INVERTER ARC WELDER MODEL 185TSW AC/DC CC STICK TIG - Lift Start HF START OPERATING MANUAL November 13, 2003 Manual No.
CONTENTS SYMBOL LEGEND .......................................................................................................................................................5 STATEMENT OF WARRANTY ...................................................................................................................................6 1.0 GENERAL INFORMATION....................................................................................................................................7 1.
13.0 PARTS LIST......................................................................................................................................................... 53 APPENDIX A – INTERCONNECT DIAGRAM ........................................................................................................ 56 APPENDIX B - AUTOMATION.................................................................................................................................
SYMBOL LEGEND Amperage STICK (Shielded Metal Arc SMAW) Voltage Pulse Current Function Hertz (frequency) Spot Time (GTAW) SEC Seconds Remote Control (Panel/Remote) % Percent Remote Function DC (Direct Current) Arc Control (SMAW) AC (Alternating Current Gas Post-Flow Standard Function Gas Pre-Flow Slope Function VRD Voltage Reduction Device Circuit Slope W/Repeat Function Negative Spot Function Positive Impulse Starting (High Frequency GTAW) Gas Input Touch Start (Lift Start TIG cir
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.
• 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 welding/cutting depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following: 1.
• Install and maintain equipment according to NEC code, refer to item 4 in Subsection 1.03, Publications. • Disconnect power source before performing any service or repairs. • Read and follow all the instructions in the Operating Manual. ARC WELDING RAYS Arc Welding/Cutting Rays can injure your eyes and burn your skin. The arc welding/cutting process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau. • secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage. • Réparez ou remplacez toute pièce usée ou endommagée. Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz. • Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement. • Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire. 1.06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : 1.
ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.
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.
2.02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of the 185TSW-power supply. Figure 2. 185TSW Model Functional Block Diagram 2.03 Transporting Methods These units are equipped with a handle for carrying purposes. WARNING 1 ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source. WARNING 2 FALLING EQUIPMENT can cause serious personal injury and equipment damage.
3.0 Installation Recommendations 3.01 Environment The Pro-Wave 185TSW is designed for use in hazardous environments.
3.03 Electrical Input Connections WARNING 4 ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. 3.03.
Input Voltage 208V 230V Fuse Size 45 Amps 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.
3.03.02 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds). Note 3 Note the available input power. Damage to the PCA could occur if 460VAC or higher is applied.
3.03.03 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following information is intended as a guide for personnel installing high frequency welding machines. Warning Explosives The high frequency section of this machine has an output similar to a radio transmitter.
3.04 Specifications Parameter Rated Output Amperes Volts Duty Cycle Duty Cycle 185TSW TIG STICK Output Current TIG Range STICK Open Circuit Voltage Dimensions Width Height Length Weight Output @ Rated Load Output Amperes Output Volts Duty Cycle KVA KW Output @ No Load KVA KW Input Volts Single Phase 208V 230V 185 17.4 25% 185A / 17.
3.05 Duty Cycle The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty cycle will decrease.
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4.0 OPERATOR CONTROLS 4.01 Pro-Wave 185TSW Controls Figure 4– Pro-Wave 185TSW Power Source 1 Control Knob This control sets the selected weld parameter, rotating it clockwise increases the parameter that is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage. 2 Remote Control Socket The 8 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source.
Socket Pin Function 1 2 Earth (Ground) Torch Switch Input (24V) to energize weld current.
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 Selection STICK HF TIG LIFT TIG Yes Yes Yes 2T operation in TIG Modes using remote devices to control contactor & current No Yes Yes 4T operation in TIG Modes with crater fill using a remote contactor device to control sequence. No Yes Yes 4T operation in TIG Modes with repeat operation and crater fill using a remote contactor device.
4.03 Weld Parameter Descriptions for Pro-Wave 185TSW Figure 5 Pro-Wave 185TSW Front Panel with Parameter Description Parameter PRE-FLOW HOT START INITIAL CUR. UP SLOPE PEAK CUR. WELD BASE (Background Current) Description This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc, once the torch trigger switch has been pressed. This control is used to dramatically reduce weld porosity at the start of a weld.
Parameter SPOT TIME PULSE WIDTH Description This parameter sets the duration of the SPOT TIME in HF TIG mode only This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSE is on. PULSE FREQ. This parameter sets the PULSE FREQUENCY when the PULSE is on. AC FREQUENCY This parameter operates in AC mode only and is used to set the frequency for the AC weld current.
4.04 Weld Parameters for Pro-Wave 185TSW Weld Mode HF LIFT STICK TIG TIG No Yes Yes Yes Yes No No Yes Yes No Yes Yes No Yes Yes Weld Parameter PRE-FLOW HOT START INITIAL CUR. UP SLOPE PEAK CUR. WELD CUR (TIG) WELD CUR (STICK) SPOT TIME PULSE WIDTH Parameter Range 0.0 to 1.0 sec 0 to 70A 5 to 185A 0 to 15 sec 5 to 185A Factory Setting 0.1 sec 20A 30A 1 sec 120A Incremental Unit 0.1 sec 1A 1A 0.1 sec 1A 5 to 185A 80A 1A No Yes Yes 5 to 160A 80A 1A Yes No No 0.5 to 5.
4.
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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. The welding current range values should be used as a guide only.
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.
1. Pulse function – Pressing this button enables the TIG current pulse functions. 2. Scroll Buttons – used to select the parameters to be set. The LED’s show which function is being adjusted on the Sequence Graph. 3. TIG Mode Functions – Pressing this button scrolls through the output TIG function modes (Standard, Slope, Slope w/repeat, Spot). 4. Digital LED display – Welding amperage and parameter values are displayed in this window.
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 • Connect remote control device. . See section 4.01, section 2 “Remote Control Socket”, for complete details of the remote device. Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph.
6.02.01 Slope Mode Sequence Switch Closed Initial Current Switch Open Up Slope Switch Closed Weld Current Down Slope Switch Open Final 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.
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) 2) 3) 4) 5) Control puddle – size and fluidity (especially out of position). Increase penetration Travel speed control Better consistent quality Decreased distortion on lighter or thinner materials. 6.02.
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. Electron emission from the weld pool (DC+) causes the oxide layers to be disrupted, the so-called “cleaning action”.
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. 7.03 Tungsten Electrode Current Ranges Electrode Diameter AC Current (Amps) DC Current (Amps) 0.040” (1.0mm) 30 – 70 30 – 60 1/16” (1.6mm) 60 – 95 60 – 115 3/32” (2.
7.05 Guide for Selecting Filler Wire Diameter Filler Wire Diameter AC Current Range (Amps) DC Current Range (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 – Filler wire selection guide NOTE 6 The filler wire diameter specified in Table 10 is a guide only, other diameter wires may be used according to the welding application. 7.
7.08 Welding Parameters for Aluminum Base Metal Thickness AC Current for Aluminum Tungsten Electrode Diameter Filler Rod Diameter (if required) Argon Gas Flow Rate Liters/min 0.040” 30-45 35-50 0.040” 1.0mm 1/16” 1.6mm 5-7 Butt/Corner Lap/ Fillet 40-60 45-70 0.040” 1.0mm 1/16” 1.6mm 5-7 Butt/Corner Lap/ Fillet 60-85 70-95 1/16” 1.6mm 1/16” 1.6mm 7 Butt/Corner Lap/ Fillet 125-150 130-160 3/32” 2.4mm 10 Butt/Corner Lap/ Fillet 180-225 190-240 3/32” 2.4mm 1/8” 3.2mm 1/8” 3.
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 cracks.
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. To clean the unit, open the enclosure (please refer to Section 8.01.
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.
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. 7 Dirty weld pool. A Electrode contaminated through contact with work piece or filler rod material. B Gas contaminated with air. A Clean the electrode by grinding off the contaminates.
Description Possible Cause C Gas flow incorrectly set, cylinder empty or the torch valve is off. 12 Arc start is not smooth. Remedy C Select the right flow rate, change cylinders or turn torch valve on. A Tungsten electrode is too A Select the right size large for the welding current. electrode. Refer to Basic TIG Welding Guide. B The wrong electrode is being B Select the right electrode used for the welding job. type. Refer to Basic TIG Welding Guide. C Gas flow rate is too high.
4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint. A Small electrodes used on heavy cold plate. B Welding current is too low. A Use larger electrodes and preheat the plate. B Increase welding current. C Wrong electrode angle. C Adjust angle so the welding arc is directed more into the base metal. D Travel speed of electrode is D Reduce travel speed of too high. electrode. E Scale or dirt on joint surface. E Clean surface before welding.
10.03 Power Source Problems Description 1 The welding arc cannot be established. Possible Cause A The Primary supply voltage A Switch ON the Primary has not been switched ON. supply voltage. B The Welding Power Source B Switch ON the Welding switch is switched OFF. Power Source. C Loose connections internally. C Have an Accredited Thermal Arc Service Agent repair the connection 2 Maximum output Defective control circuit. welding current can not be achieved with nominal Mains supply voltage.
Description Possible Cause 5 Gas flow won’t shut off. Remedy A Weld Mode (STD, SLOPE, A Strike an arc to complete REPEAT or SPOT) was the weld cycle. changed before POST-FLOW OR gas time had finished. Switch machine off then on to reset solenoid valve sequence. B Gas valve is faulty. B Have an Accredited Thermal Arc Service Agent repair or replace the gas valve C Gas valve jammed open.
11.0 Voltage Reduction Device (VRD) 11.01 VRD Specification Description VRD Open Circuit Voltage VRD Resistance VRD Turn OFF Time Pro-Wave 185TSW 15.3 to 19.8V Notes Open circuit voltage between welding terminals. 148 to 193 ohms The required resistance between welding terminals to turn ON the welding power. 0.2 to 0.3 seconds The time taken to turn OFF the welding power once the welding current has stopped. 11.
4 E04 error code displayed Output voltage exceeds the secondary voltage specification. 3 E03 error code displayed Primary (input) current too high. 2 E02 error code displayed Temperature sensor TH2 (protects secondary diodes) is greater than 80ºC for about 1 second. 1 E01 error code displayed Temperature sensor TH1 (protects IGBTs) is greater than 80ºC for about 1 second. Description Possible Cause 50 TIG torch cable and/or work lead are too long or leads are coiled.
Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage. When 3 phase machine is first turned on with the wrong Primary supply (input) voltage connected. The Primary supply (input) voltage fluctuates and is not stable. 8 E81 error code displayed Wrong Primary supply (input) voltage connected. 9 E82 error code displayed Rated voltage selection circuit abnormality. 51 A Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage.
14 E99 error code displayed Mains supply (input) voltage has been turned off but control circuit has power from the primary capacitors. The Welding Power Source’s temperature sensors have malfunctioned. 13 E94 error code displayed Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit. 52 A Main on/off switch on A Turn on/off switch on. machine has been turned off B Mains supply (input) B Have an Accredited Thermal voltage has been turned off.
Diode Diode Diode Diode Diode Fan Inductor Current Sensor HF. Unit HF. Gap Inductor Printed Circuit Board Printed Circuit Board Printed Circuit Board Printed Circuit Board Printed Circuit Board Printed Circuit Board Printed Circuit Board Printed Circuit Board D1 D2 D4 D5 D10 FAN1 FCH1 HCT1 HF.UNIT 1 PCB2 PCB3 PCB4 PCB5 PCB6 PCB7 PCB8 L105 PCB1 Description Capacitor Coupling Coil Remote Socket DWG. No. C1 CC1 CON1 13.0 PARTS LIST 53 Type & Rating ECQE12104MZ DC1250V 0.
Description Transistor Transistor Resistor (For HF Unit) Resistor Switch Solenoid Valve Transformer Transformer Transformer Thermistor Front Panel Rear Panel Side Panel Front Control Cover Rear Control Cover Protection Cover Encoder Cover PCB Cover Name Label Side Label Warning 1 Label Warning 2 Label DWG. No. Q1 Q2 R1 R2 S1 SOL1 T1 T2 T3 TH1,2 13.
DWG. No. Description Output Terminal Label Gas Outlet C-Ring Output Terminal (female) Input Cable Input Cable Clamp Heatsink Heatsink Knob Knob Cap Control Cover Sheet Flat Cable Post1(M4-M5) Post4(M4-M4) Post5(M4-M4) Post6(M5-M5) Post7(M5-M5) Post8(M5-M5) D2-4 Bus Bar CC Bus Bar S1 Bus Bar Clip Transformer Chassis Right Chassis Left Chassis Nylon Hose Output Terminal (male) Operators Manual Service Manual 13.
APPENDIX A – INTERCONNECT DIAGRAM 56
APPENDIX B - AUTOMATION JUMPER SETTING FOR "OK–TO–MOVE". Models 185TSW Three jumpers (JP1, JP2 and JP3) are provided on PC Board WK-4921 for automation purposes. This PCB is mounted horizontally on top of the unit just under the cover. This PCB can be accessed by removing the side covers by loosening 4 screws on each the front and rear panel, then removing the 4 side panel screws as well as the 2 handle screws. Carefully pull the front and rear panels outward to release and remove the side cover.
Figure 11 – Location of PCB WK-4921 59
