Tweco 185TSW DC CC Manuel d'utilisateur

November 13, 2003 Manual No. 430429-503INVERTERARCWELDERMODEL 185TSW AC/DC CCSTICKTIG - Lift StartHF STARTOPERATING MANUAL

10• Eloignez toute fumée et gaz de votre zone derespiration. Gardez votre tête hors de laplume de fumée provenant du chalumeau.• Utilisez un appareil

11nuiront à vos yeux et brûleront votre peau si vousne vous protégez pas correctement.• Pour protéger vos yeux, portez toujours uncasque ou un écran d

12ASSOCIÉS, disponible auprès de la NationalFire Protection Association, BatterymarchPark, Quincy, MA 022699. Norme 70 de la NFPA, CODE ELECTRIQUENAT

132.0 INTRODUCTION AND DESCRIPTION2.01 DescriptionThe Thermal Arc™ Model 185TSW is a self contained single-phase AC/DC arc welding power sourcewith Co

142.02 Functional Block DiagramsFigure 2 illustrates the functional block diagram of the 185TSW-power supply.Figure 2. 185TSW Model Functional Block D

153.0 Installation Recommendations3.01 EnvironmentThe Pro-Wave 185TSW is designed for use in hazardous environments.Examples of environments with incr

163.03 Electrical Input Connections WARNING 4ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal ofinput power.DO NOT TOUCH live

17Input Voltage Fuse Size208V 45 Amps230V 40 AmpsTable 1. Electrical Input ConnectionsNOTE: Fuse size is based on not more than 200 percent of the rat

183.03.02 Input PowerEach unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAINCIRCUIT SWITCH is turned on, the inrush

193.03.03 High Frequency IntroductionThe importance of correct installation of high frequency welding equipment cannot be over-emphasized. Interferen

203.04 SpecificationsParameter 185TSWRated OutputAmperesVoltsDuty Cycle18517.425%Duty Cycle TIG 185A / 17.4V @ 30%160A / 16V @ 40%130A / 15V @ 60%100A

213.05 Duty CycleThe duty cycle of a welding power source is the percentage of a ten (10) minute period that it canbe operated at a given output witho

22PAGE LEFT INTENTIONALLY BLANK

23Gnd.12345678215438765k OhmsFront view of 8-Socket Receptacle4.0 OPERATOR CONTROLS4.01 Pro-Wave 185TSW ControlsFigure 4– Pro-Wave 185TSW Power Source

24Socket Pin Function1 Earth (Ground)2Torch Switch Input (24V) to energize weld current.(connect pins 2 & 3 to turn on welding current)3Torch Swit

258 Gas InletThe Gas Inlet is a 5/8 18 UNF female gas fitting.4.02 Weld Process selection for Pro-Wave 185TSWWeld ModeWeld ProcessSelection STICKHFTIG

264.03 Weld Parameter Descriptions for Pro-Wave 185TSWFigure 5 Pro-Wave 185TSW Front Panel with Parameter DescriptionParameter DescriptionPRE-FLOWThis

27Parameter DescriptionSPOT TIMEThis parameter sets the duration of the SPOT TIME in HF TIG mode onlyPULSE WIDTHThis parameter sets the percentage on

284.04 Weld Parameters for Pro-Wave 185TSWWeld ModeWeldParameterParameterRangeFactorySettingIncrementalUnit STICKHFTIGLIFTTIGPRE-FLOW 0.0 to 1.0 sec 0

294.05 Power Source FeaturesFeature DescriptionNew Digital Control• Almost all welding parameters are adjustableTouch Panel Switches• Touch switches e

3CONTENTSSYMBOL LEGEND ...

30PAGE LEFT INTENTIONALLY BLANK

315.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG)Conventional operating procedures apply when using the Welding Power Source, i.e. connect worklead directl

326.0 SEQUENCE OF OPERATIONNOTE: Scroll Buttons are used to select the parameters to be set. TheLED’s show which function is being adjusted on the we

331. Pulse function – Pressing this button enables the TIG current pulse functions.2. Scroll Buttons – used to select the parameters to be set. The

346.02 AC or DC HF TIG Welding• Connect work lead to positive terminal• Connect TIG torch to negative terminal• Switch machine on• Set AC or DC we

356.02.01 Slope Mode SequenceNote 5Slope function operates with a Remote ON/OFF device only.1) To start Slope sequence Close remote switch contacts.

366.02.03 Pulse ControlsThe Pulse controls are used primarily to control heat input. Pulse offers a number of advantages asfollows:1) Control puddle

377.0 BASIC TIG WELDING GUIDE7.01 Explanation of “Fluttery Arc” when AC TIG Welding on AluminumThe following will assist in understanding the phenomen

387.02 Electrode PolarityConnect the TIG torch to the - / TORCH terminal and the work lead to the + / WORKterminal for direct current straight polarit

397.05 Guide for Selecting Filler Wire DiameterFiller Wire DiameterAC Current Range(Amps)DC Current Range(Amps)1/16” (1.6 mm) 30-95 20 - 903/32” (2.4

413.0 PARTS LIST...

407.08 Welding Parameters for AluminumBase MetalThicknessAC Currentfor AluminumTungstenElectrodeDiameterFiller RodDiameter(if required)Argon GasFlow R

418.0 Basic Arc Welding Guide8.01 Electrode PolarityStick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘−’terminal

429.0 ROUTINE MAINTENANCEThe only routine maintenance required for the power supply is a thorough cleaning and inspection,with the frequency depending

4310.0 BASIC TROUBLESHOOTING WARNING 9There are extremely dangerous voltages and power levels present inside this product. Donot attempt to open or r

44Description Possible Cause Remedy6 Electrode meltswhen arc is struck.A Electrode is connected to the‘+’ terminal.A Connect the electrode to the‘−’ t

45Description Possible Cause RemedyC Gas flow incorrectly set,cylinder empty or the torchvalve is off.C Select the right flow rate,change cylinders or

464Portions of theweld run do notfuse to the surfaceof the metal oredge of the joint.ABSmall electrodes used onheavy cold plate.Welding current is too

4710.03 Power Source ProblemsDescription Possible Cause Remedy1The welding arccannot beestablished.ABThe Primary supply voltagehas not been switched O

48Description Possible Cause Remedy5 Gas flow won’tshut off.A Weld Mode (STD, SLOPE,REPEAT or SPOT) waschanged before POST-FLOWgas time had finished.A

4911.0 Voltage Reduction Device (VRD)11.01 VRD SpecificationDescriptionPro-Wave185TSW NotesVRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage

5SYMBOL LEGENDAmperage STICK (Shielded Metal ArcSMAW)Voltage Pulse Current FunctionHertz (frequency) Spot Time (GTAW)SECSeconds Remote Control (Panel/

5012.0 Power Source Error CodesDescription Possible Cause Remedy Remarks1E01 error code displayedTemperature sensor TH1 (protectsIGBTs) is greater tha

51Description Possible Cause Remedy Remarks5 E11 error code displayedOver Primary supply (input)voltage at primary capacitors isexceeded for one secon

52Description Possible Cause Remedy Remarks10 E83 error code displayedCPU checks mains supply (input)voltage when the on/off switch onrear panel of ma

5313.0 PARTS LISTDWG. No. Description Type & Rating QTY. Code No. Order No.C1 Capacitor ECQE12104MZ DC1250V 0.1uF 1 42422137100 10-2270CC1 Coupl

5413.0 PARTS LIST ContinuedDWG. No. Description Type & Rating QTY. Code No. Order No.Q1 Transistor CM100DUS12F-1 600V 100A (with WK-5012 U01)1 U

5513.0 PARTS LIST ContinuedDWG. No. Description Type & Rating QTY. Code No. Order No.Output Terminal Label N4A040100 1 N4A040100 10-6658Gas Outlet

56APPENDIX A – INTERCONNECT DIAGRAM

57

58APPENDIX B - AUTOMATIONJUMPER SETTING FOR "OK–TO–MOVE". Models 185TSWThree jumpers (JP1, JP2 and JP3) are provided on PC Board WK-4921 fo

59Figure 11 – Location of PCB WK-4921

6STATEMENT OF WARRANTYLIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of itsauthorized dist

71.0 GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, andwarnings are used to highlight importantinformat

8• Install and maintain equipment according toNEC code, refer to item 4 in Subsection 1.03,Publications.• Disconnect power source before performingany

96. ANSI Standard Z49.2, FIRE PREVENTION INTHE USE OF CUTTING AND WELDINGPROCESSES, obtainable from AmericanNational Standards Institute, 1430 Broadw