Thermal Arc pro-life 250s Operating Manual
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Thermal Arc pro-life 250s Operating Manual

Thermal Arc pro-life 250s Operating Manual

Inverter arc welder
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250S
®
PRO-LITE
INVERTER ARC WELDER
Operating Manual
Version No: 1
Issue Date: June 29, 2005
Manual#: 0-4767
Operating Features: Pro-Lite 250S - South America Version

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Summary of Contents for Thermal Arc pro-life 250s

  • Page 1 250S ® PRO-LITE INVERTER ARC WELDER Operating Manual Version No: 1 Issue Date: June 29, 2005 Manual#: 0-4767 Operating Features: Pro-Lite 250S - South America Version...
  • Page 3 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. Pro-Lite Inverter Welding Power Supply Instruction Manual Number 0-4767 for: Pro-Lite 250S (South America) Spec Number 10-3082...

  • Page 4: Table Of Contents

    Table of Contents 1.0 Safety Instructions and Warnings.......................... 5 1.01 Principal Safety Standards........................... 9 1.02 Statement Of Warranty ............................15 2.0 INTRODUCTION..............................17 2.01 How to Use This Manual............................ 17 2.02 Equipment Identification ............................ 17 2.03 Receipt of Equipment............................17 2.04 Symbol Chart..............................

  • Page 5: Safety Instructions And Warnings

    PRO-LITE 250S SECTION 1: ARC WELDING 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.
  • Page 6 PRO-LITE 250S 13. In confined spaces or damp locations, do not 4. Wear protective clothing made from durable, use a welder with AC output unless it is flame-resistant material (wool and leather) and equipped with a voltage reducer. Use foot protection. equipment with DC output.
  • Page 7 PRO-LITE 250S 5. Work in a confined space only if it is well 6. Be aware that welding on a ceiling, floor, ventilated, or while wearing an air-supplied bulkhead, or partition can cause fire on the respirator. Shielding gases used for welding can hidden side.
  • Page 8 PRO-LITE 250S 5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the WARNING specific application; maintain them and associated parts in good condition. MOVING PARTS can cause injury. 6. Turn face away from valve outlet when opening cylinder valve.

  • Page 9: Principal Safety Standards

    PRO-LITE 250S To reduce magnetic fields in the workplace, use the following procedures. 1. Keep cables close together by twisting or taping them. WARNING 2. Arrange cables to one side and away from the operator. STEAM AND PRESSURIZED HOT COOL- ANT can burn face, eyes, and skin.
  • Page 10 PRO-LITE 250S PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
  • Page 11 PRO-LITE 250S 8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop pe- tite. AVERTISSEMENT 9. N’enroulez pas de câbles électriques autour de votre corps. LE RAYONNEMENT DE L’ARC PEUT 10. N’utilisez qu’une bonne prise de masse pour la BRÛLER LES YEUX ET LA PEAU;...
  • Page 12 PRO-LITE 250S 5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé. AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION AVERTISSEMENT L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les pro- LES VAPEURS ET LES FUMEES SONT jections de soudure et l’équipement surchauffé...
  • Page 13 PRO-LITE 250S 8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements AVERTISSEMENT connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci- LES ETINCELLES ET LES PROJECTIONS dessous. BRULANTES PEUVENT CAUSER DES BLESSURES.
  • Page 14 PRO-LITE 250S 5. Utilisez la polarité correcte (+ et –) de l’accumulateur. AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES. AVERTISSEMENT Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples. LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS 1.

  • Page 15: Statement Of Warranty

    OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
  • Page 16 THIS PAGE LEFT INTENTIONALLY BLANK...

  • Page 17: Introduction

    Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link: http://www.thermalarc.com June 29, 2005...

  • Page 18: Symbol Chart

    PRO-LITE 250S 2.04 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- Dangerous Voltage Welding Gun Transformer-Rectifier Purging Of Gas Increase/Decrease...

  • Page 19: Description

    PRO-LITE 250S 2.05 Description The Thermal Arc™ Model Pro-Lite 250S is a self contained three-phase DC arc welding power sources with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, and lift arc starter, for use with Gas Tungsten Arc Welding (GTAW) and Shielded Metal Arc Welding (SMAW) processes.

  • Page 20: Functional Block Diagrams

    PRO-LITE 250S 2.06 Functional Block Diagrams Figure 2 illustrates the functional block diagram of the 250S-power supply. Figure 2. 250S Model functional block diagram 2.07 Transporting Methods These units are equipped with a handle for carrying purposes. WARNING 1 ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

  • Page 21: Installation Recommendations

    Place at a distance of 12” (304.79mm) or sunlight or rain. more from walls or similar that could restrict natural airflow for cooling. WARNING 3 Thermal Arc advises that this equipment be electrically connected by a qualified electrician. June 29, 2005...

  • Page 22: Electrical Input Connections

    PRO-LITE 250S 3.03 Electrical Input Connections WARNING 4 ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.
  • Page 23 PRO-LITE 250S Input Voltage Fuse Size 380 VAC 415 VAC Table 1 Electrical Input Connections NOTE: Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code). Figure 3.

  • Page 24: Input Power

    PRO-LITE 250S 3.03.02 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT BREAKER is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).

  • Page 25: High Frequency Introduction

    PRO-LITE 250S 3.03.03 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be over- emphasized. Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following information is intended as a guide for personnel installing high frequency welding machines.

  • Page 26: Specifications

    415V Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

  • Page 27: Duty Cycle

    PRO-LITE 250S 3.05 Duty Cycle The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases.
  • Page 28 PRO-LITE 250S PAGE LEFT INTENTIONALLY BLANK June 29, 2005...

  • Page 29: Operator Controls

    PRO-LITE 250S 4.0 OPERATOR CONTROLS 4.01 Pro-Lite 250S Controls Figure 4. – Pro-Lite 250S Power Source 1 Control Knob This control sets the selected weld parameter, rotating it clockwise increases the parameter and is indicated on the digital meter. Pushing the knob in previews the actual welding voltage while welding.
  • Page 30 PRO-LITE 250S Socket Pin Function Earth (Ground) Torch Switch Input (24V) to energize weld current. (connect pins 2 & 3 to turn on welding current) Torch Switch Input (0V) to energize weld current (connect pins 2 & 3 to turn on welding current) Connect pin 4 to pin 8 to instruct machine that a remote current control device is connected (12V DC supply) 5k ohm (maximum) connection to 5k ohm remote control potentiometer...

  • Page 31: Weld Parameter Description

    PRO-LITE 250S 4.02 Weld Parameter Description Figure 5. - Pro-Lite 250S Front Panel with Parameter Description Parameter Description This parameter operates in STICK weld mode and is used to improve HOT START the start characteristics for stick electrodes. e.g. low hydrogen electrodes.

  • Page 32: Weld Parameters For Pro-Lite 250S

    PRO-LITE 250S 4.03 Weld Parameters for Pro-Lite 250S Weld Mode Weld Parameter Factory Incremental STICK LIFT TIG Parameter Range Setting Unit HOT START 0 to 70A WELD CUR 5 to 250A 230V ARC CONTROL 0 to 100% 4.04 Power Source Features Feature Description New Digital Control...
  • Page 33 PRO-LITE 250S Feature Description Self Diagnosis Using Error Codes An error code is displayed on the Digital Meter when a problem occurs with Primary supply voltage or internal component problems. Refer to troubleshooting guide. June 29, 2005...

  • Page 34: Set-Up For Smaw (Stick) And Gtaw (Tig)

    PRO-LITE 250S 5.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG) Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects.

  • Page 35: Sequence Of Operation

    PRO-LITE 250S 6.0 SEQUENCE OF OPERATION NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions.

  • Page 36: Stick Welding

    PRO-LITE 250S 6.01 Stick Welding Connect work lead to negative terminal Connect electrode lead to positive terminal Switch machine on Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph.

  • Page 37: Basic Tig Welding Guide

    PRO-LITE 250S 7.0 BASIC TIG WELDING GUIDE 7.01Electrode Polarity Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding.

  • Page 38: Guide For Selecting Filler Wire Diameter

    PRO-LITE 250S 7.04 Guide for Selecting Filler Wire Diameter Filler Wire Diameter DC Current Range (Amps) 1/16” (1.6 mm) 20 - 90 3/32” (2.4 mm) 65 - 115 1/8” (3.2 mm) 100 - 165 3/16” (4.8 mm) 200-350 Table 6 – Filler wire selection guide NOTE 5 The filler wire diameter specified in Table 6 is a guide only, other diameter wires may be used according to the welding application.
  • Page 39 PRO-LITE 250S 7.07 Welding Parameters for Steel Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Thickness for Mild for Stainless Electrode Diameter Flow Rate Joint Type Steel Steel Diameter (if required) Liters/min 35-45 20-30 Butt/Corner 0.040” 0.040” 1/16”...

  • Page 40: Welding Parameters For Steel

    PRO-LITE 250S 8.0 BASIC ARC WELDING GUIDE 8.01Electrode Polarity Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘ ’ terminal but if in doubt consult the electrode manufacturers literature. 8.02 Effects of Stick Welding Various Materials High tensile and alloy steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead...

  • Page 41: Basic Arc Welding Guide

    PRO-LITE 250S Metals being Electrode Comments joined Mild steel 6013 Ideal electrodes for all general purpose work. Features include out standing operator appeal, easy arc starting and low spatter. All positional electrode for use on Mild steel 7014 mild and galvanized steel furniture, plates, fences, gates, pipes and tanks etc.

  • Page 42: Routine Maintenance

    PRO-LITE 250S 9.0 ROUTINE MAINTENANCE The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. WARNING 8 Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.

  • Page 43: Basic Troubleshooting

    WARNING 9 There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques.

  • Page 44: Tig Welding Problems

    PRO-LITE 250S Description Possible Cause Remedy 6 Electrode melts A Electrode is connected to the A Connect the electrode to the when arc is struck. ‘+’ terminal. ‘ ’ terminal. 7 Dirty weld pool. A Electrode contaminated A Clean the electrode by through contact with work grinding off the contaminates.

  • Page 45: Stick Welding Problems

    PRO-LITE 250S Description Possible Cause Remedy 12 Arc start is not A Tungsten electrode is too A Select the right size electrode. smooth. large for the welding current. Refer to Basic TIG Welding Guide. B The wrong electrode is being B Select the right electrode used for the welding job type.
  • Page 46 PRO-LITE 250S 4 Portions of the Small electrodes used on Use larger electrodes and pre- weld run do not heavy cold plate. heat the plate. fuse to the surface Welding current is too low. Increase welding current of the metal or edge of the joint.
  • Page 47 PRO-LITE 250S 10.03 Power Source Problems Description Possible Cause Remedy 1 The welding arc The Primary supply voltage Switch ON the Primary supply cannot be has not been switched ON. voltage. established The Welding Power Source Switch ON the Welding switch is switched OFF.

  • Page 48: Power Source Problems

    In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should also be conducted by an accredited Thermal Arc service agent.
  • Page 49 PRO-LITE 250S June 29, 2005...

  • Page 50: Power Source Error Codes

    PRO-LITE 250S June 29, 2005...
  • Page 51 PRO-LITE 250S June 29, 2005...
  • Page 52 PRO-LITE 250S June 29, 2005...

  • Page 53: Parts List

    PRO-LITE 250S June 29, 2005...
  • Page 54 PRO-LITE 250S June 29, 2005...
  • Page 55 PRO-LITE 250S June 29, 2005...

  • Page 56: Appendix A - Interconnect Diagram

    PRO-LITE 250S APPENDIX A - INTERCONNECT DIAGRAM June 29, 2005...
  • Page 57 PRO-LITE 250S June 29, 2005...

  • Page 58: Appendix B - Automation

    PRO-LITE 250S APPENDIX B - AUTOMATION JUMPER SETTING FOR "OK–TO–MOVE". Models 250S/TS Three jumpers (JP1, JP2 and JP3) are provided on PC Board WK-4921 for automation purposes. This PCB is mounted horizontally on top of the unit just under the cover. This PCB can be accessed by removing the side covers by loosening 4 screws on each the front and rear panel, then removing the 4 side panel screws as well as the 2 handle screws.
  • Page 59 PRO-LITE 250S Figure 11 – Location of PCB WK-4921 June 29, 2005...
  • Page 61 Global Customer Service Contact Information Thermadyne USA Thermadyne Asia Pacific Pte Ltd 82 Benning Street 5 Shenton Way West Lebanon, NH 03784 USA #37-02 / 38-02 UIC Building Telephone: (603) 298-5711 Singapore 068808 800-752-7621 Telephone: 65-6832-8066 Fax: 800-221-4401 Fax : 65+ 6763 5812 Email: sales@thermalarc.com Thermadyne, China Thermadyne Victor Brasil...
  • Page 62 Corporate Headquarters 82 Benning Street West Lebanon, NH 03784 USA Telephone: (603) 298-5711 800-752-7621 Fascimile: 800-221-4401 Email: sales@thermalarc.com www.thermalarc.com...

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