185 AC/DC ARCMASTER Operating Manual INVERTER ARC WELDER

185 AC/DC ARCMASTER Operating Manual INVERTER ARC WELDER
185 AC/DC
ARCMASTER
®
INVERTER ARC WELDER
Art # A-07227
Operating Manual
Version No: 1
Issue Date: February 20, 2006
Manual No.: 0-4861
Operating Features:
1
GTAW
SMAW
PHASE
50Hz
60
INVERTER
208 230
V
V
CC
AC
DC
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud
to have you as our customer and will strive to provide you with
the best service and reliability in the industry. This product is backed
by our extensive warranty and world-wide service network. To
locate your nearest distributor or service agency call
1-800-752-7621, or visit us on the web at www.thermalarc.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid
potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural
and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
ArcMaster 185 AC/DC Inverter Arc Welder
Instruction Manual Number 0-4861 for:
Part Number 10-3073
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2006 by
Thermadyne Industries Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: February 20, 2006
Record the following information for Warranty purposes:
Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01
1.02
1.03
1.04
1.05
Arc Welding Hazards ...................................................................................... 1-1
Principal Safety Standards ............................................................................. 1-4
Precautions de Securite en Soudage à l’Arc ................................................... 1-5
Dangers Relatifs au Soudage à l’Arc ............................................................... 1-5
Principales Normes de Securite ..................................................................... 1-8
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Symbol Chart ................................................................................................. 2-2
2.05 Description ..................................................................................................... 2-3
2.06 Functional Block Diagrams ............................................................................. 2-4
2.07 Transporting Methods .................................................................................... 2-4
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
Environment ................................................................................................... 3-1
Location ......................................................................................................... 3-1
Electrical Input Connections ........................................................................... 3-1
Electrical Input Requirements ........................................................................ 3-2
Input Power .................................................................................................... 3-3
High Frequency Introduction .......................................................................... 3-3
High Frequency Interference .......................................................................... 3-4
Duty Cycle ...................................................................................................... 3-4
Specifications ................................................................................................. 3-5
SECTION 4:
OPERATOR CONTROLS ............................................................................. 4-1
4.01
4.02
4.03
4.04
4.05
ArcMaster 185 AC/DC Controls ...................................................................... 4-1
Weld Process Selection for ArcMaster 185 AC/DC ......................................... 4-3
Weld Parameter Descriptions for ArcMaster 185 AC/DC ................................ 4-4
Weld Parameters for ArcMaster 185 AC/DC ................................................... 4-6
Power Source Features................................................................................... 4-7
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................. 5-1
TABLETABLE
OF CONTENTS
OF CONTENTS
(continued)
SECTION 6:
SEQUENCE OF OPERATION ........................................................................ 6-1
6.01 Stick Welding ................................................................................................. 6-2
6.02 AC or DC HF TIG Welding ............................................................................... 6-2
6.03 Slope Mode Sequence .................................................................................... 6-3
6.04 Slope Mode with Repeat Sequence ................................................................ 6-3
6.05 Pulse Controls ................................................................................................ 6-4
SECTION 7:
BASIC TIG WELDING GUIDE ....................................................................... 7-1
7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum ................. 7-1
7.02 Electrode Polarity ........................................................................................... 7-2
7.03 Tungsten Electrode Current Ranges ............................................................... 7-2
7.04 Tungsten Electrode Types ............................................................................... 7-2
7.05 Guide for Selecting Filler Wire Diameter ......................................................... 7-3
7.06 Shielding Gas Selection .................................................................................. 7-3
7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe .................. 7-3
7.08 Welding Parameters for Aluminum ................................................................ 7-4
7.09 Welding Parameters for Steel ......................................................................... 7-4
SECTION 8:
BASIC ARC WELDING GUIDE ..................................................................... 8-1
8.01 Electrode Polarity ........................................................................................... 8-1
8.02 Effects of Stick Welding Various Materials ..................................................... 8-1
SECTION 9:
ROUTINE MAINTENANCE .......................................................................... 9-1
SECTION 10:
BASIC TROUBLESHOOTING ...................................................................... 10-1
10.01 TIG Welding Problems ................................................................................ 10-1
10.02 Stick Welding Problems ............................................................................. 10-4
10.03 Power Source Problems ............................................................................. 10-7
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD) ........................................................... 11-1
11.01 VRD Specification ....................................................................................... 11-1
11.02 VRD Maintenance ....................................................................................... 11-1
11.03 Switching VRD On/Off ................................................................................ 11-2
TABLE OF CONTENTS
SECTION 12:
POWER SOURCE ERROR CODES ................................................................. 12-1
SECTION 13:
PARTS LIST ......................................................................................... 13-1
13.01 Equipment Identification ............................................................................. 13-1
13.02 How To Use This Parts List ......................................................................... 13-1
APPENDIX 1: GENERAL INFORMATION ................................................................. A-1
APPENDIX 2: ARCMASTER 185 AC/DC INTERCONNECTION DIAGRAM ............................ A-2
APPENDIX 3: ARCMASTER 185 AC/DC ACCESSORIES ............................................... A-4
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
ARCMASTER 185 AC/DC
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01
Arc Welding Hazards
7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
WARNING
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
ELECTRIC SHOCK can kill.
11. Do not touch electrode while in contact with the work (ground)
circuit.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit
and machine internal circuits are also live when power
is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
1. Do not touch live electrical parts.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
February 20, 2006
1-1
ARCMASTER 185 AC/DC
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
WARNING
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
WELDING can cause fire or explosion.
5. Use approved ear plugs or ear muffs if noise level is high.
Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
WARNING
FUMES AND GASES can be hazardous to your health.
1. Protect yourself and others from flying sparks and hot metal.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
2. Do not weld where flying sparks can strike flammable material.
1. Keep your head out of the fumes. Do not breath the fumes.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
3. If ventilation is poor, use an approved air-supplied respirator.
5. Watch for fire, and keep a fire extinguisher nearby.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
Electrode Size
Filter
2
3 or 4
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
3 or 4
4 or 5
5 or 6
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in.,
Over 1/4 in., 6.4 mm
4 or 5
5 or 6
6 or 8
10
12
14
Welding or cutting
Electrode Size
Gas metal-arc
Non-ferrous base metal
All
Ferrous base metal
All
Gas tungsten arc welding
All
(TIG)
All
Atomic hydrogen welding
All
Carbon arc welding
All
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp
Filter
11
12
12
12
12
12
12
14
9
12
14
February 20, 2006
ARCMASTER 185 AC/DC
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
WARNING
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
CYLINDERS can explode if damaged.
4. Do not overfill tank — allow room for fuel to expand.
Shielding gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to treat
them carefully.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
WARNING
MOVING PARTS can cause injury.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to prevent
falling or tipping.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
3. Keep cylinders away from any welding or other electrical circuits.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
4. Never allow a welding electrode to touch any cylinder.
2. Stop engine before installing or connecting unit.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
6. Turn face away from valve outlet when opening cylinder valve.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
!
WARNING
Engines can be dangerous.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
WARNING
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
ENGINE EXHAUST GASES can kill.
3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases.
4. Do not use welder to charge batteries or jump start vehicles.
1. Use equipment outside in open, well-ventilated areas.
5. Observe correct polarity (+ and –) on batteries.
February 20, 2006
1-3
ARCMASTER 185 AC/DC
1.02
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn
face, eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
3. Allow pressure to escape before completely removing cap.
!
WARNING
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some
cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
1-4
February 20, 2006
ARCMASTER 185 AC/DC
1.03
Precautions de Securite en Soudage à l’Arc
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de
sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.04
Dangers Relatifs au Soudage à l’Arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension
dès la mise en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou
la bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à la terre
est dangereux.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
1. Ne touchez pas à des pièces sous tension.
15. Fermez solidement tous les panneaux et les capots.
2. Portez des gants et des vêtements isolants, secs et non troués.
3
Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
February 20, 2006
1-5
ARCMASTER 185 AC/DC
AVERTISSEMENT
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements
et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
portez un respirateur à adduction d’air. Les gaz protecteurs de
soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
malaises ou la mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de
filtre oculaire
Brassage tendre
au chalumeau
toutes conditions
2
Brassage fort
au chalumeau
toutes conditions
3 ou 4
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dimensions
12
Oxycoupage
mince
moins de 1 po. (25 mm)
moyen de 1 á 6 po. (25 á 150 mm)
épais
plus de 6 po. (150 mm)
2 ou 3
4 ou 5
5 ou 6
Soudage aux gaz
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
Opération de coupage
ou soudage
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plasma (PAW)
mince
moins de 1/8 po. (3 mm)
moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais
Soudage á l'arc avec
électrode enrobees
(SMAW)
4 ou 5
Gougeage Air-Arc avec
électrode de carbone
5 ou 6
mince
12
plus de 1/2 po. (12 mm)
6 ou 8
épais
14
moins de 5/32 po. (4 mm)
10
5/32 á 1/4 po. (4 á 6.4 mm)
12
mince
moins de 300 amperès
9
plus de 1/4 po. (6.4 mm)
14
moyen
de 300 á 400 amperès
12
plus de 400 amperès
14
Coupage á l'arc Plasma (PAC)
épais
1-6
February 20, 2006
ARCMASTER 185 AC/DC
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que si
l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du
soudage.
AVERTISSEMENT
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un échauffement ou un
incendie.
2. Portez des vêtements appropriés pour protéger la peau.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
February 20, 2006
1-7
ARCMASTER 185 AC/DC
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de
faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
AVERTISSEMENT
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
1-8
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
1.05
Principales Normes de Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or part
numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as
follows:
!
WARNING
A WARNING gives information regarding
possible personal injury.
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
nameplate attached to the control panel. In some cases,
the nameplate may be attached to the rear panel.
Equipment which does not have a control panel such as
gun and cable assemblies is identified only by the
specification or part number printed on the shipping
container. Record these numbers on the bottom of page
1 for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
claim. Furnish complete information concerning damage
claims or shipping errors to the location in your area
listed in the inside back cover of this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
CAUTION
A CAUTION refers to possible equipment
damage.
Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number
given in the next section. Include the Owner’s Manual
number and equipment identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
February 20, 2006
2-1
ARCMASTER 185 AC/DC
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
2-2
Spot Time
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
IPM
Inches Per Minute
Line Connection
Touch Start (GTAW)
MPM
Meters Per Minute
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
Voltage Input
t
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
Disturbance In
Ground System
Art # A-04130
115V 15A
X
%
February 20, 2006
ARCMASTER 185 AC/DC
2.05 Description
The Thermal Arc™ Model 185 AC/DC is a self contained
single-phase AC/DC arc welding power source with
Constant Current (CC) output characteristics. This unit
is equipped with a Digital Volt/Amperage Meter, gas
control valve, built in Sloper and Pulser, lift arc starter,
and high-frequency arc starter for use with Gas Tungsten
Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed
(GTAW-P) Gas Tungsten Arc Welding-Sloped (GTAW-S),
and Shielded Metal Arc Welding (SMAW) processes. The
power source is totally enclosed in an impact resistant,
flame retardant and non-conductive plastic case.
(V)
CCV
Art # A-04980
5A
NOTE
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the
welding power source. Curves of other settings will fall between the curves shown.
160A
(A)
185A
LIFT TIG Process
(A)
185A
(A)
STICK Process
(V)
CCV
10V
25A
(V)
CCV
5A
HF TIG Process
Figure 2-1: Model 185 AC/DC Volt-Ampere curve
February 20, 2006
2-3
ARCMASTER 185 AC/DC
2.06 Functional Block Diagrams
Figure 2-2 illustrates the functional block diagram of the 185 AC/DC-power supply.
DC Power
Secondary
Voltage Sensor
Input
Power
Main
Circuit
Switch
Filter
Input
Diode
Capacitor
DC Power
Primary
Voltage
Sensor
To each control circuit
+/-12VDC +15VDC
IGBT
Inverter
Thermal
Detector
Main
Transformer
(PCB14)
Output
Diodes
Thermal
Detector
Output
Inductor
Hall Current
Secondary
IGBT
Inverter
Transformer
(HCT1)
Coupling
Coil
To each control circuit Drive Themal
Sensor
+/-15VDC +18VDC
Circuit Circuit
+24VDC +5VDC
HF-UNIT Stick Mode Lift Tig Mode
Control
VRD
Output Short
Circuit
Sensing
Sensing
Circuit
Circuit
+
Sequence
Control
Torch Control
Connection
(CON1)
-
Drive
Circuit
High
Frequency
Unit
Primary
Current
Sensor
Trouble
Sensing
Circuit
+
Fan Control
Circuit
Fan
Gas Control
Circuit
Solenoid
Current
Reference
Adjustment
Adjustment &
circuit
Mode select Switches
Panel Circuit Board
Art # A-07267
Figure 2-2: 185 AC/DC Model Functional Block Diagram
2.07 Transporting Methods
This unit is equipped with a handle for carrying purposes.
!
WARNING
• Use handcart or similar device of adequate capacity.
• If using a fork lift vehicle, place and secure unit on a
proper skid before transporting.
ELECTRIC SHOCK can kill. DO NOT TOUCH
live electrical parts. Disconnect input power
conductors from de-energized supply line
before moving the welding power source.
!
WARNING
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
• Lift unit with handle on top of case.
2-4
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 3:
INSTALLATION
3.01 Environment
The ArcMaster 185 AC/DC is designed for use in adverse
environments.
Examples of environments with increased adverse
conditions are:
a. In locations in which freedom of movement is
restricted, so that the operator is forced to perform the
work in a cramped (kneeling, sitting or lying) position
with physical contact with conductive parts;
b. In locations which are fully or partially limited by
conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator;
3.03 Electrical Input Connections
!
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input
power employing lockout/tagging procedures. Lockout/
tagging procedures consist of padlocking line disconnect
switch in open position, removing fuses from fuse box,
or shutting off and red-tagging circuit breaker or other
disconnecting device.
c. In wet or damp hot locations where humidity or
perspiration considerably reduces the skin resistance of
the human body and the insulation properties of
accessories.
Environments with adverse conditions do not include
places where electrically conductive parts, in the near
vicinity of the operator, which can cause increased hazard,
have been insulated.
3.02 Location
Be sure to locate the welder according to the following
guidelines:
· In areas, free from moisture and dust.
· Ambient temperature between 0 degrees C to 40
degrees C.
· In areas, free from oil, steam and corrosive gases.
· In areas, not subjected to abnormal vibration or
shock.
· In areas, not exposed to direct sunlight or rain.
· Place at a distance of 12" (304.79mm) or more from
walls or similar boundaries that could restrict natural
airflow for cooling.
!
WARNING
Thermal Arc advises that this equipment be
electrically connected by a qualified electrician.
Februrary 20, 2006
3-1
ARCMASTER 185 AC/DC
Do not connect an input (WHITE or BLACK) conductor to
the ground terminal.
3.04 Electrical Input Requirements
Operate the welding power source from a single-phase
50/60 Hz, AC power supply. The input voltage must match
one of the electrical input voltages shown on the input
data label on the unit nameplate. Contact the local electric
utility for information about the type of electrical service
available, how proper connections should be made, and
any inspection required.
The line disconnect switch provides a safe and convenient
means to completely remove all electrical power from
the welding power supply whenever necessary to inspect
or service the unit.
Do not connect the ground (GREEN) conductor to an input
line terminal.
Refer to Figure 3-1 and:
1. Connect end of ground (GREEN) conductor to a
suitable ground. Use a grounding method that complies
with all applicable electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE)
input conductors to a de-energized line disconnect switch.
3. Use Table 3-1 and Table 3-2 as a guide to select line
fuses for the disconnect switch.
NOTE
This unit is equipped with a 250 VAC (NEMA 6-50P) plug molded on the two-conductor with earth power
cable that is connected at the welding power source for single phase electrical input power. For direct
wiring installation have a qualified person install according to all applicable codes and instructions.
Input Voltage
208V
230V
Fuse Size
60 Amps
50 Amps
Table 3-1: Electrical Input Connections
NOTE
Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source
(Based on Article 630, National Electrical Code).
Welding Power Supply
Ground Terminal
Ground Conductor
Line Disconnect Switch
Line Fuse
Primary Power Cable
Art # A-07268
Figure 3-1: Electrical Input Connections
3-2
February 20, 2006
ARCMASTER 185 AC/DC
3.05 Input Power
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is
turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly
(PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).
NOTE
Note the available input power. Damage to the PCA could occur if 575VAC or higher is applied.
The following 208/230V Primary Current recommendations are required to obtain the maximum welding current and
duty cycle from this welding equipment:
Model
ArcMaster
185AC/DC
Primary Supply Minimum Primary Current & Duty Cycle
Lead Size
Current Circuit Size
TIG
STICK
(Factory Fitted)
(Vin/Amps)
230/30
185 @ 30%
12/3 AWG
208/33
minimum
230/34
160 @ 40%
208/38
-
Table 3-2 208-230V/ Primary Current Circuit sizes to achieve maximum current
The ARC MASTER 185 AC/DC is designed for use with a generator as an input power source. Contact an accredited
Thermal Arc service agent for the proper sizing and set-up recommendations of a generator power source system. As
a general rule, depending on the type of generator used, the generator capacity should be twice the maximum rating
of the welder.
3.06 High Frequency Introduction
The importance of correct installation of high frequency
welding equipment cannot be over-emphasized.
Interference due to high frequency initiated or stabilized
arc is almost invariably traced to improper installation.
The following information is intended as a guide for
personnel installing high frequency welding machines.
!
WARNING: EXPLOSIVES
The high frequency section of this machine
has an output similar to a radio transmitter.
The machine should NOT be used in the
vicinity of blasting operations due to the
danger of premature firing.
!
WARNING: COMPUTERS
It is also possible that operation close to
computer installations may cause computer
malfunction.
Februrary 20, 2006
3-3
ARCMASTER 185 AC/DC
3.07 High Frequency Interference
3.08 Duty Cycle
Interference may be transmitted by a high frequency
initiated or stabilized arc welding machine in the following
ways:
The duty cycle of a welding power source is the percentage
of a ten (10) minute period that it can be operated at a
given output without causing overheating and damage to
the unit. If the welding amperes decrease, the duty cycle
increases. If the welding amperes are increased beyond
the rated output, the duty cycle will decrease.
1. Direct Radiation: Radiation from the machine can
occur if the case is metal and is not properly grounded.
It can occur through apertures such as open access
panels. The shielding of the high frequency unit in
the Power Source will prevent direct radiation if the
equipment is properly grounded.
2. Transmission via the Supply Lead: Without adequate
shielding and filtering, high frequency energy may be
fed to the wiring within the installation (mains) by
direct coupling. The energy is then transmitted by
both radiation and conduction. Adequate shielding
and filtering is provided in the Power Source.
3. Radiation from Welding Leads: Radiated interference
from welding leads, although pronounced in the
vicinity of the leads, diminishes rapidly with distance.
Keeping leads as short as possible will minimize this
type of interference. Looping and suspending of leads
should be avoided where possible.
4. Re-radiation from Unearthed Metallic Objects:
A major factor contributing to interference is reradiation from unearthed metallic objects close to the
welding leads. Effective grounding of such objects
will prevent re-radiation in most cases.
!
WARNING
Exceeding the duty cycle ratings will cause the
thermal overload protection circuit to become
energized and shut down the output until the
unit has cooled to normal operating
temperature.
CAUTION
Continually exceeding the duty cycle ratings
can cause damage to the welding power
source and will void the manufactures warranty.
NOTE
Due to variations that can occur in
manufactured products, claimed performance,
voltages, ratings, all capacities,
measurements, dimensions and weights
quoted are approximate only. Achievable
capacities and ratings in use and operation will
depend upon correct installation, use,
applications, maintenance and service.
3-4
February 20, 2006
ARCMASTER 185 AC/DC
3.09 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle
185ACDC
TIG
STICK
Output Current
TIG
Range
STICK
Open Circuit Voltage
Dimensions
Width
Height
Length
Weight
Output @ Rated Load
Rated Input Voltage
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Single Phase
208V
230V
185
18
30%
185A / 18V @ 30%
160A / 17V @ 60%
100A / 14V @ 100%
160A / 27V @ 40%
130A / 26V @ 60%
100A / 24V @ 100%
5 – 185 (DC)
5 – 185 (AC) @ 60Hz, 50% Cleaning
5 – 160 (DC)
5 – 160 (AC) @ 60Hz, 50% Cleaning
65V
7.08” (180mm)
14.7” (360mm)
16.54” (420mm)
37.4 lb. 17 kg
Single phase
208-230 VAC
160A
27V
40%
8.7
5.2
0.5
0.3
Amperage Draw @ Rated Load
38
34
No Load Amps
2.2
1.6
Table 3-3: Parameter Specifications
Februrary 20, 2006
3-5
ARCMASTER 185 AC/DC
NOTES
3-6
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 4:
OPERATOR CONTROLS
4.01 ArcMaster 185 AC/DC Controls
Art # A-04983
6
7
1
2
5
4
3
8
Figure 4-1: ArcMaster 185 AC/DC Power Source
1. Control Knob: This control sets the selected weld
parameter, rotating it clockwise increases the parameter
that is indicated on the digital meter. Pushing the knob
inward displays the actual welding voltage.
2 . Remote Control Socket: The 8 pin Remote Control
Socket is used to connect remote current control
devices to the welding Power Source. To make
connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
GND
2
1
Art # A-04984
Socket Pin
Function
1
Earth (Ground)
Torch Switch Input (24V) to
2
3
4
12345678
5
4
3
8
7
6
5
5k Ohms
6
Figure 4-2: 8-Socket Receptacle
7
8
(connect pins 2 & 3 to turn on
welding current)
Torch Switch Input (0V) to
energize weld current (connect
pins 2 & 3 to turn on welding
current)
Connect pin 4 to pin 8 to instruct
machine that a remote current
control device is connected (12V
DC supply)
5k ohm (maximum) connection
to 5k ohm remote control
potentiometer
Zero ohm (minimum) connection
to 5k ohm remote control
potentiometer
Wiper arm connection to 5k ohm
remote control potentiometer
Connect pin 4 to pin 8 to instruct
machine that a remote current
control device is connected (0V)
Table 4-1: Socket Pin Functions
February 20, 2006
4-1
ARCMASTER 185 AC/DC
3. Positive Terminal: Welding current flows from the
Power Source via heavy duty Dinse type terminal. It
is essential, however, that the male plug is inserted
and turned securely to achieve a sound electrical
connection.
4. Negative Terminal: Welding current flows from the
Power Source via heavy duty Dinse type terminal. It
is essential, however, that the male plug is inserted
and turned securely to achieve a sound electrical
connection.
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the bayonet terminal.
6. ON/OFF Switch: This switch connects the Primary
supply voltage to the inverter when in the ON position.
This enables the Power Supply.
!
WARNING
When the welder is connected to the Primary
supply voltage, the internal electrical
components may be at 240V potential with
respect to earth.
7. Input Cable: The input cable connects the Primary
supply voltage to the equipment.
8 . Gas Inlet: The Gas Inlet is a 5/8 –18 UNF female gas
fitting.
5. Gas Outlet: The Gas Outlet is a 5/8 –18 UNF female gas
fitting.
4-2
February 20, 2006
ARCMASTER 185 AC/DC
4.02 Weld Process selection for ArcMaster 185 AC/DC
Weld Mode
Weld Process
Selection
STICK
HF
TIG
LIFT
TIG
Yes
Yes
Yes
2T operation in TIG Modes using remote
devices to control contactor & current.
Yes
SLOPE
4T operation in TIG Modes with crater
fill using a remote contactor device to
control sequence.
REPEAT
STD
No
Yes
No
Yes
Yes
4T operation in TIG Modes with repeat
operation and crater fill using a remote
contactor device.
No
Yes
No
2T operation spot welding in HF TIG
using a remote contactor device.
No
Yes
Yes
Pulse operation in TIG Modes.
Yes
Yes
Yes
Selects AC or DC weld current.
Yes
No
Yes
Contactor operation in Stick Mode.
Yes
Yes
Yes
Selects in operation Panel board
or Remote.
SPOT
PULSE ON/OFF
Description
Contactor ON/OFF
Operation
PANEL/REMOTE
Table 4-2: Weld Process selection versus Weld Mode for ArcMaster 185 AC/DC
February 20, 2006
4-3
ARCMASTER 185 AC/DC
4.03 Weld Parameter Descriptions for ArcMaster 185 AC/DC
Art # A-07237
Figure 4-3: ArcMaster 185 AC/DC Front Panel
Parameter
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
Description
This parameter operates in TIG modes only and is used to provide gas
to the weld zone prior to striking the arc, once the torch trigger switch
has been pressed. This control is used to dramatically reduce weld
porosity at the start of a weld.
This parameter operates in all weld modes except Lift TIG mode and
is used to heat up the weld zone in TIG modes or improve the start
characteristics for stick electrodes. e.g. low hydrogen electrodes.
It sets the peak start current on top of the BASE (WELD) current.
e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps
& HOT START = 30 amps.
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and
is used to set the start current for TIG. The Start Current remains on until
the torch trigger switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to set the time
for the weld current to ramp up, after the torch trigger switch has been
pressed then released, from INITIAL CUR to PEAK or BASE current.
Table 4-3: ArcMaster 185 AC/DC Front Panel Parameter Description
4-4
February 20, 2006
ARCMASTER 185 AC/DC
PEAK CUR.
WELD
This parameter sets the PEAK weld current when in PULSE mode
This parameter sets the TIG WELD current in STD , SLOPE , REPEAT and
SPOT modes when PULSE is OFF. This parameter also sets the STICK
weld current.
This parameter sets the Background current when in Pulse TIG mode.
BASE
(BackgroundCurrent)
SPOT TIME
This parameter sets the duration of the SPOT TIME in HF TIG mode only
PULSE WIDTH
This parameter sets the percentage on time of the PULSE FREQUENCY
for PEAK weld current when the PULSE is ON.
PULSE FREQ.
This parameter sets the PULSE FREQUENCY when the PULSE is ON.
AC FREQUENCY
This parameter operates in AC mode only and is used to set the
frequency for the AC weld current.
WAVE BALANCE
This parameter is used for aluminum AC TIG mode and is used to set the
penetration to cleaning action ratio for the AC weld current. Generally
WAVE BALANCE is set to 50% for AC STICK welding. The WAVE
BALANCE control changes the ratio of penetration to cleaning action of
the AC TIG welding arc. Maximum weld penetration is achieved when
the WAVE BALANCE control is set to 10%. Maximum cleaning of heavily
oxidised aluminium or magnesium alloys is achieved when the WAVE
BALANCE control is set to 65%.
WAVE BALANCE=50%
50%
10%
(+ )
CRATER CUR.
POST-FLOW
WAVE BALANCE=65%
65%
(+ )
(+ )
(-)
(-)
(-)
50%
90%
35%
Balanced with 50% pen etration
an d 50% cle an in g
DOWN SLOPE
WAVE BALANCE=10%
M aximu m Pen etratio n and
redu ced cleaning
Maximum Cle an in g and
red uced pen etration
This parameter operates in TIG modes only and is used to set the time
for the weld current to ramp down, after the torch trigger switch has
been pressed, to CRATER CUR. This control is used to eliminate the
crater that can form at the completion of a weld.
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and
is used to set the finish current for TIG. The CRATER Current remains ON
until the torch trigger switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to adjust the
post gas flow time once the arc has extinguished. This control is used to
dramatically reduce oxidation of the tungsten electrode.
The SAVE/LOAD buttons are used to save and retrieve a total number of
5 programs into the 185 AC/DC memory.
Table 4-3 (continued): ArcMaster 185 AC/DC Front Panel Parameter Description
February 20, 2006
4-5
ARCMASTER 185 AC/DC
4.04 Weld Parameters for ArcMaster 185 AC/DC
Weld Mode
HF
STICK
TIG
Weld
Parameter
Parameter
Range
Factory
Setting
Incremental
Unit
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
PULSE PEAK CUR.
PULSE BASE CUR.
WELD CUR.
(TIG)
WELD CUR.
(STICK)
SPOT TIME
PULSE WIDTH
0.0 to 1.0 sec
0 to 70A
5 to 185A
0 to 15 sec
5 to 185A
5 to 185A
0 sec
20A
30A
1 sec
120A
5A
0.1 sec
1A
1A
0.1 sec
1A
1A
No
Yes
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
LIFT
TIG
Yes
No
Yes
Yes
Yes
Yes
5 to 185A
80A
1A
No
Yes
Yes
5 to 160A
80A
1A
Yes
No
No
0.5 to 5.0 sec
15 to 80%
2 sec
50%
No
No
Yes
Yes
Yes
Yes
PULSE FREQ.
0.5 to 500Hz
100.0Hz
No
Yes
Yes
AC FREQUENCY
WAVE BALANCE
DOWN SLOPE
CRATER CUR.
POST-FLOW
15 to 150Hz
10 to 65%
0 to 25 sec
5 to 200A
0.0 to 60 sec
60Hz
20%
3 sec
30A
10 sec
0.1 sec
1%
See
Table 4-5
1Hz
1%
0.1 sec
1A
0.1 sec
Yes
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Table 4-4: Weld Parameters for ArcMaster 185 AC/DC
PULSE FREQ. Range
0.5 to 20Hz
20 to 100Hz
100 to 500Hz
4-6
Incremental Unit
0.1Hz
1Hz
5Hz
February 20, 2006
ARCMASTER 185 AC/DC
4.05 Power Source Features
Feature
Description
New Digital Control
• Almost all welding parameters are adjustable.
Touch Panel Switches
• Touch switches eliminate mechanical damage.
Front Control Cover
• Protects front panel controls.
Digital Meter
• Displays selected weld parameter value.
• Displays weld current when welding.
• Displays weld current for 20 seconds after weld has
been completed.
• A selected weld parameter value can be adjusted at
any time even while welding.
Intelligent Fan Control
• The intelligent cooling system is designed to reduce
dust and foreign material build-up, whilst providing
optimum cooling.
• Fan speed reduces approximately 30 seconds after
machine is turned ON.
• Fan speed increases when internal components
reaches operating temperature.
ON/OFF Switch
• Primary voltage Supply ON/OFF switch located on
rear panel.
Voltage Reduction Device (VRD)
Reduces the OCV when the power supply is not in use.
Eliminates the need for add on voltage reducers and has
(shipped de-activated, field capable)
no effect on arc starting.
See Section 11 for activation instructions • VRD fully complies to IEC 60974-1.
• When Stick mode is selected the green VRD light is
ON when not welding and red when welding.
• When in TIG modes VRD is OFF.
Control Knob
• For the selected weld parameter, rotating the knob
clockwise increases the parameter.
• Rotating the knob counter-clockwise decreases the
parameter.
• A selected weld parameter value can be adjusted at
any time even while welding.
• Pushing the knob in displays actual arc voltage.
Self Diagnosis using Error Codes
• An error code is displayed on the Digital Meter when a
problem occurs with Primary supply voltage or internal
component problems. Refer to troubleshooting guide.
Table 4-6:Power Source Features
February 20, 2006
4-7
ARCMASTER 185 AC/DC
Feature
Save/Load Function
Description
•
A total number of 5 programs can be saved into the
185AC/DC memory.
SAVE the Current Weld Parameters into Memory
• Press and HOLD the SAVE button. Beep will sound and
the Digital Meter will show a number 1.
• Select a memory location by rotating the control knob,
1 to 5 is displayed on the meter.
• After selecting the desired memory location (i.e. 1 to 5),
press the right scroll button and the machine will give a
beep to confirm the weld parameters from the control
panel are saved.
LOAD (retrieve) a Program to Control Panel
• Press and HOLD the LOAD button. Beep will sound and
the Digital Meter display will show a number 1.
• Select a memory location by rotating the control knob,
1 to 5 is displayed on the meter.
After selecting the desired memory location (i.e. 1 to 5),
press the right scroll button and the machine will give a
beep to confirm the weld parameters are loaded onto the
control panel.
Table 4-6:Power Source Features con't
4-8
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the
Welding Power Source, i.e. connect work lead directly to
work piece and electrode lead is used to hold electrode.
Wide safety margins provided by the coil design ensure
that the Welding Power Source will withstand short-term
overload without adverse effects. The welding current
range values should be used as a guide only. Current
delivered to the arc is dependent on the welding arc
voltage, and as welding arc voltage varies between
different classes of electrodes, welding current at any one
setting would vary according to the type of electrode in
use. The operator should use the welding current range
values as a guide, then finally adjust the current setting
to suit the application.
!
WARNING
Before connecting the work clamp to the work
and inserting the electrode in the electrode
holder make sure the Primary power supply
is switched off.
CAUTION
Remove any packaging material prior to use.
Do not block the air vents at the front or rear
or sides of the Welding Power Source.
Art # A-07271
Figure 5-1: 185 AC/DC Set-up
CAUTION
DO NOT change the Weld Mode or Weld Process Mode until after POST-FLOW time has
finished.
February 20, 2006
5-1
ARCMASTER 185 AC/DC
NOTES
5-2
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 6:
SEQUENCE OF OPERATION
Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being
adjusted on the weld sequence graph. Refer to the Symbols Table located in the front of the manual for
Symbol descriptions.
9
1
10
2
5
8
3
7
4
6
Art # A-07272
Figure 6-1: 185 AC/DC Front Panel
1. Pulse Function: Pressing this button enables the TIG current pulse functions.
2. Remote Current Function: Pressing this buttons enables remote current functions.
3. TIG Mode Functions: Pressing this button scrolls through the output TIG function modes (Standard, Slope,
Slope w/repeat, Spot).
4. Digital LED Display: Welding amperage and parameter values are displayed in this window. Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by a warning
sound and error message on the screen.
5. Save/Load Buttons: By using the Save & Load buttons the operator can easily save up to 5 welding parameter programs.
6. Control Knob: Allows the operator to adjust the output amperage within the entire range of the power source
and sets each parameter value.
7. Process Button: This button selects between STICK, HF TIG and Lift TIG mode.
8. Scroll Buttons: Used to select the parameters to be set. The LED’s show which function is being adjusted on
the Sequence Graph.
9. AC/DC Button: Selects between AC or DC welding output.
10. Contactor Function: Pressing this buttons enables Contactor functions
February 20, 2006
6-1
ARCMASTER 185 AC/DC
6.01 Stick Welding
6.02 AC or DC HF TIG Welding
· Connect work lead to negative terminal
· Connect work lead to positive terminal
· Connect electrode lead to positive terminal
· Connect TIG torch to negative terminal
· Switch machine on
· Switch machine on
· Set AC or DC weld current. If AC is selected then set
AC FREQ to 60Hz & WAVE BALANCE to 50%.
· Set AC or DC weld current. If AC is selected then set
AC FREQ & WAVE BALANCE
· Set Contractor
· Connect remote control device if required
· Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be
set. The LED will show which function is being adjusted
on the weld sequence graph. Use the control knob to
adjust each parameter.
· Set HOT START
· Set WELD current
Commence welding
Use the Scroll Buttons to move to the parameter to be
set. The LED will show which function is being adjusted
on the weld sequence graph. Use the control knob to
adjust each parameter.
· Set PRE-FLOW time
· Set HOT START current
· Set POST-FLOW time
· Set (WELD) PEAK CUR current
· Set POST-FLOW time
Slope Mode Parameters if required
· Set INITIAL CUR current
· Set UP SLOPE time
· Set (WELD) PEAK CUR current
· Set BASE current
· Set DOWN SLOPE time
· Set CRATER CUR current
Pulse Mode parameters if required
· Set PULSE WIDTH % for PEAK CURRENT
· Set PEAK CURRENT
· Set PULSE FREQ
Commence welding
6-2
February 20, 2006
ARCMASTER 185 AC/DC
6.03 Slope Mode Sequence
Art # A-04989
Switch
Closed
Initial
Current
Switch
Open
Up
Slope
Switch
Closed
Weld Current
Down
Slope
Switch
Open
Final
Current
Postflow
Preflow
Figure 6-2: Slope Mode Sequence
NOTE
Slope function operates with a Remote
ON/OFF device only
1. To start Slope sequence Close remote switch contacts.
Once the welding arc is established the Power Source
will maintain initial current setting as long as the
remote switch contacts are closed.
2. Open Remote Switch – current increases to weld
current. Once welding arc has reached weld current
the power source will maintain weld current as long
as the remote switch contacts are open.
a. In the HF TIG mode, after Preflow time, High
Frequency is present at the torch. When the torch
is positioned close to the work the welding current
will transfer to the work and establish the arc at
the initial current setting.
3. Close Remote Switch – Welding current decreases to
final current setting. Once final welding current is
reached the power source will maintain final current
setting as long as the remote switch contacts are
closed.
b. In the Lift TIG mode, after Preflow time, Lift Start
current is present at the torch. When the electrode
is touched to the work and lifted off, the welding
arc is established at the initial current setting.
4. Open Remote Switch – Welding arc stops and post
flow begins.
6.04 Slope Mode with Repeat Sequence
The repeat function is operated during the down slope
cycle of the Slope Sequence and is active through the
down slope period only. During the down slope period,
by opening the Remote Switch contacts, the current will
increase back to weld current. Within the Down Slope
period the repeat function can be operated as many times
as desired. To continue slope cycle and end slope
sequence close remote switch contacts and allow weld
current to reach final current setting. Once final current
setting is reached, opening the Remote Switch again will
turn off the welding arc and post flow begins.
February 20, 2006
6-3
ARCMASTER 185 AC/DC
6.05 Pulse Controls
(Pulse Width)
(Pulse Frequency)
Art # A-04990
(Peak Current)
(Base)
Background
Current
Figure 6-3: Pulse Controls
The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows:
1) Control puddle – size and fluidity (especially out of position).
2) Increase penetration
3) Travel speed control
4) Better consistent quality
5) Decreased distortion on lighter or thinner materials
Pulse-current provides a system in which the welding current continuously changes between two levels. During the
periods of Peak current, heating and fusion takes place, and during the background (base) current periods, cooling
and solidification take place. Pulse Width is the time in one cycle the current remains at the peak current setting.
Pulse Frequency, measured in Hertz, is the number of cycles per second the current travels between peak and background
current settings. It is as if the foot rheostat were moved up and down to increase and decrease the welding current on
a regular basis. The faster you moved the foot rheostat up and down the faster the frequency.
6-4
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 7:
BASIC TIG WELDING GUIDE
7.01 Explanation of “Fluttery Arc” when
AC TIG Welding on Aluminum
The following will assist in understanding the
phenomenon of Arc Flutter, also referred to as Arc
Rectification.
The basic thesis is that the fluttering is caused by lack of
oxide in the weld pool.
The oxide layer on the plate reduced the energy for
electron emission. Electron emission from the weld pool
(DC+) causes the oxide layers to be disrupted, the socalled “cleaning action”. However once the cleaning action
has produced a mirror like surface on the weld pool, the
effect of the oxide layer is limited because the oxide layer
has dissipated. This makes electron emission from the
weld pool more difficult and increases the chance of arc
instability.
This idea is supported by the observation that once
fluttering starts it can be made to stop by working the arc
away from the mirror like weld pool to an area of oxide
coated material. As soon as this is done the arc settles
back to a stable condition. So while the arc is “consuming”
oxide coated plate the instability does not occur. But once
the arc is stationary, the pool becomes thoroughly
“cleaned” by election emission, the fluttering begins.
Tests conducted on various types of AC TIG power
sources, Fluttery Arc is not confined to one type of power
source or its' design, both conventional and inverter types
suffer from the same problem.
AC TIG on aluminum
1. The Problem: Arc appears unstable and pulses or flutters. ie. appears to rapidly change welding current.
Conditions that accentuate arc flutter:
Conditions that minimizes arc flutter:
• Cold work piece
• Preheat the work piece
• Very short arc length
• Increase the arc length
• Weld pool crater about 0.39” to 0.47”
(10 to 12mm) diameter
• Introduce filler rod material to the weld
pool, which introduces oxides
• Arc field in one spot to produce
“mirror” clean weld pool
• Move the weld pool around to introduce
oxides to the weld pool
• Increased cleaning action
i.e. Prolonged oxide emission from a
stationary weld pool increases the
likelihood of arc flutter
• Decrease the cleaning action by turning
the WAVE BALANCE to below 50% or
move the weld pool around
• Accentuated when tungsten running
near its current capacity, i.e. Molten ball
on end
• Use a larger diameter tungsten electrode
Table 7-1: Reduction of Arc Flutter
2. Conclusion: Fluttery Arc in AC TIG is a physical phenomenon independent of machine design.
February 20, 2006
7-1
ARCMASTER 185 AC/DC
7.02 Electrode Polarity
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight
polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of
the electrode since 70% of the heat is concentrated at the work piece.
7.03 Tungsten Electrode Current Ranges
Electrode Diameter
0.040” (1.0mm)
1/16” (1.6mm)
3/32” (2.4mm)
1/8” (3.2mm)
5/32” (4.0mm)
3/16” (4.8mm)
AC Current (Amps)
30 – 70
60 – 95
125 – 150
130 – 225
190 – 280
250 – 340
DC Current (Amps)
30 – 60
60 – 115
100 – 165
135 – 200
190 – 280
250 – 340
Table 7-2: Current ranges for various tungsten electrode sizes
7.04 Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Zirconated 1%
Ceriated 2%
Welding Application
Features
DC welding of mild steel,
stainless steel and copper
Excellent arc starting, long life,
high current carrying capacity
High quality AC welding of
aluminium, magnesium and
their alloys
Self cleaning, long life,
maintains balled end, high
current carrying capacity
AC & DC welding of mild
steel, stainless steel, copper,
aluminium, magnesium and
their alloys
Longer life, more stable arc,
easier starting, wider current
range, narrower more
concentrated arc
Color
Code
Red
White
Grey
Table 7-3: Tungsten Electrode Types
7-2
February 20, 2006
ARCMASTER 185 AC/DC
7.05 Guide for Selecting Filler Wire Diameter
NOTE
The filler wire diameter specified in Table 7-4 is a guide only, other diameter wires may be used according
to the welding application
Filler Wire Diameter
1/16” (1.6 mm)
3/32” (2.4 mm)
1/8” (3.2 mm)
3/16” (4.8 mm)
AC Current Range
(Amps)
30 - 95
125 - 160
180 - 240
220 - 320
DC Current Range
(Amps)
20 - 90
65 - 115
100 - 165
200 - 350
Table 7-4: Filler Wire Selection Guide
7.06 Shielding Gas Selection
Alloy
Aluminium & alloys
Carbon Steel
Stainless Steel
Nickel Alloy
Copper
Titanium
Shielding Gas
Argoshield is a registered trademark of BOC Gases Limited.
Welding Argon, Argoshield 80T, 81T
Welding Argon
Welding Argon, Argoshield 71T, 80T, 81T
Welding Argon, Argoshield 71T
Welding Argon, Argoshield 81T
Welding Argon, Argoshield 80T, 81T
Table 7-5: Shielding Gas Selection
7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Current Range DC
Amperes
120 - 170
Filler Rod for
Root Pass
Yes
100 - 160
Yes
90 - 130
No
Joint Preparation
Table 7-6: TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
February 20, 2006
7-3
ARCMASTER 185 AC/DC
7.08 Welding Parameters for Aluminum
Base Metal
Thickness
AC Current for
Aluminum
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
30-45
35-50
40-60
45-70
60-85
70-95
125-150
130-160
3/16”
4.8mm
¼”
6.4mm
180-225
190-240
240-280
250-320
Tungsten
Electrode
Diameter
0.040”
1.0mm
0.040”
1.0mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
1/8”
3.2mm
3/16”
4.8mm
Filler Rod
Diameter
(if required)
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
3/16”
4.8mm
Argon Gas
Flow Rate
Liters/min
5-7
5-7
7
10
10
13
Joint Type
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Table 7-7: AC TIG Welding Parameters
7.09 Welding Parameters for Steel
Base Metal
Thickness
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
3/16”
4.8mm
¼”
6.4mm
DC Current DC Current for Tungsten Filler Rod Argon Gas
for Mild
Stainless
Electrode Diameter Flow Rate
Steel
Steel
Diameter (if required) Liters/min
35-45
20-30
0.040”
1/16”
5-7
40-50
25-35
1.0mm
1.6mm
45-55
30-45
0.040”
1/16”
5-7
50-60
35-50
1.0mm
1.6mm
60-70
40-60
1/16”
1/16”
7
70-90
50-70
1.6mm
1.6mm
80-100
65-85
1/16”
3/32”
7
90-115
90-110
1.6mm
2.4mm
115-135
100-125
3/32”
1/8”
10
140-165
125-150
2.4mm
3.2mm
160-175
135-160
1/8”
5/32”
10
170-200
160-180
3.2mm
4.0mm
Joint Type
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Table 7-8: DC TIG Welding Parameters
7-4
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 8:
BASIC ARC WELDING GUIDE
8.01 Electrode Polarity
Stick electrodes are generally connected to the ‘+’ terminal
and the work lead to the ‘-’ terminal but if in doubt consult
the electrode manufacturers literature.
8.02 Effects of Stick Welding Various
Materials
High Tensile and Alloy Ateels
Copper and Alloys
The two most prominent effects of welding these steels
are the formation of a hardened zone in the weld area,
and, if suitable precautions are not taken, the occurrence
in this zone of under-bead cracks. Hardened zone and
under-bead cracks in the weld area may be reduced by
using the correct electrodes, preheating, using higher
current settings, using larger electrodes sizes, short runs
for larger electrode deposits or tempering in a furnace.
The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections
necessary to give proper fusion of weld and base metal.
Manganese Steels
The effect on manganese steel of slow cooling from high
temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.
Types of Electrodes
Arc Welding electrodes are classified into a number of
groups depending on their applications. There are a great
number of electrodes used for specialized industrial purposes, which are not of particular interest for everyday
general work. These include some low hydrogen types
for high tensile steel, cellulose types for welding large
diameter pipes, etc. The range of electrodes dealt with in
this publication will cover the vast majority of applications likely to be encountered; are all easy to use and all
will work on even the most basic of welding machines.
Cast Iron
Most types of cast iron, except white iron, are weldable.
White iron, because of its extreme brittleness, generally
cracks when attempts are made to weld it. Trouble may
also be experienced when welding white-heart malleable,
due to the porosity caused by gas held in this type of
iron.
February 20, 2006
8-1
ARCMASTER 185 AC/DC
Metals being
joined
Electrode
Comments
Mild Steel
6013
Ideal electrodes for all general
purpose work. Features include
outstanding operator appeal, easy
arc starting and low spatter.
Mild Steel
7014
All positional electrode for use on
mild and galvanized steel furniture,
plates, fences, gates, pipes and
tanks etc. Especially suitable for
vertical-down welding.
Cast Iron
99% Nickel
Suitable for joining all cast irons
except white cast iron.
Stainless Steel
318L-16
High corrosion resistance. Ideal
for dairy work, etc.
Copper, Bronze,
Brass, etc.
Bronze
5.7 ERCUSI-A
Easy to use electrode for marine
fittings, water taps and valves,
water trough float arms, etc. Also
for joining copper to steel and for
bronze overlays on steel shafts.
312-16
It will weld most problematic jobs
such as springs, shafts, broken
joints, mild steel to stainless and
alloy steel.
Not suitable for Aluminium.
High alloy steels,
dissimilar metals,
crack resistant,
all hard-to-weld
jobs.
Table 8-1: Types of Electrodes
8-2
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 9:
ROUTINE MAINTENANCE
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency
depending on the usage and the operating environment.
The unit should be wiped clean as necessary with solvents that are recommended for cleaning electrical apparatus.
Turn Power Switch to OFF before proceeding. Internal cleaning of the unit should be done every 6 months by an
authorized Thermal Arc Service Center to remove any accumulated dirt and dust. This may need to be done more
frequently under exceptionally dirty conditions.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.
February 20, 2006
9-1
ARCMASTER 185 AC/DC
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions
Each Use
Visual check of torch
Consumable parts
Visual check of
regulator and pressure
Weekly
Visually inspect the torch
body and consumables
Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all
broken parts
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
Thermal Arc Service Center
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-07331
9-2
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 10:
BASIC TROUBLESHOOTING
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to
open or repair unless you are an accredited Thermal Arc Service Agent and you have had training in power
measurements and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an accredited
Thermal Arc Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
10.01 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper
welding technique.
Description
Possible Cause
Remedy
1 Excessive bead build-up
or poor penetration or
poor fusion at edges
of weld.
Welding current is too low.
Increase weld current and/or
faulty joint preparation.
2 Weld bead too wide and
flat or undercut at edges
of weld or excessive
burn through.
Welding current is too high.
Decrease weld current.
3 Weld bead too small or
insufficient penetration or
ripples in bead are widely
spaced apart.
Travel speed too fast.
Reduce travel speed.
4 Weld bead too wide or
excessive bead build up
or excessive penetration
in butt joint.
Travel speed too slow.
Increase travel speed.
Wrong placement of filler rod.
Re-position filler rod.
5 Uneven leg length in
fillet joint.
Table 10-1: TIG Welding Problems
February 20, 2006
10-1
ARCMASTER 185 AC/DC
Description
6
Possible Cause
Electrode melts when
arc is struck.
Remedy
A
Electrode is connected to the
‘+’ terminal.
A Connect the electrode to the
‘−’ terminal.
B
WAVE BALANCE is greater
B
Reduced WAVE BALANCE
to below 50% or increase
the electrode size.
than 50%.
7
8
Dirty weld pool.
Electrode melts or
oxidizes when an
arc is struck.
A
Electrode contaminated
through contact with work
piece or filler rod material.
A
Clean the electrode by
grinding off the
contaminates.
B
Gas contaminated with air.
B
Check gas lines for cuts
and loose fitting or change
gas cylinder.
A
No gas flowing to
welding region.
A
Check the gas lines for
kinks or breaks and gas
cylinder contents.
B
Torch is clogged with dust.
B
Clean torch.
C
Gas hose is cut.
C
Replace gas hose.
D
Gas passage contains
impurities.
D
Disconnect gas hose from
torch then raise gas pressure
and blow out impurities.
E
Gas regulator turned OFF.
E
Turn ON.
F
Torch valve is turned OFF.
F
Turn ON.
G
The electrode is too small
for the welding current.
G
Increase electrode
diameter or reduce the
welding current.
H
WAVE BALANCE is set
H
Reduced WAVE BALANCE
to below 50% or increase
the electrode size.
above 50%.
9
Poor weld finish.
10 Arc flutters during
TIG welding.
Inadequate shielding gas.
Increase gas flow or
check gas line for gas
flow problems.
A
Tungsten electrode is too
large for the welding current.
A
Select the right size
electrode. Refer to Basic
TIG Welding guide.
B
Absence of oxides in the
weld pool.
B
Refer Basic TIG Welding
Guide for ways to reduce
arc flutter.
Table 10-1 (continued): TIG Welding Problems
10-2
February 20, 2006
ARCMASTER 185 AC/DC
Description
11 Welding arc cannot
be established.
12 Arc start is not
smooth.
Possible Cause
Remedy
A Work clamp is not connected to
the work piece or the work/torch
leads are not connected to the
right welding terminals.
A Connect the work clamp to the
work piece or connect the
work/torch leads to the right
welding terminals.
B Torch lead is disconnected.
B Connect it to the ‘−‘ terminal.
C Gas flow incorrectly set, cylinder
empty or the torch valve is OFF.
C Select the right flow rate,
change cylinders or turn torch
valve ON.
A Tungsten electrode is too large
for the welding current.
A Select the right size electrode.
Refer to Basic TIG
Welding Guide.
B The wrong electrode is being
used for the welding job.
B Select the right electrode type.
Refer to Basic TIG
Welding Guide.
C Gas flow rate is too high.
C Select the correct rate for the
welding job.
Refer to Basic TIG
Welding Guide.
D Incorrect shielding gas is
being used.
D Select the right shielding gas.
Refer to Basic TIG
Welding Guide.
E Poor work clamp connection
to work piece.
E Improve connection to
work piece.
Table 10-1 (continued): TIG Welding Problems
February 20, 2006
10-3
ARCMASTER 185 AC/DC
10.02 Stick Welding Problems
Description
Possible Cause
1 Gas pockets or
voids in weld metal
(Porosity).
2 Crack occurring in
weld metal soon
after solidification
commences.
3 A gap is left by
failure of the weld
metal to fill the root
of the weld.
Remedy
A Electrodes are damp.
B Welding current is too high.
C Surface impurities such as oil,
grease, paint, etc.
A Rigidity of joint.
B Insufficient throat thickness.
C Cooling rate is too high.
A Welding current is too low.
B Electrode too large for joint.
C Insufficient gap.
D Incorrect sequence.
A Dry electrodes before use.
B Reduce welding current.
C Clean joint before welding.
A Redesign to relieve weld joint of
severe stresses or use crack
resistance electrodes.
B Travel slightly slower to allow
greater build up in throat.
C Preheat plate and cool slowly.
A Increase welding current
B Use smaller diameter
electrode.
C Allow wider gap.
D Use correct build-up sequence.
Table 10-2: Stick Welding Problems
Art # A-04991
Incorrect sequence
Insufficient
gap
Figure 10-1: Example of Insufficient Gap or Incorrect Sequence
10-4
February 20, 2006
ARCMASTER 185 AC/DC
Description
Possible Cause
4 Portions of the weld A Small electrodes used on heavy
cold plate.
run do not fuse to the
surface of the metal B Welding current is too low.
or edge of the joint.
C Wrong electrode angle.
D Travel speed of electrode is
too high.
E Scale or dirt on joint surface.
Remedy
A Use larger electrodes and
pre-heat the plate.
B Increase welding current.
C Adjust angle so the welding arc is
directed more into the base metal.
D Reduce travel speed of electrode.
E Clean surface before welding.
Table 10-2 (continued): Stick Welding Problems
Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Art # A-04992
Lack of inter-run
fusion
Lack of side fusion, scale
dirt, small electrode,
amperage too low
Lack of root fusion
Figure 10-2: Example of Lack of Fusion
February 20, 2006
10-5
ARCMASTER 185 AC/DC
Description
Possible Cause
5 Non-metallic particles A Non-metallic particles may be
are trapped in the
trapped in undercut from
weld metal (slag
previous run.
inclusion).
B Joint preparation too restricted.
C Irregular deposits allow slag to
be trapped.
D Lack of penetration with slag
trapped beneath weld bead.
E Rust or mill scale is preventing
full fusion.
F Wrong electrode for position in
which welding is done.
Remedy
A If bad undercut is present, clean
slag out and cover with a run
from a smaller diameter electrode.
B Allow for adequate penetration
and room for cleaning out
the slag.
C If very bad, chip or grind out
irregularities.
D Use smaller electrode with
sufficient current to give adequate
penetration. Use suitable tools to
remove all slag from corners.
E Clean joint before welding.
F Use electrodes designed for
position in which welding is done,
otherwise proper control of slag
is difficult.
Table 10-2 (continued): Stick Welding Problems
Art # A-04993
Not cleaned, or
incorrect
electrode
Slag trapped in
undercut
Slag trapped in root
Figure 10-3: Examples of Slag Inclusion
10-6
February 20, 2006
ARCMASTER 185 AC/DC
10.03 Power Source Problems
Description
1 The welding arc
cannot be
established.
Possible Cause
A The Primary supply voltage has
not been switched ON.
B The Welding Power Source
switch is switched OFF.
A Switch ON the Primary
supply voltage.
B Switch ON the Welding
Power Source.
C Loose connections internally.
C Have an accredited Thermal
Arc Service Agent repair
the connection.
2 Maximum output
Defective control circuit.
welding current can
not be achieved with
nominal Mains
supply voltage.
3 Welding current
A Loose welding cable
connections.
reduces when
welding.
B Incorrect welding cable size.
C Improper input connections.
D Poor electrode condition.
E Wrong welding polarity.
4 No gas flow when
the torch trigger
switch is depressed.
Remedy
A Gas hose is cut.
B Gas passage contains
impurities.
C Gas regulator turned OFF.
D Torch trigger switch lead is
disconnected or switch/cable
is faulty.
Have an accredited Thermal
Arc Service Agent repair
the connection.
A Tighten all welding
cable connections.
B Use proper size and
type of cable.
C Refer to Section 2.05
Electrical Input Requirements.
D Replace electrode.
E Verify output torch
connections.
A Replace gas hose.
B Disconnect gas hose from
the rear of Power Source then
raise gas pressure and blow
out impurities.
C Turn gas regulator ON.
D Reconnect lead or repair faulty
switch/cable.
Table 10-3: Power Source Problems
February 20, 2006
10-7
ARCMASTER 185 AC/DC
Description
5 Gas flow won’t
shut OFF.
6
Possible Cause
A Weld Mode (STD, SLOPE,
REPEAT or SPOT) was changed
before POST-FLOW gas time
had finished.
A
B Gas valve is faulty.
B
C Gas valve jammed open.
C
Remedy
Strike an arc to complete the
weld cycle.
OR
Switch machine OFF then ON to
reset solenoid valve sequence.
Have an accredited Thermal
Arc Service Agent repair or
replace the gas valve.
Have an accredited Thermal
Arc Service Agent repair or
replace the gas valve.
Reduce POST-FLOW time.
D POST-FLOW control is set
D
to 60 sec.
The Weld Process Mode
The TIG electrode has
Do not change Weld Process
(STICK, HF TIG or LIFT TIG) was
been contaminated
Mode before the POST-FLOW
changed before POST-FLOW gas
gas time had finished.
due to the gas flow
shutting OFF before
time had finished.
the programmed
POST-FLOW time
has elapsed.
Table 10-3 (continued): Power Source Problems
10-8
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD)
11.01 VRD SPECIFICATION
Description
VRD Open Circuit Voltage
VRD Resistance
VRD Turn OFF Time
ArcMaster
185AC/DC
15.3 to 19.8V
Notes
Open circuit voltage between
welding terminals.
148 to 193 ohms The required resistance between
welding terminals to turn ON the
welding power.
0.2 to 0.3
The time taken to turn OFF the
seconds
welding power once the welding
current has stopped.
Table 11-1: VRD Specification
11.02 VRD MAINTENANCE
Routine inspection and testing (power source):
An inspection of the power source, an insulation resistance test and an earth resistance test should be carried out.
a. For transportable equipment, at least once every 3 months.
b. For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests.
NOTE
A transportable power source is any equipment that is not permanently connected and fixed in the position
in which it is operated.
In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests
should also be conducted by an accredited Thermal Arc service agent.
Description
VRD Open Circuit Voltage
VRD Turn ON Resistance
VRD Turn OFF Time
IEC 60974-1 Requirements
Less than 20V; at Vin=230V
Less than 200 ohms
Less than 0.3 seconds
Table 11-2: Periodic Tests
If this equipment is used in a location or an environment with a high risk of electrocution then the above tests should
be carried out prior to entering this location.
February 20, 2006
11-1
ARCMASTER 185 AC/DC
11.03 SWITCHING VRD ON/OFF
Switch the machine OFF.
A) Remove the clear plastic cover from the control panel. (see Figure 11-1)
1 Lift up the cover so it rests on the top of the unit.
2 Place a small flat bladed screw driver between the cover hinge on the front panel.
3 Gently lift the cover hinge out of the front cover mounting hole.
Remove the control's clear plastic cover.
2
2
3
1
Art # A-07079
Figure 11-1: VRD ON/OFF Step A
B) Remove the four mounting screws from the control panel. (see Figure 11-2)
Art # A-07080
1
1
2
1
1
Figure 11-2: VRD ON/OFF Step B
11-2
February 20, 2006
ARCMASTER 185 AC/DC
C) Access the VRD control by gently prying back the front panel controls to reveal the VRD ON/OFF potentiometer.
(see Figure 11-3)
D) Turning the VRD ON/OFF. (see Figure 11-3)
• To turn VRD ON: rotate the trim potentiometer on the display PCB fully clockwise. When VRD is turned ON check
that it operates as per VRD Specifications on page 11-1.
• To turn VRD OFF: rotate the trim potentiometer on the display PCB fully counter-clockwise.
CAUTION
DO NOT pull back the front panel with excessive force as this will unplug control PCB. Plugging the control
PCB back into the front panel controls can only be achieved by removing the side covers.
VR1
Art # A-07081
Figure 11-3: VRD ON/OFF Step C and D
!
WARNING
The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise
as the VRD function will be unknown for every other position.
February 20, 2006
11-3
ARCMASTER 185 AC/DC
NOTES
11-4
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 12:
POWER SOURCE ERROR CODES
Description
Possible Cause
A The Welding Power
1 E01 error code
Source’s duty cycle
displayed
has been exceeded.
Temperature sensor
TH1 (protects
B Fan ceases
IGBTs) is greater
to operate.
than 80ºC for about
1 second.
C Air flow is restricted
by vents being
blocked.
A The Welding Power
2 E02 error code
Source’s duty cycle
displayed
has been exceeded.
Temperature sensor
TH2 (protects
B Fan ceases
secondary diodes)
to operate.
is greater than 80ºC
for about 1 second.
C Air flow is restricted
by vents being
blocked.
A Primary current is
3 E03 error code
too high because
displayed
welding arc is
Primary (input)
too long.
current too high.
B Mains supply
voltage is more
than 10% below
nominal voltage .
4 E04 error code
displayed
Output voltage
exceeds the
secondary voltage
specification.
TIG torch cable
and/or work lead
are too long or
leads are coiled.
A
B
C
A
B
C
A
Remedy
Let Power Source
cool down then
keep within its
duty cycle.
Have an accredited
Thermal Arc Service
Agent investigate.
Unblock vents then
let Power Source
cool down.
Let Power Source
cool down then
keep within its
duty cycle.
Have an accredited
Thermal Arc Service
Agent investigate
Unblock vents then
let Power Source
cool down.
Reduce length of
welding arc.
Remarks
Weld current
ceases. Buzzer
sounds constantly.
Fan operates at
max speed.
E01 resets when
TH1 decreases to
70ºC for about
30 seconds.
Weld current
ceases. Buzzer
sounds constantly.
Fan operates at
max speed.
E02 resets when
TH2 decreases to
70ºC for about
30 seconds.
Weld current
ceases. Buzzer
sounds constantly.
Switch machine OFF
B Have an accredited then ON to reset
Thermal Arc Service E03 error.
Agent or a qualified
electrician check for
low Mains voltage.
Reduce the length Weld current
ceases. Buzzer
of the TIG torch
cable and/or work sounds constantly.
Switch machine OFF
lead or un-coiled
then ON to reset
leads.
E04 error.
Table 12-1 Power Source Error Codes
February 20, 2006
12-1
ARCMASTER 185 AC/DC
5 E11 error code
displayed
Over Primary supply
(input) voltage at
primary capacitors
is exceeded for
one second.
6 E14 error code
displayed
Under mains supply
(input) voltage
warning primary
capacitors is
reduced for
one second.
7 E12 error code
displayed
Under mains supply
(input) voltage
primary capacitors
is reduced for
one second.
8 E81 error code
displayed
Wrong Primary
supply (input)
voltage connected.
Primary supply
voltage is greater
than the nominal
voltage plus 10%.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Primary voltage.
Mains supply
voltage is less than
the nominal
operating voltage
less 10%.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
Mains supply
voltage is down
to a dangerously
low level.
When 3 phase
machine is first
turned ON with the
wrong Primary
supply (input)
voltage connected.
A Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check
the Mains voltage.
B Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check
the primary cable
and fuses.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
Weld current ceases.
Buzzer sounds
contstantly.
Error code E11
automatically will
reset when the
voltage reduces.
Weld current
available. Buzzer
sounds
intermittently.
Error code E14
automatically will
reset when the
voltage increases.
Weld current ceases.
Buzzer sounds
contstantly.
Error code E12
automatically will
reset when the
voltage increases.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF.
Table 12-1 (continued): Power Source Error Codes
12-2
February 20, 2006
ARCMASTER 185 AC/DC
9 E82 error code
displayed
Rated voltage
selection circuit
abnormality.
The Primary supply
(input) voltage
fluctuates and is
not stable.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF
then ON to reset
E82 error.
10 E83 error code
displayed
CPU checks mains
supply (input)
voltage when the
ON/OFF switch
on rear panel of
machine is
turned ON.
11 E85 error code
displayed
Pre-charge
abnormality.
The Primary supply
(input) voltage
fluctuates and is
not stable.
Have an accredited
Thermal Arc Service
Agent check
connector plug on
input PCB and the
Mains voltage.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF
then ON to reset
E83 error.
Due to malfunction
inside the Welding
Power Source,
primary capacitors
are not charging
correctly.
Have an accredited
Thermal Arc Service
Agent service the
machine.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF
then ON to reset
E85 error.
12 E93 error code
displayed
Memory chip
EEPROM) on
control PCB cannot
read/write weld
parameters.
Memory chip
(EEPROM) error.
Have an Accredited
Thermal Arc Service
Agent check the
control PCB.
Weld current ceases.
Buzzer sounds
constantly. Switch
machine OFF.
Table 12-1 (continued): Power Source Error Codes
February 20, 2006
12-3
ARCMASTER 185 AC/DC
13 E94 error code
The Welding Power
displayed
Source’s
Temperature sensor
temperature
TH1 for IGBTs or
sensors have
sensor TH2 for
malfunctioned.
secondary diodes
are open circuit.
A Main ON/OFF switch
14 E99 error code
on machine has
displayed
been turned OFF.
Mains supply
(input) voltage has B Mains supply
been turned OFF but
(input) voltage has
control circuit has
been turned OFF.
power from the
primary capacitors.
Have an accredited
Thermal Arc Service
Agent check or
replace the
temperature sensors.
A Turn ON/OFF
switch ON.
B Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage
and fuses.
Weld current ceases.
Buzzer sounds
constantly. Switch
machine OFF.
Weld current ceases.
Buzzer sounds
constantly. Must
switch machine OFF
then ON to reset
E99 error.
Table 12-1 (continued): Power Source Error Codes
12-4
February 20, 2006
ARCMASTER 185 AC/DC
SECTION 13:
PARTS LIST
13.01 EQUIPMENT IDENTIFICATION
13.02 HOW TO USE THIS PARTS LIST
All identification numbers as described in the Introduction chapter must be furnished when ordering parts or
making inquiries. This information is usually found on the
nameplate attached to the equipment. Be sure to include
any dash numbers following the Specification or Assembly numbers.
The Parts List is a combination of an illustration and a
corresponding list of parts which contains a breakdown
of the equipment into assemblies, subassemblies, and
detail parts. All parts of the equipment are listed except
for commercially available hardware, bulk items such as
wire, cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded to
other parts. The part descriptions may be indented to show
part relationships.
To determine the part number, description, quantity, or
application of an item, simply locate the item in question
from the illustration and refer to that item number in the
corresponding Parts List.
PART NUMBER:
ArcMaster 185 AC/DC
February 20, 2006
10-3073
13-1
ARCMASTER 185 AC/DC
QTY.
1
1
1
1
2
1
1
2
2
1
1
1
2
1
1
2
1
13-2
Description
8 pin Receptacle
Primary Switch
Panel, Upper Front
Panel, Upper Rear
Case Half
Case Front
Frame, Rear
Label, Name, 185AC/DC
Label, Side
Label, Warning
Label, Warning, Lifting
Label, Output Terminal
Terminal, Output Female
Encoder Knob
Encoder Knob, Cap
Terminal, Output Male
Operators Manual
Order No.
W7000101
W7000201
W7000301
W7000401
W7000501
W7000601
W7000701
W7000801
W7000901
W7001001
W7001101
W7001201
W7001301
10-6665
10-6666
10-2020
300x4861
February 20, 2006
ARCMASTER 185 AC/DC
APPENDIX 1: GENERAL INFORMATION
• Note the model and specification number shown on the equipment nameplate.
February 20, 2006
A-1
ARCMASTER 185 AC/DC
APPENDIX 2: ARCMASTER 185 AC/DC INTERCONNECTION DIAGRAM
1
2
+
(1)
TB5 TB6
C
PCB1
Main
Circuit
Board
[WK-5493]
P
K(7)
G(6)
P
S1
Line1
E
C
PCB8
IGBT Gate G
Circuit E
Board C
[WK-5479]
R(3)
TB1
(0)
C2E
R2
Line2
Q3
1
2
3
E
C
Q4
G
N
N
TB2
E
C
1
2
3
4
G2
E2
CN2
E1C
-
(2)
Q2
G
G1
E1
R2
S(4)
T(5)
Q1
G
CN1
D1
R5
CN3
R4
Q5
G
E
C
TB2
Q6
G
Ground
E PCB17
Filter
Circuit Board
[WK-4917]
C
CN2
1 2
REAR
PANEL
PCB9 C
IGBT Gate
Circuit G
Board E
[WK-5479] C
TB4
CN131 CN132
CN130
CN131 CN132
CN130
CT1
CT2
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
CN20
CN21
CN22
CN23
1
2
8
1
5
4
7
6
3
CON1
A-2
1
2
CN27
3
4
CN27
5
CN15
2
CN17
CN17
PCB6
Control
Circuit Board
[WK-5549]
CN18
CN18
CN14
TB0
PCB7
Filter
Circuit Board
[WK-5550]
CN20
EA
CN20
CN9
CN8
1 2
1 2 3
1 2
CN18
1 2 3
1
2
3
E4
G4
1 2 3 4 5 6
1 : Chassis Ground
2 : Contactor Control/+24VDC
3 : Contactor Control/GND
4 : Not Used
5 : Potentiometer Maximum
6 : Potentiometer Minimum(GND)
7 : Amperage Control Wiper 0-10VDC
8 : Not Used
EA
E
CN19
1 2 3
1 2 3
CN17
PCB5
Connect Circuit Board
[WK-5551]
PCB3
Control
Source
Circuit Board
[WK-5548]
Q12
G
1
2
3
4
5
6
7
CN21
CN30
CN30
E
C
E3
G3
CN31 CN32
CN31 CN32
CN1
CN4
Q11
G
CN2
C2E
E1C
CN6
CN6
1
2
3
4
E
C
1
2
3
4
CN1
SOL1
Q10
E2
G2
1
2
3
4
CN11
-
PCB4
Detect
Circuit Board
[WK-4819]
CN5
CN5
FAN1
+
E
C
E1
G1
1
2
3
4
1
2
3
4
G4
E4
CN7
R2
CN3
CN4
P
CN2
Q9
G
CN1
1
2
3
4
5
6
1 2 3 4 5
1
2
3
CN1
G3
E3
1 2 3
1 2 3
Q8
G
CN1
N
Q7
G
E
1
2
3
4
5
CN1
SIDE CHASSIS 1
E
TB3
PCB2
Link
Circuit
Board
[WK-5482]
1
2
3
4
CN33
TH2
TH1
P+21V
PGND
+
February 20, 2006
ARCMASTER 185 AC/DC
TB20
TB22
TB12
Q13
CT2
D5
G1 G1
CN1
E2 E2
E1 E1
TO1
+Output
Terminal
G2 G2
1 2 3 4 5
AC4
CT2
CT1
TB21
PCB15
IGBT Gate
Circuit
Board
[WK-3367]
G7
E7
D2
TB1
E8
G8
T1
FCH1
PCB14
IGBT Snubber
Circuit Board
[WK-5570]
D4
AC2
TB7
SH.DET+
AC1
PCB12
DIODE Snubber
Circuit Board
[WK-5615]
TB2
+
1
2
3
RY+15V
/RY_ON
HCT1
CN3
SH.DET-
1 2 3 4 5
CN1
PCB16
Filter Circuit
Board
[WK-5499]
Ground
SIDE CHASSIS 3
TO2
CC1
-Output
Terminal
34
12
CC2
+15
-15
IS
GND
R3
CC1
R1
HF.UNIT1
1 2
TB1
1
2
CN2
S+15V
1
2
3
1 2 3 4 5
1 2 3 4 5 6 7 8 9
CN8
CN9
R6
PCB13
Super Inpose
Circuit Board
[WK-5569]
CN4
/RY_ON
AC1
AC3
AC1
CN6
P+21V
PGND
SG
TB2
CN5
CN3
SH.DET+
SH.DET-
AC2
AC4
AC3
EB
S+15V
SG
N
1
2
3
4
CN1
P
R2
R2
AC3
1
2
3
4
5
6
7
8
G7
E7
G8
E8
FRONT
PANEL
1 2 3 4 5 6 7
EA
+
Ground
RY+15V
1
2
3
4
5
6
+15
-15
IS
GND
February 20, 2006
SIDE CHASSIS 2
PCB11
Encorder
Board
[WK-5528]
CN2
PCB10
Panel
Circuit Board
[WK-5527]
CN1
CN1
1 2 3 4
1 2 3 4
A-3
ARCMASTER 185 AC/DC
APPENDIX 3: ARCMASTER 185 AC/DC ACCESSORIES
ACCESSORIES
Stick Kit
TIG Kit
PART NO.
90925A
W4009105
W4009105
Dinse Connector
Adaptor
Hand Held Pendant
10-2020
10-4003
10-4014
Foot Control
10-4015
10-4016
Extension Cable
Torch Switch On/Off
Torch Switch On/Off
w/current control
10-4017
10-4018
10-4019
10-4020
10-4021
10-4006
10-4007
10-4008
10-4009
10-4010
10-4011
10-4012
10-4013
600296
600297
A-4
DESCRIPTION
Work clamp with 15’ cable and stick electrode with 15’ cable
Includes regulator/flowgauge, 12.5’ 150 Amp TIG torch
& built-in rotary amperage control.
Accessory kit includes 1 ea of 0040”x7”, 1/16”x7”, 3/32”x7”
2% Tungsten with collet & collet bodies, 1 ea 1/4”, 5/16”,
3/8” alumina cup, 15’ cable with clamp & T25 dinse plug
Includes regulator/flowgauge, 13’ 200 Amp TIG torch & built-in
On/Off switch. Accessory kit includes 1 ea. of 0040”x7”,
1/16”x7”,3/32”x7” 2% Tungsten with collet & collet bodies, 1 ea 1/4”,
5/16”,3/8” alumina cup,15’ cable with clamp & T25 dinse plug
T50mm Dinse style male plug
8-pin male to 14-pin female (6”)
Includes contactor On/Off switch and current control with 25ft
cable and 14-pin male plug
Contactor On/Off and current control with 15ft cable
and 8-pin male plug
Contactor On/Off and current control with 25ft cable and
8-pin male plug
3ft with 8-pin male plug and 8-pin female cable receptacle
15ft with 8-pin male plug and 8-pin female cable receptacle
25ft with 8-pin male plug and 8-pin female cable receptacle
50ft with 8-pin male plug and 8-pin female cable receptacle
75ft with 8-pin male plug and 8-pin female cable receptacle
15ft torch mounted with 8-pin male plug
25ft torch mounted with 8-pin male plug
15ft torch mounted with 8-pin male plug
- adapts to 5/8”-7/8” torch
15ft torch mounted with 8-pin male plug
- adapts to 7/8”-1-1/8” torch handle
15ft torch mounted with 8-pin male plug
- adapts to 1-1/8”-1-3/8” torch handle
25ft torch mounted with 8-pin male plug
- adapts to 5/8”-7/8” torch
25ft torch mounted with 8-pin male plug
- adapts to 7/8”-1-1/8” torch handle
25ft torch mounted with 8-pin male plug
- adapts to 1-1/8”-1-3/8” torch handle
Rotary amperage control 5k 15’ velcro for TD8
Rotary amperage control 5k 25’ velcro for TD8
February 20, 2006
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company ("Thermal Arc"),
warrants to customers of authorized distributors ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warranty
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair or
replacement, at Thermal Arc's sole option, of any components or parts of the product
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of
merchantability, fitness for any particular purpose, or other warranty of
quality, whether express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc with respect to any contract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whether
arising out of contract, tort, including negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.
This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchaser’s rights under this warranty
are void if the product is sold to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned goods
shall be at the Purchaser's risk and expense. This warranty dated April 1st 2006
supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered
Trademark of Thermal Arc, Inc.
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
ENGINE DRIVEN WELDERS
W ARRANTY P ERIOD
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years
LABOR
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer ............................................................. See the Engine Manufactures Warranty for
Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................ 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
PLASMA WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year
1 year
SMAW (Stick) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
GENERAL ARC EQUIPMENT
W ARRANTY P ERIOD
LABOR
Water Recirculators ....................................................................................................................... 1 year
1 year
Plasma Welding Torches.............................................................................................................180 days
180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days
Replacement repair parts .............................................................................................................90 days
Nil
Nil
MIG, TIG and Plasma welding torch consumable items................................................................... Nil
Nil
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: [email protected]
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
Cigweld, Australia
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: [email protected]
www.thermalarc.com
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