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ARCMASTER 201 TS ® Inverter Arc Welder Service Manual Art # A-10139_AB Revision: AC Issue Date: April 22, 2015 Manual No.: 0-5150 Tweco.com...
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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.
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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.
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...
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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 ....................
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TABLE OF CONTENTS This Page Intentionally Blank...
SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS 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.
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TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS 3. If ventilation is poor, use an approved air-supplied respirator. 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.
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SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS WARNING WARNING CYLINDERS can explode if damaged. MOVING PARTS can cause injury. Shielding gas cylinders contain gas under high Moving parts, such as fans, rotors, and belts can cut fingers and pressure. If damaged, a cylinder can explode. Since hands and catch loose clothing.
TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS 1.02 General Safety Information for NOTE Victor CS Regulator Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields A. Fire Prevention The following is a quotation from the General Conclusions Section Welding and cutting operations use fire or combustion as a basic of the U.S.
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SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS D. Personal Protection 2. Place the valve protection cap on the cylinder whenever mov ing it, placing it in storage, or not using it. Never drag Gas flames produce infrared radiation which may have a harm ful or roll cylinders in any way.
TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS 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.
SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier...
TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS 1.05 Servicing Hazards WARNING FLYING METAL or DIRT can injure eyes. WARNING • Wear safety glasses with side shields or face shield during The symbols shown below are used throughout this servicing. manual to call attention to and identify possible haz- ards. When you see the symbol, watch out, and follow • Be careful not to short metal tools, parts, or wires together...
SAFETY INSTRUCTIONS AND WARNINGS TWEC0 201TS • Reinstall doors, panels, covers, or guards when maintenance 1.06 EMF Information is finished and before reconnecting input power. Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields WARNING Welding current, as it flows through welding cables, will cause electromagnetic fields.
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TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS This Page Intentionally Blank Safety Instructions and Warnings 1-10 Manual 0-5150...
INTRODUCTION TWECO 201TS SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.03 Receipt of Equipment This Manual usually applies to the part numbers listed When you receive the equipment, check it against the on page i. To ensure safe operation, read the entire...
TWECO 201TS SAFETY AND INSTALLATION 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...
SAFETY AND INSTALLATION TWECO 201TS 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.
TWECO 201TS SAFETY AND INSTALLATION 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.
TWECO 201TS SAFETY AND INSTALLATION 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.
SAFETY AND INSTALLATION TWECO 201TS 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.
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TWECO 201TS SAFETY AND INSTALLATION 115VAC Input Lift Tig Max Stick Max AMPS Art # A-10159 Figure 3-4: 201TS Volt-Ampere Curves Safety and installation Manual 0-5150...
Positive Output Terminal Negative Output Terminal Art # A-10146_AB 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.
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If the Fault Indicatorlights up continueously then the primary current into the main transformer has been F. Arc Force/Down Slope Control exceeded. Have an Accredited Tweco Service Provider inspect then repair the welder. Arc Force is effective when in STICK (SMAW) Mode only.
OPERATION TWECO 201TS 4.02 Setup for Welding H. 8 Pin Control Socket The 8 pin Torch Trigger Socket is used to connect the NOTE TIG Torch Trigger Switch to the welding Power Source. Conventional operating procedures apply To make connections, align keyway, insert plug, and when using the Welding Power Source, i.e.
TWECO 201TS OPERATION 4.03 Stick (SMAW) Setup Set Process Selection Set Welding Current Switch to STICK. as specified by the Electrode Manufacturer. Set ARC Force Negative Output Positive Output Terminal Terminal (Dinse™ 50) (Dinse™ 50) Art#: A-09784 Figure 4-2: Setup for STICK (SMAW) Welding...
OPERATION TWECO 201TS 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.
TWECO 201TS OPERATION 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.
OPERATION TWECO 201TS Output Scale for 110V WARNING The inside number scale identifies the available Use the regulator for the gas and pressure output weld current for STICK or LIFT TIG weld modes. for which it is designed. NEVER alter a regu- lator for use with any other gas.
THEORY OF OPERATION TWECO 201TS SECTION 5: THEORY OF OPERATION 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.
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TWECO 201TS THEORY OF OPERATION This Page Intentionally Blank Theory of Operation Manual 0-5150...
TROUBLESHOOTING TWECO 201TS SECTION 6: TROUBLESHOOTING 6.01 Basic Troubleshooting Symptom Inspection Methods ON/OFF Switch “ON” Power Check power supply input Indicator OFF 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.
TWECO 201TS TROUBLESHOOTING 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.
TROUBLESHOOTING TWECO 201TS 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.
TWECO 201TS TROUBLESHOOTING 3. Ground screw - Carefully lift the case to access and remove the screw which connects the ground wire to the cover. Art # A-09851_AC 6.05 Clear Cover Sheet Removal Read and follow safety information in Section 6.02 before proceeding.
TROUBLESHOOTING TWECO 201TS 6.06 Pre-Power Check Measure Points for following tests Manual 0-5150 Troubleshooting...
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TWECO 201TS TROUBLESHOOTING 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.
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TROUBLESHOOTING TWECO 201TS 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.
TWECO 201TS TROUBLESHOOTING 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.
TROUBLESHOOTING TWECO 201TS 6.08 Installing Clear Cover Sheet Read and follow safety information in Section 6.02 before proceeding. 1. Replace the clear protective sheet. Art # A-10160 Manual 0-5150 Troubleshooting...
TWECO 201TS TROUBLESHOOTING 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 6-10...
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TROUBLESHOOTING TWECO 201TS 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 Manual 0-5150 6-11 Troubleshooting...
DISASSEMBLY PROCEDURE TWECO 201TS 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.
TWECO 201TS DISASSEMBLY PROCEDURE CONNECTOR LAYOUT DIAGRAM POWER 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.
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DISASSEMBLY PROCEDURE TWECO 201TS Art # A-10166_AB Art # A-10167 Manual 0-5150 Disassembly Procedure...
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TWECO 201TS DISASSEMBLY PROCEDURE Art # A-10168 Art # A-10169 Disassembly Procedure Manual 0-5150...
DISASSEMBLY PROCEDURE TWECO 201TS 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.
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TWECO 201TS DISASSEMBLY PROCEDURE Art # A-12755 Art # A-10172 Art # A-09870 Disassembly Procedure Manual 0-5150...
DISASSEMBLY PROCEDURE TWECO 201TS 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.
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TWECO 201TS DISASSEMBLY PROCEDURE Art # A-10174 Art # A-10175_AB Disassembly Procedure Manual 0-5150...
DISASSEMBLY PROCEDURE TWECO 201TS 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.
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. Art # A -10180 Disassembly Procedure 7-12...
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 Art # A- 10181...
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.
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ASSEMBLY PROCEDURE TWECO 201TS Art # A-10183 Art # A-09883 Manual 0-5150 Assembly Procedures...
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.
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ASSEMBLY PROCEDURE TWECO 201TS Art # A-12756 Art # A-10269_AB Manual 0-5150 Assembly Procedures...
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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. Art # A-10187...
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ASSEMBLY PROCEDURE TWECO 201TS Art # A-10188 Art # A-10189 Manual 0-5150 Assembly Procedures...
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. A-09951_AB A-09952_AB Assembly Procedures 8-10 Manual 0-5150...
REPLACEMENT PARTS TWECO 201TS SECTION 9: REPLACEMENT PARTS 9.01 Hardware List Description Specification Where used Unit Hexagon socket head screw GB/T70.1 M8×14 Handle EACH Cross-recessed round head screw GB/T818 M3×12 Remote socket EACH GB/T845-1985 Cross-recessed tapping screw Base Panel EACH BT4.8*13...
LIMITED WARRANTY & WARRANTY SCHEDULE 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.
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THE AMERICAS Denton, TX USA U.S. Customer Care Ph 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...
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