THERMAL ARC 180 AC/DC
USER’S MANUAL
The machine you have just acquired has taken advantages, in its production, of
Thermal Arcs' wide experience in the manufacturing of welding machines, along
with the latest technology strides in power electronics.
It will give you entire satisfaction for years if you respect all the operating and
maintenance instructions given in this manual.
We strongly suggest you read very carefully chapters concerning safety and individual protection
before using this machine.
We thank you in advance for your co-operation.
THERMADYNE INDUSTRIES reserve the right to make changes without previous notification. Illustrations, descriptions and
characteristics are not contractually binding and do not engage the responsability of the manufacturer.
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Date : 03/12/02
TABLE OF CONTENTS
WARRANTY POLICY STATEMENT...........................................................................................5
SAFETY.......................................................................................................................................6
1. ELECTROMAGNETIC COMPATIBILITY................................................................................................................6
1.1. DECLARATION OF CONFORMITY ......................................................................................................................6
1.2. INSTALLATION AND USE.....................................................................................................................................6
1.2.1. ASSESSMENT OF AREA...................................................................................................................................................7
1.2.2. METHODS OF REDUCING EMISSIONS..........................................................................................................................7
1.2.2.1. Public supply system ........................................................................................................................................................7
1.2.2.2. Maintenance of the arc welding equipment ......................................................................................................................7
1.2.2.3. Welding cables .................................................................................................................................................................7
1.2.2.4. Equipotential bonding ......................................................................................................................................................7
1.2.2.5. Earthing of the workpiece.................................................................................................................................................8
1.2.2.6. Screening and shielding....................................................................................................................................................8
2. ELECTRIC SAFETY ......................................................................................................................................................8
2.1. CONNECTION OF THE WELDING POWER SOURCE TO THE NETWORK ....................................................8
2.2. WORKING AREA.....................................................................................................................................................8
2.3. INTERVENING.........................................................................................................................................................9
2.4. MAINTENANCE.......................................................................................................................................................9
2.5. RISKS OF FIRE AND EXPLOSION ........................................................................................................................9
3. INDIVIDUAL PROTECTION........................................................................................................................................9
3.1. RISK OF EXTERNAL INJURIES.............................................................................................................................9
3.1.1. THE WHOLE BODY...........................................................................................................................................................9
3.1.2. FACE AND EYES..............................................................................................................................................................10
3.2. RISK OF INTERNAL INJURIES............................................................................................................................10
3.3. SAFETY IN THE USE OF GASES (welding with TIG or MIG inert gases).........................................................11
3.3.1. COMPRESSED GAS CYLINDERS ..................................................................................................................................11
3.3.2. PRESSURE RELIEF VALVE............................................................................................................................................ 11
3.3.3. DETAILS ABOUT GASES................................................................................................................................................11
DESCRIPTION ..........................................................................................................................12
4. GENERAL CHARACTERISTICS ..............................................................................................................................12
5. TECHNICAL CHARACTERISTICS..........................................................................................................................13
SETTING UP .............................................................................................................................14
6. CONNECTION TO THE MAIN SUPPLY..................................................................................................................14
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7. CONNECTION TO THE GROUND............................................................................................................................14
8. PRELIMINARY PRECAUTIONS...............................................................................................................................14
USING........................................................................................................................................ 15
9. DESCRIPTION OF THE FRONT PANEL.................................................................................................................15
10. DESCRIPTION OF THE BACK PANEL ...............................................................................................................17
11. MMA (
12. TIG WELDING..........................................................................................................................................................18
12.1. 2 STROKE & 4 STROKE MODE .......................................................................................................................18
12.2. BEFORE WELDING ...........................................................................................................................................19
12.3. WELDING ...........................................................................................................................................................20
12.4. USING REMOTE CONTROL.............................................................................................................................21
12.5. CONNECTION OF A COOLING UNIT.............................................................................................................21
12.6. READING PARAMETERS WHEN WELDING ................................................................................................21
12.7. VENTILATION in tig welding ............................................................................................................................21
13. WELDING WITH PULSE DC CURRENT.............................................................................................................22
14. AC CURRENT TIG WELDING ..............................................................................................................................23
15. TIG WELDING IN PULSE AC CURRENT ...........................................................................................................25
16. HIDDEN WELDING PARAMETERS ....................................................................................................................27
STICK
) WELDING .........................................................................................................................................17
MAINTENANCE ........................................................................................................................28
17. MAINTENANCE .......................................................................................................................................................28
18. SPARE PARTS...........................................................................................................................................................28
19. PCB’S CONNECTORS .............................................................................................................................................29
20. TROUBLE SHOOTING............................................................................................................................................32
21. WIRING DIAGRAM.................................................................................................................................................34
APPENDICE .............................................................................................................................. 35
22. APPENDICE : ADJUSTABLE VALUES FOR WELDING PARAMETERS .....................................................35
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THERMAL ARC 180 AC/DC
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Date : 13/12/02
WARRANTY POLICY STATEMENT
Thermal Arc 180 AC/DC unit is guaranteed 24 months from date of invoice..
Defects caused by natural wear or accidental damage (wrong assembly, defective maintenance,
abnormal use ...) or by modification of the product, which has not been accepted in writing by the
manufacturer, are not included in the guarantee.
Guarantee covers free of charge replacement of parts, which have been admittedly defective
(transport included).
Every part replaced under guarantee will be automatically invoiced after a period of 1 month in
case of non-return of the defective part.
Labour executed by the distributor is entirely at their cost. However, if you request, labour can be
performed free of charge by Thermadyne Industries, in its factory. In this case, transport to and
from Thermadyne Industries will be at the distributor’s costs.
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SAFETY
The equipment you have just acquired will give you entire satisfaction if you respect the operating and
maintenance instructions.
Its design, the specification of the components and its manufacture are in accordance with the existing rules,
French standards (NF), ISO and CEI international injunctions, EEC general lines and CEN/CENELEC
standards.
In this chapter, you will find safety rules in the use of electric arc welding power sources with coated electrodes.
We give you hereunder a list of recommendations and obligations you have to respect.
Safety rules must be observed, and particulary those relating to Decree 88.1056 dated November 14., 1988
concerning protective measures against electrical currents.
1. ELECTROMAGNETIC COMPATIBILITY
1.1. DECLARATION OF CONFORMITY
THERMADYNE Industries hereby declare that the machine object of this manual complies with the following
European regulations :
Electromagnetic compatibility :
Rule 89/336-EEC of 3/05/89 modified by rules 92/31-EEC of 28/04/1992 and 93/68-EEC of 22/07/1993.
Low voltage :
Rule 73/23-EEC of 19/02/1973 modified by rule 93/68-EEC of 22/07/1993.
and with the national legislation transposing them.
THERMADYNE Industries also declare that following harmonised standards have been applied :
EN 50199 (1995): Electromagnetic compatibility (CEM) – Product norm for arc welding material.
EN 50060 (1990): Current source for arc manual welding with limited service.
EN 60974-1: Security rules for electric welding material. Part 1: welding current sources.
EN 50192 (1995): Arc welding material – plasma cutting systems.
1.2. INSTALLATION AND USE
The machine object of this manual complies with the European regulations about electromagnetic
compatibility 89/336 CEE. It also complies with EN 50199 standard: Electromagnetic compatibility, product
standard for welding machines.
The user is responsible for installing and using the arc welding equipment according to the manufacturer’s
instructions.
If electromagnetic disturbances are detected, then it shall be the responsibility of the user of the arc 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. In other cases it could involve
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constructing an electromagnetic screen enclosing the welding power source and the work complete with
associated input filters. In all cases electromagnetic disturbances shall be reduced to the point, where they
are no longer troublesome.
NOTE - The welding circuit may or may not be earthed for safety reasons. Changing the earthing
arrangements should only be authorised by a person who is competent to assess whether the changes will
increase the risk of injury, e.g. by allowing parallel welding current return paths, which may damage the earth
circuits of other equipment.
Further guidance is given in IEC 62081 "Arc welding equipment - Installation and use" (under consideration).
1.2.1. ASSESSMENT OF AREA
Before installing arc welding equipment the user shall make an assessment of potential electromagnetic
problems in the surrounding area. The following shall be taken into account :
a) Other supply cables, control cables, signalling and telephone cables, above, below and adjacent to the arc
welding equipment;
b) Radio and television transmitters and receivers;
c) Computer and other control equipment;
d) Safety critical equipment, e.g. guarding of industrial equipment,
e) The health of the people around, e.g. the use of pacemakers and hearing aids;
f) Equipment used for calibration or measurement;
g) 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;
h) The time of day that welding or other activities are to be carried out.
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.
1.2.2. METHODS OF REDUCING EMISSIONS
1.2.2.1. Public supply system
Arc welding equipment should be connected to the public supply system according to the manufacturer’s
recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering
of the public supply system. Consideration should be given to shielding the supply cable of permanently
installed arc 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.
1.2.2.2. Maintenance of the arc welding equipment
The arc welding equipment should be routinely maintained according to the manufacturers
recommendations. All access and service doors and covers should be closed and properly fastened when
the arc welding equipment is in operation. The arc 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 stabilising devices should be adjusted and maintained according to the
manufacturer’s recommendations.
1.2.2.3. 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.
1.2.2.4. Equipotential bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
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However, metallic components bonded to the work piece will increase the risk that the operator could receive
an electric shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
1.2.2.5. Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size
and position, e.g. ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.
1.2.2.6. Screening and shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special
applications.
2. ELECTRIC SAFETY
2.1. CONNECTION OF THE WELDING POWER SOURCE TO THE NETWORK
Before connecting your equipment, you must check that:
-The meter, the safety device against over-currents, and the electric installation are compatible with the
maximum power and the supply voltage of the welding power source (refer to the instructions plates).
-The connection, either single-phase, or three-phase with earth can be effected on a socket compatible with
the welding power source cable plug.
If the cable is connected to a fixed post, the earth, if provided, will never be cut by the safety device against
electric shocks.
-The ON/OFF switch (if exists) situated on the welding power source, is turned off.
2.2. WORKING AREA
The use of arc welding implies a strict respect of safety conditions with regard to electric currents (Decree
dated 14.12.1988).
It is necessary to check that no metal piece accessible to the operators and to their assistants can come into
direct contact with a phase conductor and the neutral of the network. In case of uncertainty, this metal part
will be connected to the earth with a conductor of at least equivalent section to the largest phase conductor.
Make sure that all metal pieces that the operator could touch with a non insulated part of his body (head,
hands without gloves on, naked arms ...) is properly grounded with a conductor of at least equivalent section
to the biggest supply cable of the ground clamp or welding torch. If more than one metal ground are
concerned, they need to be all interlinked in one, which must be grounded in the same conditions.
Unless very special care have been taken, do not proceed to any arc welding or cutting in
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conductive enclosures, whether it is a confined space or the welding machine has to be left outside. Be even
more prudent when welding in humid or non ventilated areas, and if the power source is placed inside
(Decree dated 14.12.1988, Art. 4).
2.3. INTERVENING
-Before carrying out any internal checking or repair work, check that the power source has been separated
from the electrical installation by locking and guard devices.
-The current plug has to be taken out. Provisions have to be taken to prevent an accidental connection of the
plug to a socket.
-Cut-off through a fixed connecting device has to be omnipolar (phases and neutral). It is in the "OFF"
position and cannot be accidentally put into operation.
-Maintenance works of electrical equipment must be entrusted to qualified people (Section VI, Art. 46).
2.4. MAINTENANCE
Check the good state, insulation and connection of all the equipment and electrical accessories: plugs and
flexible supply cables, cables (NF A 32-510), conduits, connectors, extension cables (NF A 85-610 and
CENELEC HD 433), sockets on the power source, ground and electrode-holder clamps (NF A 85-600).
These connections and mobile accessories are marked according to standards, if consistent with the safety
rules. They can either be controlled by you or by accredited firms.
- Maintenance and repair works of conduits and liners have to be properly carried out (Section VI, Art. 47).
-Repair or replace all defective accessories
-Check periodically that the electrical connections are tightened and do not heat.
2.5. RISKS OF FIRE AND EXPLOSION
Welding can occur risks of fire or explosion. You have to pay attention to fire safety regulation
- Remove flammable or explosive materials from welding area.
- Always have sufficient fire fighting equipment
- Fire can break out from sparks even several hours after the welding work has been finished.
3. INDIVIDUAL PROTECTION
3.1. RISK OF EXTERNAL INJURIES
3.1.1. THE WHOLE BODY
Arc rays produce very bright ultra violet and infra red light. They will damage yours eyes and burn your skin if
you are not properly protected
-The welder is dressed and protected according to the constraints his works impose him.
-Insulate yourself from the workpiece and the ground. Make sure that no metal piece, especially those
connected to the network, can come into contact with the operator.
-The welder must always wear an individual insulating protection (decree of 14/12/1988, article 3-3).
Protective clothing : gloves, aprons, safety shoes offer the additional advantage to protect the operator
against burns caused by hot pieces and spatter.
This protective equipment should be kept in good order and checked on a regular basis.
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3.1.2. FACE AND EYES
-.It is absolutely necessary to protect your eyes against arc rays.
- Protect your hair and your face against sparks
The welding shield, with or without headset, is always equipped with a proper filter according to the arc
welding current (NS S 77-104 / A 88-221 / A 88.222 standards).
In order to protect shaded filter from impacts and sparks, you have to add a plain glass in front of the shield.
The helmet provided with your equipment (if requested) is equipped with a protective filter. When you want to
replace it, precise the reference and number of opacity degree of the filter. Use the shade of lens as
recommended in the instruction manual (opacity graduation number)
Protect others in the work area from arc rays by using protective booths, UV protective goggles, and if
necessary, a welding shield with appropriate protective filter on (NF S 77-104 - by A 1.5).
Opacity gradation numbers and recommended use for arc welding
Current intensity in Amps
Welding process or
connected techniques
Coated electrodes 9 10 11 12 13 14
MIG on heavy metals 10 11 12 13 14
MIG on light alloys 10 11 12 13 14 15
TIG on all metals 9 10 11 12 13 14
MAG 10 11 12 13 14 15
Air/Arc gouging 10 11 12 13 14 15
Plasma cutting 9 10 11 12 13
Depending on the conditions of use, the next highest or lowest category number may be used.
The expression “heavy metals” covers steels, alloyed steels, copper and its alloys.
The shaded areas represent applications where the welding processes are not normally used at present.
CARE : Use a higher degree of filters if welding is performed in premises which are not well lighted.
3.2. RISK OF INTERNAL INJURIES
GASES AND FUMES
Gases fumes produced during the welding process can be dangerous and hazardous to your health. Arc
welding works have to be carried out in suitable ventilated areas.
Ventilation must be adequate to remove gases and fumes during operation. All fumes produced during
welding have to be removed as soon as they are given off, and as close as possible from the place they
are produced to be the most efficient.
0.5 2.5 10 20 40 80 125 175 225 275 350 450
1 5 15 30 60 100 150 200 250 300 400 500
Vapors of chlorinated solvents can form the toxic gas phosgene when exposed to ultraviolet radiation from
an electric arc.
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3.3. SAFETY IN THE USE OF GASES (WELDING WITH TIG OR MIG INERT GASES)
3.3.1. COMPRESSED GAS CYLINDERS
Compressed gas cylinders are potentially dangerous. Refer to suppliers for proper handling procedures.
- No impact: secure the cylinders and keep them away from impacts.
- No excess heat (over 50°C)
3.3.2. PRESSURE RELIEF VALVE
Check that the pressure relief screw is slackened off before connecting to the cylinder.
Check that the union is tight before opening the valve of the cylinder. Open it slowly a fraction of a turn.
If there is a leak, NEVER tighten a union which is under pressure, but first close the valve on the cylinder.
Always check that hoses are in good condition.
3.3.3. DETAILS ABOUT GASES
Gas and gaseous mixtures containing less than 20% of CO2:
If these gases or mixtures take the place of the oxygen in the air, there is a danger of asphyxia. An
atmosphere containing less than 17% oxygen is dangerous.
hydrogen and hydrogen-based combustible gaseous mixtures
These are very light gases. In the case of leaks, they collect under the ceiling.
Provide for ventilation at ceiling level.
These are also inflammable gases. The flame of hydrogen is almost invisible. There is therefore a risk
of burns.
Air/hydrogen and oxygen/hydrogen mixtures are explosive in the following proportions:
- 4 to 74.5 % of hydrogen in air.
- 4 to 94 % of hydrogen in oxygen.
Store the bottles in the open or in a well-ventilated place.
Avoid any leakage by limiting the number of connections or couplings to a minimum.
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