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TWECO 201TS

TROUBLESHOOTING

Troubleshooting 6-2 Manual 0-5150

6.02 Checking Unit Before Applying Power

!

Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.

Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are

off before removing case.

!

Check DC bus voltage according to Section 6.07 after removing case.

!

Before troubleshooting or applying power to unit, complete the following checks to avoid causing

further damage.

6.03 Tools Needed for Troubleshooting and Servicing

Art # A-09849

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Summary of Contents for ArcMaster 201 TS

Page 1: ...Art A 10139_AB ARCMASTER 201 TS Inverter Arc Welder Service Manual Tweco com Revision AC Issue Date April 22 2015 Manual No 0 5150...

Page 2: ...stinguish ourselves from our competition through market leading innovation and truly dependable products that will stand the test of time We strive to enhance your productivity efficiency and welding...

Page 3: ...ley Lancaster England PR6 7BX www victortechnologies com Copyright 2011 2013 by Victor Technologies International Inc All rights reserved Reproduction of this work in whole or in part without written...

Page 4: ...2 1 2 05 Transportation Methods 2 1 SECTION 3 SAFETY AND INSTALLATION 3 1 3 01 Duty Cycle 3 1 3 02 Specifications 3 2 3 03 Environment 3 3 3 04 Location 3 3 3 05 Electrical Input Connections 3 4 3 06...

Page 5: ...Control Board Removal 7 1 7 03 Front Panel Assembly Removal 7 2 7 04 Front Panel Operator Interface Circuit Board PC2 Removal 7 5 7 05 Back Panel Removal 7 7 7 06 Power Switch S1 and Power Cord Remov...

Page 6: ...TABLE OF CONTENTS This Page Intentionally Blank...

Page 7: ...nd skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing 1 Wear a we...

Page 8: ...cks and openings to adjacent areas 5 Watch for fire and keep a fire extinguisher nearby 6 Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side 7 Do not weld...

Page 9: ...n flames 3 Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job 4 Do not overfill tank allow room for fuel to expand 5 Do not spill fuel If fuel is sp...

Page 10: ...ctor CS Regulator A Fire Prevention Welding and cutting operations use fire or combustion as a basic tool The process is very useful when properly controlled However it can be extremely destructive if...

Page 11: ...with care Serious accidents can result from improper handling or mis use of compressed gas cylinders DO NOT drop the cylinder knock it over or expose it to excessive heat flames or sparks DO NOT stri...

Page 12: ...ety 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinde...

Page 13: ...ncy Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Func...

Page 14: ...on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards WARNING FIRE OR EXPLOSION hazard Do not place unit on over or near combu...

Page 15: ...s Manual for welding safety precautions Use only genuine replacement parts from the manufacturer 1 06 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnet...

Page 16: ...TWECO 201TS SAFETY INSTRUCTIONS AND WARNINGS Safety Instructions and Warnings 1 10 Manual 0 5150 This Page Intentionally Blank...

Page 17: ...shipping container Record these numbers for future reference 2 03 Receipt of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment...

Page 18: ...TWECO 201TS INTRODUCTION introduction 2 2 Manual 0 5150 This Page Intentionally Blank...

Page 19: ...es at 18 volts This means that it has been designed and built to provide the rated amperage 200A for 2 minutes i e arc welding time out of every 10 minute period 20 of 10 minutes is 2 minutes During t...

Page 20: ...F 40 C 10 min Quoted figures refer to STICK MMA output 125A 25 25 0V 95A 60 23 8V 80A 100 23 2V 200A 20 28V 120A 60 24 8V 100A 100 24 0V Rated Input Current A 39A 32A for STICK MMA Welding Io 125A 25...

Page 21: ...ith increased hazard of electric shock Examples of environments with increased hazard of electric shock are A In locations in which freedom of movement is restricted so that the operator is forced to...

Page 22: ...lable how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power sup...

Page 23: ...elay in the Power Control Assembly 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 253 VAC or higher i...

Page 24: ...ng or other activities are to be carried out 8 The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may requir...

Page 25: ...tances Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to...

Page 26: ...1TS SAFETY AND INSTALLATION Safety and installation 3 8 Manual 0 5150 Art A 10159 115VAC Input 0 10 20 30 40 50 60 70 80 0 50 100 150 200 AMPS VOLTS Stick Max Lift Tig Max Figure 3 4 201TS Volt Ampere...

Page 27: ...ific application Refer to the electrode manufacture s literature for further information 4 01 Front Panel Art A 10146_AB A Power On Indicator B Fault Indicator E Welding Current Control G Gas Outlet N...

Page 28: ...eeded Leave the power on and wait for the Fault Indicator to extinguish before resuming welding Over Primary Current Protection If the Fault Indicatorlights up continueously then the primary current i...

Page 29: ...Mains Supply Voltage to the Power Source 4 02 Setup for Welding NOTE Conventional operating procedures apply when using the Welding Power Source i e connect work lead directly to work piece and elect...

Page 30: ...h located on the rear panel to OFF 2 Connect the work lead to the negative output terminal and the electrode holder cable to the positive output terminal It is essential that the male plug is inserted...

Page 31: ...K Welding NOTE Gently strike the electrode on the work piece to generate a welding arc and slowly move along the work piece while holding a consistent arc length above base metal 4 04 LIFT TIG HF TIG...

Page 32: ...o the outlet of the Argon regulator and tighten with a wrench Cau tion DO NOT over tighten 7 Connect the other end of the supplied gas hose to the gas inlet fitting on the rear panel of the welder and...

Page 33: ...he cyl inder valve reduce high cylinder pressures to suitable low working pressures for welding cutting and other applications LOW PRESSURE GAUGE DELIVERY HIGH PRESSURE GAUGE SUPPLY INLET CONNECTION O...

Page 34: ...shielding gas hose from the torch to a flow meter regulator on the cylinder In this case we will be using Argon set at a flow rate of around 20 CFH You will need to use a TIG torch that has a gas valv...

Page 35: ...er than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply AC High Frequency...

Page 36: ...TWECO 201TS THEORY OF OPERATION Theory of Operation 5 2 Manual 0 5150 This Page Intentionally Blank...

Page 37: ...3 If above voltage is incorrect disconnect the harness of J11 connector and re measure according to step 1 If still incorrect replace Main Power PCB 1 Cannot adjust Weld Current Check Control panel P...

Page 38: ...rking on unit Significant DC voltage can remain on capacitors after unit is Off Wait until all front panel LED s are off before removing case Check DC bus voltage according to Section 6 07 after remov...

Page 39: ...Troubleshooting 6 04 Case Removal Read and follow safety information in Section 6 02 before proceeding 1 Cover 2 Screws Remove the 4 screws 2 on each side of the unit Remove 2 screws from both the Fro...

Page 40: ...ully lift the case to access and remove the screw which connects the ground wire to the cover 3 Art A 09851_AC 6 05 Clear Cover Sheet Removal Read and follow safety information in Section 6 02 before...

Page 41: ...TROUBLESHOOTING TWECO 201TS Manual 0 5150 6 5 Troubleshooting 6 06 Pre Power Check Measure Points for following tests 3 4 9 2 12 11 8 13 16 7 6 5 10 17 18 14 15 1 Art A 10161...

Page 42: ...Probe Negative Probe Measure Point 6 Measure Point 5 Measure Point 8 Measure Point 7 If reading is out of voltage drop range replace main board 3 Measurement of PFC IGBT Set multimeter to diode mode...

Page 43: ...nd follow safety information in Section 6 02 before proceeding 1 ON OFF switch Power Switch Multimerer set to Measure ohms Power Switch Testing Multimeter Lead Placement Impedance Switch ON Positive m...

Page 44: ...e reading with multimeter before inspection Set multimeter to DC volt age mode Read and follow safety information in Section 6 02 before proceeding 1 DC Positive 2 DC Negative Check and make sure inpu...

Page 45: ...HOOTING TWECO 201TS Manual 0 5150 6 9 Troubleshooting 6 08 Installing Clear Cover Sheet Read and follow safety information in Section 6 02 before proceeding 1 Replace the clear protective sheet 1 Art...

Page 46: ...6 10 Manual 0 5150 6 09 Waveforms for Section 6 10 A OCV Waveform of Transformer primary Art A 09858 B Output 160A 26 4V transformer primary waveform under input 230VAC Art A 09859 C Output 160A 26 4...

Page 47: ...SHOOTING TWECO 201TS Manual 0 5150 6 11 Troubleshooting Art A 09860 D Output 125A 25V transformer primary waveform under input 110VAC Art A 09894 E Output 125A 25V output voltage waveform under input...

Page 48: ...TWECO 201TS TROUBLESHOOTING Troubleshooting 6 12 Manual 0 5150 Art A 09895_AB...

Page 49: ...2 REMOTE POT DEMAND 3 POT MAX 4 POT MIN 5 6 START RTN 7 START 8 4 1 1 2 PANEL CUR DEMAND 3 4 10 CURRENT DEMAND 9 DOWN SLOPE ARC FORCE 8 2T 4T 7 N A 6 FAULT LED 5 HF TIG 4 STICK 3 VOLTAGE TEST 2 15VDC...

Page 50: ...TWECO 201TS TROUBLESHOOTING Troubleshooting 6 14 Manual 0 5150 This Page Intentionally Blank...

Page 51: ...ly Refer to diagram on page 7 2 1 M4 Screw Remove 4 screws from Control panel 2 Disconnect J8 harness from J8 connector 3 Disconnect J7 harness from J7 connector 4 Disconnect J2 harness from J2 connec...

Page 52: ...trol PCB 7 03 Front Panel Assembly Removal Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Power supply output Negative 2 Power supply output Positive 3 Output...

Page 53: ...DISASSEMBLY PROCEDURE TWECO 201TS Manual 0 5150 7 3 Disassembly Procedure 1 2 Art A 10166_AB 3 Art A 10167...

Page 54: ...Disassembly Procedure 7 4 Manual 0 5150 TWECO 201TS DISASSEMBLY PROCEDURE 4 Art A 10168 5 6 Art A 10169...

Page 55: ...ve the WELD CURRENT KNOB by loosening the set screw 3 WELD CURRENT control mounting nut Remove mounting nut 4 Front Panel PCB3 Remove the Front Panel PCB3 from the panel 5 Panel mounting screw Remove...

Page 56: ...Disassembly Procedure 7 6 Manual 0 5150 TWECO 201TS DISASSEMBLY PROCEDURE Art A 12755 8 3 9 4 Art A 10172 5 Art A 09870...

Page 57: ...two wires from PCB1 3 Rear panel mounting SCREW Remove screw holding rear panel to chassis 4 Ground wire screw Disconnect Input cord ground wire from Main Power PCB1 using a 1 4 wench 5 Disconnect ha...

Page 58: ...Disassembly Procedure 7 8 Manual 0 5150 TWECO 201TS DISASSEMBLY PROCEDURE 3 Art A 10174 4 Art A 10175_AB...

Page 59: ...SW1 2 SW1 locking tabs Squeeze the locking tabs and push SW1 out from the rear panel 3 Input Power Cord 4 Strain relief screws Remove the two 2 screws from the strain relief 5 Input Power Cord ground...

Page 60: ...Disassembly Procedure 7 10 Manual 0 5150 TWECO 201TS DISASSEMBLY PROCEDURE 3 4 Art A 10177 1 5 7 3 Art A 10178...

Page 61: ...DISASSEMBLY PROCEDURE TWECO 201TS Manual 0 5150 7 11 Disassembly Procedure 6 2 Art A 10179...

Page 62: ...5150 TWECO 201TS DISASSEMBLY PROCEDURE 7 07 Base Panel Removal Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Remove PCB1 assembly 2 Remove Base Panel Screws 3...

Page 63: ...ures ASSEMBLY PROCEDURE TWECO 201TS SECTION 8 ASSEMBLY PROCEDURES 8 01 Installing Base Board 1 Base Panel 2 Panel screws Secure the Main Power PCB1 to the Base Panel with the Panel Screws 3 Main power...

Page 64: ...nel 1 Install ON OFF switch 2 Install power cord 3 Reconnect Input Wire on the ON OFF switch 4 Reinstall Magnet onto Ground Wire 5 Install fan 6 Reconnect power ON OFF switch to terminals on Main Powe...

Page 65: ...Manual 0 5150 8 3 Assembly Procedures ASSEMBLY PROCEDURE TWECO 201TS 6 7 Art A 10183 8 Art A 09883...

Page 66: ...ghten 5 WELD CURRENT knob Install knob onto potentiometer shaft Align the knob pointer to line up with maximum current calibration mark on the panel then tighten the set screw 6 Arc Force Down Slope C...

Page 67: ...Manual 0 5150 8 5 Assembly Procedures ASSEMBLY PROCEDURE TWECO 201TS Art A 12756 4 Art A 10269_AB 6 7 8 5...

Page 68: ...1TS ASSEMBLY PROCEDURES 9 Reinstall output terminals on front panel with 27mm wrench 10 Reconnect wires to their respective terminals using the bolts 11 Reconnect Output Terminal Bolts and tighten wit...

Page 69: ...Manual 0 5150 8 7 Assembly Procedures ASSEMBLY PROCEDURE TWECO 201TS 11 10 Art A 10188 12 Art A 10189...

Page 70: ...s into connector J12 Refer to 7 02 3 Plug harness into connector J1 4 Plug harness into connector J8 5 Plug harness into connector J7 6 Plug harness into connector J3 7 Plug harness into connector J4...

Page 71: ...Manual 0 5150 8 9 Assembly Procedures ASSEMBLY PROCEDURE TWECO 201TS 1 Art A 10160...

Page 72: ...ures 8 10 Manual 0 5150 TWECO 201TS ASSEMBLY PROCEDURES 8 05 Installing Case 1 Install Case 2 Install Screws Eight 8 screws 4 on both side panels of case 2 on front panel 2 on rear panel 1 2 A 09951_A...

Page 73: ...screw GB T13806 2 AST4 2 13 Bracket 3 EACH locking washer external serrated GB862 2 87 4 Base Panel Solenoid valve 4 EACH Screw spring washer flat washer M4 16 Rectifier bridge 2 EACH Flat washer 4 1...

Page 74: ...Inductor Magnetic Core W7003210 11 Front Control PCB3 W7003218 PCB3 12 Front Panel W7003205 13 Front Panel Label W7003219 14 Rubber Boot W7003064 15 Knob control Red 21 ODx6 ID W7003079 16 Connector...

Page 75: ...REPLACEMENT PARTS TWECO 201TS Manual 0 5150 9 3 Replacement Parts 2 5 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 20 22 23 24 25 Art A 10148_AB 26 5 1 2 1...

Page 76: ...Replacement Parts 9 4 Manual 0 5150 TWECO 201TS REPLACEMENT PARTS This Page Intentionally Blank...

Page 77: ...finger remote control 50mm dinse connection and accessory kit W4013601 Foot Control 8 pin amphenol 15ft 600285 Slider Current Control with Torch Switch 15ft suits 1 1 8 dian 26 TIG Torch Handle 10 401...

Page 78: ...TWECO 201TS ACCESSORIES Accessories 10 2 Manual 0 5150 This Page Intentionally Blank...

Page 79: ...prior written consent obtained from Victor Technologies service department UK Equipment that has been used beyond the speci cations established in the operating manual Installation not in accordance...

Page 80: ...800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 6...

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