Thermadyne Thermal Arc 185TSW Operating Manual Download Page 2

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Summary of Contents for Thermal Arc 185TSW

Page 1: ...November 13 2003 Manual No 430429 503 INVERTER ARC WELDER MODEL 185TSW AC DC CC STICK TIG Lift Start HF START OPERATING MANUAL...

Page 2: ......

Page 3: ...r Pro Wave 185TSW 28 4 05 Power Source Features 29 5 0 SET UP FOR SMAW STICK AND GTAW TIG 31 6 0 SEQUENCE OF OPERATION 32 6 01 Stick Welding 33 6 02 AC or DC HF TIG Welding 34 6 02 01 Slope Mode Seque...

Page 4: ...4 13 0 PARTS LIST 53 APPENDIX A INTERCONNECT DIAGRAM 56 APPENDIX B AUTOMATION 58...

Page 5: ...anel 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 R...

Page 6: ...rc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE...

Page 7: ...f metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercur...

Page 8: ...this manual ARC WELDING RAYS Arc Welding Cutting Rays can injure your eyes and burn your skin The arc welding cutting process produces very bright ultra violet and infra red light These arc rays will...

Page 9: ...RS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable f...

Page 10: ...teur et les autres personnes sur le lieu de travail Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du...

Page 11: ...ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les...

Page 12: ...12 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 ivret...

Page 13: ...sten Arc Welding GTAW Gas Tungsten Arc Welding Pulsed GTAW P Gas Tungsten Arc Welding Sloped GTAW S and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resi...

Page 14: ...rposes 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 EQU...

Page 15: ...ly reduces the skin resistance of the human body and the insulation properties of accessories Environments with hazardous environments do not include places where electrically conductive parts in the...

Page 16: ...the type of electrical service available how proper connections should be made and any inspection required The line disconnect switch provides a safe and convenient means to completely remove all ele...

Page 17: ...30V 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 C...

Page 18: ...ximately 5 seconds Note 3 Note the available input power Damage to the PCA could occur if 460VAC or higher is applied The following 208 230V Primary Current recommendations are required to obtain the...

Page 19: ...ne can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direc...

Page 20: ...ight 41 8 lb 19 kg Output Rated Load Output Amperes Output Volts Duty Cycle KVA KW 160A 26V 40 8 7 5 2 Output No Load KVA KW 0 5 0 13 Input Volts Single Phase 208V 230V Amperage Draw Rated Load 40 38...

Page 21: ...the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature CAUTION 1 Continually exceeding the duty cycle ratings ca...

Page 22: ...22 PAGE LEFT INTENTIONALLY BLANK...

Page 23: ...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 Socke...

Page 24: ...inse type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 4 Negative Terminal Welding current flows from the Power Source v...

Page 25: ...SLOPE No Yes Yes 4T operation in TIG Modes with crater fill using a remote contactor device to control sequence REPEAT No Yes Yes 4T operation in TIG Modes with repeat operation and crater fill using...

Page 26: ...of the BASE WELD current e g HOT START current 130 amps when BASE WELD 100 amps HOT START 30 amps INITIAL CUR This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the start...

Page 27: ...ed aluminium or magnesium alloys is achieved when the WAVE BALANCE control is set to 65 WAVE BALANCE 10 Maximum Penetration and reduced cleaning WAVE BALANCE 50 Balanced with 50 penetration and 50 cle...

Page 28: ...s Yes WELD CUR STICK 5 to 160A 80A 1A Yes No No SPOT TIME 0 5 to 5 0 sec 2 sec 0 1 sec No Yes Yes PULSE WIDTH 15 to 80 50 1 No Yes Yes PULSE FREQ 0 5 to 500Hz 100 0Hz See Table 6 No Yes Yes AC FREQUEN...

Page 29: ...l components reaches operating temperature ON OFF switch Primary voltage Supply ON OFF switch located on rear panel Voltage Reduction Device VRD Reduces the OCV when the power supply is not in use Eli...

Page 30: ...30 PAGE LEFT INTENTIONALLY BLANK...

Page 31: ...nnecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off CAUTION 3 Remove any packaging material prior Remove any pack...

Page 32: ...s 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 descri...

Page 33: ...urce also used to set each parameter value Pushing the knob inward displays the actual welding voltage 6 Process Button This button selects between STICK Lift or HF TIG mode A remote control device is...

Page 34: ...Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set PRE FLOW time Set HOT START c...

Page 35: ...as the remote switch contacts are open 3 Close Remote Switch Welding current decreases to final current setting Once final welding current is reached the power source will maintain final current sett...

Page 36: ...een two levels During the periods of Peak current heating and fusion takes place and during the background base current periods cooling and solidification take place Pulse Width is the time in one cyc...

Page 37: ...c is stationary the pool becomes thoroughly cleaned by election emission the fluttering begins Tests conducted on various types of AC TIG power sources Fluttery Arc is not confined to one type of powe...

Page 38: ...mm 190 280 190 280 3 16 4 8mm 250 340 250 340 Table 8 Current ranges for varies tungsten electrode sizes 7 04 Tungsten Electrode Types Electrode Type Ground Finish Welding Application Features Color C...

Page 39: ...s a registered trademark of BOC Gases Limited Aluminium alloys Welding Argon Argoshield 80T 81T Carbon Steel Welding Argon Stainless Steel Welding Argon Argoshield 71T 80T 81T Nickel Alloy Welding Arg...

Page 40: ...8mm 13 Lap Fillet Table 13 AC TIG welding parameter 7 09 Welding Parameters for Steel Base Metal Thickness DC Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Filler R...

Page 41: ...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...

Page 42: ...rimary capacitors to discharge To clean the unit open the enclosure please refer to Section 8 01 01 Opening the Enclosure in the 185TSW Service Manual P N 430429 512 and use a vacuum cleaner to remove...

Page 43: ...dent on the selection of the correct consumables maintenance of equipment and proper welding technique Description Possible Cause Remedy 1 Excessive bead build up or poor penetration or poor fusion at...

Page 44: ...aise gas pressure and blow out impurities E Gas regulator turned off E Turn on F Torch valve is turned off F Turn on G The electrode is too small for the welding current G Increase electrode diameter...

Page 45: ...Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in weld metal Porosity A B C Electrodes are damp Welding current is too high Surface impurities such as oil grease paint etc A...

Page 46: ...ay be trapped in undercut from previous run A If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode B Joint preparation too restricted B Allow for adequate p...

Page 47: ...3 Welding current reduces when welding A B C D E Loose welding cable connections Incorrect welding cable size Improper input connections Poor electrode condition Wrong welding polarity A B C D E Tight...

Page 48: ...rc Service Agent repair or replace the gas valve C Gas valve jammed open C Have an Accredited Thermal Arc Service Agent repair or replace the gas valve D POST FLOW control is set to 60 sec D Reduce PO...

Page 49: ...ce every 3 months and b For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests Note 7 A transportable power source is any equi...

Page 50: ...s being blocked A B C Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Weld current cea...

Page 51: ...age primary capacitors is reduced for one second Mains supply voltage is down to a dangerously low level A B Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains vol...

Page 52: ...n control PCB can not read write weld parameters Memory chip EEPROM error Have an Accredited Thermal Arc Service Agent check the control PCB Weld current ceases Buzzer sounds constantly Switch machine...

Page 53: ...200A 4V 1 11251003000 10 5003 HF UNIT 1 HF Unit HF UNIT WK 4840 U02 1 U0A632200 10 6632 HF Gap U0A601100 1 U0A601100 10 6633 L105 Inductor 1615MRE RING CORE 1 63200006500 10 6538 PCB1 Printed Circuit...

Page 54: ...646 T2 Transformer F2A708300 250A MTR 1 F2A708300 10 6646 T3 Transformer F2A758000 AC DC DTR 1 F2A758000 10 6648 TH1 2 Thermistor ERTA53D203 20K 25 C B 3950K 1 U0A733300 10 6784 Front Panel E0D005300...

Page 55: ...0 6667 Flat Cable EAA547301 1 EAA547301 10 6668 Post1 M4 M5 EBA424900 2 EBA424900 10 6669 Post4 M4 M4 EBA431100 3 EBA431100 10 6670 Post5 M4 M4 EBA431200 6 EBA431200 10 6671 Post6 M5 M5 EBA431300 1 EB...

Page 56: ...56 APPENDIX A INTERCONNECT DIAGRAM...

Page 57: ...57...

Page 58: ...pped from the factory with the jumpers set in position A This is for normal semi automatic operation utilizing a remote device such as a foot control The 8 pin remote operates as described earlier in...

Page 59: ...59 Figure 11 Location of PCB WK 4921...

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