Thermal Arc 250TS DC CC Operating Manual Download Page 13 | Manualshive

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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. The power source is
totally enclosed in an impact resistant, flame resistant and non-conductive plastic case

250A

5A

(A)

(V)

OCV

STICK Process

250A

25A

(A)

(V)

OCV

10V

250A

(A)

(V)

OCV

1A

LIFT TIG Process

HF TIG Process

Figure 1. Model 250TS volt-ampere curve

Note 1

Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the
welding power source. Curves of other settings will fall between the curves shown.

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Summary of Contents for 250TS DC CC

Page 1: ...November 11 2003 Manual No 430429 507 INVERTER ARC WELDER MODEL 250TS DC CC STICK TIG Lift Start TIG HF Start OPERATING MANUAL ...

Page 2: ......

Page 3: ...04 Weld Parameters for Pro Lite 250TS 27 4 05 Power Source Features 28 5 0 SET UP FOR SMAW STICK AND GTAW TIG 29 6 0 SEQUENCE OF OPERATION 30 6 01 Stick Welding 31 6 02 HF TIG Lift TIG Welding 32 6 02 01 Slope Mode Sequence 33 6 02 02 Slope Mode with repeat sequence 33 6 02 03 Pulse Controls 34 7 0 BASIC TIG WELDING GUIDE 35 7 01Electrode Polarity 35 7 02 Tungsten Electrode Current Ranges 35 7 03 ...

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: ...ICES 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 ...

Page 10: ...er 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 travail ou des autres parties du circuit de souda...

Page 11: ...uits 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 consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes s...

Page 12: ... 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 disponible auprès de l Association Na...

Page 13: ...gsten Arc Welding GTAW Gas Tungsten Arc Welding Pulse GTAW P Gas Tungsten Arc Welding Sloped GTSW S 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 STICK Process 250A 25A A V OCV 10V 250A A V OCV 1A LIFT TIG Process HF TIG Process Figure 1 Model 250TS volt ampere curve Note 1 V...

Page 14: ...ses 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 o...

Page 15: ...bly 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 dus...

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 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 Figure 3 Electrical Input Connections ...

Page 18: ...te the available input power Damage to the PCA could occur if 575VAC or higher is applied The following 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 Factory Fitted Minimum Primary Current Circuit Size Vin Amps TIG STICK 208 24 230 21 460 11 250A 40 208 35 230 32 3φ 460...

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: ... 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 witho...

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...

Page 22: ...22 PAGE LEFT INTENTIONALLY BLANK ...

Page 23: ...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 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 clockwise ...

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: ...Yes Yes 4T operation in TIG Modes with crater fill using a remote contactor device to control sequence REPEAT No Yes Yes 4T operation in TIG Modes with repeat operation and crater fill using a remote contactor device SPOT No Yes No 2T operation spot welding in HF TIG using a remote contactor device PULSE ON OFF No Yes Yes Pulse operation in TIG Modes Table 3 Weld Process selection verses Weld Mode...

Page 26: ...zone in TIG modes or improve the start characteristics for stick electrodes e g low hydrogen electrodes It sets the peak start current on top of the BASE WELD current e g HOT START current 130 amps when BASE WELD 100 amps HOT START 30 amps INITIAL CUR This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the start current for TIG The Start Current remains on until the tor...

Page 27: ...G modes only and is used to set the finish current for TIG The CRATER Current remains on until the torch trigger switch is released after it has been depressed POST FLOW This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished This control is used to dramatically reduce oxidation of the tungsten electrode Table 4 Weld Parameter Descriptio...

Page 28: ... 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 not in use Eliminates the need for add on voltage reducers and has no effect on arc starting VRD fully complies to IEC 60974 1 When Stick mode is ...

Page 29: ...ecting 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 Remove any packaging material prior Remove any packaging material prior Remove any packaging material prior to use Do not block the air vents at to use Do not block the air vents at to use Do not block the air vents a...

Page 30: ...G function modes Standard Slope Slope w repeat Spot 4 Digital 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 5 Control knob allows the operator to adjust the output amperage within the entire range of the power ...

Page 31: ...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 Use the control knob to adjust each parameter Set HOT START Set WELD current Commence welding ...

Page 32: ...e 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 Use the control knob to adjust each parameter Set PRE FLOW time Set HOT START current Set POST FLOW time Set WELD current Set POST FLOW time Slope Mode Parameters if required Set INTIAL CUR current Set UP SLOPE time Set WELD PEAK CUR current Set BASE current Set DOW...

Page 33: ...nt as long as the remote switch contacts are open 3 Close Remote Switch Welding current decreases to final current setting Once final welding current is reached the power source will maintain final current setting as long as the remote switch contacts are closed 4 Open Remote Switch Welding arc stops and post flow begins 6 02 02 Slope Mode with repeat sequence The repeat function is operated durin...

Page 34: ...ng the periods of Peak current heating and fusion takes place and during the background base current periods cooling and solidification take place Pulse Width is the time in one cycle the current stays at the peak current setting Pulse Frequency measured in Hertz is the number of cycles per second the current travels between peak and background current settings It is as if the foot rheostat were m...

Page 35: ...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 7 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 36: ...pplication 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 10 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 37: ... 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 38: ...en 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 applications There are ...

Page 39: ...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 13 Types of Electrodes ...

Page 40: ...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 41: ...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 42: ...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 43: ...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 44: ...ltage 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 is cut Gas passage contains impurities A B Replace gas hos...

Page 45: ... Thermal Arc Service Agent replace gas valve C Gas valve jammed open C Have an Accredited Thermal Arc Service Agent repair or replace gas valve D POST FLOW control is set to 60 sec D Reduce POST FLOW time 6 The TIG electrode has been contaminated due to the gas flow shutting off before the programmed POST FLOW time has elapsed The Weld Process Mode STICK HF TIG or LIFT TIG was changed before POST ...

Page 46: ...e 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 per...

Page 47: ...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 48: ...ayed 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 Error code E12...

Page 49: ...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 50: ... 10 6735 D2 Diode DBA200UA40 1 4582A0040 10 6687 D3 Diode DBA200UA40 1 4582A0040 10 6687 D4 Diode DBA200UA40 1 4582A0040 10 6687 D5 Diode DBA200UA40 1 4582A0040 10 6687 FAN1 Fan 109E5724H507 DC 24V 16 8W 1 U0A733500 10 6839 FCH1 Inductor F2A676900 250A TIG FCH 1 F2A676900 10 6760 HCT1 Current Sensor HC TN200V4B15M 200A 4V 1 11251003000 10 5003 HF UNIT1 HF Unit HF UNIT WK 4840 U02 1 U0A632200 10 66...

Page 51: ...ed Circuit Board WK 4917 U04 FILTER 480V 1 P0A491704 10 6740 PCB10 Printed Circuit Board WK 5019 U01 CAP PCB 1 P0A501901 10 6741 PCB11 Printed Circuit Board WK 4923 U01 B RELAY PCB 1 P0A492301 10 6742 Q1 Transistor CM100DUS12F 1 600V 100A with WK 5012 U01 1 U0A705300 10 6642 Q2 Transistor CM100DUS12F 1 600V 100A with WK 5012 U01 1 U0A705300 10 6642 R1 Resistor ERF20HMJ151 20W 150 Ω 1 40310211500 1...

Page 52: ...with Caution Label 1 U0A705600 10 6655 PCB Sheet EBA618000 For PCB11 1 EBA618000 10 6747 CC Sheet EBA554200 1 EBA554200 10 6763 Name Label N4A007800 2 N4A007800 10 6764 Side Label N4A009200 2 N4A009200 10 6657 VRD Label N4A155900 1 N4A155900 REF ONLY Warranty Label N4A155800 1 N4A155800 REF ONLY Warning Label 1 N0B891300 1 N0B891300 10 5497 Warning Label 2 N0B476400 1 N0B476400 10 5496 Output Term...

Page 53: ... 2 EBA431300 10 6672 Post7 M5 M5 EBA435900 1 EBA435900 10 6673 Post9 M5 M5 EBA491700 4 EBA491700 10 6750 Post11 M5 M5 EBA643600 3 EBA643600 10 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 606024220000 10 5...

Page 54: ...54 APPENDIX A INTERCONNECT DIAGRAM ...

Page 55: ...55 ...

Page 56: ...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 57: ...57 Figure 11 Location of PCB WK 4921 ...

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