Thermal Arc ARCMASTER 185 AC/DC Operating Manual Download

Page: 60 / 74

ARCMASTER 185 AC/DC

12-2

Feb

y 20, 2006

E11 e

code

displayed
Ove

ima

y supply

(input) voltage at
p

ima

y capacito

is exceeded fo

one second.
E14 e

code

displayed
Unde

mains supply

(input) voltage
wa

ning p

ima

capacito

s is

educed fo

one second.

A Have an acc

edited

The

mal A

c Se

vice

Agent o

a qualified

elect

ician check

the Mains voltage.

B Have an acc

edited

The

mal A

c Se

vice

Agent o

a qualified

elect

ician check

the p

ima

y cable

and fuses.

E81 e

code

displayed
W

ong P

ima

supply (input)
voltage connected.

Have an acc

edited

The

mal A

c Se

vice

Agent o

a qualified

elect

ician check the

Mains voltage.

No weld cu

ent is

available. Buzze

sounds constantly.
Switch machine OFF.

When 3 phase
machine is fi

ned ON with the

ong P

ima

supply (input)
voltage connected.

Mains supply
voltage is down
to a dange

ously

low level.

Weld cu

ent ceases.

Buzze

sounds

contstantly.
E

code E11

automatically will

eset when the

voltage

educes.

Weld cu

ent

available. Buzze

sounds
inte

mittently.

code E14

automatically will

eset when the

voltage inc

eases.

E12 e

code

displayed
Unde

mains supply

(input) voltage
p

ima

y capacito

educed fo

one second.

Weld cu

ent ceases.

Buzze

sounds

contstantly.
E

code E12

automatically will

eset when the

voltage inc

eases.

Have an acc

edited

The

mal A

c Se

vice

Agent o

a qualified

elect

ician check the

ima

y voltage.

Mains supply
voltage is less than
the nominal
ope

ating voltage

less 10%.

Have an acc

edited

The

mal A

c Se

vice

Agent o

a qualified

elect

ician check the

Mains voltage.

ima

y supply

voltage is g

eate

than the nominal
voltage plus 10%.

Table 12-1 (continued): Powe

Sou

ce E

Codes

Summary of Contents for ARCMASTER 185 AC/DC

Page 1: ...1 PHASE SMAW GTAW 230 V CC AC DC 208 V INVERTER 50 60 Hz ARCMASTER INVERTER ARC WELDER 185 AC DC Art A 07227 Operating Manual Version No 1 Issue Date February 20 2006 Manual No 0 4861 Operating Features ...

Page 2: ...utions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction Mining Automotive Aerosp...

Page 3: ...3784 603 298 5711 www thermalarc com Copyright 2006 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence acci...

Page 4: ...l Block Diagrams 2 4 2 07 Transporting Methods 2 4 SECTION 3 INSTALLATION 3 1 3 01 Environment 3 1 3 02 Location 3 1 3 03 Electrical Input Connections 3 1 3 04 Electrical Input Requirements 3 2 3 05 Input Power 3 3 3 06 High Frequency Introduction 3 3 3 07 High Frequency Interference 3 4 3 08 Duty Cycle 3 4 3 09 Specifications 3 5 SECTION 4 OPERATOR CONTROLS 4 1 4 01 ArcMaster 185 AC DC Controls 4...

Page 5: ...5 Guide for Selecting Filler Wire Diameter 7 3 7 06 Shielding Gas Selection 7 3 7 07 TIG Welding Parameters for Low Carbon Low Alloy Steel Pipe 7 3 7 08 Welding Parameters for Aluminum 7 4 7 09 Welding Parameters for Steel 7 4 SECTION 8 BASIC ARC WELDING GUIDE 8 1 8 01 Electrode Polarity 8 1 8 02 Effects of Stick Welding Various Materials 8 1 SECTION 9 ROUTINE MAINTENANCE 9 1 SECTION 10 BASIC TROU...

Page 6: ...ent Identification 13 1 13 02 How To Use This Parts List 13 1 APPENDIX 1 GENERAL INFORMATION A 1 APPENDIX 2 ARCMASTER 185 AC DC INTERCONNECTION DIAGRAM A 2 APPENDIX 3 ARCMASTER 185 AC DC ACCESSORIES A 4 LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Inside Rear Cover ...

Page 7: ... electrically live Incorrectly installed or improperly grounded equipment is a hazard 1 Do not touch live electrical parts 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself from work and ground using dry insulating mats or covers 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch open or remove line ...

Page 8: ...use fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be alert that welding ...

Page 9: ...gases 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel 2 Do not add fuel while smoking or if unit is near any sparks or open flames 3 Allow engine to cool before fueling If pos...

Page 10: ...ice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are ...

Page 11: ...e en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux 1 Ne touchez pas à des pièces sous tension 2 Portez des gants et des vêtements isolant...

Page 12: ...e s il est bien ventilé sinon portez un respirateur à adduction d air Les gaz protecteurs de soudage peuvent déplacer l oxygène de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre à la respi ration 6 Ne soudez pas à proximité d opérations de dégraissage de nettoyage ou de pulvérisation La chaleur et les rayons de l arc peuvent réagir avec des vapeurs et former des ga...

Page 13: ...ou coupez le fil au tube con tact lorsqu inutilisé après le soudage 11 Portez des vêtements protecteurs non huileux tels des gants en cuir une chemise épaisse un pantalon revers des bottines de sécurité et un casque AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules métalliques volantes En refroidissant la soudu...

Page 14: ...ER LA PEAU ET LES YEUX Les accumulateurs contiennent de l électrolyte acide et dégagent des vapeurs explosives 1 Portez toujours un écran facial en travaillant sur un accumu lateur 2 Arrêtez le moteur avant de connecter ou de déconnecter des câbles d accumulateur 3 N utilisez que des outils anti étincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour c...

Page 15: ...isted below and clicking on the Literature Library link http www thermalarc com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies is ...

Page 16: ...se Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Time Postflow Time Spot Time Sp...

Page 17: ...n 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 resistant flame retardant and non conductive plastic case V CCV 5A 160A A STICK Process V CCV 10V 25A 185A A LIFT TIG Process V CCV 5A 185A A HF TIG Process Art A 04980 Figure 2 1 Model 185 AC DC Volt Ampere...

Page 18: ...h Coil Frequency Unit Fan Control Circuit Gas Control Circuit Fan Solenoid Hall Current Transformer HCT1 Output Inductor Thermal Detector Input Power Secondary DC Power Voltage Sensor To each control circuit 12VDC 15VDC Secondary IGBT Inverter Drive Circuit Primary Current Sensor Art A 07267 Figure 2 2 185 AC DC Model Functional Block Diagram 2 07 Transporting Methods This unit is equipped with a ...

Page 19: ...e operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines In areas free from moisture and dust Ambient temperature between 0 degrees C to 40 degrees C In areas free from oil steam and corrosive gases In areas not subjected to abnormal vibration or shock In areas not exposed to direct sunlight or rain Place at a ...

Page 20: ...EN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch 3 Use Table 3 1 and Table 3 2 as a guide to select line fuses for the disconnect switch Input Voltage Fuse Size 208V 60 Amps 230V 50 Amps Table 3 1 Electrical Input Connections NOTE Fuse...

Page 21: ...e depending on the type of generator used the generator capacity should be twice the maximum rating of the welder 3 06 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 intende...

Page 22: ...be avoided where possible 4 Re radiation from Unearthed Metallic Objects A major factor contributing to interference is re radiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent re radiation in most cases 3 08 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 gi...

Page 23: ...17 kg Output Rated Load Rated Input Voltage Output Amperes Output Volts Height Length 7 08 180mm 14 7 360mm 16 54 420mm Open Circuit Voltage 65V Dimensions Width Range STICK 5 160 DC 5 160 AC 60Hz 50 Cleaning Output Current TIG 5 185 DC 5 185 AC 60Hz 50 Cleaning STICK 160A 27V 40 130A 26V 60 100A 24V 100 Duty Cycle TIG 185A 18V 30 160A 17V 60 100A 14V 100 Volts Duty Cycle 185 18 30 Parameter 185AC...

Page 24: ...ARCMASTER 185 AC DC 3 6 February 20 2006 NOTES ...

Page 25: ...d rotate threaded collar fully clockwise Art A 04984 2 1 5 4 3 6 7 8 1 2 3 4 5 6 7 8 5k Ohms GND Figure 4 2 8 Socket Receptacle Socket Pin Function 1 Earth Ground Torch Switch Input 24V to connect pins 2 3 to turn on welding current 3 Torch Switch Input 0V to energize weld current connect pins 2 3 to turn on welding current 4 Connect pin 4 to pin 8 to instruct machine that a remote current control...

Page 26: ...ound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 5 Gas Outlet The Gas Outlet is a 5 8 18 UNF female gas fitting 6 ON OFF Switch This switch connects the Primary supply voltage to the inverter when in the ON position This enables the Power Supply WARNING When the welder is connected to the Pri...

Page 27: ...or device to control sequence REPEAT No Yes Yes 4T operation in TIG Modes with repeat operation and crater fill using a remote contactor device SPOT No Yes No 2T operation spot welding in HF TIG using a remote contactor device PULSE ON OFF No Yes Yes Pulse operation in TIG Modes Yes Yes Yes Selects AC or DC weld current Contactor ON OFF Yes No Yes Contactor operation in Stick Mode Operation PANEL ...

Page 28: ...This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the start current for TIG The Start Current remains on until the torch trigger switch is released after it has been depressed UP SLOPE This parameter operates in TIG modes only and is used to set the time for the weld current to ramp up after the torch trigger switch has been pressed then released from INITIAL CUR to P...

Page 29: ... TIG modes only and is used to set the finish current for TIG The CRATER Current remains ON until the torch trigger switch is released after it has been depressed The SAVE LOAD buttons are used to save and retrieve a total number of 5 programs into the 185 AC DC memory WAVE BALANCE This parameter is used for aluminum AC TIG mode and is used to set the penetration to cleaning action ratio for the A...

Page 30: ...R 5 to 185A 5A 1A No Yes Yes WELD CUR TIG 5 to 185A 80A 1A No Yes 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 4 5 No Yes Yes AC FREQUENCY 15 to 150Hz 60Hz 1Hz Yes Yes Yes WAVE BALANCE 10 to 65 20 1 Yes Yes Yes DOWN SLOPE 0 to 25 sec 3 sec 0 1 sec No Yes Yes CRATER CUR ...

Page 31: ...erature ON OFF Switch Primary voltage Supply ON OFF switch located on rear panel Voltage Reduction Device VRD shipped de activated field capable See Section 11 for activation instructions Reduces the OCV when the power supply is not in use Eliminates the need for add on voltage reducers and has no effect on arc starting VRD fully complies to IEC 60974 1 When Stick mode is selected the green VRD li...

Page 32: ...emory location i e 1 to 5 press the right scroll button and the machine will give a beep to confirm the weld parameters from the control panel are saved LOAD retrieve a Program to Control Panel Press and HOLD the LOAD button Beep will sound and the Digital Meter display will show a number 1 Select a memory location by rotating the control knob 1 to 5 is displayed on the meter After selecting the d...

Page 33: ...age and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode hold...

Page 34: ...ARCMASTER 185 AC DC 5 2 February 20 2006 NOTES ...

Page 35: ... Spot 4 Digital LED Display Welding amperage and parameter values are displayed in this window Internal warn ings such as over temperature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen 5 Save Load Buttons By using the Save Load buttons the operator can easily save up to 5 welding param eter programs 6 Control Knob Allows the opera...

Page 36: ...ect 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 if required 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 Use the control knob to adjust each parameter Set PRE FL...

Page 37: ...e repeat function is operated during the down slope cycle of the Slope Sequence and is active through the down slope period only During the down slope period by opening the Remote Switch contacts the current will increase back to weld current Within the Down Slope period the repeat function can be operated as many times as desired To continue slope cycle and end slope sequence close remote switch ...

Page 38: ...Pulse current provides a system in which the welding current continuously changes between 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 cycle the current remains at the peak current setting Pulse Frequency measured in Hertz is the number of cycles per s...

Page 39: ...t occur But once the arc 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 power source or its design both conventional and inverter types suffer from the same problem AC TIG on aluminum 1 The Problem Arc appears unstable and pulses or flutters ie appears ...

Page 40: ... 135 200 5 32 4 0mm 190 280 190 280 3 16 4 8mm 250 340 250 340 Table 7 2 Current ranges for various tungsten electrode sizes 7 04 Tungsten Electrode Types Electrode Type Ground Finish Welding Application Features Color Code Thoriated 2 DC welding of mild steel stainless steel and copper Excellent arc starting long life high current carrying capacity Red Zirconated 1 High quality AC welding of alum...

Page 41: ... Argoshield is 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 Argon Argoshield 71T Copper Welding Argon Argoshield 81T Titanium Welding Argon Argoshield 80T 81T Alloy Table 7 5 Shielding Gas Selection 7 07 TIG Welding Parameters for Low Carbon Low Allo...

Page 42: ...Aluminum Tungsten Electrode Diameter Table 7 7 AC TIG Welding Parameters 7 09 Welding Parameters for Steel Filler Rod Diameter if required 0 040 35 45 20 30 0 040 1 16 Butt Corner 1 0mm 40 50 25 35 1 0mm 1 6mm Lap Fillet 0 045 45 55 30 45 0 040 1 16 Butt Corner 1 2mm 50 60 35 50 1 0mm 1 6mm Lap Fillet 1 16 60 70 40 60 1 16 1 16 Butt Corner 1 6mm 70 90 50 70 1 6mm 1 6mm Lap Fillet 1 8 80 100 65 85 ...

Page 43: ... cool during weld ing by quenching after each weld or skip welding to dis tribute the heat Cast Iron Most types of cast iron except white iron are weldable White iron because of its extreme brittleness generally cracks when attempts are made to weld it Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron Copper and Alloys Th...

Page 44: ...n 99 Nickel Suitable for joining all cast irons except white cast iron Stainless Steel 318L 16 High corrosion resistance Ideal for dairy work etc Copper Bronze Brass etc Bronze 5 7 ERCUSI A Easy to use electrode for marine fittings water taps and valves water trough float arms etc Also for joining copper to steel and for bronze overlays on steel shafts High alloy steels dissimilar metals crack res...

Page 45: ...re recommended for cleaning electrical apparatus Turn Power Switch to OFF before proceeding Internal cleaning of the unit should be done every 6 months by an authorized Thermal Arc Service Center to remove any accumulated dirt and dust This may need to be done more frequently under exceptionally dirty conditions CAUTION Do not blow air into the power supply during cleaning Blowing air into the uni...

Page 46: ...h body and consumables Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply 6 Months Replace all broken parts 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 Maintain more often if used under severe conditions ...

Page 47: ...s dependent 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 edges of weld Welding current is too low Increase weld current and or faulty joint preparation 2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through Welding curr...

Page 48: ...ontents B Torch is clogged with dust B Clean torch C Gas hose is cut C Replace gas hose D Gas passage contains impurities D Disconnect gas hose from torch then raise 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 or reduce the welding current H WAVE BA...

Page 49: ...lect the right flow rate change cylinders or turn torch valve ON 12 Arc start is not smooth A Tungsten electrode is too large for the welding current A Select the right size electrode Refer to Basic TIG Welding Guide B The wrong electrode is being used for the welding job B Select the right electrode type Refer to Basic TIG Welding Guide C Gas flow rate is too high C Select the correct rate for th...

Page 50: ...at thickness Cooling rate is too high A B C Redesign to relieve weld joint of severe stresses or use crack resistance electrodes Travel slightly slower to allow greater build up in throat Preheat plate and cool slowly 3 A gap is left by failure of the weld metal to fill the root of the weld A B C Welding current is too low Electrode too large for joint Insufficient gap A B C Increase welding curre...

Page 51: ...Wrong electrode angle C Adjust angle so the welding arc is directed more into the base metal D Travel speed of electrode is too high D Reduce travel speed of electrode E Scale or dirt on joint surface E Clean surface before welding Table 10 2 continued Stick Welding Problems Lack of fusion caused by dirt electrode angle incorrect rate of travel too high Lack of side fusion scale dirt small electro...

Page 52: ...trapped C If very bad chip or grind out irregularities D Lack of penetration with slag trapped beneath weld bead D Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from corners E Rust or mill scale is preventing full fusion E Clean joint before welding F Wrong electrode for position in which welding is done F Use electrodes designed f...

Page 53: ...ion 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 Tighten all welding cable connections Use proper size and type of cable Refer to Section 2 05 Electrical Input Requirements Replace electrode Verify output torch connections 4 No gas flow when the torc...

Page 54: ...c 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 POST FLOW time 6 The TIG electrode has been contaminated due to the gas flow shutting OFF before the programmed POST FLOW time has elapsed The Weld Process Mode STICK HF TIG or LIFT TIG was changed befor...

Page 55: ...r transportable equipment at least once every 3 months 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 A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated In addition to the above tests and specifically in relation to the VRD fitted t...

Page 56: ...sts on the top of the unit 2 Place a small flat bladed screw driver between the cover hinge on the front panel 3 Gently lift the cover hinge out of the front cover mounting hole Remove the control s clear plastic cover 1 2 2 3 Art A 07079 Figure 11 1 VRD ON OFF Step A B Remove the four mounting screws from the control panel see Figure 11 2 1 1 1 1 2 Art A 07080 Figure 11 2 VRD ON OFF Step B ...

Page 57: ...RD Specifications on page 11 1 To turn VRD OFF rotate the trim potentiometer on the display PCB fully counter clockwise 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 VR1 Art A 07081 Figure 11 3 VRD ON OFF Step C and D WARNING The VRD ON OFF tr...

Page 58: ...ARCMASTER 185 AC DC 11 4 February 20 2006 NOTES ...

Page 59: ...n accredited Thermal Arc Service Agent or a qualified electrician check for low Mains voltage E04 error code displayed Output voltage exceeds the secondary voltage specification 1 E01 error code displayed Temperature sensor TH1 protects IGBTs is greater than 80ºC for about 1 second Weld current ceases Buzzer sounds constantly Fan operates at max speed E01 resets when TH1 decreases to 70ºC for abou...

Page 60: ...d ON with the wrong Primary supply input voltage connected 7 Mains supply voltage is down to a dangerously low level Weld current ceases Buzzer sounds contstantly Error code E11 automatically will reset when the voltage reduces Weld current available Buzzer sounds intermittently Error code E14 automatically will reset when the voltage increases E12 error code displayed Under mains supply input vol...

Page 61: ... to reset E85 error 10 The Primary supply input voltage fluctuates and is not stable Have an accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage No weld current is available Buzzer sounds constantly Switch machine OFF then ON to reset E82 error Have an accredited Thermal Arc Service Agent check connector plug on input PCB and the Mains voltage No weld current is...

Page 62: ... electrician check the Mains voltage and fuses Have an accredited Thermal Arc Service Agent check or replace the temperature sensors Weld current ceases Buzzer sounds constantly Switch machine OFF 14 Weld current ceases Buzzer sounds constantly Must switch machine OFF then ON to reset E99 error 13 The Welding Power Source s temperature sensors have malfunctioned E99 error code displayed Mains supp...

Page 63: ...n illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded to other parts The part descriptions may be indented to show...

Page 64: ...Rear W7000401 2 Case Half W7000501 1 Case Front W7000601 1 Frame Rear W7000701 2 Label Name 185AC DC W7000801 2 Label Side W7000901 1 Label Warning W7001001 1 Label Warning Lifting W7001101 1 Label Output Terminal W7001201 2 Terminal Output Female W7001301 1 Encoder Knob 10 6665 1 Encoder Knob Cap 10 6666 2 Terminal Output Male 10 2020 1 Operators Manual 300x4861 ...

Page 65: ...ARCMASTER 185 AC DC February 20 2006 A 1 APPENDIX 1 GENERAL INFORMATION Note the model and specification number shown on the equipment nameplate ...

Page 66: ...Board WK 5548 PCB1 Main Circuit Board WK 5493 3 CN1 1 2 3 PCB6 Control Circuit Board WK 5549 CT2 CT1 SIDE CHASSIS 1 REAR PANEL E CN3 1 2 G1 E1 G2 E2 G3 E3 PCB5 Connect Circuit Board WK 5551 CN30 CN31 CN31 CN30 CN32 CN32 PCB7 Filter Circuit Board WK 5550 CN1 1 2 3 CN3 1 2 3 4 5 CN2 1 2 3 CN1 1 2 3 4 5 6 CN11 1 2 3 4 CN20 1 2 3 4 5 6 CN21 1 2 3 4 5 6 7 CN22 1 2 3 4 5 6 CN23 1 2 3 4 5 6 7 1 2 CN7 3 4...

Page 67: ... 9 CN8 1 2 3 4 5 HF UNIT1 CC2 CC1 R1 R2 AC1 AC3 CC1 AC1 AC3 R2 R6 TB1 TB2 CN1 1 2 3 4 P N CN2 1 2 P 21V PGND CN3 1 2 3 S 15V SG CN4 1 2 3 4 5 6 7 1 2 CN6 3 4 5 6 7 8 G7 E7 G8 E8 RY_ON R3 PCB13 Super Inpose Circuit Board WK 5569 HCT1 Output Terminal TO1 FCH1 PCB15 IGBT Gate Circuit Board WK 3367 G1 E1 E2 G2 G1 E1 G2 E2 PCB14 IGBT Snubber Circuit Board WK 5570 TB1 TB2 SH DET CN1 1 2 3 4 5 G7 E7 G8 E...

Page 68: ... 8 pin male plug 10 4016 Contactor On Off and current control with 25ft cable and 8 pin male plug Extension Cable 10 4017 3ft with 8 pin male plug and 8 pin female cable receptacle 10 4018 15ft with 8 pin male plug and 8 pin female cable receptacle 10 4019 25ft with 8 pin male plug and 8 pin female cable receptacle 10 4020 50ft with 8 pin male plug and 8 pin female cable receptacle 10 4021 75ft wi...

Page 69: ......

Page 70: ...therwise shall not exceed the price of the goods upon which such liability is based 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 Correction of non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser w...

Page 71: ... including but not limited to relays switches contactors solenoids fans electric motors 1 year 1 year PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150 Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years 3 years Welding Console Weld Controller Weld Timer 3 years 3 years All other original circuits and componen...

Page 72: ......

Page 73: ...strict Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L V...

Page 74: ...World Headquarters Thermadyne Holdings Corporation Suite 300 16052 Swingley Ridge Road Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com ...

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