Tweco 185TSW User Manual

INVERTER

ARC

WELDER

MODEL 185TSW AC/DC CC

STICK TIG - Lift Start HF START

OPERATING MANUAL

November 13, 2003 Manual No. 430429-503

CONTENTS

SYMBOL LEGEND .......................................................................................................................................................5

STATEMENT OF WARRANTY...................................................................................................................................6

1.0 GENERAL INFORMATION....................................................................................................................................7

1.01 Notes, Cautions and Warnings...........................................................................................................................7

1.02 Important Safety Precautions..............................................................................................................................7

1.03 Publications........................................................................................................................................................8

1.04 Note, Attention et Avertissement........................................................................................................................9

1.05 Precautions De Securite Importantes..................................................................................................................9

1.06 Documents De Reference.................................................................................................................................11

2.0 INTRODUCTION AND DESCRIPTION ..............................................................................................................13

2.01 Description ........................................................................................................................................................13

2.02 Functional Block Diagrams...............................................................................................................................14

2.03 Transporting Methods........................................................................................................................................14

3.0 Installation Recommendations.................................................................................................................................15

3.01 Environment......................................................................................................................................................15

3.02 Location.............................................................................................................................................................15

3.03 Electrical Input Connections..............................................................................................................................16

3.03.01 Electrical Input Requirements..................................................................................................................16

3.03.02 Input Power ..............................................................................................................................................18

3.03.03 High Frequency Introduction....................................................................................................................19

3.03.04 High Frequency Interference....................................................................................................................19

3.04 Specifications ....................................................................................................................................................20

3.05 Duty Cycle.........................................................................................................................................................21

4.0 OPERATOR CONTROLS......................................................................................................................................23

4.01 Pro-Wave 185TSW Controls.............................................................................................................................23

4.02 Weld Process selection for Pro-Wave 185TSW................................................................................................25

4.03 Weld Parameter Descriptions for Pro-Wave 185TSW......................................................................................26

4.04 Weld Parameters for Pro-Wave 185TSW..........................................................................................................28

4.05 Power Source Features......................................................................................................................................29

5.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG) .............................................................................................31

6.0 SEQUENCE OF OPERATION...............................................................................................................................32

6.01 Stick Welding....................................................................................................................................................33

6.02 AC or DC HF TIG Welding..............................................................................................................................34

6.02.01 Slope Mode Sequence ..............................................................................................................................35

6.02.02 Slope Mode with repeat sequence ............................................................................................................35

6.02.03 Pulse Controls...........................................................................................................................................36

7.0 BASIC TIG WELDING GUIDE.............................................................................................................................37

7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum..............................................................37

7.02 Electrode Polarity........................................................................................................ ......................................38

7.03 Tungsten Electrode Current Ranges ..................................................................................................................38

7.04 Tungsten Electrode Types .................................................................................................................................38

7.05 Guide for Selecting Filler Wire Diameter..........................................................................................................39

7.06 Shielding Gas Selection.....................................................................................................................................39

7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe.................................................................39

7.08 Welding Parameters for Aluminum................................................................................................................... 40

7.09 Welding Parameters for Steel............................................................................................................................40

8.0 Basic Arc Welding Guide........................................................................................................................................41

8.01 Electrode Polarity........................................................................................................ ......................................41

8.02 Effects of Stick Welding Various Materials...................................................................................................... 41

9.0 ROUTINE MAINTENANCE .................................................................................................................................42

10.0 BASIC TROUBLESHOOTING............................................................................................................................43

10.01 TIG Welding Problems....................................................................................................................................43

10.02 Stick Welding Problems..................................................................................................................................45

10.03 Power Source Problems...................................................................................................................................47

11.0 Voltage Reduction Device (VRD).........................................................................................................................49

11.01 VRD Specification...........................................................................................................................................49

11.02 VRD Maintenance...........................................................................................................................................49

12.0 Power Source Error Codes....................................................................................................................................50

13.0 PARTS LIST......................................................................................................................................................... 53

APPENDIX A – INTERCONNECT DIAGRAM ........................................................................................................ 56

APPENDIX B - AUTOMATION................................................................................................................................. 58

SYMBOL LEGEND

Amperage STICK (Shielded Metal Arc

Voltage Pulse Current Function

Hertz (frequency) Spot Time (GTAW)

SMAW)

SEC

Seconds Remote Control (Panel/Remote)

Percent Remote Function

DC (Direct Current) Arc Control (SMAW)

AC (Alternating Current Gas Post-Flow

Standard Function Gas Pre-Flow

Slope Function

VRD

Slope W/Repeat Function Negative

Voltage Reduction Device Circuit

Spot Function Positive

Impulse Starting (High Frequency GTAW)

Touch Start (Lift Start TIG circuit GTAW)

Gas Input

Gas Output

STATEMENT OF WARRANTY

LIMITED WARRANTY: Thermal Arc authorized distributors here after “Thermal; Arc” that its pr oducts will be free of defects in work manship or material. Should any failure to con form to thi s wa rr anty a ppear with i n th e time p er iod a ppl ica bl e to th e Th er mal Ar c pr od ucts as s tate d bel ow, Th ermal Arc shall, upon notifi cation ther eof and substanti ation that th e product ha s been store d, instal led, opera ted, and mai ntained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by s uitable repair or replacement, at Thermal Ar c’s sole option, of any components o r parts of the product d etermined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal Arc shall not under any cir cumstan ces be liable for s pecial, ind ire ct or con sequentia l d amages,

such as, but not l imited to, lost profi ts and busi ness in terruption . The re medies of the Pur chaser set forth h erein ar e exclus ive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way o r grant any other warranty.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NONAUTHORIZED PERSONS.

, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of its

The warran ty is effective fo r the time stated below beginnin g on the date that th e authoriz ed distributor delivers the products to the Purchaser. Notw iths tan ding the for egoin g, in no even t shal l the wa rra nty per iod ex tend more tha n the time sta ted plus one year from the date Thermal Arc delivere d the product to the a u thorized distributor.

POWER SUPPLIES POWER SUPPLIES & WIRE FEEDERS LABOR

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEAR 3 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEAR 3 YEAR POWER SWITCHING SEMI-CONDUCTORS & CONTROL PC BOARD 3 YEAR 3 YEAR

ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS, SOLENOIDS, PUMPS, SWITCHES, MOTORS

ENGINES: ENIGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER, SEE THE ENGINE MANUFACTUR ES WARRA NT Y FOR DE TAILS .

CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR EXCHANGES, AND ACCESSORY EQUIPMENT PLASMA TORCH AND LEADS, AND REMOTE CONTROLS

180 DAYS 180 DAYS

REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS

Warranty repair s or replace ment cla ims under this limi ted warr anty must be s ubmitted to Th ermal Arc by an a uthoriz ed Thermal Arc repair facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous Thermal Arc warranties.

Thermal Arc® is a Registered Trademark of Thermadyne Industries Inc.

Effective April 1, 2002

1.0 GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF ARC WELDING EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1800-462-2782 or your local distributor if you have any questions.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

• The kinds of fumes and gases from the arc welding/cutting depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fume s and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft welding/cutting tables, to capture fumes and gases.

• Do not use the welding torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solven ts and cleanser s. Remove all sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The arc welding process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

GASES AND FUMES

Gases and fumes produced during the Arc welding/cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workpla ce is moist or damp.

• Install and maintain eq uipment according to NEC code, refer to item 4 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the arc weld.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protec te d.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

• Provide a fire watch when working in an area where fire hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unle ss the hydrogen ga s can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Arc welding/cutting processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.

ARC WELDING RAYS

Arc Welding/Cutting Rays can injure your eyes and burn your skin. The arc welding/cutting process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suita ble clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the wor k area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as recommended in Subsection 1.03, item 4.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AN D HEA L TH ST AN D ARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, M A 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11.CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du sy stème.

ATTENTION

Toute procédure po uvant résulter l’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENT

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Il faut communiquer aux o pérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 1-800-462-2782 ou votre distributeur local si vous avez des questions.

FUMÉE et GAZ

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré pa r la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements

secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.

RAYONS D’ARC DE PLASM A

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc

nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunette s de pr otection ou une autre sorte de protec tion oculaire.

• Portez des gants de soudeur et u n vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres pe rsonnes se tr ouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Respectez le teint de lentille recommandé dans le article 4, page 5.

• Hydrogen gas may be present under aluminum workpieces during the cutting process when being cut underwater or using a water table. DO NOT cut aluminum underwater or on a water table unless the hydrogen gas can be eliminated as the hydrogen gas may detonate.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révision s les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS

ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

2.0 INTRODUCTION AND DESCRIPTION

2.01 Description

The Thermal Arc™ Model 185TSW 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.

(V)

OCV

(V)

OCV

10V

160A5A (A)

STICK Process

(V)

OCV

185A25A (A)

LIFT TIG Process HF TIG Process

Figure 1. Model 185TSW Volt-Ampere curve

185A (A)

Note 1

Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source. Curves of other settings will fall between the curves shown.

2.02 Functional Block Diagrams

Figure 2 illustrates the functional block diagram of the 185TSW-power supply.

Figure 2. 185TSW Model Functional Block Diagram

2.03 Transporting Methods

These units are equipped with a handle for carrying purposes.

WARNING 1

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

WARNING 2

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

3.0 Installation Recommendations

3.01 Environment

The Pro-Wave 185TSW is designed for u se in hazardous environments.

Examples of environments with increased hazardous environments 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, or

c) In wet or damp hot locations where humidity or perspiration considerably reduces the

skin resistance of the human body and the insulation properties of accessories.

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

3.02 Location

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

• 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 exposed to direct sunlight or

rain.

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

• In areas, not subjected to abnormal

vibration or shock.

• Place at a distance of 12” (304.79mm) or

more from walls or similar that could restrict natural airflow for cooling.

WARNING 3

3.03 Electrical Input Connections

WARNING 4

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.

3.03.01 Electrical Input Requirements

Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and any inspection required.

The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.

Note 2

These units are equipped with a two-conductor with earth power cable that is connected at the welding power source end for single-phase electrical input power.

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

Refer to figure 3 and:

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

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

3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.

Input Voltage Fuse Size

208V 45 Amps 230V 40 Amps

Table 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).

Figure 3. Electrical Input Connections

3.03.02 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 3

Note the available input power. Damage to the PCA could occur if 460VAC or higher is applied.

The following 208/230V Primary Current recommendations are required to obtain the maximum welding cur re nt and du ty cycle from this weldi ng e quip ment :

Current & Duty Cycle

TIG STICK

Model

Primary Supply

Lead Size

(Factory Fitted)

Minimum Primary

Current Circuit Size

(Vin/Amps)

230/29

185 @ 30%

Pro-Wave

185TSW

12/3 AWG

minimum

208/32 230/38 -

160 @ 40%

208/40 -

Table 2 – 208/230V Primary Current Circuit sizes to achieve maximum current

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