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Summary of Contents for Thermal Arc 250S DC CC
- Page 1 INVERTER WELDER MODEL 250S DC CC STICK TIG - Lift Start OPERATING MANUAL November 11, 2003 Manual No. 430429-506...
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Page 3: Table Of Contents
CONTENTS SYMBOL LEGEND ................................5 STATEMENT OF WARRANTY ............................6 1.0 GENERAL INFORMATION............................7 1.01 Notes, Cautions and Warnings ..........................7 1.02 Important Safety Precautions............................ 7 1.03 Publications ................................8 1.04 Note, Attention et Avertissement..........................9 1.05 Precautions De Securite Importantes........................9 1.06 Documents De Reference ............................ - Page 4 PAGE LEFT INTENTIONALLY BLANK...
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Page 5: Symbol Legend
SYMBOL LEGEND Amperage STICK (Shielded Metal Arc SMAW) Voltage Pulse Current Function Hertz (frequency) Spot Time (GTAW) Seconds Remote Control (Panel/Remote) Percent Remote Function DC (Direct Current) Arc Control (SMAW) AC (Alternating Current Gas Post-Flow Standard Function Gas Pre-Flow Slope Function Voltage Reduction Device Circuit Slope W/Repeat Function... -
Page 6: Statement Of Warranty
“Thermal; Arc” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to... -
Page 7: General Information
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. 1.0 GENERAL INFORMATION • The kinds of fumes and gases from the arc 1.01 Notes, Cautions and Warnings welding/cutting depend on the kind of Throughout this manual, notes, cautions, and metal being used, coatings on the metal, and warnings... -
Page 8: Publications
• Install and maintain equipment according to NEC code, refer to item 4 in Subsection 1.03, ARC WELDING RAYS Publications. • Disconnect power source before performing Arc Welding/Cutting Rays can injure your eyes any service or repairs. and burn your skin. The arc welding/cutting process produces very bright ultra violet and infra •... -
Page 9: Note, Attention Et Avertissement
6. ANSI Standard Z49.2, FIRE PREVENTION IN des informations à caractère important. Ces mises THE USE OF CUTTING AND WELDING en relief sont classifiées comme suit : PROCESSES, obtainable from American NOTE National Standards Institute, 1430 Broadway, New York, NY 10018 Toute opération, procédure... - Page 10 CHOC ELECTRIQUE Les chocs électriques peuvent blesser ou même FUMÉE et GAZ tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette La fumée et les gaz produits par le procédé de jet énergie électrique peut produire des chocs graves, de plasma peuvent présenter des risques et des voire mortels, pour l’opérateur et les autres dangers de santé.
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Page 11: Documents De Reference
hydrogène peut s’échapper ou se dissiper. également les autres personnes se trouvant Le gas hydrogène accumulé explosera si sur le lieu de travail. enflammé. • Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs. RAYONS D’ARC DE PLASMA •... - Page 12 RENFERMÉ PRODUITS 12. Norme CSA W117.2, CODE DE SÉCURITÉ COMBUSTIBLES, disponible auprès de la POUR LE SOUDAGE ET LA COUPE, American Welding Society, N.W. disponible auprès de l’Association des LeJeune Rd., Miami, FL 33126 Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,...
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Page 13: Introduction And Description
2.0 INTRODUCTION AND DESCRIPTION 2.01 Description The Thermal Arc™ Model Pro-Lite 250S is a self contained single/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 14: Functional Block Diagrams
2.02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of the 250S-power supply. Figure 2. 250S Model functional block diagram 2.03 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 15: Installation Recommendations
• In areas, not exposed to direct • 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. -
Page 16: Electrical Input Connections
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 17 Input Voltage Fuse Size 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. Electrical Input Connections...
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Page 18: Input Power
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 19: High Frequency Introduction
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 20: Specifications
460V 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... -
Page 21: Duty Cycle
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 22 PAGE LEFT INTENTIONALLY BLANK...
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Page 23: Operator Controls
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 24 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...
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Page 25: Weld Parameter Description
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. It sets the peak start current on top of the (WELD) current. Weld Current (Amperage)- sets the STICK and TIG WELD current. -
Page 26: Weld Parameters For 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 •... - Page 27 Feature Description • An error code is displayed on the Digital Meter Self Diagnosis Using Error Codes when a problem occurs with Primary supply voltage or internal component problems. Refer to troubleshooting guide.
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Page 28: Set-Up For Smaw (Stick) And Gtaw (Tig)
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 29: Sequence Of Operation
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 30: Stick Welding
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 31: Basic Tig Welding Guide
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 32: Guide For Selecting Filler Wire Diameter
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 6 The filler wire diameter specified in Table 6 is a guide only, other diameter wires may be used according to the welding application. -
Page 33: Welding Parameters For Steel
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” 40-50 25-35 Lap/ Fillet 1.0mm... -
Page 34: Basic Arc Welding Guide
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 35 Metals being Electrode Comments joined dairy work, etc. On stainless steels. Bronze Copper, Bronze, Easy to use electrode for marine Brass, etc. fittings, water taps and valves, water 5.7 ERCUSI-A trough float arms, etc. Also for joining copper to steel and for bronze overlays on steel shafts.
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Page 37: Basic Troubleshooting
WARNING 8 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 38 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.
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Page 39: Stick Welding Problems
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 40 4 Portions of the Small electrodes used on Use larger electrodes and pre- heavy cold plate. heat the plate. weld run do not fuse to the surface Welding current is too low. Increase welding current of the metal or edge of the joint. C Wrong electrode angle.
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Page 41: Power Source Problems
9.03 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. Power Source. -
Page 42: Voltage Reduction Device (Vrd)
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 50: Appendix A - Interconnect Diagram
APPENDIX A - INTERCONNECT DIAGRAM... -
Page 52: Appendix B - Automation
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 53 Figure 11 – Location of PCB WK-4921...
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