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Summary of Contents for Thermal Arc 250TS DC CC
- Page 1 INVERTER WELDER MODEL 250TS DC CC STICK TIG - Lift Start TIG - HF Start OPERATING MANUAL November 11, 2003 Manual No. 430429-507...
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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 Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, FUMÉE et GAZ voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
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Page 11: Documents De Reference
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne RAYONS D’ARC DE PLASMA dépassent pas les niveaux sûrs. • Pour des renseignements sur la manière de Les rayons provenant de l’arc de plasma peuvent tester le bruit, consultez l’article 1, page 5. - Page 12 American Welding Society, N.W. 12. Norme CSA W117.2, CODE DE SÉCURITÉ LeJeune Rd., Miami, FL 33126 POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des 8. Norme 51 de l’Association Américaine pour Normes Canadiennes, Standards Sales, 178 la Protection contre les Incendies (NFPA), Rexdale Boulevard, Rexdale,...
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Page 13: Introduction And Description
2.0 INTRODUCTION AND DESCRIPTION 2.01 Description The Thermal Arc™ Model Pro-Lite 250TS is a single/three-phase DC arc welding power sources with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas control valve, built in Sloper and Pulser, lift arc starter, and high-frequency arc starter for use with Gas Tungsten Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulse (GTAW-P), Gas Tungsten Arc Welding-Sloped (GTSW-S), 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 250TS-power supply. Figure 2. 250TS 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 208 VAC 75 Amps 230 VAC 70 Amps 460 VAC 20 Amps 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).
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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 250TS Controls Figure 4 – Pro-Lite 250TS 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 inward displays the actual welding voltage. - 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 Process Selection For Pro-Lite 250Ts
4.02 Weld Process selection for Pro-Lite 250TS Weld Mode Weld Process LIFT Selection STICK Description 2T operation in TIG Modes using remote devices to control contactor & current 4T operation in TIG Modes with crater fill using a remote contactor device to control SLOPE sequence. -
Page 26: Weld Parameter Description
4.03 Weld Parameter Description Figure 5. Pro-Lite 250TS Front Panel with Parameter Description Parameter Description This parameter operates in TIG modes only and is used to get gas to the weld zone prior to striking the arc, once the torch trigger switch has been pressed. -
Page 27: Weld Parameters For Pro-Lite 250Ts
Parameter Description PEAK CUR. This parameter sets the PEAK weld current when in PULSE mode WELD This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and SPOT modes when PULSE is off. This parameter also sets the STICK weld current. -
Page 28: Power Source Features
PULSE FREQ. Range Incremental Unit 0.5 to 20Hz 0.1Hz 20 to 100Hz 100 to 500Hz Table 6 – PULSE FREQ. Range and Incremental Units 4.05 Power Source Features Feature Description • Almost all welding parameters are adjustable New Digital Control •... -
Page 29: 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 30: 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 31: Stick Welding
6.01 Stick Welding • Connect work lead to negative terminal • Connect electrode lead to positive terminal • Switch machine on • Set weld current • 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 32: Hf Tig & Lift Tig Welding
6.02 HF TIG & Lift TIG Welding • Connect work lead to positive terminal • Connect TIG torch to negative terminal • Switch machine on • Set weld current. • Connect remote control device. A remote control device is required for use during LIFT TIG and HF TIG operation. -
Page 33: Slope Mode Sequence
6.02.01 Slope Mode Sequence Switch Switch Switch Switch Open Open Closed Closed Weld Current Slope Initial Final Current Current Preflow NOTE: Slope function operates with a Remote ON/OFF device only. 1) To start Slope sequence Close remote switch contacts. Once the welding arc is established the Power Source will maintain initial current setting as long as the remote switch contacts are closed. -
Page 34: Pulse Controls
6.02.03 Pulse Controls (Pulse Width) (Pulse Frequency) (Peak Current) (Base) Background Current The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows: 1) Control puddle – size and fluidity (especially out of position). 2) Increase penetration 3) Travel speed control 4) Better consistent quality... -
Page 35: 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 36: 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 9 – Filler wire selection guide NOTE 6 The filler wire diameter specified in Table 9 is a guide only, other diameter wires may be used according to the welding application. -
Page 37: 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 38: 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 39 Metals being Electrode Comments joined Copper, Bronze, 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. High Alloy Steels, 312-16 It will weld most problematical jobs...
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Page 40: 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 41 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 grinding off the contaminates. through contact with work piece or filler rod material.
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Page 42: 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 43 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. C Wrong electrode angle.
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Page 44: 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 Power switch is switched OFF. Source. - Page 45 Description Possible Cause Remedy 5 Gas flow won’t A Weld Mode (STD, SLOPE, A Strike an arc to complete the shut off REPEAT or SPOT) was weld cycle. changed before POST-FLOW gas time had finished. Switch machine off then on to reset solenoid valve sequence.
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Page 46: 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 54: Appendix A - Interconnect Diagram
APPENDIX A - INTERCONNECT DIAGRAM... -
Page 56: 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 57 Figure 11 – Location of PCB WK-4921...
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