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ARCMASTER® 185 AC/DC 200 AC/DC Service Manual

1. AQ 185 200ACDC INTERCONNECT DIAGRAM E E cs ud PCB12 14 I DIODE Snubber IGBT Snubber i Circuit Board Circuit Board WK 5615 WK 5570 I 3 93 1 D4 1 1 E OO MS I 1 1 1 1 DEP LI 1681 Gate TOI Circuit Boar 1 1 Output b acil WK 3367 Oe ll I ta 6 HT 1 11 nl 1 a 1 1 P1400 0 e mf ul po als 451 Ground m 8 PCIe i T RYON 2 1 C Filter Circuit 3 HCTI WK 5499 SIDE CHASSIS 3 1077722 TO2 A PRIT Output C o o Over maba MB 1S 1 1R3 2922 Lg E zz i HF UNITI ISiR2 2 RAH E H 1 Ha 1 ACI AC3 13 Super Inpose Circui
2. 3 3 3 07 High Frequency Interference 2 3 4 ab AR S 3 4 3 5 4 01 ArcMaster 195 200 ACDC Controls 2 2 aaa Naa cuni 4 1 SECTION 4 OPERATOR CONTROLS te NAA NAA 4 1 4 02 Weld Process Selection 4 2 4 03 Weld Parameter Descriptions for ARC MASTER 185 200 ACDC 4 3 4 04 Weld Parameters ARC MASTER 185 200 ACDC 4 5 4 05 Power Source FOOIEOR AA 4 6 SECTION 5 SET UP FOR SMAW STICK AND GTAW 5 1 SECTION 6 SEQUENCE OF OPERATION 6 1 AB ALA 6 1 6 02 AC or DG HF TIG Welding uui pni ide rd tne oct ducenta eat dude 6 1 6 05 Slope Mode SOQUENC a nte teat e bts tutta dead tesa 6 2 6 04 Slope Mode with Repeat Sequence cesses 6 2 6 05 Pulse Controls Liens 6 2 TABLE OF CONTENTS SECTION 7 ROUTINE lt lt lt lt lt lt lt lt lt lt lt lt lt
3. 3 29 High Freguency Unit HF UNIT1 1 Remove the Side Panel Reference page 10 2 2 Remove the High Freguency Gap Remove the six terminals 11 32 ARCMASTER 185 200ACDC 3 Remove the two screws two washers and detach the High Freguency Unit HF UNIT1 3 30 Hall HCT1 1 Remove the Side Panel Reference page 10 2 2 Remove the Nylon Hose Remove the four screws Remove the two terminals and open the Rear Panel 11 33 ARCMASTER 185 200ACDC 3 31 Primary Diode D1 1 Remove the Side Panel Reference page 10 2 2 Remove the PCB2 WK 5596 WK 5482 Reference page 11 7 3 Remove the two screws and four terminals Remove the two screws and then detach the Primary Diode D1 e Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 3 32 Secondary Diode D2 D4 D5 F 1 Remove the Side Panel Reference page 10 2 2 Remove the PCB13 WK 5569 Reference page 11 19 3 Remove the PCB12 WK 5615 Reference page 11 16 4 Remove the two screws and two nuts and remove the bus bar 7 MSS 11 34 ARCMASTER 185 200A
4. 10 13 SECTION 11 REPAIR PROCEDURES T 11 1 11 1 11 02 OO 11 5 mp anna 11 5 11 02 2 Notes of disassembly and assembly 11 5 11 03 Replacement Procedure Nan nicus ticus Lessons riens 11 6 PGB SATI ON 11 6 11 03 2 PGB2 WK 5595 TOSAGDG Only 11 7 11 03 3 PGB2 WK 5482 200ADDG 11 8 11 03 4 PGBS WK 5548 PGBS 5551 11 10 11 03 39 T 11 11 I IMMMXV L 11 12 UR CFA C687 VVICC5550 11 12 11 03 8 PCB8 WK 5479 IGBT 01 06 11 13 11 03 9 PCB9 WK 5479 IGBT 07 012 11 13 11 03 10 POBTO WK 5527 acento ppm Gand AA 11 14 TIUS TI POBTI 11 15 11 03 12 PCB12 WK 5615 Transformer T1 Current Trans CT2 11 16 11 09 13 PUBTS Rss Sassen qnt dosi 11 19 11 08 14 PGB TG WK 5499 essaient tetur 11 20
5. APPENDIX 3 INTERCONNECT DIAGRAM 185ACDC m oc D MEME XP CO r 5 TAW 75 185 186 e Wim om gt Q1 2 jo NM PCB1 PCB8 C 02 Main _ NGBT Gate ir Circuit Board Circuit Od 4 1 WK 5493 Board cree WK 5477 l OS 6D OAK LC 2 5 0 5 Q4 IK cn ba E2 1 CX E2531 2 K 4 EL TB2 a 06 8 G DK Su _____ i i Link G Q7 Circuit Board Circuit Board c 4917 WK 5596 PCB9 Q8 IGBT Gate 784 Circuit OK Board HA IWK 5479 Q9 Nic 60 1 E 2 6 b Q10 1 WK EX Ha 011 54411 OD ES PIK mor 3 o E PCB4 4 L EX 49 912 Circuit Board G WK 4819 nts BAK ent 5 3 FANI cns aaa a 5 5 T bib 0 cN32 CN30 i x SOL1 1 PCBS Circuit Board Conect Circuit Board
6. lt 7 1 SECTION 8 BASIC TROUBLESHOOTING ne 8 1 8 01 General Troubleshooting 8 1 8 02 Common Welding Operation Faults sene 8 1 8 03 TIG Welding Problems 4 terne 8 2 8 04 Stick Welding Problems 8 4 9 05 Power Source Problems aNd 8 6 lt _3___ __ _ 8 7 SECTION 9 VOLTAGE REDUCTION DEVICE 9 1 90l VRD Specification EEE 9 1 nasapak GA de Eug QR Ma RUD nda 9 1 9 3 Switebing VII er 9 2 SECTION 10 ADVANCED TROUBLESHOOTING 10 1 10 01 System Level Fault Isolation i aa aaa AANI ates 10 1 10 02 0pening Ahe ERGO Geor AA 10 2 10 03 Verification and Remedy to the Indicated Error Codes 10 4 10 04 Verification and Remedy to Failures without Indication Codes 10 8 10 05 Isolation TES S O PENA 10 11 10 06 Verification of the Power Input 10 12 10 07 Verification of Power Supply
7. 11 13 ARCMASTER 185 200ACDC 3 Remove the two connectors and three screws Remove the PCB9 WK 5479 Remember to install silicone rubber sheets when reinstalling the PCB9 WK 5479 3 10 PCB10 WK 5527 1 Remove the Side Panel Reference page 10 2 2 Remove the PCB11 WK 5528 Reference page 11 15 3 Remove the three latches of Front Control Cover and then the PCB10 WK 5527 11 14 ARCMASTER 185 200ACDC 3 11 PCB11 WK 5528 1 Remove the Side Panel Reference page 10 2 2 Remove the Protection Cover 4 Disconnect the one connector from the PCB10 WK 5527 Remove the four screws Pull out the Opera tion Panel and bring it down 11 15 ARCMASTER 185 200ACDC 5 Remove the one connector and two screws Remove the PCB11 WK 5528 Remove the Encoder Cover from the PCB11 WK 5528 3 12 PCB12 WK 5615 Transformer T1 Current Trans CT2 1 Remove the Side Panel Reference page 10 2 2 Remove PCB13 WK 5569 Reference page 11 19 3 Disconnect the one connector and cut the one snap band TAN NY m GA AR M GAS 11 16 ARCMASTER 185 200ACDC 5 Open the Dust Cover Sheet Remove the three screws and three terminals e Y oo
8. 3 19 Resistor on High Frequency Unit R6 1 Remove the Side Panel Reference page 10 2 2 Cut the one snap band and remove the two terminals Remove the one screw and remove the Resistor on High Frequency Unit R6 ARCMASTER 185 200ACDC 3 20 Coupling Coil CC1 1 Remove the Side Panel Reference page 10 2 2 Remove the Nylon Hose Remove the two bolts two toothed washers one washer and one terminal 11 25 ARCMASTER 185 200ACDC 5 Remove the one screw and one nut Remove the one screw and Coupling Coil CC1 3 21 Reactor FCH1 1 Remove the Side Panel Reference page 10 2 Remove the PCB16 WK 5499 Reference page 11 20 Remove the PCB14 WK 5570 Reference page 11 20 Remove the Coupling Coil CC1 Reference page 11 25 Remove the two posts two screws and two nuts kw 6 Remove the four screws and remove the Reactor FCH1 Remove the Insulating Sheet D e 42 Log gt m 14 1 IL p 1 4 A 4 11 26 ARCMASTER 185 200ACDC 3 22 Primary Thermistor TH1 1 Remove the Side Panel Reference page 10 2 2 Cut the three snap bands Disconnect the one connector Remove the one screw and then detach the P
9. Refer to section 11 3 6 for the replacement of PCB6 2 E02 Over Temperature at the secondary side Cause Occurs when an over temperature condition ofthe secondary IGBT and diode are detected Verification Remedy a Unit may be in thermal shutdown mode Review the rated duty cycle of the unit per section 2 06 Exceeding the duty cycle can damage the unit and void the warranty Refer also to section 2 07 for additional information co a Verify the ventilating condition e Maintain a clear and unobstructed distance of more than 12 in the front and more that 20 in the rear of the unit for ventilation purposes Verify and maintain clean dust free front and rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working environment is recommended Extremely dusty environments will require more frequent cleanings May 22 2006 Verify the operation of the cooling fan FAN1 and replace it if necessary e Verify the condition of Verify that there are no broken or cracked fan blades and that 1 is not producing any abnormal sounds e fbroken or cracked blades or abnormal sounds are emanating from FAN1 replace FAN e Verify the operation of the cooling fan and replace it if the condition of FAN1 is inactive Follow the instruction in section Refer to section 11 3 24 for the replacement of d Replace PCB6 WK
10. Re install the harness with a secure connection Contact the manufacturer if you find any broken connectors or a damaged wiring harness c Verify PCB4 WK 4819 and replace it if necessary Check whether there are any abnormalities on the appearance of Replace PCBA Refer to section 11 3 5 8 E82 Rated Voltage Selection Circuit abnormality Cause Rated voltage selection circuit inside the Welding Power Source is not functioning properly Verification Remedy a Verify the wiring harness and connection of CN4 on PCB4 WK 4819 Re install the harness with a secure connection Contact the manufacturer if you find any broken connectors or a damaged wiring harness b Verify PCB4 WK 4819 and replace it if necessary e Check whether there are any abnormalities on the appearance of PCBA e Replace Refer to section 11 3 5 9 E83 Abnormalities in Mains Supply Voltage Detection Cause Abnormalities such as an input voltage detection circuit Verification Remedy a Verify main supply voltage Perform what is described in the section Verification of the Power Supply Voltage Refer to section 10 07 Confirm a secure connection of the harness wired between CN2 on PCB3 WK 5548 and CN1 on PCB17 WK 4917 Re install the harness with a secure connection co Contact the manufacturer if you find any broken connectors or damaged wiring harness e
11. 4 4 May 22 2006 ARCMASTER 185 ACDC 200 ACDC 4 04 Weld Parameters for ARC MASTER 185 200 ACDC Weld Mode Weld Parameter Parameter Range Factory Setting Incremental Unit HF TIG LIFT TIG PRE FLOW 0 0 to 1 0 sec 0 sec 0 1 sec Yes Yes HOT START 0 to 70A 20A 1A Yes No 5 to 185 1 INITIAL CUR 30A 1A Yes 5 to 200A 2 UP SLOPE 0 to 15 sec 1 sec 0 1 sec Yes 5 to 185 1 PULSE PEAK CUR 120A 1A Yes 5 to 200A 2 5 to 185 1 PULSE BASE CUR 80A 1A Yes 5 to 200A 2 5 to 185 1 WELD CUR TIG 80A 1A Yes 5 to 200A 2 WELD CUR STICK 5 to 160 80A 1A No SPOT TIME 0 5 to 5 0 sec 2 sec 0 1 sec PULSE WIDTH 15 to 80 50 1 PULSE FREQ 0 5 to 500 Hz 100 0Hz See Table Table 4 5 AC FREQUENCY 15 to 150 Hz 60Hz 1Hz WAVE BALANCE 10 to 65 50 1 DOWN SLOPE 0 to 25 sec 3 sec 0 1 sec 5 to 185 1 CRATER CUR 30A 1A 5 to 200A 2 POST FLOW 0 0 to 60 sec 10 sec 0 1 sec 1 185ACDC 2 200ACDC Table 4 4 Weld Parameters for ARC MASTER 200 ACDC PULSE FREQ Range Incremental Unit 0 5 to 20Hz 0 1Hz 20 to 100Hz 1Hz 100 to 500Hz 5Hz Table 4 5 PULSE FREQ Range and Incremental Units May 22 2006 4 5 ARCMASTER 185 ACDC 200 ACDC 4 05 Power Source Features ______ O New Digital Control Almost All welding parameters are adjustable Touch Panel Switches Touch switches eliminate mechanical damage
12. DD ov vs c YOY Y N ANS Ng LES 7 Remove the PCB12 and T1 unit 11 17 ARCMASTER 185 200ACDC 8 Cut the one snap band and remove the Current Trans CT2 9 Remove the Dust Cover Sheet Extend the electrode and remove the T D Bus Bar1 T D Bus Bar2 and T Center Bus Bar 10 Remove the two PCB supporters and cushion Remove the four screws and remove the Main Trans T1 11 18 ARCMASTER 185 200ACDC 3 13 PCB13 WK 5569 1 Remove the Side Panel Reference page 10 2 2 Remove the Nylon Hose Remove the four screws Remove the two terminals and open the Rear Panel 2 NE ji 20 i ax SS aS x7 2 11 19 ARCMASTER 185 200ACDC 3 14 PCB16 WK 5499 1 Remove the Side Panel Reference page 10 2 2 Remove the Nylon Hose p 2 lt q 3 Disconnect the two connectors Remove the three PCB supporters and remove the PCB16 WK 5499 1 3 15 14 WK 5570 1 Remove the Side Panel Reference page 10 2 2 Remove the PCB16 WK 5499 Reference page 11 20 3 Remove the five screws and three terminals and remove the PCB14 WK 5570 ARCMASTER 185 200ACDC 4 Re
13. Preflow Time KG Postflow Time 2 Step Trigger HA Operation Press to initiate wirefeed and welding release to stop 4 Step Trigger TE Operation Press and hold for preflow release to start arc Press to stop arc and hold for preflow Burnback Time Disturbance In Ground System Inches Per Minute Meters Per Minute Remote Control Panel Remote Art A 04130 May 22 2006 ARCMASTER 185 ACDC 200 ACDC 2 05 Description The Thermal Arc Model 185 200 ACDC are self contained single 185 200 ACDC and three phase 200 ACDC AC DC arc welding powersource with Constant Current CC output characteristics These units are equipped with a Digital Volt Amperage Meter gas control valve built in Sloper and Pulser lift arc starter and high frequency arc starter for use with Gas Tungsten Arc Welding GTAW Gas Tungsten Arc Welding Pulsed GTAW P Gas Tungsten Arc Welding Sloped GTAW S and Shielded Metal Arc Welding SMAW pr ocesses The power source is totally en closed in an impact resistant flame retardant and non conductive plastic case NOTE Volt Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source Curves of other settings will fall between the curves shown V OCV 160A STICK Process 8 185ACDC V V OCV OCV 10V 25A 185A 5A 185A A LIFT TIG
14. WK 5548 1 2 3 4 5 6 12314 5 67 11234 516 1 IWK 5981 20 CN21 CN22 CN23 purel a CM131 on132 CN130 1 Chassis Ground poc 2 Contactor Control 24VDC 3 Contactor Control GND 3 4 Not Used 214 5 Potentiometer Maximum PCB6 Of 5 6 Potentiometer Minimum GND Control 6 Circuit Board L Nd _ _ CM17 18 I 5 i 2 3 I 0 gt CN2 CN9 CN8 1 PCB7 gt Filter sta Circuit Board CN18 CN19 i WK 5550 123 gt 4 S CM33 Ko 915 TH2 THI OG 0 3 BIO 1 L A7 185ACDC 200ACDC INTERCONNECT DIAGRAM PCB12 DIODE Snubber Circuit Board WK 5615 ACT SH DET 1 Circuit Boarp 14 IGBT Snubber Circuit Board WK 5570 SH DET _ 6 1 O Output Terminal pe 1 2 3 4 5 Ground CN1 is RYH 1 I __ __ pa ON 2 Filter Circuit 94 V 3 Bo
15. pais plus de 1 2 po 12 mm 6 ou 8 Soudage l arc avec lectrode enrobees SMAW Nuance de filtre oculaire Op ration de coupage ou soudage moins de 5 32 po 4 mm 0 5 32 1 4 po 446 4 mm 12 plus de 1 4 po 6 4 mm 14 ala a4 para pera r 4 BIN NI 1 6 SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS a 8 2 73 Operation de coupage Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux m taux ferreux Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydrog ne atomique AHW Soudage l arc avec lectrode de carbone CAW PAW Soudage l arc Plasma PAW toutes dimensions Gougeage Air Arc avec lectrode de carbone mince Coupage l arc Plasma PAC 300 4400 pus de 400 amper MN AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer _ ___ ___ Eloignez la t te des fum es pour viter de les respirer A l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate portez un respirateur adduction d air approuv Lisez les fiches signal tiques et les consignes du fabricant rela tives aux m taux aux produits consummables aux rev te
16. 11 03 15 PCB14 WK 5570 m 11 20 11 03 16 PCB17 WK 4917 n 11 21 11 03 17 Discharge Resistor R3 ausente rene 11 22 11 03 18 Current Limiting Resistor R4 R5 11 24 11 03 19 Resistor on High Frequency Unit R6 11 24 11 03 20 Coupling Gall CO1 11 25 11 08 21 Reactor FORT 11 26 11 03 22 Primary Thermistor TH1 tein cadena 11 27 11 03 23 Secondary Thermistor UZ 11 27 11 03 24 Cooling PAN 11 28 11 03 25 Solenoid Valve SOL 11 29 11 03 26 Main ON OFF Switch ST ases sanis cauti uen 11 29 11 08 27 Input Voltage Switch 93 ois usen choses nn 11 30 11 09 28 Remote Connector CONT asas 11 31 11 03 29 High Freg ency Unit HUNT ss cranii Geo aaa 11 32 12 09 30 Ball ETS 11 33 11 03 31 I I LM7 11 34 11 03 32 Secondary Diode 02 09 11 34 11 03 33 Secondary IGBT 013 PCB15 WK 3367 11 35 APPENDIX 1 PARTS LIST sa A1 T Egul prier SNUG AO ssania R Al 2 How 10 USE This Parts I A1 185 200 EM c
17. 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high 9 WARNING n 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 Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners 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 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases 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 conta
18. A1 3 APPENDIX 2 CONNECTION WIRING GUIDE A5 APPENDIX 3 185 ACDC INTERCONNECT DIAGRAM APPENDIX 3 200 ACDC INTERCONNECT DIAGRAM A9 APPENDIX 4 DIODE TESTING BASIC o aadd pat A11 LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Inside Rear Cover ARCMASTER 185 ACDC 200 ACDC SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 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 attempt to weld Safe practi
19. Front Control Cover Protects front panel controls Displays selected weld parameter value Displays weld current when welding Displays Digital Meter weld current for 20 seconds after weld has been completed A selected weld parameter value can be adjusted at any time even while welding The intelligent cooling system is designed to reduce dust and foreign material build up whilst providing optimum cooling Fan speed reduces approximately 30 seconds after Intelligent Fan Control machine is turned on Fan speed increases when internal components reach operating temperature ON OFF switch Primary voltage Supply ON OFF switch located on rear panel Reduces the OCV when the power supply is not in use Eliminates the need for add on Voltage Reduction Device voltage reducers and has no effect on arc starting VRD fully complies with IEC 60974 1 VRD When Stick mode is selected the green VRD light is ON when not welding and red when welding When in TIG modes VRD is off For the selected weld parameter rotating the knob clockwise increases the parameter Rotating the knob counter clockwise decreases the parameter A selected weld Control Knob parameter value can be adjusted at any time even while welding Pushing the knob in displays actual arc voltage Self Diagnosis Using An error code is displayed on the Digital Meter when a problem occurs with Primary sup Error Codes ply voltage or internal component problems Refer to troubleshoot
20. The WAVE BALANCE control changes the ratio of penetration to cleaning action of the AC TIG welding arc Maximum weld penetration is achieved when the WAVE BALANCE control is set to 10 Maximum cleaning of heavily oxidised aluminum or magnesium alloys is achieved when the WAVE BALANCE control is set to 65 WAVE BALANCE 50 WAVE BALANCE 10 WAVE BALANCE 65 WAVE BALANCE Balanced with 50 penetration Maximum Penetration and Maximum Cleaning and and 50 cleaning reduced cleaning reduced penetration V L V 7 This parameter operates in TIG modes only and is used to set the time for the weld current to DOWN SLOPE ramp down after the torch trigger switch has been pressed to CRATER CUR This control is used to eliminate the crater that can form at the completion of a weld This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the finish CRATER CUR current for TIG The CRATER Current remains on until the torch trigger switch is released after it has been depressed POST FLOW This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished This control is used to dramatically reduce oxidation of the tungsten t2 electrode C D The SAVE LOAD buttons are used to save and retrieve a total number of 5 programs into the 185 200ACDC memory SAUVEGARDER CHARGER Table 4 3 Continued Weld Parameter Descriptions for ARC MASTER 185 200 ACDC
21. and 2 N are on D1 See Figure 10 8 The measured voltage should be approximately 1 4 times larger than input voltage measured in 1 above Replace diode D1 if the calculated measurement is not within the corresponding range 260 360 580 120 VDC following the process in section 11 03 31 Figure 10 8 Check Points for 1 P and 2 N May 22 2006 ARCMASTER 185 ACDC 200 ACDC 6 Verify bus voltage the voltage of the electrolytic 10 07 Verification of Power Supply capacitor after rectification using a DC voltmeter Voltage The capability of the voltmeter should be more than 1000VDC Using a DC voltmeter measure between the points TB1 P and TB2 N on PCB1 WK 5477 Points TB1 P and TB2 N A PANUOD can be found on the parts side of PCB1 See Figure 11 9 The measured voltage should be Before performing any portion of the approximately 1 4 times larger than input voltage procedure below make certain the unit is measured in 1 above Replace diode D1 if the placed in the initial set up condition as calculated measurement is not within the described in section 10 05 Preparation corresponding range 260 360 580 720 VDC following the process in section 11 3 31 1 Verify Power Supply voltage using an DC voltmeter The capability of the voltmeter should be more than 50VDC Operate at all input voltages as noted on the nameplate on the rear panel when testing the power supply On the PCB3 WK 5548 and
22. un pantalon revers des bottines de s curit et un casque May 22 2006 ARCMASTER 185 ACDC 200 ACDC 4h gt AVERTISSEMENT 27 LES ETINCELLES ET LES PROJECTIONS BRULANTES 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 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau 2 LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin EE i 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 renvers es 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 tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat placez pas l
23. 09 G3 1 gt 2 CL 010 ph 2 317 Oy T 1 CN2 CN3 L WK aum l CA 4 6 G4 oo 5 E219 RZ 6 ere 2131 116 OAK PCB4 1 aia 460V 1 4 Detect CV NETS 7 I5 Z Circuit Bord 1 0 sip WK 4819 K 230V LE FE A 230V 1 CL 3 l Sons FANI CNS gt dx ES BEA BAS QUEM 5 A AA C n31 2 i ae 22 NG iz essi exo Lenso 2 SOL 5 6 PCBS Circuit Board 4 Conect Circuit Board WK 5548 1 2 3 4 sf PEL 6 7 1 2 sla sf PF als 6 7 I WK 5551 i CN20 CN22 CN23 EN CN122 CN130 a 2 Chassis Ground 3 i 1 4 Not Used ET PCB6 5 5 Potentiometer Minimum GND poc Control 5 Amperage Control Wiper 0 10VDC Circuit Board Not Used WK 554 9 Li LL al 2 5 6 3 CN20 cno gt fll ia ee 1 7 Ka Filter gt Circuit Board x Er WK 5550 E DS E CN33 TH2 THI We 1 9 Q8 IGBT Gate
24. 10 7 Check Points U1 U2 V1 V2 W1 and W2 2 If the input voltage is out of the operating range 10 12 of the unit which is 10 187 253 414 506 VAC of the rated voltage 208 230 460V verify the available power capacity at the installed site If the input voltage is within the operating range recheck the input voltage while welding as welding may cause the input voltage to decrease to a value below the operating range of the unit 3 Verify input voltage after the input switch 51 using an AC voltmeter The capability of the voltmeter should be more than 600VAC Using an AC voltmeter measure between the points U2 and V2 on the input switch 1 Using an AC voltmeter measure between the points U2 and W2 on the input switch 51 Using an AC voltmeter measure between the points V2 and W2 on the input switch 51 The location of points U2 V2 and W2 on switch 51 are indicated in Figure 10 7 When using a single phase connection the voltage can be verified only between U2 and V2 If this voltage is out of the operating range which is 10 187 253 414 506VAC of the rated voltage 208 230 460V replace S1 following the process in section 11 03 26 Verify the rectified output voltage of the input diode D1 using a DC voltmeter The capability of the voltmeter should be more than 1000VDC Using a DC voltmeter measure between the points 1 P and 2 N on D1 Points 1 P
25. 5549 Refer to section 11 3 6 for the replacement of PCB6 3 E03 Primary Over Current Failure Cause Occurs when excessive current is detected flowing into the primary side of the main transformer Verification Remedy a Confirm the operation of the machine within the rated specification Refer to the specification data sheet in Section 3 8 b Verify the secondary diode D2 D4 and 05 Refer to section 10 07 4 for the test Refer to section 11 3 32 for the replacement Verify the unit UNIT1 e Refer to section 11 3 29 for the replacement of HEUNIT 1 d Verify the secondary IGBT Q13 Refer to section 10 07 5 for the test Refer to section 11 3 33 for the replacement e Replace the Hall CT HCT1 May 22 2006 ARCMASTER 185 ACDC 200 ACDC NOTE Pay special attention to installed direction of HCT1 The Hall CT will not function properly if installed in the incorrect direction Refer to section 11 3 30 for the replacement of HCT1 4 E04 Torch Cable Failure Cause The combined length of the torch cable and the work cable is too long Verification Remedy a Verify the rated duty cycles of the torch work cable and the power supply Only use appropriate sized torch cables length and capacity The recommended total combined length of the torch and work cable is 50 feet Torch and work cable should not be coiled during welding operations Mai
26. Confirm a secure between the remote connector CON1 and the TIG torch cable Confirm a secure connection of the harness and the connections between the remote connector CON1 and PCB7 WK 5550 are all correct and there are no open circuits Contact the manufacture if you find any broken connectors or damaged wiring harnesses Confirm the proper pins outs of the remote connector at the TIG Torch side Refer to page 4 1 Confirm that there is no open circuit on the remote connector at TIG Torch side In equipment for remote control use confirm the pin specification of the connector Refer to page 4 1 Verify the condition and connections of the welding cable the stick rod holders and the ground clamp Applies to all welding modes Confirm a secure connection of the welding cable stick rod holders ground clamp and dinse connectors and there are no open circuits May 22 2006 ARCMASTER 185 ACDC 200 ACDC c Verify the no load voltage OCV Applies to STICK High Frequency TIG HF TIG mode Refer to the section Verification of No load voltage OCV on page 10 17 If performing the No Load Voltage Failure procedure does not rectify the failure perform the following tests in the sequence below Replace any defective components found 1 Secondary IGBT 013 e Verification Refer to section 10 07 6 Replacement Refer to section 11 3 33 2 Secondary diode D2 D4 D5 Verification Refer to
27. Gas valve is faulty Have an Accredited Thermal Arc Service Agent replace gas valve Gas valve jammed open Have an Accredited Thermal Arc Service Agent repair or replace gas valve POST FLOW control is set to 60 sec D Reduce POST FLOW time The TIG electrode has The Weld Process Mode STICK HF Do not change Weld Process Mode been contaminated due TIG or LIFT TIG was changed before the POS7 FLOW gas time had to the gas flow shutting before POST FLOW gas time had finished off before the pro finished grammed POST FLOW time has elapsed Table 8 3 Power Source pROBLEMS 8 6 May 22 2006 8 06 Error Codes Description 201 error code displayed Temperature sensor TH1 protects IGBTs is greater than 80 C for about 1 second E02 error code displayed Temperature sensor TH2 protects secondary diodes is greater than 80 C for about 1 second E03 error code displayed Primary input current too high E04 error code displayed Output voltage exceeds the secondary voltage specification E11 error code displayed Over Primary supply input voltage at primary capacitors is exceeded for one second E14 error code displayed Under mains supply input voltage warning primary capacitor is reduced for one second E12 error code displayed Under mains supply input voltage primary capacitors is reduced for one second May 22 2006 Possible Cause The Welding Power Source s duty cycle has been exc
28. Principal Safety Standards in section 1 02 Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operators body comes into contact with the work piece or any internal components while the unit is activated May 22 2006 ARCMASTER 185 ACDC 200 ACDC 10 01 System Level Fault Isolation If none of the suggestions provided in Section 8 have solved the problem or corrected the faulty operation the next step is to isolate one or more of the internal subassemblies that may be defective A CAUTION Perform all steps in each procedure in sequence Skipping portions of procedures or performing steps out of sequence can result in damage to the unit and possible injury or worse to the operator ARCMASTER 185 ACDC 200 ACDC 10 02 Opening the Enclosure 3 Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW 1 Confirm that the switch on the power supply and the switch on switchboard distribution panel are all OFF Art A 05662 Art A 05660 DI Pw OFS Na Figure 10 3 Screws On Front and Rear Panel Figure 10 1 Switches NOTE A CAUTION DO NOT remove the screws completely 4 Pull the front panel slightly forward and pull the rear The capacitors inside the power supply will panel slightly backward The interlocking hooks of the slowly discharged after you
29. Service Agent or a qualified electrician check the Mains voltage Have an Accredited Thermal Arc Service Agent or a qualified electrician check the primary cable and fuses Remarks Weld current ceases Buzzer sounds constantly Fan operates at max speed E01 resets when TH1 decreases to 70 C for about 30 seconds Weld current ceases Buzzer sounds constantly Fan operates at max speed E02 resets when TH2 decreases to 70 C for about 30 seconds Weld current ceases Buzzer sounds constantly Switch machine off then on to reset E03 error Weld current ceases Buzzer sounds constantly Switch machine off then on to reset E04 error Weld current ceases Buzzer sounds constantly Error code E11 automatically will reset when the voltage reduces Weld current available Buzzer sounds intermittently Error code E14 automatically will reset when the voltage increases Weld current ceases Buzzer sounds constantly Error code E12 automatically will reset when the voltage increases ARCMASTER 185 ACDC 200 ACDC Description Possible Cause Remedy Remarks 8 E81 error code displayed Wrong Primary supply input voltage connected E82 error code displayed Rated voltage selection circuit abnormality When 3 phase machine is first turned on with the wrong Primary supply input voltage connected The Primary supply input voltage fluctuates and is not stable Have an
30. When the PCB fixed screw is loosening it fastens certainly c Verify PCB4 WK 4819 and replace it if necessary Check whether there are any abnormalities on the appearance of Replace PCB4 Refer to section 11 3 5 May 22 2006 10 E85 Pre charge abnormality Cause Due to malfunction inside the Welding Power Source primary capacitors are not charging correctly Verification Remedy Verify the connection of PCB2 WK 5596 for 185 ACDC WK5482 for 200 ACDC and the rectified output voltage of the rectifier a e Verify the connection between CN2 on PCB2 and CN3 on PCB3 Confirm whether there is any breakage blown burnt cracked etc of RA and R5 which connect to TB5 and TB6 of PCB2 Perform what is described in the section Verification of the Power Supply Voltage Refer to section 10 07 b Verify the primary diode D1 Verify D1 Refer to section 10 5 2 Replace D1 Refer to section 11 3 31 c Verify the primary IGBT Q1 Q12 e Verify IGBT Refer to section 10 5 7 e Replace IGBT Refer to section 11 3 8 11 3 9 d Replace PCB2 WK 5596 and PCB4 WK 4819 Replace PCB2 and when abnormalities occur even if carries out the above mentioned verifications Refer to section 11 3 2 11 3 4 11 E94 Thermistor malfunction Cause Thermistors for detecting temperature of internal components have malfunctioned Verification Remedy a Confirm a
31. are displayed in this window Internal warnings such as over temperature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen 5 Save Load Buttons by using the Save amp Load buttons the operator can easily save up to 5 welding parameter programs 6 Control knob allows the operator to adjust the output amperage within the entire range of the power source and sets each parameter value 7 Process Button This button selects between STICK HF TIG and Lift TIG mode 8 Scroll Buttons used to select the parameters to be set The LED s show which function is being adjusted on the Sequence Graph 9 AC DC Button Selects between AC or DC welding output May 22 2006 ARCMASTER 185 ACDC 200 ACDC 10 Contactor function Pressing this button enables Contactor functions 6 01 Stick Welding Connect work lead to negative terminal Connect electrode lead to positive terminal Switch machine on e Set AC or DC weld current If AC is selected then set AC FREQ to 60Hz amp WAVE BALANCE to 50 Set Contactor Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set HOT START Set WELD current Commence welding 6 02 AC or DC HF TIG Welding Connect work lead
32. bias direction and depending on the meter function will indicate an open or OL If any diode in the module tests as faulty replace the diode module 4 Reconnect all cables to the proper terminals Forward Bias Diode Conducting CH ad Anode Cathode Figure 13 1 Forward bias diode test Reverse Bias Diode Not Conducting Cathode Anode Figure 13 2 Reverse bias diode test A11 LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 LIMITED WARRANTY Thermal Arc Inc Thermadyne Company Thermal Arc warrants to customers of authorized distributors Purchaser that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the warranty period stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or damage correct such defects by suitable repair or replacement at Thermal 5 sole option of any components or parts of the product determined by Thermal Arc to be defective This warranty is exclusive and in lieu of any warranty of merchantability fitness for any particular purpose or other warranty
33. current ceases Buzzer sounds constantly Switch machine off The Welding Power Source s temperature sensors have malfunctioned Have an Accredited Thermal Arc Service Agent check or replace the temperature sensors Weld current ceases Buzzer sounds constantly Switch machine off E99 error code displayed Mains supply input voltage has been turned off but control circuit has power from the primary capacitors A Main on off switch on machine has been turned off Mains supply input voltage has been turned off A Turn on off switch on B Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage and fuses Table 8 4 Power Source Error Codes Weld current ceases Buzzer sounds constantly Must switch machine off then on to reset E99 error May 22 2006 ARCMASTER 185 ACDC 200 ACDC SECTION 9 VOLTAGE REDUCTION DEVICE VRD 9 01 VRD Specification Description VRD Open Circuit Voltage 15 3 to 19 8V Open circuit voltage between welding terminals Notes VRD Resistance 148 to 193 ohms The required resistance between welding terminals to turn ON the welding power VRD Turn OFF Time 0 2 to 0 3 seconds The time taken to turn OFF the welding power once the welding current has stopped 9 02 VRD Maintenance Routine inspection and testing power source An inspection of the power source an insulation resistance te
34. gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background 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 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 a 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 Arrange cables to one side and away from the operator Do not coil or drape cable around the body JS Keep w
35. manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link http www thermalarc com May 22 2006 ARCMASTER 185 ACDC 200 ACDC 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 rear panel In some cases the nameplate may be attached to the control panel Equipment which does not have a name plate such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container Record these numbers on the bottom of page i for future reference 2 1 ARCMASTER 185 ACDC 200 ACDC 2 04 Symbol Chart Note that only some of these symbols will appear on your model Voltage Protective Earth Ground Line Connection Auxiliary Power Receptacle Rating Auxiliary Power 2 2 Single Phase Three Phase Three Phase Static Frequency Converter Transformer Rectifier Duty Cycle Panel Local Shielded Metal Arc Welding SMAW Gas Metal Arc Welding GMAW Gas Tungsten Arc Welding GTAW Air Carbon Arc Cutting CAC A Constant Current Constant Voltage Or Constant Potential High Temperature Fault Indication Touch Start GTAW Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Continuous Weld Mode
36. positioned close to the work the welding current will transfer to the work and establish the arc at the initial current setting b Inthe Lift TIG mode after Preflow time Lift Start current is present at the torch When the electrode is touched to the work and lifted off the welding arc is established at the initial current setting 2 Open Remote Switch current increases to weld current Once welding arc has reached weld current the power source will maintain weld current as long as the remote switch contacts are open 3 Close Remote Switch Welding current decreases to final current setting Once final welding current is reached the power source will maintain final current setting as long as the remote switch contacts are closed 4 Open Remote Switch Welding arc stops and post flow begins 6 04 Slope Mode with Repeat Sequence The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the down slope period only During the down slope period by Opening the Remote Switch contacts the current will increase back to weld current Within the Down Slope period the repeat function can operated as many times as desired To continue slope cycle and end slope 6 2 sequence close remote switch contacts and allow weld current to reach final current setting Once final current setting is reached opening the Remote Switch again will turn off the welding arc and post flow begins 6 05 Pul
37. section 10 07 4 Replacement Refer to section 11 3 32 3 Coupling coil CC1 e Replacement Refer to section 11 3 20 4 Reactor FCH1 e Replacement Refer to section 11 3 21 5 Transformer T1 Replacement Refer to section 11 3 12 6 Primary IGBT 01 012 e Verification Refer to section 10 07 5 Replacement Refer to section 11 3 8 11 3 9 7 Hall HCT1 e Replacement Refer to section 11 3 30 ARCMASTER 185 ACDC 200 ACDC 4 Operating Panel Failure LED s do not light properly or weld settings cannot be established Cause Occurs when there is a connection failure among PCB6 WK 5549 PCB10 WK 5527 and PCB6 or PCB10 are defective Verification Remedy a Verify the harness connection between CN21 on PCB6 WK 5549 and CN2 on PCB10 WK 5527 Confirm a secure connection of the harness and the connections between CN21 on PCB6 WK 5549 and CN2 on PCB10 WK 5527 Contact the manufacture if you find any broken connectors or a damaged wiring harnesses Verify the connection between PCB5 WK 5551 and PCB6 WK 5549 Replace PCB5 WK 5551 and PCB6 WK 5549 Refer to section 11 3 4 11 3 6 Replace PCB6 WK 5549 and PCB10 WK 5527 Refer to section 11 3 6 11 3 10 5 High Frequency Output Failure Unit does not generate High Frequency Cause Occurs when the unit is defective or blown Verification Remedy Ae UTION Read and unders
38. secure connection of the harness wired between CN8 9 on PCB6 WK 5549 and Thermistors TH1 TH2 Re install the harness with a secure connection Contact the manufacturer if you find any broken connectors or a damaged wiring harness May 22 2006 ARCMASTER 185 ACDC 200 ACDC b Replace thermistors TH1 TH2 0 Refer to section 11 3 22 11 3 23 Replace PCB6 WK 5549 Refer to section 11 3 6 12 E99 Initial Power Receiving Cause Occurs when the initial AC power received signal has not reached the CPU This error occurs normally during the power OFF sequence of the unit Verification Remedy a Confirm a secure connection of the harness wired between CN1 on PCB17 WK 4917 and CN2 on PCB3 WK 5548 Re install the harness with a secure connection Contact the manufacturer if you find any broken connectors or a damaged wiring harness Verify PCB4 WK 4819 and replace it if necessary Confirm a secure connection of all harnesses wired to PCB3 and PCB4 Replace PCB4 Refer to section 11 3 5 Replace PCB6 5549 Refer to section 11 3 6 ARCMASTER 185 ACDC 200 ACDC 10 04 Verification and Remedy to Failures without Indication Codes 1 Cooling Fan Failure Fan is not rotating Cause Occurs when the cooling fan FAN1 is defective damaged or the driving voltage is incorrect Verification Remedy a Verify the cooling fan FAN1 Inspect the condition of the
39. turn off the switch side case covers can now be disengaged from the of the power supply or the switch at the breaker front and rear panels box distribution panel Wait at least 5 minutes for the discharge to complete 2 Remove all screws and nuts on the side covers 4 Art 05663 Figure 10 2 Screws and Nuts Figure 10 4 Remove Front Panel May 22 2006 Remove the side covers Art A 05664 Figure 10 5 Remove Side Covers Remove protection cover sheet by removing the plastic tabs Figure 10 6 Protection Cover NOTE When you re assemble the parts conduct the above process backwards May 22 2006 ARCMASTER 185 ACDC 200 ACDC 10 3 ARCMASTER 185 ACDC 200 ACDC 10 03 Verification and Remedy to the Indicated Error Codes NOTE The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete and then remove the cases to continue your inspection and repair or maintenance inside the power supply As for the removal and installation of the case refer to section 10 02 NOTE During the Verification Remedy procedures below follow the alphabetical sequence a b and proceed with your verification and contirmation NOTE After you confirm and replace all spare parts and
40. 0 208 20 ARC MASTER 200ACDC 8 4 AWG 160 40 minimum 208 37 200 20 208 44 160 40 Table 3 4 208 230 460V Primary Current Circuit sizes to achieve maximum current 3 06 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be over emphasized Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation The following information is intended as a guide for personnel installing high frequency welding machines WARNING Explosives The high frequency section of this machine has an output similar to a radio transmitter The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing AN WARNING Computers It is also possible that operation close to computer installations may cause computer malfunction 3 3 ARCMASTER 185 ACDC 200 ACDC 3 07 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 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 Sup
41. 00 ACDC gt a AVERTISSEMENT ele eo LE RAYONNEMENT DE L ARC PEUT BRULER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE L arc de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager l ouie E Ovcc Ss 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI 249 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 3 Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Brassage tendre toutes conditions 2 au chalumeau Brassage fort toutes conditions 3 ou4 au chalumeau moins de 1 po 25 mm 3 ou4 moyen det 46 po 254150 mm 4005 plus de 6 po 150 mm 50u6 moins de 1 8 po 3 mm 40u5 moyen det 841 2po 3412mm 5ou6
42. 06 9 3 ARCMASTER 185 ACDC 200 ACDC 9 4 May 22 2006 SECTION 10 ADVANCED TROUBLESHOOTING If you are here all of the troubleshooting suggestions in Section 8 Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective This section provides the information needed to take live measurements on the various subsystems within the power supply and replace those subsystems that prove faulty CAUTION Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment A WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have training in power electronics measurement and troubleshooting techniques _ ___ _ Under no circumstances field repairs to be attempted on printed circuit boards or other subassemblies of this unit Evidence of unauthorized repairs will void the factory warranty If a subassembly is found to be defective by executing any of the procedures in this Service Manual the subassembly should be replaced with a new one The faulty subassembly should then be returned to Thermal Arc through established procedures A WARNING Disconnect primary power at the source before disassembling the power supply Frequently review the
43. 0ACDC 3 8 2 10 5 4 6 1 9 No DWG No Parts name Reference page Part No 1 CC1 Coupling Coil 11 25 W7001384 2 CT2 Current Trans 11 16 W7001304 3 D1 Primary Diode 11 34 10 6628 4 D2 Secondary Diode 11 34 10 6629 5 D4 Secondary Diode 11 34 10 6629 6 D5 Secondary Diode 11 34 10 6629 7 FCH1 Reactor 11 33 W7001502 8 HCT1 Hall C T 11 26 10 5003 9 HEUNIT High Frequency Unit 11 32 W7001399 10 T1 Main Trans 11 16 W7001456 11 3 ARCMASTER 185 200ACDC 2 DWG Parts Reference Part No CON1 Remote Connector 11 31 W7001595 FAN1 Cooling Fan 11 28 W7001307 Q13 PCB15 Secondary IGBT WK 3367 11 35 10 6643 R3 Discharge Resistor 11 22 10 5137 R4 Current Limiting Resistor 11 24 W7001452 R5 Current Limiting Resistor 11 24 W7001452 R6 Resistor on High Frequency Unit 11 24 W7001451 51 Main ON OFF Switch 11 29 W7001453 52 Input Voltage Switch 11 30 10 5222 Solenoid Valve 11 29 10 6645 Primary Thermistor 11 27 10 5228 Secondary Thermistor 11 27 10 5228 NM CI A 11 4 ARCMASTER 185 200ACDC 2 Service Tools 2 1 Tools and parts The tools and parts to be used for maintenance are shown by icons Philips S8 Long Nose Bi y PO Silicon spanner D Piliers Snap Band ha Co
44. 13 using a diode tester 3 Refer to Table 10 8 and Figure 10 17 for the checkpoints on Q13 TERMINALS COMPONENT ACCEPTABL TESTED Positive Negative VALUE lead lead Collector Emitter C1 C2E1 Open of Q13 C2E1 C1 0 2 to 0 5V By PCB15 C2E1 E2 Open connection E2 C2E1 0 2 to 0 5V Table 10 8 Tester checkpoints in the Q13 Figure 10 17 Tester checkpoints in the Q13 May 22 2006 T ARCMASTER 185 ACDC 200 ACDC Verification of No load Voltage OCV A CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described at the beginning of an above section 1 Preparation Refer to section 10 4 1 1 Verify the no load voltage in STICK mode n STICK welding mode mark and then turn potentiometer VR1 on PCB6 WK 5549 fully counter clockwise to turn off the electric shock protector function Voltage Reduction Device VRD e Contactor function is put into the state of on pushing Function button Refer to section 6 A WARNING Electric shock hazard The unit will generate OCV immediately when contactor function is put into the state of on pushing Function button at STICK mode Verify the no load voltage using a DC voltmeter The capability of the voltmeter should be more than 100VDC The normal no load voltage is approximately 65V 2 Verify the no load voltage OCV i
45. 26 CB 200 ACDC gen 3 1 IPS 6 ____ 7001725 PCB 185 ACDC gen 3 1 IPS 7 W7001423 __ gen 3 1 IPS PCB8 9 W7001318 PCB gen 3 1 IPS WK 5479 U01 GATE PCB with IRGP20B60PD W7001812 PCB WK5527 U13 GEN3 1 IPS PCB11 7001320 PCB gen 3 1 IPS 12 7001594 PCB gen 3 1 IPS 13 W7001433 PCB gen 3 1 IPS gt NI U 14 ____ 7001434 _ C8 gen 3 1 IPS 26 PCB16 W7001324 gen 3 1 IPS 27 17 10 6740 CB gen 3 1 IPS ransistor gen 3 1 IPS esistor gen 3 1 IPS 2 gt gt olal gt cof po OOF OO C2 CI gt 5 QTY 185ACDC 200ACDC PARTS LIST DWG No PartNo Resistor gen 3 1 IPS Resistor gen 3 1 IPS 32 R6 W7001451 Resistor gen 3 1 IPS Witch gen 3 1 IPS DCP 52SR50C 480V 2P 480V 185ACDC 51 witch gen 3 1 IPS DCP 103SR100C 480V 3P 480V 200ACDC S2 witch gen 3 1 IPS SDKGA4 A 1 A 200ACDC SOL1 olenoid Valve gen 3 1 IPS 5505NBR1 5 DC24V 11VA 10W with Gas ansformer gen 3 1 IPS 2 ermistor gen 3 1 IPS W7001465 __ Front gen 3 1 IPS 7001466 Panel Rear gen 3 1 IPS abel Side gen 3 1 IPS over Front gen 3 1 IPS E0C346000 over Rear gen 3 1 IPS JCA849400 185ACDC over Rear gen 3 1 IPS JDA173200 200ACDC over Protector gen 3 1 IPS E0C303200 o
46. Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage No weld current is available Buzzer sounds constantly Switch machine off No weld current is available Buzzer sounds constantly Switch machine off then on to reset E82 error E83 error code displayed CPU checks mains supply input voltage when the on off switch on rear panel of machine is turned ON E85 error code displayed Pre charge abnormality E93 error code displayed Memory chip EEPROM on control PCB can not read write weld parameters E94 error code displayed Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit The Primary supply input voltage fluctuates and is not stable Due to malfunction inside the Welding Power Source primary capacitors are not charging correctly Have an Accredited Thermal Arc Service Agent check connector plug on input PCB and the Mains voltage Have an Accredited Thermal Arc Service Agent service the machine No weld current is available Buzzer sounds constantly Switch machine off then on to reset E83 error No weld current is available Buzzer sounds constantly Switch machine off then on to reset E85 error Memory chip EEPROM error Have an Accredited Thermal Arc Service Agent check the control PCB Weld
47. B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 22 2006 ARCMASTER 185 ACDC 200 ACDC 1 03 Precautions de Securite en Soudage l Arc A 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 QU LES INSTRUCTIONS AVANT D INSTALLER UTILISER QU 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 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 apprises 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 souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 749 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce doc
48. Block Diagram 2 4 May 22 2006 2 07 Transporting Methods These units are equipped with a handle for carrying purposes A WARNING ELECTRIC SHOCK can kill 00 NOT TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving welding power source A WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift unit with handle on top of case Use hand cart or similar device of adequate capacity f using a fork lift vehicle place and secure unit on a proper skid before transporting May 22 2006 ARCMASTER 185 ACDC 200 ACDC 2 5 ARCMASTER 185 ACDC 200 ACDC May 22 2006 SECTION 3 INSTALLATION 3 01 Environment The ARC MASTER 185 ACDC 200 ACDC is designed for use in adverse environments Examples of environments with increased adverse conditions are a In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts b In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator or c In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories Environme
49. CDC 5 Remove the six screws and then detach the Secondary Diode 02 D4 D5 Do not have the wrong direction of the diodes when reinstalling Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base mm 25 VAA CC O O Da En 4 eg P Vr gt AI CEA O D 2 4 3 0 7 3 33 Secondary IGBT 013 PCB15 WK 3367 S GF 1 Remove the side cover Reference page 10 2 2 Remove the PCB16 WK 5499 Reference page 11 20 3 Remove the PCB14 WK 5570 Reference page 11 20 4 Remove the one bolt and remove the one toothed washer one washer and one terminal 11 35 ARCMASTER 185 200ACDC 6 Remove the one connector and two screws and remove the Secondary IGBT 013 Before sinstalling a new IGBT apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 11 36 APPENDIX 1 PARTS LIST 1 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Part or Assembly nu
50. CTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 Are cease nana 1 1 1 02 Principal Safety SANS 1 4 1 03 Precautions de Securite Soudage 1 5 1 04 Dangers Relatits au Soudage NANG sind 1 5 1 05 Principales Normes de Securite 1 8 SECTION 2 INTRODUCTION 2 1 2 01 HOw Use TMS Manual dan nakka aa 2 1 2 02 Equipment 1 2 1 204 SYM TEES 2 2 AA 2 3 2 06 F ncti nal Block II 201015 ANAN aaa 2 4 2 07 Transporting Method S 2 5 SECTION 3 INSTALLATION AA AA AA Der 3 1 nn maternel 3 1 3 02 Location npa nn 3 1 3 03 Electrical Input Connections 3 1 3 04 Electrical Input Requirement sisi 3 1 3 05 MAPU POWE 3 3 3 06 High Frequency Introduction 2 2 eim
51. IAL CUR This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the start current for TIG The Start Current remains on until the torch trigger switch is released after it has been depressed UP SLOPE This parameter operates in TIG modes only and is used to set the time for the weld current to ramp up after the torch trigger switch has been pressed then released from INITIAL CUR to PEAK or BASE current PEAK CUR This parameter sets the PEAK weld current when in PULSE mode WELD BASE Background Current This parameter sets the TIG WELD current in STD SLOPE REPEAT and SPOT modes when PULSE is off This parameter also sets the STICK weld current This parameter sets the Background current when in Pulse TIG mode SPOT TIME This parameter sets the duration of the SPOT TIME in HF TIG mode only PULSE WIDTH This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSE is on PULSE FREQ AC FREQUENCY May 22 2006 This parameter sets the PULSE FREQUENCY when the PULSE is on This parameter operates in AC mode only and is used to set the frequency for the AC weld current 4 3 ARCMASTER 185 ACDC 200 ACDC Parameter Description This parameter is used for aluminium AC TIG mode and is used to set the penetration to cleaning action ratio for the AC weld current Generally WAVE BALANCE is set to 50 for AC STICK welding
52. LS placed in the initial set up condition as COMPONENT ma described at the beginning of an above section TESTES 4 p 1 Preparation Refer to section 10 4 1 3 4 5 0 0 3 to 0 5V Diode of D1 5 1 Verify the voltage between the PIN 3 Positive a 2 i 3 4 5 0 o and PIN 4 Negative of connector CN11 on 0 a Open PCB3 WK 5548 while you press the torch switch Thyristor of 01 1 0 Open while in TIG Mode The capacity of the voltmeter should be more than 50VDC The location of Table 10 5 Tester checkpoints for 01 connector CN11 of PCB3 WK 5548 is indicated in Figure 10 13 When you measure the above voltage do not remove the connector Conduct the measurement while the connector plug and receptacle are still connected Figure 10 13 Verification of the SOL1 0 6 7 2 Using the measurement taken above follow the chart below for possible failure modes 1 Voltage 5 measurement Remed 1PIN 2PIN of y ni CN11 on PCB3 3 Replace PCB1 Refer to section 12 3 1 Replace SOL 1 Refer to section 12 3 25 Table 10 4 Verification of the SOL1 Below DC 18V DC 18 25V Figure 10 14 Tester checkpoints for D1 showing the interconnection diagram 3 When verifying the voltage confirm that the AC input voltage remain within the operating range of the unit The AC input does not drop below 180VAC May 22 2006 10 15 ARC
53. MASTER 185 ACDC 200 ACDC 4 Verification of the secondary Diode D2 D4 D5 1 Verify the characteristic of the secondary diode D2 D4 and D5 using a diode tester 2 Refer to Table 10 6 and Figure 10 15 for the checkpoints on D2 D4 and 05 TERMINALS OMPONENT ACCEPTABLE TESTED Positive Negative VALUE lead lead Diode 1 of D2 Anode Cathode 0 2 to 0 3V D4 and D5 Cathode Anode Open Diode 2 of D2 Anode Cathode 0 2 to 0 3V D4 and D5 Cathode Anode Open Table 10 6 Tester checkpoints for D2 D4 and D5 Anode C Figure 10 15 Tester checkpoints for D2 D4 and 05 10 16 Verification of the primary IGBT Q1 Q12 1 Check whether there are any abnormalities in the appearance of PCB8 and PCB9 2 Verify the characteristic of the primary IGBT Q1 Q12 using a diode tester 3 Refer to Table 11 7 and Figure 11 16 for the checkpoints on PCB8 and PCB9 TERMINAL TESTED Positive Negative VALUE lead lead Collector Emitter CE C 0 2 to 0 5V of Q1A Q12 with CE E Open PCB8 and PCB9 E CE 0 2 to 0 5V Table 10 7 Tester checkpoints for Q1 Q12 Figure 10 16 Tester checkpoints for Q1 Q12 May 22 2006 6 Verification of the secondary IGBT 013 1 Check whether there are any abnormalities on the appearance of PCB14 2 Verify the characteristic of the secondary IGBT Q
54. PCB6 WK 5549 measure the voltages according to the following table The check points and the reference are obtainable on the top side of PCB6 WK 5549 The locations of points are indicated in Figure 11 10 11 11 NI TB1 TB2 Figure 10 9 The check points TB1 P and TB2 N T After the replacement of D1 if the above voltage is still abnormal replace PCB1 WK 5477 Figure 10 10 Checkpoints TPO TP3 on PCB6 Check Point Reference ACCEPTABLE PCB6 PCB6 VALUE TP1 TPO 5VDC TP2 TPO 15VDC 15VDC Table 10 1 Checkpoints on PCB6 May 22 2006 10 13 ARCMASTER 185 ACDC 200 ACDC Figure 10 9 Check Points for 3 6 11 00 Check Point Reference ACCEPTABLE PCB3 PCB3 VALUE Pin 1 on CN18 Pin 3 on CN18 24VDC Table 10 2 Checkpoints CN18 on PCB3 3 If any of these voltages are not present or are below a 10 tolerance replace the PCB3 WK 5548 Refer to section 11 3 4 1 Verification of the Cooling Fan FAN1 Drive Circuitry A CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described in section 10 05 Preparation 1 Verify the condition of the cooling fan FAN1 using 10 14 a DC voltmeter The capability of the voltmeter should be more than 50VDC Using a DC voltmeter measure between PIN 1 Positive and PIN 2 Negat
55. Process HF TIG Process 200ACDC V V OCV OCV 5A 200A A 5A 200A A LIFT TIG Process HF TIG Process Figure 2 1 Figure 2 1 Model 185 200ACDC Volt Ampere curve May 22 2006 2 3 ARCMASTER 185 ACDC 200 ACDC 2 06 Functional Block Diagrams Figure 2 2 illustrates the functional block diagram of the 185 200ACDC power supply Input Main Current Couplin aii Input Inrush Current IGBT Inverter Output Output C gt Circuit h gt gt Capacitor Power Breaker plus Suppresor Module Lraosiormers Dieste Transformer Coil 4 CT 1 Thermal Control Sensor Transformer c Config 1 Drive Circuit Primary Lift Tig Mode Current Output Short Sensor Sensing Circuit DC Power Voltage Sensor Thermal Supply for Sensor Control Circuit Circuit Output Inductor To each control circuit 12VDC 20VDC 24VDC 5VDC HIM Trouble L Sensing gt Sequence 00 Circuit utput Torch Control Reference Yana Connection gt Adjustments amp Sensor CON1 Control Switches Current Adjustment Circuit Art A 04949 Figure 2 2 185 200ACDC Model Functional
56. THERMAL ARC 185 AC DC 200 AC DC ARCMASTER INVERTER ARC WELDERS Art A 07227 Service Manual Revision No AF Issue Date May 22 2006 Manual No 0 4884B Operating Features IHERMAL A WARNINGS 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 Service Manual Number 0 4884B for ArcMaster 185 AC DC Inverter Arc Welder Part Number 10 3073 ArcMaster 200 AC DC Inverter Arc Welder Part Number 10 3083 Published by Thermadyne Industries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 2007 2008 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date May 22 2006 Revision AF Date January 28 2008 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SE
57. amage to the welding power source and will void the manufactures warranty NOTE Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are approximate only Achievable capacities and ratings in use and operation will depend upon correct installation use applications maintenance and service May 22 2006 3 09 Specifications Parameter 185ACDC 200ACDC Rated Output Amperes 185 200 Volts 18 18 Duty Cycle 30 20 Duty Cycle TIG 185A 18V 30 160A 17V 60 100A 14V 100 200A 18V 20 160A 17V 40 130A 15V 60 100A 14V 100 160A 27V 40 130A 25V 60 100A 24V 100 Output Current Range 5 185 DC 5 185 AC 60Hz 50 Cleaning 5 200 DC 5 200 AC 60HZz 50 Cleaning 5 160 DC 5 160 AC 60HZz 50 Cleaning Open Circuit Voltag 65V Dimensions Width 7 08 180mm Height 14 7 360mm Length 16 54 420mm Weight 37 4 Ib 17 kg Output Rated Load Rated Input Voltage Single phase Three phase Single phase Output Amperes 160A 160A 160A Output Volts 27V 27V 27V Duty Cycle 40 40 40 KVA 9 0 7 2 9 0 KW 5 4 5 4 5 4 Output No Load KVA 0 5 0 5 0 5 KW 0 3 0 3 0 3 Input V
58. ame plate on the rear panel when testing the power supply 2 Remove the Side Panel Refer to section 10 02 3 Close primary power source wall disconnect switch or circuit breaker 4 Place power supply MAIN CIRCUIT SWITCH S1 on rear of the unit in the ON position A WARNING Dangerous voltage and power levels are present inside this unit Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operator s body comes into contact with the workpiece or any internal components while the unit is activated May 22 2006 10 11 ARCMASTER 185 ACDC 200 ACDC 10 06 Verification of the Power Input Circuitry A CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described in section 10 05 Preparation Verification of the AC Input Voltage using an AC Voltmeter 1 Verify input voltage Phase to Phase using an W1 AC voltmeter The capability of the voltmeter should be more than 600VAC Measure the point between lines U1 and V1 on the input switch S1 Measure the point between lines U1 and W1 on the input switch S1 Measure the point between lines V1 and W1 on the input switch S1 The location of points U1 V1 and W1 on switch S1 are indicated in Figure 11 7 When using a single phase connection the voltage can be verified only between U1 and V1 Figure
59. ard SIDE CHASSIS 3 HCT1 r IMV 5499 C CC1 102 la A Outpu Terminal ae ity cc2 il SiR3 CC1 Bin HF UNIT1 SiR2 1121 21 1 lt L p 1 A KOS 7 CN5 215 310 4 1 PCB13 65127 1 S Super Inpose PGND 2 O Circuit Board 1 G7 ET WK 5569 2 ED 5 15 1 e ata 216 5 58 gt 3 gt CN4 T sepe FERONT y y 15 15 GND Panel PCB11 Circuit Board none WK 5527 WK 5528 sla rr A8 9 7 SIDE CHASSIS 2 185ACDC 200ACDC INTERCONNECT DIAGRAM 200ACDC R4 od See Z CI 01 G E I HK pcBl PCB8 02 l Main IGBT Gate 5 Circuit Boar Circuit k IWK 5493 Board EF TEM payo GI 1 WK EDA H6 Sea G OK 1 1 CL Q5 253 2 4 weh ES i m es Q7 1 6 tk 1 G 3 TB4 Circui 5 Circuit DIK 5 E
60. at the source before opening the enclosure Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure refer to Section 10 02 Opening the Enclosure and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean if necessary with solvents that are recommended for cleaning electrical apparatus A CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit May 22 2006 7 1 ARCMASTER 185 ACDC 200 ACDC Maintain more often if used under severe conditions Warning Disconnect input power before maintaining Each Use Visual check of 2 Visual check of torch regulator and pressure Consumable parts Weekly Visually inspect the torch body and consumables Visually inspect the cables and leads Replace as needed 3 Montlis Clean exterior of power supply Replace all broken parts 6 Months Bring the unit to an authorized Thermal Arc Service Center to remove any accumulated dirt and dust from the interior This may need to be done more frequently under exceptionally dirty conditions Art A 07331 7 2 May 22 2006 SECTION 8 BASIC TROUBLESHOOTING 8 01 General Troubleshooting Troubleshoot
61. by Thermal Arc although most are warranted by the engine manufacturer See the Engine Manufactures Warranty for Details GMAW FCAW MIG WELDING EQUIPMENT WARRANTY PERIOD Fabricator 131 181 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year GTAW TIG amp MULTI PROCESS INVERTER WELDING EQUIPMENT 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards power switch semi conductors All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors PLASMA WELDING EQUIPMENT Ultima 150 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards power switch semi conductors Welding Console Weld Controller Weld Timer All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year SMAW Stick WELDING EQUIPMENT LABOR Dragster 85 Original Main Power Magnetics 1
62. cal circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards Engines can be dangerous 9 f WARNING ENGINE EXHAUST GASES can kill 2 ARCMASTER 185 ACDC 200 ACDC If used in a closed area vent engine exhaust outside and away from any building air intakes TA M 7 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine we WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engin
63. ces are outlined in the American National Standard 749 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 01 Are Welding Hazards 7 Use fully insulated electrode holders Never dip holder in water 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 electrode 8 Do not use worn damaged undersized or poorly spliced cables WARNING 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground ELECTRIC SHOCK can kill 11 Do not touch electrode while in contact with the work ground circuit Touching live electrical parts can cause fatal shocks or 12 Use only well maintained equipment Repair or replace damaged N gt severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live
64. components confirm that there are no damaged harnesses or connectors uninstalled or loose screws 1 E01 Over Temperature at the primary side Cause Occurs when an over temperature condition of the primary IGBT is detected Verification Remedy a Unit may be in thermal shutdown mode e Review the rated duty cycle of the unit per section 3 8 Exceeding the duty cycle can damage the unit and void the warranty Refer also to section 1 6 for additional information b Verify the ventilating condition e Maintain a clear and unobstructed distance of more than 12 in the front and more that 20 in the rear of the unit for ventilation purposes Verify and maintain clean dust free front and rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working environment is recommended Extremely dusty environments will require more frequent cleanings Verify the operation of the cooling fan FAN1 and replace it if necessary Verify the condition of FAN1 Verify that there are no broken or cracked fan blades and that FAN1 is not producing any abnormal sounds e fbroken or cracked FAN1 blades or abnormal sounds are emanating from FAN1 replace FAN1 Verify the operation of the cooling fan and replace it if the condition of FAN1 is inactive Follow the instruction in section e Refer to section 11 3 24 for the replacement of FAN1 d Replace PCB6 WK 5549
65. conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal Refer to figure 3 2 and 1 Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 BLACK and line 2 WHITE and line 3 RED input conductors to a de energized line disconnect switch 3 Use Table 3 2 and Table 3 4 as a guide to select line fuses for the disconnect switch Input Voltage Fuse Size 208V 60 Amps 230V 50 Amps Table 3 1 Electrical Input Connections 185 ACDC Input Voltage Fuse Size 208V 75 Amps 230V 60 Amps 460V 30 Amps Table 3 2 Electrical Input Connections 200ACDC 3 2 NOTE For single phase operation connect the GREEN BLACK and WHITE input conductors Isolate the RED conductor as it is not used for single phase operation NOTE Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code Welding Power Supply Ground tei s Ground Conductor Line Disconnect Switch Line Fuse N Primary Power Cable Figure 3 1 Electrical Input Connections Welding Power Supply Ground gt Ground Conductor Line Disconnect Switch Line Fuse Primary Power Cable Figure 3 2 Electrical Input Connec
66. crews Remove the two terminals and open the Rear Panel 3 Remove the C ring and detach the Solenoid Valve SOL1 When reinstalling make sure that the C ring seats in the solenoid valve groove 3 26 Main ON OFF Switch 51 1 Remove the Side Panel Reference page 10 2 2 Remove the six screws and six terminals 11 29 ARCMASTER 185 200ACDC 3 Remove the two screws and detach the Main ON OFF Switch 51 Remove the three posts 3 27 Input Voltage Switch S2 1 Remove the Side Panel Reference page 10 2 2 Remove six screws and six terminals a SL Nm ARCMASTER 185 200ACDC 4 Disconnect one connector on Remove the two screws and two nuts and then remove the Input Voltage Switch S2 3 28 Remote Connector CON1 1 Remove the Side Panel Reference page 10 2 2 Remove the Protection Cover 11 31 ARCMASTER 185 200ACDC 4 Disconnect the two connectors Remove the one screw and two ground terminals
67. ctor device Yes Yes Yes 2 m 2 m 9 gt m z SPOT 2T operation spot welding Yes No in HF TIG using a remote contactor device PULSE ON OFF No Yes Yes Pulse operation in TIG Modes Selects DC weld Yes Yes Yes current Contactor operation in Yes No Yes stick Mode Selects mode of operation Yes Yes Yes Panel or Remote T ee T P IH 25 2 2 9 ms Table 4 2 Weld Process selection verses Weld Mode for ARC MASTER 185 200ACDC May 22 2006 ARCMASTER 185 ACDC 200 ACDC 4 03 Weld Parameter Descriptions for ARC MASTER 185 200 ACDC N1B016200E Figure 4 3 ARC MASTER 185 200 ACDC Front Panel with Parameter Description Parameter Description PRE FLOW t1 This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc once the torch trigger switch has been pressed This control is used to dramatically reduce weld porosity at the start of a weld HOT START This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes e g low hydrogen electrodes It sets the peak start current on top of the BASE WELD current e g HOT START current 130 amps when BASE WELD 100 amps amp HOT START 30 amps INIT
68. d Circuit Board WK 5548 11 10 W7001314 Printed Circuit Board WK 5527 11 14 W7001812 Printed Circuit Board WK 5528 11 15 W7001320 Printed Circuit Board WK 5615 11 16 W7001594 11 19 W7001433 Printed Circuit Board WK 5570 11 20 W7001434 Printed Circuit Board WK 5499 11 20 W7001324 NI A Ol N Printed Circuit Board WK 5569 Printed Circuit Board WK 4917 11 1 11 21 10 6740 ARCMASTER 185 200ACDC 2 DWG Parts Reference Part PCB1 Printed Circuit Board WK 5477 11 6 W7001402 PCB2 Printed Circuit Board 185ACDC WK 5596 11 7 W7001408 Printed Circuit Board 200ACDC WK 5482 11 8 W7001407 PCB4 Printed Circuit Board WK 4819 11 11 10 6635 PCB5 Printed Circuit Board WK 5551 11 12 W7001417 PCB6 Printed Circuit Board 185ACDC WK 5549 11 12 7001725 PCB6 Printed Circuit Board 200ACDC WK 5549 11 12 7001726 7 Printed Circuit Board WK 5550 11 12 W7001423 PCB8 Q1 Q6 Printed Circuit Board WK 5479 Primary IGBT 11 13 7001318 NI c O PCB9 Q7 Q12 Printed Circuit Board WK 5479 Primary IGBT 11 2 11 13 W7001318 ARCMASTER 185 20
69. e 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 1 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 face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Engines produce harmful exhaust gases Do not use welder to charge batteries or jump start vehicles Boo m 1 Use equipment outside in open well ventilated areas Observe correct polarity and on batteries May 22 2006 1 3 ARCMASTER 185 200 ACDC AT P WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure 1 Do not remove radiator cap when engine is 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 This product when used for welding or cutting produces fumes or
70. e flow or Post flow time is set to 0 seconds change them to higher setting Verify the layout of the gas hose Confirm that the hose is securely connected into the fitting at the inlet and the outlet Confirm that the layout of the gas hose so that itis not bent or kinked Confirm there are no breaks burns or holes in the hose Confirm the layout of the TIG torch gas hose and that the hose adapters are properly connected Verify the wiring harness and connection of gas valve SOL1 and CN11 on PCB3 WK 5548 Verify the drive circuitry of the gas valve 5011 Verify the drive circuitry of the gas valve 5011 Refer to section 10 07 2 Replace PCB3 when abnormal Refer to section 11 3 4 Replace the PCB6 WK 5549 Refer to section 11 3 6 May 22 2006 3 No weld output NOTE When in High Frequency TIG HF TIG mode if the High Frequency is not generated present refer to High Frequency Output Failure on Page 10 10 before performing this section Cause Occurs when the remote connector CON1 or associated circuitry is defective damaged or the TIG torch cable is defective Verification Remedy A CAUTION Read and understand this entire section before proceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately a co Verify the remote connector CON1 Applies to LIFT TIG and High Frequency TIG HF TIG mode
71. e visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de 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 de documents ci dessous f AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs ARCMASTER 185 ACDC 200 ACDC 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es 2 Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent amp 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 1 Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein 2 Nefaites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue 3 Sic 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 4 Nefaites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburan
72. eeded Fan ceases to operate Air flow is restricted by vents being blocked The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked Primary current is too high because welding arc is too long Mains supply voltage is more than 10 below nominal voltage TIG torch cable and or work lead are too long or leads are coiled Primary supply voltage is greater than the nominal voltage plus 10 Mains supply voltage is less than the nominal operating voltage less 10 Mains supply voltage is down to a dangerously low level ARCMASTER 185 ACDC 200 ACDC A Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Reduce length of welding arc Have an Accredited Thermal Arc Service Agent or a qualified electrician check for low Mains voltage Reduce the length of the TIG torch cable and or work lead or un coiled leads Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Primary voltage Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Have an Accredited Thermal Arc
73. elding 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 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 Ameri can 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 Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion ANSI Standard 787 1 from American National Standards Insti tute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51
74. electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch open or remove line fuses so power cannot be turned on accidentally parts at once In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output Wear a safety harness to prevent falling if working above floor level Keep all panels and covers securely in place 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 can burn eyes and skin Noise from some processes can damage 5 Properly install and ground this equipment according to its Owner s hear Manual and national state and local codes caring 6 Turn off all equipment when not in use Disconnect power to 1 equipment if it will be left unattended out of service May 22 2006 Wear a welding helmet fitted with a proper shade of filter see ANSI 749 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended ARCMASTER 185 ACDC 200 ACDC
75. fan blades and all peripheral parts Clean the fan blades and all peripheral parts if covered with dust Cleaning and removing dust from the fan blades once every 6 months in a normal environment is recommended Extremely dusty environments will require more frequent cleanings Verify that there are no wiring harnesses entangled inside the fan confirm that the harnesses do not have any brakes in the wire or damaged connectors Replace wiring harnesses if you find any broken connectors or damaged wiring harnesses Replace the fan if there are any broken cracked or missing fan blades Refer to section 11 3 24 Verify the wiring harness between the cooling fan FAN1 and CN11 on PCB3 WK 5548 Confirm a secure connection of the harness to CN11 on PCB3 Verify the drive circuitry of the cooling fan FAN1 on Verify the drive circuitry of the cooling fan FAN1 on PCB3 Refer to section 10 07 1 Replace PCB3 if necessary Refer to section 11 3 4 2 Gas Valve Failure No Gas flow through unit Cause Occurs when the gas valve SOL1 is defective damaged or the driving voltage is incorrect Verification Remedy a c e CD Confirm that TIG welding is selected on the welding mode Do not change welding modes while welding Only change welding modes when the unit is idle torch switch OFF Verify the setting of Pre flow and Post flow on the front panel If the Pr
76. four mounting screws from the the control panel see Figure 9 2 Art A 07080 gt Figure 9 2 VRD ON OFF Step B 9 2 May 22 2006 ARCMASTER 185 ACDC 200 ACDC C Access the VRD control by gently prying back the front panel controls to reveal the VRD on off potentiometer see Figure 9 3 A CAUTION DO NOT pull back the front panel with excessive force as this will unplug control PCB Plugging the control PCB back into the front panel controls can only be achieved by removing the side covers 2 Ka deg ef VR1 n II IL eme Ot f all E E Art A 07081 89 Figure 9 3 VRD ON OFF Step and D D Turning the VRD ON OFF see Figure 9 3 To turn VRD ON rotate the trim potentiometer the display PCB fully clockwise When is turned ON check that it operates as per VRD Specifications on page 9 1 To turn OFF rotate the trim potentiometer on the display PCB fully counter clockwise A WARNING The VRD ON OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the VRD function will be unknown for every other position May 22 20
77. ght shielding gas Refer to Basic TIG Welding Guide E Improve connection to work piece Table 8 1 TIG Welding Problems 8 3 ARCMASTER 185 ACDC 200 ACDC 8 04 Stick Welding Problems 1 Gas pockets or voids in Electrodes are damp Dry electrodes before use weld metal Porosity Welding current is too high Reduce welding current Surface impurities such as oil Clean joint before welding grease paint etc Crack occurring in weld Rigidity of joint Redesign to relieve weld joint of metal soon after severe stresses or use crack solidification resistance electrodes commences Insufficient throat thickness Travel slightly slower to allow greater build up in throat Cooling rate is too high Preheat plate and cool slowly A gap is left by failure Welding current is too low Increase welding current of the weld metal to fill Electrode too large for joint Use smaller diameter the root of the weld electrode Insufficient gap Allow wider gap Incorrect sequence Use correct build up sequence Art A 04991 Incorrect sequence Insufficient gap Figure 8 1 Example of insufficient gap or incorrect sequence Portions of the weld A Small electrodes used on heavy cold Use larger electrodes and pre heat do not fuse to the plate the plate surface of the metal or Welding current is too low Increase welding current edge of the joint Wrong electrode angle Adjust angle so the welding arc is directed more into the base
78. ing and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment A WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques May 22 2006 ARCMASTER 185 ACDC 200 ACDC 8 02 Common Welding Operation Faults The following are some of the more common operating faults that occur during welding operations 1 Power Main power not connected Main power not turned on MAIN CIRCUIT BRAKER set on OFF position INPUT SELECTOR Easy Link Switch in wrong position 2 Poor Weld Wrong polarity Wrong electrode used Electrode not properly prepared Incorrect welding amperage setting Speed too slow or too fast Incorrect switch settings for intended operation Poor weld output connection s If the problem is not resolved after checking the above the following guide may suggest more specific items to check given the faulty operating symptom s you are experiencing 8 1 ARCMASTER 185 ACDC 200 ACDC 8 03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumalbes maintenance of equipment and proper welding technique 1 Excessive beard build Welding current is too low Increase weld current and or faulty up or poor penetration joint preparation or poor fus
79. ing guide A total number of 5 programs can be saved into the 185 200ACDC memory SAVE the Current Weld Parameters into Memory Press the SAVE button Select a memory location by rotating the control knob 1 to 5 is displayed on the meter After selecting the desired memory location ie 1 to 5 press the right scroll button and the machine will give a beep Save Load function to confirm the weld parameters from the control panel are saved LOAD retrieve a Program to Control Panel Press the LOAD button Select a memory location by rotating the control knob 1 to 5 is displayed on the meter After selecting the desired memory location ie 1 to 5 press the right scroll button and the machine will give a beep to confirm the weld parameters are loaded Table 4 6 Power Source Features 4 6 May 22 2006 SECTION 5 ARCMASTER 185 ACDC 200 ACDC SET UP FOR SMAW STICK AND GTAW TIG Conventional operating procedures apply when using the Welding Power Source i e connect work lead directly to work piece and electrode lead is used to hold electrode Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short term overload without adverse effects The welding current range values should be used as a guide only Current de livered to the arc is dependent on the welding arc volt age and as welding arc voltage varies between different classes of electrodes welding current at any one setting wou
80. ington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Pro tection Association Batterymarch Park Quincy MA 02269 May 22 2006 SECTION 2 INTRODUCTION 2 01 How To Use This Manual This Service Manual applies to just specification or part numbers listed on page i To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words 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 A WARNING gives information regarding possible personal injury CAUTION refers to possible equipment damage NOTE ANOTE offers helpful information concerning certain operating procedures Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual Include the manual number and equipment identification numbers Electronic copies of this
81. ining these elements can give off toxic fumes if welded Torch soldering Cd Torch brazing i y y Under 1 in 25mm Oxygen Cutting Under 1 in 25 mm Light Under 1 8 in 3 mm Gasweldimg Shielded metal arc Under 5 32 in 4 mm al 5 32 to 1 4 in Plasma arc cutting Ovrt4in 64mm 14 ioh goggles or helmet from AWS 2 73 Filter 2 Gasmeakac Ferrous base metal 12 Atomic hydrogen welding 405 Plasma arc welding Medium 1 8 10 1 2 3 12 mm 50r6 Carbon arc air gouging 8 1 1 to 6 in 25 150 mm TIG Over 1 2 in 12mm i or or i or r 0 300 10 400 Over 400 Amp 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 ft 10 7 m 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
82. ion at edges of weld 2 Weld bead too wide Welding current is too high Decrease weld current and flat or undercut at edges of weld or excessive burn through 3 Weld bead too small or Travel speed too fast Reduce travel speed insufficient penetration or ripples in bead are widely spaced apart 4 Weld bead too wide or Travel speed too slow Increase travel speed excessive bead build up or excessive penetra tion in butt joint 5 Uneven leg length in Wrong placement of filler rod Re position filler rod fillet joint 6 Electrode melts when Electrode is connected to the A Connect the electrode to the arc is struck terminal terminal 7 Dirty weld pool A Electrode contaminated through A Clean the electrode by grinding off contact with work piece or filler rod the contaminates material Gas contaminated with air Check gas lines for cuts and loose fitting or change gas cylinder 8 Electrode melts or A No gas flowing to welding region A Check the gas lines for kinks or oxidizes when an arc is breaks and gas cylinder contents struck B Torch is clogged with dust B Clean torch C Gas hose is cut C Replace gas hose Gas passage contains impurities Disconnect gas hose from torch then raise gas pressure and blow out impurities E Gas regulator turned off F Torch valve is turned off F Turnon G The electrode is too small for the G Increase electrode diameter or welding current reduce
83. ive of CN11 on PCB3 WK 5548 The location of connector CN11 of PCB3 is indicated in Figure 11 12 When you measure the above voltage do not remove the connector Conduct the measurement while the connector plug and receptacle are still connected Figure 11 12 Verification of the FAN1 Voltage measurement 5 1 2 of CN11 on PCB3 Case Rotating DC 18 25V FAN1 drive circuit is 1 normal Case Replace 2 Rotating Below DC 18V Refer to section 11 3 4 Replace PCB3 Refer to section 11 3 4 Case 3 Inactive Below DC 18V Perform 2 Verfication of Power Supply Voltage Refer to section 10 07 Case Replace the 1 4 De Refer to section 11 3 24 Table 10 3 Verification of the FAN1 During low output and standby the fan rotation slows down making exact voltage measurement impossible When verifying the voltage confirm that the AC input voltage remains within the operating range of the unit The AC input does not drop below 180VAC May 22 2006 ARCMASTER 185 ACDC 200 ACDC 2 Verification of the Gas Valve SOL1 Drive 3 Verification of the primary Diode D1 Circuliry 1 Verify the characteristic of the primary diode D1 using a diode tester A CAUTION 2 Refer bellow Table 11 5 and Figure 11 14 for the yy checkpoints on D1 Before performing any portion of the procedure below make certain the unit is TERMINA
84. ive for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shall pay no transportation costs of any kind under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty dated April 1 2006 supersedes all previous Thermal Arc warranties Thermal is a Registered Trademark of Thermal Arc Inc WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout Raider Explorer Original Main Power Stators and Inductors 3 years Original Main Power Rectifiers Control P C Boards 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year Engines and associated components are NOT warranted
85. ld vary according to the type of electrode in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application A WARNING 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 or sides of the Welding Power Source A CAUTION DO NOT change the Weld Mode or Weld Pro cess Mode until after POST FLOW time has finished May 22 2006 Figure 5 1 185 200 ACDC Set up 5 1 ARCMASTER 185 ACDC 200 ACDC May 22 2006 SECTION 6 SEQUENCE OF OPERATION NOTE Scroll Buttons are used to select the parameters to be set The LED s show which function is being adjusted on the weld sequence graph Refer to the Symbols Table located in the front of the manual for Symbol descriptions 1 9 Figure 6 1 185 200 ACDC Front Panel 1 Pulse function Pressing this button enables the TIG current pulse functions 2 Remote Current function Pressing this button enables remote current functions 3 TIG Mode Functions Pressing this button scrolls through the output TIG function modes Standard Slope Slope w repeat Spot 4 Digital LED display Welding amperage and parameter values
86. mbers 2 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a break down of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and per manently attached items which are soldered riveted or welded to other parts The part descriptions may be indented to show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the correspond ing Parts List ARC MASTER 185 10 3073 ARC MASTER 200ACDC 10 3083 DWG No Part No CONT QTY Coil Coupling gen 3 1 IPS Socket Remote gen 3 1 IPS Transformer gen 3 1 IPS 0 6628 Diode gen 3 1 IPS DFA50BA160 185ACDC 0 6769 D D ij Si alsls elele h h C a S co 5 gt 1 1 0 6629 Diode gen 3 1 IPS 0 6629 Diode gen 3 1 IPS 10 6629 Diode gen 3 1 IPS 8 FANT 7001307 gen 3 1 IPS 9 FCHi 7001502 Inductor gen 3 1 IPS Sensor Current gen 3 1 IPS F Unit gen 3 1 IPS 0 6633 F Gap gen 3 1 IPS CB gen 3 1 IPS CB gen 3 1 IPS 185ACDC CB gen 3 1 IPS 200ACDC CB gen 3 1 IPS 0 6635 CB gen 3 1 IPS W7001417 gen 3 1 IPS W70017
87. ments et aux produits nettoyants Ve travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respi ration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Nuance de filtre oculaire ou soudage toutes conditions NI toutes conditions NI toutes conditions NI toutes conditions toutes conditions NI pais mince moins de 300 amper s 12 14 May 22 2006 Ne soudez des t les galvanis es ou plaqu es au plomb ou 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 ad duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie e
88. metal Travel speed of electrode is too high D Reduce travel speed of electrode E Scale or dirt on joint surface Clean surface before welding Lack of fusion caused by dirt Art A 04992 electrode angle incorrect rate of travel too high Lack of inter run fusion Lack of side fusion scale dirt small electrode amperage too low Lack of root fusion Figure 8 2 Example of Lack of Fusion 8 4 May 22 2006 ARCMASTER 185 ACDC 200 ACDC A Non metallic particles may be trapped in undercut from previous 5 Non metallic particles are trapped in the weld metal slag inclusion run B Joint preparation too restricted C Irregular deposits allow slag to be trapped D Lack of penetration with slag trapped beneath weld bead E Rust or mill scale is preventing full fusion F Wrong electrode for position in which welding is done If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode Allow for adequate penetration and room for cleaning out the slag If very bad chip or grind out irregularities Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from corners Clean joint before welding Use electrodes designed for position in which welding is done otherwise proper control of slag is difficult Table 8 2 Stick Welding Problems Not cleaned or incorrect electrode Slag trapped in unde
89. move the three PCB supporters from the PCB14 WK 5570 3 16 PCB17 WK 4917 1 Remove the Side Panel Reference page 10 2 2 Remove the six screws and six terminals 3 Remove the four screws and then open the Rear Board ARCMASTER 185 200ACDC 4 Disconnect the one connector Remove the two screws and one ground terminal and remove the PCB17 unit 3 17 Discharge Resistor R3 1 Remove the Side Panel Reference page 10 2 2 Remove the Nylon Hose Remove the two bolts two toothed washers one washer and one terminal ARCMASTER 185 200ACDC 3 Remove the four screws and open the Front Panel 4 Cut the one snap band and disconnect the one connector X 20 aa N 9 Dr h 4 C Y Z Ps Ls 6 Y AR gt NES S 11 23 ARCMASTER 185 200ACDC 6 Remove the two screws and remove the Discharge Resistor R3 3 18 Current Limiting Resistor R4 R5 1 Remove the Side Panel Reference page 10 2 2 Remove the PCB2 WK 5596 Reference page 11 7 3 Remove the one screw and remove the Current Limiting Resistor R4 R5
90. mpaltirid 9 O mm Screwdriver 2 2 Notes of disassembly and assembly NOTE When removing the locking type connectors and board supporters disengage the locking mechanism first and then disconnect them Locking type connectors and board supporters are indicated in this manual using the following symbols black star marks for locking connectors and white star marks for locking board supports NOTE During your maintenance or repair please cut any tie wraps necessary However after your maintenance or repair please reassemble and tie wrap all components and wiring in the same manner as before the mainte nance or repair CAUTION Please note that you remove each connector grasp and pull out by the connector part only Do not pull the harness cable part WARNING The capacitors inside the power supply will slowly discharged after you turn off the switch of the power sup ply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete 11 5 ARCMASTER 185 200ACDC 3 Replacement Procedure 3 1 PCB1 WK 5477 O REF 1 Remove the Side Panel Reference page 10 2 Remove PCB2 WK 5596 WK 5482 Reference page 11 7 Remove the PCB8 WK 5479 Reference page 11 13 nm Remove the PCB9 WK 5479 Reference page 11 13 Remove the four screws Pull out the Rear Control Cove
91. n 3 1 IPS ECA887300 00X4861 perator Manual gen 3 1 IPS 185ACDC 00X4862 perator Manual gen 3 1 IPS 200ACDC Additional Information QTY JG23V101J 68W 1000 MHS20A221KI 20W 2200 520 101 20W 1000 c o 2 o jos 85 PR RO F3A063501 200A MAIN TR ERTA53D203 20k0 25 CB 3950K 00005301 00005501 00005407 I o o ES I els I EN 5 45 5 42 ENEN C2 CI C SI NI Ni Ni Ni 9 5 9 9 o op Kop oo CO 1 Label VRD gen 3 1 1PS Label VRD gen 3 1 1PS Knob gen3 1 IPS 0 i 185ACDC 200ACDC PARTS LIST A 3 185ACDC 200ACDC PARTS LIST A4 APPENDIX 2 CONNECTION WIRING GUIDE Destination PCB4 PCB3 D1 D1 2 110171 B H K L M N x lt o 5 185ACDC 200ACDC CONNECTION WIRING GUIDE
92. n High Frequency TIG mode A WARNING This welding mode produces high frequency and high voltage Extra care shall be taken to prevent electric shock 3 When in HF TIG mode the unit will generate high voltage To prevent personal harm and test equipment damage mark and then remove the indicated wire from the HF UNIT1 shown in Figure 10 18 To prevent electric shock always wrap the removed wire with electrical tape or other suitable insulation 10 17 ARCMASTER 185 ACDC 200 ACDC Figure 10 18 Removal and installation from the HF UNIT1 To disable the operation of the HF unit 4 Press the Welding mode selection button to select HF TIG welding mode While depressing the Torch switch verify the OCV using a DC voltmeter The capability of the voltmeter should be more than 100VDC The check point with a tester is the voltage between output terminal and In TIG mode the OCV ceases 3 seconds after you depress the torch switch The normal no load voltage is approximately 58 62V 7 Return the variable resistor VR1 to the original position e Fully clockwise VRD ON Fully counter clockwise OFF 8 Return connection with HF UNIT1 to the original position 10 18 May 22 2006 SECTION 11 REPAIR PROCEDURES 1 Maintenance List 2 Reference Part No Printe
93. n the terminals between AC1 AC2 TB1 TB2 10 10 May 22 2006 c CD Verify the connection between AC1 AC2 confirm that the quick disconnect terminals are inserted onto the terminals of HF UNIT1 correctly and completely Confirm there are no short circuits burnt or broken wires between AC1 and AC2 Verify and replace the Gap GAP of the High Frequency Unit HF UNIT1 Confirm that the GAP is connected to HF UNIT1 correctly and completely Confirm there is no dust or foreign debris between the space of the GAP If there are any abnormalities observed with the GAP replace the GAP setup of a gap is 1 0mm In the case of a gap 1 0mm or more high frequency voltage and a period increase In the case of a gap 1 0mm or less high frequency voltage and a period decrease Verify and replace the Current limiting Resistor R6 on HF UNIT1 If R6 is defective blown burnt cracked etc replace R6 Refer to section 11 3 19 Replace the High Frequency Unit HF UNIT Refer to section 11 3 29 Replace PCB3 WK 5548 Refer to section 11 3 4 ARCMASTER 185 ACDC 200 ACDC 10 05 Fault Isolation Tests Preparation The following initial conditions must be met prior to starting any of the procedures in this section 1 Connect the appropriate input voltage Check the name plate on the rear of the power supply for proper input voltage NOTE Operate at ALL input voltages as noted on the n
94. ntain the duty cycle of the power supply Refer to 2 09 for the recommended duty cycle Replace PCB6 WK 5549 and PCB13 WK 5569 Refer to section 11 3 6 for the replacement of PCB6 Refer to section 11 3 13 for the replacement of PCB13 5 E11 Main Supply Over Voltage Cause Main supply voltage occurs at about 275V or more Verification Remedy a Verify main supply voltage Perform what is described in a section of Verification of the Power Supply Voltage Refer to section 11 5 2 Replace PCB4 WK 4819 Verify PCB4 WK 4819 and replace it if necessary Refer to section 11 3 5 ARCMASTER 185 ACDC 200 ACDC 6 E12 Main Supply Under Voltage Cause Main supply voltage occurs in about 150V or less Verification Remedy a Verify main supply voltage Perform what is described in the section Verification of the Power Supply Voltage Refer to section 10 07 b Replace PCB4 WK 4819 e Replace PCB4 when abnormalities occur even if carries out the above mentioned verifications Refer to section 11 3 5 7 E81 Abnormal Input Voltage Cause The detection circuitry of the main supply voltage is abnormal Verification Remedy a Verify main supply voltage e Perform what is described in the section Verification of the Power Supply Voltage Refer to section 10 07 co Confirm a secure connection of the harness wired between CN2 on PCB3 WK 5548 and CN1 on PCB17 WK 4917
95. nts with adverse conditions do not include places where electrically conductive parts are in the near vicinity of the operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines e In areas free from moisture and dust Ambient temperature between O degrees C to 40 degrees C e In areas free from oil steam and corrosive gases n areas not subjected to abnormal vibration or shock e In areas not exposed to direct sunlight or rain e Place at a distance of 12 304 79mm or more from walls or similar boundaries that could restrict natural airflow for cooling A WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician May 22 2006 ARCMASTER 185 ACDC 200 ACDC 3 03 Electrical Input Connections A WARNING ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power DO NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lockout tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device 3 04 Electrical Input Requirement Operate the welding power source from a single phase 185 200 ACDC or a three phase 200 ACDC 50 60 Hz AC power s
96. of quality whether express implied or statutory Limitation of liability Thermal Arc shall not under any circumstances be liable for special indirect incidental or consequential damages including but not limited to lost profits and business interruption The remedies of the purchaser set forth herein are exclusive and the liability of thermal arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of thermal arc is authorized to change this warranty in any way or grant any other warranty and thermal arc shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or accessories which in thermal arc s sole judgment impaired the safety or performance of any thermal arc product Purchaser s rights under this warranty are void if the product is sold to purchaser by unauthorized persons The warranty is effect
97. olts Three Phase Amperage Draw Rated Load No Load Amps Amperage Draw Rated Load No Load Amps 208V 20 1 4 230V 19 1 3 460V 10 0 7 Input Volts Single Phase 208V 44 2 5 230V 40 2 2 ARCMASTER 185 ACDC 200 ACDC Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change improve or revise the specifications or design of this or any product without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes updates improvements or replacement of such items The values specified in the table above are optimal values your values may differ Individual equipment may differ from the above specifications due to in part but not exclusively to any one or more of the following variations or changes in manufactured components installation location and conditions and local power grid supply conditions May 22 2006 3 5 ARCMASTER 185 ACDC 200 ACDC May 22 2006 ARCMASTER 185 ACDC 200 ACDC SECTION 4 1 Control Knob This control sets the selected weld pa rameter rotating it clockwise increases the param OPERATOR CONTROLS eter that is indicated on the digital meter Pushing the knob inward displays the actual welding voltage 4 01 ArcMaster 185 200 ACDC Controls 2 Remote Control Socket The 8 pin Remote Control Socket is
98. 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 traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Light Under 300 Amp 9 May 22 2006 WARNING FLYING SPARKS AND HOT METAL can cause injury V Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin N 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 Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electri
99. ove the PCB3 and PCB5 unit Disconnect the two connectors 11 10 ARCMASTER 185 200ACDC 7 Disconnect the one connector and remove the two screws and then remove the PCB5 WK 5551 from the PCB3 WK 5548 Remove the one screw and one ground terminal from the PCB5 WK 5551 3 5 PCB4 WK 4819 1 Remove the Side Panel Reference page 10 2 2 Remove the two screws and three connectors and remove the PCB4 WK 4819 Disconnect the one connector ARCMASTER 185 200ACDC 3 6 PCB6 WK 5549 1 Remove the Side Panel Reference page 10 2 2 Disconnect the six connectors 3 7 PCB7 WK 5550 1 Remove the Side Panel Reference page 10 2 2 Remove the PCB6 WK 5549 Reference page 11 12 3 Remove the two screws and three connectors Remove the PCB7 WK 5550 ARCMASTER 185 200ACDC 3 8 PCB8 WK 5479 IGBT Q1 Q6 1 Remove the Side Panel Reference page 10 2 2 Remove the four screws and two IGBT Chassis 3 Remove the two connectors and three screws Remove the PCB8 WK 5479 Remember to install silicone rubber sheets when reinstalling the PCB8 WK 5479 3 9 PCB9 WK 5479 IGBT Q7 Q12 1 Remove the Side Panel Reference page 10 2 2 Remove the four screws and two IGBT Chassis
100. ply 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 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 4 3 08 Duty Cycle The duty cycle of a welding power source is the percentage of a ten 10 minute period that it can be operated at a given output without causing overheating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease A WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature A CAUTION Continually exceeding the duty cycle ratings can cause d
101. r and bring it down ARCMASTER 185 200ACDC 3 2 PCB2 WK 5596 185ACDC only 1 Remove the Side Panel Reference page 10 2 2 Disconnect the 13 connectors 4 Remove the PCB3 PCB4 PCB5 PCB6 and PCB7 unit and then disconnect the two connectors Remove the Insulated Sheet ARCMASTER 185 200ACDC 5 Remove the three screws and seven terminals Remove the PCB2 WK 5596 3 3 PCB2 WK 5482 200ACDC only 1 Remove the Side Panel Reference page 10 2 2 Disconnect the 13 connectors 11 8 ARCMASTER 185 200ACDC 3 Remove the four screws and two ground terminals 4 Remove the PCB3 PCB4 PCB5 PCB6 and PCB7 unit and then disconnect the two connectors Remove the Insulated Sheet ARCMASTER 185 200ACDC 6 Disconnect two connectors and two terminals from PCB2 WK 5482 3 4 PCB3 WK 5548 PCB5 WK 5551 1 Remove the Side Panel Reference page 10 2 Remove PCB4 WK 4819 Reference page 11 11 Remove PCB6 WK 5549 Reference page 11 12 nnm Remove 7 WK 5550 Reference page 11 12 Disconnect the 11 connectors Kk 4 XU Ne L AY 6 Remove the four screws and then the two ground terminals Rem
102. rcut Figure 8 3 Eamples of Slag May 22 2006 Art A 04993 S lt gt Slag trapped in root 8 5 ARCMASTER 185 ACDC 200 ACDC 8 05 Power Source Problems 1 The welding arc cannot The Primary supply voltage has not Switch ON the Primary supply be established been switched ON voltage B The Welding Power Source switch is B Switch ON the Welding Power switched OFF Source Loose connections internally Have an Accredited Thermal Arc Service Agent repair the connection Maximum output Defective control circuit Have an Accredited Thermal Arc welding current can not Service Agent inspect then repair the be achieved with welder nominal Mains supply voltage Welding current Poor work lead connection to the Ensure that the work lead has a reduces when welding work piece positive electrical connection to the work piece No gas flow when the Gas hose is cut Replace gas hose torch trigger switch is Gas passage contains impurities Disconnect gas hose from the rear of depressed Power Source then raise gas pressure and blow out impurities Gas regulator turned off Turn gas regulator on Torch trigger switch lead is Reconnect lead or repair faulty disconnected or switch cable is switch cable faulty Gas flow won t shut off Weld Mode S7D SLOPE REPEAT Strike an arc to complete the weld 5207 was changed before POST FLOW gas time had finished Switch machine off then on to reset solenoid valve sequence
103. rimary Thermistor TH1 Before installing a new therminstor apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 3 23 Secondary Thermistor 2 8 ABFA 1 Remove the Side Panel Reference page 10 2 2 Remove the PCB13 WK 5569 Reference page 11 19 3 Remove the PCB12 WK 5615 Reference page 11 16 4 Remove the one screw and one nut and remove the bus bar Ed F HA e a gt lt SHON gt 5 Cut the four snap bands Disconnect the one connector Remove the one screw and then detach the Secondary Thermistor TH2 Before installing a new therminstor apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base ARCMASTER 185 200ACDC 3 24 Cooling Fan FAN1 1 Remove the Side Panel Reference page 10 2 2 Remove the Nylon Hose Remove the four screws Remove the two terminals and open the Rear Panel 4 Remove the two screws and detach the Cooling Fan FAN1 e Do not install the fan in the wrong direction noting correct air flow 11 28 ARCMASTER 185 200ACDC 3 25 Solenoid Valve 5011 1 Remove the Side Panel Reference page 10 2 2 Remove the Nylon Hose Remove the four s
104. se Controls Pulse Width Pulse Frequenc pa quency Peak Current Base Background Current Figure 6 3 Pulse Control Sequence The Pulse controls are used primarily to control heat input Pulse offers a number of advantages as follows 1 Control puddle size and fluidity especially out of position Increase penetration 2 3 Travel speed control 4 Better consistent quality 5 Decreased distortion on lighter or thinner materials Pulse current provides a system in which the welding current continuously changes between two levels During the periods of Peak current heating and fusion takes place and during the background base current periods cooling and solidification take place Pulse Width is the time in one cycle the current remains at the peak current setting Pulse Frequency measured in Hertz is the number of cycles per second the current travels between peak and background current settings It is as if the foot rheostat were moved up and down to increase and decrease the welding current on a regular basis The faster you move the foot rheostat up and down the faster the frequency May 22 2006 ARCMASTER 185 ACDC 200 ACDC SECTION 7 ROUTINE MAINTENANCE The only routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment AN WARNING Disconnect primary power
105. st and an earth resistance test shall be carried out A For transportable equipment at least once every 3 months and B For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests NOTE A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated May 22 2006 In addition to the above tests and specifically in relation to the VRD fitted to this machine the following periodic tests should also be conducted by an accredited Thermal Arc service agent VRD Open Circuit Voltage IEC 60974 1 Requirements Less than 20V at Vin 460V Less than 200 ohms Resistance VRD Turn OFF Time Less than 0 3 seconds Periodic Tests If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests should be carried out prior to entering this location 9 1 ARCMASTER 185 ACDC 200 ACDC 9 03 Switching VRD On Off Switch the machine Off A Remove the clear plastic cover from the control panel see Figure 9 1 Lift up the cover so it rests on the top of the unit e Place a small flat bladed screw driver between the cover hinge on the front panel Gently lift the cover hinge out of the front cover mounting hole Remove the control s clear plastic cover Art A 07079 Figure 9 1 VRD ON OFF Step A B Remove the
106. t Board 1 GT gt WK 5569 2 gt 3 259 3 amp 4 E gt ka A A Iz 6 CES gt CI CI fol El E L7 LA lt lt EJ ii FRONT 7 5 EA CN8 CN9 1 croma RY 15V gt capt e c D SIDE CHASSIS 2 i PCB10 Panel 7 PCBIT I Circuit Board WK 5527 WK 5528 A10 APPENDIX 4 DIODE TESTING BASICS Testing of diode modules requires a digital Volt Ohmmeter that has a diode test scale Locate the diode module to be tested Remove cables from mounting studs on diodes to isolate them within the module Set the digital volt ohm meter to the diode test scale Using figure 1 and 2 check each diode in the module Each diode must be checked in both the forward bias positive to negative and reverse bias negative to positive direction 1 To check the diode in the forward bias direc tion connect the volt ohm meter positive lead to the anode positive of the diode and the negative lead to the cathode negative of the diode refer to Figure 13 1 A properly functioning diode will conduct in the forward bias direction and will indicate between 0 3 and 0 9 volts To check the diode in the reverse bias direc tion reverse the meter leads refer to Figure 13 1 A properly functioning diode will block current flow in the reverse
107. t des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie M MH Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur 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 c t Ne soudez pas un r cipient ferm tel un r servoir ou un 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 con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse
108. t renvers avant de faire d marrer le moteur M we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 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 syst me arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des protecteurs 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 en 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 ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives 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 Nutilisez que des o
109. tand this entire section before proceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately The unit will generate a High Voltage component that can cause extreme personal harm and test equipment damage Capacitors installed inside the Welding Power Source are electrically charged for a while after the Mains ON OFF switch or distribution panel switch has been turned off Before inspecting the inside of the Welding Power Source leave it for about 5 minutes after switching off power for discharging the capacitors and then remove the top and side panels a co a Verify the connection between High Frequency HF UNIT1 and Coupling Coil CC1 Verify the connection between the HF UNIT1 and CC1 confirm that the quick disconnect terminals are inserted onto the terminals of HF UNIT1 TB5 TB6 correctly and completely Confirm there are no short circuits burnt or broken wires at CC1 Replace CC1 Refer to section 11 3 20 Verify the connection between High Frequency HF UNIT1 and the current limiting resistor R2 Verify the connection between HF UNIT1 and the current limiting resistor R2 confirm that the quick disconnect terminals are inserted onto the terminals of HF UNIT1 TB3 TB4 correctly and completely Confirm there are no short circuits burnt or broken wires between the HF UNIT1 and the current limiting resistor R2 Verify the connection betwee
110. ted Industrial Park Jin Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters THERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE 96 gt St Louis MO 63017 Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com
111. the welding current 8 2 May 22 2006 ARCMASTER 185 ACDC 200 ACDC 9 Poor weld finish Inadequate shielding gas 10 Arc flutters during TIG A Tungsten electrode is too large for welding 11 Welding arc can not be established 12 Arc start is not smooth May 22 2006 the welding current B Absence of oxides in the weld pool Work clamp is not connected to the work piece or the work torch leads are not connected to the right welding terminals Torch lead is disconnected Gas flow incorrectly set cylinder empty or the torch valve is off Tungsten electrode is too large for the welding current The wrong electrode is being used for the welding job Gas flow rate is too high Incorrect shielding gas is being used Poor work clamp connection to work piece Increase gas flow or check gas line for gas flow problems A Select the right size electrode Refer to Basic TIG Welding guide Refer Basic TIG Welding Guide for ways to reduce arc flutter A Connect the work clamp to the work piece or connect the work torch leads to the right welding terminals B Connect it to the terminal C Select the right flow rate change cylinders or turn torch valve on Select the right size electrode Refer to Basic TIG Welding Guide Select the right electrode type Refer to Basic TIG Welding Guide C Select the correct rate for the welding job Refer to Basic TIG Welding Guide D Select the ri
112. tions May 22 2006 3 05 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit When the MAIN CIRCUIT SWITCH is turned on the inrush circuit provides a pre charging of the input capacitors At this point the Bus Voltages are checked and the welder is enabled after the input capacitors have charged to full operating voltage after approximately 5 seconds 185 ACDC NOTE Note the available input power Damage to the welder could occur if 460VAC or higher applied The following 208 230V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment Primary Minimum Current amp Duty Cycle Supply Primary Lead Current Size Circuit Size Factory Vin Amps Fitted 12 3 20888 185 30 AWG 10 230 30 minimum 208 44 230 40 ARC MASTER 185ACDC 160 40 Table 3 3 208 230V Primary Current Circuit sizes to achieve maximum current 200 ACDC NOTE Note the available input power Damage to the welder could occur if 575VAC or higher is applied The following 208 230 460V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment May 22 2006 ARCMASTER 185 ACDC 200 ACDC Minimum Primary Primary Supply Lead Current Size Circuit Size Factory Fitted Current amp Duty Cycle Vin Amps 208 17 200 2
113. to positive terminal Connect TIG torch to negative terminal Switch machine on e Set AC or DC weld current If AC is selected then set AC FREQ amp WAVE BALANCE Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set PRE FLOW time Set HOT START current Set POST FLOW time Set WELD PEAK CUR current Set POST FLOW time Slope Mode Parameters if required e Set INTIAL CUR current Set UP SLOPE time Set WELD PEAK CUR current Set BASE current Set DOWN SLOPE time Set CRATER CUR current 6 1 ARCMASTER 185 ACDC 200 ACDC Pulse Mode parameters if required Set PULSE WIDTH for PEAK CURRENT Set PEAK CURRENT Set PULSE FREQ Commence welding 6 03 Slope Mode Sequence Ed Up Weld Current Down Initial 51999 Slope Final Current Current Preflow Postflow Figure 6 2 Slope Mode Sequence Switch Switch Closed Open 1 To start Slope sequence Close remote switch contacts Once the welding arc is established the Power Source will maintain initial current setting as long as the remote switch contacts are closed a In the HF TIG mode after Preflow time High Frequency is present at the torch When the torch is
114. u ou 12 Nutilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pieces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux So SXALLL LLLG G O GZEAALZI 14 Portez un harnais de s curit si vous travaillez en hauteur 1 Ne touchez pas des pi ces sous tension Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables May 22 2006 1 5 ARCMASTER 185 ACDC 2
115. ument ainsi que d autres guides que vous devriez conna tre 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 04 Dangers Relatifs au Soudage l Arc 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant meme temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilisez pas de cables lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT ETRE MORTELLE 9 N enroulez pas de c bles lectriques autour de votre corps 10 Nutilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique peut tuer ou br ler gravement dudum la piece souder L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les 11 circuits internes de l quipement sont aussi sous ten sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le roulea
116. upply The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and any inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit NOTE These units are equipped with a three conductor with earth power cable that is connected at the welding power source end for single and three phase electrical input power Do not connect an input WHITE or BLACK or RED conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal 3 1 ARCMASTER 185 ACDC 200 ACDC For 185 ACDC Do not connect an input WHITE and BLACK conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal Refer to figure 3 1 and 1 Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch 3 Use Table 3 1 and Table 3 3 as a guide to select line fuses for the disconnect switch For 200 ACDC Do not connect an input WHITE or BLACK or RED
117. urely to achieve a sound elec trical connection A CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal Gas Outlet The Gas Outlet is a 5 8 18 UNF female gas fitting ON OFF Switch This switch connects the Primary supply voltage to the inverter when in the ON posi tion This enables the Power Supply A WARNING When the welder is connected to the Primary supply voltage the internal electrical compo nents may be at 720V potential with respect to earth Input Cable The input cable connects the Primary supply voltage to the equipment SMART Logic Switch Manual slide switch mounted on the back panel selects for proper input voltage If this slide is not set to the position that matches the input voltage from the electrical source the Smart Logic circuit will inhibit welding power source output The digital meter will show primary input error code 200ACDC only Gas Inlet The Gas Inlet is a 5 8 18 UNF female gas fitting 4 02 Weld Process Selection Weld Mode Parameter HF LIFT Description STICK TIG STD 2T operation in TIG Modes using remote devices to control contactor amp current 4T operation in TIG Modes with crater fill Yes Yes using a remote contactor device to control sequence 4T operation in TIG Modes with repeat No Yes Yes operation and crater fill using a remote conta
118. used to connect remote current control de vices to the welding Power Source To make connec tions align keyway insert plug and rotate threaded collar fully clockwise Front view 8 Socket Receptacle Figure 4 2 8 Socket Receptacle Earth Ground 2 Torch Switch Input 24V to connect pins 2 amp 3 to turn on welding current Torch Switch Input OV to energize weld current connect pins 2 amp 3 to turn on welding current Connect pin 4 to pin 8 to instruct machine that a remote current control device is connected 12V DC supply 5k ohm maximum connection to 5k ohm remote control potentiometer Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control potentiometer Connect pin 4 to pin 8 to instruct machine that a remote current control device is connected OV Table 4 1 Socket Pin Functions Figure 4 1 ARC MASTER 185 200ACDC Power Source May 22 2006 4 1 ARCMASTER 185 ACDC 200 ACDC 3 Positive Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal Size 50mm It is essential however that the male plug is inserted and turned securely to achieve a sound elec trical connection Negative Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal Size 50mm It is essential however that the male plug is inserted and turned sec
119. utils anti tincelles pour travailler sur un accumulateur 4 Nutilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte 4 et de l accumulateur Fa C P 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 Ma AB 1 Notez pas le bouchon de radiateur tant que le moteur n est pas refroidi 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 1 05 Principales Normes de Securite Safety in Welding and Cutting norme ANSI 749 1 American Weld ing Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 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 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arl
120. ver Encoder gen 3 1 IPS EBA514400 0 6655 over PCB gen 3 1 IPS E1B537600 with Dustcover Sheet abel Name gen 3 1 IPS N4A932900 200ACDC abel Name gen 3 1 IPS N4A932800 185ACDC abel Side gen 3 1 IPS N4A785200 abel 1 Warning gen 3 1 IPS N1B029700 abel 2 Warning gen 3 1 IPS N1B029800 10 6658 abel Output Term gen 3 1 IPS N4A040100 51 10 6733 abel Gas Input gen 3 1 IPS N4A040700 52 ______ 7001586 Label Switch gen 3 1 IPS N4A148700 53 W7001513 _ VRD gen 3 1 IPS N4A918800 W7001511 Label VRD gen 3 1 IPS N4A598700 55 ______ 10 6659 Outlet Gas gen 3 1 IPS E5A925600 with PC4 02 56 10 5184 C Ring gen 3 1 IPS 53003000600 erminal Output F gen 3 1 IPS 5 705 able Input gen 3 1 IPS SOOW AWG 12x4C 200ACDC able Input gen 3 1 IPS 32 10 3SOWBLKW R650 185ACDC lamp Input gen 3 1 IPS BA045800 eatsink gen 3 1 IPS 1B869900 7001575 Heatsink gen 3 1 IPS 1B870000 lip Spring IGBT gen 3 1 IPS 1B850100 hassis PCB1 gen 3 1 IPS 5B017400 64 W7001582 Chassis gen 3 1 IPS 36356500 65 110 6665 Knob gen 3 1 IPS 2621603 66 _______ 10 6666 Knob Cap gen 3 1 IPS 3021104 over Protector gen 3 1 IPS N1B016200 heet Rubber gen 3 1 IPS EDA227700 ost 1 M5 gen 3 1 IPS EBA643600 5 5 us Bar 1 D L gen 3 1 IPS ECA879500 us Bar 2 D L gen 3 1 IPS ECA879600 us Bar 1 T D gen 3 1 IPS ECA887200 0 6699 us 2 T D ge
121. year Original Main Power Rectifiers Control P C Boards 1 year All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year 160S 300S 400S Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year GENERAL ARC EQUIPMENT LABOR Water Recirculators 1 year Plasma Welding Torches 180 days Gas Regulators Supplied with power sources Nil MIG and TIG Torches Supplied with power sources Nil Replacement repair parts Nil MIG TIG and Plasma welding torch consumable items i Nil IHERMAL ARC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integra

ARCMASTER® 185 AC/DC 200 AC/DC Service Manual

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ARCMASTER&reg; 185 AC/DC 200 AC/DC Service Manual

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ARCMASTER® 185 AC/DC 200 AC/DC Service Manual