Thermal Arc 175 SE ARC MASTER Bedienungsanleitung

60Hz

A-08598

ARC MASTER®

INVERTER ARC WELDER

175 SE

Operating Manual

Revision No: AE Issue Date: February 24, 2009 Manual No.: 0-5054

Operating Features:

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

+44 (0) 1257 261 755, 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.

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 Thermadyne

Industries Inc. 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 Manufac-

turer assumes no liability for its use.

Operating Manual Number 0-5054 for:

Arc Master 175 SE Inverter Arc Welder Part No. W1002902

Published by:

Thermadyne Europe

Europa Building

Chorley Industrial Park

Chorley, Lancaster,

England, PR6 7BX

www.thermalarc.com

2008 by

Thermadyne Industries Inc.

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: March 20, 2008

Revision AC Date: February 24, 2009

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 Hazards....................................................................................... 1-1

1.02 Principal Safety Standards.............................................................................. 1-4

1.03 Symbol Chart.................................................................................................. 1-5

1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6

1.05 Dangers relatifs au soudage à l’arc................................................................. 1-6

1.06 Principales Normes De Securite ..................................................................... 1-9

1.07 Graphique de Symbole.................................................................................. 1-10

1.08 Declaration Of Conformity ............................................................................ 1-11

SECTION 2: INTRODUCTION............................ 2-1

2.01 How to Use This Manual................................................................................. 2-1

2.02 Equipment Identiﬁcation................................................................................. 2-1

2.03 Receipt of Equipment...................................................................................... 2-1

2.04 Description ..................................................................................................... 2-1

2.05 Transportation Methods.................................................................................. 2-1

2.06 Duty Cycle....................................................................................................... 2-1

2.07 Speciﬁcations ................................................................................................. 2-2

SECTION 3:INSTALLATION ............................................................................... 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location.......................................................................................................... 3-1

3.03 Electrical Input Connections ........................................................................... 3-1

3.04 Electromagnetic Compatibility ........................................................................ 3-3

3.05 Setup for Welding........................................................................................... 3-4

3.06 Manual Arc (STICK) Setup.............................................................................. 3-5

3.07 Lift TIG (GTAW) Setup .................................................................................... 3-6

SECTION 4:OPERATION ................................................................................... 4-1

4.01 Front Panel ..................................................................................................... 4-1

4.02 SMAW Electrode Polarity................................................................................ 4-2

4.03 Effects of Stick Welding Various Materials...................................................... 4-2

4.04 GTAW Electrode Polarity................................................................................. 4-3

4.05 Guide for Selecting Filler Wire ........................................................................ 4-3

4.06 Tungsten Electrode Current Ranges............................................................... 4-3

4.07 Shielding Gas Selection .................................................................................. 4-3

4.08 Tungsten Electrode Types ............................................................................... 4-3

4.09 TIG Welding Parameters for Steel................................................................... 4-3

4.10 Arc Welding Practice....................................................................................... 4-4

4.11 Welding Position............................................................................................. 4-4

4.12 Joint Preparations........................................................................................... 4-5

4.13 Arc Welding Technique ................................................................................... 4-5

4.14 The Welder...................................................................................................... 4-6

4.15 Striking the Arc............................................................................................... 4-6

4.16 Arc Length ...................................................................................................... 4-6

4.17 Rate of Travel.................................................................................................. 4-6

4.18 Making Welded Joints..................................................................................... 4-6

4.19 Distortion........................................................................................................ 4-8

4.20 The Cause of Distortion .................................................................................. 4-9

4.21 Overcoming Distortion Effects........................................................................ 4-9

TABLE OF CONTENTS

SECTION 5:SERVICE ....................................................................................... 5-1

5.01 Routine Maintenance and Inspection.............................................................. 5-1

5.02 STICK Welding Problems ............................................................................... 5-2

5.03 TIG Welding Problems ................................................................................... 5-3

5.04 Power Source Problems ................................................................................. 5-4

5.05 Key Spare Parts .............................................................................................. 5-4

LIMITED WARRANTY & WARRANTY SCHEDULE .........................................................2

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ............................................3

March 20, 2007 1-1 Manual 0-5054

SAFETY INSTRUCTIONS ARC MASTER 175 SE

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit

is electrically live whenever the output is on. The

input power circuit and machine internal circuits

are also live when power is on. In semiautomatic

or automatic wire welding, the wire, wire reel, drive

roll housing, and all metal parts touching the weld-

ing wire are electrically live. Incorrectly installed or

improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating

mats or covers.

4. Disconnect input power or stop engine before installing or

servicing this equipment. Lock input power disconnect switch

open, or remove line fuses so power cannot be turned on

accidentally.

5. Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to

equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water

to cool it or lay it down on the ground or the work surface.

Do not touch holders connected to two welding machines

at the same time or touch other people with the holder or

electrode.

8. Do not use worn, damaged, undersized, or poorly spliced

cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground)

circuit.

12. Use only well-maintained equipment. Repair or replace

damaged parts at once.

13. In conﬁned spaces or damp locations, do not use a welder

with AC output unless it is equipped with a voltage reducer.

Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above ﬂoor

level.

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can

damage hearing. Arc rays from the welding process

produce intense heat and strong ultraviolet rays that

can burn eyes and skin. Noise from some processes

can damage hearing.

1. Wear a welding helmet ﬁtted with a proper shade of ﬁlter (see

ANSI Z49.1 listed in Safety Standards) to protect your face

and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from ﬂash

and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, ﬂame-resistant

material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

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.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study

and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply

to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 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.

Manual 0-5054 1-2 March 20, 2008

ARC MASTER 175 SE SAFETY INSTRUCTIONS

WARNING

FUMES AND GASES can be hazardous to your

health.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

1. Keep your head out of the fumes. Do not breathe the

fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied

respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instruction for metals, consumables,

coatings, and cleaners.

5. 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.

6. Do not weld in locations near degreasing, cleaning, or

spraying operations. The heat and rays of the arc can react

with vapours to form highly toxic and irritating gases.

7. 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.

WARNING

WELDING can cause ﬁre or explosion.

Sparks and spatter ﬂy off from the welding arc.

The ﬂying sparks and hot metal, weld spatter, hot

workpiece, and hot equipment can cause ﬁres and

burns. Accidental contact of electrode or welding

wire to metal objects can cause sparks, overheating,

or ﬁre.

1. Protect yourself and others from flying sparks and hot

metal.

2. Do not weld where flying sparks can strike flammable

material.

3. Remove all ﬂammables within 35’ (10.7m) of the welding

arc. If this is not possible, tightly cover them with approved

covers.

4. Be alert that welding sparks and hot materials from welding

can easily go through small cracks and openings to adjacent

areas.

5. Watch for ﬁre, and keep a ﬁre extinguisher nearby.

6. Be aware that welding on a ceiling, ﬂoor, bulkhead, or partition

can cause ﬁre on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. 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.

9. Do not use welder to thaw frozen pipes.

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS/ANSI Z49.1:1999

Welding or Cutting

Operation

Electrode Size Metal Thickness

or Welding Current

Filter

Shade No.

Welding or Cutting

Operation

Electrode Size Metal Thickness

or Welding Current

Filter

Shade No.

Torch Soldering All 2 Gas Tungsten Arc Welding

Torch Brazing All 3 or 4 Light Under 50 Amp 10

Oxygen Cutting Medium 50 to 150 Amp 12

Light Under 1" (25mm) 3 or 4 Heavy 150 to 500 Amp 14

Medium 1" – 6" (25mm – 150mm) 4 or 5 Atomic Hydrogen Welding All 12

Heavy Over 6" (150mm) 5 or 6 Carbon Arc Welding All 14

Gas Welding Carbon Arc Gouging

Light Under 1/8 " (3mm) 4 or 5 Light 12

Medium 1/8" – 1/2" (3mm – 12mm) 5 or 6 Heavy 14

Heavy Over 1/2" (12mm) 6 or 8 Plasma Arc Welding

Shielded Metal-Arc Welding (Stick) Electrodes Light Under 20 Amp 6 to 8

Light Under 5/32" (4mm) 10 Light 20 to 100 Amp 10

Medium Under 5/32" - ¼" (4mm - 6.4mm) 12 Medium 100 to 400 Amp 12

Heavy Over ¼" (6.4mm) 14 Heavy 400 to 800 Amp 14

Gas Metal Arc Welding Plasma Arc Cutting

Light Under 60 Amp 7 Light Under 300 Amp 9

Light 60 to 160 Amp 11 Medium 300 to 400 Amp 12

Medium 160 to 250 Amp 12 Heavy 400 to 800 Amp 14

Heavy 250 to 500 Amp 14

March 20, 2007 1-3 Manual 0-5054

SAFETY INSTRUCTIONS ARC MASTER 175 SE

10. Remove stick electrode from holder or cut off welding wire

at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause

injury.

Chipping and grinding cause ﬂying metal. As welds

cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields

recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode.

Since gas cylinders are normally part of the welding

process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat,

mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining

them to a stationary support or equipment cylinder rack to

prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical

circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses,

and ﬁttings designed for the speciﬁc application; maintain

them and associated parts in good condition.

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.

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. If used in a closed area, vent engine exhaust outside and away

from any building air intakes.

WARNING

ENGINE FUEL can cause ﬁre or explosion.

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 cool before fuelling. If possible, check and

add fuel to cold engine before beginning job.

4. Do not overﬁll 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.

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.

5. Keep hands, hair, loose clothing, and tools away from

moving parts.

6. Reinstall panels or guards and close doors when

servicing is ﬁnished and before starting engine.

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.

5. Observe correct polarity (+ and –) on batteries.

Manual 0-5054 1-4 March 20, 2008

ARC MASTER 175 SE SAFETY INSTRUCTIONS

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.

WARNING

This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

know to the State of California to cause birth defects

and, in some cases, cancer. (California Health &

Safety code Sec. 25249.5 et seq.)

NOTE

Considerations About Welding And The Effects of

Low Frequency Electric and Magnetic Fields

The following is a quotation from the General Conclusions Section

of the U.S. Congress, Ofﬁce of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields - Back-

ground Paper, OTA-BP-E-63 (Washington, DC: U.S. Government

Printing Ofﬁce, May 1989): “...there is now a very large volume

of scientiﬁc ﬁndings based on experiments at the cellular level

and from studies with animals and people which clearly establish

that low frequency magnetic ﬁelds and interact with, and produce

changes in, biological systems. While most of this work is of

very high quality, the results are complex. Current scientiﬁc

understanding does not yet allow us to interpret the evidence

in a single coherent framework. Even more frustrating, it does

not yet allow us to draw deﬁnite conclusions about questions of

possible risk or to offer clear science-based advice on strategies

to minimize or avoid potential risks.”

To reduce magnetic ﬁelds in the workplace, use the following

procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the

operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from

body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also

normally recommended for pacemaker wearers.

Consult your doctor for complete information.

LEAD WARNING

This product contains chemicals, including lead,

or otherwise produces chemicals known to the

State of California to cause cancer, birth defects

and other reproductive harm. Wash hands after

handling. (California Health & Safety Code §

25249.5 et seq.)

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from

American Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126.

Safety and Health Standards, OSHA 29 CFR 1910, from

Superintendent of Documents, U.S. Government Printing Ofﬁce,

Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding

and Cutting of Containers That Have Held Hazardous Substances,

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.

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