Tweco ArcMaster 201 TS Service Manual

Art # A-10139_AB

ARCMASTER® 201 TS

Inverter Arc Welder

Service
Manual

Tweco.com

Revision: AC Issue Date: April 22, 2015 Manual No.: 0-5150

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Tweco product. We are proud to have you as our customer and
will strive to provide you with the best service and support in the industry. This product is backed by
our extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you with this high performance
product that will help you get the job done.

For more than 75 years Tweco has provided quality products you can trust, when your reputation is on
the line.

YOU ARE IN GOOD COMPANY!

Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish
ourselves from our competition through market-leading innovation and truly dependable products that
will stand the test of time.

We strive to enhance your productivity, efficiency and welding performance enabling you to excel in
your craft. We design products with the welder in mind delivering- advanced features, durability, ease
of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your
satisfaction with this product and its safe operation is our ultimate concern. Please take the time to
read the entire manual, especially the Safety Precautions.

If you have any questions or concerns regarding your new Tweco product, please contact our friendly
and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada),
or visit us on the web at www.Tweco.com

!

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.

Service Manual Number 0-5150 for:
Tweco 201 TS Power Source Arc Welder Part Number W1003802
Tweco 201 TS System with Stick/TIG Kit & Case Part Number W1003803

Published by:
Victor Technologies International, Inc.
Europa Building
Chorley Industrial Park
Chorley, Lancaster,
England, PR6 7BX

www.victortechnologies.com

Copyright 2011, 2013 by
Victor Technologies International, Inc.

All rights reserved.

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: June 10, 2011
Revision Date: April 22, 2015

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 General Safety Information for Victor CS Regulator ........................................ 1-4

1.03 Principal Safety Standards .............................................................................. 1-6

1.04 Symbol Chart .................................................................................................. 1-7

1.05 Servicing Hazards ........................................................................................... 1-8

1.06 EMF Information ............................................................................................. 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 Description ..................................................................................................... 2-1

2.05 Transportation Methods .................................................................................. 2-1

SECTION 3:

SAFETY AND INSTALLATION ....................................................................... 3-1

3.01 Duty Cycle ....................................................................................................... 3-1

3.02 Specifications ................................................................................................. 3-2

3.03 Environment ................................................................................................... 3-3

3.04 Location .......................................................................................................... 3-3

3.05 Electrical Input Connections ........................................................................... 3-4

3.06 Electromagnetic Compatibility ........................................................................ 3-6

3.07 Volt-Ampere Curves ........................................................................................ 3-7

SECTION 4:

OPERATION ........................................................................................... 4-1

4.01 Front Panel ..................................................................................................... 4-1

4.02 Setup for Welding ........................................................................................... 4-3

4.03 Stick (SMAW) Setup ....................................................................................... 4-4

4.04 LIFT TIG / HF TIG (GTAW) Setup .................................................................... 4-5

4.05 Welding Current Control Explanation .............................................................. 4-6

4.06 Victor Regulator .............................................................................................. 4-7

4.07 Leak Testing the System ................................................................................. 4-8

4.08 Lift Start TIG with the Tweco 201TS ............................................................... 4-8

SECTION 5:

theory of operation .................................................................................. 5-1

5.01 Inverter Design ............................................................................................... 5-1

TABLE OF CONTENTS

SECTION 6:

TROUBLESHOOTING ................................................................................ 6-1

6.01 Basic Troubleshooting .................................................................................... 6-1

6.02 Checking Unit Before Applying Power ............................................................ 6-2

6.03 Tools Needed for Troubleshooting and Servicing ............................................ 6-2

6.04 Case Removal ................................................................................................. 6-3

6.05 Clear Cover Sheet Removal ............................................................................. 6-4

6.06 Pre-Power Check ............................................................................................ 6-5

6.07 DC Bus Voltage Check .................................................................................... 6-8

6.08 Installing Clear Cover Sheet ............................................................................ 6-9

6.09 Waveforms for Section 6-10 ......................................................................... 6-10

6.10 Troubleshooting Circuit Diagram - 201TS .................................................... 6-13

7.01 Safety Precautions for Disassembly ............................................................... 7-1

7.02 Control Board Removal ................................................................................... 7-1

7.03 Front Panel Assembly Removal ...................................................................... 7-2

7.04 Front Panel (Operator Interface) Circuit Board PC2 Removal ......................... 7-5

7.05 Back Panel Removal ....................................................................................... 7-7

7.06 Power Switch S1 and Power Cord Removal ................................................... 7-9

7.07 Base Panel Removal ..................................................................................... 7-12

SECTION 8:

ASSEMBLY PROCEDURES .......................................................................... 8-1

8.01 Installing Base Board ...................................................................................... 8-1

8.02 Installing Back Panel ....................................................................................... 8-2

8.03 Installing Front Panel ...................................................................................... 8-4

8.04 Installing Main Control Panel and Clear Cover Sheet ...................................... 8-8

8.05 Installing Case .............................................................................................. 8-10

SECTION 9:

REPLACEMENT PARTS .............................................................................. 9-1

9.01 Hardware List ................................................................................................ 9-1

9.02 Replacement Part List ..................................................................................... 9-2

SECTION 10:

Accessories .......................................................................................... 10-1

LIMITED WARRANTY & WARRANTY SCHEDULE .................................INSIDE REAR COVER

INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER

TABLE OF CONTENTS

This Page Intentionally Blank

SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS

Manual 0-5150 1-1

Safety Instructions and Warnings

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 semi-automatic 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.

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.

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.

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.

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

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 breathe the fumes.

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

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 European Standard EN60974-1 entitled: Safety in welding and allied processes Part 2: Electrical. This
publication and other 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.

TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS

Safety Instructions and Warnings

1-2 Manual 0-5150

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.

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.

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.

WARNING

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.

Eye protection filter shade selector for welding or cutting

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

Welding or Cutting

Operation

Electrode Size

Metal Thickness

or Welding Current

Filter

Shade

No.

Welding or Cutting

Operation

Electrode Size

Metal Thickness

or Welding Current

Filter

Shade

No.

Torch soldering 2

Gas metal-arc
welding (MIG)

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

Oxygen Cutting Non-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

welding

(stick) electrodes

Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in.,

4 to 6.4 mm

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

SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS

Manual 0-5150 1-3

Safety Instructions and Warnings

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

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

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

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

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

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.

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.

!

LEAD WARNING

WARNING: This product contains chemicals, including

lead, known to the State of California to cause birth
defects and other reproductive harm.

Wash hands

after handling.

TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS

Safety Instructions and Warnings

1-4 Manual 0-5150

NOTE

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

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.

1.02 General Safety Information for
Victor CS Regulator

A. Fire Prevention

Welding and cutting operations use fire or combustion as a basic
tool. The process is very useful when properly controlled. However,
it can be extremely destructive if not performed cor rectly in the
proper environment.

1. The work area must have a fireproof floor.

2. Work benches or tables used during welding or cutting
operations must have fireproof tops.

3. Use heat resistant shields or other approved material to
protect nearby walls or unprotected flooring from sparks and
hot metal.

4. Keep an approved fire extinguisher of the proper size and
type in the work area. Inspect it regularly to ensure that
it is in proper working order. Know how to use the fire
extin guisher.

5. Move combustible materials away from the work site. If you
can not move them, protect them with fireproof covers.

!

WARNING

NEVER perform welding, heating, or cutting operations
on a container that has held toxic, combustible
or flammable liq uids, or vapors. NEVER perform
welding, heating, or cutting operations in an area
containing combustible vapors, flam mable liquids,
or explosive dust.

B. Housekeeping

!

WARNING

NEVER allow oxygen to contact grease, oil, or other
flam mable substances. Although oxygen by itself will
not burn, these substances become highly explosive.
They can ignite and burn violently in the presence of
oxygen.

Keep ALL apparatus clean and free of grease, oil and other flam­mable substances.

C. Ventilation

!

WARNING

Ade quately ventilate welding, heating, and cutting
work areas to prevent accumulation of explosive or
toxic concen trations of gases. Certain combinations
of metals, coatings, and gases generate toxic fumes.
Use respiratory protection equipment in these circum­stances. When welding/brazing, read and understand
the Material Safety Data Sheet for the welding/brazing
alloy.

SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS

Manual 0-5150 1-5

Safety Instructions and Warnings

D. Personal Protection

Gas flames produce infrared radiation which may have a harm ful
effect on the skin and especially on the eyes. Select goggles or a
mask with tempered lenses, shaded 4 or darker, to protect your eyes
from injury and provide good visibility of the work.

Always wear protective gloves and flame-resistant clothing to protect
skin and clothing from sparks and slag. Keep collars, sleeves, and
pockets buttoned. DO NOT roll up sleeves or cuff pants.

When working in a non-welding or cutting environment, always wear
suitable eye protection or face shield.

!

WARNING

Practice the following safety and operation precautions
EVERY TIME you use pressure regulation equipment.
Deviation from the following safety and operation
instructions can result in fire, explosion, damage to
equipment, or injury to the operator.

E. Compressed Gas Cylinders

The Department of Transportation (DOT) approves the design and
manufacture of cylinders that contain gases used for welding or
cutting operations.

1. Place the cylinder (Figure 1-1) where you will use it. Keep
the cylinder in a vertical position. Secure it to a cart, wall, work
bench, post, etc.

Art # A-12127

Figure 1-1: Gas Cylinders

!

WARNING

Cylinders are highly pressurized. Handle with care.
Serious accidents can result from improper handling
or mis use of compressed gas cylinders DO NOT drop
the cylinder, knock it over, or expose it to excessive
heat, flames or sparks. DO NOT strike it against other
cylinders. Contact your gas supplier or refer to CGA
P-1 “Safe Handling of Compressed Gases in Contain­ers” publication.

NOTE

CGA P-1 publication is available by writing the Com­pressed Gas Association, 4221 Walney Road, 5th
Floor, Chantilly,VA 20151-2923

2. Place the valve protection cap on the cylinder whenever
mov ing it, placing it in storage, or not using it. Never drag
or roll cylinders in any way. Use a suitable hand truck to
move cylin ders.

3. Store empty cylinders away from full cylinders. Mark them
“EMPTY” and close the cylinder valve.

4. NEVER use compressed gas cylinders without a pressure
reducing regulator attached to the cylinder valve.

5. Inspect the cylinder valve for oil, grease, and damaged
parts.

!

WARNING

DO NOT use the cylinder if you find oil, grease or dam­aged parts. Inform your gas supplier of this condition
immediately.

6. Momentarily open and close (called “cracking”) the cylinder
valve to dislodge any dust or dirt that may be present in the
valve.

CAUTION

When cracking the cylinder valve, DO NOT stand
directly in front of the cylinder valve. Always perform
cracking in a well ventilated area. If an acetylene cyl­inder sprays a mist when cracked, let it stand for 15
minutes. Then, try to crack the cylinder valve again.
If this problem persists, contact your gas supplier.

TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS

Safety Instructions and Warnings

1-6 Manual 0-5150

1.03 Principal Safety Standards

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 P-1, 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.

SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS

Manual 0-5150 1-7

Safety Instructions and Warnings

1.04 Symbol Chart

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

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

Voltage Input

Single Phase

Three Phase

Three Phase Static
Frequency Converter­Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal
Arc Welding (SMAW)

Gas Metal Arc
Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth
(Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating­Auxiliary Power

Art # A-04130_AB

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards
Workpiece With
Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld
Mode

Press to initiate wirefeed and
welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

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

4 Step Trigger
Operation

2 Step Trigger
Operation

S

See Note

See Note

S

Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.

TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS

Safety Instructions and Warnings

1-8 Manual 0-5150

1.05 Servicing Hazards

!

WARNING

The symbols shown below are used throughout this
manual to call attention to and identify possible haz­ards. When you see the symbol, watch out, and follow
the related instructions to avoid the hazard.

Only qualified persons should test, maintain, and
repair this unit.

Only qualified persons should test, maintain, and
repair this unit.

WARNING

ELECTRIC SHOCK can kill.

• Donottouchliveelectricalparts.

• TurnOffweldingpowersourceandwirefeederanddisconnect

and lockout input power using line disconnect switch, circuit
breakers, or by removing plug from receptacle, or stop engine
before servicing unless the procedure specifically requires
an energized unit.

• Insulateyourself fromground bystandingor workingon

dry insulating mats big enough to prevent contact with the
ground.

• Donotleaveliveunitunattended.

• Ifthisprocedurerequiresandenergizedunit,haveonlyper-

sonnel familiar with and following standard safety practices
do the job.

• Whentestingaliveunit,usetheone-handmethod.Donot

put both hands inside unit. Keep one hand free.

• Disconnectinputpowerconductorsfromde-energizedsupply

line BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of input

power on inverters.

• Turn Off inverters,disconnectinputpower,anddischarge

input capacitors according to instructions in Troubleshooting
Section before touching any parts.

WARNING

STATIC (ESD) can damage PC boards.

• Putongroundedwriststrap BEFORE handling boards or

parts.

• Useproperstatic-proofbagsandboxestostore,move,or

ship PC boards.

WARNING

FIRE OR EXPLOSION hazard.

• Donotplaceuniton,over,ornearcombustiblesurfaces.

• Donotserviceunitnearammables.

WARNING

FLYING METAL or DIRT can injure eyes.

• Wearsafetyglasseswithsideshieldsorfaceshieldduring

servicing.

• Becarefulnottoshortmetaltools,parts,orwirestogether

during testing and servicing.

WARNING

HOT PARTS can cause sever burns.

• Donottouchhotpartsbarehanded.

• Allowcoolingperiodbeforeworkingonequipment.

• To handle not parts, use proper tools and/orwear heavy,

insulated welding gloves and clothing to prevent burns.

WARNING

EXPLODING PARTS can cause injury.

• Failedpartscanexplodeorcauseotherpartstoexplodewhen

power is applied to inverters.

• Alwayswearafaceshieldandlongsleeveswhenservicing

inverters.

WARNING

SHOCK HAZARD from testing.

• TurnOffweldingpowersourceandwirefeederorstopengine

before making or changing meter lead connections.

• Useatleastonemeterleadthathasaself-retainingspring

clip such as an alligator clip.

• Readinstructionsfortestequipment.

WARNING

FALLING UNIT can cause injury.

• Useliftingeyetoliftunitonly,NOTrunninggear,gascylin­ders, or any other accessories.

• Useequipmentofadequatecapacitytoliftandsupportunit.

• Ifusingliftforkstomoveunit,besureforksarelongenough

to extend beyond opposite side of unit.

WARNING

MOVING PARTS can cause injury,

• Keepawayfrommovingpartssuchasfans.

• Keepawayfrompinchpointssuchasdriverolls.

• Haveonlyqualiedpersonsremovedoors,panels,covers,

or guards for maintenance as necessary.

• Keephands,hair,looseclothing,andtoolsawayfrommoving

parts.

SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS

Manual 0-5150 1-9

Safety Instructions and Warnings

• Reinstalldoors,panels,covers,orguardswhenmaintenance

is finished and before reconnecting input power.

WARNING

MAGNETIC FIELDS can affect Implanted Medical
Devices.

• WearersofPacemakersandotherImplantedMedicalDevices

should keep away from servicing areas until consulting their
doctor and the device manufacturer.

WARNING

OVERUSE can cause OVERHEATING.

• Allowcoolingperiod;followrateddutycycle.

• Reducecurrentorreducedutycyclebeforestartingtoweld

again.

• Donotblockorlterairowtounit.

WARNING

H.F. RADIATION can cause interference.

• High-frequency(H.F.)can interfere with radio navigation,

safety services, computers, and communications equipment.

• Haveonlyqualiedpersonsfamiliarwithelectronicequipment

install, test, and service H.F. producing units.

• Theuserisresponsibleforhavinga qualied electrician

promptly correct any interference problem resulting from
the installation.

• IfnotiedbytheFCC about interference, stop using the

equipment at once.

• Havetheinstallationregularlycheckedandmaintained.

• Keephigh-frequencysourcedoorsandpanelstightlyshut,

keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.

!

WARNING

READ INSTRUCTIONS.

• UseTestingBooklet(PartNo.150853)whenservicingthis

unit.

• ConsulttheOwner’sManualforweldingsafetyprecautions.

• Useonlygenuinereplacementpartsfromthemanufacturer.

1.06 EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause
electromagnetic fields. There has been and still is some concern
about such fields. However, after examining more than 500 studies
spanning 17 years of research, a special blue ribbon committee
of the National Research Council concluded that: “The body of
evidence, in the committee’s judgment, has not demonstrated
that exposure to power-frequency electric and magnetic fields is
a human-health hazard.” However, studies are still going forth and
evidence continues to be examined. Until the final conclusions of
the research are reached, you may wish to minimize your exposure
to electromagnetic fields when welding or cutting.

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

1. Keep cables close together by twisting or taping them, or using
a cable cover.

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

3. Do not coil or drape cables around your body.

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

5. Connect work clamp to workpiece as close to the weld as pos­sible.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor
and the device manufacturer before performing or going near arc
welding, spot welding, gouging, plasma arc cutting, or induction
heating operations. If cleared by your doctor, then following the
above procedures is recommended.

TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS

Safety Instructions and Warnings

1-10 Manual 0-5150

This Page Intentionally Blank

INTRODUCTION TWECO 201TS

Manual 0-5150 2-1

Introduction

SECTION 2:

INTRODUCTION

2.01 How to Use This Manual

This Manual usually applies to the 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 word 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

Gives information regarding possible per­sonal injury. Warnings will be enclosed in a
box such as this.

CAUTION

Refers to possible equipment damage. Cau­tions will be shown in bold type.

NOTE

Offers helpful information concerning certain
operating procedures. Notes will be shown
in italics

You will also notice icons from the safety section ap­pearing throughout the manual. These are to advise you
of specific types of hazards or cautions related to the
portion of information that follows. Some may have
multiple hazards that apply and would look something
like this:

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 machine. Equipment
which does not have a nameplate attached to the
machine is identified only by the specification or part
number printed on the shipping container. Record these
numbers 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.

2.04 Description

This compact inverter welding machine has infinitely
adjustable welding current from 10 to 200 amps.
The 201TS has a LIFT TIG (GTAW) and HF TIG
(GTAW) welding mode that offers stable TIG welding
characteristics with an optimized start TIG sequence to
initiate the welding arc when used with a suitable TIG
torch and shielding gas. Advanced TIG features include
8 Pin Amp Plug for remote control devices, down
slope, 2T / 4T controls, and gas solenoid operation.
It also has STICK (MMA) welding mode which uses
standard general purpose STICK (MMA) 2.5mm (3/32”)
electrodes for light gauge work, generally less than

3.2mm (1/8”) thick and STICK (MMA) 3.2mm (1/8”)

electrodes for heavier material.

2.05 Transportation Methods

!

Disconnect input power
conductors from de-energized supply line before
moving the welding power source.

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

TWECO 201TS INTRODUCTION

introduction

2-2 Manual 0-5150

This Page Intentionally Blank

SAFETY AND INSTALLATION TWECO 201TS

Manual 0-5150 3-1 Safety and

Installation

SECTION 3:

SAFETY AND INSTALLATION

3.01 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding
current output without exceeding the temperature limits of the insulation of the component parts. To explain the
10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to
operate at a 20% duty cycle, 200 amperes at 18 volts. This means that it has been designed and built to provide
the rated amperage (200A) for 2 minutes, i.e. arc welding time, out of every 10 minute period (20% of 10 minutes
is 2 minutes). During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be
allowed to cool.

110VAC INPUT

0

10

20

30

40

50

60

70

80

90

100

020406080100 120140 160

Welding Current (amps)

Duty Cycle (percentage)@40°C

Safe

Operating

Region

TIG (GTAW)

Stick (MMA)

Art # A-10141_AB

230VAC INPUT

0

10

20

30

40

50

60

70

80

90

100

020406080100 120140 160180 200

Welding Current (amps)

Duty Cycle (percentage)@40°C

Safe

Operating

Region

TIG (GTAW)

Art # A-10142_AB

Figure 3-1: Tweco 201 TS Duty Cycle

TWECO 201TS SAFETY AND INSTALLATION

Safety and installation

3-2 Manual 0-5150

3.02 Specifications

Power Source Part Number W1003802

Mains Power

Nominal Supply Voltage AC 110V AC 230V

Number of Phases Single Phase Single Phase

Input Voltage Range AC 104- 127V AC 187- 253V

Nominal Supply Frequency 50/60 Hz 50/60 Hz

Effective Input Current (l1eff) 20 Amps 16 Amps

Maximum Input Current (l1 max) ∆ 39 Amps ∆ 32 Amps

Single Phase Generator Requirements
[Continuous rating at nominal supply voltage
with maximum output for STICK (MMA) welding]

5 KVA 8 KVA

Welding Output

Welding Current Range Stick: 10 - 125 Amps

TIG: 10 - 160 Amps

Stick/TIG:

10 - 200 Amps

Nominal DC Open Circuit Voltage (OCV) 71V 71V

Welding Output, 104º F (40º C), 10 min.
(Quoted figures refer to STICK (MMA) output)

125A @ 25%, 25.0V

95A @ 60%, 23.8V

80A @ 100%, 23.2V

200A @ 20%, 28V

120A @ 60%, 24.8V

100A @ 100%, 24.0V

Rated Input Current (A) 39A 32A

for STICK (MMA) Welding Io = 125A @ 25.0V Io = 200A @ 28V

Rated Input Current (A) 30A 20.6A

for LIFT TIG/HF TIG (GTAW) Welding Io = 160A @ 16.4V Io = 200A @ 18V

Rated Output for STICK (MMA) Welding 25.0V, 125A @ 25% 28V, 200A @ 20%

Rated Output for LIFT TIG/HF TIG (GTAW)
Welding

16.4V, 160A @ 30% 18V, 200A @ 25%

Duty Cycle (%) 25% @ 125A 20% @ 200A

Welder Type Inverter Power Source

Output Terminal Type Heavy Duty DinseTM 50

Classification

Protection Class IP23S

Standards EN 60974-1 EN50199

Cooling Method Fan Cooled

Dimensions and Weight

Welding Power Source Mass 10 kg (22 lb.)

Welding Power Source Dimensions (Height x
Width x Depth)

H230mm x W135mm x D450mm

( H 9.0” x W 5.3” x D 17.7”)

∆ The recommended time delay fuse or circuit breaker size is 32 amp for 110V and 32 amp for 230V.

SAFETY AND INSTALLATION TWECO 201TS

Manual 0-5150 3-3 Safety and

Installation

Tweco continuously strives to produce the best product possible and therefore reserves the right to change, improve
or revise the specifications or design of this or any product without prior notice. Such updates or changes do not
entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements
or replacement of such items.

The values specified in the table above are optimal values, your values may differ. Individual equipment may differ
from the above specifications due to in part, but not exclusively, to any one or more of the following; variations or
changes in manufactured components, installation location and conditions and local power grid supply conditions.

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.

3.03 Environment

These units are designed for use in environments with increased hazard of electric shock. Examples of environments
with increased hazard of electric shock 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.

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

3.04 Location

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

• Inareas,freefrommoistureanddust.

• Ambienttemperaturebetween14°F(-10°C)to104°F(40°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” (300mm)ormorefromwalls orsimilarthatcould restrictnaturalairowfor

cooling

!

WARNING

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

TWECO 201TS SAFETY AND INSTALLATION

Safety and installation

3-4 Manual 0-5150

3.05 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. Lock-out/

tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box,
or shutting off and red-tagging circuit breaker or other disconnecting device.

• Electrical Input Requirements

Operate the welding power source from a 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
utility for information about the type of electrical service available, how proper connections should be made, and
inspection required. The line disconnect switch provides a safe and convenient means to completely remove all
electrical power from the welding power supply whenever necessary to inspect or service the unit.

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

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

Refer to Figure 3-3:

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

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

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

Input Voltage Circuit Breaker or Fuse Size

110V 32A

230V 32A

Table 3-1: Fuse Guide

CAUTION

The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when
welding with this product due to the amperage rating of the time-delay fuses or circuit breaker.

SAFETY AND INSTALLATION TWECO 201TS

Manual 0-5150 3-5 Safety and

Installation

Welding Power Supply

Primary Power Cable

Art# A-10143

Table 3-2: Electrical Input Connections

Input Power

Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit
provides pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the
input capacitors have charged to operating voltage (after approximately 5 seconds)

NOTE

Damage to the PCA could occur if 253 VAC or higher is applied to the Primary Power Cable.

Model Primary Supply Lead

Size (Factory Fitted)

Minimum Primary

Current Circuit Size

(Vin/Amps)

Current & Duty Cycle

LIFT TIG/ HF TIG

(GTAW)

STICK (SMAW)

Tweco 201 TS H07RN-F 2.5mm²

110V/39A - 125A @ 25%
110V/30A 160A @ 30%

-

230V/32A - 200A @ 25%
230V/21A 200A @ 25%

-

Table 3-2: Primary Circuit Sizes to Achieve Maximum Current

TWECO 201TS SAFETY AND INSTALLATION

Safety and installation

3-6 Manual 0-5150

3.06 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source
is used in a domestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.
If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment
to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may
be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an
electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input filters.
In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer Trouble-some.

B. Assessment of Area

Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in
the surrounding area. The following shall be taken into account.

1. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding
equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pace-makers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used
in the environment is compatible: this may require additional protection measures.

The size of the surrounding area to be considered will depend on the structure of the building and other activities
that are taking place. The surrounding area may extend beyond the boundaries of the premises.

C. Methods of Reducing Electromagnetic Emissions

1. Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.

If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.
Consideration should be given to shielding the supply cable of permanently installed welding equipment in
metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding
should be connected to the Welding Power Source so that good electrical contact is maintained between the
conduit and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All

access and service doors and covers should be closed and properly fastened when the welding equipment is in
operation. The welding equipment should not be modified in any way except for those changes and adjustments
covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilizing devices
should be adjusted and maintained according to the manufacturer’s recommendation

3. Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or

close to the floor level.

SAFETY AND INSTALLATION TWECO 201TS

Manual 0-5150 3-7 Safety and

Installation

4. Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However,

metallic components bonded to the work piece will increase the risk that the operator could receive a shock by
touching the metallic components and the electrode at the same time. The operator should be insulated from
all such bonded metallic components.

5. Earthing of the Work Piece

Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size

and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection
of the work piece to earth should be made by direct connection to the work piece, but in some countries where
direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according
to national regulations.

6. Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems

of interference. Screening the entire welding installation may be considered for special applications.

3.07 Volt-Ampere Curves

Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source.
Curves of other settings fall between curves shown.

Art # A-10158

230VAC Input

0

10

20

30

40

50

60

70

80

050 100 150 200 250

AMPS

VOLTS

Stick Max

Lift TIG Max

TWECO 201TS SAFETY AND INSTALLATION

Safety and installation

3-8 Manual 0-5150

Art # A-10159

115VAC Input

0

10

20

30

40

50

60

70

80

050 100 150 200

AMPS

VOLTS

Stick Max

Lift Tig Max

Figure 3-4: 201TS Volt-Ampere Curves

OPERATION TWECO 201TS

Manual 0-5150 4-1 O

peration

SECTION 4:

OPERATION

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 the electrode. 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 electrode, 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 fine tune the weld­ing current to suit the specific application. Refer to the electrode manufacture's literature for further information.

4.01 Front Panel

Art # A-10146_AB

(A) Power On Indicator

(B) Fault Indicator

(E) Welding Current
Control

(G) Gas Outlet

Negative Output Terminal

Positive Output Terminal

(I) 8 Pin Control Socket

(F) Arc Force/Down
Slope Control

(D) Process Selection Switch

(C) Trigger Mode Selection Switch

32AOUTLET

STICK
TIG

230V

110V

TIG/STICK

32AOUTLET
16AOUTLET

Figure 4-1: Tweco 201TS Controls

Front Panel

The welding power source is protected by a self re-setting thermostat. The indicator will illuminate if the duty
cycle of the power source has been exceeded. If the FAULT light illuminates wait for the FAULT light to extinguish
before resuming welding.

A. POWER Indicator

The POWER Indicator illuminates when the ON/OFF switch is in the ON position and the correct mains voltage is
present.

TWECO 201TS OPERATION

Operation

4-2 Manual 0-5150

D. Process Selection Switch

Switches between STICK (SMAW), LIFT TIG (GTAW)
and HF TIG (GTAW) modes. Refer to Section 4.03 Setup
for STICK (SMAW) Welding, 4.04 Setup for LIFT TIG
(GTAW)Welding and 4.05 Setup for HF TIG (GTAW)
Welding.

E. Welding Current Control

The welding current is increased by turning the Weld
Current Control Knob clockwise or decreased by turn­ing the Weld Current Control Knob anticlockwise. The
welding current should be set according to the specific
application. Refer to application notes in this section
for further information.

F. Arc Force/Down Slope Control

Arc Force is effective when in STICK (SMAW) Mode only.
Arc Force control provides an adjustable amount of Arc
Force (or “dig”) control. This feature can be particularly
beneficial in providing the operator the ability to com­pensate for variability in joint fit-up in certain situations
with particular electrodes. In general increasing the Arc
Force control toward ‘10’ (maximum Arc Force) allows
greater penetration control to be achieved. Down Slope
operates in TIG mode only. It is used to set the time for
weld current to ramp down. Refer to Item C (Trigger
Mode Selection Switch) for further information regard­ing Downslope operation.

G. Gas Outlet

The Gas Outlet is a 5/8”-18 UNF female gas fitting and
is utilized for the connection of a suitable TIG Torch.

B. FAULT Indicator

The welding power source is protected by a self resetting
thermostat and over primary current protection devices.
Welding can not take place if the FAULT Indicator lights
up continuously or is lights up.

Thermostat Protection

If the Fault Indicator lights up then the duty cycle of
the power source has been exceeded. Leave the power
on and wait for the Fault Indicator to extinguish before
resuming welding.

Over Primary Current Protection

If the Fault Indicatorlights up continueously then the
primary current into the main transformer has been
exceeded. Have an Accredited Tweco Service Provider
inspect then repair the welder.

C. TRIGGER Mode Switch (LIFT TIG and HF Mode Only)

2T (Normal) Mode

Press the TIG Torch Trigger Switch or Foot Control and
hold depressed to weld. Release the TIG Torch Trigger
Switch or Foot Control to stop welding. Down Slope
operates in LIFT TIG and HF TIG (GTAW) mode only.
While welding if the TIG Torch Trigger Switch is released,
the welding current ramps down to zero current over a
defined period of time. The time period is determined
by the Down Slope Control Knob (F).

4T (Latch) Mode

This mode of welding is mainly used for long weld runs.
The operator need only to press the TIG Torch Trigger
Switch to activate and then release the TIG Torch Trigger
Switch to continue to weld, then press the TIG Torch
Trigger Switch again and release the TIG Torch Trigger
Switch to stop welding. This eliminates the need for the
operator to depress the TIG Torch Trigger Switch for the
complete length of the weld. The 4T mode incorporates
a current slope function which includes a fixed current
up slope of 1 second and an adjustable current down
slope. Current slope operates in TIG Mode only. Up slope
is not adjustable and activates automatically in 4T mode
when the TIG torch trigger is depressed. To activate
the Down Slope function in 4T mode while welding,
the TIG Torch Trigger Switch must be depressed and
held while welding which will ramp the Welding Current
down to zero over a defined period of time. The time
period is determined by the Down Slope Control Knob
(F). At any time while welding if the TIG Torch Trigger
Switch is depressed and released the arc will extinguish
immediately.

OPERATION TWECO 201TS

Manual 0-5150 4-3 O

peration

H. 8 Pin Control Socket

The 8 pin Torch Trigger Socket is used to connect the
TIG Torch Trigger Switch to the welding Power Source.
To make connections, align keyway, insert plug, and
rotate threaded collar fully clockwise.

Art # A-09815_AB

12345 678

5k Ohms

21

543

876

Front View of 8 Pin Socket

Plug Pin Function

1

2 Torch Switch Input (24V) to energize

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

3

Torch Switch Input (0V) to energize weld
current. (connect pin 2&3 to turn on
welding current)

4

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

NOTE

Remote Welding Current Control is not available on
this model.

I. ON/OFF Switch (located on rear panel not shown)

This switch controls the Mains Supply Voltage to the
Power Source.

4.02 Setup for Welding

NOTE

Conventional operating procedures apply
when using the Welding Power Source, i.e.
connect work lead directly to work piece and
electrode holder and lead is connected to the
electrode. Wide safety margins provided by
the 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 fine tune the welding current to suit
the application.

WARNING

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
of the Welding Power Source.

TWECO 201TS OPERATION

Operation

4-4 Manual 0-5150

4.03 Stick (SMAW) Setup

200A

Set Welding Current
as specified by the
Electrode Manufacturer.

Set Process Selection
Switch to STICK.

Set ARC Force

Positive Output
Terminal
(Dinse™ 50)

Negative Output
Terminal
(Dinse™ 50)

Art#: A-09784

Figure 4-2: Setup for STICK (SMAW) Welding

STICK (SMAW) Mode Sequence of Operation

CAUTION

Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.

1. Switch the ON/OFF Switch (located on the rear panel) to OFF.

2. Connect the work lead to the negative output terminal, and the electrode holder cable to the positive output
terminal. It is essential that the male plug is inserted and turned fully clockwise until connector locks in place
to achieve reliable electrical connection.

NOTE

This set up is known as DC Electrode Positive or reverse polarity. Please consult with the stick electrode manufacturer for
specific polarity recommendations.

3. Connect the work clamp to your workpiece.

4. Plug the power cable into the appropriate outlet, and turn the switch to the “ON” position. The power L.E.D
light should illuminate.

5. Set the “Process Selection Switch” to STICK.

OPERATION TWECO 201TS

Manual 0-5150 4-5 O

peration

6. Set the weld current control knob to the desired amperage.

7. Set the ARC FORCE CONTROL knob to 2.

Minimum (0) provides a soft arc, low spatter & low penetration.

Medium (2) provides a normal arc, improved fusion & normal penetration.

Maximum (10) provides a hard arc & deep penetration.

8. Install a stick electrode in the electrode holder.

9. You are now ready to begin STICK Welding

NOTE

Gently strike the electrode on the work piece to generate a welding arc, and slowly move along the work piece while holding
a consistent arc length above base metal.

4.04 LIFT TIG / HF TIG (GTAW) Setup

Set Process Selection
Switch to LIFT TIG or HF TIG.

Positive Output
Terminal
(Dinse™ 50)

Negative
Output
Terminal
(Dinse™ 50)

Art # A-10100_AB

Set Welding Current
as specified by the
Electrode Manufacturer.

Secure the gas cylinder in an
upright position by chaining it
to a stationary support to prevent
falling or tipping.

Switch to 2T/4T

Set DOWN Slope

Figure 4-3: Setup for HF TIG (GTAW) Welding of 201TS

TWECO 201TS OPERATION

Operation

4-6 Manual 0-5150

HF TIG (GTAW) Sequence of Operation

CAUTION

Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.

1. Switch the ON/OFF Switch (located on the rear panel) to OFF.

2. Connect the ground (work) clamp cable to positive output terminal. It is essential that the male plug is
inserted and turned fully clockwise until connector locks in place to achieve reliable electrical connection.

3. Connect the TIG torch as follows:

a) Place the power cable into the negative output terminal. It is essential that the male plug is inserted and

turned fully clockwise until connector locks in place to achieve reliable electrical connection;

b) Place the 8 pin plug into the 8 pin socket. To make connections, align keyway, insert plug, and rotate

threaded collar fully clockwise.

c) Place the TIG torch gas hose to the gas outlet and tighten with a wrench. Caution: DO NOT over tighten.

4. Using a secured Argon cylinder, slowly crack open then close the cylinder valve while standing off to the side
of the valve. This will remove any debris that may be around the valve & regulator seat area.

5. Install the regulator (for details of VICTOR regulator, please refer to 3.09 ) and tighten with a wrench.

6. Connect one end of the supplied gas hose to the outlet of the Argon regulator and tighten with a wrench. Cau­tion: DO NOT over tighten.

7. Connect the other end of the supplied gas hose to the gas inlet fitting on the rear panel of the welder and tighten
with a wrench. Caution: DO NOT over tighten.

8. Open the Argon Cylinder Valve to the fully open position.

9. Connect the ground (work) clamp to your work piece.

10. Set the DOWN SLOPE control knob to the desire weld current ramp down time. Refer to Section 4.01.

11. Set the weld current control knob to the desired amperage.

12. The tungsten must be ground to a blunt point in order to achieve optimum welding results. It is critical to grind
the tungsten electrode in the direction the grinding wheel is turning.

13. Install the tungsten with approximately 1/8” to ¼” sticking out from the gas cup, ensuring you have correct
sized collet.

14. Tighten the back cap then open the valve on the torch.

15. Plug the power cable into the appropriate outlet, and turn the switch to the “ON” position. The power L.E.D.
light should illuminate. Set the “Process Selection Switch” to HF TIG

16. You are now ready to begin HF TIG Welding.

4.05 Welding Current Control Explanation

32 Amp Outlet

The mains power 32 Amp circuit breaker or fuse should not trip at this Weld Current value when STICK welding.

The environmental conditions that may cause the mains power 32 Amp circuit breaker or fuse to trip are:

a) High ambient temperature

b) Worn parts in circuit breaker

c) Using an extension cable

d) Low line mains power voltage

OPERATION TWECO 201TS

Manual 0-5150 4-7 O

peration

Output Scale for 110V

The inside number scale identifies the available

output weld current for STICK or LIFT TIG weld modes.

STICK Mode: Identifies the STICK weld point for

32 Amp outlet.

Exceeding these points will cause nui-

sance tripping of the circuit breaker or
fuse.

Nuisance tripping should not occur on a 16 Amp outlet.

Output Scale for 230V

The outside number scale identifies the available output
weld current for STICK or LIFT TIG/HF TIG weld modes.

Nuisance tripping should not occur on a 32A 230V outlet
for both STICK & LIFT TIG/HF TIG Modes.

Art # A-10147_AB

32 Amp Outlet

Output Scale for 110V

Output Scale for 230V

32AOUTLET

STICK

TIG

230V

110V

TIG/STICK

32AOUTLET
16AOUTLET

Figure 4-4: Current Control for 201TS

4.06 Victor Regulator

Flow gauge regulator (Figure 4-5) attached to the cyl­inder valve reduce high cylinder pressures to suitable
low working pressures for welding, cutting, and other
applications.

LOW PRESSURE
GAUGE (DELIVERY)

HIGH PRESSURE
GAUGE (SUPPLY)

INLET

CONNECTION

OUTLET

CONNECTION

PRESSURE

ADJUSTING

SCREW

A-09414_AB

Figure 4-5: Victor CS Regulator

!

WARNING

Use the regulator for the gas and pressure
for which it is designed. NEVER alter a regu­lator for use with any other gas.

Art # A-09845

Figure 4-6: Regulator to Cylinder Valve

1. Before opening the cylinder valve, turn the
regulator adjusting screw counter-clockwise
until there is no pressure on the adjusting spring
and the screw turns freely.

!

WARNING

Stand to the side of the cylinder opposite the
regulator when opening the cylinder valve.
Keep the cylinder valve between you and the
regulator. For your safety, NEVER STAND
IN FRONT OF OR BEHIND A REGULATOR
WHEN OPENING THE CYLINDER VALVE!

2. Slowly and carefully open the cylinder valve
(Figure 4-7) until the maximum pressure shows
on the high pressure gauge.

Art # A-09828

Figure 4-7: Open Cylinder Valve

TWECO 201TS OPERATION

Operation

4-8 Manual 0-5150

3. On all cylinders, except acetylene, open the valve completely to seal the valve packing. On gaugeless
regulators, the indicator will register the cylinder contents open.

4. Attach the desired downstream equipment.

4.07 Leak Testing the System

Leak test the system before putting into operation.

1. Be sure that there is a valve in the downstream equipment to turn off the gas flow.

2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery flow rate.

3. Close the cylinder valve. Watch to see if the high pressure or contents gauge drops, if it does you have a
leak in the connection between the regulator and the cylinder.

4. Once leak testing has been performed and there are no leaks in the system, slowly open the cylinder valve
and proceed.

!

WARNING

If a leak has been detected anywhere in the system, dis continue use and have the system repaired.
DO NOT use leaking equipment. Do not attempt to repair a leaking system while the system is under
pressure.

4.08 Lift Start TIG with the Tweco 201TS

Make sure that you have the appropriate shielding gas set up, attach the shielding gas hose from the torch to a
flow meter regulator on the cylinder. In this case we will be using Argon set at a flow rate of around 20 CFH. You
will need to use a TIG torch that has a gas valve, and is properly adjusted. (Tungsten, Collet, Collet body, nozzle,
and back cap).

1. Attach the TIG torch lead to the (-) terminal of the power supply.

2. Attach the work lead with ground camp to the (+) terminal of the power source, and your work piece.

NOTE

About tungsten selection for this power supply, a 2% Thoriated tungsten is generally used for DC
straight polarity welding. Point the tungsten by grinding a taper on it about 2½ times the diameter of
the tungsten used and grind a slight flat on the end, this will help stabilize the arc.

To TIG weld with the Tweco 201TS you will need to:

1. Open the torch valve and adjust the argon flow and close the valve.

2. Turn on the power supply. The switch is located on the rear panel.

3. Set the weld process to lift TIG. Set the anticipated amperage needed for the weld on the panel and turn
on the torch valve, touch the tungsten to the work, as you lift the tungsten off the work, the arc will start.

NOTE

An alternate method is to set the edge of the gas cup on the work piece. Rotate the torch so the tungsten
comes in contact with the work. Roll the torch back to lift the tungsten off the work and the arc will start.

Manual 0-5150 5-1 Theory of Operatin 5-1 Theory of Operatin

THEORY OF OPERATION TWECO 201TS

5.01 Inverter Design

What does the word inverter mean?

The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the
incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on
to a much smaller main transformer than in a conventional power supply. The AC is then rectified to extremely
smooth DC. The diagram to the below shows the basic electrical wiring of a DC output inverter power supply.

AC-High Frequency AC-High Frequency

Art # A-09846_AB

High Amperage High Amperage High Amperage Low Amperage Low Amperage Low Amperage Low Amperage

High Vo ltageHigh VoltageHigh Vo ltage Low VoltageLow VoltageLow VoltageHigh Voltage

DC-SmoothDC- RippledDC- RippledDC-Smooth

AC-

50/60Hz

Inverter Technology-Summary

Rectifier Filter IGBT TransformerRectifierInductor

SECTION 5:

THEORY OF OPERATION

TWECO 201TS THEORY OF OPERATION

Theory of Operation 5-2 5-2 Manual 0-5150

This Page Intentionally Blank

TROUBLESHOOTING TWECO 201TS

Manual 0-5150 6-1

Troubleshooting

6.01 Basic Troubleshooting

Symptom Inspection Methods

ON/OFF Switch “ON” Power
Indicator OFF

Check power supply input

Check ON/OFF switch continuity (See 6.06.7)
Check Inrush Resistor (see 6.06.6)）
Check control PCB2 J8 connector and front panel PCB3 J24 connector to make sure they

are properly inserted.

Replace front panel PCB3

Over Temp Indicator on Duty Cycle has been exceeded. Reduce weld time and allow Power Supply to cool.

Check thermostat wire connections. If the connection is properly inserted and Over Temp
Indicator is still on after short-circuit thermostat, replace control panel, otherwise replace
thermostat. (the value of thermostat is 75ºC).

Power Indicator ON, Fan
does not run

Check fan for obstruction.

Check whether J12connector on main board PCB1 is plugged in properly. Check for
+24V±10% on pins 1 and pin 2 of J12 connector.

If both above are ok, replace fan.

No Gas Flow In Lift Tig / HF
Tig Mode

Check process switch on front panel to determine whether it is functioning properly. And
put it to Lift Tig or HF Tig mode.

Make sure pin3 and pin4 of J12connector on main board PCB1 is +24V±10%

Replace gas solenoid

ON/OFF Indicator blinks Step 1. Make sure the voltage between pin 1 and pin2 of J11 connector on main power

PCB1 is - 24VDC±10%, and the voltage between pin 2 and 3 is +24VDC±10%.

Step 2. If above voltage is correct, please replace front panel PCB3.
Step 3. If above voltage is incorrect, disconnect the harness of J11 connector and re-

measure according to step 1. If still incorrect replace Main Power PCB 1

Cannot adjust Weld
Current

Check Control panel PCB 3 J26 connector and Remote control PCB4 J27 connector to
make sure they are properly inserted.

Check Current Control Potentiometer for an adjustment of 0 to 4.8vdc from Min to Max
on Front Panel PCB3. Pin1=Min, Pin2=Wiper, Pin3=Max. If adjustment cannot be made
correctly replace Front Panel PCB3.

No Open Circuit voltage Check process switch on front panel to determine whether it is functioning properly.

Check the Bus voltage on Main Power PCB1 . It should read 385VDC (see 6.05)
Turn Powersupply off and remove Mains Power. Check Input IGBT’s and Output Diodes

(see 6.06.2 and 6.06.5). If it is incorrect, replace main power PCB1.
If above is OK, replace control PCB2.

Low Weld output If input mains is 230VAC and output is limited to 125Amps output, check Front panel

PCB3 J25 connector and Main Power PCB1 J16 connector . If they are properly inserted,
replace Control PCB2

High Weld Output If input is 115V, output is near 160A, check whether it is shorted between pin1 and pin 3

on IN JC connector on main power board. If it is not, replace control board.

No HF in HF TIG mode Make sure the process switch is functioning properly, and put it to HF TIG mode.

Check TIG torch Switch for continuity. Also check wire harness on 8 pin remote
connection. If OK, measure on (PCB1) J17 pins1 and 3 for 15vdc when troch switch is
depressed.
Check the wire of HF arc starter is connection properly.
Replace the main power PCB1

SECTION 6:

TROUBLESHOOTING

TWECO 201TS TROUBLESHOOTING

Troubleshooting

6-2 Manual 0-5150

6.02 Checking Unit Before Applying Power

!

Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.

Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are

off before removing case.

!

Check DC bus voltage according to Section 6.07 after removing case.

!

Before troubleshooting or applying power to unit, complete the following checks to avoid causing

further damage.

6.03 Tools Needed for Troubleshooting and Servicing

Art # A-09849

TROUBLESHOOTING TWECO 201TS

Manual 0-5150 6-3

Troubleshooting

6.04 Case Removal

!

Read and follow safety information in Section 6.02 before proceeding.

1. Cover

2. Screws

- Remove the 4 screws, 2 on each side of the unit.

- Remove 2 screws from both the Front and Rear Panels.

1

2

A-09951_AB

2

A-09952_AB

TWECO 201TS TROUBLESHOOTING

Troubleshooting

6-4 Manual 0-5150

3. Ground screw

- Carefully lift the case to access and remove the screw which connects the ground wire to the cover.

3

Art # A-09851_AC

6.05 Clear Cover Sheet Removal

!

Read and follow safety information in Section 6.02 before proceeding.

1. Clear protective sheet

Take out clear protective sheet.

1

Art # A-10160

TROUBLESHOOTING TWECO 201TS

Manual 0-5150 6-5

Troubleshooting

6.06 Pre-Power Check

Measure Points for following tests

3

4

9

2

12

11 8

13

16

7

6

5

10

17

18

14

15

1

Art # A-10161

TWECO 201TS TROUBLESHOOTING

Troubleshooting

6-6 Manual 0-5150

!

Read and follow safety information in Section 6.02 before proceeding.

Measure point 1 to 18.

1. Measurement of Input Rectifier

Set multimeter to diode mode. Diode voltage drop reading should be in the range of 0.200 V - 0.700 V.

Positive Probe Negative Probe

Measure Point 2 Measure Point 1

Measure Point 4 Measure Point 1

Measure Point 3 Measure Point 2

Measure Point 3 Measure Point 4

If reading is out of voltage drop range, disconnect two parallel rectifiers and measure separately to deter-

mine faulty rectifier and replace it.

2. Measurement of Main IGBT

Set multimeter to diode mode. Diode voltage drop reading shuld be in the range of 0.200-0.600V.

Positive Probe Negative Probe

Measure Point 6 Measure Point 5

Measure Point 8 Measure Point 7

If reading is out of voltage drop range, replace main board.

3. Measurement of PFC IGBT

Set multimeter to diode mode. Diode voltage drop reading should be in the range of 0.200-0.600V.

Positive Probe Negative Probe

Measure Point 9 Measure Point 10

If reading is out of voltage drop range, replace main board.

4. Measurement of Boost Diode

Set multimeter to diode mode. Diode voltage drop reading should be in the range of 0.200-0.600V.

Positive Probe Negative Probe

Measure Point 12 Measure Point 11

If reading is out of voltage drop range, replace main board.

5. Measurement of Output Diode

Set multimeter to diode mode. Diode voltage drop reading should be in the range of 0.200-0.600V.

Positive Probe Negative Probe

Measure Point 13 Measure Point 14

Measure Point 15 Measure Point 16

If reading is out of voltage drop range, replace main PCB1.

TROUBLESHOOTING TWECO 201TS

Manual 0-5150 6-7

Troubleshooting

6. Measurement of In Rush Resistor R1.

Set multimeter to Ohm mode. Ohm reading should be 4Ω±5%.

Positive Probe Negative Probe

Measure Point 17 Measure Point 18

If reading is not 4ohms within ±5%, replace Resistor R1.

7. Power Switch S1 Continuity Check

3

Art # A-10265

1

2

4

!

Read and follow safety information in Section 6.02 before proceeding.

1. ON/OFF switch. Power Switch. Multimerer set to Measure ohms (Ω).

Power Switch Testing Multimeter Lead Placement Impedance

Switch ON Positive meter lead to testpoint 23

Negative meter lead to testpoint 24

0 to 1Ω

Switch ON Positive meter lead to testpoint 25

Negative meter lead to testpoint 26

1 to 1Ω

Switch OFF Positive meter lead to testpoint 23

Negative meter lead to testpoint 24

>1kΩ

Switch OFF Positive meter lead to testpoint 25

Negative meter lead to testpoint 26

>1kΩ

TWECO 201TS TROUBLESHOOTING

Troubleshooting

6-8 Manual 0-5150

6.07 DC Bus Voltage Check

!

Warning: Measure DC voltage reading with multimeter before inspection. Set multimeter to DC volt-

age mode.

!

Read and follow safety information in Section 6.02 before proceeding.

1. DC Positive

2. DC Negative

Check and make sure input capacitors are discharged and voltage is near 0 VDC. When powered up voltage

should read 385 VDC.

2

1

Art # A-10162

TROUBLESHOOTING TWECO 201TS

Manual 0-5150 6-9

Troubleshooting

6.08 Installing Clear Cover Sheet

!

Read and follow safety information in Section 6.02 before proceeding.

1. Replace the clear protective sheet.

1

Art # A-10160

TWECO 201TS TROUBLESHOOTING

Troubleshooting

6-10 Manual 0-5150

6.09 Waveforms for Section 6-10

A. OCV Waveform of Transformer primary

Art # A-09858

B.Output 160A/26.4V transformer primary waveform under input 230VAC

Art # A-09859

C. Output 160A/26.4 V output voltage waveform under input 230VAC

TROUBLESHOOTING TWECO 201TS

Manual 0-5150 6-11

Troubleshooting

Art # A-09860

D. Output 125A/25V transformer primary waveform under input 110VAC

Art # A-09894

E. Output 125A/25V output voltage waveform under input 110VAC

TWECO 201TS TROUBLESHOOTING

Troubleshooting

6-12 Manual 0-5150

Art # A-09895_AB

TROUBLESHOOTING TWECO 201TS

Manual 0-5150 6-13

Troubleshooting

6.10 Troubleshooting Circuit Diagram - 201TS

Art # A-11277_AB

INPUT 230VAC/115VAC

50/60Hz

PTC

VR

+15VDC 2

RED

WHITE

2

1

1

1

2

2

4 RTN

3

2

1

2 RTN

5

1

2

3

4

5

6

7

BLACK

RED

BLUE

BLUE

1 +24VDC

2 COMMON

3 -24VDC

1
2

1

3

1

3

1

2

+15V

-15V

1

2 REMOTE POT DEMAND

3 POT MAX

4 POT MIN56 START RTN

7 /START

8

4

1

1

2

PANEL CUR.DEMAND 3

4

10 CURRENT DEMAND

9 DOWN SLOPE/ARC FORCE

8 /2T/4T

7 N/A

6 /FAULT LED

5 HF TIG

4 STICK

3 VOLTAGE TEST

2 +15VDC

1

+15VDC

1

10

1

RED

BLACK

1

RED

BLACK

COMMON 4
CURRENT FEEDBACK 3

-15VDC 2

+15VDC 1

+24VDC 1

RTN 2

1

COMMON 7

OVER CURRENT 6

GATE DRIVE A 5

GATE DRIVE B 4

GATE DRIVE A 2

GATE DRIVE B 3

+15VDC 1

/GAS 5

HF 4

RED

WHITE

YELLOW

GRAY

BLACK

RED

2 CURRENT DEMAND

8765432

1

Current Sensor

(OT1)

(OT2)

1

TWECO 201TS TROUBLESHOOTING

Troubleshooting

6-14 Manual 0-5150

This Page Intentionally Blank

DISASSEMBLY PROCEDURE TWECO 201TS

Manual 0-5150 7-1

Disassembly Procedure

7.01 Safety Precautions for Disassembly

!

!

Read and follow safety information in Section 6.02 before proceeding.

Unplug unit before beginning Disassembly procedure.

7.02 Control Board Removal

!

Read and follow safety information in Section 6.02 before proceeding with disassembly

Refer to diagram on page 7-2.

1. M4 Screw. Remove 4 screws from Control
panel.

2. Disconnect J8 harness from J8 connector.

3 Disconnect J7 harness from J7 connector.

4. Disconnect J2 harness from J2 connector.

5. Disconnect J6 harness from J6 connector.

6. Disconnect J5 harness from J5 connector.

7. Disconnect J4 harness from J4 connector.

8. Disconnect J3 harness from J3 connector.

9. Disconnect J9 harness from J9 connector.

10. Disconnect J1 harness from J1 connector.

Ensure to unplug all harness from the main control

PCB.

5

7

8

10

9

4

1

2

3

6

Art # A-10163

Disassembly Procedure

7-2 Manual 0-5150

TWECO 201TS DISASSEMBLY PROCEDURE

CONNECTOR LAYOUT DIAGRAM

123

J1 J2

J3 J4

J5

J6

J7J8J9

OT2

OT1

POWER

VWBMWA

GUN

SOU/HF/QF

Art # A-10165

201TS Control PCB

7.03 Front Panel Assembly Removal

!

Read and follow safety information in Section 6.02 before proceeding with disassembly

1. Power supply output Negative

2 Power supply output Positive

3. Output terminal bolts. Unscrew power supply output terminal bolts.

4. Disconnect the harness from Front Panel PCB3.

5. Disconnect J29 harness from J29 connector.

6. Disconnect J24 harness from J24 connector.

DISASSEMBLY PROCEDURE TWECO 201TS

Manual 0-5150 7-3

Disassembly Procedure

1

2

Art # A-10166_AB

3

Art # A-10167

Disassembly Procedure

7-4 Manual 0-5150

TWECO 201TS DISASSEMBLY PROCEDURE

4

Art # A-10168

5

6

Art # A-10169

DISASSEMBLY PROCEDURE TWECO 201TS

Manual 0-5150 7-5

Disassembly Procedure

7.04 Front Panel (Operator Interface) Circuit Board PC2 Removal

!

Read and follow safety information in Section 6.02 before proceeding with disassembly

1. PROCESS Selector Switch Boot

Remove the rubber boot from the PROCESS Selector switch by turning the retaining nut counter clockwise.

2. WELD CURRENT Control Knob

Remove the WELD CURRENT KNOB by loosening the set screw.

3. WELD CURRENT control mounting nut

Remove mounting nut.

4. Front Panel PCB3

Remove the Front Panel PCB3 from the panel.

5. Panel mounting screw

Remove screw.

6. Trigger Selector Switch

Remove the rubber boot from the Trigger Selector Switch by turning the retaining nut counter-clockwise.

7. Arc Force/Down Slope Control Knob

Remove the Arc Force/Down Slope Control Knob by lossening the set screw.

8. Arc Force/Down slope Control Knob mounting nut

Remove mounting nut.

9. Remote Control PCB4

Remove the Remote Control PCB4.

Art # A-10266_AB

7

1

6

2

Disassembly Procedure

7-6 Manual 0-5150

TWECO 201TS DISASSEMBLY PROCEDURE

Art # A-12755

8

3

9

4

Art # A-10172

5

Art # A-09870

DISASSEMBLY PROCEDURE TWECO 201TS

Manual 0-5150 7-7

Disassembly Procedure

7.05 Back Panel Removal

!

Read and follow safety information in Section 6.02 before proceeding with disassembly

1. ON/OFF switch

2. Wire from Main PCB1.

Disconnect the two wires from PCB1.

3. Rear panel mounting SCREW.

Remove screw holding rear panel to chassis.

4. Ground wire screw.

Disconnect Input cord ground wire from Main Power PCB1 using a 1/4" wench.

5. Disconnect harness from J8 connector on Control PCB2 and carefully lift the wire free from the unit.

Refer to diagram on page 7-3.

6. Disconnect harness from J12 connector on Control PCB2 and carefully lift the wires free from the unit.

1

2

Art # A-10173

Disassembly Procedure

7-8 Manual 0-5150

TWECO 201TS DISASSEMBLY PROCEDURE

3

Art # A-10174

4

Art # A-10175_AB

DISASSEMBLY PROCEDURE TWECO 201TS

Manual 0-5150 7-9

Disassembly Procedure

6

Art # A-10176_AB

7.06 Power Switch S1 and Power Cord Removal

!

Read and follow safety information in Section 6.02 before proceeding with disassembly

1. Input Power Cord connection s to SW1.

Remove the stab-on wire connections from SW1.

2. SW1 locking tabs

Squeeze the locking tabs and push SW1 out from the rear panel.

3. Input Power Cord.

4. Strain relief screws

Remove the two (2) screws from the strain relief.

5 Input Power Cord ground wire filter.

Cut the tie-wrap and remove the magnet from the ground wire.

Pull the Input Power Cord out. It may be necessary to use a flat blade screw driver against the strain relief

tabs, prying outward (Internal side if strain relief) to help remove the cord.

6. Pull out the Input Power Cord.

7. Remove fan.

Disassembly Procedure

7-10 Manual 0-5150

TWECO 201TS DISASSEMBLY PROCEDURE

3

4

Art# A-10177

1

5

7

3

Art # A-10178

DISASSEMBLY PROCEDURE TWECO 201TS

Manual 0-5150 7-11

Disassembly Procedure

6

2

Art # A-10179

Disassembly Procedure

7-12 Manual 0-5150

TWECO 201TS DISASSEMBLY PROCEDURE

7.07 Base Panel Removal

!

Read and follow safety information in Section 6.02 before proceeding with disassembly

1. Remove PCB1 assembly.

2. Remove Base Panel Screws.

3. Remove Base Panel.

2

3

1

Art # A -10180

Manual 0-5150 8-1

Assembly Procedures

ASSEMBLY PROCEDURE TWECO 201TS

SECTION 8:

ASSEMBLY PROCEDURES

8.01 Installing Base Board

1. Base Panel

2. Panel screws

Secure the Main Power PCB1 to the Base Panel with the Panel Screws.

3. Main power PCB1 assembly

2

1

3

Art # A- 10181

Assembly Procedures

8-2 Manual 0-5150

TWECO 201TS ASSEMBLY PROCEDURES

8.02 Installing Back Panel

1. Install ON/OFF switch.

2. Install power cord.

3. Reconnect Input Wire on the ON/OFF switch.

4. Reinstall Magnet onto Ground Wire.

5. Install fan.

6. Reconnect power ON/OFF switch to terminals on Main Power PCB.

7. Reconnect Ground Wire to Main PCB.

8. Reconnect Rear Panel screws.

2

3

4

5

1

Art # A-10182

Manual 0-5150 8-3

Assembly Procedures

ASSEMBLY PROCEDURE TWECO 201TS

6

7

Art # A-10183

8

Art # A-09883

Assembly Procedures

8-4 Manual 0-5150

TWECO 201TS ASSEMBLY PROCEDURES

8.03 Installing Front Panel

1. PCB3

Place PCB1 into front panel.

2. WELD CURRENT potentiometer

Turn potentiometer shaft fully clockwise.

3. Arc Force/ Down Slope control potentiometer

Turn potentiometer shaft fully clockwise.

4. Potentiometer mounting nut.

Install nut and tighten.

5. WELD CURRENT knob

Install knob onto potentiometer shaft. Align the knob pointer to line up with maximum current calibration

mark on the panel, then tighten the set screw.

6. Arc Force/ Down Slope Control knob

Install knob onto potentiometer shaft, align the knob pointer to line up with maximum mark on the panel,

then tighten the set screw.

7. PROCESS selector switch boot.

Install boot over the switch and tighten nut onto switch.

8. Trigger Selector Switch boot

Install boot over the switch and tighten nut onto switch.

1

2

3

Art # A-10184

Manual 0-5150 8-5

Assembly Procedures

ASSEMBLY PROCEDURE TWECO 201TS

Art # A-12756

4

Art # A-10269_AB

6

7

8

5

Assembly Procedures

8-6 Manual 0-5150

TWECO 201TS ASSEMBLY PROCEDURES

9. Reinstall output terminals on front panel with 27mm wrench.

10. Reconnect wires to their respective terminals using the bolts.

11. Reconnect Output Terminal Bolts and tighten with 17mm wrench.

12. Reinstall screw.

9

Art # A-10187

Manual 0-5150 8-7

Assembly Procedures

ASSEMBLY PROCEDURE TWECO 201TS

11

10

Art # A-10188

12

Art # A-10189

Assembly Procedures

8-8 Manual 0-5150

TWECO 201TS ASSEMBLY PROCEDURES

8.04 Installing Main Control Panel and Clear Cover Sheet

1. Install 4 screws.

2. Plug harness into connector J12. Refer to 7.02.

3. Plug harness into connector J1.

4. Plug harness into connector J8.

5. Plug harness into connector J7.

6. Plug harness into connector J3.

7. Plug harness into connector J4.

8. Verify harness connections with the system schematic to insure all connections are correct.

9. Install clear protective sheet.

5

7

8

10

9

4

1

2

3

6

Art # A-10163

Manual 0-5150 8-9

Assembly Procedures

ASSEMBLY PROCEDURE TWECO 201TS

1

Art # A-10160

Assembly Procedures

8-10 Manual 0-5150

TWECO 201TS ASSEMBLY PROCEDURES

8.05 Installing Case

1. Install Case.

2. Install Screws.

- Eight (8) screws. 4 on both side panels of case, 2 on front panel, 2 on rear panel.

1

2

A-09951_AB

2

A-09952_AB

REPLACEMENT PARTS TWECO 201TS

Manual 0-5150 9-1

Replacement Parts

SECTION 9:

REPLACEMENT PARTS

9.01 Hardware List

Description Specification Where used QTY Unit

Hexagon socket head screw GB/T70.1 M8×14 Handle 2 EACH

Cross-recessed round head screw GB/T818 M3×12 Remote socket 4 EACH

Cross-recessed tapping screw

GB/T845-1985
BT4.8*13

Base Panel 2 EACH

Cross-head pan head tapping
screw

GB/T13806.2
AST4.2×13

Bracket 3 EACH

locking washer, external serrated GB862.2-87 4

Base Panel, Solenoid
valve,

4 EACH

Screw, spring washer, flat washer M4×16 Rectifier bridge 2 EACH

Flat washer 4*10

Solenoid valve, base
panel, Case

5 EACH

Cross-recessed round head screw GB/T818 M5×12 Power Cord 2 EACH

Cross-recessed pan screw GB/T818 M3×25 Fan 4 EACH

Nut GB/T6170 M3 Fan, plug 8 EACH

Nut GB/T6170 M4 Ground 1 EACH

Cross-recessed pan head screw GB/T818 M4×10

Front Panel, Rear
Panel, and Case

8 EACH

Plastic screw PF-408 Control PCB 3 EACH

Plastic screw DN-4 Control PCB 4 EACH

Replacement Parts

9-2 Manual 0-5150

TWECO 201TS REPLACEMENT PARTS

9.02 Replacement Part List

Item No Description Part No. Reference Designator

1 Handle W7003040

2 Panel, Cover W7003200

3 Rectifier 1000V,50A W7003010

4 PCB,Control,201TS W7003222 PCB2

5 Thermostat W7003016 THC1, THC2

6 Resistor,6 ohm,60W W7003055 R1

7 PCB,Power,201TS W7003216 PCB1

8 Insulation Sheet W7003214

9 Points,HF Starter,201TS W7003034

10 Output Inductor Magnetic Core W7003210

11 Front Control PCB3 W7003218 PCB3

12 Front Panel W7003205

13 Front Panel Label W7003219

14 Rubber Boot W7003064

15 Knob, control, Red, 21 ODx6 ID W7003079

16 Connector,Gas Outlet,161STL-201TS W7003212

17 Output Terminal, 50mm dinse W7003020

18 Socket,8 Pin,cable,161STL-201TS W7003220

19 Gas Solenoid W7003033

20 Current Sensor, 161-201TS W7003076 Current Sensor

21 Base Panel W7003209

22 Fan,24V DC W7003090

23 Rear Panel W7003201

24 Cable Cord,12AWG,10ft,6-50P W7003052

25 Connector,Gas Inlet,161STL-201TS W7003215

26 ON/OFF Switch W7003053 SW1

27 PCB,Remote,161STL-201TS W7003221 PCB4

REPLACEMENT PARTS TWECO 201TS

Manual 0-5150 9-3

Replacement Parts

2

5

3

4

6

7

8

9

10

11

12

13

14

15

16

17

18

19

21

20

22

23

24

25

Art # A-10148_AB

26

5

1

2

1

Replacement Parts

9-4 Manual 0-5150

TWECO 201TS REPLACEMENT PARTS

This Page Intentionally Blank

ACCESSORIES TWECO 201TS

Manual 0-5150 10-1

Accessories

SECTION 10:

ACCESSORIES

Description Part Number

26 style TIG Torch with 12.5ft lead, finger remote control, 50mm dinse connection and
accessory kit

W4013601

Foot Control, 8 pin amphenol, 15ft 600285

Slider Current Control with Torch Switch, 15ft. suits 1-1/8" dian. 26 TIG Torch Handle 10-4010

Tweco Eagle and Flag Helmet 4100-1002

Tweco Skull and Fire Helmet 4100-1004

Tweco Yellow Dragon Helmet 4100-1008

A-12273

A-12275

A-12274

TWECO 201TS ACCESSORIES

Accessories

10-2 Manual 0-5150

This Page Intentionally Blank

In accordance with the warranty periods stated below, Victor Technologies guarantees the proposed product to
be free from defects in material or workmanship when operated in accordance with the written instructions as
defined in this operating manual.

Victor Technologies 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.

Victor Technologies will repair or replace, at its discretion, any warranted parts or components that fail due to
defects in material or workmanship within the warranty period. The warranty period begins on the date of sale to
the end user.

Welding Equipment - Limited Warranty Period

Product Period

Tw

eco 201 TS

2 Years

TIG torch, electrode holder and work lead 30 Days

If warranty is being sought Victor Technologies must be notified in writing within 30 days of the failure and at
such time we will make arrangements to fulfil the warranty claim. Please contact your Victor Technologies product
supplier for the warranty repair procedure.

Victor Technologies warranty will not apply to:

• EquipmentthathasbeenmodiedbyanyotherpartyotherthanVictorTechnologies’sownserviceperson-

nel or with prior written consent obtained from Victor Technologies service department (UK).

• Equipmentthathasbeenusedbeyondthespecicationsestablishedintheoperatingmanual.

• Installationnotinaccordancewiththeinstallation/operatingmanual.

• Anyproductthathasbeensubjectedtoabuse,misuse,negligence,accident,impropercareand/ormain-

tenance including lack of lubrication, maintenance and protection, will be refused warranty.

• Failuretocleanandmaintainthemachineassetforthintheoperating,installationorservicemanual.

Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation.
This manual also offers basic troubleshooting, operational and technical details including application usage.

Using this manual correctly will ensure the quickest time possible for resolving any technical questions, application
issues or defects with your Victor Technologies product.

You may also wish to visit our web site www.victortechnologies.com select your product class and then select
literature. Here you will find documentation including:

• Operatormanuals

• Servicemanuals

• Productguides

Alternatively please contact your Victor Technologies distributor and speak with a technical representative.

NOTE

Warranty repairs must be performed by either a Victor Technologies Service Centre, a Victor Technolo­gies distributor or an Authorised Service Agent approved by the Company.

LIMITED WARRANTY & WARRANTY SCHEDULE

© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in China

THE AMERICAS

Denton, TX USA
U.S. Customer Care

Ph 1-800-426-1888 (tollfree)
Fax: [phone] (tollfree)

International Customer Care

Ph 1-940-381-1212
Fax: [phone]

Miami, FL USA
Sales Office, Latin America

Ph 1-954-727-8371
Fax: [phone]

Oakville, Ontario, Canada
Canada Customer Care

Ph 1-905-827-4515
Fax: [phone] (tollfree)

EUROPE

Chorley, United Kingdom
Customer Care

Ph [phone]
Fax: [phone]

Milan, Italy
Customer Care

Ph [phone]
Fax: [phone]

ASIA/PACIFIC

Cikarang, Indonesia
Customer Care

Ph 6221-8990-6095
Fax: [phone]

Rawang, Malaysia
Customer Care

Ph [phone]
Fax: [phone]

Melbourne, Australia
Australia Customer Care

Ph 1300-654-674 (tollfree)
Ph 61-3-9474-7400
Fax: [phone]

International

Ph 61-3-9474-7508
Fax: [phone]

Shanghai, China
Sales Office

Ph [phone]
Fax: [phone]

Singapore
Sales Office

Ph [phone]
Fax: [phone]

U.S. Customer Care: 800-426-1888 / FAX [phone]
Canada Customer Care: 905-827-4515 / FAX [phone]
International Customer Care: 940-381-1212 / FAX [phone]

INNOVATION TO SHAPE THE WORLD™