TTB 80-500, THP 160i-500i, HPT 220i / 400i Operating instructions

1. Safety

1. Safety

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.” The manufacturer shall not be liable for any damage resulting from such improper use.

• Following all the instructions in the Operating Instructions
• Carrying out all the specified inspection and maintenance work.

1. Functions of the Up/Down torch

1. Functions of the Up/Down torch

Changing the welding power:

1

Intermediate lowering:

1

Push the button forwards and hold until intermediate lowering is complete

1. Functions of the JobMaster welding torch

1. Functions 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

1. Replacing the user interface

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1. Mounting the Wearing Parts

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Screw down the torch cap

1. Mounting the Wearing Parts

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Screw down the torch cap

1. Mounting the Wearing Parts

Definition of terms: TFC = Tungsten Fast Clamp

Removing wearing parts:

1

Remove the tungsten electrode

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Remove the clamping unit

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Remove the collet

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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.

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Fit the collet

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Fit the clamping unit

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Fit the tungsten electrode

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1. Fitting the torch body and connecting the welding torch

1* Grease the O-ring on the torch body

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Push the torch body locking device fully back and at the same time turn the torch body 180°

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1. Fitting the torch body and connecting the welding torch

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1. Fitting the torch body and connecting the welding torch

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* only with water-cooled welding system

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.

1

Connect the welding torch to the interconnecting hosepack

Fit protective bag, lay coolant hoses:

2Position the protective bag as follows:

• the Fronius logo must be visible
• the loops of the protective bag must be at the top

Notes on the following diagrams:
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

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• 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

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• 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

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• Align the coolant connections with each other and in the center of the insulating tube (1)

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• * = 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 (→)

1. Connecting the 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.

1

Connect the welding torch to the interconnecting hosepack

Fit protective bag, lay coolant hoses:

2Position the protective bag as follows:

• the Fronius logo must be visible
• the loops of the protective bag must be at the top

Notes on the following diagrams:
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 (→)

1. Connecting the 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.

1

Connect the welding torch to the interconnecting hosepack

Fit the protective bag:

2Position the protective bag as follows:

• the Fronius logo must be visible
• the loops of the protective bag must be at the top

Notes on the following diagrams:
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 (→)

1. Changing the torch body of a gas-cooled welding torch

Remove the torch body:

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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

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Push the torch body locking device fully back and at the same time turn the torch body 180°

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1. Changing the torch body of a water-cooled welding torch

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

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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.

6Check the coolant flow:
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

1. Changing the torch body of a water-cooled welding torch

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

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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.

7Check the coolant flow:
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

1. Preventing the torch body from being changed

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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.

1. Notes on flexible torch bodies

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.

1. Notes on flexible torch bodies

1. Notes on flexible torch bodies

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

1. Notes on flexible torch bodies

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.

1. Articulated torch bodies

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.

1. Articulated torch bodies

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.

1. Service, maintenance and disposal

1. Service, maintenance and disposal

• 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

1. Service, maintenance and disposal

Materials should be disposed of according to valid local and national regulations.

1. Troubleshooting

This product meets the requirements set out in standard IEC 60974-7.

1. Technical data

This product meets the requirements set out in standard IEC 60974-7.

1. Technical data

1. Technical data

1. Technical data

1. Technical data

1. Technical data

1. Technical data