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VIKING WELDER

Manual No. 0-2538

First Edition

July 1996

Operating Manual

Models 210/250GM CV/DC

MIG Power Supplies

Summary of Contents for Viking 210GM

Page 1: ...VIKING WELDER Manual No 0 2538 First Edition July 1996 Operating Manual Models 210 250GM CV DC MIG Power Supplies...

Page 2: ...anual Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1996 Thermal Dynamics Corporation All rights reserved Reproduction of t...

Page 3: ...s 13 4 INSTALLATION RECOMMENDATIONS 13 4 1 Environment 13 4 2 Location 13 4 3 Ventilation 14 4 4 Mains Supply Voltage Requirements 14 4 5 Alternative Mains Supply Voltages 14 5 SET UP FOR COMPACT VIKI...

Page 4: ...10 1 Setting of the Power Source 24 10 2 Position of MIG Torch 24 10 3 Distance from the MIG Torch Nozzle to the Work Piece 24 10 4 Travel Speed 24 10 5 Electrode Wire Size Selection 24 10 6 Stitch We...

Page 5: ...ig torch nozzles 22 Table 8 Mig torch conduits 22 Table 9 0 9mm 035 1 2mm 045 wire deposition rate 25 FIGURES Figure 1 Viking duty cycle curves 10 Figure 2 Voltage settings for Viking 210GM 250GM 15 F...

Page 6: ...nd gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases f...

Page 7: ...rovide a fire watch when working in an area where fire hazards may exist NOISE Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed safe limits You must protect...

Page 8: ...550 N W LeJeune Rd Miami FL 33126 8 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy...

Page 9: ...tion AVERTISSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 5 Prec...

Page 10: ...m e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 7 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter l...

Page 11: ...sque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un...

Page 12: ...Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA...

Page 13: ...hall not except as expressly provided herein exceed the price of the goods upon which such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAI...

Page 14: ...trically in accordance with local regulations iii Excessive heat in the welding cables may cause fire Never weld with poor electrical connections damaged welding cables or exceed the welding cable cur...

Page 15: ...age or improper repair by anyone other than appropriately qualified persons approved by THERMAL DYNAMICS 2 5 Duty Cycle The rated duty cycle of a welding Power Source is the operating time it may be u...

Page 16: ...utput 8 3kVA 8 3kVA 8 3kVA 8 3kVA 11 2kVA 11 2kVA 11 2kVA 11 2kVA Supply Watts max output 7060W 7060W 7060W 7060W 9450W 9450 W 9450W 9450W Machine Efficiency max output 57 57 57 57 58 58 58 58 Power F...

Page 17: ...0 1 2mm 045 Flux Cored 0 8mm 030 0 9mm 035 1 2mm 045 Operating Temperature Range 00 to 400 C 320 F to 1040 F Wire Spool Size 15Kg Maximum Spot Time Range 0 to 2 3 Seconds Stitch on Time 0 to 2 3 Secon...

Page 18: ...tting or lying position with physical contact with conductive parts ii In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or acci...

Page 19: ...for the following Mains supply voltages Machine Mains Supply Lead Size Lead Current Rating Lead Length Machine Voltage Setting Duty Cycle Viking210GM 10 3213 10 AWG 30 Amps 3 metre 10ft 230V 210A 40...

Page 20: ...wire size marking facing outwards h Fit the electrode wire spool to the wire reel hub located behind the electrode wire compartment door Ensure that the drive dog pin engages the mating hole in the wi...

Page 21: ...Viking 210GM 250GM 16 6 WELDING GUIDE VIKING 210GM...

Page 22: ...Viking 210GM 250GM 17 7 WELDING GUIDE VIKING 250GM...

Page 23: ...Switch The Coarse Voltage Control switch turns off the fan and auxiliary power in the STANDBY position It sets the voltage level to the welding terminals in the remaining positions increasing the volt...

Page 24: ...The critical component for thermal protection is the rectifier stack which is fitted with a thermal overload cut out device If the overload operates then the machine should be left to cool for approxi...

Page 25: ...ler applies pressure to the grooved roller via screw adjustable spring pressure The adjustable spring screw should be adjusted to a minimum pressure that will provide satisfactory wire feed without sl...

Page 26: ...consumable parts See your THERMAL DYNAMICS distributor for details 1 2 3 4 5 6 7 22 23 8 14 9 13 12 10 11 18 17 15 16 Figure 6 Exploded view of MIG torch 9 2 MIG Torch Components Item Part No Descrip...

Page 27: ...7 9 5mm 3 8 EL22A37F 9 5mm 3 8 EL22CT37F 12 7mm 1 2 EL22A50 12 7mm 1 2 EL22CT50 12 7mm 1 2 EL22A50F 12 7mm 1 2 EL22CT50F 12 7mm 1 2 EL22I50P 12 7mm 1 2 EL22CT50P 15 9mm 5 8 EL22A62 15 9mm 5 8 EL22CT62...

Page 28: ...nt c When the wire conduit stop meets the end of the connector plug and the new raw end extends through the end of the conductor tube the Allen screw in the connector plug must be securely tightened o...

Page 29: ...ameter and dimensions of the workpiece If the Wirespeed is too high for the welding voltage stubbing will occur as the wire dips into the molten pool and does not melt Welding in these conditions norm...

Page 30: ...of the smaller electrode wire sizes 0 9mm 035 wire cost approx 10 more than 1 2mm 045 but is deposited approx 15 faster Higher current density or smaller diameter wire also gives deeper penetration as...

Page 31: ...e frequency depending on the usage and the operating environment WARNING 5 Disconnect the Viking from the Mains supply voltage before disassembling Special maintenance is not necessary for the control...

Page 32: ...AL METER is selected to read current vi Short circuit the TORCH TRIGGER terminals to energise output welding terminals CAUTION 7 Do not allow the Viking to remain ON under load for more than ONE minut...

Page 33: ...inants range from no gas around the welding arc to dirt on the work piece surface Porosity can be reduced by checking the following points 1 Gas cylinder contents and flow meter Ensure that the gas cy...

Page 34: ...ng through the feed roller if excessive pressure is applied to the pressure roller adjuster Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size Swarf i...

Page 35: ...int angle or gap C Shielding gas incorrect C Change to a gas which gives higher penetration 3 Lack of fusion Voltage too low Increase voltage by increasing voltage selection switches position 4 Excess...

Page 36: ...ntact supply authority 8 Arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly The MIG torch has been connected to the wrong voltage polari...

Page 37: ...Mains supply voltage is ON and contactor in the Power Source operates but wire does not feed when the torch trigger switch is depressed Tweco Torch has been damaged internally trigger wires are makin...

Page 38: ...10 6154 10 6155 Solenoid Valve 10 6181 10 6181 Wire Reel Lock Pin 10 6188 10 6188 Wire Reel Hub 10 6018 10 6018 Indicator Light 10 6164 10 6164 Welding Current Terminals 10 6127 10 6127 Work Lead Plu...

Page 39: ...se 21 24V Fine 4 Coarse 18 20V Fine 4 Primary Current 208V Coarse 30 35V Fine 4 Figure 10 Volt Amp curves of the Viking 210 0 10 20 30 40 50 60 0 25 50 75 100 125 150 175 200 225 250 Welding Current O...

Page 40: ...Viking 210GM 250GM 35 14 VIKING 210GM CIRCUIT DIAGRAM...

Page 41: ...Viking 210GM 250GM 36 15 VIKING 250GM CIRCUIT DIAGRAM...

Page 42: ...Viking 210GM 250GM 37 16 PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM CAT NO 10 6100...

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