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INVERTER ARC WELDER - Victor Technologies

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2. 37 6 02 03 Pulse Controls este PP ille e 38 7 0 ROUTINE MAINTENANCE ener ener then 39 8 0 BASIC 40 8 01 TIG Welding Problems ss 40 8 02 Stick Welding Problemas eiae te en eie et 42 8 03 Power source Problems a oto en te eate ete E Ree te 44 9 0 VOLTAGE REDUCTION DEVICE VRD inner 46 9 00 VRID oue OS UTR ette eet eot teo en tee 46 9 02 VRD iier tee e A e bete dog ie aat 46 10 0 POWER SOURCE ERROR CODES eerte ttes notet eene dna even 47 11 0 ADVANCED TROUBLESHOOTING teen thee tret tt tree tetro te tots etti tet ner one tetro rots tn rotos 50 11 01 System Level Fault Tsolation iii tette terere tette teet eer ire bee det edere even 51 11 01 01 Opening the Enclosure iet tecti ds 51 11 01 02 Verification and Remedy to the Indicated Error Codes 53 11 01 03 Verification and Remedy to Failures without Indication Codes 59 11 01 04 Fault Isolation Tests ceo da 63 19 01 04 01 Preparation ui tete ER ere e teet eae see ea eet oe 63 11 01 04 02 Verification of the Power Input Circuitry ss 63 11 01 04 03 Power Supply V
3. conduct the above process backwards When you re assemble the parts 82 11 02 04 04 PCB5 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the three mounting screws of PCBS 3 Remove the two locking connectors attached to PCBS 4 Disconnect PCBS from the two board supporters 5 Swing down the top of PCB5 and remove the four connectors attached to PCBS 6 Remove PCBS from the main frame of the power supply When you re assemble the parts conduct the above process backwards 88 11 02 04 05 PCB6 PCB7 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the protection cover over the front panel 3 Remove the cap on the control knob loosen the screw and remove the knob Note 24 During the re installation of the knob tighten the screw such that there is a space of 2mm between the control panel and the rear of the knob 4 Remove the four mounting screws of the control panel 5 Carefully swing down the top of the control panel slightly 6 Carefully disengage the lock and disconnect the flat ribbon cable 7 Disconnect the three additional connectors from PCB6 8 Disconnect and remove PCB6 from PCB7 by pulling the two PCB s apart 9 Carefully disengage the lock and disconnect the flat ribbon cable from PCB6 10 Remove the four mounting screws and remove PCB7
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7. 99901 _ 0098698 0Oo098 cHdid xwusieH 9990 X 00 0096 9990 ___ Ooossrovgd duelo ejge9 du vve9 0l 0O000 Lle0ZS dOS 9 M X19 MOS OL elqegmduf ____ ___0999 0 __ 00692066692 2 0 69990 O08S0 VON 20 2 009770v83 qJemoseo 8999 01 OOLOPOVEN Lt OO0LOPOvtN egeiieuuuejindino uonduoseg DMA 0 1611 SLAVd 07 APPENDIX A INTERCONNECT DIAGRAM IGBT Gate Circuit Board WK5012 Circuit Board Filter WK4917 sas La 5 Circuit Board Circuit Board WK4914 WK4819 ee CN 16 CN 17 CN 18 CN2 CN 1 CN3 t CHASSIS 1 Circuit Board WK4921 Front View Case Ground Contactor Control 1 24VDC Contactor Control 2 GND 12VDC Supply Potentiometer Maximum E eG ee Potentiometer Minimum GND Amperage Control Wiper 0 10VDC Remote Installed 12VDC 1 2 3 4 5 6 7 8 122 Output Terminal PCB11 IGBT Gate Circuit Board WK3367 Output Terminal PCB5 IGBT Circuit Board WK4916 HF UNIT 1 PCB4 2nd Diode Circuit Board WK4915 PCB6 ntro Control Circuit Board WK5157 PCB7 Panel Circ
8. Gas flow rate is too high Select the correct rate for the welding job Refer to Basic TIG Welding Guide Incorrect shielding gas 15 Select the right shielding gas being used Refer to Basic TIG Welding Guide Poor work clamp connection Improve connection to work to work piece piece 8 02 Stick Welding Problems 1 Gas pockets or Electrodes are damp Dry electrodes before use voids in weld Welding current is too high Reduce welding current metal Porosity Surface impurities such as Clean joint before welding oil grease paint etc Crack occurring Rigidity of joint Redesign to relieve weld joint in weld metal of severe stresses or use crack soon after resistance electrodes solidification Insufficient throat thickness Travel slightly slower to commences allow greater build up in Cooling rate is too high throat Preheat plate and cool slowly A gap is left by Welding current is too low Increase welding current failure of the weld Electrode too large for joint Use smaller diameter metal to fill the electrode root of the weld Insufficient gap Allow wider gap Incorrect sequence Use correct build up sequence Incorrect sequence Insufficient gap Figure 7 Example of insufficient gap or incorrect sequence 42 Portions of the weld run do not fuse to the surface of the metal or edge of the joint Lack of fusion caused by dirt electrode angle incorrect rate of travel too high Lack
9. SEOPE roti nda 114 12 02 03 LIFT TIG REPEAT MO o e rot tt eee ite et tart re nee 115 12 08 Mode C ER 115 12 03 07 HE TIESTO Mode oerte A 115 12 03 02 HE TIG SEOPE Modern ts eite Mao RERO o da a 116 12 03 03 REPEAT RR RR a OA 116 12 03 04 HE TIG SPOT Mode rr rte T Re Ur e 117 13 0 PARTS AA 118 APPENDIX INTERCONNECT DIAGRAM ere 122 APPENDIX SIGNAL NAME LIST A a E AE 124 APPENDIX C HARDWARE erien 129 APPENDIX D DIODE TESTING BASICS 130 APPENDIX irit e ede e e ara n e v e aree dens 132 SYMBOL LEGEND V Amperage STICK Shielded Metal Arc Dr SMAW Voltage Pulse Current Function Hz Hertz frequency Spot Time GTAW SEC Seconds Remote Control Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current SUN N Gas Post Flow Standard Function Gas Pre Flow Slope Function lt 7 Voltage Reduction Device Circuit 2 Slope W Repeat Function EE Negative Spot Function P
10. Thermistor Failure Cause Occurs when the thermistor for the temperature detection circuitry is open Verification Remedy a Verify the wiring harness and connection between CN8 on PCB6 WK 5157 and thermistors TH1 and TH2 e Confirm a secure connection of the harness wired between CN8 on PCB6 and and TH2 and re install the harnesses with a secure connection Contact the manufacturer if you find any broken connectors or damaged wiring harnesses b Replace thermistors TH1 and TH2 Refer to section 11 02 07 for the replacement of TH1 and TH2 c Replace PCB6 WK 5157 Refer to section 11 02 04 05 for the replacement of PCB6 14 E99 Initial Power Receiving Cause Occurs when the initial AC power received signal has not reached the CPU Note 13 This error occurs normally during the power OFF sequence of the unit Verification Remedy a Verify the wiring harness and connection of CN1 on PCB8 WK 4917 on PCBI WK 4914 Confirm a secure connection of the harness wired between CN1 on PCB8 and and re install the harness with a secure connection e Contact the manufacturer if you find any broken connectors or damaged wiring harness b Verify and replace PCB2 WK 4819 During the installation of PCB2 and confirm that the PCB s are securely fastened in place No loose screws e Refer to section 11 02 04 01 for the replacement of PCB2 c Replace PCB6 WK 5
11. Contact the manufacturer if you find any broken connectors or damaged wiring harnesses While depressing the Torch switch verify the OCV using a DC voltmeter The capability of the voltmeter should be more than 100VDC Note 20 In TIG mode the OCV ceases 3 seconds after you depress the torch switch The normal no load voltage is approximately 62V Return potentiometer VR1 to the original position Reconnect the wires to the H F Unitl 71 11 01 04 07 Output Load Test This test verifies that the output current amperage controls are functioning properly A clamp type amperage meter or equivalent meter capable of reading approximately 300A full scale will be needed for this test CAUTION 13 Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described at the beginning of this section 1 Connect the POSITIVE and NEGATIVE OUTPUT TERMINALS to a piece of metal separated by approximately three feet one meter 2 Connect the clamp on amperage meter or equivalent to the output loop between the POSITIVE and NEGATIVE OUTPUT TERMINALS 3 Place the power supply PRIMARY POWER SWITCH on the rear of the unit to the ON position 4 Press the Welding mode selection button to select HF TIG welding mode Press the AC DC selection button to select DC mode WARNING 12 This welding mode produces high frequency and high voltage Extra care shal
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13. Replace PCB5 WK 4916 Refer to section 11 02 04 04 for the replacement and installation of 5 62 11 01 04 Fault Isolation Tests 11 01 04 01 Preparation The following initial conditions must be met prior to starting any of the procedures in this section 11 01 04 1 Connect the appropriate input voltage Check the data tag on the rear of the power supply for the proper input voltage Note 15 Operate at ALL input voltages as noted on the nameplate on the rear panel when testing the power supply 2 Close primary power source wall disconnect switch or circuit breaker 3 Place the power supply MAIN CIRCUIT SWITCH 51 on rear of unit in the ON position A WARNING 11 Dangerous voltage and power levels are present inside this unit Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operator s body comes into contact with the workpiece or any internal components while the unit is activated 11 01 04 02 Verification of the Power Input Circuitry Refer to Note 9 on page 53 Refer to Note 11 on page 53 1 Verify the AC input voltage using z an AC voltmeter Verify input voltage Phase to Phase using an AC voltmeter Ul The capability of the voltmeter should be more than 300V AC VI Measure the point between lines UI and V1 on the input switch 51 A The location of points U1 and Vlon switch S1 are indicated in Figure 10 F
14. c Verify the secondary IGBT Q2 Refer to section 11 02 06 03 for the test and replacement of Q2 d Verify the H F unit HF UNITI Refer to section 11 02 11 for the replacement of HF UNIT 1 e Verify the primary IGBT Q1 Refer to section 11 02 06 02 for the test and replacement of 01 f Replace the Hall CT HCTI Note 12 Pay special attention to installed direction of HCT1 The Hall CT will not function properly if installed in the incorrect direction Refer to section 11 02 09 for the replacement of HCTI 11 E04 Torch Cable Failure Cause The combined length of the torch cable and the work cable is too long Verification Remedy a Verify the rated duty cycles of the torch work cable and the power supply e Only use appropriate sized torch cables length and capacity The recommended total combined length of the torch and work cable is 50 feet Torch and work cable should not be coiled during welding operations Maintain the duty cycle of the power supply Refer to section 3 04 for the recommended duty cycle b Replace PCB6 WK 5157 and PCB5 WK 4916 Refer to section 11 02 04 05 for the replacement of PCB6 and section 11 02 04 04 for PCBS 12 E93 Memory Failure Cause Occurs when the memory fails to save the requested welding parameters Verification Remedy a Replace PCB6 WK 5157 Refer to section 11 02 04 05 for the replacement of PCB6 57 13 E94
15. d l arc de plasma produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res combustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou inflammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail e Procurez une bonne a ration de toutes les fum es inflammables ou explosives Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper 11 Le gas hydrog ne accumul explosera si enflamm EJ D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies
16. more from walls or similar that could restrict natural airflow for cooling 3 Thermal Arc advises that this equipment be electrically connected by qualified electrician 16 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 01 Electrical Input Requirements Operate the welding power source from a single phase 50 60 Hz AC power supply The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about 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 electrical power from the welding power supply whenever necessary to inspect or service the unit Note 2 These units are equipped with a two conductor with earth power cable that is connected at the welding power source end for single phase electrical input power Do not connect an input WHITE or BL
17. question tout m tal pouvant contenir un ou plusieurs des l ments suivants AVERTISSEMENT antimoine cadmium mercure argent chrome nickel Toute proc dure pouvant provoquer arsenic cobalt plomb des blessures de l op rateur ou des baryum e im autres personnes se trouvant dans la b ryllium mangan se zone de travail en cas de non respect vanadium de la proc dure en question Lisez toujours les fiches de donn es sur la 1 05 Precautions De Securite J s curit des mati res sigle am ricain Importantes MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS AVERTISSEMENT contiennent des renseignements quant la quantit et la nature de la fum e et des gaz L OP RATION ET LA pouvant poser des dangers de sant MAINTENANCE DU MATERIEL Pour des informations sur la mani re de tester DE SOUDAGE A L ARC AU JET la fum e et les gaz de votre lieu de travail DE PLASMA PEUVENT consultez l article 1 et les documents cit s PRESENTER DES RISQUES ET la page 5 DES DANGERS DE SANTE a Utilisez un quipement sp cial tel que des Il faut communiquer aux op rateurs et tables de coupe d bit d eau ou courant au personnel TOUS les dangers descendant pour capter la fum e et les gaz posco E E N utilisez pas le chalumeau au jet de plasma possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions d
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19. 9 Read and understand this entire section before proceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately a Verify the 8 pin connector Applies to LIFT TIG and High Frequency TIG HF TIG mode Confirm a secure connection between CONI of the 8 pin connector and the remote device Confirm a secure connection of the harness and the connections between CONI and PCB3 WK 4921 are all correct and there are no open circuits e Contact the manufacture if you find any broken connectors or damaged wiring harnesses e Confirm the proper pins outs of the 8 pin connector on the remote device side Refer to section 4 01 Confirm that there is no open circuit on the 8 pin connector at the remote device side b Verify the condition and connections of the welding cable the stick rod holders and the ground clamp Applies to all welding modes e Confirm a secure connection of the welding cable stick rod holders ground clamp and dinse connectors and there are no open circuits c Verify the no load voltage OCV Applies to STICK High Frequency TIG HF TIG mode e Refer to the section Verification of No load voltage No in section 11 01 04 06 first before continuing this section If performing the No Load Voltage Failure procedure does not rectify the failure perform the following tests in the sequence below Replace any defective components fo
20. Table 9 and Figure 21 for the checkpoints on D2 COMPONENT ACCEPTABLE TESTED ositive egative VALUE lead lead Anode Cathode 0 2 to 0 3V Cathode Anode Open circuit Anode Cathode 0 2 to 0 3V Diode Cathode Anode Open circuit Table 9 D2 D4 and D5 tester checkpoints Anode ES O O Cathode J Cathode Figure 21 D2 D4 and D5 tester checkpoints b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCB4 See section 11 02 04 03 3 Remove the three standoffs 4 Remove the one remaining screw holding the bus bar and remove the bus bar 5 Remove the two mounting screws of diode D2 and remove the diode noting the direction of the diode 94 Note 30 When you re assemble the parts conduct the above process backwards Additionally when installing the diode apply 11 5 in lb force to the diode base screws Note 31 Pay attention to the direction of the diode when installing the diode Refer to Note 26 on page 89 95 PAGE LEFT INTENTIONALLY BLANK 96 11 02 06 05 Diode D4 05 a Test Procedure 1 Verify the characteristic of the diode D4 and DS using a diode tester 2 Refer the Table 9 and Figure 21 for the checkpoints on D4 and DS b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCBA See section 11 02 04 03 3 Remove the six stan
21. WK 4917 and on PCB1 WK 4914 e Confirm a secure connection of the harness between on 8 and on e Contact the manufacturer if you find any broken connectors or damaged wiring harnesses c Verify PCB2 WK 4819 for burned or discolored components or printed circuit board Confirm that the PCB is securely fastened in place No loose screws Refer to section 11 02 04 01 for the replacement of PCB2 2 E82 Rated voltage selection circuit abnormality Cause Failure detected by the input voltage detection circuit etc Verification Remedy a Verify the wiring harness and connection of CN4 on PCB2 WK 4819 e Confirm a secure connection of CN4 on PCB2 e Contact the manufacturer if you find any broken connectors or damaged wiring harnesses b Verify PCB2 WK 4819 for burned or discolored components or printed circuit board 58 Confirm that the PCB is securely fastened in place No loose screws Refer to section 11 02 04 01 for the replacement of PCB2 3 E83 Abnormal mains supply voltage Cause Failure detected by the input voltage detection circuit etc Verification Remedy a Verify the AC input voltage using a voltmeter Follow the instruction in section 11 01 04 02 b Verify the wiring harness and connection of CN1 on PCB8 WK 4917 and on WK 4914 e Confirm a secure connection of the harness between CN1 on PCB8 and on Cont
22. between the HF unit and c Verify the connection between the terminals between AC1 AC2 Verify the connection between ACI AC2 confirm that the quick disconnect terminals are inserted onto the terminals of Unitl correctly and completely e Confirm there are no short circuit in the harness between ACI AC2 d Verify and replace the Gap GAP of the High Frequency Unit e Confirm that the GAP is connected Unit correctly and completely e Confirm there is no dust or foreign debris between the space of the GAP Ifthere are any abnormalities observed with the GAP replace the GAP The GAP is factory set for an optimal setting for most welding applications It is recommended that the GAP setting not be changed The GAP is factory set at 0 8mm Ifthe GAP is increased larger than 0 8mm the HF voltage increases and the frequency tends to decrease If the GAP is increased too much HF will no longer be generated Ifthe GAP is decreased smaller than 0 8mm the HF voltage decreases and the frequency tends to increase e Verify and replace the Current limiting Resistor of the High Frequency Unitl e If RI is defective blown burnt cracked etc replace Refer to section 11 02 13 for the replacement and installation of f Replace the High Frequency Unit Refer to section 11 02 11 for the replacement and installation of Unitl g
23. de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Respectez le teint de lentille recommand dans le article 4 page 5 Hydrogen gas may be present under aluminum workpieces during the cutting process when being cut underwater or using a water table DO NOT cut aluminum underwater or on a water table unless the hydrogen gas can be eliminated as the hydrogen gas may detonate Gr Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d tez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie Pour prot ger votre contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail e Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d p
24. energized and shut down the output until the unit has cooled to normal operating temperature CAUTION 1 Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty NOTE 5 Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are approximate only Achievable capacities and ratings in use and operation will depend upon correct installation use applications maintenance and service 22 PAGE LEFT INTENTIONALLY BLANK 23 4 0 OPERATOR CONTROLS 4 01 Pro Wave 185TSW Controls A THERNADYNE Company 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 To make connections align keyway insert plug and rotate threaded collar fully clockwise Gnd n 213145 TE 8 Front view of 8 Socket Receptacle 25 Earth Ground Torch Switch Input 24V to energize weld current connect pins 2 amp 3 to turn on welding current 3 Torch Switch Input 0V to energize weld
25. from the panel 11 Remove the dust cover from PCB7 When you re assemble the parts conduct the above process backwards 85 11 02 04 06 PCB8 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the two screws from the switch along with four lug terminals 3 Remove the one locking connector When you re assemble the parts conduct the above process backwards 86 11 02 05 Switch S1 Replacement Procedure 1 2 3 4 Remove the side covers See section 11 01 01 Remove PCBS See section 11 02 04 06 Remove the two screws from the switch along with four lug terminals Remove the two mounting screws and remove the switch 87 11 02 06 Semiconductors 11 02 06 01 Diode D1 a Test Procedure 1 Verify the characteristic of the diode D1 using a diode tester 2 Refer the Table 6 and Figure 17 18 for the checkpoints on D1 COMPONENT TERMINALS ACCEPTABLE TESTED Positive lead Negative lead VALUE DideoDi RW 545 Open creat pee 9 ui Sue Vegan Table 6 D1 tester checkpoints Figure 17 D1 tester checkpoints 2 Figure 18 D1 interconnection diagram 88 b Replacement Procedure 1 2 3 4 5 Remove the side covers See section 11 01 01 Remove See section 11 02 04 01 Remove the four screws along with the cables and capacitors Remove the one stan
26. in the Power Source will prevent direct radiation if the equipment 15 properly grounded Transmission via the Supply Lead Without adequate shielding and filtering high frequency energy may be fed to the wiring within the installation mains by direct coupling The energy 1s then transmitted by both radiation and conduction Adequate shielding and filtering is provided in the Power Source Radiation from Welding Leads Radiated interference from welding leads although pronounced in the vicinity of the leads diminishes rapidly with distance Keeping leads as short as possible will minimize this type of interference Looping and suspending of leads should be avoided where possible 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 20 3 04 Specifications Parameter 185TSW Rated Output Amperes 185 Volts 17 4 Duty Cycle 25 Duty Cycle TIG 185 17 4V a 30 160A 16V 40 130A 15V 60 100A 14V 100 STICK 1604 26V a 40 130A 25V 60 100A 25V a 100 Output Current TIG 5 185 DC 5 185 AC 60Hz 50 Cleaning Range STICK 5 160 DC 5 160 AC 60Hz 50 Cleaning Open Circuit Voltage 69V Dimensions Width 7 08 180mm Height 14 7 360mm Length 16 54 420mm Weig
27. of both transformers 3 Check for continuity across the secondary windings of both transformers 4 Check for isolation between the primary winding and the secondary winding of both transformers b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove See section 11 02 04 01 3 Remove PCB4 and PCBS See section 11 02 04 03 and 11 02 04 04 4 Open up the front frame See section 11 02 08 01 5 Open up the rear frame See section 11 02 10 6 Remove transformer T3 See section 11 02 08 03 7 Remove the reactor FCHI See section 11 02 08 02 8 Remove the insulation sheet for the transformer 9 Remove the four mounting screws of the fixture and pull out the transformer metal housing 10 Remove the one screw along with the lug terminals and remove the T1 T2 bus bar assembly 11 Remove the one screw of the T1 T2 bus bar assembly and disconnect T1 12 Remove the one screw of the remaining T2 bus bar assembly and disconnect T2 When you re assemble the parts conduct the above process backwards 105 PAGE LEFT INTENTIONALLY BLANK 106 11 02 09 Hall Current Transformer HCT HCT1 a Test Procedure 1 Remove the locking connector CN9 attached to PCB3 2 With an Ohmmeter set the Rx10 scale measure between the pins on plug CN9 as follows Pin 4 and Pin 1 about 3 to 5 MO Pin 4 and Pin 2 about 20 b Replacement Procedure 1 Remove t
28. of side fusion scale dirt small electrode amperage too low 5 Non metallic parti cles are trapped in the weld metal slag inclusion Not cleaned or incorrect eiectrode A Non metallic particles may Small electrodes used on heavy cold plate Welding current is too low B Wrong electrode angle Travel speed of electrode is too high Scale or dirt on joint surface Lack of inter run fusion Lack of Root Fusion be trapped in undercut from previous run Joint preparation too restricted Irregular deposits allow slag to be trapped Lack of penetration with slag D trapped beneath weld bead Rust or mill scale is preventing full fusion Wrong electrode for position F in which welding is done Slag trapped in undercut A Use larger electrodes and pre heat the plate Increase welding current Adjust angle so the welding arc is directed more into the base metal Reduce travel speed of electrode Clean surface before welding Figure 8 Example of lack of fusion A If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode Allow for adequate penetration and room for cleaning out the slag If very bad chip or grind out irregularities Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from corners Clean joint before welding Use electrodes designed for
29. position in which welding is done otherwise proper control of slag is difficult Figure 9 Examples of slag inclusion 43 8 03 Power Source Problems The welding arc A The Primary supply voltage A Switch ON the Primary cannot be established B C Maximum output welding current can not be achieved with nominal Mains supply voltage Welding current reduces when welding 4 No gas flow when the torch trigger switch is depressed has not been switched ON The Welding Power Source switch is switched OFF Loose connections internally Defective control circuit Loose welding cable connections Incorrect welding cable size Improper input connections Poor electrode condition Wrong welding polarity Gas hose is cut Gas passage contains impurities Gas regulator turned off Torch trigger switch lead is disconnected or switch cable is faulty 44 supply voltage Switch ON the Welding Power Source Please refer to the following chapter Please refer to the following chapter 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 Replace gas hose Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities Turn gas regulator on Reconnect lead or repair faulty switch cable 5 Gas flow
30. recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment Primary Supply Minimum Primary Current amp Duty Cycle Lead Size Current Circuit Size TIG Factory Fitted Vin Amps Pro Wave 12 3 AWG 208 32 185TSW minimum 230 38 WEA 160 40 Table 2 208 230V Primary Current Circuit sizes to achieve maximum current 19 3 03 03 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 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 The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing Computers It is also possible that operation close to computer installations may cause computer malfunction 3 03 04 High Frequency Interference Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways Direct Radiation Radiation from the machine can occur if the case is metal and 15 not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit
31. record and then remove the harness from the gas valve 4 Remove the C ring of the gas valve at the rear frame using C ring pliers Remove the gas valve e When you re assemble the parts conduct the above process backwards 111 11 02 13 Current Limiting Resistor for HEUNIT1 R1 a Test Procedure 1 Inspect the Resistor R1 for signs of overheating or loose connections 2 With an Ohmmeter set the Rx1 scale measure between both ends of the terminals The measurement should be about 1500 b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Open up the front frame See section 11 02 08 01 3 Remove the two connectors 4 Remove the one mounting screw of R1 and remove a MJ soa ER Q When you re assemble the parts conduct the above process backwards 112 12 0 SEQUENCE TIMING DIAGRAMS 12 01 STICK Mode 12 01 01 STICK with VRD DISABLED Voltage Reduction Device Figure 22 shows the STICK timing waveforms with the VRD control disabled Turning potentiometer VR1 on PCB6 WK 5157 all the way to counter clockwise will disable the VRD Arc control Output Current Iw Hot start PEATE A t Melo e Er eR AO LU E E EM E enda OCV Output Voltage Arc control level about 18V Figure 22 STICK mode timing with the VRD DISABLED 12 01 02 STICK with VRD ENABLED Voltage Reduction Device Figure 23 shows the STICK timing waveforms with the
32. supply voltage to the equipment 8 Gas Inlet The Gas Inlet is a 5 8 18 UNF female gas fitting 26 4 02 Weld Process selection Pro Wave 185TSW Weld Mode Weld Process Selection Description 2T operation in TIG Modes using remote devices to control contactor amp current AT operation in TIG Modes with crater fill using a remote contactor device to control sequence AT operation in TIG Modes with repeat operation and crater fill using a remote REPEAT contactor device 2T operation spot welding in HF TIG using a remote contactor device Pulse operation in TIG Modes PULSE ON OFF Selects AC or DC weld current Table 3 Weld Process selection verses Weld Mode for Pro Wave 185TSW 27 4 03 Weld Parameter Descriptions for Pro Wave 185TSW Figure 5 Pro Wave 185TSW Front Panel with Parameter Description Parameter 7 PRE FLOW HOT START INITIAL CUR UP SLOPE PEAK CUR WELD BASE Background Current SPOT TIME 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 This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes e g low hydroge
33. 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 Current delivered to the arc is dependent on the welding arc voltage 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 7 Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary ower supply is switched off CAUTION 3 Remove any packaging material prior to use Do not block the air vents at the front or rear or sides of the Welding Power Source CAUTION 4 DO NOT change the Weld Mode or Weld Process Mode until after POST FLOW time has finished Figure 6 185TSW AC DC Set up 33 6 0 SEQUENCE OF OPERATION O 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 34 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 adjus
34. the output load test If the results of any step differ from those above then refer to the various test procedures in this section to isolate the problem 73 11 02 Subsystem Test and Replacement Procedures 11 02 01 Preparation This section provides specific procedures for verifying the operation and replacement of each subsystem within the power supply Before undertaking any of these procedures eliminate the obvious first visually inspect the suspect subsystem for physical damage overheating and loose connections 11 02 02 Test and Replacement Parts List uaaa eS o news 74 11 02 08 03 11 02 08 04 11 02 08 04 11 02 11 11 02 08 01 11 02 08 02 8 8 3 Z g o o N g Coupling Coil O 3 Pa Transformer HF UNIT 1 High Frequency Unit Ln 75 Ce e nn d a o oe TT CIE Ls nori ET 76 11 02 03 Service Tools Nut Driver Open End Box Philips Head Slotted Head Torque Wrench Wrench Screwdriver Screwdriver Doug Nose RES ine onal Critter CRing Eliers Nut driver and open end box wrench sizes Tie Wrap Note 22 When removing the locking type connectors and board supporters disengage the locking mechanism first and then disconnect them Note 23 Locking type connectors and board support
35. 01 Figure 11 The check points R2 C1 A and E2 B 6 Verify bus voltage the voltage of the electrolytic capacitor after rectification using a DC voltmeter The capability of the voltmeter should be more than 400VDC Using a DC voltmeter measure between the points E2 B and C1 A on PCBI WK 4914 Points E2 B and C1 A can be found on the solder side of PCB1 See Figure 11 The measured voltage should be approximately 1 4 times larger than input voltage measured in 1 above Replace diode D1 if the calculated measurement is not within the corresponding range DC260 360 V following the process in section 11 02 06 01 7 After the replacement of D1 if the above voltage is still abnormal replace PCBI WK 4914 64 11 01 04 03 Power Supply Voltage Test 1 Connect the power supply to a source of rated input voltage Check the data tag on the rear of the power supply for the proper input voltage Refer to Note 15 on page 63 2 Apply power to the unit and place the switch of the power supply to the ON position 3 On the PCB1 WK 4914 measure the voltages according to the following table The test point and the reference are obtainable on the solder side of PCB1 WK 4914 The location of points TP0 3 6 11 00 are indicated in Figure 12 Test Point Reference ACCEPTABLE PCB1 WK 4914 PCB1 WK 4914 VALUE TP1 12VDC 65 4 If any of these voltages are not present or a
36. 01 04 04 2 Gas Valve Failure No Gas flow through unit Cause Occurs when the gas valve is defective damaged or the driving voltage is incorrect Verification Remedy a Confirm that TIG welding is selected on the welding mode Donot change welding modes while welding e Only change welding modes when the unit is idle torch switch OFF Verify the setting of Pre flow and Post flow on the front panel e Ifthe Pre flow or Post flow time is set to 0 seconds change them to higher setting b Verify the layout the of the gas hose e Confirm that the hose is securely connected into the fitting at the inlet and the outlet Confirm that the layout of the gas hose so that it is not bent or kinked Confirm there are no breaks burns or holes in the hose 59 Confirm the layout of the TIG torch gas hose and that the hose adapters are properly connected c Gas Valve 5011 voltage tests and replacement Follow the instruction in section 11 01 04 05 d Replace the PCB6 WK 5157 Refer to section 11 02 04 05 for the replacement and installation of PCB6 3 No weld output Note 14 When in High Frequency TIG HF TIG mode if the High Frequency is not generated present refer to High Frequency Output Failure on Page 57 before performing this section Cause Occurs when the 8 pin connector or associated circuitry is defective damaged or the TIG torch cable is defective Verification Remedy CAUTION
37. 1 04 06 Verification of No load Voltage OCV a Verify the no load voltage in Stick mode CAUTION 11 Electric shock hazard The unit will generate OCV immediately when STICK mode is selected 1 In STICK welding mode mark and then turn potentiometer VR1 on PCB6 WK 5157 all the way to the right and turn off the electric shock protector function Voltage Reduction Device VRD 2 Verify the no load voltage using a DC voltmeter The capability of the voltmeter should be more than 100VDC 3 The normal no load voltage is approximately 62V b Verify the no load voltage in High Frequency TIG HF TIG mode CAUTION 12 Electric shock hazard and test equipment damage The unit will generate OCV along with a High Voltage component that can cause extreme personal harm and test equipment damage Note 19 When in HF TIG mode the unit will generate high voltage To prevent personal harm and test equipment damage remove the indicated wires from Unit1 shown in Figure 16 To prevent electric shock always wrap the removed wires with electrical tape or other suitable insulation Figure 16 Remove the indicated wires from the H F Unit1 7 1 2 3 4 5 6 7 Confirm a secure connection between CONI of the 8 pin connector and the remote device Confirm a secure connection of the harness and the connections between CONI and PCB3 WK 4921 are all correct and there are no open circuits
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39. 1 for the replacement of PCB2 6 E12 Low Input Voltage Failure Cause Occurs when the input voltage is less than approximately 150VAC 1 1 41 of the maximum value of the sinusoidal wave Verification Remedy a Verify input voltage Follow the instruction in section 11 01 04 02 b Replace PCB2 WK 4819 e Ifthe voltage and current available is determined to be sufficient replace PCB2 Refer to section 11 02 04 01 for the replacement of PCB2 7 E14 Low Input Voltage Warning Cause Occurs when the input voltage is less than approximately 173VAC 1 1 41 of the maximum value of the sinusoidal wave Verification Remedy a Verify input voltage Follow the instruction in section 11 01 04 02 b Replace PCB2 WK 4819 e Ifthe voltage and current available is determined to be sufficient replace PCB2 Refer to section 11 02 04 01 for the replacement of PCB2 8 E01 at the primary side Cause Occurs when an over temperature condition of the primary IGBT is detected Verification Remedy a Unit may be in thermal shutdown mode e Review the rated duty cycle of the unit per section 3 04 Exceeding the duty cycle can damage the unit and void the warranty Refer also to section 3 05 for additional information b Verify the ventilating condition Maintain a clear and unobstructed distance of more than 30cm in the front and more that 50cm in the rear of
40. 10119 lt sr jo oued UO YIJIMS JJO UO UdYM ndur Ajddns sxyoouo opoo 10119 q 11 0 ADVANCED TROUBLESHOOTING If you are here all of the troubleshooting suggestions in Section 8 Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective This section provides the information needed to take live measurements on the various subsystems within the power supply and replace those subsystems that prove faulty CAUTION 6 Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment A WARNING 9 There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have training in power electronics measurement and troubleshooting techniques Under no circumstances are field repairs to be attempted on printed circuit boards or other subassemblies of this unit Evidence of unauthorized repairs will void the factory warranty If a subassembly is found to be defective by executing any of the procedures in this Service Manual the subassembly should be replaced with a new one The faulty subassembly should then be returned to Thermal Arc through established procedures WA
41. 157 Refer to section 11 02 04 05 for the replacement of PCB6 58 11 01 03 Verification and Remedy to Failures without Indication Codes Refer to Note 9 on Page 53 Refer to Note 10 on Page 53 Refer to Note 11 on Page 53 1 Cooling Fan Failure Fan is not rotating Cause Occurs when the cooling fan is defective damaged or the driving voltage is incorrect Verification Remedy a Verify the cooling fan FANI e Inspect the condition of the fan blades and all peripheral parts Clean the fan blades and all peripheral parts 1f covered with dust Cleaning and removing dust from the fan blades once every 6 months in a normal environment is recommended Extremely dusty environments will require more frequent cleanings e Verify that there are no wiring harnesses entangled inside the fan confirm that the harnesses do not have any brakes in the wire or damaged connectors e Contact the manufacture if you find any broken connectors or damaged wiring harnesses e Replace the fan if there are any broken cracked or missing fan blades Refer to section 11 02 10 for replacement of FANI b Verify the wiring harness between the cooling fan FAN1 and CN7 on PCB3 WK 4921 e Confirm a secure connection of the harness to CN7 on PCB3 e Contact the manufacture if you find any broken connectors or damaged wiring harnesses c Cooling fan voltage tests and replacement of the cooling fan FAN1 e Follow the instruction in section 11
42. 3 03 Electrical Input Connections eee ete iaa 17 3 03 01 Electrical Input Requirements ceci eee eee e e de e ere ERE RUE 17 3 03 02 Input POWEE rs rene tete He Eee re EET E EE Eg Pa e Nn Ee ARE En E PR UE NE ER DEREN Te 19 3 03 03 High Frequency Introduction vest eise estes E 20 3 03 04 High Frequency Interference eee ete o Soest SISTERS x cosas ue 20 3 04 Specifications curet terrre tutes e etoile eset i ER ete 21 305 Duty C yele De 22 4 ct 25 4 01 Pro Wave 185TSW Controls nasa 25 4 02 Weld Process selection for Pro Wave 185TSW sise 27 4 03 Weld Parameter Descriptions for Pro Wave 185 28 4 04 Weld Parameters for Pro Wave 185 TSW sse nennen enne ron ron rra enne nnns 30 4 05 Power Source Features mme dent ted b ot 31 5 0 SET UP FOR SMAW STICK AND TIG sese 33 6 0 SEQUENCE OE OPERATION nero esters RR NEUE RERO EEUU NER ERR UE teste 34 6 01 Stick Welding esed o node ete atte a etre ir e ede e tte 35 6 02 AC or DC TIG Welding ha in a e RARO De EO RP RR re mtd 36 6 02 01 Slope Mode Sequences 5 timet e d EO HH ae tele ee 37 6 02 02 Slope Mode with repeat
43. 8 A poroo1 o1d T IN 10105 2 a 2 dod zd ISI APPENDIX C HARDWARE Description L A B Code No Order No Post1 M4 M5 9mm 4 5 424900 10 6669 5 5 EBA643600 10 6751 53602020600 10 6803 129 APPENDIX D DIODE TESTING BASICS Testing of diode modules requires a digital Volt Ohmmeter that has a diode test scale Locate the diode module to be tested Remove cables from mounting studs on diodes to isolate them within the module Set the digital volt ohm meter to the diode test scale Using figure 1 and 2 check each diode in module Each diode must be checked in both forward bias positive to negative and reverse bias negative to positive direction 5 To check the diode in the forward bias direction connect the volt ohm meter positive lead to the anode positive of the diode and the negative lead to the cathode negative of the diode refer to figure 1 A properly functioning diode will conduct in the forward bias direction and will indicate between 0 3 and 0 9 volts 6 To check the diode in the reverse bias direction reverse the meter leads refer to figure 1 A properly functioning diode will block current flow in the reverse bias direction and depending on the meter function will indicate an open or 7 If any diode in the module tests as faulty replace the diode module 8 Reconnect all cables t
44. ACK conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal Refer to figure 3 and l Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes Connect ends of line 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch 17 Input Voltage Fuse Size 208V 45 Amps 230V 40 Amps Table 1 Electrical Input Connections Note 3 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 Weiding Power Supply zd t Ground Conductor Ground Terminal 7 USS Line Fuse SS Primary Power Cable Figure 3 Electrical Input Connections 18 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 4 Note the available input power Damage to the PCA could occur if 460V AC or higher is applied The following 208 230V Primary Current
45. DE DEEE EW D NN JHERMAL A THERMADYNE Company INVERTER ARC WELDER MODEL 185TSW AC DC CC STICK TIG Lift Start HF START SERVICE MANUAL February 7 2005 Manual No 430429 512 5 SYMBOL LEGEN D vases i end Rhone eniro RTI casio vk ev doesn direi te i t vee ees dir ov e 5 STATEMENT OF WARRANTY ci nere nap erbe tannins ER E venue ere bie ie 6 kO GENERAL INFORMATION ten eee e eee ee Pede A e ree e rte ueber eee aer Ta tones 7 1 01 Notes Cautions and Warnings sise 7 1 02 Important Safety Precautions seen 7 1 03 on o RB n Re IE Pe EM ERE ER IET e ill QE Eos 8 1 04 Note Attention et Avertissement usines tese 10 1 05 Precautions De Securite Importantes er 10 1 06 Documents De Reference 12 2 0 INTRODUCTION AND 2 2 2 eene aieeaa nn nn tnr ttr enne 14 2 01 e al UB es iet OE E eem 14 2 02 Functional Block Diagrams enses e eO TE ERE re 15 2 03 Transporting Methods 5 dieere ea 15 3 0 INSTALLATION RECOMMENDATIONS eene nennen re teens 16 3 01 Environment nien A HE CR Dele ead HG ele neo eme 16 3 02 L6cation ect ene PER HR UR e POETE TO Ee ede dE ed ELE eH Ee E Po ake RH Cede 16
46. ION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 00 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from M 9 al American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 9 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWSFA 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND
47. Mode Figure 27 shows the HF TIG STD timing waveforms with PULSE control ON and OFF STD MODE Contactor Jj ON E HF Solenoid Preflowtime Hot cur Hot start_ Pulse frequency Output current Figure 27 HF TIG STD mode timing 115 12 03 02 HF TIG SLOPE Mode Figure 28 shows the HF TIG SLOPE timing waveforms with PULSE control ON and OFF SLOPE MODE Contactor HF Solenoid Output current Initial cur A CEE ES RTE Up slope time Downslope tine Figure 28 HF TIG SLOPE mode timing 12 03 03 HF TIG REPEAT Mode Figure 29 shows the HF TIG REPEAT timing waveforms with PULSE control ON and OFF Initial cur O A A spe steer essed REPEAT MODE Contactor HF Solenoid CMM COMMENTI Output current slope time Downslopetine Figure 29 HF TIG REPEAT mode timing 116 12 03 04 HF TIG SPOT Mode Figure 30 shows the HF TIG SPOT timing waveforms with PULSE control ON and OFF SPOT MODE Contactor HF Solenoid Preflowtine Spottine gt Hot start_ Hot cur Output current Figure 30 HF TIG SPOT mode timing 117 13 0 PARTS LIST QNSE A VO SN 257 ATAN NINA FCH1 HF UNIT1 118 6IT L799 0L 9041460 90N 1167 pJeog pejuud ___ 889d 0799 01
48. O Y 2 O O e O O O 2 O JO Z 9 IN S INO 2 O JO e Y O JO O 2 961 21482 uoqqu 1614 20815 uoneorunumuo 185 20815 uoqqu 1814 91 91 Ep E E O O jeusis 20 1901 801815 20 LEO eund 80815 20 LEO eusis 20 LEO eund p smmor re apa pe J i 2 O ba 2 O 18815 uonoojoq 28930 A Mdu wa o a pavas OGAcI por eisur 8 9 01 0 Jodi OM UIN e dund 9 9NO xww s s gage E v Wc cur 5 d xs MN 618p L9 TIOS 1167 SI6r 9167 1515 1 67 V V ISI V iei e TAIM pam HORE aed dns ESSE ES 8 nduy eusits 92D LED 1 815 920 LED Arepuosss eusits 920 LED eusits 9120 LED Arepuosss 01 0 JOdIM o qeo 1214 1214 o qeo 1214 o qeo 1214 o qeo 1214 o qeo
49. PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard 7882 PRACTICE FOR RESPIRATORY PROTECTION obtainable American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement 2 FUM E et GAZ Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises La fum e et les gaz produits par le proc d de jet en relief sont classifi es comme suit de plasma peuvent pr senter des risques et des dangers de sant NOTE Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Toute op ration proc dure renseignement g n ral sur lequel il importe d insister davantage ou qui l efficacit de e Utilisez un appareil respiratoire fonctionnement du syst me alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz ATTENTION Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en
50. Preflow time High Frequency is present at the torch When the torch is positioned close to the work the welding current will transfer to the work and establish the arc at the initial current setting b In the Lift TIG mode after Preflow time Lift Start current is present at the torch When the electrode is touched to the work and lifted off the welding arc is established at the initial current setting 2 Open Remote Switch current increases to weld current Once welding arc has reached weld current the power source will maintain weld current as long 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 setting as long as the remote switch contacts are closed 4 Open Remote Switch Welding arc stops and post flow begins 6 02 02 Slope Mode with repeat sequence The 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 operated as many times as desired To continue slope cycle and end slope sequence close remote switch contacts and allow weld current to reach final current setting Once final current setting is reached opening the Remote Switch again will
51. REED A ets ane EYE tn 92 11 02 06 04 Diode Dessin n rm e m HER RR ERE EE e Faden PR CRETAE CHEN PEE nine is 94 11 02 06 05 Diode Di D Suoria erni rt RP REO ERR T RECENTE C ne ane nie 97 11 02 07 EBD into teet tette tse ie cette i a da E erts 98 1 1 02 08 COIlS AR a eee o es ete actions uet teo 100 11 02 08 01 Coupling Coil CC inner 100 1 1 02 08 02 Reactor 102 11 02 08 03 Transformer 3 02 0 0 0 0 010000 011000000 iii 103 11 02 08 04 Transformer T1 T2 eter te tee t iere beetle 104 11 02 09 Hall Current Transformer HOT eee 107 11 02 10 FANI Replacement Procedure ss 108 11 02 11 HF UNITI Replacement Procedure seen 110 11 02 12 Gas Valve 5011 Replacement Procedure ss 111 11 02 13 Current Limiting Resistor for HF UNITI RI 112 12 0 SEQUENCE TIMING 8 2 0 2 2 00 442 00081 ente enter corn ttr Dn tis Dn tinent Dn 113 12 0t STICK refert reed ede PR ER TER ERES HC ETHER ee 113 12 01 01 STICK with VRD DISABLED Voltage Reduction Device 113 12 01 02 STICK with VRD ENABLED Voltage Reduction Device 113 1 t eee rete ne e er eR CR RE RE d Re e E o eee n pere de 114 12 02 07 LIFE TIG S TD MOdS ii Delo 114 12 02 02 LIET
52. RNING 10 Disconnect primary power at the source before disassembling the power supply Frequently review the Important Safety Precautions in section 1 02 Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operator s body comes into contact with the work piece or any internal components while the unit is activated 50 11 01 System Level Fault Isolation If none of the suggestions provided in Section 8 have solved the problem or corrected the faulty operation the next step is to isolate one or more of the internal subassemblies that may be defective CAUTION 7 Perform all steps in each procedure in sequence Skipping portions of procedures or performing steps out of sequence can result in damage to the unit and possible injury or worse to the operator 11 01 01 Opening the Enclosure 1 Confirm that the switch of power supply and the switch on switchboard distribution panel are all OFF CAUTION 8 The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete 2 Remove all screws and nuts on the side covers 3 Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW Note 7 DO NOT remove the screws completely 51 4 Pu
53. UCTORS amp CONTROL PC BOARD 3 YEAR 3 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR BUT NOT LIMITED TO CONTACTORS RELAYS SOLENOIDS PUMPS SWITCHES MOTORS ENGINES ENIGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS CONSOLES CONTROL EQUIPMENT HEAT 1 YEAR 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT PLASMA TORCH AND LEADS AND REMOTE CONTROLS 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS 90 DAYS 90 DAYS Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty 30 days of purchaser s notice of any Warranty Claim No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser returned goods shall be at the Purchaser s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc Effective April 1 2002 Use an air supplied respirator if ventilation is 1 0 GENERAL INFORMATION not adequate to remove all fumes and gases 1 01 Notes Cautions and Warninas The kinds of fumes and gases from the arc 5 9 welding cutting depend on the kind of metal being used coatings on the metal and the
54. VRD function enabled Turning potentiometer VR1 on PCB6 WK 5157 all the way clockwise will enable the VRD I DET Arc control Output Voltage m i Arc control level i about 18V SE PEO E S AEE ANE O Figure 23 STICK mode timing with the VRD ENABLED 113 12 02 LIFT TIG Mode 12 02 01 LIFT TIG STD Mode Figure 24 shows the LIFT TIG STD timing waveforms with PULSE control ON and OFF STD MODE Contactor Electrode short short Solenoid nl Pulse width Le Pre flow time Post flow tine i i wooo mmmn Pulse fequenc Output current US Uno 25A fixed Lif only Figure 24 LIFT TIG STD mode timing 12 02 02 LIFT TIG SLOPE Mode Figure 25 shows the LIFT TIG SLOPE timing waveforms with PULSE control ON and OFF SLOPE MODE Contactor ON ON ON ON Electrode short short Solenoid E 191 UM eee eee Output current T Su Initial cur E Crater cur Ns ee ee eee ae ne Me 1 1 y I slope time Downslope time Figure 25 LIFT TIG SLOPE mode timing 114 12 02 03 LIFT TIG REPEAT Mode Figure 26 shows the LIFT TIG REPEAT timing waveforms with PULSE control ON and OFF REPEAT MODE Contactor Electrode Solenoid CET pent Initial cur Up slope tine Down slope time Figure 26 LIFT TIG REPEAT mode timing 12 03 HF TIG Mode 12 03 01 HF TIG STD
55. _ en _ 1 tof eso pare w l 9188 1801 Keung SE CA fu paeae3moa mimo J Pero smgeswAmd suo st esos ma __ __ E spumsupe c dec WD oa A A ATAN asso E p xr Jp rp xn pz SS 5 AN panas wp o ec su gt s puo AAN OS usc O E 7775 wu P pp J st 6 tro tTIND ER EN PA AE MEE NES ET T wr ENS enoa ame SED 100 618 1966 TIOS 1167 167 9167 1515 1 67 V V ISI V FI6F HIA ih es EE ES 6161515151515 151556565665 861 eonou MOUM SUID 0 SOAIOSOI EULIOUL E 77 E a 277 ju p s _ __ few eusig
56. act the manufacturer if you find any broken connectors or damaged wiring harnesses c Verify PCB2 WK 4819 for burned or discolored components or printed circuit board e Confirm that the PCB is securely fastened in place No loose screws Refer to section 11 02 04 01 for the replacement of PCB2 4 E85 Pre Charge Error Cause Occurs after you apply power when a failure is detected during the preliminary charging of the capacitors Verification Remedy a Verify the AC input voltage and the Capacitor Bus Voltage on PCB1 WK 4914 Follow the instruction in section 11 01 04 02 b Verify the input diode D1 e Refer to section 11 02 06 01 for the test and replacement of D1 c Verify the IGBT QI Refer to section 11 02 06 02 for the test and replacement of Q1 d Replace PCB1 WK 4914 and PCB2 WK 4819 Ifthe tests in the above sections a b c are within expected results and the unit is still defective replace PCB1 and PCB2 Refer to section 11 02 04 01 for the replacement of PCB1 and PCB2 S E11 High Input Voltage Failure Cause Occurs when the input voltage is more than approximately 275V AC 1 1 41 of the maximum value of the sinusoidal wave Verification Remedy a Verify input voltage e Follow the instruction in section 11 01 04 02 54 b Replace PCB2 WK 4819 e Ifthe voltage and current available is determined to be sufficient replace PCB2 Refer to section 11 02 04 0
57. arc weld Be sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles Provide a fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion A Noise can cause permanent hearing loss Arc welding cutting processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For information on how to test for noise see item 1 in Subsection 1 03 Publications in 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 damage your eyes and burn your skin if you are not properly protected To
58. assent pas les niveaux 5015 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 x plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 7491 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 2871 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z49 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American Nationa
59. crews and 23 in Ib force to the terminal screws Note 28 When replacing the IGBT apply heat sink compound Shinetsu silicon G 747 or equivalent uniformly to the base surface of the IGBT 91 11 02 06 03 IGBT Q2 a Test Procedure 1 Confirm there are no abnormal appearances on PCB11 WK 3367 2 Verify the characteristic of the diode Q2 using a diode tester 3 Refer the Table 8 and Figure 20 for the checkpoints on Q2 COMPONENT five ACCEPTABLE TESTED 5 VALUE lead lead Collector Emitter of Q2 with C1 3 C2EI 1 Open circuit PCB11 C2EI 1 C1 3 0 2 to 0 4V Collector Emitter of Q2 with C2EI 1 E2 2 Open circuit PCB11 E2 2 C2EI 1 0 2 to 0 4V Table 8 Q2 tester checkpoints 2 1 1 Figure 20 Q2 tester checkpoints b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCBS See section 11 02 04 04 3 Remove the three standoffs along with the cables 4 Remove the two mounting screws of IGBT Q2 and remove the IGBT Note 29 When you re assemble the parts conduct the above process backwards Additionally when installing the IGBT apply 27 5 inlb force to the IGBT base screws and 23 in Ib force to the terminal screws Refer to Note 28 on page 91 93 11 02 06 04 Diode 02 a Test Procedure 1 Verify the characteristic of the diode D2 using a diode tester 2 Refer the
60. current connect pins 2 amp 3 to turn on welding current 4 Connect pin 4 to pin 8 to instruct machine that a remote current control device is connected 12V DC supply 5k ohm maximum connection to 5k ohm remote control potentiometer Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control potentiometer Connect pin 4 to pin 8 to instruct machine that a remote current control device 15 connected 0V 3 Positive Terminal Welding current flows from the Power Source via heavy duty Dinse 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 via heavy duty Dinse type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION 2 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 A WARNING 6 When the welder is connected to the Primary supply voltage the internal electrical components maybe at 240V potential with respect to earth 7 Input Cable The input cable connects the Primary
61. different processes You must be very careful when cutting or welding any metals Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as tollo which may contain one or more of the NOTE following Antimony Chromium Mercury An operation procedure i Arsenic Cobalt Nickel background information which 75 Barium Copper Selenium requires additional emphasis or is helpful in efficient operation of the Bedam pier p Cadmium Manganese system Vanadium mmm CAUTION Always read the Material Safety Data Sheets DS that shoul li ith th A procedure which if not properly MS 2 per DRE me material you are using These MSDSs will followed may cause damage to the give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health WARNING For information on how to test for fumes and gases in your workplace refer to item 1 in A procedure which if not properly Subsection 1 03 Publications in this manual f 1 M 2 22 Use special equipment such as water p 24 P 8 down draft welding cutting tables to capture fumes and gases Do not use the welding torch in an area where 1 02 Important Safety Precautions combustible or explosive gases or materials are located WARNING Phosgene a toxic gas is generated from the vapors of chlor
62. dns surrey SA9IYI ueno poripenb y ENF 19591 0 uou YIJMS 8001 Kpuejsuoo spunos 192218 00 SI SUIPJOM osneooq ysy 00 quomo Lewd S SLII SUIPIOM Jo YIU 00 SI 4 opoo 009 pexoo q JULIA SJU9A SPUO99S QE 11098 13 1104 19 SJUDA xoo qu Aq SI 10 2204 01 Sosea1oop sjoso1 ZOA poods PUO99S 1 10 0 08 soje1odo uey 01949 u99q 1972918 SI soporp repuooos spunos 192214 AMP uym 4993 sey 21949 AMP s oounog 61291014 Josuas ounjeuoduuo L soseoo JUILINI umop 009 121 SUIPIOM 991 opoo 10119 204 SUIMO OJ 0 oseo d oje1odo 01 soseoo UBA 009 8 SJU9A Spuooes QE MOF 19 9901401 Aq SI 10 2204 01 sjoso1 OA poods PUO99S 1 moqe ye soje1odo uey 01949 u99q 10 08 1978918 SI SLANT Kpuejsuoo spunos 192214 AMP uym doo sey 21949 s oounog 51291010 HL Josuas ounjeuoduuo p oAA umop 009 oounog Imod 19 Y
63. doff Remove the two mounting screws of diode D1 and remove the diode Note 25 When you re assemble the parts conduct the above process backwards Additionally when installing the diode apply 23 inlb force to tighten the diode base screws and the terminal screws Note 26 When replacing the diode apply heat sink compound Shinetsu silicon G 747 or equivalent uniformly to the base surface of the diode 89 11 02 06 02 IGBT Q1 a Test Procedure 1 Confirm there are no abnormal appearances on PCB10 WK 5012 2 Verify the characteristic of the diode using a diode tester 3 Refer the Table 7 and Figure 19 for the checkpoints on COMPONENT Pound N ACCEPTABLE TESTED VALUE lead lead Collector Emitter of Q1 with Cl C2El Open circuit PCB10 2 1 C1 0 2 to 0 5V Collector Emitter of Q1 with C2El E2 Open circuit PCB10 2 2 1 0 2 to 0 5V Table 7 Q1 tester checkpoints Figure 19 Q1 tester checkpoints b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove See section 11 02 04 01 3 Remove the three standoffs along with the cables 4 Remove the one locking connector attached to the gate PCB 5 Remove the two mounting screws of IGBT Q1 and remove the IGBT 90 Note 27 When you re assemble the parts conduct the above process backwards Additionally when installing the IGBT apply 27 5 in lb force to the IGBT base s
64. doffs 4 Remove the two remaining screws holding the bus bar and remove the bus bar 5 Remove the two each mounting screws of diodes D4 and D5 and remove the diodes noting the direction of the diodes Refer to Note 29 on page 93 Refer to Note 30 on page 95 Refer to Note 26 on page 89 9 7 11 02 07 Thermistors TH1 TH2 a Test Procedure 1 Select the Ohms scale on the digital meter 2 Disconnect the connector at CN8 on PCB6 3 The resistance of a good sensor measured between pins 1 and 2 on the connector should be in the 10kQ to 21 6kQ range with the reading decreasing as the temperature of the power supply increases A shorted reading indicates a bad sensor and it should be replaced 4 The resistance of a good sensor measured between pins 3 and 4 on the connector should be in the 10kQ to 21 6kQ range with the reading decreasing as the temperature of the power supply increases shorted reading indicates a bad sensor and it should be replaced b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove See section 11 02 04 01 3 Remove the one mounting screw of the thermistor and remove the thermistor 4 Remove PCB4 and PCBS See section 11 02 04 03 11 02 04 04 5 Remove the one mounting screw of thermistor and remove the thermistor 98 6 Remove one connector attached to PCB6 7 Remove the thermistor from the main fram
65. e of the power supply When you re assemble the parts conduct the above process backwards Note 32 When replacing the thermistors apply heat sink compound Shinetsu silicon G 747 or equivalent uniformly to the base surface of the thermistors 99 11 02 08 11 02 08 01 Coupling Coil CC1 a Test Procedure 1 Inspect the Coupling Coil for signs of overheating or loose connections 2 Check for continuity through the coupling coil by measuring between the terminals at each end b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the two bolts which mount the lug connections to the output terminals 3 Unlock and remove the gas tube as shown in the illustration 4 Remove the four screws of the front frame and open the front frame as shown in the illustration 100 5 Disconnect the coupling coil terminals from the H F UNITI 6 Cut off the tie wrap and remove the insulation tube 7 Remove all remaining screws and nuts and remove the coupling coil When you re assemble the parts conduct the above process backwards 101 11 02 08 02 Reactor FCH1 a Test Procedure 1 Inspect the Reactor FCHI for signs of overheating or loose connections 2 Check for continuity through the reactor by measuring the terminals at each end b Replacement Procedure 1 Remove the side covers See sect
66. e s curit et toutes les consignes avant d utiliser le mat riel Composez le 1 800 462 2782 ou votre distributeur local si vous avez des questions 10 dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur 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 circuit de soudage R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de travail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout travail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc
67. e the configuration of an arc establish signal and remote contactor but the unit s front panel would control the amperage OK TO MOVE 1 1 1 e Set position factory shipping POSITION 0 J P1 A 9 o Remote Short 4 to 8 JP2 A Panel Open en Use OK TO MOVE signal POSITION JP1 B B eo Max Load 5 24V 50ma AN REMOTE PANEL M OK TO MOVE RELAY 132 Figure 33 Location of PCB WK 4921 133
68. erminals B Torch lead is disconnected Remedy A Connect the electrode to the terminal B Reduced WAVE BALANCE to below 50 or increase the electrode size A Clean the electrode by grinding off the contaminates B Check gas lines for cuts and loose fitting or change gas cylinder A Check the gas lines for kinks or breaks and gas cylinder contents Clean torch Replace gas hose Disconnect gas hose from torch then raise gas pressure and blow out impurities Turn on Turn on Increase electrode diameter or reduce the welding current Reduced WAVE BALANCE to below 50 or increase the electrode size Increase gas flow or check gas line for gas flow problems Select the right size electrode Refer to Basic TIG Welding guide B Refer Basic TIG Welding Guide for ways to reduce arc flutter A Connect the work clamp to the work piece or connect the work torch leads to the right welding terminals B Connect it to the terminal Description Possible Cause Remedy Gas flow incorrectly set C Select the right flow rate cylinder empty or the torch change cylinders or turn valve is off torch valve on 12 Arc start is not Tungsten electrode is too Select the right size smooth large for the welding current electrode Refer to Basic TIG Welding Guide The wrong electrode is being Select the right electrode used for the welding job type Refer to Basic TIG Welding Guide
69. ers are indicated in this manual using the following symbols black star marks for locking connectors and white star marks for locking board supports 77 11 02 04 Printed Circuit Boards 11 02 04 01 PCB1 PCB2 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the eight mounting screws of PCBI 3 Remove the two mounting screws of PCB3 78 4 Unlock the board support clips and pull the board forward 5 Remove the six locking connectors attached to 6 Remove PCBI from the main frame of the power supply When you re assemble the parts conduct the above process backwards 79 PAGE LEFT INTENTIONALLY BLANK 80 11 02 04 02 PCB3 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the three mounting screws of PCB3 3 Remove the five locking connectors attached to PCB3 4 Carefully disengage the locks and disconnect the flat ribbon cable 5 Disconnect PCB3 from the PCBI by pulling PCB3 in the direction of the arrow sign as shown When you re assemble the parts conduct the above process backwards 81 11 02 04 03 PCB4 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the thirteen mounting screws of PCB4 3 Swing down the top of PCB4 and remove the two locking connectors attached to 4 Remove PCB4 from the main frame of the power supply
70. fore opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure please refer to the Section Opening the Enclosure and use vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean if necessary with solvents that are recommended for cleaning electrical apparatus CAUTION 5 Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit 39 8 0 BASIC TROUBLESHOOTING WARNING 9 There are extremely dangerous voltages and power levels present inside this product not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and ou 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 The basic level of troubleshooting is that which can be performed without special equipment or knowledge 8 01 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables maintenance of equipment and proper welding technique Excessive bead Welding current 15 too low Increase weld current and or build up or poor faulty joint preparation penetration or poor fusion at edges of weld 2 Weld bead too Welding current i
71. he maximum Voltage and Amperage output capabilities of the welding power source Curves of other settings will fall between the curves shown 14 2 02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of the 185 TSW power supply Down Transformers Diode T3 Input Main Et Pm gran Diode Inverter Thermal 5 Deleclor Primary Voltage Sensor Hall Current Output Secondary Transformer HCT1 Main Output Transformers Diodes T1 T2 Delector IGBT Stick Model Lift Tig Mode VRD Output Short Sensing Sensing Circuit Circuit Trouble High Frequency Sensing Unit Circuit SS Fan Control Sequence Torch Control e Control onnection Gas Control Circuit S Vies Thermal 2 HF UNIT To each control circuit Drive Sensor Control 12006 18VDC Circuit Circuit Circuit CON1 Current Reference Adjustment Adjustments 4 Circuit Mode select Switches Panel Circuit Board 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 Lift unit with handle on top of case U
72. he side covers See section 11 01 01 2 Open up the front frame See section 11 02 08 01 3 Remove the one mounting nut for the HCT 4 Remove the one connector from the HCT 5 Slide the HCT in the direction of the arrow sign as illustrated 6 Cut offthe tie wrap from the cables and remove the 2 1 When you re assemble the parts conduct the above process backwards 1077 11 02 10 FAN1 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Unlock and the remove the gas valve hose Refer to section 11 02 12 3 Mark record and then remove the harness from the gas valve 108 5 Remove the locking connector 7 attached to PCB3 6 Remove the two mounting screws and remove the fan e When you re assemble the parts conduct the above process backwards 109 11 02 11 UNIT1 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Unlock and the remove the gas valve hose 3 Remove the two mounting screws of transformer T3 4 Slide the transformer slightly in the direction of the arrow sign as illustrated 5 Remove the two mounting screws of the HF UNIT1 and remove the HF UNITI When you re assemble the parts conduct the above process backwards 110 11 02 12 Gas Valve 5011 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Unlock and the remove the gas valve hose 3 Mark
73. ht 41 8 Ib 19 kg Output Rated Load Rated Input Voltage Single phase 230VAC Output Amperes 160A Output Volts 26V Duty Cycle 40 KVA 8 7 KW 5 2 Output No Load KVA 0 5 KW 0 13 Input Volts Single Phase Amperage Draw Rated Load No Load Amps 208V 40 22 230V 38 1 6 Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change improve or revise the specifications or design of this or any product without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes updates improvements or replacement of such items The values specified in the table above are optimal values your values may differ Individual equipment may differ from the above specifications due to in part but not exclusively to any one or more of the following variations or changes in manufactured components installation location and conditions and local power grid supply conditions 21 3 05 Duty Cycle The duty cycle of a welding power source 15 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 WARNING 5 Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become
74. igure 10 Check points U1 U2 V1 and V2 2 If the input voltage is of the operating range of the unit which is 10 187 253 VAC of the rated voltage 208 230V verify the available power capacity at the installed site If the input voltage is within the operating range recheck the input voltage while welding as welding may cause the input voltage to decrease to a value below the operating range of the unit 3 Verify input voltage after the input switch S1 using an AC voltmeter The capability of the voltmeter should be more than 300V Using an AC voltmeter measure between the points U2 and V2 on the input switch 51 The location of points U2 and V2 on switch Slare indicated in Figure 10 4 If this voltage is out of operating range which is 10 187 253 VAC of the rated voltage 208 230V AC replace S1 following the process in section 11 02 05 5 Verify the rectified output voltage of the input diode D1 using a DC voltmeter The capability of the voltmeter should be more than 400VDC Using a DC voltmeter measure between the points R2 and CI A on PCB1 WK 4914 Points R2 and C1 A are obtainable on the solder side of PCB1 See Figure 11 The measured voltage should be approximately 1 4 times larger than input voltage measured in 1 above Replace diode D1 if the calculated measurement is not within the corresponding range DC260 360 V following the process in section 11 02 06
75. inated solvents and cleansers OPERATION AND Remove all sources of these vapors MAINTENANCE OF ARC WELDING EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS ELECTRIC SHOCK PO SOUR Electric Shock can injure or kill The arc welding To prevent possible injury read process uses and produces high voltage electrical understand and follow all warnings energy This electric energy can cause severe or safety precautions and instructions fatal shock to the operator or others in the before using the equipment Call 1 workplace 800 462 2782 or your local distributor if you have any questions Never touch any parts that are electrically live or hot Wear dry gloves and clothing Insulate GASES AND FUMES yourself from the work piece or other parts of the welding circuit Gases and fumes produced during the Arc welding cutting process can be dangerous and hazardous to your health Extra care must be taken when the workplace is moist or damp Repair or replace all worn or damaged parts Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume 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 A AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the
76. ion 11 01 01 2 Remove PCB3 4 and 5 See sections 11 02 04 02 11 02 04 03 11 02 04 04 3 Remove two standoffs and two screws along with the terminal lugs from the reactor 4 Open the front frame See section 11 02 08 01 5 Remove the four mounting screws of the reactor and remove the reactor from the main frame of the power supply PA When you re assemble the parts conduct the above process backwards 102 11 02 08 03 Transformer T3 a Test Procedure 1 Inspect the Transformer T3 for signs of overheating or loose connections 2 Check for continuity across the primary windings of both transformers 3 Check for continuity across the secondary windings of both transformers 4 Check for isolation between the primary winding and the secondary winding of both transformers b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the HF UNITI See section 11 02 11 3 Remove the two screws from the switch along with four lug terminals 4 Remove one locking connector 5 Remove the one screw along with one lug terminal 6 Remove the transformer T3 from the main frame of the power supply When you re assemble the parts conduct the above process backwards 11 02 08 04 Transformer T1 T2 a Test Procedure 1 Inspect the Transformer T1 T2 for signs of overheating or loose connections 2 Check for continuity across the primary windings
77. l Standards Institute 1430 Broadway New York NY 10018 Norme A6 0 de l Association Am ricaine du Soudage AWS LE SOUDAGE LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr s de 1 National Fire Protection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 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 NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationa
78. l be taken to prevent electric shock 5 Select WELD position press control knob Set minimum current counterclockwise 6 Depress the torch switch The amperage meter will indicate approximately 5 Amps 7 Slowly turn the Control Knob clockwise to the maximum of the power supply then counterclockwise back to 5 Amps as the control returns to its minimum position The amperage meter should indicate a continuous range of Amperes between the 5 Amps minimum and the 185A maximum 8 Set minimum current counterclockwise 9 Press the Welding mode selection button to select STICK welding mode The amperage meter will indicate approximately 5 Amps 72 A WARNING 13 At this time some voltage is applied to the stick electrode holder Never touch the current conducting portion of it Extra care shall be taken to prevent electric shock Further to prevent the risk of striking the arc inadvertently care shall be taken to keep the work piece to be welded away from the said electrode holder 10 Slowly turn the Control Knob clockwise to the maximum of the power supply then counterclockwise back to 5 Amps as the control returns to its minimum position The amperage meter should indicate a continuous range of Amperes between the 5 Amps minimum and the 160A maximum 11 Place the power supply MAIN CIRCUIT SWITCH on the rear of the unit to the OFF position 12 Remove the dead short between the OUTPUT TERMINALS Note 21 This completes
79. le Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Norme AWSF41 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI 7882 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 12 LEFT INTENTIONALLY BLANK 13 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 This unit is equipped with a Digital Volt Amperage Meter gas control valve built in Sloper and Pulser lift arc starter and high frequency arc starter for use with Gas Tungsten 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 5A 160A A STICK Process v v 10V 25A 185A A 5A 185A A LIFT TIG Process HF TIG Process Figure 1 Model 185TSW Volt Ampere curve Note 1 Volt Ampere curves show t
80. ll the front panel slightly forward and pull the rear panel slightly backward The interlocking hooks of the side case covers can now be disengaged from the front and rear panels 5 Remove the side covers 6 Remove protection cover sheet by removing the plastic tabs Note 8 When you re assemble the parts conduct the above process backwards 52 11 01 02 Verification and Remedy to the Indicated Error Codes Note 9 The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete and then remove the cases to continue your inspection and repair or maintenance inside the power supply As for the removal and installation of the case refer to section 11 01 01 Note 10 During the Verification Remedy procedures below follow the alphabetical sequence a b c and proceed with your verification and confirmation Note 11 After you confirm and replace all spare parts and components confirm that there are no damaged harnesses or connectors uninstalled or loose screws 1 E81 Abnormal Input Voltage Cause Failure detected by the input voltage detection circuit etc Verification Remedy a Verify the AC input voltage using a voltmeter e Follow the instruction in section 11 01 04 02 b Verify the wiring harness and connection of on PCB8
81. n electrodes It sets the peak start current on top of the BASE WELD current e g HOT START current 130 amps when BASE WELD 100 amps amp HOT START 30 amps This parameter operates in SLOPE or REPEAT AT 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 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 PEAK or BASE current This parameter sets the PEAK weld current when in PULSE mode This parameter sets the TIG WELD current in STD SLOPE REPEAT and SPOT modes when PULSE is off This parameter also sets the STICK weld current This parameter sets the Background current when in Pulse TIG mode This parameter sets the duration of the SPOT TIME in HF TIG mode only 28 PULSE WIDTH PULSE FREQ AC FREQUENCY WAVE BALANCE DOWN SLOPE CRATER CUR POST FLOW lj Description This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSE is on This parameter sets the PULSE FREQUENCY when the PULSE is on This parameter operates in AC mode only and is used to set the frequency for the AC weld current This parameter is used for aluminum AC TIG mode and is used to set the penetratio
82. n to cleaning action ratio for the AC weld current Generally WAVE BALANCE is set to 50 for AC STICK welding The WAVE BALANCE control changes the ratio of penetration to cleaning action of the AC TIG welding arc Maximum weld penetration is achieved when the WAVE BALANCE control is set to 10 Maximum cleaning of heavily oxidised aluminium or magnesium alloys is achieved when the WAVE BALANCE control is set to 65 WAVE BALANCE 50 50 WAVE BALANCE 10 10 WAVE BALANCE 65 65 50 Balanced with 50 penetration and 50 cleaning p C 90 Maximum Penetration and reduced cleaning 35 Maximum Cleaning and reduced penetration ES This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down after the torch trigger switch has been pressed to CRATER CUR This control is used to eliminate the crater that can form at the completion of a weld This parameter operates in SLOPE or REPEAT 4T 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 This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished This control is used to dramatically reduce oxidation of the tungsten electrode Table 4 Weld Parameter Descriptions for Pro Wave 185TSW 29 4 04 Weld Pa
83. ng 85 6 02 DC HF TIG Welding e Connect work lead to positive terminal Connect TIG torch to negative terminal e Switch machine on e Set AC or DC weld current If AC is selected then set AC FREQ 8 WAVE BALANCE e 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 15 being adjusted on the weld sequence graph Use the control knob to adjust each parameter e Set PRE FLOW time e Set HOT START current Set POST FLOW time Set WELD current Set POST FLOW time Slope Mode Parameters if required e Set INTIAL CUR current e Set UP SLOPE time e Set WELD PEAK CUR current Set BASE current e Set DOWN SLOPE time Set CRATER CUR current Pulse Mode parameters if required e Set PULSE WIDTH for PEAK CURRENT Set PEAK CURRENT e Set PULSE FREQ Commence welding 36 6 02 01 Slope Mode Sequence Switch Switch Switch Switch Closed Open Closed Open Up Weld Current Down Slope Slope Final Current Initial Current Postflow Note 6 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 a In the HF TIG mode after
84. o the proper terminals Forward Bias Diode Conducting Anode Cathode Figure 31 Forward bias diode test 130 Reverse Bias Diode Not Conducting Cathode Anode Figure 32 Reverse bias diode test 131 APPENDIX E 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 Remove two plastic clips holding the PCB protective cover in place and lift the sheet up and over the unit The jumpers will be accessible on the top portion of the PCB See figure on next page for the location of the PCB All units are shipped 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 this manual Placing all jumpers in position B would be primarily used for automation with an arc establish relay remote amperage and contactor An arc establish signal is located from pins 4 and 8 when in this mode Placing jumpers JP1 and JP2 in B position and jumper JP3 in A position would hav
85. oltage Testo ie i e dee cet tre ie 65 11 01 04 04 Verification of the Cooling Fan FANI Drive Circuitry ss 67 11 01 04 05 Verification of the Solenoid Valve SOLI Drive 69 11 01 04 06 Verification of No load Voltage No OCV 70 11 01 04 07 Output Load Test etae te i Wik ee dt ee fue th dd ene TA slt 72 11 02 Subsystem Test and Replacement Procedures ss 74 11 02 0 I Preparati n ic aeree ete ette f ei reae t e etd e e eise ae d 74 11 02 02 Test and Replacement Parts Licuado 74 11 02 03 Service TOS cidcid si ile cr SA 77 11 02 04 Printed Circuit Boards uice tere edet p lere ce ede ER Ae 78 11 02 04 01 PCB1 PCB2 Replacement Procedure 78 11 02 04 02 PCB3 Replacement Procedure ses 81 11 02 04 03 PCB4 Replacement Proc dure eee eee edt ee Eee eee eee deeds 82 11 02 04 04 PCBS Replacement Procedure 83 11 02 04 05 PCB6 PCB7 Replacement Procedure 84 11 02 05 Switch S1 Replacement Procedure ss 87 11 02 06 Semiconductors ouo itecto te m ce nine e PATER e RR ERA va ieee eee 88 11 02 06 01 Diode D ss ne sienne ni RO EXPE ER QURE ERR 88 11 02 06 02IGBT QI c t eret t re m I HERR RI ERE RE EET EUR END RENTRER EQ UR E HE 90 11 02 06 03IGBT Q2 cti rtr calcio ERREUR RE TORRE T TREE DERE
86. ont and more that 50cm in the rear of the unit for ventilation purposes e Verify and maintain clean dust free front and rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working environment is recommended Extremely dusty environments will require more frequent cleanings c Verify the operation of the cooling fan FANI and replace it if necessary e Verify the condition of FANI Verify that there are no broken or cracked fan blades and that FANI 1s not producing and abnormal sounds e If broken or cracked FANI blades or abnormal sounds are emanating from replace FANI e Refer to section 11 02 10 for the replacement of FANI Refer to section 11 01 04 04 for addition FANI tests d Verify the operation of the cooling fan and replace it if the condition of FANI is inactive Follow the instruction in section 11 01 04 04 e Replace PCB6 WK 5157 Refer to section 11 02 04 05 for the replacement of PCB6 10 E03 Primary Over Current Failure Cause Occurs when excessive current is detected flowing into the primary side of the main transformer 56 Verification Remedy a Confirm the operation of the machine within the rated specification Refer to the specification data sheet in Section 3 04 b Verify the secondary diode D2 D4 and D5 e Refer to section 11 02 06 04 for the test and replacement of D2 and section 11 02 06 05 for D4 and DS
87. ositive Impulse Starting High lt Gas Input Frequency GTAW Touch Start Lift Start TIG gt Gas Output circuit GTAW LIMITED WARRANTY Thermal Arc Inc 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 Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal Arc shall not under any circumstances be liable for special indirect or consequential damages such as but not limited to lost profits and business interruption The remedies of
88. ow DC 18V Conduct the Verification of the power input circuitry in section 11 01 04 02 Replace FANI DEN Refer to section 11 02 10 Continued on next page 67 17 This welding unit has feature that will slow the rotational speed of the cooling fan during low output current and while in standby Under these conditions the voltages in the above table will be inaccurate therefore when verifying the voltage do so during the failure condition Note 18 When verifying the voltage confirm that the AC input voltage remain within the operating range of the unit The AC input does not drop below 180VAC 68 11 01 04 05 Verification of Solenoid Valve 5011 Drive Circuitry 1 Verify the voltage between the PIN 1 and PIN 3 of connector CN12 on PCB1 WK 4914 while you press the torch switch while in TIG Mode The capacity of the voltmeter should be more than 50VDC The location of connector CN12 of PCB1 WK 4914 is indicated in Figure 15 Refer to Note 16 on page 63 Figure 15 The location of connector CN12 of PCB1 WK 4914 2 Using the measurement taken above follow the chart below for possible failure modes Voltage Measurement Between PIN 1 PIN 3 of CN12 on Remedy 1 Below DC 18V Replace PCB1 WK 4914 Refer to section 11 02 04 01 Replace SOLI Case 2 DC 18 25 Refer to section 11 02 12 Refer to Note 18 on page 68 69 11 0
89. protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as recommended in Subsection 1 03 item 4 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 6 ANSI Standard Z49 2 FIRE PREVENT
90. rameter value can be adjusted at any time even while welding e The intelligent cooling system is designed to reduce dust and foreign material build up whilst providing optimum cooling e Fan speed reduces approximately 30 seconds after machine is turned on e Fan speed increases when internal components reaches operating temperature e Primary voltage Supply ON OFF switch located on rear panel 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 e VRD fully complies to IEC 60974 1 e When Stick mode is selected the green VRD light is ON when not welding and red when welding e When in TIG modes VRD is off For the selected weld parameter rotating the knob clockwise increases the parameter e Rotating the knob counter clockwise decreases the parameter A selected weld parameter value can be adjusted at any time even while welding e Pushing the knob in displays actual arc voltage e An error code is displayed on the Digital Meter when a problem occurs with Primary supply voltage or internal component problems Refer to troubleshooting guide 31 LEFT INTENTIONALLY BLANK 32 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
91. rameters Pro Wave 185TSW Weld Mode Weld Parameter Factory Incremental Parameter Range Setting Unit PRE FLOW 0 0 to 1 0 sec 0 1 sec 0 1 sec HOT START 0 to 70A 20A INITIAL CUR 5to 185A 30A lA UP SLOPE 0 to 15 sec sec 0 1 sec PEAK CUR 5to 185A 120A lA 5 10 185 80 1A E a 5 to 160A 80A 1A SPOT TIME 0 5 to 5 0 sec 2 sec 0 1 sec PULSE WIDTH 15 to 8096 5096 1 See Table 6 AC FREQUENCY 15 to 150Hz 50Hz 1Hz WAVE BALANCE 10 to 65 50 1 DOWN SLOPE 0 to 25 sec 3 sec 0 1 sec CRATER CUR 5 to 185 30A 1A POST FLOW 0 0 to 60 sec 10 sec 0 1 sec PULSE FREO 0 5to500Hz 100 0Hz Table 5 Weld Parameters for Pro Wave 185TSW PULSE Range Incremental Unit 0 5 to 20Hz 0 1Hz 20 to 100Hz 1Hz 100 to 500Hz 5Hz Table 6 PULSE FREQ Range and Incremental Units 30 4 05 Power Source Features Feature New Digital Control Touch Panel Switches Front Control Cover Digital Meter Intelligent Fan Control ON OFF switch Voltage Reduction Device VRD Control Knob Self Diagnosis Using Error Codes Description e Almost all welding parameters are adjustable e Touch switches eliminate mechanical damage e Protects front panel controls e Displays selected weld parameter value e Displays weld current when welding e Displays weld current for 20 seconds after weld has been completed A selected weld pa
92. ransportable equipment at least once 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 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 to this machine the following periodic tests should also be conducted by an accredited Thermal Arc service agent Description IEC 60974 1 Requirements VRD Open Circuit Voltage Less than 20V at Vin 230V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0 3 seconds If this equipment is used in a location or environment with a high risk of electrocution then the above tests should be carried out prior to entering this location 46 LV IJO1IO POY 19591 0 Udy JJO YMS po roo un po roo 9 repuooos spunos 2 peaj JO pue 9 q89 210 10 00 pea spoooxo MdMO soseoo JUILINI PIOM q13U9 JO pue 482 220 DI L opoo 10119 04 Ioydeyo euruou SuIMO OJ SIOFOI MOTO 01 JO SUEN MOT 10 SI d
93. re below a 10 tolerance replace PCB1 WK 4914 5 On the PCB3 WK 4921 measure the voltages according to the following table The location of points 0 3 6 7 are indicated in Figure 13 c 2 PCB3WK 4921 45 vo am 1 2 3 Figure 13 The check points TP0 3 6 7 Test Point Reference ACCEPTABLE PCB3 WK 4921 PCB3 WK 4921 VALUE TP1 T 12VDC PO 6 Ifany of these voltages are not present or are below a 10 tolerance replace PCB3 WK 4921 66 11 01 04 04 Verification of the Cooling Fan FAN1 Drive Circuitry 1 Verify the condition of the cooling fan FANI using a DC voltmeter The capability of the voltmeter should be more than 50VDC Using a DC voltmeter measure between PIN 1 and PIN 2 of CN7 on PCB3 WK 4921 The location of connector CN7 of PCB3 WK 4921 is indicated in Figure 14 Note 16 When you measure the above voltage do not remove the connector Conduct the measurement while the connector plug and receptacle are still connected Figure 14 The location of connector CN7 of PCB3 WK 4921 2 Using the measurement taken above follow the chart below for possible failure modes Voltage measurement PIN 1 PIN 2 of CN7 on Remedy PCB3 Rotating DC 18 25 Fan drive circuit is normal f Replace PCB3 WK 4921 pompes doy Refer to section 11 02 04 02 Fan Status Replace PCB3 WK 4921 Refer to section 11 02 04 02 y Case 3 Inactive Bel
94. s too high Decrease weld current wide and flat or undercut at edges of weld or excessive burn through 3 Weld bead too Travel speed too fast Reduce travel speed small or insufficient penetration or ripples in bead are widely spaced apart 4 Weld bead too Travel speed too slow Increase travel speed wide or excessive bead build up or excessive penetra tion in butt joint 5 Uneven leg length Wrong placement of filler Re position filler rod in fillet joint rod 40 Description Electrode melts when arc is struck Dirty weld pool Electrode melts or oxidizes when an arc is struck Poor weld finish Arc flutters during TIG welding Welding arc can not be established Possible Cause A Electrode is connected to the terminal B WAVE BALANCE is greater than 50 Electrode contaminated through contact with work piece or filler rod material B Gas contaminated with air A No gas flowing to welding region Torch is clogged with dust Gas hose is cut Gas passage contains impurities Gas regulator turned off Torch valve is turned off The electrode is too small for the welding current WAVE BALANCE is set above 50 Inadequate shielding gas Tungsten electrode is too large for the welding current B Absence of oxides in the weld pool A Work clamp is not connected to the work piece or the work torch leads are not connected to the right welding t
95. se handcart or similar device of adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting 15 3 0 INSTALLATION RECOMMENDATIONS 3 01 Environment The Pro Wave 185TSW is designed for use in adverse environments Examples of environments with increased adverse conditions are a In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts b In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator or c In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories Environments with adverse conditions do not include places where electrically conductive parts are in the near vicinity of the operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines nareas free from moisture and dust e Ambient temperature between 0 degrees C to 40 degrees C e In areas free from oil steam and e In areas not subjected to abnormal corrosive gases vibration or shock e areas not exposed to direct sunlight or e Place at a distance of 12 304 79mm or rain
96. secure connection between PCB1 and PCB3 d Replacement of PCB3 WK 4921 and PCB6 WK 5157 Refer to section 11 02 04 02 for the replacement and installation of PCB3 and section 11 02 04 05 for PCB6 S High Frequency Output Failure Unit does not generate High Frequency Cause Occurs when the H F unit is defective or blown Verification Remedy CAUTION 10 Read and understand this entire section before proceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately The unit will generate a High Voltage component that can cause extreme personal harm and test equipment damage a Verify the connection between High Frequency Unit1 and Coupling Coil 61 e Verify the connection between Unit and confirm that the quick disconnect terminals are inserted onto the terminals of Unit CC2 correctly and completely e Confirm there are no short circuits burnt or broken wires between the HF unit and the CCI Refer to section 11 02 08 01 for the replacement and installation of CC1 b Verify the connection between High Frequency Unit1 and Current limiting Resistor R1 e Verify the connection between Unit and confirm that the quick disconnect terminals are inserted onto the terminals of H F Unit R1 R2 correctly and completely e Confirm there are no short circuits burnt or broken wires
97. ted 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 Internal warnings 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 Control knob allows the operator to adjust the output amperage within the entire range of the power source 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 required for use during LIFT TIG and HF TIG operation See section 4 01 section 2 Remote Control Socket for complete details of the remote device 7 AC DC Button Selects between AC or DC welding output 6 01 Stick Welding e Connect work lead to negative terminal Connect electrode lead to positive terminal e Switch machine on e Set AC or DC weld current If AC is selected then set AC FREQ to 60Hz amp WAVE BALANCE to 50 e Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set The LED will show which function 15 being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set HOT START e Set WELD current Commence weldi
98. the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein 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 PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor POWER SUPPLIES POWER SUPPLIES amp WIRE FEEDERS LABOR MAIN POWER MAGNETICS STATIC amp ROTATING 3 YEAR 3 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEAR 3 YEAR POWER SWITCHING SEMI COND
99. the unit for ventilation purposes e Verify and maintain clean dust free front and rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working environment is recommended Extremely dusty environments will require more frequent cleanings 55 c Verify the operation of the cooling fan FANI and replace it if necessary Verify the condition of FANI Verify that there are no broken or cracked fan blades and that FANI 1s not producing anY abnormal sounds Ifbroken or cracked FANI blades or abnormal sounds are emanating from FANI replace FANI e Refer to section 11 02 10 for the replacement of FANI Refer to section 11 01 04 04 for addition FANI tests d Verify the operation of the cooling fan and replace it if the condition of FANI is inactive Follow the instruction in section 11 01 04 04 e Replace PCB6 WK 5157 Refer to section 11 02 04 05 for the replacement of PCB6 9 E02 Over Temperature at the secondary side Cause Occurs when an over temperature condition of the secondary diode is detected Verification Remedy a Unit may be in thermal shutdown mode e Review the rated duty cycle of the unit per section 3 04 Exceeding the duty cycle can damage the unit and void the warranty Refer also to section 3 05 for additional information b Verify the ventilating condition Maintain a clear and unobstructed distance of more than 30cm in the fr
100. turn off the welding arc and post flow begins 37 6 02 03 Pulse Controls Pulse Width Peak Current Base Background Current The Pulse controls are used primarily to control heat input Pulse offers a number of advantages as follows 1 Control puddle size and fluidity especially out of position 2 Increase penetration 3 Travel speed control 4 Better consistent quality 5 Decreased distortion on lighter or thinner materials 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 second the current travels between peak and background current settings It is as if the foot rheostat were moved up and down to increase and decrease the welding current on a regular basis The faster you moved the foot rheostat up and down the faster the frequency 38 7 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 be
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102. und 1 IGBT Q2 Refer to the Section 11 02 06 03 60 2 4 5 7 Diode D2 D4 and DS Refer to the Section 11 02 06 04 and 11 02 06 05 Coupling coil CC1 Refer to the Section 11 02 08 01 Reactor FCH1 Refer to the Section 11 02 08 02 Transformer T1 and T2 Refer to the Section 11 02 08 04 IGBT QI Refer to the Section 11 02 06 02 Hall CT HCT1 Refer to the Section 11 02 09 4 Operating Panel Failure LED s do not light properly or weld settings cannot be establish Cause Occurs when there 15 a connection failure among PCB6 WK 5157 PCB7 WK 5198 and PCB3 WK 4921 or PCB6 and PCB3 are defective Verification Remedy a Verify the harness connection between CN4 on PCB3 WK 4921 and on PCB6 WK 5157 Confirm a secure connection of the harness and the connections between CN16 on PCB2 and on PCB6 e Contact the manufacture if you find any broken connectors or damaged wiring harnesses b Verify the connection between PCB6 WK 5157 and PCB7 WK 5198 Confirm that all four connectors between PCB6 and PCB7 are tightly connected Confirm the condition of the pins on the connectors and the connectors themselves if bent pins or damaged connectors are found replace the suspected PCB Refer to section 11 02 04 05 for the replacement and installation of PCB6 and PCB7 c Venfy the connection between PCB1 WK 4914 and PCB3 WK 4921 e Confirm a
103. won t A Weld Mode STD SLOPE Strike an arc to complete shut off 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 Gas valve is faulty Have an Accredited Replace gas valve Please refer to the following chapter Gas valve jammed open Have an Accredited Repair or replace gas valve Please refer to the following chapter POST FLOW control is set to 0 Reduce POST FLOW time 6 The TIG electrode The Weld Process Mode Do not change Weld has been STICK HF TIG or LIFT Process Mode before the contaminated due TIG was changed before POST FLOW gas time had to the gas flow POST FLOW gas time had finished shutting off before finished the programmed POST FLOW time has elapsed 45 9 0 VOLTAGE REDUCTION DEVICE VRD 9 01 VRD Specification Pro Wave Description 185TSW Notes VRD Open Circuit Voltage 15 3 to 19 8V Open circuit voltage between welding terminals VRD Resistance 148 to 193 ohms The required resistance between welding terminals to turn ON the welding power VRD Turn OFF Time 0 2 to 0 3 seconds The time taken to turn OFF the welding power once the welding current has stopped 9 02 VRD Maintenance Routine inspection and testing power source An inspection of the power source an insulation resistance test and an earth resistance test should be carried out a For t

INVERTER ARC WELDER - Victor Technologies

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