Thermal Arc 250S DC CC, Operating Manual

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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 ...................................................................................................................................... 11
2.0 INTRODUCTION AND DESCRIPTION ................................................................................................................... 13
2.01 Description ............................................................................................................................................................. 13
2.02 Functional Block Diagrams .................................................................................................................................... 14
2.03 Transporting Methods............................................................................................................................................. 14
3.0 INSTALLATION RECOMMENDATIONS................................................................................................................ 15
3.01 Environment ........................................................................................................................................................... 15
3.02 Location.................................................................................................................................................................. 15
3.03 Electrical Input Connections................................................................................................................................... 16
3.03.01 Electrical Input Requirements ....................................................................................................................... 16
3.03.02 Input Power ................................................................................................................................................... 18
3.03.03 High Frequency Introduction......................................................................................................................... 19
3.03.04 High Frequency Interference ......................................................................................................................... 19
3.04 Specifications ......................................................................................................................................................... 20
3.05 Duty Cycle.............................................................................................................................................................. 21
4.0 OPERATOR CONTROLS ........................................................................................................................................... 23
4.01 Pro-Lite 250S Controls ........................................................................................................................................... 23
4.02 Weld 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
7.05 Shielding Gas Selection.......................................................................................................................................... 32
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ...................................................................... 32
7.07 Welding Parameters for Steel ................................................................................................................................. 33
8.0 BASIC ARC WELDING GUIDE ................................................................................................................................ 34
8.01Electrode Polarity .................................................................................................................................................... 34
8.02 Effects of Stick Welding Various Materials ........................................................................................................... 34
9.0 BASIC TROUBLESHOOTING................................................................................................................................... 37
9.01 TIG Welding Problems........................................................................................................................................... 37
9.02 Stick Welding Problems ......................................................................................................................................... 39
9.03 Power Source Problems.......................................................................................................................................... 41
10.0 VOLTAGE REDUCTION DEVICE (VRD).............................................................................................................. 42
10.01 VRD Specification................................................................................................................................................ 42
10.02 VRD Maintenance ................................................................................................................................................ 42
11.0 POWER SOURCE ERROR CODES ......................................................................................................................... 43
12.0 PARTS LIST .............................................................................................................................................................. 46
APPENDIX A - INTERCONNECT DIAGRAM............................................................................................................... 50
APPENDIX B - AUTOMATION ...................................................................................................................................... 52