Thermal Arc 250S DC CC Operating Manual Download Page 1

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November 11, 2003

Manual No. 430429-506

INVERTER

ARC

WELDER

MODEL 250S DC CC

STICK

TIG - Lift Start

OPERATING MANUAL

Summary of Contents for 250S DC CC

Page 1: ...November 11 2003 Manual No 430429 506 INVERTER ARC WELDER MODEL 250S DC CC STICK TIG Lift Start OPERATING MANUAL ...

Page 2: ......

Page 3: ...Parameter Description 25 4 03 Weld Parameters for Pro Lite 250S 26 4 04 Power Source Features 26 5 0 SET UP FOR SMAW STICK AND GTAW TIG 28 6 0 SEQUENCE OF OPERATION 29 6 01 Stick Welding 30 6 02 DC LIFT TIG Welding 30 7 0 BASIC TIG WELDING GUIDE 31 7 01Electrode Polarity 31 7 02 Tungsten Electrode Current Ranges 31 7 03 Tungsten Electrode Types 31 7 04 Guide for Selecting Filler Wire Diameter 32 7...

Page 4: ...4 PAGE LEFT INTENTIONALLY BLANK ...

Page 5: ...Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current Gas Post Flow Standard Function Gas Pre Flow Slope Function VRD Voltage Reduction Device Circuit Slope W Repeat Function Negative Spot Function Positive Impulse Starting High Frequency GTAW Gas Input Touch Start Lift Start TIG circuit GTAW Gas Output ...

Page 6: ...Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty i...

Page 7: ...of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are usin...

Page 8: ...n this manual ARC WELDING RAYS Arc Welding Cutting Rays can injure your eyes and burn your skin The arc welding cutting process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other p...

Page 9: ...CES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note a...

Page 10: ...ECTRIQUE 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 voire mortels pour l opérateur et les autres personnes sur le lieu de travail Ne touchez jamais une pièce sous tension ou vive portez des gants et des vêtements secs Isolez vous de la pièce de trava...

Page 11: ...iter une perte permanente de l ouïe Pour protéger votre ouïe contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Protégez également les autres personnes se trouvant sur le lieu de travail Il faut mesurer les niveaux sonores afin d assurer que les décibels le bruit ne dépassent pas les niveaux sûrs Pour des renseignements sur la manière de tester le bruit consu...

Page 12: ...INDRES disponible auprès de l Association des Gaz Comprimés Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA W117 2 CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE disponible auprès de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 ivret NWSA BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE disponib...

Page 13: ...r use with Gas Tungsten Arc Welding GTAW and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resistant flame resistant and non conductive plastic case 250A 5A A V OCV 18V 270A 160A STICK Process LIFT TIG Process Figure 1 Model 250S volt ampere curve Note 1 Volt Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power s...

Page 14: ...poses 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 WARNING 2 FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift unit with handle on top of case Use handcart or similar device of adequate capacity If using a fork lift vehicle place and secure unit...

Page 15: ...ly reduces the skin resistance of the human body and the insulation properties of accessories Environments with hazardous environments do not include places where electrically conductive parts in the near vicinity of the operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines In areas free from moisture and dust...

Page 16: ...ection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit Note 2 These units are equipped with a three conductor with earth power cable that is connected at the welding power source end for single and three phase electrical input power Do not connect an in...

Page 17: ...70 460 20 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 ...

Page 18: ... power Damage to the PCA could occur if 575VAC or higher is applied The following 208 230 460V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment Current Duty Cycle Model Primary Supply Lead Size Minimum Primary Current Circuit Size Vin Phase Amps TIG STICK 208 3 24 230 3 21 460 3 11 250A 40 208 3 35 230 3 32 8 4 AWG minimu...

Page 19: ...ine can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded Transmission via the Supply Lead Without adequate shielding and filtering high frequency energy may be fed to the wiring within the installation main...

Page 20: ...30V 40 40 12 5 15 7 9 4 9 4 Output No Load KVA KW 0 5 0 5 0 13 0 13 Input Volts Three Phase 208V 230V 460V Input Volts Single Phase 208V 230V 460V Amperage Draw Rated Load 35 32 16 75 68 No Load 1 3 1 1 0 7 2 2 1 6 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 wi...

Page 21: ... the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature CAUTION 1 Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty NOTE 5 Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities...

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Page 23: ...he 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 2 Remote Control Socket The 8 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source To make connections align keyway insert plug and rotate threaded collar fully clockwi...

Page 24: ...on 4 Negative Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION 2 Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 5 ON OFF Switch This switch connects the Primary su...

Page 25: ...ak start current on top of the WELD current A Weld Current Amperage sets the STICK and TIG WELD current ARC CONTROL This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability LIFT TIG mode of operation A remote control device is required for use during LIFT TIG operation See section 4 01 section 2 Remote Control Socket for complete det...

Page 26: ...ligent cooling system is designed to reduce dust and foreign material build up whilst providing optimum cooling Fan speed reduces approximately 30 seconds after machine is turned on Fan speed increases when internal components reaches operating temperature ON OFF switch Primary voltage Supply ON OFF switch located on rear panel Voltage Reduction Device VRD Reduces the OCV when the power supply is ...

Page 27: ...ure 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 ...

Page 28: ... in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application Figure 6 250S Set up WARNING 7 Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off CAUTION 3 Remove any packaging material prior to use Do Remove any packaging mate...

Page 29: ...LED display Welding amperage and parameter values are displayed in this window Internal warnings such as over temperature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen 3 Control knob allows the operator to adjust the output amperage within the entire range of the power source also used to set each parameter value 4 Process Button ...

Page 30: ... Set Arc Control Commence welding 6 02 DC 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 operation See section 4 01 section 2 Remote Control Socket for complete details of the remote device Use the Scroll Buttons to move to the...

Page 31: ...0 040 1 0mm 30 60 1 16 1 6mm 60 115 3 32 2 4mm 100 165 1 8 3 2mm 135 200 5 32 4 0mm 190 280 3 16 4 8mm 250 340 Table 4 Current ranges for varies tungsten electrode sizes 7 03 Tungsten Electrode Types Electrode Type Ground Finish Welding Application Features Color Code Thoriated 2 DC welding of mild steel stainless steel and copper Excellent arc starting Long life High current carrying capacity Red...

Page 32: ...application 7 05 Shielding Gas Selection Alloy Shielding Gas Aluminium alloys Argon Carbon Steel Argon Stainless Steel Argon Nickel Alloy Argon Copper Argon Titanium Argon Table 7 Shielding gas selection 7 06 TIG Welding Parameters for Low Carbon Low Alloy Steel Pipe Electrode Type Diameter Current Range DC Amperes Filler Rod for Root Pass Joint Preparation Thoriated 2 3 32 2 4 mm 120 170 Yes Thor...

Page 33: ... 1 6mm 5 7 Lap Fillet 45 55 30 45 Butt Corner 0 045 1 2mm 50 60 35 50 0 040 1 0mm 1 16 1 6mm 5 7 Lap Fillet 60 70 40 60 Butt Corner 1 16 1 6mm 70 90 50 70 1 16 1 6mm 1 16 1 6mm 7 Lap Fillet 80 100 65 85 Butt Corner 1 8 3 2mm 90 115 90 110 1 16 1 6mm 3 32 2 4mm 7 Lap Fillet 115 135 100 125 Butt Corner 3 16 4 8mm 140 165 125 150 3 32 2 4mm 1 8 3 2mm 10 Lap Fillet 160 175 135 160 Butt Corner 6 4mm 17...

Page 34: ... be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron Copper and alloys The most important factor is the high rate of heat conductivity of copper making preheating of heavy sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their appli...

Page 35: ...r taps and valves water trough float arms etc Also for joining copper to steel and for bronze overlays on steel shafts High Alloy Steels Dissimilar Metals Crack Resistance All Hard To Weld Jobs 312 16 It will weld most problematical jobs such as springs shafts broken joins mild steel to stainless and alloy steels Not suitable for Aluminum Table 10 Types of Electrodes ...

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Page 37: ...dent on the selection of the correct consumables maintenance of equipment and proper welding technique Description Possible Cause Remedy 1 Excessive bead build up or poor penetration or poor fusion at edges of weld Welding current is too low Increase weld current and or faulty joint preparation 2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through Welding current is ...

Page 38: ...f E Turn on F Torch valve is turned off F Turn on G The electrode is too small for the welding current G Increase electrode diameter or reduce the welding current 9 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for gas flow problems 10 Arc flutters during TIG welding A Tungsten electrode is too large for the welding current A Select the right size electrode Refer to...

Page 39: ...voids in weld metal Porosity A B C Electrodes are damp Welding current is too high Surface impurities such as oil grease paint etc A B C Dry electrodes before use Reduce welding current Clean joint before welding 2 Crack occurring in weld metal soon after solidification commences A B C Rigidity of joint Insufficient throat thickness Cooling rate is too high A B C Redesign to relieve weld joint of ...

Page 40: ...may be trapped in undercut from previous run A If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode B Joint preparation too restricted B Allow for adequate penetration and room for cleaning out the slag C Irregular deposits allow slag to be trapped C If very bad chip or grind out irregularities D Lack of penetration with slag trapped beneath weld bead D ...

Page 41: ...g current can not be achieved with nominal Mains supply voltage Defective control circuit Have an Accredited Thermal Arc Service Agent inspect then repair the welder 3 Welding current reduces when welding Poor work lead connection to the work piece Ensure that the work lead has a positive electrical connection to the work piece 4 No gas flow when the torch trigger switch is depressed A B Gas hose ...

Page 42: ...every 3 months and b For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests Note 7 A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated In addition to the above tests and specifically in relation to the VRD fitted to this machine the following perio...

Page 43: ...diodes is greater than 80ºC for about 1 second A B C The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked A B C Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Weld current ceases Buzzer sounds constantly Fan operat...

Page 44: ...or code displayed Under mains supply input voltage primary capacitors is reduced for one second Mains supply voltage is down to a dangerously low level A B Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Have an Accredited Thermal Arc Service Agent or a qualified electrician check the primary cable fuses Weld current ceases Buzzer sounds constantly E...

Page 45: ...ases Buzzer sounds constantly Switch machine off 11 E94 error code displayed Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit The Welding Power Source s temperature sensors have malfunctioned Have an Accredited Thermal Arc Service Agent check or replace the temperature sensors Weld current ceases Buzzer sounds constantly Switch machine off 12 E99 error code disp...

Page 46: ...200V4B15M 200A 4V 1 11251003000 10 5003 PCB1 Printed Circuit Board WK 4914 U02 MAIN_PCB with Insulation Sheet EBA501500 with Thunder Label 1 U0A674900 10 6737 PCB2 Printed Circuit Board WK 4819 U01 DETECT PCB 1 P0A481901 10 6635 PCB3 Printed Circuit Board WK 4921 U02 CONNECT PCB 1 P0A492102 10 6636 PCB4 Printed Circuit Board WK 4915 U02 2ND DIODE with Thunder Label 1 U0A722000 10 6738 PCB5 Printed...

Page 47: ...2 Transistor CM100DUS12F 1 600V 100A with WK 5012 U01 1 U0A705300 10 6642 S1 Switch DCP 103SR100C 480V 3P 1 25850003700 10 6857 S2 Switch SDKGA4 A 1 A 250V 5A 1 24704531400 10 5222 T1 Transformer F2A767200 250A MTR HV 1 F2A767200 10 6744 T2 Transformer F2A767200 250A MTR HV 1 F2A767200 10 6744 TH1 2 Thermistor ERTA53D203 20K 25ºC B 3950K 1 U0A733300 10 6784 ...

Page 48: ...BA618000 For PCB11 1 EBA618000 10 6747 Name Label N4A056000 2 N4A056000 10 6746 Side Label N4A009200 2 N4A009200 10 6657 Warning Label 1 N0B891300 1 N0B891300 10 5497 Warning Label 2 N0B476400 1 N0B476400 10 5496 Output Terminal Label N4A040300 1 N4A040300 10 6748 Output Terminal female TRAK BE35 70S 2 26999025900 10 6660 Input Cable SOOW AWG8X4C L 3 4m 1 U0A722400 REF ONLY Input Cable Clamp EBA04...

Page 49: ... 6751 D2 5 Bus Bar EBA366300 1 EBA366300 10 6752 CC Bus Bar EBA707600 1 EBA707600 10 6753 S1 Bus Bar ECA321000 3 ECA321000 10 6868 Output Bus Bar1 EBA456400 1 EBA456400 10 6754 Output Bus Bar2 EBA456600 1 EBA456600 10 6755 Clip 74 NATURAL 4 606024220 10 5259 Transformer Chassis JCA903200 1 JCA903200 10 6678 Right Chassis J2C970700 1 J2C970700 10 6679 Left Chassis J2C970800 1 J2C970800 10 6680 Outp...

Page 50: ...50 APPENDIX A INTERCONNECT DIAGRAM ...

Page 51: ...51 ...

Page 52: ...hipped from the factory with the jumpers set in position A This is for normal semi automatic operation utilizing a remote device such as a foot control The 8 pin remote operates as described earlier in this manual Placing all jumpers in position B would be primarily used for automation with an arc establish relay remote amperage and contactor An arc establish signal is located from pins 4 and 8 wh...

Page 53: ...53 Figure 11 Location of PCB WK 4921 ...

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