Tweco 200-ACDC User Manual

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200 AC/DC

ARCMASTER

INVERTER ARC WELDER

Operating Manual

Version No: 1 Issue Date: April 13, 2006 Manual No.: 0-4903

Operating Features:

200

Amp

Art # A-07235

INVERTER

230

WE APPRECIA TE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-752-7621, or visit us on the web at www.thermalarc.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

WARNINGS

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

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

ArcMaster 200 AC/DC Inverter Arc Welder Instruction Manual Number 0-4903 for: Part Number 10-3088

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: April 13, 2006

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

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

1.03 Precautions de Securite en Soudage à l’Arc ................................................... 1-5

1.04 Dangers Relatifs au Soudage à l’Arc ............................................................... 1-5

1.05 Principales Normes de Securite ..................................................................... 1-8

1.06 Declaration Of Conformity .............................................................................. 1-9

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

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

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

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Symbol Chart ................................................................................................. 2-2

2.05 Description ..................................................................................................... 2-3

2.06 Functional Block Diagrams ............................................................................. 2-4

2.07 Transporting Methods .................................................................................... 2-4

SECTION 3:

INSTALLATION ....................................................................................... 3-1

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

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

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

3.04 Electrical Input Requirements ........................................................................ 3-2

3.05 Input Power .................................................................................................... 3-3

3.06 High Frequency Introduction .......................................................................... 3-3

3.07 High Frequency Interference .......................................................................... 3-4

3.08 Duty Cycle ...................................................................................................... 3-4

3.09 Specifications ................................................................................................. 3-5

SECTION 4:

OPERATOR CONTROLS ............................................................................. 4-1

4.01 ArcMaster 200 AC/DC Controls ...................................................................... 4-1

4.02 Weld Process Selection for ArcMaster 200 AC/DC ......................................... 4-3

4.03 Weld Parameter Descriptions for ArcMaster 200 AC/DC ................................ 4-4

4.04 Weld Parameters for ArcMaster 200 AC/DC ................................................... 4-6

4.05 Power Source Features................................................................................... 4-7

SECTION 5:

SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................. 5-1

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 6:

SEQUENCE OF OPERATION ........................................................................ 6-1

6.01 Stick Welding ................................................................................................. 6-2

6.02 AC or DC HF TIG Welding ............................................................................... 6-2

6.03 Slope Mode Sequence .................................................................................... 6-3

6.04 Slope Mode with Repeat Sequence ................................................................ 6-3

6.05 Pulse Controls ................................................................................................ 6-4

SECTION 7:

BASIC TIG WELDING GUIDE ....................................................................... 7-1

7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum ................. 7-1

7.02 Electrode Polarity ........................................................................................... 7-2

7.03 Tungsten Electrode Current Ranges ............................................................... 7-2

7.04 Tungsten Electrode Types............................................................................... 7-2

7.05 Guide for Selecting Filler Wire Diameter ......................................................... 7-3

7.06 Shielding Gas Selection .................................................................................. 7-3

7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe .................. 7-3

7.08 Welding Parameters for Aluminum ................................................................ 7-4

7.09 Welding Parameters for Steel ......................................................................... 7-4

SECTION 8:

BASIC ARC WELDING GUIDE ..................................................................... 8-1

8.01 Electrode Polarity ........................................................................................... 8-1

8.02 Effects of Stick Welding Various Materials ..................................................... 8-1

SECTION 9:

ROUTINE MAINTENANCE .......................................................................... 9-1

SECTION 10:

BASIC TROUBLESHOOTING ...................................................................... 10-1

10.01 TIG Welding Problems................................................................................ 10-1

10.02 Stick Welding Problems ............................................................................. 10-4

10.03 Power Source Problems ............................................................................. 10-7

SECTION 11:

VOLTAGE REDUCTION DEVICE (VRD) ........................................................... 11-1

11.01 VRD Specification ....................................................................................... 11-1

11.02 VRD Maintenance ....................................................................................... 11-1

11.03 Switching VRD On/Off ................................................................................ 11-2

TABLE OF CONTENTS

SECTION 12:

POWER SOURCE ERROR CODES ................................................................. 12-1

APPENDIX 1: GENERAL INFORMATION ................................................................. A-1

APPENDIX 2: ARCMASTER 200 AC/DC INTERCONNECTION DIAGRAM ............................ A-2

APPENDIX 3: ARCMASTER 200 AC/DC ACCESSORIES ............................................... A-4

LIMITED WARRANTY AND SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

ARCMASTER 200 AC/DC

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.

April 13, 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 AC/DC

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.

1-2

Eye protection filter shade selector for welding or cutting

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

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

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

April 13, 2006

WARNING

ARCMASTER 200 AC/DC

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.

April 13, 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 AC/DC

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.

1-4

April 13, 2006

ARCMASTER 200 AC/DC

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.

April 13, 2006

1-5

ARCMASTER 200 AC/DC

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) 2 ou 3

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

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

1-6

April 13, 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 AC/DC

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.

April 13, 2006

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1-7

ARCMASTER 200 AC/DC

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.

April 13, 2006

ARCMASTER 200 AC/DC

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

April 13, 2006

1-9

ARCMASTER 200 AC/DC

1-10

April 13, 2006

ARCMASTER 200 AC/DC

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s 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.

2.02 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.

2.03 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.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number given in the next section. Include the Owner’s 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

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

April 13, 2006

2-1

ARCMASTER 200 AC/DC

2.04 Symbol Chart

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

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

Burnback Time

Disturbance In Ground System

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

2-2

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

April 13, 2006

2.05 Description

ARCMASTER 200 AC/DC

The Thermal Arc™ Model 200 AC/DC is a self contained single-phase AC/DC arc welding power source 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 retardant and non-conductive plastic case.

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.

(V) OCV

5A 160A (A)

STICK Process (V) OCV

Art # A-07443

10V

25A 200A

(A)

LIFT TIG Process (V) OCV

200A

(A)

HF TIG Process

Figure 2-1: Model 200 AC/DC Volt-Ampere curve

April 13, 2006

2-3

ARCMASTER 200 AC/DC

2.06 Functional Block Diagrams

Figure 2-2 illustrates the functional block diagram of the 200 AC/DC-power supply.

DC Powe r

Input

Power

Ma i n

Circuit

Switch

Fil ter

Input

Diod e

Secondary

Voltage Sensor

Capacitor

DC Power Primary

Voltage Sensor

To eac h control circuit

+/-15VDC +18 VDC

Thermal Detec tor

+24VDC +5VDC

Trouble Sensing

Inverter

Circuit

IGBT

To eac h control circuit

+/-12VDC +15VDC

Ma i n

Transformer

(PCB 14)

Themal

Drive

Sensor

Circuit

Primary Current

Sensor

Ou tpu t

Diod es

Thermal Detec tor

HF-UNIT

Stick Mode

Control

Circ uit

VRD

Sensing

Circuit

Out pu t

Induc tor

Lift Tig Mode

Out pu t Sh ort

Sensing

Circuit

Secondary

IGBT

Inverter

Drive

Circ uit

Hall Current

Transformer

Couplin g

Coil

High

Frequ enc y

Unit

(HC T1 )

Current

circuit

Mode select Switches

Panel Circuit Board

Sequence

Control

Torch Control

Connecti on

(CON1)

Adjustment

Figure 2-2: 200 AC/DC Model Functional Block Diagram

2.07 Transporting Methods

This unit is 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.

Referenc e

Adjus tment &

Fan Control

Gas C on trol

Art # A-07267

Circuit

Fan

Solenoid

• Use handcart or similar device of adequate capacity.

• If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

• Lift unit with handle on top of case.

2-4

April 13, 2006

ARCMASTER 200 AC/DC

SECTION 3:

INSTALLATION

3.01 Environment

The ArcMaster 200 AC/DC 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;

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.

3.03 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.

Environments with adverse conditions 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.

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 boundaries that could restrict natural airflow for cooling.

WARNING

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

April 13, 2006

3-1

ARCMASTER 200 AC/DC

3.04 Electrical Input Requirements

Do not connect an input (BROWN or BLUE) conductor to

the ground terminal. Operate the welding power source from a single-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

Do not connect the ground (YELLOW/GREEN) conductor

to an input line terminal.

Refer to Figure 3-1 and: utility for information about the type of electrical service

available, how proper connections should be made, and any inspection required.

1. Connect end of ground (YELLOW/GREEN) conductor

to a suitable ground. Use a grounding method that

complies with all applicable electrical codes. 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.

2. Connect ends of line 1 (BROWN) and line 2 (BLUE)

input conductors to a de-energized line disconnect switch.

3. Use Table 3-1 and Table 3-2 as a guide to select line

fuses for the disconnect switch.

NOTE

This unit is equipped with a 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.

Input Voltage Fuse Size

230V 60 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).

Welding Power Supply

Ground Terminal

Ground Conduct or

Line Di sc onnect Swit ch

Line Fuse

Pri mary Power Cable

3-2

Art # A-07268

Figure 3-1: Electrical Input Connections

April 13, 2006

ARCMASTER 200 AC/DC

3.05 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. 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

Note the available input power. Damage to the PCA could occur if 400VAC or higher is applied.

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

Primary Supply

Model

ArcMaster

200 AC/DC

Table 3-2: 230V/ Primary Current Circuit sizes to achieve maximum current

The ARC MASTER 200 AC/DC 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.

Lead Size

(Factory Fitted)

2.5mm sq/3 minimum

Minimum Primary

Current Circuit Size

(Vin/Amps)

230/33 230/38 - 160 @ 40%

Current & Duty Cycle

TIG STICK

200 @ 30%

3.06 High Frequency Introduction

WARNING: EXPLOSIVES

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.

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.

April 13, 2006

WARNING: COMPUTERS

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

3-3

ARCMASTER 200 AC/DC

3.07 High Frequency Interference

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.

3.08 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

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.

3-4

April 13, 2006

3.09 Specifications

(DC)

(

)

Parameter 200 AC/DC Rated Out

eres

Am Volts Duty Cycle

Duty Cycle TIG

Output Current TIG

Range STICK

Open Circuit Voltage 65V

Dimensions

Width 7.08” Height

Length Weight 41.8 lb. 19 kg

Output @ Rated Load

Rated Input Voltage Output Amperes Output Volts Duty Cycle KVA KW

Output @ No Load

KVA KW

Input Volts Single Phase

230V

STICK

ARCMASTER 200 AC/DC

Table 3-3: Parameter Specifications

200 18 20%

200A / 18V @ 20% 160A / 17V @ 40% 130A / 16V @ 60% 100A / 14V @ 100% 160A / 27V @ 40% 130A / 26V @ 60% 100A / 24V @ 100% 5 – 200 5 – 200 (AC) @ 60Hz, 50% Cleaning

5 – 160 5 – 160 (AC) @ 60Hz, 50% Cleaning

180mm

14.7” (360mm

16.54” (420mm)

Single phase 160A 27V 40%

8.7

5.2

0.5

0.13 Amperage Draw @ Rated Load No Load Amps

38 1.6

April 13, 2006

3-5

ARCMASTER 200 AC/DC

NOTES

3-6

April 13, 2006

OPERATOR CONTROLS

4.01 ArcMaster 200 AC/DC Controls

ARCMASTER 200 AC/DC

SECTION 4:

Art # A-07444

Figure 4-1: ArcMaster 200 AC/DC Power Source

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.

Art # A-04984

5k Ohms

543

678

GND

12345678

Figure 4-2: 8-Socket Receptacle

Socket Pin Function

1 Earth (Ground) 2

Torch Switch Input (24V) to (connect pins 2 & 3 to turn on

welding current)

3 Torch Switch Input (0V) to

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

4 Connectpin4topin8toinstruct

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

5 5k ohm (maximum) connection

to 5k ohm remote control potentiometer

6 Zero ohm (minimum) connection

to 5k ohm remote control potentiometer

7 Wiper arm connection to 5k ohm

remote control potentiometer

8 Connectpin4topin8toinstruct

machine that a remote current control device is connected (0V)

April 13, 2006

Table 4-1: Socket Pin Functions

4-1

ARCMASTER 200 AC/DC

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.

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.

CAUTION

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

5. Gas Outlet: 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 male 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.

8 . Gas Inlet: The Gas Inlet is a BSP-3/8 inch male gas

fitting.

4-2

April 13, 2006

4.02 Weld Process Selection for ArcMaster 200 AC/DC

ARCMASTER 200 AC/DC

Weld Process

Selection

STD

SLOPE

REPEAT

SPOT

PULSE ON/OFF

Weld Mode

STICK

Yes Yes Yes

No Yes Yes

No Yes No

No Yes Yes Pulse operation in TIG Modes

TIG

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.

Contactor ON/OFF

Operation

PANEL/REMOTE

Yes Yes Yes Selects AC or DC weld current

Table 4-2: Weld Process selection versus Weld Mode for ArcMaster 200 AC/DC

Yes No Yes Contactor operation in Stick Mode

Yes Yes Yes

Selects in operation Panel board or Remote

April 13, 2006

4-3

ARCMASTER 200 AC/DC

4.03 Weld Parameter Descriptions for ArcMaster 200 AC/DC

Art # A-07237

Figure 4-3: ArcMaster 200 AC/DC Front Panel

Parameter 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

PRE-FLOW

HOT START

INITIAL CUR.

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

HOT START

e.g.

HOT START

This parameter operates in 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.

current = 130 amps when

= 30 amps

SLOPE

BASE (WELD)

REPEAT

current.

= 100 amps &

(4T) TIG modes only and

4-4

UP SLOPE

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

Table 4-3: ArcMaster 200 AC/DC Front Panel Parameter Description

April 13, 2006

ARCMASTER 200 AC/DC

PEAK CUR.

WELD

BASE

(BackgroundCurrent)

SPOT TIME

PULSE WIDTH

PULSE FREQ.

AC FREQUENCY

WAVE BALANCE

This parameter sets the PEAK weld current when in This parameter sets the TIG WELD current in

SPOT

modes when

PULSE

is OFF. This parameter also sets the STICK

PULSE

mode

STD, SLOPE, REPEAT

and

weld current. This parameter sets the Background current when in Pulse TIG mode.

This parameter sets the duration of the This parameter sets the percentage on time of the

for PEAK weld current when the This parameter sets the

PULSE FREQUENCY

PULSE

SPOT TIME

is ON.

when the

HF TIG

mode only

PULSE FREQUENCY

PULSE

is ON.

This parameter operates in AC mode only and is used to set the frequency for the AC weld current.

This parameter is used for aluminum AC TIG mode and is used to set the penetration to cleaning action ratio for the AC weld current. Generally

WAVE BALANCE BALANCE

control changes the ratio of penetration to cleaning action of

is set to 50% for AC

STICK

welding. The

WAVE

the AC TIG welding arc. Maximum weld penetration is achieved when

WAVE BALANCE

the oxidised aluminium or magnesium alloys is achieved when the

BALANCE

WAVE BALANCE=50%

control is set to 65%.

control is set to 10%. Maximum cleaning of heavily

WAVE

WAVE BALANCE=10%

10%50% 65%

(+ )(+ ) (+ )

WAVE BALANCE=65%

DOWN SLOPE

CRATER CUR.

POST-FLOW

(-)(-) (-)

Balanced with 50% penetration

and 50% cleaning

Maximum Penetra tion and

90%50% 35%

reduced cleaning

Maximum Cleaning and

reduced penetration

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

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.

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 the 200AC/DC memory.

April 13, 2006

Table 4-3 (continued): ArcMaster 200 AC/DC Front Panel Parameter Description

4-5

ARCMASTER 200 AC/DC

4.04 Weld Parameters for ArcMaster 200 AC/DC

Weld HF

Parameter STICK TIG

PRE-FLOW

HOT START

INITIAL CUR.

UP SLOPE

PEAK CUR.

WELD CUR

(TIG)

WELD CUR (STICK)

Parameter

Range

0.0 to 1.0 sec 0.1 sec 0.1 sec No Yes Yes 0 to 70A 20A 1A Yes Yes No

5 to 185A 30A 1A No Yes Yes

0 to 15 sec 1 sec 0.1 sec No Yes Yes

5 to 185A 120A 1A No Yes Yes

5 to 185A 80A

5 to 160A 80A 1A Yes No No

Factory

Setting

Incremental

Unit

1A No

Weld Mode

LIFT TIG

Yes Yes

SPOT TIME

PULSE WIDTH

PULSE FREQ.

AC FREQUENCY WAVE BALANCE

DOWN SLOPE CRATER CUR.

POST-FLOW

0.5 to 5.0 sec 2 sec 0.1 sec No Yes Yes

15 to 80% 50% 1% No Yes Yes

0.5 to 500Hz 100.0Hz No

15 to 150Hz 50Hz 1Hz Yes Yes Yes

10 to 65% 50% 1% Yes Yes Yes

0 to 25 sec 3 sec 0.1 sec No Yes Yes

5 to 185A 30A 1A No Yes Yes

0.0 to 60 sec 10 sec 0.1 sec No Yes Yes

Table 4-4: Weld Parameters for ArcMaster 200 AC/DC

PULSE FREQ.

0.5 to 20Hz 0.1Hz

20 to 100Hz 1Hz

100 to 500Hz 5Hz

Range Incremental Unit

See

Table 6

Yes Yes

4-6

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

April 13, 2006

4.05 Power Source Features

Feature Description

New Digital Control Touch Panel Switches Front Control Cover Digital Meter

Intelligent Fan Control

ON/OFF Switch

Voltage Reduction Device (VRD)

See Section 11 for de-activation

instructions

Control Knob

Self Diagnosis using Error Codes

ARCMASTER 200 AC/DC

• 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

• 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

• 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 counter-clockwise 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

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

Digital Meter

when a

April 13, 2006

Table 4-6: Power Source Features

4-7

ARCMASTER 200 AC/DC

Feature Description

Save/Load Function

• A total number of 5 programs can be saved into the

185AC/DC memory.

SAVE

the Current Weld Parameters into Memory

• Press and HOLD the

the Digital Meter will show a number 1.

• Select a memory location by rotating the control knob,

1 to 5 is displayed on the meter.

• After selecting the desired memory location (i.e. 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 and HOLD the

the Digital Meter display will show a number 1.

• Select a memory location by rotating the control knob,

1 to 5 is displayed on the meter.

After selecting the desired memory location (i.e. 1 to 5), press the right scroll button and the machine will give a beep to confirm the weld parameters are loaded onto the control panel.

Table 4-6:Power Source Features con't

SAVE

LOAD

button. Beep will sound and

4-8

April 13, 2006

SECTION 5:

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

Conventional operating procedures apply when using the 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, then finally adjust the current setting to suit the application.

WARNING

ARCMASTER 200 AC/DC

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

Remove any packaging material prior to use. Do not block the air vents at the front or rear or sides of the Welding Power Source.

CAUTION

DO NOT change the Weld Mode or Weld Process Mode until after POST-FLOW time has finished.

Art # A-07271

Figure 5-1: 200 AC/DC Set-up

April 13, 2006

5-1

ARCMASTER 200 AC/DC

NOTES

5-2

April 13, 2006

ARCMASTER 200 AC/DC

SECTION 6:

SEQUENCE OF OPERATION

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 the Symbols Table located in the front of the manual for Symbol descriptions.

4 6

Figure 6-1: 200 AC/DC Front Panel

Art # A-07272

1. Pulse Function: Pressing this button enables the TIG current pulse functions.

2. Remote Current Function: Pressing this buttons enables remote current functions.

3. TIG Mode Functions: Pressing this button scrolls through the output TIG function modes (Standard, Slope, Slope w/repeat, Spot).

4. 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.

5. Save/Load Buttons: By using the Save & Load buttons the operator can easily save up to 5 welding parameter programs.

6. Control Knob: Allows the operator to adjust the output amperage within the entire range of the power source and sets each parameter value.

7. Process Button: This button selects between STICK, HF TIG and Lift TIG mode.

8. Scroll Buttons: Used to select the parameters to be set. The LED’s show which function is being adjusted on the Sequence Graph.

9. AC/DC Button: Selects between AC or DC welding output.

10. Contactor Function: Pressing this buttons enables Contactor functions

April 13, 2006

6-1

ARCMASTER 200 AC/DC

6.01 Stick Welding

· Connect work lead to negative terminal

· Connect electrode lead to positive terminal

· Switch machine on

· Set

or DC weld current. If AC is selected then set

AC FREQ

· Set Contractor

· Connect remote control device if required

Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

· Set

Commence welding

to 60Hz &

HOT START

WELD

current

WAVE BALANCE

to 50%.

6.02 AC or DC HF TIG Welding

· Connect work lead to positive terminal

Connect TIG torch to negative terminal

Switch machine on

Set AC or DC weld current. If AC is selected then set

AC FREQ

Connect remote control device if required

Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

· Set

Slope Mode Parameters if required

WAVE BALANCE

PRE-FLOW HOT START POST-FLOW

time

current

time

(WELD) PEAK CUR POST-FLOW

time

current

· Set

INITIAL CUR

· Set

UP SLOPE

· Set (WELD)

· Set

BASE

current

· Set

DOWN SLOPE

· Set

CRATER CUR

Pulse Mode parameters if required

· Set

PULSE WIDTH

Set PEAK CURRENT

· Set

PULSE FREQ

Commence welding

current

time

PEAK CUR

time

current

% for

current

PEAK CURRENT

6-2

April 13, 2006

6.03 Slope Mode Sequence

Switch Closed

Switch Open

Switch Closed

ARCMASTER 200 AC/DC

Art # A-04989

Switch Open

Initial

Slope

Weld Current

Current

Preflow

Figure 6-2: Slope Mode Sequence

NOTE

Slope function operates with a Remote ON/OFF device only

1. To start Slope sequence Close remote switch contacts. Once the welding arc is established the Power Source will maintain initial current setting as long as the remote switch contacts are closed.

a. In the HF TIG mode, after Preflow time, High

Frequency is present at the torch. When the torch is positioned close to the work the welding current will transfer to the work and establish the arc at the initial current setting.

Down

Slope

Final

Current

Postflow

2. Open Remote Switch – current increases to weld current. Once welding arc has reached weld current the power source will maintain weld current as long as the remote switch contacts are open.

3. Close Remote Switch – Welding current decreases to final current setting. Once final welding current is reached the power source will maintain final current setting as long as the remote switch contacts are closed.

b. In the Lift TIG mode, after Preflow time, Lift Start

current is present at the torch. When the electrode is touched to the work and lifted off, the welding arc is established at the initial current setting.

6.04 Slope Mode with Repeat Sequence

The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the down slope period only. During the down slope period, by opening the Remote Switch contacts, the current will increase back to weld current. Within the Down Slope period the repeat function can be operated as many times as desired. To continue slope cycle and end slope sequence close remote switch contacts and allow weld current to reach final current setting. Once final current setting is reached, opening the Remote Switch again will turn off the welding arc and post flow begins.

4. Open Remote Switch – Welding arc stops and post flow begins.

April 13, 2006

6-3

ARCMASTER 200 AC/DC

6.05 Pulse Controls

(Pulse Width) (Pulse Frequency)

Art # A-04990

(Peak Current)

(Base)

Background

Current

Figure 6-3: Pulse Controls

The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows:

1) Control puddle – size and fluidity (especially out of position).

2) Increase penetration

3) Travel speed control

4) Better consistent quality

5) Decreased distortion on lighter or thinner materials Pulse-current provides a system in which the welding current continuously changes between two levels. During the

periods of Peak current, heating and fusion takes place, and during the background (base) current periods, cooling and solidification take place. Pulse Width is the time in one cycle the current remains at the peak current setting. Pulse Frequency, measured in Hertz, is the number of cycles per second the current travels between peak and background current settings. It is as if the foot rheostat were moved up and down to increase and decrease the welding current on a regular basis. The faster you moved the foot rheostat up and down the faster the frequency.

6-4

April 13, 2006

SECTION 7:

BASIC TIG WELDING GUIDE

ARCMASTER 200 AC/DC

7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum

The following will assist in understanding the phenomenon of Arc Flutter, also referred to as Arc Rectification.

The basic thesis is that the fluttering is caused by lack of oxide in the weld pool.

The oxide layer on the plate reduced the energy for electron emission. Electron emission from the weld pool (DC+) causes the oxide layers to be disrupted, the socalled “cleaning action”. However once the cleaning action has produced a mirror like surface on the weld pool, the effect of the oxide layer is limited because the oxide layer has dissipated. This makes electron emission from the weld pool more difficult and increases the chance of arc instability.

AC TIG on aluminum

1. The Problem: Arc appears unstable and pulses or flutters. ie. appears to rapidly change welding current

This idea is supported by the observation that once fluttering starts it can be made to stop by working the arc away from the mirror like weld pool to an area of oxide coated material. As soon as this is done the arc settles back to a stable condition. So while the arc is “consuming” oxide coated plate the instability does not occur. But once the arc is stationary, the pool becomes thoroughly “cleaned” by election emission, the fluttering begins.

Tests conducted on various types of AC TIG power sources, Fluttery Arc is not confined to one type of power source or its' design, both conventional and inverter types suffer from the same problem.

Conditions that accentuate arc flutter: Conditions that minimizes arc flutter:

• Cold work piece • Preheat the work piece

• Very short arc length • Increase the arc length

• Weld pool crater about 0.39” to 0.47”

(10 to 12mm) diameter

• Arc field in one spot to produce

“mirror” clean weld pool

• Increased cleaning action

i.e. Prolonged oxide emission from a stationary weld pool increases the likelihood of arc flutter

• Accentuated when tungsten running

near its current capacity, i.e. Molten ball on end

• Introduce filler rod material to the weld

pool, which introduces oxides

• Move the weld pool around to introduce

oxides to the weld pool

• Decrease the cleaning action by turning

WAVE BALANCE

the move the weld pool around

• Use a larger diameter tungsten electrode

to below 50% or

Table 7-1: Reduction of Arc Flutter

2. Conclusion: Fluttery Arc in AC TIG is a physical phenomenon independent of machine design.

April 13, 2006

7-1

ARCMASTER 200 AC/DC

7.02 Electrode Polarity

Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity. 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.

7.03 Tungsten Electrode Current Ranges

Electrode Diameter AC Current (Amps) DC Current (Amps)

0.040” (1.0mm) 30 – 70 30 – 60 1/16” (1.6mm) 60 – 95 60 – 115 3/32” (2.4mm) 125 – 150 100 – 165

1/8” (3.2mm) 130 – 225 135 – 200 5/32” (4.0mm) 190 – 280 190 – 280 3/16” (4.8mm) 250 – 340 250 – 340

Table 7-2: Current ranges for various tungsten electrode sizes

7.04 Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

Welding Application Features

DC welding of mild steel, stainless steel and copper

High quality AC welding of aluminium, magnesium and their alloys

AC & DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys

Table 7-3: Tungsten Electrode Types

Excellent arc starting, long life, high current carrying capacity

Self cleaning, long life, maintains balled end, high current carrying capacity

Longer life, more stable arc, easier starting, wider current range, narrower more concentrated arc

Color

Code

Red

White

Grey

7-2

April 13, 2006

ARCMASTER 200 AC/DC

7.05 Guide for Selecting Filler Wire Diameter

NOTE

The filler wire diameter specified in Table 7-4 is a guide only, other diameter wires may be used according to the welding application

Filler Wire Diameter

1/16” (1.6 mm) 30 - 95 20 - 90 3/32” (2.4 mm) 125 - 160 65 - 115

1/8” (3.2 mm) 180 - 240 100 - 165

3/16” (4.8 mm) 220 - 320 200 - 350

7.06 Shielding Gas Selection

Alloy

Aluminium & alloys Welding Argon, Argoshield 80T, 81T Carbon Steel Welding Argon Stainless Steel Welding Argon, Argoshield 71T, 80T, 81T Nickel Alloy Welding Argon, Argoshield 71T Copper Welding Argon, Argoshield 81T Titanium Welding Argon, Argoshield 80T, 81T

AC Current Range DC Current Range

(Amps) (Amps)

Table 7-4: Filler Wire Selection Guide

Shielding Gas

Argoshield is a registered trademark of BOC Gases Limited.

Table 7-5: Shielding Gas Selection

7.07 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)

Table 7-6: TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Current Range DC

Amperes

120 - 170 Yes

100 - 160 Yes

90 - 130 No

Filler Rod for

Root Pass

Joint Preparation

April 13, 2006

7-3

ARCMASTER 200 AC/DC

7.08 Welding Parameters for Aluminum

Base Metal

Thickness

0.040” 30-45 0.040” 1/16” Butt/Corner

1.0mm 35-50 1.0mm 1.6mm Lap/ Fillet

0.045” 40-60 0.040” 1/16” Butt/Corner

1.2mm 45-70 1.0mm 1.6mm Lap/ Fillet 1/16” 60-85 1/16” 1/16” Butt/Corner

1.6mm 70-95 1.6mm 1.6mm Lap/ Fillet

1/8” 3/32” 3/32”

3.2mm 2.4mm 2.4mm

3/16” 180-225 1/8” 1/8” Butt/Corner

4.8mm 190-240 3.2mm 3.2mm Lap/ Fillet

¼” 240-280 3/16” 3/16” Butt/Corner

6.4mm 250-320 4.8mm 4.8mm Lap/ Fillet

AC Current for

Aluminum

125-150 130-160

Table 7-7: AC TIG Welding Parameters

Tungsten Electrode Diameter

1/8”

3.2mm

Filler Rod

Diameter

(if required)

Argon Gas

Flow Rate Liters/min

5-7

Joint Type

Butt/Corner

Lap/Fillet

7.09 Welding Parameters for Steel

Base Metal

Thickness

0.040” 35-45 20-30 0.040” 1/16” Butt/Corner

1.0mm 40-50 25-35 1.0mm 1.6mm Lap/ Fillet

0.045” 45-55 30-45 0.040” 1/16” Butt/Corner

1.2mm 50-60 35-50 1.0mm 1.6mm Lap/ Fillet 1/16” 60-70 40-60 1/16” 1/16” Butt/Corner

1.6mm 70-90 50-70 1.6mm 1.6mm Lap/ Fillet

1/8” 80-100 65-85 1/16” 3/32” Butt/Corner

3.2mm 90-115 90-110 1.6mm 2.4mm Lap/ Fillet 3/16” 115-135 100-125 3/32” 1/8” Butt/Corner

4.8mm 140-165 125-150 2.4mm 3.2mm Lap/ Fillet

¼” 160-175 135-160 1/8” 5/32” Butt/Corner

6.4mm 170-200 160-180 3.2mm 4.0mm Lap/ Fillet

DC Current

for Mild

Steel

DC Current for

Stainless

Steel

Tungsten

Electrode

Diameter

Filler Rod

Diameter

(if required)

Argon Gas Flow Rate Liters/min

5-7

Joint Type

7-4

Table 7-8: DC TIG Welding Parameters

April 13, 2006

SECTION 8:

BASIC ARC WELDING GUIDE

8.01 Electrode Polarity

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

8.02 Effects of Stick Welding Various Materials

ARCMASTER 200 AC/DC

High Tensile and Alloy Ateels

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 porosity caused by gas held in this type 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 fusion of weld and base metal.

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 everyday 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 publication will cover the vast majority of applications likely to be encountered; are all easy to use and all will work on even the most basic of welding machines.

April 13, 2006

8-1

ARCMASTER 200 AC/DC

Metals being

joined

Mild Steel 6013 Ideal electrodes for all general

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

Copper, Bronze, Brass, etc.

Electrode Comments

purpose work. Features include outstanding operator appeal, easy arc starting and low spatter.

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

except white cast iron.

for dairy work, etc.

Bronze

5.7 ERCUSI-A

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.

High alloy steels, dissimilar metals, crack resistant, all hard-to-weld jobs.

312-16 It will weld most problematic jobs

such as springs, shafts, broken joints, mild steel to stainless and alloy steel. Not suitable for Aluminium.

Table 8-1: Types of Electrodes

8-2

April 13, 2006

ARCMASTER 200 AC/DC

SECTION 9:

ROUTINE MAINTENANCE

The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

The unit should be wiped clean as necessary with solvents that are recommended for cleaning electrical apparatus. Turn Power Switch to OFF before proceeding. Internal cleaning of the unit should be done every 6 months by an authorized Thermal Arc Service Center to remove any accumulated dirt and dust. This may need to be done more frequently under exceptionally dirty conditions.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

April 13, 2006

9-1

ARCMASTER 200 AC/DC

Warning! Disconnect input power before maintaining.

Each Use

ntain more often

Mai if used under severe conditions

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Replace all broken parts

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

9-2

6 Months

Bring the unit to an authorized Thermal Arc Service Center to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

Art # A-07331

April 13, 2006

ARCMASTER 200 AC/DC

SECTION 10:

BASIC TROUBLESHOOTING

WhARNING

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.

10.01 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.

Weld bead too wide and flat or undercut at edges of weld or excessive burn through.

Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart.

Weld bead too wide or excessive bead build up or excessive penetration in butt joint.

Uneven leg length in fillet joint.

Welding current is too low.

Welding current is too high. Decrease weld current.

Travel speed too fast. Reduce travel speed.

Travel speed too slow. Increase travel speed.

Wrong placement of filler rod. Re-position filler rod.

Increase weld current and/or faulty joint preparation.

April 13, 2006

Table 10-1: TIG Welding Problems

10-1

ARCMASTER 200 AC/DC

Description Possible Cause Remedy

Electrode melts when arc is struck.

7 Dirty weld pool. A

B Gas contaminated with air. B

Electrode melts or oxidizes when an

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

Electrode is connected to the ‘+’ terminal.

WAVE BALANCE

than 50%.

Electrode contaminated through contact with work piece or filler rod material.

No gas flowing to welding region.

Gas passage contains impurities.

is greater

Connect the electrode to the ‘−’ terminal.

Reduced

to below 50% or increase

the electrode size.

Clean the electrode by grinding off the contaminates.

Check gas lines for cuts and loose fitting or change gas cylinder.

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

Disconnect gas hose from torch then raise gas pressure and blow out impurities.

WAVE BALANCE

E Gas regulator turned OFF. E Turn ON. F Torch valve is turned OFF. F Turn ON. G

9 Poor weld finish. Inadequate shielding gas.

Arc flutters during

TIG welding.

The electrode is too small for the welding current.

WAVE BALANCE

above 50%.

Tungsten electrode is too large for the welding current.

Absence of oxides in the weld pool.

is set

Increase electrode diameter or reduce the welding current.

Reduced

to below 50% or increase

the electrode size. Increase gas flow or

check gas line for gas flow problems.

Select the right size electrode. Refer to Basic TIG Welding guide.

Refer Basic TIG Welding Guide for ways to reduce arc flutter.

Table 10-1 (continued): TIG Welding Problems

WAVE BALANCE

10-2

April 13, 2006

ARCMASTER 200 AC/DC

Description Possible Cause Remedy

Welding arc cannot be established.

B Torch lead is disconnected. B C

Arc start is not smooth.

C Gas flow rate is too high. C

Work clamp is not connected to the work piece or the work/torch leads are not connected to the right welding terminals.

Gas flow incorrectly set, cylinder empty or the torch valve is OFF.

Tungsten electrode is too large for the welding current.

The wrong electrode is being used for the welding job.

Incorrect shielding gas is being used.

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

Connect it to the ‘−‘ terminal.

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

Select the right size electrode. Refer to Basic TIG Welding Guide.

Select the right electrode type. Refer to Basic TIG Welding Guide.

Select the correct rate for the welding job. Refer to Basic TIG Welding Guide.

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

Poor work clamp connection to work piece.

Table 10-1 (continued): TIG Welding Problems

Improve connection to work piece.

April 13, 2006

10-3

ARCMASTER 200 AC/DC

10.02 Stick Welding Problems

Description Possible Cause Remedy

Gas pockets or

voids in weld metal (Porosity).

2 Crack occurring in

weld metal soon after solidification commences.

3 A gap is left by

failure of the weld metal to fill the root of the weld.

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

Electrodes are damp.

Welding current is too high.

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

Rigidity of joint.

Insufficient throat thickness.

Cooling rate is too high. Welding current is too low.

Electrode too large for joint.

Insufficient gap.

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.

Table 10-2: Stick Welding Problems

Art # A-04991

Incorrect sequence

Insufficient gap

Figure 10-1: Example of Insufficient Gap or Incorrect Sequence

10-4

April 13, 2006

ARCMASTER 200 AC/DC

Description Possible Cause Remedy

4 Portions of the weld

run do not fuse to the surface of the metal

Small electrodes used on heavy cold plate.

Welding current is too low.

or edge of the joint. C Wrong electrode angle. C Adjust angle so the welding arc is

D Travel speed of electrode is

too high.

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

Table 10-2 (continued): Stick Welding Problems

Use larger electrodes and pre-heat the plate.

Increase welding current.

directed more into the base metal.

D Reduce travel speed of electrode.

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

Lack of inter-run fusion

Lack of side fusion, scale dirt, small electrode,

Lack of root fusion

amperage too low

Figure 10-2: Example of Lack of Fusion

Art # A-04992

April 13, 2006

10-5

ARCMASTER 200 AC/DC

Description Possible Cause Remedy

5 Non-metallic particles

are trapped in the weld metal (slag inclusion).

B Joint preparation too restricted. B Allow for adequate penetration

C Irregular deposits allow slag to

D Lack of penetration with slag

E Rust or mill scale is preventing

F Wrong electrode for position in

A Non-metallic particles may be

trapped in undercut from previous run.

be trapped.

trapped beneath weld bead.

full fusion.

which welding is done.

A If bad undercut is present, clean

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

and room for cleaning out the slag.

C If very bad, chip or grind out

irregularities.

D 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.

Not cleaned, or incorrect electrode

Table 10-2 (continued): Stick Welding Problems

Art # A-04993

Slag trapped in undercut

Slag trapped in root

Figure 10-3: Examples of Slag Inclusion

10-6

April 13, 2006

10.03 Power Source Problems

Description Possible Cause Remedy

The welding arc cannot be established.

The Primary supply voltage has not been switched ON.

The Welding Power Source switch is switched OFF.

ARCMASTER 200 AC/DC

Switch ON the Primary supply voltage.

Switch ON the Welding Power Source.

C Loose connections internally. C

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

Welding current reduces when welding.

4 No gas flow when

the torch trigger switch is depressed.

C Gas regulator turned OFF. C Turn gas regulator ON. D Torch trigger switch lead is

Defective control circuit.

Loose welding cable

connections. Incorrect welding cable size.

Improper input connections.

Poor electrode condition.

Wrong welding polarity.

Gas hose is cut.

Gas passage contains impurities.

disconnected or switch/cable is faulty.

Have an accredited Thermal Arc Service Agent repair the connection.

Tighten all welding

cable connections. Use proper size and

type of cable. Refer to Section 2.05

Electrical Input Requirements.

Replace electrode.

Verify output torch connections.

A B Replace gas hose.

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

D Reconnect lead or repair faulty

switch/cable.

Table 10-3: Power Source Problems

April 13, 2006

10-7

ARCMASTER 200 AC/DC

Description Possible Cause Remedy

5 Gas flow won’t

shut OFF.

B Gas valve is faulty. B Have an accredited Thermal

C Gas valve jammed open. C Have an accredited Thermal

6 The TIG electrode has

been contaminated due to the gas flow shutting OFF before the programmed

POST-FLOW

has elapsed.

time

A Weld Mode (

REPEAT

before had finished.

POST-FLOW

to 60 sec.

The Weld Process Mode

(STICK, HF TIG or LIFT TIG) was changed before time had finished.

STD, SLOPE

SPOT

) was changed

POST-FLOW

control is set

POST-FLOW

gas time

A Strike an arc to complete the

weld cycle. OR Switch machine OFF then ON to reset solenoid valve sequence.

Arc Service Agent repair or replace the gas valve.

D Reduce

Do not change Weld Process

Mode before the

gas

gas time had finished.

POST-FLOW

time.

POST-FLOW

Table 10-3 (continued): Power Source Problems

10-8

April 13, 2006

VOLTAGE REDUCTION DEVICE (VRD)

11.01 VRD SPECIFICATION

Description 200 AC/DC Notes

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

VRD Resistance 148 to 193 ohms The required resistance between

VRD Turn OFF Time 0.2 to 0.3

SECTION 11:

ArcMaster

terminals.

welding terminals to turn ON the welding power. The time taken to turn OFF the welding

seconds

Table 11-1: VRD Specification

power once the welding current has stopped.

ARCMASTER 200 AC/DC

11.02 VRD MAINTENANCE

Routine inspection and testing (power source): An inspection of the power source, an insulation resistance test and an earth resistance test should be carried out. a. For transportable equipment, at least once every 3 months. b. For fixed equipment, at least once every 12 months. The owners of the equipment shall keep a suitable record of the periodic tests.

NOTE

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 Less than 20V; at Vin=230V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0.3 seconds

Table 11-2: Periodic Tests

If this equipment is used in a location or an environment with a high risk of electrocution then the above tests should be carried out prior to entering this location.

April 13, 2006

11-1

ARCMASTER 200 AC/DC

11.03 SWITCHING VRD ON/OFF

Switch the machine OFF. A) Remove the clear plastic cover from the control panel. (see Figure 11-1)

1 Lift up the cover so it rests on the top of the unit. 2 Place a small flat bladed screw driver between the cover hinge on the front panel. 3 Gently lift the cover hinge out of the front cover mounting hole.

Remove the control's clear plastic cover.

Figure 11-1: VRD ON/OFF Step A

B) Remove the four mounting screws from the control panel. (see Figure 11-2)

Art # A-07080

Art # A-07079

11-2

Figure 11-2: VRD ON/OFF Step B

April 13, 2006

ARCMASTER 200 AC/DC

C) Access the VRD control by gently prying back the front panel controls to reveal the VRD ON/OFF potentiometer.

(see Figure 11-3)

D) Turning the VRD ON/OFF. (see Figure 11-3)

• To turn VRD ON: rotate the trim potentiometer (VR1) on the display PCB fully clockwise. When VRD is turned ON check that it operates as per VRD Specifications on page 11-1.

• To turn VRD OFF: rotate the trim potentiometer (VR1) on the display PCB fully counter-clockwise.

CAUTION

DO NOT pull back the front panel with excessive force as this will unplug control PCB. Plugging the control PCB back into the front panel controls can only be achieved by removing the side covers.

VR1

Figure 11-3: VRD ON/OFF Step C and D

Art # A-07081

WARNING

The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter-clockwise as the VRD function will be unknown for every other position.

April 13, 2006

11-3

ARCMASTER 200 AC/DC

NOTES

11-4

April 13, 2006

SECTION 12:

POWER SOURCE ERROR CODES

Description Possible Cause Remedy Remarks

1 E01 error code

displayed Temperature sensor TH1 (protects IGBTs) is greater than 80ºC for about 1 second.

2 E02 error code

displayed Temperature sensor TH2 (protects secondary diodes) is greater than 80ºC for about 1 second.

3 E03 error code

displayed Primary (input) current too high.

E04 error code

4 TIG torch cable

displayed Output voltage exceeds the secondary voltage specification.

A The Welding Power

Source’s duty cycle has been exceeded.

B Fan ceases

to operate.

C Air flow is restricted

by vents being blocked.

A The Welding Power

Source’s duty cycle has been exceeded.

B Fan ceases

to operate.

C Air flow is restricted

by vents being blocked.

A Primary current is

too high because welding arc is too long.

B Mains supply

voltage is more than 10% below nominal voltage .

and/or work lead are too long or leads are coiled.

ARCMASTER 200 AC/DC

A Let Power Source

cool down then keep within its duty cycle.

B Have an accredited

Thermal Arc Service Agent investigate.

C Unblock vents then

let Power Source cool down.

A Let Power Source

cool down then keep within its duty cycle.

B Have an accredited

Thermal Arc Service Agent investigate

C Unblock vents then

let Power Source cool down.

A Reduce length of

welding arc.

B Have an accredited

Thermal Arc Service Agent or a qualified electrician check for low Mains voltage.

Reduce the length of the TIG torch cable and/or work lead or un-coiled leads.

Weld current ceases. Buzzer sounds constantly. Fan operates at max speed. E01 resets when TH1 decreases to 70ºC for about 30 seconds.

Weld current ceases. Buzzer sounds constantly. Fan operates at max speed. E02 resets when TH2 decreases to 70ºC for about 30 seconds.

Weld current ceases. Buzzer sounds constantly. Switch machine OFF then ON to reset E03 error.

Weld current ceases. Buzzer sounds constantly. Switch machine OFF then ON to reset E04 error.

April 13, 2006

Table 12-1 Power Source Error Codes

12-1

ARCMASTER 200 AC/DC

E11 error code

5 Primary supply

displayed Over Primary supply (input) voltage at

voltage is greater than the nominal

voltage plus 10%. primary capacitors is exceeded for one second. E14 error code

displayed Under mains supply (input) voltage warning primary

Mains supply

voltage is less than

the nominal

operating voltage

less 10%. capacitors is reduced for one second.

7 Mains supply

E12 error code displayed Under mains supply (input) voltage

voltage is down

to a dangerously

low level. primary capacitors is reduced for one second.

E81 error code

8 When 3 phase

displayed Wrong Primary supply (input) voltage connected.

machine is first

turned ON with the

wrong Primary

supply (input)

voltage connected.

Have an accredited Thermal Arc Service Agent or a qualified electrician check the Primary voltage.

Have an accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage.

A Have an accredited

Thermal Arc Service Agent or a qualified electrician check the Mains voltage.

B Have an accredited

Thermal Arc Service Agent or a qualified electrician check the primary cable and fuses.

Have an accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage.

Weld current ceases. Buzzer sounds contstantly. Error code E11 automatically will reset when the voltage reduces. Weld current available. Buzzer sounds intermittently. Error code E14 automatically will reset when the voltage increases.

Weld current ceases. Buzzer sounds contstantly. Error code E12 automatically will reset when the voltage increases.

No weld current is available. Buzzer sounds constantly. Switch machine OFF.

12-2

Table 12-1 (continued): Power Source Error Codes

April 13, 2006

E82 error code

9 The Primary supply

displayed Rated voltage selection circuit abnormality.

E83 error code

10 The Primary supply

displayed CPU checks mains supply (input) voltage when the on/off switch on rear panel of machine is turned ON.

(input) voltage fluctuates and is not stable.

ARCMASTER 200 AC/DC

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 and the Mains voltage.

No weld current is available. Buzzer sounds constantly. Switch machine OFF then ON to reset E82 error.

No weld current is available. Buzzer sounds constantly. Switch machine OFF then ON to reset E83 error.

E85 error code

displayed Pre-charge abnormality.

E93 error code

12 Memory chip

displayed Memory chip (EEPROM) on control PCB cannot read/write weld parameters.

Due to malfunction inside the Welding Power Source, primary capacitors are not charging correctly.

(EEPROM) error.

Table 12-1 (continued): Power Source Error Codes

Have an accredited Thermal Arc Service Agent service the machine.

Have an Accredited Thermal Arc Service Agent check the control PCB.

No weld current is available. Buzzer sounds constantly. Switch machine OFF then ON to reset E85 error.

Weld current ceases. Buzzer sounds constantly. Switch machine OFF.

April 13, 2006

12-3

ARCMASTER 200 AC/DC

E94 error code

13 The Welding Power

displayed Temperature sensor TH1 for IGBTs or sensor TH2 for

Source’s temperature sensors have malfunctioned.

Have an accredited Thermal Arc Service Agent check or replace the temperature sensors.

Weld current ceases. Buzzer sounds constantly. Switch machine OFF.

secondary diodes are open circuit.

14 Weld current ceases.

E99 error code displayed Mains supply (input) voltage has been turned OFF but control circuit has

A Main ON/OFF switch

on machine has been turned OFF.

B Mains supply

(input) voltage has

been turned OFF. power from the primary capacitors.

A Turn ON/OFF

switch ON.

B Have an accredited

Thermal Arc Service Agent or a qualified electrician check the Mains voltage

Buzzer sounds constantly. Must switch machine OFF then ON to reset E99 error.

and fuses.

Table 12-1 (continued): Power Source Error Codes

12-4

April 13, 2006

APPENDIX 1: GENERAL INFORMATION

• Note the model and specification number shown on the equipment nameplate.

ARCMASTER 200 AC/DC

April 13, 2006

A-1

ARCMASTER 200 AC/DC

APPENDIX 2: ARCMASTER 200 AC/DC INTERCONNECTION DIAGRAM

TB6

TB5

L101

Ground

L103

SIDE CHASSIS 1

REAR

PA NE L

1 2 3 4 5 6

FAN 1

SOL1

1 : Chassis Ground 2 : Contactor Control/+24VDC 3 : Contactor Control/GND 4 : Not Used 5 : Potentiometer Maximum 6 : Potentiometer Minimum(GND) 7 : Amperage Control Wiper 0-10VDC 8 : Not Used

2 3 4

CON1

TB1

CE Filter

Circuit Bord

[WK-5861]

TB2 TB4

PCB17

Filter

Circuit Bord

[WK-4917]

CN1

123

CN2

CN1

CN11

TB0

PCB18

TB5

K(7)

G(6)

R(3)

TB3

S(4)

T(5)

Ground

SIDE CHASSIS 2

12345

CN3

1 2 3 4

CN31 CN30

CN131 CN130

1 2

CN27

4 5

PCB4

Detect

Circuit Bord

CN4

[WK-4819]

CN5 CN6 CN4

CN32

PCB5

Conect Circuit Bord

[WK-5551]

CN132

CN17

TB0

CN14

PCB7

Filter

Circuit Bord

CN15

[WK-5550]

(1)

(0)

(2)

CN18

CN30CN31

CN130CN131

CN20

1 2

1 2 3 4 5

1 2 3

CN3

TB2

PCB2

Link

Circuit Bord

[WK-5482]

CN2

CN1

123

C2E

E1C

CN1CN6CN5

PCB3

Control Souce

Circuit Bord

[WK-5548]

CN18

123

C2EE1C

CN7

1 2 3 4

Circuit Bord

[WK-5493]

TB1

TB2

TB3

TB4

CT1 CT2

123456

CN20

123

CN33

PCB1

Main

G1 E1

G2 E2

G3 E3

G4 E4

1234567

Circuit Bord

[WK-5549]

CN912CN8

123

TH2 TH1

PCB8

IGBT Gate

Circuit Bord

[WK-5479]

1 2

CN1

1 2

CN2

3 4

PCB9

IGBT Gate

Circuit Bord

[WK-5479]

1 2

CN1

1 2

CN2

3 4

CN21

PCB6

Control

G E

Q10

G E

Q11

G E

Q12

G E

123456

CN19

123

P+21V

CN22

PGND

1234567

CN23

CN17

CN21

CN1

1 2

2 3

3 4

4 5

5 6

6 7

1 2

2 3

3 4

1 2

2 3

3 4

A-2

April 13, 2006

ARCMASTER 200 AC/DC

TB7

TB12

S+15V

12345

CN8

CT2

CT1

AC3

123456789

AC4

CN9

TB20

TB22

TB21

AC4

AC2

PCB12

DIODE Snubber

Circuit Bord

[WK-5615]

AC2 AC1

SH.DET-

SH.DET+

HCT1

P+21V PGND

S+15V

/RY_ON

FCH1

+15

-15

1 2 3 4

1 2

1 2 3

GND

PCB14

IGBT Snubber

Circuit Bord

[WK-5570]

SH.DET+

PCB15

IGBT Gate

Circuit Bord

[WK-3367]

CN1

12345

G7E7G8

TB1 TB2

RY+ 15V

SH.DET-

TB1 TB2

CN1

CN2

CN3

1234567

/RY_ON

PCB13 Super Inpose Circuit Bord

[WK-5569]

CN4

CN5

Q13

CN6

RY+ 15V

1 2 3 4 5 6 7 8

1 2 3

12345

CN1

PCB16

Filter Circuit

CN3

Bord

[WK-5499]

CC1

CC2

HF.UNIT1

AC1 AC3

CC1

SIDE CHASSIS 3

FRONT PA NE L

Ground

TO1

Ground

TO2

AC3

AC1

+Output

Terminal

Torch/Gas

Terminal

-Output

Terminal

April 13, 2006

+15

-15 IS

GND

1 2 3 4 5 6

PCB10

Panel

Circuit Board

[WK-5527]

CN2

CN1

1234

PCB11

Encorder

Board

[WK-5528]

CN1

1234

SIDE CHASSIS 2

Art # A-07446

A-3

ARCMASTER 200 AC/DC

APPENDIX 3: ARCMASTER 200 AC/DC ACCESSORIES

PART NO. DESCRIPTION

10-4016 Remote Foot control 7.6m lead and plug 10-4014 Remote Hand Pendant 7.6m lead and plug 10-9811 Plug for Remote or TIG Torch Button

A-4

April 13, 2006

NOTES

ARCMASTER 200 AC/DC

April 13, 2006

A-5

LIMITED WARRANTY AND SCHEDULE

This information applies to Thermadyne products that were purchased in the United Kingdom

April 2006

Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in the owner’s manual supplied with the machine. Thermadyne welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment.

Thermadyne warranty will not apply to:

1. Equipment that has been modified by any other party other than Thermadyne’s own service personnel or

with prior written consent obtained from Thermadyne service department (UK).

2. Equipment that has been used beyond the specifications established in the owners manual.

3. Installation not in accordance with the installation/service manual.

4. Failure to clean and maintain the machine as set forth in the owner, installation or service manual.

If warranty is being sought, please contact Thermadyne's UK warranty department for a warranty authorization returns form.

Welding Equipment - Limited Warranty Period Product Period

200S, 300S, 400S, 200TS, 300TS, 400TS, 400 MST, 200AC/DC, 300AC/DC, PowerMaster 320SP, 400SP, 500SP, Fabricator 200, Ultrafeed VA4000, Portafeed VS212 3 Years 150SE, 155SE, 250SE, 400SE, 250TE, 400TE, 180AC/DC, 250AC/DC, 400AC/DC Fabricator 250, Fabricator 330, Fabricator 400, Fabricator 450, 220GMS 2 Years Options and Accessories 6 Months Repair and Replacement Parts 3 Months Torch Consumables None

Cutting Equipment -Limited Warranty Period Product Period

CutMaster 38, 51, 81,101, 151 3 Years PakMaster 150XL, Drag-Gun Plus 2 Years CutSkill C-35A, C-70A, C-100A, Drag-Gun 1 Year 1TorchTM, SureLokTM Torches and PCH 120 1 Year Other Torches 6 Months Repair Parts 3 Months

Arc Accessories - Limited Warranty Period Product Period

All Products 1 Month Consumables None Torch Consumables None

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

World Headquarters

Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017

Telephone: (636) 728-3000 Fascimile: Email: sales@thermalarc.com

(636) 728-3010

www.thermalarc.com

Tweco 200-ACDC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.05 Principales Normes de Securite

1.06 Declaration Of Conformity

2.01 How To Use This Manual

2.02 Equipment Identification

2.03 Receipt Of Equipment

2.04 Symbol Chart

2.05 Description

2.06 Functional Block Diagrams

2.07 Transporting Methods

3.01 Environment

3.03 Electrical Input Connections

3.02 Location

3.04 Electrical Input Requirements

3.05 Input Power

3.06 High Frequency Introduction

3.07 High Frequency Interference

3.08 Duty Cycle

3.09 Specifications

4.01 ArcMaster 200 AC/DC Controls

4.02 Weld Process Selection for ArcMaster 200 AC/DC

4.03 Weld Parameter Descriptions for ArcMaster 200 AC/DC

4.04 Weld Parameters for ArcMaster 200 AC/DC

4.05 Power Source Features

6.01 Stick Welding

6.02 AC or DC HF TIG Welding

6.03 Slope Mode Sequence

6.04 Slope Mode with Repeat Sequence

6.05 Pulse Controls

7.02 Electrode Polarity

7.03 Tungsten Electrode Current Ranges

7.04 Tungsten Electrode Types

7.05 Guide for Selecting Filler Wire Diameter

7.06 Shielding Gas Selection

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

7.08 Welding Parameters for Aluminum

7.09 Welding Parameters for Steel

8.01 Electrode Polarity

8.02 Effects of Stick Welding Various Materials

10.01 TIG Welding Problems

10.02 Stick Welding Problems

10.03 Power Source Problems

11.01 VRD SPECIFICATION

11.02 VRD MAINTENANCE

11.03 SWITCHING VRD ON/OFF

APPENDIX 1: GENERAL INFORMATION

APPENDIX 2: ARCMASTER 200 AC/DC INTERCONNECTION DIAGRAM

APPENDIX 3: ARCMASTER 200 AC/DC ACCESSORIES

LIMITED WARRANTY AND SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION