Thermal Arc 175 SE ARCMASTER Instruction manual

50
60

Hz

A-08598

175 SE

®

ARC MASTER

INVERTER ARC WELDER

Operating Manual

Revision No: AE Issue Date: February 24, 2009 Manual No.: 0-5054
Operating Features:

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud
to have you as our customer and will strive to provide you with
the best service and reliability in the industry. This product
is backed by our extensive warranty and world-wide service
network. To locate your nearest distributor or service agency call
[phone], or visit us on the web at www.Thermalarc.

com.

This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through market­leading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.

!

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufac­turer assumes no liability for its use.

Operating Manual Number 0-5054 for:
Arc Master 175 SE Inverter Arc Welder Part No. W1002902

Published by:
Thermadyne Europe
Europa Building
Chorley Industrial Park
Chorley, Lancaster,
England, PR6 7BX

www.thermalarc.com

Copyright
Thermadyne Industries Inc.

®

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused
by any error or omission in this Manual, whether such error results from negligence, accident, or any other
cause.

Publication Date: March 20, 2008
Revision AC Date: February 24, 2009

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

©

2008 by

Equipment Serial #: ____________________________________

i

TABLE OF CONTENTS

SECTION 1:SAFETY INSTRUCTIONS AND WARNINGS ................................................ 1-1

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

1.02 Principal Safety Standards .............................................................................. 1-4

1.03 Symbol Chart .................................................................................................. 1-5

1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6

1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6

1.06 Principales Normes De Securite ..................................................................... 1-9

1.07 Graphique de Symbole .................................................................................. 1-10

1.08 Declaration Of Conformity ............................................................................ 1-11

SECTION 2: INTRODUCTION ............................ 2-1

2.01 How to Use This Manual ................................................................................. 2-1

2.02 Equipment Identification ................................................................................. 2-1

2.03 Receipt of Equipment ...................................................................................... 2-1

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

2.05 Transportation Methods .................................................................................. 2-1

2.06 Duty Cycle ....................................................................................................... 2-1

2.07 Specifications ................................................................................................. 2-2

SECTION 3:INSTALLATION ............................................................................... 3-1

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

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

3.03 Electrical Input Connections ........................................................................... 3-1

3.04 Electromagnetic Compatibility ........................................................................ 3-3

3.05 Setup for Welding ........................................................................................... 3-4

3.06 Manual Arc (STICK) Setup .............................................................................. 3-5

3.07 Lift TIG (GTAW) Setup .................................................................................... 3-6

SECTION 4:OPERATION ................................................................................... 4-1

4.01 Front Panel ..................................................................................................... 4-1

4.02 SMAW Electrode Polarity ................................................................................ 4-2

4.03 Effects of Stick Welding Various Materials ...................................................... 4-2

4.04 GTAW Electrode Polarity ................................................................................. 4-3

4.05 Guide for Selecting Filler Wire ........................................................................ 4-3

4.06 Tungsten Electrode Current Ranges ............................................................... 4-3

4.07 Shielding Gas Selection .................................................................................. 4-3

4.08 Tungsten Electrode Types ............................................................................... 4-3

4.09 TIG Welding Parameters for Steel ................................................................... 4-3

4.10 Arc Welding Practice ....................................................................................... 4-4

4.11 Welding Position ............................................................................................. 4-4

4.12 Joint Preparations ........................................................................................... 4-5

4.13 Arc Welding Technique ................................................................................... 4-5

4.14 The Welder ...................................................................................................... 4-6

4.15 Striking the Arc ............................................................................................... 4-6

4.16 Arc Length ...................................................................................................... 4-6

4.17 Rate of Travel .................................................................................................. 4-6

4.18 Making Welded Joints ..................................................................................... 4-6

4.19 Distortion ........................................................................................................ 4-8

4.20 The Cause of Distortion .................................................................................. 4-9

4.21 Overcoming Distortion Effects ........................................................................ 4-9

TABLE OF CONTENTS

SECTION 5:SERVICE ....................................................................................... 5-1

5.01 Routine Maintenance and Inspection .............................................................. 5-1

5.02 STICK Welding Problems ............................................................................... 5-2

5.03 TIG Welding Problems ................................................................................... 5-3

5.04 Power Source Problems ................................................................................. 5-4

5.05 Key Spare Parts .............................................................................................. 5-4

LIMITED WARRANTY & WARRANTY SCHEDULE .........................................................2

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ............................................3

SAFETY INSTRUCTIONS ARC MASTER 175 SE

!

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS
KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL
BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator
does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study
and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply

to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication
and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL

INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit
is electrically live whenever the output is on. The
input power circuit and machine internal circuits
are also live when power is on. In semiautomatic
or automatic wire welding, the wire, wire reel, drive
roll housing, and all metal parts touching the weld­ing wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating
mats or covers.

4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.

5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water
to cool it or lay it down on the ground or the work surface.
Do not touch holders connected to two welding machines
at the same time or touch other people with the holder or
electrode.

9. Do not wrap cables around your body.

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

11. Do not touch electrode while in contact with the work (ground)
circuit.

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

13. In confined spaces or damp locations, do not use a welder
with AC output unless it is equipped with a voltage reducer.
Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above floor
level.

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can
damage hearing. Arc rays from the welding process
produce intense heat and strong ultraviolet rays that
can burn eyes and skin. Noise from some processes
can damage hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face
and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

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

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

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

8. Do not use worn, damaged, undersized, or poorly spliced
cables.

March 20, 2007 1-1 Manual 0-5054

Manual 0-5054 1-2 March 20, 2008

ARC MASTER 175 SE SAFETY INSTRUCTIONS

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS/ANSI Z49.1:1999

Welding or Cutting

Operation

Electrode Size Metal Thickness

or Welding Current

Filter

Shade No.

Welding or Cutting

Operation

Electrode Size Metal Thickness

or Welding Current

Filter

Shade No.
Torch Soldering All 2 Gas Tungsten Arc Welding

Torch Brazing All 3 or 4 Light Under 50 Amp

10

Oxygen Cutting Medium

50 to 150 Amp 12

Light Under 1" (25mm) 3 or 4 Heavy

150 to 500 Amp 14

Medium 1" – 6" (25mm – 150mm) 4 or 5 Atomic Hydrogen Welding

All 12

Heavy Over 6" (150mm) 5 or 6 Carbon Arc Welding

All 14

Gas Welding Carbon Arc Gouging

Light Under 1/8 " (3mm) 4 or 5 Light 12

Medium 1/8" – 1/2" (3mm – 12mm) 5 or 6 Heavy 14

Heavy Over 1/2" (12mm) 6 or 8 Plasma Arc Welding

Shielded Metal-Arc Welding (Stick) Electrodes

Light Under 20 Amp 6 to 8

Light Under 5/32" (4mm) 10 Light 20 to 100 Amp 10

Medium

Under 5/32" - ¼" (4mm - 6.4mm)

12

Medium 100 to 400 Amp 12

Heavy

Over ¼" (6.4mm)

14

Heavy 400 to 800 Amp 14

Gas Metal Arc Welding Plasma Arc Cutting

Light Under 60 Amp 7 Light Under 300 Amp 9

Light

60 to 160 Amp 11 Medium 300 to 400 Amp 12

Medium

160 to 250 Amp 12 Heavy 400 to 800 Amp 14

Heavy

250 to 500 Amp 14

WARNING

FUMES AND GASES can be hazardous to your
health.

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

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

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

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

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

5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can react
with vapours to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from
the weld area, the area is well ventilated, and if necessary,
while wearing an air-supplied respirator. The coatings and any
metals containing these elements can give off toxic fumes if
welded.

WARNING

WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc.

The flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, overheating,
or fire.

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

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

3. Remove all flammables within 35’ (10.7m) of the welding
arc. If this is not possible, tightly cover them with approved
covers.

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

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

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

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area
as practical to prevent welding current from travelling long,
possibly unknown paths and causing electric shock and fire
hazards.

9. Do not use welder to thaw frozen pipes.

SAFETY INSTRUCTIONS ARC MASTER 175 SE

!

10. Remove stick electrode from holder or cut off welding wire
at contact tip when not in use.

WARNING

WARNING

FLYING SPARKS AND HOT METAL can cause
injury.

Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields
recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.

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

2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.

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

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

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

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

ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks
or open flames.

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

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

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

WARNING

MOVING PARTS can cause injury.

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

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

2. Stop engine before installing or connecting unit.

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

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

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

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

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

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

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

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

2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

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

2. Stop engine before disconnecting or connecting battery
cables.

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

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

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

March 20, 2007 1-3 Manual 0-5054

Manual 0-5054 1-4 March 20, 2008

ARC MASTER 175 SE SAFETY INSTRUCTIONS

!

WARNING

STEAM AND PRESSURIZED HOT COOLANT can
burn face, eyes, and skin.

The coolant in the radiator can be very hot and
under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine
to cool.

2. Wear gloves and put a rag over cap area when removing
cap.

3. Allow pressure to escape before completely removing cap.

This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
know to the State of California to cause birth defects
and, in some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)

Considerations About Welding And The Effects of
Low Frequency Electric and Magnetic Fields

The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields - Back­ground Paper, OTA-BP-E-63 (Washington, DC: U.S. Government
Printing Office, May 1989): “...there is now a very large volume
of scientific findings based on experiments at the cellular level
and from studies with animals and people which clearly establish
that low frequency magnetic fields and interact with, and produce
changes in, biological systems. While most of this work is of
very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does
not yet allow us to draw definite conclusions about questions of
possible risk or to offer clear science-based advice on strategies
to minimize or avoid potential risks.”

WARNING

NOTE

LEAD WARNING

This product contains chemicals, including lead,
or otherwise produces chemicals known to the
State of California to cause cancer, birth defects
and other reproductive harm. Wash hands after
handling. (California Health & Safety Code §

25249.5 et seq.)

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126.

Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding
and Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face
Protection, ANSI Standard Z87.1, from American National
Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.

To reduce magnetic fields in the workplace, use the following
procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the
operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from
body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.

SAFETY INSTRUCTIONS ARC MASTER 175 SE

Gas Tungsten Arc
Welding (GTAW)

Air Carbon Arc
Cutting (CAC-A)

Constant Current

Constant Voltage
Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static
Frequency Converter­Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal
Arc Welding (SMAW)

Gas Metal Arc
Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth
(Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating­Auxiliary Power

Art # A-04130

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards
Workpiece With
Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld
Mode

Press to initiate wirefeed and
welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.

4 Step Trigger
Operation

2 Step Trigger
Operation

1.03 Symbol Chart

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

March 20, 2007 1-5 Manual 0-5054

Manual 0-5054 1-6 March 20, 2008

ARC MASTER 175 SE SAFETY INSTRUCTIONS

!

1.04 Precautions De Securite En Soudage A L’arc

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU
ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel
et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être ap­prises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage
et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors
que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires
à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de
ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET
D’ESSAI.

1.05 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler
gravement. L’électrode et le circuit de soud­age sont sous tension dès la mise en circuit. Le
circuit d’alimentation et les circuits internes de
l’équipement sont aussi sous tension dès la mise
en marche. En soudage automatique ou semi­automatique avec fil, ce dernier, le rouleau ou la
bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le
fil de soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à
la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

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

MISE EN GARDE

souder. Ne touchez pas aux porte-électrodes raccordés à
deux sources de courant en même temps. Ne jamais toucher
quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre
de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit
de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou
remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de
source de courant alternatif, à moins qu’il soit muni d’un
réducteur de tension. Utilisez plutôt une source de courant
continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

3 Isolez-vous de la pièce à souder et de la mise à la terre au

moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou ar­rêtez le moteur avant de l’installer ou d’en faire l’entretien.
Bloquez le commutateur en circuit ouvert ou enlevez les
fusibles de l’alimentation afin d’éviter une mise en marche
accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon
le manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.

6. Arrêtez tout équipement après usage. Coupez l’alimentation
de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais
plonger les porte-électrodes dans l’eau pour les refroidir.
Ne jamais les laisser traîner par terre ou sur les pièces à

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES
YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER
L’OUIE.

L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux
et la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après)
pour vous protéger le visage et les yeux lorsque vous soudez
ou que vous observez l’exécution d’une soudure.

AVERTISSEMENT

SAFETY INSTRUCTIONS ARC MASTER 175 SE

2. Portez des lunettes de sécurité approuvées. Des écrans
latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour
protéger les autres des coups d’arc ou de l’éblouissement;
avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables
(laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille ap­prouvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGERE­USES POUR LA SANTE.

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

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

2. A l’intérieur, assurez-vous que l’aire de soudage est bien
ventilée ou que les fumées et les vapeurs sont aspirées à
l’arc.

3. Si la ventilation est inadequate, portez un respirateur à ad­duction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consummables, aux
revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz pro­tecteurs de soudage peuvent déplacer l’oxygène de l’air et

ainsi causer des malaises ou la mort. Assurez-vous que l’air
est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou
au cadmium que si les zones à souder ont été grattées à
fond, que si l’espace est bien ventilé; si nécessaire portez
un respirateur à adduction d’air. Car ces revêtements et tout
métal qui contient ces éléments peuvent dégager des fumées
toxiques au moment du soudage.

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU
UNE EXPLOSION

L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections
de soudure et l’équipement surchauffé peuvent
causer un incendie et des brûlures. Le contact ac­cidentel de l’électrode ou du fil-électrode avec un
objet métallique peut provoquer des étincelles, un
échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et
du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes
ou des projections peuvent atteindre des matériaux inflam­mables.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de

coupage ou soudage

Brassage tendre au
chalumeau

Brassage fort au
chalumeau

Oxycoupage métaux ferreux toutes conditions 12

mince moins de 1 po. (25 mm) 2 ou 3

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

épais plus de 6 po. (150 mm) 5 ou 6

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

Soudage á l'arc avec elec­trode enrobees (SMAW)

Dimension d'électrode
ou Epiasseur de métal

ou Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

moins de 5/32 po. (4 mm) 10

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance
de filtre

oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz
avec fil plein (GMAW)

Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)

Soudage á l'hydrogène
atomique (AHW)

Soudage á l'arc avec
électrode de carbone (CAW)

Gougeage Air-Arc avec
électrode de carbone

Coupage á l'arc Plasma (PAC)

épais plus de 400 amperès 14

Dimension d'électrode
ou Epiasseur de métal

ou Intensité de courant

toutes conditions 12

toutes conditions 12

toutes conditions 12

Nuance
de filtre

oculaire

March 20, 2007 1-7 Manual 0-5054

Manual 0-5054 1-8 March 20, 2008

ARC MASTER 175 SE SAFETY INSTRUCTIONS

3. Enlevez toutes matières inflammables dans un rayon de 10,
7 mètres autour de l’arc, ou couvrez-les soigneusement avec
des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage suscep­tibles de pénétrer dans des aires adjacentes par de petites
ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée
de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l’autre
côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un
baril.

8. Connectez le câble de soudage le plus près possible de la
zone de soudage pour empêcher le courant de suivre un long
parcours inconnu, et prévenir ainsi les risques d’électrocution
et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil au tube­contact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants
en cuir, une chemise épaisse, un pantalon revers, des bottines
de sécurité et un casque.

5. N’utilisez que des bouteilles de gaz protecteur, des déten­deurs, des boyauxs et des raccords conçus pour chaque ap­plication spécifique; ces équipements et les pièces connexes
doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la
bouteille lors de son ouverture.

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

8. Lisez et respectez les consignes relatives aux bouteilles de
gaz comprimé et aux équipements connexes, ainsi que la
publication P-1 de la CGA, identifiée dans la liste de docu­ments ci-dessous.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEU-

VENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

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

2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur,
loin des prises d’air du bâtiment.

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULAN­TES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure
peut projeter du éclats de laitier.

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

2. Portez des vêtements appropriés pour protéger la
peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER

Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles endommagées
peuvent exploser. Comme les bouteilles font nor­malement partie du procédé de soudage, traitez-les
avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources
de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un
cadre fixe pour les empêcher de tomber ou d’être renver­sées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout
soudage.

4. Empêchez tout contact entre une bouteille et une électrode
de soudage.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU
UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrête z le moteur avant d e vérifier le niveau e
carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source
d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire
le plein de carburant ou d’en vérifier le niveau au début du
soudage.

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

5. Faites attention de ne pas renverser de carburant. Nettoyez
tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER
DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs,
des rotors et des courroies peuvent couper doigts
et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le
moteur.

SAFETY INSTRUCTIONS ARC MASTER 175 SE

3. Seules des personnes qualifiées doivent démonter des pro­tecteurs ou des capots pour faire l’entretien ou le dépannage
nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements
amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes
après des travaux d’entretien et avant de faire démarrer le
moteur.

Ce produit contient des produits chimiques, comme
le plomb, ou engendre des produits chimiques,
reconnus par l’état de Californie comme pouvant
être à l’origine de cancer, de malformations fœtales
ou d’autres problèmes de reproduction. Il faut se
laver les mains après toute manipulation. (Code
de Californie de la sécurité et santé, paragraphe

25249.5 et suivants)

1.06 Principales Normes De Securite

PLOMB AVERTISSEMENT

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU­LATEUR PEUT BRULER LA PEAU ET LES YEUX.

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

1. Portez toujours un écran facial en travaillant sur un accumu­lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des
câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.

4. N’utilisez pas une source de courant de soudage pour
charger un accumulateur ou survolter momentanément un
véhicule.

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

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.

Safety in Welding and Cutting, norme ANSI Z49.1, American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.

Recommended Safe Practices for the Preparation for Welding
and Cutting of Containers That Have Held Hazardous Substances,
norme AWS F4.1, American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P­1, Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2
Association canadienne de normalisation, Standards Sales, 276
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face
Protection, norme ANSI Z87.1, American National Standards
Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

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

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

2. Mettez des gants et posez un torchon sur le bouchon pour
l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.

March 20, 2007 1-9 Manual 0-5054

Manual 0-5054 1-10 March 20, 2008

ARC MASTER 175 SE SAFETY INSTRUCTIONS

Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)

Decoupe Arc Carbone
(CAC-A)

Courant Constant

Tension Constante
Ou Potentiel Constant

Haute Température

Force d'Arc

Amorçage de L’arc au
Contact (GTAW)

Inductance Variable

Tension

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur
Transformateur-Redresseur

Tension dangereuse

Hors Tension

Sous Tension

Panneau/Local

Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)

Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Distant

Facteur de Marche

Pourcentage

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de Prise­Source Auxiliaire

Art # A-07639

115V 15A

t

t1

t2

%

X

IPM

MPM

t

Fusible

Déroulement du Fil

Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension

Durée de Pré-Dèbit

Durée de Post-Dèbit

Duréc du Pulse

Soudure Par Point

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

Purge Du Gaz

Mode Continu de
Soudure

Pouces Par Minute

Mètres Par Minute

Torch de Soudage

Probléme de Terre

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

Détente à 4-Temps

Détente à 2-Temps

V

1.07 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

SAFETY INSTRUCTIONS ARC MASTER 175 SE

1.08 Declaration Of Conformity

Manufacturer: Thermadyne Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European
Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this
Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC Directive” (European Council
Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

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

National Standard and Technical Specifications

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

• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

• ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to welding equipment and associated
accessories.

• For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192 when
used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

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

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

Manufacturers responsible representative:

Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

March 20, 2007 1-11 Manual 0-5054

ARC MASTER 175 SE SAFETY INSTRUCTIONS

Manual 0-5054 1-12 March 20, 2008

INTRODUCTION ARC MASTER 175 SE

!

!

SECTION 2:

INTRODUCTION

2.01 How to Use This Manual

This Operating Manual applies the part numbers
listed on page i. If none are underlined, they are all
covered by this manual. To ensure safe operation,
read the entire manual, including the chapter on safety
instructions and warnings. Throughout this manual,
the word WARNING, CAUTION and NOTE may appear.
Pay particular attention to the information provided
under these headings. These special annotations are
easily recognized as follows:

WARNING

Gives information regarding possible per­sonal injury. Warnings will be enclosed in
a box such as this.

CAUTION

Refers to possible equipment damage.
Cautions will be shown in bold type.

NOTE

as described above along with a full description of
the parts in error.

2.04 Description

This compact inverter welding machine has infinitely
adjustable welding current from 5 to 175 amps. It
runs standard general purpose SMAW 3/32” (2.5mm)
electrodes for light gauge work, generally less than
1/8” (3.2mm) thick, and SMAW 1/8” (3.2mm) elec­trodes for heavier material. The unit also has a Lift TIG
(GTAW) welding mode that offers stable TIG welding
characteristics when used with a suitable TIG torch
and shielding gas.

2.05 Transportation Methods

CAUTION

ELECTRIC SHOCK can kill. DO NOT TOUCH

live electric parts. Disconnect input power
conductors from de-energized supply
line before moving the welding power
source.

Offers helpful information concerning
certain operating procedures. Notes will
be shown in italics.

2.02 Equipment Identification

The unit’s identification number (specification or part
number), model, and serial number usually appear
on a nameplate attached to the machine. Equipment
which does not have a nameplate attached to the
machine is identified only by the specification or part
number printed on the shipping container. Record
these numbers 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

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 secure unit on a proper skid before
transporting.

2.06 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, 175 amperes at 27 volts. This means that it
has been designed and built to provide the rated
amperage (175A) for 2 minutes, i.e. arc welding time,

March 20, 2008 2-1 Manual 0-5054

ARC MASTER 175 SE INTRODUCTION

W1002902

Welding current range 5 - 175 Amps

Nominal DC Open Circuit Voltage (OCV) 65

175A @ 20%, 27.0V
110A @ 60%, 24.4V

80A @ 100%, 23.2V
Rated input current (A) for STICK Welding 40A

IȠ = 175A @ 27V

Rated input current (A) for TIG Welding 25A

IȠ = 175A @ 17V

Rated output for STICK Welding 175A @ 20%, 27V

Rated output for TIG Welding 175A @ 20%, 17V

Duty cycle (%) 175 @ 20%

Welder type Inverter Power Source

Output Terminal Type Dinse™ 50

Number of Phases Single Phase

Nominal Supply Voltage AC 230 ±15%

Nominal supply frequency 50/60 Hz

Effective Input Current (l1eff) 17 Amps

Maximum Input Current (l1 max) Δ 40 Amps

Single Phase Genorator Requirements 1 KVA

Protection Class IP23S

Standard(s) EN 60974-1

EN50199

Cooling Method Fan Cooled

Welding power source mass 14.33lb (6.5kg)

H 13.0" x W5.1" x D 9.0"

(H 330mm x W 130mm x D 230mm)

Power Source Part Number

Welding Output

Welding output, 40ºC, 10 min. (quoted figures refer to SMAW
output)

Dimensions and Weight

Dimension power source (DxWxH)

Mains Power

Classification

2.07 Specifications

∆ Motor start fuses or thermal circuit breakers are recommended for this application. Check local
requirements for your situation in this regard.

Thermal Arc continuously strives to produce the best product possible and therefore reserves the
right to change, improve or revise the specifications or design of this or any product without prior
notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped
to the corresponding changes, updates, improvements or replacement of such items.

The values specified in the table above are optimal values, your values may differ. Individual equip­ment may differ from the above specifications due to in part, but not exclusively, to any one or
more of the following; variations or changes in manufactured components, installation location
and conditions and local power grid supply conditions.

NOTE

Manual # 0-5054 2-2 March 20, 2008

INSTALLATION ARC MASTER 175 SE

!

!

SECTION 3:

INSTALLATION

3.01 Environment

These units are designed for use in environments
with increased hazard of electric shock. Examples
of environments with increased hazard of electric
shock are:

A. In locations in which freedom of movement is

restricted, so that the operator is forced to perform
the work in a cramped (kneeling, sitting or lying)
position with physical contact with conductive
parts.

B. In locations which are fully or partially limited by

conductive elements, and in which there is a high
risk of unavoidable or accidental contact by the
operator.

C. In wet or damp hot locations where humidity

or perspiration considerably reduces the skin
resistance of the human body and the insulation
properties of accessories.

Environments with 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:

3.03 Electrical Input Connections

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE

is present after removal of input power.

DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input

power employing lockout/tagging procedures. Lock­out/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.

• Electrical Input Requirements

Operate the welding power source from a single-phase
50/60 Hz, AC power supply. The input voltage must
match one of the electrical input voltages shown on
the input data label on the unit nameplate. Contact the
local electric utility for information about the type of
electrical service available, how proper connections
should be made, and inspection required. The line
disconnect switch provides a safe and convenient
means to completely remove all electrical power
from the welding power supply whenever necessary
to inspect or service the unit.

• In areas, free from moisture and dust.

• Ambient temperature between 32°F to 104°F
(0°C to 40°C).

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

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

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

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

WARNING

Thermal Arc advises that this equipment be electrically
connected by a qualified electrician.

Do not connect an input (WHITE or BLACK) conductor
to the ground terminal.

Do not connect the ground (GREEN) conductor to an
input line terminal.

March 20, 2008 3-1 Manual 0-5054

ARC MASTER 175 SE INSTALLATION

Manual # 0-5054 3-2 March 20, 2008

Ground Terminal

Primary Power Cable

Line Fuse

Line Disconnect Switch

Ground Conductor

Art #: A-08462_AB

Arc Master 175 SE 13 AWG (1.5mm² ) 230V/25A 175A@20% -

230V/40A - 175A@20%

Current & Duty Cycle

TIG STICK

Minimum Primary

Current Circuit Size

(Vin/Amps)

Model

Primary Supply Lead Size

(Factory Fitted)

Refer to Figure 1:

1. Connect end of ground (GREEN or GREEN/YELLOW) conductor to a suitable ground. Use a grounding method that
complies with all applicable electrical codes.

2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line disconnect switch.

3. Use Table 3-1 as a guide to select line fuses for the disconnect switch

Input Voltage Fuse Size

230V 40 Amps

Table 3-1: Electrical Connections1: Electrical Connections Electrical Connections

.

Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on
Article 630, National Electrical Code).

Welding Power Supply

Figure 3-1: Electrical Input Connections

Input Power

Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides
pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the input capacitors
have charged to operating voltage (after approximately 5 seconds)

NOTE

Damage to the PCA could occur if 265 VAC or higher is applied to the Primary Power Cable.

Table 3-2: Primary Supply Lead

INSTALLATION ARC MASTER 175 SE

!

3.04 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 Trouble-some.

NOTE

For 230 VAC operation, have a qualified person install
according to applicable codes, and instructions.

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, signalling 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. Mains Supply
Welding equipment should be connected to the mains

supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take
additional precautions such as filtering of the mains
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. In
particular, the spark gaps of arc striking and stabilizing
devices should be adjusted and maintained according
to the manufacturer’s recommendation

3. Welding Cables
The welding cables should be kept as short as possible

and should be positioned close together, running at or
close to the floor level.

4. Equipotential Bonding
Bonding of all metallic components in the welding instal-

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

5. Earthing of the Work Piece
Where the work piece is not bonded to earth for electri-

cal 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 suit-able 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.

March 20, 2008 3-3 Manual 0-5054

ARC MASTER 175 SE INSTALLATION

Manual # 0-5054 3-4 March 20, 2008

!

3.05 Setup for Welding

NOTE

Conventional operating procedures apply when us­ing the Welding Power Source, i.e. connect work
lead directly to work piece and electrode lead is used
to hold electrode. Wide safety margins provided by
the design ensure that the Welding Power Source
will withstand short-term overload without adverse
effects. The welding current range values should be
used as a guide only. Current delivered to the arc is
dependent on the welding arc voltage, and as weld­ing arc voltage varies between different classes of
electrodes, welding current at any one setting would
vary according to the type of electrode in use. The
operator should use the welding current range values
as a guide then fine tune the welding current to suit
the application.

WARNING

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

CAUTION

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

INSTALLATION ARC MASTER 175 SE

Set Welding Current
as Specified by the
Electrode Manufacturer

Set Process Selection
Switch to Manual Arc

Positive Output Terminal
(Dinse™ 50)

Negative Output Terminal
(Dinse™ 50)

Art #: A-08469_AC

3.06 Manual Arc (STICK) Setup

Figure 3-2: Setup for Manual Arc (STICK) Welding

Manual Arc Sequence of Operation

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

2. Connect the earth clamp lead to the Negative Output
Terminal and electrode holder lead to the Positive
Output Terminal. Consult the electrode manufacture's
packaging for the correct electrode polarity.

3. Plug the Power Source in and switch the power switch
ON.

4. Set the Process Switch to Manual Arc.

5. Set the Weld Current control to the desired welding
current.

6. Switch the ON/OFF Switch (located on the rear panel)
to the ON position. This will immediately energize the
power supply up to the output terminals and the elec­trode holder.

7. Commence welding. If necessary, readjust the Weld
Current control to obtain the welding condition re­quired.

8. After completion of welding the Power Source should
be left turned ON for 2 to 3 minutes. This allows the
fan to run and cool the internal components.

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

March 20, 2008 3-5 Manual 0-5054

ARC MASTER 175 SE INSTALLATION

Set Welding Current
as Specified by the
Electrode Manufacturer

Set Process Selection
Switch to LIFT TIG

Positive Output Terminal

(Dinse™ 50)

Negative Output Terminal

(Dinse™ 50)

Art #: A-08470_AB

Secure the gas cylinder in an
upright position by chaining them
to a stationary support to prevent
falling or tipping

3.07 Lift TIG (GTAW) Setup

Lift TIG Sequence of Operation

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

2. Connect the earth clamp to the Positive Output Terminal,
torch cable to the Negative Output Terminal and gas
hose to the output of an Argon regulator.

3. Plug the Power Source in and switch the power switch
ON.

4. Set the Process Selection Switch to Lift TIG.

5. Set the Weld Current control to the desired welding
current.

6. Switch the ON/OFF Switch to the ON position.

Figure 3-3: Setup for Lift TIG (GTAW) Welding

7. Commence welding. If necessary, readjust the Weld
Current control to obtain the welding condition re­quired.

8. After completion of welding the Power Source should
be left turned ON for 2 to 3 minutes. This allows the
fan to run and cool the internal components.

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

Manual # 0-5054 3-6 March 20, 2008

OPERATION ARC MASTER 175 SE

17 5

16 0

5

60

80

10 0

12 0

14 0

40

20

A R C M A S T E R

175 SE

Weldskill

(A) Process
Selection
Switch

(B) Power On
Indicator

(C) Over Heat
Indicator

(D) Welding
Current
Control

Art #: A-08478

SECTION 4:

OPERATION

Conventional operating procedures apply when using the
Welding Power Source, i.e. connect work lead directly to
work piece and electrode lead is used to hold the electrode.
The welding current range values should be used as a guide
only. Current delivered to the arc is dependent on the weld­ing arc voltage, and as welding arc voltage varies between
different classes of electrode, welding current at any one
setting would vary according to the type of electrode in use.
The operator should use the welding current range values
as a guide then fine tune the welding current to suit the
specific application. Refer to the electrode manufacture's
literature for further information.

4.01 Front Panel

Front Panel

The welding power source is protected by a self re-setting
thermostat. The indicator will illuminate if the duty cycle
of the power source has been exceeded. If the Over Heat
light illuminates wait for the Over Heat light to extinguish
before resuming welding.

(A) Process Selection Switch

Switches between Lift TIG and Manual Arc (STICK) Weld­ing modes.

(B) Power On Indicator
The Power ON Indicator illuminates when the ON/OFF

switch is in the ON position and the nominal mains volt­age is present.

(C) Over Heat Indicator

The welding power source is protected by a self resetting
thermostat. The indicator will illuminate if the duty cycle
of the power source has been exceeded. If the Over Heat
light illuminates wait for the Over Heat light to extinguish
before resuming welding.

(D) Welding Current Control

The welding current is increased by turning the Weld Cur­rent control knob clockwise or decreased by turning the
Weld Current control knob anti-clockwise. The welding
current should be set according to the specific application.
Refer to the electrode manufacture's literature for further
information.

(E) ON/OFF Switch (located on rear panel (not shown)

This switch controls the Mains Supply Voltage to the Power
Source.

Figure 4-1: 175 SE Control Panel

March 20, 2008 4-1 Manual 0-5054

ARC MASTER 175 SE OPERATION

4.02 SMAW Electrode Polarity

Stick electrodes are generally connected to the "+"
Positive Output Terminal and the work lead to the
"−" Negative Output Terminal but if in doubt consult
the electrode manufacturer's literature for further
information.

4.03 Effects of Stick Welding Various Materials

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.

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.

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.

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.

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
and are all easy to use.

Metal Being Joined Electrode Comments

Mild Steel E6013

Mild Steel E7014 All positional electrode for use on mild and

Cast Iron 99% Nickel Suitable for joining all cast irons except white

Stainless Steel E318L-16 High corrosion resistance. Ideal for dairy work

Copper, Bronze, Brass, Etc. Bronze

5.7 ERCUSI-A

High Alloy Steel, Dissimilar

Metals, Crack Resistance, All

Hard-To Weld jobs

E312-16

Ideal electrodes for all general purpose work,
features include outstanding operator appeal,
easy arc starting, and low spatter.

galvanized steel furniture, plates, fences, gates,
pipes and tanks, etc. Especially suitable for
vertical-down welding.

cast iron.

etc.
Easy to use electrode for marine fittings, water

taps and valves, water through floats arms, etc.
Also for joining copper to steel and for bronze
overlays on steel shafts.

It will weld most problematic job such as springs,
shafts, broken joins, mild steel to stainless and
alloy steels. Not suitable for aluminium.

Manual # 0-5054 4-2 March 20, 2008

OPERATION ARC MASTER 175 SE

Joint

Mild Steel Stainless Steel Type

0.040” 35-45 20-30 1/16” 10 CFH Butt/Corner

(1.0mm) 40-50 25-35 (1.6mm) (5 LPM) Lap/ Fillet

0.045” 45-55 30-45 1/16” 13 CFH Butt/Corner

(1.2mm) 50-60 35-50 (1.6mm) (6 LPM) Lap/ Fillet

1/16” 60-70 40-60 1/16” 15 CFH Butt/Corner

(1.6mm) 70-90 50-70 (1.6mm) (7 LPM) Lap/ Fillet

1/8” 80-100 65-85 3/32” 15 CFH Butt/Corner

(3.2mm) 90-115 90-110 (2.4mm) (7 LPM) Lap/ Fillet

3/16” 115-135 100-125 1/8” 21 CFH Butt/Corner

4.8mm 140-165 125-150 (3.2mm) (10 LPM) Lap/ Fillet
¼” 160-175 135-160 1/8” 5/32” 21 CFH Butt/Corner

(6.4mm) 170-200 160-180 (3.2mm) (4.0mm) (10 LPM) Lap/ Fillet

Base Metal

Thickness

DC Current

Electrode
Diameter

Filler Rod

Diameter

1/16”

(1.6mm)

3/32”

(2.4mm)

Argon Gas
Flow Rate

0.040”

(1.0mm)

0.040”

(1.0mm)

1/16”

(1.6mm)

4.04 GTAW Electrode Polarity

Connect the TIG torch to the "-" Negative Output
Terminal and the work lead to the "+" Positive Output
Terminal for direct current straight polarity. Direct
current straight polarity is the most widely used
polarity for DC TIG welding. It allows limited wear of
the electrode since 70% of the heat is concentrated
at the work piece.

4.05 Guide for Selecting Filler Wire

Electrode Diameter DC Current

.040” (1.0mm) 30 - 60
1/16” (1.6mm) 60 - 115
3/32” (2.4mm) 100 - 165

1/8” (3.2mm) 135 - 175

4.08 Tungsten Electrode Types

4.06 Tungsten Electrode Current Ranges

Electrode Diameter DC Current

.040” (1.0mm) 25 - 85

1/16” (1.6mm) 50 - 160

4.07 Shielding Gas Selection

Alloy Shielding Gas

Carbon Steel Welding Argon

Stainless Steel Welding Argon

Nickel Alloy Welding Argon

Copper Welding Argon

Titanium Welding Argon

Electrode Type

(Ground Finish) Welding Application Features Colour Code

Thoriated 2% DC welding of mild steel, stainless

steel and copper.

Ceriated 2% AC & DC welding of mild steel,

stainless steel, copper aluminium
magnesium and their alloys.

4.09 TIG Welding Parameters for Steel

Excellent arc starting, long life,
high current carrying capacity.

Longer life, more stable arc,
easier starting, wilder current
range, narrower more concen­trated arc.

Red

Grey

March 20, 2008 4-3 Manual 0-5054

ARC MASTER 175 SE OPERATION

Art # A-07687

Art # A-07688

Art # A-07689

Art # A-07690

Art A-07691

Art # A-07692

Art# A-07693

Art # A-07694

4.10 Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined.
Naturally enough, different types of electrodes would be used for different metals as described in the preceding
section.

4.11 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 4-2 through 4-9.

Figure 4-2: Flat position, down hand butt weld

Figure 4-3: Flat position, gravity fillet weld

Figure 4-4: Horizontal position, butt weld

Figure 4-6: Vertical position, butt weld

Figure 4-7: Vertical position, fillet weld

Figure 4-8: Overhead position, butt weld

Figure 4-5: Horizontal - Vertical (HV) position

Figure 4-9: Overhead position, fillet weld

Manual # 0-5054 4-4 March 20, 2008

OPERATION ARC MASTER 175 SE

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

1.6mm (1/16”)

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-07695_AB

4.12 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 4-10.

Figure 4-10: Typical joint designs for arc welding

4.13 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 down
hand 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.

March 20, 2008 4-5 Manual 0-5054

ARC MASTER 175 SE OPERATION

Art # A-07696

4.14 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. Don’t
hold your body tense. A taut attitude of mind and a
tensed body will soon make you feel tired. Relax and
you will find that the job becomes much easier. You
can add much to your peace of mind by wearing a
leather apron and gauntlets. You won’t be worrying
then about being burnt or sparks setting alight to
your clothes.

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. If the lead is slung over your shoulder,
it allows greater freedom of movement and takes a
lot of weight off your hand. Be sure the insulation on
your cable and electrode holder is not faulty, otherwise
you are risking an electric shock.

4.15 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.

4.16 Arc Length

The securing of an arc length necessary to produce
a neat weld soon becomes almost automatic. You
will find that 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. Contact or “touch-weld”
electrodes such as E7014 do not stick in this way, and
make welding much easier.

4.17 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 20° 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.

4.18 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 4-12, 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 70° to 90° included angle.
This allows full penetration of the weld metal to the
root. Using a 1/8" (3.2mm) E7014 electrode at 120
amps, deposit a run of weld metal on the bottom of
the joint.

Figure 4-11: Striking an arc

Manual # 0-5054 4-6 March 20, 2008

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 20° from vertical,
and the rate of travel not too fast, will help eliminate

OPERATION ARC MASTER 175 SE

Art # A-07697

Art # A-07698

Art # A-07699

Art # A-07700

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.

Figure 4-12: Butt weld

about 20° away from the perpendicular position to
prevent slag from running ahead of the weld. Refer
to Figure 4-14. 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
edge. Multi-runs can be made as shown in Figure 4-

15. Weaving in HV fillet welds is undesirable.

Figure 4-14: Electrode position for HV fillet weld

Figure 4-13: 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 4-13. 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 cross­section made by depositing metal in the corner of two
faces meeting at right angles. Refer to Figure 4-5.

Figure 4-15: Multi-runs in HV fillet weld

C. Vertical Welds

1. Vertical Up
Tack weld a three feet length of angle iron

to your work bench in an upright position.
Use a 1/8" (3.2mm) E7014 electrode and
set the current at 120 amps. Make yourself
comfortable on a seat in front of the job and
strike the arc in the corner

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. Using a 1/8" (3.2mm)
E7014 electrode at 120 amps, position angle iron
with one leg horizontal and the other vertical. 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 45°
from the vertical. Some electrodes require to be sloped

March 20, 2008 4-7 Manual 0-5054

ARC MASTER 175 SE OPERATION

Art # A-07701

Art # A-07702

Art # A-07703

Art # A-07704

of the fillet. The electrode needs to be about 10°

from the horizontal to enable a good bead to
be deposited. Refer Figure 4-16. 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 4-17 illustrates multi-run
technique and Figure 4-18 shows the effects of
pausing at the edge of weave and of weaving
too rapidly.

Figure 4-16: Single run vertical fillet weld

2. Vertical Down
The E7014 electrode makes welding in this

position particularly easy. Use a 1/8" (3.2mm)
electrode at 120 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 45°.

3. Overhead Welds
Apart from the rather awkward position

necessary, overhead welding is not much
more difficult that down hand 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 45° to the horizontal
and tilted 10° in the line of travel (Figure 4-

19). 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. Use a 1/8" (3.2mm)
E6012 electrode at 120 amps, and deposit the
first run by simply drawing the electrode along
at a steady rate. You will notice that the weld
deposit is rather convex, due to the effect of
gravity before the metal freezes.

Figure 4-19: Overhead fillet weld

Figure 4-17: Multi run vertical fillet weld

4.19 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

Figure 4-18: Examples of vertical fillet welds

Manual # 0-5054 4-8 March 20, 2008

that will subsequently occur. The study of distortion is
so complex that only a brief outline can be attempted
hear.

OPERATION ARC MASTER 175 SE

Art # A-07706

Art # A-07705

4.20 The Cause of Distortion

Distortion is cause by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11% in volume on
cooling to room temperature. This means that a cube
of molten metal would contract approximately 2.2%
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 excessive, e.g. a heavy section of
plate, then the weld metal may crack. Even in cases
where the weld metal does not crack, there will still
remain stresses “locked-up” in the structure. If the
joint material is relatively weak, for example, a butt
joint in 5/64" (2.0mm) sheet, the contracting weld
metal may cause the sheet to become distorted.

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

While welding is proceeding, a relatively small volume
of the adjacent plate material is heated to a very high
temperature and attempts to expand in all directions.
It is able to do his 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 4-20 and
4- 21 illustrate how distortion is created.

Figure 4-21: Parent metal contraction

4.21 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
4-25 through 4-28 for various weld sequences.
Choice of a suitable weld sequence is probably the
most effective method of overcoming distortion,
although an unsuitable sequence may exaggerate it.
Simultaneous welding of both sides of a joint by two
welders is often successful in eliminating distortion.

C. Restraint of Parts

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

D. Presetting

It is possible in some cases to tell from past experience
or to find by trial and error (or less frequently, to
calculate) how much distortion will take place in a
given welded structure. By correct pre-setting of the
components to be welded, constructional stresses
can be made to pull the parts into correct alignment.
A simple example is shown in Figure 4-22.

Figure 4-20: Parent metal expansion

March 20, 2008 4-9 Manual 0-5054

ARC MASTER 175 SE OPERATION

Art # A-07707

Art # A-07708

B

PreheatPreheat

Dotted lines show effect if no preheat is used

Weld

C

Art # A-07709

Art # A-07710

Art # A-07711

Art # A-07712

Art # A-07713

E. Preheating

Suitable preheating of parts of the structure other
than the area to be welded can be sometimes used
to reduce distortion. Figure 4-23 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.

Figure 4-26: Step back sequence

Figure 4-22: Principle of presetting

Figure 4-27: Chain intermittent welding

Figure 4-23: Reduction of distortion by preheating

Figure 4-24: Examples of distortion

Figure 4-28: Staggered intermittent welding

Figure 4-25: Welding sequence

Manual # 0-5054 4-10 March 20, 2008

SERVICE ARC MASTER 175 SE

!

Warning!
Disconnect input power before maintaining.

Each Use

Visual check of
regulator and pressure

Visual check of torch
Consumable parts

Weekly

Visually inspect
the torch body
and consumables

Visually inspect the
cables and leads.
Replace as needed

3 Months

Clean
exterior
of power supply

6 Months

Replace all
broken parts

Bring the unit to an authorized
Thermal Arc Service Centre
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.

Maintain more often
if used under severe
conditions

Art # A-08549_AC

SECTION 5:

SERVICE

5.01 Routine Maintenance and Inspection

The only routine maintenance required for the power
supply is a thorough cleaning and inspection, with the
frequency depending on the usage and the operating
environment.

WARNING

There are extremely dangerous voltages and power levels
present inside this product. Disconnect primary power at
the source before opening the enclosure. Wait at least two
minutes before opening the enclosure to allow the primary
capacitors to discharge.

To clean the unit, open the enclosure and use a vacuum
cleaner to remove any accumulated dirt and dust. The unit
should also be wiped clean, if necessary; with solvents that
are recommended for cleaning electrical apparatus.

CAUTION

Do not blow air into the power supply during cleaning.
Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause
damage to the unit.

March 20, 2008 5-1 Manual 0-5054

ARC MASTER 175 SE SERVICE

Manual # 0-5054 5-2 March 20, 2008

Insufficient Gap

Incorrect Sequence

Art # A-05866_AC

Art # A-05867_AC

Lack of
inter-run fusion

Lack of side fusion,
scale dirt, small electrode,
amperage too low

Lack of root fusion

Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high

Not cleaned,
or incorrect
electrode

Slag
trapped in
undercut

Slag trapped in root

Art # A-05868_AB

5.02 STICK Welding Problems

Description Possible Cause Remedy

1. Gas pockets or voids in weld
metal (Porosity).

2. Crack occurring in weld
metal soon after solidification
commences.

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

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

A. Electrodes are damp.
B. Welding current is too

high.

C. Surface impurities such as

oil, grease, paint, etc.

A. Rigidity of joint.

B. Insufficient throat thickness.

C. Cooling rate is too high.
A. Welding current is too low.

B. Electrode too large for joint.
C. Insufficient gap.
D. Incorrect sequence.

A. Small electrodes used on

heavy cold plate.

B. Welding current is too low.

A. Dry electrodes before use.
B. Reduce welding current.

C. Clean joint before welding

A. Redesign to relieve weld joint

of severe stresses or use crack
resistance electrodes.

B. Travel slightly slower to allow

greater build up in throat.

C. Preheat plate and cool slowly.
A. Increase welding current

B. Use smaller diameter electrode.
C. Allow wider gap.
D. Use correct build-up sequence.

A. Use larger electrodes and pre-heat

the plate.

B. Increase welding current

5. Non-metallic particles are
trapped in the weld metal
(slag inclusion).

C. Wrong electrode angle.

D. Travel speed of electrode is

too high.

E. Scale or dirt on joint sur-

face.

A. Non-metallic particle s

may be trapped in under­cut from previous run.

B. Joint preparation too res-

tricted.

C. Irregular deposits allow slag

to be trapped.

D. Lack of penetration with

slag trapped beneath weld
bead.

E. Rust or mill scale is pre-

venting full fusion.

F. Wrong electrode for position

in which welding is done.

C. Adjust angle so the welding arc

is directed more into the base
metal

D. Reduce travel speed of elect-

rode

E. Clean surface before welding.

A. If bad undercut is present, clean

slag out and cover with a run from
a smaller diameter electrode.

B. Allow for adequate penetration and

room for cleaning out the slag.

C. If very bad, chip or grind out

irregularities.

D. Use smaller electrode with

sufficient current to give adequate
penetration. Use suitable tools to
remove all slag from corners.

E. Clean joint before welding.

F. Use electrodes designed for

position in which welding is done,
otherwise proper control of slag is
difficult.

SERVICE ARC MASTER 175 SE

5.03 TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding
technique.

Description Possible Cause Remedy

1. Excessive beard 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 when arc is
struck.

7. Dirty weld pool. A. El e ctr o de c ont a min a ted

8. Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas

9. Arc f lutt e rs dur ing TI G
welding.

10. Welding arc cannot be esta­blished.

11. Electrode melts or oxidizes
when an arc is struck.

Welding current is too low Increase weld current and/or

change joint preparation.

Welding current is too high. Decrease welding current.

Travel speed too fast. Reduce travel speed.

Travel speed is too slow. Increase travel speed.

Wrong placement of filler rod. Re-position filler rod.

Electrode is connected to the

“+” Positive Output Terminal.

through contact with work
piece or filler rod material.

B. Gas contaminated with air.

Tungsten electrode is too large

for the welding current.

A. Work clamp is not connected

to the work piece or the work/
torch leads are not connected to
the correct welding terminals.

B. Torch lead is disconnected.

C. Gas flow incorrectly set, cyl-

inder empty or the torch valve
is off.

A. No gas is flowing to welding

region.
B. Torch is clogged with dust.
C. Gas hose is cut.
D. Gas passage contains impuri-

ties.

E. Gas regulator turned off.
F. Torch valve is turned off.

G. The electrode is too small for

the welding current.

Connect the electrode to the

“-“ Negative Output Terminal.

A. Cl ean the ele ctr ode by

grinding contaminates off.

B. Check gas lines for cuts and

loose fitting or change gas
cylinder.

line for problems

Select the right size electrode.

Refer to section Tungsten Elec­trode Current Ranges.

A. Connect the work clamp to

the work piece or connect
the work/torch leads to the
correct welding terminals.

B. Connect it to the “-“ Negative

Output Terminal.

C. Select the right flow rate,

change cylinder or turn torch
valve on.

A. Check the gas lines for kinks

or breaks or cylinder contains

gas.
B. Clean torch.
C. Replace gas hose.
D. Disconnect gas hose from

torch then raise gas pressure

and blow out impurities.
E. Turn on.
F. Turn on.
G. Increase electrode diameter or

reduce the welding current.

March 20, 2008 5-3 Manual 0-5054

ARC MASTER 175 SE SERVICE

!

TIG Welding Problems Continued

Description Possible Cause Remedy

12. Arc start is not smooth. A. Tungsten electrode is too large
for the welding cur-rent.

B. The wrong electrode is being

used for the welding job.

C. Gas flow rate is too high.

D. Incorrect shield gas is being

used.

E. Poor work clamp connection to

work piece.

WARNING

There are extremely dangerous voltages and power levels present inside this product. Do not attempt to repair unless
you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting
techniques. If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited
Thermal Arc Service Agent for repair.

A. Refer to section Tungsten Electrode

Current Ranges for the correct size.

B. Refer to section Tungsten Electrode

Types for the correct electrode type.

C. Select the correct flow rate for the

welding job.
D. Use 100% argon for TIG welding.
E. Improve connection to work piece.

5.04 Power Source Problems

Description Possible Cause Remedy

1. The welding arc cannot be
established.

2. The welding arc cannot be
established when the Over Heat
Indicator is illuminated

3. Maximum output we lding
current cannot be achieved with
nominal Mains supply voltage.

4. Welding current reduces when
welding.

A. The Primary supply voltage

B. The Welding Power Source

C. Loose connections internally.

The machines duty cycle has been
exceeded

Defective control circuit Have an Accredited Thermal Arc

Poor work lead connection to the
work piece.

5.05 Key Spare Parts

has not been switched ON.

switch is switched OFF.

A. Switch ON the Primary supply

voltage.

B. Switch ON the Welding Power

Source.

C. Have an Accredited Thermal

Arc Service Provider repair the
connection.

Wait for the Over Heat Indicator to
extinguish before resuming welding

Service Provider inspect then repair
the welder.

Ensure that the work lead has a
positive electrical connection to the
work piece.

Part No. Description Part No. Description

W7003003 PCB Front Panel ArcMaster 175 SE W7003018
W7003007 PCB Control 175 SE W7003020
W7003009 Fan 175 SE W7003022
W7003010 Rectifier Input Bridge 175 SE W7003023
W7003011 PCB Power 175 SE W7003024
W7003013 Current Sensor 175 SE W7003025
W7003016 Thermistor 175 SE

Manual # 0-5054 5-4 March 20, 2008

Inductor 175 SE

Output Terminal 175 SE

Panel Front 175 SE

Panel Rear 175 SE

Panel Cover 175 SE

Panel Base 175 SE

LIMITED WARRANTY & WARRANTY SCHEDULE

In accordance with the warranty periods stated below, Thermadyne guarantees the proposed product to be free from
defects in material or workmanship when operated in accordance with the written instructions as defined in this operat­ing manual.

Thermadyne welding products are manufactured for use by commercial and industrial users and trained personnel with
experience in the use and maintenance of electrical welding and cutting equipment.

Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material
or workmanship within the warranty period. The warranty period begins on the date of sale to the end user.

Welding Equipment - Limited Warranty Period
Product Period

ArcMaster 175 SE 2 Years

Electrode holder and work lead 30 Days

If warranty is being sought Thermadyne must be notified in writing within 30 days of the failure and at such time we
will make arrangements to fulfil the warranty claim. Please contact your Thermadyne product supplier for the warranty
repair procedure.

Thermadyne warranty will not apply to:

• Equipment that has been modified by any other party other than Thermadyne’s own service personnel or with
prior written consent obtained from Thermadyne service department (UK).

• Equipment that has been used beyond the specifications established in the operating manual.

• Installation not in accordance with the installation/operating manual.

• Any product that has been subjected to abuse, misuse, negligence, accident, improper care and/or maintenance
including lack of lubrication, maintenance and protection, will be refused warranty.

• Failure to clean and maintain the machine as set forth in the operating, installation or service manual.

Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation. This
manual also offers basic troubleshooting, operational and technical details including application usage.

Using this manual correctly will ensure the quickest time possible for resolving any technical questions, application issues
or defects with your Thermadyne product.

You may also wish to visit our web site www.thermadyne.com select your product class and then select literature. Here
you will find documentation including:

• Operator manuals

• Service manuals

• Product guides

Alternatively please contact your Thermadyne distributor and speak with a technical representative.

NOTE

Warranty repairs must be performed by either a Thermadyne Service Centre, a Thermadyne distributor or an
Authorised Service Agent approved by the Company.

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne Europe

Europa Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park

- Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: [phone]
Fax: [phone]

Thermadyne Italia

Via Bolsena 7
20098 S. Giuliano
Milan, Italy
Tel: [phone]

Fax: [phone]

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

World Headquarters

Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

www.thermalarc.com