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.
• Donottouchliveelectricalparts.
• TurnOffweldingpowersourceandwirefeederanddisconnect
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.
• Insulateyourself fromground bystandingor workingon
dry insulating mats big enough to prevent contact with the
ground.
• Donotleaveliveunitunattended.
• Ifthisprocedurerequiresandenergizedunit,haveonlyper-
sonnel familiar with and following standard safety practices
do the job.
• Whentestingaliveunit,usetheone-handmethod.Donot
put both hands inside unit. Keep one hand free.
• Disconnectinputpowerconductorsfromde-energizedsupply
line BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists after removal of input
power on inverters.
• Turn Off inverters,disconnectinputpower,anddischarge
input capacitors according to instructions in Troubleshooting
Section before touching any parts.
WARNING
STATIC (ESD) can damage PC boards.
• Putongroundedwriststrap BEFORE handling boards or
parts.
• Useproperstatic-proofbagsandboxestostore,move,or
ship PC boards.
WARNING
FIRE OR EXPLOSION hazard.
• Donotplaceuniton,over,ornearcombustiblesurfaces.
• Donotserviceunitnearammables.
WARNING
FLYING METAL or DIRT can injure eyes.
• Wearsafetyglasseswithsideshieldsorfaceshieldduring
servicing.
• Becarefulnottoshortmetaltools,parts,orwirestogether
during testing and servicing.
WARNING
HOT PARTS can cause sever burns.
• Donottouchhotpartsbarehanded.
• Allowcoolingperiodbeforeworkingonequipment.
• To handle not parts, use proper tools and/orwear heavy,
insulated welding gloves and clothing to prevent burns.
WARNING
EXPLODING PARTS can cause injury.
• Failedpartscanexplodeorcauseotherpartstoexplodewhen
power is applied to inverters.
• Alwayswearafaceshieldandlongsleeveswhenservicing
inverters.
WARNING
SHOCK HAZARD from testing.
• TurnOffweldingpowersourceandwirefeederorstopengine
before making or changing meter lead connections.
• Useatleastonemeterleadthathasaself-retainingspring
clip such as an alligator clip.
• Readinstructionsfortestequipment.
WARNING
FALLING UNIT can cause injury.
• Useliftingeyetoliftunitonly,NOTrunninggear,gascylinders, or any other accessories.
• Useequipmentofadequatecapacitytoliftandsupportunit.
• Ifusingliftforkstomoveunit,besureforksarelongenough
to extend beyond opposite side of unit.
WARNING
MOVING PARTS can cause injury,
• Keepawayfrommovingpartssuchasfans.
• Keepawayfrompinchpointssuchasdriverolls.
• Haveonlyqualiedpersonsremovedoors,panels,covers,
or guards for maintenance as necessary.
• Keephands,hair,looseclothing,andtoolsawayfrommoving
parts.
SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS
Manual 0-5150 1-9
Safety Instructions and Warnings
• Reinstalldoors,panels,covers,orguardswhenmaintenance
is finished and before reconnecting input power.
WARNING
MAGNETIC FIELDS can affect Implanted Medical
Devices.
• WearersofPacemakersandotherImplantedMedicalDevices
should keep away from servicing areas until consulting their
doctor and the device manufacturer.
WARNING
OVERUSE can cause OVERHEATING.
• Allowcoolingperiod;followrateddutycycle.
• Reducecurrentorreducedutycyclebeforestartingtoweld
again.
• Donotblockorlterairowtounit.
WARNING
H.F. RADIATION can cause interference.
• High-frequency(H.F.)can interfere with radio navigation,
safety services, computers, and communications equipment.
• Haveonlyqualiedpersonsfamiliarwithelectronicequipment
install, test, and service H.F. producing units.
• Theuserisresponsibleforhavinga qualied electrician
promptly correct any interference problem resulting from
the installation.
• IfnotiedbytheFCC about interference, stop using the
equipment at once.
• Havetheinstallationregularlycheckedandmaintained.
• Keephigh-frequencysourcedoorsandpanelstightlyshut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
!
WARNING
READ INSTRUCTIONS.
• UseTestingBooklet(PartNo.150853)whenservicingthis
unit.
• ConsulttheOwner’sManualforweldingsafetyprecautions.
• Useonlygenuinereplacementpartsfromthemanufacturer.
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:
• Inareas,freefrommoistureanddust.
• Ambienttemperaturebetween14°F(-10°C)to104°F(40°C).
• Inareas,freefromoil,steamandcorrosivegases.
• Inareas,notsubjectedtoabnormalvibrationorshock.
• Inareas,notexposedtodirectsunlightorrain.
• Placeat adistanceof12” (300mm)ormorefromwalls orsimilarthatcould restrictnaturalairowfor
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.
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