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186 AC/DC Operating Manual Inverter

1. Inside Rear Cover SAFETY INSTRUCTIONS 186 AC DC INVERTER SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS A WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUCTION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions oafe 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 practices 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 Arc Welding Hazards 9 Properly install and gro
2. Lo Rr 22 WZ 22 TI rout u A SEE TES Il ST ILLA 11221 ESS II 222 ZZ S p IS TZ SZ Ix TO A 11232 Figure 3 2 Rear Panel Manual 0 5237 959 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP 1 Positive Welding Terminal Positive Welding Terminal 2 50mm dinse Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 2 8 Pin Control Socket The 8 pin receptacle is used to connect a trigger switch or remote control to the welding Power Source circuitry To make connections align keyway insert plug and rotate threaded collar fully clockwise The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the 8 pin receptacle NOTE When not using a Remote disconnect any remote control device or it may limit the preview and actual output current range Socket Pin PartNumber Descripion 3 Trigger Switch Input Not used Remote Control 5k ohm Potentiometers Maximum 06 Remote Control 5k ohm Potentiometers Minimum Remote Control 5k ohm Potentiometer Wiper Table 3 2 8 Pin Control Plug Configuration
3. Duty Cycle PERCENTAGE 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 Welding Current AMPS A 11493 Figure 2 2 186 AC DC Duty Cycle Manual 0 5237 2 3 INTRODUCTION INTRODUCTION 2 09 Specifications 186 AC DC INVERTER Thermal Arc 186 AC DC INVERTER W1006300 Power Source Weight 48 4lbs 22 kg Fan Cooled Runs Continually Power Source Dimensions H15 5 xW9 45 xD18 7 H 400mm x W 240mm x D 475mm Applicable Standards Approvals CSA E60974 1 00 UL60974 1 IEC 60974 1 Number of Phases Nominal Supply Frequency 50 60Hz Welder Type Inverter Power Source Welding Current Range STICK Mode 9 170A DC Stick 5 200A DC TIG Welding Current Range TIG Mode Nominal Supply Voltage 208V Effective Input Current See Note 1 STICK TIG Maximum Input Current oingle Phase Generator Requirement See Note 2 STICK SMAW Welding Output 40 C 10 min GTAW Welding Output 40 C 10 min Open circuit voltage Protection Class 16 4A 16 5A 9 5KVA 7KW 170A Q 15 26 8V 100A 60 24 0V 80A 100 23 2V 200A 20 18V 116A 60 14 6V 90A Q 100 13 6V 230V 15 5A 14 1A 34 9A 32 4A 10 170A AC Stick 30 200 AC LIFT TIG 10 200A AC HF TIG 0 3 VDC 50VAC 235 Table 2 1 186 AC DC Specification Note 1 The Effective Input Current should be
4. 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 electrical 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 SAFETY INSTRUCTIONS AND WARNINGS 186 AC DC INVERTER 6 Turn face away from valve outlet when opening cylinder valve 7 Keep protective cap in place over valve except when cylinder is in use or connected for use 8 Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards A WARNING Engines can be dangerous WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Use equipment outside in open well ventilated areas 2 Ifusedina closed area vent engine exhaust outside and away from any building air intakes ENGINE FUEL cause fire or explosion WARNING Engine fuel is highly flammable 1 Stop engine before checking or adding fuel 2 Do not add fuel while smoking or if unit is near any sparks or open flames 3 Allow engine to coo
5. Current Frequency Current PURGE E TRIGGER AC FREQUENCY WAVE BALANCE ARC FORCE FORWARD 166 AC DC PORTABLE WELDING SYSTEM SYST ME SOUDER PORTABLE m Adjust programming parameter Press to go forward go back using the Multi Function Control knob between programming status D s 11497 AB Figure 3 6 LIFT TIG and HF TIG Programming Mode Programming Parameter Adjustment Device Pre Flow 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 0 0 to 1 0 second dramatically reduce weld porosity at the start of a weld Initial Current This parameter operates in 4T modes only and is used to set the start current for TIG The Start Current remains on until the Amps torch trigger switch is released after it has been depressed to 200 Amps DC TIG mode Note The maximum initial current 30 to 200 Amps AC LIFT TIG mode available will be limited to the set 10 to 200A AC HF TIG mode value of the weld current INSTALLATION OPERATION AND SETUP 3 12 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER _ Programming Parameter Adjustment Device Up Slope This parameter operates in 4T TIG modes only and is used to set the time for the weld current to ramp up after the torch trigger switch
6. 3 Negative Welding Terminal Negative Welding Terminal 50 mm dinse Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal 4 Shielding Gas Outlet The Shielding Gas Outlet located on the front panel is a 5 8 18 UNF female gas fitting and is utilized for the connection of a suitable TIG Torch 5 Power ON Indicator The POWER ON indicator illuminates when the ON OFF switch 20 is in the ON position and the correct mains voltage is present 6 Fault Indicator Thermal Overload or Primary Circuit Overcurrent The Fault Indicator will illuminate in conjunction with an Err 001 displayed on the ammeter and voltmeter digital displays if either of the following two conditions exists INSTALLATION OPERATION AND SETUP 3 6 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER 1 Thermal Overload This is due to the duty cycle of the power source being exceeded Once the power source cools sufficiently it will automatically reset and the Fault Indicator and Err 001 will go off and the power source is then able to continue welding During the time of cooling the power source should remain ON such that the fan continues to operate allowing the unit to cool sufficiently If afte
7. 50 5se 456 t5cfh 7V m __ 6 __ 6sec 456 t5cfh 7V m 10 150A 13sec S e 170A 13sec 180A 13sec 17 8 17 8 17 8 verter PORTABLE WELDING MACHINE Set Up Guide 50 5s 456 i5cfh 7Um 6 se 456 t5cfh zVm If Required Note LIFT TIG HF TIG set up guide parameters may vary depending upon welding position and joint design Pulse Set Up Guide Panel Set Up Guide SELECT MATERIAL BASE HIGH PROCESS SELECTION SELECTION METAL SIZE CURRENT WIDTH FREQUENCY CURRENT 60 1 Hz Pulse Select __6 50 1HzPulse 30A i 390 Mone 125A 65 1HzPulse 50A AC Mode AC or DC 195A 60 1HzPuise 75A Only un 85A 60 1HzPulse 40A 150A 60 tHzPuse 50A Note Butt or Fillet Joint types can be used in Pulse mode Set up guide parameters may vary depending upon welding position APPENDIX A 2 Manual 0 5237 APPENDIX 186 AC DC INVERTER STICK Set Up Guide SELECT MODE ELECTRODE ELECTRODE LIFT TIG HE TIG Notes PROCESS SELECTION SELECTION DIAMETER 2 4 mm 3 2 mm 4 0 mm Gas is 100 Pure Argon a Wave balance is 30 3 Weld Current Range 50 75A 70 110A 80 145A AC Mode Only Arc F
8. Figure 4 9 Typical Joint Designs for Arc Welding Manual 0 5237 4 3 BASIC WELDING GUIDE 186 AC DC INVERTER BASIC WELDING Arc Welding Technique A Word to Beginners For those who have not yet done any welding the simplest way to commence is to run beads on a piece of scrap plate Use mild steel plate about 1 4 6 0mm thick and a 1 8 3 2mm electrode Clean any paint loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position Make sure that the work clamp is making good electrical contact with the work either directly or through the work table For light gauge material always clamp the work lead directly to the job otherwise a poor circuit will probably result The Welder Place yourself in a comfortable position before beginning to weld Get a seat of suitable height and do as much work as possible sitting down Place the work so that the direction of welding is across rather than to or from your body The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down Be sure the insulation on your cable and electrode holder is not faulty otherwise you are risking an electric shock Striking the Arc Practice this on a piece of scrap plate before going on to more exacting work You may at first experience difficulty due to the tip of the electrode sticking to the work piece This is cause
9. Include all equipment identification numbers as de scribed above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 04 Description The Thermal Arc 186 AC DC is a single phase constant current welding inverter capable of performing SMAW STICK GTAW HF TIG and GTAW LIFT TIG welding processes The unit is equipped with digital amperage and voltage meters and a host of other features in order to fully satisfy the broad operating needs of the modern user The unit is also fully compliant to Standard CSA E 60974 1 00 and UL 60974 1 The 186 AC DC provides excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures The fol lowing instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source Please read these instructions thoroughly before using the unit INTRODUCTION INTRODUCTION 2 05 User Responsibility This equipment will perform as per the information con tained herein when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Defective equipment including welding leads should not be used Parts that are broken
10. Welding Power Supply Operating Manual Number 0 5237 for Thermal Arc 186 AC DC Machine Only Part Number W1006300 Thermal Arc 186 AC DC System Part Number W1006301 Thermal Arc 186 AC DC System W Cart Part Number W1006302 Thermal Arc 186 AC DC System W FT Control Part Number W1006303 Thermal Arc 186 AC DC System W FT Control amp Cart Part Number W1006304 Published by Victor Technologies Inc 16052 Swingley Ridge Road suite 300 St Louis MO 63017 USA www victortechnologies com Copyright 2012 2013 by Victor Technologies 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 September 29 2012 Revision AB Date February 4 2013 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 Arc Welding 1 1 1 02 General Safety Information For Victor CS 1 5 1 03 Principal Safety 9tandardS
11. 1 7 IP ee a 1 8 1 05 Precautions De Securite En Soudage A LAIC Ne 1 9 1 06 Dangers relatifs au soudage 1 9 1 07 Informations G n rales de 58 1 13 1 08 Principales Normes De Securite 42 20 1 15 109 Graphique SE eeu SR S 1 16 1 10 Declaration Of Conformity 1 17 SECTION 2 Dag iU NIU rr 2 1 2 01 How To Use This Manual 2 1 2 02 Equipment 2 1 2 03 Receipt of Equipment 2 1 204 DesCriphON Dni adr 2 1 2 05 User Responsibility eee 2 2 206 Transporting 05 22224442 eoe 2 2 2 07 Packaged MIS essence 2 2 URDU 2 3 er 2 4 210 Optional 2 5 2 11 Volt Ampere CUFV6S ne ee 2 6 SECTION 3 INSTALLATION OPERATION AND 5 3 1 3 01 3 1 3 02 0187 a NN eee 3 1 _______ _ ___ 3 1 3 04 Mains Supply Voltage Requirements 3 1 3 05 High Frequency Introduction usce cede eo aee dosi e Er tet baa 3 2 3 06 Frequency IDEE TETBRDB 3 3 3 07 Electromagnetic Compatibility end rotes 3 3 3 08 186 AC DC Power Source Controls Indica
12. Flow Flow Press amp hold Release Press amp hold Release Trigger Trigger Trigger Trigger A 11410_AB Figure 3 4 9 Wave Balance Arc Force Indicator This indicator light will illuminate when programming Wave Balance AC HF TIG mode only or Arc Force STICK mode only 10 Forward Programming Button Pressing this button will advance to the next step in the programming sequence 11 Multifunction Control The multifunction control knob is used to adjust welding current It is also used to adjust parameters when in programming mode 12 Back Programming Button Pressing this button will go back to the previous step in the programming sequence 13 AC frequency Indicator This indicator light will illuminate when programming AC Frequency AC HF TIG mode only 14 Purge Button Press the PURGE button to purge the gas line in LIFT and HF TIG modes To PURGE the shielding gas line in LIFT TlG and HF TIG modes press the PURGE button and release The indicator will illuminate and shielding gas will purge for a preset period of 15 seconds This cannot be adjusted To stop shielding gas from purging within this time press the PURGE button and release and the purge indicator will extinguish and shielding gas will cease INSTALLATION OPERATION AND SETUP 3 8 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER 15 Pulse Button Press the PULSE button to toggle Pulse On and OFF in LIFT TIG and HF TIG modes 16 Programming Paramete
13. 186 AC DC INVERTER BASIC WELDING Metal Being Joined Electrode Comments Mild Steel E6011 This electrode is used for all position welding or for welding on rusty dirty less than new metal It has a deep penetrating arc and is often the first choice for repair or maintenance work Mild Steel E6013 This all position electrode is used for welding clean new sheet metal Its soft arc has minimal spatter moderate penetration and an easy to clean slag Mild Steel E7014 All positional ease to use electrode for use on thicker steel than E6013 Especially suitable sheet metal lap joints and fillet welds general purpose plate welding A low hydrogen all position electrode used when quality is an issue orforhard to weld metals It has the capability of producing more uniform weld metal which has better impact properties at low temperatures Mild Steel E 018 Cast Iron Stainless Steel Welding Position Suitable for joining all cast irons except white cast iron E318L 16 High corrosion resistances Ideal for dairy work etc The electrodes dealt with in this publication can be used in most positions i e they are suitable for welding in flat horizontal vertical and overhead positions Numerous applications call for welds to be made in positions intermediate between these Some of the common types of welds are shown in Figures 4 5 through 4 12 Art A 07687 M
14. 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 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 Portez des v tements en mat riaux ignifuges et dura bles laine et cuir et des chaussures de s curit Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev 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 respi rer 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 relatives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ne travaillez dans un espace confin que s il est bien ventil 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 grais sage
15. E Poor work clamp con E Improve connection to work piece nection to work piece 10 Arc flutters during Tungsten electrode is Select the right size tungsten electrode welding too large for the weld Refer to Table 4 3 Tungsten Electrode ing current Selection Chart BASIC WELDING GUIDE 4 16 Manual 0 5237 SERVICE 186 AC DC INVERTER SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 9 01 Basic Troubleshooting A WARNING There are extremely dangerous voltage and power levels present inside this product Do not attempt to open or repair unless you are a qualified electrical tradesperson and you have had training in power measurements and troubleshooting techniques If major complex subassemblies are faulty then the Welding Power Source must be returned to an accredited Thermal Arc Service Provider for repair The basic level of troubleshooting is that which can be performed without special equipment or knowledge Refer also to section 4 for solving welding problems 5 02 Power Source Problems FAULT CAUSE REMEDY 1 Mains supply voltage is A Power source is not in the A Setthe power source to the ON power indicator is correct mode of operation correct mode of operation with illuminated however unit the process selection switch will not commence welding Faulty torch trigger B Repair or replace torch trigger when the torch trigger switch lead switch is depressed 2 Mains supply voltage is A Primary con
16. Connect the other end of the supplied gas hose to the gas inlet fitting on the rear panel of the welder and tighten with a wrench Caution DO NOT over tighten 8 Open the Argon Cylinder Valve to the fully open position 9 Connect the ground work clamp to your work piece 10 Set the DOWN SLOPE control knob to the desire weld current ramp down time 11 Set the weld current control knob to the desired amperage 12 The tungsten must be ground to a blunt point in order to achieve optimum welding results It is critical to grind the tungsten electrode in the direction the grinding wheel is turning 13 Install the tungsten with approximately 1 8 3 2mm 4 6 0mm sticking out from the gas cup ensuring you have correct sized collet 14 Tighten the back cap then open the valve on the torch 15 Plug the power cable into the appropriate outlet and turn the switch to the ON position The power L E D light should illuminate Set the Process Selection Switch to LIFT TIG 16 You are now ready to begin TIG Welding Manual 0 5237 3 21 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP NOTE When the 186 AC DC is used with a Remote Foot Control in depress foot control to maximum to allow max current to be previewed adjusted on the front panel To avoid premature arcing please ensure the Torch is located away from your work piece 3 15 Setup for STICK SMAW Welding A Connect the Electrode Holde
17. 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 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 adduction 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 Manual 0 5237 1 11 186 AC DC INVERTER AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE O UNE EXPLOSION L arc produit des tincellies et des pro Jections Les particules volantes le m tal chaud les projections de soudure et l qui pement surchauff peuvent causer un incen die et 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 Prot gez vous ainsi que les autres contre les tin celles et du m tal chaud Ne soudez pas dans un endroit o 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 soi gneusement 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 peti
18. material may reduce the welders output welding current POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 4 Manual 0 5237 186 AC DC INVERTER SPARE PARTS SECTION 6 KEY SPARE PARTS 6 01 Power Source A 11500 AC Figure 6 1 KEY SPARE PARTS 6 1 Manual 0 5237 186 AC DC INVERTER SPARE PARTS Mem Part Number Description ________ 1 W7005500 PCB display SSS ___2 WwWr005503 aux power supply __ O ___3 700552 PCBHE 2 4 W7005504 PCB186ACDC __ 2 5 WwWr005505 PCB AC output drive __ 22 6 W7005506 PCB control 0 0 22 ___8 W7005538 Side Panel 02 9 W7005509 Coil __ Table 6 1 KEY SPARE PARTS 6 2 Manual 0 5237 186 AC DC INVERTER CIRCUIT DIAGRAM APPENDIX APPENDIX 1 po JILUHW3HOS WALSAS 307939981 249 Ule 3H 3 v12 990 6 CNOI193S 10 41 05 80108340 3NUd LNOYS 3O AYOMLAY 00550024 3NUd 1 083 V O 1109 uL T oan St jH31NI 791235 6 2 NOSSIN NId OI NO88I3 NId 6 2 Ja3lNI 791035 NOWWOD 9d ba A w w w ec V D D m 5 OGA S E X T K AN K 4 gr D eee 2NOWWOI NNS pun D AlddNS N3MOd 3mnoA aw _ 35 131 T DamST ET mm gu P
19. starting Wider current ium magnesium and range Narrower more their alloys concentrated arc Table 4 5 Tungsten Electrode Types Base AC Current for Tungsten Filler Rod Diameter Argon Gas JOINT Metal Aluminium Electrode if required Flow Rate TYPE Thickness Diameter 1 16 60 80 1 16 1 16 15 CFM Butt Corner 1 6mm 70 90 1 6mm 1 6mm 7 LPM Lap Fillet 1 8 125 145 3 32 1 16 3 32 17 CFM Butt Corner 3 2mm 140 160 2 4mm 1 6mm 2 4mm 8 LPM Lap Fillet Table 4 6 Aluminium Welding Material Manual 0 5237 4 13 BASIC WELDING GUIDE 186 AC DC INVERTER BASIC WELDING Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Flow Joint Type Thickness for Mild Stainless Electrode Diameter if Rate Steel Steel Diameter required 0 040 35 45 20 30 0 040 1 16 10 CFH 5 LPM Butt Corner 1 0mm 40 50 25 35 1 0mm 1 6mm Lap Fillet 0 045 45 55 30 45 0 040 1 16 13 CFH 6 LPM Butt Corner 1 2mm 50 60 35 50 1 0mm 1 6mm Lap Fillet 1 16 60 70 40 60 1 16 1 16 15 CFH 7 LPM Butt Corner 1 6mm 70 90 50 70 1 6mm 1 6mm Lap Fillet 1 8 80 100 65 85 1 16 3 32 15 CFH 7 LPM Butt Corner 3 2mm 90 115 90 110 1 6mm 2 4mm Lap Fillet 3 16 115 135 100 125 3 32 1 8 21 CFH 10 LPM Butt Corner 4 6mm 140 165 125 150 2 4mm 3 2mm Lap Fillet 1 4 160 175 135 160 1 8 5 32 21 10 LPM Butt Corner 6 4mm 170 200 160 180 3 2mm 4 0mm Lap Fillet Table 4 7 Welding Rate TIG Welding is generally regarded as a speciali
20. 0 to 70A max 170A weld current e g HOT START current 130 amps when WELD 100 amps amp HOT START 30 amps Weld Current This parameter sets the TIG WELD current when PULSE is OFF This parameter also sets the STICK weld current Amps 5 to 170A DC STICK mode 10 to 170A AC STICK mode Arc Force STICK Mode only Arc Force is effective when in STICK Mode only Arc Force control provides and adjustable amount of Arc Force 0107 control This feature can be particularly beneficial in Volts providing the operator the ability to compensate for variability in joint fit up in certain situations 0 to 100 with particular electrodes In general increasing the Arc Force control toward 100 maximum Arc Force allows greater penetration control to be achieved Table 3 3 3 10 186 AC DC LIFT TIG and HF TIG Programming Mode Press the PROCESS SELECTION button to select LIFT TIG or HF TIG mode Press the MODE switch to toggle between AC and DC welding output Press FORWARD or BACK to cycle through available programming functions Use the Multi Function Control to adjust the parameter selected Manual 0 5237 3 11 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP THERMAL RC V SEC gt o Hz l PULSE PROCESS E Hier LIFT TIG m Curent Width LE Hot 1 f Down le Start si Low Ne Initial il gi pss Crater 7
21. 200 Amp Electrode Holder with 13ft 4m Lead e Tweco 200 Amp Work Clamp with 10ft 3m Lead 26 Torch 13ft 4m Lead with Integrated Controls amp Accessory e Oft 2 75m Power Cord and NEMA6 50P 230V AC Plug e Victor Argon Flow Gauge amp 12 5 ft 3 8m Hose e 4 General Purpose Stick Electrodes E6013 e Shoulder Strap Operating Manual amp CD e Thermal Arc Cap Figure 2 1 186 AC DC Packaged System Manual 0 5237 INTRODUCTION 186 AC DC INVERTER 2 08 Duty Cycle The rated duty cycle of a Welding Power Source is a statement of the time it may be operated at its rated weld ing current output without exceeding the temperature limits of the insulation of the component parts To explain the 10 minute duty cycle period the following example is used Suppose a Welding Power Source is designed to operate at a 20 duty cycle 200 amperes at 18 0 volts This means that it has been designed and built to provide the rated amperage 200A for 2 minutes i e arc welding time out of every 10 minute period 20 of 10 minutes is 2 minutes During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool The thermal cut out will operate if the duty cycle is exceeded 100 90 80 186 AC DC 70 60 SMAW STICK 40 30 SAFE OPERATING REGION TIG amp STICK GTAW TIG 20
22. 4 or darker to protect your eyes from injury and provide With care Serious accidents can result from good visibility of the work improper handling or misuse of compressed gas cylinders DO NOT arop the cylinder Always wear protective gloves and flame resistant clothing knock it over or expose it to excessive heat to protect skin and clothing from sparks and slag Keep flames or sparks DO NOT strike it against collars sleeves and pockets buttoned DO NOT roll up other cylinders Contact your gas supplier sleeves or cuff pants or refer to CGA P 1 Safe Handling of Com When working in a non welding or cutting environment pressed Gases in Containers publication always wear suitable eye protection or face shield NOTE CGA P 1 publication is available by writing the Compressed Gas Association 4221 WARNIN Walney Road 5th Floor Chantilly VA 20151 Practice the following safety and operation 2923 precautions EVERY TIME you use pressure regulation equipment Deviation from the following safety and operation instructions can result in fire explosion damage to equipment or injury to the operator E Compressed Gas Cylinders 3 Store empty cylinders away from full cylinders The Department of Transportation DOT approves the Mark them EMPTY and close the cylinder design and manufacture of cylinders that contain gases valve used for welding or cutting operations 4 NEVER use compressed gas cylinders without a pre
23. EN 60974 1 Safety in Welding and Allied Processes Part 2 Electrical This includes an insula tion resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc original specifications If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in EN 60974 1 then the above tests should be carried out prior to entering this location POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 2 Manual 0 5237 SERVICE 186 AC DC INVERTER A Testing Schedule 1 For transportable equipment at least once every 3 months and 2 For fixed equipment at least once every 12 months The owners of the equipment shall Keep a suitable record of the periodic tests and a system of tagging includ ing the date of the most recent inspection transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated B Insulation Resistance Minimum insulation resistance for in service Thermal Arc Inverter Power Sources shall be measured at a volt age of 500V between the parts referred to in Table 5 2 below Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met Minimum Insulation Components to be Tested Resistance Input circu
24. Hexible cord is of the multi core tough rubber or plastic sheathed type of adequate rating correctly connected and in good condition 2 Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short Circuit 3 The Welding System is clean internally especially from metal filing slag and loose material Manual 0 5237 5 3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 186 AC DC INVERTER SERVICE E Accessories Accessory equipment including output leads electrode holders torches wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition All unsafe accessories shall not be used F Repairs If any parts are damaged for any reason it is recommended that replacement be performed by an accredited Thermal Arc Service Provider Power Source Calibration A Schedule Output testing of all Thermal Arc Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall within specified levels Calibration intervals shall be as outlined below 1 For transportable equipment at least once every 3 months and 2 For fixed equipment at least once every 12 months If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in EN 60974 1 then the above tests should be carried out prior to entering this locatio
25. International Customer Care 940 381 1212 Form No 0 5237 12 07 12 2012 Victor Technologies International Inc www victortechnologies com Printed in China
26. LA 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 Manual 0 5237 SAFETY INSTRUCTIONS NOTE Considerations About Welding And The Effects of Low Frequency Electric and Mag netic Fields The following is a quotation from the General Conclu sions 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 very large volume of scientific findings based on experiments at the cel lular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with and produce changes in biologi cal 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
27. MOTT34 ENOWWOI ind SAUIS3ESH L 1 2m d TT 4 29 990 6 LAdLNO JE ees 9 3101 2055002 A3SUINOO3S 2 02v 990 6 J 92S 998 8 20SS 02M 949d 1 990 6 WU a V NTT 10 Cu dog T NOWWOD V 4 o 294Abe CN J o ac V V 20461 E 2 DGAST EH x DA 2 oo d mm CU dcl sans r3 TAN 1 0429 VINA E MO113A 72978 C 628 990 8 O 90 M d 4 4 4 4 a 990 8 JAAST O S82d 15004 0 002 72978 L 1 L aum fT 39 ARPENDIX 1 Manual 0 5237 A 11810 186 AC DC INVERTER APPENDIX APPENDIX 2 186 AC DC SETUP GUIDE LIFT TIG HF TIG Set Up Guide 6 SELECT MODE MATERIAL JOINT TUNGSTEN POST SELECT TIG PROCESS SELECTION SELECTION METAL SIZE TYPE FILLER ROD SIZE CURRENT FREQUENCY FLOW CUP SIZE GAS FLOW 65A 5sec 456 15cth 7Vm 85A 1504 456 15 71 135A 150Hz 11sec 160A 100Hz 13sec 170A 80Hz 13sec 200A 80Hz 135 200A 80Hz 13sec
28. contiennent des gaz protec teurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin 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 quipe ments et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation 1 12 SAFETY INSTRUCTIONS 8 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 AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGE REUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs 1 Util
29. cut D Replace gas hose E Gas passage contains E Disconnect gas hose from the rear of impurities Power Source then raise gas pressure and blow out impurities F Gas regulator turned F Turn on off G The electrode is too G Increase electrode diameter or reduce the small for the welding welding current current Power source is set for Set Power Source to LIFT or HF TIG STICK welding Manual 0 5237 4 15 BASIC WELDING GUIDE 186 AC DC INVERTER BASIC WELDING FAULT CAUSE REMEDY Dirty weld pool Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates piece or filler rod mate rial B Work piece surface Clean surface foreign material on it C Gas contaminated with C Check gas lines for cuts and loose fitting or change gas cylinder 8 Poor weld finish Inadequate shielding Increase gas flow or check gas line for gas gas flow problems 9 Arc start is not smooth A Tungsten electrode is Select the right size tungsten electrode too large for the weld Refer to Table 4 3 Tungsten Electrode ing current Selection Chart B The wrong electrode B Select the right tungsten electrode type is being used for the Refer to Table 4 5 Tungsten Electrode welding job Selection Chart C Gas flow rate is too C Select the right rate for the welding job high Refer to Table 4 7 D Incorrect shielding gas D Select the right shielding gas is being used
30. faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la 186 AC DC INVERTER 5 Utilisez la polarit correcte et de l accumulateur C A AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROI DISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour Laissez la pression s chapper avant d ter compl tement le bouchon 1 07 Informations G n rales de S curit Borie Pr vention D incendie Les op rations de soudage utilisent le feu ou la combustion comme outil de base Ce processus est tr s utile quand il est correctement contr l 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 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 d AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLO SER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lec trolyte acide et d gage
31. has been pressed then released from Initial Current to High or Weld current Weld Current This parameter sets the TIG WELD current when PULSE is OFF This parameter also sets the STICK weld current Amps 5 to 200A DC TIG mode 30 to 200A AC LIFT mode 10 to AC HF mode High Current This parameter sets the High weld current when in PULSE mode Amps 10 to 200A DC TIG mode 30 to 200A m mode Low Current The lowest point in the pulse is called the Low Current Amps 5 to 200A DC HF mode 30 to 200A AC LIFT TIG mode 10 to n AC HF mode Pulse Width This parameter sets the percentage on time of the PULSE FREQUENCY for High weld ss current when the PULSE is ON Volts 15 to 80 Pulse Frequency This parameter sets the PULSE FREQUENCY when the PULSE is ON Manual 0 5237 3 13 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP Rs Down Slope This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down after the torch Volts trigger switch has been pressed to crater current This control is 0 0 to 25 0 seconds used to eliminate the crater that can form at the completion of a weld Crater Current This parameter operates in 4T modes only and is used to set the finish current for TIG The CRATER Current remains Amps ON until the torch trigger switch is released a
32. metal adjacent to ma Welding arc is too long and has not been filled by the weld 0 metal undercut Angle of the electrode is incorrect Joint preparation does not D allow correct electrode angle Electrode too large for joint Insufficient deposit time at F edge of weave Small electrodes used on A heavy cold plate Portions of the weld run do not fuse to the surface of the metal or edge of the joint Welding current is too low B Wrong electrode angle Travel speed of electrode is too high ocale or dirt on joint surface Lack of fusion caused by dirt Art A 04972 electrode angle incorrect rate of travel too high Lack of inter run fusion 2 Lack of side fusion scale dirt small electrode amperage too low Lack of Root Fusion Gas pockets or voids in weld metal porosity High levels of sulphur in steel Electrodes are damp C Welding current is too high ourface impurities such as D oil grease paint etc Welding in a windy envi ronment Electrode damaged i e flux F coating incomplete Manual 0 5237 Reduce welding current Reduce the length of the welding arc Electrode should not be inclined less than 45 to the vertical face Allow more room in joint for manipulation of the electrode Use smaller gauge electrode Pause for a moment at edge of weave to allow weld metal buildup Use larger electrodes and preheat the plate In
33. ou des poussi res explosives B Entretien des Locaux A AVERTISSEMENT Ne laissez jamais l oxyg ne en contact avec la graisse l huile ou d autres substances inflammables Bien que l oxyg ne ellem me ne br le pas ces substances peuvent deve nir extr mement explosives Elles peuvent prendre feu et br ler violemment en pr sence Gardez Tous les appareils propres et exempts de graisse huile ou autres substances inflammables A AVERTISSEMENT Ventilez les zones de soudage chauffage et d coupage de facon ad quate pour viter l accumulation de gaz explosifs ou toxiques Certaines combinaisons de m taux rev te ments et gaz g n rent des fum es toxiques Utilisez un quipement de protection res piratoire dans ces circonstances Si vous soudez ou brasez lisez et assimilez la fiche technique de s curit de mat riau relative l allage de soudage brasage C A ration D Protection Personnelle Les flammes de gaz produisent une radiation infrarouge qui peut avoir un effet n faste sur la peau et particu li rement sur les yeux Choisissez des lunettes ou un masque avec des verres tremp s assombris au niveau 4 ou plus sombre pour prot ger vos yeux des dommages et garder une bonne visibilit sur le travail SAFETY INSTRUCTIONS AND WARNINGS 1 14 SAFETY INSTRUCTIONS Portez en permanence des gants de protection et des v tements ignifuges pour la protection de la peau et des v teme
34. regulator for damaged threads dirt dust grease oil or other flammable substances Remove dust and dirt with a clean cloth Be sure the inlet swivel filter is clean and in place Attach the regulator Figure 3 9 to the cylinder valve Tighten securely with a wrench A WARNING DO NOT attach or use the regulator if oil grease flammable substances or damage is present Have a Art A 09845 xU Figure 3 8 Regulator to Cylinder Valve 6 Before opening the cylinder valve turn the regulator adjusting screw counterclockwise until there is no pressure on the adjusting spring and the screw turns freely 7 Relief Valve where provided The relief valve is designed to protect the low pressure side of the regulator from high pressures Relief valves are not intended to protect downstream equipment from high pressures A WARNING DO NOT tamper with the relief valve or remove it from the regulator A WARNING Stand to the side of the cylinder opposite the regulator when opening the cylinder valve Keep the cylinder valve between you and the regulator For your safety NEVER STAND IN FRONT OF OR BEHIND A REGULATOR WHEN OPENING THE CYLINDER VALVE 8 Slowly and carefully open the cylinder valve Figure 3 9 until the maximum pressure shows on the high pressure gauge Manual 0 5237 3 17 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP Art A 09828 Figure 3 9 Open Cylinder Valve 9 Open the cy
35. shrinking volume and still be attached to the edge of the joint If the restraint is very great as for example in a heavy section of plate the weld metal may crack Even in cases where the weld metal does not crack Figure 4 20 Parent Metal Contraction Overcoming Distortion Effects There are several methods of minimizing distortion effects BASIC WELDING GUIDE there will still remain stresses Locked up in the structure If the joint material is relatively weak for example a butt joint in 5 64 2 0mm sheet the contracting weld metal may cause the sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone While welding is proceeding a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the surface of the plate i e through the weld but when it attempts to expand across the weld or along the weld it meets considerable resistance and to fulfil the desire for continued expansion it has to deform plastically that is the metal adjacent to the weld is ata high temperature and hence rather soft and by expanding pushes against the cooler harder metal further away and tends to bulge or is upset When the weld area begins to cool the Upset metal attempts to contract as much as it expanded but because it has been upset it does not resum
36. to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts 2 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 3 In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories B Environments with increased hazard of electric shock do not include places where electrically conductive parts 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 In areas free from moisture and dust B Ambient temperature between 0 C to 40 C C In areas free from oil steam and corrosive gases D In areas not subjected to abnormal vibration or shock In areas not exposed to direct sunlight or rain F Place at a distance of 12 300 mm or more from walls or similar that could restrict natural air flow for cooling Manual 0 5237 G Theenclosure design of this power source meets the requirements of P235 as outlined in EN 60529 This provides adequate protection against solid objects greater than 0 5 12mm and direct protection from vertical drops Under no circumstances should the unit be operated or connected in a micro e
37. 4 1 and IEC 60974 1 applicable to welding equipment and associated accessories e 2002 95 EC RoHS directive e Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Victor Technologies has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Tom Wermert Senior Brand Manager Thermal Arc Victor Technologies 16052 Swingley Ridge Road Chesterfield Missouri 63017 USA Intertek 3163339 RoHS Manual 0 5237 1 17 SAFETY INSTRUCTIONS AND WARNINGS 186 AC DC INVERTER SAFETY INSTRUCTIONS This page left blank intentionally SAFETY INSTRUCTIONS AND WARNINGS 1 18 Manual 0 5237 INTRODUCTION 186 AC DC INVERTER SECTION 2 INTRODUCTION 2 01 How To Use This Manual To ensure safe operation read the entire manual includ ing the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular atten tion to the information provided under these headings These special annotations are eas
38. Figure 4 1 Flat Position Down Hand Butt Weld Figure 4 2 Flat Position Gravity Fillet Weld i nt Art A 07691 Figure 4 5 Vertical Position Butt Weld Art A 07692 Figure 4 6 Vertical Position Fillet Weld Art A 07689 Art A 07693 Figure 4 7 Overhead Position Butt Weld Figure 4 4 Horizontal Vertical HV Position BASIC WELDING GUIDE 4 2 Manual 0 5237 BASIC WELDING 186 AC DC INVERTER Art A 07694 Figure 4 8 Overhead Position Fillet Weld Joint Preparations In many cases it will be possible to weld steel sections without any special preparation For heavier sections and for repair work on castings etc it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 9 Open Square Butt Single Vee Butt Joint Joint 1 16 1 6mm max Gap varies from 1 16 1 6mm to 3 16 4 8mm P depending on plate thickness 1 16 1 6mm PN Single Vee Butt Joint ida Double Vee Butt Joint ue 1 16 1 6mm max Lap Joint 1 16 nu Tee Joints Fillet Joint Fillet both sides of the joint Corner Weld Edge Joint J Plug Weld Plug Weld Art A 10672
39. G or HF Mode Note See Appendix A3 for TIG torch contents and trigger switch options Manual 0 5237 3 19 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP NOTE If the torch has a remote torch current control fitted then it will require to be connected to the 8 pin socket Refer to section 3 08 2 Remote Control Socket for further information E Fit the welding grade shielding gas regulator flowmeter to the shielding gas cylinder refer to Section 3 12 then connect the shielding gas hose from the regulator flowmeter outlet to the gas INLET on the rear of the 186 AC DC Power Source Connect the gas hose from the TIG torch to the gas OUTLET on the front of the 186 AC DC Power Source WARNING Before connecting the work clamp to the work make sure the mains power supply is switched off Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable Stationary support to prevent falling or tipping Negative Welding n Terminal Positive Welding Terminal A 11498 AB 8 Pin Control Socket Tig Torch Figure 3 10 Setup for TIG Welding INSTALLATION OPERATION AND SETUP 3 20 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER NOTE When the 186 AC DC is used with a Remote Foot Control in depress foot control to maximum to allow max current to be previewed adjusted on the front panel To avoid prematu
40. IHERMAL A RC INVERTER ARC WELDING MACHINE 180 AC DC PULSE Jy 2 210 caren PURGE fow FREQUENCY 9 BACK 8 2 lt Inverter Art A 11491 AB erating Manual Revision AB Issue Date February 4 2013 Manual No 0 5237 Operating Features C US LISTED INVERTER AC 208 1200 pene A X SC BE 50422 3163339 THERMAL ARC 4 WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Arc product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 462 2782 USA and 1 905 827 4515 Canada or visit us on the web at www thermalarc com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product We have made every effort to provide you with accurate instructions drawings and photographs of the product s while writing this manual However errors do occur and we apologize if there are any con
41. Metal Preflow Time Arc Welding SMAW t1 Gas Metal Arc V june Gas Tungsten Arc i 2 Step Trigger Hertz cycles sec Welding GTAW 4 Operation g Press to initiate wirefeed and Air Carbon Arc welding release to stop f Fe queney Cutting CAC A 9 E Ma Press hold for preflow release Constant Voltage to start arc Press to stop arc and Or Constant Potential hold for preflow Direct Current DC High Temperature V Protective Earth ee Fault Indication Ground Inches Per Minute Line Arc Force Meters Per Minute 115 15A Receptacle Rating NY Auxiliary Power Art A 04130 AB Note For environments with increased hazard of electrical shock Power Supplier bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed tips if equipped with properly installed standoff guides Cannot be with household garbage SAFETY INSTRUCTIONS AND WARNINGS 1 8 Manual 0 5237 SAFETY INSTRUCTIONS 186 AC DC INVERTER 1 05 Precautions De Securite En Soudage A 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 OU LES INST
42. ND SETUP 186 AC DC INVERTER INSTALLATION SETUP INSTALLATION OPERATION AND SETUP 3 24 Manual 0 5237 BASIC WELDING 186 AC DC INVERTER SECTION 4 BASIC WELDING GUIDE 4 01 STICK SMAW Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available Small welding machines will only provide sufficient current amperage to run the smaller size electrodes For thin sections it is necessary to use smaller electrodes otherwise the arc may burn holes through the job A little practice will soon establish the most suitable electrode for a given application Storage of Electrodes Always store electrodes in a dry place and in their original containers Electrode Polarity Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity The WORK LEAD is connected negative polarity and is connected to the work piece If in doubt consult the electrode data sheet or your nearest Accredited Thermal Arc Distributor Effects of Stick Welding Various Materials A High Tensile and Alloy Steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area and if suitable precautions are not taken the occurrence in this zone of under bead cracks Hardened zone and under bead cracks in the weld area may be reduced by using the correct electrode
43. RUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre 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 Z49 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez connaitre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 06 Dangers relatifs au soudage 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres l arc 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l
44. a gas hose to a regulated Shielding Gas Supply The shielding Gas inlet is located on the rear of the Power Source 22 Cooling Fan The 186 AC DC is fitted with a cooling fan that will operate continuously when the ON OFF switch on the rear panel is switched to the ON position 3 09 186 AC DC STICK Programming Mode Press the PROCESS SELECTION button to select STICK mode Press the MODE switch to toggle between AC and DC welding output Press FORWARD or BACK to cycle through available programming functions Use the Multi Function Control to adjust the Parameter selected While welding the Multi Function Control directly controls the WELD CURRENT THERMAL AR Ee PULSE mm dumme PROCESS MASERA O ali SI tow 8 mS PURGE Des TRIGGER 6 FREQUENCY WAVE BALANCE ARC FORCE 4 BACK 2 FORWARD 1664coc Inverter PORTABLE WELDING SYSTEM SYST ME SOUDER PORTABLE Adjust programming parameter Press to go forward go back between programming status LED s A 11496 AB Figure 3 5 Stick Programming Mode INSTALLATION OPERATION AND SETUP 3 10 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER trame Parameter 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 the Amps peak start current on top of the WELD current
45. ag pool from getting ahead of the arc To complete the joint in thin plate turn the job over clean the slag out of the back and deposit a similar weld 20 30 Electrode Tack Weld AH Tack Weld Art A 07697 AB Figure 4 11 Butt Weld Art A 07698 Figure 4 12 Weld Build up Sequence Heavy plate will require several runs to complete the joint After completing the first run chip the slag out and clean the weld with a wire brush It is important to do this to prevent slag being trapped by the second run oubsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4 12 The width of weave should not be more than three times the core wire diameter of the electrode When the joint is completely filled the back is either machined ground or gouged out to remove slag which may be trapped in the root and to prepare a suitable joint for depositing the backing run If a backing bar is used it is not usually necessary to remove this since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld Manual 0 5237 4 5 BASIC WELDING GUIDE BASIC WELDING GUIDE 186 AC DC INVERTER B Fillet Welds These are welds of approximately triangular cross section made by depositing metal in the corner of two faces meeting at right angles Refer to Figure 4 4 piece of angle iron is a suitable specimen with which to begin or tw
46. ame time the electrode has to move along the plate to form a bead The electrode is directed at the weld pool at about 20 from the vertical The rate of travel has to be adjusted so that a well formed bead is produced If the travel is too fast the bead will be narrow and strung out and may even be broken up into individual globules If the travel is too slow the weld metal piles up and the bead will be too large BASIC WELDING GUIDE 4 4 Manual 0 5237 BASIC WELDING 186 AC DC INVERTER Making Welded Joints Having attained some skill in the handling of an electrode you will be ready to go on to make up welded joints A Butt Welds Set up two plates with their edges parallel as shown in Figure 4 11 allowing 1 16 1 6mm to 3 32 2 4mm gap between them and tack weld at both ends This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment Plates thicker than 1 4 6 0mm should have their mating edges bevelled to form a 70 to 90 included angle This allows full penetration of the weld metal to the root Do not weave the electrode but maintain a steady rate of travel along the joint sufficient to produce a well formed bead At first you may notice a tendency for undercut to form but keeping the arc length short the angle of the electrode at about 20 from vertical and the rate of travel not too fast will help eliminate this The electrode needs to be moved along fast enough to prevent the sl
47. and la bouteille pourrait se renverser Quand vous ouvrez fermez rapidement la vanne de bouteille ne vous tenez pas directement devant Op rez toujours cette op ration dans une zone bien ventil e Si une bouteille d ac tyl ne crache un brouillard laissez reposer pendant 15 minutes Essayez de nouveau la vanne Si le probl me persiste contactez votre four nisseur de gaz 1 08 Principales Normes De Securite Safety in Welding and Cutting norme ANSI 449 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 oafety and Health Standards OSHA 29 CFR 1910 Supe rintendent 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 docu ment P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Association canadienne de normalisation Stan dards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection norme ANSI Z87 1 American National otandards Ins
48. ased A filler metal may also be added manually in some circumstances depending on the welding application A 09658 AB Gas Cup Either Ceramic Work Piece High Impact or Can Be Any Commercial Water Cooled Metal Tungsten Electrode Non Consumable Welds Made With or Without Addition of Filler Metal Inert Gas Shields Electrode and Weld Puddle Figure 4 28 TIG Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0mm 30 60 1 16 1 6mm 60 115 Table 4 3 Current Ranges for Various Tungsten Electrode Sizes BASIC WELDING GUIDE 4 12 Manual 0 5237 BASIC WELDING 186 AC DC INVERTER Guide for Selecting Filler Wire Diameter Filler Wire Diameter DC Current Range Amps 1 16 1 6mm 20 90 1 6mm 3 32 2 4mm 65 115 1 8 3 2mm 100 165 3 16 4 8mm 200 350 Table 4 4 Filler Wire Selection Guide Tungsten Electrode Types Electrode Type sons Ground Finish Welding Application Color Code DC welding of mild Excellent arc starting Thoriated 2 steel stainless steel Long life High current and copper carrying capacity High quality AC weld Self cleaning Long ing of aluminium life Maintains balled magnesium and their end High current car alloys rying capacity Zirconated 1 AC amp DC welding of Longer life More mild steel stainless stable arc Easier Ceriated 2 steel copper alumin
49. athing these fumes and gases can be recommended hazardous to your health AWS F2 2 2001 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Numbers Minimum Suggested B Protective Shade No Shade Comfort Less than 3 32 2 4 Less than 60 7 Shielded Metal Arc Welding 3 32 5 32 2 4 4 0 60 160 8 10 SMAW 5 32 1 4 4 0 6 4 160 250 10 12 More than 1 4 6 4 290 550 11 14 Less than 60 1 60 160 10 11 160 250 10 12 250 550 10 14 Gas Metal Arc Welding GMAW and Flux Cored Arc Welding FCAW Less than 50 8 10 50 150 8 12 150 500 10 14 2 Gas Tungsten arc Welding GTAW Less than 10 1 Air Carbon Arc Cutting CAC A 500 11 14 00 1000 Less than 20 6 6 to 8 20 100 8 10 100 400 12 400 800 14 Less than 20 4 20 40 5 40 60 6 Plasma Arc Cutting PAC 60 80 8 80 300 9 300 400 12 400 800 14 Asa rule of thumb start with a shade that is too dark to see the weld zone Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum In oxyfuel gas welding cutting or brazing where the torch and or the flux produces a high yellow light it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum Plasma Arc Welding PAW SAFETY INSTRUCTIONS AND WARNINGS 1 2 0 5237 SAFETY INSTRUCTIONS 1 Keep your head out of the fumes Do not breat
50. ator for use with any other gas NOTE Regulators purchased with open 1 6 1 4 3 6 or 1 2 NPT ports must be assembled to their intended system 1 Note the maximum inlet pressure stamped on the regulator DO NOT attach the regulator to a system that has a higher pressure than the maximum rated pressure stamped on the regulator 2 The regulator body will be stamped IN or HP at the inlet port Attach the inlet port to the system supply pressure connection 3 If gauges to be attached to the regulator and the regulator is stamped and listed by third party i e UL or The following requirements must be met a Inlet gauges over 1000 PSIG 6 87 mPa shall conform with the requirements of UL 404 Indicating Pressure Gauges for Compressed Gas Service b Low pressure gauges must be UL recognized for the class of regulator they are being used on accord ing to UL252A INSTALLATION OPERATION AND SETUP 3 16 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER A WARNING DO NOT use a regulator that delivers pressure exceeding the pressure rating of the downstream equipment unless provisions are made to prevent over pressurization i e system relief valve Make sure the pressure rating of the downstream equipment is compatible with the maximum delivery pressure of the regulator 4 Besure that the regulator has the correct pressure rating and gas service for the cylinder used 5 Carefully inspect the
51. ch as filtering of the Electricity Supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure Maintenance of Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions Welding Cables The welding cables should be kept as short as possible and should be positioned close together but never coiled and running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing grounding of the Work Piece Where the work piece is not bonded to earth
52. crease welding current Adjust angle so the welding arc is directed more into the base metal Reduce travel speed of electrode Clean surface before welding Figure 2 Example of Lack of Fusion Use an electrode that is designed for high sul phur steels Dry electrodes before use Reduce welding current Clean joint before welding Shield the weld area from the wind Discard damaged electrodes and only use elec trodes with a complete flux coating BASIC WELDING GUIDE 186 AC DC INVERTER BASIC WELDING FAULT CAUSE REMEDY Crack occurring in A Rigidity of joint Redesign to relieve weld joint of severe stresses weld metal soon or use crack resistance electrodes after solidification B insufficient throat thick Travel slightly slower to allow greater build up in commences ness throat C Weld current is too high C Decrease welding current Art A 04973 Not cleaned or Slag trapped in incorrect undercut eiectrode Figure 3 Example of Slag Inclusion Table 4 2 Welding Problems SMAW STICK 4 03 TIG GTAW Basic Welding Technique Gas Tungsten Arc Welding GTAW or TIG Tungsten Inert Gas as it is commonly referred to is a welding process in which fusion is produced by an electric arc that is established between a single tungsten non consumable electrode and the work piece Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon b
53. d by making too heavy a contact with the work and failing to withdraw the electrode quickly enough A low amperage will accentuate it This freezing on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck As soon as the arc is established maintain a 1 16 1 6mm to 1 8 3 2mm gap between the burning electrode end and the parent metal Draw the electrode slowly along as it melts down Another difficulty you may meet is the tendency after the arc is struck to withdraw the electrode so far that the arc is broken again A little practice will soon remedy both of these faults Figure 4 10 Striking an Arc Arc Length The securing of an arc length necessary to produce a neat weld soon becomes almost automatic You will find that a long arc produces more heat A very long arc produces a crackling or spluttering noise and the weld metal comes across in large irregular blobs The weld bead is flattened and spatter increases A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in If this should happen give the electrode a quick twist back over the weld to detach it Rate of Travel After the arc is struck your next concern is to maintain it and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away At the s
54. e its former shape and the contraction of the new shape exerts a strong pull on adjacent metal Several things can then happen The metal in the weld area is stretched plastic deformation the job may be pulled out of shape by the powerful contraction stresses distortion or the weld may crack in any case there will remain locked up stresses the job Figures 4 19 and 4 20 illustrate how distortion is created 4 8 A Peening This is done by hammering the weld while it is still hot The weld metal is flattened slightly and because of this the tensile stresses are reduced a little The effect of peening is relatively shallow and is not advisable on the last layer B Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out oee Figures 4 20 through 4 23 for various weld sequences Choice of a suitable weld sequence is probably the most effective method of overcoming distortion although an unsuitable sequence may exaggerate it Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion C Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some cases to tell from past experience or to find by tr
55. e liability of VICTOR TECHNOLOGIES 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 VICTOR TECHNOLOGIES whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY VICTOR TECHNOLOGIES PRODUCT THISWARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the paces 1 extend more than the time stated plus 1 year from the date VICTOR TECHNOLOGIESO delivered the product to the authorized distributor WARRANTY SCHEDULE IHERMAL Arc 5 Years Parts 3 Years Labor ArcMaster Excelarc Fabricator Fabstar PowerMaster Portafeed Ultrafeed Ultima 150 WC 100B 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards 3 years on Power Supply Components 2 Years Parts and Labor Unless specified Auto Darkening Welding Helmet electronic Lens 1 Month Harness Assy Victor Regu
56. eavily oxidized aluminium or magnesium alloys is achieved when the WAVE BALANCE is set to 65 Wave Balance 50 Wave Balance 10 Wave Balance 65 50 90 35 Balanced with 50 penetration Maximum Penetration and Maximum Cleaning and and 50 cleaning reduced cleaning reduced penetration LY ER A 11223 Table 3 5 AC TIG Wave Balance Manual 0 5237 3 15 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP 3 11 Short Circuit Protection While Welding To prolong the useful life of a TIG tungsten electrode and eliminate tungsten contamination to welding point the 186 AC DC incorporates special circuitry In all TIG processes after the welding arc has established if the tungsten electrode touches the work the current defaults to 33 amps If the short exists for more than 1 2 seconds the output is turned off In STICK mode if the electrode touches the work for more than two seconds the welding current is reduced to 0 Amps 3 12 Victor Regulator Pressure regulator Figure 3 7 attached to the cylinder valve reduce high cylinder pressures to suitable low working pressures for welding cutting and other applications HIGH PRESSURE FLOW GAUGE GAUGE SUPPLY INLET CONNECTION OUTLET CONNECTION ADJUSTING SCREW A 09414_AB Figure 3 7 Victor CS Regulator WARNING Use the regulator for the gas and pressure for which it is designed NEVER alter a regul
57. essment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account 1 Other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment Radio and television transmitters and receivers Computer and other control equipment Safety critical equipment e g guarding of industrial equipment The health of people around e g the use of pace makers and hearing aids Equipment used for calibration and measurement Manual 0 5237 3 3 INSTALLATION OPERATION AND SETUP C A N 186 AC DC INVERTER INSTALLATION SETUP f 8 The time of day that welding or other activities are to be carried out The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional protection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises C 1 Methods of Reducing Electromagnetic Emissions Electricity Supply Welding equipment should be connected to the Electricity Supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions su
58. 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 Keep welding Power Source and cables as far away from body as practical SR The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete Information ABOUT PACEMAKERS Manual 0 5237 186 AC DC INVERTER 1 02 General Safety Information For Victor CS Regulator A Fire Prevention Welding and cutting operations use fire or combustion as a basic tool The process is very useful when properly controlled However it can be extremely destructive if not performed correctly in the proper environment 1 The work area must have a fireproof floor 2 Work benches or tables used during welding or cutting operations must have fireproof tops Useheat resistant shields or other approved mate rial to protect nearby walls or unprotected flooring from sparks and hot metal Keepan approved fire extinguisher of the proper size and type in the work area Inspect it regu larly to ensure that it is in proper working order Know how to use the fire extinguisher Move combustible materials away from the work site If you can not move them protect them with fireproof covers A WARNING NEVER perform welding heating or cut ting ope
59. for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the work piece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by direct connection to the work piece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations ecreening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening the entire welding installation may be considered for special applications INSTALLATION OPERATION AND SETUP 3 4 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER 3 08 186 AC DC Power Source Controls Indicators and Features 19 19 5 V SEC PROCESS TRIGGER Crater Current Post Flow CT WAVE BALANCE aN ARC FORCE FORWARD GO Q 4 Figure 3 1 Controls on Front Panel A T
60. fter it has been 9 to 200A DC TIG mode depressed 30 to 200A AC TIG mode Note The maximum crater 10 to 200A AC HF TIG mode current available will be limited to the set value of the weld current 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 electrode AC Frequency This parameter operates in AC mode only and is used to set the frequency for the AC weld current INSTALLATION OPERATION AND SETUP 3 14 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER Wave Balance This parameter operates in AC TIG mode and is used to set the penetration to cleaning action ratio for the weld current Volts Generally WAVE BALANCE is set 10 to 65 to 50 from the factory for AC TIG Welding The WAVE BALANCE control changes the ratio of penetration to cleaning action of the AC TIG welding arc Maximum weld penetration is achieved when the WAVE BALANCE control is set to 10 Maximum cleaning of heavily oxidized aluminium or magnesium alloys is achieved when the WAVE BALANCE control is set to 65 Table 3 4 WAVE BALANCE is used for aluminium welding in AC HF TIG or AC LIFT TIG mode It is used to set the ratio of penetration to cleaning action for the AC TIG welding arc Maximum weld penetration is achieved when the WAVE BALANCE is set to 10 Maximum cleaning of h
61. h trigger switch to cease welding NOTE When operating in GTAW HF and LIFT modes the power source will remain active until the selected down slope time has elapsed AMPS High Current Low Current Arc Terminated Minimum Current TIME Le Post re Arc Ignited OW Flow A 11409 Press amp hold Release Trigger Trigger Figure 3 3 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue In this mode the operator can press and release the torch trigger and the output will remain active To deactivate the power source the Manual 0 5237 3 7 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP trigger switch must again be depressed and realized thus eliminating the need for the operator to hold the torch trigger Note that when operating GTAW HF and LIFT TIG modes the power source will remain activated until the selected down slope time has elapsed NOTE This Up Slope operates in 4T 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 Current to High or Wela Current AMPS High Current Weld Current Down Up Slope Arc Terminated Initial Slope Current Crater Current TIME Post Pre
62. haser used replacement parts or accessories which in VICTOR TECHNOLOGIES s Sole judgment impaired the safety or performance of any VICTOR TECHNOLOGIES product Purchaser s rights under this warranty are void if the product is sold to purchaser by unauthorized persons This page left blank intentionally THE AMERICAS Denton TX USA U S Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Miami FL USA Sales Office Latin America Ph 1 954 727 8371 Fax 1 954 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 VICTOR TECHNOLOGIES INNOVATION TO SHAPE THE WORLD U S Customer Care 800 426 1888 Canada Customer Care 905 827 4515
63. he the fumes finside 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 containing these elements can give off toxic fumes If welded Te 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 WARNING Protect yourself and others from flying sparks and hot metal Do not weld where flying spar
64. he Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 SAFETY INSTRUCTIONS AND WARNINGS 186 AC DC INVERTER SAFETY INSTRUCTIONS 1 04 Symbol Chart Note that only some of these symbols will appear on your model Wire Feed Towards Off 3 Three Phase Workpiece With Output Voltage Off Three Phase Static Dangerous Voltage Frequency Converter Welding Gun Transformer Rectifier Continuous Weld FAI Spot Weld Mode 2 Wire Feed Function Circuit Breaker AC Auxiliary Power A Shielded
65. his page left blank intentionally APPENDIX A 4 Manual 0 5237 STATEMENT OF WARRANTY Effective 08 01 2011 This warranty supersedes all previous VERRE VICTOR TECHNOLOGIES warranties LIMITED WARRANTY VICTOR TECHNOLOGIES warrants that its products will be free of defects in 2 or material Should any failure to conform to this warranty appear within the time period applicable to the VICTOR TECHNOLOGIES products as stated below VICTOR TECHNOLOGIES shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with VICTOR TECHNOLOGIES S specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at VICTOR TECHNOLOGIES s sole option of any components or parts of the product determined by VICTOR TECHNOLOGIES to be defective THISWARRANTYISEXCLUSIVEANDISINLIEUOF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY VICTOR TECHNOLOGIES shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of urchased or replacement goods or claims of customers of distributor hereinafter Purchaser or service interruption The remedies of the Purchaser set forth herein are exclusive and th
66. ial and error or less frequently to calculate how much distortion will take place in a given welded structure By correct pre setting of the components to be welded constructional stresses can be made to pull the parts into correct alignment A simple example is shown in Figure 4 21 Manual 0 5237 BASIC WELDING 186 AC DC INVERTER E Preheating Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion Figure 4 22 shows a simple NN application By removing the heating source from b e and c as soon as welding is completed the sections Block Sequence The spaces between the welds are b and c will contract at a similar rate thus reducing filled in when the welds are cool distortion Figure 4 24 Welding Sequence Preheat Dotted lines show effect if no preheat is used Figure 4 22 Reduction of Distortion by Preheating Art A 07709 Figure 4 23 Examples of Distortion Figure 4 27 Staggered Intermittent Welding Manual 0 5237 4 9 BASIC WELDING GUIDE 186 AC DC INVERTER 4 02 STICK SMAW Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current varying A gap is left by failure of the weld metal to fill the root of the weld Non metallic par ticles are trapped in the weld metal Incorrect sequence Insufficient gap BASIC WELDING GUIDE ARC FORCE control knob is set at a value that causes the welding current to va
67. ily recognized as follows WARNING gives information regarding possible personal injury A CAUTION A CAUTION refers to possible equipment damage NOTE A NOTE offers helpful information concern ing certain operating procedures You will also notice icons from the safety section ap pearing throughout the manual These are to advise you of specific types of hazards or cautions related to the portion of information that follows Some may have multiple hazards that apply and would look something like this 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 control panel In some cases the nameplate may be attached to the rear panel or bot tom of the machine Equipment which does not have a control panel such as gun and cable assemblies is identi fied only by the specification or part number printed on the shipping container Record these numbers on the bottom of page ii for future reference Manual 0 5237 2 03 Receipt of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the back cover of this manual
68. installer ou d en faire D l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter ____ AVERTISSEMENT une mise en marche accidentelle L ELECTROCUTION PEUT ETRE MORTELLE 5 Veuillez installer cet quipement et le mettre Une d charge lectrique peut tuer ou la terre selon le manuel d utilisation et les codes br ler gravement L lectrode et le circuit nationaux provinciaux et locaux applicables de soudage sont sous tension d s la mise 6 Arr tez tout quipement apr s usage Coupez l ali en circuit Le circuit d alimentation et les mentation de l quipement s il est hors d usage ou circuits internes de l quipement sont aussi inutilis sous tension d s la mise en marche En soudage automatique ou semi automatique 7 N utilisez que des porte lectrodes bien isol s Ne avec fil ce dernier le rouleau ou la bobine jamais plonger les porte lectrodes dans l eau pour de fil le logement des galets d entrainement les refroidir Ne jamais les laisser tra ner par terre ou et toutes les pi ces m talliques en contact sur les pi ces souder Ne touchez pas aux porte avec le fil de soudage sont sous tension lectrodes raccord s deux sources de courant en Un quipement inad quatement install ou m me temps Ne jamais toucher quelqu un d autre inad quatement mis la terre est dangereux avec l lectrode ou le porte lectrode 1 Ne touchez pas des pi ces sou
69. isez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b ti ment LE CARBURANT PEUR CAUSER UN INCEN DIE O UNE EXPLOSION AVERTISSEMENT Le carburant est hautement inflammable Arr tez le moteur avant de v rifier le niveau e car burant ou de faire le plein Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue oi c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur Manual 0 5237 SAFETY INSTRUCTIONS AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pieces en mouvement tels des ventila teurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s Avant d installer ou de connecter un syst me arr tez le moteur Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour
70. it including any connected control circuits to welding circuit including any connected control circuits All circuits to exposed conductive parts Welding circuit including any connected control circuits to any auxiliary circuit which operates at a voltage not exceeding extra low voltage Separate welding circuit to separate welding circuit Table 5 2 Minimum Insulation Resistance Requirements Thermal Arc Inverter Power Sources C Earthing Welding circuit including any connected control circuits to any auxiliary circuit which operates at a voltage exceeding extra low voltage The resistance shall not exceed 10 between any metal of a power source where such metal is required to be earthed and 1 The earth terminal of a fixed power source or 2 The earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring the integrity of fixed wiring sup plying Thermal Arc welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below 1 For outlets wiring and associated accessories supplying transportable equipment at least once every 3 months and 2 Foroutlets wiring and associated accessories supplying fixed equipment at least once every 12 months D General Maintenance Checks Welding equipment should be regularly checked by an accredited Thermal Arc Service Provider to ensure that 1
71. ks 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 Bealert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Manual 0 5237 9 186 AC DC INVERTER Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes 10 Remove stick electrode from holder or cut off 1 2 welding wire at contact tip when not in use Ah gt 2 WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended Wear proper body protection to protect skin re 7 WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully
72. l before fuelling If possible check and add fuel to cold engine before beginning job 4 Donotoverfill tank allow room for fuel to expand 5 Do not spill fuel If fuel is spilled clean up before starting engine WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing SAFETY INSTRUCTIONS AND WARNINGS 1 4 SAFETY INSTRUCTIONS 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 9 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery 2 Stop engine before disconnecting or connecting battery cables 3 Do not allow tools to cause sparks when working on a battery 4 Do not use welder to charge batteries or jump start vehicles 9 Observe correct polarity and on batteries C F e
73. lator for Fabricator 181i No labor 1 Years Parts and Labor Unless specified 95S Water recirculators All Plasma Welding consols i e WC 1 Controller WT Timer WF 100 Capstain Feeder etc 180 days parts and Labor Unless specified Plasma Welding Torch and leads packages Gas Regulators Supplied with power sources No Labor 90 days parts No Labor Remote Controls MIG and TIG Torches Supplied with power sources Replacement repair parts 30 days parts No Labor MIG Torch for Fabricator 181i 5 2 1 years Parts No Labor FirePower Welders VICTOR 5 Years Parts No Labor Victor Professional Victor Technologies limited warranty shall not apply to Consumable Parts for MIG TIG Plasma welding Plasma cutting and Oxy fuel torches O rings fuses filters or other parts that fail due normal wear Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized VICTOR TECHNOLOGIES repair facility within thirty 30 days of the repair No employee agent or representative of VICTOR TECHNOLOGIES is authorized to change this warranty in any way or grant any other warranty and VICTOR TECHNOLOGIES shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfillment of VICTOR TECHNOLOGIES s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purc
74. les Contactez votre fournisseur de gaz ou reportezvous la publication CGA P 1 Manipulation s curis e des gaz compri m s en conteneur pour plus d informations Sur l utilisation et la manutention des bouteilles AVIS Ce document CGA p t peut tre obtenu en crivant Compressed Gas Association 4221 Walney Roed 5th Floor Chantilly VA 20151 2923 USA Placez le bouchon de protection de vanne sur la bouteille chaque fois que vous la d placez ou ne l utilisez pas Ne faites jamais glisser ou rouler d aucune mani re les bouteilles Utilisez un diable appropri pour les d placer Entreposez les bouteilles vides l cart des bou teilles pleines Marquez les VIDE et refermez leur vanne N utilisez JAMAIS des bouteilles de gaz comprim sans un r gulateur de pression en s rie sur la vanne de bouteille Inspectez la vanne de bouteille pour y d tec ter de l huile ou de la graisse ou d s pi ces endommag es A AVERTISSEMENT N UTILISEZ PAS la bouteille si vous trou vez de l huile de la graisse ou des pi ces endommag es Informez imm diatement votre fournisseur de gaz de cet tat 6 Ouvrez et fermez momentan ment la vanne de la bouteille d logeant ainsi d ventu Iles pous si res ou salet s qui pourraient tre pr sentes dans la vanne Manual 0 5237 1 15 186 AC DC INVERTER A Mise en Garde Ouvrez la vanne de bouteille l g rement Si vous l ouvrez trop en gr
75. linder valve completely to seal the valve packing On gaugeless regulators the indicator will register the cylinder contents open Keep the cylinder valve wrench if one is required on the cylinder valve to turn off the cylinder quickly If necessary 10 Attach the desired downstream equipment 3 13 Specification for TIG Torch 1 SPECIFICATION FOR TIG TORCH PART NO W4013600 TO SUIT THERMAL ARC 186AC DC TIG Torch Contents include 1x26 TIG Torch with Long Back Cap 12 5 ft lead length 10 5 gas hose length 9 5 control lead with 8 pin plug and Rigid Head Remote Control Cartridge Potentiometer with integrated on off switch installed A 11556 NOTE The additional switches controls below are interchangeable with the installed control in the TIG torch INSTALLATION OPERATION AND SETUP 3 18 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER ART A 11587 Control module with Control module with Control module with push button on off push button on off switch roller potentiometer and switch only with roller potentiometer integrated on off switch Additional On Off Switch Cartridge in a Sealed Plastic Bag Additional On Off Switch Remote Amperage Control Cartridge in a Sealed Plastic Bag NOTE You will not be able to view the pre set amperage on the power source with this control amperage will not be viewable until the arc is initiated D A 11557 2 VR 1 x Accessory Kit contai
76. ll automatically Illuminating reset and the Fault Indicator and TN Err 001 will go off and the power source is then able to continue welding During the time of cooling the power source should remain ON such that the fan continues to operate allowing the unit to cool sufficiently If after 30 minutes with the fan running the Fault Indicator has not gone OFF then have an Accredited Thermal Arc Service Provider check the power source B Primary Circuit Overload This is due to primary circuit component s malfunctioning which results in excessive primary circuit current Switch the power source to OFF immediately to allow all components to cool down for at least 30 minutes If after 30 minutes Err 001 is displayed and Fault Indicator illuminates when the power source is switched back ON turn the power source OFF and have an Accredited Thermal Arc Service Provider check the power source Table 5 1 Power Source Problem 5 03 Routine Service and Calibration Requirements A WARNING There are extremely dangerous voltage and power levels present inside this Inverter Power Source Do not attempt to open or repair unless you are an accredited Thermal Arc Service Provider Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling Routine Inspection Testing amp Maintenance The inspection and testing of the power source and associated accessories shall be carried out in accordance with Section 5 of
77. llic 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 07 Electromagnetic Compatibility WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation A Installation and Use Users Responsibility The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the welding circuit see NOTE below In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer Troublesome NOTE The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment B Ass
78. missing plainly worn distorted or contaminated should be replaced immediately Should such repairs or replacements become necessary it is recommended that such repairs be carried out by ap propriately qualified persons approved by Thermal Arc Advice in this regard can be obtained by contacting an Accredited Thermal Arc Distributor This equipment or any of its parts should not be altered from standard specification without prior written ap proval of Thermal Arc The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modifica tion from standard specification faulty maintenance damage or improper repair by anyone other than ap propriately qualified persons approved by Thermal Arc 2 06 Transporting Methods This unit is equipped with a handle for carrying pur poses gt gt WARNING ELECTRIC SHOCK can kill DO NOT TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving the welding power source Ne WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage gt Lift unit with handle on top of case Use handcart or similar device of adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting INTRODUCTION 186 AC DC INVERTER 2 07 Packaged Items e 186 AC DC Inverter Power Source e weco
79. n B Calibration Requirements Where applicable the tests outlined in Table 5 3 below shall be conducted by an accredited Thermal Arc service provider Testing Requirements Output current A to be checked to ensure it falls within applicable Thermal Arc power source specifica tions Output Voltage V to be checked to ensure it falls within applicable Thermal Arc power source specifica Accuracy of digital meters to be checked to ensure it falls within applicable Thermal Arc power source Table 5 3 Calibration Parameters Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified C Calibration Equipment All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question Only test equipment with valid calibration certificates NATA certi fied laboratories shall be utilized 5 04 Cleaning the Welding Power Source A WARNING There are dangerous voltage and power levels present inside this product Do not attempt to open or repair unless you are a qualified electrical tradesperson Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling To clean the Welding Power Source open the enclosure and use a vacuum cleaner to remove any accumulated dirt metal filings slag and loose material Keep the shunt and lead screw surfaces clean as accumulated foreign
80. ning 1 x Short Back Cap 1 x Collet Body 1 8 3 2mm 1 x Collet Body 3 32 2 4mm 1 x Collet Body 1 16 1 6mm 1 x Collet 1 8 3 2mm 1 x Collet 3 32 2 4mm 1 x Collet 1 16 1 6mm 1 x Nozzle Alumina 5 1 x Nozzle Alumina 1 x Nozzle Alumina 1 x Tungsten Electrode 1 8 3 2mm Thoriated Type red band 1 x Tungsten Electrode 3 32 2 4 mm Thoriated Type red band and 1 x Tungsten Electrode 1 16 1 6mm Thoriated Type red band 3 14 Setup for TIG GTAW Welding A Select Lift TIG or HF TIG mode with the process selection control refer to Section 3 08 7 for further information B Connect the TIG Torch to the negative welding terminal Welding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Connect the work lead to the positive welding terminal Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection A CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal D Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below The TIG torch will require a trigger switch to operate in Lift TI
81. nt des vapeurs explosives Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d con necter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momen tan ment un v hicule Manual 0 5237 1 13 1 Lazone doit comporter un sol ignifug 2 Les tablis ou tables utilis s pendant les op ra tions de soudage doivent avoir un rev tement ignifuge 3 Utilisez des crans r sistants la chaleur ou en mat riau approuv pour prot ger les cloisons proches ou le sol vuln rable des tincelles et du m tal chaud 4 Gardez un extincteur approuv du bon type et de la bonne taille dans la zone de travail Inspectez le r guli rement pour vous assurer qu il est en tat de fonctionner Apprenez vous en servir 5 Enlevez tous les mat riaux combustibles de la zone de travail Si vous ne pouvez pas les enlever prot gez les avec une couvre ignifuge SAFETY INSTRUCTIONS AND WARNINGS 186 AC DC INVERTER A AVERTISSEMENT JAMAIS d op rations de soudage sur un r cipient quia contenu des liquides ou vapeurs toxiques combustibles ou inflamma bles N effectuez JAMAIS d op rations de sou dage dans une zone contenant des vapeurs combustibles des liquides inflammables
82. nts contre les tincelles et le laitier Gardez col manches et poches boutonn s ne faut pas remonter vos manches ou les pantalons revers Quand vous travaillez dans un environnement non d di au soudage ou d coupage portez toujours une protection des yeux appropri es ou un masque facial A AVERTISSEMENT Mettez en pratique les proc dures de s curit et de mode op ratoire suivantes chaque fois que vous utilisez cet appareil de r gulation de pression Si vous d viez de ces proc dures cela peut entra ner incendie explosion d g ts mat riels et ou blessures corporelles pour l op rateur E Bouteilles de Gaz Comprim Le D partement des Transports am ricain DOT approuve la conception et la fabrication des bouteilles qui contiennent les gaz utilis s pour les op rations de soudage ou de d coupage 1 Placez la bouteille Le sch ma 1 l o elle sera uti lis e Gardez la en position verticale Fixez la sur un chariot une cloison un tabli etc Le sch ma 1 1 Cylindres de gaz Manual 0 5237 SAFETY INSTRUCTIONS A AVERTISSEMENT Les bouteilles sont sous haute pression Manipu lez les avec pr cautions Des accidents s rieux peuvent r sulter d une mauvaise manutention ou dun mauvais emploi des bouteilles de gaz comprim NE faites PAS tomber la bouteille ne la cognez pas ne l exposez pas une chaleur excessive aux flammes ou tincelles NE la cognez PAS contre d autres bouteil
83. nvironment that will exceed the stated conditions For further information please refer to EN 60529 H Precautions must be taken against the power source toppling over The power source must be located on a suitable horizontal surface in the upright position when in use This equipment should be electrically connected by a qualified electrician 3 03 Ventilation 2 WARNING WARNING gt Since the inhalation of welding fumes can be harmful ensure that the welding area is effectively ventilated 3 04 Mains Supply Voltage Requirements 2 EE gt The Mains supply voltage should be within 15 of the rated mains supply voltage Too low a voltage may cause poor welding performance Too high a supply voltage will cause components to overheat and possibly fail The Welding Power Source must be e Correctly installed if necessary by a qualified electrician e Correctly earthed electrically in accordance with local regulations e Connected to the correct size power point and fuse as per the Specifications on page 3 2 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP 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 Lock out tagging procedures consist of padlocking line di
84. o lengths of strip steel may be tacked together at right angles This is known as a horizontal vertical HV fillet Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45 from the vertical Some electrodes require to be sloped about 20 away from the perpendicular position to prevent slag from running ahead of the weld Refer to Figure 4 13 Do not attempt to build up much larger than 1 4 6 4mm width with a 1 8 3 2mm electrode otherwise the weld metal tends to sag towards the base and undercut forms on the vertical leg Multi runs can be made as shown in Figure 4 14 Weaving in HV fillet welds is undesirable 45 from vertical 60 70 from line of weld Art A 07699 AB Figure 4 13 Electrode Position for HV Fillet Weld Art A 07700 AB Figure 4 14 Multi runs in HV Fillet Weld 4 6 BASIC WELDING C Vertical Welds 1 Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet The electrode needs to be about 10 from the horizontal to enable a good bead to be deposited Refer Figure 4 15 Use a short arc and do not attempt to weave on the first run When the first run has been completed de slag the weld deposit and begin the second run at the bottom This time a slight weaving motion is necessary
85. orce d Polarity Selection DC Reverse Polarity Positive 2 Weld Current Range 70 95A 100 135A 145 170A Arc Force Polarity Selection DC Reverse Polarity Positive 3 Weld Current Range 70 95A 100 145A 135 170A Arc Force Polarity Selection DC Reverse Polarity Positive 2 Weld Current Range 70 110A 90 160A 130 170A Arc Force Polarity Selection DC Reverse Polarity Positive RC EL IHERMAL 3 Weld Current Range MSN 100 160A Arc Force Polarity Selection DC Reverse Polarity Positive This set up information is 6 Weld Current Range __80 604 55 95A 80 140A intended to act as a guide only Arc Force Please refer to operating manual m tar further information Polarity Selection DC Reverse Polarity Positive Note STICK set up guide parameters may vary depending upon welding position joint design Select Process TER Fine LIFT TIG HF TIG 2T Mode AC or DC 4T Mode AC or DC AC or DC or STICK Pre Flow Pre Flow Hot Start Hot Start HF TIG Only Hot Start HF TIG Only Weld Current Weld Current Initial Current Arc Force Down Slope Up Slope ES Post Flow Weld Current P meme Wave Balance AC TIG Only Down Slope gt Adjust AC Frequency AC TIG Only Crater Current FORWARD Parameters Post Flow Wave Balance AC TIG Only AC Frequency AC TIG Only 831761 AB Manual 0 5237 A 3 APPENDIX 186 AC DC INVERTER APPENDIX T
86. our d marrer l alimentation du fils et la soudure le rel cher pour arr ter D tente 4 Temp Maintenez appuyez pour pr d bit relailez pour initier l arc Appuyez pour arr ter l arc et mainteuir pour pr d bit Probl me de Terre EJ Pouces Par Minute M tres Par Minute Art 07639 Avis Pour les environnements avec des risques de choc lectrique le fournisseur d nergie portant la marquelS conforme EN50192 lorsqu utilis en conjonction avec des lampes de poche avec des conseils expos s si quip s avec des guide hauteur de buse correctement install Ne pas d poser avec les d chets m nagers SAFETY INSTRUCTIONS AND WARNINGS 1 16 Manual 0 5237 SAFETY INSTRUCTIONS 186 AC DC INVERTER 1 10 Declaration Of Conformity Manufacturer Victor Technologies Address 16052 Swingley Ridge Road Suite 300 St Louis MO 63017 USA The equipment described in this manual has been designed to all applicable aspects and regulations of the Low Voltage Directive 2006 95 EC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are CSA 60974 1 UL6097
87. play actual welding current should a remote device be connected the maximum setting of the power source will be determined by the respective front panel control irrespective of the remote control device setting As an example if the output current on the power source front panel is set to 50 and the remote control device is set to 100 the maximum achievable output from the unit will be 50 Should 100 output be required the respective power source front panel control must be set to 100 in which case the remote device will then be able to control between 0 100 output 19 Digital Voltmeter Parameter meter The digital volt meter is used to display the actual output voltage of the power source It is also used to display Parameters in Programming Mode Depending on the Programming Parameter selected the status indictor adjacent to the volt meter will illuminate to show the units of the programming parameter When welding the volt meter will display actual welding voltage Manual 0 5237 3 9 INSTALLATION OPERATION AND SETUP 186 AC DC INVERTER INSTALLATION SETUP 20 0N OFF Switch This Switch is located on the rear of the Power Source and turns mains power off and on A WARNING When the front digital displays are lit the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential 21 Shielding Gas Inlet Unit has a 5 8 Inert gas fitting suitable for connection of
88. r 30 minutes with the fan running the Fault Indicator has not gone OFF then have an Accredited Thermal Arc Service Provider check the power source 2 Primary Circuit Overcurrent This is due to primary circuit component s malfunctioning which results in excessive primary circuit current Switch OFF the power source immediately to allow all components to cool down for at least 30 minutes If after 30 minutes Err 001 is displayed and Fault Indicator illuminates when the power source is switched back ON turn the power source OFF and have an Accredited Thermal Arc Service Provider check the power source 1 Process Selection Button The process selection control is used to select the desired welding mode Three modes are available GTAW LIFT GTAW and SMAW Stick modes Note that when the unit is powered off the mode selection control will automatically default to LIFT TIG mode This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up 8 Trigger Mode Control Button HF TIG and LIFT TIG Mode only The trigger mode control is used to switch the functionality of the torch trigger between 2T normal and 4T latch mode 2T Normal Mode In this mode the torch trigger must remain depressed for the welding output to be active Press and hold the torch trigger to activate the power source weld Release the torc
89. r Indicators Front Panel Display Indicators The Front Panel LED indicators serve two purposes First they show what process and what parameter is selected and the value of that parameter The AMP DISPLAY shows only amperage values measured in AMPS the VOLT DISPLAY can indicate Voltage Time Percentage or Frequency The UNITES lights indicate the unit of measurement for the reading on the VOLT DISPLAY Volts V Seconds SEC Percent 9e Hertz HZ Only the parameters that are applicable to a specific PROCESS MODE or TRIGGER SELECTION will light when using the FORWARD or BACK programming switches Secondly during the welding process the following sequence indicators will light to indicate the specific phase of the weld process which is active TIG STICK PREFLOW WELD CURRENT HOT START INITIAL CURRENT 4T UPSLOPE 4T WELD CURRENT PULSING OFF HIGH CURRENT PULSING ON LOW CURRENT PULSING ON DOWNSLOPE CRATER CURRENT 41 POST FLOW 17 Mode Button 18 Press the MODE button to toggle AC and DC output in all Process modes Digital Ammeter The digital amperage meter is used to display both the pre set current and actual output current of the power source At times of non welding the amperage meter will display a pre set preview amperage value This value can be adjusted by varying the multifunction control when the Programming Parameter Indicator light shows WELD CURRENT When welding the amperage meter will dis
90. r lead to the positive welding terminal If in doubt consult the electrode manufacturer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection B Connect the work lead to the negative welding terminal If in doubt consult the electrode manufacturer Welding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Select STICK mode with the process selection control refer to Section 3 08 7 for further information A WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the mains power supply is switched off Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source A CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal INSTALLATION OPERATION AND SETUP 3 22 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER THERMAL A RC PULSE Negative Welding Terminal Positive Welding Terminal TM A 11499 AB Work Lead Figure 3 11 Setup for Manual Arc Welding Manual 0 5237 3 23 INSTALLATION OPERATION A
91. rations on a container that has held toxic combustible or flammable liquids or vapors NEVER perform welding heating or cutting operations in an area containing combustible vapors flammable liquids or explosive dust B Housekeeping A WARNING NEVER allow oxygen to contact grease oil or other flammable substances Although oxy gen by itself will not burn these substances become highly explosive They can ignite and burn violently in the presence of oxygen Keep ALL apparatus clean and free of grease oil and other flammable substances SAFETY INSTRUCTIONS AND WARNINGS 186 AC DC INVERTER SAFETY INSTRUCTIONS C Ventilation 1 Place the cylinder Figure 1 1 where you will use it Keep the cylinder in a vertical position A Secure it to a cart wall work bench post etc WARNING Adequately ventilate welding heating and cutting work areas to prevent accumula tion of explosive or toxic concentrations of gases Certain combinations of metals coatings and gases generate toxic fumes Use respiratory protection equipment in these circumstances When welding brazing read and understand the Material Safety Data Sheet for the welding brazing alloy Figure 1 1 Gas Cylinders D Personal Protection Gas flames produce infrared radiation which may have WARNING a harmful effect on the skin and especially on the eyes Select goggles or a mask with tempered lenses shaded Cylinders are highly pressurized Handle
92. re arcing please ensure the Torch is located away from your work piece LIFT TIG GTAW Sequence of Operation A CAUTION Before any welding is to begin be sure to wear all appropriate and recommended safety equipment 1 Switch the ON OFF Switch located on the rear panel to OFF 2 Connect the ground work clamp cable to positive output terminal It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection 3 Connect the TIG torch as follows a Place the power cable into the negative output terminal It is essential that the male plug is inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection b Place the 8 pin plug into the 8 pin socket To make connections align keyway insert plug and rotate threaded collar fully clockwise c Place the TIG torch gas hose to the gas outlet and tighten with a wrench Caution DO NOT over tighten 4 Using a secured Argon cylinder slowly crack open then close the cylinder valve while standing off to the side of the valve This will remove any debris that may be around the valve amp regulator seat area 5 Install the regulator for details of VICTOR regulator please refer to 3 18 and tighten with a wrench 6 Connect one end of the supplied gas hose to the outlet of the Argon regulator and tighten with a wrench Caution DO NOT over tighten 7
93. ry excessively with the arc length Welding current too low B Electrode too large for joint Insufficient gap Non metallic particles may A be trapped in undercut from previous run Joint preparation too restricted Irregular deposits allow slag to be trapped Lack of penetration with slag trapped beneath weld bead Rust or mill scale is pre venting full fusion Wrong electrode for posi tion in which welding is done BASIC WELDING Reduce the ARC FORCE control knob until weld ing current is reasonably constant while prohibit ing the electrode from sticking to the work piece when you dig the electrode into the workpiece Increase welding current Use smaller diameter electrode Allow wider gap If a bad undercut is present clean slag bout and cover with a run from a smaller gauge 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 comers Clean joint before welding Use electrodes designed for position in which welding is done otherwise proper control of slag is difficult Figure 1 Example of insufficient gap or incorrect sequence 4 10 Manual 0 5237 BASIC WELDING 186 AC DC INVERTER FAULT CAUSE REMEDY 4 groove has been Welding current is too formed in the base high
94. s preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace B Manganese Steels The effect on manganese steel of slow cooling from high temperatures is to embrittle it For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat C Cast Iron Most types of cast iron except white iron are weldable White iron because of its extreme brittleness generally cracks when attempts are made to weld it Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron D Copper and Alloys The most important factor is the high rate of heat conductivity of copper making pre heating of heavy sections necessary to give proper fusion of weld and base metal E Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile steel cellulose types for welding large diameter pipes etc The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered are all easy to use Manual 0 5237 4 1 BASIC WELDING GUIDE
95. s or covers 13 In confined spaces or damp locations do not use a welder with output unless it is equipped with 4 Disconnect input power or stop engine before voltage reducer Use equipment with DC output installing or servicing this equipment Lock input mE power disconnect switch open or remove line fuses 14 Wear a safety harness to prevent falling if working so power cannot be turned on accidentally above floor level Manual 0 5237 1 1 SAFETY INSTRUCTIONS AND WARNINGS 186 AC DC INVERTER SAFETY INSTRUCTIONS 15 Keep all panels and covers securely in place Use protective screens or barriers to protect others from flash glare warn others to watch the arc 7 4 Wear protective clothing made from durable ANG flame resistant material wool and leather and foot ARC RAYS can burn eyes and skin NOISE protection can damage hearing Arc rays from the 5 Use approved ear plugs or ear muffs if noise level welding process produce intense heat and is high strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing gt 1 Wear a welding helmet fitted with a proper shade WARNING _____ of filter see ANSI 249 1 listed in Safety Standards FUMES AND GASES can be hazardous to to protect your face and eyes when welding or your health watching Welding produces fumes and gases 2 Wear approved safety glasses Side shields Bre
96. s tension 8 N utilisez pas de c bles lectriques us s endom mag s mal piss s ou de section trop petite 2 Portez des gants et des v tements isolants secs et non trou s 9 N enroulez pas de c bles lectriques autour de votre COrps Manual 0 5237 19 SAFETY INSTRUCTIONS WARNINGS 186 AC DC INVERTER 10 N utilisez qu une bonne prise de masse pour la mise la terre de la pi ce souder 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 12 N utilisez que des quipements en bon tat R parez ou remplacez aussit t les pi ces endommag es 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 SAFETY INSTRUCTIONS Ah M e AVERTISSEMENT LE RAYONNEMENT DE L ARC PEUT BR LER 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 louie 14 Portez un harnais de s curit si vous travaillez en hauteur 15 Fermez solidement tous les panneaux et les capots 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 ye
97. sconnect switch in open position removing fuses from fuse box or shutting OFF and red tagging circuit breaker or other disconnecting device Power Cords Included With Power Supply Attached to the power supply is an input power cord with a 208 230Volt 50 Amp NEMA 6 50 P for plug A WARNING An electrical shock or fire hazard is probable if the following electrical service guide recommendations are not followed These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding Power Source Phase Supply Supply Voltage 208 230V AC Input Current at Maximum Output 32 Amps Maximum Recommended Fuse or Circuit Breaker Rating 50 Amps Time Delay Fuse UL class RK5 Refer to UL248 Maximum Recommended Fuse or Circuit Breaker Rating 90 Amps Normal Operating UL class K5 Refer to UL248 Minimum Recommended Cord Size 12 AWG Maximum Recommended Extension Cord Length 50 ft Minimum Recommended Grounding Conductor Size 12 AWG Table 3 1 Electrical Service Guide 3 05 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be overemphasized Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation The following information is intended as a guide for personnel installing high frequency welding machines The high frequency section of this machine has an output similar to a radio
98. sed process that requires operator competency While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual For further information please refer to www victortechnologies com or contact Thermal Arc BASIC WELDING GUIDE 4 14 Manual 0 5237 BASIC WELDING 186 AC DC INVERTER 4 04 TIG GTAW Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or Welding current is too Increase weld current and or faulty joint poor penetration or poor low preparation fusion at edges of weld 2 Weld bead too wide and Welding current is too Decrease weld current flat or undercut at edges high 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 penetration in butt joint 5 Uneven leg length in fillet Wrong placement of Re position filler rod joint filler rod 6 Electrode melts or oxidises A Torch lead connected A Connect torch lead to negative welding when an arc is struck to positive welding terminal terminal B No gas flowing to weld B Check the gas lines for kinks or breaks ing region and gas cylinder contents C Torch is clogged with C Clean torch dust or dirt D Gas hose is
99. ssure reducing regulator attached to the cylinder valve 2 Place the valve protection cap on the cylinder whenever moving it placing it in storage or not using it Never drag or roll cylinders in any way Use a suitable hand truck to move cylinders 5 Inspect the cylinder valve for oil grease and damaged parts SAFETY INSTRUCTIONS AND WARNINGS 1 6 Manual 0 5237 SAFETY INSTRUCTIONS A WARNING DO NOT use the cylinder if you find oil grease or damaged parts Inform your gas supplier of this condition immediately 6 Momentarily open and close called cracking the cylinder valve to dislodge any dust or dirt that may be present in the valve A CAUTION Open the cylinder valve slightly If you open the valve too much the cylinder could tip over When cracking the cylinder valve DO NOT stand directly in front of the cylinder valve Always perform cracking in a well ventilated area If an acetylene cylinder sprays a mist when cracked let it stand for 15 minutes Then try to crack the cylinder valve again If this problem persists contact your gas supplier Manual 0 5237 186 AC DC INVERTER 1 03 Principal Safety Standards safety in Welding and Cutting ANSI Standard 249 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 t
100. tained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is a Global Brand of Arc Welding Products for Victor Technologies We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction Mining Automotive Aerospace Engineering Rural and DIY Hobbyist We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry 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
101. tes 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 pla fond 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 10 Otez l lectrode du porte lectrode ou coupez le fil au tube contact lorsqu inutilis apr s le soudage 11 Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque SAFETY INSTRUCTIONS AND WARNINGS SAFETY INSTRUCTIONS AND WARNINGS 186 AC DC INVERTER p we AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroi dissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protec trices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau AVERTISSEMENT LES BOUTEILLES ENDOMMAGEES PEU VENT EXPLOSER Les bouteilles
102. titute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 SAFETY INSTRUCTIONS AND WARNINGS 186 AC DC INVERTER 1 09 Graphique de Symbole Seulement certains de ces symboles appara tront sur votre mod le Sous Tension Hors Tension 4 Tension dangereuse EN Augmentez Diminuer O O Disjoncteur Source AC Auxiliaire Intensit de Courant Tension Hertz cycles sec Courant Continue DC Terre de Protection e Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Tri Phase Statique Fr quence Convertisseur Transformateur Redresseur Distant Facteur de Marche Pourcentage Panneau Local Soudage Arc Electrique Avec Electrode Enrob SMAW Soudage L arc Avec Fil Electrodes Fusible GMAW Soudage L arc Avec Electrode Non Fusible GTAW Decoupe Arc Carbone CAC A Courant Constant Tension Constante Ou Potentiel Constant Haute Temp rature Indication d erreur mol Amorcage de L arc au Contact GTAW Inductance Variable SAFETY INSTRUCTIONS D roulement du Fil Alimentation du Fil Vers la Pi ce de Fabrication Hors Tension Torche de Soudage Purge Du Gaz Mode Continu de Soudure Soudure Par Point Dur c du Pulse Dur e de Pr D bit Dur e de Post D bit a 2 Temps Appuyez p
103. to cover the first run and obtain good fusion at the edges At the completion of each side motion pause for a moment to allow weld metal to build up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 4 16 illustrates multi run technique and Figure 4 17 shows the effects of pausing at the edge of weave and of weaving too rapidly Art A 07701 Weaving motion for second and subsequent runs Pause at edge of weave Figure 4 16 Multi Run Vertical Fillet Weld Manual 0 5237 BASIC WELDING 186 AC DC INVERTER CORRECT INCORRECT LITT TT Pause at edge of Note weld contour weave allows weld when insufficient metal to build up pause at edge and eliminates of weave undercut Art A 07703 Figure 4 17 Examples of Vertical Fillet Welds 2 Vertical Down Use a 1 8 3 2mm electrode at 100 amps The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag The electrode should point upwards at an angle of about 45 3 Overhead Welds Apart from the rather awkward position necessary overhead welding is not much more difficult that downhand welding Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the work bench or hold in a
104. tors and Features 3 5 3 09 186 AC DC STICK Programming 3 10 3 10 186 AC DC LIFT TIG and HF TIG Programming Mode 3 11 3 11 Short Circuit Protection While Welding enn 3 16 SEIL 3 16 3 13 Specification for TIG 3 18 3 14 Setup for TIG GTAW Welding anses 3 19 3 15 Setup for STICK SMAW Welding 2 2 3 22 TABLE OF CONTENTS SECTION 4 BASIG WELDING GUIDE i 4 1 4 01 STICK SMAW Basic Welding 4 1 4 02 STICK SMAW Welding Troubleshooting 4 10 403 TIG GTAW Basic Welding 4 12 404 6 GTAW Welding Problems 4 15 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE 5 1 5 01 KOUDE SO OO 5 1 5 02 Power Source Problems ir 5 1 5 03 Routine Service and Calibration Requirements eene 5 2 5 04 Cleaning the Welding Power Source ne 5 4 SECTION 6 KEY SPARE PARTS 2 6 1 6 01 We 6 1 APPENDIX 1 CIRCUIT A 1 APPENDIX 2 186 AC DC SETUP GUIDE A 2 IIMITED WARRANTY ad ne EYES am in Inside Rear Cover WARRANTY
105. transmitter The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing WARNING COMPUTER It is also possible that operation close to computer installations may cause computer malfunction WARNING EXPLOSIVES INSTALLATION OPERATION AND SETUP 3 2 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER 3 06 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 oource will prevent direct radiation if the equipment is properly grounded 2 Transmission via the Supply Lead Without adequate shielding and filtering high frequency energy may be fed to the wiring within the installation mains by direct coupling The energy is then transmitted by both radiation and conduction Adequate shielding and filtering is provided in the Power Source 3 Radiation from Welding Leads Radiated interference from welding leads although pronounced in the vicinity of the leads diminishes rapidly with distance Keeping leads as short as possible will minimise this type of interference Looping and suspending of leads should be avoided wherever possible 4 Re Radiation from Unearthed Meta
106. trol fuse is blown Replace primary control fuse ON Indicator light is not lit B Broken connection in primary Have Accredited Thermal Arc and welding arc cannot be Circuit Service Provider check primary established Circuit 3 Fault Indicator is illuminated Duty cycle of power source has Leave the power source and unit will not commence been exceeded switched ON and allow it to welding when the torch cool Note that fault indicator trigger switch is depressed must be extinguished prior to commencement of welding 4 Welding output continues A Trigger mode selection is in 4T A Change to 2T NORMAL mode when torch trigger released LATCH mode B Torch trigger leads shorted B Repair or replace Torch trigger lead 5 Welding output voltage Poor or no work lead contact Clean work clamp area and ensure is present when the good electrical contact torch trigger switch is depressed but arc cannot be established not present when torch lead trigger depressed arc is struck the VE terminal VE terminal welding large for the welding current electrode Service Provider check HF circuit Manual 0 5237 5 1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 186 AC DC INVERTER SERVICE Error Code Err 001 is A Thermal Overload This is due to the duty cycle of displayed on the digital the power source being exceeded displays in conjunction Once the power source cools with the Fault Indicator sufficiently it wi
107. und this equipment according to its Owner s Manual and national state and local m codes 6 Turn OFF all equipment when not in use Disconnect WARNING power to equipment if it will be left unattended or out of service ELECTRIC SHOCK can kill 7 Use fully insulated electrode holders Never dip Touching live electrical parts can cause fatal holder in water to cool it or lay it down on the ground Shocks or severe burns The electrode and orthe work surface Do not touch holders connected Work circuit 15 electrically live whenever the to two welding machines at the same time or touch output is on The input power circuit and other people with the holder or electrode machine internal circuits are also live when power is on In semi automatic or automatic 9 Do not use worn damaged undersized or poorly wire welding the wire wire reel drive roll spliced cables housing and all metal parts touching the 9 Do not wrap cables around your body welding wire are electrically live Incorrectly installed or improperly grounded equipment 10 Ground the workpiece to a good electrical earth is a hazard ground 1 Do not touch live electrical parts 11 Do not touch electrode while in contact with the work ground circuit 2 Wear dry hole free insulating gloves and body protection 12 Use only well maintained equipment Repair or replace damaged parts at once 3 Insulate yourself from work and ground using dry insulating mat
108. used for the determination of cable size amp supply requirements Note 2 Generator Requirements at the Maximum Output Duty Cycle INTRODUCTION 2 4 Manual 0 5237 INTRODUCTION 2 10 Optional Accessories 26 Style TIG Torch with Remote Current Control Part No W4013600 Basic Utility c e a Part No W4014700 Part No W4013200 Part No 4100 1004 Manual 0 5237 2 5 186 AC DC INVERTER INTRODUCTION INTRODUCTION 186 AC DC INVERTER 2 11 Volt Ampere Curves Voltage Amperage Curves shows maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown 2 gt 5 5 Welding Current AMPS A 11583 Figure 2 3 186 AC DC Volt Amp Curves INTRODUCTION 2 6 Manual 0 5237 INSTALLATION SETUP 186 AC DC INVERTER SECTION 3 INSTALLATION OPERATION AND SETUP 3 01 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in EN 60974 1 Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock Please refer to relevant local standards for further information prior to using in such areas A Examples of environments with increased hazard of electric shock are 1 In locations in which freedom of movement is restricted so that the operator is forced
109. ux lorsque vous soudez ou que vous observez l ex cution d une soudure AWS F2 2 2001 R2010 Modifi avec l accord de l American Welding Society AWS Miami Florida Soudage l arc Me lectrode enrob e proc d SMAW soudage l arc sous gaz avec fil plein proc d GMAW et soudage avec fil fourr proc d Soudage l lectrode r fractaire proc d GTAW l arc avec lectrode de carbone et jet d air proc d AAC poudage l arc au plasma proc d PAW Guide de teinte des lentilles Taille de l lectrode Courant en mm po amperes Clair Sombre Numero de teinte recommandee Confort Gamme _ d intensit minimum ANO Po ANO AN 9 4 E ROCTDOOIR BROX En r gle g n rale commencer avec une teinte plus fonc e pour voir la zone de soudage R duire ensuite progressivement vers la teinte qui permet de voir la zone de soudage sans d passer le minimum Lors du Soudage du ou du brasage au gaz oxyg n la torche ou le fondant produit une puissante lumi re jaune il est pr de la lumi re visible SAFETY INSTRUCTIONS AND WARNINGS rable d utiliser un fi Tableau 1 1 1 10 qui absorbe cette lumi re jaune ou le sodium du spectre Manual 0 5237 SAFETY INSTRUCTIONS
110. vice so that the specimen is positioned in the overhead position as shown in the sketch The electrode is held at 45 to the horizontal and tilted 10 in the line of travel Figure 4 18 The tip of the electrode may be touched lightly on the metal which helps to give a steady run A weave technique is not advisable for overhead fillet welds Tilted 10 in line of travel to pipe Figure 4 18 Overhead Fillet Weld Distortion Distortion in some degree is present in all forms of welding In many cases it is so small that it is barely perceptible but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur The study of distortion is so complex that only a brief outline can be attempted hear Manual 0 5237 4 7 BASIC WELDING GUIDE 186 AC DC INVERTER The Cause of Distortion BASIC WELDING Art A 07705_AB Weld Upsetting o Distortion is caused by Expansion with compression A Contraction of Weld Metal juo Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature This means that a cube of molten metal would contract approximately 2 2 per cent in each of its three dimensions In a welded joint the metal becomes attached to the side of the joint and cannot contract freely Therefore cooling causes the weld metal to flow plastically that is the weld itself has to stretch if it is to overcome the effect of

186 AC/DC Operating Manual Inverter

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