ThermalArc_180-220-2
Contents
1. IHERMAL H THERMAL ARC 180 AC DC THERMAL ARC 220 AC DC THERMAL ARC 250 AC DC USER S MANUAL The machine you haue just acgaired taken aduantages its production of Thermal 7a wide experience ia the manufacturing of welding machines along with the latest techuolegy strides ia power electronics Tt will give you entire satisfaction for years if you respect all the operating aud We strougly suggest you read very carefully chapters concerning safety aud tudividual protection We you aduauce your co operation THERMADYNE INDUSTRIES reserve the right to make changes without previous notification Illustrations descriptions and characteristics are not contractually binding and do not engage the responsability of the manufacturer USER S MANUAL Page 2 40 THERMAL ARC m ACID IHERMAL ARC Date 18 1207 7 18 12 07 TABLE OF CONTENTS POLICY STATEMENT SAFETY Ll u y i EP eee E eR Sun PUES 6 14 SDBCLARATION OF Z SSD Q S Su p duis 0 2 0 1 2 1 ASSBSSNIBNT uu S 7 2026 METHODS OF REDUCING BENIDSSIONJS s buku 7 1 2 2 1 gt OSI NS 7 2 fi f L224 JBEguipotental DOM UNC E L2. Digital display voltage intensity displayed setting key pre gas time setting key F4 F5 F6 F8 _ upslope time setting key x F9 Weldingcurentandotherparameters knob gt F10 Knob for arc down slope time adjustment 0 F11 _ post gas time setingKey F12 _ 2 stroke 4 stroke setting key F14 _ Welding mode lt TIG Stick setting key 88 pulse low current gt setting key 6 ERC AC current frequency setting key Balance cleaning penetration setting key F18 lt current in Amps displayed indicator 4 4 O F19 voltage displayed Volts indicator 4 F20 JjWamingindicato F21 j 2strke indicatr Y F22 Jj 4strke indicatr F24 lt TIG welding indicator F25 lt Stick welding indicator F26 indi AC current indicator pulse current indicator PINOUT OF THE FEMALE SOCKET F1 You can use the power source with a torch with potentiometer optional Potentiometer s value has to be 10K ohms The connection is centralised to the female socket F1 as described below PINS CONNECTION 1 jJTochtniggr 0 2 JjTocht iggr 0 0 4 Cursor ofthe torch potentiometer 5 Maximumofthetorchpotentiometer USER S MANUAL THERMAL ARC IHE
3. 9 DESCRIPTION OF THE FRONT PANEL eoa deep iei e Cocteau bisa 15 10 DESCRIPTION OF THE BACK PANEL u lu u u a c u sS 17 MMA STICK VV EL DING uu 17 MW EEDINC 15 121 2 AS TER OIE MODE uu u a 18 12 2 BEFORE atch E 19 12 3 WEEDING E 20 12 4 USING REMOTECONTROL brute Ud tutes 2 12 5 CONNECTION OF A COOLING E 21 12 6 READING PARAMETERS WHEN WELDING ur u u ee 2 277 VENTILATION ti tie weld a a ee Sal aii 21 WEEDING WIEHPULSEDC CURRP EN L eei Q 22 14 JAACCURRENLETIG D h u SD 23 15 WELDING IN PUESE AC CURRENT 25 T6 HIDDEN WELDING PARAMETERS 26 PER MAINTENANCE 27 I8 PARTS Q 27 I9 PCBS CONNECTORS 30 20 TROUBLESHOOTING SL Pho Do pesti n
4. Embase Frigosta EL Couleurs des fils Noir gt a Marron gt 1 Rouge gt 2 Orange gt 3 Jaune gt 4 Uert gt 5 Bleu 6 Violet gt 7 Gris gt Blanc gt 8 U91908 SORTIE 1 8 BluF 638U us 3 ol B1uF 638U 4 5 TRANS HF L in Cr cr gt THERMAL ARC 250 AC DC Wiring diagram 104 22 APPENDICE ADJUSTABLE VALUES FOR WELDING PARAMETERS THERMAL ARC THERMAL ARC THERMAL ARC 180 AC DC 220 AC DC 250 ACIDC Factory settings MMA Stick welding TIG welding meu Post gas time 3 25 Oos 9 99 44 O ignition TIG AC Pulse frequency 0 2 99 9 Pulse cycle ratio EN 20 80 EN EE Pulse low current 3 welding current AC current frequency no 20 250 Balance 20 60 40 cleaning penetration Thermadyne Industries Ltd U K IHERMAL ARC 44 01257 224 802 Thermadyne Industries Ltd Netherlands Hoofddorp Holland Tel 31 23 561 4182 Fax 31 23 565 5074 Thermadyne Industries Ltd Italia Milan Italy Tel 39 039 204 991 Fax 39 039 204 9922 PTA Plasmatechnik Germany Westerburg Germany Tel 49 2663 915666 Fax 49 2663 915667 THERMADYNE INDUSTRIES reserve the right to make changes without
5. European regulations about electromagnetic compatibility 89 336 It also complies with EN 60974 10 standard Electromagnetic compatibility product standard for welding machines The user is responsible for installing and using the arc welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the arc 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 In other cases it could involve USER S MANUAL Page 6 40 THERMAL ARC THERMAL AIRC lso 220 250Acpc ne constructing an electromagnetic screen enclosing the welding power source the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome NOTE The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorised 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 in IEC 62081 Arc welding equipment Installation and use under consideration 1 2 1 ASSESSMENT OF AREA Before installing arc welding eq
6. adn aS 36 21 WIRING DIAGRAMS ua 37 APPENDICE 22 APPENDICE ADJUSTABLE VALUES FOR WELDING PARAMETERS 39 USER S MANUAL Page 4 40 THERMAL ARC THERMAL AIRC __180 220 250 acioc ii Thermal Arc 180 AC DC 220 AC DC and 250 AC DC units are guaranteed 24 months from date of invoice Defects caused by natural wear or accidental damage wrong assembly defective maintenance abnormal use or by modification of the product which has not been accepted in writing by the manufacturer are not included in the guarantee Guarantee covers free of charge replacement of parts which have been admittedly defective transport included Every part replaced under guarantee will be automatically invoiced after a period of 1 month in case of non return of the defective part Labour executed by the distributor is entirely at their cost However if you request labour can be performed free of charge by Thermadyne Industries in its factory In this case transport to and from Thermadyne Industries will be at the distributor s costs USER S MANUAL Page 5 40 THERMAL ARC THERMAL AIRC lso 220 250Acpc ne equipment you just acquired will give you entire satisfaction if you respect the operating maintenance instructions lts design the specification of the components and its manufacture are in accorda
7. control 12 5 CONNECTION OF A COOLING UNIT Connect directly the cooling unit to the female socket B3 Use a water cooled torch Connect the water plug to the cooling unit according to the water circulation The machine starts the cooling unit automatically when necessary Lack of water or water circuit blocked create a default 12 6 READING PARAMETERS WHEN WELDING When welding digital display F5 shows welding current in Amps measured by the machine It is possible to read the welding voltage when pressing the setting key F6 The value is displayed in Volts indicator F18 goes out and F19 illuminates 12 7 VENTILATION IN TIG WELDING Fan allows the cooling of electronic components In TIG welding ventilation doesn t start systematically When welding the component s temperature rise starts the ventilation and fixes the fan s speed which will change according to temperature This method is a good solution between cooling and protection from dust s circulation in the machine NOTE When ambient temperature is high the fan can operate for a short period even if you are not welding In MMA stick mode ventilation is permanent USER S MANUAL Page 21 40 THERMAL ARC IHERMAL ARC 0229 29 lt Date 18 12 07 13 WELDING WITH PULSE DC CURRENT The THERMAL 180 AC DC 220 AC DC and 250 AC DC units have got a pulse current function built in To set the pulse current press the setting key F15 The indicat
8. fire or explosion You have to pay attention to fire safety regulation Remove flammable or explosive materials from welding area Always have sufficient fire fighting equipment Fire can break out from sparks even several hours after the welding work has been finished 3 INDIVIDUAL PROTECTION 3 1 RISK OF EXTERNAL INJURIES 3 1 1 THE WHOLE BODY Arc rays produce very bright ultra violet and infra red light They will damage yours eyes and burn your skin if you are not properly protected The welder is dressed and protected according to the constraints his works impose him Insulate yourself from the workpiece and the ground Make sure that no metal piece especially those connected to the network can come into contact with the operator The welder must always wear an individual insulating protection decree of 14 12 1988 article 3 3 Protective clothing gloves aprons safety shoes offer the additional advantage to protect the operator against burns caused by hot pieces and spatter This protective equipment should be kept in good order and checked on a regular basis USER S MANUAL Page 9 40 THERMAL ARC Notice NOT 034 180 220 250 AC DC IHERMAL RC ne 3 1 2 FACE AND 5 It is absolutely necessary to protect your eyes against arc rays Protect your hair and your face against sparks The welding shield with or without headset is always equipped with a proper filter according to the ar
9. from all such bonded metallic components 1 2 2 5 Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations 1 2 2 6 Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 2 ELECTRIC SAFETY 2 1 CONNECTION OF THE WELDING POWER SOURCE TO THE NETWORK Before connecting your equipment you must check that The meter the safety device against over currents and the electric installation are compatible with the maximum power and the supply voltage of the welding power source refer to the instructions plates The connection either single phase or three phase with earth can be effected on a socket compatible with the we
10. generator Pin 14 not used Pin 15 Negative polarity of shunt Pin 16 Negative output of generator PCB L93101 main supply and filter PCB THERMAL ARC 180 220 AC DC Connector J1 amp J2 230VAC secured main supply Connector J3 amp J4 230VAC main supply Connector J5 5V auxiliary supply only when overvoltage mode is active Connector J6 Pin 1 to pin 1 of cooling socket when used Pin 2 to pin 5 of cooling socket when used Pin 3 amp 5 230VAC to primary coil of auxiliary transformer Pin 4 not used Pin 6 to pin 4 of cooling socket when used Connector J7 amp J8 protective earth PCB L93191 main supply and filter PCB THERMAL ARC 250 AC DC Connector J1 J2 J3 3x400V AC input Connector J4 J6 J7 J8 Protective Earth USER S MANUAL Page 33 40 THERMAL ARC Notice NOT 034 JHERMAL ARC 180 220 250 AC DC Date 18 12 07 Connector J5 Phase fault phase missing information Connector J9 Pin 1 amp 3 400VAC to auxiliary transformer Connector 1 Pin 1 amp 3 400VAC to pin 4 amp 6 of cooling unit socket PCB L93121 Secondary block PCB THERMAL ARC 180 220 and 250 AC DC Connector J1 Pin 1 amp 2 welding output compares to the electronic ground which is the Pin 3 earth protection Connector J2 Pin 1 amp 3 connections for the 200 Ohm 200W discharge resistors Pin 2 not used Connector J3 Pin 1 amp 3 connections for t
11. not striked Pin 11 Fan control PWM from front panel Pin 12 15V AC signal Pin 13 Positive polarity of shunt same as positive output of generator Pin 14 Negative polarity of shunt USER S MANUAL Page 31 40 THERMAL ARC IHERMAL ARC Date 15 12 07 Pin 15 Negative output generator Connector J3 Pin 1 amp 2 thermostat loop 1 Pin 3 amp 4 thermostat loop 2 Pin 5 amp 7 18VAC supplies Pin 6 electronic ground Pin 8 amp 9 shunt information Pin 10 polarity of welding output Connector J4 Pin 1 amp 2 not used Pin 3 amp 4 12VDC fan Connector J6 amp J8 primary connections of main transformer Connector J7 of inverter Connector J9 of inverter PCB L93021 Front panel PCB THERMAL ARC 180 220 and 250 AC DC Connector J1 multiplexed datas to from front panel keyboard Connector J2 Pin 1 20V DC Pin 2 20V DC Pin 3 overvoltage AC fault return Pin 4 AC IGBT control Pin 5 AC IGBT control Pin 6 remote control or torch s potentiometer value Pin 7 15V AC signal used for torch trigger detection Pin 8 Open drain for HF ON OFF control Pin 9 input of torch trigger detection Pin 10 Open drain for gas ON OFF control Pin 11 Open drain for cooler pump ON OFF control Pin 12 Cooling default input 20V when default Pin 13 Over voltage protection or phase missing input Pin 14 NTC thermistor return 0 5V for primary
12. previous notification Illustrations descriptions and characteristics are not contractually binding and do not engage the responsability of the manufacturer
13. rature ambiante de 40 180 AC DC 220 250 ACIDC PRIMARY Power Supply pas phase 1096 Frequency TIG welding Maximum primary current Maximum power consumption Main supply protection A Power factor cos 0 SECONDARY Off load voltage MMA stick welding Welding current 45 A 200 Welding current at 50 A Welding current at 60 A 160 170 190 Welding current at 100 170 TIG welding Welding current range 3 to 250 Welding current at 30 Lo 9m _ 20 250 Welding current at 50 d o Welding current at 60 210 180 Welding current at 100 96 Courant alternatif AC current Frequency Waves form Balance cleaning penetration From 20 to 250 square waves Cleaning from 2096 penetration 80 to 60 penetration 40 N low current From 3 to welding current From 0 2 to 99 9 Cycle ratio From 20 to 80 _ __ _ C U U U U U UTU C T U T U U U U U U C UU U UU UTU C UTU TU TU CTU _Protectiondegree o OPR 2 Insulationclass H Standards EN60944EN69741 USER S MANUAL THERMAL ARC IHERMAL ARC Date 15 12 07 6 CONNECTION TO THE MAIN SUPPLY The power source THERMAL ARC 180 and 220 AC DC must be connected to a single phase 230V 50 Hz 60 Hz mains ground with a tolerance of 1396 The power source THERMAL ARC 250 AC DC must be connected to a three phase 400V 50 Hz 60 Hz mains ground with a tolerance o
14. three phase power supply THERMAL ARC 180 and 220 AC DC units have built in over voltage protection THERMAL ARC 250 AC DC units detect lack of one phase on the supply These 2 machines can be supplied by engine driven generators They offer a very high quality of welding in 1 stick welding Exceptional arc characteristics with a microprocessor that ensures regulation and perfect blade appearence and spatter control Maximum user s comfort strengthened by arc force and anti stick 2 TIG welding Ignition of the arc can be made with high frequency or using a lift arc technique either in 2 stroke or in 4 stroke modes Welding with DC or AC current Integrated pulse current totally controlled through the microprocessor Powerful and direct H F Female socket on the back side for a direct connection to a cooling unit These power sources are perfectly suited to welding in TIG DC for high alloyed steels stainless steels copper and copper alloys titanium TIG AC for aluminium and its alloys magnesium Stick welding with coated electrodes of all types in positive or negative polarity 5 TECHNICAL CHARACTERISTICS PT T n 372 THERMAL ARC 180 220 AC DC L 407 mm THERMAL ARC 250 AC DC L 457 mm DIMENSIONS in mm USER S MANUAL Page 12 40 THERMAL ARC IHERMAL ARC 0229 29 Date 15 12 07 Ces caract ristiques sont donn es pour une temp
15. ventilated areas and if the power source is placed inside Decree dated 14 12 1988 Art 4 2 3 INTERVENING Before carrying out any internal checking or repair work check that the power source has been separated from the electrical installation by locking and guard devices The current plug has to be taken out Provisions have to be taken to prevent an accidental connection of the plug to a socket Cut off through a fixed connecting device has to be omnipolar phases and neutral It is in the OFF position and cannot be accidentally put into operation Maintenance works of electrical equipment must be entrusted to qualified people Section VI Art 46 2 4 MAINTENANCE Check the good state insulation and connection of all the equipment and electrical accessories plugs and flexible supply cables cables NF A 32 510 conduits connectors extension cables NF A 85 610 and CENELEC HD 433 sockets on the power source ground and electrode holder clamps NF A 85 600 These connections and mobile accessories are marked according to standards if consistent with the safety rules They can either be controlled by you or by accredited firms Maintenance and repair works of conduits and liners have to be properly carried out Section VI Art 47 Repair or replace all defective accessories Check periodically that the electrical connections are tightened and do not heat 2 5 RISKS OF FIRE AND EXPLOSION Welding can occur risks of
16. 0s Release the key when your setting is finished e Welding current Set the welding current from 3A to maximum value with potentiometer F9 The value can be read on the display F5 and indicator F18 illuminates 12 3 WELDING Select tungsten electrode Place on the torch a tungsten electrode thoriated 2 or 496 or even better electrode DLZ Itrium Lanthane Zirconium or lanthane not so radioactive Grid electrode s head at 60 or 90 See adviced electrode s diameter adapted to welding current Electrode s diameter mm 1 16 20 24 30 40 0 90 190 170 300 H F ignition Place the tungsten electrode a few mm away from the workpiece Press the trigger on After the selected pre gas time the arc strikes The high frequency stops The welding current increases during the up slope time between the value of initial current and the value of welding current chosen The value of the initial current Ig is pre adjusted at 50 of the value of welding current chosen but it is possible to adjust see chapter 16 At the end of the weld the arc fades away during the down slope time and the welding current reduces from the welding current chosen to the final current The final current 19 is pre adjusted to but it is possible to adjust it see chapter 16 The arc goes out The gas flows according to the post gas time to ensure the protection of the tungsten as well as of the weld pool PAE ignition Put the tun
17. 6096 which is a good solution between the 2 modes and allow aluminium welding in almost all the cases 6 Select tungsten electrode Place a tungsten electrode pure or DLZ Itrium Lanthane Zirconium or lanthane without radiation For low current use the smallest diameter possible For very low current 3A to 15A use only grinded tungsten electrode Electrode s diameter mm 1 16 20 24 3 30 40 50 Welding AC current 40 80 60 110 70 140 90 180 160 240 230 340 Welding For the adjustment of other parameters and for welding see instructions given in chapter 12 DC Current TIG welding USER S MANUAL Page 24 40 THERMAL ARC IHERMAL 180 220 250 ACDC Re Date 18 12 07 15 TIG WELDING IN PULSE AC CURRENT The selection of TIG in AC current welding mode is made in 4 stages Select TIG welding mode Press the setting key F14 to choose TIG welding mode the indicator F24 illuminates To adjust the parameters see instructions given in chapter 12 DC Current TIG welding Select lt pulse DC current welding mode Press the setting key F15 one time to choose pulse DC current welding mode the indicator F27 illuminates indicator F26 OFF To adjust the parameters see instructions given in chapter 13 TIG welding in pulse DC current 6 Select lt AC current gt welding mode Press the setting key F15 one time to choose lt pulse current welding mo
18. ARC 180 220 AC DC Connector J1 Pin 1 duty cycle limitation input image of primary inverter current Pin 2 15V DC Pin PWM 1 output for IGBT1 control Pin 4 electronic ground Pin 5 ENABLE input for inverter start stop 0 4V Pin 6 electronic ground Pin 7 20V DC Pin 8 current control input 0 3 4V Pin 9 PWM2 output for IGBT2 control Pin 10 20V DC Pin 11 striked arc information OV when striked 5V when not striked Pin 12 Arc force control input not used on 160TE Pin 13 Positive polarity of shunt same as positive output of generator Pin 14 not used Pin 15 Negative polarity of shunt Pin 16 Negative output of generator Connector J2 Pin 1 electronic ground Pin 2 open drain for thermal default led on off Pin 3 15V DC Pin 4 current control input 0 3 4V Pin 5 Arc force control output Pin 6 ENABLE output for inverter start stop 0 5V Pin 7 20V DC Pin 8 20V DC Pin 9 NTC thermistor return 0 5V for primary temperature measurement Pin 10 striked arc information OV when striked 5V when not striked Pin 11 Fan control PWM from front panel Pin 12 15V AC signal Pin 13 Positive polarity of shunt same as positive output of generator Pin 14 Negative polarity of shunt Pin 15 Negative output of generator USER S MANUAL THERMAL ARC Notice NOT 034 IHERMAL 180 220 250 AC DC Date 18 12 07 Connector J3 Pin 1 amp 2 thermostat loop 1 P
19. CE 1 15911 Blackfrontframe 2 0592 MAIN PCB without heat sinks for THERMAL ARC 180 220 AC DC E32408 SMINVE MAIN PCB without heat sinks for THERMAL ARC 250 AC DC ne for THERMAL 280 AC DC _ 7 507015 DiodeSTTB120060 gt O 8 591015 IGBT GA200SA60S 1 9 Transformer for THERMAL ARC 180 and 220 AC DC T18704 Transformer for THERMAL ARC 250 AC DC 10 728303 JInducor 1 0 0 0 11 E10011 Completeferie 12 T02013 Auxiliary transformer 80VA 13 L93021 9 Frontface PCB CI302 22 L BEES Filter PCB CI 310 for THERMAL ARC 180 and 220 AC DC L93191 Filter PCB CI 319 for THERMAL ARC 250 AC DC 15 193072 X JjRegulaionPCB CI307 16 19321 SecondarlyblockPCB CI312 222 v Single phase rectifier bridge 35A for 180 and 220 AC DC Three phase rectifier bridge 35A for THERMAL ARC 250 AC DC 18 P02100 Resistor 120W 100o0hms gt 1 1 1 1 19 20 for THERMALE ARC 180 and 220 ACPO G02011 Commutator for THERMAL ARC 250 AC DC 21 1597 Shunt 22 BO00009TH 24 0162 jKnobdiam23 25 CO02025 jFemalesocket5pins 60425 5 pins for C02025 26 F12004 1 Gasoutputt3 BBSP 1808 Gas valve output 12 100 3 8 BSP 28 C02612 12 socketwithout
20. E 7 2 8 J222 65 Se 8 2 LEG IRICSARKETY 5 ei RE 8 21 CONNECTION OF THE WELDING POWER SOURCE TO NETWORK 8 22 ARPA aah m cnet ea kahata 8 290 ANTERVENIN 9 NAN 9 2 55 RISKSOFFIREAND EXPLOSION 9 Se ION 9 3d Z 9 3 1 1 SPAS VV BODY 9 3 1 2 10 See SRS IRON TE RINT TIN TES Y bu ys 10 3 3 SAFETY IN USE OF GASES welding with TIG or MIG inert gaseSs LI 3 3 1 COMPRESSED GAS hua S kaa eta Fette e oem 11 3 3 2 PRESENT 1 3 3 3 IDE IGS ES 11 DESCRIPTION 4 GENERALCHARACTERISTIC Su 12 S5 MAECHNICALCHARACTEREDSTIGS EN xeu e eS eun EE u aa Waaay aasawa awa 12 SETTING UP 6 CONNECTION TO THE MAIN SUPPLE NR EHE 14 USER S MANUAL Page 3 40 THERMAL ARC THERMAL ls0 220 2s0Acpc de CONNECTION EO THE GROUND ul u 14 8 PRELIMINARY PRECAUTIONS 222250600 I 14
21. RMAL ARC DK Date 18 12 07 10 DESCRIPTION OF THE BACK PANEL 85 ITEM DESCRIPTION LB Female socket for remote control B2 ON OFF main switch B3 Female socket for connexion to cooler unit B4 Gasinput B5 Input cable 11 MMA STICK WELDING Connect the power source to the main supply and the ground as explained in the chapter Setting up aS para 6 and 7 Connect the ground cable and the electrode holder to the appropriate power connections F4 and F3 according to the electrode polarity being used refer to the electrodes manufacturer s datasheets Start up the power source with the main switch ON OFF B2 When you start the machine the orange indicator F20 illuminates during 2s and then goes out if no failure has been found Select MMA stick welding mode with setting key F14 the indicator F25 illuminates Adjust welding current with potentiometer F9 Digital display F5 shows the selected current in Amps indicator F18 illuminates Place the electrode on the workpiece in order to strike the arc NOTE The welding current of ELEKTROTIG 220 AC DC in MMA welding mode could be adjusted from 3 to 200A in TIG welding mode from 3 to 220A The welding current of ELEKTROTIG 250 AC DC in MMA welding mode could be adjusted from 3 to 220A in TIG welding mode from 3 to 250A Arc force control Arc force control is not adjustable but it is optimised for
22. c welding current NS S 77 104 A 88 221 A 88 222 standards In order to protect shaded filter from impacts and sparks you have to add a plain glass in front of the shield The helmet provided with your equipment if requested is equipped with a protective filter When you want to replace it precise the reference and number of opacity degree of the filter Use the shade of lens as recommended in the instruction manual opacity graduation number Protect others in the work area from arc rays by using protective booths UV protective goggles and if necessary a welding shield with appropriate protective filter on NF S 77 104 by A 1 5 Opacity gradation numbers and recommended use for arc welding Current intensitv in Amps Welding process or 125 175 225 275 350 450 connected techniques 100 150 200 250 300 400 500 Coated electrodes MIG on heavy metals MIG on light alloys quo 39 3 Depending on the conditions of use the next highest or lowest category number may be used The expression heavy metals covers steels alloyed steels copper and its alloys The shaded areas represent applications where the welding processes are not normally used at present CARE Use a higher degree of filters if welding is performed in premises which are not well lighted 3 2 RISK OF INTERNAL INJURIES GASES AND FUMES Gases fumes produced during the welding process can be dangerous and hazardous to your health Arc welding wo
23. de the indicator F26 illuminates indicator F27 dies out To adjust the parameters see instructions given in chapter 14 AC current TIG welding O Select pulse AC current welding mode Press the setting key F15 one time to choose pulse AC current welding mode the indicators F26 and F27 illuminate NOTE In this case indicators F26 and F27 ON you could not make any more adjustments that the reason why you have to do them in previous stages To make any modification change the welding mode with the setting key F15 Indicator F26 ON and indicator F27 OFF modification of AC current parameters Indicator F27 ON and indicator F26 OFF modification of pulse current parameters At the end of modifications come back to pulse AC current welding mode indicators F26 and F27 ON Tpulse li b pulse low current In pulse high current TAc x Tputse pulse frequency b I I Hr Tac AC current frequency il USER S MANUAL Page 25 40 THERMAL ARC IHERMAL ARC DK Date 18 12 07 16 HIDDEN WELDING PARAMETERS Some welding parameters are not directly adjustable Pre heat time at ignition in TIG AC welding mode initial current final current Hot start time To adjust these parameters press in the same time setting keys F7 and F14 then release The indicator F18 A goes out Turn potenti
24. e parameter s value is displayed by digital display F5 When adjusting a current the indicator F18 illuminates A Amps In the other case it is OFF Then the unit of the value displayed is written on the setting key Pre gas Press the setting key F7 adjust the pre gas time with the potentiometer F9 When the potentiometer is at the minimum the pre gas time is 0 15 and at the maximum the pre gas time is 5s The value can be read on the display F5 The indicator F18 or F19 goes out The pre adjusted value is 0 05 Release the key when your setting is finished OUp slope time Press the setting key F8 adjust the up slope time with the potentiometer F9 When the potentiometer is at the minimum the up slope time is Os and at the maximum the up slope time is 10s USER S MANUAL Page 19 40 THERMAL ARC IHERMAL ARC lt Date 18 12 07 The value be read display 5 indicator F18 F19 goes out The pre adjusted value is 1 05 Release the key when your setting is finished e Down slope time Adjust the down slope time between Os to 16s with the potentiometer F10 OPost gas Press the setting key F11 adjust the post gas time with the potentiometer F9 When the potentiometer is at the minimum the pre gas time is 3s and at the maximum the pre gas time is 25s The value can be read on the display F5 The indicator F18 or F19 goes out The pre adjusted value is 5
25. f 1096 It has built in over voltage protection which allows engine driven generator supply Main supply must be protected by fuses or circuit breaker according to the value I1 written on the specifications of the power source It is strongly suggested to use a differential protection for the operator s safety 7 CONNECTION TO THE GROUND For the operator s protection the power source must be correctly grounded according to the International Protections Norms It is absolutely necessary to provide a good ground connection installation with the green yellow lead of the power cable This will avoid discharges caused by accidental contacts with grounded pieces If no earth connection has been set a high risk of electric shock through the chassis of the unit remains possible 8 PRELIMINARY PRECAUTIONS For the good operation of your welding power source make sure that the air flow produced by the fan inside the unit is not obstructed Also try to operate in a non dusty area Avoid all impacts exposure to damp areas or excessive temperatures USER S MANUAL Page 14 40 180 220 250 AC DC USING 9 DESCRIPTION OF THE FRONT PANEL J 2x 1 TOS ONCEDE 2 USER S MANUAL Page 15 40 THERMAL ARC IHERMAL ARC lt Date 18 12 07 F1 Female socket for torch s signals connection F2 Gasoutput
26. gh current warm time t and the total time th t5 of the pulse in 96 leR t th tp When F26 OFF and F27 ON press the setting key F17 adjust the cycle ratio with the potentiometer F9 The value in 96 can be read on the display F5 When the potentiometer is at the minimum the ratio is of 20 and when it is at the maximum it is of 80 The ratio pre adjusted is 50 Release the key when your setting is finished For welding see indications in chapter 12 NOTE When welding you can read alternately on the display F5 values of high and low current Only the value of high current can be adjusted with remote control 14 AC CURRENT TIG WELDING Select of lt TIG AC current gt welding mode Select lt TIG welding gt with the setting key F14 the indicator F24 illuminates Press 2 times the setting key F15 in order to select lt AC current gt x the indicator F26 illuminates indicator F27 OFF Set lt AC current gt parameters AC welding current Frequency adjustment The frequency is the number of periods per second Tac Tp Tp Fac 1 Tacin Hz When F26 ON and F27 OFF press the setting key F16 adjust the frequency with the potentiometer F9 The value in Hz can be read on the display F5 USER S MANUAL Page 23 40 THERMAL ARC IHERMAL ARC lt Date 18 12 07 When the potentiometer is at the minimum the frequency is 20 Hz and at the maximum the f
27. gsten electrode in direct contact with the workpiece Push on the trigger Raise the torch slowly The arc strikes The welding cycle will then be the same as described above NOTE This type of ignition is especially useful when welding in surroundings sensitive to radioelectric disturbances next to computers or digital controlled equipments USER S MANUAL Page 20 40 THERMAL ARC IHERMAL AIRC 180 220 250Acpc Date 18 12 07 12 4 USING REMOTE CONTROL CAUTION Do not connect at the same time remote control to socket B1 and torch with potentiometer to socket F1 Using remote control RC01 or RC04 The unit recognises the remote control RC01 as soon as you plug it in female socket B1 The unit recognises the foot pedal remote control 04 as soon as you plug it in female socket F1 Using torch with potentiometer The generator is equiped to work with all torches with potentiometer of 10kQ The connection is centralised on the female socket F1 as described in chapter 9 The unit recognises the torch with remote control as soon as you plug it in female socket F1 IMPORTANT using the potentiometer of remote control or torch you can adjust the welding current from 3A to the current selected with the main potentiometer F9 of the power source This value is displayed on F5 when the potentiometer of the remote control is on maximum This allow you to set the welding current with fine adjustment directly on the remote
28. he HF transformer primary coil Pin 2 not used Connector J4 Pin 1 amp 2 torch trigger Pin 3 minimum of the torch potentiometer Pin 4 cursor of the torch potentiometer Pin 5 maximum of the torch potentiometer Connector J5 Pin 1 amp 2 torch trigger Pin 3 20V Pin 4 minimum of the torch potentiometer Pin 5 cursor of the torch potentiometer Pin 6 maximum of the torch potentiometer Connector J6 Pin 1 20V DC Pin 2 20V DC Pin 3 overvoltage AC fault return Pin 4 AC IGBT control Pin 5 AC IGBT control Pin 6 remote control or torch s potentiometer value Pin 7 15V AC signal used for torch trigger detection Pin 8 Open drain for HF ON OFF control Pin 9 input of torch trigger detection Pin 10 Open drain for gas ON OFF control Pin 11 Open drain for cooler pump ON OFF control USER S MANUAL Page 34 40 THERMAL ARC IHERMAL ARC Date 15 12 07 Pin 12 Cooling default input 20V when default Pin 13 Over voltage protection or phase missing input Pin 14 NTC thermistor return 0 5V for secondary temperature measurement Pin 15 electronic ground Connector J7 Pin 1 amp 3 electronic ground Pin 2 NTC thermistor return 0 5V for secondary temperature measurement Pin 4 Main supply overvoltage information 5V Connector J8 Pin 1 amp 2 gas solenoid connections 230VAC Connector J9 Pin 1 amp 3 insulated 230VAC input from the auxi
29. he machine 12 TIG WELDING 12 1 2 STROKE amp 4 STROKE MODE 2 STROKE MODE Down slope Down slope Welding current 1 Pre gas O Q E e NORMAL CYCLE Down slope Pre gas x Post gas h Ah 4 RESTARTING THE CYCLE DURING POST GAS RESTARTING THE CYCLE DURING DOWN SLOPE Down slope Down slope Welding current USER S MANUAL Page 18 40 THERMAL ARC IHERMAL ARC DK Date 18 12 07 4 STROKE MODE Welding current Down slope I Pre gas Gas 1 2 Post gas 12 2 BEFORE WELDING connect the power source to the main supply and the ground as explained in the chapter Setting up gt as para 6 and 7 connect the ground cable to the power connection F4 and the torch to the F3 start up the power source with the main switch ON OFF B2 select the TIG welding mode with the key 14 to light indicator F24 Check that the indicators F26 and F27 are extinguished If not press the setting key F15 to extinguish them select the 2 stroke or 4 stroke welding mode with the key F12 If the mode 4 stroke is selected the indicator F22 illuminates If the mode 2 stroke is selected the indicator F21 illuminates select the ignition mode with the key F13 If HF ignition is selected the indicator F23 illuminates set the TIG cycle parameters During their adjustment th
30. imum current of the machine 180A for THERMAL 180 AC DC 220A for the THERMAL 220 AC DC and 250A for THERMAL 250 AC DC If final current chosen is more than welding current the machine will automatically adjust the final current to welding current If initial current is more than welding current the machine will automatically adjust the initial current to welding current Adjustment of Hot start time Stick welding Adjust the Hot start time with the potentiometer F9 The value can be read on the display F5 Time can be adjusted between 0 0s and 5 0s The pre adjusted value is 0 0s The over current at ignition is 20 USER S MANUAL Page 26 40 THERMAL ARC IHERMAL ARC 0229 29 Date 15 12 07 17 MAINTENANCE CAUTION BEFORE OPENING the unit disconnect the power source from the mains Voltages are high and dangerous inside the machine In spite of their robustness THERMAL ARC power sources require some regular maintenance Once every 6 months more often in dusty surroundings the machine must be blown through with dry oilfree compressed air check all connections for electrical continuity Checkall cable connections including ribbon cables 18 SPARE PARTS 18 SPARE PARTS USER S MANUAL Page 27 40 THERMAL A 180 220 250 AC DC IHERMAL ARC Date 18 12 07 83 USER S MANUAL THERMAL ARC IHERMAL ARC MAINTENAN
31. in 3 amp 4 thermostat loop 2 Pin 5 amp 7 18VAC supplies Pin 6 electronic ground Pin 8 amp 9 shunt information Pin 10 polarity of welding output Connector J4 Pin 1 amp 2 not used Pin 3 amp 4 12VDC fan Connector J6 amp J8 primary connections of main transformer Connector J7 of inverter Connector J9 of inverter PCB L92863 primary block PCB THERMAL ARC 250 AC DC Connector J1 Pin 1 duty cycle limitation input image of primary inverter current Pin 2 15V DC Pin 3 PWM 1 output for IGBT1 control Pin 4 electronic ground Pin 5 ENABLE input for inverter start stop 0 4V Pin 6 electronic ground Pin 7 20V DC Pin 8 current control input 0 3 4V Pin 9 PWM2 output for IGBT2 control Pin 10 20V DC Pin 11 striked arc information OV when striked 5V when not striked Pin 12 Arc force control input not used on 160TE Pin 13 Positive polarity of shunt same as positive output of generator Pin 14 not used Pin 15 Negative polarity of shunt Pin 16 Negative output of generator Connector J2 Pin 1 electronic ground Pin 2 open drain for thermal default led on off Pin 3 15V DC Pin 4 current control input 0 3 4V Pin 5 Arc force control output Pin 6 ENABLE output for inverter start stop 0 5V Pin 7 20V DC Pin 8 20V DC Pin 9 NTC thermistor return 0 5V for primary temperature measurement Pin 10 striked arc information OV when striked 5V when
32. 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 1 2 2 2 Maintenance of the arc welding equipment The arc welding equipment should be routinely maintained according to the manufacturers recommendations All access and service doors and covers should be closed and properly fastened when the arc welding equipment is in operation The arc 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 stabilising devices should be adjusted and maintained according to the manufacturer s recommendations 1 2 2 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 1 2 2 4 Equipotential bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered USER S MANUAL Page 7 40 THERMAL ARC THERMAL AIRC 99 22 25 ne EN However metallic components bonded to the work piece will increase the risk that the operator could receive an electric shock by touching these metallic components and the electrode at the same time The operator should be insulated
33. lding power source cable plug If the cable is connected to a fixed post the earth if provided will never be cut by the safety device against electric shocks The ON OFF switch if exists situated on the welding power source is turned off 2 3 WORKING AREA The use of arc welding implies a strict respect of safety conditions with regard to electric currents Decree dated 14 12 1988 It is necessary to check that no metal piece accessible to the operators and to their assistants can come into direct contact with a phase conductor and the neutral of the network In case of uncertainty this metal part will be connected to the earth with a conductor of at least equivalent section to the largest phase conductor Make sure that all metal pieces that the operator could touch with a non insulated part of his body head hands without gloves on naked arms is properly grounded with a conductor of at least equivalent section to the biggest supply cable of the ground clamp or welding torch If more than one metal ground are concerned they need to be all interlinked in one which must be grounded in the same conditions Unless very special care have been taken do not proceed to any arc welding or cutting in USER S MANUAL Page 8 40 THERMAL ARC THERMAL AIRC lso 220 250Acpc ne EN conductive enclosures whether it is a confined space or the welding machine has to be left outside Be even more prudent when welding in humid or non
34. liary transformer Connector J10 Pin 1 cooling unit ON OFF control open drain Pin 2 cooling unit flow warning return optocouplor input Pin 3 amp 4 common point for cooling unit control USER S MANUAL Page 35 40 THERMAL ARC IHERMAL ARC Date 15 12 07 20 TROUBLESHOOTING BEWARE BEFORE ANY INTERNAL INTERVENTION disconnect the power source from the power DIGITAL DISPLAY AND ORANGE INDICATOR F20 OFF NO SUPPLY INPUT VOLTAGE OVER RATED LIMIT THERMAL ARC 180 AC DC 220 AC DC Power source supplied between 2 phases 400V Lack of one phase DIGITAL DISPLAY SHOW tH AND ORANGE INDICATOR F20 ON WARMING UP Duty cycle over rated particulary if ambient t Let the machine cool it will automatically start again is gt 25 Insufficient cooling air Clean the air inlets Very dusty machine Open the machine and blow it through Fan doesn t start Replace the fan DIGITAL DISPLAY SHOW CO AND ORANGE INDICATOR F20 ON COOLING UNIT DEFAULT if a cooling unit is connected DIGITAL DISPLAY SHOW AC AND ORANGE INDICATOR F20 ON AC SECONDARY CIRCUIT DEFAULT AC current frequency too high Torch length too long Wrong electrode polarity Use the right polarity according to the indications of electrode s manufacturer IGNITION FAILURE Wrong polarity Check the connection Ground to power terminal cancel it No gas arrives to the machine Check the gas supply No gas goes out
35. nce with the existing rules French standards NF ISO and CEI international injunctions EEC general lines and CEN CENELEC standards In this chapter you will find safety rules in the use of electric arc welding power sources with coated electrodes We give you hereunder a list of recommendations and obligations you have to respect Safety rules must be observed and particulary those relating to Decree 88 1056 dated November 14 1988 concerning protective measures against electrical currents 1 ELECTROMAGNETIC COMPATIBILITY 1 1 DECLARATION OF CONFORMITY THERMADYNE Industries hereby declare that the machine object of this manual complies with the following European regulations Electromagnetic compatibility Rule 89 336 EEC of 3 05 89 modified by rules 92 31 EEC of 28 04 1992 and 93 68 EEC of 22 07 1993 Low voltage Rule 73 23 EEC of 19 02 1973 modified by rule 93 68 EEC of 22 07 1993 and with the national legislation transposing them THERMADYNE Industries also declare that following harmonised standards have been applied EN 60974 10 2003 Electromagnetic compatibility CEM Product norm for arc welding material EN 50060 1990 Current source for arc manual welding with limited service EN 60974 1 Security rules for electric welding material Part 1 welding current sources EN 50192 1995 Arc welding material plasma cutting systems 1 2 INSTALLATION AND USE The machine object of this manual complies with the
36. of the machine Check the gas valve Initial current too low Check the value of initial current see chapter 14 In pulse current welding arc is on and off Check the low current value low current too low USER S MANUAL 21 WIRING DIAGRAMS PLATINE L93121 gt SORTIE 2xGAZB0SA60S Bl 2x100 Ohm 120LI a r gt ara o o 1 at ic AG Sts 1 8 BluF 63BU STTB12006TU1 C i 3 amp eiBtuF 3BU m I ur riv e 5 L K z c Embase B TRANS_HF Frigosta EL C B0403 oh 5 2 n 1 Chi ae c r 1 mao M 2 z Cobb 4 B 4 2 SHIT sssssesesevesex 599999 24284 d gt a 2 246 l 2 c i C aD B PLATINE L93101 2 2 gt la oa 2 1 Chassi A a V4 5 4 5 4 ig 0422 47 6 8 Es sasan T gt NN gt 43 EE D fum 6 8 sd eS 6 8 1 1 a z Couleurs des fils H N 1 Q L E m d z Noir gt amp n 6 5 2 gt 1 Rouge gt 2 eo o E Drange gt 3 CTN 47k 0 04258 B Cr Jaune gt 4 5 gt Uert gt 5 a a Bleu gt 6 THERMAL ARC 180 AC DC THERMAL ARC 220 AC DC Violet gt 7 i OO Wiring diagram BAS asm Rev 107
37. ometer F9 until value 33 for adjustment of pre heat time at ignition in TIG AC welding mode 40 for adjustment of initial current 41 for adjustment of final current 42 for adjustment of Hot start time 238 for return of pre adjusted values factory settings Press any key to finish selection Adjustment of pre heat time at ignition in TIG AC welding mode This time is the duration of the first positive alternating at the ignition in TIG AC welding mode Chosen a long time gives a better ignition Unfortunatly it damages grinded electrode s head Adjust the time with potentiometer F9 The value can be read on display F5 The time can be adjusted from 0 15 to 1 05 It is pre adjusted to 0 15 Adjustment of initial current 14 Adjust the current with potentiometer F9 The value can be read on display F5 The initial current can be adjusted between 3A and maximum current of the machine 180A for THERMAL ARC 180 AC DC 220A for the THERMAL 220 AC DC and 250A for THERMAL 250 AC DC If initial current is less than 3A the machine will automatically adjust the initial current to the pre adjusted value i e 50 of welding current If initial current is more than welding current the machine will automatically adjust the initial current to welding current Adjustment of final current 1 Adjust the current with potentiometer F9 The value can be read on display F5 The final current can be adjusted between 3A and max
38. or F27 illuminates indicator F26 OFF To remove the pulse current press the setting key F15 until indicator F27 fade out high current up slope Down slope 50 2 Pre gas Post gas low current 2 Welding current ty PULSE CYCLE e Adjustment of the pulse high current Adjust the high current with the potentiometer F9 The value can be read on display F5 O Adjustment of the pulse low current When F26 OFF and F27 ON press the setting key F15 for 3 s Maintain the key pressed and adjust the low current s value with the potentiometer F9 The value can be read on the display F5 When the potentiometer is at the minimum the current is 3A and at the maximum it is high pulse current value The low current is pre adjusted at 30A Release the key when your setting is finished e Adjustment of the frequency The frequency is the number of pulses per second Fouse 1 th t in Hz When F26 OFF and F27 ON press the setting key F16 and adjust the frequency with the potentiometer F9 The value in Hz can be read on the display F5 When the potentiometer is at the minimum the frequency is 0 2 Hz and at the maximum the frequency is 99 9 Hz The frequency is pre adjusted at 20 Hz Release the key when your setting is finished USER S MANUAL Page 22 40 THERMAL ARC IHERMAL ARC DK Date 18 12 07 O Cycle ratio The cycle ratio is the ratio between the time of hi
39. ous hydrogen and hydrogen based combustible gaseous mixtures These are very light gases In the case of leaks they collect under the ceiling Provide for ventilation at ceiling level These are also inflammable gases The flame of hydrogen is almost invisible There is therefore a risk of burns Air hydrogen and oxygen hydrogen mixtures are explosive in the following proportions 4 to 74 5 of hydrogen in air 4 to 94 of hydrogen in oxygen otore the bottles in the open or in a well ventilated place Avoid any leakage by limiting the number of connections or couplings to a minimum USER S MANUAL Page 11 40 THERMAL ARC JHERMAL ARC 180 220 250 AC DC Date 18 12 07 X meum po 4 GENERAL CHARACTERISTICS THERMAL ARC 180 AC DC 220 AC DC and 250 AC DC welding machines have been designed as integrated and portable units using the newest techniques in power electronics based on an inverter process with IGBT wich enables the following aconsiderable reduction of weight and volume the dynamic control of the welding current the specific protection of power components a high power in a small space at a very low power consumption With their innovative design these machines are both robust plastic front and back panel new internal conception and ergonomic The THERMAL ARC 180 and 220 AC DC units must be connected to a single phase power supply and the THERMAL ARC 250 AC DC units to a
40. pins 02613 10 pins for C02612 1 1 1 1 1 1 1111 02614 02612 in option 2 eet for THERMAL ARG 180 and 5 1059041 Chassis for THERMAL ARC 180 220 105902 for THERMAL ARC 250 AC DC 105933 Panel for THERMAL ARC 180 and 220 AC DC 105935 Panel for THERMAL ARC 250 AC DC ES 105932 Cover for THERMAL ARC 180 and 220 AC DC O J 105934 Cover for THERMAL ARC 250 AC DC J15021 2 Handle for THERMAL ARC 180 and 220 AC DC J15021 3 Handle for THERMAL ARC 250 AC DC 105919 Bottom of the front face B04038 Thermistor CTN 47K T03005 Ferrite for THERMAL ARC 250 AC DC USER S MANUAL Page 29 40 THERMAL ARC IHERMAL ARC Date 15 12 07 19 PCB S CONNECTORS PCBs in THE MACHINE THERMAL ARC 180 AC DC and 220 AC DC 92861 286 PCB for primary block E11208 SMI 93051 600V IGBT module PCB L93072 307 PCB regulator L93021 302 front panel PCB L93101 310 PCB main supply and filter L93121 313 PCB HF gas and secondary blockPCB PCBs in THE MACHINE THERMAL ARC 250 AC DC 92865 286 PCB for primary block E11208 SMI L93052 1200V IGBT module PCB L93072 307 PCB regulator L93021 302 front panel PCB L93191 319 PCB main supply and filter L93121 312 PCB HF gas and secondary blockPCB PCB L92861 primary block PCB THERMAL
41. requency is 250 Hz High frequencies allow arc concentration and reduce the area affected by the arc on the workpiece The frequency is pre adjusted at 100 Hz Release the key when your setting is finished Balance adjustment This adjustment has an effect upon the proportion of positive current in the arc The balance is Tp Tp Tp in 9o Penetration The negative halfcycle Tp is longer than the positive Tp You need a lower welding current which allows e less heating of the tungsten electrode which allows longer time between electrode grinding e reduction of the affected area on the workpiece Use for clean workpiece only Cleaning The positive alternating Tp is longer than the negative one Tp which heat the tungsten electrode and means e higher welding current e more important tungsten electrode diameter e electrode s rounded so the arc is less directional e larger affected area on the workpiece Use for dirty workpiece only When 26 ON and F27 OFF press the setting key F17 adjust the balance with the potentiometer F9 The value in 9o of cleaning ratio can be read on the display F5 Release the key when your setting is finished 50 of balance means that the 2 alternating positive and negative are equal Balance can be adjusted from 20 to 60 cleaning In order to maintain a sharp tungsten it is better to use a shorter cleaning time The balance is pre adjusted to 40 cleaning 40 penetration
42. rks have to be carried out in suitable ventilated areas Ventilation must be adequate to remove gases and fumes during operation All fumes produced during welding have to be removed as soon as they are given off and as close as possible from the place they are produced to be the most efficient Vapors of chlorinated solvents can form the toxic gas phosgene when exposed to ultraviolet radiation from an electric arc USER S MANUAL Page 10 40 THERMAL ARC IHERMAL ARC 180 220 250 AC DC Rev 07 u SAFETY MEE 3 3 SAFETY IN THE USE OF GASES WELDING WITH TIG OR MIG INERT GASES 3 3 1 COMPRESSED GAS CYLINDERS Compressed gas cylinders are potentially dangerous Refer to suppliers for proper handling procedures No impact secure the cylinders and keep them away from impacts No excess heat over 50 C 3 32 PRESSURE RELIEF VALVE Check that the pressure relief screw is slackened off before connecting to the cylinder Check that the union is tight before opening the valve of the cylinder Open it slowly a fraction of a turn If there is a leak NEVER tighten a union which is under pressure but first close the valve on the cylinder Always check that hoses are in good condition 3 3 3 DETAILS ABOUT GASES Gas and gaseous mixtures containing less than 20 of If these gases or mixtures take the place of the oxygen in the air there is a danger of asphyxia An atmosphere containing less than 17 oxygen is danger
43. temperature measurement Pin 15 electronic ground Connector J3 J4 options not used Connector J5 matches with J2 of L92861 PCB Pin 1 electronic ground Pin 2 open drain for thermal default led on off Pin 3 15V DC Pin 4 current control input 0 3 4V Pin 5 Arc force control output Pin 6 ENABLE output for inverter start stop 0 5V Pin 7 20V DC Pin 8 20V DC USER S MANUAL Page 32 40 THERMAL ARC IHERMAL ARC Date 15 12 07 Pin 9 thermistor return 0 5V for primary temperature measurement Pin 10 striked arc information OV when striked 5V when not striked Pin 11 Fan control PWM from front panel Pin 12 15V AC signal Pin 13 Positive polarity of shunt same as positive output of generator Pin 14 Negative polarity of shunt Pin 15 Negative output of generator PCB L93072 Regulator PCB THERMAL ARC 180 220 and 250 AC DC Connector J1 Pin 1 duty cycle limitation input image of primary inverter current Pin 2 15V DC Pin PWM 1 output for IGBT1 control Pin 4 electronic ground Pin 5 ENABLE input for inverter start stop 0 4V Pin 6 electronic ground Pin 7 20V DC Pin 8 current control input 0 3 4V Pin 9 PWM2 output for IGBT2 control Pin 10 20V DC Pin 11 striked arc information OV when striked 5V when not striked Pin 12 Arc force control input not used on 160TE Pin 13 Positive polarity of shunt same as positive output of
44. uipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the arc welding equipment b Radio and television transmitters and receivers C Computer and other control equipment d Safety critical equipment e g guarding of industrial equipment e The health of the people around e g the use of pacemakers and hearing aids f Equipment used for calibration or measurement g The immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h The time of day that welding or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises 1 2 2 METHODS OF REDUCING EMISSIONS 1 2 2 1 Public supply system Arc welding equipment should be connected to the public supply system according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the public supply system Consideration should be given to shielding the supply cable of permanently installed arc welding equipment
45. welding with a large range of rutile and basic electrodes Hot start time The Hot start is an over current of 2096 higher than the welding current chosen The hot start time pre adjusted is Os no over current but it is possible to adjust it until 5s see chapter 16 Using remote control RC01 or RC04 The unit recognises the remote control as soon as you plug it in female socket B1 USER S MANUAL Page 17 40 THERMAL ARC IHERMAL ARC DK Date 18 12 07 IMPORTANT using the potentiometer of the remote control you can adjust the welding current from 3A to the current selected with the main potentiometer F9 of the power source This value is displayed on F5 when the potentiometer of the remote control is on maximum This allows you to set the welding current with fine adjustment directly on the remote control Reading the parameters when welding When welding digital display F5 shows welding current in Amps measured by the machine It is possible to read the welding voltage when pressing the setting key F6 The value is displayed in Volts indicator F18 goes out and F19 illuminates Press setting key F6 in order to display current s value again Ventilation in MMA stick welding Fan allows the cooling of electronic components Ventilation is permanent Fan speed changes according to the components temperature This method is a good solution between cooling and protection from dust circulation in t
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