7
ARCMASTER® 175 S
Inverter Arc Welder
Operating
Manual
English
Português (Brasil)
A-08598_AB
Revision: AG Issue Date: November 20, 2014 Manual No.: 0-5054
Tweco.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on receiving your new Tweco product. We are proud to have you as our customer and
will strive to provide you with the best service and support in the industry. This product is backed by
our extensive warranty and world-wide service network.
We know you take pride in your work and we feel privileged to provide you with this high performance
product that will help you get the job done.
For more than 75 years Tweco has provided quality products you can trust, when your reputation is on
the line.
YOU ARE IN GOOD COMPANY!
Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish
ourselves from our competition through market-leading innovation and truly dependable products that
will stand the test of time.
We strive to enhance your productivity, efficiency and welding performance enabling you to excel in
your craft. We design products with the welder in mind delivering- advanced features, durability, ease
of use and ergonomic comfort.
Above all, we are committed to a safer working environment within the welding industry. Your
satisfaction with this product and its safe operation is our ultimate concern. Please take the time to
read the entire manual, especially the Safety Precautions.
If you have any questions or concerns regarding your new Tweco product, please contact our friendly
and knowledgeable Customer Service Team at:
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or visit us on the web at www.Tweco.com
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use.
Operating Manual Number 0-5054 for:
Arc Master 175 S Inverter Arc Welder Part No. W1002903
Published by:
Victor Technologies Europe
Europa Building
Chorley Industrial Park
Chorley, Lancaster,
England, PR6 7BX
www.victortechnologies.com
Copyright
Victor Technologies International, Inc.
®
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused
by any error or omission in this Manual, whether such error results from negligence, accident, or any other
cause.
Publication Date: March 20, 2008
Revision Date: November 20, 2014
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
©
2008, 2009, 2010, 2011, 2012, 2013 by
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 Principal Safety Standards .............................................................................. 1-4
1.03 Symbol Chart .................................................................................................. 1-5
1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6
1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6
1.06 Principales Normes De Securite ..................................................................... 1-9
1.07 Graphique de Symbole .................................................................................. 1-10
1.08 Declaration of Conformity ............................................................................. 1-11
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How to Use This Manual ................................................................................. 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt of Equipment ...................................................................................... 2-1
2.04 Description ..................................................................................................... 2-1
2.05 Transportation Methods .................................................................................. 2-1
2.06 Duty Cycle ....................................................................................................... 2-1
2.07 Specifications ................................................................................................. 2-2
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Electrical Input Connections ........................................................................... 3-1
3.04 Electromagnetic Compatibility ........................................................................ 3-2
3.05 Setup for Welding ........................................................................................... 3-4
3.06 Manual Arc (STICK) Setup .............................................................................. 3-5
3.07 Lift TIG (GTAW) Setup .................................................................................... 3-6
SECTION 4:
OPERATION .......................................................................................... 4-1
4.01 Front Panel ..................................................................................................... 4-1
4.02 SMAW Electrode Polarity ................................................................................ 4-2
4.03 Effects of Stick Welding Various Materials ...................................................... 4-2
4.04 GTAW Electrode Polarity ................................................................................. 4-3
4.05 Guide for Selecting Filler Wire ........................................................................ 4-3
4.06 Tungsten Electrode Current Ranges ............................................................... 4-3
4.07 Shielding Gas Selection .................................................................................. 4-3
4.08 Tungsten Electrode Types ............................................................................... 4-3
4.09 TIG Welding Parameters for Steel ................................................................... 4-3
4.10 Arc Welding Practice ....................................................................................... 4-4
4.11 Welding Position ............................................................................................. 4-4
4.12 Joint Preparations ........................................................................................... 4-5
4.13 Arc Welding Technique ................................................................................... 4-5
4.14 The Welder ...................................................................................................... 4-6
4.15 Striking the Arc ............................................................................................... 4-6
4.16 Arc Length ...................................................................................................... 4-6
4.17 Rate of Travel .................................................................................................. 4-6
TABLE OF CONTENTS
4.18 Making Welded Joints ..................................................................................... 4-6
4.19 Distortion ........................................................................................................ 4-8
4.20 The Cause of Distortion .................................................................................. 4-9
4.21 Overcoming Distortion Effects ........................................................................ 4-9
SECTION 5:
SERVICE .............................................................................................. 5-1
5.01 Routine Maintenance and Inspection .............................................................. 5-1
5.02 STICK Welding Problems ............................................................................... 5-2
5.03 TIG Welding Problems ................................................................................... 5-3
5.04 Power Source Problems ................................................................................. 5-4
5.05 Key Spare Parts .............................................................................................. 5-4
LIMITED WARRANTY & WARRANTY SCHEDULE .................................INSIDE REAR COVER
INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER
This Page Left Blank Intentionally
SAFETY INSTRUCTIONS ARC MASTER 175 S
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/
INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator
does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study
and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices
apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication
and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL
INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit
is electrically live whenever the output is on. The
input power circuit and machine internal circuits
are also live when power is on. In semiautomatic
or automatic wire welding, the wire, wire reel, drive
roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water
to cool it or lay it down on the ground or the work surface. Do
not touch holders connected to two welding machines at the
same time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced
cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace
damaged parts at once.
13. In confined spaces or damp locations, do not use a welder
with AC output unless it is equipped with a voltage reducer.
Use equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can
damage hearing. Arc rays from the welding process
produce intense heat and strong ultraviolet rays that
can burn eyes and skin. Noise from some processes
can damage hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face
and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
WARNING
FUMES AND GASES can be hazardous to your
health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
Manual 0-5054 1-1 SAFETY INSTRUCTIONS AND WARNINGS
ARC MASTER 175 S SAFETY INSTRUCTIONS
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can react
with vapours to form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from
the weld area, the area is well ventilated, and if necessary,
while wearing an air-supplied respirator. The coatings and any
metals containing these elements can give off toxic fumes if
welded.
WARNING
WELDING can cause fire or explosion.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable
material.
3. Remove all flammables within 35’ (10.7m) of the welding
arc. If this is not possible, tightly cover them with approved
covers.
4. Be alert that welding sparks and hot materials from welding
can easily go through small cracks and openings to adjacent
areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area
as practical to prevent welding current from travelling long,
possibly unknown paths and causing electric shock and fire
hazards.
9. Do not use welder to thaw frozen pipes.
Sparks and spatter fly off from the welding arc.
The flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, overheating,
or fire.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS/ANSI Z49.1:1999
Welding or Cutting
Operation
Torch Soldering All 2 Gas Tungsten Arc Welding
Torch Brazing All 3 or 4 Light Under 50 Amp 10
Oxygen Cutting Medium 50 to 150 Amp 12
Light Under 1” (25mm) 3 or 4 Heavy 150 to 500 Amp 14
Medium 1” – 6” (25mm – 150mm) 4 or 5 Atomic Hydrogen Welding All 12
Heavy Over 6” (150mm) 5 or 6 Carbon Arc Welding All 14
Gas Welding Carbon Arc Gouging
Light Under 1/8 “ (3mm) 4 or 5 Light 12
Medium 1/8” – 1/2” (3mm – 12mm) 5 or 6 Heavy 14
Heavy Over 1/2” (12mm) 6 or 8 Plasma Arc Welding
Shielded Metal-Arc Welding (Stick) Electrodes Light Under 20 Amp 6 to 8
Light Under 5/32” (4mm) 10 Light 20 to 100 Amp 10
Medium Under 5/32” - ¼” (4mm - 6.4mm) 12 Medium 100 to 400 Amp 12
Heavy Over ¼” (6.4mm) 14 Heavy 400 to 800 Amp 14
Gas Metal Arc Welding Plasma Arc Cutting
Light Under 60 Amp 7 Light Under 300 Amp 9
Light 60 to 160 Amp 11 Medium 300 to 400 Amp 12
Medium 160 to 250 Amp 12 Heavy 400 to 800 Amp 14
Heavy 250 to 500 Amp 14
Electrode Size Metal Thickness
or Welding Current
Filter
Shade
No.
Welding or Cutting
Operation
Electrode Size
Metal Thickness
or Welding Current
Filter
Shade
No.
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5054
SAFETY INSTRUCTIONS ARC MASTER 175 S
10. Remove stick electrode from holder or cut off welding wire
at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain
them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder
is in use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in
Safety Standards.
!
WARNING
Engines can be dangerous.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks
or open flames.
3. Allow engine to cool before fuelling. If possible, check and
add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and
hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from
moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
Manual 0-5054 1-3 SAFETY INSTRUCTIONS AND WARNINGS
STEAM AND PRESSURIZED HOT COOLANT can
burn face, eyes, and skin.
The coolant in the radiator can be very hot and
under pressure.
1. Do not remove radiator cap when engine is hot. Allow engine
to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
WARNING
ARC MASTER 175 S SAFETY INSTRUCTIONS
1.02 Principal Safety Standards
WARNING: This product contains chemicals,
including lead, known to the State of California to
cause birth defects and other reproductive harm.
Wash hands after handling.
Considerations About Welding And The Effects of
Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government
Printing Office, May 1989): “...there is now a very large volume of
scientific findings based on experiments at the cellular level and
from studies with animals and people which clearly establish that
low frequency magnetic fields interact with, and produce changes
in, biological systems. While most of this work is of very high
quality, the results are complex. Current scientific understanding
does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us
to draw definite conclusions about questions of possible risk or
to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
!
LEAD WARNING
NOTE
Safety in Welding and Cutting, ANSI Standard Z49.1, from
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126.
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding
and Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face
Protection, ANSI Standard Z87.1, from American National
Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5054
SAFETY INSTRUCTIONS ARC MASTER 175 S
1.03 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
Hertz (cycles/sec)
Frequency
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
t2
Preflow Time
Postflow Time
2 Step Trigger
Operation
t1
Press to initiate wirefeed and
welding, release to stop.
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
115V 15A
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.
Receptacle RatingAuxiliary Power
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
V
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
IPM
MPM
S
S
4 Step Trigger
Operation
Burnback Time
Inches Per Minute
Meters Per Minute
See Note
See Note
Art # A-04130_AB
Manual 0-5054 1-5 SAFETY INSTRUCTIONS AND WARNINGS
ARC MASTER 175 S SAFETY INSTRUCTIONS
1.04 Precautions De Securite En Soudage A L’arc
!
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAIS-
SEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT
CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS
AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel
et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage
et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors
que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires
à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de
ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET
D’ESSAI.
1.05 Dangers relatifs au soudage à l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler
gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le
circuit d’alimentation et les circuits internes de
l’équipement sont aussi sous tension dès la mise
en marche. En soudage automatique ou semiautomatique avec fil, ce dernier, le rouleau ou la
bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le
fil de soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à
la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre au
moyen de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez
le moteur avant de l’installer ou d’en faire l’entretien. Bloquez
le commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon
le manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.
6. Arrêtez tout équipement après usage. Coupez l’alimentation
de l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais
plonger les porte-électrodes dans l’eau pour les refroidir.
Ne jamais les laisser traîner par terre ou sur les pièces à
souder. Ne touchez pas aux porte-électrodes raccordés à
MISE EN GARDE
deux sources de courant en même temps. Ne jamais toucher
quelqu’un d’autre avec l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre
de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit
de soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou
remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de
source de courant alternatif, à moins qu’il soit muni d’un
réducteur de tension. Utilisez plutôt une source de courant
continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES
YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER
L’OUIE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux
et la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après)
pour vous protéger le visage et les yeux lorsque vous soudez
ou que vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans
latéraux sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour
protéger les autres des coups d’arc ou de l’éblouissement;
avertissez les observateurs de ne pas regarder l’arc.
SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5054
SAFETY INSTRUCTIONS ARC MASTER 175 S
4. Portez des vêtements en matériaux ignifuges et durables
(laine et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien
ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consummables, aux
revêtements et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et
ainsi causer des malaises ou la mort. Assurez-vous que l’air
est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou
au cadmium que si les zones à souder ont été grattées à
fond, que si l’espace est bien ventilé; si nécessaire portez
un respirateur à adduction d’air. Car ces revêtements et tout
métal qui contient ces éléments peuvent dégager des fumées
toxiques au moment du soudage.
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE OU
UNE EXPLOSION
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections
de soudure et l’équipement surchauffé peuvent
causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un
objet métallique peut provoquer des étincelles, un
échauffement ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et
du métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes
ou des projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10,
7 mètres autour de l’arc, ou couvrez-les soigneusement avec
des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites
ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée
de la main.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Opération de
coupage ou soudage
Brassage tendre au
chalumeau
Brassage fort au
chalumeau
Oxycoupage métaux ferreux toutes conditions 12
mince moins de 1 po. (25 mm) 2 ou 3
moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5
épais plus de 6 po. (150 mm) 5 ou 6
Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12
mince moins de 1/8 po. (3 mm) 4 ou 5
moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12
épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14
Soudage á l'arc avec electrode enrobees (SMAW)
Dimension d'électrode
ou Epiasseur de métal
ou Intensité de courant
toutes conditions 2
toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11
moins de 5/32 po. (4 mm) 10
5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9
plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12
Nuance
de filtre
oculaire
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Gougeage Air-Arc avec
électrode de carbone
Coupage á l'arc Plasma (PAC)
épais plus de 400 amperès 14
Dimension d'électrode
ou Epiasseur de métal
ou Intensité de courant
toutes conditions 12
toutes conditions 12
toutes conditions 12
Nuance
de filtre
oculaire
Manual 0-5054 1-7 SAFETY INSTRUCTIONS AND WARNINGS
ARC MASTER 175 S SAFETY INSTRUCTIONS
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l’autre
côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la
zone de soudage pour empêcher le courant de suivre un long
parcours inconnu, et prévenir ainsi les risques d’électrocution
et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tubecontact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants
en cuir, une chemise épaisse, un pantalon revers, des bottines
de sécurité et un casque.
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEU-
VENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et
bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur,
loin des prises d’air du bâtiment.
AVERTISSEMENT
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure
peut projeter du éclats de laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles endommagées
peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les
avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources
de chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un
cadre fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout
soudage.
4. Empêchez tout contact entre une bouteille et une électrode
de soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes
doivent être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la
bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation
ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de
gaz comprimé et aux équipements connexes, ainsi que la
publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU
UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau e
carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source
d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire
le plein de carburant ou d’en vérifier le niveau au début du
soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez
tout carburant renversé avant de faire démarrer le moteur.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER
DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs,
des rotors et des courroies peuvent couper doigts
et mains, ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le
moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage
nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements
amples et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes
après des travaux d’entretien et avant de faire démarrer le
moteur.
SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5054
SAFETY INSTRUCTIONS ARC MASTER 175 S
À la lumière des connaissances scientifiques actuelles, il nous est
encore impossible d’interpréter les évidences en un seul cadre de
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte acide
et dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un accumulateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des
câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut
être brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est
pas refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour
l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
référence cohérent. La situation est toutefois très contrariante.
En effet, il nous est aussi impossible de tirer des conclusions
définitives quant aux risques éventuels ou de proposer des
stratégies fondées sur des faits scientifiques visant à atténuer
ou éviter des risques potentiels ».
Pour atténuer les champs magnétiques sur les lieux de travail,
respectez les procédures qui suivent :
1. Maintenez les câbles l’un près de l’autre en les
entrelaçant ou les reliant ensemble au ruban.
2. Acheminez les câbles à un côté du soudeur, le plus loin
possible.
3. N’enroulez pas de câble autour du corps.
4. Maintenez le bloc d’alimentation du poste de soudage
et les câbles aussi loin que possible du corps.
STIMULATEURS CARDIAQUES :
Les procédures décrites ci-dessus sont
habituellement celles recommandées pour les
porteurs de stimulateurs cardiaques. Pour de plus
amples renseignements, consulter un médecin.
1.06 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding
and Cutting of Containers That Have Held Hazardous Substances,
norme AWS F4.1, American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
!
PLOMB AVERTISSEMENT
AVERTISSEMENT : Ce produit contient des produits
chimiques, notamment du plomb, reconnu par
l’État de la Californie pour causer des malformations congénitales et d’autres dommages touchant
le système reproductif.
Se laver les mains après
manipulation.
REMARQUE
Facteurs relatifs au soudage et aux effets des
champs magnétiques et électriques de basse
fréquence
Voici une citation tirée du chapitre des conclusions générales du
document de base de l’Office of Technology Assessment (bureau
des évaluations technologiques) de l’U.S. Congress, « Biological
Effects of Power Frequency Electric & Magnetic Fields », OTABP-E-63 (Washington, DC : U.S. Government Printing Office, mai
1989) : « ... il existe de nos jours, un nombre très élevé de travaux
scientifiques qui rapportent les résultats d’expériences menées
au niveau cellulaire et d’études auprès d’homme et d’animaux qui
établissent nettement le rapport entre les champs magnétiques
de basse fréquence et les systèmes biologiques, soit par des
interactions ou des modifications. Quoique la plupart de ces
travaux soient de très bonne qualité, les résultats sont complexes.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2
Association canadienne de normalisation, Standards Sales, 276
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face
Protection, norme ANSI Z87.1, American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Manual 0-5054 1-9 SAFETY INSTRUCTIONS AND WARNINGS
ARC MASTER 175 S SAFETY INSTRUCTIONS
1.07 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
SousTension
Hors Tension
Tension dangereuse
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Fusible
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
Courant Continue (DC)
X
%
Mono Phasé
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur
Transformateur-Redresseur
Distant
Facteur de Marche
Pourcentage
Panneau/Local
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Decoupe Arc Carbone
(CAC-A)
Courant Constant
Tension Constante
Ou Potentiel Constant
Haute Température
Déroulement du Fil
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Torch de Soudage
Purge Du Gaz
Mode Continu de
Soudure
Soudure Par Point
Duréc du Pulse
t
t1
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
Durée de Pré-Dèbit
Durée de Post-Dèbit
t2
Détente à 2-Temps
Détente à 4-Temps
Probléme de Terre
t
Terre de Protection
Ligne
Connexion de la Ligne
Source Auxiliaire
115V 15A
Note: Pour les environnements avec des risques de choc électrique, le fournisseur d'énergie portant la marque conforme
à EN50192 lorsqu'utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à
l'hauteur de buse correctement installé.
Ne pas déposer avec les déchets ménagers.
Classement de PriseSource Auxiliaire
Force d'Arc
Amorçage de L’arc au
Contact (GTAW)
Inductance Variable
Tension
V
IPM
MPM
S
Pouces Par Minute
Mètres Par Minute
Voir Note
Voir Note
Art # A-07639_AB
S
SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5054
SAFETY INSTRUCTIONS ARC MASTER 175 S
1.08 Declaration of Conformity
Declaration of Conformity
We Victor Technologies International Inc.
of 16052 Swingley Ridge Road
Suite 300
Chestereld, MO 63033 U.S.A.
in accordance with the following Directive(s):
•2006/95/EC The Low Voltage Directive
•2004/108/EC The Electromagnetic Compatibility (EMC) Directive
hereby declare that:
Equipment: Welding Power Source
Model Name/Number: Arc Master 175S
Market Release Date: January 16, 2014
is in conformity with the applicable requirements of the following harmonized standards:
•EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC)
requirements
•EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
Classification: The equipment described in this document is Class A and intended for industrial use.
Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
Address:Victor Technologies International Inc.
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Date: November 20, 2014
Steve Ward
V.P. Europe and General Manager
(Signature)
(Full Name)
(Position)
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those
locations, due to conducted as well as radiated disturbances.
Manual 0-5054 1-11 SAFETY INSTRUCTIONS AND WARNINGS
ARC MASTER 175 S SAFETY INSTRUCTIONS
Classification: The equipment described in this manual is Class A and intended for industrial use.
!
Warning
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those
locations, due to conducted as well as radiated disturbances.
SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5054
INTRODUCTION ARC MASTER 175 S
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual
This Operating Manual applies the part numbers listed on
page i. If none are underlined, they are all covered by this
manual. To ensure safe operation, read the entire manual,
including the chapter on safety instructions and warnings.
Throughout this manual, the word WARNING, CAUTION
and NOTE may appear. Pay particular attention to the
information provided under these headings. These special
annotations are easily recognized as follows:
!
WARNING
Gives information regarding possible personal
injury.
CAUTION
Refers to possible equipment damage. Cautions will be shown in bold type.
NOTE
Offers helpful information concerning certain
operating procedures. Notes will be shown
in italics.
2.04 Description
This compact inverter welding machine has infinitely adjustable welding current from 5 to 175 amps. It runs standard
general purpose SMAW 3/32” (2.5mm) electrodes for light
gauge work, generally less than 1/8” (3.2mm) thick, and
SMAW 1/8” (3.2mm) electrodes for heavier material. The
unit also has a Lift TIG (GTAW) welding mode that offers
stable TIG welding characteristics when used with a suitable
TIG torch and shielding gas.
2.05 Transportation Methods
CAUTION
ELECTRIC SHOCK can kill. DO NOT TOUCH
live electric parts. Disconnect input power conductors from de-energized supply line before
moving the welding power source.
!
WARNING
FALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
nameplate attached to the machine. Equipment which does
not have a nameplate attached to the machine is identified
only by the specification or part number printed on the shipping container. Record these numbers for future reference.
2.03 Receipt of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there is
any damage, notify the carrier immediately to file a claim.
Furnish complete information concerning damage claims
or shipping errors to the location in your area listed in the
inside back cover of this manual. Include all equipment
identification numbers as described above along with a full
description of the parts in error.
Lift unit with handle on top of case. Use handcart or similar
device of adequate capacity. If using a fork lift vehicle, place
secure unit on a proper skid before transporting.
2.06 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding
current output without exceeding the temperature limits of
the insulation of the component parts. To explain the 10
minute duty cycle period the following example is used.
Suppose a Welding Power Source is designed to operate at
a 20% duty cycle, 175 amperes at 27 volts. This means that
it has been designed and built to provide the rated amperage
(175A) for 2 minutes, i.e. arc welding time, out of every 10
minute period (20% of 10 minutes is 2 minutes). During
the other 8 minutes of the 10 minute period the Welding
Power Source must idle and allowed to cool.
Manual 0-5054 2-1 iNTRODUCTION
ARC MASTER 175 S INTRODUCTION
2.07 Specifications
Power Source Part Number W1003202
Welding Output
Welding current range 5 - 175 Amps
Nominal DC Open Circuit Voltage (OCV) 65
Welding output, 40ºC, 10 min. (quoted figures refer to
SMAW output)
Rated input current (A) for STICK Welding
Rated input current (A) for TIG Welding
Rated output for STICK Welding 175A @ 20%, 27V
Rated output for TIG Welding 175A @ 20%, 17V
Duty cycle (%) 175 @ 20%
Welder type Inverter Power Source
Output Terminal Type 35/50mm Dinse™
Mains Power
Number of Phases Single Phase
Nominal Supply Voltage AC 230 ±15%
Nominal supply frequency 50/60 Hz
Effective Input Current (l1eff) 17 Amps
Maximum Input Current (l1 max) ∆ 40 Amps
Single Phase Genorator Requirements 10 KVA
Classification
Protection Class IP23S
Standard(s) EN 60974-1
Cooling Method Fan Cooled
Dimensions and Weight
Welding power source mass 14.33lb (6.5kg)
Dimension power source (DxWxH)
(H 330mm x W 130mm x D 230mm)
175A @ 20%, 27.0V
110A @ 60%, 24.4V
80A @ 100%, 23.2V
40A
Iο = 175A @ 27V
25A
Iο = 175A @ 17V
EN50199
H 13.0" x W5.1" x D 9.0"
∆ Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your
situation in this regard.
NOTE
Tweco continuously strives to produce the best product possible and therefore reserves the right to change,
improve or revise the specifications or design of this or any product without prior notice. Such updates or
changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes,
updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment may
differ from the above specifications due to in part, but not exclusively, to any one or more of the following;
variations or changes in manufactured components, installation location and conditions and local power
grid supply conditions.
iNTRODUCTION 2-2 Manual 0-5054
INSTALLATION ARC MASTER 175 S
SECTION 3:
INSTALLATION
3.01 Environment
These units are designed for use in environments with
increased hazard of electric shock. Examples of environments with increased hazard of electric shock are:
A. In locations in which freedom of movement is
restricted, so that the operator is forced to perform
the work in a cramped (kneeling, sitting or lying)
position with physical contact with conductive
parts.
B. In locations which are fully or partially limited by
conductive elements, and in which there is a high
risk of unavoidable or accidental contact by the
operator.
C. In wet or damp hot locations where humidity
or perspiration considerably reduces the skin
resistance of the human body and the insulation
properties of accessories.
Environments with increased hazard of electric shock
do not include places where electrically conductive
parts in the near vicinity of the operator, which can
cause increased hazard, have been insulated.
3.02 Location
Be sure to locate the welder according to the following guidelines:
• Inareas,freefrommoistureanddust.
• Ambient temperature between 32°F to 104°F
(0°Cto40°C).
• In areas, free from oil, steam and corrosive
gases.
• Inareas,notsubjectedtoabnormalvibrationor
shock.
3.03 Electrical Input Connections
!
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT
DC VOLTAGE is present after removal of
input power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input
power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
• Electrical Input Requirements
Operate the welding power source from a single-phase
50/60 Hz, AC power supply. The input voltage must
match one of the electrical input voltages shown on
the input data label on the unit nameplate. Contact the
local electric utility for information about the type of
electrical service available, how proper connections
should be made, and inspection required. The line
disconnect switch provides a safe and convenient
means to completely remove all electrical power
from the welding power supply whenever necessary
to inspect or service the unit.
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.
• In areas,notexposedtodirectsunlightor
rain.
• Place at a distance of 12” (300mm) or more
from walls or similar that could restrict natural
air flow for cooling
!
WARNING
Tweco advises that this equipment be electrically connected by a qualified electrician.
Manual 0-5054 3-1 INSTALLATION
Refer to Figure 1:
1. Connect end of ground (GREEN or GREEN/YELLOW)
conductor to a suitable ground. Use a grounding
method that complies with all applicable electrical
codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE)
input conductors to a de-energized line disconnect
switch.
3. Use Table 3-1 as a guide to select line fuses for the
disconnect switch
ARC MASTER 175 S INSTALLATION
Input Voltage Fuse Size
230V 40 Amps
Table 3-1: Electrical Connections
.
Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on
Article 630, National Electrical Code).
Welding Power Supply
Ground Conductor
Ground Terminal
Line Disconnect Switch
Line Fuse
Primary Power Cable
Art #: A-08462_AB
Input Power
Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides
pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the input capacitors
have charged to operating voltage (after approximately 5 seconds)
Figure 3-1: Electrical Input Connections
NOTE
Damage to the PCA could occur if 265 VAC or higher is applied to the Primary Power Cable.
Model
Arc Master 175 S 13 AWG (1.5mm² ) 230V/25A 175A@20% -
Primary Supply Lead Size
(Factory Fitted)
Table 3-2: Primary Supply Lead
Minimum Primary
Current Circuit Size
(Vin/Amps)
230V/40A - 175A@20%
Current & Duty Cycle
TIG STICK
3.04 Electromagnetic Compatibility
!
WARNING
Extra precautions for Electromagnetic Compatibility may be required when this Welding Power
Source is used in a domestic situation.
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.
If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to
resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as
INSTALLATION 3-2 Manual 0-5054
INSTALLATION ARC MASTER 175 S
simple as earthing the welding circuit, see NOTE below. In
other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the
work, complete with associated input filters. In all cases,
electromagnetic disturbances shall be reduced to the point
where they are no longer Trouble-some.
NOTE
For 230 VAC operation, have a qualified
person install according to applicable
codes, and instructions.
B. Assessment of Area
Before installing welding equipment, the user shall make
an assessment of potential electromagnetic problems in
the surrounding area. The following shall be taken into
account.
1. Other supply cables, control cables, signalling and
telephone cables; above, below and adjacent to the
welding equipment.
2. Radio and television transmitters and receivers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of industrial
equipment.
5. The health of people around, e.g. the use of pacemakers and hearing aids.
6. Equipment used for calibration and measurement.
7. The time of day that welding or other activities are to
be carried out.
8. The immunity of other equipment in the environment:
the user shall ensure that other equipment being used
in the environment is compatible: this may require
additional protection measures.
The size of the surrounding area to be considered will
depend on the structure of the building and other activities
that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
and properly fastened when the welding equipment is
in operation. The welding equipment should not be
modified in any way except for those changes and adjustments covered in the manufacturer’s instructions. In
particular, the spark gaps of arc striking and stabilizing
devices should be adjusted and maintained according
to the manufacturer’s recommendation
3. Welding Cables
The welding cables should be kept as short as possible
and should be positioned close together, running at or
close to the floor level.
4. Equipotential Bonding
Bonding of all metallic components in the welding
installation and adjacent to it should be considered.
However, metallic components bonded to the work
piece will increase the risk that the operator could receive a shock by touching the metallic components and
the electrode at the same time. The operator should be
insulated from all such bonded metallic components.
5. Earthing of the Work Piece
Where the work piece is not bonded to earth for electri-
cal safety, nor connected to earth because of its size
and position, e.g. ship’s hull or building steelwork, a
connection bonding the work piece to earth may reduce
emissions in some, but not all instances. Care should
be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other
electrical equipment. Where necessary, the connection
of the work piece to earth should be made by direct
connection to the work piece, but in some countries
where direct connection is not permitted, the bonding
should be achieved by suit-able capacitance, selected
according to national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables and
equipment in the surrounding area may alleviate
problems of interference. Screening the entire welding
installation may be considered for special applications.
C. Methods of Reducing Electromagnetic
Emissions
1. Mains Supply
Welding equipment should be connected to the mains
supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary
to take additional precautions such as filtering of
the mains supply. Consideration should be given to
shielding the supply cable of permanently installed
welding equipment in metallic conduit or equivalent.
Shielding should be electrically continuous throughout
its length. The shielding should be connected to the
Welding Power Source so that good electrical contact
is maintained between the conduit and the Welding
Power Source enclosure.
2. Maintenance of Welding Equipment
The welding equipment should be routinely maintained
according to the manufacturer’s recommendations. All
access and service doors and covers should be closed
Manual 0-5054 3-3 INSTALLATION
ARC MASTER 175 S INSTALLATION
3.05 Setup for Welding
NOTE
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work
lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided
by the design ensure that the Welding Power Source will withstand short-term overload without
adverse effects. The welding current range values should be used as a guide only. Current delivered
to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding current at any one setting would vary according to the type
of electrode in use. The operator should use the welding current range values as a guide then fine
tune the welding current to suit the application.
!
WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode holder
make sure the Primary power supply is switched off.
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
INSTALLATION 3-4 Manual 0-5054
INSTALLATION ARC MASTER 175 S
3.06 Manual Arc (STICK) Setup
Set Welding Current
as Specified by the
Electrode Manufacturer
Set Process Selection
Switch to Manual Arc
Positive Output Terminal
(Dinse™ 50)
Negative Output Terminal
(Dinse™ 50)
Figure 3-2: Setup for Manual Arc (STICK) Welding
Manual Arc Sequence of Operation
1. Switch the ON/OFF Switch (located on the rear panel)
to OFF.
2. Connect the earth clamp lead to the Negative Output
Terminal and electrode holder lead to the Positive
Output Terminal. Consult the electrode manufacture's
packaging for the correct electrode polarity.
3. Plug the Power Source in and switch the power switch
ON.
4. Set the Process Switch to Manual Arc.
5. Set the Weld Current control to the desired welding
current.
Art #: A-08469_AC
6. Switch the ON/OFF Switch (located on the rear panel)
to the ON position. This will immediately energize the
power supply up to the output terminals and the electrode holder.
7. Commence welding. If necessary, readjust the Weld
Current control to obtain the welding condition required.
8. After completion of welding the Power Source should
be left turned ON for 2 to 3 minutes. This allows the
fan to run and cool the internal components.
9. Switch the ON/OFF Switch (located on the rear panel)
to the OFF position.
Manual 0-5054 3-5 INSTALLATION
ARC MASTER 175 S INSTALLATION
3.07 Lift TIG (GTAW) Setup
Set Process Selection
Switch to LIFT TIG
Secure the gas cylinder in an
upright position by chaining them
to a stationary support to prevent
falling or tipping
Negative Output Terminal
(Dinse™ 50)
Set Welding Current
as Specified by the
Electrode Manufacturer
Figure 3-3: Setup for Lift TIG (GTAW) Welding
Lift TIG Sequence of Operation
1. Switch the ON/OFF Switch (located on the rear panel)
to OFF.
2. Connect the earth clamp to the Positive Output Terminal,
torch cable to the Negative Output Terminal and gas
hose to the output of an Argon regulator.
3. Plug the Power Source in and switch the power switch
ON.
4. Set the Process Selection Switch to Lift TIG.
5. Set the Weld Current control to the desired welding
current.
6. Switch the ON/OFF Switch to the ON position.
Positive Output Terminal
(Dinse™ 50)
Art #: A-08470_AB
7. Commence welding. If necessary, readjust the Weld
Current control to obtain the welding condition required.
8. After completion of welding the Power Source should
be left turned ON for 2 to 3 minutes. This allows the
fan to run and cool the internal components.
9. Switch the ON/OFF Switch (located on the rear panel)
to the OFF.
INSTALLATION 3-6 Manual 0-5054
OPERATION ARC MASTER 175 S
(C) Over Heat
SECTION 4:
OPERATION
Conventional operating procedures apply when using the
Welding Power Source, i.e. connect work lead directly to
work piece and electrode lead is used to hold the electrode.
The welding current range values should be used as a guide
only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between
different classes of electrode, welding current at any one
setting would vary according to the type of electrode in use.
The operator should use the welding current range values
as a guide then fine tune the welding current to suit the
specific application. Refer to the electrode manufacture's
literature for further information.
4.01 Front Panel
Front Panel
The welding power source is protected by a self re-setting
thermostat. The indicator will illuminate if the duty cycle
of the power source has been exceeded. If the Over Heat
light illuminates wait for the Over Heat light to extinguish
before resuming welding.
(A) Process Selection Switch
Switches between Lift TIG and Manual Arc (STICK) Welding modes.
(B) Power On Indicator
The Power ON Indicator illuminates when the ON/OFF
switch is in the ON position and the nominal mains voltage is present.
(C) Over Heat Indicator
The welding power source is protected by a self resetting
thermostat. The indicator will illuminate if the duty cycle
of the power source has been exceeded. If the Over Heat
light illuminates wait for the Over Heat light to extinguish
before resuming welding.
(D) Welding Current Control
The welding current is increased by turning the Weld Current control knob clockwise or decreased by turning the
Weld Current control knob anti-clockwise. The welding
current should be set according to the specific application.
Refer to the electrode manufacture's literature for further
information.
(E) ON/OFF Switch (located on rear panel (not shown)
This switch controls the Mains Supply Voltage to the Power
Source.
(B) Power On
Indicator
(A) Process
Selection
Switch
Indicator
(D) Welding
Current
Control
Art #: A-08478_AB
Figure 4-1: 175 S Control Panel
Manual 0-5054 4-1 OPERATION
ARC MASTER 175 S OPERATION
4.02 SMAW Electrode Polarity
Stick electrodes are generally connected to the "+"
Positive Output Terminal and the work lead to the
"−" Negative Output Terminal but if in doubt consult
the electrode manufacturer's literature for further
information.
4.03 Effects of Stick Welding Various Materials
High Tensile and Alloy Steels
The two most prominent effects of welding these
steels are the formation of a hardened zone in the
weld area, and, if suitable precautions are not taken,
the occurrence in this zone of under-bead cracks.
Hardened zone and under-bead cracks in the weld
area may be reduced by using the correct electrodes,
preheating, using higher current settings, using larger
electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.
Manganese Steels
The effect on manganese steel of slow cooling from
high temperatures is to embrittle it. For this reason it
is absolutely essential to keep manganese steel cool
during welding by quenching after each weld or skip
welding to distribute the heat.
Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld
it. Trouble may also be experienced when welding
white-heart malleable, due to the porosity caused by
gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat
conductivity of copper, making pre-heating of heavy
sections necessary to give proper fusion of weld and
base metal.
Types of Electrodes
Arc Welding electrodes are classified into a number
of groups depending on their applications. There are
a great number of electrodes used for specialized
industrial purposes which are not of particular interest
for everyday general work. These include some low
hydrogen types for high tensile steel, cellulose types
for welding large diameter pipes, etc. The range of
electrodes dealt with in this publication will cover the
vast majority of applications likely to be encountered
and are all easy to use.
Metal Being Joined Electrode Comments
Mild Steel E6013
Mild Steel E7014 All positional electrode for use on mild and
Cast Iron 99% Nickel Suitable for joining all cast irons except white
Stainless Steel E318L-16 High corrosion resistance. Ideal for dairy work
Copper, Bronze, Brass, Etc. Bronze
5.7 ERCUSI-A
High Alloy Steel, Dissimilar
Metals, Crack Resistance, All
Hard-To Weld jobs
E312-16
Ideal electrodes for all general purpose work,
features include outstanding operator appeal,
easy arc starting, and low spatter.
galvanized steel furniture, plates, fences, gates,
pipes and tanks, etc. Especially suitable for
vertical-down welding.
cast iron.
etc.
Easy to use electrode for marine fittings, water
taps and valves, water through floats arms, etc.
Also for joining copper to steel and for bronze
overlays on steel shafts.
It will weld most problematic job such as springs,
shafts, broken joins, mild steel to stainless and
alloy steels. Not suitable for aluminium.
OPERATION 4-2 Manual 0-5054
OPERATION ARC MASTER 175 S
4.04 GTAW Electrode Polarity
Connect the TIG torch to the "-" Negative Output
Terminal and the work lead to the "+" Positive Output
Terminal for direct current straight polarity. Direct
current straight polarity is the most widely used
polarity for DC TIG welding. It allows limited wear of
the electrode since 70% of the heat is concentrated
at the work piece.
4.05 Guide for Selecting Filler Wire
Electrode Diameter DC Current
.040” (1.0mm) 30 - 60
1/16” (1.6mm) 60 - 115
3/32” (2.4mm) 100 - 165
1/8” (3.2mm) 135 - 175
4.08 Tungsten Electrode Types
4.06 Tungsten Electrode Current Ranges
Electrode Diameter DC Current
.040” (1.0mm) 25 - 85
1/16” (1.6mm) 50 - 160
4.07 Shielding Gas Selection
Alloy Shielding Gas
Carbon Steel Welding Argon
Stainless Steel Welding Argon
Nickel Alloy Welding Argon
Copper Welding Argon
Titanium Welding Argon
Electrode Type
(Ground Finish) Welding Application Features Colour Code
Thoriated 2% DC welding of mild steel, stainless
steel and copper.
Ceriated 2% AC & DC welding of mild steel,
stainless steel, copper aluminium
magnesium and their alloys.
4.09 TIG Welding Parameters for Steel
DC Current
Base Metal
Thickness
(3.2mm) 90-115 90-110 (2.4mm) (7 LPM) Lap/ Fillet
4.8mm 140-165 125-150 (3.2mm) (10 LPM) Lap/ Fillet
¼” 160-175 135-160 1/8” 5/32” 21 CFH Butt/Corner
(6.4mm) 170-200 160-180 (3.2mm) (4.0mm) (10 LPM
Excellent arc starting, long life,
high current carrying capacity.
Longer life, more stable arc,
easier starting, wilder current
range, narrower more concentrated arc.
Electrode
Diameter
0.040”
(1.0mm)
0.040”
(1.0mm)
1/16”
(1.6mm)
1/16”
(1.6mm)
3/32”
(2.4mm)
Filler Rod
Diameter
Argon Gas
Flow Rate
) Lap/ Fillet
Red
Grey
Joint
epyTleetS sselniatSleetS dliM
renroC/ttuBHFC 01”61/103-0254-53”040.0
telliF /paL)MPL 5()mm6.1(53-5205-04)mm0.1(
renroC/ttuBHFC 31”61/154-0355-54”540.0
telliF /paL)MPL 6()mm6.1(05-5306-05)mm2.1(
renroC/ttuBHFC 51”61/106-0407-06”61/1
telliF /paL)MPL 7()mm6.1(07-0509-07)mm6.1(
renroC/ttuBHFC 51”23/358-56001-08”8/1
renroC/ttuBHFC 12”8/1521-001531-511”61/3
Manual 0-5054 4-3 OPERATION
ARC MASTER 175 S OPERATION
4.10 Arc Welding Practice
The techniques used for arc welding are almost identical regardless of what types of metals are being joined.
Naturally enough, different types of electrodes would be used for different metals as described in the preceding
section.
4.11 Welding Position
The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in
flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions
intermediate between these. Some of the common types of welds are shown in Figures 4-2 through 4-9.
Art # A-07687
Figure 4-2: Flat position, down hand butt weld
Art A-07691
Art # A-07688
Figure 4-3: Flat position, gravity fillet weld
Art # A-07689
Figure 4-4: Horizontal position, butt weld
Figure 4-6: Vertical position, butt weld
Art # A-07692
Figure 4-7: Vertical position, fillet weld
Art# A-07693
Figure 4-8: Overhead position, butt weld
Art # A-07690
Figure 4-5: Horizontal - Vertical (HV) position
Art # A-07694
Figure 4-9: Overhead position, fillet weld
OPERATION 4-4 Manual 0-5054
OPERATION ARC MASTER 175 S
Open Square Butt
Single Vee Butt Joint
Not less than
4.12 Joint Preparations
In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections
and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being
joined to ensure proper penetration of the weld metal and to produce sound joints.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be
removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-10.
Joint
Gap varies from
1.6mm (1/16”) to 4.8mm (3/16”)
depending on plate thickness
Single Vee Butt Joint
Lap Joint
Fillet Joint
Corner Weld
Not less than
45°
Double Vee Butt Joint
(Fillet both sides of the
Tee Joints
joint)
Edge Joint
1.6mm (1/16”)
1.6mm (1/16”)
70°
Not less than
70°
1.6mm (1/16” ) max
1.6mm (1/16”) max
Plug Weld Plug Weld
Art # A-07695_AE
Figure 4-10: Typical joint designs for arc welding
4.13 Arc Welding Technique
A Word to Beginners
For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of
scrap plate. Use mild steel plate about 1/4" (6.0mm) thick and a 1/8" (3.2mm) electrode. Clean any paint, loose
scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the down
hand position. Make sure that the work clamp is making good electrical contact with the work, either directly
or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise
a poor circuit will probably result.
Manual 0-5054 4-5 OPERATION
ARC MASTER 175 S OPERATION
20°
4.14 The Welder
Place yourself in a comfortable position before
beginning to weld. Get a seat of suitable height and
do as much work as possible sitting down. Don’t
hold your body tense. A taut attitude of mind and a
tensed body will soon make you feel tired. Relax and
you will find that the job becomes much easier. You
can add much to your peace of mind by wearing a
leather apron and gauntlets. You won’t be worrying
then about being burnt or sparks setting alight to
your clothes.
Place the work so that the direction of welding is
across, rather than to or from, your body. The electrode
holder lead should be clear of any obstruction so that
you can move your arm freely along as the electrode
burns down. If the lead is slung over your shoulder,
it allows greater freedom of movement and takes a
lot of weight off your hand. Be sure the insulation on
your cable and electrode holder is not faulty, otherwise
you are risking an electric shock.
4.15 Striking the Arc
Practice this on a piece of scrap plate before going on
to more exacting work. You may at first experience
difficulty due to the tip of the electrode “sticking” to
the work piece. This is caused by making too heavy
a contact with the work and failing to withdraw
the electrode quickly enough. A low amperage will
accentuate it. This freezing-on of the tip may be
overcome by scratching the electrode along the plate
surface in the same way as a match is struck. As soon
as the arc is established, maintain a 1/16" (1.6mm)
to 1/8" (3.2mm) gap between the burning electrode
end and the parent metal. Draw the electrode slowly
along as it melts down.
Another difficulty you may meet is the tendency, after
the arc is struck, to withdraw the electrode so far
that the arc is broken again. A little practice will soon
remedy both of these faults.
Art # A-07696_AB
1.6 mm (1/16”)
4.16 Arc Length
The securing of an arc length necessary to produce a
neat weld soon becomes almost automatic. You will
find that A very long arc produces a crackling or spluttering noise and the weld metal comes across in large,
irregular blobs. The weld bead is flattened and spatter
increases. A short arc is essential if a high quality weld
is to be obtained although if it is too short there is the
danger of it being blanketed by slag and the electrode
tip being solidified in. If this should happen, give the
electrode a quick twist back over the weld to detach it.
Contact or “touch-weld” electrodes such as E7014 do
not stick in this way, and make welding much easier.
4.17 Rate of Travel
After the arc is struck, your next concern is to maintain
it, and this requires moving the electrode tip towards
the molten pool at the same rate as it is melting away.
At the same time, the electrode has to move along the
plate to form a bead. The electrode is directed at the
weldpoolatabout20°fromthevertical.Therateof
travel has to be adjusted so that a well-formed bead
is produced.
If the travel is too fast, the bead will be narrow and
strung out and may even be broken up into individual
globules. If the travel is too slow, the weld metal piles
up and the bead will be too large.
4.18 Making Welded Joints
Having attained some skill in the handling of an
electrode, you will be ready to go on to make up
welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in
Figure 4-12, allowing 1/16" (1.6mm) to 3/32" (2.4mm)
gap between them and tack weld at both ends. This
is to prevent contraction stresses from the cooling
weld metal pulling the plates out of alignment. Plates
thicker than 1/4" (6.0mm) should have their mating
edgesbevelledtoforma70°to90°includedangle.
This allows full penetration of the weld metal to the
root. Using a 1/8" (3.2mm) E7014 electrode at 120
amps, deposit a run of weld metal on the bottom of
the joint.
Do not weave the electrode, but maintain a steady rate
of travel along the joint sufficient to produce a well-
OPERATION 4-6 Manual 0-5054
Figure 4-11: Striking an arc
formed bead. At first you may notice a tendency for
undercut to form, but keeping the arc length short, the
angleoftheelectrodeatabout20°fromvertical,and
the rate of travel not too fast, will help eliminate this.
The electrode needs to be moved along fast enough to
OPERATION ARC MASTER 175 S
20°-30°
Art # A-07699_AB
prevent the slag pool from getting ahead of the arc. To
complete the joint in thin plate, turn the job over, clean
the slag out of the back and deposit a similar weld.
Electrode
Tack Weld
Figure 4-12: Butt weld
Art # A-07698
Figure 4-13: Weld build up sequence
Tack Weld
Art # A-07697_AB
Heavy plate will require several runs to complete the
joint. After completing the first run, chip the slag out
and clean the weld with a wire brush. It is important
to do this to prevent slag being trapped by the second
run. Subsequent runs are then deposited using either
a weave technique or single beads laid down in the
sequence shown in Figure 4-13. The width of weave
should not be more than three times the core wire
diameter of the electrode. When the joint is completely
filled, the back is either machined, ground or gouged
out to remove slag which may be trapped in the root,
and to prepare a suitable joint for depositing the
backing run. If a backing bar is used, it is not usually
necessary to remove this, since it serves a similar
purpose to the backing run in securing proper fusion
at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular crosssection made by depositing metal in the corner of two
faces meeting at right angles. Refer to Figure 4-5.
A piece of angle iron is a suitable specimen with
which to begin, or two lengths of strip steel may be
tacked together at right angles. Using a 1/8" (3.2mm)
E7014 electrode at 120 amps, position angle iron
with one leg horizontal and the other vertical. This
is known as a horizontal-vertical (HV) fillet. Strike
the arc and immediately bring the electrode to a
position perpendicular to the line of the fillet and
about45°fromthevertical.Someelectrodesrequire
tobeslopedabout20°awayfromtheperpendicular
position to prevent slag from running ahead of the
weld. Refer to Figure 4-14. Do not attempt to build
up much larger than 1/4" (6.4mm) width with a 1/8"
(3.2mm) electrode, otherwise the weld metal tends
to sag towards the base, and undercut forms on the
vertical edge. Multi-runs can be made as shown in
Figure 4-15. Weaving in HV fillet welds is undesirable.
45° from
vertical
60° - 70° from line
of weld
Figure 4-14: Electrode position for HV fillet weld
Art # A-07700_AB
6
3
1
Figure 4-15: Multi-runs in HV fillet weld
5
2
4
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron
to your work bench in an upright position.
Use a 1/8" (3.2mm) E7014 electrode and
set the current at 120 amps. Make yourself
comfortable on a seat in front of the job
and strike the arc in the corner of the fillet.
The electrode needs to be about 10° from
the horizontal to enable a good bead to be
deposited. Refer Figure 4-16. Use a short arc,
and do not attempt to weave on the first run.
When the first run has been completed de-slag
the weld deposit and begin the second run at
the bottom. This time a slight weaving motion
is necessary to cover the first run and obtain
good fusion at the edges. At the completion of
each side motion, pause for a moment to allow
weld metal to build up at the edges, otherwise
undercut will form and too much metal will
accumulate in the centre of the weld. Figure
4-17 illustrates multi-run technique and Figure
4-18 shows the effects of pausing at the edge
of weave and of weaving too rapidly.
Manual 0-5054 4-7 OPERATION
ARC MASTER 175 S OPERATION
Art # A-07701
Figure 4-16: Single run vertical fillet weld
Art # A-07702
3. Overhead Welds
Apart from the rather awkward position
necessary, overhead welding is not much
more difficult that down hand welding. Set
up a specimen for overhead welding by first
tacking a length of angle iron at right angles
to another piece of angle iron or a length of
waste pipe. Then tack this to the work bench
or hold in a vice so that the specimen is
positioned in the overhead position as shown
inthesketch.Theelectrodeisheldat45°to
thehorizontalandtilted10°inthelineoftravel
(Figure 4-19). The tip of the electrode may be
touched lightly on the metal, which helps to
give a steady run. A weave technique is not
advisable for overhead fillet welds. Use a 1/8"
(3.2mm) E6012 electrode at 120 amps, and
deposit the first run by simply drawing the
electrode along at a steady rate. You will notice
that the weld deposit is rather convex, due to
the effect of gravity before the metal freezes.
Figure 4-17: Multi run vertical fillet weld
Art # A-07703
Figure 4-18: Examples of vertical fillet welds
2. Vertical Down
The E7014 electrode makes welding in this
position particularly easy. Use a 1/8" (3.2mm)
electrode at 120 amps. The tip of the electrode
is held in light contact with the work and the
speed of downward travel is regulated so that
the tip of the electrode just keeps ahead of the
slag. The electrode should point upwards at
anangleofabout45°.
Art # A-07704
Figure 4-19: Overhead fillet weld
4.19 Distortion
Distortion in some degree is present in all forms of
welding. In many cases it is so small that it is barely
perceptible, but in other cases allowance has to be
made before welding commences for the distortion
that will subsequently occur. The study of distortion is
so complex that only a brief outline can be attempted
hear.
OPERATION 4-8 Manual 0-5054
OPERATION ARC MASTER 175 S
Upsetting
Weld
4.20 The Cause of Distortion
Distortion is cause by:
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11% in volume on
cooling to room temperature. This means that a cube
of molten metal would contract approximately 2.2%
in each of its three dimensions. In a welded joint, the
metal becomes attached to the side of the joint and
cannot contract freely. Therefore, cooling causes the
weld metal to flow plastically, that is, the weld itself
has to stretch if it is to overcome the effect of shrinking
volume and still be attached to the edge of the joint.
If the restraint is excessive, e.g. a heavy section of
plate, then the weld metal may crack. Even in cases
where the weld metal does not crack, there will still
remain stresses “locked-up” in the structure. If the
joint material is relatively weak, for example, a butt
joint in 5/64" (2.0mm) sheet, the contracting weld
metal may cause the sheet to become distorted.
B. Expansion and Contraction of Parent Metal in
the Fusion Zone:
While welding is proceeding, a relatively small volume
of the adjacent plate material is heated to a very high
temperature and attempts to expand in all directions.
It is able to do his freely at right angles to the surface
of the plate (i.e., “through the weld”), but when it
attempts to expand “across the weld” or “along the
weld”, it meets considerable resistance, and to fulfil
the desire for continued expansion, it has to deform
plastically, that is, the metal adjacent to the weld is
at a high temperature and hence rather soft, and, by
expanding, pushes against the cooler, harder metal
further away, and tends to bulge (or is “upset”).
When the weld area begins to cool, the “upset” metal
attempts to contract as much as it expanded, but,
because it has been “upset”, it does not resume its
former shape, and the contraction of the new shape
exerts a strong pull on adjacent metal. Several things
can then happen.
The metal in the weld area is stretched (plastic
deformation), the job may be pulled out of shape
by the powerful contraction stresses (distortion), or
the weld may crack, in any case, there will remain
“locked-up” stresses in the job. Figures 4-20 and
4- 21 illustrate how distortion is created.
Hot
Weld
Hot
Expansion with
compression
Cool
Permanent Upset
Contraction
with tension
Art # A-07705_AB
Figure 4-20: Parent metal expansion
Art # A-07706_AC
Figure 4-21: Parent metal contraction
4.21 Overcoming Distortion Effects
There are several methods of minimizing distortion
effects.
A. Peening
This is done by hammering the weld while it is still
hot. The weld metal is flattened slightly and because of
this the tensile stresses are reduced a little. The effect
of peening is relatively shallow, and is not advisable
on the last layer.
B. Distribution of Stresses
Distortion may be reduced by selecting a welding
sequence which will distribute the stresses suitably
so that they tend to cancel each other out. See Figures
4-25 through 4-28 for various weld sequences.
Choice of a suitable weld sequence is probably the
most effective method of overcoming distortion,
although an unsuitable sequence may exaggerate it.
Simultaneous welding of both sides of a joint by two
welders is often successful in eliminating distortion.
C. Restraint of Parts
Forcible restraint of the components being welded is
often used to prevent distortion. Jigs, positions, and
tack welds are methods employed with this in view.
D. Presetting
It is possible in some cases to tell from past experience
or to find by trial and error (or less frequently, to
calculate) how much distortion will take place in a
given welded structure. By correct pre-setting of the
components to be welded, constructional stresses
can be made to pull the parts into correct alignment.
A simple example is shown in Figure 4-22.
Manual 0-5054 4-9 OPERATION
ARC MASTER 175 S OPERATION
E. Preheating
Suitable preheating of parts of the structure other
than the area to be welded can be sometimes used
to reduce distortion. Figure 4-23 shows a simple
application. By removing the heating source from b
and c as soon as welding is completed, the sections
b and c will contract at a similar rate, thus reducing
distortion.
Art # A-07707
Figure 4-22: Principle of presetting
Art # A-07708
B
Weld
C
PreheatPreheat
1
2
3
4
Art # A-07711_AB
Figure 4-26: Step back sequence
Art # A-07712
Figure 4-27: Chain intermittent welding
Art # A-07713_AB
Dotted lines show effect if no preheat is used
Figure 4-23: Reduction of distortion by preheating
Art # A-07709
Figure 4-24: Examples of distortion
3
Art # A-07710_AB
1
2
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
Figure 4-28: Staggered intermittent welding
Figure 4-25: Welding sequence
OPERATION 4-10 Manual 0-5054
SERVICE ARC MASTER 175 S
SECTION 5:
SERVICE
5.01 Routine Maintenance and Inspection
The only routine maintenance required for the power supply
is a thorough cleaning and inspection, with the frequency
depending on the usage and the operating environment.
!
WARNING
There are extremely dangerous voltages and power levels
present inside this product. Disconnect primary power at
the source before opening the enclosure. Wait at least two
minutes before opening the enclosure to allow the primary
capacitors to discharge.
Warning!
Disconnect input power before maintaining.
Each Use
To clean the unit, open the enclosure and use a vacuum
cleaner to remove any accumulated dirt and dust. The unit
should also be wiped clean, if necessary; with solvents
that are recommended for cleaning electrical apparatus.
CAUTION
Do not blow air into the power supply during cleaning.
Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause
damage to the unit.
Maintain more often
if used under severe
conditions
Visual check of
regulator and pressure
Visually inspect
the torch body
and consumables
Replace all
broken parts
Art # A-08549_AD
Visual check of torch
Consumable parts
Weekly
Visually inspect the
cables and leads.
Replace as needed
3 Months
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
Tweco Service Centre
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Manual 0-5054 5-1 SERVICE
ARC MASTER 175 S SERVICE
Art # A-05866_AC
Lack of fusion caused by dirt,
5.02 STICK Welding Problems
Description Possible Cause Remedy
1. Gas pockets or voids in weld
metal (Porosity).
2. Crack occurring in weld
metal soon after solidification
commences.
3. A gap is left by failure of the weld
metal to fill the root of the weld.
Incorrect Sequence
Insufficient Gap
4. Portions of the weld run do
not fuse to the surface of the
metal or edge of the joint
A. Electrodes are damp.
B. Welding current is too
high.
C. Surface impurities such as
oil, grease, paint, etc.
A. Rigidity of joint.
B. Insufficient throat thickness.
C. Cooling rate is too high.
A. Welding current is too low.
B. Electrode too large for joint.
C. Insufficient gap.
D. Incorrect sequence.
A. Small electrodes used on
heavy cold plate.
B. Welding current is too low.
A. Dry electrodes before use.
B. Reduce welding current.
C. Clean joint before welding
A. Redesign to relieve weld joint
of severe stresses or use crack
resistance electrodes.
B. Travel slightly slower to allow
greater build up in throat.
C. Preheat plate and cool slowly.
A. Increase welding current
B. Use smaller diameter electrode.
C. Allow wider gap.
D. Use correct build-up sequence.
A. Use larger electrodes and pre-heat
the plate.
B. Increase welding current
electrode angle incorrect,
rate of travel too high
Art # A-05867_AC
Lack of side fusion,
scale dirt, small electrode,
amperage too low
Lack of
inter-run fusion
Lack of root fusion
5. Non-metallic particles are
trapped in the weld metal
(slag inclusion).
Slag
trapped in
Not cleaned,
or incorrect
electrode
undercut
Art # A-05868_AC
Slag trapped in root
C. Wrong electrode angle.
D. Travel speed of electrode is
too high.
E. Scale or dirt on joint sur-
face.
A. Non-metallic particles
may be trapped in undercut from previous run.
B. Joint preparation too res-
tricted.
C. Irregular deposits allow slag
to be trapped.
D. Lack of penetration with
slag trapped beneath weld
bead.
E. Rust or mill scale is pre-
venting full fusion.
C. Adjust angle so the welding arc
is directed more into the base
metal
D. Reduce travel speed of elect-
rode
E. Clean surface before welding.
A. If bad undercut is present, clean
slag out and cover with a run from
a smaller diameter electrode.
B. Allow for adequate penetration and
room for cleaning out the slag.
C. If very bad, chip or grind out
irregularities.
D. Use smaller electrode with
sufficient current to give adequate
penetration. Use suitable tools to
remove all slag from corners.
E. Clean joint before welding.
F. Wrong electrode for position
SERVICE 5-2 Manual 0-5054
in which welding is done.
F. Use electrodes designed for
position in which welding is done,
otherwise proper control of slag is
difficult.
SERVICE ARC MASTER 175 S
5.03 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding
technique.
Description Possible Cause Remedy
1. Excessive beard build-up or
poor penetration or poor fusion
at edges of weld.
2. Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through.
3. Weld bead too small or insufficient penetration or ripples in
bead are widely spaced apart.
4. Weld bead too wide or excessive
bead build up or excessive
penetration in butt joint.
5. Uneven leg length in fillet
joint.
6. Electrode melts when arc is
struck.
7. Dirty weld pool. A. Electrode contaminated
8. Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas
9. Arc flutters during TIG
welding.
10. Welding arc cannot be established.
11. Electrode melts or oxidizes
when an arc is struck.
Welding current is too low Increase weld current and/or
change joint preparation.
Welding current is too high. Decrease welding current.
Travel speed too fast. Reduce travel speed.
Travel speed is too slow. Increase travel speed.
Wrong placement of filler rod. Re-position filler rod.
Electrode is connected to the
“+” Positive Output Terminal.
through contact with work
piece or filler rod material.
B. Gas contaminated with air.
Tungsten electrode is too large
for the welding current.
A. Work clamp is not connected
to the work piece or the work/
torch leads are not connected to
the correct welding terminals.
B. Torch lead is disconnected.
C. Gas flow incorrectly set, cyl-
inder empty or the torch valve
is off.
A. No gas is flowing to welding
region.
B. Torch is clogged with dust.
C. Gas hose is cut.
D. Gas passage contains impuri-
ties.
E. Gas regulator turned off.
F. Torch valve is turned off.
G. The electrode is too small for
the welding current.
Connect the electrode to the
“-“ Negative Output Terminal.
A. Clean the electrode by
grinding contaminates off.
B. Check gas lines for cuts and
loose fitting or change gas
cylinder.
line for problems
Select the right size electrode.
Refer to section Tungsten Electrode Current Ranges.
A. Connect the work clamp to
the work piece or connect
the work/torch leads to the
correct welding terminals.
B. Connect it to the “-“ Negative
Output Terminal.
C. Select the right flow rate,
change cylinder or turn torch
valve on.
A. Check the gas lines for kinks
or breaks or cylinder contains
gas.
B. Clean torch.
C. Replace gas hose.
D. Disconnect gas hose from
torch then raise gas pressure
and blow out impurities.
E. Turn on.
F. Turn on.
G. Increase electrode diameter or
reduce the welding current.
Manual 0-5054 5-3 SERVICE
ARC MASTER 175 S SERVICE
TIG Welding Problems Continued
Description Possible Cause Remedy
12. Arc start is not smooth. A. Tungsten electrode is too large
for the welding cur-rent.
B. The wrong electrode is being
used for the welding job.
C. Gas flow rate is too high.
D. Incorrect shield gas is being
used.
E. Poor work clamp connection to
work piece.
!
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to repair unless
you are an Accredited Tweco 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
Tweco Service Agent for repair.
A. Refer to section Tungsten Electrode
Current Ranges for the correct size.
B. Refer to section Tungsten Electrode
Types for the correct electrode type.
C. Select the correct flow rate for the
welding job.
D. Use 100% argon for TIG welding.
E. Improve connection to work piece.
5.04 Power Source Problems
Description Possible Cause Remedy
1. The welding arc cannot be
established.
2. The welding arc cannot be
established when the Over Heat
Indicator is illuminated
3. Maximum output welding
current cannot be achieved with
nominal Mains supply voltage.
4. Welding current reduces when
welding.
A. The Primary supply voltage
B. The Welding Power Source
C. Loose connections internally.
The machines duty cycle has been
exceeded
Defective control circuit Have an Accredited Tweco Service
Poor work lead connection to the
work piece.
5.05 Key Spare Parts
has not been switched ON.
switch is switched OFF.
A. Switch ON the Primary supply
voltage.
B. Switch ON the Welding Power
Source.
C. Have an Accredited Tweco Service
Provider repair the connection.
Wait for the Over Heat Indicator to
extinguish before resuming welding
Provider inspect then repair the
welder.
Ensure that the work lead has a
positive electrical connection to the
work piece.
Part No. Description Part No. Description
W7003003 PCB Front Panel ArcMaster 175 S W7003018
W7003007 PCB Control 175 S W7003020
W7003009 Fan 175 S W7003022
W7003010 Rectifier Input Bridge 175 S W7003023
W7003011 PCB Power 175 S W7003024
W7003013 Current Sensor 175 S W7003025
W7003016 Thermistor 175 S W7003053
SERVICE 5-4 Manual 0-5054
Inductor 175 S
Output Terminal 175 S
Panel Front 175 S
Panel Rear 175 S
Panel Cover 175 S
Panel Base 175 S
ON / OFF Switch
This Page Left Blank Intentionally
LIMITED WARRANTY & WARRANTY SCHEDULE
In accordance with the warranty periods stated below, Victor Technologies guarantees the proposed product to be free
from defects in material or workmanship when operated in accordance with the written instructions as defined in this
operating manual.
Victor Technologies welding products are manufactured for use by commercial and industrial users and trained personnel
with experience in the use and maintenance of electrical welding and cutting equipment.
Victor Technologies will repair or replace, at its discretion, any warranted parts or components that fail due to defects
in material or workmanship within the warranty period. The warranty period begins on the date of sale to the end user.
Welding Equipment - Limited Warranty Period
Product Period
ArcMaster 175 S 2 Years
Electrode holder and work lead 30 Days
If warranty is being sought Victor Technologies must be notified in writing within 30 days of the failure and at such time
we will make arrangements to fulfil the warranty claim. Please contact your Victor Technologies product supplier for the
warranty repair procedure.
Victor Technologies warranty will not apply to:
•EquipmentthathasbeenmodiedbyanyotherpartyotherthanVictorTechnologies’sownservicepersonnelor
with prior written consent obtained from Victor Technologies service department (UK).
•Equipmentthathasbeenusedbeyondthespecicationsestablishedintheoperatingmanual.
•Installationnotinaccordancewiththeinstallation/operatingmanual.
•Anyproductthathasbeensubjectedtoabuse,misuse,negligence,accident,impropercareand/ormaintenance
including lack of lubrication, maintenance and protection, will be refused warranty.
•Failuretocleanandmaintainthemachineassetforthintheoperating,installationorservicemanual.
Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation. This
manual also offers basic troubleshooting, operational and technical details including application usage.
Using this manual correctly will ensure the quickest time possible for resolving any technical questions, application issues
or defects with your Victor Technologies product.
You may also wish to visit our web site www.victortechnologies.com select your product class and then select literature.
Here you will find documentation including:
•Operatormanuals
•Servicemanuals
•Productguides
Alternatively please contact your Victor Technologies distributor and speak with a technical representative.
NOTE
Warranty repairs must be performed by either a Victor Technologies Service Centre, a Victor Technologies distributor or
an Authorised Service Agent approved by the Company.
This Page Left Blank Intentionally
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U.S. Customer Care
Ph 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
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Ph 1-940-381-1212
Fax: 1-940-483-8178
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