Page 1
185 AC/DC
®
ARCMASTER
INVERTER ARC WELDER
Operating Manual
Art # A-07227
Version No: 1 Issue Date: February 20, 2006 Manual No.: 0-4861
Operating Features:
INVERTER
Hz
208
230
CC
V
V
AC
DC
GTAW
SMAW
1
PHASE
50
60
Page 2
WE APPRECIA TE 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 distr ibutor or ser vice agency call
1-800-752-7621, or visit us on the web at www.thermalarc.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety P
potential hazards that may exist when working with this product.
recautions. They will help you to avoid
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.
Page 3
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
ArcMaster 185 AC/DC Inverter Arc Welder
Instruction Manual Number 0-4861 for:
Part Number 10-3073
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2006 by
Thermadyne Industries Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: February 20, 2006
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________
i
Page 4
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 Precautions de Securite en Soudage à l’Arc ................................................... 1-5
1.04 Dangers Relatifs au Soudage à l’Arc ............................................................... 1-5
1.05 Principales Normes de Secur ite ..................................................................... 1-8
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Symbol Chart ................................................................................................. 2-2
2.05 Description ..................................................................................................... 2-3
2.06 Functional Block Diagrams ............................................................................. 2-4
2.07 Transporting Methods .................................................................................... 2-4
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location ......................................................................................................... 3-1
3.03 Electrical Input Connections ........................................................................... 3-1
3.04 Electrical Input Requirements ........................................................................ 3-2
3.05 Input Power .................................................................................................... 3-3
3.06 High Frequency Introduction .......................................................................... 3-3
3.07 High Frequency Interference .......................................................................... 3-4
3.08 Duty Cycle ...................................................................................................... 3-4
3.09 Specifications ................................................................................................. 3-5
SECTION 4:
OPERATOR CONTROLS ............................................................................. 4-1
4.01 ArcMaster 185 AC/DC Controls ...................................................................... 4-1
4.02 Weld Process Selection for ArcMaster 185 AC/DC ......................................... 4-3
4.03 Weld Par
ameter Descriptions for ArcMaster 185 AC/DC ................................ 4-4
4.04 Weld Parameters for ArcMaster 185 AC/DC ................................................... 4-6
4.05 Power Source Features................................................................................... 4-7
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................. 5-1
Page 5
TABLE OF CONTENTS (continued)TABLE OF CONTENTS
SECTION 6:
SEQUENCE OF OPERATION ........................................................................ 6-1
6.01 Stick Welding ................................................................................................. 6-2
6.02 AC or DC HF TIG Welding ............................................................................... 6-2
6.03 Slope Mode Sequence .................................................................................... 6-3
6.04 Slope Mode with Repeat Sequence ................................................................ 6-3
6.05 Pulse Controls ................................................................................................ 6-4
SECTION 7:
BASIC TIG WELDING GUIDE ....................................................................... 7-1
7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum ................. 7-1
7.02 Electrode Polarity ........................................................................................... 7-2
7.03 Tungsten Electrode Current Ranges ............................................................... 7-2
7.04 Tungsten Electrode Types............................................................................... 7-2
7.05 Guide for Selecting Filler Wire Diameter ......................................................... 7-3
7.06 Shielding Gas Selection .................................................................................. 7-3
7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe .................. 7-3
7.08 Welding Parameters for Aluminum ................................................................ 7-4
7.09 Welding Parameters for Steel ......................................................................... 7-4
SECTION 8:
BASIC ARC WELDING GUIDE ..................................................................... 8-1
8.01 Electrode Polarity ........................................................................................... 8-1
8.02 Effects of Stick Welding Various Materials ..................................................... 8-1
SECTION 9:
ROUTINE MAINTENANCE .......................................................................... 9-1
SECTION 10:
BASIC TROUBLESHOOTING ...................................................................... 10-1
10.01 TIG Welding Problems................................................................................ 10-1
10.02 Stick Welding Problems ............................................................................. 10-4
10.03 Power Source Problems ............................................................................. 10-7
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD) ........................................................... 11-1
11.01 VRD Specification ....................................................................................... 11-1
11.02 VRD Maintenance ....................................................................................... 11-1
11.03 Switching VRD On/Off ................................................................................ 11-2
Page 6
TABLE OF CONTENTS
SECTION 12:
POWER SOURCE ERROR CODES ................................................................. 12-1
SECTION 13:
PARTS LIST ......................................................................................... 13-1
13.01 Equipment Identification ............................................................................. 13-1
13.02 How To Use This Parts List......................................................................... 13-1
APPENDIX 1: GENERAL INFORMATION ................................................................. A-1
APPENDIX 2: ARCMASTER 185 AC/DC INTERCONNECTION DIAGRAM ............................ A-2
APPENDIX 3: ARCMASTER 185 AC/DC ACCESSORIES ............................................... A-4
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
Page 7
ARCMASTER 185 AC/DC
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
!
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled:
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.
SAFETY IN WELDING AND CUTTING. This publication and other
7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear
a safety harness to prevent falling if working above floor
level.
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.
February 20, 2006
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.
1-1
Page 8
ARCMASTER 185 AC/DC
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
WARNING
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.
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 breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
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 traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Eye protection filter shade selector for welding or cutting
Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter
Torch soldering 2 Gas metal-arc
Torch brazing 3 or 4Non-ferrous base metal All 11
Oxygen C utting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All12
Heavy Over 6 in., 150 mm 5 or 6Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 P lasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
1-2
(goggles or helmet), from AWS A6.2-73.
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
February 20, 2006
Page 9
WARNING
ARCMASTER 185 AC/DC
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
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.
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
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
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.
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.
February 20, 2006
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.
1-3
Page 10
ARCMASTER 185 AC/DC
1.02 Principal Safety Standards
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.
WARNING
!
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some
cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
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, Ameri-
can 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 P1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together
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:
by twisting or taping them.
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
1-4
February 20, 2006
Page 11
ARCMASTER 185 AC/DC
1.03 Precautions de Securite en Soudage à l’Arc
MISE EN GARDE
!
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” p
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de
sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.04 Dangers Relatifs au Soudage à l’Arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension
dès la mise en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou
la bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à la terre
est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccor
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.
résente les pratiques sécuritaires à suivre.
dés à deux sources de courant en
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
February 20, 2006
1-5
Page 12
ARCMASTER 185 AC/DC
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
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
rsque le niveau de bruit est élevé.
lo
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.
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
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
Soudage á l'arc avec
électrode 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
épais plus de 6 po. (150 mm) 5 ou 6
épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14
moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)
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
filtr e 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
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
toutes conditions 12
toutes conditions 12
toutes conditions 12
épais plus de 400 amperès 14
Nuance de
filtr e oculaire
1-6
February 20, 2006
Page 13
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
ARCMASTER 185 AC/DC
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un échauffement ou un
incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêche
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
r le courant de suivre un long parcours
1. Por tez un écran facial ou des lunettes pr otectrices
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.
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.
February 20, 2006
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1-7
Page 14
ARCMASTER 185 AC/DC
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de
faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
AVERTISSEMENT
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour tr availler 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.
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.
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
1.05 Principales Normes de Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
1-8
Cutting and Welding Processes, norme 51B NFPA, National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA 02269.
February 20, 2006
Page 15
ARCMASTER 185 AC/DC
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or part
numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as
follows:
WARNING
!
A WARNING gives information regarding
possible personal injury.
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
nameplate attached to the control panel. In some cases,
the nameplate may be attached to the rear panel.
Equipment which does not have a control panel such as
gun and cable assemblies is identified only by the
specification or part number printed on the shipping
container. Record these numbers on the bottom of page
1 for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
claim. Furnish complete information concerning damage
claims or shipping errors to the location in your area
listed in the inside back cover of this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number
given in the next section. Include the Owner’s Manual
number and equipment identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
February 20, 2006
2-1
Page 16
ARCMASTER 185 AC/DC
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Wire Feed Function
Wire Feed Towards
Workpiece With
t1
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
Preflow Time
Postflow Time
t2
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
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
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
Burnback Time
t
Disturbance In
Ground System
IPM
MPM
Inches Per Minute
Meters Per Minute
115V 15A
2-2
Receptacle RatingAuxiliary Power
Voltage Input
V
Art # A-04130
February 20, 2006
Page 17
2.05 Description
ARCMASTER 185 AC/DC
The Thermal Arc™ Model 185 AC/DC is a self contained
single-phase AC/DC arc welding power source with
Constant Current (CC) output characteristics. This unit
is equipped with a Digital Volt/Amperage Meter, gas
control valve, built in Sloper and Pulser, lift arc starter,
and high-frequency arc starter for use with Gas Tungsten
Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed
(GTAW-P) Gas Tungsten Arc Welding-Sloped (GTAW-S),
and Shielded Metal Arc Welding (SMAW) processes. The
power source is totally enclosed in an impact resistant,
flame retardant and non-conductive plastic case.
NOTE
Volt-Ampere curves show the maximum Volt-
age and Amperage output capabilities of the
welding power source. Curves of other settings will fall between the curves shown.
(V)
CCV
5A 160A (A)
STICK Process
(V)
CCV
Art # A-04980
10V
25A 185A
(A)
LIFT TIG Process
(V)
CCV
5A
185A
(A)
HF TIG Process
Figure 2-1: Model 185 AC/DC Volt-Ampere curve
February 20, 2006
2-3
Page 18
ARCMASTER 185 AC/DC
2.06 Functional Block Diagrams
Figure 2-2 illustrates the functional block diagram of the 185 AC/DC-power supply.
DC Powe r
Input
Power
Ma i n
Circuit
Switch
Fil ter
Input
Diod e
Secondary
Voltage Sensor
Capacitor
DC Power
Primary
Voltage
Sensor
To eac h control circuit
+/-15VDC +18 VDC
Thermal
Detec tor
+24VDC +5VDC
Trouble
Sensing
Inverter
Circuit
IGBT
To eac h control circuit
+/-12VDC +15VDC
Ma i n
Transformer
(PCB 14)
Themal
Drive
Sensor
Circuit
Circuit
Primary
Current
Sensor
Ou tpu t
Diod es
Thermal
Detec tor
HF-UNIT
Stick Mode
Control
Circ uit
VRD
Sensing
Circuit
+-
Out pu t
Induc tor
Lift Tig Mode
Out pu t Sh ort
Sensing
Circuit
Secondary
IGBT
Inverter
Drive
Circ uit
Hall Current
Transformer
Couplin g
Coil
High
Frequ enc y
Unit
(HC T1 )
+
-
Current
circuit
Mode select Switches
Panel Circuit Board
Sequence
Control
Torch Control
Connecti on
(CON1)
Adjustment
Figure 2-2: 185 AC/DC Model Functional Block Diagram
2.07 Transporting Methods
This unit is equipped with a handle for carrying purposes.
WARNING
!
ELECTRIC SHOCK can kill. DO NOT TOUCH
live electrical parts. Disconnect input power
conductors from de-energized supply line
before moving the welding power source.
Referenc e
Adjus tment &
Fan Control
Gas C on trol
Art # A-07267
Circuit
Circuit
Fan
Solenoid
• Use handcart or similar device of adequate capacity.
• If using a fork lift vehicle, place and secure unit on a
proper skid before transporting.
WARNING
!
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
• Lift unit with handle on top of case.
2-4
February 20, 2006
Page 19
ARCMASTER 185 AC/DC
SECTION 3:
INSTALLATION
3.01 Environment
The ArcMaster 185 AC/DC is designed for use in adverse
environments.
Examples of environments with increased adverse
conditions are:
a. In locations in which freedom of movement is
restricted, so that the operator is forced to perform the
work in a cramped (kneeling, sitting or lying) position
with physical contact with conductive parts;
b. In locations which are fully or partially limited by
conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator;
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.
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.
Environments with adverse conditions do not include
places where elect
vicinity of the operator, which can cause increased hazard,
have been insulated.
rically conductive parts, in the near
3.02 Location
Be sure to locate the welder according to the following
guidelines:
·
In areas, free from moisture and dust.
·
Ambient temperature between 0 degrees C to 40
degrees C.
·
In areas, free from oil, steam and corrosive gases.
·
In areas, not subjected to abnormal vibration or
shock.
·
In areas, not exposed to direct sunlight or rain.
·
Place at a distance of 12" (304.79mm) or more from
walls or similar boundaries that could restrict natural
airflow for cooling.
WARNING
!
Thermal Arc advises that this equipment be
electrically connected by a qualified electrician.
Februrary 20, 2006
3-1
Page 20
ARCMASTER 185 AC/DC
3.04 Electrical Input Requirements
Do not connect an input (WHITE or BLACK) conductor to
the ground terminal.
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
Do not connect the ground (GREEN) conductor to an input
line terminal.
Refer to Figure 3-1 and:
utility for information about the type of electrical service
available, how proper connections should be made, and
any inspection required.
1. Connect end of ground (GREEN) conductor to a
suitable ground. Use a grounding method that complies
with all applicable electrical codes.
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.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE)
input conducto
rs to a de-energized line disconnect switch.
3. Use Table 3-1 and Table 3-2 as a guide to select line
fuses for the disconnect switch.
NOTE
This unit is equipped with a 250 VAC (NEMA 6-50P) plug molded on the two-conductor with earth power
cable that is connected at the welding power source for single phase electrical input power. For direct
wiring installation have a qualified person install according to all applicable codes and instructions.
Input Voltage Fuse Size
208V 60 Amps
230V 50 Amps
Table 3-1: Electrical Input Connections
NOTE
Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source
(Based on Article 630, National Electrical Code).
Welding Power Supply
Ground Terminal
Ground Conduct or
Line Di sc onnect Swit ch
Line Fuse
Pri mary Power Cable
Art # A-07268
Figure 3-1: Electrical Input Connections
3-2
February 20, 2006
Page 21
ARCMASTER 185 AC/DC
3.05 Input Power
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is
turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly
(PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).
NOTE
Note the available input power. Damage to the PCA could occur if 575VAC or higher is applied.
The following 208/230V Primary Current recommendations are required to obtain the maximum welding current and
duty cycle from this welding equipment:
Primary Supply
Model
ArcMaster
185AC/DC
Table 3-2 208-230V/ Primary Current Circuit sizes to achieve maximum current
The ARC MASTER 185 AC/DC is designed for use with a generator as an input power source. Contact an accredited
Thermal Arc service agent for the proper sizing and set-up recommendations of a generator power source system. As
a general rule, depending on the type of generator used, the generator capacity should be twice the maximum rating
of the welder.
Lead Size
(Factory Fitted)
12/3 AWG
minimum
Minimum Primary
Current Circuit Size
(Vin/Amps)
230/30 208/33 230/34 208/38 -
Current & Duty Cycle
TIG STICK
185 @ 30%
160 @ 40%
3.06 High Frequency Introduction
The importance of correct installation of high frequency
welding equipment cannot be over-emphasized.
Interference due to high frequency initiated or stabilized
arc is almost invariably traced to improper installation.
The following information is intended as a guide for
personnel installing high frequency welding machines.
The high frequency section of this machine
has an output similar to a radio transmitter.
The machine should NOT be used in the
vicinity of blasting operations due to the
danger of premature firing.
WARNING: EXPLOSIVES
!
Februrary 20, 2006
WARNING: COMPUTERS
!
It is also possible that operation close to
computer installations may cause computer
malfunction.
3-3
Page 22
ARCMASTER 185 AC/DC
3.07 High Frequency Interference
Interference may be transmitted by a high frequency
initiated or stabilized arc welding machine in the following
ways:
1. Direct Radiation: Radiation from the machine can
occur if the case is metal and is not properly grounded.
It can occur through apertures such as open access
panels. The shielding of the high frequency unit in
the Power Source will prevent direct radiation if the
equipment is properly grounded.
2. Transmission via the Supply Lead: Without adequate
shielding and filtering, high frequency energy may be
fed to the wiring within the installation (mains) by
direct coupling. The energy is then transmitted by
both radiation and conduction. Adequate shielding
and filtering is provided in the Power Source.
3. Radiation from Welding Leads: Radiated interference
from welding leads, although pronounced in the
vicinity of the leads, diminishes
Keeping leads as short as possible will minimize this
type of interference. Looping and suspending of leads
should be avoided where possible.
4. Re-radiation from Unearthed Metallic Objects:
A major factor contributing to inter ference is re-
radiation from unearthed metallic objects close to the
welding leads. Effective grounding of such objects
will prevent re-radiation in most cases.
rapidly with distance.
3.08 Duty Cycle
The duty cycle of a welding power source is the percentage
of a ten (10) minute period that it can be operated at a
given output without causing overheating and damage to
the unit. If the welding amperes decrease, the duty cycle
increases. If the welding amperes are increased beyond
the rated output, the duty cycle will decrease.
WARNING
!
Exceeding the duty cycle ratings will cause the
thermal overload protection circuit to become
energized and shut down the output until the
unit has cooled to normal operating
temperature.
CAUTION
Continually exceeding the duty cycle ratings
can cause damage to the welding power
source and will void the manufactures war-
ranty.
NOTE
Due to variations that can occur in
manufactured products, claimed performance,
voltages, ratings, all capacities,
measurements, dimensions and weights
quoted are approximate only. Achievable
capacities and ratings in use and operation will
depend upon correct installation, use,
applications, maintenance and service.
3-4
February 20, 2006
Page 23
3.09 Specifications
p
p
p
y Cy
g
g
p
p
p
g
g
(
)
)
)
(DC)
g
)
g
y Cy
p
p
Parameter 185ACDC
Rated Out
Am
eres
Volts
Dut
Duty Cycle TIG 185A / 18V @ 30%
Output Current TIG 5 – 185 (DC
Range STICK 5 – 160
Open Circuit Voltage 65V
Dimensions
Width
Hei
ht
Len
Wei
Output @ Rated Load
Rated In
ut Amperes
Out
Out
ut Volts
Dut
KVA
KW
Out
ut @ No Load
KVA
KW
ut Vo lts Single Phase
In
ut
cle
th
ht 37.4 lb. 17 k
ut Voltage
cle
208V
230V
185
18
30%
160A / 17V @ 60%
100A / 14V @ 100%
STICK 160A / 27V @ 40%
130A / 26V @ 60%
100A / 24V @ 100%
5 – 185 (AC) @ 60Hz, 50% Cleanin
5 – 160 (AC) @ 60Hz, 50% Cleanin
7.08”
180mm
14.7” (360mm
16.54” (420mm
Single phase
208-230 VAC
160A
27V
40%
8.7
5.2
0.5
0.3
erage Draw @ Rated Load No Load Amps
Am
38 2.2
34 1.6
ARCMASTER 185 AC/DC
Februrary 20, 2006
Table 3-3: Parameter Specifications
3-5
Page 24
ARCMASTER 185 AC/DC
NOTES
3-6
February 20, 2006
Page 25
OPERATOR CONTROLS
4.01 ArcMaster 185 AC/DC Controls
1
2
ARCMASTER 185 AC/DC
SECTION 4:
Art # A-04983
6
7
3
5
4
Figure 4-1: ArcMaster 185 AC/DC Power Source
1. Control Knob: This control sets the selected weld
parameter, rotating it clockwise increases the parameter
that is indicated on the digital meter. Pushing the knob
inward displays the actual welding voltage.
2 . Remote Control Socket: The 8 pin Remote Control
Socket is used to connect remote current control
devices to the welding Power Source. To make
connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
Art # A-04984
5k Ohms
21
543
678
GND
12345678
Figure 4-2: 8-Socket Receptacle
8
Socket Pin Function
1Earth (Ground)
2
Torch Switch Input (24V) to
(connect pins 2 & 3 to turn on
welding current)
3Torch Switch Input (0V) to
energize weld current (connect
pins 2 & 3 to turn on welding
current)
4 Connectpin4topin8toinstruct
machine that a remote current
control device is connected (12V
DC supply)
5 5k ohm (maximum) connection
to 5k ohm remote control
potentiometer
6Zero ohm (minimum) connection
to 5k ohm remote control
potentiometer
7Wiper arm connection to 5k ohm
remote control potentiometer
8 Connectpin4topin8toinstruct
machine that a remote current
control device is connected (0V)
February 20, 2006
Table 4-1: Socket Pin Functions
4-1
Page 26
ARCMASTER 185 AC/DC
3. Positive Terminal: Welding current flows from the
Power Source via heavy duty Dinse type terminal. It
is essential, however, that the male plug is inserted
and turned securely to achieve a sound electrical
connection.
4. Negative Terminal: Welding current flows from the
Power Source via heavy duty Dinse type terminal. It
is essential, however, that the male plug is inserted
and turned securely to achieve a sound electrical
connection.
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the bayonet terminal.
5. Gas Outlet: The Gas Outlet is a 5/8 –18 UNF female gas
fitting.
6. ON/OFF Switch: This switch connects the Primary
supply voltage to the inverter when in the ON position.
This enables the Power Supply.
WARNING
!
When the welder is connected to the Primary
supply voltage, the internal electrical
components may be at 240V potential with
respect to earth.
7. Input Cable: The input cable connects the Primary
supply voltage to the equipment.
8 . Gas Inlet: The Gas Inlet is a 5/8 –18 UNF female gas
fitting.
4-2
February 20, 2006
Page 27
4.02 Weld Process selection for ArcMaster 185 AC/DC
ARCMASTER 185 AC/DC
Weld Process
Selection
STD
SLOPE
REPEAT
SPOT
PULSE ON/OFF
Weld Mode
STICK
Yes Yes Yes
HF
TIG
LIFT
TIG
Description
2T operation in TIG Modes using remote
devices to control contactor & current.
4T operation in TIG Modes with crater
No Yes Yes
fill using a remote contactor device to
control sequence.
4T operation in TIG Modes with repeat
No Yes Yes
operation and crater fill using a remote
contactor device.
No Yes No
2T operation spot welding in HF TIG
using a remote contactor device.
No Yes Yes Pulse operation in TIG Modes.
Contactor ON/OFF
Operation
PANEL/REMOTE
Yes Yes Yes Selects AC or DC weld current.
Yes No Yes Contactor operation in Stick Mode.
Table 4-2: Weld Process selection versus Weld Mode for ArcMaster 185 AC/DC
Yes Yes Yes
Selects in operation Panel board
or Remote.
February 20, 2006
4-3
Page 28
ARCMASTER 185 AC/DC
4.03 Weld Parameter Descriptions for ArcMaster 185 AC/DC
Art # A-07237
Figure 4-3: ArcMaster 185 AC/DC Front Panel
Parameter Description
This parameter operates in TIG modes only and is used to provide gas
to the weld zone prior to striking the arc, once the torch trigger switch
has been pressed. This control is used to dramatically reduce weld
PRE-FLOW
HOT START
INITIAL CUR.
porosity at the start of a weld.
This parameter operates in all weld modes except Lift TIG mode and
is used to heat up the weld zone in TIG modes or improve the start
characteristics for stick electrodes. e.g. low hydrogen electrodes.
It sets the peak start current on top of the
HOT START
e.g.
&
HOT START
This parameter operates in
is used to set the start current for TIG. The Start Current remains on until
the torch trigger switch is released after it has been depressed.
current = 130 amps when
= 30 amps.
SLOPE
or
BASE (WELD)
BASE (WELD)
REPEAT
current.
= 100 amps
(4T) TIG modes only and
UP SLOPE
This parameter operates in TIG modes only and is used to set the time
for the weld current to ramp up, after the torch trigger switch has been
pressed then released, from INITIAL CUR to PEAK or BASE current.
Table 4-3: ArcMaster 185 AC/DC Front Panel Parameter Description
4-4
February 20, 2006
Page 29
ARCMASTER 185 AC/DC
PEAK CUR.
WELD
BASE
(BackgroundCurrent)
SPOT TIME
PULSE WIDTH
PULSE FREQ.
AC FREQUENCY
WAVE BALANCE
This parameter sets the PEAK weld current when in
This parameter sets the TIG WELD current in
SPOT
modes when
PULSE
is OFF. This parameter also sets the STICK
PULSE
mode
STD, SLOPE, REPEAT
and
weld current.
This parameter sets the Background current when in Pulse TIG mode.
This parameter sets the duration of the
This parameter sets the percentage on time of the
for PEAK weld current when the
This parameter sets the
PULSE FREQUENCY
PULSE
SPOT TIME
is ON.
when the
in
HF TIG
mode only
PULSE FREQUENCY
PULSE
is ON.
This parameter operates in AC mode only and is used to set the
frequency for the AC weld current.
This parameter is used for aluminum AC TIG mode and is used to set the
penetration to cleaning action ratio for the AC weld current. Generally
WAVE BALANCE
BALANCE
control changes the ratio of penetration to cleaning action of
is set to 50% for AC
STICK
welding. The
WAVE
the AC TIG welding arc. Maximum weld penetration is achieved when
WAVE BALANCE
the
oxidised aluminium or magnesium alloys is achieved when the
BALANCE
WAVE BALANCE=50%
control is set to 65%.
control is set to 10%. Maximum cleaning of heavily
WAVE
WAVE BALANCE=10%
10%50% 65%
(+ )(+ ) (+ )
WAVE BALANCE=65%
DOWN SLOPE
CRATER CUR.
POST-FLOW
(-)(-) (-)
Balanced with 50% penetration
and 50% cleaning
Maximum Penetra tion and
90%50% 35%
reduced cleaning
Maximum Cleaning and
reduced penetration
This parameter operates in TIG modes only and is used to set the time
for the weld current to ramp down, after the torch trigger switch has
been pressed, to
CRATER CUR.
This control is used to eliminate the
crater that can form at the completion of a weld.
This parameter operates in
SLOPE
or
REPEAT
(4T) TIG modes only and
is used to set the finish current for TIG. The CRATER Current remains ON
until the torch trigger switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to adjust the
post gas flow time once the arc has extinguished. This control is used to
dramatically reduce oxidation of the tungsten electrode.
The SAVE/LOAD buttons are used to save and retrieve a total number of
5 programs into the 185 AC/DC memory.
Table 4-3 (continued): ArcMaster 185 AC/DC Front Panel Parameter Description
February 20, 2006
4-5
Page 30
ARCMASTER 185 AC/DC
4.04 Weld Parameters for ArcMaster 185 AC/DC
Weld Mode
Weld
Parameter
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
PULSE PEAK CUR.
PULSE BASE CUR.
WELD CUR.
(TIG)
WELD CUR.
(STICK)
SPOT TIME
PULSE WIDTH
PULSE FREQ.
AC FREQUENCY
WAVE BALANCE
DOWN SLOPE
CRATER CUR.
POST-FLOW
Parameter
Range
0.0 to 1.0 sec 0 sec 0.1 sec No Yes Yes
0 to 70A 20A 1A Yes Yes No
5 to 185A 30A 1A No Yes Yes
0 to 15 sec 1 sec 0.1 sec No Yes Yes
5 to 185A 120A 1A No Yes Yes
5 to 185A 5A 1A No Yes Yes
5 to 185A 80A 1A No Yes Yes
5 to 160A 80A 1A Yes No No
0.5 to 5.0 sec 2 sec 0.1 sec No Yes Yes
15 to 80% 50% 1% No Yes Yes
0.5 to 500Hz 100.0Hz
15 to 150Hz 60Hz 1Hz Yes Yes Yes
10 to 65% 20% 1% Yes Yes Yes
0 to 25 sec 3 sec 0.1 sec No Yes Yes
5 to 200A 30A 1A No Yes Yes
0.0 to 60 sec 10 sec 0.1 sec No Yes Yes
Factory
Setting
Incremental
Unit
See
Table 4-5
STICK
No Yes Yes
HF
TIG
LIFT
TIG
Table 4-4: Weld Parameters for ArcMaster 185 AC/DC
PULSE FREQ.
0.5 to 20Hz 0.1Hz
20 to 100Hz 1Hz
100 to 500Hz 5Hz
4-6
Range Incremental Unit
February 20, 2006
Page 31
4.05 Power Source Features
Feature Description
New Digital Control
Touch Panel Switches
Front Control Cover
Digital Meter
Intelligent Fan Control
ON/OFF Switch
Voltage Reduction Device (VRD)
(shipped de-activated, field capable)
See Section 11 for activation instructions
Control Knob
Self Diagnosis using Error Codes
ARCMASTER 185 AC/DC
• Almost all welding parameters are adjustable.
• Touch switches eliminate mechanical damage.
• Protects front panel controls.
• Displays selected weld parameter value.
• Displays weld current when welding.
• Displays weld current for 20 seconds after weld has
been completed.
• A selected weld parameter value can be adjusted at
any time even while welding.
• The intelligent cooling system is designed to reduce
dust and foreign material build-up, whilst providing
optimum cooling.
• Fan speed reduces approximately 30 seconds after
machine is turned ON.
• Fan speed increases when internal components
reaches operating temperature.
• Primary voltage Supply ON/OFF switch located on
rear panel.
Reduces the OCV when the power supply is not in use.
Eliminates the need for add on voltage reducers and has
no effect on arc starting.
• VRD fully complies to IEC 60974-1.
• When Stick mode is selected the green VRD light is
ON when not welding and red when welding.
• When in TIG modes VRD is OFF.
• For the selected weld parameter, rotating the knob
clockwise increases the parameter.
• Rotating the knob counter-clockwise decreases the
parameter.
• A selected weld parameter value can be adjusted at
any time even while welding.
• Pushing the knob in displays actual arc voltage.
• An error code is displayed on the
problem occurs with Primary supply voltage or internal
component problems. Refer to troubleshooting guide.
Digital Meter
when a
February 20, 2006
Table 4-6:Power Source Features
4-7
Page 32
ARCMASTER 185 AC/DC
Feature Description
Save/Load Function
• A total number of 5 programs can be saved into the
185AC/DC memory.
SAVE
the Current Weld Parameters into Memory
• Press and HOLD the
the Digital Meter will show a number 1.
• Select a memory location by rotating the control knob,
1 to 5 is displayed on the meter.
• After selecting the desired memory location (i.e. 1 to 5),
press the right scroll button and the machine will give a
beep to confirm the weld parameters from the control
panel are saved.
LOAD
(retrieve) a Program to Control Panel
• Press and HOLD the
the Digital Meter display will show a number 1.
• Select a memory location by rotating the control knob,
1 to 5 is displayed on the meter.
After selecting the desired memory location (i.e. 1 to 5),
press the right scroll button and the machine will give a
beep to confirm the weld parameters are loaded onto the
control panel.
Table 4-6:Power Source Features con't
SAVE
LOAD
button. Beep will sound and
button. Beep will sound and
4-8
February 20, 2006
Page 33
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the
Welding Power Source, i.e. connect work lead directly to
work piece and electrode lead is used to hold electrode.
Wide safety margins provided by the coil design ensure
that the Welding Power Source will withstand short-term
overload without adverse effects. The welding current
range values should be used as a guide only. Current
delivered to the arc is dependent on the welding arc
voltage, and as welding arc voltage varies between
different classes of electrodes, welding current at any one
setting would vary according to the type of electrode in
use. The operator should use the welding current range
values as a guide, then finally adjust the current setting
to suit the application.
WARNING
!
ARCMASTER 185 AC/DC
Before connecting the work clamp to the work
and inserting the electrode in the electrode
holder make sure the Primary power supply
is switched off.
CAUTION
Remove any packaging material prior to use.
Do not block the air vents at the front or rear
or sides of the Welding Power Source.
CAUTION
DO NOT change the Weld Mode or Weld Process Mode until after POST-FLOW time has
finished.
Art # A-07271
Figure 5-1: 185 AC/DC Set-up
February 20, 2006
5-1
Page 34
ARCMASTER 185 AC/DC
NOTES
5-2
February 20, 2006
Page 35
ARCMASTER 185 AC/DC
SECTION 6:
SEQUENCE OF OPERATION
Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being
adjusted on the weld sequence graph. Refer to the Symbols Table located in the front of the manual for
Symbol descriptions.
1
9
10
2
8
5
3
7
4 6
Figure 6-1: 185 AC/DC Front Panel
Art # A-07272
1. Pulse Function: Pressing this button enables the TIG current pulse functions.
2. Remote Current Function: Pressing this buttons enables remote current functions.
3. TIG Mode Functions: Pressing this button scrolls through the output TIG function modes (Standard, Slope,
Slope w/repeat, Spot).
4. Digital LED Display: Welding amperage and parameter values are displayed in this window. Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by a warning
sound and error message on the screen.
5. Save/Load Buttons: By using the Save & Load buttons the operator can easily save up to 5 welding parameter programs.
6. Control Knob: Allows the operator to adjust the output amperage within the entire
and sets each parameter value.
7. Process Button: This button selects between STICK, HF TIG and Lift TIG mode.
8. Scroll Buttons: Used to select the parameters to be set. The LED’s show which function is being adjusted on
the Sequence Graph.
9. AC/DC Button: Selects between AC or DC welding output.
10. Contactor Function: Pressing this buttons enables Contactor functions
February 20, 2006
range of the power source
6-1
Page 36
ARCMASTER 185 AC/DC
6.01 Stick Welding
· Connect work lead to negative terminal
· Connect electrode lead to positive terminal
· Switch machine on
· Set
AC
or DC weld current. If AC is selected then set
AC FREQ
· Set Contractor
· Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be
set. The LED will show which function is being adjusted
on the weld sequence graph. Use the control knob to
adjust each parameter.
· Set
· Set
Commence welding
to 60Hz &
HOT START
WELD
current
WAVE BALANCE
to 50%.
6.02 AC or DC HF TIG Welding
· Connect work lead to positive terminal
·
Connect TIG torch to negative terminal
·
Switch machine on
·
Set AC or DC weld current. If AC is selected then set
AC FREQ
·
Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be
set. The LED will show which function is being adjusted
on the weld sequence graph. Use the control knob to
adjust each parameter.
· Set
· Set
· Set
· Set
· Set
Slope Mode Parameters if required
&
WAVE BALANCE
PRE-FLOW
HOT START
POST-FLOW
time
current
time
(WELD) PEAK CUR
POST-FLOW
time
current
· Set
INITIAL CUR
· Set
UP SLOPE
· Set (WELD)
· Set
BASE
current
· Set
DOWN SLOPE
· Set
CRATER CUR
Pulse Mode parameters if required
· Set
PULSE WIDTH
·
Set PEAK CURRENT
· Set
PULSE FREQ
Commence welding
current
time
PEAK CUR
time
current
% for
current
PEAK CURRENT
6-2
February 20, 2006
Page 37
6.03 Slope Mode Sequence
Switch
Closed
Switch
Open
Switch
Closed
ARCMASTER 185 AC/DC
Art # A-04989
Switch
Open
Initial
Up
Slope
Weld Current
Current
Preflow
Figure 6-2: Slope Mode Sequence
NOTE
Slope function operates with a Remote
ON/OFF device only
1. To start Slope sequence Close remote switch contacts.
Once the welding arc is established the Power Source
will maintain initial current setting as long as the
remote switch contacts are closed.
a. In the HF TIG mode, after Preflow time, High
Frequency is present at the torch. When the torch
is positioned close to the work the welding current
will transfer to the work and establish the arc at
the initial current setting.
Down
Slope
Final
Current
Postflow
2. Open Remote Switch – current increases to weld
current. Once welding arc has reached weld current
the power source will maintain weld current as long
as the remote switch contacts are open.
3. Close Remote Switch – Welding current decreases to
final current setting. Once final welding current is
reached the power source will maintain final current
setting as long as the r
closed.
emote switch contacts are
b. In the Lift TIG mode, after Preflow time, Lift Start
current is present at the torch. When the electrode
is touched to the work and lifted off, the welding
arc is established at the initial current setting.
6.04 Slope Mode with Repeat Sequence
The repeat function is operated during the down slope
cycle of the Slope Sequence and is active through the
down slope period only. During the down slope period,
by opening the Remote Switch contacts, the current will
increase back to weld current. Within the Down Slope
period the repeat function can be operated as many times
as desired. To continue slope cycle and end slope
sequence close remote switch contacts and allow weld
current to reach final current setting. Once final current
setting is reached, opening the Remote Switch again will
turn off the welding arc and post flow begins.
4. Open Remote Switch – Welding arc stops and post
flow begins.
February 20, 2006
6-3
Page 38
ARCMASTER 185 AC/DC
6.05 Pulse Controls
(Pulse Width) (Pulse Frequency)
Art # A-04990
(Peak Current)
(Base)
Background
Current
Figure 6-3: Pulse Controls
The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows:
1) Control puddle – size and fluidity (especially out of position).
2) Increase penetration
3) Travel speed control
4) Better consistent quality
5) Decreased distortion on lighter or thinner materials
Pulse-current provides a system in which the welding current continuously changes between two levels. During the
periods of Peak current, heating and fusion takes place, and during the background (base) current periods, cooling
and solidification take place. Pulse Width is the time in one cycle the current remains at the peak current setting.
Pulse Frequency, measured in Hertz, is the number of cycles per second the current travels between peak and background
current settings. It is as if the foot rheostat wer
e moved up and down to increase and decrease the welding current on
a regular basis. The faster you moved the foot rheostat up and down the faster the frequency.
6-4
February 20, 2006
Page 39
SECTION 7:
BASIC TIG WELDING GUIDE
ARCMASTER 185 AC/DC
7.01 Explanation of “Fluttery Arc” when
AC TIG Welding on Aluminum
The following will assist in understanding the
phenomenon of Arc Flutter, also referred to as Arc
Rectification.
The basic thesis is that the fluttering is caused by lack of
oxide in the weld pool.
The oxide layer on the plate reduced the energy for
electron emission. Electron emission from the weld pool
(DC+) causes the oxide layers to be disrupted, the socalled “cleaning action”. However once the cleaning action
has produced a mirror like surface on the weld pool, the
effect of the oxide layer is limited because the oxide layer
has dissipated. This makes electron emission from the
weld pool more difficult and increases the chance of arc
instability.
AC TIG on aluminum
1. The Problem: Arc appears unstable and pulses or flutters. ie. appears to rapidly change welding current
This idea is supported by the observation that once
fluttering starts it can be made to stop by working the arc
away from the mirror like weld pool to an area of oxide
coated material. As soon as this is done the arc settles
back to a stable condition. So while the arc is “consuming”
oxide coated plate the instability does not occur
the arc is stationary, the pool becomes thoroughly
“cleaned” by election emission, the fluttering begins.
Tests conducted on various types of AC TIG power
sources, Fluttery Arc is not confined to one type of power
source or its' design, both conventional and inverter types
suffer from the same problem.
. But once
.
Conditions that accentuate arc flutter: Conditions that minimizes arc flutter:
• Cold work piece • Preheat the work piece
• Very short arc length • Increase the arc length
• Weld pool crater about 0.39” to 0.47”
(10 to 12mm) diameter
• Arc field in one spot to produce
“mirror” clean weld pool
• Increased cleaning action
i.e. Prolonged oxide emission from a
stationary weld pool increases the
likelihood of arc flutter
• Accentuated when tungsten running
near its current capacity, i.e. Molten ball
on end
• Introduce filler rod material to the weld
pool, which introduces oxides
• Move the weld pool around to introduce
oxides to the weld pool
• Decrease the cleaning action by turning
WAVE BALANCE
the
move the weld pool around
• Use a larger diameter tungsten electrode
to below 50% or
Table 7-1: Reduction of Arc Flutter
2. Conclusion: Fluttery Arc in AC TIG is a physical phenomenon independent of machine design.
February 20, 2006
7-1
Page 40
ARCMASTER 185 AC/DC
7.02 Electrode Polarity
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight
polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of
the electrode since 70% of the heat is concentrated at the work piece.
7.03 Tungsten Electrode Current Ranges
Electrode Diameter AC Current (Amps) DC Current (Amps)
0.040” (1.0mm) 30 – 70 30 – 60
1/16” (1.6mm) 60 – 95 60 – 115
3/32” (2.4mm) 125 – 150 100 – 165
1/8” (3.2mm) 130 – 225 135 – 200
5/32” (4.0mm) 190 – 280 190 – 280
3/16” (4.8mm) 250 – 340 250 – 340
Table 7-2: Current ranges for various tungsten electrode sizes
7.04 Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Zirconated 1%
Ceriated 2%
Welding Application Features
DC welding of mild steel,
stainless steel and copper
High quality AC welding of
aluminium, magnesium and
their alloys
AC & DC welding of mild
steel, stainless steel, copper,
aluminium, magnesium and
their alloys
Table 7-3: Tungsten Electrode Types
Excellent arc starting, long life,
high current carrying capacity
Self cleaning, long life,
maintains balled end, high
current carrying capacity
Longer life, more stable arc,
easier starting, wider current
range, narrower more
concentrated arc
Color
Code
Red
White
Grey
7-2
February 20, 2006
Page 41
ARCMASTER 185 AC/DC
7.05 Guide for Selecting Filler Wire Diameter
NOTE
The filler wire diameter specified in Table 7-4 is a guide only, other diameter wires may be used according
to the welding application
Filler Wire Diameter
1/16” (1.6 mm) 30 - 95 20 - 90
3/32” (2.4 mm) 125 - 160 65 - 115
1/8” (3.2 mm) 180 - 240 100 - 165
3/16” (4.8 mm) 220 - 320 200 - 350
7.06 Shielding Gas Selection
Alloy
Aluminium & alloys Welding Argon, Argoshield 80T, 81T
Carbon Steel Welding Argon
Stainless Steel Welding Argon, Argoshield 71T, 80T, 81T
Nickel Alloy Welding Argon, Argoshield 71T
Copper Welding Argon, Argoshield 81T
Titanium Welding Argon, Argoshield 80T, 81T
AC Current Range DC Current Range
(Amps) (Amps)
Table 7-4: Filler Wire Selection Guide
Shielding Gas
Argoshield is a registered trademark of BOC Gases Limited.
Table 7-5: Shielding Gas Selection
7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Table 7-6: TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Current Range DC
Amperes
120 - 170 Yes
100 - 160 Yes
90 - 130 No
Filler Rod for
Root Pass
Joint Preparation
February 20, 2006
7-3
Page 42
ARCMASTER 185 AC/DC
7.08 Welding Parameters for Aluminum
Base Metal
Thickness
0.040” 30-45 0.040” 1/16” Butt/Corner
1.0mm 35-50 1.0mm 1.6mm Lap/ Fillet
0.045” 40-60 0.040” 1/16” Butt/Corner
1.2mm 45-70 1.0mm 1.6mm Lap/ Fillet
1/16” 60-85 1/16” 1/16” Butt/Corner
1.6mm 70-95 1.6mm 1.6mm Lap/ Fillet
1/8” 3/32” 3/32”
3.2mm 2.4mm 2.4mm
3/16” 180-225 1/8” 1/8” Butt/Corner
4.8mm 190-240 3.2mm 3.2mm Lap/ Fillet
¼” 240-280 3/16” 3/16” Butt/Corner
6.4mm 250-320 4.8mm 4.8mm Lap/ Fillet
AC Current for
Aluminum
125-150
130-160
Table 7-7: AC TIG Welding Parameters
Tungsten
Electrode
Diameter
1/8”
3.2mm
Filler Rod
Diameter
(if required)
Argon Gas
Flow Rate
Liters/min
5-7
5-7
7
10
10
13
Joint Type
Butt/Corner
Lap/Fillet
7.09 Welding Parameters for Steel
Base Metal
Thickness
0.040” 35-45 20-30 0.040” 1/16” Butt/Corner
1.0mm 40-50 25-35 1.0mm 1.6mm Lap/ Fillet
0.045” 45-55 30-45 0.040” 1/16” Butt/Corner
1.2mm 50-60 35-50 1.0mm 1.6mm Lap/ Fillet
1/16” 60-70 40-60 1/16” 1/16” Butt/Corner
1.6mm 70-90 50-70 1.6mm 1.6mm Lap/ Fillet
1/8” 80-100 65-85 1/16” 3/32” Butt/Corner
3.2mm 90-115 90-110 1.6mm 2.4mm Lap/ Fillet
3/16” 115-135 100-125 3/32” 1/8” Butt/Corner
4.8mm 140-165 125-150 2.4mm 3.2mm Lap/ Fillet
¼” 160-175 135-160 1/8” 5/32” Butt/Corner
6.4mm 170-200 160-180 3.2mm 4.0mm Lap/ Fillet
DC Current
for Mild
Steel
DC Current for
Stainless
Steel
Tungsten
Electrode
Diameter
Filler Rod
Diameter
(if required)
Argon Gas
Flow Rate
Liters/min
5-7
5-7
7
7
10
10
Joint Type
Table 7-8: DC TIG Welding Parameters
7-4
February 20, 2006
Page 43
SECTION 8:
BASIC ARC WELDING GUIDE
8.01 Electrode Polarity
Stick electrodes are generally connected to the ‘+’ terminal
and the work lead to the ‘-’ terminal but if in doubt consult
the electrode manufacturers literature.
8.02 Effects of Stick Welding Various
Materials
ARCMASTER 185 AC/DC
High Tensile and Alloy Ateels
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 ir
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.
on, except white iron, are weldable.
Copper and Alloys
The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections
necessary to give proper fusion of weld and base metal.
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 pur-
poses, which are not of particular interest for everyday
general wor
for high tensile steel, cellulose types for welding large
diameter pipes, etc. The range of electrodes dealt with in
this publication will cover the vast majority of applications likely to be encountered; are all easy to use and all
will work on even the most basic of welding machines.
k. These include some low hydrogen types
February 20, 2006
8-1
Page 44
ARCMASTER 185 AC/DC
Metals being
Electrode Comments
joined
Mild Steel 6013 Ideal electrodes for all general
purpose work. Features include
outstanding operator appeal, easy
arc starting and low spatter.
Mild Steel 7014 All positional electrode for use on
mild and galvanized steel furniture,
plates, fences, gates, pipes and
tanks etc. Especially suitable for
vertical-down welding.
Cast Iron 99% Nickel Suitable for joining all cast irons
except white cast iron.
Stainless Steel 318L-16 High corrosion resistance. Ideal
for dairy work, etc.
Copper, Bronze,
Brass, etc.
Bronze
5.7 ERCUSI-A
Easy to use electrode for marine
fittings, water taps and valves,
water trough float arms, etc. Also
for joining copper to steel and for
bronze overlays on steel shafts.
High alloy steels,
dissimilar metals,
crack resistant,
all hard-to-weld
jobs.
312-16 It will weld most problematic jobs
such as springs, shafts, broken
joints, mild steel to stainless and
alloy steel.
Not suitable for Aluminium.
Table 8-1: Types of Electrodes
8-2
February 20, 2006
Page 45
ARCMASTER 185 AC/DC
SECTION 9:
ROUTINE MAINTENANCE
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency
depending on the usage and the operating environment.
The unit should be wiped clean as necessary with solvents that are recommended for cleaning electrical apparatus.
Turn Power Switch to OFF before proceeding. Internal cleaning of the unit should be done every 6 months by an
authorized Thermal Arc Service Center to remove any accumulated dirt and dust. This may need to be done more
frequently under exceptionally dirty conditions.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.
February 20, 2006
9-1
Page 46
ARCMASTER 185 AC/DC
Warning!
Disconnect input power before maintaining.
Visual check of
regulator and pressure
Visually inspect the torch
body and consumables
Maintain more often
if used under severe
conditions
Each Use
Visual check of torch
Consumable parts
Weekly
Visually inspect the
cables and leads.
Replace as needed
Replace all
broken parts
3 Months
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
Thermal Arc Service Center
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-07331
9-2
February 20, 2006
Page 47
ARCMASTER 185 AC/DC
SECTION 10:
BASIC TROUBLESHOOTING
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to
open or repair unless you are an accredited Thermal Arc Service Agent and you have had training in power
measurements and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an accredited
Thermal Arc Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
10.01 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper
welding technique.
Description Possible Cause Remedy
1
Excessive bead build-up
or poor penetration or
poor fusion at edges
of weld.
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.
Welding current is too low.
Welding current is too high. Decrease weld current.
Travel speed too fast. Reduce travel speed.
Travel speed too slow. Increase travel speed.
Wrong placement of filler rod. Re-position filler rod.
Increase weld current and/or
faulty joint preparation.
February 20, 2006
Table 10-1: TIG Welding Problems
10-1
Page 48
ARCMASTER 185 AC/DC
Description Possible Cause Remedy
6
Electrode melts when
arc is struck.
B
7 Dirty weld pool. A
B Gas contaminated with air. B
8
Electrode melts or
oxidizes when an
arc is struck.
B Torch is clogged with dust. B Clean torch.
C Gas hose is cut. C Replace gas hose.
D
A
Electrode is connected to the
‘+’ terminal.
WAVE BALANCE
than 50%.
Electrode contaminated
through contact with work
piece or filler rod material.
A
No gas flowing to
welding region.
Gas passage contains
impurities.
is greater
A
Connect the electrode to the
‘−’ terminal.
B
Reduced
to below 50% or increase
the electrode size.
A
Clean the electrode by
grinding off the
contaminates.
Check gas lines for cuts
and loose fitting or change
gas cylinder.
A
Check the gas lines for
kinks or breaks and gas
cylinder contents.
D
Disconnect gas hose from
torch then raise gas pressure
and blow out impurities.
WAVE BALANCE
E Gas regulator turned OFF. E Turn ON.
F Torch valve is turned OFF. F Turn ON.
G
H
9 Poor weld finish. Inadequate shielding gas.
10
Arc flutters during
TIG welding.
B
The electrode is too small
for the welding current.
WAVE BALANCE
above 50%.
A
Tungsten electrode is too
large for the welding current.
Absence of oxides in the
weld pool.
is set
G
Increase electrode
diameter or reduce the
welding current.
H
Reduced
to below 50% or increase
the electrode size.
Increase gas flow or
check gas line for gas
flow problems.
A
Select the right size
electrode. Refer to Basic
TIG Welding guide.
B
Refer Basic TIG Welding
Guide for ways to reduce
arc flutter.
Table 10-1 (continued): TIG Welding Problems
WAVE BALANCE
10-2
February 20, 2006
Page 49
ARCMASTER 185 AC/DC
Description Possible Cause Remedy
11
Welding arc cannot
be established.
A
Work clamp is not connected to
the work piece or the work/torch
leads are not connected to the
right welding terminals.
B Torch lead is disconnected. B
C
Gas flow incorrectly set, cylinder
empty or the torch valve is OFF.
12
Arc start is not
smooth.
B
A
Tungsten electrode is too large
for the welding current.
The wrong electrode is being
used for the welding job.
C Gas flow rate is too high. C
D
Incorrect shielding gas is
being used.
A
Connect the work clamp to the
work piece or connect the
work/torch leads to the right
welding terminals.
Connect it to the ‘−‘ terminal.
C
Select the right flow rate,
change cylinders or turn torch
valve ON.
A
Select the right size electrode.
Refer to Basic TIG
Welding Guide.
B
Select the right electrode type.
Refer to Basic TIG
Welding Guide.
Select the correct rate for the
welding job.
Refer to Basic TIG
Welding Guide.
D
Select the right shielding gas.
Refer to Basic TIG
Welding Guide.
E
Poor work clamp connection
to work piece.
Table 10-1 (continued): TIG Welding Problems
E
Improve connection to
work piece.
February 20, 2006
10-3
Page 50
ARCMASTER 185 AC/DC
10.02 Stick Welding Problems
Description Possible Cause Remedy
Gas pockets or
1
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.
D Incorrect sequence. D Use correct build-up sequence.
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.
Welding current is too low.
A
Electrode too large for joint.
B
Insufficient gap.
C
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.
Increase welding current
A
Use smaller diameter
B
electrode.
Allow wider gap.
C
Table 10-2: Stick Welding Problems
Art # A-04991
Incorrect sequence
Insufficient
gap
Figure 10-1: Example of Insufficient Gap or Incorrect Sequence
10-4
February 20, 2006
Page 51
ARCMASTER 185 AC/DC
Description Possible Cause Remedy
A
4 Portions of the weld
run do not fuse to the
surface of the metal
Small electrodes used on heavy
cold plate.
B
Welding current is too low.
or edge of the joint.
C Wrong electrode angle. C Adjust angle so the welding arc is
D Travel speed of electrode is
too high.
E Scale or dirt on joint surface. E Clean surface before welding.
Table 10-2 (continued): Stick Welding Problems
A
Use larger electrodes and
pre-heat the plate.
B
Increase welding current.
directed more into the base metal.
D Reduce travel speed of electrode.
Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Lack of inter-run
fusion
Lack of side fusion, scale
dirt, small electrode,
Lack of root fusion
amperage too low
Figure 10-2: Example of Lack of Fusion
Art # A-04992
February 20, 2006
10-5
Page 52
ARCMASTER 185 AC/DC
Description Possible Cause Remedy
5 Non-metallic particles
are trapped in the
weld metal (slag
inclusion).
B Joint preparation too restricted. B Allow for adequate penetration
C Irregular deposits allow slag to
D Lack of penetration with slag
E Rust or mill scale is preventing
F Wrong electrode for position in
A Non-metallic particles may be
trapped in undercut from
previous run.
be trapped.
trapped beneath weld bead.
full fusion.
which welding is done.
A If bad undercut is present, clean
slag out and cover with a run
from a smaller diameter electrode.
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.
Not cleaned, or
incorrect
electrode
Table 10-2 (continued): Stick Welding Problems
Art # A-04993
Slag trapped in
undercut
Slag trapped in root
Figure 10-3: Examples of Slag Inclusion
10-6
February 20, 2006
Page 53
10.03 Power Source Problems
Description Possible Cause Remedy
1
The welding arc
cannot be
established.
A
The Primary supply voltage has
not been switched ON.
B
The Welding Power Source
switch is switched OFF.
ARCMASTER 185 AC/DC
A
Switch ON the Primary
supply voltage.
B
Switch ON the Welding
Power Source.
C Loose connections internally. C
2
Maximum output
welding current can
not be achieved with
nominal Mains
supply voltage.
3
Welding current
reduces when
welding.
4 No gas flow when
the torch trigger
switch is depressed.
C Gas regulator turned OFF. C Turn gas regulator ON.
D Torch trigger switch lead is
Defective control circuit.
Loose welding cable
A
connections.
Incorrect welding cable size.
B
Improper input connections.
C
Poor electrode condition.
D
Wrong welding polarity.
E
A
Gas hose is cut.
B
Gas passage contains
impurities.
disconnected or switch/cable
is faulty.
Have an accredited Thermal
Arc Service Agent repair
the connection.
Have an accredited Thermal
Arc Service Agent repair
the connection.
Tighten all welding
A
cable connections.
Use proper size and
B
type of cable.
Refer to Section 2.05
C
Electrical Input Requirements.
D
Replace electrode.
E
Verify output torch
connections.
A B Replace gas hose.
Disconnect gas hose from
the rear of Power Source then
raise gas pressure and blow
out impurities.
D Reconnect lead or repair faulty
switch/cable.
Table 10-3: Power Source Problems
February 20, 2006
10-7
Page 54
ARCMASTER 185 AC/DC
Description Possible Cause Remedy
5 Gas flow won’t
shut OFF.
B Gas valve is faulty. B Have an accredited Thermal
C Gas valve jammed open. C Have an accredited Thermal
D
6 The TIG electrode has
been contaminated
due to the gas flow
shutting OFF before
the programmed
POST-FLOW
has elapsed.
time
A Weld Mode (
REPEAT
before
had finished.
POST-FLOW
to 60 sec.
The Weld Process Mode
(STICK, HF TIG or LIFT TIG) was
changed before
time had finished.
STD, SLOPE
or
SPOT
) was changed
POST-FLOW
control is set
POST-FLOW
gas time
,
A Strike an arc to complete the
weld cycle.
OR
Switch machine OFF then ON to
reset solenoid valve sequence.
Arc Service Agent repair or
replace the gas valve.
Arc Service Agent repair or
replace the gas valve.
D Reduce
Do not change Weld Process
Mode before the
gas
gas time had finished.
POST-FLOW
time.
POST-FLOW
Table 10-3 (continued): Power Source Problems
10-8
February 20, 2006
Page 55
VOLTAGE REDUCTION DEVICE (VRD)
11.01 VRD SPECIFICATION
Description Notes
VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between
VRD Resistance 148 to 193 ohms The required resistance between
VRD Turn OFF Time 0.2 to 0.3
SECTION 11:
ArcMaster
185AC/DC
welding terminals.
welding terminals to turn ON the
welding power.
The time taken to turn OFF the
seconds
Table 11-1: VRD Specification
welding power once the welding
current has stopped.
ARCMASTER 185 AC/DC
11.02 VRD MAINTENANCE
Routine inspection and testing (power source):
An inspection of the power source, an insulation resistance test and an earth resistance test should be carried out.
a. For transportable equipment, at least once every 3 months.
b. For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests.
NOTE
A transportable power source is any equipment that is not permanently connected and fixed in the position
in which it is operated.
In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests
should also be conducted by an accredited Thermal Arc service agent.
Description IEC 60974-1 Requirements
VRD Open Circuit Voltage Less than 20V; at Vin=230V
VRD Turn ON Resistance Less than 200 ohms
VRD Turn OFF Time Less than 0.3 seconds
Table 11-2: Periodic Tests
If this equipment is used in a location or an environment with a high risk of electrocution then the above tests should
be carried out prior to entering this location.
February 20, 2006
11-1
Page 56
ARCMASTER 185 AC/DC
11.03 SWITCHING VRD ON/OFF
Switch the machine OFF.
A) Remove the clear plastic cover from the control panel. (see Figure 11-1)
1 Lift up the cover so it rests on the top of the unit.
2 Place a small flat bladed screw driver between the cover hinge on the front panel.
3 Gently lift the cover hinge out of the front cover mounting hole.
Remove the control's clear plastic cover.
2
3
1
Figure 11-1: VRD ON/OFF Step A
B) Remove the four mounting screws from the control panel. (see Figure 11-2)
Art # A-07080
1
2
1
2
Art # A-07079
11-2
1
Figure 11-2: VRD ON/OFF Step B
1
February 20, 2006
Page 57
ARCMASTER 185 AC/DC
C) Access the VRD control by gently prying back the front panel controls to reveal the VRD ON/OFF potentiometer.
(see Figure 11-3)
D) Turning the VRD ON/OFF. (see Figure 11-3)
• To turn VRD ON: rotate the trim potentiometer on the display PCB fully clockwise. When VRD is turned ON check
that it operates as per VRD Specifications on page 11-1.
• To turn VRD OFF: rotate the trim potentiometer on the display PCB fully counter-clockwise.
CAUTION
DO NOT pull back the front panel with excessive force as this will unplug control PCB. Plugging the control
PCB back into the front panel controls can only be achieved by removing the side covers.
VR1
Figure 11-3: VRD ON/OFF Step C and D
Art # A-07081
The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise
as the VRD function will be unknown for every other position.
February 20, 2006
!
WARNING
11-3
Page 58
ARCMASTER 185 AC/DC
NOTES
11-4
February 20, 2006
Page 59
SECTION 12:
POWER SOURCE ERROR CODES
Description Possible Cause Remedy Remarks
1 E01 error code
displayed
Temperature sensor
TH1 (protects
IGBTs) is greater
than 80ºC for about
1 second.
2 E02 error code
displayed
Temperature sensor
TH2 (protects
secondary diodes)
is greater than 80ºC
for about 1 second.
3 E03 error code
displayed
Primary (input)
current too high.
E04 error code
4 TIG torch cable
displayed
Output voltage
exceeds the
secondary voltage
specification.
A The Welding Power
Source’s duty cycle
has been exceeded.
B Fan ceases
to operate.
CAir flow is restricted
by vents being
blocked.
A The Welding Power
Source’s duty cycle
has been exceeded.
B Fan ceases
to operate.
CAir flow is restricted
by vents being
blocked.
APrimary current is
too high because
welding arc is
too long.
B Mains supply
voltage is more
than 10% below
nominal voltage .
and/or work lead
are too long or
leads are coiled.
ARCMASTER 185 AC/DC
ALet Power Source
cool down then
keep within its
duty cycle.
B Have an accredited
Thermal Arc Service
Agent investigate.
C Unblock vents then
let Power Source
cool down.
ALet Power Source
cool down then
keep within its
duty cycle.
B Have an accredited
Thermal Arc Service
Agent investigate
C Unblock vents then
let Power Source
cool down.
A Reduce length of
welding arc.
B Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check for
low Mains voltage.
Reduce the length
of the TIG torch
cable and/or work
lead or un-coiled
leads.
Weld current
ceases. Buzzer
sounds constantly.
Fan operates at
max speed.
E01 resets when
TH1 decreases to
70ºC for about
30 seconds.
Weld current
ceases. Buzzer
sounds constantly.
Fan operates at
max speed.
E02 resets when
TH2 decreases to
70ºC for about
30 seconds.
Weld current
ceases. Buzzer
sounds constantly.
Switch machine OFF
then ON to reset
E03 error.
Weld current
ceases. Buzzer
sounds constantly.
Switch machine OFF
then ON to reset
E04 error.
February 20, 2006
Table 12-1 Power Source Error Codes
12-1
Page 60
ARCMASTER 185 AC/DC
E11 error code
5Primary supply
displayed
Over Primary supply
(input) voltage at
voltage is greater
than the nominal
voltage plus 10%.
primary capacitors
is exceeded for
one second.
E14 error code
6 Mains supply
displayed
Under mains supply
(input) voltage
warning primary
voltage is less than
the nominal
operating voltage
less 10%.
capacitors is
reduced for
one second.
7 Mains supply
E12 error code
displayed
Under mains supply
(input) voltage
voltage is down
to a dangerously
low level.
primary capacitors
is reduced for
one second.
E81 error code
8 When 3 phase
displayed
Wrong Primary
supply (input)
voltage connected.
machine is first
turned ON with the
wrong Primary
supply (input)
voltage connected.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Primary voltage.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
A Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check
the Mains voltage.
B Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check
the primary cable
and fuses.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
Weld current ceases.
Buzzer sounds
contstantly.
Error code E11
automatically will
reset when the
voltage reduces.
Weld current
available. Buzzer
sounds
intermittently.
Error code E14
automatically will
reset when the
voltage increases.
Weld current ceases.
Buzzer sounds
contstantly.
Error code E12
automatically will
reset when the
voltage increases.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF.
Table 12-1 (continued): Power Source Error Codes
12-2
February 20, 2006
Page 61
ARCMASTER 185 AC/DC
E82 error code
9The Primary supply
displayed
Rated voltage
selection circuit
abnormality.
E83 error code
10 The Primary supply
displayed
CPU checks mains
supply (input)
voltage when the
ON/OFF switch
on rear panel of
machine is
turned ON.
E85 error code
11
displayed
Pre-charge
abnormality.
E93 error code
12 Memory chip
displayed
Memory chip
EEPROM) on
control PCB cannot
read/write weld
parameters.
(input) voltage
fluctuates and is
not stable.
(input) voltage
fluctuates and is
not stable.
Due to malfunction
inside the Welding
Power Source,
primary capacitors
are not charging
correctly.
(EEPROM) error.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
Have an accredited
Thermal Arc Service
Agent check
connector plug on
input PCB and the
Mains voltage.
Have an accredited
Thermal Arc Service
Agent service the
machine.
Have an Accredited
Thermal Arc Service
Agent check the
control PCB.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF
then ON to reset
E82 error.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF
then ON to reset
E83 error.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF
then ON to reset
E85 error.
Weld current ceases.
Buzzer sounds
constantly. Switch
machine OFF.
February 20, 2006
Table 12-1 (continued): Power Source Error Codes
12-3
Page 62
ARCMASTER 185 AC/DC
E94 error code
13 The Welding Power
displayed
Temperature sensor
TH1 for IGBTs or
sensor TH2 for
Source’s
temperature
sensors have
malfunctioned.
secondary diodes
are open circuit.
E99 error code
14 Weld current ceases.
displayed
Mains supply
(input) voltage has
been turned OFF but
control circuit has
A Main ON/OFF switch
on machine has
been turned OFF.
B Mains supply
(input) voltage has
been turned OFF.
power from the
primary capacitors.
Have an accredited
Thermal Arc Service
Agent check or
replace the
temperature sensors.
ATurn ON/OFF
switch ON.
B Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage
and fuses.
Weld current ceases.
Buzzer sounds
constantly. Switch
machine OFF.
Buzzer sounds
constantly. Must
switch machine OFF
then ON to reset
E99 error.
Table 12-1 (continued): Power Source Error Codes
12-4
February 20, 2006
Page 63
SECTION 13:
PARTS LIST
ARCMASTER 185 AC/DC
13.01 EQUIPMENT IDENTIFICATION
All identification numbers as described in the Introduction chapter must be furnished when ordering parts or
making inquiries. This information is usually found on the
nameplate attached to the equipment. Be sure to include
any dash numbers following the Specification or Assembly numbers.
13.02 HOW TO USE THIS PARTS LIST
The Parts List is a combination of an illustration and a
corresponding list of parts which contains a breakdown
of the equipment into assemblies, subassemblies, and
detail parts. All parts of the equipment are listed except
for commercially available hardware, bulk items such as
wire, cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded to
other parts. The part descriptions may be indented to show
part relationships.
To determine the part number, description, quantity, or
application of an item, simply locate the item in question
from the illustration and refer to that item number in the
corresponding Parts List.
PART NUMBER:
ArcMaster 185 AC/DC 10-3073
February 20, 2006
13-1
Page 64
ARCMASTER 185 AC/DC
QTY. Description Order No.
1 8 pin Receptacle
1 Primary Switch W7000201
1 Panel, Upper Front W7000301
1 Panel, Upper Rear W7000401
2 Case Half W7000501
1 Case Front W7000601
1 Frame, Rear W7000701
2 Label, Name, 185AC/DC
2 Label, Side W7000901
1 Label, Warning W7001001
1 Label, Warning, Lifting W7001101
1 Label, Output Terminal W7001201
2 Terminal, Output Female W7001301
1 Encoder Knob 10-6665
1 Encoder Knob, Cap 10-6666
2 Terminal, Output Male 10-2020
1 Operators Manual 300x4861
W7000101
W7000801
13-2
February 20, 2006
Page 65
APPENDIX 1: GENERAL INFORMATION
• Note the model and specification number shown on the equipment nameplate.
ARCMASTER 185 AC/DC
February 20, 2006
A-1
Page 66
ARCMASTER 185 AC/DC
APPENDIX 2: ARCMASTER 185 AC/DC INTERCONNECTION DIAGRAM
R4
TB6
Ground
+
SIDE CHASSIS 1
REAR
PA NE L
N
P
R2
1
2
3
4
5
6
FAN 1
+-
1
2
SOL1
1 : Chassis Ground
2 : Contactor Control/+24VDC
3 : Contactor Control/GND
4 : Not Used
5 : Potentiometer Maximum
6 : Potentiometer Minimum(GND)
7 : Amperage Control Wiper 0-10VDC
8 : Not Used
3
4
EA
45
8
67
CON1
Line1
Line2
E
PCB17
Filter
Circuit Board
[WK-4917]
CN1
CN1
CN11
12
3
R5
12
123
CN2
EA
S1
12345
CN3
1
2
3
4
CN31 CN30
Connect Circuit Board
CN131 CN130
TB0
1
2
1
2
CN27
3
4
CN27
5
D1
+
(1)
K(7)
G(6)
R(3)
(0)
S(4)
-
T(5)
(2)
PCB4
Detect
Circuit Board
CN4
[WK-4819]
CN5 CN6 CN4
CN30CN31
CN32
CN32
PCB5
[WK-5551]
CN130CN131
CN132
CN132
CN17
CN18
CN17
CN18
CN14
PCB7
Filter
Circuit Board
CN15
[WK-5550]
1
2
CN20
3
TB5
1
2
CN3
P
P
R2
R2
N
N
PCB2
Link
Circuit
Board
[WK-5482]
1
2
3
CN2
4
5
CN1
123
E1C
CN1CN6CN5
Control
Circuit Board
[WK-5548]
TB2
C2E
PCB3
Source
CN18
123
C2EE1C
CN7
[WK-5493]
TB1
TB2
TB3
TB4
1
CT1
2
CT2
3
4
123456
CN20
CN20
12
123
CN33
PCB1
Main
Circuit
Board
G1
E1
G2
E2
G3
E3
G4
E4
E1
G1
Circuit Board
[WK-5549]
CN912CN8
123
TH2 TH1
IGBT Gate
[WK-5479]
1
2
3
1
2
3
4
[WK-5479]
1
2
3
1
2
3
4
1234567
PCB6
Control
PCB8
Circuit
Board
CN1
CN2
PCB9
IGBT Gate
Circuit
Board
CN1
CN2
CN21
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
E2
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q9
Q10
Q11
Q12
G2
CN19
123
P+21V
Q8
E3
123456
CN22
PGND
G3
1234567
CN23
CN17
CN17
CN21
CN21
CN1
CN1
E4
G4
1
1
2
2
3
3
4
4
5
5
6
6
7
7
1
1
2
2
3
3
4
4
1
1
2
2
3
3
4
4
A-2
February 20, 2006
Page 67
ARCMASTER 185 AC/DC
TB7
CT2
TB12
SG
S+15V
12345
CN8
T1
CT2
CT1
EB
AC3
123456789
AC4
TB20
CN9
TB22
TB21
AC4
AC2
PCB12
DIODE Snubber
Circuit Board
[WK-5615]
AC2 AC1
SH.DET-
SH.DET+
D4
D5
D2
P
N
P+21V
PGND
S+15V
SG
/RY_ON
FCH1
HCT1
2
1
+15
-15
4
3
IS
GND
1
2
3
4
1
2
1
2
3
PCB14
IGBT Snubber
Circuit Board
[WK-5570]
SH.DET+
PCB15
IGBT Gate
Circuit
Board
[WK-3367]
CN1
12345
E7G8E8
G7
TB1 TB2
RY+15V
SH.DET-
TB1 TB2
CN1
CN2
CN3
1234567
/RY_ON
PCB13
Super Inpose
Circuit Board
[WK-5569]
CN4
G1
E1
G2
E2
12
CN5
Q13
G1
E1
G2
E2
R3
CN6
RY+15V
TO1
+Output
Terminal
1
2
3
12345
CN1
PCB16
Filter Circuit
CN3
Board
[WK-5499]
CC1
CC2
HF.UNIT1
AC1 AC3
CC1
R1
R2
Ground
+
SIDE CHASSIS 3
TO2
R2
-Output
Terminal
R6
AC3
AC1
1
2
3
4
5
6
7
8
G7
E7
G8
E8
FRONT
PANEL
EA
Ground
+
February 20, 2006
+15
-15
IS
GND
1
2
3
4
5
6
PCB10
Panel
Circuit Board
[WK-5527]
CN2
CN1
1234
PCB11
Encorder
Board
[WK-5528]
CN1
1234
SIDE CHASSIS 2
A-3
Page 68
ARCMASTER 185 AC/DC
APPENDIX 3: ARCMASTER 185 AC/DC ACCESSORIES
ACCESSORIES PART NO. DESCRIPTION
Stick Kit 90925A Work clamp with 15’ cable and stick electrode with 15’ cable
TIG Kit W4009105 Includes regulator/flowgauge, 12.5’ 150 Amp TIG torch
Accessory kit includes 1 ea of 0040”x7”, 1/16”x7”, 3/32”x7”
2% Tungsten with collet & collet bodies, 1 ea 1/4”, 5/16”,
W4009105 Includes regulator/flowgauge, 13’ 200 Amp TIG torch & built-in
Dinse Connector 10-2020
Adaptor 10-4003 8-pin male to 14-pin female (6”)
Hand Held Pendant 10-4014 Includes contactor On/Off switch and current control with 25ft
Foot Control 10-4015 Contactor On/Off and current control with 15ft cable
10-4016 Contactor On/Off and current control with 25ft cable and
Extension Cable 10-4017 3ft with 8-pin male plug and 8-pin female cable receptacle
10-4018 15ft with 8-pin male plug and 8-pin female cable receptacle
10-4019 25ft with 8-pin male plug and 8-pin female cable receptacle
10-4020 50ft with 8-pin male plug and 8-pin female cable receptacle
10-4021 75ft with 8-pin male plug and 8-pin female cable receptacle
Torch Switch On/Off 10-4006
10-4007 25ft torch mounted with 8-pin male plug
Torch Switch On/Off
w/current control
10-4009 15ft torch mounted with 8-pin male plug
10-4010 15ft torch mounted with 8-pin male plug
10-4011 25ft torch mounted with 8-pin male plug
10-4012 25ft torch mounted with 8-pin male plug
10-4013 25ft torch mounted with 8-pin male plug
600296 Rotary amperage control 5k 15’ velcro for TD8
600297 Rotary amperage control 5k 25’ velcro for TD8
& built-in rotary amperage control.
3/8” alumina cup, 15’ cable with clamp & T25 dinse plug
On/Off switch. Accessory kit includes 1 ea. of 0040”x7”,
1/16”x7”,3/32”x7” 2% Tungsten with collet & collet bodies, 1 ea 1/4”,
5/16”,3/8” alumina cup,15’ cable with clamp & T25 dinse plug
T50mm Dinse style male plug
cable and 14-pin male plug
and 8-pin male plug
8-pin male plug
15ft torch mounted with 8-pin male plug
10-4008 15ft torch mounted with 8-pin male plug
- adapts to 5/8”-7/8” torch
- adapts to 7/8”-1-1/8” torch handle
- adapts to 1-1/8”-1-3/8” torch handle
- adapts to 5/8”-7/8” torch
- adapts to 7/8”-1-1/8” torch handle
- adapts to 1-1/8”-1-3/8” torch handle
A-4
February 20, 2006
Page 69
Page 70
LIMITED WARRANTY
y
r
t
f
f
r
y
y
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
®
LIMITED WARRANTY: Thermal Arc
warrants to customers of authorized distributors ("Purchaser") that its produc ts will be free
of defects in workmanship or material. Should any failure to conform to this warrant
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommendat ions and recogn ized standard ind ustry practice, and not subjec t to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair o
replacement, at Thermal Arc's sole option, of any components or parts of the produc
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty o
merchantability, fitness for any particular purpose, or other warranty o
quality, whether express, implied, or statutory.
Limitation of liability: The rmal Arc shall no t under any circum stances be liable for sp ecial,
indirect, incidental, or consequential damag es, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc with respect to any contract, or anything do ne in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whethe
arising out of contract, tort, including n egligence or strict liability, or under any war ranty,
or otherwise, shall not exceed the price of the goods u pon which such liability is based.
, Inc., A Thermadyne Company ("Thermal Arc"),
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound b
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.
This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchaser’s rights under this warrant
are void if the product is sold to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned good s
shall be at the Purchaser's risk and expense. This warranty dated April 1
supersedes all previous Thermal Arc warranties. Thermal Arc
®
is a Registered
st
2006
Trademark of Thermal Arc, Inc.
Page 71
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years
Origina l Main Power Rectifiers, Control P.C. Boards................................................................... 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer............................................................. See the Engine Manufactures Warranty for
Details
GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .................3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors...................................................................1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics....................................................................................................5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .................3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors...................................................................1 year
PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years 3 years
Welding Console, Weld Controller, Weld Time r ........................................................................... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator................................1 year
SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Dragster 85
Original Main Power Magnetics.....................................................................................................1 year 1 year
Original Main Power Rectifiers, Control P.C. Boards....................................................................1 year 1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year
160S, 300S, 400S
Original Main Power Magnetics....................................................................................................5 years 3 years
Origina l M a i n P ower Rectifier s , C o nt r o l P .C . B o a rds ...... .. .. .... .. ... .. .. .. .. .. .. .. .. ..... .. .. .. .. .. .. .. .. .. .. ..... .. 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year
GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR
Water Recirculators....................................................................................................................... 1 year 1 year
Plasma Welding Torches.............................................................................................................180 days 180 days
Gas Regulators (Supplied with power sources)..........................................................................180 days Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil
Replacement repair parts.............................................................................................................90 days Nil
MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil
3 years
3 years
1 year
1 year
1 year
1 year
1 year
1 year
Page 72
Page 73
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
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: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Page 74
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
Telephone: (636) 728-3000
Fascimile:
(636) 728-3010
Email: sales@thermalarc.com
www.thermalarc.com
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