Thermal Arc 185 AC Service Manual
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Thermal Arc 185 AC Service Manual

Inverter arc welders
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185 AC/DC
200 AC/DC

Service Manual

ARCMASTER
INVERTER ARC WELDERS
Revision No: AE.04
Operating Features:
GTAW
®
Art # A-07227
Issue Date: May 22, 2006
50
INVERTER
Hz
60
SMAW
Manual No.: 0-4884B
AC
CC
DC

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Summary of Contents for Thermal Arc 185 AC

  • Page 1: Service Manual

    185 AC/DC 200 AC/DC ARCMASTER ® INVERTER ARC WELDERS Art # A-07227 Service Manual Revision No: AE.04 Issue Date: May 22, 2006 Manual No.: 0-4884B Operating Features: INVERTER GTAW SMAW...
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Service Manual Number 0-4884B for: ArcMaster 185 AC/DC Inverter Arc Welder Part Number 10-3073 ArcMaster 200 AC/DC Inverter Arc Welder...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............1-1 1.01 Arc Welding Hazards ..................1-1 1.02 Principal Safety Standards ................1-4 1.03 Precautions de Securite en Soudage à l’Arc ........... 1-5 1.04 Dangers Relatifs au Soudage à l’Arc ............... 1-5 1.05 Principales Normes de Securite ..............
  • Page 5 TABLE OF CONTENTS (continued) TABLE OF CONTENTS SECTION 7: ROUTINE MAINTENANCE ................7-1 SECTION 8: BASIC TROUBLESHOOTING ................ 8-1 8.01 General Troubleshooting ................8-1 8.02 Common Welding Operation Faults ..............8-1 8.03 TIG Welding Problems ................... 8-2 8.04 Stick Welding Problems ................. 8-4 8.05 Power Source Problems .................
  • Page 6 11.03.12 PCB12 (WK-5615), Transformer (T1), Current Trans (CT2) ....11-16 11.03.13 PCB13 (WK-5569) ................11-19 11.03.14 PCB16 (WK-5499) ................11-20 11.03.15 PCB14 (WK-5570) ................11-20 11.03.16 PCB17 (WK-4917 ................11-21 11.03.17 Discharge Resistor (R3) ..............11-22 11.03.18 Current Limiting Resistor (R4, R5) ............11-24 11.03.19 Resistor on High Frequency Unit (R6) ..........

  • Page 7: Safety Instructions And Warnings

    ARCMASTER 185 ACDC 200 ACDC 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.
  • Page 8 ARCMASTER 185 ACDC 200 ACDC 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. WELDING can cause fire or explosion.
  • Page 9 ARCMASTER 185 ACDC 200 ACDC 2. If used in a closed area, vent engine exhaust outside and away from any building air intakes. WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

  • Page 10: Principal Safety Standards

    ARCMASTER 185 ACDC 200 ACDC 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S.

  • Page 11: Precautions De Securite En Soudage À L'arc

    ARCMASTER 185 ACDC 200 ACDC 1.03 Precautions de Securite en Soudage à l’Arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
  • Page 12 ARCMASTER 185 ACDC 200 ACDC AVERTISSEMENT AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX POUR LA SANTE. ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. Le soudage dégage des vapeurs et des fumées L’arc de soudage produit une chaleur et des rayons dangereuses à...
  • Page 13 ARCMASTER 185 ACDC 200 ACDC 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 AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.

  • Page 14: Principales Normes De Securite

    ARCMASTER 185 ACDC 200 ACDC 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien Les accumulateurs contiennent de l’électrolyte acide et ventilées. dégagent des vapeurs explosives. 2. Si vous utilisez ces équipements dans un endroit confiné, les 1. Portez toujours un écran facial en travaillant sur un accumu-lateur. fumées d’échappement doivent être envoyées à...

  • Page 15: Introduction

    Include the manual number and equipment identification numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link: http://www.thermalarc.com May 22, 2006...

  • Page 16: Symbol Chart

    ARCMASTER 185 ACDC 200 ACDC 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier...

  • Page 17: Description

    ARCMASTER 185 ACDC 200 ACDC 2.05 Description The Thermal Arc™ Model 185/200 ACDC are self-contained single (185/200 ACDC) and three -phase (200 ACDC) AC/ DC arc welding powersource with Constant Current (CC) output characteristics. These units are equipped with a...

  • Page 18: Functional Block Diagrams

    ARCMASTER 185 ACDC 200 ACDC 2.06 Functional Block Diagrams Figure 2-2 illustrates the functional block diagram of the 185/200ACDC-power supply. Input Main Coupling Current Input Output Inrush Current IGBT Inverter Output Capacitor Circuit Diode Suppresor Module Transformers Diodes Power Breaker Transformer Coil (CT-1)

  • Page 19: Transporting Methods

    ARCMASTER 185 ACDC 200 ACDC 2.07 Transporting Methods These units are equipped with a handle for carrying purposes. WARNING ELECTRIC SHOCK can kill. • DO NOT TOUCH live electrical parts. • Disconnect input power conductors from de- energized supply line before moving welding power source.
  • Page 20 ARCMASTER 185 ACDC 200 ACDC May 22, 2006...

  • Page 21: Installation

    • Place at a distance of 12" (304.79mm) or more from walls or similar boundaries that could restrict natural airflow for cooling. WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician. May 22, 2006...
  • Page 22 ARCMASTER 185 ACDC 200 ACDC [For 185 ACDC] NOTE For single phase operation, connect the Do not connect an input (WHITE and BLACK) conductor to the ground terminal. Do not connect the ground GREEN, BLACK and WHITE input conductors. (GREEN) conductor to an input line terminal. Isolate the RED conductor as it is not used for single phase operation.

  • Page 23: Input Power

    ARCMASTER 185 ACDC 200 ACDC 3.05 Input Power Primary Minimum Current & Duty Cycle Supply Primary Each unit incorporates an INRUSH circuit and input Model Lead Current voltage sensing circuit. When the MAIN CIRCUIT SWITCH Size Circuit Size STICK is turned on, the inrush circuit provides a pre-charging of (Factory Fitted) (Vin/Amps)

  • Page 24: High Frequency Interference

    ARCMASTER 185 ACDC 200 ACDC 3.07 High Frequency Interference 3.08 Duty Cycle Interference may be transmitted by a high frequency The duty cycle of a welding power source is the percentage initiated or stabilized arc welding machine in the following of a ten (10) minute period that it can be operated at a ways: given output without causing overheating and damage to...

  • Page 25: Specifications

    Phase Thermal Arc 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.
  • Page 26 ARCMASTER 185 ACDC 200 ACDC May 22, 2006...

  • Page 27: Arcmaster 185/200 Acdc Controls

    ARCMASTER 185 ACDC 200 ACDC SECTION 4: 1. Control Knob: This control sets the selected weld pa- rameter, rotating it clockwise increases the param- OPERATOR CONTROLS eter that is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage. 4.01 ArcMaster 185/200 ACDC Controls 2.

  • Page 28: Weld Process Selection

    ARCMASTER 185 ACDC 200 ACDC 3. Positive Terminal: Welding current flows from the 4.02 Weld Process Selection Power Source via heavy duty Dinse type terminal (Size 50mm). It is essential, however, that the male plug is Weld Mode inserted and turned securely to achieve a sound elec- Description Parameter LIFT...

  • Page 29: Weld Parameter Descriptions For Arc Master 185/200 Acdc

    ARCMASTER 185 ACDC 200 ACDC 4.03 Weld Parameter Descriptions for ARC MASTER 185/200 ACDC Figure 4-3: ARC MASTER 185/200 ACDC Front Panel with Parameter Description Parameter Description PRE-FLOW 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 30 ARCMASTER 185 ACDC 200 ACDC This parameter is used for aluminium AC TIG mode and is used to set the penetration to cleaning action ratio for the AC weld current. Generally WAVE BALANCE is set to 50% for AC STICK welding. The WAVE BALANCE control changes the ratio of penetration to cleaning action of the AC TIG welding arc.

  • Page 31: Weld Parameters For Arc Master 185/200 Acdc

    ARCMASTER 185 ACDC 200 ACDC 4.04 Weld Parameters for ARC MASTER 185/200 ACDC Weld Mode Weld Parameter Parameter Range Factory Setting Incremental Unit STICK HF TIG LIFT TIG PRE-FLOW 0.0 to 1.0 sec 0 sec 0.1 sec HOT START 0 to 70A 20 A 5 to 185A INITIAL CUR.

  • Page 32: Power Source Features

    ARCMASTER 185 ACDC 200 ACDC 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. Displays weld current when welding. Displays weld current for 20 seconds after weld has been completed.

  • Page 33: Set-Up For Smaw (Stick) And Gtaw (Tig)

    ARCMASTER 185 ACDC 200 ACDC SECTION 5: SET-UP FOR SMAW (STICK) AND GTAW (TIG) Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects.
  • Page 34 ARCMASTER 185 ACDC 200 ACDC May 22, 2006...

  • Page 35: Sequence Of Operation

    ARCMASTER 185 ACDC 200 ACDC SECTION 6: 10. Contactor function: Pressing this button enables Contactor functions. SEQUENCE OF OPERATION 6.01 Stick Welding NOTE • Connect work lead to negative terminal. Scroll Buttons are used to select the parameters • Connect electrode lead to positive terminal. to be set.

  • Page 36: Slope Mode Sequence

    ARCMASTER 185 ACDC 200 ACDC Pulse Mode parameters if required. sequence close remote switch contacts and allow weld current to reach final current setting. Once final current • Set PULSE WIDTH % for PEAK CURRENT. setting is reached opening the Remote Switch again will •...

  • Page 37: Routine Maintenance

    ARCMASTER 185 ACDC 200 ACDC SECTION 7: 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 Disconnect primary power at the source before opening the enclosure.
  • Page 38 6 Months Bring the unit to an authorized Thermal Arc Service Center to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

  • Page 39: Basic Troubleshooting

    ARCMASTER 185 ACDC 200 ACDC SECTION 8: 8.02 Common Welding Operation Faults BASIC TROUBLESHOOTING The following are some of the more common operating faults that occur during welding operations: 1. Power: 8.01 General Troubleshooting • Main power not connected Troubleshooting and repairing this unit is a process which •...

  • Page 40: Tig Welding Problems

    ARCMASTER 185 ACDC 200 ACDC 8.03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumalbes, maintenance of equipment and proper welding technique. Description Possible Cause Remedy 1 Excessive beard build- Welding current is too low Increase weld current and/or faulty up or poor penetration joint preparation...
  • Page 41 ARCMASTER 185 ACDC 200 ACDC Description Possible Cause Remedy 9 Poor weld finish Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems. 10 Arc flutters during TIG A Tungsten electrode is too large for A Select the right size electrode. Refer welding the welding current.

  • Page 42: Stick Welding Problems

    ARCMASTER 185 ACDC 200 ACDC 8.04 Stick Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in Electrodes are damp Dry electrodes before use weld metal (Porosity) Welding current is too high Reduce welding current Surface impurities such as oil, Clean joint before welding grease, paint, etc.
  • Page 43 ARCMASTER 185 ACDC 200 ACDC 5 Non-metallic particles A Non-metallic particles may be A If bad undercut is present, clean slag are trapped in the weld trapped in undercut from previous out and cover with a run from a metal (slag inclusion) smaller diameter electrode.

  • Page 44: Power Source Problems

    The Welding Power Source switch is Switch ON the Welding Power switched OFF. Source. C Loose connections internally. C Have an Accredited Thermal Arc Service Agent repair the connection. 2 Maximum output Defective control circuit Have an Accredited Thermal Arc...

  • Page 45: Error Codes

    TH1 (protects IGBTs) Fan ceases to operate. Have an Accredited Fan operates at max is greater than 80°C Air flow is restricted by Thermal Arc Service speed. for about 1 second. vents being blocked. Agent investigate. Unblock vents then let...
  • Page 46 E81 error code When 3 phase machine is Have an Accredited No weld current is displayed first turned on with the Thermal Arc Service Agent available. Wrong Primary wrong Primary supply or a qualified electrician Buzzer sounds constantly. supply (input) (input) voltage connected.

  • Page 47: Voltage Reduction Device (Vrd)

    ARCMASTER 185 ACDC 200 ACDC SECTION 9: VOLTAGE REDUCTION DEVICE (VRD) 9.01 VRD Specification: Description 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...

  • Page 48: Switching Vrd On/Off

    ARCMASTER 185 ACDC 200 ACDC 9.03 Switching VRD On/Off Switch the machine Off. A) Remove the clear plastic cover from the control panel (see Figure 9-1). • Lift up the cover so it rests on the top of the unit •...
  • Page 49 ARCMASTER 185 ACDC 200 ACDC C) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see Figure 9-3). CAUTION DO NOT pull back the front panel with excessive force as this will unplug control PCB. Plugging the control PCB back into the front panel controls can only be achieved by removing the side covers.
  • Page 50 ARCMASTER 185 ACDC 200 ACDC May 22, 2006...

  • Page 51: Advanced Troubleshooting

    ARCMASTER 185 ACDC 200 ACDC SECTION 10: 10.01 System-Level Fault Isolation ADVANCED TROUBLESHOOTING If none of the suggestions provided in Section 8 have solved the problem or corrected the faulty operation, the next step is to isolate one or more of the internal If you are here, all of the troubleshooting suggestions in subassemblies that may be defective.

  • Page 52: Opening The Enclosure

    ARCMASTER 185 ACDC 200 ACDC 3. Loosen the screws on the front panel and the rear 10.02 Opening the Enclosure panel by turning them approximately two turns CCW. 1. Confirm that the switch on the power supply and the switch on switchboard (distribution panel) are all OFF. Art # A-05662 Art # A-05660 Figure 10-3: Screws On Front and Rear Panel...
  • Page 53 ARCMASTER 185 ACDC 200 ACDC 5. Remove the side covers. Art # A-05664 Figure 10-5: Remove Side Covers 6. Remove protection cover sheet by removing the plastic tabs. Art # A-05665 Figure 10-6: Protection Cover NOTE When you re-assemble the parts, conduct the above process backwards.

  • Page 54: Verification And Remedy To The Indicated Error Codes

    ARCMASTER 185 ACDC 200 ACDC • Verify and maintain clean, dust free, front and 10.03 Verification and Remedy to the rear airflow paths. Cleaning and removing dust Indicated Error Codes from the front and rear panels once every six months in a normal working environment is NOTE recommended.
  • Page 55 ARCMASTER 185 ACDC 200 ACDC c) Verify the operation of the cooling fan, FAN1, NOTE and replace it if necessary. Pay special attention to installed direction of • Verify the condition of FAN1. Verify that there HCT1. The Hall CT will not function properly if are no broken or cracked fan blades and that installed in the incorrect direction.
  • Page 56 ARCMASTER 185 ACDC 200 ACDC 6. E12 "Main Supply Under Voltage" 8. E82 "Rated Voltage Selection Circuit abnormality" Cause Cause Main supply voltage occurs in about 150V or less. Rated voltage selection circuit inside the Welding Power Source is not functioning properly. Verification/Remedy Verification/Remedy a) Verify main supply voltage.
  • Page 57 ARCMASTER 185 ACDC 200 ACDC 10. E85 "Pre-charge abnormality" b) Replace thermistors (TH1, TH2). Cause • Refer to section 11.3.22, 11.3.23. Due to malfunction inside the Welding Power c) Replace PCB6 (WK-5549). Source, primary capacitors are not charging • Refer to section 11.3.6. correctly.

  • Page 58: Verification And Remedy To Failures Without Indication Codes

    ARCMASTER 185 ACDC 200 ACDC 2. “Gas Valve Failure” (No Gas flow through unit) 10.04 Verification and Remedy to Failures without Indication Codes Cause Occurs when the gas valve (SOL1) is defective, damaged or the driving voltage is incorrect. 1. “Cooling Fan Failure” (Fan is not rotating.) Verification/Remedy Cause a) Confirm that TIG welding is selected on the...
  • Page 59 ARCMASTER 185 ACDC 200 ACDC 3. “No weld output” c) Verify the no-load voltage (OCV). (Applies to STICK, High Frequency TIG (HF TIG) mode.) NOTE • Refer to the section "Verification of No-load When in High Frequency TIG (HF TIG) mode, voltage (OCV)"...
  • Page 60 ARCMASTER 185 ACDC 200 ACDC 4. “Operating Panel Failure” (LED’s do not light 5. “High Frequency Output Failure” (Unit does not properly or weld settings cannot be established.) generate High Frequency.) Cause Cause Occurs when there is a connection failure Occurs when the H.F.

  • Page 61: Fault Isolation Tests

    ARCMASTER 185 ACDC 200 ACDC • Verify the connection between AC1-AC2, 10.05 Fault Isolation Tests confirm that the quick-disconnect terminals Preparation: are inserted onto the terminals of HF UNIT1 correctly and completely. The following initial conditions must be met prior to starting any of the procedures in this section.

  • Page 62: Verification Of The Power Input Circuitry

    ARCMASTER 185 ACDC 200 ACDC 3) Verify input voltage after the input switch (S1) 10.06 Verification of the Power Input using an AC voltmeter. (The capability of the Circuitry voltmeter should be more than 600VAC.) • Using an AC voltmeter, measure between the CAUTION points U2 and V2 on the input switch, S1.

  • Page 63: Verification Of Power Supply Voltage

    ARCMASTER 185 ACDC 200 ACDC 6) Verify bus voltage (the voltage of the electrolytic 10.07 Verification of Power Supply capacitor after rectification) using a DC voltmeter. Voltage (The capability of the voltmeter should be more than 1000VDC.) Using a DC voltmeter, measure between the points TB1 (P) [+] and TB2 (N) [-] CAUTION on PCB1 (WK-5477).
  • Page 64 ARCMASTER 185 ACDC 200 ACDC Pin 1 Pin 3 1pin 2pin PCB3 PCB3 CN11 CN18 Figure 11-12: Verification of the FAN1 Figure 10-9: Check Points for TP0-3, 6-11, 00 Voltage Check Point Reference ACCEPTABLE measurement. FAN1 PCB3 PCB3 VALUE (PIN1-PIN2 of Remedy Status CN11 on...
  • Page 65 ARCMASTER 185 ACDC 200 ACDC 2. Verification of the Gas Valve, SOL1, Drive 3. Verification of the primary Diode (D1) Circuitry 1) Verify the characteristic of the primary diode, D1, using a diode tester. CAUTION 2) Refer bellow Table 11-5 and Figure 11-14 for the checkpoints on D1.
  • Page 66 ARCMASTER 185 ACDC 200 ACDC 4. Verification of the secondary Diode (D2, 5. Verification of the primary IGBT (Q1-Q12) D4, D5) 1) Check whether there are any abnormalities in the 1) Verify the characteristic of the secondary diode, appearance of PCB8 and PCB9. D2, D4 and D5, using a diode tester.
  • Page 67 ARCMASTER 185 ACDC 200 ACDC 6. Verification of the secondary IGBT (Q13) Verification of No-load Voltage (OCV) 1) Check whether there are any abnormalities on the appearance of PCB14. CAUTION 2) Verify the characteristic of the secondary IGBT Before performing any portion of the (Q13), using a diode tester.
  • Page 68 ARCMASTER 185 ACDC 200 ACDC Figure 10-18: Removal and installation from the HF UNIT1 (To disable the operation of the HF unit.) 4) Press the Welding mode selection button to select HF TIG welding mode. 5) While depressing the Torch switch, verify the OCV using a DC voltmeter.

  • Page 69: Repair Procedures

    SECTION 11 REPAIR PROCEDURES MAINTENANCE Maintenance List DWG No. Parts name Reference page Part No. 11-10 W7001314 PCB3 Printed Circuit Board (WK-5548) 11-14 W7001319 PCB10 Printed Circuit Board (WK-5527) 11-15 W7001320 PCB11 Printed Circuit Board (WK-5528) 11-16 W7001594 PCB12 Printed Circuit Board (WK-5615) 11-19 W7001433 PCB13...
  • Page 70 ARCMASTER 185ACDC / 200ACDC Part No. DWG No. Parts name Reference page PCB1 Printed Circuit Board (WK-5477) 11-6 W7001402 Printed Circuit Board 185ACDC (WK-5596) 11-7 W7001408 PCB2 Printed Circuit Board 200ACDC (WK-5482 ) 11- 8 W7001407 11-11 10-6635 PCB4 Printed Circuit Board (WK-4819) 11-12 W7001417 PCB5...
  • Page 71 ARCMASTER 185ACDC / 200ACDC DWG No. Parts name Reference page Part No. 11-25 W7001384 Coupling Coil 11-16 W7001304 Current Trans 11-34 10-6628 Primary Diode 11-34 10-6629 Secondary Diode 11-34 10-6629 Secondary Diode 11-34 10-6629 Secondary Diode 11-33 W7001502 FCH1 Reactor 11-26 10-5003 HCT1...
  • Page 72 ARCMASTER 185ACDC / 200ACDC DWG No. Parts name Reference page Part No. 11-31 W7001595 CON1 Remote Connector 11-28 W7001307 FAN1 Cooling Fan 11-35 10-6643 Q13 (PCB15) Secondary IGBT (WK-3367) 11-22 10-5137 Discharge Resistor 11-24 W7001452 Current Limiting Resistor 11-24 W7001452 Current Limiting Resistor 11-24 W7001451...

  • Page 73: Service Tools

    ARCMASTER 185ACDC / 200ACDC Service Tools 2.1 Tools and parts The tools and parts to be used for maintenance are shown by icons. Philips Head Long Nose Silicon Spanner C-Ring Pliers Snap Band Pliers Screwdriver Compound (5.5, 8, 10, 17mm) 2.2 Notes of disassembly and assembly NOTE When removing the locking type connectors and board supporters, disengage the locking mechanism first...

  • Page 74: Replacement Procedure

    ARCMASTER 185ACDC / 200ACDC Replacement Procedure 3.1 PCB1 (WK-5477) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove PCB2 (WK-5596, WK-5482). [Reference page: 11-7] 3) Remove the PCB8 (WK-5479). [Reference page: 11-13] 4) Remove the PCB9 (WK-5479). [Reference page: 11-13] 5) Remove the four screws.

  • Page 75: Pcb2 (Wk-5596) 185Acdc Only

    ARCMASTER 185ACDC / 200ACDC 3.2 PCB2 (WK-5596) 185ACDC only 1) Remove the Side Panel. [Reference page: 10-2] 2) Disconnect the 13 connectors. CN17 CN19 CN21 CN11 3) Remove the four screws and two ground terminals. 4) Remove the PCB3, PCB4, PCB5, PCB6, and PCB7 unit and then disconnect the two connectors. Remove the Insulated Sheet.

  • Page 76: Pcb2 (Wk-5482) 200Acdc Only

    ARCMASTER 185ACDC / 200ACDC 5) Remove the three screws and seven terminals. Remove the PCB2 (WK-5596). 6) Disconnect the three connectors and two terminal from the PCB2 (WK-5596). 3.3 PCB2 (WK-5482) 200ACDC only 1) Remove the Side Panel. [Reference page: 10-2] 2) Disconnect the 13 connectors.
  • Page 77 ARCMASTER 185ACDC / 200ACDC 3) Remove the four screws and two ground terminals. 4) Remove the PCB3, PCB4, PCB5, PCB6, and PCB7 unit and then disconnect the two connectors. Remove the Insulated Sheet. CN15 CN14 5) Remove seven screws and five terminals. Remove the PCB2 (WK-5482). 11 –...

  • Page 78: Pcb3 (Wk-5548), Pcb5 (Wk-5551)

    ARCMASTER 185ACDC / 200ACDC 6) Disconnect two connectors and two terminals from PCB2 (WK-5482). 3.4 PCB3 (WK-5548), PCB5 (WK-5551) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove PCB4 (WK-4819). [Reference page: 11-11] 3) Remove PCB6 (WK-5549). [Reference page: 11-12] 4) Remove PCB7 (WK-5550).

  • Page 79: Pcb4 (Wk-4819)

    ARCMASTER 185ACDC / 200ACDC 7) Disconnect the one connector and remove the two screws, and then remove the PCB5 (WK-5551) from the PCB3 (WK-5548). Remove the one screw and one ground terminal from the PCB5 (WK-5551). CN20 8) Disconnect the two connectors from the PCB3 (WK-5548). CN18 CN33 3.5 PCB4 (WK-4819)

  • Page 80: Pcb6 (Wk-5549)

    ARCMASTER 185ACDC / 200ACDC 3.6 PCB6 (WK-5549) 1) Remove the Side Panel. [Reference page: 10-2] 2) Disconnect the six connectors. CN21 CN17 CN20 3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549). CN27 CN18 CN32 CN30 CN31 3.7 PCB7 (WK-5550) 1) Remove the Side Panel.

  • Page 81: Pcb8 (Wk-5479) (Igbt (Q1~Q6)

    ARCMASTER 185ACDC / 200ACDC 3.8 PCB8 (WK-5479) (IGBT (Q1~Q6)) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the four screws and two IGBT Chassis. 3) Remove the two connectors and three screws. Remove the PCB8 (WK-5479). Remember to install silicone rubber sheets when reinstalling the PCB8 (WK-5479). 3.9 PCB9 (WK-5479) (IGBT (Q7~Q12)) 1) Remove the Side Panel.

  • Page 82: Pcb10 (Wk-5527)

    ARCMASTER 185ACDC / 200ACDC 3) Remove the two connectors and three screws. Remove the PCB9 (WK-5479). Remember to install silicone rubber sheets when reinstalling the PCB9 (WK-5479). 3.10 PCB10 (WK-5527) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the PCB11 (WK-5528). [Reference page: 11-15] 3) Remove the three latches of Front Control Cover and then the PCB10 (WK-5527).

  • Page 83: Pcb11 (Wk-5528)

    ARCMASTER 185ACDC / 200ACDC 3.11 PCB11 (WK-5528) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the Protection Cover. 3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob. 4) Disconnect the one connector from the PCB10 (WK-5527). Remove the four screws. Pull out the Opera- tion Panel and bring it down.

  • Page 84: Pcb12 (Wk-5615), Transformer (T1), Current Trans (Ct2)

    ARCMASTER 185ACDC / 200ACDC 5) Remove the one connector and two screws. Remove the PCB11 (WK-5528). Remove the Encoder Cover from the PCB11 (WK-5528). 3.12 PCB12 (WK-5615), Transformer (T1), Current Trans (CT2) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove PCB13 (WK-5569).
  • Page 85 ARCMASTER 185ACDC / 200ACDC 5) Open the Dust Cover Sheet. Remove the three screws and three terminals. 6) Remove the 16 screws. 7) Remove the PCB12 and T1 unit. 11 – 17...
  • Page 86 ARCMASTER 185ACDC / 200ACDC 8) Cut the one snap band and remove the Current Trans (CT2). 9) Remove the Dust Cover Sheet. Extend the electrode and remove the T-D Bus Bar1, T-D Bus Bar2 and T Center Bus Bar. 10) Remove the two PCB supporters and cushion. Remove the four screws and remove the Main Trans (T1).

  • Page 87: Pcb13 (Wk-5569)

    ARCMASTER 185ACDC / 200ACDC 3.13 PCB13 (WK-5569) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel. 3) Disconnect the six connectors and remove the two screws and two terminals. 4) Remove the two screws and two PCB supporters and remove the PCB13 (WK-5569).

  • Page 88: Pcb16 (Wk-5499)

    ARCMASTER 185ACDC / 200ACDC 3.14 PCB16 (WK-5499) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the Nylon Hose. 3) Disconnect the two connectors. Remove the three PCB supporters and remove the PCB16 (WK-5499). 3.15 PCB14 (WK-5570) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the PCB16 (WK-5499).

  • Page 89: Pcb17

    ARCMASTER 185ACDC / 200ACDC 4) Remove the three PCB supporters from the PCB14 (WK-5570). 3.16 PCB17 (WK-4917) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the six screws and six terminals. 3) Remove the four screws and then open the Rear Board. 11 –...

  • Page 90: Discharge Resistor (R3)

    ARCMASTER 185ACDC / 200ACDC 4) Disconnect the one connector. Remove the two screws and one ground terminal and remove the PCB17 unit. 5) Remove the two screws and remove the S1 Bus Bar from the PCB17 (WK-4917). 3.17 Discharge Resistor (R3) 1) Remove the Side Panel.
  • Page 91 ARCMASTER 185ACDC / 200ACDC 3) Remove the four screws and open the Front Panel. 4) Cut the one snap band and disconnect the one connector. 5) Remove the one screw and one nut and remove the one terminal. 11 – 23...

  • Page 92: Current Limiting Resistor (R4, R5)

    ARCMASTER 185ACDC / 200ACDC 6) Remove the two screws and remove the Discharge Resistor (R3). 3.18 Current Limiting Resistor (R4, R5) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the PCB2 (WK-5596). [Reference page: 11-7] 3) Remove the one screw and remove the Current Limiting Resistor (R4, R5). 3.19 Resistor on High Frequency Unit (R6) 1) Remove the Side Panel.

  • Page 93: Coupling Coil (Cc1)

    ARCMASTER 185ACDC / 200ACDC 3.20 Coupling Coil (CC1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the Nylon Hose. Remove the two bolts, two toothed washers, one washer, and one terminal. 3) Remove the four screws and open the Front Panel. 4) Remove the two terminals.

  • Page 94: Reactor (Fch1)

    ARCMASTER 185ACDC / 200ACDC 5) Remove the one screw and one nut. Remove the one screw and Coupling Coil (CC1). 3.21 Reactor (FCH1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the PCB16 (WK-5499). [Reference page: 11-20] 3) Remove the PCB14 (WK-5570). [Reference page: 11-20] 4) Remove the Coupling Coil (CC1).

  • Page 95: Primary Thermistor (Th1)

    ARCMASTER 185ACDC / 200ACDC 3.22 Primary Thermistor (TH1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Cut the three snap bands. Disconnect the one connector. Remove the one screw and then detach the Primary Thermistor (TH1). Before installing a new therminstor, apply a uniform coat of silicone compound (Shinetsu Silicone G- 747 or equivalent) on the base.

  • Page 96: Cooling Fan (Fan1)

    ARCMASTER 185ACDC / 200ACDC 3.24 Cooling Fan (FAN1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel. 3) Cut the four snap bands and disconnect the one connector. CN11 4) Remove the two screws and detach the Cooling Fan (FAN1).

  • Page 97: Solenoid Valve (Sol1)

    ARCMASTER 185ACDC / 200ACDC 3.25 Solenoid Valve (SOL1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel. 3) Remove the C-ring and detach the Solenoid Valve (SOL1). When reinstalling, make sure that the C-ring seats in the solenoid valve groove.

  • Page 98: Input Voltage Switch (S2)

    ARCMASTER 185ACDC / 200ACDC 3) Remove the two screws and detach the Main ON/OFF Switch (S1). Remove the three posts. 3.27 Input Voltage Switch (S2) 1) Remove the Side Panel. [Reference page:10-2] 2) Remove six screws and six terminals. 3) Remove four screws and open the Rear Board. 11 –...

  • Page 99: Remote Connector (Con1)

    ARCMASTER 185ACDC / 200ACDC 4) Disconnect the one connector CN4 on the PCB4. Remove the two screws and two nuts and then remove the Input Voltage Switch (S2). 3.28 Remote Connector (CON1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the Protection Cover.

  • Page 100: High Freguency Unit (Hf.unit1)

    ARCMASTER 185ACDC / 200ACDC 4) Disconnect the two connectors. Remove the one screw and two ground terminals. CN15 CN14 5) Remove the two screws and Remote Socket (CON1). 3.29 High Freguency Unit (HF.UNIT1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the High Freguency Gap.

  • Page 101: Hall C.t. (Hct1)

    ARCMASTER 185ACDC / 200ACDC 3) Remove the two screws, two washers and detach the High Freguency Unit (HF. UNIT1). 3.30 Hall C.T. (HCT1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel. 3) Remove the one screw and one nut.

  • Page 102: Primary Diode (D1)

    ARCMASTER 185ACDC / 200ACDC 4) Remove the one screw. Remove the Hall C. T. (HCT1) while slighty pressing down the bus bar. 3.31 Primary Diode (D1) 1) Remove the Side Panel. [Reference page: 10-2] 2) Remove the PCB2 (WK-5596, WK-5482). [Reference page: 11-7] 3) Remove the two screws and four terminals.

  • Page 103: Secondary Igbt (Q13) (Pcb15 (Wk-3367)

    ARCMASTER 185ACDC / 200ACDC 5) Remove the six screws and then detach the Secondary Diode (D2, D4, D5). Do not have the wrong direction of the diodes when reinstalling. Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.
  • Page 104 ARCMASTER 185ACDC / 200ACDC 6) Remove the one connector and two screws and remove the Secondary IGBT (Q13). Before sinstalling a new IGBT, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base. 11 – 36...

  • Page 106: Appendix 1: Parts List

    A PPEN D I X 1 PA R TS LI ST Equi pm ent I dent i f i cat i on Al li dent i f i cat i on num ber s as descr i bed i n t he I nt r oduct i on chapt erm ustbe f ur ni shed w hen or der i ng par t s or m aki ng i nqui r i es.Thi s i nf or m at i on i s usual l y f ound on t he nam epl at e at t ached t o t he equi pm ent .Be sur e t o i ncl ude any dash num ber s f ol l ow i ng t he Par torAssem bl y num ber s.
  • Page 107 185A C D C /200A C D C PA R TS LI ST No. DWG No. Part No. Description Additional Information QTY. 10-5137 Resistor, gen 3.1, IPS JG23V101J 68W 100Ω R4-5 W7001452 Resistor, gen 3.1, IPS MHS20A221KI 20W 220Ω W7001451 Resistor, gen 3.1, IPS MHS20A101KI 20W 100Ω...
  • Page 108 185A C D C /200A C D C PA R TS LI ST 69 74 A- 3...
  • Page 109 185ACDC / 200ACDC PARTS LIST...

  • Page 110: Appendix 2 Connection Wiring Guide

    APPENDIX 2 CONNECTION WIRING GUIDE CONNECTION WIRING GUIDE APPENDIX 2 Connection Wiring Guide Destination PCB2 PCB4 PCB2 PCB3 PCB2 PCB3 PCB3 PCB17 PCB3 FAN1 PCB3 CN11 SOL1 PCB3 CN20 PCB8 PCB3 CN21 PCB8 PCB3 CN22 PCB9 PCB3 CN23 PCB9 PCB3 CN18 PCB7 CN20...
  • Page 111 185ACDC / 200ACDC CONNECTION WIRING GUIDE CN21 PCB17 CN17 PCB6 CN20 FAN1 CN33 PCB4 SOL1 PCB10 PCB11 CN18 PCB7 CN11 CN20 CN15 CN22 CN14 CN20 CN23 CON1 CN21 PCB9 PCB3 PCB8 PCB16 PCB2 PCB15 HCT1 PCB13...
  • Page 112 APPENDIX 3 INTERCONNECT DIAGRAM APPENDIX 3 INTERCONNECT DIAGRAM INTERCONNECT DIAGRAM INTERCONNECT DIAGRAM 185ACDC PCB8 PCB1 K(7) IGBT Gate Main G(6) Circuit Circuit Board Board [WK-5493] R(3) [WK-5477] Line1 S(4) Line2 T(5) Ground PCB17 PCB2 Filter Link Circuit Board Circuit Board [WK-4917] [WK-5596] PCB9...
  • Page 113 185ACDC / 200ACDC INTERCONNECT DIAGRAM PCB12 PCB14 DIODE Snubber IGBT Snubber Circuit Board Circuit Board [WK-5615] [WK-5570] FCH1 TB20 PCB15 TB22 IGBT Gate Circuit Board +Output TB12 [WK-3367] Terminal TB21 1 2 3 4 5 1 2 3 4 5 Ground RY+15V PCB16...
  • Page 114 185ACDC / 200ACDC INTERCONNECT DIAGRAM 200ACDC PCB8 PCB1 K(7) IGBT Gate Main Circuit G(6) Circuit Board Board [WK-5493] R(3) [WK-5479] Line1 S(4) Line2 Line3 T(5) Ground PCB2 PCB17 Link Filter Circuit Board Circuit Board [WK-5482] [WK-4917] PCB9 IGBT Gate SIDE CHASSIS 1 Circuit Board REAR...
  • Page 115 185ACDC / 200ACDC INTERCONNECT DIAGRAM PCB12 PCB14 DIODE Snubber IGBT Snubber Circuit Board Circuit Board [WK-5615] [WK-5570] FCH1 TB20 PCB15 TB22 IGBT Gate Circuit Board +Output TB12 [WK-3367] Terminal TB21 1 2 3 4 5 1 2 3 4 5 Ground RY+15V PCB16...

  • Page 116: Appendix 4 Diode Testing Basics

    APPENDIX 4 DIODE TESTING BASICS DIODE TESTING BASIC APPENDIX 4 DIODE TESTING BASIC Testing of diode modules requires a digital Volt/ Ohmmeter that has a diode test scale.Locate the diode module to be tested.Remove cables from mounting studs on diodes to isolate them within the module.Set the digital volt/ohm meter to the diode test scale.Using figure 1 and 2, check each diode in the module.

  • Page 118: Limited Warranty

    No employee, agent, or representative of thermal arc is authorized to change this warranty in any way or grant any other warranty, and thermal arc shall not be bound by any such attempt.

  • Page 119: Warranty Schedule

    WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. April 2006 ENGINE DRIVEN WELDERS ARRANTY ERIOD ABOR Scout, Raider, Explorer Original Main Power Stators and Inductors .................. 3 years 3 years Original Main Power Rectifiers, Control P.C. Boards ..............3 years...

  • Page 121: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne Asia Sdn Bhd Thermadyne USA Lot 151, Jalan Industri 3/5A 2800 Airport Road Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 800-426-1888 West Malaysia Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 122 World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 Fascimile: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.com...

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