Tweco 185TSW User Manual

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INVERTER

ARC

WELDER

MODEL 185TSW AC/DC CC

STICK TIG - Lift Start HF START

OPERATING MANUAL

November 13, 2003 Manual No. 430429-503

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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

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

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

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

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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

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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

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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.

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• 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

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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.

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• 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

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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

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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

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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.

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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.

Page 15

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

Page 16

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.

Page 17

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

Page 18

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

Page 19

3.03.03 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following information is intended as a guide for personnel installing high frequency welding machi nes.

Warning

Explosives

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.

Computers

It is also possible that operation close to computer installations may cause computer malfunction.

3.03.04 High Frequency Interference

Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following way s:

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 w ill preve nt d irect radiat ion if t he equipmen t is pr operly grounded.

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. A dequate sh ield ing and fil ter ing is provided in the Power S ource.

Radiation from Welding Leads

Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with distance. Keeping leads as short as possible will minimize this type of interference. Looping and sus pending of leads sho uld be avo ided where pos sib le.

Re-radiation from Unearthed Metallic Objects

A major factor contributing to interference is re-radiation from unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent re-radiation in most cases.

Page 20

3.04 Specifications

Parameter 185TSW Rated Output Amperes Volts Duty Cycle Duty Cycle TIG 185A / 17.4V @ 30%

Output Current TIG 5 – 185 (DC)

Range STICK 5 – 160 (DC)

Open Circuit Voltage 69V

Dimensions

Width Height Length Weight 41.8 lb. 19 kg

Output @ Rated Load

Output Amperes Output Volts Duty Cycle KVA KW

Output @ No Load

KVA KW

Input Volts Single Phase

208V 230V

185

17.4 25%

160A / 16V @ 40% 130A / 15V @ 60% 100A / 14V @ 100%

STICK 160A / 26V @ 40%

130A / 25V @ 60% 100A / 25V @ 100%

5 – 185 (AC) @ 60Hz, 50% Cleaning

5 – 160 (AC) @ 60Hz, 50% Cleaning

7.08” (180mm)

14.7” (360mm)

16.54” (420mm)

160A 26V 40%

8.7

5.2

0.5

0.13 Amperage Draw @ Rated Load

40 38

No Load Amps

2.2

1.6

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

Page 21

3.05 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 5

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 1

Continually exceeding the duty cycle rat ings can cause damage to the welding power source and will void the manufactures warranty.

NOTE 4

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.

Page 22

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Page 23

4.0 OPERATOR CONTROLS

4.01 Pro-Wave 185TSW Controls

Figure 4– Pro-Wave 185TSW 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 S ocke t i s use d t o connec t remo te current con trol devices to the welding Power Source. To make connect ion s, a lig n keyway, insert plug, and rotate threaded collar fully cloc kwise.

Gnd.

543 876

12345678

Front view of 8-Sock et Receptacle

5k Ohms

Page 24

Socket Pin Function

1 Earth (Ground) 2

Torch Switch Input (24V) to energ ize we ld curren t. (connect pins 2 & 3 to turn on wel ding current)

Torch Switch Input (0V) to e nergize weld current (connect pins 2 & 3 to turn on wel ding current)

Connect pin 4 to pin 8 to instruct machine that a remote current control

device is connected (12V DC supply ) 5 5k ohm (maximum) connection to 5k ohm rem ote co ntro l po tent io meter 6

Zero ohm (minimum) connection to 5k ohm re mote control

potentiometer 7 Wiper arm connection to 5 k oh m r em ote control potentiomete r 8 Connect pin 4 to pin 8 to instruct machine that a remote current control

device is connected (0V)

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 2

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 f emale g as fitting.

6 ON/OFF Switch

This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Sup ply.

WARNING 6

When the welder is connected to the Primary supply voltage, the internal electrical components maybe at 240V potential with respect to earth.

7 Input Cable

The input cable connects the Primary supply voltage to the equipment.

Page 25

8 Gas Inlet

The Gas Inlet is a 5/8 18 UNF fe ma le g a s fit ti ng .

4.02 Weld Process selection for Pro-Wave 185TSW

Weld Mode

Weld Process

Selection STICK

STD

SLOPE

REPEAT

SPOT

PULSE ON/OFF

TIG

LIFT

TIG Description

Yes Yes Yes 2T operation in TIG Modes using remote

devices to control contactor & current

No Yes Yes 4T operation in TIG Modes with crater fill

using a remote contactor device to control sequence.

No Yes Yes 4T operation in TIG Modes with repeat

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

Yes Yes Yes Selects AC or DC weld current

Table 3 – Weld Process selection verses Weld Mode for Pro-Wave 185TSW

Page 26

4.03 Weld Parameter Descriptions for Pro-Wave 185TSW

Figure 5 Pro-Wave 185TSW Front Panel with Parameter Description

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 porosity at

PRE-FLOW

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

HOT START

characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the BASE (WELD) current.

e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps &

HOT START = 30 amps

INITIAL CUR.

This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the start current for TIG. The Start Current remains on until the torch trigger switch is released after it has been depressed.

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

PEAK CUR.

WELD

This parameter sets the PEAK weld current when in PULSE mode This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and

SPOT modes when PULSE is off. This parameter also sets the STICK weld current.

BASE

This parameter sets the Background current when in Pulse TIG mode.

(Background

Current)

Page 27

Parameter Description

SPOT TIME

PULSE WIDTH

PULSE FREQ.

AC FREQUENCY

WAVE BALANCE

This parameter sets the duration of the SPOT TIME in HF TIG mode only This parameter sets the percentage on time of the PULSE FREQUENCY

for PEAK weld current when the PULSE is on. This parameter sets the PULSE FREQUENCY when the 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 is set to 50% for AC STICK welding. The WAVE BALANCE control changes the ratio of penetration to cleaning action of

the AC TIG welding arc. Maximum weld penetration is achieved when the WAVE BALANCE control is set to 10%. Maximum cleaning of heavily oxidised aluminium or magnesium alloys is achieved when the WAVE BALANCE control is set to 65%.

WAVE BALA NCE=50%

WAVE BALA NCE=10%

10%50% 65%

WAVE BALA NCE=65%

(+ )(+ ) (+ )

DOWN SLOPE

CRATER CUR.

POST-FLOW

Table 4 – Weld Parameter Descriptions for Pro-Wave 185TSW

(- )(- ) (- )

90%50% 35%

Balanced with 50% pene trat ion

and 50% cleaning

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.

Maximum Penetration and

reduced cleaning

Maximum Cleani ng a nd

reduced penetr ation

Page 28

4.04 Weld Parameters for Pro-Wave 185TSW

Weld Mode

Weld

Parameter

Range

Factory

Setting

Incremental

Unit STICK

TIG

LIFT

TIG

PRE-FLOW 0.0 to 1.0 sec 0.1 sec 0.1 sec No Yes Yes

HOT START 0 to 70A 20A 1A Yes Yes No

INITIAL CUR. 5 to 185A 30A 1A No Yes Yes

UP SLOPE 0 to 15 sec 1 sec 0.1 sec No Yes Yes PEAK CUR. 5 to 185A 120A 1A No Yes Yes WELD CUR

(TIG)

WELD CUR

(STICK)

5 to 185A 80A 1A No Yes Yes

5 to 160A 80A 1A Yes No No

SPOT TIME 0.5 to 5.0 sec 2 sec 0.1 sec No Yes Yes

PULSE WIDTH 15 to 80% 50% 1% No Yes Yes

PULSE FREQ. 0.5 to 500Hz 100.0Hz

See

No Yes Yes

Table 6

AC FREQUENCY 15 to 150Hz 50Hz 1Hz Yes Yes Yes WAVE BALANCE 10 to 65% 50% 1% Yes Yes Yes

DOWN SLOPE 0 to 25 sec 3 sec 0.1 sec No Yes Yes CRATER CUR. 5 to 185A 30A 1A No Yes Yes

POST-FLOW 0.0 to 60 sec 10 sec 0.1 sec No Yes Yes

Table 5 – Weld Parameters for Pro-Wave 185TSW

PULSE FREQ. Range Incremental Unit

0.5 to 20Hz 0.1Hz

20 to 100Hz 1Hz

100 to 500Hz 5Hz

Table 6 – PULSE FREQ. Range and Incremental Units

Page 29

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)

• 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.

Control Knob

Self Diagnosis Using Error Codes

• 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 Digital Meter

when a problem occurs with Primary supply voltage or internal component problems. Refer to troubleshooting guide.

Page 30

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Page 31

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

Conventional operating procedures apply when using t he 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 cu rre n t se tting to s ui t t he app lic ati on.

Figure 6– 185TSW AC/DC Set-up

WARNING 7

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 3

Remove any packaging material prior

Remove any packaging material priorRemove any packaging material prior to use. Do not block the air vents at

to use. Do not block the air vents at

to use. Do not block the air vents atto use. Do not block the air vents at the front or rear or sides of the

the front or rear or sides of the

the front or rear or sides of thethe front or rear or sides of the Welding Power Source.

Welding Power Source.

Welding Power Source.Welding Power Source.

CAUTION 4

DO NOT change the Weld Mode or

DO NOT change the Weld Mode orDO NOT change the Weld Mode or Weld Process Mode until after POST-

Weld Process Mode until after POST-

Weld Process Mode until after POST-Weld Process Mode until after POSTFLOW time has finished.

FLOW time has finished.

FLOW time has finished.FLOW time has finished.

Page 32

6.0 SEQUENCE OF OPERATION

123

NOTE: 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.

Figure 7 185TSW Front Panel

Page 33

1. Pulse function – Pressing this button enables the TIG current pulse functions.

2. Scroll Buttons – used to select the parameters to be set. The LED’s show which function is being

adjusted on the Sequence Graph.

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. Control knob – allows the operator to adjust the output amperage within the entire range of the power

source, also used to set each parameter value.

Pushing the knob inward displays the actual welding

voltage.

6. Process Button – This button selects between STICK, Lift or HF TIG mode. A remote control

device is required for use during LIFT TIG and HF TIG operation. See section 4.01, section 2 “Remote Control Socket”, for complete details of the remote device.

7. AC/DC Button – Selects between AC or DC welding output.

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 t o 60Hz & WAVE

BALANCE to 50%.

• Connect remote control device if required

Use the Scroll Button s t o m ove t o t he pa rame ter to be set . T he LED will show which function is being adjusted on t he weld sequence g raph. Use the con trol kno b to adj us t each parameter.

• Set HOT START

• Set WELD current

Commence welding

Page 34

6.02 AC or DC HF TIG Welding

• Connect work lead to positive terminal

• Connect TIG torc h to neg ative terminal

• Switch machine on

• Set AC or DC weld current. If AC is selected then set AC FREQ & WAVE BALANCE

• Connect remote control device. . See section 4.0 1, sec tio n 2 “ Remo te Control Socket”,

for complete deta il s of the remote device.

Use the Scroll Button s t o m ove t o t he pa rame ter to be set . T he LED will show which function is being adjusted on t he weld sequence g raph. Use the con trol kno b to adj us t each parameter.

• Set PRE-FLOW time

• Set HOT START current

• Set POST-FLOW time

• Set WELD current

• Set POST-FLOW time

Slope Mode Parameters if required

• Set INTIAL CUR current

• Set UP SLOPE time

• Set (WELD) PEAK CUR current

• Set BASE current

• Set DOWN SLOPE time

• Set CRATER CUR current

Pulse Mode parameters if required

• Set PULSE WIDTH % for PEAK CURRENT

• Set PEAK CURRENT

• Set PULSE FREQ

Commence welding

Page 35

6.02.01 Slope Mode Sequence

Switch Closed

Preflow

Initial

Current

Slope

Switch Open

Weld Current

Down

Slope

Switch Closed

Switch Open

Final

Current

Postflow

Note 5

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.

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.

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 remote switch contacts are closed.

4) Open Remote Switch – Welding arc stops and post flow begins.

6.02.02 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 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.

Page 36

6.02.03 Pulse Controls

(Pulse Width) (Pulse Frequency)

(Peak Current)

(Base)

Background

Current

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.

6.02.03 Puls e controls continued

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 were moved up and down to increase and decr ease the welding current on a regular basis. The faster you moved the foot rheostat up and down the faster the frequency.

Page 37

7.0 BASIC TIG WELDING GUIDE

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 flu tteri ng 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 so-called “cleaning action”. However once the cleaning action has produced a mirror like surface 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.

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. But once the arc is stationary, the pool becomes thoroughly “cleaned” by election emiss ion, the f luttering beg ins .

Tests conducted on various types of AC TIG power sources, Fluttery Arc is not confined to one type of power source or it’s design, both conventional and inverter types suffer from the same problem.

AC TIG on aluminum

The Problem: Arc appears unstable and pulses or flutters. ie. appears to rapidly change welding

current.

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.

ie. Prolonged oxide emission from a stationary weld pool increases the likelihood of arc flutter,

• Accentuated when tungsten running

near its current capacity, ie. 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 the WAVE BALANCE to below 50% or move the weld pool around.

• Use a larger diameter tungsten

electrode.

Table 7 – Reduction of Arc Flutter

Conclusion: Fluttery arc in AC TIG is a physical phenomenon independent of machine design.

Page 38

7.02 Electrode Polarity

Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight po larity. 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 8 – Current ranges for varies tungsten electrode sizes

7.04 Tungsten Electrode Types

Electrode Type

Welding Application Features Color

(Ground

Finish)

DC welding of mild steel,

Thoriated 2%

stainless steel and copper.

High quality AC welding of

Zirconated 1%

aluminium, magnesium and their alloys.

AC & DC welding of mild

Ceriated 2%

steel, stainless steel, copper, aluminium, magnesium and their alloys

Table 9 – 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.

Code

Red

White

Grey

Page 39

7.05 Guide for Selecting Filler Wire Diameter

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

Table 10 – Filler wire selection guide

The filler wire diameter specified in Table 10 is a guide only, other diameter wires may be used according to the welding

application.

7.06 Shielding Gas Selection

Alloy Shielding Gas

AC Current Range

(Amps)

DC Current Range

(Amps)

NOTE 6

Argoshield is a registered trademark of BOC Gases

Limited.

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

Table 11 – 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)

Current Range DC

Amperes

120 - 170 Yes

100 - 160 Yes

90 - 130 No

Filler Rod for

Root Pass

Joint Preparation

Table 12 – TIG welding parameters for low carbon & low alloy steel pipe

Page 40

7.08 Welding Parameters for Aluminum

Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm 1/16”

1.6mm

1/8”

3.2mm

3/16”

4.8mm

¼”

6.4mm

AC Current

for Aluminum

30-45 Butt/Corner 35-50

40-60 Butt/Corner 45-70

60-85 Butt/Corner 70-95

125-150 Butt/Corner 130-160

Tungsten Electrode Diameter

0.040”

1.0mm

0.040”

1.0mm 1/16”

1.6mm 3/32”

2.4mm

Filler Rod

Diameter

(if required)

1/16”

1.6mm 1/16”

1.6mm 3/32”

2.4mm

Argon Gas

Flow Rate

Liters/min

5-7

Joint Type

Lap/ Fillet

1/8”

3.2mm 180-225 Butt/Corner 190-240

240-280 Butt/Corner 250-320

1/8”

3.2mm

3/16”

4.8mm

1/8”

3.2mm 3/16”

4.8mm

Lap/ Fillet

Table 13 – AC TIG welding parameter

7.09 Welding Parameters for Steel

Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm 1/16”

1.6mm

1/8”

3.2mm 3/16”

4.8mm

¼”

6.4mm

DC Current

for Mild

Steel

DC Current for Stainless

Steel

35-45 20-30 Butt/Corner 40-50 25-35

45-55 30-45 Butt/Corner 50-60 35-50

60-70 40-60 Butt/Corner 70-90 50-70

80-100 65-85 Butt/Corner 90-115 90-110

115-135 100-125 Butt/Corner 140-165 125-150

160-175 135-160 Butt/Corner 170-200 160-180

Tungsten

Electrode

Diameter

0.040”

1.0mm

0.040”

1.0mm 1/16”

1.6mm 1/16”

1.6mm 3/32”

2.4mm

1/8”

3.2mm

Filler Rod

Diameter

(if required)

1/16”

1.6mm 1/16”

1.6mm 3/32”

2.4mm

1/8”

3.2mm 5/32”

4.0mm

Argon Gas

Flow Rate

Liters/min

5-7

Joint Type

Lap/ Fillet

Table 14 – DC TIG welding parameters

Page 41

8.0 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 consu lt the electrode manufacturers literature.

8.02 Effects of Stick Welding Various Materials

High tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

Manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the poros ity caused by gas held in this ty pe of iron.

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 fusi on of wel d an d base meta l.

Types of Electrodes

Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great number of electrodes used for specialized industrial purposes, which are not of particular interest for everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc. The range of electrodes dealt with in this publica ti on w il l cove r the vast majority of a pplications likely to be encounter ed; are all easy to use and all will work on even the most basic of welding machines.

Page 42

9.0 ROUTINE MAINTENANCE

The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usag e and the operat ing enviro nmen t.

WARNING 8

Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.

To clean the unit, open the enclosure (please refer to Section 8.01.01, Opening the Enclosure in the 185TSW Service Manual P/N 430429-512) and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean, if necessary; with solvents that are recommended for cleaning electrical apparatus.

CAUTION 5

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.

Page 43

10.0 BASIC TROUBLESHOOTING

WARNING 9

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

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.

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.

Increase weld current and/or faulty joint preparation.

Uneven leg length in fillet joint.

Wrong placement of filler rod.

Re-position filler rod.

Page 44

Description Possible Cause Remedy

6 Electrode melts

A Electrode is connected to the

when arc is struck.

B WAVE BALANCE is greater

7 Dirty weld pool. A

B Gas contaminated with air. B Check gas lines for cuts and

Electrode melts or

A 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 Gas passage contains

‘+’ terminal.

than 50%.

Electrode contaminated through contact with work piece or filler rod material.

No gas flowing to welding region.

impurities.

A Connect the electrode to the

‘−’ terminal.

B Reduced WAVE BALANCE

to below 50% or increase the electrode size.

Clean the electrode by grinding off the contaminates.

loose fitting or change gas cylinder.

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.

E Gas regulator turned off. E Turn on.

F Torch valve is turned off. F Turn on.

G The electrode is too small for

the welding current.

H WAVE BALANCE is set

above 50%.

9 Poor weld finish. Inadequate shielding gas.

Arc flutters during TIG welding.

Tungsten electrode is too large for the welding current.

B Absence of oxides in the

weld pool.

Welding arc can not be established.

Work clamp is not connected to the work piece or the work/torch leads are not connected to the right welding terminals.

G Increase electrode diameter

or reduce the welding current.

H Reduced WAVE BALANCE

to below 50% or increase the electrode size.

Increase gas flow or check gas line for gas flow problems.

Select the right size electrode. Refer to Basic TIG Welding guide.

B Refer Basic TIG Welding

Guide for ways to reduce arc flutter.

Connect the work clamp to the work piece or connect the work/torch leads to the right welding terminals.

B Torch lead is disconnected. B

Connect it to the ‘−‘ terminal.

Page 45

Description Possible Cause Remedy

Arc start is not smooth.

C Gas flow incorrectly set,

cylinder empty or the torch valve is off.

Tungsten electrode is too large for the welding current.

C Select the right flow rate,

change cylinders or turn torch valve on.

Select the right size electrode. Refer to Basic TIG Welding Guide.

The wrong electrode is being used for the welding job.

Select the right electrode type. Refer to Basic TIG Welding Guide.

C Gas flow rate is too high. C Select the correct rate for the

welding job. Refer to Basic TIG Welding Guide.

D Incorrect shielding gas is

being used.

D Select the right shielding gas.

Refer to Basic TIG Welding Guide.

E Poor work clamp connection

to work piece.

E Improve connection to work

piece.

10.02 Stick Welding Problems

Description Possible Cause Remedy

1 Gas pockets or

voids in weld metal (Porosity).

2 Crack occurring

in weld metal soon after solidification commences.

A gap is left by

failure of the weld

metal to fill the root of the weld.

Electrodes are damp.

Welding current is too high.

Surface impurities such as

Dry electrodes before use.

Reduce welding current.

Clean joint before welding.

oil, grease, paint, etc.

Rigidity of joint.

Redesign to relieve weld joint of severe stresses or use crack resistance electrodes.

Insufficient throat thickness.

Travel slightly slower to allow greater build up in

Cooling rate is too high.

throat. Preheat plate and cool slowly.

Welding current is too low. Electrode too large for joint.

Increase welding current

Use smaller diameter electrode.

Insufficient gap.

Allow wider gap.

D Incorrect sequence. D Use correct build-up

sequence.

Figure 8– Example of insufficient gap or incorrect

sequence

Page 46

Portions of the

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

ABSmall electrodes used on

heavy cold plate. Welding current is too low.AB

Use larger electrodes and preheat the plate.

Increase welding current.

C Wrong electrode angle. C Adjust angle so the welding

arc is directed more into the base metal.

Travel speed of electrode is too high.

Reduce travel speed of electrode.

E Scale or dirt on joint surface. E Clean surface before welding.

Figure 9 – Example of lack of fusion

Non-metallic parti-

cles are trapped in the weld metal (slag inclusion).

A Non-metallic particles may

be trapped in undercut from previous run.

B Joint preparation too

restricted.

Irregular deposits allow slag to be trapped.

D Lack of penetration with slag

trapped beneath weld bead.

E Rust or mill scale is

preventing full fusion.

Wrong electrode for position in which welding is done.

A If bad undercut is present,

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

B Allow for adequate

penetration and room for cleaning out the slag.

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.

Use electrodes designed for position in which welding is done, otherwise proper control of slag is difficult.

Figure 10 – Examples of slag inclusion

Page 47

10.03 Power Source Problems

Description Possible Cause Remedy

The welding arc cannot be established.

ABThe Primary supply voltage

has not been switched ON. The Welding Power Source

switch is switched OFF.

C Loose connections internally. C Have an Accredited

ABSwitch ON the Primary

supply voltage. Switch ON the Welding

Power Source.

Thermal Arc Service Agent repair the connection

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.

Defective control circuit. Have an Accredited

Thermal Arc Service Agent repair the connection

Loose welding cable connections.

Incorrect welding cable size.

Tighten all welding cable connections.

Use proper size and type of cable.

Improper input connections.

Refer to Section 2.05 Electrical Input Requirements.

Poor electrode condition.

Wrong welding polarity.

Replace electrode.

Verify output torch connections.

Gas hose is cut.

Gas passage contains impurities.

ABReplace gas hose.

Disconnect gas hose from the rear of Power Source then raise gas pressure and

blow out impurities. C Gas regulator turned off. C Turn gas regulator on. D Torch trigger switch lead is

disconnected or switch/cable

D Reconnect lead or repair

faulty switch/cable.

is faulty.

Page 48

Description Possible Cause Remedy

5 Gas flow won’t

shut off.

6 The TIG electrode

has been contaminated due to the gas flow shutting off before the programmed POST-FLOW time has elapsed.

A Weld Mode (STD, SLOPE,

REPEAT or SPOT) was changed before POST-FLOW gas time had finished.

A Strike an arc to complete

the weld cycle. OR Switch machine off then on to reset solenoid valve sequence.

B Gas valve is faulty. B Have an Accredited

Thermal Arc Service Agent repair or replace the gas valve

C Gas valve jammed open. C Have an Accredited

Thermal Arc Service Agent repair or replace the gas valve

D POST-FLOW control is set to

D Reduce POST-FLOW time.

60 sec. The Weld Process Mode

(STICK, HF TIG or LIFT TIG) was changed before POST-FLOW gas time had

Do not change Weld Process Mode before the POST-FLOW gas time had finished.

finished.

Page 49

11.0 Voltage Reduction Device (VRD)

11.01 VRD Specification

Pro-Wave

Description

VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between welding

VRD Resistance 148 to 193 ohms The required resistance between welding

VRD Turn OFF Time 0.2 to 0.3 seconds The time taken to turn OFF the we ldi ng

1 1.02 VRD Maintenance

Routine inspection a nd te s ting (power sourc e) 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; and b) For fixed equipment, at least once every 12 months.

185TSW Notes

terminals.

terminals to turn O N the welding power.

power once the welding current has stopped.

The owners of the equipment shall keep a sui table record of the peri odic tes ts.

Note 7

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

If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests sh oul d be carried ou t pri or t o installation at this location.

Page 50

Weld current ceases.

Buzzer sounds constantly.

Fan operates at max

speed.

Let Power Source cool down

then keep within its duty

cycle.

Have an Accredited Thermal

E01 resets when TH1

decreases to 70ºC for

about 30 seconds.

Arc Service Agent

investigate.

Unblock vents then let Power

Source cool down.

Weld current ceases.

Buzzer sounds constantly.

Fan operates at max

speed.

Let Power Source cool down

then keep within its duty

cycle.

E02 resets when TH2

decreases to 70ºC for

about 30 seconds.

Have an Accredited Thermal

Arc Service Agent investigate

Unblock vents then let Power

Weld current ceases.

Buzzer sounds constantly.

Switch machine off then

on to reset E03 error.

Source cool down.

Reduce length of welding arc.

Have an Accredited Thermal

Arc Service Agent or a

qualified electrician check for

low Mains voltage.

Weld current ceases.

Buzzer sounds constantly.

Reduce the length of the TIG

torch cable and/or work lead

Switch machine off then

or un-coiled leads.

on to reset E04 error.

The Welding Power A

Source’s duty cycle has

been exceeded.

Fan ceases to operate.

Air flow is restricted by

vents being blocked.

The Welding Power A

Source’s duty cycle has

been exceeded.

Fan ceases to operate.

Air flow is restricted by

vents being blocked.

Primary current is too high

because welding arc is too

long.

Mains supply voltage is

more than 10% below

nominal voltage .

TIG torch cable and/or work

lead are too long or leads

are coiled.

Description Possible Cause Remedy Remarks

12.0 Power Source Error Codes

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.

Primary (input) current too high.

3 E03 error code displayed

E04 error code displayed 4

Output voltage exceeds the

secondary voltage specification.

Page 51

Weld current ceases.

Buzzer sounds constantly.

Have an Accredited Thermal

Arc Service Agent or a

Error code E11

automatically will reset

qualified electrician check the

Primary voltage.

when the voltage reduces.

Weld current available.

Buzzer sounds

Have an Accredited Thermal

Arc Service Agent or a

intermittently.

Error code E14

automatically will reset

when the voltage

increases.

Weld current ceases.

Buzzer sounds constantly.

Error code E12

automatically will reset

when the voltage

increases.

qualified electrician check the

Mains voltage.

Have an Accredited Thermal

Arc Service Agent or a

qualified electrician check the

Mains voltage.

Have an Accredited Thermal

Arc Service Agent or a

qualified electrician check the

No weld current is

available.

Buzzer sounds constantly.

Switch machine off.

No weld current is

available.

Buzzer sounds constantly.

Switch machine off then

on to reset E82 error.

primary cable and fuses.

Have an Accredited Thermal

Arc Service Agent or a

qualified electrician check the

Mains voltage.

Have an Accredited Thermal

Arc Service Agent or a

qualified electrician check the

Mains voltage.

Primary supply voltage is

greater than the nominal

voltage plus 10%.

Mains supply voltage is less

than the nominal operating

voltage less 10%.

Mains supply voltage is

down to a dangerously low

level.

When 3 phase machine is

first turned on with the

wrong Primary supply

(input) voltage connected.

The Primary supply (input)

voltage fluctuates and is not

stable.

Description Possible Cause Remedy Remarks

Over Primary supply (input)

5 E11 error code displayed

voltage at primary capacitors is

exceeded for one second.

Under mains supply (input) voltage

warning primary capacitors is

reduced for one second.

6 E14 error code displayed

Under mains supply (input) voltage

primary capacitors is reduced for

one second.

7 E12 error code displayed

8 E81 error code displayed

Wrong Primary supply (input)

voltage connected.

Rated voltage selection circuit

abnormality.

9 E82 error code displayed

Page 52

No weld current is

available.

Buzzer sounds constantly.

Have an Accredited Thermal

Arc Service Agent check

connector plug on input PCB

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.

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.

Weld current ceases.

Buzzer sounds constantly.

Have an Accredited Thermal

Arc Service Agent check or

Switch machine off.

replace the temperature

Weld current ceases.

Buzzer sounds constantly.

Must switch machine off

then on to reset E99 error.

sensors

Turn on/off switch on.

Have an Accredited Thermal

Arc Service Agent or a

qualified electrician check the

Mains voltage and fuses.

The Primary supply (input)

voltage fluctuates and is not

stable.

Due to malfunction inside

the Welding Power Source,

primary capacitors are not

charging correctly.

Memory chip (EEPROM)

error.

The Welding Power

Source’s temperature

sensors have malfunctioned.

Main on/off switch on A

machine has been turned off

Mains supply (input)

voltage has been turned off.

Description Possible Cause Remedy Remarks

CPU checks mains supply (input)

10 E83 error code displayed

voltage when the on/off switch on

rear panel of machine is turned ON.

Pre-charge abnormality.

11 E85 error code displayed

12 E93 error code displayed

Memory chip (EEPROM) on

control PCB can not read/write

weld parameters.

E94 error code displayed

Temperature sensor TH1 for IGBTs

or sensor TH2 for secondary diodes

are open circuit.

E99 error code displayed

Mains supply (input) voltage has

been turned off but control circuit

has power from the primary

capacitors.

Page 53

1 U0A706100 10-6627

1 U0A705100 10-6634

1 U0A705200 10-6637

13.0 PARTS LIST

DWG. No. Description Type & Rating QTY. Code No. Order No.

C1 Capacitor ECQE12104MZ DC1250V 0.1uF 1 42422137100 10-2270

CC1 Coupling Coil F2A636900 185A CC 1 F2A636900 10-6626

CON1 Remote Socket 206433-1 8P

(with Wiring Assembly)

D1 Diode DFA50BA160 1 454160160 10-6628

D2 Diode DBA200UA60 1 4583A0060 10-6629

D4 Diode DBA200UA60 1 4583A0060 10-6629

D5 Diode DBA200UA60 1 4583A0060 10-6629

D10 Diode S2VB60 600V 1 444014023 10-6630

FAN1 Fan 109E5724H507 DC 24V 16.8W 1 U0A733500 10-6839

FCH1 Inductor F2A676800 185A AC/DC FCH 1 F2A676800 10-6631

HCT1 Current Sensor HC-TN200V4B15M 200A 4V 1 11251003000 10-5003

HF. Gap U0A601100 1 U0A601100 10-6633

HF.UNIT 1 HF. Unit HF.UNIT (WK-4840 U02) 1 U0A632200 10-6632

(with Insulation Sheet EBA501500)

with Thunder Label

L105 Inductor 1615MRE RING CORE 1 63200006500 10-6538

PCB1 Printed Circuit Board WK-4914 U04 MAIN_PCB

PCB2 Printed Circuit Board WK-4819 U01 DETECT PCB 1 P0A481901 10-6635

PCB3 Printed Circuit Board WK-4921 U02 CONNECT_PCB 1 P0A492102 10-6636

PCB4 Printed Circuit Board WK-4915 U04 2ND_DIODE

with Thunder Label

PCB5 Printed Circuit Board WK-4916 U02 2_IGBT_PCB 1 P0A491602 10-6638

PCB6 Printed Circuit Board WK-5157 U05 TIG CONTROL 1 P0A515705 10-6846

PCB7 Printed Circuit Board WK-4920 U10 AC TIG PANEL 1 P0A492010 10-6640

PCB8 Printed Circuit Board WK-4917 U06 FILTER_240V 1 P0A491706 10-6641

Page 54

1 U0A705300 10-6642

(with WK-5012 U01)

1 U0A705400 10-6643

(with WK-3367 U04)

1 40310211500 10-5081

2 40511000200 10-5137

ERF20HMJ151 20W 150 Ω

JG23V101J 68W 100 Ω

1 U0A705700 10-6645

(with Gas Inlet and PC4-02)

1 U0A733300 10-6784

C B=3950K

ERTA53D203 20K"/25

13.0 PARTS LIST Continued

DWG. No. Description Type & Rating QTY. Code No. Order No.

Q1 Transistor CM100DUS12F-1 600V 100A

Q2 Transistor GCA200CA60

R1 Resistor (For HF Unit)

R2 Resistor

S1 Swit ch DCP-52SR50C-480V 2P-480V 1 25850003500 10-6644

SOL1 Solenoid Valve 5505NBR1.5 DC24V 11VA/10W

T1 Transformer F2A708300 250A MTR 1 F2A708300 10-6646

T2 Transformer F2A708300 250A MTR 1 F2A708300 10-6646

T3 Transformer F2A758000 AC/DC DTR 1 F2A758000 10-6648

TH1,2 Thermistor

Front Panel E0D005300 1 E0D005300 10-6890

Rear Panel E0D005500 1 E0D005500 10-6891

Side Panel E0D006100 2 E0D006100 10-6650

Front Control Cover J4B493400 1 J4B493400 10-6651

Rear Control Cover JCA849400 (with Label) 1 U0A705500 10-6652

Protection Cover E0C303200 1 E0C303200 10-6653

Encoder Cover EBA514400 1 EBA514400 10-6654

PCB Cover E1B537600 (with Caution Label) 1 U0A705600 10-6655

Name Label N4A007600 2 N4A007600 10-6656

Side Label N4A009200 2 N4A009200 10-6657

Warning 1 Label N0B891300 1 N0B891300 10-5497

Warning 2 Label N0B476400 2 N0B476400 10-5496

Page 55

Output Terminal Label N4A040100 1 N4A040100 10-6658

Gas Outlet EBA077600 (with PC4-02) 1 U0A705800 10-6659

C-Ring 2 53003000600 10-5184

Output Terminal (female) TRAK-BE35-70S 2 26999025900 10-6660

Input Cable 132” 10/3 SOW BLK W/6-50P 1 52031130000 10-6844

Input Cable Clamp EBA045800 1 EBA045800 10-6662

Heatsink E1B538500 1 E1B538500 10-6663

Heatsink E1B538600 1 E1B538600 10-6664

Knob 2621603 1 50990001600 10-6665

Knob Cap 3021104 1 50990000300 10-6666

Control Cover Sheet N0B882200 1 N0B882200 10- 6667

Flat Cable EAA547301 1 EAA547301 10-6668

Post1(M4-M5) EBA424900 2 EBA424900 10-6669

Post4(M4-M4) EBA431100 3 EBA431100 10-6670

Post5(M4-M4) EBA431200 6 EBA431200 10-6671

Post6(M5-M5) EBA431300 1 EBA431300 10-6672

Post7(M5-M5) EBA435900 3 EBA435900 10-6673

Post8(M5-M5) EBA436000 3 EBA436000 10-6674

D2-4 Bus Bar EBA305600 2 EBA305600 10-6675

CC Bus Bar EBA306200 1 EBA306200 10-6676

S1 Bus Bar ECA321000 2 ECA321000 10-6677

Clip #74 NATURAL (Plastic Tab) 4 60602422000 10-5259

Transformer Chassis JCA903200 1 JCA903200 10-6678

Right Chassis J2C970700 1 J2C970700 10-6679

Left Chassis J2C970800 1 J2C970800 10- 6680

Nylon Hose T0425B Nylon Hose L=0.5m 1 U0A706000 10-6681

Output Terminal (male) TRAK-SK50 2 26999025800 10-2020

Operators Manual 1 430429-503

Service Manual 430429-512

13.0 PARTS LIST Continued

DWG. No. Description Type & Rating QTY. Code No. Order No.

Page 56

APPENDIX A – INTERCONNECT DIAGRAM

Page 57

Page 58

APPENDIX B - AUTOMATION

JUMPER SETTING FOR "OK–TO–MOVE". Models 185TSW

Three jumpers (JP1, JP2 and JP3) are provided on PC Board WK-4921 for automation purposes. This PCB is mounted horizontally on top of the unit just under the cover. This PCB can be accessed by removing the side covers by loosening 4 screws on each the front and rear panel, then removing the 4 side panel screws as well as the 2 handle screws. Carefully pull the front and rear panels outward to release and remove the side cover. Remove two plastic clips holding the PCB protective cover in place and lift the sheet up and over the unit. The jumpers will be accessible on the top portion of the PCB. See figure on next page for the location of the PCB. All units are shipped from the factory with the jumpers set in position "A". This is for normal semiautomatic operation utilizing a remote device, such as a foot control. The 8-pin remote operates as described earlier in this manual. Placing all jumpers in position "B" would be primarily used for automation with an arc establish relay, remote amperage and contactor. An arc-establish signal is located from pins 4 and 8 when in this mode. Placing jumpers JP1 and JP2 in "B" position and jumper JP3 in "A" position would have the configuration of an arc-establish signal and remote contactor, but the unit’s front panel would control the amperage.

JP1 A COM B

JP3

WK-4921

COM

•

Set All "A" position : factory shipping

JP2 A COM B

POSITION JP1 A JP2 A JP3 A

•

Use "OK TO MOVE signal"

POSITION JP1 B B JP2 B B JP3 B A A/V REMOTE PANEL

OK-TO-MOVE RELAY

CN6 CON1

4 4

CN6 CON1

4 4

CN6 CON1

4 4

8 8

Remote : Short 4 to 8 Panel : Open

Max Load: 24V 50ma.

OK TO MOVE RELAY

Page 59

Figure 11 – Location of PCB WK-4921