Thermal Arc pro-life 250s, Operating Manual

Page 1: ...PRO LITE Version No 1 Issue Date June 29 2005 Manual 0 4767 Operating Features Pro Lite 250S South America Version INVERTER ARC WELDER Operating Manual 250S ...

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Page 3: ...ew Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2005 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results fr...

Page 4: ...or Pro Lite 250S 32 4 04 Power Source Features 32 5 0 SET UP FOR SMAW STICK AND GTAW TIG 34 6 0 SEQUENCE OF OPERATION 35 6 01 Stick Welding 36 6 02 DC LIFT TIG Welding 36 7 0 BASIC TIG WELDING GUIDE 37 7 01Electrode Polarity 37 7 02 Tungsten Electrode Current Ranges 37 7 03 Tungsten Electrode Types 37 7 04 Guide for Selecting Filler Wire Diameter 38 7 05 Shielding Gas Selection 38 7 06 TIG Welding...

Page 5: ...me time or touch other people with the holder or electrode 8 Do not use worn damaged undersized or poorly spliced cables 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once SECTION 1 ARC WELDING SAFETY INST...

Page 6: ...s Breathing these fumes and gases can be hazardous to your health 1 Keep your head out of the fumes Do not breath the fumes 2 If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases 3 If ventilation is poor use an approved air supplied respirator 4 Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and ...

Page 7: ...terials from welding can easily go through small cracks 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 on closed containers such as tanks or drums 8 Connect work cable to the work as close to the welding area as practical to prevent welding current f...

Page 8: ...nning job 4 Do not overfill tank allow room for fuel to expand 5 Do not spill fuel If fuel is spilled clean up before starting engine WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only ...

Page 9: ... or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also nor mally re...

Page 10: ...NTRETIEN ET D ESSAI AVERTISSEMENT L ELECTROCUTION PEUT ETRE MORTELLE Une décharge électrique peut tuer ou brûler gravement L électrode et le circuit de soudage sont sous tension dès la mise en circuit Le cir cuit d alimentation et les circuits internes de l équipement sont aussi sous tension dès la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobin...

Page 11: ... des coups d arc ou de l éblouissement avertissez les observateurs de ne pas regarder l arc 4 Portez des vêtements en matériaux ignifuges et durables laine et cuir et des chaussures de sécurité Opération de coupage ou soudage Dimension d électrode ou Epiasseur de métal ou Intensité de courant Nuance de filtre oculaire Opération de coupage ou soudage Dimension d électrode ou Epiasseur de métal ou I...

Page 12: ...TISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des étincellies et des projections Les particules volantes le métal chaud les pro jections de soudure et l équipement surchauffé peuvent causer un incendie et des brûlures Le contact accidentel de l électrode ou du fil électrode avec un objet métallique peut provoquer des étincelles un échauffement ou un incendie 1 Protége...

Page 13: ... 6 Ne placez pas le visage face à l ouverture du robinet de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation 8 Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes ainsi que la publication P 1 de la CGA identifiée dans la liste de documents ci dessous AVERTISSEM...

Page 14: ...cule 5 Utilisez la polarité correcte et de l accumulateur AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut être brûlant et sous pression 1 N ôtez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ôter 3 Laiss...

Page 15: ... authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTYARE VOID IF REPLACEMENT PARTS ORACCESSORIES ARE USED WHICH IN THERMALARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OFANY THERMALARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective...

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Page 17: ...rature Library link http www thermalarc com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification...

Page 18: ...r Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Time Postflow Time Spot Time Spot Weld Mode Continuous Weld Mode Pr...

Page 19: ...GTAW 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 18V 270A 160A STICK Process LIFT TIG Process Figure 1 Model 250S 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 ...

Page 20: ...LECTRIC 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 on a proper skid...

Page 21: ...ance of the human body and the insulation properties of accessories Environments with adverse conditions do not include places where electrically conductive parts are 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 x In areas free from moisture and dust x Ambient temperature b...

Page 22: ...ice available 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 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...

Page 23: ...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 PRO LITE 250S 23 June 29 2005 ...

Page 24: ...onds Note 3 Note the available input power Damage to the PCA could occur if 575VAC or higher is applied The following 380 415V 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 Minimum Primary Current Circuit Size Vin Phase Amps TIG STICK 380 3 13 415 3 11 250A 40 380 3 19 ...

Page 25: ...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 mains by direct coupl...

Page 26: ...ously 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 without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes updates improvements or replacement of such items The values specified in the table above are opt...

Page 27: ...rload 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 4 Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements di...

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Page 29: ... parameter rotating it clockwise increases the parameter and is indicated on the digital meter Pushing the knob in previews the actual welding voltage while welding 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 PRO LITE 250S...

Page 30: ...a heavy duty Dinse type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 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 con...

Page 31: ... on top of the WELD current A Weld Current Amperage sets the STICK and TIG WELD current ARC CONTROL This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability LIFT TIG mode of operation A remote control device is required for use during LIFT TIG operation See section 4 01 section 2 Remote Control Socket for complete details of the remo...

Page 32: ...tem is designed to reduce dust and foreign material build up whilst providing optimum cooling x Fan speed reduces approximately 30 seconds after machine is turned on x Fan speed increases when internal components reaches operating temperature ON OFF switch x 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 E...

Page 33: ...elf Diagnosis Using Error Codes x An error code is displayed on the Digital Meter when a problem occurs with Primary supply voltage or internal component problems Refer to troubleshooting guide PRO LITE 250S 33 June 29 2005 ...

Page 34: ...e welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application WARNING 7 Before connecting the work clamp to the work and inserting the electrode i...

Page 35: ...ing 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 3 Control knob allows the operator to adjust the output amperage within the entire range of the power source also used to set each parameter value 4 Process Button This button sele...

Page 36: ...l Commence welding 6 02 DC LIFT TIG Welding x Connect work lead to positive terminal x Connect TIG torch to negative terminal x Switch machine on x Set weld current x Connect remote control device A remote control device is required for use during LIFT TIG operation See section 4 01 section 2 Remote Control Socket for complete details of the remote device Use the Scroll Buttons to move to the para...

Page 37: ...0 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 4 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 Ceriated 2 DC w...

Page 38: ... Shielding Gas Selection Alloy Shielding Gas Aluminium alloys Argon Carbon Steel Argon Stainless Steel Argon Nickel Alloy Argon Copper Argon Titanium Argon Table 7 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 Thoriated 2 3 32 2 4...

Page 39: ...illet 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 170 200 160 180 1 ...

Page 40: ...er each weld or skip welding to distribute the heat Cast Iron Most types of cast iron except white iron are weldable White iron because of its extreme brittleness generally cracks when attempts are made to weld it Trouble may also be experienced when 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 rat...

Page 41: ...ns except white cast iron Stainless steel 318L 16 High corrosion resistance Ideal for dairy work etc On stainless steels Copper Bronze Brass etc Bronze 5 7 ERCUSI A Easy to use electrode for marine fittings water taps and valves 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 ...

Page 42: ... the primary capacitors to discharge To clean the unit open the enclosure please refer to the 160S Service Manual P N 430429 513 and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean if necessary with solvents that are recommended for cleaning electrical apparatus CAUTION 4 Do not blow air into the power supply during cleaning Blowing air into the uni...

Page 43: ...ection 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 too high Decrea...

Page 44: ...rch 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 Basic TIG Weldi...

Page 45: ...tal 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 severe stresses ...

Page 46: ...n 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 Use smaller elec...

Page 47: ... C Loose connections internally C Have an Accredited Thermal Arc Service Agent repair the connection 2 Maximum output welding current can not be achieved with nominal Mains supply voltage 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 h...

Page 48: ... 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 6 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 peri...

Page 49: ... 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 operates at max speed E...

Page 50: ... 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 aut...

Page 51: ...an not read write weld parameters Memory chip EEPROM error Have an Accredited Thermal Arc Service Agent check the control PCB Weld current ceases 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 ...

Page 52: ... 1 11251003000 10 5003 PCB1 Printed Circuit Board WK 4914 U02 MAIN_PCB with Insulation Sheet EBA501500 with Thunder Label 1 U0A674900 10 6737 PCB2 Printed Circuit Board WK 4819 U01 DETECT PCB 1 P0A481901 10 6635 PCB3 Printed Circuit Board WK 4921 U02 CONNECT PCB 1 P0A492102 10 6636 PCB4 Printed Circuit Board WK 4915 U02 2ND DIODE with Thunder Label 1 U0A722000 10 6738 PCB5 Printed Circuit Board WK...

Page 53: ...0DUS12F 1 600V 100A with WK 5012 U01 1 U0A705300 10 6642 S1 Switch DCP 103SR100C 480V 3P 1 25850003700 10 6857 S2 Switch SDKGA4 A 1 A 250V 5A 1 24704531400 10 5222 T1 Transformer F2A767200 250A MTR HV 1 F2A767200 10 6744 T2 Transformer F2A767200 250A MTR HV 1 F2A767200 10 6744 TH1 2 Thermistor ERTA53D203 20K 25ºC B 3950K 1 U0A733300 10 6784 PRO LITE 250S 53 June 29 2005 ...

Page 54: ...ame Label N4A056000 2 N4A056000 10 6746 Side Label N4A009200 2 N4A009200 10 6657 VRD INSIDE label N4A155900 1 N4A155900 10 6683 Warning Label 1 N0B891300 1 N0B891300 10 5497 Warning Label 2 N0B476400 1 N0B476400 10 5496 Output Terminal Label N4A040300 1 N4A040300 10 6748 Output Terminal female TRAK BE35 70S 2 26999025900 10 6660 Input Cable SOOW AWG8X4C L 3 4m 1 U0A722400 REF ONLY Input Cable Clam...

Page 55: ...366300 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 606024220 10 5259 Transformer Chassis JCA903200 1 JCA903200 10 6678 Right Chassis J2C970700 1 J2C970700 10 6679 Left Chassis J2C970800 1 J2C970800 10 6680 Output Terminal male TRAK ...

Page 56: ...APPENDIX A INTERCONNECT DIAGRAM PRO LITE 250S June 29 2005 56 ...

Page 57: ...PRO LITE 250S 57 June 29 2005 ...

Page 58: ...actory 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 when in this mode P...

Page 59: ...Figure 11 Location of PCB WK 4921 PRO LITE 250S 59 June 29 2005 ...

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Page 61: ...hire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne Asia Pacific Pte Ltd 5 Shenton Way 37 02 38 02 UIC Building Singapore 068808 Telephone 65 6832 8066 Fax 65 6763 5812 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Par...

Page 62: ...Corporate Headquarters 82 Benning Street West Lebanon NH 03784 USA Telephone 603 298 5711 800 752 7621 Fascimile 800 221 4401 Email sales thermalarc com www thermalarc com ...