Professional Documents
Culture Documents
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
SYMBOL LEGEND
Amperage
Voltage
Hertz (frequency)
SEC
Seconds
Percent
Remote Function
DC (Direct Current)
AC (Alternating Current
Gas Post-Flow
Standard Function
Gas Pre-Flow
Slope Function
VRD
Negative
Spot Function
Positive
Gas Input
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 Arcs 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 Arcs 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 ARCS 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 NONAUTHORIZED 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
LABOR
3 YEAR
3 YEAR
3 YEAR
3 YEAR
3 YEAR
3 YEAR
1 YEAR
1 YEAR
1 YEAR
1 YEAR
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 purchasers 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 Purchasers risk and expense. This warranty supersedes all previous Thermal Arc
warranties.
Thermal Arc is a Registered Trademark of Thermadyne Industries Inc.
Antimony
Arsenic
Barium
Beryllium
Cadmium
Vanadium
An
operation,
procedure,
or
background
information
which
requires additional emphasis or is
helpful in efficient operation of the
system.
CAUTION
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
OPERATION
AND
MAINTENANCE
OF
ARC
WELDING EQUIPMENT CAN BE
DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.
ELECTRIC SHOCK
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
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.
3.
8.
lefficacit
de
fonctionnement du systme.
ATTENTION
Toute procdure pouvant rsulter
lendommagement du matriel en cas
de non-respect de la procdure en
question.
AVERTISSEMENT
Toute procdure pouvant provoquer
des blessures de loprateur ou des
autres personnes se trouvant dans la
zone de travail en cas de non-respect
de la procdure en question.
LOPRATION
ET
LA
MAINTENANCE DU MATRIEL
DE SOUDAGE LARC AU JET
DE
PLASMA
PEUVENT
PRSENTER DES RISQUES ET
DES DANGERS DE SANT.
CHOC ELECTRIQUE
Les chocs lectriques peuvent blesser ou mme
tuer. Le procd au jet de plasma requiert et
produit de lnergie lectrique haute tension. Cette
nergie lectrique peut produire des chocs graves,
voire mortels, pour loprateur et les autres
personnes sur le lieu de travail.
FUME et GAZ
La fume et les gaz produits par le procd de jet
de plasma peuvent prsenter des risques et des
dangers de sant.
Eloignez toute fume et gaz de votre zone de
respiration. Gardez votre tte hors de la
plume de fume provenant du chalumeau.
cadmium
chrome
cobalt
cuivre
manganse
mercure
nickel
plomb
slnium
INCENDIE ET EXPLOSION
10
1.
BRUIT
Le bruit peut provoquer une perte permanente de
loue. Les procds de soudage larc de plasma
peuvent provoquer des niveaux sonores
suprieurs aux limites normalement acceptables.
Vous d4ez vous protger les oreilles contre les
bruits forts afin dviter une perte permanente de
loue.
11
RENFERM
DES
PRODUITS
COMBUSTIBLES, disponible auprs de la
American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126
GAZ
AVEC
ALIMENTATION EN OXYGENE POUR LE
SOUDAGE, LA COUPE ET LES PROCDS
ASSOCIS, disponible auprs de la National
Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
14.
Norme
AWSF4.1
de
lAssociation
Amricaine
de
Soudage,
RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRPARATION LA
COUPE
ET
AU
SOUDAGE
DE
CONTENEURS ET TUYAUX AYANT
RENFERM DES PRODUITS DANGEREUX
, disponible auprs de la American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL
33126
12
(V)
OCV
OCV
18V
10V
160A
5A
25A
STICK Process
250A
(A)
LIFT-TIG Process
Note 1
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the
welding power source. Curves of other settings will fall between the curves shown.
13
WARNING 1
ELECTRIC 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.
14
b.
c.
Environments with hazardous environments do not include places where electrically conductive
parts 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:
WARNING 3
Thermal Arc advises that this equipment be electrically connected by a qualified
electrician.
15
WARNING 4
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of
input power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging
procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open
position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other
disconnecting device.
3.03.01 Electrical Input Requirements
Operate the welding power source from a single/three-phase 50/60 Hz, AC power supply. The
input voltage must match one of the electrical input voltages shown on the input data label on the
unit nameplate. Contact the local electric utility for information about the type of electrical
service 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 and three phase electrical input power.
Do not connect an input (WHITE or BLACK or RED) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
Refer to figure 3 and:
1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that
complies with all applicable electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors to a deenergized line disconnect switch.
3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.
Note 3
For Single-Phase operation connect the GREEN, BLACK and WHITE input conductors.
Insolate the RED Conductor, it is not used for Single-phase operation.
16
Input Voltage
208
230
460
Fuse Size
75
70
20
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).
17
Note 4
Note the available input power. Damage to the PCA could occur if 575VAC or higher is
applied.
The following 208-230/460V Primary Current recommendations are required to obtain the maximum
welding current and duty cycle from this welding equipment:
Model
Primary Supply
Lead Size
Minimum Primary
Current Circuit Size
(Vin/Phase/Amps)
Current
& Duty Cycle
TIG
208/3/24
230/3/21
8/4 AWG minimum
460/3/11
(Factory Fitted)
208/3/35
250A @ 40%
230/3/32
PRO-LITE 250S
STICK
250A @ 40%
460/3/16
208/1/51
8/3 AWG minimum
230/1/46
208/1/75
230/1/68
250A @ 40%
250A @ 40%
18
19
3.04 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle
Output Current
Range
Open Circuit Voltage
Dimensions
Width
Height
Length
Weight
Output @ Rated Load
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Three Phase
208V
230V
460V
Input Volts Single Phase
208V
230V
460V
250S
208-230/460VAC
250
30
40%
250A / 30V @ 40%
190A / 27V @ 60%
5 250 Amps
69V
7.08 (180mm)
14.17 (360mm)
16.54 (420mm)
39.68 lb. 18 kg
Three-phase
250A
30V
40%
12.5
9.4
Single-phase
250A
30V
40%
15.7
9.4
0.5
0.5
0.13
0.13
Amperage Draw @ Rated Load
35
32
16
75
68
-
No Load
1.3
1.1
0.7
2.2
1.6
-
Thermal Arc continuously 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.
20
WARNING 5
Exceeding the duty cycle ratings will cause the thermal overload 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 5
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and weights quoted are approximate only. Achievable
capacities and ratings in use and operation will depend upon correct installation, use, applications,
maintenance and service.
21
22
Gnd.
2
12345678
6
5k Ohms
23
Socket Pin
Function
1
2
Earth (Ground)
Torch Switch Input (24V) to energize weld current.
(connect pins 2 & 3 to turn on welding current)
Torch Switch Input (0V) to energize weld current
(connect pins 2 & 3 to turn on welding current)
Connect pin 4 to pin 8 to instruct machine that a remote current control device
is connected (12V DC supply)
5k ohm (maximum) connection to 5k ohm remote control potentiometer
Zero ohm (minimum) connection to 5k ohm remote control potentiometer
Wiper arm connection to 5k ohm remote control potentiometer
Connect pin 4 to pin 8 to instruct machine that a remote current control device
is connected (0V)
3
4
5
6
7
8
3 Positive 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.
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 connections can cause overheating and result in the male plug
being fused in the bayonet terminal.
5 ON/OFF Switch
This switch connects the Primary supply voltage to the inverter when in the ON position.
This enables the Power Supply.
WARNING 6
When the welder is connected to the Primary supply voltage, the internal electrical
components maybe at primary potential with respect to earth.
6 Input Cable
The input cable connects the Primary supply voltage to the equipment.
SMART Logic Switch (Not Shown)
Manual slide switch mounted on the back panel selects for proper input voltage. If this slide
is not set to the position that matches the input voltage from the electrical source the Smart
Logic circuit will inhibit welding power source output. The digital meter will show primary
input error code.
24
Parameter
HOT START
Description
This parameter operates in STICK weld mode and is used to improve
the start characteristics for stick electrodes. e.g. low hydrogen
electrodes. It sets the peak start current on top of the (WELD) current.
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 remote device.
STICK Mode of operation
25
Parameter
Range
0 to 70A
5 to 250A 230V
0 to 100%
Factory
Setting
20A
80A
10%
Incremental
Unit
1A
1A
1%
STICK
LIFT TIG
Yes
Yes
Yes
No
Yes
No
Description
Almost all welding parameters are adjustable
Digital Meter
ON/OFF switch
Voltage Reduction Device (VRD)
Control Knob
26
Feature
Self Diagnosis Using Error Codes
Description
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.
27
28
3
Figure 7. - 250S Front Panel
1. Scroll Buttons used to select the parameters to be set. The LEDs show which function is
being adjusted on the weld sequence graph.
2. Digital LED display Welding 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 selects between STICK or Lift TIG mode. 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.
29
30
DC Current (Amps)
0.040 (1.0mm)
30 60
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
Ceriated 2%
Welding Application
Features
31
Color
Code
Red
Grey
DC Current Range
(Amps)
20 - 90
65 - 115
100 - 165
200-350
Shielding Gas
Current Range DC
Amperes
Thoriated 2%
3/32 (2.4 mm)
120 - 170
Yes
Thoriated 2%
3/32 (2.4 mm)
100 - 160
Yes
Thoriated 2%
3/32 (2.4 mm)
90 - 130
No
Joint Preparation
Table 8 TIG welding parameters for low carbon & low alloy steel pipe
32
Joint Type
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
1/8
3.2mm
80-100
90-115
65-85
90-110
1/16
1.6mm
3/32
2.4mm
Butt/Corner
Lap/ Fillet
3/16
4.8mm
115-135
140-165
100-125
125-150
3/32
2.4mm
1/8
3.2mm
10
Butt/Corner
Lap/ Fillet
6.4mm
160-175
170-200
135-160
160-180
1/8
3.2mm
5/32
4.0mm
10
Butt/Corner
Lap/ Fillet
33
Metals being
joined
Electrode
Comments
Mild steel
6013
Mild steel
7014
Cast iron
99% Nickel
Stainless steel
318L-16
34
Metals being
joined
Electrode
Comments
dairy work, etc. On stainless steels.
Copper, Bronze,
Brass, etc.
Bronze
5.7 ERCUSI-A
312-16
35
36
Possible Cause
1 Excessive bead
build-up or poor
penetration or poor
fusion at edges of
weld.
37
Remedy
Description
Possible Cause
Remedy
6 Electrode melts
A Electrode is connected to the A Connect the electrode to the
when arc is struck.
+ terminal.
terminal.
B
B
7 Dirty weld pool.
A Electrode contaminated
through contact with work
piece or filler rod material.
B Gas contaminated with air.
38
Description
12 Arc start is not
smooth.
Possible Cause
Possible Cause
1 Gas pockets or
A Electrodes are damp.
voids in weld metal B Welding current is too high.
(Porosity).
C Surface impurities such as
oil, grease, paint, etc.
2 Crack occurring in A Rigidity of joint.
weld metal soon
after solidification
commences
B Insufficient throat thickness.
3 A gap is left by
failure of the weld
metal to fill the
root of the weld.
Remedy
Remedy
A Dry electrodes before use.
B Reduce welding current.
C Clean joint before welding.
A Redesign to relieve weld joint
of severe stresses or use crack
resistance electrodes.
B Travel slightly slower to allow
greater build up in throat.
C Preheat plate and cool slowly.
A Increase welding current
B Use smaller diameter
electrode.
C Allow wider gap.
D Use correct build-up sequence.
39
4 Portions of the
weld run do not
fuse to the surface
of the metal or
edge of the joint.
E
F
40
Possible Cause
Remedy
2 Maximum output
Defective control circuit
Have an Accredited Thermal
welding current can
Arc Service Agent inspect
not be achieved
then repair the welder.
with nominal
Mains supply
voltage.
3 Welding current
Poor work lead connection to
Ensure that the work lead has
reduces when
the work piece.
a positive electrical
welding
connection to the work piece.
4 No gas flow when A Gas hose is cut.
A Replace gas hose.
the torch trigger
B Gas passage contains
B Disconnect gas hose from the
switch is
impurities.
rear of Power Source then
depressed.
raise gas pressure and blow
out impurities.
C Gas regulator turned off.
C Turn gas regulator on.
41
Pro-Lite
250S
15.3 to 19.8V
Notes
42
Description
43
Possible Cause
B Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check for low Mains
voltage.
Remedy
Remarks
44
Possible Cause
Description
Have an Accredited
Thermal Arc Service Agent
check connector plug on
input PCB
Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the Mains voltage
A Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the Mains voltage
B Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the primary cable &
fuses.
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 voltage.
Remedy
No weld current is
available.
Buzzer sounds constantly.
Switch machine off.
No weld current is
available.
Buzzer sounds constantly.
Switch machine off.
Remarks
45
No weld current is
available.
Buzzer sounds constantly.
Switch machine off then on
to reset E83 error.
Remarks
Have an Accredited
Weld current ceases.
Thermal Arc Service Agent Buzzer sounds constantly.
check or replace the
Switch machine off.
temperature sensors.
Have an Accredited
Weld current ceases.
Thermal Arc Service Agent Buzzer sounds constantly.
check the control PCB
Switch machine off.
Have an Accredited
Thermal Arc Service Agent
check connector plug on
input PCB and the Mains
voltage
Remedy
Possible Cause
Description
Diode
Diode
Diode
Diode
Diode
Fan
Inductor
Current Sensor
Printed Circuit Board
D1
D2
D3
D4
D5
FAN1
FCH1
HCT1
PCB1
PCB2
PCB3
PCB4
PCB5
PCB6
PCB7
PCB10
PCB11
DWG. No.
Description
C1
Capacitor
CON1
Remote Socket
46
1
1
1
1
1
1
1
1
1
1
1
1
P0A515703
P0A492011
P0A491704
P0A501901
P0A492301
P0A481901
P0A492102
U0A722000
454170160
4582A0040
4582A0040
4582A0040
4582A0040
U0A733500
F2A719500
11251003000
U0A674900
QTY.
Code No.
1
42422137100
1
U0A706100
10-6845
10-6739
10-6740
10-6741
10-6742
10-6635
10-6636
10-6738
10-6735
10-6687
10-6687
10-6687
10-6687
10-6839
10-6736
10-5003
10-6737
Order No.
10-2270
10-6627
Transistor
Switch
Switch
Transformer
Transformer
Thermistor
Q2
S1
S2
T1
T2
TH1, 2
DWG. No.
Description
Q1
Transistor
47
1
25850003700
24704531400
F2A767200
F2A767200
U0A733300
U0A705300
QTY
Code No.
1
U0A705300
10-6857
10-5222
10-6744
10-6744
10-6784
10-6642
Order No.
10-6642
DWG. No.
Description
Front Panel
Rear Panel
Side Panel
Front Control Cover
Rear Control Cover
Protection Cover
Encoder Cover
PCB Cover
PCB Sheet
Name Label
Side Label
Warning Label 1
Warning Label 2
Output Terminal Label
Output Terminal
(female)
Input Cable
Input Cable Clamp
Heatsink
Heatsink
Knob
Knob Cap
Control Cover Sheet
Flat Cable
48
QTY
1
1
2
1
1
1
1
1
1
2
2
1
1
1
2
U0A722400
EBA045800
E1B538500
E1B538600
50990001600
50990000300
N0B882300
EAA547301
Code No.
U0A722100
U0A722200
E0D006100
J4B493400
U0A722300
E0C303200
EBA514400
U0A705600
EBA618000
N4A056000
N4A009200
N0B891300
N0B476400
N4A040300
26999025900
REF. ONLY
10-6662
10-6663
10-6664
10-6665
10-6666
10-6749
10-6668
Order No.
10-6648
10-6649
10-6650
10-6651
10-6745
10-6653
10-6654
10-6655
10-6747
10-6746
10-6657
10-5497
10-5496
10-6748
10-6660
DWG. No.
Description
Post4(M4-M4)
Post5(M4-M4)
Post6(M5-M5)
Post7(M5-M5)
Post9(M5-M5)
Post11(M5-M5)
D2-5 Bus Bar
CC Bus Bar
S1 Bus Bar
Output Bus Bar1
Output Bus Bar2
Clip
Transformer Chassis
Right Chassis
Left Chassis
Output Terminal (male)
Operating Manual
Service Manual
49
QTY
4
8
2
1
4
3
1
1
3
1
1
4
1
1
1
2
1
Code No.
EBA431100
EBA431200
EBA431300
EBA435900
EBA491700
EBA643600
EBA366300
EBA707600
ECA321000
EBA456400
EBA456600
606024220
JCA903200
J2C970700
J2C970800
26999025800
K1A208600
Order No.
10-6670
10-6671
10-6672
10-6673
10-6750
10-6751
10-6752
10-6753
10-6868
10-6754
10-6755
10-5259
10-6678
10-6679
10-6680
10-2020
430429-506
430429-516
50
51
APPENDIX B - AUTOMATION
JUMPER SETTING FOR "OKTOMOVE". Models 250S/TS
Three jumpers (JP1, JP2 and JP3) are provided on PC Board WK-4921 for automation purposes. This
PCB is mounted horizontally on top of the unit just under the cover. This PCB can be accessed by
removing the side covers by loosening 4 screws on each the front and rear panel, then removing the 4
side panel screws as well as the 2 handle screws. Carefully pull the front and rear panels outward to
release and remove the side cover. Remove two plastic clips holding the PCB protective cover in place
and lift the sheet up and over the unit. The jumpers will be accessible on the top portion of the PCB.
See figure on next page for the location of the PCB.
All units are shipped from the factory with the jumpers set in position "A". This is for normal semiautomatic 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.
Placing jumpers JP1 and JP2 in "B" position and jumper JP3 in "A" position would have the
configuration of an arc-establish signal and remote contactor, but the units front panel would control
the amperage.
JP1
A COM
B
WK-4921
JP3
CN6
CON1
B
COM
JP2
A COM
JP1
JP2
JP3
OK-TO-MOVE
RELAY
POSITION
A
A
A
CN6
CON1
4
Remote : Short 4 to 8
Panel : Open
JP1
JP2
JP3
A/V
POSITION
B
B
B
B
B
A
REMOTE PANEL
CN6
CON1
4
Max Load:
24V 50ma.
OK TO MOVE
RELAY
52
53