ESAB ET 186i AC/DC, Operating Manual

Page 1: ...3163339 R vision AA Issue Date June 1 2016 Manual No 0 5425 Operating Manual ESAB ET 186i AC DC Inverter Arc Welder esab com Art A 13113...

Page 2: ...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...

Page 3: ...served 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 los...

Page 4: ...reof contained in this manual and accom panying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked period...

Page 5: ...ns Supply Voltage Requirements 3 1 3 05 High Frequency Introduction 3 2 3 06 High Frequency Interference 3 2 3 07 Electromagnetic Compatibility 3 3 3 08 ET 186i AC DC Power Source Controls Indicators...

Page 6: ...1 5 01 Basic Troubleshooting 5 1 5 02 Power Source Problems 5 1 5 03 Routine Service and Calibration Requirements 5 2 5 04 Cleaning the Welding Power Source 5 4 SECTION 6 KEY SPARE PARTS 6 1 6 01 Powe...

Page 7: ...rted up no one is unprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from drafts 4 Personal safety equipment Always wear recommended personal safety equipment...

Page 8: ...ter lens and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby...

Page 9: ...DC provides excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures The follow ing instructions detail how to correctly and saf...

Page 10: ...d sup ply line before moving the welding power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift unit with handle on top of case Use handcart or similar devi...

Page 11: ...wer Source Applicable Standards Approvals CSA E60974 1 00 UL60974 1 IEC 60974 1 Number of Phases 1 Nominal Supply Frequency 50 60Hz Welding Current Range STICK Mode 5 170A DC Stick 10 170A AC Stick We...

Page 12: ...maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown 60 70 80 90 100 e volts ET 186i AC DC 0 10 20 30 40 50 0 20 40 60 80 100 12...

Page 13: ...using in such areas A Examples of environments with increased hazard of electric shock are 1 In locations in which freedom of movement is re stricted so that the operator is forced to perform the work...

Page 14: ...lar to a radio transmitter The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing WARNING It is also possible that operation close to computer inst...

Page 15: ...d television transmitters and receivers 3 Computer and other control equipment 4 Safety critical equipment e g guarding of industrial equipment 5 The health of people around e g the use of pace makers...

Page 16: ...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...

Page 17: ...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...

Page 18: ...r check the power source b Primary Circuit Overcurrent This is due to primary circuit component s malfunctioning which results in excessive primary circuit current Switch OFF the power source immediat...

Page 19: ...n 4T TIG modes only and is used to set the time for the weld current to ramp up after the torch trigger switch has been pressed then released from Initial Current to High or Weld Current Press hold Tr...

Page 20: ...ameters 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 fol lowing sequence i...

Page 21: ...mponents are at Mains voltage potential 21 Shielding Gas Inlet Unit has a 5 8 Inert gas fitting suitable for connection of a gas hose to a regulated Shielding Gas Supply The Shielding Gas inlet is loc...

Page 22: ...ld 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 Ar...

Page 23: ...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 adjus...

Page 24: ...has been depressed Note The maximum initial current available will be limited to the set value of the weld current Amps 5 to 200 Amps DC TIG mode 30 to 200 Amps AC LIFT TIG mode 10 to 200A AC HF TIG...

Page 25: ...t to ramp down after the torch trigger switch has been pressed to crater current This control is used to eliminate the crater that can form at the completion of a weld V SEC Hz Volts 0 0 to 25 0 secon...

Page 26: ...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 V SEC Hz Volts 10 to 6...

Page 27: ...her 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 con nection 3...

Page 28: ...remove it from the regulator 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 NEV...

Page 29: ...ith roller potentiometer Control module with roller potentiometer and integrated on off switch Additional On Off Switch Cartridge in a Sealed Plastic Bag Additional On Off Switch Remote Amperage Contr...

Page 30: ...nnect 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 TIG or HF TIG Mode NOTE S...

Page 31: ...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 essent...

Page 32: ...ble 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 NO...

Page 33: ...ET 186i AC DC Manual 0 5425 3 21 INSTALLATION OPERATION AND SETUP Art A 13118 Positive Welding Terminal Work Lead Negative Welding Terminal Electrode Holder 2 0 0 A Figure 3 11 Setup for Manual Arc We...

Page 34: ...ESAB ET 186i AC DC INSTALLATION OPERATION AND SETUP 3 22 Manual 0 5425 This Page Intentionally Blank...

Page 35: ...under bead cracks in the weld area may be reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tem...

Page 36: ...eet metal lap joints and fillet welds general purpose plate welding Mild Steel E7018 A low hydrogen all position electrode used when quality is an issue or for hard to weld metals It has the capabilit...

Page 37: ...9 Typical Joint Designs for Arc 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 Us...

Page 38: ...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 same time the electrode has...

Page 39: ...oot of the weld 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 A piece of angl...

Page 40: ...ifficult 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...

Page 41: ...l methods of minimizing distortion effects 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...

Page 42: ...ck Sequence The spaces between the welds are filled in when the welds are cool 2 3 Figure 4 24 Welding Sequence Art A 07711_AB 4 3 2 1 Figure 4 25 Step Back Sequence Art A 07428_AB Figure 4 26 Chain I...

Page 43: ...ts allow slag to be trapped C If very bad chip or grind out irregularities D Lack of penetration with slag trapped beneath weld bead D Use smaller electrode with sufficient current to give adequate pe...

Page 44: ...r in steel A Use an electrode that is designed for high sulphur steels B Electrodes are damp B Dry electrodes before use C Welding current is too high C Reduce welding current D Surface impurities suc...

Page 45: ...n the welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Electrod...

Page 46: ...p Fillet Table 4 6 Aluminium Welding Material Base Metal Thickness DC Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow R...

Page 47: ...n an arc is struck A Torch lead connected to positive welding terminal A Connect torch lead to negative welding terminal B No gas flowing to welding region B Check the gas lines for kinks or breaks an...

Page 48: ...g electrode is being used for the welding job B Select the right tungsten electrode type Refer to Table 4 5 Tungsten Electrode Selection Chart C Gas flow rate is too high C Select the right rate for t...

Page 49: ...nnot be established A B Primary control fuse is blown Broken connection in primary circuit A B Replace primary control fuse Have an Accredited ESAB Service Provider check primary circuit 3 Fault Indic...

Page 50: ...minates when the power source is switched back ON turn the power source OFF and have an Accredited ESAB Service Provider check the power source Table 5 1 Power Source Problem 5 03 Routine Service and...

Page 51: ...h 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 supplying ESAB welding power...

Page 52: ...riodic 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 sha...

Page 53: ...ESAB ET 186i AC DC Manual 0 5425 6 1 KEY SPARE PARTS SECTION 6 KEY SPARE PARTS 6 01 Power Source 1 2 3 4 5 6 7 10 13 14 16 9 11 A 11500_AC 15 12 12 25 23 21 8 19 17 18 20 24 28 Figure 6 1...

Page 54: ...13 Dinse Socket 50mm 13 W7005568 Control socket 8 pin including wire harness 14 W7005514 Gas outlet front panel 15 W7005515 Switch On Off 16 W7003076 CT output 17 W7005539 Inductor 186AC DC 18 W700551...

Page 55: ...HF TIG AC DC MODE PULSE PURGE BACK FORWARD A V Encode AC DC I z I s I 2 I e I 1 Pre Flow Post Flow Initial Current Up Slope Down Slope Crater Current Base Current Frequency f w Width High Current Low...

Page 56: ...RRENT AC FREQUENCY POST FLOW 16 ga 1 6 mm Butt 1 16 1 6 mm 65A 150 Hz 5 sec 16 ga 1 6 mm Fillet 1 16 1 6 mm 85A 150 Hz 6 sec 1 8 3 2 mm Butt 3 32 2 4 mm 135A 150 Hz 11 sec 1 8 3 2 mm Fillet 3 32 2 4 m...

Page 57: ...5 95A 80 140A Arc Force Polarity Selection STICK 3 32 2 4 mm 1 8 3 2 mm 5 32 4 0 mm Weld Current Range 50 75A 70 110A 80 145A Arc Force Polarity Selection Weld Current Range 70 95A 100 135A 145 170A A...

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