186 AC/DC Operating Manual Inverter

186 AC/DC Operating Manual Inverter

186 AC/DC

Inverter

ArC welDIng MAChIne

Operating Manual

Art # A-11491_AB

Revision: AB

Operating Features:

Issue Date: February 4, 2013 Manual No.: 0-5237

50

60

Hz

3163339

LIFT TIG

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 worldwide service network. To locate your nearest distributor or service agency call

1-800-462-2782 (USA) and 1-905-827-4515 (Canada), 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.

We have made every effort to provide you with accurate instructions, drawings, and photographs of the product(s) while writing this manual. However errors do occur and we apologize if there are any contained in this manual.

Due to our constant effort to bring you the best products, we may make an improvement that does not get reflected in the manual. If you are ever in doubt about what you see or read in this manual with the product you received, then check for a newer version of the manual on our website or contact our customer support for assistance.

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 Victor Technologies. 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 market-leading, 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.

Welding Power Supply

Operating Manual Number 0-5237 for:

Thermal Arc 186 AC/DC, Machine Only

Thermal Arc 186 AC/DC, System

Thermal Arc 186 AC/DC, System W/Cart

Thermal Arc 186 AC/DC, System W/FT Control

Thermal Arc 186 AC/DC, System W/FT Control & Cart

Published by:

Victor Technologies, Inc.

16052 Swingley Ridge Road,

Suite 300 St, Louis, MO 63017

USA www.victortechnologies.com

Copyright 2012, 2013 by

Victor Technologies, Inc.

All rights reserved.

Part Number W1006300

Part Number W1006301

Part Number W1006302

Part Number W1006303

Part Number W1006304

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: September 29, 2012

Revision AB Date: February 4, 2013

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

____________________________________

____________________________________

____________________________________ ii

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 General Safety Information For Victor CS Regulator ......................................... 1-5

1.03 Principal Safety Standards .............................................................................. 1-7

1.04 Symbol Chart .................................................................................................. 1-8

1.05 Precautions De Securite En Soudage A L’arc .................................................. 1-9

1.06 Dangers relatifs au soudage à l’arc ................................................................. 1-9

1.07 Informations Générales de Sécurité .............................................................. 1-13

1.08 Principales Normes De Securite ................................................................... 1-15

1.09 Graphique de Symbole .................................................................................. 1-16

1.10 Declaration Of Conformity ............................................................................ 1-17

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 Description ..................................................................................................... 2-1

2.05 User Responsibility ......................................................................................... 2-2

2.06 Transporting Methods ..................................................................................... 2-2

2.07 Packaged Items .............................................................................................. 2-2

2.08 Duty Cycle ....................................................................................................... 2-3

2.09 Specifications ................................................................................................. 2-4

2.10 Optional Accessories ...................................................................................... 2-5

2.11 Volt-Ampere Curves ........................................................................................ 2-6

SECTION 3:

INSTALLATION, OPERATION AND SETUP ........................................................ 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Ventilation ....................................................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-1

3.05 High Frequency Introduction .......................................................................... 3-2

3.06 High Frequency Interference ........................................................................... 3-3

3.07 Electromagnetic Compatibility ........................................................................ 3-3

3.08 186 AC/DC Power Source Controls, Indicators and Features .......................... 3-5

3.09 186 AC/DC - STICK Programming Mode ...................................................... 3-10

3.10 186 AC/DC – LIFT TIG and HF TIG Programming Mode .............................. 3-11

3.11 Short Circuit Protection While Welding ......................................................... 3-16

3.12 Victor Regulator ............................................................................................ 3-16

3.13 Specification for TIG Torch ........................................................................... 3-18

3.14 Setup for TIG (GTAW) Welding ..................................................................... 3-19

3.15 Setup for STICK (SMAW) Welding .............................................................. 3-22

TABLE OF CONTENTS

SECTION 4:

BASIC WELDING GUIDE ............................................................................ 4-1

4.01 STICK (SMAW) Basic Welding Technique ....................................................... 4-1

4.02 STICK (SMAW) Welding Troubleshooting ..................................................... 4-10

4.03 TIG (GTAW) Basic Welding Technique .......................................................... 4-12

4.04 TIG (GTAW) Welding Problems ..................................................................... 4-15

SECTION 5: POWER SOURCE PROBLEMS

AND ROUTINE SERVICE REQUIREMENTS ........................................................ 5-1

5.01 Basic Troubleshooting .................................................................................... 5-1

5.02 Power Source Problems ................................................................................. 5-1

5.03 Routine Service and Calibration Requirements ............................................... 5-2

5.04 Cleaning the Welding Power Source ............................................................... 5-4

SECTION 6:

KEY SPARE PARTS ................................................................................... 6-1

6.01 Power Source ................................................................................................. 6-1

APPENDIX 1 : CIRCUIT DIAGRAM ........................................................................ A-1

APPENDIX 2 : 186 AC/DC SETUP GUIDE ................................................................ A-2

lIMITED WARRANTY,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.......Inside Rear Cover

WARRANTY SCHEDULE...................................................................Inside Rear Cover

SAFETY INSTRUCTIONS 186 AC/DC INVERTER

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

WARNING

ELECTRIC SHOCK can kill.

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 semi-automatic 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.

1. Do not touch live electrical parts.

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.

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.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work

(ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

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.

Manual 0-5237 1-1 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER

15. Keep all panels and covers securely in place.

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.

SAFETY INSTRUCTIONS

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases.

Breathing these fumes and gases can be hazardous to your health.

AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida

Guide for Shade Numbers

Process

Electrode Size in.

(mm)

Arc Current

(Amperes)

Minimum

Protective

Shade

Suggested*

Shade No.

(Comfort)

Shielded Metal Arc Welding

(SMAW)

Less than 3/32 (2.4)

3/32-5/32 (2.4-4.0)

5/32-1/4 (4.0-6.4)

More than 1/4 (6.4)

Less than 60

60-160

160-250

250-550

7

8

10

11

-

10

12

14

Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding

(FCAW)

Gas Tungsten arc Welding

(GTAW)

Air Carbon Arc Cutting (CAC-A)

Plasma Arc Welding (PAW)

 

 

(Light)

(Heavy)

 

Less than 60

60-160

160-250

250-550

Less than 50

50-150

150-500

Less than

500

500-1000

Less than 20

20-100

100-400

400-800

8

8

10

7

10

10

10

10

11

6

8

10

11

-

11

12

14

10

12

14

12

14

6 to 8

10

12

14

Plasma Arc Cutting (PAC)

 

Less than 20

20-40

40-60

60-80

80-300

300-400

400-800

8

9

10

6

8

4

5

9

12

14

6

8

4

5

* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5237

SAFETY INSTRUCTIONS

1. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

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 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 airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

186 AC/DC INVERTER

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

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 travelling 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.

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

WELDING can cause fire or explosion.

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.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

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.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

WARNING

CYLINDERS can explode if damaged.

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.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

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.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

Manual 0-5237 1-3 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

!

WARNING

Engines can be dangerous.

SAFETY INSTRUCTIONS

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

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 fuelling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

WARNING

SPARKS can cause BATTERY GASES TO

EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

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.

3. Allow pressure to escape before completely removing cap.

SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5237

SAFETY INSTRUCTIONS

NOTE

Considerations About Welding And The

Effects of Low Frequency Electric and Magnetic Fields

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.

186 AC/DC INVERTER

1.02 General Safety Information For

Victor CS Regulator

A Fire Prevention

Welding and cutting operations use fire or combustion as a basic tool. The process is very useful when properly controlled. However, it can be extremely destructive if not performed cor rectly in the proper environment.

1. The work area must have a fireproof floor.

2. Work benches or tables used during welding or cutting operations must have fireproof tops.

3. Use heat resistant shields or other approved material to protect nearby walls or unprotected flooring from sparks and hot metal.

4. Keep an approved fire extinguisher of the proper size and type in the work area. Inspect it regularly to ensure that it is in proper working order.

Know how to use the fire extin guisher.

5. Move combustible materials away from the work site. If you can not move them, protect them with fireproof covers.

!

WARNING

NEVER perform welding, heating, or cutting operations on a container that has held toxic, combustible or flammable liq uids, or vapors. NEVER perform welding, heating, or cutting operations in an area containing combustible vapors, flam mable liquids, or explosive dust.

B Housekeeping

!

WARNING

NEVER

allow oxygen to contact grease, oil, or other flam mable substances. Although oxygen by itself will not burn, these substances become highly explosive. They can ignite and burn violently in the presence of oxygen.

Keep ALL apparatus clean and free of grease, oil and other flammable substances.

Manual 0-5237 1-5 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER

C Ventilation

!

WARNING

Ade quately ventilate welding, heating, and cutting work areas to prevent accumulation of explosive or toxic concen trations of gases. Certain combinations of metals, coatings, and gases generate toxic fumes.

Use respiratory protection equipment in these circumstances. When welding/brazing, read and understand the Material Safety Data

Sheet for the welding/brazing alloy.

D Personal Protection

Gas flames produce infrared radiation which may have a harm ful effect on the skin and especially on the eyes.

Select goggles or a mask with tempered lenses, shaded

4 or darker, to protect your eyes from injury and provide good visibility of the work.

Always wear protective gloves and flame-resistant clothing to protect skin and clothing from sparks and slag. Keep collars, sleeves, and pockets buttoned. DO NOT roll up sleeves or cuff pants.

When working in a non-welding or cutting environment, always wear suitable eye protection or face shield.

!

WARNING

Practice the following safety and operation precautions EVERY TIME you use pressure regulation equipment. Deviation from the following safety and operation instructions can result in fire, explosion, damage to equipment, or injury to the operator.

E Compressed Gas Cylinders

The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases used for welding or cutting operations.

SAFETY INSTRUCTIONS

1. Place the cylinder (Figure 1-1) where you will use it. Keep the cylinder in a vertical position.

Secure it to a cart, wall, work bench, post, etc.

Figure 1-1: Gas Cylinders

!

WARNING

Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or mis use of compressed gas cylinders DO NOT drop the cylinder, knock it over, or expose it to excessive heat, flames or sparks. DO NOT strike it against other cylinders. Contact your gas supplier or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.

NOTE

CGA P-1 publication is available by writing the Compressed Gas Association, 4221

Walney Road, 5th Floor, Chantilly,VA 20151-

2923

2. Place the valve protection cap on the cylinder whenever mov ing it, placing it in storage, or not using it. Never drag or roll cylinders in any way.

Use a suitable hand truck to move cylin ders.

3. Store empty cylinders away from full cylinders.

Mark them “EMPTY” and close the cylinder valve.

4. NEVER use compressed gas cylinders without a pressure reducing regulator attached to the cylinder valve.

5. Inspect the cylinder valve for oil, grease, and damaged parts.

SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5237

SAFETY INSTRUCTIONS

!

WARNING

DO NOT use the cylinder if you find oil, grease or damaged parts. Inform your gas supplier of this condition immediately.

6. Momentarily open and close (called “cracking”) the cylinder valve to dislodge any dust or dirt that may be present in the valve.

CAUTION

Open the cylinder valve slightly. If you open the valve too much, the cylinder could tip over. When cracking the cylinder valve, DO

NOT stand directly in front of the cylinder valve. Always perform cracking in a well ventilated area. If an acetylene cylinder sprays a mist when cracked, let it stand for

15 minutes. Then, try to crack the cylinder valve again. If this problem persists, contact your gas supplier.

186 AC/DC INVERTER

1.03 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.

Safe Handling of Compressed Gases in Cylinders, CGA

Pamphlet P-1, 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.

Manual 0-5237 1-7 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER

1.04 Symbol Chart

Note that only some of these symbols will appear on your model.

SAFETY INSTRUCTIONS

On

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth

(Ground)

Line

Line Connection

Single Phase

Three Phase

Three Phase Static

Frequency Converter-

Transformer-Rectifier

Remote

X

%

Duty Cycle

Percentage

Panel/Local

Shielded Metal

Arc Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Gas Tungsten Arc

Welding (GTAW)

Air Carbon Arc

Cutting (CAC-A)

Constant Current

Constant Voltage

Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Wire Feed Function

Wire Feed Towards

Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld

Mode

Spot Weld Mode

t1 t

Spot Time

Preflow Time

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

IPM

Inches Per Minute

MPM

Meters Per Minute

S

See Note

See Note

Auxiliary Power

115V 15A

Receptacle Rating-

Auxiliary Power

Variable Inductance

V

Voltage Input

Art # A-04130_AB when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.

Cannot be disposed with household garbage.

SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5237

SAFETY INSTRUCTIONS

1.05 Precautions De Securite En Soudage A L’arc

186 AC/DC INVERTER

1.06 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

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.

1. Ne touchez pas à des pièces sous tension.

!

2. Portez des gants et des vêtements isolants, secs et non troués.

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.

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.

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.

Manual 0-5237 1-9 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER

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.

15. Fermez solidement tous les panneaux et les capots.

SAFETY INSTRUCTIONS

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER

LES YEUX ET LA PEAU; LE BRUIT PEUT

ENDOMMAGER L’OUIE.

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.

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.

AWS F2.2 : 2001 (R2010), Modifié avec l’accord de l’American Welding Society (AWS), Miami, Florida

Guide de teinte des lentilles

Procédé d’arc

(ampères) d’intensité minimum recommandée*

(Confort)

électrode enrobée (procédé

SMAW)

Soudage à l’arc sous gaz avec fil plein (procédé fourré (procédé FCAW)

Coupage à l’arc avec

électrode de carbone et jet d’air (procédé AAC)

Soudage à l’arc au plasma

(procédé PAW)

Moins de 2,4 (3/32)

3/32-5/32 (2,4-4,0)

Plus de 1/4 (6,4)

(Clair)

(Sombre)

Moins de 60

60-160

160-250

250-550

Moins de 60

60-160

160-250

250-550

Moins de 50

150-500

Moins de

500 500-

1000

Moins de 20

20-100

100-400

400-800

Moins de 20

20-40

60-80

80-300

300-400

400-800

7

8

10

11

7

10

10

10

8

10

10

11

8

9

10

4

5

6

8

6

8

10

11

-

10

12

14

-

11

12

14

10

14

12

14

6 à 8

10

12

14

4

5

6

8

9

12

14

* En règle générale, commencer avec une teinte plus foncée pour voir la zone de soudage. Réduire ensuite progressivement vers la teinte qui permet de voir la zone de soudage sans dépasser le minimum. Lors du soudage, du coupage ou du brasage au gaz oxygéné, la torche ou le fondant produit une puissante lumière jaune; il est préférable d’utiliser un filtre qui absorbe cette lumière jaune ou le sodium du spectre de la lumière visible.

Tableau 1-1

SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5237

SAFETY INSTRUCTIONS

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.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT

DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

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.

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.

186 AC/DC INVERTER

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE

OU UNE EXPLOSION

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.

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.

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.

Manual 0-5237 1-11 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER SAFETY INSTRUCTIONS

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 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.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGE-

REUX

LES GAZ D’ECHAPPEMENT DES MOTEURS

PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

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.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEU-

VENT 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.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCEN-

DIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

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.

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.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant.

Nettoyez tout carburant renversé avant de faire démarrer le moteur.

SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5237

SAFETY INSTRUCTIONS 186 AC/DC INVERTER

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

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

LA VAPEUR ET LE LIQUIDE DE REFROI-

DISSEMENT BRULANT SOUS PRESSION

PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

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.

1.07 Informations Générales de

Sécurité

A Prévention D’incendie

Les opérations de soudage utilisent le feu ou la combustion comme outil de base. Ce processus est très utile quand il est cor rectement contrôlé.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLO-

SER UN ACCUMULATEUR; L’ELECTROLYTE

D’UN ACCUMU-LATEUR PEUT BRULER LA

PEAU ET LES YEUX.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

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.

Manual 0-5237

1. La zone doit comporter un sol ignifugé.

2. Les établis ou tables utilisés pendant les opérations de soudage doivent avoir un revêtement ignifuge.

3. Utilisez des écrans résistants à la chaleur ou en matériau approuvé pour protéger les cloisons proches ou le sol vul nérable des étincelles et du métal chaud.

4. Gardez un extincteur approuvé du bon type et de la bonne taille dans la zone de travail. Inspectez-le régulièrement pour vous assurer qu’il est en état de fonctionner. Apprenez à vous en servir.

5. Enlevez tous les matériaux combustibles de la zone de travail. Si vous ne pouvez pas les enlever, protégez-les avec une cou vre ignifuge.

1-13 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER

!

AVERTISSEMENT

N’effectuez

JAMAIS

d’opérations de soudage sur un récipient qui a contenu des liquides ou vapeurs toxiques, combustibles ou inflammables. N’effectuez

JAMAIS

d’opérations de soudage dans une zone contenant des vapeurs combustibles, des liquides inflammables ou des poussières explosives.

B Entretien des Locaux

!

AVERTISSEMENT

Ne laissez jamais l’oxygène en contact avec la graisse, l’huile ou d’autres substances inflammables. Bien que l’oxygène elle même ne brûle pas, ces substances peuvent devenir extrême ment explosives. Elles peuvent prendre feu et brûler violem ment en présence d’oxygène.

Gardez

TOUS

les appareils propres et exempts de graisse, huile ou autres substances inflammables.

C Aération

!

AVERTISSEMENT

Ventilez les zones de soudage, chauffage et découpage de façon adéquate pour éviter l’accumulation de gaz explosifs ou toxiques.

Certaines combinaisons de métaux, revêtements et gaz génèrent des fumées toxiques:

Utilisez un équipement de protection respiratoire dans ces circonstances. Si vous soudez ou brasez, lisez et assimilez la fiche technique de sécurité de matériau relative à l’alliage de soudage/brasage.

D Protection Personnelle

Les flammes de gaz produisent une radiation infrarouge qui peut avoir un effet néfaste sur la peau, et particulièrement sur les yeux. Choisissez des lunettes ou un masque avec des verres trempés assombris au niveau 4 ou plus sombre, pour protéger vos yeux des dommages et garder une bonne visibilité sur le travail.

SAFETY INSTRUCTIONS

Portez en permanence des gants de protection et des vête ments ignifuges pour la protection de la peau et des vêtements contre les étincelles et le laitier. Gardez col, manches et poches boutonnés. Il ne faut pas remonter vos manches ou les pantalons à revers.

Quand vous travaillez dans un environnement non dédié au soudage ou découpage, portez toujours une protection des yeux appropriées ou un masque facial.

!

AVERTISSEMENT

Mettez en pratique les procédures de sécurité et de mode opératoire suivantes à chaque fois que vous utilisez cet appareil de régulation de pression. Si vous déviez de ces procédures, cela peut entraîner incendie, explosion, dégâts matériels et/ou blessures corporelles pour l’opérateur.

E Bouteilles de Gaz Comprimé

Le Département des Transports américain (DOT) approuve la conception et la fabrication des bouteilles qui contiennent les gaz utilisés pour les opérations de soudage ou de découpage.

1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la en position verticale. Fixez-la sur un chariot une cloison, un établi, etc.

Le schéma 1-1: Cylindres de gaz

SAFETY INSTRUCTIONS AND WARNINGS 1-14 Manual 0-5237

SAFETY INSTRUCTIONS

!

AVERTISSEMENT

Les bouteilles sont sous haute pression. Manipulez-les avec précautions. Des accidents sérieux peuvent résulter d’une mauvaise manutention ou d’un mauvais emploi des bouteilles de gaz comprimé. NE faites PAS tomber la bouteille, ne la cognez pas, ne l’exposez pas à une chaleur excessive, aux flammes ou étincelles. NE la cognez

PAS contre d’autres bouteilles. Contactez votre fournisseur de gaz ou reportez vous à la publication

CGA P-1 “Manipulation sécurisée des gaz comprimés en conteneur” pour plus d’informations sur l’utilisation et la manutention des bouteilles.

AVIS

Ce document CGA p. t peut être obtenu en

écrivant à “Compressed Gas Association”,

4221 Walney Roed, 5th Floor. Chantilly, VA

20151.2923, USA.

2. Placez le bouchon de protection de vanne sur la bouteille à chaque fois que vous la déplacez ou ne l’utilisez pas. Ne faites jamais glisser ou rouler d’aucune manière les bouteilles. Utilisez un diable approprié pour les déplacer.

3. Entreposez les bouteilles vides à l’écart des bouteilles pleines. Marquez-les “VIDE” et refermez leur vanne.

4. N’utilisez

JAMAIS

des bouteilles de gaz comprimé sans un régulateur de pression en série sur la vanne de bouteille.

5. Inspectez la vanne de bouteille pour y détecter de l’huile ou de la graisse, ou dès pièces endommagées.

!

AVERTISSEMENT

N’UTILISEZ PAS la bouteille si vous trouvez de l’huile, de la graisse ou des pièces endommagées. Informez immédiate ment votre fournisseur de’ gaz de cet état.

6. Ouvrez et fermez momentanément la vanne de la bouteille, délogeant ainsi d’éventu lIes poussières ou saletés. qui pour raient être présentes dans la vanne.

186 AC/DC INVERTER

Mise en Garde

Ouvrez la vanne de bouteille légèrement.

Si vous l’ouvrez trop en grand, la bouteille pourrait se renverser. Quand vous ouvrez/ fermez rapidement la vanne de bouteille, ne vous tenez pas directement devant. Opérez toujours cette opération dans une zone bien ventilée. Si une bouteille d’acétylène crache un brouillard, laissez reposer pendant 15 minutes. Essayez de nouveau la vanne. Si le problème persiste, con tactez votre fournisseur de gaz.

1.08 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.

Manual 0-5237 1-15 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER

1.09 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Sous Tension

Mono Phasé

SAFETY INSTRUCTIONS

Hors Tension

Tension dangereuse

Augmentez/Diminuer

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur

Transformateur-Redresseur

Distant

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication

Hors Tension

Torche de Soudage

Purge Du Gaz

Disjoncteur

Source AC Auxiliaire

X

%

Facteur de Marche

Pourcentage

Mode Continu de

Soudure

Soudure Par Point

Fusible

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Panneau/Local

Soudage Arc Electrique

Avec Electrode Enrobé

(SMAW)

Soudage á L’arc Avec

Fil Electrodes Fusible

(GMAW)

Soudage á L’arc Avec

Electrode Non Fusible

(GTAW)

Decoupe Arc Carbone

(CAC-A)

Courant Constant

Tension Constante

Ou Potentiel Constant

Haute Température

t1 t

Duréc du Pulse

Durée de Pré-Dèbit

t2 t

Durée de Post-Dèbit

Détente à 2-Temps

Appuyez pour démarrer l’alimentation du fils et la soudure, le relâcher pour arrêter.

Détente à 4-Temps

Maintenez appuyez pour pré-dèbit, relailez pour initier l’arc. Appuyez pour arrêter l’arc, et mainteuir pour pré-dèbit.

Probléme de Terre

Terre de Protection

Indication d’erreur

IPM

Pouces Par Minute

Ligne

Force d’Arc

MPM

Mètres Par Minute

Connexion de la Ligne

Amorçage de L’arc au

Contact (GTAW) S

Voir Note

Source Auxiliaire Inductance Variable

Voir Note

115V 15A

Classement de Prise-

Source Auxiliaire

V

Tension

Art # A-07639F_AC

à EN50192 lorsqu’utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à l’hauteur de buse correctement installé.

Ne pas déposer avec les déchets ménagers.

SAFETY INSTRUCTIONS AND WARNINGS 1-16 Manual 0-5237

SAFETY INSTRUCTIONS

1.10 Declaration Of Conformity

186 AC/DC INVERTER

Manufacturer:

Address:

Victor Technologies

16052 Swingley Ridge Road, Suite 300

St Louis, MO 63017

USA

The equipment described in this manual has been designed to all applicable aspects and regulations of the ‘Low

Voltage Directive’ (2006/95 EC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

• CSA E60974-1, UL60974-1 and IEC 60974-1 applicable to welding equipment and associated accessories.

• 2002/95/EC RoHS directive

• Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative:

Wermert

Senior Brand Manager Thermal Arc

Technologies

16052 Swingley Ridge Road

Chesterfield, Missouri 63017 USA

3163339

Manual 0-5237 1-17 SAFETY INSTRUCTIONS AND WARNINGS

186 AC/DC INVERTER

This page left blank intentionally.

SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS AND WARNINGS 1-18 Manual 0-5237

INTRODUCTION 186 AC/DC INVERTER

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual 2.03 Receipt of Equipment

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.

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 back cover of this manual.

Include all equipment identification numbers as described above along with a full description of the parts in error.

Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

You will also notice icons from the safety section appearing throughout the manual. These are to advise you of specific types of hazards or cautions related to the portion of information that follows. Some may have multiple hazards that apply and would look something like this:

2.04 Description

The Thermal Arc 186 AC/DC is a single phase constant current welding inverter capable of performing SMAW

(STICK), GTAW (HF TIG) and GTAW (LIFT TIG) welding processes. The unit is equipped with digital amperage and voltage meters, and a host of other features in order to fully satisfy the broad operating needs of the modern user. The unit is also fully compliant to Standard CSA E

60974-1-00 and UL 60974.1.

The 186 AC/DC provides excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures. The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source. Please read these instructions thoroughly before using the unit.

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, or bottom of the machine. 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 ii for future reference.

Manual 0-5237 2-1 INTRODUCTION

INTRODUCTION 186 AC/DC INVERTER

2.05 User Responsibility 2.07 Packaged Items

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided.

This equipment must be checked periodically. Defective equipment (including welding leads) should not be used.

Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Thermal Arc.

Advice in this regard can be obtained by contacting an

Accredited Thermal Arc Distributor.

This equipment or any of its parts should not be altered from standard specification without prior written approval of Thermal Arc. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Thermal Arc.

• 186 AC/DC Inverter Power Source

• Tweco 200 Amp Electrode Holder with 13ft (4m)

Lead

• Tweco 200 Amp Work Clamp with 10ft (3m) Lead

• 26 TIG Torch 13ft (4m) Lead with Integrated

Controls & Accessory

• 9ft (2.75m) Power Cord and NEMA6-50P 230V

AC Plug

• Victor Argon Flow Gauge & 12.5 ft (3.8m) Hose

• 4 General Purpose Stick Electrodes (E6013)

• Shoulder Strap

• Operating Manual & CD

• Thermal Arc Cap

2.06 Transporting Methods

This unit is equipped with a handle for carrying purposes.

!

WARNING

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.

Use handcart or similar device of adequate capacity.

If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

Figure 2-1: 186 AC/DC Packaged System

INTRODUCTION 2-2 Manual 0-5237

50

40

70

60

90

80

30

20

10

0

0

INTRODUCTION 186 AC/DC INVERTER

2.08 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 200 amperes at 18.0 volts. This means that it has been designed and built to provide the rated amperage (200A) for 2 minutes, i.e. arc welding time, out of every 10 minute period (20% of 10 minutes is 2 minutes). During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.

100

SMAW (STICK)

SAFE OPERATING REGION

(TIG & STICK)

186 AC/DC

GTAW (TIG)

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

Welding Current (AMPS)

A-11493

Figure 2-2: 186 AC/DC Duty Cycle

Manual 0-5237 2-3 INTRODUCTION

INTRODUCTION 186 AC/DC INVERTER

2.09 Specifications

Part Number

Power Source Weight

Power Source Dimensions

Cooling

Welder Type

Description

Applicable Standards / Approvals

Number of Phases

Nominal Supply Frequency

Welding Current Range (STICK Mode)

Welding Current Range (TIG Mode)

Thermal Arc 186 AC/DC INVERTER

W1006300

48.4lbs (22 kg)

H15.75"xW9.45"xD18.7"

(H 400mm x W 240mm x D 475mm)

Fan Cooled (Runs Continually)

Inverter Power Source

CSA E60974-1-00 / UL60974-1 / IEC 60974-1

5 - 170A (DC Stick)

5 - 200A (DC TIG)

1

50/60Hz

10-170A (AC Stick)

30-200A (AC LIFT TIG)

208V

10-200A (AC HF TIG)

230V Nominal Supply Voltage

Effective Input Current (I

1eff

) (See Note 1)

STICK

TIG

Maximum Input Current (I

1max

)

STICK

TIG

Single Phase Generator Requirement (See Note 2)

STICK (SMAW)

Welding Output, 40ºC, 10 min.

TIG (GTAW)

Welding Output, 40ºC, 10 min.

Open circuit voltage

Protection Class

16.4A

16.5A

15.5A

14.1A

35.6A

35.4A

9.5KVA (7KW)

170A @ 15%, 26.8V

100A @ 60%, 24.0V

80A @ 100%, 23.2V

200A @ 20%, 18V

116A @ 60%, 14.6V

90A @ 100%, 13.6V

70.3 VDC / 50VAC

IP23S

34.9A

32.4A

Table 2-1: 186 AC/DC Specification

Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements.

Note 2: Generator Requirements at the Maximum Output Duty Cycle.

INTRODUCTION 2-4 Manual 0-5237

INTRODUCTION 186 AC/DC INVERTER

2.10 Optional Accessories

26 Style TIG Torch with Remote Current Control .....Part No.

W4013600

Basic Utility Cart .......................................................... Part No. W4014700

Foot Control ................................................................. Part No. W4013200

Tweco Helmet (USA Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 4100-1004

Manual 0-5237 2-5 INTRODUCTION

INTRODUCTION 186 AC/DC INVERTER

2.11 Volt-Ampere Curves

Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source.

Curves of other settings fall between curves shown.

100

50

40

30

20

90

80

70

60

10

0

0 20 40 60 80

186 AC/DC

100 120 140

Welding Current (AMPS)

160 180 200 220

A-11583

240

TIG

STICK

Figure 2-3: 186 AC/DC Volt-Amp Curves

INTRODUCTION 2-6 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

SECTION 3:

INSTALLATION, OPERATION AND SETUP

3.01 Environment

These units are designed for use in environments with increased hazard of electric shock as outlined in EN

60974.1. Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock. Please refer to relevant local standards for further information prior to using in such areas.

G. The enclosure design of this power source meets the requirements of IP23S as outlined in EN 60529. This provides adequate protection against solid objects

(greater than 0.5" (12mm)), and direct protection from vertical drops. Under no circumstances should the unit be operated or connected in a micro environment that will exceed the stated conditions.

For further information please refer to EN 60529.

A. Examples of environments with increased hazard of electric shock are:

H. Precautions must be taken against the power source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

1. 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.

WARNING

2. 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.

This equipment should be electrically connected by a qualified electrician.

3.03 Ventilation

3. In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories.

B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

!

WARNING

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

3.04 Mains Supply Voltage

Requirements

3.02 Location

Be sure to locate the welder according to the following guidelines:

A. In areas, free from moisture and dust.

B. Ambient temperature between 0° C to 40° C.

C. In areas, free from oil, steam and corrosive gases.

D. In areas, not subjected to abnormal vibration or shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 12" (300 mm) or more from walls or similar that could restrict natural air flow for cooling.

The Mains supply voltage should be within ± 15% of the rated mains supply voltage. Too low a voltage may cause poor welding performance. Too high a supply voltage will cause components to overheat and possibly fail.

The Welding Power Source must be:

• Correctly installed, if necessary, by a qualified electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point and fuse as per the Specifications on page 3-2.

Manual 0-5237 3-1 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

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. Lock-out/ 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.

Power Cords Included With Power Supply

Attached to the power supply is an input power cord with a 208/230Volt 50 Amp NEMA 6-50 P for plug.

WARNING

An electrical shock or fire hazard is probable if the following electrical service guide recommendations are not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding Power Source.

Supply Voltage

Input Current at Maximum Output

Maximum Recommended Fuse* or Circuit Breaker Rating

* Time Delay Fuse, UL class RK5. Refer to UL248

Maximum Recommended Fuse^ or Circuit Breaker Rating

^Normal Operating , UL class K5. Refer to UL248

Minimum Recommended Cord Size

Maximum Recommended Extension Cord Length

Minimum Recommended Grounding Conductor Size

Table 3-1: Electrical Service Guide

50 / 60 Hz Single

Phase Supply

208/230V AC

32 Amps

50 Amps

50 Amps

12 AWG

50 ft

12 AWG

3.05 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. 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 COMPUTER

It is also possible that operation close to computer installations may cause computer malfunction.

INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

3.06 High Frequency Interference

Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways.

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 minimise this type of interference. Looping and suspending of leads should be avoided wherever possible.

4. Re-Radiation from Unearthed Metallic Objects: A major factor contributing to interference is re-radiation from unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent reradiation in most cases.

3.07 Electromagnetic Compatibility

!

WARNING

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input filters.

In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer Troublesome.

NOTE

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

B. Assessment of Area

Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account.

1. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pace-makers and hearing aids.

6. Equipment used for calibration and measurement.

Manual 0-5237 3-3 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

7. The time of day that welding or other activities are to be carried out.

8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

C. Methods of Reducing Electromagnetic Emissions

1. Electricity Supply

Welding equipment should be connected to the Electricity Supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the Electricity Supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions.

3. Welding Cables

The welding cables should be kept as short as possible and should be positioned close together but never coiled and running at or close to the floor level.

4. Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Earthing/grounding of the Work Piece

Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to earth should be made by direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

6. Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications.

INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

3.08 186 AC/DC Power Source Controls, Indicators and Features

18 19 5

17

16

AC

DC

A V

VOLTS

SECONDS

PERCENT (%)

FREQ (Hz) t1

Pre

Flow

Hot

Start

Hot

Start

I z

Initial

Current

Amps

Up

Slope

I s

Weld

Current

I

1

High Current w

I

2 f

Volts

Down

Slope

I e

Crater

Current t2

Post

Flow

WAVE BALANCE

ARC FORCE

POWER

FAULT

7

6

15

14

13

12

200

AC/DC

Inverter

WeldSkill

8

9

10

11

8

1 2

Figure 3-1: Controls on Front Panel

3 4

A-11495_AB

20

OFF

ON

21

22

Manual 0-5237

A-11232

Figure 3-2: Rear Panel

3-5 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

1. Positive Welding Terminal

Positive Welding Terminal 2" (50mm) dinse. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

2. 8 Pin Control Socket

The 8 pin receptacle is used to connect a trigger switch or remote control to the welding Power Source circuitry:

To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the 8 pin receptacle.

NOTE

When not using a Remote, disconnect any remote control device or it may limit the preview and actual output current range.

Socket Pin

3

4

1

2

5

6

7

8

Not used

Trigger Switch Input

Trigger Switch Input

Not used

Remote Control 5k ohm Potentiometers Maximum

Remote Control 5k ohm Potentiometers Minimum

Remote Control 5k ohm Potentiometer Wiper

Not used

Part Number / Description

Table 3-2: 8 Pin Control Plug Configuration

3. Negative Welding Terminal

5

8

2

4

7

1

3

6

A-11228

Negative Welding Terminal 50 mm dinse. Welding current flows from the Power Source via heavy duty bayonet type terminals. 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 terminal.

4. Shielding Gas Outlet

The Shielding Gas Outlet located on the front panel is a 5/8-18 UNF female gas fitting and is utilized for the connection of a suitable TIG Torch.

5. Power ON Indicator

The POWER ON indicator illuminates when the ON/OFF switch (20) is in the ON position and the correct mains voltage is present.

6. Fault Indicator (Thermal Overload or Primary Circuit Overcurrent)

The Fault Indicator will illuminate in conjunction with an “Err 001” displayed on the ammeter and voltmeter digital displays if either of the following two conditions exists

INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

1. Thermal Overload

This is due to the duty cycle of the power source being exceeded. Once the power source cools sufficiently it will automatically reset and the Fault Indicator and Err 001 will go off and the power source is then able to continue welding. During the time of cooling the power source should remain ON such that the fan continues to operate allowing the unit to cool sufficiently. If after 30 minutes with the fan running the Fault

Indicator has not gone OFF then have an Accredited Thermal Arc Service Provider check the power source.

2. Primary Circuit Overcurrent

This is due to primary circuit component(s) malfunctioning which results in excessive primary circuit current. Switch OFF the power source immediately to allow all components to cool down for at least 30 minutes. If after 30 minutes “Err 001” is displayed and Fault Indicator illuminates when the power source is switched back ON turn the power source OFF and have an Accredited Thermal Arc Service Provider check the power source.

7. Process Selection Button

The process selection control is used to select the desired welding mode. Three modes are available, GTAW

(LIFT TIG), GTAW (HF TIG) and SMAW (Stick) modes.

Note that when the unit is powered off the mode selection control will automatically default to LIFT TIG mode.

This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up.

8. Trigger Mode Control Button (HF TIG and LIFT TIG Mode only)

The trigger mode control is used to switch the functionality of the torch trigger between 2T (normal), and 4T

(latch mode).

2T Normal Mode

In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.

NOTE

When operating in GTAW (HF and LIFT TIG modes), the power source will remain active until the selected down slope time has elapsed.

High

Low

A-11409

Figure 3-3

4T Latch Mode

This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the

Manual 0-5237 3-7 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

trigger switch must again be depressed and realized, thus eliminating the need for the operator to hold the torch trigger.

Note that when operating in GTAW (HF and LIFT TIG modes), the power source will remain activated until the selected down slope time has elapsed

NOTE

This Up Slope operates in (4T) 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 Current to High or Weld

Current.

AMPS

High

Current

Weld

Current

Initial

Current

Arc Ignited

Pre

Flow

Press & hold

Trigger

Release

Trigger

Up

Slope

Crater

Current

Press & hold

Trigger

Down

Slope

Post

Flow

Release

Trigger

Arc Terminated

TIME

A-11410_AB

Figure 3-4

9. Wave Balance / Arc Force Indicator

This indicator light will illuminate when programming Wave Balance (AC HF TIG mode only) or Arc Force

(STICK mode only).

10. Forward Programming Button

Pressing this button will advance to the next step in the programming sequence.

11. Multifunction Control

The multifunction control knob is used to adjust welding current.

It is also used to adjust parameters when in programming mode.

12. Back Programming Button

Pressing this button will go back to the previous step in the programming sequence.

13. AC frequency Indicator

This indicator light will illuminate when programming AC Frequency (AC HF TIG mode only).

14. Purge Button

Press the PURGE button to purge the gas line in LIFT TIG and HF TIG modes. To PURGE the shielding gas line in LIFT TIG and HF TIG modes press the PURGE button and release. The indicator will illuminate and shielding gas will purge for a preset period of 15 seconds. (This cannot be adjusted). To stop shielding gas from purging within this time press the PURGE button and release and the purge indicator will extinguish and shielding gas will cease.

INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

15 Pulse Button

Press the PULSE button to toggle Pulse On and OFF in LIFT TIG and HF TIG modes

16. Programming Parameter Indicators (Front Panel Display Indicators)

The Front Panel LED indicators serve two purposes. First, they show what process and what parameter is selected and the value of that parameter. The AMP DISPLAY shows only amperage values measured in AMPS, the VOLT DISPLAY can indicate Voltage, Time, Percentage, or Frequency. The UNITES lights indicate the unit of measurement for the reading on the VOLT DISPLAY: Volts (V), Seconds (SEC), Percent (%),Hertz (HZ). Only the parameters that are applicable to a specific PROCESS, MODE, or TRIGGER SELECTION will light when using the FORWARD or BACK programming switches. Secondly, during the welding process, the following sequence indicators will light to indicate the specific phase of the weld process which is active:

HOT START

INITIAL CURRENT (4T)

UPSLOPE (4T)

WELD CURRENT (PULSING OFF)

HIGH CURRENT (PULSING ON)

LOW CURRENT (PULSING ON)

DOWNSLOPE

CRATER CURRENT (4T)

POST FLOW

17. Mode Button

Press the MODE button to toggle AC and DC output in all Process modes

18. Digital Ammeter

The digital amperage meter is used to display both the pre-set current and actual output current of the power source.

At times of non-welding, the amperage meter will display a pre-set (preview) amperage value. This value can be adjusted by varying the multifunction control when the Programming Parameter Indicator light shows

WELD CURRENT .

When welding, the amperage meter will display actual welding current.

Should a remote device be connected the maximum setting of the power source will be determined by the respective front panel control, irrespective of the remote control device setting. As an example, if the output current on the power source front panel is set to 50% and the remote control device is set to 100%, the maximum achievable output from the unit will be 50%. Should 100% output be required, the respective power source front panel control must be set to 100%, in which case the remote device will then be able to control between 0-100% output.

19. Digital Voltmeter / Parameter meter

The digital volt meter is used to display the actual output voltage of the power source. It is also used to display

Parameters in Programming Mode.

Depending on the Programming Parameter selected, the status indictor adjacent to the volt meter will illuminate to show the units of the programming parameter.

When welding, the volt meter will display actual welding voltage.

Manual 0-5237 3-9 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

20. ON / OFF Switch

This Switch is located on the rear of the Power Source and turns mains power off and on.

!

WARNING

When the front digital displays are lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential

21. Shielding Gas Inlet

Unit has a 5/8" Inert gas fitting suitable for connection of a gas hose to a regulated Shielding Gas Supply. The

Shielding Gas inlet is located on the rear of the Power Source.

22. Cooling Fan

The 186 AC/DC is fitted with a cooling fan that will operate continuously when the ON/OFF switch on the rear panel is switched to the ON position.

3.09 186 AC/DC - STICK Programming Mode

Press the PROCESS SELECTION button to select STICK mode.

Press the MODE switch to toggle between AC and DC welding output.

Press FORWARD or BACK to cycle through available programming functions.

Use the Multi Function Control to adjust the Parameter selected.

While welding the Multi Function Control directly controls the WELD CURRENT.

MODE

PULSE

I z

PURGE t1

AC FREQUENCY

A

I s

I

1

High Current w

Width f

Frequency

I

2

V

V

SEC

%

Hz

I e

PROCESS

LIFT TIG

HF TIG

STICK t2

WAVE BALANCE

ARC FORCE

TRIGGER

2T

4T

BACK

P O R T A B L E W E L D I N G S Y S T E M

FORWARD

Adjust programming parameter

Press to go forward / go back between programming status

LED’s

A-11496_AB

Figure 3-5: Stick Programming Mode

INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

Programming Parameter

Hot Start

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 the peak start current on top of the WELD current.

Adjustment Device Display

Amps

0 to 70A (max 170A weld current) e.g. HOT START current = 130 amps when

WELD = 100 amps & HOT START = 30 amps

Weld Current

This parameter sets the TIG WELD current when PULSE is OFF. This parameter also sets the STICK weld current.

Amps

Arc Force (STICK Mode only)

Arc Force is effective when in STICK Mode only. Arc Force control provides and adjustable amount of Arc Force (or "dig") control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit-up in certain situations with particular electrodes. In general increasing the Arc Force control toward 100% (maximum

Arc Force) allows greater penetration control to be achieved.

Table 3-3

3.10 186 AC/DC – LIFT TIG and HF TIG Programming Mode

Press the PROCESS SELECTION button to select LIFT TIG or HF TIG mode.

Press the MODE switch to toggle between AC and DC welding output.

Press FORWARD or BACK to cycle through available programming functions.

Use the Multi Function Control to adjust the parameter selected.

5 to 170A (DC STICK mode)

10 to 170A (AC STICK mode)

V

SEC

%

Hz

Volts

0 to 100%

Manual 0-5237 3-11 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

MODE

PULSE

PURGE

A V

V

SEC

%

Hz t1

Pre

Flow

Hot

Start

I z

Initial

Current

Up

Slope

AC FREQUENCY

I s

Weld

Current

I

1

High Current w

Width f

Frequency

I

2

Low

Current

Down

Slope

PROCESS

I e

Crater

Current t2

Post

Flow

WAVE BALANCE

ARC FORCE

TRIGGER

2T

4T

LIFT TIG

HF TIG

STICK

BACK

P O R T A B L E W E L D I N G S Y S T E M

FORWARD

Adjust programming parameter using the Multi Function Control knob

Press to go forward / go back between programming status

LED’s

A-11497_AB

Figure 3-6: LIFT TIG and HF TIG Programming Mode

Programming Parameter

Pre-Flow

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.

Initial Current

This parameter operates in (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.

Note: The maximum initial current available will be limited to the set value of the weld current.

Adjustment Device Display

Volts

0.0 to 1.0 second

Amps

V

SEC

%

Hz

5 to 200 Amps (DC TIG mode)

30 to 200 Amps (AC LIFT TIG mode)

10 to 200A (AC HF TIG mode)

INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

Programming Parameter

Up Slope

This parameter operates in (4T)

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 Current to

High or Weld current.

Weld Current

This parameter sets the TIG

WELD current when PULSE is

OFF. This parameter also sets the

STICK weld current.

Adjustment Device Display

Volts

0.0 to 15.0 seconds

V

SEC

%

Hz

Amps

5 to 200A (DC TIG mode)

30 to 200A (AC LIFT TIG mode)

10 to 200A (AC HF TIG mode)

High Current

This parameter sets the High weld current when in PULSE mode.

Amps

10 to 200A (DC TIG mode)

30 to 200A (AC TIG mode)

Low Current

The lowest point in the pulse is called the Low Current.

Pulse Width

This parameter sets the percentage on time of the PULSE

FREQUENCY for High weld current when the PULSE is ON.

Pulse Frequency

This parameter sets the PULSE

FREQUENCY when the PULSE is

ON.

Amps

5 to 200A (DC HF TIG mode)

30 to 200A (AC LIFT TIG mode)

10 to 200A (AC HF TIG mode)

V

SEC

%

Hz

Volts

15 to 80%

Volts

0.5 to 200 Hz

V

SEC

%

Hz

Manual 0-5237 3-13 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

Programming Parameter

Down Slope

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 current. This control is used to eliminate the crater that can form at the completion of a weld.

Crater Current

This parameter operates in (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.

Note: The maximum crater current available will be limited to the set value of the weld current.

Post Flow

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.

AC Frequency

This parameter operates in AC

TIG mode only and is used to set the frequency for the AC weld current.

Adjustment Device Display

Volts

0.0 to 25.0 seconds

Amps

Volts

0.0 to 60.0 seconds

Volts

V

SEC

%

Hz

V

SEC

%

Hz

5 to 200A (DC TIG mode)

30 to 200A (AC TIG mode)

10 to 200A (AC HF TIG mode)

V

SEC

%

Hz

15 to 150 Hz

INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

Programming Parameter

Wave Balance

This parameter operates in 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% from the factory for AC

TIG 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 oxidized aluminium or magnesium alloys is achieved when the WAVE BALANCE control is set to 65%.

Adjustment Device

Table 3-4

WAVE BALANCE is used for aluminium welding in AC HF TIG or AC LIFT TIG mode

Display

Volts

10 to 65%

V

SEC

%

Hz

It is used to set the ratio of penetration to cleaning action for the AC TIG welding arc.

Maximum weld penetration is achieved when the WAVE BALANCE is set to 10%. Maximum cleaning of heavily oxidized aluminium or magnesium alloys is achieved when the WAVE BALANCE is set to 65%.

Wave Balance = 50%

50%

(+)

Wave Balance = 10% Wave Balance = 65%

10%

(+)

65%

(+)

(-)

50%

Balanced with 50% penetration and 50% cleaning

(-)

90%

Maximum Penetration and reduced cleaning

(-)

35%

Maximum Cleaning and reduced penetration

A-11223

Table 3-5: AC TIG Wave Balance

Manual 0-5237 3-15 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

3.11 Short Circuit Protection While Welding

To prolong the useful life of a TIG tungsten electrode and eliminate tungsten contamination to welding point, the

186 AC/DC incorporates special circuitry.

In all TIG processes, after the welding arc has established, if the tungsten electrode touches the work the current defaults to 33 amps. If the short exists for more than 1-2 seconds, the output is turned off.

In STICK mode, if the electrode touches the work for more than two seconds the welding current is reduced to

0 Amps.

3.12 Victor Regulator

Pressure regulator (Figure 3-7) attached to the cylinder valve reduce high cylinder pressures to suitable low working pressures for welding, cutting, and other applications.

FLOW GAUGE

HIGH PRESSURE

GAUGE (SUPPLY)

INLET

CONNECTION

OUTLET

CONNECTION

PRESSURE

ADJUSTING

SCREW

A-09414_AB

Figure 3-7: Victor CS Regulator

!

WARNING

Use the regulator for the gas and pressure for which it is designed. NEVER alter a regulator for use with any other gas.

NOTE

Regulators purchased with open 1/8", 1/4", 3/8", or 1/2" NPT ports must be assembled to their intended system.

1. Note the maximum inlet pressure stamped on the regulator. DO NOT attach the regulator to a system that has a higher pressure than the maximum rated pressure stamped on the regulator.

2. The regulator body will be stamped “IN" or “HP" at the inlet port. Attach the inlet port to the system supply pressure connection.

3. If gauges are to be attached to the regulator and the regu lator is stamped and listed by a third party (i.e.

“UL" or “ETL"). The following requirements must be met: a) Inlet gauges over 1000 PSIG (6.87 mPa) shall conform with the requirements of UL 404, “Indicating

Pressure Gauges for Compressed Gas Service." b) Low pressure gauges must be UL recognized for the class of regulator they are being used on according to UL252A.

INSTALLATION, OPERATION AND SETUP 3-16 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

!

WARNING

DO NOT use a regulator that delivers pressure exceeding the pressure rating of the downstream equipment unless pro visions are made to prevent over-pressurization (i.e. system relief valve). Make sure the pressure rating of the down stream equipment is compatible with the maximum delivery pressure of the regulator.

4. Be sure that the regulator has the correct pressure rating and gas service for the cylinder used.

5. Carefully inspect the regulator for damaged threads, dirt, dust, grease, oil, or other flammable substances.

Remove dust and dirt with a clean cloth. Be sure the inlet swivel filter is clean and in place. Attach the regulator (Figure 3-9) to the cylinder valve. Tighten securely with a wrench.

!

WARNING

DO NOT attach or use the regulator if oil, grease, flamma ble substances or damage is present! Have a qualified repair technician clean the regulator or repair any damage.

Art # A-09845

Figure 3-8: Regulator to Cylinder Valve

6. Before opening the cylinder valve, turn the regulator adjusting screw counterclockwise until there is no pressure on the adjusting spring and the screw turns freely.

7. Relief Valve (where provided): The relief valve is designed to protect the low pressure side of the regulator from high pres sures. Relief valves are not intended to protect down stream equipment from high pressures.

!

WARNING

DO NOT tamper with the relief valve or remove it from the regulator.

!

WARNING

Stand to the side of the cylinder opposite the regulator when opening the cylinder valve. Keep the cylinder valve between you and the regulator. For your safety, NEVER STAND IN FRONT OF OR BEHIND

A REGULATOR WHEN OPENING THE CYLINDER VALVE!

8. Slowly and carefully open the cylinder valve (Figure 3-9) until the maximum pressure shows on the high pressure gauge.

Manual 0-5237 3-17 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

Art # A-09828

Figure 3-9: Open Cylinder Valve

9. Open the cylinder valve completely to seal the valve packing. On gaugeless regulators, the indicator will register the cylinder contents open.

CAUTION

Keep the cylinder valve wrench, if one is required, on the cylinder valve to turn off the cylinder quickly, if necessary.

10. Attach the desired downstream equipment.

3.13 Specification for TIG Torch

1. SPECIFICATION FOR TIG TORCH PART NO: W4013600 TO SUIT THERMAL ARC 186AC/DC

TIG Torch Contents include:

1 x 26 TIG Torch with Long Back Cap, 12.5 ft lead length, 10.5" gas hose length, 9.5" control lead with 8 pin plug and Rigid Head.

Remote Control Cartridge, Potentiometer with integrated on/off switch (installed).

A-11556

NOTE: The additional switches/controls below are interchangeable with the installed control in the TIG torch.

INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

ART# A-11587

Control module with push button on/off switch only.

Control module with push button on/off switch with roller potentiometer.

Additional On/Off Switch Cartridge in a Sealed Plastic Bag.

Control module with roller potentiometer and integrated on/off switch.

Additional On/Off Switch-Remote Amperage Control Cartridge in a Sealed Plastic Bag (NOTE: You will not be able to view the pre-set amperage on the power source with this control, amperage will not be viewable until the arc is initiated).

A-11557

1 x Accessory Kit containing 1 x Short Back Cap, 1 x Collet Body 1/8" (3.2mm),

1 x Collet Body 3/32" (2.4mm), 1 x Collet Body 1/16" (1.6mm), 1 x Collet 1/8" (3.2mm), 1 x Collet 3/32" (2.4mm),

1 x Collet 1/16" (1.6mm), 1 x Nozzle Alumina No5, 1 x Nozzle Alumina No6, 1 x Nozzle Alumina No7, 1 x Tungsten

Electrode 1/8" (3.2mm) Thoriated Type (red band), 1 x Tungsten Electrode 3/32" (2.4 mm) Thoriated Type (red band) and 1 x Tungsten Electrode 1/16" (1.6mm) Thoriated Type (red band).

3.14 Setup for TIG (GTAW) Welding

A. Select Lift TIG or HF TIG mode with the process selection control (refer to Section 3.08.7 for further information).

B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via heavy duty bayonet type terminals. 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.

D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below. The TIG torch will require a trigger switch to operate in Lift TIG or HF TIG Mode.

Note: See Appendix A3 for TIG torch contents and trigger switch options.

Manual 0-5237 3-19 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

NOTE

If the TIG torch has a remote TIG torch current control fitted then it will require to be connected to the

8 pin socket. (Refer to section 3.08.2 Remote Control Socket for further information).

E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.12) then connect the shielding gas hose from the regulator/flowmeter outlet to the gas INLET on the rear of the

186 AC/DC Power Source. Connect the gas hose from the TIG torch to the gas OUTLET on the front of the 186

AC/DC Power Source.

!

WARNING

Before connecting the work clamp to the work make sure the mains power supply is switched off.

Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

MODE

A V

V

SEC

%

Hz

PULSE

PURGE t1

Pre

Flow

Hot

Start

I z

Initial

Current

AC FREQUENCY

Up

Slope

I s

Weld

Current

I

1

High Current w

Width f

Frequency

I

2

Low

Current

Down

Slope

PROCESS

I e

Crater

Current

Post

Flow t2

WAVE BALANCE

ARC FORCE

TRIGGER

2T

4T

LIFT TIG

HF TIG

STICK

FORWARD BACK

P O R T A B L E W E L D I N G S Y S T E M

Positive Welding

Terminal (+)

8

Work Lead

8 Pin Control Socket

Tig Torch

Figure 3-10: Setup for TIG Welding

A-11498_AB

INSTALLATION, OPERATION AND SETUP 3-20

Negative Welding

Terminal (-)

Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

NOTE

When the 186 AC/DC is used with a Remote Foot Control in, depress foot control to maximum to allow max current to be previewed/adjusted on the front panel. To avoid premature arcing, please ensure the

TIG Torch is located away from your work piece.

LIFT TIG (GTAW) Sequence of Operation

CAUTION

Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.

1. Switch the ON/OFF Switch (located on the rear panel) to OFF.

2. Connect the ground (work) clamp cable to positive output terminal. It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection.

3. Connect the TIG torch as follows: a) Place the power cable into the negative output terminal. It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection; b) Place the 8 pin plug into the 8 pin socket. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. c) Place the TIG torch gas hose to the gas outlet and tighten with a wrench. Caution: DO NOT over tighten.

4. Using a secured Argon cylinder, slowly crack open then close the cylinder valve while standing off to the side of the valve. This will remove any debris that may be around the valve & regulator seat area.

5. Install the regulator (for details of VICTOR regulator, please refer to 3.18) and tighten with a wrench.

6. Connect one end of the supplied gas hose to the outlet of the Argon regulator and tighten with a wrench.

Caution: DO NOT over tighten.

7. Connect the other end of the supplied gas hose to the gas inlet fitting on the rear panel of the welder and tighten with a wrench. Caution: DO NOT over tighten.

8. Open the Argon Cylinder Valve to the fully open position.

9. Connect the ground (work) clamp to your work piece.

10. Set the DOWN SLOPE control knob to the desire weld current ramp down time.

11. Set the weld current control knob to the desired amperage.

12. The tungsten must be ground to a blunt point in order to achieve optimum welding results. It is critical to grind the tungsten electrode in the direction the grinding wheel is turning.

13. Install the tungsten with approximately 1/8" (3.2mm) to ¼" (6.0mm) sticking out from the gas cup, ensuring you have correct sized collet.

14. Tighten the back cap then open the valve on the torch.

15. Plug the power cable into the appropriate outlet, and turn the switch to the “ON" position. The power L.E.D. light should illuminate. Set the “Process Selection Switch" to LIFT TIG.

16. You are now ready to begin TIG Welding.

Manual 0-5237 3-21 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

NOTE

When the 186 AC/DC is used with a Remote Foot Control in, depress foot control to maximum to allow max current to be previewed/adjusted on the front panel. To avoid premature arcing, please ensure the

TIG Torch is located away from your work piece.

3.15 Setup for STICK (SMAW) Welding

A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.

Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Select STICK mode with the process selection control (refer to Section 3.08.7 for further information)

!

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the mains power supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the

Welding Power Source.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

INSTALLATION, OPERATION AND SETUP 3-22 Manual 0-5237

INSTALLATION/SETUP 186 AC/DC INVERTER

Positive Welding

Terminal (+)

MODE

PULSE

PURGE t1

Start

I z

Initial

Current

AC FREQUENCY

A

I s

I

1

Width f

Frequency

I

2

V

V

SEC

%

Hz

I e

Crater

Current t2

PROCESS

LIFT TIG

HF TIG

STICK

WAVE BALANCE

ARC FORCE

TRIGGER

2T

4T

BACK

P O R T A B L E W E L D I N G S Y S T E M

FORWARD

Negative Welding

Terminal (-)

8

Electrode Holder

Work Lead

A-11499_AB

200A

Figure 3-11: Setup for Manual Arc Welding.

Manual 0-5237 3-23 INSTALLATION, OPERATION AND SETUP

186 AC/DC INVERTER INSTALLATION/SETUP

INSTALLATION, OPERATION AND SETUP 3-24 Manual 0-5237

BASIC WELDING 186 AC/DC INVERTER

SECTION 4:

BASIC WELDING GUIDE

4.01 STICK (SMAW) Basic Welding Technique

Size of Electrode

The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes.

For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode for a given application.

Storage of Electrodes

Always store electrodes in a dry place and in their original containers.

Electrode Polarity

Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited Thermal Arc Distributor.

Effects of Stick Welding Various Materials

A. High Tensile and Alloy Steels

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.

B. 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.

C. 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.

D. Copper and Alloys

The most important factor is the high rate of heat conductivity of copper, making pre-heating of heavy sections necessary to give proper fusion of weld and base metal.

E. 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.

Manual 0-5237 4-1 BASIC WELDING GUIDE

186 AC/DC INVERTER BASIC WELDING

Metal Being Joined

Mild Steel

Mild Steel

Mild Steel

Mild Steel

Cast Iron

Stainless Steel

Welding Position

Electrode

E6011

E6013

E7014

Comments

This electrode is used for all-position welding or for welding on rusty, dirty, less-than-new metal. It has a deep, penetrating arc and is often the first choice for repair or maintenance work.

This all-position, electrode is used for welding clean, new sheet metal. Its soft arc has minimal spatter, moderate penetration and an easy-to-clean slag.

All positional, ease to use electrode for use on thicker steel than

E6013. Especially suitable sheet metal lap joints and fillet welds, general purpose plate welding.

E7018

Eni-Cl

A low-hydrogen, all-position electrode used when quality is an issue or for hard-to-weld metals. It has the capability of producing more uniform weld metal, which has better impact properties at low temperatures.

Suitable for joining all cast irons except white cast iron.

E318L-16 High corrosion resistances. Ideal for dairy work etc.

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-5 through 4-12.

Art # A-07687

Figure 4-1: Flat Position, Down Hand Butt Weld

Art A-07691

Figure 4-5: Vertical Position, Butt Weld

Art # A-07688

Figure 4-2: Flat Position, Gravity Fillet Weld

Art # A-07692

Figure 4-6: Vertical Position, Fillet Weld

Art # A-07689

Figure 4-3: Horizontal Position, Butt Weld

Art # A-07690

Figure 4-4: Horizontal-Vertical (HV) Position

BASIC WELDING GUIDE 4-2

Art# A-07693

Figure 4-7: Overhead Position, Butt Weld

Manual 0-5237

BASIC WELDING 186 AC/DC INVERTER

Art # A-07694

Figure 4-8: Overhead Position, Fillet Weld

Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-9.

Open Square Butt

Joint

Gap varies from

1/16” (1.6mm) to 3/16” (4.8mm)

depending on plate thickness

Single Vee Butt Joint

Not less than

70°

1/16” (1.6mm) max

Single Vee Butt Joint

Not less than

45°

1/16” (1.6mm)

Double Vee Butt Joint

Not less than

70°

1/16” (1.6mm) max

Lap Joint

Fillet Joint

Corner Weld

Tee Joints

(Fillet both sides of the joint)

Edge Joint

1/16” (1.6mm)

Plug Weld Plug Weld

Art # A-10672

Figure 4-9: Typical Joint Designs for Arc Welding

Manual 0-5237 4-3 BASIC WELDING GUIDE

186 AC/DC INVERTER BASIC WELDING

Arc Welding Technique - A Word to Beginners

For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 1/4" (6.0mm) thick and a 1/8" (3.2mm) electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position. Make sure that the work clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

The Welder

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down.

Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down.

Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock.

Striking the Arc

Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience difficulty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck.

As soon as the arc is established, maintain a 1/16" (1.6mm) to 1/8" (3.2mm) gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difficulty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

20°

Art # A-07696_AB

1.6 mm (1/16”)

Figure 4-10: Striking an Arc

Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will find that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in. If this should happen, give the electrode a quick twist back over the weld to detach it.

Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules.

If the travel is too slow, the weld metal piles up and the bead will be too large.

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BASIC WELDING 186 AC/DC INVERTER

Making Welded Joints

Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in Figure 4-11, allowing 1/16" (1.6mm) to 3/32" (2.4mm) gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment. Plates thicker than 1/4" (6.0mm) should have their mating edges bevelled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a wellformed bead. At first you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this.

The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc.

To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

20°-30°

Electrode

Tack Weld

Tack Weld

Figure 4-11: Butt Weld

Art # A-07697_AB

Art # A-07698

Figure 4-12: Weld Build up Sequence

Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run.

Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-12. The width of weave should not be more than three times the core wire diameter of the electrode. When the joint is completely filled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

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186 AC/DC INVERTER BASIC WELDING

B. Fillet Welds

C. Vertical Welds

1. Vertical Up

These are welds of approximately triangular crosssection made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure

4-4.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. This is known as a horizontal-vertical (HV) fillet. Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about

45º from the vertical. Some electrodes require to be sloped about 20º away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 4-13. Do not attempt to build up much larger than 1/4" (6.4mm) width with a 1/8" (3.2mm) electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-14. Weaving in HV fillet welds is undesirable.

Tack weld a three feet length of angle iron to your work bench in an upright position. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet.

The electrode needs to be about 10º from the horizontal to enable a good bead to be deposited. Refer Figure 4-15. Use a short arc, and do not attempt to weave on the first run.

When the first run has been completed de-slag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necessary to cover the first run and obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure

4-16 illustrates multi-run technique and Figure

4-17 shows the effects of pausing at the edge of weave and of weaving too rapidly.

45° from vertical

Art # A-07701

60° - 70° from line of weld

Art # A-07699_AB

Figure 4-13: Electrode Position for HV Fillet Weld

Art # A-07700_AB

6

3

1

5

2

4

Figure 4-`14: Multi-runs in HV Fillet Weld

Figure 4-15: Single Run Vertical Fillet Weld

Art # A-07702

Figure 4-16: Multi Run Vertical Fillet Weld

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BASIC WELDING 186 AC/DC INVERTER

Art # A-07703

Figure 4-17: Examples of Vertical Fillet Welds

2. Vertical Down

Use a 1/8" (3.2mm) electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag.

The electrode should point upwards at an angle of about 45º.

3. Overhead Welds

Apart from the rather awkward position necessary, overhead welding is not much more difficult that downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-18). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead fillet welds.

Art # A-07704

Figure 4-18: Overhead Fillet Weld

Distortion

Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.

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186 AC/DC INVERTER BASIC WELDING

The Cause of Distortion

Art # A-07705_AB

Weld

Upsetting

Distortion is caused by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to flow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint in 5/64" (2.0mm) sheet, the contracting weld metal may cause the sheet to become distorted.

B. Expansion and Contraction of Parent Metal in the Fusion Zone:

While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or

"along the weld", it meets considerable resistance, and to fulfil the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset". When the weld area begins to cool, the

"upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal. Several things can then happen.

The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain

"locked-up" stresses in the job. Figures 4-19 and

4- 20 illustrate how distortion is created.

Art # A-07706_AC

Hot

Weld

Hot

Expansion with compression

Cool

Figure 4-19: Parent Metal Expansion

Permanent Upset

Contraction with tension

Figure 4-20: Parent Metal Contraction

Overcoming Distortion Effects

There are several methods of minimizing distortion effects.

A. Peening

This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.

B. Distribution of Stresses

Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out.

See Figures 4-20 through 4-23 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack welds are methods employed with this in view.

D. Presetting

It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment. A simple example is shown in Figure 4-21.

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BASIC WELDING 186 AC/DC INVERTER

E. Preheating

3

Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-22 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

1

Art # A-07710_AB

2

Block Sequence.

The spaces between the welds are filled in when the welds are cool.

Figure 4-24: Welding Sequence

1

2

3

4

Preheat

Art # A-07707

Figure 4-21: Principle of Presetting

Art # A-07708

B

Weld

C

Preheat

Art # A-07711_AB

Figure 4-25: Step back Sequence

Dotted lines show effect if no preheat is used

Figure 4-22: Reduction of Distortion by Preheating

Art # A-07709

Art # A-07428_AB

Figure 4-26: Chain Intermittent Welding

Art # A-07713_AB

Figure 4-23: Examples of Distortion

Figure 4-27: Staggered Intermittent Welding

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186 AC/DC INVERTER BASIC WELDING

4.02 STICK (SMAW) Welding Troubleshooting

FAULT

1 Welding current varying

CAUSE

ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length.

REMEDY

Reduce the ARC FORCE control knob until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig" the electrode into the workpiece.

2 A gap is left by failure of the weld metal to fill the root of the weld.

A Welding current too low

B Electrode too large for joint.

C Insufficient gap.

A Increase welding current.

B Use smaller diameter electrode.

C Allow wider gap.

3 Non-metallic particles are trapped in the weld metal.

A Non-metallic particles may be trapped in undercut from previous run.

A If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode.

B Joint preparation too restricted.

C Irregular deposits allow slag to be trapped.

B Allow for adequate penetration and room for cleaning out the slag.

C If very bad, chip or grind out irregularities.

D Lack of penetration with slag trapped beneath weld bead.

D Use smaller electrode with sufficient current to give adequate penetration. Use suitable tools to remove all slag from comers.

E Clean joint before welding.

E Rust or mill scale is preventing full fusion.

F Wrong electrode for position in which welding is done.

F Use electrodes designed for position in which welding is done, otherwise proper control of slag is difficult.

Art: A-04971

Figure 1 - Example of insufficient gap or incorrect sequence

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BASIC WELDING 186 AC/DC INVERTER

FAULT CAUSE REMEDY

4 A groove has been formed in the base metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut).

A Welding current is too high.

C Angle of the electrode is incorrect.

A Reduce welding current.

B Welding arc is too long.

B Reduce the length of the welding arc.

C Electrode should not be inclined less than 45° to the vertical face.

D Joint preparation does not allow correct electrode angle.

D Allow more room in joint for manipulation of the electrode.

E Electrode too large for joint.

E Use smaller gauge electrode.

F Insufficient deposit time at edge of weave.

F Pause for a moment at edge of weave to allow weld metal buildup.

5 Portions of the weld run do not fuse to the surface of the metal or edge of the joint.

A Small electrodes used on heavy cold plate.

A Use larger electrodes and preheat the plate.

B Welding current is too low. B Increase welding current.

C Wrong electrode angle.

C Adjust angle so the welding arc is directed more into the base metal.

D Travel speed of electrode is too high.

E Scale or dirt on joint surface.

D Reduce travel speed of electrode.

E Clean surface before welding.

Art: A-04972

6 Gas pockets or voids in weld metal (porosity)

Figure 2: Example of Lack of Fusion

A High levels of sulphur in steel.

B Electrodes are damp.

C Welding current is too high.

A Use an electrode that is designed for high sulphur steels.

B Dry electrodes before use.

C Reduce welding current.

D Surface impurities such as oil, grease, paint, etc.

D Clean joint before welding.

E Welding in a windy environment.

E Shield the weld area from the wind.

F Electrode damaged i.e. flux coating incomplete.

F Discard damaged electrodes and only use electrodes with a complete flux coating.

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186 AC/DC INVERTER BASIC WELDING

FAULT

7 Crack occurring in weld metal soon after solidification commences

CAUSE

A Rigidity of joint.

B Insufficient throat thickness.

REMEDY

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 Weld current is too high. C Decrease welding current.

Art: A-04973

Figure 3: Example of Slag Inclusion

Table 4-2: Welding Problems SMAW (STICK)

4.03 TIG (GTAW) Basic Welding Technique

Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based. A filler metal may also be added manually in some circumstances depending on the welding application.

A-09658_AB

Work Piece

Can Be Any Commercial

Metal

Gas Cup

Either Ceramic,

High-lmpact or

Water Cooled

Metal

Tungsten Electrode

Non-Consumable

Welds Made With or Without

Addition of Filler Metal

Inert Gas

Shields Electrode and Weld Puddle

Figure 4-28: TIG Welding Application Shot

Tungsten Electrode Current Ranges

Electrode Diameter

0.040" (1.0mm)

1/16" (1.6mm)

3/32" (2.4mm)

1/8" (3.2mm)

DC Current (Amps)

30-60

60-115

100-165

135-200

5/32" (4.0mm) 190-280

3/16" (4.8mm) 250-340

Table 4-3: Current Ranges for Various Tungsten Electrode Sizes

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BASIC WELDING 186 AC/DC INVERTER

Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)

1/16" (1.6mm)

3/32" (2.4mm)

20-90

65-115

1/8" (3.2mm) 100-165

3/16" (4.8mm) 200-350

Table 4-4: Filler Wire Selection Guide

Tungsten Electrode Types

Electrode Type

(Ground Finish)

Color Code

Thoriated 2%

Zirconated 1%

Welding Application Features

DC welding of mild steel, stainless steel and copper

High quality AC welding of aluminium, magnesium and their alloys.

Excellent arc starting,

Long life, High current carrying capacity

Self cleaning, Long life, Maintains balled end, High current carrying capacity.

Red

White

Ceriated 2%

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.

Table 4-5 Tungsten Electrode Types

Grey

Base

Metal

Thickness

1/16"

1.6mm

1/8"

3.2mm

AC Current for

Aluminium

60-80

70-90

125-145

140-160

Tungsten

Electrode

Diameter

1/16"

1.6mm

3/32"

2.4mm

Filler Rod Diameter

(if required)

1/16"

1.6mm

1/16"-3/32"

1.6mm - 2.4mm

Table 4-6 Aluminium Welding Material

Argon Gas

Flow Rate

15 CFM

7 LPM

17 CFM

8 LPM

JOINT

TYPE

Butt/Corner

Lap/Fillet

Butt/Corner

Lap/Fillet

Manual 0-5237 4-13 BASIC WELDING GUIDE

186 AC/DC INVERTER BASIC WELDING

0.040"

1.0mm

0.045"

1.2mm

1/16"

1.6mm

1/8"

3.2mm

3/16"

4.8mm

1/4"

6.4mm

Base Metal

Thickness

DC Current for Mild

Steel

35-45

40-50

45-55

50-60

60-70

70-90

80-100

90-115

115-135

140-165

160-175

170-200

DC Current for Stainless

Steel

20-30

25-35

30-45

35-50

40-60

50-70

65-85

90-110

100-125

125-150

135-160

160-180

Tungsten

Electrode

Diameter

0.040"

1.0mm

0.040"

1.0mm

Filler Rod

Diameter (if required)

1/16"

1.6mm

1/16"

1.6mm

1/16"

1.6mm

1/16"

1.6mm

1/16"

1.6mm

3/32"

2.4mm

3/32"

2.4mm

1/8"

3.2mm

1/8"

3.2mm

5/32"

4.0mm

Table 4-7: Welding Rate

Argon Gas Flow

Rate

Joint Type

10 CFH(5 LPM) Butt/Corner

Lap/Fillet

13 CFH(6 LPM) Butt/Corner

Lap/Fillet

15 CFH(7 LPM) Butt/Corner

Lap/Fillet

15 CFH(7 LPM) Butt/Corner

Lap/Fillet

21 CFH(10 LPM) Butt/Corner

Lap/Fillet

21 CFH(10 LPM) Butt/Corner

Lap/Fillet

TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG

Welding process is outside the scope of this Operating Manual. For further information please refer to www.

victortechnologies.com or contact Thermal Arc.

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BASIC WELDING 186 AC/DC INVERTER

4.04 TIG (GTAW) Welding Problems

FAULT

1 Excessive bead build up or poor penetration or poor fusion at edges of weld.

2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through.

3 Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart.

CAUSE

Welding current is too low

Welding current is too high

Travel speed too fast

REMEDY

Increase weld current and/or faulty joint preparation.

Decrease weld current.

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.

5 Uneven leg length in fillet joint

Wrong placement of filler rod

Re-position filler rod.

6 Electrode melts or oxidises when an arc is struck.

A Torch lead connected to positive welding terminal.

A Connect torch lead to negative welding terminal.

B No gas flowing to welding region.

B Check the gas lines for kinks or breaks and gas cylinder contents.

C Torch is clogged with dust or dirt.

D Gas hose is cut.

C Clean torch.

D Replace gas hose.

E Gas passage contains impurities.

E Disconnect gas hose from the rear of

Power Source then raise gas pressure and blow out impurities.

F Turn on.

F Gas regulator turned off.

G The electrode is too small for the welding current.

G Increase electrode diameter or reduce the welding current.

H Power source is set for

STICK welding.

H Set Power Source to LIFT TIG or HF TIG mode.

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186 AC/DC INVERTER BASIC WELDING

FAULT

7 Dirty weld pool

8 Poor weld finish

9 Arc start is not smooth.

CAUSE REMEDY

A Electrode contaminated by contact with work piece or filler rod material.

A Clean the electrode by grinding off the contaminates.

B Work piece surface has foreign material on it.

B Clean surface.

C Gas contaminated with air.

C Check gas lines for cuts and loose fitting or change gas cylinder.

Inadequate shielding gas.

A Tungsten electrode is too large for the welding current.

Increase gas flow or check gas line for gas flow problems.

A Select the right size tungsten electrode.

Refer to Table 4-3 Tungsten Electrode

Selection Chart.

B The wrong electrode is being used for the welding job.

B Select the right tungsten electrode type.

Refer to Table 4-5 Tungsten Electrode

Selection Chart.

C Gas flow rate is too high.

C Select the right rate for the welding job.

Refer to Table 4-7.

D Incorrect shielding gas is being used.

D Select the right shielding gas.

E Poor work clamp connection to work piece.

E Improve connection to work piece.

10 Arc flutters during TIG welding.

Tungsten electrode is too large for the welding current.

Select the right size tungsten electrode.

Refer to Table 4-3 Tungsten Electrode

Selection Chart.

BASIC WELDING GUIDE 4-16 Manual 0-5237

SERVICE 186 AC/DC INVERTER

SECTION 5: POWER SOURCE PROBLEMS

AND ROUTINE SERVICE REQUIREMENTS

5.01 Basic Troubleshooting

!

WARNING

There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson 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 Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge. Refer also to section 4 for solving welding problems.

5.02 Power Source Problems

FAULT

1 Mains supply voltage is

ON, power indicator is illuminated however unit will not commence welding when the torch trigger switch is depressed.

2 Mains supply voltage is

ON. Indicator light is not lit and welding arc cannot be established.

3 Fault Indicator is illuminated and unit will not commence welding when the torch trigger switch is depressed.

4 Welding output continues when torch trigger released

5 Welding output voltage is present when the torch trigger switch is depressed but arc cannot be established.

6 Welding output voltage is not present when torch trigger depressed

7 TIG electrode melts when arc is struck.

8 Arc flutters during TIG welding.

9 No HF output in HF mode

A

B

CAUSE

Power source is not in the correct mode of operation.

Faulty torch trigger.

A

B

Set the power source to the correct mode of operation with the process selection switch.

Repair or replace torch trigger switch/lead.

REMEDY

A

B

A

B

Primary control fuse is blown.

Broken connection in primary circuit.

Duty cycle of power source has been exceeded.

Trigger mode selection is in 4T

(LATCH) mode

Torch trigger leads shorted

Poor or no work lead contact.

A

B

A

B

Replace primary control fuse.

Have an Accredited Thermal Arc

Service Provider check primary circuit.

Leave the power source switched ON and allow it to cool. Note that fault indicator must be extinguished prior to commencement of welding.

Change to 2T (NORMAL) mode

Repair or replace Torch / trigger lead

Clean work clamp area and ensure good electrical contact.

Faulty trigger switch / lead

TIG torch is connected to the (+) VE terminal.

Tungsten electrode is too large for the welding current.

HF Circuit faulty

Repair or replace Torch / trigger lead

Connect the TIG torch to the (-)

VE terminal.

Select the correct size of tungsten electrode.

Have an Accredited Thermal Arc

Service Provider check HF circuit.

Manual 0-5237 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

186 AC/DC INVERTER SERVICE

FAULT

Error Code “Err 001” is displayed on the digital displays in conjunction with the Fault Indicator

Illuminating.

CAUSE

A Thermal Overload

REMEDY

This is due to the duty cycle of the power source being exceeded.

Once the power source cools sufficiently it will automatically reset and the Fault Indicator and

Err 001 will go off and the power source is then able to continue welding. During the time of cooling the power source should remain ON such that the fan continues to operate allowing the unit to cool sufficiently. If after 30 minutes with the fan running the

Fault Indicator has not gone OFF then have an Accredited Thermal

Arc Service Provider check the power source.

B Primary Circuit Overload

This is due to primary circuit component(s) malfunctioning which results in excessive primary circuit current. Switch the power source to OFF immediately to allow all components to cool down for at least 30 minutes.

If after 30 minutes “Err 001” is displayed and Fault Indicator illuminates when the power source is switched back ON turn the power source OFF and have an

Accredited Thermal Arc Service

Provider check the power source.

Table 5-1: Power Source Problem

5.03 Routine Service and Calibration Requirements

!

WARNING

There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited Thermal Arc Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

Routine Inspection, Testing & Maintenance

The inspection and testing of the power source and associated accessories shall be carried out in accordance with Section 5 of EN 60974.1: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc original specifications.

If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in

EN 60974.1, then the above tests should be carried out prior to entering this location.

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-2 Manual 0-5237

SERVICE 186 AC/DC INVERTER

A. Testing Schedule

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.

A transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated.

B. Insulation Resistance

Minimum insulation resistance for in-service Thermal Arc Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5-2 below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.

Components to be Tested

Minimum Insulation

Resistance (MΩ)

Input circuit (including any connected control circuits) to welding circuit

(including any connected control circuits)

All circuits to exposed conductive parts

Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage exceeding extra low voltage

5

2.5

10

Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage not exceeding extra low voltage

1

Separate welding circuit to separate welding circuit

1

Table 5-2: Minimum Insulation Resistance Requirements: Thermal Arc Inverter Power Sources

C. Earthing

The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be earthed, and -

1. The earth terminal of a fixed power source; or

2. The earth terminal of the associated plug of a transportable power source

Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying Thermal Arc welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below -

1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every

3 months; and

2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12 months.

D. General Maintenance Checks

Welding equipment should be regularly checked by an accredited Thermal Arc Service Provider to ensure that:

1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition.

2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit.

3. The Welding System is clean internally, especially from metal filing, slag, and loose material.

Manual 0-5237 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

186 AC/DC INVERTER SERVICE

E. Accessories

Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall not be used.

F. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited

Thermal Arc Service Provider.

Power Source Calibration

A. Schedule

Output testing of all Thermal Arc Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall within specified levels. Calibration intervals shall be as outlined below -

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in EN 60974.1, then the above tests should be carried out prior to entering this location.

B. Calibration Requirements

Where applicable, the tests outlined in Table 5-3 below shall be conducted by an accredited Thermal Arc service provider.

Testing Requirements

Output current (A) to be checked to ensure it falls within applicable Thermal Arc power source specifications

Output Voltage (V) to be checked to ensure it falls within applicable Thermal Arc power source specifications

Accuracy of digital meters to be checked to ensure it falls within applicable Thermal Arc power source specifications

Table 5-3: Calibration Parameters

Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified.

C. Calibration Equipment

All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question. Only test equipment with valid calibration certificates (NATA certified laboratories) shall be utilized.

5.04 Cleaning the Welding Power Source

!

WARNING

There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal filings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current.

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-4 Manual 0-5237

SPARE PARTS 186 AC/DC INVERTER

SECTION 6:

KEY SPARE PARTS

6.01 Power Source

24

21

15

7

6

5

3

2

20

10

1

25

11

4

23

12

13

12

14

19

16

9

Figure 6-1

18

28

17

A-11500_AC

8

Manual 0-5237 6-1 KEY SPARE PARTS

24

25

26

27

28

19

20

21

22

23

29

30

8

9

10

11

12

13

5

6

7

Item

1

2

3

4

14

15

16

17

18

186 AC/DC INVERTER SPARE PARTS

Part Number

186 AC/DC Spare Parts

Description

W7005500 PCB display

W7005503 PCB aux power supply

W7005502 PCB HF

W7005504 PCB 186ACDC

W7005505 PCB AC output drive

W7005506 PCB control

W7005507 PCB secondary rectifier

W7005538 Side Panel

W7005509 Coil coupling HF

W7005622 Fan assembly

W7003033 Gas solenoid assembly

W7005513 Dinse Socket 50mm²

W7003036 Control socket 8 pin (including wire harness)

W7005514 Gas outlet, front panel

W7005515 Switch, On/Off

W7003076 CT, output

W7005539 Inductor 186AC/DC

W7005517 Base Panel

W7005531 Front panel

W7005516 Rear panel

W7005518 Panel, Top Cover

W7003215 Gas inlet fitting(not shown)

W7005537 Control knob, (25mm

2

OD)

W7005536 Handle

W7004952 CT, primary

W7005501 Shroud, Knob, Front Panel (not shown)

W7004930 Shielding Gas Hose Assy (not shown)

W7005511 Transformer

831761 Set-Up Guide, English (not shown)

831762 Set-Up Guide, French (not shown)

Table 6-1

KEY SPARE PARTS 6-2 Manual 0-5237

APPENDIX 186 AC/DC INVERTER

APPENDIX 1 : CIRCUIT DIAGRAM

Manual 0-5237 A-1

A-11810

APPENDIX

186 AC/DC INVERTER APPENDIX

APPENDIX 2 : 186 AC/DC SETUP GUIDE

APPENDIX A-2 Manual 0-5237

APPENDIX 186 AC/DC INVERTER

Manual 0-5237 A-3 APPENDIX

186 AC/DC INVERTER APPENDIX

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APPENDIX A-4 Manual 0-5237

Statement of Warranty

Effective 08/01/2011

This warranty supersedes all previous

VICTOR TECHNOLOGIES® warranties.

LIMITED WARRANTY: VICTOR TECHNOLOGIES® warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the VICTOR TECHNOLOGIES® products as stated below,VICTOR

TECHNOLOGIES® shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with VICTOR TECHNOLOGIES®’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at VICTOR TECHNOLOGIES®’s sole option, of any components or parts of the product determined by VICTOR TECHNOLOGIES® to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY

OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: VICTOR TECHNOLOGIES® shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption.

The remedies of the Purchaser set forth herein are exclusive and the liability of VICTOR

TECHNOLOGIES® 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 VICTOR TECHNOLOGIES® whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES

ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY VICTOR

TECHNOLOGIES® PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED 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 1 year from the date VICTOR

TECHNOLOGIES® delivered the product to the authorized distributor.

Warranty SCHeDULe

5 Years Parts* / 3 Years Labor

ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster

Portafeed, Ultrafeed, Ultima 150, WC 100B

* 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards.

* 3 years on Power Supply Components

2 Years Parts and Labor Unless specified

Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy

Victor Regulator for Fabricator 181i (No labor)

1 Years Parts and Labor Unless specified

95S, Water recirculators

All Plasma Welding consols (i.e WC-1 Controller, WT Timer,

WF-100 Capstain Feeder, etc)

180 days parts and Labor Unless specified

Plasma Welding Torch and leads packages

Gas Regulators "Supplied with power sources" (No Labor)

90 days parts / No Labor

Remote Controls

MIG and TIG Torches (Supplied with power sources)

Replacement repair parts

30 days parts / No Labor

MIG Torch for Fabricator 181i

5-2-1 years Parts / No Labor

FirePower® Welders

5 Years Parts / No Labor

Victor® Professional

Victor Technologies limited warranty shall not apply to:

Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that fail due normal wear

* Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized VICTOR TECHNOLOGIES® repair facility within thirty (30) days of the repair.

* No employee, agent, or representative of VICTOR TECHNOLOGIES® is authorized to change this warranty in any way or grant any other warranty, and

VICTOR TECHNOLOGIES® shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of VICTOR TECHNOLOGIES®’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 VICTOR TECHNOLOGIES®'s sole judgment, impaired the safety or performance of any VICTOR TECHNOLOGIES® product. Purchaser’s rights under this warranty are void if the product is sold to purchaser by unauthorized persons.

This page left blank intentionally.

THE AMERICAS

Denton, TX USA

U.S. Customer Care

Ph: 1-800-426-1888 (tollfree)

Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph: 1-940-381-1212

Fax: 1-940-483-8178

Miami, FL USA

Sales Office, Latin America

Ph: 1-954-727-8371

Fax: 1-954-727-8376

Oakville, Ontario, Canada

Canada Customer Care

Ph: 1-905-827-4515

Fax: 1-800-588-1714 (tollfree)

EUROPE

Chorley, United Kingdom

Customer Care

Ph: +44 1257-261755

Fax: +44 1257-224800

Milan, Italy

Customer Care

Ph: +39 0236546801

Fax: +39 0236546840

ASIA/PACIFIC

Cikarang, Indonesia

Customer Care

Ph: 6221-8990-6095

Fax: 6221-8990-6096

Rawang, Malaysia

Customer Care

Ph: +603 6092-2988

Fax: +603 6092-1085

Melbourne, Australia

Australia Customer Care

Ph: 1300-654-674 (tollfree)

Ph: 61-3-9474-7400

Fax: 61-3-9474-7391

International

Ph: 61-3-9474-7508

Fax: 61-3-9474-7488

Shanghai, China

Sales Office

Ph: +86 21-64072626

Fax: +86 21-64483032

Singapore

Sales Office

Ph: +65 6832-8066

Fax: +65 6763-5812

China

T E C H N O L O G I E S

I N N O V A T I O N T O S H A P E T H E W O R L D

U.S. Customer Care: 800-426-1888

Canada Customer Care: 905-827-4515

International Customer Care: 940-381-1212

Form No. 0-5237 (12/07/12) © 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in China

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