TECHNODATA

Germany
Description and operating manual
TIG orbital welding system

IM 99 /

Version 24 13 a

TECHNODATA GmbH
Remscheid

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a

These operating instructions must be read before commissioning!

Failure to do so may be dangerous! Machines may only be operated by personnel
familiar
with the appropriate safety regulations!
CONTENT
1

TECHNICAL DESCRIPTION ....................................................................................................5

1.1
1.2
1.3

TECHNICAL
TECHNICAL
TECHNICAL

2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
3.1
3.2
3.3
3.4

4
4.1
4.2
4.3

5
5.1
5.2
5.3
5.4
5.5

DESCRIPTION OF THE
DESCRIPTION OF THE

OPERATING INSTRUCTION ...................................................................................................8

2.1

....................................................................................6
IM-99 CONTROL UNIT ............................................................................7
WELDING HEAD T-250 ...........................................................................7

DESCRIPTION OF THE POWER SOURCE

INSTRUCTION POWER SOURCE .................................................................................................................9

Electric mains.............................................................................................................................9
Gas connection ..........................................................................................................................9
Ground cable..............................................................................................................................9
Switching on...............................................................................................................................9
Torch connection.......................................................................................................................9

WELDING ...............................................................................................................................10
GENERAL REMARKS ..............................................................................................................................10
WELDING WITH INVERTER POWER SOURCE 300A/DC.........................................................................11
TIG HAND WELDING ..............................................................................................................................12
TIG WELDING WITH ORBITAL WELDING HEAD ..........................................................................................13

REMOTE CONTROL ..............................................................................................................13

CHOICE OF MENU ..................................................................................................................................13
SET UP MENU PASSWORD..................................................................................................................14
MENU INPUT PARAMETERS................................................................................................................14
4.3.1
Submenu Times....................................................................................................................15
4.3.2
Submenu Counters ..............................................................................................................15
4.3.3
Submenu Current .................................................................................................................16
4.3.4
Submenu Sector program ...................................................................................................17
4.3.5
Submenu Wire pass swich..................................................................................................17
4.3.6
Submenu Tube-tube program.............................................................................................18
4.3.7
Submenu Gas test................................................................................................................19
4.3.8
Submenu Synchronisation..................................................................................................19
4.3.9
Submenu Memory Program Save.......................................................................................20
4.3.10
Submenu Memory Program Read out................................................................................20
4.3.11
Submenu Actual Welding Program Print...........................................................................21
4.3.12
Submenu Operating data ....................................................................................................21

MENU REMOTE CONTROL ...............................................................................................21

ALARM INDICATION ...............................................................................................................................22
ADJUSTMENT MAX- CURRENT.............................................................................................................23
ADJUSTMENT ROTATION SPEED..........................................................................................................23
ADJUSTMENT WIRE SPEED .................................................................................................................23
GENERAL REMARK ................................................................................................................................23

page - 1 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

Leverkuser Strae 65

*
*

e-mail: info@tdaD-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
For Your Safety:
The machines bear the conformity mark - and thus comply with the
EC Low Voltage Guideline (73/23/EEC) / EC EMV Directive (89/336/EEC)
(The CE Mark is only required in EC member states)
In compliance with VDE 0544 (EN 60974-1), the machines can be used in
environments with
an increased electrical hazard.
Warning: Observe accident prevention regulations!
NOTE: As you operate the IM 99 you have to pay attention to existing appropriat
e safety
regulations. Once again we point to the regulation that the IM 99 is about to
be
completely checked once a year.
Refresher examination on electrical equipment due to VDE 702 / BGV / A3
.

IF YOU DONT PAY ATTENTION THE MANUFACTURERS GUARANTEE WILL BECOME NULL AND VOID!
Use as per regulation:
The IM 99 is exclusively to be used in sense of regulation in accordance to us
ability. (See also
chapter: commissioning.)
Irregular use as per regulation:
Dangerous and hazardous situation for human beings, animals and material assets
may ocurre if
the IM 99 is about to be:
Irregular used as per regulation.
Used by not trained or supervised personnel.
Changed improper or modified.
Ignoring the following safety procedures can be fatal.
Before undertaking welding tasks, put on prescribed dry protective clothing, e.g
. gloves.
Protect eyes and face with protective visor.

Electric shocks can be fatal

The machine may only be connected to correctly earthed sockets.
Only operate with intact connection lead including protective conductor and saf
ety plug.
An improperly repaired plug or damaged mains cable insulation can cause elec
tric shocks.
The machine may only be opened by qualified and authorised personnel.
Before opening, pull out the mains plug. Switching off is not sufficient. Wait for
2 minutes until capacitors are discharged.
Always put down welding torch, stick electrode holder in an insulated condition
.

page - 2 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

Leverkuser Strae 65

*
*

e-mail: info@tdaD-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
Even touching low voltages can cause you to jump and lead to accidents, so:
Secure yourself from falls before working on platforms or scaffolding.
When welding, operate handle earth tongs, torch and workpiece properly, not i
n ways for
Which they are not intended. Do not touch live parts with bare skin.
Only replace electrodes when wearing dry gloves.
Never use torches or earth cables with damaged insulation.
Smoke and gases can lead to breathing difficulties and poisoning.
Do not breathe in smoke and gases.
Ensure that there is sufficient fresh air.
Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarb
on
Fumes can be converted into poisonous phosgene by ultraviolet radiation.
Workpiece, flying sparks and droplets are hot
Keep children and animals well away from the working area. Their behaviour
is unpredictable.
Move containers with inflammable or explosive liquids away from the working a
rea.
There is a danger of fire and explosion.
Never heat explosive liquids, dust or gases by welding or cutting. There is also
a danger of
explosions when apparently harmless substances develop high pressures in en
closed
containers by heating.
Take care to avoid fire hazards
Any kind of fire hazards must be avoided. Flames can form e.g. when sparks a
re
flying, when parts are glowing or hot slag is present.

A constant check must be kept on whether fire hazards have been created in t
he
Working area.
Highly inflammable objects, such as matches and cigarette lighters for example
,
must not be carried in trouser pockets.
You must ensure that fire extinguishing equipment - appropriate to the welding
process - is
available close to the welding work area and that easy access is possible.
Take care to avoid fire hazards
Containers in which fuels or lubricants have been present must be thoroughly
cleaned before welding begins. It is not sufficient simply for the receptacle to b
e empty.
After a workpiece has been welded, it must only be touched or brought into co
ntact with
inflammable material when it has cooled down sufficiently.
Loose welding connections can completely destroy protective conductor system
s
of interior installations and cause fires. Before beginning welding work, ensure
that the
handle earth tongs are properly fixed to the workpiece or welding bench and th
at there is
a direct electrical connection from the workpiece to the power source.
Noise exceeding 70 dBA can cause permanent hearing damage
Wear suitable earmuffs or plugs.
Ensure that other people who spend time in the working area are not inconveni
enced
by the noise.
Secure gas cylinder
page - 3 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
Place shielding gas cylinders in the holders provided for them and secure with
safety chains.
Take care when handling cylinders; do not throw or heat, guard against them
toppling over.
When moving by crane, take off the gas cylinder from the welding machine.
Caution: Interference by electric and electromagnetic fields can be caused by the w
elding
machine or by the high-voltage pulses of the ignition unit.
As laid down in Electromagnetic Compatibility Standard EN 50199, the machin
es
are intended for use in industrial areas; if they are operated e.g. in residential

environments problems can occur in ensuring electromagnetic compatibility.

The functioning of heart pacemakers can be adversely affected when you are
standing near the welding machine.
Malfunctioning of electronic equipment (e.g. EDP, CNC equipment) in the vicinit
y of the
welding location is possible.
Other mains supply leads, trip leads, signal and telecommunications leads abo
ve,
under and near the welding device may be subject to interference.
Warning: Electromagnetic interference must be reduced to such a level that it no lo
nger
constitutes interference.
Possible reduction measures:
Welding equipment should be serviced regularly. (see Sect. Maintenance and c
are)
Welding leads should be as short as possible and run closely together on or n
ear to the
ground.
Selective shielding of other leads and equipment in the environment can reduc
e radiation.
Caution: Repairs and modifications may only be carried out by authorised, trained,
specialist personnel.
The warranty becomes null and void in the event of unauthorised interference.
Our operating instructions will provide you with an introduction into the safe use o
f the
machine.
Therefore please read them closely and only start work when you are familiar with
them.
Transport and Installation
The machines may only be transported and operated in an upright position.
Before moving, pull out mains plug and place on the machine.
Secure high-pressure shielding gas cylinder with safety chain to prevent it from
toppling
over.
Do not roll over hoses or cables.
Place the shielding gas cylinder in the cylinder holder and secure it in place with t
he
securing chain.
Maximum permissible cylinder size at internal pressure:
200 bar, up to 50 l geometrical volume
300 bar, up to 33 l geometrical volume
When the current source is moved and positioned, it is only secure against falling
to an
angle of 15 (as specified in EN 60974-1). Special attention should be paid to the
fact that,
when the machine is moved, additional danger results from obstacles on the floor
as
page - 4 TEL: +49 2191 463 10 0
gmbh.com

FAX: +49 2191 463 10 11

e-mail: info@tda-

TECHNODATA GmbH
Remscheid

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
these can cause additional tilting moments.
Safety rules for crane transport:
Carefully observe the accident prevention regulations VBG 9, VBG 9a and VGB 15.
Lift with the crane at all 4 ring screws simultaneously
Ensure an even distribution of the load to all four ropes and maintain an angle
of at least 60 of the suspension ropes
Use only ring chains or suspension ropes of equal length (at least 1 m).
Load hooks with securing cleats and skackles of corresponding size to DIN 82 101, F
orm A.
Use minimum rated size 0.4.
Before lifting with a crane, always remove the shielding gas cylinder from the weldi
ng
machine.
Never lift other loads together with the welding machine, e.g. persons, toolboxes,
wire spools etc.
Avoid jerks when raising and lowering the welding machine.
Environmental conditions:
The welding machine can be operated in a location where there is no risk of explosio
n at
an ambient temperature of 0C to +40C and
a relative air humidity up to 50% at 40C.
where the surrounding air is free of unusual amounts of dust, acids, corrosive
gases or
substances etc., insofar as they do not occur during welding.
Examples of unusual operating conditions:
Unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, exc
essive
quantities of dust such as grinding dusts etc., severe weather conditions, unusual con
ditions
near the coast or on board ship.
When installing the machine, ensure a free inlet and outlet of air. The unit is tested to
protection class IP23, i.e.:
Protection against penetration of solid foreign bodies > 12mm,
Protection against water spray up to an angle of 60 to the vertical.

1 Technical description
The TECHNODATA tube welding equipment IM-99 is the result of many years
of experience
concerning procedures and equipment of orbital TIG-welding systems. High te
chnology, easy
page - 5 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
handling and maintenance, high reliability and flexibility are aims of the dev
elopment of our
products. Easy and fast adjustments on all required welding functions are possible. T
he equipment
consists of a welding head and a combined power source with an integrated control
unit with a 8line digital readout enabling a comfortable man-machine usage. The basic design
of the welding
head enables tube to tube sheet weldings from 10 mm to 78 mm internal tube diame
ter. For larger
diameters the welding head can be equipped with a special extension up to approx.
100 mm tube
I.D. For internal bore welds special torches in various diameters and length
s are available.
Weldings can be done also with or without filler wire. The welding head can be
equipped with a
double gas shield for covering the entire weld area, such as titanium weldings. P
recision ground
spindles and centering cartridges guarantee constant and perfect welds, du
e to the exact
centering. With the three legs support is obtained, that the rotation of the weldi
ng head during
welding process is exactly rectangular to the tube sheet. The three legs can be adju
sted in radial,
axial or peripheral direction, in order to find the suitable support area between the tub
es.

1.1 Technical description of the power source

The power source of the tube to tube sheet welding equipment IM-99 DC has been
developed for
TIG weldings, manually or mechanized. A mostly advanced 300 A DC inverter power
modul is the
heart of the power source.

The INVERTER power source operates with a frequency of 25 kHz to 60 kHz instead
of 50 cycles,
common power sources operate with. Firstly the net current becomes equaliz
ed and then a
transistor alternator with bipolar transistors provides the fequency of 25 - 60 k-cycles.
The middle-frequented current now is trasmitted via the transformator of the transistor
alternator to the
secondary side. The current transmitted to the secondary side will be equalized a
nd provided for
usage.
By adding a transistor alternator on the secondary side in FET technology the IN
VERTER power
source can provide alternating current as well. Most modern microprocessor techn
ology controls
the INVERTER power source.
Advantages of INVERTER technology:
Substantial weight reduction
Substantial reduction of raw material input
High efficiency, low power cost
High cos
High dynamic control of all parameters
High independence of all parameters from variation of input voltages
Much better welding characteristics, which are favorable when welding "difficult"
materials like
titanium, high alloyed steels and aluminum.
Control and adjustment
The control and adjustment of the INVERTER power source is obtained by the microp
rocessor unit
IM-99" with remote control and 8-line digital readout, keyboard and multi-fold
potentiometers.
page - 6 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
Cooling
The power source is equipped with an integrated cooling system.
The inverter power part is aircooled.
The connected torches are water cooled.

The cooling system consists of:

cooling-liquid tank
heat exchanger with aircooling
circular piston pump
quick action chucks for hose connections

It provides the necessary cooling of the torches and other parts of the orbital welding
heads.

1.2 Technical description of the IM-99 control unit

The control unit IM-99 consists of a microprocessor control system, assembled
on a separate
board with all necessary components, incorporated in the power source, having a
remote control
with 8-line display, function keys and potentiometers for high current, rotation
speed and wire
speed, which can freely be used at any place just limited by the length of the connecti
ng cable.
The microprocessor system provides a lot of possibilities, to meet the const
antly increasing
demands of tube-tube sheet and tube-tube joints. The orbital welding head T250 for tube-tube
sheet weldings as well as the orbital welding head SZ or Z33-36 as well
as hand torches
alternatively can be connected to the power source. The control unit automaticall
y indicates the
type of equipment which is connected without any hardware changes. The display
with the 8-line
readout, keyboard and the potentiometers has been assembled in robust remote contr
ol housing.
Via function keys on the remote control different menues can be selected, show
n on the 8-line
display, and all parameters can be adjusted according to the requirem
ents, and stored
automatically. The change of the parameters can be done just by inputting
new parameters.
Selection of the menu "Remote control" enables the start of a welding cycle by
using the push
button of the welding head or the function keys of the keyboard of the remote
control. Thus a
complete welding cycle can be done with the preselected parameters.

1.3 Technical description of the welding head T-250

When designing the following main aspects were taken into consideration:

1.

Easy handling
page - 7 -

TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
2.
3.

Adaptability to the weld parameters required

Exact torch turning control

1.
The handling of the welding head is extremely simple. Even unskilled
operators will have no
difficulty producing perfect weld - seams. The cartridge is inserted into the tu
be, the gun is
moved forward until the adjustable legs are touching the tube sheet, the
start button is
pressed and the weld cycle starts.
A fully automatic weld procedure now takes place. The torch positio
n can easily be
adjusted with a knurled nut (tubus ring) in axial direction and with an adjustin
g nut driver in
radial direction. A stable holding device takes care of a trouble free
wire feed. Also
changing the tungsten electrode can be executed quickly. Easy handling mak
es it possible
for the operator to operate two guns at the same time.
2.
The tube i.d. ranges from from 10 to 78 mm without any additional
equipment. Because of
the adjustable electrode angle fillet weldings up to 45 mm tube internal d
iameter can be
done. Should larger diameters be required, extensions may be added for
up to 100 mm
tube I.D. For internal bore welds special torches in various diameters and
lengths will be
manufactured on request. For weldings simultaneously with filler wire a small
compact wire
feed unit is attached. This turns with the torch rotation and prevents unre
gular wire feed
occured by twisting wire. When welding highly oxidizing metals, such as ti
tanium, a front
protection shield is used which gives additional gas coverage. It has clea
r lenses which
allow the operator to observe the weld as it proceeds.
An extra hose for this protection gas is as standard included. The torch is liq
uid-cooled, in
order to be able to weld preheated tube sheets up to 250 centigrades. If the
heat is still too
high, a water cooled protection shield can be assembled in front of the gun.

Examples of joint configurations:

An accurate rotation of the welding head is the result of a cartridge equipped with 2
rows of spring
loaded balls and a spindle (mandrel) together with a 3 point support of the gun.

2 Operating instruction

page - 8 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a

2.1 Instruction power source

Caution !!

High tension !!

Life danger !!

Note:
Any repair work, disasembly of the side covers and cover plates
only can be
executed by qualified, authorised people, obbaying the safety
regulations.
Removing the covers may cause the loss of any warrenty agreement
between
the user and TECHNODATA. The covers only may be removed a
fter at least
two minutes after disconnection with the network.
Before connecting the power source to the mains all co
vers must be
assembled.
This is not only necessary by safety reasons but also b
ecause of the
functioning of the cooling systems.

2.1.1

Electric mains

The machine is set in factory at the voltage given with your order. If no infor
mation about the
voltage is given by the user, the unit will be set at 400 V three phase current. Pay a
ttention to the
voltage printed on the label at the back side of the power source.cable. The
mains plug must
comply to country regulations and must be connected by an expert.
2.1.2

Gas connection

At the backside of the power source the connection joint for the gashose is situated.
The gashose
with pressure regulator is connected between gas bottle valve and connection j
oint. Check for
leaks. Open the gas bottle valve slowly.
Caution:
Secure the gas bottle with the chain to housing of the power source. When m
oving the power
source the transport of power source and gas bottle should be done separately.
2.1.3

Ground cable

Provide clean ground connection as close as possible to the welding area. The gr
ound cable will
be connected in tip jack with the symbol ( + ) and locked by right hand turn.
2.1.4

Switching on

When all connections are made properly, the equipment is switched on by mea
ns of the main
switch. On the display of the remote control the main menu can be seen (Unit ready f
or use).
2.1.5

Torch connection

page - 9 TEL: +49 2191 463 10 0

gmbh.com

FAX: +49 2191 463 10 11

e-mail: info@tda-

TECHNODATA GmbH
Remscheid

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
The hose package of the torch (Welding head T 250 or TIG torch) are connecte
d to the central
connection with a sleeve nut. The liquid cooling inlet and outlet hoses must be
plugged into the
corresponding quick couplings; pay attention to the colour coding.
A.

Control cable T-250

Connect the plug with the according base plug.

B.

Control cable TIG torch

Connect the plug with the according base plug.
Electrode - diam.
Mm
1,0
1,6
2,4
3,2

Welding current
A
15 - 80
70 - 150
150 - 250
250 - 400

3 Welding
3.1 General remarks
Automatic switch off
If the power source is started without ingnition the unit will switch off automatical
ly after about 4
seconds. Once the arc is interrupted longer than 4 seconds, the unit will swich off as
well.
This safety feature is provided in order to avoid
uncontrolled ingnitions
material damages
loss of gas
accidents
Capacity of tungsten electrodes
In spite of these recommendations it is possible to weld most of all material
s with electrode
diameter 2,4 mms even with lowest current values.
When applying the DC welding method, there are used tungsten electrodes with 2 %
Thorium (DIN
32 528). Thorium-free tungsten electrodes can be used as well.
When welding with higher current values the use of gas diffusers may increase the li
fe time of the
torch.

Caution:
The electrode never should touch the work piece or weld bath. In case
this happens,
the electrode must be reground.
Hints for electrode care:

page - 10 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
Always keep the electrode clean. The electrodes have been carefully cleaned by the
manufacturer.
Dirty electrodes contaminate the weld seam and therefore reduce the welding quality.
Never break electrodes. Mark the electrode where it should be shortened and
cut with pliers.
Always keep the electrode properly shaped. For DC-welding, the tip should b
e ground at an
included angle of 40 degrees.
The electrode must remain bright and silvery. Changed colour (blue to black) sho
ws that there is
not enough gas post flow.
Normally the tungsten electrode has a length of 175 mm. This length should be
sufficient for 30
working hours. Excessive consumption indicates that the unit should be checked for
malfunctions.
High-frequency ignition unit:
The built-in HF unit permits trouble-free arc starting when TIG welding.
Welding cycle diagram

3.2 Welding with IM 99

When welding with the IM 99 the complete welding cycle runs off according to
the preselected
values. All parameters for the connected welding head and the welding itself
are put into the
page - 11 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
microprocessor via the keyboard and the multi-fold potentiometers of the remo
te control. See
diagram on next page.
A complete welding cycle for a one-pass TIG welding with filler wire runs off as
follows:
A.
The welding cycle is started by pushing the start button of the welding head
or pushing the
function key "Start/Stop" on the keyboard of the remote control.
Protection gas now flows and the distance between tungsten electrode
and workpiece
becomes conductive because of high voltage sparks in this area.
A'.
A stable arc now has been established.
B.
The continuous current increase starts.
C.
The welding current has reached it pre-selected max. value. The pulsing
starts, if selected,
and the paddle forming takes place during the preselected time.
D.
During the upslope the workpiece becomes heated up continuously in the area
of the arc.
A welding bath of sufficient dimension has been obtained and the rotation of
the torch can
start as well as the feed of the filler wire.
E.
The torch completes a circle of 360 degrees. Normally after 360 degrees the
filler wire feed
stops.

E'.
In case filler wire is wanted in the overlap area as well, it can be preselected
accordingly.
F.
After completing the overlap the down-slope starts.
G.
The welding current will be decreased continuously.
H.
The arc disappears. The rotation of the torch will be executed with max.
speed to the initial
starting point.
I.
The feed of protection gas stops.
K.
The starting point is reached, the welding cycle is finished.
An new welding cycle can be started after repositioning of the welding head.

300
SIMULATION

WIRE
PROGRAM

START

ROTATION

STOP

RIGHT

7
ABCD

4
MNOP

1
YZ!?

_
+/*=

SECTOR
PROGRAM

PULS
PROGRAM

WIRE

CYCLE

FORWARD

END

8
EFGH

5
QRST

2
C1-C 4

TUBE-TUBE
SYNCHRO
SYNCHRO
WIRE
PROGRAM
ROTATION
FILLERWIRE 1;2;1+2pass

F6

F5

F7

F8

9
IJKL

LIST

ACK

6
UVWX

3.3 TIG hand welding

PREV

<>()

0
%#:

page - 12 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
After connecting the hand torch to the power source at the base plug and connectio
n of the quick
action chucks of the water hoses and the plug of the control cable, the hand torch is
ready for use
if the power source is swiched on.
The hand torch has a "4-function" operation:
1.
Push button of torch:
phase

Gas preflow, ignition, initial arc

2.
Release button of torch:
current or, if

Welding with preselected high

wanted, with pulsing. High/low curr

ent
3.

Push button of hand torch:

Start down-slope, crater filling

4.

Release button of hand torch:

end of welding cycle and postgas

Parameter-selection see "function of the keyboard" of the remote control.

3.4

TIG welding with orbital welding head

for tube-tubesheet- or tube-tube-welding connections

After connecting the required orbital welding head to the power source at the
base plug and
connection of the quick action chucks of the water hoses with the plug of the c
ontrol cable, the
head is ready for use if the power source is switched on.
Parameter-selection see "function of the keyboard" of the remote control.

4 Remote control
Keyboard and display enable a "menu-controlled" input of
parameters (dialog-system). All necessary parameters for
a complete welding cycle can be put in directly via the
keybard. By using the fuction keys "F7 - F8", and START
STOP; ROTATION RIGHT; WIRE FORWARD;
CYCLE END; SIMULATION; WIRE ON/OFF; all functions
necessary for a welding cycle - also in simulation - can be
performed.
An operating time counter as well as a cycle counter is
available
for continuous
controland
even
a welding
There are 3 Potentiometers for the
high current-,
rotation speed-,
fillerduring
wire speed
cycle. Printer can be connected as well (option).
-adjustment.
The actually welding parameters showing in the display
are able to store (max. capacity 40 program blocs)
4.1 Choice of menu
.Read in and out to the dispay.
page - 13 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
After switching on the power source the display shows:

Input parameters
Remote control

By using the arrow keys below the function keys F7 - F8 the required menu can be
selected. The
cursor on the left side of the display indicates the selected menu. After pressing the "
enter"-key the
selected menu can be seen on the display. Further menues can be selected the same
way.
If there is a "+" mark on the right side, this indicates that further lines can be choosen
in the display
by using the arrow keys, as the display has only 8 lines.
By pressing the "MAIN" key the start menu will be activated and from there on furthe
r menues can
be selected again.
By pressing the PREV key the overplaced menu is activated.

4.2 Set up menu Password

The menu Input Parameters can be activated, if the correct password (usua
lly 3 figures) is
entered, available for authorised personnel.
When leaving factory the password is "999" but can be changed in the menu "
Password" (only
figures). For changing the password scroll the cursor down, till the display
shows change
password 999 and select your own password and enter.
After selection of password and enter the menu " input parameters " is activated.
Before this the
following menues appear on the display:

###

Enter Password for entry menu input parameters

By pressing the "MAIN" key the start menu will be activated and from there on furthe
r menues can
be selected again.
By pressing the PREV key the overplaced menu is activated.

4.3 Menu Input parameters

The input of the 3-digit-password and enter the menu "input parameters will appear
in the display
and the following menues can be selected:
> Times

> Counter

> Current

> Sector program

> Actual welding progam print
> Gas test
ARC-Voltage

> Tube-tube program

> Synchronisation
> Operating data

> Wire pass switch

> Program memory
> Monitoring - Current /

With the arrow keys the different menues can be selected and activated by pressing "
ENTER.
By pressing "MAIN" the start menu will be activated and from there on further
menues can be
selected again.
page - 14 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
By pressing PREV the overplaced menu is activated.
4.3.1

Submenu Times

The following times can be selected or adjusted: (Input in 1 / 10 sec.)

nt

Pregas
Up-Slope
Puddleform
Down-slope
Postgas
Wire backward

Up slope time from basic current to adjusted high curre

Arc time from ignition to rotation start
Down slope time from high current to basic current
Time of wire backward moving when welding is finished

For the choice of the next submenu:

Counters
Current
Sector program

The input of the different times can be realized by pressing the digit keys on th
e left side of the
keyboard. The units are 1/10 sec.
Use the arrow keys for selection of the different times and enter.
The procedure for selection of further menues can be done as already described.
4.3.2

Submenu Counters

The following counters can be selected:

Welding cycle

Endposition
Wire 1. pass
Wire 2. pass

For the choice of the next submenu:

Set current
Set times
Sector control

The input of the different values can be realized by pressing the digit keys on the
left side of the
keyboard. The number of impulses for 360 angle-degrees are dependend on the type
of connected
orbital welding head. (See technical description of the selected welding head).

page - 15 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
Example:
Using the tube-tube sheet welding head T-250 60 impulses represent 360 angle
degrees, which
means that 1 impulse represents 6 rotation angle degrees.
Use the arrow keys for selection of the different counters and quit with "enter".
The welding pass consists of one complete rotation = 360 degrees (60 impulses) plu
s overlap e.g.
61 or 62 impulses (= 366 / 372 rotation angle degrees) for a "one pass" welding cycle
.
If a "two-pass" welding cycle should be executed the complete welding cycle
consists of 120
impulses plus overlap = 121 or 122 impulses.
During the complete welding pass the selected current values and times are activate
d, before the
down-slope takes place.
When selecting the parameter "endposition" the following rule must be obbeyed:
Should the starting position always be the same (e.g. "10 hours") the head must co
mplete the last
rotation, already started for overlap and down-slope. For an "one-pass" weld
ing the counter
consequently must be set on "120", for a "two-pass" welding on "180".
The counter "Wire 1. pass" usually is set on 60 impulses which means feed of filler w
ire during one

complete revolution.
The counter "Wire 2. pass" is set on 120 impulses which means feed of filler
wire during two
complete revolutions.
Of course, variations from these values are possible (e.g. 59 or 61 impulses feed of f
iller wire for a
"one-pass" welding or 119 or 121 impulses for a "two-pass" welding).
The procedure for selection of further menues can be done as already described.
4.3.3

Submenu Current

The following parameters can be selected:

F8 = Pulse-program ON / OFF
# # # A current-min
# # # A current-max
# # # / 100 sec. puls-min
# # # / 100 sec. puls-max
For the choice of the next submenu:
Sector program
Counters
Times
Using the function key "F8" the pulsing can be swichted on or off.
The input of the "min-current" values can be realized by pressing the digit keys on
the left side of
the keyboard. The units are "Ampere" (theoretical input option 0 - 300 A).
The input of "max-current" values must be done by means of the multi-fold potent
iometer on the
remote control, related to "max-current". The variation of values can be seen on the
display.
page - 16 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
Important remark:
the input

If the "Sector program" (see below) is swiched "on"

of
max-current only can be realized via the digit keys on

the keyboard.
The pulsing times for "max-current" and "min-current" are entered in values of 1/100
sec.
The procedure for selection of further menues can be done as already described.

4.3.4

Submenu Sector program

The sector program enables the input of the following parameters in 10 free selective
sectors:

F8 = Sector program "ON / OFF"

Max-current (A)
Rotation speed (%)
Wire speed (%)
Counter (Sector angle impulses)

>
> sectors 1-10
> free selective
> 1 impuls = 6 degrees

For the choice of the next submenu:

Times
Counters
Current

With the function key "F8" the sector program is swiched ON / OFF and is indicated
by a LED on
the top of the keyboard. The system enables the splitting of the total welding
cycle in 10 free
selective sectors. Within these sectors the following parameters can be selected indivi
dually:

Max-current in Ampere
Rotation speed in percent of max. speed
Wire speed in percent of the max. speed

}
}

of the connected
welding head

The input of the values can be realized by pressing the arrow keys on the
right side of the
keyboard. Quit with "enter". When the sector control system is swiched "ON",
The 3 potentiometers are out of function.
The "welding cycle" preselected in menu "Counters" can be shared into maximum 10
sectors. After
counting the preselected impulses, the cycle end program starts. The sum of select
ed counters in
the sector program must be as high or higher than the preselectedwelding c
ycle in menu
Counters.
The procedure for selection of further menues can be done as already described.
4.3.5

Submenu Wire pass switch

The following options are given:

Wire 1. pass
page - 17 TEL: +49 2191 463 10 0
gmbh.com

FAX: +49 2191 463 10 11

e-mail: info@tda-

TECHNODATA GmbH
Remscheid

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a

F7
F8

=
=

Wire 2. pass
Wire 1. + 2. pass

For the choice of the next menu:

Set times
Set counters
Set current
Sector control
Tube-tube program
Remote control
The option "wire 1. pass" is selected automatically via the remote control (se
e menu "remote
control" / wire ON / OFF ).
Pressing the function key "F7" provides filler wire feed during the second pass if in
menu "remote
control" the wire is swiched "ON".
Pressing the function key "F8" provides filler wire during pass one and two, if i
n menu "remote
control" the wire is swiched "ON".
The procedure for selection of further menues can be done as already described.
4.3.6

Submenu Tube-tube program

The submenu tube-tube program enables the adjustment of tube-tube welding as

follows
F7 =
tube-tube program ON / OFF
F8 =
left with wire ON / OFF
# TUBE TUBE PROGRAM
F7 =
Automatic right / left ON / OFF
F8 =
change program start left / right
For choice of the next submenu:
Times
Counters
Current
By pressing the function key F7 the welding program for tube-tube sheet welding
is switched to
tube-tube welding.
This means, the welding head rotation starts anticlockwise until the torch is in star
tposition. Then
the welding process is started automatically and the welding head moves clock
wise. When the

welding cycle is finished, the welding head is in open position and can be dismounted
easily.
When the function F8 is activated, the program cycle of the tube-tube welding
changes! Welding
takes place during the anticlockwise moving without filler wire feeding. When t
he first pass is
finished, the welding process is started again and the head moves clockwise
(welding with or
without filler wire).

page - 18 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

Leverkuser Strae 65

e-mail: info@tda-

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
By pressing the function key F6, the first pass is welded with filler wire.
Attention:

The wire nozzle must be adjusted correctly !

The cycle start shows the direction of the welding start (right / left)
If the welding process has to be interrupted (for example in case of emergency of for
repair-welds)
the welding direction might have to be changed. Press F5 to find the correct
program start direction (left = anticlockwise / right = clockwise).
The procedure for selection of further menues can be done as already described.
4.3.7

Submenu Gas test

In the submenu Gas Test the following options are offered:

F8 =
Gas Test ON / OFF
For the choice of the next submenue
Times
Counters
Current
Sector program

While the function F8 is activated, gas flow according to the selected quantity
is provided. By
checking the gas flow correct adjustment is possible.
The procedure for selection of further menues can be done as already described.
4.3.8

Submenu Synchronisation

The following options are given:

F7 =
Synchronisation rotation ON / OFF
F8 =
Synchronisation wire
ON / OFF
For the choice of the next menu:
Times
Counters
Current
The use of synchronisation is possible only if the pulsing is in function. With the fun
ction key "F7"
the synchronisation for rotation can be swiched on or off. During the function
"synchronisation
rotation" the welding head stops rotation during high current and rotates only duri
ng low current.
With the function key "F8" the synchronisation for wire can be swiched on o
r off. During the
function "synchronisation wire" the filler wire feed takes place only during high current.

page - 19 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
The procedure for selection of further menues can be done as already described.
4.3.9

Submenu Memory Program Save

Select Program No.

F8

( 1 - 40 )

Save

Order No.: # # # #

Tube ##,## x ##,## mms

For the choice of the next menu:

Program read out
For saving a parameter set for a special application select the program no. ( 1 40 ), setting the
cursor on program no. with the arrow keys and confirm with enter.
After that the save menue has to be choosen by pressing the function key F8
The full set of actual parameters are now saved in the selected memory program.
It is possible to describe the welding job to be saved by inserting four figures in ord
er-no. and the
tube size in tube before saving the parameter set.

The values of the max. current, rotation speed, and wire speed are saved,
when they
are written in the sector program
Memory of potentiometer values is not possible !
4.3.10

Submenu Memory Program Read out

Program No. ( 1 40 )
( indicates the last readed out program-no.)
Select Program No. ( 1 - 40 )

F7 =
F8 +

F8 +

Release read out

SIMULATION OFF
Read out program
SIMULATION ON
Print program

On / Off

For the choice of the next menu:

Program save
For welding with memory parameter sets with one of the programs saved b
efore, select the
program by setting the cursor on select program no., with the arrow keys, put
in the program
no. ( 1 - 40 ) and confirm with enter.
After that the read out menue has to be choosen by pressing the function ke
y F7 . The full
parameter set, saved on that program number is now readable by scrolling with the ar
row key.
page - 20 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

Leverkuser Strae 65

e-mail: info@tda-

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
To activate this parameter set F8= Release read out has to be pressed and then
F7 during the
next 30 seconds.
When F8 is pressed sector program is switched on automaticely.
For printing the parameters of the choosen program: Connect the cable of TECHNO
DATA printer
Type CBM -910 to the receptacle in front of the remote control housing and connect
the printer to
mains voltage ( standard AC / 220 V / 1-phase ).

Press function key F 8 , and the parameters saved in the choosen program are pri
nted.
4.3.11 Submenu Actual Welding Program Print

F8

Print

For printing the actual parameters connect the cable of TECHNODATA printer Ty
pe CBM -910
to the receptacle in front of the remote control housing and connect the printer to m
ains voltage (
standard AC / 220 V / 1-phase ).
Press function key F 8 , and the actual parameters are printed.
By scrolling the display with the arrow key the full parameter set can be read.
On the print you find date and time of printing, and you have the opportuni
ty to write down
additional informations as Order No., Welders name, Equipment no., Tube size,
Tube material,
Tube sheet thickness, Tube sheet material, Filler wire ( type and size ), Remarks.
4.3.12

Submenu Operating data

This menu shows actual values related to the unit:

Hours
Welding cycles
Welding time (real welding time during cycle)
Cycle time

5 Menu Remote control

With the function keys "F7 - F8" the following controls and functions are possible:

=
Welding program Start/Stop

=
Rotation right

=
Wire forward
page - 21 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a

=
=
=
F7 =
F8 =

Cycle end
Simulation ON / OFF
Wire program ON /OFF
Rotation left
Wire backwards

The function key "Start / Stop" has the same function as the "Start /Emergency stop"
button at the
handle of the welding head. Pressing this function key, the welding cycle starts. Pr
essing the key
during the welding cycle will interrupt the cycle immediately (without downslope).
In the display the following alarm information can be read:
"Emergency stop activated
Press "F8" for cancellation".
After cancellation the menu "Remote control" is activated and the welding cycle
can be started
again.
With the function key "ROTATION RIGHT" the clockwise rotation of the torch can be a
ctivated. The
rotation will take place as long as the function key is pressed. This enables positionin
g of the torch
e.g. for the starting position. If function key "F7" is pressed , the torch rotates anticloc
kwise.
With the function key "WIRE FORWARD" the wire feed is activated manually as long
as the key is
pressed. During the wire feed the direction of the wire feed can be checked
and adjusted if
necessary. If function key "F8" is pressed, the wire will be fed back.
Using function key "WIRE ON/OFF" the wire feed during the welding cycle can be sw
iched "on" or
"off". This function can be used even during the welding cycle.
If the function key "SIMULATION ON/OFF" = simulation is activated (ON /OFF), the w
hole welding
cylcle takes place without arc ignition. This enables to check the rotation speed, the
wire quantity,
position of torch during cycle and the wire feed. After pressing function key
F5, the welding
program is activated.
If the function key "CYCLE END" is activated during a welding cycle the weldin
g stops and the
down slope is started. Using this function, repair weldings can be done (less than a c
omplete cycle
of e.g. 366 degrees.)

5.1 Alarm indication

The display shows

"Gas shortage - check gas flow
"Water shortage - check water flow".

or

page - 22 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
After termination of the shortage the alarm can be cancelled by pressing the function
key "F8". The
welding cycle can be started again.

5.2 Adjustment max- current

With the Potentiometer on the remote control for "max-current" the max-current c
an be adjusted
stepless. The actual value in Ampere can be seen in menu "set current" !
If the menu "sector parameter" is activated, the
function of this potentimeter is swiched off !

(input only by digit

keys)

5.3 Adjustment rotation speed

With the Potentiometer on the remote control for "rotation speed"
the rotatio
n speed can be
adjusted stepless. The value on the potentiometer represents the fraction of 999 whi
ch represents
100 %. E.G. value one the potentiomer: 450 = 45 % of max. rotation speed.

5.4 Adjustment wire speed

With the Potentiometer on the remote control for "wire speed" the wire speed
can be adjusted
stepless. The value on the potentiometer represents the fraction of 999 which repr
esents 100 %.
E.G. value one the potentiomer: 450 = 45 % of max. wire speed (and quantity).

5.5 General remark

Maintenance and care

Under normal operating conditions these welding machines are largely mainten
ance
free and require a minimum of care. However, a number of points should be ob
served
to guarantee fault-free operation of your welding machine. Among these are
regular
cleaning and checking, as described below, depending on the level of contami
nation in
the environment and the usage time of the welding machine.
Cleaning, testing and repairing of the welding machines may only be carried out by
competent personnel. In the event of failure to comply with any one of the followin
g tests
the machine must not be operated again until the fault has been rectified.

5.6 Cleaning
To do this, carefully disconnect the machine from the mains.
PULL OUT THE MAINS PLUG!
(Switching off or unscrewing the fuse is not adequate isolation).
Wait for 2 minutes until the capacitors have discharged. Remove the casing cover.
The individual components should be handled as follows:
page - 23 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

Leverkuser Strae 65

*
*

e-mail: info@tdaD-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
Current source Depending on the amount of dust, blow out current source using oiland
moisture-free compressed air.
Electronics, circuit boards Do not blow on electronic components or circuit boards w
ith the
compressed air stream but suck clean using a vacuum cleaner.
Repetition test according to VDE 0702 and VBG 15
Test sequence:
Quarterly test: 1. Visual check of correct condition
2. Measurement of protective conductor resistance
Annual test: 1. Visual check of correct condition
2. Measurement of protective conductor resistance
3. Measurement of insulation resistance following internal
cleaning of the power source
4. Measurement of open circuit voltage
5. Function test of the welding machine
Visual check of correct condition

The machine must be inspected for externally visible faults (without opening the machi
ne). During
this inspection, attention must be paid, for example, to the following points:
External faults in mains plug and mains cable, e.g. insulation faults, scorch or pressur
e marks.
Defects in anti-kink protection and the strain relief of the connection lead, mains
switch.
Faults in welding leads, tube package, plug fixture, arc torch.
Signs of an overload and improper use.
Damage to stop points and casing.
Improper interference and modifications.
The type plate and warning symbol must be present and legible.
Repair work
Repair and maintenance work may only be performed by specialist staff. In all service
matters,
always consult your dealer. Return deliveries of defective equipment subject to warrant
y may only
be made through your dealer. When replacing parts, use only original spare parts.
When ordering spare parts, the machine type, serial number and item number of the
machine, as
well as the type description and item number of the spare part must be quoted.

If repair or maintenance work is carried out on this machine

by personnel who are not trained and authorised to undertake such w
ork,
the right to claim under the warranty lapses.
Description to find source of error by the Orbital welding equipment, Type IM-99
Remove of casing sheets and casing cover ! The equipment should be complete read
y to use.
Be careful by switch on the equipment because it is under power !!!
Switch on the main switch only without starting a cycle.
CARD TRDC2 ( right side middle )
page - 24 TEL: +49 2191 463 10 0
gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
LED
LED
LED
LED
LED
LED
LED

red +5V / +15V / -15V lights on when the equipment was started
STOER
dark, light on by an error ( main error )
IPRUE
dark, light on by error primary over current
PRUE
dark, light on by error primary over voltage
PRUN
dark, light on by error primary under voltage
TEMP
dark, light on by overheating of Inverter
RGLSPR
dark, light on by an externally governor stop was installed

At the terminal gib X2/15 and X2/8 are 10V/DC

CARD SPW2 ( left side - middle )
LED1 red must be on always if the equipment was started.
At the terminal gib X4/1 and X4/2 are 16V/AC .
CARD DW 7,5 ( left side middle )
At the terminal L1, L2, L3 are the main current 3 x 400V/AC.
Transformer ( right side - down )
Secondary voltage 42V/AC
Transformer 1-A2 ( up )
Secondary voltage 24V/DC, green LED must be shining.
CARD WK3 ( right side - down )
LED2
LED1
them

dark, light on - fuse F 2 ( water pump ) is damaged.

dark, light on - fuse F 1 ( ignition unit and gas valve ) is damaged and one of
is activated.

CARD 1-A1 ( up )
At the terminal L and N - main current 30V/AC
LED Power and RUN green lights on if the equipment was started
LED red input signs
X0 dark
X1 dark or light on
head

light on, if the start bottom at the welding head is pressing

dependent on the position of the micro switch in the welding

page - 25 TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
X2 dark

light on, if the welding current is flowing)

X3 light on
X4 light on
damaged
X5 dark ( free )
X6 light on
head ) is
X7 dark

dark, if gas is missing or flow control is damaged

dark, if water pump, flow control or fuses F2 on WK3 are
dark, bridge G to I in the 14-pole-plug of the hose ( welding
missing
light on if the start bottom at the hand torch is be pressed

LED red output signs

Y0 Y 7 dark

Analog Module 1-A1/K0 K2

LED red 24V and A-D resp. D-A lights must be on if the equipment was started
Starting the welding cycle !
CARD TRI 1 resp. 4 ( left side - middle )
LED red 1 and 2

lights on if the equipment was started

output Y1 of SPS 1-A1 light on if no welding current is flowing

too
CARD TRDC2 ( right side - middle )
LED STR/STP
LED IGRO

light on if the equipment was started

light on if no welding current is flowing too
light on if welding current is flowing

!! ATTENTION : main switch of power source on OFF and pull the current cable out of th
e plug

CARD DW 7,5 ( left side - middle )

Remove cable from terminal X4/1 and X4/2 and measure the resistance ( appr. 68 oh
m)
The same by X7/1 / X7/2 and X8/1 / X8/2.
Control fuses S1 and S2 ( 160 mA ).

CARD TRDC2 ( right side - middle ) remove

Remove cable from the diode module and measure in the range of 2 kohm
~
+
O
O
O
~
+
O
O
O
~
+
page - 26 -

TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
O

CARD SPW2 ( left side - middle ) remove

Downside on the left side behind DW 7,5 control main current rectifier and measure
front view of
main current rectifier
+
O
O
~
~
~
O
O
O
Upside on the left side behind DW 7.5 - control thyristor diode modul measure in the r
ange of
2 kohm - front view of thyristor diode modul
A
O

K
O

AK
O

CARD TRI 1 resp. 4 ( left side - middle ) - remove

upside
primary switch PLUS U3
downside
primary switch MINUS U4
measure in the range of 2 kohm
primary switch PLUS U3

O
O
page - 27 -

TEL: +49 2191 463 10 0

gmbh.com
TECHNODATA GmbH
Remscheid

FAX: +49 2191 463 10 11

e-mail: info@tda-

Leverkuser Strae 65

D-42897

Description and operating manual TIG orbital welding system IM 99 Version 24

13 a
O
O
primary switch MINUS U4
O

O
O
O
O

Wiring SPW2 / TRI1/4 and DW 7,5

SPW2 terminal X2/1 TRI1 terminal X2/1
SPW2 terminal X2/2 TRI1 terminal X2/2
SPW2 terminal X1/1 DW7,5 terminal X9/1
SPW2 terminal X1/2 DW7,5 terminal X9/2
SPW2 terminal X4/1 DW7,5 terminal X3/1
SPW2 Klemme X4/2 DW7,5 terminal X3/2
SPW2 terminal X5/1 thyristor modul connection upside ( 1 )
SPW2 terminal X5/2 thyristor modul connection middle U2 ( K ).
Technical changes, up-dates, modifications and change of industrial designs prior to
any
announcement.

page - 28 TEL: +49 2191 463 10 0

gmbh.com

FAX: +49 2191 463 10 11

e-mail: info@tda-

TIG 300 DC
50
1
1
a

12.2000

Orbital-welding Vers.: 24 13
system IM 99
3-A
Power source TI 04
G 300 DC
Design /
Front view

241303-A.vec

24 13 0
24 13

Inverter TIG 300

DC

Stl.-Nr.:

TECHNODATA

Kunde:

Dat 12.20 Kom.-Nr.:

um 00
Bea R.Kia
rb. ups
Ges 241303p. B.vec

Remscheid
Germany

( Stro Vers.: 24 13 Zg.-Nr.:

Type: OrbitalRohreinschweianla mquelle / P 24 13 03 - B
ower
source
ge
24 13 04
)
OrbitalBaugruppe:
welding systemIM 9 Aufbau / De
Unit= 0.4 Blatt: 0
9
sign / Side
2
view

Chambergas

Zusatzgas

ChambergasOn-Off
ZusatzgasEin-Aus

17
16

12.2000

Orbital-welding Vers.: 24 13
system IM 99
3-C
Powersource TIG04
300 DC
Desig

241303-C.vec

24 13 0
24 13

n-plan

230V~

230V
Zusatzgas

P3

Chamber gas

17

230V

230V

FX2N - 16 MR
Mini-DIN 8-pos
Male

Y 7
Y 7

16

Dat 12.20 Kom.-Nr.:

um 00
Bea R.Kia
rb. ups
Ges 241302p. B.vec

Remscheid
Germany

Baugruppe:Steuerung / Control
Type: Orbitalsystem
Rohreinschweianlage Typ
Zg.-Nr.: 24 13 02 - B
IM 99
24 13 04
Orbital-welding
Software: Wick 01
system Vers.: 24 13
Power source TIG 3
Unit= 1.6 B
00 DC
latt: 02

TECHNODATA

Kunde:

1-A1/K1

FX2N-4AD

FX2N-4DA

0V

X2/

Stl.-Nr.:

CH3

CH4
WIRE
SECTOR
PULS

PROGRAM

12.2000

Orbital-Rohreinschweianlage 24 13 02 - C
Vers.: 24 13
24 13 04
Orbital-welding system IM 99
Power source TIG 300 DC
Control system

241302-C.vec

Remote control E 300

( rear view )

HEAD 1
HEAD 2
SIMULATION
PROGRAM
PROGRAM

WIRE
1;2;1+2 pass

PROGRAM

PROGRAM

TUBE-TUBE

ROTAT
WIR CYCLE
START
ION
E
END
RIG FORWA
HT
RD

F5

F6

F7

F8

LIST

ACK

8
9
ABCD

EFGH

IJKL

6
MNOP

QRST

UVWX

PREV

MAIN

3
YZ!?

C1-C4
<> ()

_
+/*=

%#:

rot
blau

wei
grn

Max. Current
Rotation
Filler wire
schwarz

OrbitalVers.: 24 13 24 13 02 - D
Rohreinschweia
24 13 04
nlage
Orbital-welding
system IM 99
Power source TI
G 300 DC
Control s
ystem

12.2000
241302-D.vec

130 133
40 73 80 90
51
17.
26 25 24 15 16 45 14 36 34 12 109 1318111 6 7 64 33 8 35 3710 70 717
2 79 74 75 76 7783 85 93 91 96 99 98103108
1
7
52
66
22
23

53
54

21
20
43,44

100

59
105
58
104
107
106

4.1 4.2
15.1

5.2 50

62

97

87 88

38
39

92

27 28 4860 61 9 11 42 41 31 32
29 49
30

17.1
26 25 24

51
52
66

22
23

53
54

21
20
43,44

100
59
58

51
53
52
54
58

31 03 - 00a

3103-00a.vec
Glocke / Brennereinheit

83
85
96
99
98
108
86
84
90

105
76
97

103
104

89

107

80

106

79
78, 82

77

83
94

95

88
92

120
84
03.2000

101
31 03 - 00B

3103-00B.vec
Zusatz- Drahteinheit

1.6

TUBE WELDING a

nd TUBE EXPANDING

for HEAT EXCHANGER- an

d BOILER MANUFACTURES
d
d. Jul.12.2004

PARTSLIST
page:

orbital welding head type T-250

version 31.03
POS.
LABEL
NUMBER
01
179288001
02
179288002
03
179288003
04/1
179288004/1
04/2
179288004/2
05/3
179288005/3
05/4
179288005/4
06
179288006
07
179288007
08
179288008
09
179288009
10
179288010

ITEM

11
12
13
14
15
16
17
17a
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

D
179288011
ESCRIPTION
179288012
179288013
main -shaft
179288014
centering sup
179288015
port
179288016
flange
179288017/1
rotor current c
179288017/2
oupling
179288018
stator current
179288019
coupling
179288020
insulating flag
179288021
e stator
179288022
insulating piec
179288023
e rotor
179288024
connecting rin
179288025
g
179288026
stator gas wat
179288027
er coupling
179288028
bearing block
179288029
feeder block
179288030
crown wheel
179288031
crown wheel
179288032
tubus bearing
179288033
ring
179288034
tubus setting r
179288035
ing
179288036
tubus glyding
179288037
ring
179288038
tubus conter ri
179288039
ng
tubus base rin
g
point piece for
basing leg
basing leg of
3 ports

housing central body

housing cap
torch
torch holder
torch slide
collet for torch
insulating piece for torch slide
Base block for torch holder
torch slide holder
Connecting plate
fitting for gas-water return
fitting for water preflow
fitting for water preflow
rotation-motor
handle
suspension
baller bearing front
baller bearing back side
snap ring front side
snap ring back side
push buttom start stop
protection for push buttom

QUANTITY

1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
2,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00

1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
3,00
3,00

TEL.: +49 2191 463 10 0

info@tda-gmbh.de

FAX: +49 2191 463 10 11

nd TUBE EXPANDING

E-MAIL:

TUBE WELDING a
for HEAT EXCHANGER- an

d BOILER MANUFACTURES
d
d. Jul.12.2004

PARTSLIST
page:

orbital welding head type T-250

version 31.03
POS.
LABEL
NUMBER
40
179288040
41
129520332
42
179288042
43
129274307

ITEM

44
48
49
50
51
52
53
54
58
59
60

129274023
179288048
179288049
179288050
179288051
179288052
179288053
179288054
129280204
129274043
129274043

ESCRIPTION

pin
micro switch f
or orbital weld
ing head
holder for mic
ro switch
clamping slee
ve
insulating seal
nut for fitting
nut for fitting
hold down nut

clamping piece wire guide support

pin for wire guide support
insulating sleeve
clamping piece for wire giude nozzle
wire guide nozzle
viton hose
viton hose
61
1,00
62
179288062
64
179288064
70
179288070
71
179288071
72
179288072
74
179288074
75
179288075
76
179288076
77
179288077
78
179288078
79
179288079
80
179288080
82
179288082
83
179288083

QUANTITY

12,00
1,00
1,00
1,00
1,00
1,00
3,00
3,00

2,00
1,00
1,00
1,00
1,00
2,00
1,00

179560616
84
85
86
87
88
89
90
91
92
93
94
95

179288084
179288085
179288086
179288087
179288088
179288089
179288090
179288091
179288092
179288093
179288094
179288095

flange for
motor rotati
on
seal ( quad
ring )
block for c
arbon supp
ort
carbon gui
de
carbon bru
shes
support for
wire protec
tor
wire protec
tor
shaft for wi
re unit
flange for s
lip ring
socket
slip ring
slip ring
socket
housing for
wire feeder
cap of hou
sing for wir
e feeder
shaft for wi
re feeder
shaft for wi
re feeder
crown whe
el for wire f
eeder
crown whe
el wire fee
d motor
wire feeder
roller

shaft
distance ring
base flange for wire feed motor
baller bearing
base flange for spool holder
wire feed motor

1,00
1,00
1,00
1,00
1,00
1,00
2,00
1,00
1,00
1,00
2,00
1,00
1,00

1,00
5,00
1,00
2,00
2,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00

TEL.: +49 2191 463 10 0

info@tda-gmbh.de

FAX: +49 2191 463 10 11

nd TUBE EXPANDING

E-MAIL:

TUBE WELDING a
for HEAT EXCHANGER- an

d BOILER MANUFACTURES
d
d. Jul.12.2004

PARTSLIST
page:

orbital welding head type T-250

version 31.03
POS.
LABEL
NUMBER
96
179288096
97
179288097
98
179288098
99
129274041
100
129274041
101
179288101
103
179288103

ITEM

104
105
106
107
108
109
110
111
113
114
115
120
122
127
129
130
133
136

179288104
179288105
179288106
179288107
179288108
179288109
179288110
179288111
179288113
179288114
179288115
179288120
179288122
179288127
129274304
179288130
179288133
179288136

ESCRIPTION

wire nozzle
wire nozzle
wire nozzle fo
r wire guide h
ose
wire feeding h
ose
wire feeding h
ose
screw
spool hoder
spring
conter nut
friction plate
washer for spr
ing
nut
snap ring
Guide pin
Baller spring s
crew

baller bearing
snap ring
screw
baller bearing
current cable
screw
ceramic nozzle size 6
needle bearing
headless screw M3 x 8
headless screw M3 x 8

QUANTITY
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00
1,00

1,00
1,00
1,00
1,00
1,00
2,00
2,00
1,00
1,00
1,00
1,00
1,00
1,00

TEL.: +49 2191 463 10 0

FAX: +49 2191 463 10 11

E-MAIL: info@tda-gmbh.de