Thermal Arc 95S Operating Manual Download Page 1

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Art # A-08597_AB

THERMAL ARC

INVERTER ARC WELDER

95 S

Operating

Manual

Revision: AB

Issue Date: March 26, 2009

Manual No.: 0-5086

Operating Features:

Summary of Contents for 95S

Page 1: ...50 60 Hz Art A 08597_AB THERMAL ARC INVERTER ARC WELDER 95 S Operating Manual Revision AB Issue Date March 26 2009 Manual No 0 5086 Operating Features...

Page 2: ...recautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide ThermalArci...

Page 3: ...tries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2009 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or i...

Page 4: ...ut Connections 3 1 3 04 Electromagnetic Compatibility 3 4 3 05 Setup for Welding 3 5 3 06 STICK SMAW Setup 3 6 3 07 Lift TIG GTAW Setup 3 7 SECTION 4 OPERATION 4 1 4 01 Front Panel 4 1 4 02 SMAW Elect...

Page 5: ...TICK Welding Problems 5 2 5 03 TIG Welding Problems 5 3 5 04 Power Source Problems 5 4 APPENDIX 1 REPLACEMENT PARTS A 1 APPENDIX 2 OPTIONS AND ACCESSORIES A 2 APPENDIX 3 system schematic A 3 LIMITED W...

Page 6: ......

Page 7: ...t 14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays fro...

Page 8: ...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 weldin...

Page 9: ...harmful exhaust gases 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes WARNING ENGINE FUEL can cause...

Page 10: ...offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or...

Page 11: ...c Welding GMAW 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...

Page 12: ...ement des galets d entrainement et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux 1...

Page 13: ...e d graissage de nettoy age ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants 7 Ne soudez des t les galvanis es ou...

Page 14: ...m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approu v es Des crans lat raux sont recommand s 2 Portez des v...

Page 15: ...nt de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT S...

Page 16: ...ge Intensit de Courant Tension Hertz cycles sec Fr quence N gatif Positif Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Ar...

Page 17: ...hipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in...

Page 18: ...4 kg Welding Power Source Dimensions Height x Width x Depth H 13 0 x W 5 1 x D 9 0 H 330mm x W 130mm x D 230mm The recommended time delay fuse or circuit breaker size is 30 amp An individual branch c...

Page 19: ...o abnormal vibration or shock In areas not exposed to direct sunlight or rain Place at a distance of 12 300mm or more from walls or similar that could restrict natural air flow for cooling WARNING The...

Page 20: ...t Connections CAUTION The time delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when welding with this product due to the amperage rating of the time delay fus...

Page 21: ...y PCA will turn on after the input capacitors have charged to operating voltage after approximately 5 seconds NOTE Damage to the PCA could occur if 133 VAC or higher is applied to the Primary Power Ca...

Page 22: ...dditional protection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend...

Page 23: ...he surrounding area may alleviate problems of interference Screening the entire welding installation may be considered for special applications 3 05 Setup for Welding NOTE Conventional operating proce...

Page 24: ...recommendations 3 06 STICK SMAW Setup 3 Connect the ground clamp to your workpiece 4 Plug the power cable into the appropriate outlet and turn the switch to the ON position The power L E D light shou...

Page 25: ...the cylinder valve while standing off to the side of the valve This will remove any debris that may be around the valve regulator seat area 4 Install the regulator and tighten with a wrench 5 Connect...

Page 26: ...roximately 1 8 to sticking out from the gas cup ensuring you have correct sized collet 13 Tighten the back cap 14 You are now ready to begin TIG Welding NOTE Open the gas valve on TIG torch handle and...

Page 27: ...TIG and STICK Welding modes B Power On Indicator The Power ON Indicator illuminates when the ON OFF switch is in the ON position and the nominal mains voltage is present C Over Heat Indicator The weld...

Page 28: ...t factor is the high rate of heat conductivity of copper making pre heating of heavy sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc Welding electrodes are clas...

Page 29: ...16 1 6mm 13 CFH 6 LPM Butt Corner 50 60 35 50 Lap Filler 1 16 1 6mm 60 70 40 60 1 16 1 6mm 1 16 1 6mm 15 CFH 7 LPM Butt Corner 70 90 50 70 Lap Filler 1 8 3 2mm 80 100 65 85 1 16 1 16mm 3 32 2 4mm 15C...

Page 30: ...in flat horizontal vertical and overhead positions Numerous applications call for welds to be made in positions intermediate between these Some of the common types of welds are shown in Figures 4 2 t...

Page 31: ...ug Weld Not less than 70 Single Vee Butt Joint Not less than 45 1 16 1 6mm max Art A 07695_AB 4 12 Joint Preparations In many cases it will be possible to weld steel sections without any special prepa...

Page 32: ...along the plate surface in the same way as a match is struck As soon as the arc is established maintain a 1 16 1 6mm to 1 8 3 2mm gap between the burning electrode end and the parent metal Draw the el...

Page 33: ...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 prop...

Page 34: ...ip of the electrode just keeps ahead of the slag The electrode should point upwards at an angle of about 45 3 Overhead Welds Apart from the rather awkward position necessary overhead welding is not mu...

Page 35: ...three dimensions In a welded joint the metal becomes attached to the side of the joint and cannot contract freely Therefore cooling causes the weld metal to flow plastically that is the weld itself ha...

Page 36: ...eted the sections b and c will contract at a similar rate thus reducing distortion Art A 07707 Figure 4 22 Principle of presetting Art A 07708 B Preheat Preheat Dotted lines show effect if no preheat...

Page 37: ...with solvents that are recommended for cleaning electrical apparatus CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with...

Page 38: ...rent B Use smaller diameter electrode C Allow wider gap D Use correct build up sequence 4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint A Small electrodes used...

Page 39: ...grinding contaminates off B 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 problems 9 Arc flutter...

Page 40: ...ode Current Ranges for the correct size B Refer to section Tungsten Electrode Types for the correct electrode type C Select the correct flow rate for the welding job D Use 100 argon for TIG welding E...

Page 41: ...rent Sensor 95S W7003013 Thermistor 95S W7003016 Terminal Output 95S W7003019 Handle 95S W7003040 Knob Control Red 20 OD x 6 ID W7003041 Panel Base 95S W7003042 Panel Cover 95S W7003043 Panel Front 95...

Page 42: ...UNF Hose Connection 600300 Power Adapter 115V 20A Socket to 15A Plug W4013300 USA Graphics Auto Darkening welding helmet spare cover lens and operating manual W4011700 Canadian Graphics Auto Darkenin...

Page 43: ...Manual 0 5086 APPENDIX 3 system schematic AC 1 AC 3 2 4 24V L TRANS2 OC Pr2 OC1 OC2 Pr1 DR1 DR2 DR5 DR6 DR3 DR4 DR7 DR8 DR1 DR2 DR3 DR4 DR5 DR8 DR6 DR7 OC1 OC2 K1 AC115V 60HZ OUT OUT FAN LED1 LED2 VR1...

Page 44: ...THERMAL ARC 95 S APPENDIX Manual 0 5086 A 4 Appendix This Page Intentionally Blank...

Page 45: ...ing out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or rep...

Page 46: ...STP Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years 3 years All other original circuits and components including bu...

Page 47: ...strict Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul E...

Page 48: ...World Headquarters Thermadyne Holdings Corporation Suite 300 16052 Swingley Ridge Road St Louis MO 63017 Telephone 636 728 3000 FAX 636 728 3010 Email sales thermalarc com www thermalarc com...

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