Thermal Arc 250S DC CC Manuel utilisateur

November 11, 2003 Manual No. 430429-506

INVERTER

ARC

WELDER

MODEL 250S DC CC

STICK

TIG - Lift Start

OPERATING MANUAL

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

PAGE LEFT INTENTIONALLY BLANK

SYMBOL LEGEND

Amperage STICK (Shielded Metal Arc

SMAW)

Voltage Pulse Current Function

Hertz (frequency) Spot Time (GTAW)

SEC Seconds Remote Control (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

STATEMENT OF WARRANTY

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of its

authorized distributors hereafter “Thermal; Arc” that its products will be free of defects in workmanship or material. Should any

failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below, Thermal Arc

shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance

with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to

misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of

any components or parts of the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU

OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special, indirect or consequential damages,

such as, but not limited to, lost profits and business interruption. The remedies of the Purchaser set forth herein are exclusive and the

liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach

thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising

out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the

price of the goods upon which such liability is based. No employee, agent, or representative of Thermal 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 is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the

Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from

the date Thermal Arc delivered the product to the authorized distributor.

POWER SUPPLIES POWER SUPPLIES & WIRE FEEDERS LABOR

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEAR 3 YEAR

ORIGINAL MAIN POWER RECTIFIER 3 YEAR 3 YEAR

POWER SWITCHING SEMI-CONDUCTORS & CONTROL PC BOARD 3 YEAR 3 YEAR

ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS,

SOLENOIDS, PUMPS, SWITCHES, MOTORS

ENGINES: ENIGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE

MANUFACTURER, SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS.

CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR

EXCHANGES, AND ACCESSORY EQUIPMENT

PLASMA TORCH AND LEADS, AND REMOTE CONTROLS 180 DAYS 180 DAYS

REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc

repair facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind will be paid

under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the

Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous Thermal Arc

warranties.

Thermal Arc® is a Registered Trademark of Thermadyne Industries Inc.

Effective April 1, 2002

1.0 GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and

warnings are used to highlight important

information. These highlights are categorized as

follows:

NOTE

An operation, procedure, or

background information which

requires additional emphasis or is

helpful in efficient operation of the

system.

CAUTION

A procedure which, if not properly

followed, may cause damage to the

equipment.

WARNING

A procedure which, if not properly

followed, may cause injury to the

operator or others in the operating

area.

1.02 Important Safety Precautions

WARNING

OPERATION AND

MAINTENANCE OF ARC

WELDING EQUIPMENT CAN BE

DANGEROUS AND HAZARDOUS

TO YOUR HEALTH.

To prevent possible injury, read,

understand and follow all warnings,

safety precautions and instructions

before using the equipment. Call 1-

800-462-2782 or your local distributor

if you have any questions.

GASES AND FUMES

Gases and fumes produced during the Arc

welding/cutting process can be dangerous and

hazardous to your health.

• Keep all fumes and 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 from the arc

welding/cutting depend on the kind 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 using. These MSDSs will

give you the information regarding the kind

and amount of fumes and gases that may be

dangerous to your health.

• For information on how to test for fumes and

gases in your workplace, refer to item 1 in

Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or

down draft welding/cutting tables, to

capture fumes and gases.

• Do not use the welding torch in an area

where combustible or explosive gases or

materials are located.

• Phosgene, a toxic gas, is generated from the

vapors of chlorinated solvents and cleansers.

Remove all sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The arc welding

process uses and produces high voltage electrical

energy. This electric energy can cause severe or

fatal shock to the operator or others in the

workplace.

• Never touch any parts that are electrically

“live” or “hot.”

• Wear dry gloves and clothing. Insulate

yourself from the work piece or other parts

of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace

is moist or damp.

• Install and maintain equipment according to

NEC code, refer to item 4 in Subsection 1.03,

Publications.

• Disconnect power source before performing

any service or repairs.

• Read and follow all the instructions in the

Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag,

sparks, or the arc weld.

• Be sure there is no combustible or flammable

material in the workplace. Any material that

cannot be removed must be protected.

• Ventilate all flammable or explosive vapors

from the workplace.

• Do not cut or weld on containers that may

have held combustibles.

• Provide a fire watch when working in an

area where fire hazards may exist.

• Hydrogen gas may be formed and trapped

under aluminum workpieces when they are

cut underwater or while using a water table.

DO NOT cut aluminum alloys underwater

or on a water table unless the hydrogen gas

can be eliminated or dissipated. Trapped

hydrogen gas that is ignited will cause an

explosion.

NOISE

Noise can cause permanent hearing loss. Arc

welding/cutting processes can cause noise levels

to exceed safe limits. You must protect your ears

from loud noise to prevent permanent loss of

hearing.

• To protect your hearing from loud noise,

wear protective ear plugs and/or ear muffs.

Protect others in the workplace.

• Noise levels should be measured to be sure

the decibels (sound) do not exceed safe

levels.

• For information on how to test for noise, see

item 1 in Subsection 1.03, Publications, in

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

protective eye wear.

• Wear welding gloves and suitable clothing to

protect your skin from the arc rays and

sparks.

• Keep helmet and safety glasses in good

condition. Replace lenses when cracked,

chipped or dirty.

• Protect others in the work area from the arc

rays. Use protective booths, screens or

shields.

• Use the shade of lens as recommended in

Subsection 1.03, item 4.

1.03 Publications

Refer to the following standards or their latest

revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS,

29CFR 1910, obtainable from the

Superintendent of Documents, U.S.

Government Printing Office, Washington, D.C.

20402

2. ANSI Standard Z49.1, SAFETY IN WELDING

AND CUTTING, obtainable from the American

Welding Society, 550 N.W. LeJeune Rd, Miami,

FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC

WELDING AND GAS WELDING AND

CUTTING, obtainable from the Superintendent

of Documents, U.S. Government Printing

Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR

OCCUPATION AND EDUCATIONAL EYE

AND FACE PROTECTION, obtainable from

American National Standards Institute, 1430

Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from

the American National Standards Institute,

1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN

THE USE OF CUTTING AND WELDING

PROCESSES, obtainable from American

National Standards Institute, 1430 Broadway,

New York, NY 10018

7. AWS Standard A6.0, WELDING AND

CUTTING CONTAINERS WHICH HAVE

HELD COMBUSTIBLES, obtainable from

American Welding Society, 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, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL

CODE, obtainable from the National Fire

Protection Association, Batterymarch Park,

Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND

WELDING PROCESSES, obtainable from the

National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269

11.CGA Pamphlet P-1, SAFE HANDLING OF

COMPRESSED GASES IN CYLINDERS,

obtainable from the Compressed Gas

Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING, obtainable from

the Canadian Standards Association, Standards

Sales, 178 Rexdale Boulevard, Rexdale, Ontario,

Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY

BIBLIOGRAPHY obtainable from the National

Welding Supply Association, 1900 Arch Street,

Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1,

RECOMMENDED SAFE PRACTICES 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,” “attention,” et

“avertissement” sont utilisés pour mettre en relief

des informations à caractère important. Ces mises

en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou

renseignement général sur lequel il

importe d’insister davantage ou qui

contribue à l’efficacité de

fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas

de non-respect de la procédure en

question.

AVERTISSEMENT

Toute procédure pouvant provoquer

des blessures de l’opérateur ou des

autres personnes se trouvant dans la

zone de travail en cas de non-respect

de la procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENT

L’OPÉRATION ET LA

MAINTENANCE DU MATÉRIEL

DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT

PRÉSENTER DES RISQUES ET

DES DANGERS DE SANTÉ.

Il faut communiquer aux opérateurs et

au personnel TOUS les dangers

possibles. Afin d’éviter les blessures

possibles, lisez, comprenez et suivez

tous les avertissements, toutes les

précautions de sécurité et toutes les

consignes avant d’utiliser le matériel.

Composez le + 1-800-462-2782 ou

votre distributeur local si vous avez

des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet

de plasma peuvent présenter des risques et des

dangers de santé.

• Eloignez toute fumée et gaz de votre zone de

respiration. Gardez votre tête hors de la

plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à

alimentation en air si l’aération fournie ne

permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de

l’arc de plasma dépendent du genre de métal

utilisé, des revêtements se trouvant sur le

métal et des différents procédés. Vous devez

prendre soin lorsque vous coupez ou soudez

tout métal pouvant contenir un ou plusieurs

des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse

vanadium

• Lisez toujours les fiches de données sur la

sécurité des matières (sigle américain

“MSDS”); celles-ci devraient être fournies

avec le matériel que vous utilisez. Les MSDS

contiennent des renseignements quant à la

quantité et la nature de la fumée et des gaz

pouvant poser des dangers de santé.

• Pour des informations sur la manière de

tester la fumée et les gaz de votre lieu de

travail, consultez l’article 1 et les documents

cités à la page 5.

• Utilisez un équipement spécial tel que des

tables de coupe à débit d’eau ou à courant

descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma

dans une zone où se trouvent des matières

ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la

fumée provenant des solvants et des

produits de nettoyage chlorés. Eliminez

toute source de telle fumée.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser 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 soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone

de travail est humide ou moite.

• Montez et maintenez le matériel

conformément au Code électrique national

des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant

tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du

Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter

des scories chaudes, des étincelles ou de l’arc de

plasma. Le procédé à l’arc de plasma produit du

métal, des étincelles, des scories chaudes pouvant

mettre le feu aux matières combustibles ou

provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible

ou inflammable ne se trouve sur le lieu de

travail. Protégez toute telle matière qu’il est

impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les

fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les

conteneurs ayant pu renfermer des matières

combustibles.

• Prévoyez une veille d’incendie lors de tout

travail dans une zone présentant des dangers

d’incendie.

• Le gas hydrogène peut se former ou

s’accumuler sous les pièces de travail en

aluminium lorsqu’elles sont coupées sous

l’eau ou sur une table d’eau. NE PAS couper

les alliages en aluminium sous l’eau ou sur

une table d’eau à moins que le gas

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