Rival TIG 185 DC User manual

TIG 185 DC Operating Manual

03
EN
TIG 185 DC. Operating manual.
Important Notice: This document has been prepared by Ryval, as general information and does not contain and is not to be taken as containing any specific instructions. The
document has been prepared in good faith and is professional opinion only. Information in this document has been derived from third parties, and though Ryval believes it to
be reliable as at the time of printing, Ryval makes no representation or warranty as to the accuracy, reliability or completeness of information in this document and does not
assume any responsibility for updating any information or correcting any error or omission which may become apparent after the document has been issued. Neither Ryval
nor any of its agents has independently verified the accuracy of the information contained in this document. The information in this document is commercial in confidence and
is not to be reproduced. The recipient acknowledges and agrees that it must make its own independent investigation and should consider seeking appropriate professional
recommendation in reviewing and evaluating the information. This document does not take into account the particular circumstances of the recipient and the recipient should
not rely on this document in making any decisions, including but not limited to business, safety or other operations decisions. Except insofar as liability under any statute cannot
be excluded, Ryval and its affiliates, directors, employees, contractors and consultants do not accept any liability (whether arising in contract, tort or otherwise) for any error
or omission in this document or for any resulting loss or damage (whether direct, indirect, consequential or otherwise) suffered by the recipient of this document or any other
person relying on the information contained herein. The recipient agrees that it shall not seek to sue or hold Ryval or their respective agents liable in any such respect for the
provision of this document or any other information.
Congratulations on purchasing the Ryval TIG 185 DC welding
machine. The products in Ryval’s manual metal arc range perform
with reliability and have the backing of one of the world’s leading
suppliers of welding products.
This operating manual provides the basic knowledge required for MMA
and DC TIG welding, as well as highlighting important areas of how to
operate the TIG 185 DC welding machine.
For more information or support please contact your local Ryval supplier.
Welcome to a better way of welding.

04 05
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TIG 185 DC. Operating manual.TIG 185 DC. Operating manual.
Contents.
Page
03 Welcome to a better way of welding
06 1. Recommended safety precautions
1.1 Health hazard information
1.2 Personal protection
1.3 Cylinder safety
1.4 Electrical shock
1.5 User responsibility
08 2. Gas Tungsten Arc Welding (GTAW/TIG)
2.1 Introduction
2.2 Process
2.3 Process variables
2.4 Shielding gas selection
2.5 Consumable selection
2.6 Non-consumable tungstens –
tungsten electrode selector chart
11 3. Manual Metal Arc Welding (MMAW)
3.1 Introduction
3.2 Process
3.3 Welding machine
3.4 Welding technique
3.5 Electrode selection
3.6 Types of joints
14 4. Package contents
Page
15 5. Control panel
16 6. TG 185 DC Operation
6.1 Power
6.2 Shielding gas
6.3 TIG torch connection
6.4 MMA operation
6.5 TIG welding operation
18 7. Technical specifications
19 8. Troubleshooting guide
21 9. Periodic maintenance
9.1 Daily maintenance
9.2 Regular power source maintenance
22 10. Warranty information
10.1 Terms of warranty
10.2 Limitations on warranty
10.3 Warranty period
10.4 Warranty repairs
23 11. Recommended safety guidelines

06 07
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TIG 185 DC. Operating manual.TIG 185 DC. Operating manual.
1. Recommended safety precautions.
Clothing
Suitable clothing must be worn to prevent excessive exposure to UV
radiation and sparks. An adjustable helmet, flameproof loose fitting
cotton clothing buttoned to the neck, protective leather gloves, spats,
apron and steel capped safety boots are highly recommended.
Recommended filter shades for arc welding
Less than 150 amps
150 to 250 amps
250 to 300 amps
300 to 350 amps
Over 350 amps
Shade 10*
Shade 11*
Shade 12
Shade 13
Shade 14
* Use one shade darker for aluminium
1.3 Cylinder safety
1Cylinder valve hand-wheel, 2Back-plug, 3Bursting disc
Operator wearing personal
protective equipment (PPE)
in safe position
Backview of typical
cylinder valve
1
2
3
Ten points about cylinder safety
1. Read labels and Material Safety Data Sheet (MSDS) before use.
2. Store upright and use in well ventilated, secure areas away from
pedestrian or vehicle thoroughfare.
3. Guard cylinders against being knocked violently or being allowed to
fall.
4. Wear safety shoes, glasses and gloves when handling and connecting
cylinders.
5. Always move cylinders securely with an appropriate trolley. Take care
not to turn the valve on when moving a cylinder.
6. Keep in a cool, well-ventilated area, away from heat sources, sources
of ignition and combustible materials, especially flammable gases.
7. Keep full and empty cylinders separate.
8. Keep ammonia-based leak detection solutions, oil and grease away
from cylinders and valves.
9. Never use force when opening or closing valves.
10.Don’t repaint or disguise markings and damage. If damaged, return
cylinders to Ryval immediately.
Cylinder valve safety
When working with cylinders or operating cylinder valves, ensure that
you wear appropriate protective clothing – gloves, boots and safety
glasses. When moving cylinders, ensure that the valve is not accidentally
opened in transit.
Before operating a cylinder valve:
→Ensure that the system you are connecting the cylinder into is
suitable for the gas and pressure involved.
→Ensure that any accessories (such as hoses attached to the cylinder
valve, or the system being connected to) are securely connected.
A hose, for example, can potentially flail around dangerously if it is
accidentally pressurised when not restrained at both ends.
→Stand to the side of the cylinder so that neither you nor anyone else
is in line with the back of the cylinder valve. This is in case a back-
plug is loose or a bursting disc vents. The correct stance is shown in
the diagram.
When operating the cylinder valve:
→Open it by hand by turning the valve hand-wheel anti-clockwise. Use
only reasonable force.
→Ensure that no gas is leaking from the cylinder valve connection or
the system to which the cylinder is connected. Do not use ammonia
based leak detection fluid as this can damage the valve. Approved
leak detection fluid can be obtained from your Ryval supplier.
→When finished with the cylinder, close the cylinder valve by hand
by turning the valve hand-wheel in a clockwise direction. Use only
reasonable force.
Remember NEVER tamper with the valve. If you suspect the valve is
damaged, DO NOT use it. Report the issue to Ryval and arrange for the
cylinder to be returned to Ryval.
1.4 Electrical shock
→Never touch ‘live’ electrical parts
→Always repair or replace worn or damaged parts
→Disconnect the power source before performing any maintenance or
service
→Earth all work materials
→Never work in moist or damp areas.
Avoid electric shock by:
→Wearing dry insulated boots
→Wearing dry leather gloves
→Never changing electrodes with bare hands or wet gloves
→Never cooling electrode holders in water
→Working on a dry insulated floor where possible
→Never hold the electrode and holder under your arm.
1.5 User responsibility
→Read the Operating Manual prior to installation of this machine.
→Unauthorised repairs to this equipment may endanger the technician
and operator and will void your warranty. Only qualified personnel
approved by Ryval should perform repairs.
→Always disconnect mains power before investigating equipment
malfunctions.
→Parts that are broken, damaged, missing or worn should be replaced
immediately.
→Equipment should be cleaned periodically.
PLEASE NOTE that under no circumstances should any equipment or
parts be altered or changed in any way from the standard specification
without written permission given by Ryval. To do so, will void the
Equipment Warranty.
1.1 Health hazard information
The actual process of welding is one that can cause a variety of hazards.
All appropriate safety equipment should be worn at all times, i.e.
headwear, respiratory, hand and body protection. Electrical equipment
should be used in accordance with the manufacturer’s recommendations.
Eyes
The process produces ultraviolet rays that can injure and cause
permanent damage. Fumes can cause irritation.
Skin
Arc rays are dangerous to uncovered skin.
Inhalation
Welding fumes and gases are dangerous to the health of the operator
and to those in close proximity. The aggravation of pre-existing
respiratory or allergic conditions may occur in some workers. Excessive
exposure may cause conditions such as nausea, dizziness, dryness and
irritation of eyes, nose and throat.
1.2 Personal protection
Respiratory
Confined space welding should be carried out with the aid of a fume
respirator or air supplied respirator.
→You must always have enough ventilation in confined spaces. Be alert
to this at all times.
→Keep your head out of the fumes rising from the arc.
→Fumes from the welding of some metals could have an adverse effect
on your health. Don’t breathe them in. If you are welding on material
such as stainless steel, nickel, nickel alloys or galvanised steel,
further precautions are necessary.
→Wear a respirator when natural or forced ventilation is not good
enough.
Eye protection
A welding helmet with the appropriate welding filter lens for the
operation must be worn at all times in the work environment. The
welding arc and the reflecting arc flash gives out ultraviolet and infrared
rays. Protective welding screen and goggles should be provided for
others working in the same area.

08 09
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TIG 185 DC. Operating manual.TIG 185 DC. Operating manual.
2. Gas Tungsten Arc Welding (GTAW/TIG).
Shielding gas is directed into the arc area by the welding torch and a
gas lens within the torch distributes the shielding gas evenly over the
weld area. In the torch the welding current is transferred to the tungsten
electrode from the copper conductor. The arc is then initiated by one of
several methods between the tungsten and the workpiece.
During TIG welding, the arc can be initiated by several means:
Scratch start
With this method, the tungsten electrode is physically scratched on the
surface of the workpiece and the arc is initiated at the full amperage
set by the operator. The incidence of the tungsten melting at the high
initiation amperage is high and tungsten inclusions in the weld metal are
quite common.
High frequency start
During High Frequency start, the arc will ‘jump’ towards the workpiece
if a critical distance is reached. With this method, there is no incidence
of tungsten inclusions happening. High Frequency is only available on
certain types of machines and it can affect nearby electronic equipment.
Lift Arc™
During this method of arc initiation, the tungsten is actually touching the
workpiece. This occurs at very low amperage that is only sufficient to
pre-heat, not melt the tungsten. As the tungsten is moved off the plate,
the arc is established. With this method, there is little chance of tungsten
inclusion occurring.
2.3 Process variables
DCEN
When direct-current electrode-negative (straight polarity) is used:
→Electrons strike the part being welded at a high speed
→Intense heat on the base metal is produced
→The base metal melts very quickly
→Ions from the inert gas are directed towards the negative electrode at
a relatively slow rate
→Direct current with straight polarity does not require post-weld
cleaning to remove metal oxides
2.1 Introduction
The Tungsten Inert Gas, or TIG process, uses the heat generated by an
electric arc struck between a non-consumable tungsten electrode and
the workpiece to fuse metal in the joint area and produce a molten
weld pool. The arc area is shrouded in an inert or reducing gas shield to
protect the weld pool and the non-consumable electrode. The process
may be operated autogenously, that is, without filler, or filler may be
added by feeding a consumable wire or rod into the established weld
pool.
2.2 Process
1Shielding gas, 2Arc, 3TIG filler rod, 4Weld pool, 5Collet, 6Tungsten Electrode,
7Workpiece
Schematic of the TIG welding process
1
2
3
4
5
6
7
Direct or alternating current power sources with constant current output
characteristics are normally employed to supply the welding current.
For DC operation the tungsten may be connected to either output
terminal, but is most often connected to the negative pole. The output
characteristics of the power source can have an effect on the quality of
the welds produced.
Use of DCEN
For a given diameter of tungsten electrode, higher amperage can be
used with straight polarity. Straight polarity is used mainly for welding:
→Carbon steels
→Stainless steels
→Copper alloys
The increased amperage provides:
→Deeper penetration
→Increased welding speed
→A narrower, deeper, weld bead
DCEP
The DCEP (reverse polarity) is different from the DCEN in the following
ways:
→High heat is produced on the electrode rather than on the base metal
→The heat melts the tungsten electrode tip
→The base metal remains relatively cool compared to straight polarity
→Relatively shallow penetration is obtained
→An electrode whose diameter is too large will reduce visibility and
increase arc instability
Use of DCEP
→Intense heat means a larger diameter of electrode must be used with
DCEP
→Maximum welding amperage should be relatively low (approximately
six times lower than with DCEN)
2.4 Shielding gas selection
Brass
Cobalt-based alloys
Copper nickel (Monel)
Deoxidised copper
Nickel alloys (Inconel)
Mild steel
Magnesium alloys
0.5% Molybdenum
Silicon bronze
Stainless steel
Titanium alloys
With argon, the arc is stable and there is little smoke.
Argon provides a stable, easy-to-control arc.
Argon gives a stable, easy-to-control arc. Also used for welding copper nickel to steel.
Helium is preferred as it helps greatly in counteracting thermal conductivity of copper. A mixture of 75% helium and 25%
argon (Alushield Heavy) produces a stable arc, less heat than an arc produced with helium alone.
Argon produces a very stable arc. Helium is recommended for automatic welding at high speeds
For manual welding, argon is recommended. Successful welding depends on the skill of the welder. Helium is preferred for:
→high speed automatic welding
→where deeper penetration than with argon is required
→small HAZ
Argon recommended with continuous high frequency AC. Produces good arc stability and good cleaning action
Pure argon or helium is recommended. For good welding ductility, welding must be carried out in a draught-free area.
Argon decreases internal tension in base metal and in the weld since there is less penetration with this gas compared to
helium.
Argon is the most commonly used gas for stainless steel. Helium can be used if better penetration is required.
Argon produces a stable arc. Helium is recommended for high speed welding.
DCEN – Narrow bead, deep penetration DCEP – Wide bead, shallow penetration
Nozzle Nozzle
Ions IonsElectrons Electrons

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TIG 185 DC. Operating manual.TIG 185 DC. Operating manual. 1110
2.5 Consumable selection
Filling rod
Filler rod diameter (mm) Thickness of metal (mm)
2
3
4
4 or 5
5 or 6
0.5–2
2–5
5–8
8–12
12 or more
2.6 Non-consumable tungstens – tungsten electrode selector chart
Copper alloys, Cu-NI alloys and nickel alloys
Thickness range
All
Only thin sections
Only thick sections
Desired results
General purpose
Control penetration
Increase penetration
or travel speed
Welding
current
DCSP
ACHF
DCSP
Electrode type
2% Thoriated
(EW-Th2)
2% Ceriated
(EW-Ce2)
Zirconiated
(EW-Zr)
2% Ceriated
(EW-Ce2)
Shielding gas
75% Argon/
25% Helium
75% Argon/
25% Helium
Argon
75% Argon/
25% Helium
Tungsten performance characteristics
Best stability at medium currents. Good arc starts.
Medium tendency to spit. Medium erosion rate.
Low erosion rate. Wide current range. AC or DC.
No spitting. Consistent arc starts. Good stability.
Use on lower currents only. Spitting on starts.
Rapid erosion rates at higher currents.
Low erosion rate. Wide current range. AC or DC.
No spitting. Consistent arc starts. Good stability.
Mild steels, carbon steels, alloy steels, stainless steels and titanium alloys
Thickness range
All
Only thin sections
Only thick sections
Desired results
General
purpose
Control penetration
Increase penetration
or travel speed
Welding
current
DCSP
ACHF
DCSP
Electrode type
2% Thoriated
(EW-Th2)
2% Ceriated
(EW-Ce2)
2%
Lanthanated
(EWG-La2)
Zirconiated
(EW-Zr)
2% Ceriated
(EW-Ce2)
2%
Lanthanated
(EWG-La2)
Shielding gas
75% Argon/
25% Helium
75% Argon/
25% Helium
75% Argon/
25% Helium
Argon
75% Argon/
25% Helium
Helium
Tungsten performance characteristics
Best stability at medium currents. Good arc starts.
Medium tendency to spit. Medium erosion rate.
Low erosion rate. Wide current range. AC or DC.
No spitting. Consistent arc starts. Good stability.
Lowest erosion rate. Widest current range on DC.
No spitting. Best DC arc starts and stability.
Use on lower current only. Spitting on starts.
Rapid erosion rates at higher currents.
Low erosion rate. Wide current range. No spitting.
Consistent arc starts. Good stability.
Lowest erosion rate. Highest current range.
No spitting. Best DC arc starts and stability.
3. Manual Metal Arc Welding (MMAW).
reversal is called a ‘half cycle’ and repeats as long as the current
flows. The rate of change of direction of current flow is known as the
‘frequency’ of the supply and is measured by the number of cycles
completed per second.
3.3 Welding machine
Basic welding machine and cables
The choice of welding machine is based mostly on the following factors:
→primary voltage, e.g. 240 volt or 380 volt
→output amperage required, e.g. 140 amps
→output required, e.g. AC or DC +/-
→duty cycle required, e.g. 35% @ 140 amps
→method of cooling, e.g. air-cooled or oil-cooled method of output
amperage control, e.g. tapped secondary lugs
→infinitely variable control
Having decided on a welding machine, appropriate accessories are
required. These are items such as welding cables, clamps, electrode
holder, chipping hammer, helmet, shaded and clear lenses, skull cap,
gloves and other personal protective equipment.
3.1 Introduction
The main purpose of this manual is to help the welder with limited
experience to obtain a better understanding of the process, and to
acquire a reasonable degree of proficiency in the least possible time.
Even welders with experience may benefit from the information in this
manual.
3.2 Process
Manual Metal Arc welding is the process of joining metals where an
electric arc is struck between the metal to be welded (parent metal) and
a flux-coated filler wire (the electrode). The heat of the arc melts the
parent metal and the electrode which mix together to form, on cooling, a
continuous solid mass.
Before arc welding can be carried out, a suitable power source is
required. Two types of power sources may be used for arc welding, direct
current (DC) or alternating current (AC).
1Weld metal, 2Slag, 3Flux covering, 4Core wire, 5Arc, 6Weld pool, 7Workpiece
1
2
3
4
5
67
The essential difference between these two power sources is that, in the
case of DC, the current remains constant in magnitude and flows in the
same direction. Similarly, the voltage in the circuit remains constant in
magnitude and polarity (i.e. positive or negative).
In the case of AC however, the current flows first in one direction and
then the other. Similarly, the voltage in the circuit changes from positive
to negative with changes in direction of current flow. This complete

EN
TIG 185 DC. Operating manual.TIG 185 DC. Operating manual. 1312
Welding current
Correct current selection for a particular job is an important factor in arc
welding. With the current set too low, difficulty is experienced in striking
and maintaining a stable arc. The electrode tends to stick to the work,
penetration is poor and beads with a distinct rounded profile will be
deposited.
Excessive current is accompanied by overheating of the electrode. It will
cause undercut, burning through of the material, and give excessive
spatter. Normal current for a particular job may be considered as the
maximum which can be used without burning through the work, over-
heating the electrode or producing a rough spattered surface, i.e. the
current in the middle of the range specified on the electrode package is
considered to be the optimum.
In the case of welding machines with separate terminals for different
size electrodes, ensure that the welding lead is connected to the correct
terminal for the size electrode being used. When using machines with
adjustable current, set on the current range specified.
The limits of this range should not normally be exceeded.
Arc length
To start the arc, the electrode should be gently scraped on the work until
the arc is established. There is a simple rule for the proper arc length;
it should be the shortest arc that gives a good surface to the weld. An
arc that is too long reduces penetration, produces spatter and gives a
rough surface finish to the weld. An excessively short arc will cause
sticking of the electrode and rough deposits that are associated with
slag inclusions.
For downhand welding, it will be found that an arc length not greater
than the diameter of the core wire will be most satisfactory. Overhead
welding requires a very short arc, so that a minimum of metal will be
lost. Certain Ryval electrodes have been specially designed for ‘touch’
welding. These electrodes may be dragged along the work and a
perfectly sound weld is produced.
Electrode angle
The angle which the electrode makes with the work is important to
ensure a smooth, even transfer of metal. The recommended angles for
use in the various welding positions are covered later.
3.4 Welding technique
Successful welding depends on the following factors:
→selection of the correct electrode
→selection of the correct size of the electrode for the job
→correct welding current
→correct arc length
→correct angle of electrode to work
→correct travel speed
→correct preparation of work to be welded
3.5 Electrode selection
As a general rule the selection of an electrode is straight forward, in that
it is only a matter of selecting an electrode of similar composition to the
parent metal. It will be found, however, that for some metals there is a
choice of several electrodes, each of which has particular properties to
suit specific classes of work. Often, one electrode in the group will be
more suitable for general applications due to its all round qualities.
Electrode size
The size of the electrode is generally dependent on the thickness of the
section being welded, and the larger the section the larger the electrode
required. In the case of light sheet the electrode size used is generally
slightly larger than the work being welded. This means that if 1.5 mm
sheet is being welded, 2.0 mm diameter electrode is the recommended
size. The following table gives the recommended maximum size of
electrodes that may be used for various thicknesses of section.
Recommended electrode sizes
Average thickness of plate or
section
≤ 1.5 mm
1.5–2.0 mm
2.0–5.0 mm
5.0–8.0 mm
≥ 8.0 mm
Maximum recommended
electrode diameter
2.0 mm
2.5 mm
3.15 mm
4.0 mm
5.0 mm
For further help on choosing the right electrode for your work please
contact your local Ryval supplier.
Correct travel speed
The electrode should be moved along in the direction of the joint being
welded at a speed that will give the size of run required. At the same
time the electrode is fed downwards to keep the correct arc length at all
times.
Correct travel speed for normal welding applications varies between
approximately 125–375 mm per minute, depending on electrode size,
size of run required and the amperage used.
Excessive travel speeds lead to poor fusion, lack of penetration, etc.
Whilst too slow a rate of travel will frequently lead to arc instability, slag
inclusions and poor mechanical properties.
Correct work preparation
The method of preparation of components to be welded will depend on
equipment available and relative costs. Methods may include sawing,
punching, shearing, lathe cut-offs, flame cutting and others. In all
cases edges should be prepared for the joints that suit the application.
The following section describes the various joint types and areas of
application.
3.6 Types of joints
This system is capable of several types of weld, from Butt through to
Fillet welds.

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TIG 185 DC. Operating manual.TIG 185 DC. Operating manual. 1514
4. Package contents. 5. Control panel.
5
4
2
1
678
3
12
11
10
9
Front panel layout
1Current meter, 2Pulse frequency switch, 3Power indicator light, 4MMA/TIG switch, 5Over-heating indicator, 6Current selection knob, 7Downslope adjustment,
8On/off switch, 9Negative dinse connector, 10Gas output, 11Contactor control, 12Positive dinse connector
Package contents
→TIG 185 DC welding machine
→Power cable and plug
→MMA electrode holder 300A
→Earth clamp and return lead
→TIG torch and gas outlet connections
→Operating manual.

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TIG 185 DC. Operating manual.TIG 185 DC. Operating manual. 1716
6.4 MMA operation
The TIG 185 DC can be used as a MMA welding machine by fitting an
electrode holder and work return lead to the respective dinse connectors
9+ 12 (dependant on the type of electrodes being used. Please consult
the packaging supplied by the manufacturer for correct polarities).
When using your TIG 185 DC machine in the MMA mode, ensure that the
TIG/MMA selector switch is in the MMA position. 4
6.5 TIG welding operation
The TIG 185 DC is fitted with a High Frequency (HF) start mode. The
arc will be initiated by keeping a distance of 2–4 mm between the
workpiece and the tungsten. The HF will be initiated by depressing the
contactor switch. Once the arc is initiated, the HF will automatically turn
off.
6.1 Power
The machine is designed to operate on a 240V ±15% input single phase
AC outlet. Ensure that there is adequate ventilation around the machine
when it is connected to the mains powersupply.
6.2 Shielding gas
When working the machine in the TIG mode of welding the process
requires a shielding gas. The shielding gas can be supplied via a pressure
regulator to the machine from either a fixed installation or single
cylinder of gas.
If a cylinder of gas is used, please ensure that the cylinder is securely
fastened before starting any welding operation.
Refer to the application section for the selection of the correct shielding
gas.
6.3 TIG torch connection
The TIG 185 DC machine is rated at 200A at 60% duty cycle.
→The torch is fitted to the machine by means of the Safe Lock dinse
back end. For DC (–) TIG operation, 9fit the torch back end to the
negative dinse connection. Similarly for DC (+), 12 fit the torch back
end to the positive dinse connection.
→The gas hose is fitted to the gas fitting (GAS) located on the front
bottom panel of the machine. 10
→The contactor lead is fitted to the contactor control fitting marked. 11
6.5.2 For DC pulse TIG welding
DC welding of thin material can further be enhanced by using the pulse
mode. When using the pulse mode for DC applications, the current will
be varied between the welding current and a pre-selected background
current. Additionally, the pulse frequency can be adjusted. By adjusting
the pulse frequency, the optimum heat input for a particular application
can be obtained.
The TIG 185 DC has two pre-selected pulse frequencies. These can be
selected by setting the pulse frequency switch 2to low frequency (2Hz)
or high frequency (200Hz). As a general rule, increasing the frequency
will increase the heat input into the plate.
6.5.3 Downslope control
The downslope of the welding current can be adjusted by adjusting the
Downslope Adjustment Control. 7By increasing the downslope control
time, it allows for better crater filling characteristics.
6.5.1 For direct current (DC) TIG welding
Select the correct size and type of non-consumable tungsten and
shielding gas for the application.
For DC– applications (most commonly used polarity) connect the TIG
torch to the negative Dinse plug connector and the work return lead to
the positive dinse plugconnector.
-
+
-
+
GTAW with DCEN produces deep penetration because it concentrates the heat in
the joint area. No cleaning action occurs with this. The heat generated by the arc
using this polarity occurs in the work thus a smaller electrode can be used as well
as a smaller gas cup and gas flow. The more concentrated arc allows for faster travel
speeds.
For DC+ applications connect the TIG torch to the positive dinse plug
connector and the work return lead to the negative dinse plug connector.
In this mode most of the heat is generated within the non-consumable
tungsten and the heat input into the plate is reduced resulting in lower
penetration depths. Larger tungstens are normally selected for this
application.
Ensure that the MMA/TIG selector switch is in the TIG position. 4
6. TIG 185 DC operation.

EN
TIG 185 DC. Operating manual.TIG 185 DC. Operating manual. 1918
7. Technical specifications. 8. Troubleshooting guide.
Problem
Excessive electrode
consumption
Erratic arc
Inclusion of tungsten
or oxides in weld
Cause
Inadequate gas flow
Improper size electrode for current required
Operating of reverse polarity
Electrode contamination
Excessive heating inside torch
Electrode oxidising during cooling
Shield gas incorrect
Incorrect voltage (arc too long)
Current too low for electrode size
Electrode contaminated
Joint too narrow
Contaminated shield gas. Dark stains on the electrode or
weld bead indicate contamination
Base metal is oxidised, dirty or oily
Poor scratch starting technique
Excessive current for tungsten size used
Accidental contact of electrode with puddle
Accidental contact of electrode to filler rod
Using excessive electrode extension
Inadequate shielding or excessive drafts
Wrong gas
Heavy surface oxides not being removed
Solution
Increase gas flow
Use larger electrode
Use larger electrode or change polarity
Remove contaminated portion, then prepare again
Replace collet. Try wedge collet or reverse collet
Increase downslope
Change to Argon (no oxygen or CO₂)
Maintain short arc length
Use smaller electrode or increase current
Remove contaminated portion, then prepare again
Open joint groove
The most common cause is moisture or aspirated air in gas
stream. Use welding grade gas only. Find the source of the
contamination and eliminate it promptly
Use appropriate chemical cleaners, wire brush, or abrasives
prior to welding
Many codes do not allow scratch starts. Use copper strike
plate. Use high frequency arc starter
Reduce the current or use larger electrode
Maintain proper arc length
Maintain a distance between electrode and filler metal
Reduce the electrode extension to recommended limits
Increase gas flow, shield arc from wind, or use gas lens
Do not use ArO₂ or ArCO₂ GMAW (MIG) gases for TIG welding
Use wire brush and clean the weld joint prior to welding
Specifications
Part no.
Power voltage AC
Frequency
No-load voltage
Rated input current
Output current
Rated output voltage
Duty cycle
No-load loss
Arc initiation
Efficiency
Power factor
Insulation grade
Housing protection grade
Weight
Dimensions L x W x H
MMA
Ryval DC TIG 185
AC240V±15%
50/60 Hz
61 V
30.1 A
10 to 160 A
26.4 V
60% at 150 A
100% at 114 A
40 W
HF
80%
0.73
F
IP21
8.4 kg
430 x 185 x 306 mm
TIG
Ryval DC TIG 185
AC240V±15%
50/60 Hz
61 V
25,6 A
10 to 185 A
18 V
70% at 185 A
100% at 170 A
40 W
HF
80%
0.73
F
IP21
8.4 kg
430 x 185 x 306 mm

EN
TIG 185 DC. Operating manual.TIG 185 DC. Operating manual. 2120
Problem
Porosity in weld
deposit
Cracking in welds
Inadequate shielding
Arc blow
Short parts life
Cause
Entrapped impurities, hydrogen, air, nitrogen, water vapour
Defective gas hose or loose connection
Filler material is damp (particularly aluminium)
Filler material is oily or dusty
Alloy impurities in the base metal such as sulfur,
phosphorous, lead and zinc
Excessive travel speed with rapid freezing of weld trapping
gases before they escape
Contaminated shield gas
Hot cracking in heavy section or with metals which are hot
shorts
Crater cracks due to improperly breaking the arc or
terminating the weld at the joint edge
Post weld cold cracking due to excessive joint restraint,
rapid cooling or hydrogen embrittlement
Centreline cracks in single pass weld
Underbead cracking from brittle microstructure
Gas flow blockage or leak in hoses or torch
Excessive travel speed exposes molten weld to atmospheric
contamination
Wind or drafts
Excessive electrode stickout
Excessive turbulence in gas stream
Induced magnetic field from DC weld current
Arc is unstable due to magnetic influence
Cup shattering or cracking in use
Short collet life
Short torch head life
Solution
Do not weld on wet material. Remove condensation from
line with adequate gas pre-flow time
Check hoses and connections for leaks
Dry filler metal in oven prior to welding
Replace filler metal
Change to a different alloy composition which is weldable.
These impurities can cause a tendency to crack when hot
Lower the travel speed
Replace the shielding gas
Preheat. Increase weld bead cross-section size. Change weld
bead contour. Use metal with fewer alloy impurities
Reverse direction and weld back into previous weld at edge.
Use Amprak or foot control to manually downslope current
Preheat prior to welding. Use pure or non-contaminated gas.
Increase the bead size. Prevent craters or notches. Change
the weld joint design
Increase bead size. Decrease root opening.
Use preheat. Prevent craters
Eliminate sources of hydrogen, joint restraint
and use preheat
Locate and eliminate the blockage or leak
Use slower travel speed or carefully increase the flow rate
to a safe level below creating excessive turbulence. Use a
trailing shield cup
Set up screens around the weld area
Reduce electrode stickout. Use a larger size cup
Change to gas safer parts or gas lens parts
Rearrange the split ground connection
Reduce weld current and use arc length as short as possible
Change cup size or type. Change tungsten position
Ordinary style is split and twists or jams
Change to wedge style
Do not operate beyond rated capacity. Use water cooled
model. Do not bend rigid torches
9. Periodic maintenance.
WARNING
Only authorised electricians should carry out repairs and internal
servicing.
Modification of the primary input plug or fitment of a lower rated
primary input plug will render the warranty null and void.
The working environment or amount of use the machine receives should
be taken into consideration when the planning maintenance frequency
of your system.
Preventative maintenance will ensure trouble-free welding and increase
the life of the machine and its consumables.
9.1 Daily maintenance
Perform the following maintenance daily:
→Clean the electrode holder and TIG torch‘s gas nozzle. Replace
damaged or worn parts.
→Check the TIG torch‘s electrode. Replace or sharpen, if necessary.
→Check the tightness of welding and earth cable connections.
→Check the condition of mains and welding cables and replace
damaged cables.
→See that there is enough space in front of and back of the unit for
ventilation.
9.2 Regular power source maintenance
→Check the electrical connections of the unit at least twice a year.
→Clean oxidised connections and tighten.
→Inner parts of the machine should be cleaned with a vacuum cleaner
and soft brush.
→Do not use any pressure-washing devices.
→Do not use compressed air as pressure may pack dirt even more
tightly into components.

EN
TIG 185 DC. Operating manual.TIG 185 DC. Operating manual. 2322
10. Warranty information.
10.3 Warranty period
The warranty is valid for 12 months from the date of purchase provided
the machine is used within the published specification limits.
10.4 Warranty repairs
A Ryval approved service provider must be informed within the warranty
period of any warranty defect. The customer must provide proof of
purchase and serial number of the equipment when making a warranty
claim. Warranty repairs may only be carried out by approved Ryval
service providers. Please contact your local Ryval supplier for more
information.
10.1 Terms of warranty
The TIG 185 DC machine has a limited warranty that covers
manufacturing and material defects only. The warranty is affected on the
day of purchase and does not cover any freight, packaging and insurance
costs. Verbal promises that do not comply with the terms of warranty are
not binding on the warrantor.
10.2 Limitations on warranty
The following conditions are not covered under terms of warranty: loss or
damage due to or resulting from natural wear and tear, non-compliance
with operating and maintenance instructions, connection to incorrect
or faulty voltage supply (including voltage surges outside equipment
specs), incorrect gas pressure overloading, transport or storage damage
or fire or damage due to natural causes (e.g. lightning or flood). This
warranty does not cover direct or indirect expenses, loss, damage or
costs including, but not limited to, daily allowances or accommodation
and travelling costs.
Modification of the primary input plug or fitment of a lower rated
primary input plug will render the warranty null and void.
NOTE
Under the terms of warranty, welding torches and their consumables
are not covered. Direct or indirect damage due to a defective product
is not covered under the warranty. The warranty is void if changes are
made to the product without approval of the manufacturer, or if repairs
are carried out using non-approved spare parts. The warranty is void if a
non-authorised agent carries outrepairs.
11. Recommended safety guidelines.
→Leads and cables should be kept clear of passageways.
→Keep fire extinguishing equipment at a handy location in the shop.
→ Keep primary terminals and live parts effectivelycovered.
→Never strike an electrode on any gas cylinder.
→Never use oxygen for venting containers.
Some safety precautions Ryval recommends are as follows:
→Repair or replace defective cables immediately.
→Never watch the arc except through lenses of the correct shade.
→In confined spaces, adequate ventilation and constant observation
are essential.
Diagram and safety explanation
Electrical safety alert Wear dry, insulated gloves
Welding electrode causing
electric shock
Insulate yourself from work and ground
Fumes and gases coming from
welding process
Disconnect input power before working on
equipment
Welding arc rays Keep head out of fumes
Read instruction manual Use forced ventilation or local exhaust to
remove fumes
Become trained Use welding helmet with correct shade of
filter

ISS/506695/UKS/1213
BOC
Customer Service Centre, Priestley Road, Worsley, Manchester M28 2UT
[e-mail]
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