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THERMAL ARC 180 AC/DC

USER’S MANUAL

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Summary of Contents for 180 AC

Page 1: ...THERMAL ARC 180 AC DC USER S MANUAL ...

Page 2: ...ears if you respect all the operating and maintenance instructions given in this manual We strongly suggest you read very carefully chapters concerning safety and individual protection before using this machine We thank you in advance for your co operation THERMADYNE INDUSTRIES reserve the right to make changes without previous notification Illustrations descriptions and characteristics are not co...

Page 3: ...ng of the workpiece 8 1 2 2 6 Screening and shielding 8 2 ELECTRIC SAFETY 8 2 1 CONNECTION OF THE WELDING POWER SOURCE TO THE NETWORK 8 2 2 WORKING AREA 8 2 3 INTERVENING 9 2 4 MAINTENANCE 9 2 5 RISKS OF FIRE AND EXPLOSION 9 3 INDIVIDUAL PROTECTION 9 3 1 RISK OF EXTERNAL INJURIES 9 3 1 1 THE WHOLE BODY 9 3 1 2 FACE AND EYES 10 3 2 RISK OF INTERNAL INJURIES 10 3 3 SAFETY IN THE USE OF GASES welding...

Page 4: ...DE 18 12 2 BEFORE WELDING 19 12 3 WELDING 20 12 4 USING REMOTE CONTROL 21 12 5 CONNECTION OF A COOLING UNIT 21 12 6 READING PARAMETERS WHEN WELDING 21 12 7 VENTILATION in tig welding 21 13 WELDING WITH PULSE DC CURRENT 22 14 AC CURRENT TIG WELDING 23 15 TIG WELDING IN PULSE AC CURRENT 25 16 HIDDEN WELDING PARAMETERS 27 MAINTENANCE 28 17 MAINTENANCE 28 18 SPARE PARTS 28 19 PCB S CONNECTORS 29 20 TR...

Page 5: ... by the manufacturer are not included in the guarantee Guarantee covers free of charge replacement of parts which have been admittedly defective transport included Every part replaced under guarantee will be automatically invoiced after a period of 1 month in case of non return of the defective part Labour executed by the distributor is entirely at their cost However if you request labour can be p...

Page 6: ...of 28 04 1992 and 93 68 EEC of 22 07 1993 Low voltage Rule 73 23 EEC of 19 02 1973 modified by rule 93 68 EEC of 22 07 1993 and with the national legislation transposing them THERMADYNE Industries also declare that following harmonised standards have been applied EN 50199 1995 Electromagnetic compatibility CEM Product norm for arc welding material EN 50060 1990 Current source for arc manual weldin...

Page 7: ...other activities are to be carried out 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 1 2 2 METHODS OF REDUCING EMISSIONS 1 2 2 1 Public supply system Arc welding equipment should be connected to the public supply system according to the m...

Page 8: ...HE NETWORK Before connecting your equipment you must check that The meter the safety device against over currents and the electric installation are compatible with the maximum power and the supply voltage of the welding power source refer to the instructions plates The connection either single phase or three phase with earth can be effected on a socket compatible with the welding power source cabl...

Page 9: ...standards if consistent with the safety rules They can either be controlled by you or by accredited firms Maintenance and repair works of conduits and liners have to be properly carried out Section VI Art 47 Repair or replace all defective accessories Check periodically that the electrical connections are tightened and do not heat 2 5 RISKS OF FIRE AND EXPLOSION Welding can occur risks of fire or ...

Page 10: ...cted techniques 0 5 2 5 10 20 40 80 125 175 225 275 350 450 1 5 15 30 60 100 150 200 250 300 400 500 Coated electrodes 9 10 11 12 13 14 MIG on heavy metals 10 11 12 13 14 MIG on light alloys 10 11 12 13 14 15 TIG on all metals 9 10 11 12 13 14 MAG 10 11 12 13 14 15 Air Arc gouging 10 11 12 13 14 15 Plasma cutting 9 10 11 12 13 Depending on the conditions of use the next highest or lowest category ...

Page 11: ... the valve on the cylinder Always check that hoses are in good condition 3 3 3 DETAILS ABOUT GASES Gas and gaseous mixtures containing less than 20 of CO2 If these gases or mixtures take the place of the oxygen in the air there is a danger of asphyxia An atmosphere containing less than 17 oxygen is dangerous hydrogen and hydrogen based combustible gaseous mixtures These are very light gases In the...

Page 12: ...tion These units can be supplied by engine driven generators They offer a very high quality of welding in 1 stick welding Exceptional arc characteristics with a microprocessor that ensures regulation and perfect blade appearence and spatter control Maximum user s comfort strengthened by arc force and anti stick 2 TIG welding Ignition of the arc can be made with high frequency or using a lift arc t...

Page 13: ...DARY Off load voltage V 50 60 Minimum secondary current A 3 MMA stick and TIG welding Welding current at 50 A 180 Welding current at 60 A 160 Welding current at 100 A 140 Courant alternatif AC current Frequency Hz From 20 to 250 Waves form square waves Balance cleaning penetration Cleaning from 20 penetration 80 to 60 penetration 40 Pulse current low current A From 3 to welding current Frequency H...

Page 14: ...ety 7 CONNECTION TO THE GROUND For the operator s protection the power source must be correctly grounded according to the International Protections Norms It is absolutely necessary to provide a good ground connection installation with the green yellow lead of the power cable This will avoid discharges caused by accidental contacts with grounded pieces If no earth connection has been set a high ris...

Page 15: ...Notice NOT 034 THERMAL ARC 180 AC DC Rev 00 Date 03 12 02 USING USER S MANUAL Page 15 36 9 DESCRIPTION OF THE FRONT PANEL ...

Page 16: ... pulse low current setting key F16 pulse frequency setting key AC current frequency setting key F17 pulse cycle ratio setting key Balance cleaning penetration setting key F18 current in Amps displayed indicator F19 voltage displayed in Volts indicator F20 Warning indicator F21 2 stroke indicator F22 4 stroke indicator F23 H F ignition indicator F24 TIG welding indicator F25 Stick welding indicator...

Page 17: ...OFF B2 When you start the machine the orange indicator F20 illuminates during 2s and then goes out if no failure has been found Select MMA stick welding mode with setting key F14 the indicator F25 illuminates Adjust welding current with potentiometer F9 Digital display F5 shows the selected current in Amps indicator F18 illuminates Place the electrode on the workpiece in order to strike the arc Ar...

Page 18: ...ding the parameters when welding When welding digital display F5 shows welding current in Amps measured by the machine It is possible to read the welding voltage when pressing the setting key F6 The value is displayed in Volts indicator F18 goes out and F19 illuminates Press setting key F6 in order to display current s value again Ventilation in MMA stick welding Fan allows the cooling of electron...

Page 19: ... stroke is selected the indicator F22 illuminates If the mode 2 stroke is selected the indicator F21 illuminates select the ignition mode with the key F13 If HF ignition is selected the indicator F23 illuminates set the TIG cycle parameters During their adjustment the parameter s value is displayed by digital display F5 When adjusting a current the indicator F18 illuminates A Amps In the other cas...

Page 20: ...F18 illuminates 12 3 WELDING Select tungsten electrode Place on the torch a tungsten electrode thoriated 2 or 4 or even better electrode DLZ Itrium Lanthane Zirconium or lanthane not so radioactive Grid electrode s head at 60 or 90 See adviced electrode s diameter adapted to welding current Electrode s diameter mm 1 1 6 2 0 2 4 3 0 4 0 Welding DC current A 75 50 120 90 190 130 250 170 300 250 400 ...

Page 21: ...ontrol as soon as you plug it in female socket F1 IMPORTANT using the potentiometer of remote control or torch you can adjust the welding current from 3A to the current selected with the main potentiometer F9 of the power source This value is displayed on F5 when the potentiometer of the remote control is on maximum This allow you to set the welding current with fine adjustment directly on the rem...

Page 22: ...C DC units have got an integrated pulse current function To set the pulse current press the setting key F15 The indicator F27 illuminates indicator F26 OFF To remove the pulse current press the setting key F15 until indicator F27 fade out XAdjustment of the pulse high current Adjust the high current with the potentiometer F9 The value can be read on display F5 YAdjustment of the pulse low current ...

Page 23: ...s finished Cycle ratio The cycle ratio is the ratio between the time of high current warm time th and the total time th tb of the pulse in i e R th th tb When F26 OFF and F27 ON press the setting key F17 adjust the cycle ratio with the potentiometer F9 The value in can be read on the display F5 When the potentiometer is at the minimum the ratio is of 20 and when it is at the maximum it is of 80 Th...

Page 24: ...ect upon the proportion of positive current in the arc The balance is TD TD TP in Penetration The negative halfcycle TP is longer than the positive TD You need a lower welding current which allows less heating of the tungsten electrode which allows longer time between electrode grinding reduction of the affected area on the workpiece Use for clean workpiece only Cleaning The positive alternating T...

Page 25: ...50 40 80 60 110 70 140 90 180 160 240 230 340 Welding For the adjustment of other parameters and for welding see instructions given in chapter 12 DC Current TIG welding 15 TIG WELDING IN PULSE AC CURRENT The selection of TIG in AC current welding mode is made in 4 stages X Select TIG welding mode Press the setting key F14 to choose TIG welding mode the indicator F24 illuminates To adjust the param...

Page 26: ...se indicators F26 and F27 ON you could not make any more adjustments that the reason why you have to do them in previous stages To make any modification change the welding mode with the setting key F15 Indicator F26 ON and indicator F27 OFF modification of AC current parameters Indicator F27 ON and indicator F26 OFF modification of pulse current parameters At the end of modifications come back to ...

Page 27: ... time can be adjusted from 0 1s to 1 0s It is pre adjusted to 0 1s Adjustment of initial current Id Adjust the current with potentiometer F9 The value can be read on display F5 The initial current can be adjusted between 3A and maximum current of the machine If initial current is less than 3A the machine will automatically adjust the initial current to the pre adjusted value i e 50 of welding curr...

Page 28: ...e mains Voltages are high and dangerous inside the machine In spite of their robustness THERMAL ARC power sources require some regular maintenance Once every 6 months more often in dusty surroundings the machine must be blown through with dry oilfree compressed air check all connections for electrical continuity Checkall cable connections including ribbon cables 18 SPARE PARTS ...

Page 29: ...e 35A 18 P02100 Resistor 120W 100 ohms 19 G02010 commutator 20 G10005 Commutator handle 21 I05977 Shunt 22 B00009 TH Front fascia 23 B01060 Knob diam 14 24 B01062 Knob diam 23 25 C02025 Female socket 5 pins C04025 Male plug 5 pins for C02025 26 F12004 Gas output 3 8 BSP 27 F04002 Gas valve 220V F18008 Gas valve output F12 100 M3 8 BSP 28 C02612 12 pins Female socket without pins C02613 10 female p...

Page 30: ...generator Connector J2 Pin 1 electronic ground Pin 2 open drain for thermal default led on off Pin 3 15V DC Pin 4 current control input 0 3 4V Pin 5 Arc force control output Pin 6 ENABLE output for inverter start stop 0 5V Pin 7 20V DC Pin 8 20V DC Pin 9 NTC thermistor return 0 5V for primary temperature measurement Pin 10 striked arc information 0V when striked 5V when not striked Pin 11 Fan cont...

Page 31: ...ator PCB L93101 main supply and filter PCB Connector J1 J2 230VAC secured main supply Connector J3 J4 230VAC main supply Connector J5 5V auxiliary supply only when overvoltage mode is active Connector J6 Pin 1 to pin 1 of cooling socket when used Pin 2 to pin 5 of cooling socket when used Pin 3 5 230VAC to primary coil of auxiliary transformer Pin 4 not used Pin 6 to pin 4 of cooling socket when u...

Page 32: ...output of generator Pin 14 Negative polarity of shunt Pin 15 Negative output of generator 20 TROUBLE SHOOTING BEWARE BEFORE ANY INTERNAL INTERVENTION disconnect the power source from the power supply Internal voltages are high and dangerous POSSIBLE CAUSES CHECKING REMEDY DIGITAL DISPLAY AND ORANGE INDICATOR F20 OFF NO SUPPLY ON OFF main switch is OFF Put the switch ON Power supply cable is cut Ch...

Page 33: ...oo long Reduce torch length Stop the machine and restart it IMPROPER WELDING Wrong electrode polarity Use the right polarity according to the indications of electrode s manufacturer IGNITION FAILURE Wrong polarity Check the connection Torch to power terminal Ground to power terminal Pre gas time selected You must wait for the end of the pre gas flow or cancel it No gas arrives to the machine Check...

Page 34: ...21 WIRING DIAGRAM ...

Page 35: ...ope time s 0 0 10 0 1 0 Down slope time s 0 16 Hot start time s 0 0 5 0 0 0 Pre heat time at ignition TIG AC s 0 1 1 0 0 1 Initial current A 3 180 50 maximum current Final current A 3 180 3 Pulse frequency Hz 0 2 99 9 20 Pulse cycle ratio 20 80 50 Pulse low current A 3 welding current 30 AC current frequency Hz 20 250 100 Balance cleaning penetration 20 60 40 ...

Page 36: ...hermadyne Industries Ltd Italia Milan Italy Tel 39 039 204 991 Fax 39 039 204 9922 PTA Plasmatechnik Germany Westerburg Germany Tel 49 2663 915666 Fax 49 2663 915667 THERMADYNE INDUSTRIES reserve the right to make changes without previous notification Illustrations descriptions and characteristics are not contractually binding and do not engage the responsability of the manufacturer ...

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