Thermal Arc ARCMASTER 200 TS Service Manual

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200 TS

ARCMASTER

INVERTER ARC WELDER

Service Manual

Art # A-06912

Revision No: AB Issue Date: May 7, 2008 Manual No.: 0-4941B Operating Features:

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

ArcMaster 200 TS CE Inverter Arc Welder Service Manual Number 0-4941B for: Part Number 10-3085

Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: May 22, 2006 Revision AB Date: May 7, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

CONTENTS

1 SAFETY INSTRUCTIONS AND WARNINGS

1 Arc Welding Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1– 1

2 PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

3 PRECAUTIONS DE SECURITE EN SOUNDAGE A L’ARC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1– 5

4 Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 6

5 PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

6 STATEMENT OF WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 10

7 DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 12

2 INTRODUCTION

1 How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2 Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

3 Receipt Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

4 Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2– 2

5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2– 3

6 Functional Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

Transporting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2– 4

3 INSTALLATION

1 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3– 1

2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3 Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

4 Electrical Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

5 Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

6 High Frequency Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3– 2

7 High Frequency Interference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3– 3

8 Duty Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3– 3

9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3– 4

4 OPERATOR CONTROL

1 ARC MASTER 200TS Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

2 Weld Process selection for 200TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2

Weld Parameter Descriptions for ARC MASTER 200TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

4 Weld Parameters for ARC MASTER 200TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4– 4

4.1 Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 4

5 Power Source Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5

5 SET-UP FOR SMAW (STICK) AND GTAW (TIG)

6 SEQUENCE OF OPERATION

1 Stick Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 1

2 HF TIG & Lift TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 1

3 Slope Mode Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2

4 Slope Mode with repeat sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2

5 Pulse Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

7 ROUTINE MAINTENANCE

8 BASIC TROUBLESHOOTING

1 TIG Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 1

2 Stick Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

3 Power Source Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – 4

9 VOLTAGE REDUCTION DEVICE (VRD)

1 VRD Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9– 1

2 VRD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9– 1

3 Switching VRD On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2

10 POWER SOURCE ERROR CODE

11 ADVANCED TROUBLESHOOTING

1 System-Level Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 1

1.1 Opening the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 1

2 Verification and Remedy to the Indicated Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3

2.1 E01 “Over-Temperature at the primary side” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 3

2.2 E02 “Over-Temperature at the secondary side”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3

2.3 E03 “

2.4 E94 “Thermistor malfunction”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 4

2.5 E99 “Initial Power Receiving”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 4

3 Verification and Remedy to Failures without Indication Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 5

3.1 “Cooling Fan (FAN1) Failure” (Fan is not rotating.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 5

3.2 “Gas Valve Failure” (No Gas flow through unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 5

3.3 “No weld output” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 6

3.4 “Operating Panel Failure” (LED’s do not light properly or welding setting cannot be establish

3.5 “High Frequency Output Failure” (Unit does not generate High Frequency.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 7

4 Fault Isolation Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8

4.1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8

5 Verification of the Power Input Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8

5.1 Verification of the AC input voltage using an AC voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 8

5.2 Verification of the Power Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 9

5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 10

5.4 Verification of the Gas Valve, SOL1, Drive Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11

5.5 Verification of the primary Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11

5.6 Verification of the secondary Diode (D2, D3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 12

5.7 Verification of the primary IGBT (Q1A-Q4C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 12

5.8 Verification of No-load Voltage (OCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 13

Primary Over-Current Failure

” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11–4

ed.) . . . . . . . . . . . . . .11–6

12 MAINTENANCE

1 Subsystem Test and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 1

1.1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1

1.2 Test and Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 1

2 Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 4

2.1 Tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4

2.2 Notes of disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4

3 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 5

3.1 PCB1 (WK-5713) and Primary Diode D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 5

3.2 PCB2 (WK-5417), Capacitor C1 and Resistor R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–8

3.3 PCB3 (WK-5609) and T1 “Transformer” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 10

3.4 PCB4 (WK-5449) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 11

3.5 PCB5 (WK-5448) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 12

3.6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 13

3.7 PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 14

3.8 D2 and D3 “Secondary Diode” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 15

3.9 C.C. “Coupling Coil” and FCH1 “Reactor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 15

3.10 CT1 “Hole Current Trans” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 17

3.11 FAN1 “Cooling Fan” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 18

3.12 HF UNIT1 “High Frequency Unit”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–19

3.13 SOL1 “Solenoid GAS Valve” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 20

3.14 C101-C102 “Capacitor”, L101 “Ring Core” and S1 “Switch” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21

3.15 CON1 “Remote Receptacle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 22

3.16 TH1 “Primary Thermistor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 23

3.17 TH2 “Secondary Thermistor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 23

3.18 C103 “Capacitor” and L102 “Reactor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 24

3.19 L103 “Reactor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 24

3.20 C2 “Capacitor” and R2 “Resistor”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 25

CONTENTS

APPENDIX 1 PARTS LIST

1 Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1

2 How To Use This Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1

APPENDIX 2 CONNECTION WIRING GUIDE

APPENDIX 3 INTERCONNECT DIAGRAM

APPENDIX 4 DIODE TESTING BASICS

ARCMASTER 200 TS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,

OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

SAFETY IN WELDING AND CUTTING. This publication and other

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

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

9. Do not wrap cables around your body.

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

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

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

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

1. Do not touch live electrical parts.

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

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

May 22, 2006

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

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ARCMASTER 200 TS

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

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

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

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

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

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

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

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

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

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

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

Eye protection filter shade selector for welding or cutting

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen C utting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

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(goggles or helmet), from AWS A6.2-73.

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

May 22, 2006

WARNING

ARCMASTER 200 TS

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

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

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

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

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

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

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

May 22, 2006

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

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

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ARCMASTER 200 TS

1.02 Principal Safety Standards

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals know to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety code Sec.

25249.5 et seq.)

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May

1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures:

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

2. Arrange cables to one side and away from the operator.

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

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

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

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ARCMASTER 200 TS

1.03 Precautions de Securite en Soudage à l’Arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.04 Dangers Relatifs au Soudage à l’Arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen

de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

May 22, 2006

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ARCMASTER 200 TS

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

mince moins de 1 po. (25 mm

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

épais plus de 6 po. (150 mm) 5 ou 6

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

) 3 ou 4

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec fil plein (GMAW)

Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydrogène atomique (AHW) Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

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May 22, 2006

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

AVERTISSEMENT

ARCMASTER 200 TS

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.

May 22, 2006

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

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ARCMASTER 200 TS

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

1.05 Principales Normes de Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.

1-8

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

May 22, 2006

ARCMASTER 200 TS

1.06 Declaration Of Conformity

Manufacturer: Thermadyne Corporation Address: 82 Benning Street

West Lebanon, New Hampshire 03784 USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC Directive” (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

• CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

• UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

• ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.

• For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

• Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative:

Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

May 22, 2006

1-9

ARCMASTER 200 TS

1-10

May 22, 2006

2 INTRODUCTION

How To Use This Manual

This Service Manual applies to just specification or part numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows.

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

INTRODUCTION

Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identification numbers as described above along with a full description of the parts in error.

Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to uncrate the unit.

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number back cover of this manual. Include the manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link:

http://www.thermalarc.com

Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

in your area listed in the inside

2 – 1

Symbol Chart

Note that only some of these symbols will appear on your model.

200TS 2 INTRODUCTION

SEC

Amperage

Voltage

Hertz (frequency)

Seconds

Percent

DC (Direct Current)

AC (Alternating Current)

STICK (Shielded Metal Arc SMAW)

Pulse Current Function

Spot Time (GTAW)

Remote Control (Panel/Remote)

Remote Function

Arc Control (SMAW)

Gas Post-Flow

Standard Function

Slope Function

Slope W/Repeat Function

Spot Function

Impulse Starting (High Frequency GTAW)

Touch Start (Lift Start TIG circuit GTAW)

2 – 2

VRD

Gas Pre-Flow

Voltage Reduction Device Circuit

Negative

Positive

Gas Input

Gas Output

200TS 2 INTRODUCTION

Description

The Thermal ArcTM Model 200TS is a self contained single-phase DC arc welding power sources with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas control valve, built in Sloper and Pulser, lift arc starter, and high-frequency arc starter for use with Gas Tungsten Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed (GTAW-P) Gas Tungsten Arc Welding-Sloped (GTAW-S), 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

(V)

OCV

10V

160A1A (A)

STICK Process LIFT TIG Process HF TIG Process

Figure 2-1: Model 200TS Volt-Ampere curve

200A25A (A)

(V)

OCV

200A (A)

NOTE

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.

2 – 3

Functional Block Diagrams

Figure 2-2 illustrates the functional block diagram of the 200TS-power supply.

200TS 2 INTRODUCTION

Input

Power

Main

Circuit

Switch

Input

Diode

Filter

Capacitor

DC Power Primary Voltage

Sensor

To each control circuit

+/-12VDC +18VDC +24VDC +5VDC

Torch Control

Connection

(CON1)

Figure 2 -2: 200TS Model Functional Block Diagram

Transporting Methods

IGBT

Inverter

Thermal

Detector

Trouble

Sensing

Circuit

Thermal

Sensor

Circuit

Main

Transformers

(T1)

Drive

Circuit

Primary

Circuit

Sensor

Current

Adjustment

Circuit

Output Diodes

HF Unit

Panel Circuit Board

Stick Mode

Control

Circuit

Sequence

Sensing

Circuit

Control

Reference

Adjustment &

Mode select Switch

VRD

Lift Tig Mode

Output Short

Sensing

Circuit

Output

Inductor

Fan Control

Circuit

Gas Control

Circuit

Hall Current Transformer

(HCT1)

Coupling

Coil

High

Frequency

Unit

Fan

Solenoid

These units are equipped with a handle for carrying purposes.

WARNING

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

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.

2 – 4

3 INSTALLATION

Environment

The ARC MASTER 200TS is designed for use in adverse environments.

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

Location

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

 In areas, free from moisture and dust.  Ambient temperature between 0 degrees C to

40 degrees C.

 In areas, free from oil, steam and corrosive

gases.

 In areas, not subjected to abnormal vibration or

shock.

 In areas, not exposed to direct sunlight or rain.  Place at a distance of 12" (304.79mm) or more

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

WARNING

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

INSTALLATION

Electrical Input Connections

WARNING

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.

Electrical Input Requirements

Operate the welding power source from a singlephase 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 any 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

This unit is equipped with a 250 VAC (NEMA 650P) plug molded on the two-conductor with earth power cable that is connected at the welding power source for single phase electrical input power. For direct wiring installation have a qualified person install according to all applicable codes and instructions.for single and three phase electrical input power.

Do not connect an input (BROWN or BLUE) conductor to the ground terminal.

Do not connect the ground (GREEN) conductor to an input line terminal.

3 – 1

200TS 3 INSTALLATION

Refer to figure 3-1 and:

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

2. Connect ends of line 1 (BROWN) and line 2 (BLUE) input conductors to a de-energized line disconnect switch.

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

Input Voltage Fuse Size

115 VAC 40 Amps

230 VAC 40 Amps

Table 3-1: 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).

Weiding Power Supply

Ground Terminal

Ground Conductor

Line Disconnect Switch

The following 115-230V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment:

Primary

Supply Lead

Model

ARC

MASTER

200TS

Table 3-2: 115-230V Primary Current Circuit sizes to

Size

(Factory

Fitted)

2.5mm sq13 minimum

achieve maximum current

Minimum

Primary

Current Circuit Size (Vin/Amps)

115/21

230/33

115/36 -

230/40

Current & Duty Cycle

TIG STICK

85@

100% 200@

20%

85@

100% 160@

35%

The ARC MASTER 200TS is designed for use with a generator as an input power source. Contact an accredited Thermal Arc service agent for the proper sizing and set-up recommendations of a generator power source system. As a general rule, depending on the type of generator used, the generator capacity should be twice the maximum rating of the welder.

Line Fuse

Primary Power Cable

Figure 3- 1: Electrical input connections

Input Power

Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors. At this point the Bus Voltages are checked and the welder is enabled after the input capacitors have charged to full operating voltage (after approximately 5 seconds).

NOTE

Note the available input power. Damage to the welder could occur if 460VAC or higher is applied.

High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be over-emphasized. 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 machines.

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 – 2

200TS 3 INSTALLATION

High Frequency Interfer-

Duty Cycle

ence

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

1. 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 will prevent direct radiation if the equipment is properly grounded.

2. Transmission via the Supply Lead:

Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction. Adequate shielding and filtering is provided in the Power Source.

3. 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 suspending of leads should be avoided where possible.

4. Re-radiation from Unearthed Metallic Objects:

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

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

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

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

NOTE

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.

3 – 3

200TS 3 INSTALLATION

Specifications

Parameter 200TS

Rated Output 115VAC

Amperes

Vol ts

Duty Cycle

TIG

Duty Cycle

STICK

Output Current Range

Open Circuit Voltage 57V Dimensions

Width

Height

Length

Weight

Output@Rated Load 115V

Output Amperes

Output Volts

Duty Cycle

KVA

Output@No Load

KVA

Input Volts Single Phase

230V

TIG 1 - 200 (230V), 1 - 85 (115V) STICK

85A

13V

100%

200A / 18V @ 20%

130A / 15V @ 60%

100A / 14V @ 100%

85A / 13V @ 100%

160A / 27V @ 35%

130A / 25V @ 60%

100A / 24V @ 100%

85A / 23V @ 100%

1 - 160 (230V), 1 - 85 (115V)

5.12" (130mm)

10.24" (260mm)

12.60" (320mm)

17.63 lb. 8.0 kg

85A 160A

23V 27V

100% 35%

4.4 8.7

2.4 5.2

0.2

0.1

Amperage Draw

@Rated Load

40 1.0

to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location and conditions and local power grid supply conditions.

230VAC

200A

18V

20%

230VAC

115VAC

230VAC

115VAC

230V

No Load

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 without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications due

3 – 4

4 OPERATOR CONTROL

ARC MASTER 160TS Controls

130

260

1. Control Knob: This control sets the selected weld parameter, rotating it clockwise increases the parameter that is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage.

2. Remote Control Socket: The 8 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded

collar fully clockwise.

2 1

5 4 3

678

Front view 8-Socket Receptacle

GND

1 2 3 4 5 6 7 8

Ohms

320

Figure 4 - 2: 8-Socket Receptacle

Socket

1 Earth (Ground).

Torch Switch Input (24V) to

(connect pins 2 & 3 to turn on welding current).

Torch Switch Input (0V) to energize weld

current (connect pins 2 & 3 to turn on welding current).

Connect pin 4 to pin 8 to instruct machine that

a remote current control device is connected (12V DC supply).

5k ohm (maximum) connection to 5k ohm

remote control potentiometer.

Zero ohm (minimum) connection to 5k ohm

remote control potentiometer.

Wiper arm connection to 5k ohm remote control

potentiometer.

Connect pin 4 to pin 8 to instruct machine that

a remote current control device is connected (0V).

Table 4 - 1: Socket Pin Functions

Function

Figure 4 - 1: ARC MASTER 160S Power Source

4 – 1

200TS 4 OPERATOR CONTROL

3. Positive Terminal: Welding current flows from the Power Source via heavy duty Dinse type terminal (

25 mm) 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 (

25 mm) It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

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

5. Torch/Gas Terminal: Torch/Gas Terminal is an all-in-one design of the Gas Outlet and the Negative Terminal. Gas Outlet is a BSP-3/8 inch female gas fitting.

6. ON/OFF Switch: This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Supply.

WARNING

When the welder is connected to the Primary supply voltage, the internal electrical components may be at 240V potential with respect to earth.

7. Input Cable: The input cable connects the Primary supply voltage to the equipment.

8. Gas Inlet: The Gas Inlet is BSP-3/8 inch female gas fitting.

Weld Process selection for 200TS

Weld Mode

Weld Process

Selection

STICK MIG

Yes Yes Yes

STD

SLOPE

No Yes Yes

REPEAT

No Yes Yes

No Yes No

SPOT

No Yes Yes

PULSE ON/OFF

Table 4 - 2: Weld Process selection verses Weld Mode for

200TS

LIFT

TIG

Description

2T operation in TIG Modes using remote devices to control contactor & current

4T operation in TIG Modes with crater fill using a remote contactor device to control sequence.

4T operation in TIG Modes with repeat operation and crater fill using a remote contactor device.

2T operation spot welding in HF TIG using a remote contactor device.

Pulse operation in TIG Modes

4 – 2

200TS 4 OPERATOR CONTROL

Weld Parameter Descriptions for ARC MASTER 200TS

Figure 4- 3: ARC MASTER 200TS Front Panel with Parameter

Parameter Description

PRE-FLOW

HOT START

INITIAL CUR.

UP SLOPE

PEAK CUR. This parameter sets the PEAK weld current when in PULSE mode.

WELD

BASE (Background Current) This parameter sets the Background current when in Pulse TIG mode.

SPOT TIME This parameter sets the duration of the SPOT TIME in HF TIG mode only.

PULSE WIDTH

PULSE FREQ. This parameter sets the PULSE FREQUENCY when the PULSE is on.

DOWN SLOPE

CRATER CUR.

Description

This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc, once the torch trigger switch has been pressed. This control is used to dramatically reduce weld porosity at the start of a weld.

This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the BASE (WELD) current. e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps & HOT START = 30 amps

This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the start current for TIG. The Start Current remains on until the torch trigger switch is released after it has been depressed.

This parameter operates in TIG modes only and is used to set the time for the weld current to ramp up, after the torch trigger switch has been pressed then released, from INITIAL CUR to PEAK or BASE current.

This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and SPOT modes when PULSE is off. This parameter also sets the STICK weld current.

This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSE is on.

This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down, after the torch trigger switch has been pressed, to CRATER CUR. This control is used to eliminate the crater that can form at the completion of a weld.

This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the finish current for TIG. The CRATER Current remains on until the torch trigger switch is released after it has been depressed.

4 – 3

Parameter Description

POST-FLOW This parameter operates in TIG modes only and is used to adjust the post gas flow time

once the arc has extinguished. This control is used to dramatically reduce oxidation of the tungsten electrode.

The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into

SAVE LOAD

AUVEGARDER CHARGER

Weld Parameters for ARC MASTER 200TS

the 200TS memory.

Table 4 - 3: Weld Parameter Descriptions for ARC MASTER 200TS

4.1 Weld Parameters

200TS 4 OPERATOR CONTROL

Weld

Parameter Parameter

PRE-FLOW 0.0 to 1.0 sec 0.1 sec 0.1 sec No Yes Yes

HOT START 0 to 70A 20A 1A Yes Yes No

INITIAL CUR. 1 to 200A 30A 1A No Yes Yes

UP SLOPE 0 to 15 sec 1 sec 0.1 sec No Yes Yes

PEAK CUR. 1 to 160A 120A 1A No Yes Yes

WELD CUR (STICK)

WELD CUR (TIG)

SPOT TIME 0.5 to 5.0 sec 2 sec 0.1 sec No Yes No

PULSE WIDTH 15 to 80% 50% 1% No Yes Yes

PULSE FREQ. 0.5 to 500Hz 100.0Hz See Table 4-5 No Yes Yes

DOWN SLOPE 0 to 25 sec 3 sec 0.1 sec No Yes Yes

CRATER CUR. 1 to 200A 30A 1A No Yes Yes

POST-FLOW 0.0 to 60 sec 10 sec 0.1 sec No Yes Yes

PULSE FREQ. Range Incremental Unit

0.5 to 20Hz 0.1Hz

20 to 100Hz 1Hz

100 to 500Hz 5Hz

1 to 160A 230V

1 to 85A 115V

1 to 200A 230V

1 to 85A 115V

Range

Table 4 - 4: Weld Parameters for ARC MASTER 200TS

Factory

Setting

80A 1A Yes Yes Yes

Incremental Unit

STICK

Weld Mode

MIG

LIFT

TIG

Table 4- 5: PULSE FREQ. Range and Incremental Units

4 – 4

200TS 4 OPERATOR CONTROL

Power Source Features

Feature Description

New Digital Control

Touch Panel Switches

Front Control Cover

 Almost all welding parameters are adjustable.

 Touch switches eliminate mechanical damage.

 Protects front panel controls.

 Displays selected weld parameter value.

Digital Meter

 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.

ON/OFF switch

Save/Load Function

Voltage Reduction Device (VRD)

Control Knob

Self Diagnosis Using Error Codes

 Primary voltage Supply ON/OFF switch located on rear panel.

 A total number of 5 programs can be saved into the 200TS memory.

SAVE the Current Weld Parameters into Memory

 Press the SAVE button.  Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter.  After selecting the desired memory location (ie 1 to 5), press the right scroll button and

the machine will give a beep to confirm the weld parameters from the control panel are saved.

LOAD (retrieve) a Program to Control Panel

 Press the LOAD button.  Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter.  After selecting the desired memory location (ie 1 to 5), press the right scroll button and

the machine will give a beep to confirm the weld parameters from the control panel are loaded.

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.

 An error code is displayed on the Digital Meter when a problem occurs with Primary sup-

ply voltage or internal component problems. Refer to troubleshooting guide.

Table 4-6: Power Source Features

4 – 5

+ 67 hidden pages

Thermal Arc ARCMASTER 200 TS Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual