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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

is a guide only, other diameter wires may be used according to the welding

application.

7.06 Shielding Gas Selection

Alloy

Shielding Gas

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

Table 11 – Shielding gas selection

7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Electrode Type &

Diameter

Current Range DC

Amperes

Filler Rod for

Root Pass

Joint Preparation

Thoriated 2%

3/32” (2.4 mm)

120 - 170

Yes

Thoriated 2%

3/32” (2.4 mm)

100 - 160

Yes

Thoriated 2%

3/32” (2.4 mm)

90 - 130

Table 12 – TIG welding parameters for low carbon & low alloy steel pipe

Содержание Thermal Arc 185TSW

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

Страница 2: ......

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 22: ...22 PAGE LEFT INTENTIONALLY BLANK...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 30: ...30 PAGE LEFT INTENTIONALLY BLANK...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 56: ...56 APPENDIX A INTERCONNECT DIAGRAM...

Страница 57: ...57...

Страница 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...

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

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