REHM TIG.STAR 170 DC User manual

GB
OPERATING INSTRUCTIONS
TIG inert gas welding equipment
TIGER DIGITAL 230 DC / AC/DC ULTRA/HIGH
TIGER DIGITAL 180 DC / AC/DC ULTRA/HIGH
TIG.STAR 170 DC / AC/DC

Operating instructions
2
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
TIG.STAR 170 DC / AC/DC
Rehm GmbH u. Co. KG
Ottostraße 2
D-73066 Uhingen
Telephone: [phone]
Telefax: +49 (0)7161/3007-20
e-mail: [e-mail]
Internet: http://www.rehm-online.de
Doc. No.: 7302430
Date of issue: 23/02/2023
 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patenteddesigns.
The manufacture based on these documents is not allowed.
Subject to change.

List of contents
3
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 I1 and pulse time t1 32
6.1.6 Welding current I2 and pulse time t2 32
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 le 34
6.1.11 Gas post flow time 35

List of contents
4
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

List of contents
5
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

Introduction
6
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.

Introduction
7
1.2 General description
Fig.1 TIGER DIGITAL (in the background with a water cooling unit)

Introduction
8
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.

Introduction
9
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
 Enumerations proceeded by a bullet point: General enumerations
 Enumerations proceeded by a square: Work or maintenance steps that must
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.
The safety symbols used in this manual: Section 2.1
Typographic
distinctions
Safety
symbols

Safety information
10
2 Safety information
2.1 Warning symbols in these operating instructions
Warnings and
symbols
This
or a symbol that more accurately specifies the risk can be found in
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.

Safety information
11
2.3 Notes and requirements
The system was developed and designed by the generally accepted rules of
technology.
Nevertheless, residual dangers to the life and limb of the operator or the risk of
damage to the system or other property may still arise in the use of the system.
Safety equipment must never be dismantled or put out of operation as this will result in dangerous hazards
and the intended use of the system is no longer guaranteed. The dismantling of
safety devices for equipping, repairing and maintenance is described in detail.
The safety devices must be refitted immediately on completion of such work.
When using external aids and agents (for example, solvents for cleaning) the
user of the system is responsible for ensuring the safety of the unit.
All safety instructions and warnings and the nameplate on / near the system must
be kept visible and legible.
The occupational safety and health regulations serve as safety references. They
must be observed.
The special safety instructions given in the main text must also be observed in
addition to the safety instructions given in this section.
Beside the advice given in these operating instructions, the general safety and
accident prevention regulations (in Germany, among others UVV BGV A3, TRBS
2131 and BGR 500 Chapter 2:26 (previously VGB 15) "Welding, cutting and
allied processes" and particularly the conditions for arc welding and cutting
contained therein or the corresponding national regulations) must be observed.
Also observe the safety information signs on the factory floor of the operator.
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.
TIGER DIGITAL TIG inert gas welding systems may only be used
 as intended
 in an absolutely perfect condition
TIGER DIGITAL inert gas welding equipment is designed in accordance with EN
60974-1 Arc welding equipment - welding power sources for overvoltage
category III and pollution degree 3 and in accordance with EN 60974-10 Arc
welding equipment - electromagnetic compatibility (EMC) for Group 2 Class A
and should be suitable for use in all areas, except residential areas that are
connected directly to a public low-voltage supply system. It may possibly be
difficult to ensure electromagnetic compatibility in these areas due to both
conducted and radiated interference. For this purpose the use of appropriate
measures to meet the requirements (filters for mains connection, shields such as
shielded cables, the shortest possible welding cables, earthing of the workpiece,
potential equalization) and assessment of the environment (such as computers,
controllers, radio and television broadcasters, adjacent people, for example
required in the use of cardiac pacemakers) are required. The responsibility for
any fault lies with the user. For more information and recommendations, see,
inter alia, DIN EN60974-10: 2008-09, Annex A.
Hazards of non
-
compliance
Safety
instruction
Applications

Safety information
12
Operation and storage of the unit outside the specified range is considered to be
improper. The manufacturer is not liable for any resulting damage.
Ambient air temperature range:
- In operation: -10°C to +40°C (14 °F to 104 °F)
- During transport and storage: -20°C to +55°C (-4 °F to 131 °F)
Relative humidity:
- to 50% at 40°C (104 °F)
- to 90% at 20°C (68 °F)
Ambient air:
Free of unusual amounts of dust, acids, corrosive gases or substances, etc.,
unless they are produced during welding.
Altitude above sea level: Up to 2000m (6500 ft)
The unit may be connected and operated from a single phase 2-wire
system with earthed neutral conductor.
For TIGER DIGITAL 230 AC/DC and TIGER DIGITAL 230 DC
The unit complies with IEC61000-3-12.
For TIGER DIGITAL 180 AC/DC and TIGER DIGITAL 180 DC
Caution: This unit does not meet the requirements of EN / IEC 61000-3-12.
If the unit is to be connected to a public power supply then
it may be necessary, after consultation with the operator of the supply network,
to ensure that the unit can be connected.
This is the responsibility of the operator or the user of the unit.
REHM welding equipment should be operated only by persons who are trained
and instructed in the use and maintenance of welding equipment. Only qualified,
assigned and trained personnel may work on and with the system.
These operating instructions contain important information on how this unit can
be operated safely, properly and economically. A copy of the operating
instructions must be constantly at hand in a suitable place at the site of use of the
system. Before using the system be sure to read the information compiled in
these operating instructions. These include important instructions on use of the
equipment that enable the full technical advantages of the RHEM equipment to
be exploited. See also the information on repair and maintenance, operating
safety and functional reliability.
These operating instructions are not a substitute for the practical teaching by the
REHM service personnel.
Documentation for any additional operation that may be present must also be
observed.
Changes to the system or the mounting or incorporation of additional equipment
is not permitted. Doing so will invalidate any warranty and liability claims.
Third-party intervention and putting out of operation of safety devices invalidates
all warranty claims.
Qualification of the
operating
personnel
Purpose of the
document
Changes to
the system
Requirements on
the mains supply
Environmental
conditions

Unit description
13
3 Unit description
TIGER DIGITAL without water cooling
TIGER DIGITAL with optional water cooling unit
Fig.2 Unit description

Unit description
14
No. Symbol Function / description
1 Control panel - See "Description of controls"
2 Control panel push and rotary encoder
3 Shielding gas connection - TIG welding torch
4
Current socket "negative"
TIG: TIG welding torch
Electrode: Workpiece or electrode holder
5 Torch / remote control jack
6
Current socket "positive"
TIG: workpiece
Electrode: Workpiece or electrode holder
7 Cooling air inlet
8 Drawer – storage for electrodes, gas nozzles, etc.
9 Main switch - On / Off
10 Power cable
11 Shield gas feed connection - shield gas cylinder
12 Water cooling unit connection – Optional
13 Cooling air outlet
14 Coolant inlet to coolant filling
15 Coolant level window
16 Connection coolant return (red)
17 Connection coolant supply (Blue)
18 Fuse water cooling unit
Table 1 Equipment labelling on the front and back

Function description
15
4 Function description
4.1 Overview of the operating panel
Fig.3 TIGER Digital operating panel

Function description
16
4.2 Operation description
4.2.1 Controls
Controls Function
Fig.4 Quick program buttons
Quick program buttons P1-P4
Fig.5 Main screen
Main screen
Operation via rotary encoder with push-
knob and buttons for menu selection in
the 4 corners of the screen
Fig.6 Function buttons
Function buttons (from left to right)
Butto
n
Submenu
“Submenu”
List of all
submenus
Butto
n
Main screen
“Home”
Jumps directly to
the first screen
page
Butto
n
Back
“Back”
Always jumps
back one level
Fig.7 Corner function buttons
Corner menu selection buttons
Direct menu buttons for the selection
menus located in the 4 screen corners;
arranged around the rotary encoder.
Fig.8 Push and rotary encoder
Rotary encoder with push-knob
Moves the pointer (cursor) on the
screen clockwise or counter clockwise.
Positions reached are highlighted in
colour and are activated by pressing
the rotary encoder knob.

Function description
17
4.2.2 Operating functions
Fig.9 Screen functions
No. Symbols Description / function Ultra
AC/DC
Ultra
DC
High
AC/DC
High
DC
BF1 Corner menu welding processes
TIG welding    
Electrode welding    
Electrode booster function    
BF2
Main display panel with function text
   
BF3
Corner menu operating modes
2 cycle: LiftArc or with HF ignition    
4 cycle: LiftArc or with HF ignition    
Spot welding with HF    
Interval with HF   ─ ─
BF4
Corner menu pulse
1
3
2
4
5
6
7
8
9

Function description
18
No. Symbols Description / function Ultra
AC/DC
Ultra
DC
High
AC/DC
High
DC
Pulse off    
Conventional pulsing    
High-frequency pulse (hyper pulse)   ─ ─
BF5
Corner menu polarity
Alternating current (AC)  ─  ─
Dual Wave  ─ ─ ─
DC positive pole (DC+)  ─  ─
DC negative pole (DC-)    
BF6
TIG welding parameter curve
The following shows the setting possibilities from left to right
Gas pre-flow time   ─ ─
Ignition power   ─ ─
Starting current and starting current
time   ─ ─
Slope-up time   ─ ─
Welding current I1 and pulse time t1
alternative t1/t2 hyperpulse frequency    

Function description
19
No. Symbols Description / function Ultra
AC/DC
Ultra
DC
High
AC/DC
High
DC
Welding current I2 and pulse time t2
alternative t1/t2 hyperpulse frequency    
Slope-down time    
End-crater current
End-crater current time





─

─
Gas post flow time    
BF7 Menu AC settings
F
AC waveform (adjustable)
f AC frequency (adjustable)
B AC balance (adjustable)
AC AC time DualWave
(adjustable)
DC DC time DualWave
(adjustable)
All




─
─
─
─
─
Auto


─
─
─
─
─
─
─
BF8 Menu spot welding and interval
Spot time
Pause time (only in interval mode)




─
─
─
─
BF9 Status line    
Table 2 Operating panel main screen

Function description
20
No. Symbols Description / function Ultra
AC/DC
Ultra
DC
High
AC/DC
High
DC
BF10 Sub menu buttons    
BF11
Back button “Home” and “Back”    
BF12
Function Assist see Chap. 7.2   ─ ─
BF13
Function program (Jobs)
see Chap. 7.3   ─ ─
BF14 Settings (Setup) see Chap. 8    
BF15
Error message see Chap. 9
and
14.3
   
BF16 Left in the status line:
Operating and temperature displays    
BF17 Right in the status line:
Remote control display    
Table 3 Other control functions and submenus