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175TE Operating Manual

1. narran cnn 4 11 4 23 Overcoming Distortion Effects VU 4 11 SECTION 5 5 1 5 01 Routine Maintenance and Inspection 5 1 5 02 STICK Welding Problems conan nano 5 2 CN OO Problems 5 3 5 04 Power Source 5 4 APPENDIX 1 REPLACEMENT PARTS 222222 sica ii ce ee 1 APPENDIX 2 OPTIONS AND 5 A 2 LIMITED WARRANTY amp WARRANTY SCHEDULE SAFETY INSTRUCTION ARG MASTER 175TE SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUCTION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Some of these practices apply to equipment connected to power lines other practices apply to engine driven equipment Anyone not having extensive training in welding and cutting practices should not att
2. Bring the unit to an authorized Thermal Arc Service Centre to remove any accumulated dirt and dust from the interior This may need to be done more frequently under exceptionally dirty conditions Art A 08549 Manual 0 5116 5 1 Service MASTER 175 9 02 STICK WELDING PROBLEMS SERVICE Description Possible Cause Remedy 1 Gas pockets or voids in weld A Electrodes are damp A Dry electrodes before use meta Porosity Welding current is too B Reduce welding current high C Surface impurities such as Clean joint before welding oil grease paint etc 2 Crack occurring in weld A Rigidity of joint A Redesign to relieve weld joint metal soon after solidification of severe stresses or use crack commences resistance electrodes B Insufficient throat thickness B Travel slightly slower to allow greater build up in throat C Cooling rate is too high C Preheat plate and cool slowly 3 Agapisleftbyfailureoftheweld A Welding current is too low A Increase welding current metal to fill the B Electrode too large for joint B Use smaller diameter electrode C Insufficient gap C Allow wider gap Incorrect Sequence D Incorrect sequence D Use correct build up sequence Insufficient Gap 4 Portions of the weld run do A Small electrodes used on A Use larger electrodes and pre heat not fuse to the surface of the
3. Weld Current control to the desired welding current Switch the ON OFF Switch to the ON position Depress the torch trigger switch to commence welding If necessary readjust the Weld Current control to obtain the welding condition required After completion of welding the Power Source Should be left turned ON for 2 to 3 minutes This allows the fan to run and cool the internal components Switch the ON OFF Switch located on the rear panel to the OFF position Installation 175 INSTALLATION This Page Intentionally Blank Installation 3 8 Manual 0 5116 OPERATION ARC MASTER 175 TE SECTION 4 OPERATION 4 01 General Safety Precautions Read and understand the safety instructions at the beginning of this manual prior to operating this machine WARNING be sure to put on proper protective clothing and eye safeguards welding coat apron gloves and welding helmet with proper lenses installed See Safety Instructions and Warnings chapter included in this manual Neglect of these precautions may result in personal injury WARNING Make all connections to the power source including electrode and work cables as well as remote control cables with the power source turned off These connections could be electrically live with the power switch ON 4 02 Overview Conventional operating procedures apply when using the Welding Power Source 1 connect work le
4. 4 16 The Welder Place yourself in a comfortable position before beginning to weld Get a seat of suitable height and do as much work as possible sitting down Do not hold your body tense A taut attitude of mind and tensed body will soon make you feel tired Relax and you will find that the job becomes much easier You can add much to your peace of mind by wearing a leather apron and gauntlets You won t be worrying then about being burnt or sparks setting alight to your clothes Place the work so that the direction of welding is across rather than to or from your body The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down If the lead is slung over your shoulder it allows greater freedom of movement and takes a lot of weight off your hand Be sure the insulation on your cable and electrode holder is not faulty otherwise you are risking an electric shock 4 17 Striking the Arc Practice this ona piece of scrap plate before going on to more exacting work You may at first experience difficulty due to the tip of the electrode sticking to the work piece This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough A low amperage will accentuate it This freezing on of the tip may be overcome by scratching the electrode along the plate Surface in the same way as a match is struck As soon as the a
5. Manual 0 5116 SERVICE 9 03 TIG WELDING PROBLEMS ARC MASTER 175 TE Weld quality is dependent on the selection of the correct consumables maintenance of equipment and proper welding technique Description 1 Excessive beard build up or poor penetration or poor fusion at edges of weld 2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through 3 Weld bead too small or insuf ficient penetration or ripples in bead are widely spaced apart 4 Weld bead too wide or excessive bead build up or excessive penetration in butt joint Welding current is too low Welding current is too high Travel speed too fast Travel speed is too slow Possible Cause Remedy Increase weld current and or change joint preparation Decrease welding current Reduce travel speed Increase travel speed 5 Uneven leg length in fillet Wrong placement of filler rod Re position filler rod joint 6 Electrode melts when arc is Electrode is connected to the struck Positive Output Terminal 7 Dirty weld pool through contact with work piece or filler rod material B Gas contaminated with air Connect the electrode to the Negative Output Terminal A Electrode contaminated A Clean the electrode by grinding contaminates off B Check gas lines for cuts and loose fitting or change gas cylinder 8 Poor weld finish Inadequate shielding gas Increase gas flow
6. Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off A CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source Manual 0 5116 3 5 Installation 175 3 08 Manual Arc STICK Setup Set Process Selection Switch to Manual Arc Set Welding Current as specified by the Electrode Manufacturer CURE UCT il aos Negative Output RL Terminal Ja RL Dinse 50 INSTALLATION 230 POWER SOURCE ER gt Positive Output Terminal Dinse 50 Art A 08668_AB Figure 3 2 Setup for Manual Arc STICK Welding Manual Arc Sequence of Operation 1 Switch the ON OFF Switch located on the rear panel to OFF 2 Connect the earth clamp lead to the Negative Output Terminal and electrode holder lead to the Positive Output Terminal Consult the electrode manufacture s packaging for the correct electrode polarity 3 Plug the Power Source in and switch the power switch ON 4 Setthe Process Switch to Manual Arc 5 Weld Current control to the desired welding current Installation 3 6 6 Switch the ON OFF Switch located on the rear panel to the ON position This will immediately energize the power
7. 2 Maintenance of Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendation Installation 3 4 INSTALLATION 3 Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the Same time The operator should be insulated from all such bonded metallic components Earthing of the Work Piece Where the work piece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull building steelwork a connection bonding the work piece to earth may reduce emissions in some but not all instances Care should be taken to
8. N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 oafe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Association canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safety Instruction MASTER 175 1 07 Graphique de Symbole Seulement certains de ces symboles sur votre modele jeme lin Tri Phase Statique Tension dangereuse Distant X Facteur de Marche ACD LE Fr quence Convertisseur CS Augmentez Diminuer Transformateur Redresseur Source AC Auxiliaire CS Intensit de Courant Tension Hertz cycles sec Fr quence CCE ESC Pourcentage O Panneau Local Soudage Arc Electrique Avec Electrode Enrob SMAW Soudage Avec Fil Electrodes Fusible GMAW Soudage a L arc Avec Electrode Non Fusible GTAW Decoupe Arc Carbone CAC A E Courant Constant Tension Consta
9. Safety Instruction Manual 0 5116 1 7 MASTER 175 1 10 11 Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit ou des particules volantes ou des projections peuvent atteindre des mat riaux inflam mables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage tibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur a port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre cote soudez pas un r cipient ferm tel un r servoir ou baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube contact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRUL
10. bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste docu ments ci dessous AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEU VENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs 1 8 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confine les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable Arr tez moteur avant de v rifier le niveau e carburant ou de faire le plein Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouveme
11. cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines e In areas free from moisture and dust e Ambient temperature between 32 F to 104 F 0 C to 40 C e n areas free from oil steam and corrosive gases e nareas not subjected to abnormal vibration or shock e n areas not exposed to direct sunlight or rain Place at a distance of 12 300mm or more from walls or similar that could restrict natural air flow for cooling A WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician Manual 0 5116 3 03 Electrical Input Connections A WARNING ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE 15 present after removal of input power DO NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lock out 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 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 avai
12. clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery 2 Stop engine before disconnecting or connecting battery cables 3 Do not allow tools to cause sparks when working on a battery 4 Do not use welder to charge batteries or jump start vehicles 5 Observe correct polarity and on batteries AT WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin Safety Instruction MASTER 175 The coolant radiator be very hot under pressure 1 Donotremove radiator cap when engine 1 hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap WARNING This product when used for welding or cutti
13. internes de e uu l quipement sont aussi sous tension d s la mise 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit en marche En soudage automatique ou semi de soudage terre automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pieces m talliques en contact avec le 12 N utilisez que des quipements en bon tat R parez ou remplacez aussit t les pi ces endommag es fil de soudage sont sous tension Un quipement 13 Dans des espaces confin s ou mouill s n utilisez pas de inad quatement install ou inad quatement mis source de courant alternatif moins qu il soit muni d un la terre est dangereux r ducteur de tension Utilisez plut t une source de courant pru O NIE NR SH continu 1 Ne touchez pas des pi ces sous tension 14 Portez un harnais de s curit si vous travaillez en hauteur 2 Portez des gants et des v tements isolants secs et non trou s 15 Fermez solidement tous les panneaux et les capots 3 Isolez vous de la pi ce souder et de la mise la terre au ik moyen de tapis isolants ou autres ry 4 D connectez la prise d alimentation de l quipement ou ar IAN AVERTISSEMENT r tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur circuit ouvert ou enlevez les LE RAYONNEMENT DE L ARC PEUT BRULER LES fusibles de l alimentation afin d vite
14. its three dimensions In a welded joint the metal becomes attached to the side of the joint and cannot contract freely Therefore cooling causes the weld metal to flow plastically that is the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint If the restraint is excessive e g a heavy section of plate then the weld metal may crack Even in cases where the weld metal does not crack there will still remain stresses locked up in the structure If the joint material is relatively weak for example a butt joint in 5 64 2 0mm Sheet the contracting weld metal may cause the sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone While welding is proceeding a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do his freely at right angles to the surface of the plate i e through the weld but when it attempts to expand across the weld or along the weld it meets considerable resistance and to fulfil the desire for continued expansion it has to deform plastically that is the metal adjacent to the weld is at a high temperature and hence rather soft and by expanding pushes against the cooler harder metal further away and tends to bulge or is upset When the weld area begins to cool the upset metal att
15. of this manual Include all equipment identification numbers as described above along with a full description of the parts in error 2 04 Description ArcMaster 175 TE This compact heavy duty inverter welding machine has infinitely adjustable welding current from 5 10 175 amps lt runs standard general purpose 098 2 5mm electrodes for light gauge work generally less than 118 3 0mm thick and 1 8 3 2mm 157 4 0mm electrodes for heavier material The unit also has a lift and HF TIG function that offers stable TlG welding characteristics when used with a suitable TIG torch and shielding gas 2 05 Packaged Items 175 Inverter Power Source Electrode Holder with 5m Lead 16mm e Work Clamp with 5m Lead 16mm e TIG Torch e TIG Torch Accessories e Plastic Tool Case e Operating Manual Introduction ARGMASTER 175 2 06 Transportation Methods CAUTION ELECTRIC SHOCK kill DO TOUCH live electric parts Disconnect input power conductors from de energized supply line before moving the welding power source A WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift unit with handle on top of case Use handcart or similar device of adequate capacity If using a fork lift vehicle place secure unit on a proper skid before transporting 2 07 Duty Cycle The rated duty cycle of a Welding Power Source is a statement of the time it may b
16. prevent the earthing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by direct connection to the work piece but in some countries where direct connection is not permitted the bonding should be achieved by suit able capacitance selected according to national regulations screening and Shielding selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening the entire welding installation may be considered for Special applications Manual 0 5116 INSTALLATION ARCMASTER 175 TE 3 07 Setup for Welding NOTE Conventional operating procedures apply when using the Welding Power Source e connect work lead directly to work piece and electrode lead is used to hold electrode Wide safety margins provided by the 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 fine tune the welding current to suit the application A WARNING
17. souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrogenes La norme 749 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez connaitre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 05 Dangers relatifs au soudage 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans pour les refroidir l are Ne jamais les laisser trainer par terre ou sur les pi ces a souder touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT __ 8 Nutilisez pas de cables lectriques us s endommag s mal L ELECTROCUTION PEUT ETRE MORTELLE Une d charge lectrique peut tuer ou br ler 9 N enroulez pas de cables lectriques autour de votre corps gravement L lectrode et le circuit de soud 10 N utilisez qu une bonne prise de masse pour la mise la terre age sont sous tension d s la mise en circuit Le de la pi ce souder circuit d alimentation et les circuits
18. 18 Examples of vertical fillet welds deposited Refer Figure 4 16 Use a short arc 2 Vertical Down and do not attempt to weave on the first run The E7014 electrode makes welding in this When the first run has been completed de slag position particularly easy Use a 1 8 3 2mm the weld deposit and begin the second run at electrode at 120 amps The tip of the electrode e weaving MONO is held in light contact with the work and the 5 necessary to cover the first run and obtain speed of downward travel is regulated so that good fusion at the edges At the completion of the tip of the electrode just keeps ahead of the each side motion pause for a moment to allow slag The electrode should point upwards at weld metal to build up at the edges otherwise an angle of about 45 undercut will form and too much metal will accumulate in the centre of the weld Figure 3 Overhead Welds 4 17 illustrates multi run technique and Figure 4 18 shows the effects of pausing at the edge of weave and of weaving too rapidly Apart from the rather awkward position necessary overhead welding 1 not much more difficult that down hand welding Set up a specimen for overhead welding by first tacking length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch The electro
19. AN TES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier AAA E 1 Portez un cran facial ou des lunettes protectrices ap prouv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau AVERTISSEMENT LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec Soin SS es Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renver 5665 Safety Instruction SAFETY INSTRUCTIONS Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d ten deurs des boyauxs et des raccords pour chaque ap plication sp cifique ces quipements et les pieces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de
20. High Frequency dr ad 3 3 3 05 High Frequency MOTTO RO 3 3 3 06 Electromagnetic Compatibility EE inicias 3 3 3 07 Setup for Welding 3 4 3 08 Manual Arc STICK 3 5 3 09 HF GTAW Setup 3 6 TABLE CONTENTS SECTION 4 0PERATI N 4 1 4 01 General Safety Precautions 4 1 02 NR 4 1 ADS coda iaa 4 2 4 04 Electrode 4 4 4 05 Effects of Stick Welding Various Materials 4 4 4 06 GTAW Electrode arras 4 5 4 07 Guide for Selecting Filler Wire 4 5 4 08 Tungsten Electrode Current Ranges nne 4 5 4509 Shielding Gas Selection dense 4 5 G0 Tungsten io ee a ae 4 5 4 11 TIG Welding Parameters for 4 6 412 GARG VV Cod ce 4 6 4195 Weding 95 RE 4 7 414 4 8 4 15 Arc Welding Technique nnns 4 8 4 16 A 14 44 4 9 SUI A m 4 9 A 4 9 CU CURRERE 4 9 4 20 Making Welded dt medetur 4 9 4 21 Bie 4 11 422 Cause of Distortion 00
21. IHERMAL RC 1 0 ARG MASTERS INVERTER ARG WELDER E 2 TERMAT Ac an crea Lia 1 IHERMAL A RC Weldskill 7 Art A 08667 anta Product Classification CLASS A Revision AD Issue Date October 9 2013 Manual No 0 5116 Operating Features IHERMAL A RC WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Arc product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 44 0 1257 261 755 or visit us on the web at www Thermalarc com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product Your Satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction Mining Automotive Aerospac
22. Intentionally Blank Operation 4 14 Manual 0 5116 SERVICE ARC MASTER 175 TE SECTION 5 SERVICE 5 01 ROUTINE MAINTENANCE AND To clean the unit open the enclosure and use a INSPECTION vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean if The only routine maintenance required for the power necessary with solvents that are recommended for supply is a thorough cleaning and inspection withthe cleaning electrical apparatus frequency depending on the usage and the operating environment A CAUTION AN Do not blow air into the power supply WARNING during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit There are extremely dangerous voltages and power levels present inside this product Disconnect primary power at the source before opening the enclosure Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge Maintain more often Warning if used under severe Disconnect input power before maintaining Each Use Visual check of Visual check of torch regulator and pressure Consumable parts fh Weekly Visually inspect the torch body lt AO Visually inspect the F e and consumables cables and leads Replace as needed gt lt Replace all Clean broken parts exterior of power supply 3 Months ce 6 Months
23. LD HEADQUARTERS Miami FL USA Sales Office Latin America Ph 1 954 727 8371 Fax 1 954 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree Customer Care UK 44 0 1257 261 755 Fax 44 0 1257 224 800 Customer Care Italy 39 02 36546801 Fax 39 02 36546480 EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 2010 Thermadyne Industries Inc ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 www thermadyne com A Global Cutting amp Welding Market Leader 16052 Swingley Ridge Road Suite 300 St Louis Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Missouri 63017 U S A Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 www thermadyne com Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 Printed in U S A
24. MASTER 175 enough to prevent the pool from getting ahead of the arc To complete the joint in thin plate turn the job over clean the slag out of the back and deposit a similar weld 207 307 Electrode Tack Weald Art A 07698 Figure 4 13 Weld build up sequence Heavy plate will require several runs to complete the joint After completing the first run chip the slag out and clean the weld with a wire brush It is important to do this to prevent slag being trapped by the second run Subsequent runs are then deposited using either a weave technique or single beads laid down in the Sequence shown in Figure 4 13 The width of weave Should not be more than three times the core wire diameter of the electrode When the joint is completely filled the back is either machined ground or gouged out to remove slag which may be trapped in the root and to prepare a suitable joint for depositing the backing run If a backing bar is used it is not usually necessary to remove this since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld Operation 4 10 OPERATION B Fillet Welds These are welds of approximately triangular cross section made by depositing metal in the corner of two faces meeting at right angles Refer to Figure 4 5 A piece of angle iron is a suitable specimen with which to begin or two lengths of strip steel may be tacked together at right angles Usin
25. a and if suitable precautions are not taken the occurrence in this zone of under bead cracks Hardened zone and under bead cracks in the weld area may be reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace Manganese Steels The effect on manganese steel of slow cooling from high temperatures is to embrittle it For this reason it is absolutely essential to keep manganese steel cool OPERATION during welding by quenching after each weld or skip welding to distribute the heat Cast Iron Most types of cast iron except white iron are weldable White iron because of 15 extreme brittleness generally cracks when attempts are made to weld it Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron Copper and Alloys The most important factor is the high rate of heat conductivity of copper making pre heating of heavy Sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile steel cellulose types for welding larg
26. ad directly to work piece and electrode lead is used to hold the electrode 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 electrode 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 fine tune the welding current to suit the specific application Refer to the electrode manufactures literature for further information Manual 0 5116 4 1 Operation ARG MASTER 175 4 03 FrontPanel Front Panel The welding power source Is protected by a self re setting thermostat The indicator will illuminate if the duty cycle of the power source has been exceeded If the Over Heat light illuminates wait for the Over Heat light to extinguish before resuming welding A Power On Indicator F Arc Force Down slope Control G Gas Outlet 1 Torch Trigger Socket Negative Output Terminal Positive Output Terminal Figure 4 1 175 TE Control Panel Operation 4 2 Manual 0 5116 OPERATION A Power ON Indicator The Power ON Indicator illuminates when the ON OFF switch is in the ON position and the correct mains voltage is present B Over Heat Indicator The welding power source 15 protected by a Self resetting thermostat The indicator will illuminate if the du
27. all applicable aspects and regulations of the EMC Directive European Council Directive 2004 108 EC and to the National legislation for the enforcement of this Directive Manufacturer Thermadyne Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA Type of Equipment Arc Welder Model Number Arc Master 175TE serial Number Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture Market Release Date Dec 12 2008 Classification The equipment described in this manual is Class A and intended for industrial use Warning This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic compatibility in those locations due to conducted as well as radiated disturbances The product is designed and manufactured to a number of standards and technical requirements Among them are Harmonized Standard of EMC Directive EN 60974 10 2007 Arc Welding Equipment Part 10 Electromagnetic compatibility EMC requirements Harmonized Standard of Low Voltage Directive EN 60974 1 2005 Arc Welding Equipment Part 1 Welding power sources Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing pro ces
28. any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date February 17 2009 Revision Date October 9 2013 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND 8 1 1 1 01 Arc Welding 5 24 2455 1 1 1 02 Principal 1 4 1 03 Symbol Char 1 5 1 04 Precautions De Securite En Soudage A Late occse 1 6 1 05 Dangers relatifs au soudage etu eetutna deretur nus 1 6 1 06 Principales Normes De acia 1 9 LO Graphique de Symbole 1 10 OOo 7 1 11 SECTION 2 2 1 2 01 How to Use This Manual 2 1 2 02 CTD 2 1 2 03 nn 2 1 2 04 A PP 2 1 2 05 A Ae 2 1 200 Transporation sra 2 2 207 AA 2 2 208 RE a ed a die 2 2 209 2 3 SECTION 3 INSTALLATION 3 1 3 01 e e UE O 3 1 3 02 o MERE 3 1 3 03 Electrical Input Connections s ess dotes a 3 1 3 04
29. ariable Inductance Voltage Input Art 04130 AB 4 Step Trigger Operation Press and hold for preflow release to start arc Press to stop arc and hold for preflow Burnback Time Inches Per Minute Note For environments with increased hazard of electrical shock Power Supplier bearing the mark conform to EN50192 Manual 0 5116 1 5 safety Instruction MASTER 175 SAFETY INSTRUCTIONS 1 04 Precautions De Securite En Soudage MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre ap prises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de
30. ble around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information LEAD WARNING This product contains chemicals including lead or otherwise produces chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling California Health Safety Code 25249 5 et seq safety Instruction SAFETY INSTRUCTIONS 1 02 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 749 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Ca
31. both sides of a joint by two welders is often successful in eliminating distortion C Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some cases to tell from past experience or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structure By correct pre setting of the components to be welded constructional stresses can be made to pull the parts into correct alignment A simple example is shown in Figure 4 22 E Preheating suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion Figure 4 23 shows a simple application By removing the heating source from B and C as soon as welding is completed the sections B and C will contract at a similar rate thus reducing distortion Preheat Preheat Dotted lines show effect if no preheat is used Figure 4 23 Reduction of distortion by preheating Manual 0 5116 ARC MASTER 175 TE Art A 07709 Block Sequence The spaces between the welds are filled in when the welds are cool Figure 4 25 Welding sequence Figure 4 27 Chain intermittent welding Art A 07713_AB Figure 4 28 Staggered intermittent welding Operation MASTER 175 OPERATION This Page
32. ces are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the welding circuit see NOTE below In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer trouble some NOTE For 230 VAC operation have a qualified person install according to applicable codes and instructions NOTE The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Further guidance is given IEC 974 13 Arc Welding Equipment Installation and use under preparation B Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account 3 3 Installation 175 1 Other supply cables control cables signalling telephone cables above below and adjacent to the w
33. de is held at 45 to the horizontal and tilted 10 in the line of travel Figure 4 19 The tip of the electrode may be touched lightly on the metal which helps to give a steady run weave technique 15 not advisable Art A 07701 Gs for overhead fillet welds Use 1 8 3 2mm E6012 electrode at 120 amps and deposit the Figure 4 16 Single run vertical fillet weld first run by simply drawing the electrode along at a steady rate You will notice that the weld deposit is rather convex due to the effect of gravity before the metal freezes Art A 07704 Weaving motion forsecond and subsequent runs Tilted 10 in line of travel 45 to le Angle tacked to pipe Figure 4 17 Multi run vertical fillet weld Figure 4 19 Overhead fillet weld Manual 0 5116 4 11 Operation MASTER 175 OPERATION 4 21 Distortion Distortion in some degree 15 present in all forms of welding In many cases it is so small that it is barely per ceptible but in other cases allowance has to be made before welding commences for the distortion that will Subsequently occur The study of distortion is so complex that only a brief outline can be attempted here 4 22 The Cause of Distortion Distortion is cause by A Contraction of Weld Metal Molten steel shrinks approximately 11 in volume on cooling to room temperature This means that a cube of molten metal would contract approximately 2 2 in each of
34. derlined they are all covered by this manual To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the word WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows A WARNING Gives information regarding possible personal injury Warnings will be enclosed a box such as this A CAUTION Refers to possible equipment damage Cautions will be shown in bold type NOTE Offers helpful information concerning certain operating procedures Notes will be shown in italics 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the machine Equipment which does not have a nameplate attached to the machine 1 identified only by the specification or part number printed on the shipping container Record these numbers for future reference Manual 0 5116 2 1 2 03 Receipt of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover
35. e Wear protective clothing made from durable flame resistant material wool and leather and foot protection 8 Do not use worn damaged undersized or poorly spliced cables Manual 0 5116 1 1 Safety Instruction MASTER 175 A 0 8 WARNING FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health 1 Keep your head out of the fumes Do not breathe the fumes 2 inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases 3 If ventilation is poor use an approved air supplied respirator 4 Read the Material Safety Data Sheets 5055 and the manufacturer s instruction for metals consumables coatings and cleaners 5 Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe 6 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapours to form highly toxic and irritating gases 7 Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these element
36. e Engineering Rural and DIY Hobbyist We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery Superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry A WARNINGS 4 A A A A EA c Read and understand this entire manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Operating Manual Number 0 5116 for Arc Master 175 TE TIG STICK Package System No W1003003 Arc Master 175 TE Power Source Part No W1003002 Published by Thermadyne Europe Europa Building Chorley Industrial Park Chorley Lancaster England PR6 7BX www thermalarc com Copyright 9 2009 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by
37. e Post Gas Flow time is proportional to the Welding Current For example if the Welding Current is set to 10 amps the Post Gas Flow time will be approximately 3 0 1 seconds For a Welding Current set to 175 Amps the Post Gas Flow time will be approximately 6 1 0 seconds The Post Gas Flow time cannot be adjusted independently of the Welding Current Torch Trigger Socket The 8 pin Torch Trigger Socket is used to connect the TIG Torch Trigger Switch to the welding Power Source To make connections align keyway insert plug and rotate threaded collar fully clockwise 1123141516718 TIG torch O trigger switch 2 Torch Switch Input to energise weld current 8 Pin Socket 3 Torch Switch Input to Front View energise weld current Art A 08956 NOTE Remote Welding Current Control is not available on this model J ON OFF Switch located on rear panel not shown This switch controls the Mains Supply Voltage to the Power Source 4 3 Operation MASTER 175 4 04 SMAW Electrode Polarity Stick electrodes are generally connected to the Positive Output Terminal and the work lead to the Negative Output Terminal but if in doubt consult the electrode manufacturer s literature for further information 4 05 Effects of Stick Welding Various Materials High Tensile and Alloy Steels The two most prominent effects of welding these Steels are the formation of a hardened zone in the weld are
38. e diameter pipes etc The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered and are all easy to use Ideal electrodes for all general purpose work features include outstanding operator ap Metal Being Joined Electrode Comments Mild Steel E6013 Mild Steel E 014 99 Nickel peal easy arc starting and low spatter All positional electrode for use on mild and galvanized steel furniture plates fences gates pipes and tanks etc Especially suit able for vertical down welding suitable for joining all cast irons except white cast iron Stainless Steel E318L 16 High corrosion resistance Ideal for dairy Work etc Bronze 5 7 ERCUSI A Copper Bronze Brass Etc High Alloy Steel Dissimilar E312 16 Metals Crack Resistance All Hard To Weld jobs Operation 4 4 Easy to use electrode for marine fittings water taps and valves water through floats arms etc Also for joining copper to steel and for bronze overlays on steel shafts It will weld most problematic job such as springs shafts broken joins mild steel to stainless and alloy steels Not suitable for aluminium Manual 0 5116 175 4 06 GTAW Electrode Polarity Connect the TIG torch to the Negative Output Terminal and the work lead to the Positive Output Terminal for direct current straight polarity Direct current stra
39. e operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts explain the 10 minute duty cycle period the following example is used Suppose a Welding Power Source is designed to operate at a 2096 duty cycle 175 amperes at 26 8 volts This means that it has been designed and built to provide the rated amperage 175A for 2 minutes i e arc welding time out of every 10 minute period 20 of 10 minutes is 2 minutes During the other 8 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool Inintroduction 2 2 INTRODUCTION 2 08 User Responsibility This equipment will perform as per the informationcontained herein when installed operated maintaineand repaired in accordance with the instructions provided This equipment must be checked periodically Defective equipment including welding leads should not be used Parts that are broken missing plainly worn distorted or contaminated should be replaced immediately should such repairs or replacements become necessary it is recommended that such repairs be carried out by appropriately qualified persons approved by Thermal Arc Advice in this regard can be obtained by contacting accredited Thermal Arc Distributor This equipment or any of its parts should not be altered from standard specification without prior written approval of Thermal Arc The user of this equipment shall ha
40. echniques used for arc welding are almost identical regardless of what types of metals are being joined Naturally enough different types of electrodes would be used for different metals as described in the preceding section 1 8 80 100 65 85 1 16 3 2mm 90 115 90 110 1 16mm 3 16 4 8mm 3 32 E 1 8 1 6mm 1 4 6 4mm ema Operation 4 6 Manual 0 5116 4 13 Welding Position The electrodes dealt with in this publication can be used in most positions 1 6 they are suitable for welding in flat horizontal vertical and overhead positions Numerous applications call for welds to be made in positions intermediate between these Some of the common types of welds are shown in Figures 4 2 through 4 9 Art A 07690 Figure 4 5 Horizontal Vertical HV position AO TONES Art A 07691 Figure 4 6 Vertical position butt weld Manual 0 5116 4 7 ARC MASTER 175 TE Art A 07692 Figure 4 7 Vertical position fillet weld Art A 07693 Figure 4 8 Overhead position butt weld Art A 07694 Figure 4 9 Overhead position fillet weld Operation MASTER 175 OPERATION 4 14 Joint Preparations In many cases it will be possible to weld steel sections without any special preparation For heavier sections and for repair work on castings etc it will be necessary to cut or grind an angle betwee
41. el de l lectrode ou du fil lectrode avec un coupage ou soudage Brassage fort au chalumeau Oxycoupage duction d air approuv Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Op ration de SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Nuance de filtre oculaire Brassage tendre au toutes conditions 2 chalumeau toutes conditions 3 O 4 m taux non ferreux toutes conditions Op ration de coupage Soudage l arc sous gaz avec fil plein GMAW objet m tallique peut provoquer des tincelles un chauffement ou un incendie Dimension d lectrode Nuance ou Epiasseur de m tal de filtre ou Intensit de courant oculaire soudage Soudage l hydrog ne de 1 6 po 25 150 mm 4005 atomique AHW toutes conditions Soudage l arc avec plus de 6 po 150 mm 5ou6 lectrode de carbone CAW toutes conditions Gougeage Air Arc avec moins de 1 8 po 3 mm 40u5 oyes 184172 po 8412 mm Sous plus 1 2 12 mm Soudage l arc avec elec trode enrobees SMAW MOINS de 5 82 po 4 mm l arc Plasma Soudage sous gaz avec moins de 1 25 mm 2003 lectrode de tungst ne GTAW toutes conditions po 4 464 mm moins de 300 amper s pais plus de 400 amperes 14
42. elding equipment 2 Radio and television transmitters and receivers 3 Computer and other control equipment 4 Safety critical equipment e g guarding of industrial equipment 5 The health of people around e g the use of pace makers and hearing aids 6 Equipment used for calibration and measurement 7 Thetime of day that welding or other activities are to be carried out 9 The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment 15 compatible this may require additional protection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises C Methods of Reducing Electromagnetic Emissions 1 Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration Should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure
43. embly PCA will turn on after the input capacitors have charged to operating voltage after approximately 5 seconds NOTE Damage to the PCA could occur if 265 VAC or higher 15 applied to the Primary Power Cable Primary Supply Lead Size Minimum Primary Current amp Duty Cycle Factory Fitted Current Circuit Size STICK 230V 25A 175 20 Arc Master 175 TE 13 AWG 1 5mm Table 3 2 Primary Supply Lead Installation 3 2 Manual 0 5116 INSTALLATION 3 04 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be overemphasized 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 A WARNING EXPLOSIVE 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 WARNING COMPUTERS It is also possible that operation close to computer installations may cause computer malfunction 3 05 High Frequency Interference Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways 1 Direct Radiation Radiation from the machine can occur if the case is metal and is not properly grounded It can
44. empt to weld Safe practices are outlined in the American National Standard 249 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 04 Arc Welding Hazards 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground 11 Donottouch electrode while in contact with the work ground Circuit 12 Use only well maintained equipment Repair or replace ELECTRIC SHOCK can kill damaged parts at once Touching live electrical parts can cause fatal shocks 13 In confined spaces or damp locations do not use a welder or severe burns The electrode and work circuit with AC output unless it is equipped with a voltage reducer is electrically live whenever the output is on The Use equipment with DC output input power circuit and machine internal circuits 14 Wear a safety harness to prevent falling if working above floor are also live when power 15 on semiautomatic level or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the weld 15 Keep all panels and covers securely in place ing wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard B 1 Do not touch live electr
45. empts to contract as much as it expanded but because it has been upset it does not resume its former shape and the contraction of the new shape exerts a strong pull on adjacent metal several things can then happen The metal in the weld area is stretched plastic deformation the job may be pulled out of shape by the powerful contraction stresses distortion or the weld may crack in any case there will remain locked up stresses in the job Figures 4 20 and 4 21 illustrate how distortion is created Art 07705 Weld Upsetting Expansion with gt compression Cool Figure 4 21 Parent metal contraction 4 23 Overcoming Distortion Effects There are several methods of minimizing distortion effects A Peening This is done by hammering the weld while it is still hot The weld metal is flattened slightly and because of this the tensile stresses are reduced a little The effect of peening is relatively shallow and is not advisable on the last layer Operation 4 12 Manual 0 5116 OPERATION B Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out See Figures 4 25 through 4 28 for various weld sequences Choice of a suitable weld sequence is probably the most effective method of overcoming distortion although an unsuitable sequence may exaggerate it simultaneous welding of
46. endix A 2 Manual 0 5116 NOTES NOTES NOTES WARKAN Y WARKAN ICL In accordance with the warranty periods stated below Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in this operating manual Thermadyne welding products are manufactured for use by commercial and industrial users and trained per sonnel with experience in the use and maintenance of electrical welding and cutting equipment Thermadyne will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the warranty period The warranty period begins on the date of sale to the end user Welding Equipment Limited Warranty Period Product ArcMaster 175 TE TIG Torch Electrode holder and work lead 30 Days If warranty is being sought Thermadyne must be notified in writing within 30 days of the failure and at such time we will make arrangements to fulfil the warranty claim Please contact your Thermadyne product supplier for the warranty repair procedure Thermadyne warranty will not apply to e Equipment that has been modified by any other party other than Thermadyne s own service personnel or with prior written consent obtained from Thermadyne service department Uk e Equipment that has been used beyond the specifications established in the operating manual e Installation n
47. g a 1 8 3 2mm 014 electrode at 120 amps position angle iron with one leg horizontal and the other vertical This is known as a horizontal vertical HV fillet Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45 from the vertical Some electrodes require to be sloped about 20 away from the perpendicular position to prevent slag from running ahead of the weld Refer to Figure 4 14 Do not attempt to build up much larger than 1 4 6 4mm width with a 1 8 3 2mm electrode otherwise the weld metal tends to sag towards the base and undercut forms on the vertical edge Multi runs can be made as shown in Figure 4 15 Weaving in HV fillet welds is undesirable 45 from vertical 60 70 from line gt Art 07699 Figure 4 14 Electrode position for fillet weld Figure 4 15 Multi runs in HV fillet weld Manual 0 5116 OPERATION MASTER 175 C Vertical Welds CORRECT INCORRECT 1 Vertical Up Tack weld a three feet length of angle iron to your work bench upright position ause d Use 1 8 3 2mm E7014 electrode and weave allows weld 5 set the current at 120 amps Make yourself 4 pause at edge comfortable on a seat in front of the job rec aes and strike the arc in the corner of the fillet The electrode needs to be about 10 from the horizontal to enable a good bead to be Figure 4
48. heavy cold plate the plate metal or edge of the joint B Welding current is too low B Increase welding current 2 Wrong electrode angle C Adjust angle so the welding arc is directed more into the base metal Art A 05867_AC Lack of inter run fusion D Travel speed of electrode is D Reduce travel speed of elect scale dirt small electrode too high rode amperage too low Lack of root fusion E Scale or dirt on joint sur E Clean surface before welding face 5 Non metallic particles are A Non metallic particles A If bad undercut is present clean trapped in the weld metal may be trapped in under Slag out and cover with arun from slag inclusion cut from previous run a smaller diameter electrode Allow for adequate penetration and E SS B Joint preparation too res room for cleaning out the slag rapped S tricted Dee C If very bad chip or grind out Slag trapped in root rreg u la riti 65 0 Use smaller electrode with sufficient current to give adequate D Lack of penetration with penetration Use suitable tools to slag trapped beneath weld remove all slag from corners bead E Rust or mill scale is pre E Clean joint before welding venting full fusion Wrong electrode for position F Use electrodes designed for Service in which welding is done 5 2 position in which welding is done otherwise proper control of slag 15 difficult
49. ical parts A e WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself from work and ground using dry insulating mats or covers 4 Disconnect input power or stop engine before installing or can burn eyes and skin Noise from some processes servicing this equipment Lock input power disconnect switch can damage hearing i E line fuses so power cannot be turned 4 Wear a welding helmet fitted with a proper shade of filter see ANSI 749 1 listed in Safety Standards to protect your face 5 Properly install and ground this equipment according to its and eyes when welding or watching Owner s Manual and national state and local codes 2 Wear approved safety glasses Side shields recommended 6 Turn off all equipment when not in use Disconnect power to 3 Use protective screens or barriers to protect others from flash equipment if it will be left unattended or out of service and glare warn others not to watch the arc 7 Use fully insulated electrode holders Never dip holder in water 4 to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same time or touch other people with the holder or 5 Use approved ear plugs or ear muffs if noise level is high electrod
50. ight polarity is the most widely used polarity for DC welding It allows limited wear of the electrode since 70 of the heat is concentrated at the work piece 4 07 Guide for Selecting Filler Wire Filler Wire Diameter DC Current Amps 040 1 0mm 30 60 1 16 1 6mm 60 115 3 32 2 4mm 100 165 1 8 3 2mm 135 175 4 08 Tungsten Electrode Current Ranges Electrode Diameter DCCurrent 040 1 0mm 25 85 1 16 1 6mm 50 160 4 09 Shielding Gas Selection 4 10 Tungsten Electrode Types Electrode Type Welding Application Colour Ground Finish Code Thoriated 2 DC welding of mild steel stainless Excellent arc starting long high steel and copper current carrying capacity Ceriated 2 AC amp DC welding of mild steel Longer life more stable arc easier Grey stainless steel copper aluminum starting wider current range magnesium and their alloys narrower 4 more concentrated arc Manual 0 5116 4 5 Operation 175 4 11 TIG Welding Parameters for Steel Base Metal DC Current Electrode FillerRod Argon Thickness tea Diameter Diameter Flow Rate Type Steel 0 040 0 040 1 16 1 0mm 1 0mm 1 6mm 5 LPM 0 045 0 040 1 16 1 22mm 1 0mm 1 6mm 6 LPM 1 16 1 16 1 16 1 6mm 7 LPM 3 32 15 1 8 21 21 Lae 4 12 Arc Welding Practice 5 32 4 0mm The t
51. itches between Manual Arc Lift TIG and HF TIG modes Refer to Section 3 08 Setup for Manual Arc Welding and 3 09 Setup for Welding E Welding Current Control The welding current is increased by turning the Weld Current Control Knob clockwise or decreased by turning the Weld Current Control Knob anticlockwise The welding current should be set according to the specific application Refer to application notes in this section for further information Manual 0 5116 ARC MASTER 175 TE F Arc Force Down Slope Control Arc Force is effective when in Manual Arc Mode only Arc Force control provides an adjustable amount of Arc Force or dig control This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit up in certain situations with particular electrodes In general increasing the Arc Force control toward 10 maximum Arc Force allows greater penetration control to be achieved Down Slope operates in TIG mode only It is used to set the time for weld current to ramp down Refer to Item C Trigger Mode Selection switch for further information regarding Downslope operation G Gas Outlet The Gas Outlet is a 5 8 18 UNF female gas fitting and is utilised for the connection of a suitable TIG Torch H Post Gas Flow Post Gas Flow is the time Gas flows after the arc has extinguished This is used to cool and reduce oxidisation of the Tungsten Electrod
52. lable how proper connections Should be made and 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 Do not connect an input WHITE or BLACK conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal 3 1 Installation ARCMASTER 175 INSTALLATION Refer to Figure 3 1 1 Connect end of ground GREEN or GREEN YELLOW conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 BLUE and line 2 BROWN input conductors to a de energized line disconnect switch 3 Use Table 3 1 as a guide to select line fuses for the disconnect switch Input Voltage 230 40 Amps Table 3 1 Electrical Connections 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 bu gt tx Ground Conductor Ground Terminal Line Disconnect Switch yen J Line Fuse Primary Power Cable Figure 3 1 Electrical Input Connections Art A 08462_AB Input Power Each unit incorporates an INRUSH circuit When the MAIN CIRCUIT SWITCH is turned on the inrush circuit provides pre charging for the input capacitors A relay in the Power Control Ass
53. minal Mains voltage welder 3 Welding current reduces Poor work lead connection to the work Ensure that the work lead has a positive is struck terminal terminal 5 electrode too large for the welding welding current electrode produced Manual Arc or Lift Mode Mode B Torch Trigger Switch lead is B Reconnect or repair TIG torch trigger C High Frequency Spark Gap too wide C Have an Accredited Thermal Arc Short circuited service Provider adjust spark gap to be 0 5 0 6mm 7 Gas when the TIG Gas Regulator is turned off A Turn Gas Regulator on Torch Trigger Switch 15 depressed Gas Hose 5 cut B Replace Gas Hose C Gas passage contains impurities C Disconnect Gas Hose from the rear of the power source then raise the gas pressure and blow out impurities D Torch Trigger Switch lead is D Reconnect or repair TIG torch trigger disconnected or switch lead 15 faulty switch lead Service 5 4 Manual 0 5116 APPENDIX ARC MASTER 175 TE APPENDIX 1 REPLACEMENT PARTS Manual 0 5116 A 1 Appendix MASTER 175 APPENDIX APPENDIX 2 OPTIONS AND ACCESSORIES PartNo Description 0 W4012700 Torch TIG 17 10ft 50mm Dinse W7003038 Torch Repair Kit AM 175TE W4012800 Case Toolbox 175TE with labels fitted W4011900 Claret Helmet Variable shade 9 13 Auto Darkening W4012000 Black w Graphics Helmet Variable shade 9 13 Auto Darkening App
54. n the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 10 Open Square Butt Single Vee Butt Joint ee Joint CES E 1 6mm 1 16 max Gap varies from S 7 1 6mm 1 16 to 4 8mm 3 1 6 I lt 5 1 6mm 1 16 a Single Vee Joint 9578 Double Vee Butt Joint 1 6mm 1 16 max Lap Joint 1 6mm 1 16 uM w Tee Joints Fillet Joint Fillet both sides of the joint Corner Weld Edge Joint A Plug Weld Plug Weld Art 07695 Figure 4 10 joint designs for arc welding 4 15 Arc Welding Technique A Word to Beginners For those who have not yet done any welding the simplest way to commence 1 to run beads on a piece of scrap plate Use mild steel plate about 1 4 6 0mm thick and a 1 8 3 2mm electrode Clean any paint loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the down hand position Make sure that the work clamp is making good electrical contact with the work either directly or through the work table For light gauge material always clamp the work lead directly to the job otherwise a poor circuit will probably result Operation 4 8 Manual 0 5116
55. nadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard 487 1 from American National standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 4 Manual 0 5116 SAFETY INSTRUCTION 1 03 Symbol Chart ARC MASTER 175TE Note that only some of these symbols will appear on your model die Dangerous Voltage Increase Decrease O O Circuit Breaker AC Auxiliary Power EXT Hertz cycles sec pem Direct Current Ground De Do Auxiliary Power Receptacle Rating Auxiliary Power Wire Feed Function Wire Feed Towards O Workpiece With Output Voltage Off Welding Gun ra Purging Of Gas Three Phase Static Frequency Converter Transformer Rectifier Continuous Weld x Duty Cycle Mode O Panel Local Spot Time E Shielded Metal FA Preflow Time one Arc Welding SMAW Gas Metal Arc i 5 Postflow Time LE Gas Tungsten Arc 2 Step Trigger SY Welding GTAW V Operation Press to initiate wirefeed and welding release to stop 7 Air Carbon Arc Cutting CAC A nu Constant Current Constant Voltage Or Constant Potential High Temperature Fault Indication Arc Force V
56. ng produces fumes or gases which contain chemicals know to the State of California to cause birth defects some cases cancer California Health 8 Safety code Sec 25249 5 NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section ofthe U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Back ground Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 00 not coil or drape ca
57. nt tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples EIE S Manual 0 5116 SAFETY INSTRUCTION 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un systeme arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des pro tecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces mouvement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN AC CUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives 1 Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survol
58. nte Ou Potentiel Constant Haute Temp rature IN Amorcage de L arc au Contact GTAW A Inductance Variable Ex pn SE Terre de Protection Courant Continue DC Do Connexion de la Ligne Source Auxiliaire Classement de Prise ESA Source Auxiliaire SAFETY INSTRUCTIONS D roulement du Fil Alimentation du Fil Vers la Piece de Fabrication Hors Tension Torch de Soudage Purge Du Gaz Mode Continu de Soudure Soudure Par Point Dur c du Pulse Dur e de Pr Debit Dur e de Post Debit D tente a 2 Temps yy Appuyez pour deruarer Palimentation du fils et la soudure le relacher pour arr ter D tente a 4 Temps Maintenez appuyez pour pr debit relailez pour initier Appuyez pour arr ter l arc et mainteuir pour pr debit Probl me de Terre Pouces Par Minute Mata Dair lac anmrannamante avian rieniiac AA nhan Alantrianiia la fniirniccanr A Anaraia nnrtantla marnan ic ex oantarma Safety Instruction 1 10 Manual 0 5116 SAFETY INSTRUCTION MASTER 175TE 1 08 Declaration Of Conformity Declaration of Conformity CE Application of Council Directive s The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 2006 95 EC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to
59. occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded 2 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 is then transmitted by both radiation and conduction Adequate shielding and filtering is provided in the Power Source 3 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 Manual 0 5116 ARCMASTER 175 TE 4 Re radiation from Unearthed Metallic Objects A major factor contributing to interference is re radiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent re radiation in most cases 3 06 Electromagnetic Compatibility WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation A Installation and Use Users Responsibility The user 1 responsible for installing and using the welding equipment according to the manufacturer s instructions electromagnetic disturban
60. or check gas line for problems 9 Arc flutters during TIG welding Tungsten electrode is too large for the welding current 10 Welding arc cannot be esta A Work clamp is not connected blished to the work piece or the work torch leads are not connected to the correct welding terminals B Torch lead is disconnected C Gas flow incorrectly set cyl inder empty or the torch valve is Off 11 Electrode melts or oxidizes when an arc 15 struck No gas is flowing to welding region Torch is clogged with dust Gas hose is cut Gas passage contains impuri ties Gas regulator turned off Torch valve is turned off The electrode is too small for the welding current Manual 0 5116 5 3 select the right size electrode Refer to section Tungsten Elec trode Current Ranges Connect the work clamp to the work piece or connect the work torch leads to the correct welding terminals Connect it to the Negative Output Terminal Select the right flow rate change cylinder or turn torch valve on Check the gas lines for kinks or breaks or cylinder contains gas Clean torch Replace gas hose Disconnect gas hose from torch then raise gas pressure and blow out impurities Turn on urn on Increase electrode diameter or reduce the welding current Service MASTER 175 SERVICE TIG Welding Problems Continued Possible Cause 12 Arc start i
61. orm a bead The electrode is directed at the weld pool at about 20 from the vertical The rate of travel has to be adjusted so that a well formed bead 1 produced If the travel is too fast the bead will be narrow and strung out and may even be broken up into individual globules If the travel is too slow the weld metal piles up and the bead will be too large 4 20 Making Welded Joints Having attained some skill in the handling of an electrode you will be ready to go on to make up welded joints A Butt Welds oet up two plates with their edges parallel as shown in Figure 4 12 allowing 1 16 1 6mm to 3 32 2 4mm gap between them and tack weld at both ends This 15 to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment Plates thicker than 1 4 6 0mm should have their mating edges bevelled to form a 70 to 90 included angle This allows full penetration of the weld metal to the root Using a 1 8 3 2mm E7014 electrode at 120 amps deposit a run of weld metal on the bottom of the joint Do not weave the electrode but maintain a steady rate of travel along the joint sufficient to produce a well formed bead At first you may notice a tendency for undercut to form but keeping the arc length short the angle of the electrode at about 20 from vertical and the rate of travel not too fast will help eliminate this The electrode needs to be moved along fast 4 9 Operation
62. ot in accordance with the installation operating manual e Any product that has been subjected to abuse misuse negligence accident improper care and or maintenance including lack of lubrication maintenance and protection will be refused warranty e Failure to clean and maintain the machine as set forth in the operating installation or service manual Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation This manual also offers basic troubleshooting operational and technical details including application usage Using this manual correctly will ensure the quickest time possible for resolving any technical questions ap plication issues or defects with your Thermadyne product You may also wish to visit our web site www thermadyne com select your product class and then select lit erature Here you will find documentation including e Operator manuals e Service manuals e Product guides Alternatively please contact your Thermadyne distributor and speak with a technical representative NOTE Warranty repairs must be performed by either a Thermadyne Service Centre a Thermadyne dis tributor or an Authorised Service Agent approved by the Company THE AMERICAS Denton TX USA U S Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Form No 0 5183 12 17 2010 THERMADYNE WOR
63. ponding 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 Manual 0 5116 2 3 Introduction ARCMASTER 175 INTRODUCTION Inintroduction 2 4 Manual 0 5116 INSTALLATION ARCMASTER 175 TE SECTION 3 INSTALLATION 3 01 Environment These units are designed for use in environments with increased hazard of electric shock Examples of environments with increased hazard of electric shock are A In locations in which freedom of movement 1 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 1 a high risk of unavoidable or accidental contact by the operator 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 increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator which can
64. r une mise en marche YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER accidentelle L OUIE 5 Veuillez installer cet quipement et le mettre la terre selon L arc de soudage produit une chaleur et des rayons le manuel d utilisation et les codes nationaux provinciaux et ultraviolets intenses susceptibles de br ler les yeux locaux applicables et la peau Le bruit caus par certains proc d s peut endommager 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis Safety Instruction 1 6 Manual 0 5116 SAFETY INSTRUCTION 1 Portez une casque de soudeur avec filtre oculaire nuance appropri e consultez la norme 51 749 indiqu e ci apres pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure ARC MASTER 175TE Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ne travaillez dans un espace confin que s il est bien ventil 2 Portez des lunettes de s curit approuv es Des crans sinon portez un respirateur adduction d air Les gaz pro lat raux sont recommand s tecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air 3 Entourez l aire de soudage de rideaux ou de cloisons pour est propre la respiration p
65. rc is established maintain a 1 16 1 6mm to 1 8 3 2mm gap between the burning electrode end and the parent metal Draw the electrode slowly along as it melts down Another difficulty you may meet is the tendency after the arc is struck to withdraw the electrode so far that the arc is broken again A little practice will soon remedy both of these faults 20 Art A 07696_AB A X7 1 32 1 6 mm 1 167 P d gt y y Figure 4 11 Striking an arc Manual 0 5116 MASTER 175 TE 4 18 Arc Length The securing of an arc length necessary to produce a neat weld soon becomes almost automatic You will find that very long arc produces a crackling or spluttering noise and the weld metal comes across in large irregular blobs The weld bead 15 flattened and spatter increases short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by Slag and the electrode tip being solidified in If this Should happen give the electrode a quick twist back over the weld to detach it Contact or touch weld electrodes such as E 014 do not stick in this way and make welding much easier 4 19 Rate of Travel After the arc is struck your next concern is to maintain it and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away At the same time the electrode has to move along the plate to f
66. rot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc Ne soudez pas proximit d op rations de d graissage de nettoyage de pulv risation La chaleur les rayons de 4 2 des v tements en ignifuges et durables peuvent r agir avec des vapeurs et former des gaz hautement laine et cuir et des chaussures de s curit toxiques et irritants 5 Portez un casque antibruit ou des bouchons d oreille ap Ne soudez des t les galvanis es ou plaqu es au plomb ou prouv s lorsque le niveau de bruit est lev au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur adduction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es LES VAPEURS ET LES FUMEES SONT DANGERE AT USES POUR LA SANTE ES Le soudage d gage des vapeurs et des fum es 1 dangereuses respirer LE SOUDAGE PEUT CAUSER UN INCENDIE O 1 Eloignez la t te des fum es pour viter de les respirer UNE EXPLOSION 2 l int rieur assurez vous que l aire de soudage est bien L 2 ventil e ou que les fum es et les vapeurs sont aspir es i de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact ac 3 Sila ventilation est inadequate portez un respirateur ad cident
67. s This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermadyne Corp has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturer s Authorized Representative steve Ward Operation s Director Address Thermadyne Europe ASN nw Europa Building Signature Chorley N Industrial Park Chorley Lancashire ul England PR6 7BX Steve Ward Date Dec 12 2008 Full Name V P Europe and General Manager Position Manual 0 5116 1 11 Safety Instruction MASTER 175 SAFETY INSTRUCTIONS Classification The equipment described in this manual 15 Class and intended for industrial use Warning This Class equipment 15 not intended for use in residential locations where the electrical power 15 provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic compatibility in those locations due to conducted as well as radiated disturbances Safety Instruction 1 12 Manual 0 5116 INTRODUCTION ARG MASTER 175 TE SECTION 2 INTRODUCTION 2 01 How to Use This Manual This Operating Manual applies the part numbers listed on page If none are un
68. s can give off toxic fumes if welded SAFETY INSTRUCTIONS prx i Vole LM WARNING WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 10 7m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Eye protection filter shade selector for welding or cutting goggles or helmet from AWS ANSI Z49 1 1999 Electrode Size Metal Thickness Filter Welding or Cutting Electrode Size Metal Filter Cutting Operation or Welding Curren
69. s not smooth Tungsten electrode istoo large A Refer to section Tungsten Electrode for the welding cur rent Current Ranges for the correct size The wrong electrode is being Refer to section Tungsten Electrode used for the welding job Types for the correct electrode type Gas flow rate is too high C Select the correct flow rate for the welding job Incorrect shield gas is being D Use 100 argon for TIG welding used Improve connection to work piece Poor work clamp connection to work piece A WARNING E There are extremely dangerous voltages and power levels present inside this product Do not attempt to repair unless you are an Accredited Thermal Arc Service Agent and you 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 9 04 POWER SOURCE PROBLEMS 1 The welding arc cannotbe The Primary supply voltage has not Switch ON the Primary supply voltage established been switched ON B The Welding Power Source switch 1 Switch ON the Welding Power Source switched OFF C Loose connections internally C Have an Accredited Thermal Arc Service Provider repair the connection 2 Maximum output welding Defective control circuit Have an Accredited Thermal Arc current cannot be achieved Service Provider inspect then repair the with no
70. supply up to the output terminals and the electrode holder Commence welding If necessary readjust the Weld Current control to obtain the welding condition required 9 After completion of welding the Power Source should be left turned ON for 2 to 3 minutes This allows the fan to run and cool the internal components 9 Switch the ON OFF Switch located on the rear panel to the OFF position Manual 0 5116 INSTALLATION 3 09 HF TIG Lift TIG GTAW Setup set Welding Current as specified by the Electrode Manufacturer Gas Outlet 5 8 18 UNF _ SV py 2 7 7 4 7 Q p Y Negative Output Terminal Dinse 50 BS 7 ARCMASTER 175 secure the gas cylinder an upright position by chaining it to a stationary support to prevent falling or tipping Positive Output Terminal Dinse 50 Art A 08669_AB Figure 3 3 Setup for Lift GTAW Welding HF TIG Lift TIG Sequence of Operation 1 Switch the ON OFF Switch located on the rear panel to OFF 2 Connect the earth clamp to the Positive Output Terminal torch cable to the Negative Output Terminal 9 pin plug to the 9 pin socket and gas hose to the output of an Argon regulator 3 Plug the Power Source in and switch the power switch ON 4 Process Selection Switch to HF TIG or LIFT TIG Manual 0 5116 3 5
71. t Shade No Operation Thickness or Welding Current Shade No Welding or Torch Soldering As tungsten are welding Heavy Over 6 150mm Carbon Arc Welding Gas Welding Carbon Arc Gouging Light Under 1 8 3mm Light Medium 1 8 3mm 1 2 12mm 9 or 6 Heavy Over 1 2 12mm Plasma Arc Welding 2 LS Shielded Metal Arc Welding Stick Electrodes Under 20 Amp 6to 8 0 2 4 2 4 0 2 um meom 7 o wo 3 Manual 0 5116 Safety Instruction 1 2 SAFETY INSTRUCTION 10 Remove stick electrode from holder or cut off welding wire at contact tip when not in use h a WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw slag 1 Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin LI WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully 1 Protect compressed gas cylinders from excessive heat mechanical shocks and arcs 2 Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping 3 Keep cylinders away from any welding or other electrical circuits 4 Ne
72. ter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur Mn FA AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et Sous pression 1 N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Manual 0 5116 1 9 ARC MASTER 175TE 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant d ter compl tement le bouchon Pb PLOMB AVERTISSEMENT Ce produit contient des produits chimiques comme le plomb ou engendre des produits chimiques reconnus par l tat de Californie comme pouvant tre l origine de cancer de malformations foetales ou d autres problemes de reproduction Il faut se laver les mains apr s toute manipulation Code de Californie de la s curit et sant paragraphe 25249 5 et suivants 1 06 Principales Normes De Securite Safety in Welding and Cutting norme ANSI 749 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550
73. ty cycle of the power source has been exceeded If the Over Heat light illuminates wait for the Over Heat light to extinguish before resuming welding C Trigger Mode Selection Switch TIG Mode only Normal Mode Press the TIG Torch Trigger Switch and hold depressed to weld Release the TIG Torch Trigger Switch to stop welding Downslope operates in TIG mode only Whilst welding if the TIG Torch Trigger Switch is released the welding current ramps down to zero current over a defined period of time The time period is determined by the Downslope Control Knob F Latch Mode This mode of welding is mainly used for long weld runs The operator need only to press the TIG Torch Trigger Switch to activate and then release the TIG Torch Trigger Switch to continue to weld then press the Torch Trigger Switch again and release the TIG Torch Trigger Switch to stop welding This eliminates the need for the operator to depress the TIG Torch Trigger Switch for the complete length of the weld Downslope operates in TIG Mode only To activate the Downslope function in Latch mode whilst welding the TIG Torch Trigger Switch must be depressed and held which will ramp the Welding Current down to zero over a defined period of time The time period is determined by the Downslope Control Knob F At any time whilst welding if the Torch Trigger Switch is depressed and released the arc will extinguish immediately D Process Selection Switch ow
74. ve the sole responsibility for any malfunction which results from improper use or unauthorised modification from standard specification faulty maintenance damage or improper repair by anyone other than appropriately qualified persons approved by Thermal Arc Manual 0 5116 INTRODUCTION MASTER 175 2 09 Specifications Power Source Part Number W1003002 5 175 Amps Welding Output 104 F 40 C 10 min 175A 20 27 0V quoted figures refer to SMAW output 110A 60 24 4V 80A 100 23 2V Rated Input Current A for STICK Welding 40 Amps Rated Input Current A for TIG Welding 24 Amps 175A 0 20 270 175A 0 20 TV DS BD Dimensions and Weight H 13 0 x W5 1 x D 10 0 Dimension Power Source DxWxH H 330mm m D 255mm X X A The recommended motor start fuse or thermal circuit breaker size is 40 amp An individual branch circuit capable of carrying 40 amperes and protected by fuses or circuit breaker is recommended for this application 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 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 corres
75. ver allow a welding electrode to touch any cylinder 5 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition 6 Turn face away from valve outlet when opening cylinder valve 7 Keep protective cap in place over valve except when cylinder is in use or connected for use 9 Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards WARNING Engines can be dangerous WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Use equipment outside in open well ventilated areas 2 Ifused in a closed area vent engine exhaust outside and away from any building air intakes Manual 0 5116 1 3 ARC MASTER 175TE y WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel 2 Do not add fuel while smoking or if unit is near any sparks or open flames 3 Allow engine to cool before fuelling possible check and add fuel to cold engine before beginning job 4 Do not overfill tank allow room for fuel to expand 5 Do not spill fuel If fuel is spilled clean up before starting engine 2 WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose

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