Rohrman Schweißtechnik TIG User manual

Operation Instructions
Welding Torches TIG
EN 60 974-7
Rohrman Schweißtechnik GmbH
Hosterfeldstraße 2 · D-41747 Viersen
Tel. [phone]
Fax [phone]
www.rohrman.de
[e-mail]
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 1

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Information regarding this operation manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Accompanying documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Warning notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Hazard sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Users responsability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Requirements for personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Electrical control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Torch specic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Construction and funktion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Principle construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5 Starting the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Assembly of gasnozzle and electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Connection to the welding powersource . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Connection to the cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 Checks prior to start welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 Welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Interruption of the welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Maintenance/cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Cleaning of welding torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.3 Electrode grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4 Replace of wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8 Trouble remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table of Contents
2
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 2

1 General
1.1 Informations to this operation manual
This operation manual contains important instructions for the treatment
of TIG welding torches during the instalation, setting up and the operation,
about the maintenance and care as also of the disposal.
The precondition for secure, intended and economic operation is the
compliance with all safety instructions and treatment instructions.
The notice of the instructions helps avoiding hazards, deminishes repair-
cost and downtime and increases lifetime of the welding torch.
Moreover the actual accident prevention regulations and safety rules of
the welding location must be observed.
This operation manual should be read carefully before beginning of all
work! It is part of the product performance and should be kept near the
welding torch accessible for the personel at any time.
1.2 Further applicable documents
Each torch will be delivered with a specic data sheet. This data sheet
contains torch specic informations and is part of this operation manual.
If no data sheet is attached please ask your distributor.
Because the welding torch operates with a power source, a wire feeder
and optionally a cooling unit, the operation manuals of these equipments
should also be observed.
1.3 Copyright
This document is copyrighted by law.
Any reproduction or reprinting, also in part, as well as reproduction of
pictures and symbols of this document, also in altered state is only
allowed with written consent of the manufacturer.
General
3
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 3

1.4 Explanation of symbols
Warning notices are additionally noticed by warning symbols.
In this operation manual the following warning symbols are used:
General
4
SIGNIFICATIONSYMBOL
General warning notice
Danger of electrical power
Explosion danger
Danger of re
Burning danger
Risk of inhalation of toxic substances
Danger of strong UV-radiation
Danger of radioactive substances
General notices and useful advices for handling
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 4

1.5 Warning notices
The warning notices as used in this operation manual are introduced by
signalwords which bring to express the extend of the hazard. The warning
symbol points additionally to the kind of hazard.
In this operation manual the following warning notices are used:
A warning notice of this kind of danger level signalizes a threadning dan-
gerous situation. If the dangerous situation will not be avoided, this
leads to death or to serious injuries. These instructions must be followed
in order to avoid the danger of death or of serious injuries of personnel.
A warning notice of this kind of danger level signalizes a possible dan-
gerous situation. If the the dangerous situation will not be avoided this
could lead to death or to serious injuries. These instructions must be
complied in order to avoid the danger of death or of serious injuries of
personel.
A warning notice of this kind of danger level signalises a possible dan-
gerous situation. If this situation will not be avoided it could lead to
slight or moderate injuries. These instructions must be complied in order
to avoid personal injuries.
General
5
DANGER
PRECAUTION
Risk of injury!
Consequences of ignoring …
notices for avoidance
CAUTION
Risk of personelx damage … !
Consequences of ignoring …
notices for avoidance
Danger for life!
Consequences of ignoring …
notices for avoidance
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 5

A reference signies additional informations, important for the later
treatment, or for easier adaptation of the described work step.
1.6 Limited liability
All disclosures and notices in this operation manual have been collected
taking in account of all valid standards and regulations, the state of art
as well as our long standing knowledge and experience.
We reserve alterations of the discussed welding torches in the context
of further devellopments. From the notices, pictures and descriptions in
this operation manual claims cannot be derived.
The manufacturer does not accept liability for damages and operational
disruptions caused by:
non-compliance of this operation manual,
improper use,
use of inadaquately trained personnel,
use of improper operating materials,
faulty connection,
non use of original Rohrman components,
technical alterations not corresponded with Rohrman
Schweißtechnik,
non-implementation of required maintenance.
Rohrman Schweißtechnik is liable for any of his errors or omissions,
excluded further claims which do not reect the context of the duties
from the in the contract entered warrenty obligations. Damage compen-
sation regardless on whatever legal grounds they derive are excluded.
General
6
Text of reference …
REFERENCE
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 6

1.7 Warranty
We, Rohrman Schweißtechnik GmbH, deliver a tested quality product.
At the time of delivery we warrant for an error free product, free from ma-
terial- or processing errors and suitable for the intented use to the state
of art and to the legal regulations.
Warranty claims can be raised only for fabrication errors, but not for
damages caused by natural wear or improper use. No warranty will be
taken for poor work results. Wear parts are excluded from the warranty.
The Warranty policy covers no damages or functional defects caused by
improper use as there are:
not following the notices in this operation manual,
improper installation or -assembly,
inadequate maintenance,
altering of product against original state,
overloading, misuse or improper use,
mechanical damages caused by collision or accident.
General
7
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 7

2 Safety
2.1 General
This chapter serves for important references of all safety aspects for
the optimal security of personel as well as the secure and trouble-free
use.
2.2 The intended use
The welding torches of the series TIG are meant exclusively for welding
with inert gas (Argon) of low- and high alloyed steel and light alloys. They
meet EN 60 974-7. They do not represent a device as having individual
functions of performance. The TIG-arc welding will only be possible in
connection with a power source.
The application may only be performed by trained, professional personel
in complyance with the relevant regulations. Any other use byond its
intended purpose does not comply with these regulations.
Claims of any kind due to damage of non-intented use are excluded. The
risk bears only the operator.
Safety
8
WARNING
Danger when non complied use!
Any use beyond the intended purpose can lead to dangerous
situations.
Use the welding torch only for the intended purpose.
Follow all notices and instructions of this operation manual.
WARNING
Danger for not following the security notices!!
Substancial danger can arise if the security notices and handling
instructions in this operation manual will not be followed.
All warning notices and – instructions must be observed.
Also must be observed the security notices in the aplicable
documents.
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 8

2.3 Security notices
For safe handling of the welding torch the following security notices
should be noted:
Welding operations should only be performed and performed by pro-
fessional personel who have knowledge of the relevant regulations
of arc welding.
Personel should wear dry protective cloth and eye protection.
Welding operations should not be performed in potential explosive
environment.
Personel with pacemaker or other medical implant should not
perform operations with TIG-arc welding equipment.
The TIG-welding torch and – hose and cable package should be
checked on outside visible damages. A damaged welding torch
should not be put in operation.
Check the orderly state of the power source and the cooling unit as
well as the function of the remote control elements before starting
the operation.
Repair of the welding torch or of the connection lead should only be
made by an authorized professional shop or by the factory service.
Substancial dangers for the user might occur by inexpertly repairs.
Defect parts should only be exchanged by original Rohrman compo-
nents. Only these parts may garantee the security requirements.
The welding torch should be put aside so that no contact with current
conducting parts may occur.
During maintenance and cleaning the power source should be turned
off.
The torch package should not be put over hot or sharp edges.
Safety
9
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 9

2.4 Sources of danger
In the following the direct and indirect sources of danger, which may lead
to accidents with TIG-arc welding, are listed.
2.4.1 Electric current
2.4.2 Radioactive substances
2.4.3 Strong heat devellopment
Safety
10
DANGER
Danger for life by electrical current!
By contact with leads or loaded workpieces danger for life exists!
Pay attention to the following notices in order to avoid hazards by
contact with electrical power:
Wear dry protective cloth.
Take insulation precautions when distance to conductive parts
is less than 2 meters.
Switch off the power source during all maintenance on the
welding torch.
DANGER
Danger for life by radioactive substances!
With welding and grinding of thorium containing tungsten elec-
trodes radioactive substances are set free.
Use appropriate grinding machine with exhausting facility.
DANGER
Burning hazard!
The TIG-torch head, the workpiece, ying sparks and spatters are
hot and may cause burning. The following references should be
noted to avoid burnings:
Protect the eyes for ying sparks and spatters.
Wear suitable protective cloth.
With overhead welding carry additional head protection.
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 10

2.4.4 Strong radiation
2.4.5 Harmful subtances in the breathing air
2.4.6 Danger of injury by the welding wire
Safety
11
WARNING
Danger of strong radiation during welding!
During the welding procedure emerges a strong radiation in the
area of the arc!
Please obey the following notices in order to avoid injuries by
strong radiation:
Wear eye protection with radiation safeguard lter.
Protect open skin against UV-radiation.
Protect other people by shielding the welding area.
PRECAUTION
Possible engraving injury by the welding electrode!
By the scharp pointed tungsten electrode engraving injuries
may occur.
Put a protective cap on the electrode or recess the electrode
in the nozzle.
WARNING
Danger by harmful substances!
Harmful smoke and gases may occur during the welding procedure!
Please note the following notices in order to avoid harmful sub-
stances in the breathing air:
Workpieces degreased with chlorine containing x
Solvents should be rinsed thoroughly with water in order to avoid
toxic phosgene gas.
Extract smoke and gases by a suitable exhausting.
Wear a respirator when exhausting may not be possible.
Pay attention to the wind direction when welding outside.
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 11

2.4.7 Explosion danger
2.4.8 Fire hazard
Safety
12
DANGER
Explosion danger during welding!
Welding on containers, apparatus or pipelines may lead to explo-
sions. Please obey the following directions in order to avoid the
unleash of explosions:
Please obtain the approval for welding operations. Never weld
in areas marked as potentially explosive .
Make sure that no explosive atmosphere existst in the welding
area.
Empty the container, clean and ll with protective atmosphere.
Make sure that no excess pressure arises.
WARNING
Fire hazard while welding!
Fire may occur during and after welding! Please obey the following
notices in order to avoid the arising of re:
Remove or cover amable materials from the working area or
from the workwear.
Seal or shield areas with incombustible materials.
Provide extinguishing agent.
Organise before and after welding re posts or re guards.
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 12

2.4.9 Dangers of the work area
Safety
13
WARNING
Various dangers of the work area!
Depending on the nature of the work area indirect dangers may oc-
cur! Please note the following references in order to avoid injuries:
Use an adaquate welding unit in the case of increased danger
by humid enviroment or humid wear and place the welding unit
beyond the dangerous area. Secure the welding unit by an RCD
(FI interruptor )
Use additional insulation against contact of electrical leads in
conned areas (distance of less than 2 meters).
Please remove additional equipment from the work area in order
to prevent stray current or burning of the safety line.
Secure gasbottles against overthrowing.
In work areas with a noise level > 80 db(A) please wear
ear-protection.
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 13

2.5 Reponsability of the operator
As the welding torch is used in the comercial sector, the operator is
subject of the legal duties of occupational health and safety regulations.
Additional to the work safety regulations in this operational manual
safety, accident prevention and enviromental regulations must be adhered
to.
The operator must …
must inform himself re the valid work security regulations and must
determine specic dangers which arise from special work circum-
stances at the location. If the work place is permanently installed he
should execute in form of operating instructions.
set the unambiguous competence of personell for installation, opera-
tion, maintenance and cleaning.
ensure that all cooperaters dealing with the TIG-welding torch read
and understand this operation manual. Moreover he should retrain
personell and inform them re the dangers arising from TIG-welding
torches.
supervise the security- and danger concious work of personnel in
accordance with this operation manual and valid regulations.
ensure the accessability of this operation manual and all further regu-
lations to operation- and maintenance personel.
set the operation responsability and allow the operater to refuse
adverse safety instructions from third party !
provide necessary protection equipment.
Moreover the operator is reponsable for faultless condion of the welding
torch. Therefore the operator must …
ensure that the maintenance- and cleaning interval as described will
be respected.
verify regulary the security provisions on functional competence and
completeness.
Ensure that combination of welding torch and power source match
according EMV- regulation 2004/108/EG.
Safety
14
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 14

2.6 Personel requirements
2.6.1 Qualification of personel
In this operation manual the following qualications for the different eld
activities will be described:
Technical personel
is on account of its technical education, knowledges and experierences
as well of his familiarity with relevant provisions in the situation to
carry out the work entrusted to him and rekognise and avoid inde-
pendently possible dangers.
Personel with limited reaction capability for instance by drugs, alcohol or
medicine are not licened.
Personel in training, teaching or instructing position or in the context of
education should only be active under supervision of experienced
Personel!
Safety
15
WARNING
Danger of injury with inadaquate qualification.
Improper handling could lead to signicant personal- or property
damage.
All work should be carried out by qualied peronel.
With selection of personel, please pay attention to the age- and
occupation-specic regulations on the work location.
NOTICE
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 15

2.7 Personel protection equipment
Wear the following protection equipment with all work with the TIG-welding
torch:
Please, wear the following protection when working with the TIG-welding
torch depending on the work area.:
Safety
16
WARNING
Danger of injuries by the use of faulty or missing protection
equipment!
It is mandatory to wear personel protection equipment in order
to minimize health impairments.
Always wear the neccesary protection equipment for the
respective job.
Follow the attached notices for the personel protection
equipment in the work area.
Tight, ame retardant safety cloth
Additional leather apron to protect for burning with certain jobs
Welding gloves to protect for burnings, radiation and electrical
contact
Safety shoes with steel noses and insulating, oilrestent
security sole
Face protection with suitable lter to protect the eyes and sight
against ashes, burnings and strong UV-radiation
Safety helmet to protect the head for falling objects.
Suitable head protection when overhead welding
Ear protection in enviroments with a noise level of > 80 db(A)
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 16

3 Technical Data
3.1 General data
All informations are valid for hose and cable packag of 4 m.
Technical Data
17
TIG
Tungsten electrode acc EN 6848
depending on torch type
(see datasheet)
all
acc DIN EN 439
handguided machineguided
IP3X IP2X
113 VSS 141 VSS
DC or AC (see data sheet)
regulary negative
10 kV
50 Hz
–10 … +40 °C
–25 ... +55 °C
< 90 % (at 20 °C)
Air or Water
0.7 l/min
2.5 bar
3.5 bar
40 °C
60 °C
800 W
Welding process:
Electrode:
Max. electrode length:
Welding position:
Protective gas:
Guidance:
Type of protection:
Voltage demensioning (peak value):
Current type:
Polarity of electrode (bei DC):
Max. ignition tension:
Breakdown voltage:
Enviroment temperature at work place:
Temperature in store:
Relative humidity:
Cooling:
With watercooled torches:
Flow rate (min.):
Entrance pressure (min.):
Entrance pressure (max.):
Entrance temperature (max.):
Exit temperature (max.):
Cooling capacity (min.)
(depending on application)
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 17

3.2 Remote control
3.3 Torch specific data
The datasheets contain informations on the capacity rating of the TIG-
torch. The drawings show the assembly and application of the respective
wear parts and components.
Technical data
18
The TIG-torch specic data are listed in the attached data sheet.
This datasheet is part of this operation manual.
NOTICE
0,02 – 42 V (DC and AC)
0,01 – 100 mA
1 W (resistive load)
linear 1 W at 40 °C
Switch tension
Switch current
Switch-performance max.
Potentiometer
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 18

Structure and function
19
4 Structure and function
4.1 Description of structure
With TIG-welding an arc is generated between tungsten electrode and
the work piece which melts the work piece. The arc and the weld puddle
are protected by inert gas (Argon). Eventually ller metal can be added.
The welding power is transferred by the collet or guide to the tungsten
electrode.
The cooling takes place by the ambient air (air cooled) or by cooling
liquid (water cooled).
4.2 Scope of supply
Take the cooling method from the enclosed datasheet
NOTICE
The scope of supply may vary to the type of TIG-torch. Take the
exact scope as described on the attached datasheet and compair
with the delivery note.
Check the supply on comleteness and on visible damages. report
and write an incomplete or damaged supply immediately to your
distributor or supplier and to your forwarding agent.
NOTICE
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 19

Technical data
20
4.3 Principle construction
With the standard torch 2-stroke operating mode is possible.
Depending on the execution of the power-source further remote
controls may be integrated in the handle of the TIG-torch. The type
of connection is adapted to the type of power source. For further
information, please look in the data sheet of the torch and in the
operation manual of the power source.
NOTICE
1
2
3
4
5
6 7
1 Back cap
2 Torchbody
3 Gasket (optional)
4 Ceramic Nozzle
5 Tungtsten Electrode
6 Switch
7 Handle (optional with additional re-
mote controls)
8 Kink protection
9 Connection nut
10 Central connection (alternativ con-
nections available)
11 Connection cooling (optional)
12 Control connection power source
(optional)
8
910
11
12
BA_WIG-Brenner_GB_BA-WIG-GB 04.11.14 16:32 Seite 20