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Thermal Arc 202 AC/DC, Operating Manual

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 APPENDIX                                                                       202 AC/DC INVERTER

Manual 0-5239  

A-1 

APPENDIX

APPENDIX: CIRCUIT DIAGRAM

Q1

D1

A

N

E

IN

PU

T

RECT

IF

IE

R

R1

R1

POSI

TIVE

NEGA

TIVE

FA

N 

24VD

C

G1

C3

Q2

G2

T1

R3

C5

D3

NEGATIVE

POSITIVE

HA

LL 

EFFECT

CT

2

MA

IN

 CONTROL 

BO

AR

D

WE

LD

IN

G 

TERMIN

AL

S

DC 

BO

AR

D

SW

1

C1

R2

C4

C2

D2

D4

R4

C6

Q3

G3

Q4

G4

C7

C8

L1

T2

SOFT ST

AR

T

WA

AC

DC

DRI

VE

DRI

VER

SS

POWER

SOU

HF 

BO

AR

D

HFOU

T

HF

SOUI

N

AC

 DR

IV

E 

BO

AR

D

JB

ACPOUT

ACOUT

GD1

GD2

QF/HF

DI

SPL

AY

 BO

AR

D

J2 (10)

JB (10)

DCI

N

SOLENO

ID

POWER SUPPLY BOARD

POWER/FJ

DC-IN

DY2

DY1

8 PIN REM

OT

E

GUN

OT

TH

1

TH

2

NTCS

WV

WE

LD POSITIVE

WE

LD NEGATIVE

WE

LD POSITIVE

WE

LD NEGATIVE

EM

C

FI

LTER

CT

1

OC

MOD

FAN

240VAC

240VAC

0VAC

0VAC

220VAC

A-11227_AB

Summary of Contents for 202 AC/DC

Page 1: ...A 11401 202 AC DC Operating Manual Revision AB Issue Date August 6 2012 Manual No 0 5239 Operating Features inverter arc welding machine ...

Page 2: ...gize if there are any contained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance YOU ARE IN GOOD COMPAN...

Page 3: ...orley Lancaster England PR6 7BX www victortechnologies com Copyright 2012 by Victor Technologies 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 ...

Page 4: ...n 2 3 2 09 Duty Cycle 2 4 2 10 Optional Accessories 2 5 SECTION 3 INSTALLATION OPERATION AND SETUP 3 1 3 01 Environment 3 1 3 02 Location 3 1 3 03 Ventilation 3 1 3 04 Mains Supply Voltage Requirements 3 1 3 05 High Frequency Introduction 3 2 3 06 High Frequency Interference 3 2 3 07 Electromagnetic Compatibility 3 2 3 08 202 AC DC Power Source Controls Indicators and Features 3 4 3 09 202 AC DC S...

Page 5: ...W Welding Problems 4 13 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Basic Troubleshooting 5 1 5 02 Power Source Problems 5 1 5 03 Routine Service and Calibration Requirements 5 2 5 04 Cleaning the Welding Power Source 5 4 SECTION 6 KEY SPARE PARTS 6 1 6 01 Power Source 6 1 APPENDIX CIRCUIT DIAGRAM THERMAL ARC LIMITED WARRANTY TERMS TERMS OF WARRANTY JANUARY 2012 ...

Page 6: ......

Page 7: ...und 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 wo...

Page 8: ...Guide for Shade Numbers Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No Comfort Shielded Metal Arc Welding SMAW Less than 3 32 2 4 3 32 5 32 2 4 4 0 5 32 1 4 4 0 6 4 More than 1 4 6 4 Less than 60 60 160 160 250 250 550 7 8 10 11 10 12 14 Gas Metal Arc Welding GMAW and Flux Cored Arc Welding FCAW Less than 60 60 160 160 250 250 550 7 10 10 10 11 12 14 G...

Page 9: ... 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 ...

Page 10: ...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...

Page 11: ... 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 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 S...

Page 12: ... 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 Rating Auxiliary Power Art A 10663_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 Postflo...

Page 13: ...and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process Thi...

Page 14: ...202 AC DC SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS AND WARNINGS 1 8 Manual 0 5239 This Page Intentionally Blank ...

Page 15: ...ide back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 01 How To Use This Manual To ensure safe operation read the entire manual including the cha...

Page 16: ...s or replacements become necessary it is recommended that such re pairs be carried out by appropriately qualified persons approved by Thermal Arc Advice in this regard can be obtained by contacting an Accredited Thermal Arc Distributor This equipment or any of its parts should not be al tered from standard specification without prior written approval of Thermal Arc The user of this equipment shall...

Page 17: ...ut 40ºC 10 min 170A 15 26 8V 100A 60 24 0V 80A 100 23 2V TIG GTAW Welding Output 40ºC 10 min 200A 20 18V 116A 60 14 6V 90A 100 13 6V Open circuit voltage 70 3V DC 50 VAC Protection Class IP23S Table 2 1 202 AC DC Specification NOTE Note 1 The Effective Input Current should be used for the determination of cable size supply requirements Note 2 Generator Requirements at the Maximum Output Duty Cycle...

Page 18: ...ower Source is designed to operate at a 20 duty cycle 200 amperes at 18 0 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 The thermal cut out will operate i...

Page 19: ...s on page 2 5 3 01 Environment This machine is not designed for use in environments with increased hazard of electric shock as outlined in EN 60974 1 Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock Please refer to relevant local standards for further information prior to using in such areas A Examples of environments with incr...

Page 20: ... interference Looping and suspending of leads should be avoided wherever possible 4 Re Radiation from Unearthed Metallic Objects A major factor contributing to interference is re radiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent re radiation in most cases 3 07 Electromagnetic Compatibility WARNING Extra precautions for Electromagn...

Page 21: ...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 stabilising devices should be adjusted and maintained according to the manufacturer s recommendations 3 Welding Cables The welding cables should be ke...

Page 22: ...ope Base Current Peak Current Width Trough Current Frequency Down Slope Crater Current Post Flow WeldSkill PORTABLE WELDING MACHINE 200AC DC Inverter 8 1 2 3 4 A 11403 Iz Is I2 Ie I1 MODE PULSE PURGE PROCESS LIFT TIG V SEC Hz HF TIG STICK 2T 4T TRIGGER BACK FORWARD AC FREQUENCY WAVE BALANCE ARC FORCE Pre Flow Post Flow Initial Current Up Slope Down Slope Crater Current Base Current Frequency f w W...

Page 23: ...rminal Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal 4 Shielding Gas Outlet The Shielding Gas Outlet located on the front panel...

Page 24: ...de 2T Normal Mode In this mode the torch trigger must remain depressed for the welding output to be active Press and hold the torch trigger to activate the power source weld Release the torch trigger switch to cease welding A 11409 High Low Figure 3 3 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue In this mode the operator can press and release t...

Page 25: ...ress the PULSE button to toggle Pulse On and OFF in LIFT TIG and HF TIG modes 16 Programming Parameter Indicators These indicator lights will illuminate when programming 17 Mode Button Press the MODE button to toggle AC and DC output in LIFT TIG HF TIG and STICK 18 Digital Ammeter The digital amperage meter is used to display both the pre set current and actual output current of the power source A...

Page 26: ...itted with a cooling fan that will operate continuously when the On Off switch on the rear panel is switched to the On position 3 09 202 AC DC STICK Programming Mode Press the PROCESS button to select STICK mode Press the MODE switch to toggle between AC and DC welding output When AC is selected the frequency is fixed at 50Hz The Programming LED s are always active Press FORWARD or BACK to cycle t...

Page 27: ...ld current Base Current This parameter sets the TIG WELD current when PULSE is OFF This parameter also sets the STICK weld current Amps 5 to 170A DC STICK mode 10 to 170A AC STICK mode Arc Force STICK Mode only Arc Force is effective when in Manual Arc Mode only Arc Force control provides and adjustable amount of Arc Force or dig control This feature can be particularly beneficial in providing the...

Page 28: ...Low Current Hot Start t1 t2 202 A V Press to go forward go back between programming status LED s Adjust programming parameter using the Multi Function Control knob A 11405 Figure 3 6 LIFT TIG and HF TIG Programming Mode Programming Parameter Adjustment Device Display Pre Flow This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc once the to...

Page 29: ... weld current when in PULSE mode Amps 10 to 200A DC TIG mode 30 to 200A AC TIG mode Low Current The lowest point in the pulse is called the Low Current Amps 5 to 200A DC HF TIG mode 30 to 200A AC LIFT TIG mode 10 to 200A AC HF TIG mode Pulse Width This parameter sets the percentage on time of the PULSE FREQUENCY for High weld current when the PULSE is ON V SEC Hz Volts 15 to 80 Pulse Frequency Thi...

Page 30: ... and is used to set the frequency for the AC weld current V SEC Hz Volts 15 to 150 Hz Wave Balance This parameter operates in AC TIG mode and is used to set the penetration to cleaning action ratio for the AC weld current Generally WAVE BALANCE is set to 50 for AC STICK welding The WAVE BALANCE control changes the ratio of penetration to cleaning action of the AC TIG welding arc Maximum weld penet...

Page 31: ...cond In STICK mode if the electrode touches the work for more than two seconds the welding current is reduced to 0 Amps 3 12 Victor Regulator Pressure regulator Figure 3 7 attached to the cylinder valve reduce high cylinder pressures to suitable low working pressures for welding cutting and other applications LOW PRESSURE GAUGE DELIVERY HIGH PRESSURE GAUGE SUPPLY INLET CONNECTION OUTLET CONNECTION...

Page 32: ...e Make sure the pressure rating of the down stream equipment is compatible with the maximum delivery pressure of the regulator 5 Be sure that the regulator has the correct pressure rating and gas service for the cylinder used 6 Carefully inspect the regulator for damaged threads dirt dust grease oil or other flammable substances Remove dust and dirt with a clean cloth Be sure the inlet swivel filt...

Page 33: ...ssure gauge Art A 09828 Figure 3 9 Open Cylinder Valve 10 On all cylinders except acetylene open the valve completely to seal the valve packing On gaugeless regulators the indicator will register the cylinder contents open 11 On acetylene cylinders open the valve 3 4 of a turn and no more than 1 1 2 WARNING Acetylene delivery pressure must not exceed 15 PSIG 103 kPa or 30 PSIG 207 kPa Acetylene ca...

Page 34: ...the male plug being fused in the bayonet terminal D Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below The TIG torch will require a trigger switch to operate in Lift TIG or HF TIG Mode NOTE If the TIG torch has a remote TIG torch current control fitted then it will require to be connected to the 8 pin socket Refer to section 3 08 2 Rem...

Page 35: ...t Up Slope Down Slope Crater Current Base Current Frequency f w Width High Current Low Current Hot Start t1 t2 202 A V Figure 3 10 Setup for TIG Welding NOTE When the 202AC DC is used with a Remote Foot Control disconnect the foot control to allow max current to be previewed adjusted then re connect foot control max current that has been pre set will be output when foot control is fully depressed ...

Page 36: ... with the process selection control refer to Section 3 08 7 for further information WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the mains power supply is switched off CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source CAUTION Loose welding terminal conn...

Page 37: ... zone and under bead cracks in the weld area may be reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace B Manganese Steels The effect on manganese steel of slow cooling from high temperatures is to embrittle it For this reason it is absolutely essential to keep manganese st...

Page 38: ...ially suitable sheet metal lap joints and fillet welds general purpose plate welding Mild Steel E7018 A low hydrogen all position electrode used when quality is an issueorforhard to weldmetals Ithasthecapabilityofproducing more uniform weld metal which has better impact properties at low temperatures Cast Iron Eni Cl Suitable for joining all cast irons except white cast iron Stainless Steel E318L ...

Page 39: ...rt A 07695_AE Figure 4 9 Typical Joint Designs for Arc Welding Arc Welding Technique A Word to Beginners For those who have not yet done any welding the simplest way to commence is to run beads on a piece of scrap plate Use mild steel plate about 6 0mm thick and a 3 2mm electrode Clean any paint loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried ...

Page 40: ...e a neat weld soon becomes almost automatic You will find that a long arc produces more heat A very long arc produces a crackling or spluttering noise and the weld metal comes across in large irregular blobs The weld bead is flattened and spatter increases A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag...

Page 41: ...e When the joint is completely filled the back is either machined ground or gouged out to remove slag which may be trapped in the root and to prepare a suitable joint for depositing the backing run If a backing bar is used it is not usually necessary to remove this since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld B Fillet Welds These are welds ...

Page 42: ...hows the effects of pausing at the edge of weave and of weaving too rapidly Art A 07701 Figure 4 15 Single Run Vertical Fillet Weld Art A 07702 Figure 4 16 Multi Run Vertical Fillet Weld Art A 07703 Figure 4 17 Examples of Vertical Fillet Welds 2 Vertical Down Use a 3 2mm electrode at 100 amps The tip of the electrode is held in light contact with the work and the speed of downward travel is regul...

Page 43: ...elatively weak for example a butt joint in 2 0mm sheet the contracting weld metal may cause the sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone While welding is proceeding a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the ...

Page 44: ...components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some cases to tell from past experience or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structure By correct pre setting of the components to be welded constructional stres...

Page 45: ...joint B Use smaller diameter electrode C Insufficient gap C Allow wider gap 3 Non metallic par ticles are trapped in the weld metal A Non metallic particles may be trapped in undercut from previous run A If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode B Joint preparation too restricted B Allow for adequate penetration and room for cleaning out the s...

Page 46: ...n do not fuse to the surface of the metal or edge of the joint A Small electrodes used on heavy cold plate A Use larger electrodes and preheat the plate B Welding current is too low B Increase welding current C Wrong electrode angle C Adjust angle so the welding arc is directed more into the base metal D Travel speed of electrode is too high D Reduce travel speed of electrode E Scale or dirt on jo...

Page 47: ...y an electric arc that is established between a single tungsten non consumable electrode and the work piece Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based A filler metal may also be added manually in some circumstances depending on the welding application Welds Made With or Without Addition of Filler Metal Work Piece C...

Page 48: ...AC weld ing of aluminium magnesium and their alloys Self cleaning Long life Maintains balled end High current car rying capacity White Ceriated 2 AC DC welding of mild steel stainless steel copper alumin ium magnesium and their alloys Longer life More stable arc Easier starting Wider current range Narrower more concentrated arc Grey Table 4 5 Tungsten Electrode Types Base Metal Thickness AC Curren...

Page 49: ... is generally regarded as a specialised process that requires operator competency While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual For further information please refer to www victortechnologies com or contact Thermal Arc 4 04 TIG GTAW Welding Problems FAULT CAUSE...

Page 50: ... A Clean the electrode by grinding off the contaminates B Work piece surface has foreign material on it B Clean surface C Gas contaminated with air C Check gas lines for cuts and loose fitting or change gas cylinder 8 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for gas flow problems 9 Arc start is not smooth A Tungsten electrode is too large for the weld ing curre...

Page 51: ...ing arc cannot be established A B Primary control fuse is blown Broken connection in primary circuit A B Replace primary control fuse Have an Accredited Thermal Arc Service Provider check primary circuit 3 Fault Indicator is illuminated and unit will not commence welding when the torch trigger switch is depressed Duty cycle of power source has been exceeded Leave the power source switched ON and a...

Page 52: ... of the most recent inspection A transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated B Insulation Resistance Minimum insulation resistance for in service Thermal Arc Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5 2 below Power sources that do not meet the...

Page 53: ...y by a competent person to ensure that the equipment is in a safe and serviceable condition All unsafe accessories shall not be used F Repairs If any parts are damaged for any reason it is recommended that replacement be performed by an ac credited Thermal Arc Service Provider Power Source Calibration A Schedule Output testing of all Thermal Arc Inverter Power Sources and applicable accessories sh...

Page 54: ...libration certificates NATA certified laboratories shall be utilized 5 04 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product Do not attempt to open or repair unless you are a qualified electrical tradesperson Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling To clean the Welding Power Source open t...

Page 55: ...ARE PARTS 202 AC DC INVERTER Manual 0 5239 6 1 KEY SPARE PARTS SECTION 6 KEY SPARE PARTS 6 01 Power Source 1 2 3 4 5 6 7 8 10 13 14 16 9 11 A 11408 15 12 12 28 25 22 21 23 28 19 17 18 26 20 24 Figure 6 1 ...

Page 56: ...oupling HF 10 W7005512 Fan assembly 11 W7003033 Gas solenoid assembly 12 W7005513 Dinse Socket 50mm 13 W7003036 Control socket 8 pin 14 W7005514 Gas outlet front panel 15 W7005515 Switch On Off 16 W7003076 CT output 17 W7005511 Transformer 202AC DC 18 W7005510 Inductor 202AC DC 19 W7005534 Base Panel 20 W7005531 Front panel 21 W7005532 Rear panel 22 W7005535 Panel Top Cover 23 W7005605 Gas inlet f...

Page 57: ... TERMINALS DC BOARD SW1 C1 R2 C4 C2 D2 D4 R4 C6 Q3 G3 Q4 G4 C7 C8 L1 T2 SOFT START WA AC DC DRIVE DRIVER SS POWER SOU HF BOARD HFOUT HF SOUIN AC DRIVE BOARD JB ACPOUT ACOUT GD1 GD2 QF HF DISPLAY BOARD J2 10 JB 10 DCIN SOLENOID POWER SUPPLY BOARD POWER FJ DC IN DY2 DY1 8 PIN REMOTE GUN OT TH1 TH2 NTCS WV WELD POSITIVE WELD NEGATIVE WELD POSITIVE WELD NEGATIVE EMC FILTER CT1 OC MOD FAN 240VAC 240VAC...

Page 58: ......

Page 59: ...or Technologies s own service person nel or with prior written consent obtained from Victor Technologies Service Department UK Equipment that has been used beyond the specifications established in the operating manual Installation not in accordance with the installation operating manual Any product that has been subjected to abuse misuse negligence or accident improper care and or maintenance incl...

Page 60: ...ng Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 676...

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