Thermal Arc 250S DC CC Operating Manual [en, fr]

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INVERTER

ARC

WELDER

MODEL 250S DC CC

STICK TIG - Lift Start

November 11, 2003 Manual No. 430429-506

OPERATING MANUAL

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CONTENTS

SYMBOL LEGEND ............................................................................................................................................................5

STATEMENT OF WARRANTY........................................................................................................................................6

1.0 GENERAL INFORMATION.........................................................................................................................................7

1.01 Notes, Cautions and Warnings................................................................................................................................7

1.02 Important Safety Precautions....................................................................................................................................7

1.03 Publications.............................................................................................................................................................8

1.04 Note, Attention et Avertissement.............................................................................................................................9

1.05 Precautions De Securite Importantes.......................................................................................................................9

1.06 Documents De Reference......................................................................................................................................11

2.0 INTRODUCTION AND DESCRIPTION ...................................................................................................................13

2.01 Description .............................................................................................................................................................13

2.02 Functional Block Diagrams....................................................................................................................................14

2.03 Transporting Methods.............................................................................................................................................14

3.0 INSTALLATION RECOMMENDATIONS................................................................................................................15

3.01 Environment...........................................................................................................................................................15

3.02 Location..................................................................................................................................................................15

3.03 Electrical Input Connections...................................................................................................................................16

3.03.01 Electrical Input Requirements.......................................................................................................................16

3.03.02 Input Power ...................................................................................................................................................18

3.03.03 High Frequency Introduction.........................................................................................................................19

3.03.04 High Frequency Interference......................................................................................................................... 19

3.04 Specifications .........................................................................................................................................................20

3.05 Duty Cycle..............................................................................................................................................................21

4.0 OPERATOR CONTROLS...........................................................................................................................................23

4.01 Pro-Lite 250S Controls...........................................................................................................................................23

4.02 Weld Parameter Description...................................................................................................................................25

4.03 Weld Parameters for Pro-Lite 250S........................................................................................................................26

4.04 Power Source Features...........................................................................................................................................26

5.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG) ..................................................................................................28

6.0 SEQUENCE OF OPERATION....................................................................................................................................29

6.01 Stick Welding.........................................................................................................................................................30

6.02 DC LIFT TIG Welding...........................................................................................................................................30

7.0 BASIC TIG WELDING GUIDE..................................................................................................................................31

7.01Electrode Polarity....................................................................................................................................................31

7.02 Tungsten Electrode Current Ranges .......................................................................................................................31

7.03 Tungsten Electrode Types ......................................................................................................................................31

7.04 Guide for Selecting Filler Wire Diameter...............................................................................................................32

7.05 Shielding Gas Selection..........................................................................................................................................32

7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe......................................................................32

7.07 Welding Parameters for Steel.................................................................................................................................33

8.0 BASIC ARC WELDING GUIDE................................................................................................................................34

8.01Electrode Polarity....................................................................................................................................................34

8.02 Effects of Stick Welding Various Materials...........................................................................................................34

9.0 BASIC TROUBLESHOOTING...................................................................................................................................37

9.01 TIG Welding Problems...........................................................................................................................................37

9.02 Stick Welding Problems.........................................................................................................................................39

9.03 Power Source Problems..........................................................................................................................................41

10.0 VOLTAGE REDUCTION DEVICE (VRD)..............................................................................................................42

10.01 VRD Specification................................................................................................................................................42

10.02 VRD Maintenance................................................................................................................................................42

11.0 POWER SOURCE ERROR CODES.........................................................................................................................43

12.0 PARTS LIST..............................................................................................................................................................46

APPENDIX A - INTERCONNECT DIAGRAM...............................................................................................................50

APPENDIX B - AUTOMATION ......................................................................................................................................52

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PAGE LEFT INTENTIONALLY BLANK

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SYMBOL LEGEND

Amperage STICK (Shielded Metal Arc

Voltage Pulse Current Function

Hertz (frequency) Spot Time (GTAW)

SMAW)

SEC

Seconds Remote Control (Panel/Remote)

Percent Remote Function

DC (Direct Current) Arc Control (SMAW)

AC (Alternating Current Gas Post-Flow

Standard Function Gas Pre-Flow

Slope Function

VRD

Slope W/Repeat Function Negative

Voltage Reduction Device Circuit

Spot Function Positive

Impulse Starting (High Frequency GTAW)

Touch Start (Lift Start TIG circuit GTAW)

Gas Input

Gas Output

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STATEMENT OF WARRANTY

LIMITED WARRANTY: Thermal Arc authorized distributors hereafter “Thermal; Arc” that its products will be free of defects in workmans hip or material. Should any failure to con form to thi s wa rr anty a ppear with i n th e time p er iod a ppl ica bl e to th e Th er mal Ar c pr od ucts as s tate d bel ow, Th ermal Arc shall, upon notificati on the reof and s ubstan tiation that the pr oduct ha s been stored , ins talle d, opera ted, a nd ma intaine d in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by s uitable repair or replacement, at Thermal Ar c’s sole option, of any components o r parts of the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal Arc shall not under any cir cumstan ces be liable for s pecial, ind ire ct or con sequentia l d amages,

such as, but not l imited to, lost profi ts and busi ness in terruption . The re medies of the Pur chaser set forth h erein ar e exclus ive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the ma nufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant an y other warranty.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NONAUTHORIZED PERSONS.

, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of its

The warran ty is effective fo r the time stated below beginnin g on the date that th e authoriz ed distributor delivers the products to the Purchaser. Notw iths tan ding the for egoin g, in no even t shal l the wa rra nty per iod ex tend more tha n the time sta ted plus one year from the date Thermal Arc delivered the prod uct to the authorized distr ibutor.

POWER SUPPLIES POWER SUPPLIES & WIRE FEEDERS LABOR

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEAR 3 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEAR 3 YEAR POWER SWITCHING SEMI-CONDUCTORS & CONTROL PC BOARD 3 YEAR 3 YEAR

ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS, SOLENOIDS, PUMPS, SWITCHES, MOTORS

ENGINES: ENIGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER, SEE THE ENGINE MANUFACTUR ES WARRA NT Y FOR DE TAILS .

CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR EXCHANGES, AND ACCESSORY EQUIPMENT PLASMA TORCH AND LEADS, AND REMOTE CONTRO LS

180 DAYS 180 DAYS

REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS

Warranty repair s or replace ment cla ims under this limi ted warr anty must be s ubmitted to Th ermal Arc by an a uthoriz ed Thermal Arc repair facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous Thermal Arc warranties.

Thermal Arc® is a Registered Trademark of Thermadyne Industries Inc.

Effective April 1, 2002

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1.0 GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Prec autions

WARNING

OPERATION AND MAINTENANCE OF ARC WELDING EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1800-462-2782 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the Arc welding/cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

• The kinds of fumes and gases from the arc welding/cutting depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fume s and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft welding/cutting tables, to capture fumes and gases.

• Do not use the welding torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solven ts and cleanser s. Remove all sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The arc welding process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workpla ce is moist or damp.

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• Install and maintain eq uipment according to NEC code, refer to item 4 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the arc weld.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protec te d.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

• Provide a fire watch when working in an area where fire hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unle ss the hydrogen ga s can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Arc welding/cutting processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.

ARC WELDING RAYS

Arc Welding/Cutting Rays can injure your eyes and burn your skin. The arc welding/cutting process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suita ble clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the wor k area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as recommended in Subsection 1.03, item 4.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AN D HEA L TH ST AN D ARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

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6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11.CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du sy stème.

ATTENTION

Toute procédure po uvant résulter l’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENT

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Il faut communiquer aux o pérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 1-800-462-2782 ou votre distributeur local si vous avez des questions.

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief

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FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré pa r la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas

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hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.

RAYONS D’ARC DE PLASM A

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunette s de pr otection ou une autre sorte de protec tion oculaire.

• Portez des gants de soudeur et u n vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres pe rsonnes se tr ouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Respectez le teint de lentille recommandé dans le article 4, page 5.

• Hydrogen gas may be present under aluminum workpieces during the cutting process when being cut underwater or using a water table. DO NOT cut aluminum underwater or on a water table unless the hydrogen gas can be eliminated as the hydrogen gas may detonate.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez

également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révision s les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT

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RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

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2.0 INTRODUCTION AND DESCRIPTION

2.01 Description

The Thermal Arc™ Model Pro-Lite 250S is a self contained single/three-phase DC arc welding power sources with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, and lift arc starter, for use with Gas Tungsten Arc Welding (GTAW) and Shielded Metal Arc Welding (SMAW) processes. The power source is totally enclosed in an impact resistant, flame resistant and non-conductive plastic case.

(V)

OCV

18V

160A

250A5A (A)

270A

(V)

OCV

10V

250A25A (A)

STICK Process LIFT-TIG Process

Figure 1. Model 250S volt-ampere curve

Note 1

Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source. Curves of other settings will fall between the curves shown.

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2.02 Functional Block Diagrams

Figure 2 illustrates the functional block diagram of the 250S-power supply.

Figure 2. 250S Model functional block diagram

2.03 Transporting Methods

These units are equipped with a handle for carrying purposes.

WARNING 1

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

WARNING 2

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

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3.0 INSTALLATION RECOMMENDATIONS

3.01 Environment

The Pro-Lite 250S is desig ned for use i n ha zardou s env ironment s.

Examples of environments with increased hazardous environments are -

a. In locations in which freedom of movement is restricted, so that the operator is forced

to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts;

b. In locations which are fully or partially limited by conductive elements, and in which

there is a high risk of unavoidable or accidental contact by the operator, or

c. In wet or damp hot locations where humidity or perspiration considerably reduces the

skin resistance of the human body and the insulation properties of accessories.

Environments with hazardous environments do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

3.02 Location

Be sure to locate the welder according to the following guidelines:

• In areas, free from moisture and

dust.

• In areas, free from oil, steam and

corrosive gases.

• In areas, not exposed to direct

sunlight or rain.

• Ambient temperature between 0 degrees

C to 40 degrees C.

• In areas, not subjected to abnormal

vibration or shock.

• Place at a distance of 12” (304.79mm) or

more from walls or similar that could restrict natural airflow for cooling.

WARNING 3

Thermal Arc advises that this equipment be electrically connected by a qualified electrician.

Page 16

3.03 Electrical Input Connections

WARNING 4

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

3.03.01 Electrical Input Requirements

Operate the welding power source from a single/three-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required.

The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.

Note 2

These units are equipped with a three-conductor with earth power cable that is connected at the welding power source end for single and three phase electrical input power.

Do not connect an input (WHITE or BLACK or RED) conductor to the ground terminal. Do not connect the ground (GREEN) conductor to an input line terminal.

Refer to figure 3 and:

1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes.

2. Connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors to a deenergized line disconnect switch.

3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.

Note 3

For Single-Phase operation connect the GREEN, BLACK and WHITE input conductors. Insolate the RED Conductor, it is not used for Single-phase operation.

Page 17

Input Voltage Fuse Size

208 75 230 70 460 20

Table 1 Electrical Input Connections

NOTE: Fuse size is based on not more than 200 percent of the rated input amperage of the welding

power source (Based on Article 630, National Electrical Code).

Figure 3. Electrical Input Connections

Page 18

3.03.02 Input Power

Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT BREAKER is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).

Note 4

Note the available input power. Damage to the PCA could occur if 575VAC or higher is applied.

The following 208-230/460V Primary Current recommendations are required to obtain the maximum welding current and d uty cycle from this welding equipment:

Model

PRO-LITE 250S

Table 2 – 230/460V Primary Current Circuit sizes to achieve maximum current

Primary Supply

Lead Size

8/4 AWG minimum

(Factory Fitted)

8/3 AWG minimum

Minimum Primary

Current Circuit Size

(Vin/Phase/Amps)

208/3/24 230/3/21 -

460/3/11 208/3/35 230/3/32 460/3/16 208/1/51 230/1/46 208/1/75 230/1/68

Current

& Duty Cycle

TIG STICK

250A @ 40%

Page 19

3.03.03 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following information is intended as a guide for personnel installing high frequency welding machi nes.

Warning

Explosives

The high frequency section of this machine has an output similar to a radio transmitter. The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing.

Computers

It is also possible that operation close to computer installations may cause computer malfunction.

3.03.04 High Frequency Interference

Interference may be transmitted by a high frequency initiated or stabilized arc-welding machine in the following way s:

Direct Radiation

Radiation from the machine can occur if the case is metal and is not properly grounded. It can occur through apertures such as open access panels. The shielding of the high frequency unit in the Power Source w ill preve nt d irect radiat ion if t he equipmen t is pr operly grounded.

Transmission via the Supply Lead

Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the installation (mains) b y direct coupling. The energy is then transmitted by both radiation and conduction. A dequate sh ield ing and fil ter ing is provided in the Power S ource.

Radiation from Welding Leads

Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with distance. Keeping leads as short as possible will minimize this type of interference. Looping and sus pending of leads sho uld be avo ided where pos sib le.

Re-radiation from Unearthed Metallic Objects

A major factor contributing to interference is re-radiation from unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent re-radiation in most cases.

Page 20

3.04 Specifications

Parameter 250S Rated Output Amperes Volts Duty Cycle

208-230/460VAC 250 30 40%

Duty Cycle 250A / 30V @ 40%

190A / 27V @ 60% Output Current 5 – 250 Amps Range Open Circuit Voltage 69V

Dimensions

Width Height Length

7.08” (180mm)

14.17” (360mm)

16.54” (420mm)

Weight 39.68 lb. 18 kg

Output @ Rated Load

Output Amperes Output Volts Duty Cycle KVA KW

Three-phase Single-phase

250A 250A

30V 30V

40% 40%

12.5 15.7

9.4 9.4

Output @ No Load

KVA KW

Input Volts Three Phase

0.5 0.5

0.13 0.13

Amperage Draw @ Rated Load

208V 230V 460V

Input Volts Single Phase

208V 230V 460V

35 32 16

75 68

No Load

1.3

1.1

0.7

2.2

1.6

Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product wi thout prior notice. Such updates or changes do not entitle the bu yer of eq uipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

Page 21

3.05 Duty Cycle

The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty cycle will decrease.

WARNING 5

Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature.

CAUTION 1

Continually exceeding the duty cycle rat ings can cause damage to the welding power source and will void the manufactures warranty.

NOTE 5

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

Page 22

PAGE LEFT INTENTIONALLY BLANK

Page 23

4.0 OPERATOR CONTROLS

4.01 Pro-Lite 250S Controls

Figure 4. – Pro-Lite 250S Power Source

1 Control Knob

This control sets the selected weld parameter, rotating it clockwise increases the parameter and is indicated on the digital meter. Pushing the knob in previews the actual welding voltage while welding.

2 Remote Control Socket

The 8 pin Remote Control S ocke t i s use d t o connec t remo te current con trol devices to the welding Power Source. To make connect ion s, a lig n keyway, insert p lug, and rota te threaded collar fully cloc kwise.

Gnd.

543 876

Front view of 8-Socket Receptacle

12345678

5k Ohms

Page 24

Socket Pin Functio n

1 Earth (Ground) 2

Torch Switch Input (24V) to energ ize we ld curren t. (connect pins 2 & 3 to turn on wel ding current)

Torch Switch Input (0V) to e nergize weld current (connect pins 2 & 3 to turn on wel ding current)

Connect pin 4 to pin 8 to instruct machine that a remote current control device

is connected (12V DC supply) 5 5k ohm (maximum) connection to 5k ohm rem ote co ntro l po tent io meter 6 Zero ohm (minimum) connection to 5k ohm re mote control potentiometer 7 Wiper arm connection to 5 k oh m r em ote control potentiome ter 8 Connect pin 4 to pin 8 to instruct machine that a remote current control device

is connected (0V)

3 Positive Terminal

Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

4 Negative Terminal

Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION 2

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

5 ON/OFF Switch

This switch connects the Primary suppl y voltage to the inverter when in the ON position. This enables the Power Sup ply.

WARNING 6

When the welder is connected to the Primary supply voltage, the internal electrical components maybe at primary potential with respect to earth.

6 Input Cable

The input cable connects the Primary supply voltag e to the eq uip ment.

SMART Logic Switch (Not Sho wn)

Manual slide switch mounted on the back panel selects for proper input voltage. If this slide is not set to the position that matches the input voltage from the electrical source the Smart Logic circuit will inhibit welding power source output. The digital meter will show primary input error code.

Page 25

4.02 Weld Parameter Description

Figure 5. - Pro-Lite 250S Front Panel with Parameter Description

Parameter Description

This parameter operates in STICK weld mode and is used to improve

HOT START

the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the (WELD) current.

Weld Current (Amperage)- sets the STICK and TIG WELD current.

ARC CONTROL - This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability.

LIFT TIG mode of operation. A remote control device is required for use during LIFT TIG operation. See section 4.01, section 2 “Remote Control Socket”, for complete details of the remote device.

STICK Mode of operation

Table 3 – Weld Parameter Descriptions

Page 26

4.03 Weld Parameters for Pro-Lite 250S

Weld Mode

Weld

Parameter

Range

Factory

Setting

Incremental

Unit

STICK LIFT TIG

HOT START 0 to 70A 20A 1A Yes No WELD CUR 5 to 250A 230V 80A 1A Yes Yes

ARC CONTROL 0 to 100% 10% 1% Yes No

4.04 Power Source Features

Feature Description

New Digital Control Touch Panel Switches Front Control Cover Digital Meter

• Almost all welding parameters are adjustable

• Touch switches eliminate mechanical damage

• Protects front panel controls

• Displays selected weld parameter value

• Displays weld current when welding

• Displays weld current for 20 seconds after weld

has been completed

• A selected weld parameter value can be adjusted at

any time even while welding

Intelligent Fan Control

• The intelligent cooling system is designed to

reduce dust and foreign material build-up, whilst providing optimum cooling.

• Fan speed reduces approximately 30 seconds after

machine is turned on

• Fan speed increases when internal components

reaches operating temperature

ON/OFF switch

Voltage Reduction Device (VRD)

Control Knob

• Primary voltage Supply ON/OFF switch located

on rear panel

Reduces the OCV when the power supply is not in use. Eliminates the need for add on voltage reducers and has no effect on arc starting.

• VRD fully complies to IEC 60974-1

• When Stick mode is selected the green VRD light

is ON when not welding and red when welding.

• When in TIG modes VRD is off.

• For the selected weld parameter, rotating the knob

clockwise increases the parameter

• Rotating the knob counterclockwise decreases the

parameter

• A selected weld parameter value can be adjusted at

any time even while welding

• Pushing the knob in displays actual arc voltage.

Page 27

Feature Description

Self Diagnosis Using Error Codes

• An error code is displayed on the Digital Meter

when a problem occurs with Primary supply voltage or internal component problems. Refer to troubleshooting guide.

Page 28

5.0 SET-UP FOR SMAW (STICK) AND GTAW (TI G )

Conventional operating procedures apply when using t he Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding current at any one setting would vary according to the type of electrode in use. The operator should use the welding current range values as a guide, the n f ina l ly adjust the current se tting to suit the app lic ati on.

Figure 6. – 250S Set-up

WARNING 7

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off.

CAUTION 3

Remove any packaging material prior to use. Do

Remove any packaging material prior to use. DoRemove any packaging material prior to use. Do not block the air vents at the front or rear or sides

not block the air vents at the front or rear or sides

not block the air vents at the front or rear or sidesnot block the air vents at the front or rear or sides of the Welding Power Source.

of the Welding Power Source.

of the Welding Power Source.of the Welding Power Source.

Page 29

6.0 SEQUENCE OF OPERATION

NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions.

Figure 7. - 250S Front Panel

1. Scroll Buttons – used to select the parameters to be set. The LED’s show which function is

being adjusted on the weld sequence graph.

2. Digital LED display – Welding amperage and parameter values are displayed in this window.

Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen.

3. Control knob – allows the operator to adjust the output amperage within the entire range of the

power source also used to set each parameter value.

4. Process Button – This button selects between STICK or Lift TIG mode. A remote control device

is required for use during LIFT TIG operation. See section 4.01, section 2 “Remote Control Socket”, for complete details of the remote device.

Page 30

6.01 Stick Welding

• Connect work lead to negative terminal

• Connect electrode lead to positive terminal

• Switch machine on

• Connect remote control device if required

Use the Scroll Button s t o m ove t o t he pa rame ter to be set . T he LED will show which function is being adjusted on t he weld sequence g raph. Use the con trol kno b to adj us t each parameter.

• Set HOT START

• Set WELD current

• Set Arc Contr ol

Commence welding

6.02 DC LIFT TIG Welding

• Connect work lead to positive terminal

• Connect TIG torc h to neg ative terminal

• Switch machine on

• Set weld curren t.

• Connect remote control device. A remote con trol device is required for use during LIFT

TIG operation. See section 4.01, secti on 2 “ Remote Contr ol Socket”, for c ompl e te details of the remote device.

Use the Scroll Button s t o m ove t o t he pa rame ter to be set . T he LED will show which function is being adjusted on t he weld sequence g raph. Use the con trol kno b to adj us t each parameter.

• Set WELD current

Commence welding

Page 31

7.0 BASIC TIG WELDING GUIDE

7.01Electrode Polarity

Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight po larity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece.

7.02 Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30 – 60 1/16” (1.6mm) 60 – 115 3/32” (2.4mm) 100 – 165

1/8” (3.2mm) 135 – 200 5/32” (4.0mm) 190 – 280 3/16” (4.8mm) 250 – 340

Table 4 – Current ranges for varies tungsten electrode sizes

7.03 Tungsten Electrode Types

Electrode Type

Welding Application Features

(Ground

Finish)

DC welding of mild steel,

Thoriated 2%

stainless steel and copper.

DC welding of mild steel,

Ceriated 2%

stainless steel, copper, aluminium, magnesium and their alloys

Excellent arc starting, Long life, High current carrying capacity.

Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc.

Table 5 – Tungsten electrode types

Color

Code

Red

Grey

Page 32

7.04 Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range

1/16” (1.6 mm) 20 - 90 3/32” (2.4 mm) 65 - 115

1/8” (3.2 mm) 100 - 165

3/16” (4.8 mm) 200-350

Table 6 – Filler wire selection guide

NOTE 6

The filler wire diameter specified in Table 6 is a guide only, other diameter wires may be used according to the welding application.

7.05 Shielding Gas Selection

Alloy Shielding Gas

(Amps)

Aluminium & alloys Argon Carbon Steel Argon Stainless Steel Argon Nickel Alloy Argon Copper Argon Titanium Argon

Table 7 – Shielding gas selection

7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Electrode Type &

Diameter

Thoriated 2%

3/32” (2.4 mm)

Thoriated 2%

3/32” (2.4 mm)

Thoriated 2%

3/32” (2.4 mm)

Current Range DC

Amperes

120 - 170 Yes

100 - 160 Yes

90 - 130 No

Filler Rod for

Root Pass

Joint Preparation

Table 8 – TIG welding parameters for low carbon & low alloy steel pipe

Page 33

7.07 Welding Parameters for Steel

Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm 1/16”

1.6mm

1/8”

3.2mm 3/16”

4.8mm

¼”

6.4mm

DC Current

for Mild

Steel

35-45 20-30 Butt/Corner 40-50 25-35

45-55 30-45 Butt/Corner 50-60 35-50

60-70 40-60 Butt/Corner 70-90 50-70

80-100 65-85 Butt/Corner 90-115 90-110

115-135 100-125 Butt/Corner 140-165 125-150

160-175 135-160 Butt/Corner 170-200 160-180

DC Current

for Stainless

Steel

Tungsten Electrode Diameter

0.040”

1.0mm

0.040”

1.0mm 1/16”

1.6mm 1/16”

1.6mm 3/32”

2.4mm

1/8”

3.2mm

Filler Rod

Diameter

(if required)

1/16”

1.6mm 1/16”

1.6mm 3/32”

2.4mm

1/8”

3.2mm 5/32”

4.0mm

Argon Gas

Flow Rate

Liters/min

5-7

Joint Type

Lap/ Fillet

Table 9 – DC TIG welding parameters

Page 34

8.0 BASIC ARC WELDING GUIDE

8.01Electrode Polarity

Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘−’ terminal but if in doubt consu lt the electrode manufacturers literature.

8.02 Effects of Stick Welding Various Materials

High tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and 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 tempering in a furnace.

Manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the poros ity caused by gas held in t his ty pe of iron.

Copper and alloys

The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to give proper fusi on of wel d an d base meta l.

Types of Electrodes

Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyda y general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc. The range of electrodes dealt with in this publica ti on w il l cove r the vast majority of applications like ly to be encountered; are all easy to use and all will work on even the most basic of welding machines.

Metals being

joined

Mild steel 6013

Mild steel 7014 All positional electrode for use on

Cast iron 99% Nickel Suitable for joining all cast irons

Stainless steel 318L-16 High corrosion resistance. Ideal for

Electrode Comments

Ideal electrodes for all general purpose work. Features include out standing operator appeal, easy arc starting and low spatter.

mild and galvanized steel furniture, plates, fences, gates, pipes and tanks etc. Especially suitable for verticaldown welding.

except white cast iron.

Page 35

Metals being

joined

Copper, Bronze, Brass, etc.

High Alloy Steels, Dissimilar Metals, Crack Resistance. All Hard-To-Weld Jobs.

Electrode Comments

dairy work, etc. On stainless steels.

Bronze

5.7 ERCUSI-A

312-16 It will weld most problematical jobs

Easy to use electrode for marine fittings, water taps and valves, water trough float arms, etc. Also for joining copper to steel and for bronze overlays on steel shafts.

such as spring s, shafts, broken joins mild steel to stainless and alloy steels. Not suitable for Aluminum.

Table 10 - Types of Electrodes

Page 36

PAGE LEFT INTENTIONALLY BLANK

Page 37

9.0 BASIC TROUBLESHOOTING

WARNING 8

There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques.

If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair.

The basic level of troubleshooting is that which can be performed without special equipment or knowledge.

9.01 TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.

Description Possible Cause Remedy

Excessive bead build-up or poor penetration or poor fusion at edges of weld.

2 Weld bead too

wide and flat or undercut at edges of weld or excessive burn through

3 Weld bead too

small or insufficient penetration or ripples in bead are widely spaced apart

4 Weld bead too

wide or excessive bead build up or excessive penetration in butt joint

Welding current is too low

Increase weld current and/or faulty joint preparation

Welding current is too high Decrease weld current

Travel speed too fast Reduce travel speed

Travel speed too slow Increase travel speed

Uneven leg length in fillet joint

Wrong placement of filler rod Re-position filler rod

Page 38

Description Possible Cause Remedy

6 Electrode melts

when arc is struck.

A Electrode is connected to the

‘+’ terminal.

7 Dirty weld pool. A Electrode contaminated

through contact with work piece or filler rod material.

B Gas contaminated with air. B Check gas lines for cuts and

Electrode melts or oxidizes when an

No gas flowing to welding region.

arc is struck.

B Torch is clogged with dust. B Clean torch C Gas hose is cut. C Replace gas hose. D Gas passage contains

impurities.

E Gas regulator turned off. E Turn on. F Torch valve is turned off. F Turn on.

A Connect the electrode to the

‘−’ terminal.

A Clean the electrode by

grinding off the contaminates.

loose fitting or change gas cylinder.

Check the gas lines for kinks or breaks and gas cylinder contents.

D Disconnect gas hose from

torch then raise gas pressure and blow out impurities.

G The electrode is too small for

the welding current.

G Increase electrode diameter

or reduce the welding current.

9 Poor weld finish. Inadequate shielding gas. Increase gas flow or check

gas line for gas flow problems.

10 Arc flutters during

TIG welding.

A Tungsten electrode is too

large for the welding current.

A Select the right size electrode.

Refer to Basic TIG Welding guide.

B Absence of oxides in the

weld pool.

B Refer Basic TIG Welding

Guide for ways to reduce arc flutter.

11 Welding arc can

not be established.

A Work clamp is not connected

to the work piece or the work/torch leads are not connected to the right

A Connect the work clamp to

the work piece or connect the work/torch leads to the right welding terminals.

welding terminals. B Torch lead is disconnected. B C

Gas flow incorrectly set,

cylinder empty or the torch

valve is off.

Connect it to the ‘−‘ terminal.

Select the right flow rate, change cylinders or turn torch valve on.

Page 39

Description Possible Cause Remedy

12 Arc start is not

smooth.

A Tungsten electrode is too

large for the welding current.

B The wrong electrode is being

used for the welding job

C Gas flow rate is too high. C Select the correct rate for the

Incorrect shielding gas is being used.

E Poor work clamp connection

to work piece.

9.02 Stick Welding Problems

Description Possible Cause Remedy

Gas pockets or

voids in weld metal (Porosity).

Electrodes are damp.

Welding current is too high.

Surface impurities such as oil, grease, paint, etc.

Crack occurring in

Rigidity of joint. weld metal soon after solidification commences

3 A gap is left by

failure of the weld

Insufficient throat thickness.

Cooling rate is too high.

Welding current is too low.

Electrode too large for joint. metal to fill the root of the weld.

Insufficient gap.

D Incorrect sequence. D Use correct build-up sequence.

A Select the right size electrode.

Refer to Basic TIG Welding Guide.

B Select the right electrode

type. Refer to Basic TIG Welding Guide

welding job. Refer to Basic TIG Welding Guide.

Select the right shielding gas. Refer to Basic TIG Welding Guide.

E Improve connection to work

piece.

Dry electrodes before use.

Reduce welding current.

Clean joint before welding.

Redesign to relieve weld joint of severe stresses or use crack resistance electrodes.

Travel slightly slower to allow greater build up in throat.

Preheat plate and cool slowly.

Increase welding current

Use smaller diameter electrode.

Allow wider gap.

Figure 8 – Example of insufficient gap or incorrect sequence

Page 40

Portions of the

weld run do not fuse to the surface of the metal or edge of the joint.

ABSmall electrodes used on

heavy cold plate. Welding current is too low.AB

Use larger electrodes and preheat the plate.

Increase welding current

C Wrong electrode angle. C Adjust angle so the welding

arc is directed more into the base metal

Travel speed of electrode is too high.

Reduce travel speed of electrode

E Scale or dirt on joint surface. E Clean surface before welding.

Figure 9 – Example of lack of fusion

Non-metallic parti-

cles are trapped in the weld metal (slag inclusion).

A Non-metallic particles may

be trapped in undercut from previous run.

Joint preparation too restricted.

C Irregular deposits allow slag

to be trapped.

Lack of penetration with slag trapped beneath weld bead.

E Rust or mill scale is

preventing full fusion.

F Wrong electrode for position

in which welding is done.

A If bad undercut is present,

clean slag out and cover with a run from a smaller diameter electrode.

Allow for adequate penetration and room for cleaning out the slag.

C If very bad, chip or grind out

irregularities.

Use smaller electrode with sufficient current to give adequate penetration. Use suitable tools to remove all slag from corners.

E Clean joint before welding.

F Use electrodes designed for

position in which welding is done, otherwise proper control of slag is difficult.

Figure 10 – Examples of slag inclusion

Page 41

9.03 Power Source Problems

Description Possible Cause Remedy

The welding arc cannot be established

ABThe Primary supply voltage

has not been switched ON.

The Welding Power Source

switch is switched OFF.

ABSwitch ON the Primary supply

voltage. Switch ON the Welding

Power Source.

2 Maximum output

welding current can not be achieved with nominal Mains supply voltage.

3 Welding current

reduces when welding

4 No gas flow when

the torch trigger switch is depressed.

C Loose connections internally. C

Have an Accredited Thermal Arc Service Agent repair the connection.

Defective control circuit Have an Accredited Thermal

Arc Service Agent inspect then repair the welder.

Poor work lead connection to

the work piece.

Ensure that the work lead has a positive electrical connection to the work piece.

ABGas hose is cut.

Gas passage contains

impurities.

ABReplace gas hose.

Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities.

C Gas regulator turned off. C Turn gas regulator on.

Page 42

10.0 VOLTAGE REDUC TI ON DEVICE (VRD)

10.01 VRD Specification

Pro-Lite

Description

250S

VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between welding

terminals

VRD Resistance 148 to 193 ohms The required resistance between welding

terminals to turn O N the welding power

VRD Turn OFF Time 0.2 to 0. 3 secon ds The time taken to turn OFF the we ldi ng

power once the welding current has stopped

10.02 VRD Maintenance

Routine inspection a nd te s ting (power sourc e) An inspection of the power source, an insulation resistance test and an earth resistance test

shall b e carried out.

a) For transportable equipment, at least once every 3 months; and b) For fixed equipment, at least once every 12 months.

Notes

The owners of the equipment shall keep a sui table record of the peri odic tes ts.

Note 7

A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated.

In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should also be conducted by an accredited Thermal Arc service agent.

Description IEC 60974-1 Requirements

VRD Open Circuit Voltage L ess than 20 V; a t Vi n=208-230V or 460V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0.3 seconds

If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests sh ould be carried ou t pri or t o enter ing thi s location.

Page 43

Weld current ceases.

Buzzer sounds constantly.

Fan operates at max speed.

E01 resets when TH1

decreases to 70ºC for about

30 seconds.

Let Power Source cool

down then keep within its

duty cycle.

Have an Accredited

Thermal Arc Service Agent

investigate

Unblock vents then let

Weld current ceases.

Buzzer sounds constantly.

Power Source cool down.

Let Power Source cool

down then keep within its

Fan operates at max speed.

E02 resets when TH1

duty cycle.

Have an Accredited

decreases to 70ºC for about

30 seconds.

Thermal Arc Service Agent

investigate

Weld current ceases.

Buzzer sounds constantly.

Switch machine off then on

to reset E03 error.

Unblock vents then let

Power Source cool down.

Reduce length of welding

arc.

Have an Accredited

Thermal Arc Service Agent

or a qualified electrician

check for low Mains

voltage.

The Welding Power A

Source’s duty cycle has

been exceeded.

Fan ceases to operate.

Air flow is restricted by

vents being blocked

The Welding Power A

Source’s duty cycle has

been exceeded.

Fan ceases to operate.

Air flow is restricted by

vents being blocked

Primary current is too high A

because welding arc is too

long.

Mains supply voltage is

more than 10% below

nominal voltage

Description Possible Cause Remedy Remarks

E01 error code displayed

Temperature sensor TH1 (protects

IGBTs) is greater than 80ºC for

about 1 second

11.0 POWER SOURCE ERROR CODES

2 E02 error code displayed

Temperature sensor TH2 (protects

secondary diodes) is greater than

80ºC for about 1 second

Primary (input) current too high

3 E03 error code displayed

Page 44

Weld current ceases.

Buzzer sounds constantly.

Have an Accredited

Thermal Arc Service Agent

Error code E11

automatically will reset

or a qualified electrician

check the Primary voltage.

when the voltage reduces.

Weld current available.

Buzzer sounds

intermittently.

Have an Accredited

Thermal Arc Service Agent

or a qualified electrician

Error code E14

automatically will reset

check the Mains voltage.

when the voltage increases.

Weld current ceases.

Buzzer sounds constantly.

Have an Accredited

Thermal Arc Service Agent

Error code E12

automatically will reset

or a qualified electrician

check the Mains voltage

when the voltage increases.

Have an Accredited

No weld current is

available.

Buzzer sounds constantly.

Switch machine off.

No weld current is

available.

Buzzer sounds constantly.

Switch machine off.

Thermal Arc Service Agent

or a qualified electrician

check the primary cable &

fuses.

Have an Accredited

Thermal Arc Service Agent

or a qualified electrician

check the Mains voltage

Have an Accredited

Thermal Arc Service Agent

check connector plug on

input PCB

Primary supply voltage is

greater than the nominal

voltage plus 10%

Mains supply voltage is less

than the nominal operating

voltage less 10%.

Mains supply voltage is

down to a dangerously low

level.

When 3 phase machine is

first turned on with the

wrong Primary supply

(input) voltage connected

Link switch plug not

connected

Description Possible Cause Remedy Remarks

Over Primary supply (input)

voltage at primary capacitors is

exceeded for one second

4 E11 error code displayed

5 E14 error code displayed

Under mains supply (input) voltage

warning primary capacitors is

reduced for one second

Under mains supply (input) voltage

primary capacitors is reduced for

one second

6 E12 error code displayed

Wrong Primary supply (input)

7 E81 error code displayed

voltage connected

Link switch plug not connected

8 E82 error code displayed

Page 45

No weld current is

available.

Have an Accredited

Thermal Arc Service Agent

Buzzer sounds constantly.

Switch machine off then on

to reset E83 error.

Weld current ceases.

check connector plug on

input PCB and the Mains

voltage

Have an Accredited

Buzzer sounds constantly.

Switch machine off.

Thermal Arc Service Agent

check the control PCB

Weld current ceases.

Buzzer sounds constantly.

Have an Accredited

Thermal Arc Service Agent

Switch machine off.

check or replace the

temperature sensors.

Weld current ceases.

Buzzer sounds constantly.

Must switch machine off

then on to reset E99 error.

Turn on/off switch on.

Have an Accredited

Thermal Arc Service Agent

or a qualified electrician

check the Mains voltage and

fuses

The Primary supply (input)

voltage fluctuates and is not

stable.

Memory chip (EEPROM)

error

The Welding Power

Source’s temperature

sensors have malfunctioned.

Main on/off switch on A

machine has been turned off

Mains supply (input)

voltage has been turned off

Description Possible Cause Remedy Remarks

CPU checks mains supply (input)

voltage when the on/off switch on

rear panel of machine is turned ON.

9 E83 error code displayed

10 E93 error code displayed

Memory chip (EEPROM) on

control PCB can not read/write

weld parameters

Temperature sensor TH1 for IGBTs

or sensor TH2 for secondary diodes

are open circuit

E99 error code displayed

Mains supply (input) voltage has

been turned off but control circuit

has power from the primary

capacitors

11 E94 error code displayed

Page 46

1 U0A706100 10-6627

1 U0A674900 10-6737

1 U0A722000 10-6738

Assembly)

12.0 PARTS LIST

DWG. No. Description Type & Rating QTY. Code No. Order No.

C1 Capacitor ECQE12104MZ DC1250V 0.1uF 1 42422137100 10-2270

CON1 Remote Socket 206433-1 8P (with Wiring

D1 Diode DFA75BA160 1 454170160 10-6735

(with Insulation Sheet EBA501500)

with Thunder Label

D2 Diode DBA200UA40 1 4582A0040 10-6687

D3 Diode DBA200UA40 1 4582A0040 10-6687

D4 Diode DBA200UA40 1 4582A0040 10-6687

D5 Diode DBA200UA40 1 4582A0040 10-6687

FAN1 Fan 109E5724H507 DC 24V 16.8W 1 U0A733500 10-6839

FCH1 Inductor F2A719500 FCH 1 F2A719500 10-6736

HCT1 Current Sensor HC-TN200V4B15M 200A 4V 1 11251003000 10-5003

PCB1 Printed Circuit Board WK-4914 U02 MAIN_PCB

PCB2 Printed Circuit Board WK-4819 U01 DETECT PCB 1 P0A481901 10-6635

with Thunder Label

PCB3 Printed Circuit Board WK-4921 U02 CONNECT PCB 1 P0A492102 10-6636

PCB4 Printed Circuit Board WK-4915 U02 2ND DIODE

PCB5 Printed Circuit Board WK-5157 U03 TIG CONTROL 1 P0A515703 10-6845

PCB6 Printed Circuit Board WK-4920 U11 STICK 1 P0A492011 10-6739

PCB7 Printed Circuit Board WK-4917 U04 FILTER 480V 1 P0A491704 10-6740

PCB10 Printed Circuit Board WK-5019 U01 CAP PCB 1 P0A501901 10-6741

PCB11 Printed Circuit Board WK-4923 U01 B RELAY PCB 1 P0A492301 10-6742

Page 47

1 U0A705300 10-6642

(with WK-5012 U01)

1 U0A705300 10-6642

(with WK-5012 U01)

DWG. No. Description Type & Rating QTY Code No. Order No.

12.0 PARTS LIST Continued

Q1 Transistor CM100DUS12F-1 600V 100A

Q2 Transistor CM100DUS12F-1 600V 100A

S1 Switch DCP-103SR100C-480V 3P 1 25850003700 10-6857

S2 Switch SDKGA4-A-1-A 250V 5A 1 24704531400 10-5222

T1 Transformer F2A767200 250A MTR HV 1 F2A767200 10-6744

T2 Transformer F2A767200 250A MTR HV 1 F2A767200 10-6744

TH1, 2 Thermistor ERTA53D203 20K"/25ºC B=395 0K 1 U0A733300 10-6784

Page 48

Front Panel E0D005300 1 U0A722100 10-6648

Rear Panel E0D005500 1 U0A722200 10-6649

Side Panel E0D006100 2 E0D006100 10-6650

TRAK-BE35-70S 2 26999025900 10-6660

Front Control Cover J4B493400 1 J4B493400 10-6651

Rear Control Cover JDA173200 1 U0A722300 10-6745

Protection Cover E0C303200 1 E0C303200 10-6653

Encoder Cover EBA514400 1 EBA514400 10-6654

PCB Cover E1B537600 (with Caution Label) 1 U0A705600 10-6655

PCB Sheet EBA618000 For PCB11 1 EBA618000 10-6747

Name Label N 4A05 6000 2 N4A056000 10-6746

Side Label N4A009200 2 N4A009200 10-6657

Warning Label 1 N0B891300 1 N0B891300 10-5497

Warning Label 2 N0B476400 1 N0B476400 10-5496

Output Terminal Label N4A040300 1 N4A040300 10-6748

Output Terminal

(female)

Input Cable SOOW AWG8X4C L=3.4m 1 U0A722400 REF. ONLY

Input Cable Clamp EBA045800 1 EBA045800 10-6662

Heatsink E1B538500 1 E1B538500 10-6663

Heatsink E1B538600 1 E1B538600 10-6664

Knob 2621603 1 50990001600 10-6665

Knob Cap 3021104 1 50990000300 10-6666

Control Cover Sheet N0B882300 1 N0B882300 10-6749

Flat Cable EAA547301 1 EAA547301 10-6668

DWG. No. Description Type & Rating QTY Code No. Order No.

12.0 PARTS LIST Continued

Page 49

Post4(M4-M4) EBA431100 4 EBA431100 10-6670

Post5(M4-M4) EBA431200 8 EBA431200 10-6671

Post6(M5-M5) EBA431300 2 EBA431300 10-6672

Post7(M5-M5) EBA435900 1 EBA435900 10-6673

Post9(M5-M5) EBA491700 4 EBA491700 10-6750

Post11(M5-M5) EBA643600 3 EBA643600 10-6751

D2-5 Bus Bar EBA366300 1 EBA366300 10-6752

CC Bus Bar EBA707600 1 EBA707600 10-6753

S1 Bus Bar ECA321000 3 ECA321000 10-6868

Output Bus Bar1 EBA456400 1 EBA456400 10-6754

Output Bus Bar2 EBA456600 1 EBA456600 10-6755

Clip #74 NATURAL 4 606024220 10-5259

Transformer Chassis JCA903200 1 JCA903200 10-6678

Right Chassis J2C970700 1 J2C970700 10-6679

Left Chassis J2C970800 1 J2C970800 10-6680

Output Terminal (male) TRAK-SK50 2 26999025800 10-2020

Operating Manual K1A208600 250S 1 K1A208600 430429-506

Service Manual 430429-516

DWG. No. Description Type & Rating QTY Code No. Order No.

12.0 PARTS LIST Continued

Page 50

APPENDIX A - INTERCONNECT DIAGRAM

Page 51

Page 52

APPENDIX B - AUTOMATI ON

JUMPER SETTING FOR "OK–TO–MOVE". Models 250S/TS

Three jumpers (JP1, JP2 and JP3) are provided on PC Board WK-4921 for automation purposes. This PCB is mounted horizontally on top of the unit just under the cover. This PCB can be accessed by removing the side covers by loosening 4 screws on each the front and rear panel, then removing the 4 side panel screws as well as the 2 handle screws. Carefully pull the front and rear panels outward to release and remove the side cover. Remove two plastic clips holding the PCB protective cover in place and lift the sheet up and over the unit. The jumpers will be accessible on the top portion of the PCB. See figure on next page for the location of the PCB. All units are shipped from the factory with the jumpers set in position "A". This is for normal semiautomatic operation utilizing a remote device, such as a foot control. The 8-pin remote operates as described earlier in this manual. Placing all jumpers in position "B" would be primarily used for automation with an arc establish relay, remote amperage and contactor. An arc-establish signal is located from pins 4 and 8 when in this mode. Placing jumpers JP1 and JP2 in "B" position and jumper JP3 in "A" position would have the configuration of an arc-establish signal and remote contactor, but the unit’s front panel would control the amperage.

JP1 A COM B

JP3

WK-4921

COM

•

Set All "A" position : factory shipping

JP2 A COM B

POSITION JP1 A JP2 A JP3 A

•

Use "OK TO MOVE signal"

POSITION JP1 B B JP2 B B JP3 B A

A/V REMOTE PANEL

OK-TO-MOVE RELAY

CN6 CON1

4 4

CN6 CON1

4 4

CN6 CON1

4 4

8 8

Remote : Short 4 to 8 Panel : Open

Max Load: 24V 50ma.

OK TO MOVE RELAY

Page 53

Figure 11 – Location of PCB WK-4921