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Thermal Arc 200 AC/DC ARCMASTER - User Manual

Thermal Arc 200 AC/DC ARCMASTER
122 pages
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SMAW
GTAW
CC
AC
DC
INVERTER
50
60
Hz
ARCMASTER
®
INVERTER ARC WELDERS
185 AC/DC
200 AC/DC
Art # A-07227
Service Manual
Revision No: AE.04 Issue Date: May 22, 2006 Manual No.: 0-4884B
Operating Features:

Table of Contents

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Summary

Section 1: Safety Instructions and Warnings

Arc Welding Hazards

Describes hazards related to arc welding and necessary precautions for safe operation.

Principal Safety Standards

Lists relevant safety standards like ANSI Z49.1, OSHA 29 CFR 1910, and others.

French Safety Precautions

Details safety precautions in French for arc welding procedures.

French Welding Hazards

Describes hazards related to arc welding in French.

French Main Safety Standards

Lists main safety standards in French.

Section 2: Introduction

How to Use This Manual

Provides guidance on how to effectively use the service manual.

Equipment Identification

Explains how to identify the welding unit and its serial number.

Symbol Chart

Defines symbols used on the welding machine and in the manual.

Product Description

Describes the features and capabilities of the welding power source.

Functional Block Diagrams

Illustrates the functional components and their interconnections.

Transporting Methods

Provides instructions for safely moving the welding unit.

Section 3: Installation

Installation Environment

Specifies suitable environmental conditions for operating the welder.

Installation Location

Provides guidelines for selecting an appropriate location for the welder.

Electrical Input Connections

Details how to safely connect the welder to the electrical power supply.

Electrical Input Requirements

Outlines the necessary electrical supply specifications for the welder.

Input Power Requirements

Specifies the primary current requirements and circuit sizes for optimal performance.

High Frequency Introduction

Discusses the importance of correct installation for high frequency welding.

High Frequency Interference

Explains potential sources and mitigation of HF interference.

Duty Cycle Explained

Defines duty cycle and its impact on welder operation and longevity.

Technical Specifications

Lists detailed technical specifications for the 185ACDC and 200ACDC models.

Section 4: Operator Controls

Operator Controls Overview

Identifies and describes the controls and features on the front panel.

Weld Process Selection

Details how to select different welding modes and processes.

Weld Parameter Descriptions

Explains the function of various welding parameters available on the machine.

Weld Parameter Settings

Provides a table of weld parameters and their ranges for different modes.

Power Source Features

Lists and describes the key features of the welding power source.

Section 5: Set-up for SMAW (Stick) and GTAW (TIG)

Section 6: Sequence of Operation

Stick Welding Sequence

Step-by-step instructions for performing stick welding.

AC;DC HF TIG Welding Sequence

Instructions for setting up and performing HF TIG welding.

Slope Mode Sequence

Describes the sequence of operations for slope mode welding.

Slope Mode with Repeat Sequence

Explains the repeat function within the slope mode sequence.

Pulse Control Functions

Details the function and advantages of pulse controls for heat input.

Section 7: Routine Maintenance

Section 8: Basic Troubleshooting

General Troubleshooting Guide

General advice for troubleshooting and repairing the welding unit.

Common Welding Faults

Lists common faults encountered during welding operations.

TIG Welding Troubleshooting

Troubleshooting guide for common issues encountered during TIG welding.

Stick Welding Troubleshooting

Troubleshooting guide for common issues encountered during stick welding.

Power Source Troubleshooting

Troubleshooting common problems related to the power source.

Error Code Reference

Lists and explains error codes displayed by the unit.

Section 9: Voltage Reduction Device (VRD)

VRD Specifications

Provides technical specifications for the Voltage Reduction Device.

VRD Maintenance Procedures

Outlines routine inspection and testing procedures for the VRD.

Switching VRD On;Off

Step-by-step instructions for enabling or disabling the VRD.

Section 10: Advanced Troubleshooting

System-Level Fault Isolation

Guides on isolating defective subassemblies when basic troubleshooting fails.

Opening the Enclosure

Instructions on how to safely open the welder's enclosure.

Error Code Verification & Remedy

Procedures to verify and fix issues indicated by error codes.

Failure Verification & Remedy

Troubleshooting steps for failures not accompanied by error codes.

Fault Isolation Tests

Outlines preparation and safety for fault isolation testing.

Power Input Circuitry Verification

Procedures to test the integrity of the power input circuitry.

Power Supply Voltage Verification

Steps to verify various power supply voltages within the unit.

Section 11 Repair Procedures

Maintenance List

Lists maintenance items and their reference pages.

Service Tools and Notes

Details tools, parts, and notes for disassembly and assembly.

Component Replacement Procedures

Step-by-step instructions for replacing various internal components.

Appendix 1: Parts List

Equipment Identification

Details how to identify parts and furnish information for ordering.

How To Use This Parts List

Explains how to use the illustration and parts list for identification.

Appendix 2: Connection Wiring Guide

Appendix 3: 185 ACDC Interconnect Diagram

Appendix 3: 200 ACDC Interconnect Diagram

Appendix 4: Diode Testing Basics

Thermal Arc 200 AC/DC ARCMASTER Specifications

General IconGeneral
Input Voltage230 V
Input PhaseSingle Phase
Input Frequency50/60 Hz
Output Current Range5 - 200 A
Duty Cycle30%
AC/DC OutputYes
Pulse WeldingYes
HF StartYes
Open Circuit Voltage80V
Welding ProcessesTIG, Stick

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