page (→)
WARNING!
Danger of slipping due to overflowing coolant container. If using a MultiControl cooling unit, be aware that an overfilled coolant container can overflow when emptying hosepacks longer than 4 m (13 ft. 1.48 in.).
This can result in severe personal injury and damage to property.
Follow the instructions for filling the torch hosepack in the cooling unit operating instructions.
CAUTION!
Risk of damage from operation without sufficient coolant.
This can result in damage to property.
As soon as a good return flow is visible in the coolant container of the cooling unit after starting up the power source, ensure that there is sufficient coolant in the cooling unit.
Connecting the water-cooled extension hosepack
The extension hosepack comes with a protective bag in which the interface connecting the extension hosepack to the torch hosepack is placed.
NOTE!
When carrying out the work described below, ensure that the cables and hoses are not kinked, pinched, abraded or otherwise damaged.
NOTE!
Risk due to damaged O-ring on the welding torch connection.
A damaged O-ring on the welding torch connection can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the welding torch connection is undamaged.
1
Connect the welding torch to the interconnecting hosepack
Fit protective bag, lay coolant hoses:
2Position the protective bag as follows:
left = power source end (A)
right = welding torch end (B)
- the Fronius logo must be visible
- the loops of the protective bag must be at the top
left = power source end (A)
right = welding torch end (B)
3Open the protective bag:
- Push both zip pulls to the right as far as they will go
- Pull the bottom end of the tape out of the zip pulls
4Place the interface connecting the extension hosepack and the torch hosepack in the inside pocket of the protective bag
5
- * = Velcro strips on the inside pocket (inside pocket not shown)
- Secure the interface in the inside pocket with 2 Velcro strips
6
- Route the coolant hose from the extension hosepack (A) to the interface as shown
- Wrap the coolant hose from the torch hosepack (B) around the torch hosepack 3 times and route to the interface
- Connect the coolant hoses
7
- Route the second coolant hose from the extension hosepack (A) behind the torch hosepack (B) to the interface as shown
- Wrap the second coolant hose from the torch hosepack (B) around the extension hosepack (A) 3 times as shown and route back to the interface
- Connect the coolant hoses
8
- Align the coolant connections with each other and in the center of the insulating tube (1)
9
- * = Inside pocket
- Attach the two Velcro strips supplied to the inside pocket
10
- * = Inside pocket
- Assemble the TIG Multi Connector and position it next to the inside pocket
11Close the protective bag
12Connect the interconnecting hosepack to the power source
- The interconnecting hosepack is connected in the same way as the welding torch - see section Connecting the welding torch from page (→)
WARNING!
Danger of slipping due to overflowing coolant container. If using a MultiControl cooling unit, be aware that an overfilled coolant container can overflow when emptying hosepacks longer than 4 m (13 ft. 1.48 in.).
This can result in severe personal injury and damage to property.
Follow the instructions for filling the torch hosepack in the cooling unit operating instructions.
CAUTION!
Risk of damage from operation without sufficient coolant.
This can result in damage to property.
As soon as a good return flow is visible in the coolant container of the cooling unit after starting up the power source, ensure that there is sufficient coolant in the cooling unit.
Connecting the gas-cooled extension hosepack
The extension hosepack comes with a protective bag in which the interface connecting the extension hosepack to the torch hosepack is placed.
NOTE!
When carrying out the work described below, ensure that the cables and hoses are not kinked, pinched, abraded or otherwise damaged.
NOTE!
Risk due to damaged O-ring on the torch body.
A damaged O-ring on the torch body can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the torch body is undamaged.
1
Connect the welding torch to the interconnecting hosepack
Fit the protective bag:
2Position the protective bag as follows:
left = power source end (A)
right = welding torch end (B)
- the Fronius logo must be visible
- the loops of the protective bag must be at the top
left = power source end (A)
right = welding torch end (B)
3Open the protective bag:
- Push both zip pulls to the right as far as they will go
- Pull the bottom end of the tape out of the zip pulls
4Place the interface connecting the extension hosepack and the torch hosepack in the inside pocket of the protective bag
5
- * = Velcro strips on the inside pocket (inside pocket not shown)
- Secure the interface in the inside pocket with 2 Velcro strips
6
- * = Inside pocket
- Attach the two Velcro strips supplied to the inside pocket
7
- * = Inside pocket
- Assemble the TIG Multi Connector and position it next to the inside pocket
8Close the protective bag
9Connect the interconnecting hosepack to the power source
- The interconnecting hosepack is connected in the same way as the welding torch - see section Connecting the welding torch from page (→)
Changing the torch body of a gas-cooled welding torch
Changing the torch body
Remove the torch body:
1
2
3
4Remove contamination from the hosepack interface
5Remove contamination from the torch body interface
6Fit the protective cap to the torch body interface
Fit the torch body:
CAUTION!
Danger due to incompatible system components.
This can result in damage to property.
Only connect torch bodies and hosepacks that are using the same type of cooling.
Only fit gas-cooled torch bodies to gas-cooled hosepacks.
NOTE!
Risk due to damaged O-ring on the torch body.
A damaged O-ring on the torch body can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the torch body is undamaged.
1* Grease the O-ring on the torch body
2
3
Push the torch body locking device fully back and at the same time turn the torch body 180°
4
CAUTION!
Danger due to incorrectly fitted torch body.
This can result in damage to property.
Ensure that the locking device is fully forward after fitting the torch body - only then is the torch body properly fitted and locked.
Changing the torch body
Remove the torch body:
1
2
3
4Remove contamination from the hosepack interface
5Remove contamination from the torch body interface
6Fit the protective cap to the torch body interface
Fit the torch body:
CAUTION!
Danger due to incompatible system components.
This can result in damage to property.
Only connect torch bodies and hosepacks that are using the same type of cooling.
Only fit gas-cooled torch bodies to gas-cooled hosepacks.
NOTE!
Risk due to damaged O-ring on the torch body.
A damaged O-ring on the torch body can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the torch body is undamaged.
1* Grease the O-ring on the torch body
2
3
Push the torch body locking device fully back and at the same time turn the torch body 180°
4
CAUTION!
Danger due to incorrectly fitted torch body.
This can result in damage to property.
Ensure that the locking device is fully forward after fitting the torch body - only then is the torch body properly fitted and locked.
Changing the torch body of a water-cooled welding torch
Automatic emptying of the welding torch and changing the torch body
CAUTION!
Danger from switched on power source during automatic emptying of the welding torch.
Unintentional arc ignitions can occur.
Follow the instructions for automatic emptying of the welding torch in the cooling unit Operating Instructions, the power source Operating Instructions, and on the power source control panel.
When carrying out the work on the torch body as described below, keep at least 1 m (39.37 in.) away from electrically conductive objects.
Empty the welding torch automatically (e.g., with CU 600t /MC) and remove the torch body:
1Empty the torch hosepack using the corresponding cooling unit function
2
3
4
5Remove contamination and coolant residues from the hosepack interface
6Remove contamination and coolant residues from the torch body interface
7Fit the protective cap to the torch body interface
Fit the torch body:
CAUTION!
Danger due to incompatible system components.
This can result in damage to property.
Only connect torch bodies and hosepacks that are using the same type of cooling.
Only fit water-cooled torch bodies to water-cooled hosepacks.
NOTE!
Risk due to damaged O-ring on the torch body.
A damaged O-ring on the torch body can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the torch body is undamaged.
1* Grease the O-ring on the torch body
2
3
Push the torch body locking device fully back and at the same time turn the torch body 180°
4
CAUTION!
Danger due to incorrectly fitted torch body.
This can result in damage to property.
Ensure that the locking device is fully forward after fitting the torch body - only then is the torch body properly fitted and locked.
5Press the gas-test button on the power source
Shielding gas flows out for 30 s.
Shielding gas flows out for 30 s.
6Check the coolant flow:
You must be able to see a strong return flow into the cooling unit coolant container.
You must be able to see a strong return flow into the cooling unit coolant container.
7Perform a test weld and check the quality of the weld
Automatic emptying of the welding torch and changing the torch body
CAUTION!
Danger from switched on power source during automatic emptying of the welding torch.
Unintentional arc ignitions can occur.
Follow the instructions for automatic emptying of the welding torch in the cooling unit Operating Instructions, the power source Operating Instructions, and on the power source control panel.
When carrying out the work on the torch body as described below, keep at least 1 m (39.37 in.) away from electrically conductive objects.
Empty the welding torch automatically (e.g., with CU 600t /MC) and remove the torch body:
1Empty the torch hosepack using the corresponding cooling unit function
2
3
4
5Remove contamination and coolant residues from the hosepack interface
6Remove contamination and coolant residues from the torch body interface
7Fit the protective cap to the torch body interface
Fit the torch body:
CAUTION!
Danger due to incompatible system components.
This can result in damage to property.
Only connect torch bodies and hosepacks that are using the same type of cooling.
Only fit water-cooled torch bodies to water-cooled hosepacks.
NOTE!
Risk due to damaged O-ring on the torch body.
A damaged O-ring on the torch body can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the torch body is undamaged.
1* Grease the O-ring on the torch body
2
3
Push the torch body locking device fully back and at the same time turn the torch body 180°
4
CAUTION!
Danger due to incorrectly fitted torch body.
This can result in damage to property.
Ensure that the locking device is fully forward after fitting the torch body - only then is the torch body properly fitted and locked.
5Press the gas-test button on the power source
Shielding gas flows out for 30 s.
Shielding gas flows out for 30 s.
6Check the coolant flow:
You must be able to see a strong return flow into the cooling unit coolant container.
You must be able to see a strong return flow into the cooling unit coolant container.
7Perform a test weld and check the quality of the weld
Manually empty welding torch and change torch body
Manually empty the welding torch and remove the torch body:
1Switch off the power source and disconnect from the grid
2Wait for the cooling unit to run down
3Shut off the coolant supply hose from the cooling unit
4Purge the coolant supply hose with compressed air at maximum 4 bar (58.02 psi)
- This will cause a large part of the coolant to flow back into the coolant container
5
6
7
8Remove contamination and coolant residues from the hosepack interface
9Remove contamination and coolant residues from the torch body interface
10Fit the protective cap to the torch body interface
Fit the torch body:
CAUTION!
Danger due to incompatible system components.
This can result in damage to property.
Only connect torch bodies and hosepacks that are using the same type of cooling.
Only fit water-cooled torch bodies to water-cooled hosepacks.
NOTE!
Risk due to damaged O-ring on the torch body.
A damaged O-ring on the torch body can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the torch body is undamaged.
1* Grease the O-ring on the torch body
2
3
Push the torch body locking device fully back and at the same time turn the torch body 180°
4
CAUTION!
Danger due to incorrectly fitted torch body.
This can result in damage to property.
Ensure that the locking device is fully forward after fitting the torch body - only then is the torch body properly fitted and locked.
5Connect the power source to the grid and switch on
6Press the gas-test button on the power source
Shielding gas flows out for 30 s.
Shielding gas flows out for 30 s.
7Check the coolant flow:
You must be able to see a strong return flow into the cooling unit coolant container.
You must be able to see a strong return flow into the cooling unit coolant container.
8Perform a test weld and check the quality of the weld
Preventing the torch body from being changed
Preventing the torch body from being changed
1
2
3
Preventing the torch body from being changed
1
2
3
Notes on flexible torch bodies
Device concept
The flexible TIG torch bodies can be bent in all directions and thus individually adapted to a wide variety of situations and applications.
Flexible torch bodies are used, for example, in cases of limited part accessibility or difficult welding positions.
However, the material of a flexible torch body is weakened with every change in shape, so the number of times it can be bent is also limited.
Bending and number of bends are explained in the following sections.
Device concept
The flexible TIG torch bodies can be bent in all directions and thus individually adapted to a wide variety of situations and applications.
Flexible torch bodies are used, for example, in cases of limited part accessibility or difficult welding positions.
However, the material of a flexible torch body is weakened with every change in shape, so the number of times it can be bent is also limited.
Bending and number of bends are explained in the following sections.
Bending possibilities
Definition of torch body bending
A bend is a one-time change in shape that deviates from the original shape by at least 20°.
A smallest possible bending radius has been defined so that the bending action does not occur at a few certain points but as uniformly as possible over a long length.
The bending radius must not be less than this.
The smallest possible bending radius is 25 mm (1 in.).
A bend must not exceed the maximum bending angle.
The maximum bending angle is 45°.
Bending back to the original shape is considered a bend in its own right.
Example: 45° bends
| (1) | Initial situation: 0° |
| (2) | Movement from 0° to 45° upwards = First bend |
| (3) | Movement from 45° back to 0° = Second bend |
| (4) | Movement from 0° to 45° downwards = Third bend |
| (5) | Movement from 45° back to 0° = Fourth bend |
Maximum number of torch body bends
With a bending radius of more than 25 mm (1 in.) and a maximum bending angle = 45°, the following can be achieved
- Gas-cooled welding torches bent at least 1000 times,
- Water-cooled welding torches bent at least 200 times.
Articulated torch bodies
Device concept
The articulated torch bodies can be individually adapted to a wide variety of situations and applications, for example in the case of restricted part accessibility or difficult welding positions.
Due to the articulated joint, the welder's hand is closer to the torch handle and thus to the torch triggers.
With articulated welding torches, no material weakening occurs during setup.
Device concept
The articulated torch bodies can be individually adapted to a wide variety of situations and applications, for example in the case of restricted part accessibility or difficult welding positions.
Due to the articulated joint, the welder's hand is closer to the torch handle and thus to the torch triggers.
With articulated welding torches, no material weakening occurs during setup.
Assembling and setting up an articulated torch body
The articulated torch body is assembled in the same way as a conventional torch body - see Fitting the torch body on page (→).
Twist the front part of the articulated torch body to adapt it to the job in hand:
1
CAUTION!
Danger if the articulated torch body is screwed out too far.
The torch body may be damaged.
Unscrew the front part of the articulated torch body by no more than 1 turn.
Service, maintenance and disposal
Prohibited
Prohibited
Maintenance at every start-up
- Check wearing parts, replace faulty wearing parts
- Purge the gas nozzle of welding spatter
In addition to the above list of steps to be carried out at every start-up, for water-cooled welding torches:
- Ensure that all coolant connections are leak-tight
- Ensure that there is a proper coolant return flow
Disposal
Materials should be disposed of according to valid local and national regulations.
Troubleshooting
Troubleshooting
Troubleshooting
Welding torch cannot be connected
| Cause: | Bayonet lock bent |
| Remedy: | Replace bayonet lock |
No welding current
Power source switched on, power source indication illuminates, shielding gas present
| Cause: | Incorrect ground connection |
| Remedy: | Establish proper ground connection |
| Cause: | Power cable in welding torch interrupted |
| Remedy: | Replace welding torch |
| Cause: | Tungsten electrode loose |
| Remedy: | Tighten tungsten electrode using torch cap |
| Cause: | Wearing parts loose |
| Remedy: | Tighten wearing parts |
No function after pressing torch trigger
Power source switched on, power source indication illuminates, shielding gas present
| Cause: | Power plug not plugged in |
| Remedy: | Plug in power plug |
| Cause: | Welding torch or welding torch control line faulty |
| Remedy: | Replace welding torch |
| Cause: | Plug connections "torch trigger/control line/power source" faulty |
| Remedy: | Check plug connection / send power source or welding torch to service team |
| Cause: | PCB in welding torch faulty |
| Remedy: | Replace PCB |
HF flashover at welding torch connection
| Cause: | Welding torch connection not sealed |
| Remedy: | Replace O-ring on the bayonet lock |
HF flashover at the shell-type handle
| Cause: | Hosepack is not sealed |
| Remedy: | Replace hosepack |
| Cause: | Shielding gas hose connection to torch body not sealed |
| Remedy: | Adjust and seal hose |
No shielding gas
All other functions present
| Cause: | Gas cylinder empty |
| Remedy: | Change gas cylinder |
| Cause: | Gas pressure regulator faulty |
| Remedy: | Replace gas pressure regulator |
| Cause: | Gas hose kinked, damaged, or not attached |
| Remedy: | Attach and straighten gas hose. Replace faulty gas hose |
| Cause: | Welding torch faulty |
| Remedy: | Replace welding torch |
| Cause: | Gas solenoid valve faulty |
| Remedy: | Contact service team (have gas solenoid valve replaced) |
Poor-quality weld properties
| Cause: | Incorrect welding parameters |
| Remedy: | Check settings |
| Cause: | Incorrect ground connection |
| Remedy: | Check ground connection and terminal for polarity |
Welding torch gets very hot
| Cause: | Welding torch is inadequately dimensioned |
| Remedy: | Observe duty cycle and load limits |
| Cause: | For water-cooled systems only: Coolant flow too low |
| Remedy: | Check water level, water flow rate, water contamination, etc. Coolant pump blocked: Switch on shaft of coolant pump at the gland using a screwdriver |
| Cause: | For water-cooled systems only: "Cooling unit Ctrl" parameter is set to "OFF". |
| Remedy: | In the Setup menu, set the "Cooling unit Ctrl" parameter to "Aut" or "ON". |
Porosity of weld seam
| Cause: | Spattering in the gas nozzle, causing inadequate gas shield for weld seam |
| Remedy: | Remove welding spatter |
| Cause: | Holes in gas hose or imprecise gas hose connection |
| Remedy: | Replace gas hose |
| Cause: | O-ring at central connector is cut or faulty |
| Remedy: | Replace O-ring |
| Cause: | Moisture/condensate in the gas line |
| Remedy: | Dry gas line |
| Cause: | Gas flow too strong or weak |
| Remedy: | Correct gas flow |
| Cause: | Inadequate quantity of gas at the start or end of welding |
| Remedy: | Increase gas pre-flow and gas post-flow |
| Cause: | Too much parting agent applied |
| Remedy: | Remove excess parting agent/apply less parting agent |
Poor ignition properties
| Cause: | Unsuitable tungsten electrode (e.g., WP electrode for DC welding) |
| Remedy: | Use suitable tungsten electrode |
| Cause: | Wearing parts loose |
| Remedy: | Screw on wearing parts tightly |
Gas nozzle is cracked
| Cause: | Tungsten electrode not protruding far enough out of the gas nozzle |
| Remedy: | Have tungsten electrode protrude more out of the gas nozzle |
Technical data
General
This product meets the requirements set out in standard IEC 60974-7.
NOTE!
The performance data specifications only apply when using standard wearing parts.
When using gas lenses and shorter gas nozzles, the welding current is reduced.
NOTE!
The welding current specifications apply to gas-cooled torch bodies only from a length of 65 mm (2.56 in.).
When using shorter torch bodies, the welding current is reduced by 30%.
NOTE!
When welding at the power limit of the welding torch, use larger tungsten electrodes and gas nozzle opening diameters to increase the service life of the wearing parts.
Take amperage, AC balance, and AC current offset into account as performance-enhancing factors.
General
This product meets the requirements set out in standard IEC 60974-7.
NOTE!
The performance data specifications only apply when using standard wearing parts.
When using gas lenses and shorter gas nozzles, the welding current is reduced.
NOTE!
The welding current specifications apply to gas-cooled torch bodies only from a length of 65 mm (2.56 in.).
When using shorter torch bodies, the welding current is reduced by 30%.
NOTE!
When welding at the power limit of the welding torch, use larger tungsten electrodes and gas nozzle opening diameters to increase the service life of the wearing parts.
Take amperage, AC balance, and AC current offset into account as performance-enhancing factors.
Gas-cooled torch body -
TTB 80, TTB 160, TTB 220, TTB 260
| TTB 80 G | TTB 160 G / F |
|---|---|---|
DC welding current | 35% D.C.1) / 80 A | 35% D.C.1) / 160 A |
60% D.C.1) / 60 A | 60% D.C.1) / 120 A | |
100% D.C.1) / 50 A | 100% D.C.1) / 90 A | |
AC welding current | 35% D.C.1) / 30 A | 35% D.C.1) / 120 A |
60% D.C.1) / 90 A | ||
100% D.C.1) / 70 A | ||
Shielding gas | Argon | Argon |
Electrode diameter |
| 1.0 - 3.2 mm |
| TTB 160 G / F | TTB 160 P S G1) |
|---|---|---|
DC welding current | 35% D.C.1) / 160 A | 35% D.C.1) / 160 A |
60% D.C.1) / 120 A | 60% D.C.1) / 120 A | |
100% D.C.1) / 90 A | 100% D.C.1) / 90 A | |
AC welding current | 35% D.C.1) / 120 A | 35% D.C.1) / 120 A |
60% D.C.1) / 90 A | 60% D.C.1) / 90 A | |
100% D.C.1) / 70 A | 100% D.C.1) / 70 A | |
Shielding gas | Argon | Argon |
Electrode diameter | 1.0 - 2.4 mm | 1.0 - 3.2 mm |
| TTB 220 G | TTB 220 A G F | TTB 220 P G F |
|---|---|---|---|
DC welding current | 35% D.C.1) / 220 A | 35% D.C.1) / 220 A | 35% D.C.1) / 220 A |
60% D.C.1) / 170 A | 60% D.C.1) / 170 A | 60% D.C.1) / 160 A | |
100% D.C.1) / 130 A | 100% D.C.1) / 130 A | 100% D.C.1) / 130 A | |
AC welding current | 35% D.C.1) / 180 A | 35% D.C.1) / 180 A | 35% D.C.1) / 170 A |
60% D.C.1) / 130 A | 60% D.C.1) / 120 A | 60% D.C.1) / 120 A | |
100% D.C.1) / 100 A | 100% D.C.1) / 100 A | 100% D.C.1) / 100 A | |
Shielding gas | Argon | Argon | Argon |
Electrode diameter | 1.0 - 4.0 mm | 1.0 - 4.0 mm | 1.0 - 4.0 mm |
| TTB 220 P S G2) | TTB 220 P G TFC3) | TTB 260 G |
|---|---|---|---|
DC welding current | 35% D.C.1) / 220 A | 35% D.C.1) / 220 A | 35% D.C.1) / 260 A |
60% D.C.1) / 170 A | 60% D.C.1) / 170 A | 60% D.C.1) / 200 A | |
100% D.C.1) / 130 A | 100% D.C.1) / 130 A | 100% D.C.1) / 150 A | |
AC welding current | 35% D.C.1) / 180 A | 35% D.C.1) / 180 A | 35% D.C.1) / 200 A |
60% D.C.1) / 130 A | 60% D.C.1) / 130 A | 60% D.C.1) / 160 A | |
100% D.C.1) / 100 A | 100% D.C.1) / 100 A | 100% D.C.1) / 120 A | |
Shielding gas | Argon | Argon | Argon |
Electrode diameter | 1.0 - 4.0 mm | 1.0 - 3.2 mm | 1.0 - 4.0 mm |
| 1) | D.C. = Duty cycle |
| 2) | Articulated torch body |
| 3) | TFC clamping system |
Water-cooled torch body -
TTB 180, TTB 300, TTB 400, TTB 500
| TTB 180 W | TTB 300 W |
|---|---|---|
DC welding current | 60% D.C.1) / 180 A | 60% D.C.1) / 300 A |
100% D.C.1) / 140 A | 100% D.C.1) / 230 A | |
AC welding current | 60% D.C.1) / 140 A | 60% D.C.1) / 250 A |
100% D.C.1) / 110 A | 100% D.C.1) / 190 A | |
Shielding gas | Argon | Argon |
Electrode diameter | 1.0 - 3.2 mm | 1.0 - 3.2 mm |
Minimum coolant flow Qmin | 1 l/min | 1 l/min |
| TTB 400 W F | TTB 500 W |
|---|---|---|
DC welding current | 60% D.C.1) / 400 A | 60% D.C.1) / 500 A |
100% D.C.1) / 300 A | 100% D.C.1) / 400 A | |
AC welding current | 60% D.C.1) / 320 A | 60% D.C.1) / 400 A |
100% D.C.1) / 250 A | 100% D.C.1) / 300 A | |
Shielding gas | Argon | Argon |
Electrode diameter | 1.0 - 4.0 mm | 1.0 - 6.4 mm |
Minimum coolant flow Qmin | 1 l/min | 1 l/min |
| 1) | D.C. = Duty cycle |
Gas-cooled hosepack –
THP 160i,
THP 220i,
THP 260i
| THP 160i | THP 220i |
|---|---|---|
DC welding current | 35% D.C.1) / 160 A | 35% D.C.1) / 220 A |
60% D.C.1) / 120 A | 60% D.C.1) / 170 A | |
100% D.C.1) / 90 A | 100% D.C.1) / 130 A | |
AC welding current | 35% D.C.1) / 120 A | 35% D.C.1) / 180 A |
60% D.C.1) / 90 A | 60% D.C.1) / 130 A | |
100% D.C.1) / 70 A | 100% D.C.1) / 100 A | |
Length | 4.0 / 8.0 m | 4.0 / 8.0 m |
Maximum permitted open circuit voltage (U0) | 113 V | 113 V |
Maximum permitted striking voltage (UP) | 10 kV | 10 kV |
| THP 260i |
|---|---|
DC welding current at 10 min / 40 °C (104 °F) | 35% D.C.1) / 260 A |
60% D.C.1) / 200 A | |
100% D.C.1) / 150 A | |
AC welding current at 10 min / 40 °C (104 °F) | 35% D.C.1) / 200 A |
60% D.C.1) / 160 A | |
100% D.C.1) / 120 A | |
Length | 4.0 / 8.0 m |
Maximum permitted open circuit voltage (U0) | 113 V |
Maximum permitted striking voltage (UP) | 10 kV |
| 1) | D.C. = Duty cycle |
Water-cooled hosepack – THP 300i,
THP 400i,
THP 500i
| THP 300i | THP 400i |
|---|---|---|
DC welding current | 60% D.C.1) / 300 A | 60% D.C.1) / 400 A |
100% D.C.1) / 230 A | 100% D.C.1) / 300 A | |
AC welding current | 60% D.C.1) / 250 A | 60% D.C.1) / 350 A |
100% D.C.1) / 190 A | 100% D.C.1) / 270 A | |
Shielding gas | Argon | Argon |
Minimum coolant flow Qmin | 1 l/min | 1 l/min |
Length | 4.0 / 8.0 m | 4.0 / 8.0 m |
Lowest cooling capacity as per IEC standard 60974-2 as function of hosepack length | 650 / 650 W | 950 / 950 W |
Minimum coolant flow Qmin | 1 l/min | 1 l/min |
Minimum coolant pressure pmin | 3 bar | 3 bar |
Maximum coolant pressure pmax | 5.5 bar | 5.5 bar |
Maximum permitted open circuit voltage (U0) | 113 V | 113 V |
Maximum permitted striking voltage (UP) | 10 kV | 10 kV |
| THP 500i |
|---|---|
DC welding current at 10 min / 40 °C (104 °F) | 60% D.C.1) / 500 A |
100% D.C.1) / 400 A | |
AC welding current at 10 min / 40 °C (104 °F) | 60% D.C.1) / 400 A |
100% D.C.1) / 300 A | |
Shielding gas | Argon |
Minimum coolant flow Qmin | 1 l/min |
Length | 4.0 / 8.0 m |
Lowest cooling capacity as per IEC standard 60974-2 as function of hosepack length | 1200 / 1750 W |
Minimum coolant flow Qmin | 1 l/min |
Minimum coolant pressure pmin | 3 bar |
Maximum coolant pressure pmax | 5.5 bar |
Maximum permitted open circuit voltage (U0) | 113 V |
Maximum permitted striking voltage (UP) | 10 kV |
| 1) | D.C. = Duty cycle |
Gas-cooled extension hosepack -
HPT 220i G
| HPT 220i EXT G |
|---|---|
DC welding current at 10 min / 40 °C (104 °F) | 35% D.C.1) / 220 A |
60% D.C.1) / 170 A | |
100% D.C.1) / 130 A | |
AC welding current at 10 min / 40 °C (104 °F) | 35% D.C.1) / 180 A |
60% D.C.1) / 130 A | |
100% D.C.1) / 100 A | |
Shielding gas | Argon |
Length | 10.0 m |
Maximum permitted open circuit voltage (U0) | 113 V |
Maximum permitted striking voltage (UP) | 10 kV |
| 1) | D.C. = Duty cycle |
Water-cooled extension hosepack- HPT 400i
| HPT 400i EXT W |
|---|---|
DC welding current at 10 min / 40 °C (104 °F) | 60% D.C.1) / 400 A |
100% D.C.1) / 300 A | |
AC welding current at 10 min / 40 °C (104 °F) | 60% D.C.1) / 350 A |
100% D.C.1) / 270 A | |
Shielding gas | Argon |
Length | 10.0 m |
Maximum permitted open circuit voltage (U0) | 113 V |
Maximum permitted striking voltage (UP) | 10 kV |
Lowest cooling capacity as per IEC standard 60974-2 as function of hosepack length | 750 / 750 W |
Minimum coolant flow Qmin | 1 l/min |
Minimum coolant pressure pmin | 3 bar |
Maximum coolant pressure pmax | 5.5 bar |
Maximum permitted open circuit voltage (U0) | 113 V |
Maximum permitted striking voltage (UP) | 10 kV |
| 1) | D.C. = Duty cycle |