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Summary of Contents for Thermadyne Thermal Arc 185TSW
- Page 1 INVERTER WELDER MODEL 185TSW AC/DC CC STICK TIG - Lift Start HF START OPERATING MANUAL November 13, 2003 Manual No. 430429-503...
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Page 3: Table Of Contents
CONTENTS SYMBOL LEGEND ...............................5 STATEMENT OF WARRANTY ...........................6 1.0 GENERAL INFORMATION............................7 1.01 Notes, Cautions and Warnings ...........................7 1.02 Important Safety Precautions..........................7 1.03 Publications ................................8 1.04 Note, Attention et Avertissement........................9 1.05 Precautions De Securite Importantes........................9 1.06 Documents De Reference ..........................11 2.0 INTRODUCTION AND DESCRIPTION ......................13 2.01 Description ................................13 2.02 Functional Block Diagrams ..........................14 2.03 Transporting Methods............................14... - Page 4 13.0 PARTS LIST................................. 53 APPENDIX A – INTERCONNECT DIAGRAM ......................56 APPENDIX B - AUTOMATION..........................58...
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Page 5: Symbol Legend
SYMBOL LEGEND Amperage STICK (Shielded Metal Arc SMAW) Voltage Pulse Current Function Hertz (frequency) Spot Time (GTAW) Seconds Remote Control (Panel/Remote) Percent Remote Function DC (Direct Current) Arc Control (SMAW) AC (Alternating Current Gas Post-Flow Standard Function Gas Pre-Flow Slope Function Voltage Reduction Device Circuit Slope W/Repeat Function... -
Page 6: Statement Of Warranty
STATEMENT OF WARRANTY LIMITED WARRANTY: Thermal Arc , Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of its ® authorized distributors hereafter “Thermal; Arc” that its products will be free of defects in workmanship or material. Should any... -
Page 7: General Information
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. 1.0 GENERAL INFORMATION • The kinds of fumes and gases from the arc 1.01 Notes, Cautions and Warnings welding/cutting depend on the kind of Throughout this manual, notes, cautions, and metal being used, coatings on the metal, and warnings... -
Page 8: Publications
• Install and maintain equipment according to NEC code, refer to item 4 in Subsection 1.03, ARC WELDING RAYS Publications. • Disconnect power source before performing Arc Welding/Cutting Rays can injure your eyes any service or repairs. and burn your skin. The arc welding/cutting process produces very bright ultra violet and infra •... -
Page 9: Note, Attention Et Avertissement
6. ANSI Standard Z49.2, FIRE PREVENTION IN des informations à caractère important. Ces mises THE USE OF CUTTING AND WELDING en relief sont classifiées comme suit : PROCESSES, obtainable from American NOTE National Standards Institute, 1430 Broadway, New York, NY 10018 Toute opération, procédure... - Page 10 • Eloignez toute fumée et gaz de votre zone de secs. Isolez-vous de la pièce de travail ou des respiration. Gardez votre tête hors de la autres parties du circuit de soudage. plume de fumée provenant du chalumeau. • Réparez ou remplacez toute pièce usée ou •...
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Page 11: Documents De Reference
nuiront à vos yeux et brûleront votre peau si vous 1.06 Documents De Reference ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de • Pour protéger vos yeux, portez toujours un plus amples renseignements : casque ou un écran de soudeur. - Page 12 ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA...
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Page 13: Introduction And Description
2.0 INTRODUCTION AND DESCRIPTION 2.01 Description The Thermal Arc™ Model 185TSW is a self contained single-phase AC/DC arc welding power source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas control valve, built in Sloper and Pulser, lift arc starter, and high-frequency arc starter for use with Gas Tungsten Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed (GTAW-P) Gas Tungsten Arc Welding-Sloped (GTAW-S), and Shielded Metal Arc Welding (SMAW) processes. -
Page 14: Functional Block Diagrams
2.02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of the 185TSW-power supply. Figure 2. 185TSW Model Functional Block Diagram 2.03 Transporting Methods These units are equipped with a handle for carrying purposes. WARNING 1 ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source. -
Page 15: Installation Recommendations
3.0 Installation Recommendations 3.01 Environment The Pro-Wave 185TSW is designed for use in hazardous environments. Examples of environments with increased hazardous environments are - a) In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts;... -
Page 16: Electrical Input Connections
3.03 Electrical Input Connections WARNING 4 ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. - Page 17 Input Voltage Fuse Size 208V 45 Amps 230V 40 Amps Table 1. Electrical Input Connections NOTE: Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code). Figure 3.
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Page 18: Input Power
3.03.02 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds). -
Page 19: High Frequency Introduction
3.03.03 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be over- emphasized. Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following information is intended as a guide for personnel installing high frequency welding machines. -
Page 20: Specifications
3.04 Specifications Parameter 185TSW Rated Output Amperes Volts 17.4 Duty Cycle Duty Cycle 185A / 17.4V @ 30% 160A / 16V @ 40% 130A / 15V @ 60% 100A / 14V @ 100% STICK 160A / 26V @ 40% 130A / 25V @ 60% 100A / 25V @ 100% Output Current 5 –... -
Page 21: Duty Cycle
3.05 Duty Cycle The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases. - Page 22 PAGE LEFT INTENTIONALLY BLANK...
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Page 23: Operator Controls
4.0 OPERATOR CONTROLS 4.01 Pro-Wave 185TSW Controls Figure 4– Pro-Wave 185TSW Power Source 1 Control Knob This control sets the selected weld parameter, rotating it clockwise increases the parameter that is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage. - Page 24 Socket Pin Function Earth (Ground) Torch Switch Input (24V) to energize weld current. (connect pins 2 & 3 to turn on welding current) Torch Switch Input (0V) to energize weld current (connect pins 2 & 3 to turn on welding current) Connect pin 4 to pin 8 to instruct machine that a remote current control device is connected (12V DC supply) 5k ohm (maximum) connection to 5k ohm remote control potentiometer...
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Page 25: Weld Process Selection For Pro-Wave 185Tsw
8 Gas Inlet The Gas Inlet is a 5/8 18 UNF female gas fitting. 4.02 Weld Process selection for Pro-Wave 185TSW Weld Mode Weld Process LIFT Selection STICK Description 2T operation in TIG Modes using remote devices to control contactor & current 4T operation in TIG Modes with crater fill using a remote contactor device to control SLOPE... -
Page 26: Weld Parameter Descriptions For Pro-Wave 185Tsw
4.03 Weld Parameter Descriptions for Pro-Wave 185TSW Figure 5 Pro-Wave 185TSW Front Panel with Parameter Description Parameter Description This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc, once the torch trigger switch has been pressed. - Page 27 Parameter Description SPOT TIME This parameter sets the duration of the SPOT TIME in HF TIG mode only PULSE WIDTH This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSE is on. PULSE FREQ.
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Page 28: Weld Parameters For Pro-Wave 185Tsw
4.04 Weld Parameters for Pro-Wave 185TSW Weld Mode Weld Parameter Factory Incremental LIFT Parameter Range Setting Unit STICK PRE-FLOW 0.0 to 1.0 sec 0.1 sec 0.1 sec HOT START 0 to 70A INITIAL CUR. 5 to 185A UP SLOPE 0 to 15 sec 1 sec 0.1 sec PEAK CUR. -
Page 29: Power Source Features
4.05 Power Source Features Feature Description • Almost all welding parameters are adjustable New Digital Control • Touch switches eliminate mechanical damage Touch Panel Switches • Protects front panel controls Front Control Cover • Displays selected weld parameter value Digital Meter •... - Page 30 PAGE LEFT INTENTIONALLY BLANK...
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Page 31: Set-Up For Smaw (Stick) And Gtaw (Tig)
5.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG) Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects. -
Page 32: Sequence Of Operation
6.0 SEQUENCE OF OPERATION NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted on the weld sequence graph. Refer to the Symbols Table located in the front of the manual for Symbol descriptions. -
Page 33: Stick Welding
1. Pulse function – Pressing this button enables the TIG current pulse functions. 2. Scroll Buttons – used to select the parameters to be set. The LED’s show which function is being adjusted on the Sequence Graph. 3. TIG Mode Functions – Pressing this button scrolls through the output TIG function modes (Standard, Slope, Slope w/repeat, Spot). -
Page 34: Ac Or Dc Hf Tig Welding
6.02 AC or DC HF TIG Welding • Connect work lead to positive terminal • Connect TIG torch to negative terminal • Switch machine on • Set AC or DC weld current. If AC is selected then set AC FREQ & WAVE BALANCE •... -
Page 35: Slope Mode Sequence
6.02.01 Slope Mode Sequence Switch Switch Switch Switch Closed Closed Open Open Down Weld Current Slope Slope Initial Final Current Current Postflow Preflow Note 5 Slope function operates with a Remote ON/OFF device only. 1) To start Slope sequence Close remote switch contacts. Once the welding arc is established the Power Source will maintain initial current setting as long as the remote switch contacts are closed. -
Page 36: Pulse Controls
6.02.03 Pulse Controls (Pulse Width) (Pulse Frequency) (Peak Current) (Base) Background Current The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows: 1) Control puddle – size and fluidity (especially out of position). 2) Increase penetration 3) Travel speed control 4) Better consistent quality... -
Page 37: Basic Tig Welding Guide
7.0 BASIC TIG WELDING GUIDE 7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum The following will assist in understanding the phenomenon of Arc Flutter, also referred to as Arc Rectification. The basic thesis is that the fluttering is caused by lack of oxide in the weld pool. The oxide layer on the plate reduced the energy for electron emission. -
Page 38: Electrode Polarity
7.02 Electrode Polarity Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece. -
Page 39: Guide For Selecting Filler Wire Diameter
7.05 Guide for Selecting Filler Wire Diameter Filler Wire Diameter AC Current Range DC Current Range (Amps) (Amps) 1/16” (1.6 mm) 30-95 20 - 90 3/32” (2.4 mm) 125-160 65 - 115 1/8” (3.2 mm) 180-240 100 - 165 3/16” (4.8 mm) 220-320 200-350 Table 10 –... -
Page 40: Welding Parameters For Aluminum
7.08 Welding Parameters for Aluminum Base Metal AC Current Tungsten Filler Rod Argon Gas Thickness for Aluminum Electrode Diameter Flow Rate Joint Type Diameter (if required) Liters/min 30-45 Butt/Corner 0.040” 1/16” 0.040” 35-50 Lap/ Fillet 1.0mm 1.6mm 1.0mm 40-60 Butt/Corner 0.040”... -
Page 41: Basic Arc Welding Guide
8.0 Basic Arc Welding Guide 8.01 Electrode Polarity Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘−’ terminal but if in doubt consult the electrode manufacturers literature. 8.02 Effects of Stick Welding Various Materials High tensile and alloy steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead... -
Page 42: Routine Maintenance
9.0 ROUTINE MAINTENANCE The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. WARNING 8 Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge. -
Page 43: Basic Troubleshooting
10.0 BASIC TROUBLESHOOTING WARNING 9 There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair. - Page 44 Description Possible Cause Remedy 6 Electrode melts A Electrode is connected to the A Connect the electrode to the when arc is struck. ‘+’ terminal. ‘−’ terminal. B WAVE BALANCE is greater B Reduced WAVE BALANCE than 50%. to below 50% or increase the electrode size.
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Page 45: Stick Welding Problems
Description Possible Cause Remedy C Gas flow incorrectly set, C Select the right flow rate, cylinder empty or the torch change cylinders or turn valve is off. torch valve on. 12 Arc start is not A Tungsten electrode is too A Select the right size smooth. - Page 46 4 Portions of the Small electrodes used on Use larger electrodes and pre- weld run do not heavy cold plate. heat the plate. fuse to the surface Welding current is too low. Increase welding current. of the metal or edge of the joint. C Wrong electrode angle.
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Page 47: Power Source Problems
10.03 Power Source Problems Description Possible Cause Remedy 1 The welding arc The Primary supply voltage Switch ON the Primary cannot be has not been switched ON. supply voltage. established. The Welding Power Source Switch ON the Welding switch is switched OFF. Power Source. - Page 48 Description Possible Cause Remedy 5 Gas flow won’t A Weld Mode (STD, SLOPE, A Strike an arc to complete shut off. REPEAT or SPOT) was the weld cycle. changed before POST-FLOW gas time had finished. Switch machine off then on to reset solenoid valve sequence.
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Page 49: Voltage Reduction Device (Vrd)
11.0 Voltage Reduction Device (VRD) 11.01 VRD Specification Pro-Wave Description 185TSW Notes VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between welding terminals. VRD Resistance 148 to 193 ohms The required resistance between welding terminals to turn ON the welding power. VRD Turn OFF Time 0.2 to 0.3 seconds The time taken to turn OFF the welding power once the welding current has... - Page 56 APPENDIX A – INTERCONNECT DIAGRAM...
- Page 58 APPENDIX B - AUTOMATION JUMPER SETTING FOR "OK–TO–MOVE". Models 185TSW Three jumpers (JP1, JP2 and JP3) are provided on PC Board WK-4921 for automation purposes. This PCB is mounted horizontally on top of the unit just under the cover. This PCB can be accessed by removing the side covers by loosening 4 screws on each the front and rear panel, then removing the 4 side panel screws as well as the 2 handle screws.
- Page 59 Figure 11 – Location of PCB WK-4921...
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