Page 1
3163339
ESAB ET 186i AC/DC
Inverter Arc Welder
Operating
Manual
Révision : AA Issue Date: June 1, 2016 Manual No.: 0-5425
Art# A-13113
esab.com
Page 2
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to
provide you with the best service and reliability in the industry. This product is backed by our extensive
warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on
the web at www.esab.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
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 developing technologically advanced products to achieve a safer working
environment within the welding industry.
Page 3
WARNING
!
Welding Power Supply
ESAB ET 186i AC/DC Inverter Arc Welder
Operating Manual Number 0-5425
Published by:
ESAB
2800 Airport Rd.
Denton, TX 76208
www.esab.com
Copyright 2015 by ESAB
All rights reserved.
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.
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.
Original Publication Date: June 1, 2016
Revision Date:
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________
Purchase Date:__________________________________ __________
Power Supply Serial #:___________________________ __________
Torch Serial #:___________________________________ __________
ii
Page 4
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar
with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be
sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions
provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be
used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service
advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use,
faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
PROTECT YOURSELF AND OTHERS!
!
OPERATING.
Page 5
TABLE OF CONTENTS
SECTION 1: SAFETY ........................................................................................ 1-1
1.0 Safety Precautions .......................................................................................... 1-1
SECTION 2 SYSTEM:
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 ....................................................................................................... 2-2
2.09 Specifications ................................................................................................. 2-3
2.10 Optional Accessories ...................................................................................... 2-4
2.11 Volt-Ampere Curves ........................................................................................ 2-4
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 ........................................................................... 3-2
3.07 Electromagnetic Compatibility ........................................................................ 3-3
3.08 ET 186i AC/DC Power Source Controls, Indicators and Features .................... 3-4
3.09 ET 186i AC/DC - STICK Programming Mode .................................................. 3-9
3.10 ET ET 186i AC/DC – LIFT TIG and HF TIG Programming Mode .................... 3-11
3.11 Short Circuit Protection While Welding ......................................................... 3-15
3.12 Victor Regulator ............................................................................................ 3-15
3.13 Specification for TIG Torch ........................................................................... 3-17
3.14 Setup for TIG (GTAW) Welding ..................................................................... 3-18
3.15 Setup for STICK (SMAW) Welding .............................................................. 3-20
SECTION 4:
BASIC WELDING GUIDE ............................................................................ 4-1
4.01 STICK (SMAW) Basic Welding Technique ....................................................... 4-1
4.02 STICK (SMAW) Welding Troubleshooting ....................................................... 4-9
4.03 TIG (GTAW) Basic Welding Technique .......................................................... 4-11
4.04 TIG (GTAW) Welding Problems ..................................................................... 4-13
Page 6
TABLE OF CONTENTS
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 : ET 186i AC/DC SETUP GUIDE ............................................................ A-2
Page 7
ESAB ET 186i AC/DC
SECTION 1: SAFETY
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works
on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements
that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in
addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the
operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, flame proof
clothing, safety gloves.
- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualified electrician.
- Appropriate fire extinguishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary cutting protection and accessories.
Manual 0-5425 1-1 SAFETY INSTRUCTIONS AND WARNINGS
Page 8
ESAB ET 186i AC/DC
WARNING
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from
your breathing zone and the general area.
ARC R AYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and
filter lens and wear protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable
materials nearby.
Arc welding and cutting can be injurious to yourself and others.
Take precautions when welding and cutting. Ask for your employer's
safety practices which should be based on manufacturers' hazard
data.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT-
ING.
PROTECT YOURSELF AND OTHERS!
Do not use the power source for thawing frozen pipes.
WARNING
CAUTION
CAUTION
Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.
This product is solely intended for metal removal. Any other use
may result in personal injury and / or equipment damage.
CAUTION
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5425
Read and understand the instruction manual before
installing or operating.
!
Page 9
ESAB ET 186i AC/DC
!
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or part numbers listed on page i.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION,
DANGER, and NOTE may appear. Pay particular attention to
the information provided under these headings. These special
annotations are easily recognized as follows:
NOTE!
An operation, procedure, or background
information which requires additional
emphasis or is helpful in efficient operation of the system.
CAUTION
!
A procedure which, if not properly followed, may cause damage to the equipment.
2.02 Equipment Identification
The unit’s identification number (specification or part number), model, and serial number usually appear on a data tag
attached to the rear panel. Equipment which does not have
a data tag such as torch and cable assemblies are identified only by the specification or part number printed on
loosely attached card or the shipping container. Record these
numbers on the bottom of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the invoice
to make sure it is complete and inspect the equipment for
possible damage due to shipping. If there is any damage,
notify the carrier immediately to file a claim. Furnish complete
information concerning damage claims or shipping errors to
the location in your area listed in the inside back cover of this
manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
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.
2.04 Description
WARNING
A procedure which, if not properly followed, may cause injury to the operator or
others in the operating area.
WARNING
Gives information regarding possible
electrical shock injury. Warnings will be
enclosed in a box such as this.
DANGER
Means immediate hazards which, if not
!
Additional copies of this manual may be purchased by contacting ESAB at the address and phone number in your area listed
on back cover of this manual. Include the Owner’s Manual
number and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the ESAB web site
listed below
http://www.esab.com
avoided, will result in immediate, serious
personal injury or loss of life.
The ESAB ET 186i 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 ET 186i 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.
Manual 0-5425 2-1 INTRODUCTION
Page 10
ESAB ET 186i AC/DC
!
!
Art# A-13114
2.05 User Responsibility
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
ESAB. Advice in this regard can be obtained by contacting an
Accredited ESAB Distributor.
This equipment or any of its parts should not be altered from
standard specification without prior written approval of ESAB.
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 ESAB.
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.
Figure 2-1: ET 186i AC/DC Packaged System
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.
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.
2.07 Packaged Items
• ET 186i AC/DC Inverter Power Source
• ESAB 200 Amp Electrode Holder with 13ft (4m) Lead
• ESAB 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
• ESAB Cap
INTRODUCTION 2-2 Manual 0-5425
Page 11
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)
SAFE OPERATING REGION
(TIG & STICK)
0
0
10
20
30
40
60
70
50
80
100
90
Duty Cycle (PERCENTAGE)
GTAW (TIG)
SMAW (STICK)
A-11493
186 AC/DC
2.09 Specifications
ESAB ET 186i AC/DC
Figure 2-2: ET 186i AC/DC Duty Cycle
Part Number W1006300
Power Source Weight 48.4lbs (22 kg)
Power Source Dimensions H15.75"xW9.45"xD18.7"
Cooling Fan Cooled (Runs Continually)
Welder Type Inverter Power Source
Applicable Standards / Approvals CSA E60974-1-00 / UL60974-1 / IEC 60974-1
Number of Phases 1
Nominal Supply Frequency 50/60Hz
Welding Current Range (STICK Mode) 5 - 170A (DC Stick) 10-170A (AC Stick)
Welding Current Range (TIG Mode) 5 - 200A (DC TIG) 30-200A (AC LIFT TIG)
Nominal Supply Voltage 208V 230V
Effective Input Current (I1eff) (See Note 1)
STICK
TIG
Maximum Input Current (I1max)
STICK
TIG
Single Phase Generator Requirement (See Note 2) 9.5KVA (7KW)
STICK (SMAW)
Welding Output, 40ºC, 10 min.
TIG (GTAW)
Welding Output, 40ºC, 10 min.
Open circuit voltage 70.3 VDC / 50VAC
Protection Class IP23S
Description ESAB ET 186i AC/DC INVERTER
(H 400mm x W 240mm x D 475mm)
10-200A (AC HF TIG)
16.4A
16.5A
35.6A
35.4A
170A @ 15%, 26.8V
15.5A
14.1A
34.9A
32.4A
100A @ 60%, 24.0V
80A @ 100%, 23.2V
200A @ 20%, 18V
116A @ 60%, 14.6V
90A @ 100%, 13.6V
Table 2-1: ET 186i AC/DC Specification
Manual 0-5425 2-3 INTRODUCTION
Page 12
ESAB ET 186i AC/DC
e
NOTE!
The Effective Input Current should be used for the determination of cable size & supply requirements.
Generator Requirements at the Maximum Output Duty Cycle.
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
ESAB Helmet (USA Only) ............................ Part No. 4100-1004
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
90
80
ET 186i AC/DC
70
60
(volts)
50
TIG
Output Voltag
40
STICK
30
20
10
0
020406080100 120 140 160 180 200 220 240
Figure 2-3: ET 186i AC/DC Volt-Amp Curves
INTRODUCTION 2-4 Manual 0-5425
Welding Current (AMPS)
A-11583
Page 13
INSTALLATION, OPERATION AND SETUP
!
3.01 Environment
ESAB ET 186i AC/DC
SECTION 3:
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.
A. Examples of environments with increased hazard of electric
shock are:
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.
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.
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.
3.02 Location
Be sure to locate the welder according to the following guidelines:
A. In areas, free from moisture and dust.
WARNING
This equipment should be electrically connected by a qualified electrician.
3.03 Ventilation
!
WARNING
Since the inhalation of welding fumes can
be harmful, ensure that the welding area
is effectively ventilated.
3.04 Mains Supply Voltage
Requirements
WARNING
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.
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.
G. The enclosure design of this power source meets the re-
quirements 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.
H. Precautions must be taken against the power source top-
pling over. The power source must be located on a suitable
horizontal surface in the upright position when in use.
Manual 0-5425 3-1 INSTALLATION, OPERATION AND SETUP
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.
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
Page 14
ESAB ET 186i AC/DC
!
!
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.
50 / 60 Hz Single
Phase Supply
Supply Voltage
Input Current at Maximum Output 32 Amps
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 12 AWG
Maximum Recommended Extension Cord Length 50 ft
Minimum Recommended Grounding Conductor Size 12 AWG
Table 3-1: Electrical Service Guide
208/230V AC
50 Amps
50 Amps
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
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
It is also possible that operation close to computer installations may cause computer malfunction.
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 re-radiation in most cases.
INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5425
Page 15
ESAB ET 186i AC/DC
!
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.
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
Manual 0-5425 3-3 INSTALLATION, OPERATION AND SETUP
Page 16
ESAB ET 186i AC/DC
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 compo-
nents 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.
3.08 ET 186i AC/DC Power Source Controls, Indicators and Features
17
16
15
14
13
12
18
19
5
6
7
8
9
10
11
Art# A-13115
INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5425
1 2
Figure 3-1: Controls on Front Panel
3
4
Page 17
20
A-11232
A-11228
ESAB ET 186i AC/DC
ON
OFF
21
22
Figure 3-2: Rear Panel
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 Part Number / Description
1 Not used
2 Trigger Switch Input
2
1
3 Trigger Switch Input
5
4
4 Not used
5 Remote Control 5k ohm Potentiometers Maximum
8
3
7
6
6 Remote Control 5k ohm Potentiometers Minimum
7 Remote Control 5k ohm Potentiometer Wiper
8 Not used
Table 3-2: 8 Pin Control Plug Configuration
3. Negative Welding Terminal
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
Manual 0-5425 3-5 INSTALLATION, OPERATION AND SETUP
Page 18
ESAB ET 186i AC/DC
CAUTION
!
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
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
a. 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 ESAB Service Provider check the power source.
b. 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 ESAB 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.
INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5425
Page 19
ESAB ET 186i AC/DC
AMPS
TIME
Trigger
Current
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 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.
High
Current
Weld
Current
Initial
Press & hold
Trigger
Arc Ignited
Pre
Flow
Release
Up
Slope
Crater
Current
Press & hold
Trigger
Down
Slope
Arc Terminated
Post
Flow
Release
Trigger
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).
A-11410_AB
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.
Manual 0-5425 3-7 INSTALLATION, OPERATION AND SETUP
Page 20
ESAB ET 186i AC/DC
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.
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:
TIG STICK
PREFLOW WELD CURRENT
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.
INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5425
Page 21
ESAB ET 186i AC/DC
!
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.
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 ET 186i 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 ET 186i 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.
Art# A-13116
Adjust programming parameter
Manual 0-5425 3-9 INSTALLATION, OPERATION AND SETUP
Press to go forward / go back
Figure 3-5: Stick Programming Mode
Page 22
ESAB ET 186i AC/DC
Programming Parameter Adjustment Device Display
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.
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.
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.
Amps
0 to 70A (max 170A weld current)
Amps
5 to 170A (DC STICK mode)
10 to 170A (AC STICK mode)
V
SEC
%
Hz
Volts
0 to 100%
Table 3-3
INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5425
Page 23
ESAB ET 186i AC/DC
Art# A-13116
3.10 ET ET 186i 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.
Adjust programming parameter
Figure 3-6: LIFT TIG and HF TIG Programming Mode
Press to go forward / go back
between programming status LED’s
Manual 0-5425 3-11 INSTALLATION, OPERATION AND SETUP
Page 24
ESAB ET 186i AC/DC
Programming Parameter Adjustment Device Display
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.
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.
V
SEC
%
Hz
Volts
0.0 to 1.0 second
Amps
5 to 200 Amps (DC TIG mode)
30 to 200 Amps (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
V
SEC
%
Hz
Volts
0.0 to 15.0 seconds
Amps
High Current
This parameter sets the High weld
current when in PULSE mode.
INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5425
5 to 200A (DC TIG mode)
30 to 200A (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
Amps
10 to 200A (DC TIG mode)
30 to 200A (AC TIG mode)
Page 25
Programming Parameter Adjustment Device Display
Low Current
The lowest point in the pulse is
called the Low Current.
5 to 200A (DC HF TIG mode)
30 to 200A (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
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.
0.5 to 200 Hz
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
0.0 to 25.0 seconds
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
5 to 200A (DC TIG mode)
30 to 200A (AC TIG mode)
10 to 200A (AC HF TIG mode)
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
0.0 to 60.0 seconds
electrode.
ESAB ET 186i AC/DC
Amps
V
SEC
%
Hz
Volts
15 to 80%
V
SEC
%
Hz
Volts
V
SEC
%
Hz
Volts
Amps
V
SEC
%
Hz
Volts
Manual 0-5425 3-13 INSTALLATION, OPERATION AND SETUP
Page 26
ESAB ET 186i AC/DC
A-11223
Programming Parameter Adjustment Device Display
AC Frequency
This parameter operates in AC
TIG mode only and is used to
set the frequency for the AC weld
current.
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%.
Table 3-4
Volts
15 to 150 Hz
Volts
10 to 65%
V
SEC
%
Hz
V
SEC
%
Hz
WAVE BALANCE is used for aluminium welding in AC HF TIG or AC LIFT TIG mode
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% Wave Balance = 10% Wave Balance = 65%
10%50% 65%
(+)(+) (+)
(-)(-) (-)
90%50% 35%
Balanced with 50% penetration
and 50% cleaning
Maximum Penetration and
reduced cleaning
Table 3-5: AC TIG Wave Balance
Maximum Cleaning and
reduced penetration
INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5425
Page 27
ESAB ET 186i AC/DC
LOW PRESSURE
GAUGE (DELIVER
HIGH PRESSURE
!
!
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 ET 186i 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.
Y)
OUTLET
CONNECTION
A-09414_AB
GAUGE (SUPPLY)
INLET
CONNECTION
PRESSURE
ADJUSTING
SCREW
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.
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.
Manual 0-5425 3-15 INSTALLATION, OPERATION AND SETUP
Page 28
ESAB ET 186i AC/DC
!
Art # A-09828
A-09845_AB
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 pressures. 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
!
8. Slowly and carefully open the cylinder valve (Figure 3-9) until the maximum pressure shows on the high pressure gauge.
9. Open the cylinder valve completely to seal the valve packing. On gaugeless regulators, the indicator will register the cylin-
!
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!
Figure 3-9: Open Cylinder Valve
der 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.
INSTALLATION, OPERATION AND SETUP 3-16 Manual 0-5425
Page 29
ESAB ET 186i AC/DC
A-11556_AB
switch only.
with roller potentiometer.
roller potentiometer and
integrated on/o switch.
A-11557_AB
3.13 Specification for TIG Torch
1. SPECIFICATION FOR TIG TORCH PART NO: W4013600 TO SUIT ESAB ET 186iAC/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).
NOTE!
The additional switches/controls below are interchangeable with the installed control in the TIG torch.
ART# A-11587
Control module with
push button on/o
Control module with
push button on/o switch
Control module with
Additional On/Off Switch Cartridge in a Sealed Plastic Bag.
Additional On/Off Switch-Remote Amperage Control Cartridge in a Sealed Plastic Bag (NOTE: You will not be able to view the preset amperage on the power source with this control, amperage will not be viewable until the arc is initiated).
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).
Manual 0-5425 3-17 INSTALLATION, OPERATION AND SETUP
Page 30
ESAB ET 186i AC/DC
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
!
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.
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the bayonet terminal.
NOTE!
See Appendix A3 for TIG torch contents and trigger switch options.
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 ET 186i AC/DC Power Source. Connect
the gas hose from the TIG torch to the gas OUTLET on the front of the ET 186i 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.
INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5425
Page 31
ESAB ET 186i AC/DC
Art# A-13117
Positive Welding
Terminal (+)
8 Pin Control Socket
Tig Torch
NOTE!
When the ET 186i 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
LIFT TIG (GTAW) Sequence of Operation
the TIG Torch is located away from your work piece.
CAUTION
!
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
b) Place the 8 pin plug into the 8 pin socket. To make connections, align keyway, insert plug, and rotate threaded collar fully
Manual 0-5425 3-19 INSTALLATION, OPERATION AND SETUP
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
clockwise until connector locks in place to achieve reliable electrical connection;
clockwise.
Figure 3-10: Setup for TIG Welding
Page 32
ESAB ET 186i AC/DC
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.
NOTE!
When the ET 186i 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
!
!
INSTALLATION, OPERATION AND SETUP 3-20 Manual 0-5425
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.
Page 33
ESAB ET 186i AC/DC
200A
Positive Welding
Terminal (+)
Art# A-13118
Electrode Holder
Figure 3-11: Setup for Manual Arc Welding.
Negative
Welding
Terminal (-)
Work Lead
Manual 0-5425 3-21 INSTALLATION, OPERATION AND SETUP
Page 34
ESAB ET 186i AC/DC
This Page Intentionally Blank
INSTALLATION, OPERATION AND SETUP 3-22 Manual 0-5425
Page 35
ESAB ET 186i AC/DC
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 Tweco 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 0-5425 4-1 BASIC WELDING GUIDE
Page 36
ESAB ET 186i AC/DC
Art # A-07688
Art # A-07689
Art # A-07690
Metal Being Joined Electrode Comments
Mild Steel E6011 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.
Mild Steel E6013 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.
Mild Steel E7014 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.
Mild Steel E7018 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.
Cast Iron Eni-Cl Suitable for joining all cast irons except white cast iron.
Stainless Steel E318L-16 High corrosion resistances. Ideal for dairy work etc.
Welding Position
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
Figure 4-2: Flat Position, Gravity Fillet Weld
Figure 4-3: Horizontal Position, Butt Weld
Art A-07691
Figure 4-5: Vertical Position, Butt Weld
Art # A-07692
Figure 4-6: Vertical Position, Fillet Weld
Art# A-07693
Figure 4-7: Overhead Position, Butt Weld
Figure 4-4: Horizontal-Vertical (HV) Position
BASIC WELDING GUIDE 4-2 Manual 0-5425
Art # A-07694
Figure 4-8: Overhead Position, Fillet Weld
Page 37
ESAB ET 186i AC/DC
Gap varies from
1/16” (1.6mm) to 3/16” (4.8mm)
depending on plate thickness
Joint
Open Square Butt
1/16” (1.6mm) max
1/16” (1.6mm)
Single Vee Butt Joint
Not less than
70°
Double Vee Butt Joint
1/16” (1.6mm)
Lap Joint
Tee Joints
(
Fillet both sides of the
joint)
Edge Joint
Fillet Joint
Corner Weld
Plug Weld Plug Weld
Not less than
70°
Single Vee Butt Joint
Not less than
45°
1/16” (1.6mm) max
Art # A-10672
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.
Figure 4-9: Typical Joint Designs for Arc 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.
Manual 0-5425 4-3 BASIC WELDING GUIDE
Page 38
ESAB ET 186i AC/DC
20°
1.6 mm (1/16”)
Art # A-07697_AB
T
20°-30°
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.
Art # A-07696_AB
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.
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 well-formed 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.
ack Weld
BASIC WELDING GUIDE 4-4 Manual 0-5425
Figure 4-11: Butt Weld
Electrode
Tack Weld
Page 39
ESAB ET 186i AC/DC
Art # A-07699_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.
B. Fillet Welds
These are welds of approximately triangular cross-section 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.
45° from
vertical
60° - 70° from line
of weld
Figure 4-13: Electrode Position for HV Fillet Weld
Art # A-07700_AB
6
Manual 0-5425 4-5 BASIC WELDING GUIDE
3
1
5
2
4
Figure 4-`14: Multi-runs in HV Fillet Weld
Page 40
ESAB ET 186i AC/DC
C. Vertical Welds
1. Vertical Up
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.
Art # A-07701
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 4-15: Single Run Vertical Fillet Weld
Figure 4-18: Overhead Fillet Weld
Art # A-07702
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.
The Cause of Distortion
Distortion is caused by:
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11 per cent in volume on
Figure 4-16: Multi Run Vertical Fillet Weld
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
Art # A-07703
remain stresses "Locked-up" in the structure. If the joint
Figure 4-17: Examples of Vertical Fillet Welds
BASIC WELDING GUIDE 4-6 Manual 0-5425
Page 41
ESAB ET 186i AC/DC
Art # A-07705_AB
Weld
Upsetting
Weld
Permanent Upset
Art # A-07708
Preheat
Dotted lines show effect if no preheat is used
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.
tion, 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.
E. Preheating
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.
Expansion with
compression
Hot
Hot
Cool
Figure 4-19: Parent Metal Expansion
Art # A-07706_AC
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 distor-
Art # A-07707
Figure 4-21: Principle of Presetting
B
Weld
C
Preheat
Figure 4-22: Reduction of Distortion by Preheating
Art # A-07709
Figure 4-23: Examples of Distortion
Manual 0-5425 4-7 BASIC WELDING GUIDE
Page 42
ESAB ET 186i AC/DC
Art # A-07710_AB
filled in when the welds are cool.
4
Art # A-07711_AB
1
2
Block Sequence.
The spaces between the welds are
3
Figure 4-24: Welding Sequence
1
2
3
Figure 4-25: Step Back Sequence
Art # A-07428_AB
Figure 4-26: Chain Intermittent Welding
Art # A-07713_AB
Figure 4-27: Staggered Intermittent Welding
BASIC WELDING GUIDE 4-8 Manual 0-5425
Page 43
4.02 STICK (SMAW) Welding Troubleshooting
Art: A-04971
FAULT CAUSE REMEDY
ESAB ET 186i AC/DC
1 Welding current
varying
2 A gap is left by
failure of the weld
metal to fill the
root of the weld.
3 Non-metallic
particles are
trapped in the
weld metal.
ARC FORCE control knob
is set at a value that causes
the welding current to vary
excessively with the arc
length.
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.
A Welding current too low A Increase welding current.
B Electrode too large for joint. B Use smaller diameter electrode.
C Insufficient gap. C Allow wider gap.
A Non-metallic particles may
be trapped in undercut from
A If a bad undercut is present clean slag bout and
cover with a run from a smaller gauge electrode.
previous run.
B Joint preparation too
restricted.
C
Irregular deposits allow slag
B Allow for adequate penetration and room for
cleaning out the slag.
C If very bad, chip or grind out irregularities.
to be trapped.
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 Rust or mill scale is
E Clean joint before welding.
preventing full fusion.
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).
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.
Figure 1 - Example of insufficient gap or incorrect sequence
A Welding current is too high. A Reduce welding current.
B Welding arc is too long. B Reduce the length of the welding arc.
C Angle of the electrode is
incorrect.
D Joint preparation does not
allow correct electrode
C Electrode should not be inclined less than 45° to
the vertical face.
D Allow more room in joint for manipulation of the
electrode.
angle.
E Electrode too large for joint. E Use smaller gauge electrode.
F Insufficient deposit time at
Manual 0-5425 4-9 BASIC WELDING GUIDE
edge of weave.
F Pause for a moment at edge of weave to allow
weld metal buildup.
Page 44
ESAB ET 186i AC/DC
FAULT CAUSE REMEDY
5 Portions of the
weld run do not
fuse to the surface
of the metal or
edge of the joint.
6 Gas pockets or
voids in weld
metal (porosity)
A Small electrodes used on
A Use larger electrodes and preheat the plate.
heavy cold 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
D Reduce travel speed of electrode.
too high.
E Scale or dirt on joint surface. E Clean surface before welding.
Art: A-04972
Figure 2: Example of Lack of Fusion
A High levels of sulphur in
steel.
A Use an electrode that is designed for high
sulphur steels.
B Electrodes are damp. B Dry electrodes before use.
7 Crack occurring in
weld metal soon
after solidification
commences
C Welding current is too high. C Reduce welding current.
D Surface impurities such as
D Clean joint before welding.
oil, grease, paint, etc.
E Welding in a windy
E Shield the weld area from the wind.
environment.
F Electrode damaged i.e. flux
coating incomplete.
F Discard damaged electrodes and only use
electrodes with a complete flux coating.
A Rigidity of joint. A Redesign to relieve weld joint of severe stresses
or use crack resistance electrodes.
B Insufficient throat thickness. B Travel slightly slower to allow greater build up in
throat.
C Weld current is too high. C Decrease welding current.
Art: A-04973
Table 4-2: Welding Problems SMAW (STICK)
BASIC WELDING GUIDE 4-10 Manual 0-5425
Figure 3: Example of Slag Inclusion
Page 45
ESAB ET 186i AC/DC
Welds Made With or Without
Tungsten Electrode
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.
Art # A-09658_AC
Gas Cup
Either Ceramic,
Work Piece
Can Be Any Commercial
Metal
High-lmpact or
Water Cooled
Metal
Non-Consumable
Addition of Filler Metal
Tungsten Electrode Current Ranges
Electrode Diameter DC Current (Amps)
0.040" (1.0mm) 30-60
Table 4-3: Current Ranges for Various Tungsten Electrode Sizes
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter DC Current Range (Amps)
Inert Gas
Shields Electrode
and Weld Puddle
Figure 4-28: TIG Welding Application Shot
1/16" (1.6mm) 60-115
3/32" (2.4mm) 100-165
1/8" (3.2mm) 135-200
5/32" (4.0mm) 190-280
3/16" (4.8mm) 250-340
1/16" (1.6mm) 20-90
Manual 0-5425 4-11 BASIC WELDING GUIDE
3/32" (2.4mm) 65-115
1/8" (3.2mm) 100-165
3/16" (4.8mm) 200-350
Table 4-4: Filler Wire Selection Guide
Page 46
ESAB ET 186i AC/DC
Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Zirconated 1%
Ceriated 2%
Base
Metal
Thickness
1/16"
1.6mm
1/8"
3.2mm
Welding Application Features Color Code
DC welding of mild
steel, stainless steel
and copper
High quality AC
welding of aluminium,
magnesium and their
alloys.
AC & DC welding
of mild steel,
stainless steel,
copper, aluminium,
magnesium and their
alloys
AC Current for
Aluminium
60-80
70-90
125-145
140-160
Excellent arc starting,
Long life, High current
carrying capacity
Self cleaning, Long
life, Maintains balled
end, High current
carrying capacity.
Longer life, More
stable arc, Easier
starting, Wider current
range, Narrower more
concentrated arc.
Table 4-5 Tungsten Electrode Types
Tungsten
Electrode
Filler Rod Diameter
(if required)
Diameter
1/16"
1.6mm
3/32"
2.4mm
Table 4-6 Aluminium Welding Material
1/16"
1.6mm
1/16"-3/32"
1.6mm - 2.4mm
Argon Gas
Flow Rate
15 CFM
7 LPM
17 CFM
8 LPM
Red
White
Grey
JOINT
TYPE
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/Fillet
Base Metal
Thickness
0.040"
1.0mm
0.045"
1.2mm
1/16"
1.6mm
1/8"
3.2mm
3/16"
4.8mm
1/4"
6.4mm
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 Tweco.
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
Filler Rod
Diameter (if
required)
0.040"
1.0mm
0.040"
1.0mm
1/16"
1.6mm
1/16"
1.6mm
3/32"
2.4mm
1/8"
3.2mm
Table 4-7: Welding Rate
1/16"
1.6mm
1/16"
1.6mm
1/16"
1.6mm
3/32"
2.4mm
1/8"
3.2mm
5/32"
4.0mm
Argon Gas Flow
Joint Type
Rate
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
BASIC WELDING GUIDE 4-12 Manual 0-5425
Page 47
4.04 TIG (GTAW) Welding Problems
FAULT CAUSE REMEDY
ESAB ET 186i AC/DC
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.
4 Weld bead too wide or
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet
joint
6 Electrode melts or oxidises
when an arc is struck.
Welding current is too
low
Welding current is too
high
Travel speed too fast Reduce travel speed.
Travel speed too slow Increase travel speed.
Wrong placement of
filler rod
A Torch lead connected
to positive welding
terminal.
Increase weld current and/or faulty joint
preparation.
Decrease weld current.
Re-position filler rod.
A Connect torch lead to negative welding
terminal.
B No gas flowing to
welding region.
C Torch is clogged with
dust or dirt.
D Gas hose is cut. D Replace gas hose.
E Gas passage contains
impurities.
F Gas regulator turned
off.
G The electrode is too
small for the welding
current.
H Power source is set for
STICK welding.
7 Dirty weld pool A Electrode contaminated
by contact with work
piece or filler rod
material.
B Check the gas lines for kinks or breaks
and gas cylinder contents.
C Clean torch.
E Disconnect gas hose from the rear of
Power Source then raise gas pressure
and blow out impurities.
F Turn on.
G Increase electrode diameter or reduce the
welding current.
H Set Power Source to LIFT TIG or HF TIG
mode.
A Clean the electrode by grinding off the
contaminates.
Manual 0-5425 4-13 BASIC WELDING GUIDE
B Work piece surface has
foreign material on it.
C Gas contaminated with
air.
B Clean surface.
C Check gas lines for cuts and loose fitting
or change gas cylinder.
Page 48
ESAB ET 186i AC/DC
FAULT CAUSE REMEDY
8 Poor weld finish Inadequate shielding
gas.
9 Arc start is not smooth. A Tungsten electrode
is too large for the
welding current.
B The wrong electrode
is being used for the
welding job.
C Gas flow rate is too
high.
D Incorrect shielding gas
is being used.
E Poor work clamp
connection to work
piece.
10 Arc flutters during TIG
welding.
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 Select the right tungsten electrode type.
Refer to Table 4-5 Tungsten Electrode
Selection Chart.
C Select the right rate for the welding job.
Refer to Table 4-7.
D Select the right shielding gas.
E Improve connection to work piece.
Select the right size tungsten electrode.
Refer to Table 4-3 Tungsten Electrode
Selection Chart.
BASIC WELDING GUIDE 4-14 Manual 0-5425
Page 49
ESAB ET 186i AC/DC
!
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 ESAB 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 CAUSE REMEDY
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 releasedA
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 HF Circuit faulty Have an Accredited ESAB Service
A
Power source is not in the
correct mode of operation.
B
Faulty torch trigger.
A BPrimary 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
B
Torch trigger leads shorted
Poor or no work lead contact. Clean work clamp area and ensure
Faulty trigger switch / lead Repair or replace Torch / trigger
TIG torch is connected to
the (+) VE terminal.
Tungsten electrode is too
large for the welding current.
A
Set the power source to the
correct mode of operation with
the process selection switch.
B
Repair or replace torch trigger
switch/lead.
A BReplace primary control fuse.
Have an Accredited ESAB 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.
A
Change to 2T (NORMAL) mode
B
Repair or replace Torch / trigger
lead
good electrical contact.
lead
Connect the TIG torch to the (-)
VE terminal.
Select the correct size of tungsten
electrode.
Provider check HF circuit.
Manual 0-5425 5-1 SERVICE
Page 50
ESAB ET 186i AC/DC
FAULT CAUSE REMEDY
Error Code “Err 001” is
displayed on the digital
displays in conjunction
with the Fault Indicator
Illuminating.
A
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 ESAB
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 ESAB Service Provider
check the power source.
Table 5-1: Power Source Problem
5.03 Routine Service and Calibration Requirements
WARNING
!
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 ESAB 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.
A. Testing Schedule
SERVICE 5-2 Manual 0-5425
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 ESAB Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
Page 51
ESAB ET 186i AC/DC
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 ESAB 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
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
Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage not exceeding extra low voltage
Separate welding circuit to separate welding circuit
Minimum Insulation
Resistance (MΩ)
5
2.5
10
1
1
Table 5-2: Minimum Insulation Resistance Requirements: ESAB 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 ESAB 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 ESAB 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.
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 ESAB Service Provider.
Power Source Calibration
A. Schedule
Output testing of all ESAB 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.
Manual 0-5425 5-3 SERVICE
Page 52
ESAB ET 186i AC/DC
!
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 ESAB service provider.
Testing Requirements
Output current (A) to be checked to ensure it falls within applicable ESAB power source specifications
Output Voltage (V) to be checked to ensure it falls within applicable ESAB power source specifications
Accuracy of digital meters to be checked to ensure it falls within applicable ESAB 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.
SERVICE 5-4 Manual 0-5425
Page 53
6.01 Power Source
ESAB ET 186i AC/DC
SECTION 6:
KEY SPARE PARTS
24
21
15
23
12
1
13
12
14
7
19
5
6
16
2
3
11
4
25
28
17
9
A-11500_AC
20
10
8
Manual 0-5425 6-1 KEY SPARE PARTS
18
Figure 6-1
Page 54
ESAB ET 186i AC/DC
Item Part Number Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
W7005500
W7005503
W7005502
W7005504
W7005505
W7005506
W7005507
W7005538 Side Panel
W7005509
W7005520
W7003033 Gas solenoid assembly
W7005513 Dinse Socket 50mm²
W7005568 Control socket 8 pin (including wire harness)
W7005514
W7005515
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
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)
ET 186i AC/DC Spare Parts
PCB display
PCB aux power supply
PCB HF
PCB 186ACDC
PCB AC output drive
PCB control
PCB secondary rectifier
Coil coupling HF
Fan assembly
Gas outlet, front panel
Switch, On/Off
2
OD)
Table 6-1
KEY SPARE PARTS 6-2 Manual 0-5425
Page 55
APPENDIX 1 : CIRCUIT DIAGRAM
A-12318_AE
HF TIG
AC~DC
MODE
PULSE
PURGE
BACK
FORWARD
A
V
Encode
AC
DC
I
z
I
s
I
2
I
e
I
1
Pre
Flow
Post
Flow
Initial
Current
Up
Slope
Down
Slope
Crater
Current
Base
Current
Frequency
f
w
Width
High Current
Low
Current
Hot
Start
t1
t2
V
SEC%Hz
9.066.470-E
IN
QF/HF
8.066.526-K
9.066.416-I
1
J1
ESAB ET 186i AC/DC
Manual 0-5425 A-1 APPENDIX
Page 56
Art# A-13120
Pre
Flow
Initial
Current
Up
Slope
Base
Current
Frequency
f
w
Width
High Current
Hot
Start
t1
A
I
z
I
s
I
1
MODE
PULSE
PURGE
BACK FORWARD
AC FREQUENCY
Select
Mode:
or
2
DCAC
SELECT
PROCESS
MODE
SELECTION
MATERIAL
SELECTION
BASE
METAL SIZE
HIGH
CURRENT
WIDTH FREQUENCY
LOW
CURRENT
16 ga. (1.6 mm) 120A 60% 100 Hz Pulse 55A
1/8" (3.2 mm) 170A 60% 1 Hz Pulse 60A
16 ga. (1.6 mm) 65A 50% 1 Hz Pulse 30A
1/8" (3.2 mm) 125A 65% 1 Hz Pulse 50A
3/16" (4.7 mm) 195A 60% 1 Hz Pulse 75A
16 ga. (1.6 mm) 85A 60% 1 Hz Pulse 40A
1/8" (3.2 mm) 150A 60% 1 Hz Pulse 50A
a b
1 2
*
- If Required
Aluminum
Mild Steel
Stainless
Steel
4, 5, 6 15 cfh (7 l/m)
4, 5, 6 15 cfh (7 l/m)
6, 7 17 cfh (8 l/m)
6, 7 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
Pulse
Pulse
AC
16 ga. (1.6 mm) Butt 1/16" (1.6 mm) 50A - 5 sec.
16 ga. (1.6 mm) Fillet 1/16" (1.6 mm) 60A - 6 sec.
1/8" (3.2 mm) Butt 3/32" (2.4 mm) 125A - 11 sec.
1/8" (3.2 mm) Fillet 3/32" (2.4 mm) 125A - 13 sec.
3/16" (4.7 mm) Butt 1/8" (3.2 mm) 170A - 13 sec.
3/16" (4.7 mm) Fillet 1/8" (3.2 mm) 200A - 13 sec.
Mild
Steel
LIFT TIG
/HF TIG
LIFT TIG
/HF TIG
Note: Butt or Fillet Joint types can be used in Pulse mode. Set-up guide parameters may vary depending upon welding position.
SELECT
PROCESS
MODE
SELECTION
MATERIAL
SELECTION
BASE
METAL SIZE
JOINT
TYPE
TUNGSTEN /
FILLER ROD SIZE*
WELD
CURRENTACFREQUENCY
POST
FLOW
16 ga. (1.6 mm) Butt 1/16" (1.6 mm) 65A 150 Hz 5 sec.
16 ga. (1.6 mm) Fillet 1/16" (1.6 mm) 85A 150 Hz 6 sec.
1/8" (3.2 mm) Butt 3/32" (2.4 mm) 135A 150 Hz 11 sec.
1/8" (3.2 mm) Fillet 3/32" (2.4 mm) 150A 150 Hz 13 sec.
3/16" (4.7 mm) Butt 1/8" (3.2 mm) 160A 100 Hz 13 sec.
3/16" (4.7 mm) Fillet 1/8" (3.2 mm) 170A 80 Hz 13 sec.
1/4" (6.4 mm) Butt 1/8" (3.2 mm) 200A 80 Hz 13 sec.
1/4" (6.4 mm) Fillet 1/8" (3.2 mm) 200A 80 Hz 13 sec.
16 ga. (1.6 mm) Butt 1/16" (1.6 mm) 50A - 5 sec.
16 ga. (1.6 mm) Fillet 1/16" (1.6 mm) 60A - 6 sec.
1/8" (3.2 mm) Butt 3/32" (2.4 mm) 110A - 11 sec.
1/8" (3.2 mm) Fillet 3/32" (2.4 mm) 150A - 13 sec.
3/16" (4.7 mm) Butt 1/8" (3.2 mm) 170A - 13 sec.
3/16" (4.7 mm) Fillet 1/8" (3.2 mm) 170A - 13 sec.
1/4" (6.4 mm) Butt 1/8" (3.2 mm) 175A - 13 sec.
1/4" (6.4 mm) Fillet 1/8" (3.2 mm) 180A - 13 sec.
Aluminum
HF TIG
LIFT TIG
/HF TIG
Stainless
Steel
a b c d
1 2
DC (-)
DC(-)
AC
SELECT TIG
CUP SIZE
SELECT
GAS FLOW
4, 5, 6 15 cfh (7 l/m)
4, 5, 6 15 cfh (7 l/m)
6, 7 17 cfh (8 l/m)
6, 7 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
4, 5, 6 15 cfh (7 l/m)
4, 5, 6 15 cfh (7 l/m)
6, 7 17 cfh (8 l/m)
6, 7 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
7, 8 17 cfh (8 l/m)
3
3
LIFT TIG / HF TIG Notes
Gas is 100% Pure Argon.
Wave balance is 30%
(AC Mode Only)
Note: LIFT TIG / HF TIG set-up guide parameters may vary depending upon welding position and joint design.
Pulse Notes
Wave
Balance
is 30%
(AC Mode
Only)
DC(-)
LIFT TIG / HF TIG SET-UP GUIDE
PULSE SET-UP GUIDE PANEL SET-UP GUIDE
This set-up information
is intended to act as a
guide only.
Please refer to operating
manual for further
information.
MATERIALS:
Base: 2 mil thick white substrate with 3 mil clear overlaminate
Overlaminate: .see above
Adhesive: 3M Grade 468
NOTES: Cutout (1) Indicated by color shown :
Yellow - PMS 012C
Grey - Cool Gray 10C
White
Black - PMS Black or RAL 9005 equivalent
Grey - Cool Gray 2C
DATEBYREVISIONS
REV
AA
ART
For Production Use. VCN-01616
05/31/16
Information proprietary to ESAB
ESAB ET 186i AC/DC
APPENDIX 2 : ET 186i AC/DC SETUP GUIDE
APPENDIX A-2 Manual 0-5425
Page 57
ET 186i AC/DC
SET-UP GUIDE
WAVE BALANCE
ARC FORCE
Post
Flow
Up
Slope
Down
Slope
Crater
Current
Base
Current
Frequency
f
w
Width
High Current
Low
Current
t2
A
I
z
I
s
I
2
I
e
I
1
PROCESS
LIFT TIG
V
SEC
%
Hz
HF TIG
STICK
2T
4T
TRIGGER
V
832214_AA
Select Process:
LIFT TIG, HF TIG,
or STICK
Adjust
Parameters
STICK
2T Mode (AC or DC) 4T Mode (AC or DC) (AC or DC)
Pre Flow
Hot Start (HF TIG Only)
Weld Current
Down Slope
Post Flow
Wave Balance (AC TIG Only)
AC Frequency (AC TIG Only)
Pre Flow
Hot Start (HF TIG Only)
Initial Current
Up Slope
Weld Current
Down Slope
Crater Current
Post Flow
Wave Balance (AC TIG Only)
AC Frequency (AC TIG Only)
Hot Start
Weld Current
Arc Force
1
3
LIFT TIG & HF TIG
a b
1 2
Weld Current (Range)
- 100-160A -
Arc Force
- - -
Polarity Selection
Weld Current (Range)
30-60A 55-95A 80-140A
Arc Force
- - -
Polarity Selection
STICK
3/32"
(2.4 mm)
1/8"
(3.2 mm)
5/32"
(4.0 mm)
Weld Current (Range)
50-75A 70-110A 80-145A
Arc Force
- - -
Polarity Selection
Weld Current (Range)
70-95A 100-135A 145-170A
Arc Force
- - -
Polarity Selection
Weld Current (Range)
70-95A 100-145A 135-170A
Arc Force
- - -
Polarity Selection
Weld Current (Range)
70-110A 90-160A 130-170A
Arc Force
- - -
Polarity Selection
E6011
E6013
E7014
E7018
STICK
E308L-16
E316L-16
E7024
Note: STICK set-up guide parameters may vary depending upon welding position, joint design.
SELECT
PROCESS
MODE
SELECTION
ELECTRODE
DIAMETER
DC Reverse Polarity (Positive)
DC Reverse Polarity (Positive)
DC Reverse Polarity (Positive)
DC Reverse Polarity (Positive)
DC Reverse Polarity (Positive)
DC Reverse Polarity (Positive)
3
3
3
3
3
3
ELECTRODE
SELECTION
DC(+)
DC(+)
LIFT TIG / HF TIG Notes
Gas is 100% Pure Argon.
Wave balance is 30%
(AC Mode Only)
STICK SET-UP GUIDE
This set-up information
is intended to act as a
guide only.
Please refer to operating
manual for further
information.
DATEBYREVISIONS
05/31/16
ESAB ET 186i AC/DC
Manual 0-5425 A-3 APPENDIX
Page 58
ESAB ET 186i AC/DC
This Page Blank Intentionally
APPENDIX A-4 Manual 0-5425
Page 59
Page 60
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 70 233 075
Fax: +32 15 257 944
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone numbers to our distributors in other
countries, please visit our home
page
www.esab.eu
www.esab.eu
©2015 ESAB Welding and Cutting Products
Printed in China
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