Ac DC Inverter

202 AC/DC
INVERTER
ARC WELDING MACHINE
Service Manual
A-11595
Revision: AD Issue Date: August 3, 2015 Manual No.: 0-5240

Operating Features:
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud to have
you as our customer and will strive to provide you with the best service and
reliability in the industry. This product is backed by our extensive warranty
and world-wide service network. To locate your nearest distributor or
service agency call +44 (0) 1257 261 755, or visit us on the web at www.
Thermalarc.com.
This Service Manual has been designed to instruct you on the correct use
and operation of your Thermal Arc product. Your satisfaction with this
product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions.
They will help you to avoid potential hazards that may exist when working
with this product.
We have made every effort to provide you with accurate instructions,

drawings, and photographs of the product(s) while writing this manual.
However errors do occur and we apologize if there are any contained in this
manual.
Due to our constant effort to bring you the best products, we may make
an improvement that does not get reflected in the manual. If you are ever
in doubt about what you see or read in this manual with the product you
received, then check for a newer version of the manual on our website or
contact our customer support for assistance.
YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for Victor
Technologies We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-leading,

dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales
and marketing expertise.
Above all, we are committed to develop technologically advanced products

to achieve a safer working environment within the welding industry.
! WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement,
the Manufacturer assumes no liability for its use.
Welding Power Supply

Service Manual Number 0-5240 for:
Thermal Arc 202 AC/DC Part Number W1006305

Thermal Arc 202 AC/DC Package Part Number W1006306
Published by:
Victor Technologies Europe
Europa Building
Chorley Industrial Park
Chorley, Lancaster,
England, PR6 7BX
www.victortechnologies.com
Copyright 2012, 2013, 2014, 2015 by

Victor Technologies, 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 from negligence, accident, or any other cause.
Publication Date: November 2, 2012

Revision Date: August 3, 2015
Record the following information for Warranty purposes:
Where Purchased: _____________________________________
Purchase Date: _____________________________________
Equipment Serial #: _____________________________________
ii
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS........................................................ 1-1
1.01 Arc Welding Hazards........................................................................................ 1-1
1.02 Principal Safety Standards............................................................................... 1-4
1.03 Symbol Chart................................................................................................... 1-5
1.04 Servicing Hazards............................................................................................ 1-6
1.05 EMF Information.............................................................................................. 1-7
SECTION 2:
INTRODUCTION....................................................................................... 2-1
2.01 How to Use This Manual.................................................................................. 2-1
2.02 Equipment Identification.................................................................................. 2-1
2.03 Receipt of Equipment....................................................................................... 2-1
2.04 Description...................................................................................................... 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 High Frequency Introduction........................................................................... 3-3
3.06 High Frequency Interference............................................................................ 3-4
3.07 Electromagnetic Compatibility......................................................................... 3-4
3.08 Volt-Ampere Curves......................................................................................... 3-6
SECTION 4:
OPERATION............................................................................................ 4-1
4.01 202AC/DC Power Source Controls, Indicators and Features............................ 4-1
4.02 202 AC/DC - STICK Programming Mode......................................................... 4-5
4.03 202 AC/DC – LIFT TIG and HF TIG Programming Mode ................................. 4-6
4.04 Short Circuit Protection While Welding.......................................................... 4-10
4.05 Setup for TIG (GTAW) Welding...................................................................... 4-10
4.06 Setup for STICK (MMA) Welding ................................................................. 4-12
SECTION 5:
THEORY OF OPERATION............................................................................. 5-1
5.01 Inverter Design................................................................................................ 5-1
SECTION 6:
TROUBLESHOOTING................................................................................. 6-1
6.01 Basic Troubleshooting-Power Source Faults.................................................... 6-1
6.02 Advanced Troubleshooting............................................................................... 6-2
6.03 Test Equipment and Tools ............................................................................... 6-2
6.04 Visually Inspect................................................................................................ 6-2
6.05 Preliminary DC Bus measurement of the main inverter board......................... 6-3
6.06 Preliminary check of the main inverter board.................................................. 6-4
6.07 Check main input rectifier................................................................................ 6-4
6.08 DC Bus voltage measurement.......................................................................... 6-4
6.09 PCB Connectors............................................................................................... 6-5
TABLE OF CONTENTS
6.10 DIP switch settings, Control PCB................................................................... 6-14
6.11 Calibration..................................................................................................... 6-15
6.12 Main Circuit Description................................................................................ 6-16
6.13 Circuit Diagram.............................................................................................. 6-17
SECTION 7:
DISASSEMBLY PROCEDURE........................................................................ 7-1
7.01 Safety Precautions for Disassembly................................................................ 7-1
7.02 Case Removal.................................................................................................. 7-1
7.03 Control Board Removal.................................................................................... 7-2
7.04 Auxiliary Power Supply PCB2 Removal........................................................... 7-3
7.05 PCB3 Removal................................................................................................. 7-4
7.06 PCB4 Removal................................................................................................. 7-5
7.07 PCB5 Removal................................................................................................. 7-5
7.08 Front Panel assembly Removal ....................................................................... 7-6
7.09 Front Panel (operator Interface) Circuit Board PCB Removal........................... 7-7
7.10 Back Panel Removal........................................................................................ 7-8
7.11 Main Power PCB1 Removal............................................................................. 7-9
7.12 Main Power PCB2 Removal........................................................................... 7-10
7.13 Power Switch S1, Fan and Power Cord Removal........................................... 7-11
SECTION 8:
ASSEMBLY PROCEDURES........................................................................... 8-1
8.01 Installing Main Power PCB1............................................................................ 8-1
8.02 Installing Main Power PCB2............................................................................ 8-2
8.03 Installing Front Panel....................................................................................... 8-3
8.04 Installing Rear Panel........................................................................................ 8-4
8.05 Installing PCB5................................................................................................ 8-5
8.06 Installing PCB4................................................................................................ 8-5
8.07 Installing PCB3................................................................................................ 8-6
8.08 Installing Auxiliary Power Supply PCB2........................................................... 8-6
8.09 Installing Control Board................................................................................... 8-7
8.10 Installing Case................................................................................................. 8-8
SECTION 9:
KEY SPARE PARTS.................................................................................... 9-1
9.01 Power Source.................................................................................................. 9-1
LIMITED WARRANTY & WARRANTY SCHEDULE
SAFETY INSTRUCTIONS AND WARNINGS 202 AC/DC
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
! WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS
KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL
BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the European Standard EN60974-1 entitled: Safety in welding and allied processes Part 2: Electrical. This
publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
12. Use only well-maintained equipment. Repair or replace

1.01 Arc Welding Hazards damaged parts at once.
13. In confined spaces or damp locations, do not use a welder
with AC output unless it is equipped with a voltage reducer.
WARNING Use equipment with DC output.
ELECTRIC SHOCK can kill. 14. Wear a safety harness to prevent falling if working above floor
level.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is 15. Keep all panels and covers securely in place.
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live
when power is on. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing, and all WARNING
metal parts touching the welding wire are electrically
live. Incorrectly installed or improperly grounded ARC RAYS can burn eyes and skin; NOISE can dam-
equipment is a hazard age hearing.
1. Do not touch live electrical parts. Arc rays from the welding process produce intense
2. Wear dry, hole-free insulating gloves and body protection. heat and strong ultraviolet rays that can burn eyes and
skin. Noise from some processes can damage hearing.
3. Insulate yourself from work and ground using dry insulating
mats or covers. 1. Use a Welding Helmet or Welding Faceshield fitted with a
proper shade of filter (see ANSI Z49.1 and AS 1674 listed in
4. Disconnect input power or stop engine before installing or Safety Standards) to protect your face and eyes when welding
servicing this equipment. Lock input power disconnect switch or watching.
open, or remove line fuses so power cannot be turned on 2. Wear approved safety glasses. Side shields recommended.
accidentally.
5. Properly install and ground this equipment according to its 3. Use protective screens or barriers to protect others from flash
Owner’s Manual and national, state, and local codes. and glare; warn others not to watch the arc.
6. Turn off all equipment when not in use. Disconnect power to 4. Wear protective clothing made from durable, flame-resistant
equipment if it will be left unattended or out of service. material (wool and leather) and foot protection.
7. Use fully insulated electrode holders. Never dip holder in 5. Use approved ear plugs or ear muffs if noise level is high.
water to cool it or lay it down on the ground or the work 6. Never wear contact lenses while welding.
surface. Do not touch holders connected to two welding
machines at the same time or touch other people with the
holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced WARNING
cables.
FUMES AND GASES can be hazardous to your health.
9. Do not wrap cables around your body. Welding produces fumes and gases. Breathing these
10. Ground the workpiece to a good electrical (earth) ground. fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
11. Do not touch electrode while in contact with the work (ground)
circuit.
Manual 0-5240 1-1 Safety Instructions and Warnings
202 AC/DC SAFETY INSTRUCTIONS AND WARNINGS
2. If inside, ventilate the area and/or use exhaust at the arc to 1. Wear approved face shield or safety goggles. Side shields
remove welding fumes and gases. recommended.
3. If ventilation is poor, use an approved air-supplied respirator. 2. Wear proper body protection to protect skin.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
and cleaners.
WARNING
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for CYLINDERS can explode if damaged.
welding can displace air causing injury or death. Be sure the Shielding gas cylinders contain gas under high
breathing air is safe. pressure. If damaged, a cylinder can explode. Since
6. Do not weld in locations near degreasing, cleaning, or gas cylinders are normally part of the welding process,
spraying operations. The heat and rays of the arc can react be sure to treat them carefully.
with vapours to form highly toxic and irritating gases.
1. Protect compressed gas cylinders from excessive heat,
7. Do not weld on coated metals, such as galvanized, lead, or mechanical shocks, and arcs.
cadmium plated steel, unless the coating is removed from the 2. Install and secure cylinders in an upright position by chaining
weld area, the area is well ventilated, and if necessary, while them to a stationary support or equipment cylinder rack to
wearing an air-supplied respirator. The coatings and any metals prevent falling or tipping.
containing these elements can give off toxic fumes if welded.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a welding electrode to touch any cylinder.
WARNING
5. Use only correct shielding gas cylinders, regulators, hoses, and
WELDING can cause fire or explosion. fittings designed for the specific application; maintain them and
Sparks and spatter fly off from the welding arc. associated parts in good condition.
The flying sparks and hot metal, weld spatter, hot 6. Turn face away from valve outlet when opening cylinder
workpiece, and hot equipment can cause fires and valve.
burns. Accidental contact of electrode or welding wire
to metal objects can cause sparks, overheating, or fire. 7. Keep protective cap in place over valve except when cylinder is
1. Protect yourself and others from flying sparks and hot metal. in use or connected for use.
2. Do not weld where flying sparks can strike flammable 8. Read and follow instructions on compressed gas cylinders,
material. associated equipment, and CGA publication P-1 listed in Safety
Standards.
3. Remove all flammables within 35 ft (10.7 m) of the welding
arc. If this is not possible, tightly cover them with approved
covers.
WARNING
4. Be alert that welding sparks and hot materials from welding
can easily go through small cracks and openings to adjacent MOVING PARTS can cause injury.
areas.
Moving parts, such as fans, rotors, and belts can cut fingers and
5. Watch for fire, and keep a fire extinguisher nearby. hands and catch loose clothing.
6. Be aware that welding on a ceiling, floor, bulkhead, or 1. Keep all doors, panels, covers, and guards closed and
partition can cause fire on the hidden side. securely in place.
7. Do not weld on closed containers such as tanks or drums. 2. Stop engine before installing or connecting unit.
8. Connect work cable to the work as close to the welding area 3. Have only qualified people remove guards or covers for
as practical to prevent welding current from travelling long, maintenance and troubleshooting as necessary.
possibly unknown paths and causing electric shock and fire
hazards. 4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
9. Do not use welder to thaw frozen pipes.
5. Keep hands, hair, loose clothing, and tools away from
10. Remove stick electrode from holder or cut off welding wire at moving parts.
contact tip when not in use.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
Safety Instructions and Warnings 1-2 Manual 0-5240

AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
Minimum Suggested*
Electrode Size in. Arc Current
Process Protective Shade No.
(mm) (Amperes)
Shade (Comfort)
Less than 3/32 (2.4) Less than 60 7 -
Shielded Metal Arc Welding 3/32-5/32 (2.4-4.0) 60-160 8 10
(SMAW) 5/32-1/4 (4.0-6.4) 160-250 10 12
More than 1/4 (6.4) 250-550 11 14
Less than 60 7 -
Gas Metal Arc Welding (GMAW)
60-160 10 11
and Flux Cored Arc Welding 　
160-250 10 12
(FCAW)
250-550 10 14
Less than 50 8 10
Gas Tungsten arc Welding
　 50-150 8 12
(GTAW)
150-500 10 14
Less than
(Light) 10 12
Air Carbon Arc Cutting (CAC-A) 500
(Heavy) 11 14
500-1000
Less than 20 6 6 to 8
20-100 8 10
Plasma Arc Welding (PAW) 　
100-400 10 12
400-800 11 14
Less than 20 4 4
20-40 5 5
40-60 6 6
Plasma Arc Cutting (PAC) 　 60-80 8 8
80-300 8 9
300-400 9 12
400-800 10 14
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter
shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas
welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable
to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.

1.02 Principal Safety Standards
! WARNING Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
This product, when used for welding or cutting, pro-
duces fumes or gases which contain chemicals know Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
to the State of California to cause birth defects and, in dent of Documents, U.S. Government Printing Office, Washington,
some cases, cancer. (California Health & Safety code D.C. 20402.
Sec. 25249.5 et seq.)
Recommended Safe Practices for the Preparation for Welding and
NOTE Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding
Considerations About Welding And The Effects of Low Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Frequency Electric and Magnetic Fields
National Electrical Code, NFPA Standard 70, from National Fire
The following is a quotation from the General Conclusions Section Protection Association, Batterymarch Park, Quincy, MA 02269.
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields - Background Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing from Compressed Gas Association, 1235 Jefferson Davis Highway,
Office, May 1989): “...there is now a very large volume of scientific Suite 501, Arlington, VA 22202.
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency Code for Safety in Welding and Cutting, CSA Standard W117.2, from
magnetic fields and interact with, and produce changes in, biological Canadian Standards Association, Standards Sales, 178 Rexdale
systems. While most of this work is of very high quality, the results Boulevard, Rexdale, Ontario, Canada M9W 1R3.
are complex. Current scientific understanding does not yet allow Safe Practices for Occupation and Educational Eye and Face Pro-
us to interpret the evidence in a single coherent framework. Even tection, ANSI Standard Z87.1, from American National Standards
more frustrating, it does not yet allow us to draw definite conclu- Institute, 1430 Broadway, New York, NY 10018.
sions about questions of possible risk or to offer clear science-based
advice on strategies to minimize or avoid potential risks.” Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
To reduce magnetic fields in the workplace, use the following
procedures. Safety in welding and allied processes Part 1: Fire Precautions, AS
1674.1-1997 from SAI Global Limited, www.saiglobal.com.
1. Keep cables close together by twisting or taping them.
Safety in welding and allied processes Part 2: Electrical, AS 1674.2-
2. Arrange cables to one side and away from the operator. 2007 from SAI Global Limited, www.saiglobal.com.
3. Do not coil or drape cable around the body. Filters for eye protectors - Filters for protection against radiation
4. Keep welding power source and cables as far away from body generated in welding and allied operations AS/NZS 1338.1:1992
as practical. from SAI Global Limited, www.saiglobal.com.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.

1.03 Symbol Chart
Note that only some of these symbols will appear on your model.
ON Single Phase Wire Feed Function
Wire Feed Towards

OFF Three Phase Workpiece With
Output Voltage OFF.
Three Phase Static
Dangerous Voltage Frequency Converter- Welding Gun
Transformer-Rectifier
Increase/Decrease Remote Purging Of Gas
X
Continuous Weld
Circuit Breaker Duty Cycle
Mode
AC Auxiliary Power % Percentage Spot Weld Mode
Fuse Panel/Local Spot Time

t
Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)
Gas Metal Arc

Voltage t2
Postflow Time
Welding (GMAW)
Gas Tungsten Arc 2 Step Trigger

Hertz (cycles/sec) Welding (GTAW) Operation
Press to initiate wirefeed and
Air Carbon Arc welding, release to stop.
Frequency
Cutting (CAC-A)
Negative Constant Current 4 Step Trigger

Operation
Press and hold for preflow, release
Constant Voltage to start arc. Press to stop arc, and
Positive
Or Constant Potential hold for preflow.
Direct Current (DC) High Temperature

t Burnback Time
Protective Earth
Fault Indication
(Ground) IPM Inches Per Minute
Line Arc Force

MPM Meters Per Minute
Line Connection Touch Start (GTAW)

S See Note
Auxiliary Power Variable Inductance See Note
115V 15A Receptacle Rating- Pulse Welding

V Voltage Input
Auxiliary Power
Art # A-10663_AB

1.04 Servicing Hazards
! WARNING
WARNING
FLYING METAL or DIRT can injure eyes.
The symbols shown below are used throughout this • Wear safety glasses with side shields or face shield during
manual to call attention to and identify possible haz- servicing.
ards. When you see the symbol, watch out, and follow
• Be careful not to short metal tools, parts, or wires together
the related instructions to avoid the hazard.
during testing and servicing.
Only qualified persons should test, maintain, and
repair this unit.
Only qualified persons should test, maintain, and WARNING
repair this unit.
HOT PARTS can cause sever burns.
• Do not touch hot parts bare handed.

WARNING • Allow cooling period before working on equipment.
• To handle not parts, use proper tools and/or wear heavy,
ELECTRIC SHOCK can kill.
insulated welding gloves and clothing to prevent burns.
• Do not touch live electrical parts.
• Turn Off welding power source and wire feeder and disconnect
and lockout input power using line disconnect switch, circuit WARNING
breakers, or by removing plug from receptacle, or stop engine
before servicing unless the procedure specifically requires an EXPLODING PARTS can cause injury.
energized unit. • Failed parts can explode or cause other parts to explode when
• Insulate yourself from ground by standing or working on power is applied to inverters.
dry insulating mats big enough to prevent contact with the • Always wear a face shield and long sleeves when servicing
ground. inverters.
• Do not leave live unit unattended.
• If this procedure requires and energized unit, have only per-
sonnel familiar with and following standard safety practices
WARNING
do the job.
• When testing a live unit, use the one-hand method. Do not SHOCK HAZARD from testing.
put both hands inside unit. Keep one hand free.
• Turn Off welding power source and wire feeder or stop engine
• Disconnect input power conductors from de-energized supply before making or changing meter lead connections.
line BEFORE moving a welding power source.
• Use at least one meter lead that has a self-retaining spring
SIGNIFICANT DC VOLTAGE exists after removal of input clip such as an alligator clip.
power on inverters.
• Read instructions for test equipment.
• Turn Off inverters, disconnect input power, and discharge
input capacitors according to instructions in Troubleshooting
Section before touching any parts.
WARNING
FALLING UNIT can cause injury.
WARNING
• Use lifting eye to lift unit only, NOT running gear, gas cylinders,
STATIC (ESD) can damage PC boards. or any other accessories.
• Put on grounded wrist strap BEFORE handling boards or parts. • Use equipment of adequate capacity to lift and support unit.
• Use proper static-proof bags and boxes to store, move, or • If using lift forks to move unit, be sure forks are long enough
ship PC boards. to extend beyond opposite side of unit.
WARNING
WARNING
MOVING PARTS can cause injury,
FIRE OR EXPLOSION hazard.
• Keep away from moving parts such as fans.
• Do not place unit on, over, or near combustible surfaces.
• Keep away from pinch points such as drive rolls.
• Do not service unit near flammables.
• Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
• Keep hands, hair, loose clothing, and tools away from moving
parts.

• Reinstall doors, panels, covers, or guards when maintenance
is finished and before reconnecting input power. 1.05 EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
WARNING Welding current, as it flows through welding cables, will cause
electromagnetic fields. There has been and still is some concern
MAGNETIC FIELDS can affect Implanted Medical
about such fields. However, after examining more than 500 studies
Devices.
spanning 17 years of research, a special blue ribbon committee
• Wearers of Pacemakers and other Implanted Medical Devices of the National Research Council concluded that: “The body of
should keep away from servicing areas until consulting their evidence, in the committee’s judgment, has not demonstrated
doctor and the device manufacturer. that exposure to power-frequency electric and magnetic fields is
a human-health hazard.” However, studies are still going forth and
evidence continues to be examined. Until the final conclusions of
the research are reached, you may wish to minimize your exposure
WARNING to electromagnetic fields when welding or cutting.
OVERUSE can cause OVERHEATING. To reduce magnetic fields in the workplace, use the following
procedures:
• Allow cooling period; follow rated duty cycle.
1. Keep cables close together by twisting or taping them, or using
• Reduce current or reduce duty cycle before starting to weld a cable cover.
again.
2. Arrange cables to one side and away from the operator.
• Do not block or filter airflow to unit.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator
WARNING as practical.
H.F. RADIATION can cause interference. 5. Connect work clamp to workpiece as close to the weld as pos-
sible.
• High-frequency (H.F.) can interfere with radio navigation,
About Implanted Medical Devices:
safety services, computers, and communications equipment.
• Have only qualified persons familiar with electronic equipment Implanted Medical Device wearers should consult their doctor
install, test, and service H.F. producing units. and the device manufacturer before performing or going near arc
welding, spot welding, gouging, plasma arc cutting, or induction
• The user is responsible for having a qualified electrician
heating operations. If cleared by your doctor, then following the
promptly correct any interference problem resulting from
above procedures is recommended
the installation.
• If notified by the FCC about interference, stop using the
equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
! WARNING
READ INSTRUCTIONS.
• Use Testing Booklet (Part No. 150 853) when servicing this
unit.
• Consult the Owner’s Manual for welding safety precau-
tions.
• Use only genuine replacement parts from the manufac-
turer.

Notes

INTRODUCTION 202 AC/DC
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual 2.03 Receipt of Equipment
To ensure safe operation, read the entire manual, includ- When you receive the equipment, check it against the
ing the chapter on safety instructions and warnings. invoice to make sure it is complete and inspect the
Throughout this manual, the word WARNING, CAU- equipment for possible damage due to shipping. If there
TION and NOTE may appear. Pay particular attention to is any damage, notify the carrier immediately to file a
the information provided under these headings. These claim. Furnish complete information concerning damage
special annotations are easily recognized as follows: claims or shipping errors to the location in your area
listed in the inside back cover of this manual. Include
! WARNING
all equipment identification numbers as described above
along with a full description of the parts in error.
Gives information regarding possible per- 2.04 Description

sonal injury. Warnings will be enclosed in a
box such as this. The Thermal Arc 202 AC/DC is a single phase constant
current welding inverter capable of performing MMA
(Stick), GTAW (HF TIG) and GTAW (Lift TIG) welding
CAUTION processes. The unit is equipped with digital amperage
Refers to possible equipment damage. Cau- and voltage meters, and a host of other features in
tions will be shown in bold type. order to fully satisfy the broad operating needs of the
modern user. The unit is also fully compliant to European
NOTE Standard EN 60974-1 and IEC 60974.1.
Offers helpful information concerning certain
The 202 AC/DC provides excellent welding performance
operating procedures. Notes will be shown
across a broad range of applications when used with the
in italics
correct welding consumables and procedures. The fol-
You will also notice icons from the safety section ap- lowing instructions detail how to correctly and safely set
pearing throughout the manual. These are to advise you up the machine and give guidelines on gaining the best
of specific types of hazards or cautions related to the efficiency and quality from the Power Source. Please
portion of information that follows. Some may have read these instructions thoroughly before using the unit.
multiple hazards that apply and would look something
like this: 2.05 Transportation Methods
! Disconnect input power

2.02 Equipment Identification conductors from de-energized supply line before
moving the welding power source.
The unit’s identification number (specification or part
Lift unit with handle on top of case. Use handcart or
number), model, and serial number usually appear
similar device of adequate capacity. If using a fork
on a nameplate attached to the machine. Equipment
lift vehicle, secure the unit on a proper skid before
which does not have a nameplate attached to the
transporting.
machine is identified only by the specification or part
number printed on the shipping container. Record these
numbers for future reference.
Manual 0-5240 2-1 Introduction

202 AC/DC INTRODUCTION
Notes
Introduction 2-2 Manual 0-5240

SAFETY AND INSTALLATION 202 AC/DC
SECTION 3:
SAFETY AND INSTALLATION
3.01 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding
current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10
minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate
at a 20% duty cycle, 200 amperes at 18.0 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 the other 8 minutes of the 10 minute period the Welding Power Source must idle and be
allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.
100
90
Duty Cycle (PERCENTAGE)
80 202 AC/DC
70
60
MMA (STICK)
50
GTAW (TIG)
40
30 SAFE OPERATING REGION

20
(TIG & STICK)
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
Welding Current (AMPS) A-11402
Figure 3-1: 202 AC/DC Duty Cycle
Manual 0-5240 3-1 Safety and Installation

202 AC/DC SAFETY AND INSTALLATION
3.02 Specifications
Description Thermal Arc 202 AC/DC
Part Number W1006305
Power Source Mass 22 kg
Power Source Dimensions H 400mm x W 240mm x D 475mm
Cooling Fan Cooled
Welder Type Inverter Power Source
European Standards EN 60974-1 / IEC 60974-1
Number of Phases 1
Nominal Supply Voltage 230V +/- 15%
Nominal Supply Frequency 50/60Hz
Welding Current Range (DC STICK Mode) 10 – 170A
Welding Current Range (DC TIG Mode) 10 - 200A
Effective Input Current (I1eff) (note1)
STICK 15.5A
TIG 14.1A
Maximum Input Current (I1max)
STICK 34.9A
TIG 32.4A
Single Phase Generator Requirement (note2) 9.5kVA
STICK (MMA) 170A @ 15%, 26.8V
Welding Output, 40ºC, 10 min. 100A @ 60%, 24.0V
80A @ 100%, 23.2V
TIG (GTAW) 200A @ 20%, 18V
Welding Output, 40ºC, 10 min. 116A @ 60%, 14.6V
90A @ 100%, 13.6V
Open circuit voltage 70.3V DC / 50 VAC
Protection Class IP23S
Table 3-1: 202 AC/DC Specification
NOTE
Note 1: The Effective Input Current should be used for the determination of cable size & supply
requirements.
Note 2: Generator Requirements at the Maximum Output Duty Cycle.
Note 3: Motor start fuses or thermal circuit breakers are recommended for this application. Check local
requirements for your situation in this regard.
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.
Safety and Installation 3-2 Manual 0-5240

3.03 Environment
This machine is not designed for use in environments with increased hazard of electric shock as outlined in EN
60974.1. Additional safety precautions may be required when using unit in an environment with increased hazard
of electric shock. Please refer to relevant local standards for further information prior to using in such areas.
A. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in
a cramped (kneeling, sitting or lying) position with physical contact with conductive parts.
B. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator.
C. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the
human body and the insulation properties of accessories.
Environments with increased hazard of electric shock do not include places where electrically conductive parts in
the near vicinity of the operator, which can cause increased hazard, have been insulated.
3.04 Location
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust.
• Ambient temperature between -10°C to 40° C (14°F to 104° F).
• In areas, free from oil, steam and corrosive gases.
• In areas, not subjected to abnormal vibration or shock.
• In areas, not exposed to direct sunlight or rain.
• Place at a distance of 300mm (12”) or more from walls or similar that could restrict natural air flow for
cooling
• The enclosure design of this power source meets the requirements of IP23S as outlined in EN 60529. This
provides adequate protection against solid objects (greater than 12mm), and direct protection from vertical
drops. Under no circumstances should the unit be operated or connected in a micro environment that will
exceed the stated conditions. For further information please refer to EN 60529.
• Precautions must be taken against the power source toppling over. The power source must be located on
a suitable horizontal surface in the upright position when in use.
! WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3.05 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference
due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following
information is intended as a guide for personnel installing high frequency welding machines.
! WARNING EXPLOSIVES
The high frequency section of this machine has an output similar to a radio transmitter. The machine
should NOT be used in the vicinity of blasting operations due to the danger of premature firing

cases this remedial action may be as simple as earthing
! WARNING COMPUTER
the welding circuit, see NOTE below. In other cases it
could involve constructing an electromagnetic screen
enclosing the Welding Power Source and the work,
It is also possible that operation close to complete with associated input filters. In all cases,
computer installations may cause computer electromagnetic disturbances shall be reduced to the
malfunction. point where they are no longer Trouble-some.
NOTE
3.06 High Frequency Interference The welding circuit may or may not be
Interference may be transmitted by a high frequency earthed for safety reasons. Changing the
initiated or stabilised arc welding machine in the earthing arrangements should only be
following ways. authorised by a person who is competent to
assess whether the changes will increase the
1. Direct Radiation: Radiation from the machine can risk of injury, e.g. by allowing parallel welding
occur if the case is metal and is not properly grounded. current return paths which may damage the
It can occur through apertures such as open access earth circuits of other equipment. Further
panels. The shielding of the high frequency unit in guidance is given in IEC 974-13 Arc Welding
the Power Source will prevent direct radiation if the Equipment - Installation and use (under
equipment is properly grounded. preparation).
2. Transmission via the Supply Lead: Without
adequate shielding and filtering, high frequency energy B. Assessment of Area
may be fed to the wiring within the installation (mains) Before installing welding equipment, the user shall make
by direct coupling. The energy is then transmitted by an assessment of potential electromagnetic problems
both radiation and conduction. Adequate shielding and in the surrounding area. The following shall be taken
filtering is provided in the Power Source. into account.
3. Radiation from Welding Leads: Radiated interference 1. Other supply cables, control cables, signaling and
from welding leads, although pronounced in the vicinity telephone cables; above, below and adjacent to the
of the leads, diminishes rapidly with distance. Keeping welding equipment.
leads as short as possible will minimise this type of
interference. Looping and suspending of leads should 2. Radio and television transmitters and receivers.
be avoided wherever possible.
3. Computer and other control equipment.
4. Re-Radiation from Unearthed Metallic Objects: A
4. Safety critical equipment, e.g. guarding of industrial
major factor contributing to interference is re-radiation
equipment.
from unearthed metallic objects close to the welding
leads. Effective grounding of such objects will prevent 5. The health of people around, e.g. the use of pace-
re-radiation in most cases. makers and hearing aids.
6. Equipment used for calibration and measurement.
3.07 Electromagnetic Compatibility
7. The time of day that welding or other activities are
to be carried out.
WARNING 8. The immunity of other equipment in the environment:
Extra precautions for Electromagnetic the user shall ensure that other equipment being
Compatibility may be required when this used in the environment is compatible: this may
Welding Power Source is used in a domestic require additional protection measures.
situation. The size of the surrounding area to be considered
will depend on the structure of the building and other
A. Installation and Use - Users Responsibility activities that are taking place. The surrounding area
may extend beyond the boundaries of the premises.
The user is responsible for installing and using the
welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are
detected then it shall be the responsibility of the user
of the welding equipment to resolve the situation with
the technical assistance of the manufacturer. In some
C. Methods of Reducing Electromagnetic Emissions
1. Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.
If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.
Consideration should be given to shielding the supply cable of permanently installed welding equipment in
metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding
should be connected to the Welding Power Source so that good electrical contact is maintained between the
conduit and the Welding Power Source enclosure.
2. Maintenance of Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All
access and service doors and covers should be closed and properly fastened when the welding equipment is in
operation. The welding equipment should not be modified in any way except for those changes and adjustments
covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilizing devices
should be adjusted and maintained according to the manufacturer’s recommendation
3. Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at or
close to the floor level.
4. Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. However,
metallic components bonded to the work piece will increase the risk that the operator could receive a shock by
touching the metallic components and the electrode at the same time. The operator should be insulated from
all such bonded metallic components.
5. Earthing of the Work Piece
Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size
and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce
emissions in some, but not all instances. 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 earth should be made by direct connection to the work piece, but in some countries where
direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according
to national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems
of interference. Screening the entire welding installation may be considered for special applications.

3.08 Volt-Ampere Curves
Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source.
Curves of other settings fall between curves shown.
100
90
80
70
202 AC/DC
60
e (volts)
Output Voltage
50
TIG
40 STICK
30
20
10
0
0 20 40 60 80 100 120 140 160 180 200 220 240
Welding Current (AMPS) A-11602
Figure 3-2: 202 AC/DC Volt-Ampere Curves

INSTALLATION/SETUP 202 AC/DC INVERTER
SECTION 4:
INSTALLATION, OPERATION AND SETUP
4.01 202 AC/DC Power Source Controls, Indicators and Features
18 19 5
17
MODE
MODE
A V
V
VOLTS
6
AC SEC
SECONDS
16 %
PERCENT (%) POWER
7
DC
Hz (Hz)
FREQ FAULT
Peak
Amps I1
Current Volts
PULSE
PULSE PROCESS
PROCESS
Is High Current
LIFTTIG
TIG
Hot w LIFT
Start Trough
Base
Base I2
Current HFTIG
TIG
Current Width
Width
HF
Hot Iz Up Current Ie
Up f Low Down
Down
Start Slope Slope STICK
t1
Slope Current Slope t2
STICK
Initial
Initial Frequency Crater
Crater
Current Frequency Current
Current Current
Pre Post
PURGE
PURGE Pre
Flow
Post
Flow TRIGGER
TRIGGER
Flow Flow
8
WAVE WAVE
BALANCE
BALANCE 2TNORMAL
2T
AC FREQUENCY
FREQUENCY
15
AC (ARC FORCE)
ARC FORCE
4TLATCH
4T
9
BACK FORWARD
202
BACK FORWARD
14
200 AC/DC
PORTABLE WELDING MACHINE
Inverter
WeldSkill
10
13
12
11
Art # A-11403_AC
1 2 3 4
Figure 4-1: 202 AC/DC Controls, Indicators and Features on Front Panel
20
ON
OFF
21
22
A-11232
Figure 4-2: Rear Panel
Manual 0-5240 4-1 INSTALLATION, OPERATION AND SETUP

1. Positive Welding Terminal
Positive Welding Terminal. Welding current flows from the Power Source via heavy duty bayonet type
terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.
2. 8 Pin Control Socket
The 8 pin receptacle is used to connect a trigger switch or remote control to the welding Power Source
circuitry:
To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket
information is included in the event the supplied cable is not suitable and it is necessary to wire a plug
or cable to interface with the 8 pin receptacle.
Socket Pin Part Number / Description

1 Not used
2 Trigger Switch Input
3 Trigger Switch Input
4 Not used
5 Remote Control 5k ohm Potentiometers Maximum
6 Remote Control 5k ohm Potentiometers Minimum
7 Remote Control 5k ohm Potentiometer Wiper
8 Not used
Table 4-1: 8 Pin Interconnection Control Plug Configuration

3. Negative Welding Terminal
Negative Welding Terminal. Welding current flows from the Power Source via heavy duty bayonet type
terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
4. Shielding Gas Outlet
The Shield Gas Outlet located on the front panel is a 5/8-18 UNF female gas fitting and is utilised for the
connection of a suitable TIG Torch.
5. Power ON Indicator
The POWER ON indicator illuminates when the ON/OFF switch (20) is in the ON position and the correct
mains voltage is present.
6. Thermal Overload Indicator Light
This welding power source is protected by a self resetting thermostat. The indicator will illuminate if
the duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate
the output of the power source will be disabled. Once the power source cools down this light will go
OFF and the over temperature condition will automatically reset. Note that the mains power switch
should remain in the on position such that the fan continues to operate thus allowing the unit to cool
sufficiently. Do not switch the unit off should a thermal overload condition be present.
7. Process Selection Button
INSTALLATION, OPERATION AND SETUP 4-2 Manual 0-5240

The process selection control is used to select the desired welding mode. Three modes are available,
GTAW (LIFT TIG), GTAW (HF TIG) and MMA (Stick) modes.
Note that when the unit is powered off the mode selection control will automatically default to LIFT TIG
for Stick or LIFT TIG modes and HF TIG for HF TIG mode.
This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the
unit and mistakenly be in contact with the work piece during power up.
8. Trigger Mode Control Button (HF TIG and LIFT TIG Mode only)
The trigger mode control is used to switch the functionality of the of the torch trigger between 2T
(normal), and 4T (latch mode).
2T Normal Mode
In this mode, the torch trigger must remain depressed for the welding output to be active. Press and
hold the torch trigger to activate the power source (weld). Release the torch trigger switch to cease
welding.
High
Low
A-11409
Figure 4-3
4T Latch Mode
This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode
the operator can press and release the torch trigger and the output will remain active. To deactivate the
power source, the trigger switch must again be depressed and realised, thus eliminating the need for
the operator to hold the torch trigger.
Note that when operating in GTAW (HF and LIFT TIG modes), the power source will remain activated
until the selected down slope time has elapsed
AMPS
High
Current
Weld
Current
Down
Arc Ignited Slope Arc Terminated
Up
Initial Slope
Current Crater
Current
TIME
Post
Pre Flow
Flow
Press & hold Release Press & hold Release

Trigger Trigger Trigger Trigger A-11410_AB
Figure 4-4

9. Wave Balance / Arc Force Indicator
This indicator light will illuminate when programming Wave Balance (AC HF TIG mode only) or Arc
Force (STICK mode only).
10. Forward Programming Button
Pressing this button will advance to the next step in the programming sequence.
11. Multifunction Control
The multifunction control knob is used to adjust welding current.
It is also used to adjust parameters when in programming mode.
12. Back Programming Button

Pressing this button will go back to the previous step in the programming sequence.
13 .AC frequency Indicator
This indicator light will illuminate when programming AC Frequency (AC HF TIG mode only).
14. Purge Button
Press and hold the PURGE button to purge the gas line in LIFT TIG and HF TIG modes. To PURGE the
shielding gas line in LIFT TIG and HF TIG modes press the PURGE button and release. The indicator will
illuminated and shielding gas will purge for a preset period of 15 seconds. (This cannot be adjusted).
To stop shielding gas from purging within this time press the PURGE button and release and the purge
indicator will extinguish and shielding gas will cease.
15 Pulse Button
Press the PULSE button to toggle Pulse On and OFF in LIFT TIG and HF TIG modes
16. Programming Parameter Indicators
These indicator lights will illuminate when programming.
17. Mode Button
Press the MODE button to toggle AC and DC output in LIFT TIG, HF TIG and STICK.
18. Digital Ammeter
The digital amperage meter is used to display both the pre-set current and actual output current of the
power source.
At times of non-welding, the amperage meter will display a pre-set (preview) amperage value. This
value can be adjusted by varying the multifunction control when the Programming Parameter Indicator
light shows BASE CURRENT.
When welding, the amperage meter will display actual welding current.
Should a remote device be connected the maximum setting of the power source will be determined by
the respective front panel control, irrespective of the remote control device setting. As an example, if
the output current on the power source front panel is set to 50% and the remote control device is set to
100%, the maximum achievable output from the unit will be 50%. Should 100% output be required, the
respective power source front panel control must be set to 100%, in which case the remote device will
then be able to control between 0-100% output.
19. Digital Voltmeter / Parameter meter
The digital volt meter is used to display the actual output voltage of the power source. It is also used to
display Parameters in Programming Mode.
Depending on the Programming Parameter selected, the status indictor adjacent to the volt meter will
illuminate to show the units of the programming parameter.
When welding, the volt meter will display actual welding voltage.
20. On / Off Switch (not shown)
This Switch is located on the rear of the Power Source and turns mains power off and on.
! WARNING
When the front digital displays are lit, the machine is connected to the Mains supply voltage and
the internal electrical components are at Mains voltage potential.
21. Shielding Gas Inlet
The Shielding Gas Inlet is a quick disconnect nipple suitable for connection of a gas hose to a regulated
Shielding Gas Supply. The Shielding Gas inlet is located on the rear of the Power Source.
22. Cooling Fan
The 202 AC/DC is fitted with a cooling fan that will operate continuously when the On/Off switch on the
rear panel is switched to the On position.
4.02 202 AC/DC - STICK Programming Mode

Press the PROCESS button to select STICK mode.
Press the MODE switch to toggle between AC and DC welding output. When AC is selected the frequency is
fixed at 50Hz.
The Programming LED’s are always active. Press FORWARD or BACK to cycle through available
programming functions.
Use the Multi Function Control to adjust the Parameter selected.
While welding the Multi Function Control directly controls the BASE CURRENT
MODE
A V
V
SEC
%
Hz
I1
PULSE PROCESS
Is High Current
LIFT TIG
w
Base I2 HF TIG
Current Width
Hot Iz Up f Down Ie
Start Slope Low
Current Slope STICK
t1 t2
Current Current
Pre Post
PURGE Flow Flow TRIGGER
WAVE BALANCE 2T
AC FREQUENCY
ARC FORCE
4T
BACK FORWARD
202
P O R TA B L E WELDING SYSTEM
Adjust programming parameter Press to go forward / go back

between programming status
LED’s Art # A-11404_AC
Figure 4-5: Stick Programming Mode

Programming Parameter Adjustment Device Display
Hot Start
This parameter operates in all weld modes
except LIFT TIG mode and is used to heat up
the weld zone in TIG modes or improve the
start characteristics for stick electrodes the Amps
peak start current on top of the BASE (WELD)
current. 0 to 70A (max 170A weld current)
e.g. HOT START current = 130 amps when
BASE (WELD) = 100 amps & HOT START = 30
amps
Base Current
This parameter sets the TIG WELD current
when PULSE is OFF. This parameter also sets
the STICK weld current.
Amps
5 to 170A (DC STICK mode)

10 to 170A (AC STICK mode)
Arc Force (STICK Mode only) V
Arc Force is effective when in Manual Arc SEC
Mode only. Arc Force control provides and %

Hz
adjustable amount of Arc Force (or "dig")
control. This feature can be particularly Volts
beneficial in providing the operator the ability
to compensate for variability in joint fit-up in 0 to 100%
certain situations with particular electrodes. In
general increasing the Arc Force control toward
100% (maximum Arc Force) allows greater
penetration control to be achieved.
Table 4-2
4.03 202 AC/DC – LIFT TIG and HF TIG Programming Mode

Press the PROCESS button to select LIFT TIG or HF TIG mode.
Press the MODE switch to goggle between AC and DC welding output.
The Programming LED’s are always active. Press FORWARD or BACK to cycle through available
programming functions.
Use the Multi Function Control Knob to adjust the parameter selected.

MODE
A V
V
SEC
%
Hz
I1
PULSE PROCESS
Is High Current
LIFT TIG
w
Base I2 HF TIG
Current Width
Hot Iz Up f Down Ie
Start Slope Low
Current Slope STICK
t1 t2
Current Current
Pre Post
WAVE BALANCE 2T
AC FREQUENCY
ARC FORCE
4T
BACK FORWARD
202
Adjust programming parameter Press to go forward / go back

using the Multi Function Control knob between programming status
LED’s Art # A-11405_AC
Figure 4-6: LIFT TIG and HF TIG Programming Mode

Programming Parameter Adjustment Device Display
Pre-Flow V
This parameter operates in SEC
TIG modes only and is used to %

Hz
provide gas to the weld zone
prior to striking the arc, once Volts
the torch trigger switch has been
pressed. This control is used to 0.0 to 1.0 second
dramatically reduce weld porosity
at the start of a weld.
Initial Current
This parameter operates in (4T)
TIG modes only and is used to
set the start current for TIG. The
Start Current remains on until the Amps
torch trigger switch is released
after it has been depressed. 5 to 200 Amps (DC TIG mode)
Note: The maximum initial current 30 to 200 Amps (AC LIFT TIG mode)
available will be limited to the set 10 to 200A (AC HF TIG mode)
value of the base current.
Up Slope V
This parameter operates in (4T) SEC
TIG modes only and is used to %

Hz
set the time for the weld current
Volts
to ramp up, after the torch trigger
switch has been pressed then 0.0 to 15.0 seconds
released, from Initial Current to
High or BASE current.

Base Current
This parameter sets the TIG
WELD current when PULSE is
OFF. This parameter also sets the
STICK weld current. Amps
5 to 200A (DC TIG mode)

30 to 200A (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
High Current
This parameter sets the High weld
current when in PULSE mode.
Amps
10 to 200A (DC TIG mode)

30 to 200A (AC TIG mode)
Low Current
The lowest point in the pulse is
called the Low Current.
Amps
5 to 200A (DC HF TIG mode)

30 to 200A (AC LIFT TIG mode)
10 to 200A (AC HF TIG mode)
Pulse Width V
This parameter sets the SEC
percentage on time of the PULSE %

Hz
FREQUENCY for High weld
current when the PULSE is ON. Volts
15 to 80%
Pulse Frequency V
This parameter sets the PULSE SEC
FREQUENCY when the PULSE is %

Hz
ON..
Volts
0.5 to 200 Hz
Down Slope V
This parameter operates in TIG SEC
modes only and is used to set %

Hz
the time for the weld current
to ramp down, after the torch Volts
trigger switch has been pressed,
to crater current. This control is 0.0 to 25.0 seconds
used to eliminate the crater that
can form at the completion of a
weld.

Crater Current
This parameter operates in (4T)
TIG modes only and is used to
set the finish current for TIG.
The CRATER Current remains Amps
ON until the torch trigger switch
is released after it has been 5 to 200A (DC TIG mode)
depressed. 30 to 200A (AC TIG mode)
Note: The maximum crater 10 to 200A (AC HF TIG mode)
current available will be limited to
the set value of the base current.
Post Flow V
This parameter operates in TIG SEC
modes only and is used to adjust %

Hz
the post gas flow time once
the arc has extinguished. This Volts
control is used to dramatically
reduce oxidation of the tungsten 0.0 to 60.0 seconds
electrode.
AC Frequency V
This parameter operates in AC SEC
TIG mode only and is used to %

Hz
set the frequency for the AC weld
current. Volts
15 to 150 Hz
Wave Balance V
This parameter operates in AC SEC
TIG mode and is used to set the %

Hz
penetration to cleaning action
ratio for the AC weld current. Volts
Generally WAVE BALANCE is set
10 to 65%
to 50% for AC STICK welding.
The WAVE BALANCE control
changes the ratio of penetration
to cleaning action of the AC TIG
welding arc. Maximum weld
penetration is achieved when
the WAVE BALANCE control is
set to 10%. Maximum cleaning
of heavily oxidised aluminium or
magnesium alloys is achieved
when the WAVE BALANCE control
is set to 65%.
Table 4-2
WAVE BALANCE is used for aluminium welding in AC HF TIG or AC LIFT TIG mode
It is used to set the ratio of penetration to cleaning action for the AC TIG welding arc.
Maximum weld penetration is achieved when the WAVE BALANCE is set to 10%. Maximum cleaning of
heavily oxidised aluminium or magnesium alloys is achieved when the WAVE BALANCE is set to 65%.

Wave Balance = 50% Wave Balance = 10% Wave Balance = 65%
50% 10% 65%

(+) (+) (+)
(-) (-) (-)

50% 90% 35%
Balanced with 50% penetration Maximum Penetration and Maximum Cleaning and
and 50% cleaning reduced cleaning reduced penetration
A-11223
Table 4-3: AC TIG Wave Balance
4.04 Short Circuit Protection While Welding

To prolong the useful life of a TIG tungsten electrode, the 202 AC/DC incorporates special circuitry.
In DC LIFT TIG mode, if the tungsten electrode touches the work the welding current is reduced to 40
Amps.
In DC HF TIG mode, if the tungsten electrode touches the work the welding current is reduced to 30 Amps
within 1 second.
In STICK mode, if the electrode touches the work for more than two seconds the welding current is reduced
to 0 Amps.
4.05 Setup for TIG (GTAW) Welding

A. Select Lift TIG or HF TIG mode with the process selection control (refer to Section 4.01.7 for further
information).
B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source
via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned
securely to achieve a sound electrical connection.
C. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power
Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and
turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being
fused in the bayonet terminal.
D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as
shown below. The TIG torch will require a trigger switch to operate in Lift TIG or HF TIG Mode.
NOTE
If the TIG torch has a remote TIG torch current control fitted then it will require to be connected
to the 8 pin socket. (Refer to section 4.01.2 Remote Control Socket for further information).
E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section
4.05) then connect the shielding gas hose from the regulator/flowmeter outlet gas INLET on the rear of
the 202 AC/DC Power Source. Connect the gas hose from the TIG torch to the gas OUTLET on the front
of the 202 AC/DC Power Source.
! WARNING
Before connecting the work clamp to the work make sure the mains power supply is switched
off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable
stationary support to prevent falling or tipping.
MODE
A V
V
SEC
%
Hz
I1
PULSE PROCESS
Is High Current
LIFT TIG
w
Base I2 HF TIG
Current Width
Hot Iz Up f Down Ie
Start Slope Low
Current Slope STICK
t1 t2
Current Current
Pre Post
WAVE BALANCE 2T
AC FREQUENCY
ARC FORCE
4T
BACK FORWARD
202
Negative Welding
Positive Welding Terminal (-)
Terminal (+)
Work Lead
Art # A-11406_AC
8 Pin Control Socket
Tig Torch
Figure 3-10: Setup for TIG Welding
NOTE
When the 202 AC/DC is used with a Remote Foot Control, disconnect the foot control to allow
max current to be previewed/adjusted, then reconnect foot control, Max current that has been
preset will be output when foot control is fully depressed during welding. To avoid premature
arcing, please ensure the TIG Torch is located away from your work piece.

4.06 Setup for STICK (MMA) Welding
A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode
manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It
is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical
connection.
B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode
manufacturer. Welding current flows from the power source via heavy duty bayonet type terminals. It
is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical
connection.
C. Select STICK mode with the process selection control (refer to Section 3.08.7 for further information)
! WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode holder
make sure the mains power supply is switched off.
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being
fused in the bayonet terminal.
MODE
A V
V
SEC
%
Hz
I1
PULSE PROCESS
Is High Current
LIFT TIG
w
Base I2 HF TIG
Current Width
Hot Iz Up f Down Ie
Start Slope Low
Current Slope STICK
t1 t2
Current Current
Pre Post
WAVE BALANCE 2T
AC FREQUENCY
ARC FORCE
4T
BACK FORWARD
202
Negative Welding
Positive Welding Terminal (-)
Terminal (+)
Art # A-11407_AC
Electrode Holder
Work Lead
0A
20
Figure 4-11: Setup for Manual Arc Welding

THEORY OF OPERATION 202 AC/DC
SECTION 5:
THEORY OF OPERATION
5.01 Inverter Design
What does the word inverter mean?
The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the
incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on
to a much smaller main transformer 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.
Inverter Technology - Summary
Rectifier Filter IGBT Transformer Rectifier Inductor
AC -50/60Hz DC -Rippled DC -Smooth AC -23K Hz AC -23K Hz DC - Rippled DC -Smooth

High Voltage High Voltage High voltage High Voltage Low Voltage Low Voltage Low Voltage
Low Amperage Low Amperage Low Amperage Low Amperage High Amperage High Amperage High Amperage
Art # A-09846
Manual 0-5240 5-1 Theory of Operation

202 AC/DC THEORY OF OPERATION
Notes
Theory of Operation 5-2 Manual 0-5240

TROUBLESHOOTING 202 AC/DC
SECTION 6:
TROUBLESHOOTING
6.01 Basic Troubleshooting-Power Source Faults
The following table is a guide for analyzing problems and making repairs to the Power Source.
Fault Possible Cause Remedy
1 There is no weld A The main Power Switch is set to OFF A Set main Power Switch to ON
output and all front B Control fuse is blown B Replace Line fuse
panel displays are off C The main Power Switch is faulty C Replace main Power Switch
D Loose connection to EMC board D Tighten connections
E Faulty Power Inverter board E Replace Power Inverter board
F Faulty Control board F Replace Control board
G Faulty Display board G Replace Display board
2 There is no weld A The internal protection circuit to shut A Check to see if mains supply
output and all front the unit down if the mains supply voltage is >274VAC. A
panel displays are off voltage is too high has operated generator with poor voltage
or flickering on & off regulation may cause a supply
voltage in excess of 274VAC.
Connect Power Source to a
supply voltage <274VAC.
3 There is no weld A Unit has overheated A Allow unit to cool with
output and the yellow fan running until over
over temperature light temperature light extinguishes
is on B Airflow inlet or outlet ducts are B Remove blockages from
blocked airflow ducts
C Fan does not operate C Replace fan. Check fan wiring
is not damaged
4 Mode switch does not A Faulty Display board A Replace Display board
change welding mode
5 No HF output when A Faulty HF board A Replace HF board
HF mode is selected
6 A welding arc can A Work Lead cable too small A Use correct weld cable size
be established but B Loose welding connections B Tighten welding connections
the weld is erratic or C Loose earth clamp C Tighten earth clamp
inconsistent D Incorrect weld polarity selected D Correct weld polarity.
E No shielding gas E Refer to weld consumable
manufacturers recommended
polarity
F Wind blows shielding gas away F Connect shielding gas
G Incorrect TIG tungsten electrode G Shield welding area from
draughts
H Poorly prepared or worn TIG H Use correct tungsten type
tungsten Regrind tungsten to correct
shape
Table 6-1: Power Source Faults
Manual 0-5240 6-1 Troubleshooting

202 AC/DC TROUBLESHOOTING
6.02 Advanced Troubleshooting
If the problem cannot be solved by the basic (external) troubleshooting guide, the Power Source cover will have
to be removed to allow the technician to analyze failures with a few common tools.
! WARNING
Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow
two minutes for capacitors to discharge after disconnection from mains supply voltage.
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 Test Equipment and Tools

• Digital Multimeter
• DC clip-on ammeter
• Screwdriver and spanner
• Oscilloscope & isolating transformer
6.04 Visually Inspect

Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or
arcing of PCB, transformers, switches, or rectifier when a failure occurs. Carefully inspect all components within
these units.
Look in particular for the following:
a) Loose or broken wires or connectors.
b) Burned or scorched parts or wires or evidence of arcing.
c) Any accumulation of metal dust or filings that may have caused shorting or arcing.
If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of components
used in the Power Source.
Locate the faulty component(s) then replace where necessary.
Troubleshooting 6-2 Manual 0-5240

6.05 Preliminary DC Bus measurement of the main inverter board
! Read and follow safety information in Section 6.02 before proceeding.
! Check DC bus voltage has discharged to less than 5VDC before servicing. Ensure the mains supply plug
is disconnected from receptacle
1 4 6
10
11
A-11421
3 5 2 8
DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage OFF
Upper capacitor bank Positive meter lead to testpoint 1 0 VDC
Negative meter lead to testpoint 2
Lower capacitor bank Positive meter lead to testpoint 2 0 VDC
Table 6-2: DC BUS, Multimeter set to measure DC volts

6.06 Preliminary check of the main inverter board

IGBT Testing Multimeter Lead Placement Diode Voltage
Positive meter lead to testpoint 4
IGBT T3 &T4 0.2 – 0.8 VDC
Positive meter lead to testpoint 3
IGBT T5 & T6 0.2 – 0.8 VDC
Table 6-3: IGBT’s, Multimeter set to measure Diode Voltage
IGBT Testing Multimeter Lead Placement Ohms
IGBT T3 & T4 Positive meter lead to testpoint 1 >150 Ω
IGBT T5 & T6 Positive meter lead to testpoint 5 >150 Ω
Table 6-4: IGBT’s, Multimeter set to measure ohms (Ω)
Inrush PTC Multimeter Lead Placement Ohms
PTC Positive meter lead to testpoint 6 0 to 100 Ω
Table 6-5: Inrush PTC, Multimeter set to measure ohms (Ω)
6.07 Check main input rectifier

Input Rectifier Testing Multimeter Lead Placement Diode Voltage
AC1 to DC+ Positive meter lead to testpoint 8 0.2 – 0.8 VDC
AC2 to DC+ Positive meter lead to testpoint 10 0.2 – 0.8 VDC
AC1 to DC- Positive meter lead to testpoint 11 0.2 – 0.8 VDC
AC2 to DC- Positive meter lead to testpoint 11 0.2 – 0.8 VDC
Table 6-6: Input Rectifier, Multimeter set to measure Diode Voltage
6.08 DC Bus voltage measurement
Apply voltage to the Power Source.
! WARNING
There are extremely dangerous voltage and power levels present inside these Power Sources. Do not
attempt to diagnose or repair unless you have had training in power electronics measurement and
troubleshooting techniques.
Once power is applied to the Power Source, there are extremely hazardous voltage and power levels present.
Do not touch any live parts.

DC Bus Testing Multimeter Lead Placement Voltage with
Supply voltage
OFF
Upper capacitor bank Positive meter lead to testpoint 1 168 VDC +/-10%
Lower capacitor bank Positive meter lead to testpoint 2 168 VDC +/-10%
Overall capacitor bank Positive meter lead to testpoint 1 336 VDC +/-10%
Table 6-7: DC BUS, Multimeter set to measure DC volts
Note: These DC voltages are at nominal mains supply voltage of 240VAC.
6.09 PCB Connectors
1 EMC filter PCB
A-11422
Header Pin Pin function signal

ACIN1 Supply side ACTIVE 240 VAC
ACIN2 Supply side NEUTRAL 0 VAC
ACOUT1 Load side ACTIVE 240 VAC
ACOUT2 Load side NEUTRAL 0 VAC
GND Earth
Table 6-8: EMC Header pin function

2 Power Supply PCB
DCIN DY2 DY1
C41
1
R41
1 1
DY3
DY3
POWER/FJ
1
8.066.526--G
R28
A-11423_AB
DCIN Header Pin Pin function signal

1 Mains Supply ACTIVE 320 VDC
2 Mains Supply NEUTRAL 0 VDC
Table 6-9: DCIN Header pin function (connects to mains supply)
DY1 Header Pin Pin function signal

1 +24 VDC 24 VDC
2 0 VDC 0 VDC
Table 6-10: DY1 Header pin function (connects to souin header on HF PCB)
DY2 Header Pin Pin function signal

1 +24 VDC 24 VDC
2 0 VDC 0 VDC
Table 6-11: DY2 Header pin function (connects to SOU header on main control PCB)
POWER/FJ Header Pin Pin function signal
1 +24 VDC 24 VDC
2 0 VDC 0 VDC
3 -24 VDC -24 VDC
4 -24 VDC -24 VDC
5 0 VDC 0 VDC
Table 6-12: POWER/FJ Header pin function (connects to POWER header on main control PCB)
3 HF filter PCB

WELD+ Positive Welding Terminal
WELD- Negative Welding Terminal
GND Earth Earth
Table 6-13: EMC Header pin function

4 HF PCB
R6
HF 1
1 R2
SOU V1
R3
R1
1
4
A-11424_AB
220V COIL
COIL Header Pin Pin function signal

1 +24 VDC 700VAC +/-10%
2 GND (ARC starter primary input) 700VAC +/-10%
Table 6-14: ARC starter primary input
HOU Header Pin Pin function signal

1 +24 VDC +24VDC
2 GND 0VDC
Table 6-15: HOU Header pin function (connects to QY1 header on Power Supply PCB)
HF Header Pin Pin function signal
1 HF on / off
2 0 VDC 0 VDC
Table 6-16: HF Header pin function (connects to QF/HF header on main control PCB)
220V Header Pin Pin function signal
1 240 VAC
2 240 VAC 0 VDC
Table 6-17: 220V Header pin function
HFOUT Header Pin Pin function signal
1 HF transformer primary (warning high voltage) Do not measure
with multimeter
2 HF transformer primary (warning high voltage) Do not measure
with multimeter
Table 6-18: HFOUT Header pin function (connects to HF transformer)

5 AC/DC Drive PCB
DC-
DC+
A-11425
TR2 TR1

TR1 Output 1 of main welding inverter transformer VAC
DC+ Positive of welding current rectifier VDC
DC- Negative of welding current rectifier VDC
Table 6-19: Header pin function (connects to main Inverter transformer)

6 Display PCB
A-11426
J1 (10 pin)
J1 Header Pin Pin function signal

1 +5 VDC 5 VDC
2 Serial interface
3 Serial interface
4 Serial interface
5 Serial interface
6 Serial interface
7 Serial interface
8 Serial interface
9 Serial interface
10 0 VDC 0 VDC
Table 6-20: J1 Header pin function (connects to J2(JB) header on main control PCB)

7 Primary Side Inverter PCB
OC DCOUT SD
1
1
1
IN
1
A-11427_AB
DRIVE Header Pin Pin function signal

1 +15 VDC 15 VDC
2 PWM signal 1
3 PWM signal 2
4 PWM signal 2
5 PWM signal 1
6 Current Transformer Signal
7 0 VDC 0 VDC
Table 6-21: DRIVE Header pin function (connects to DRIVE header on control PCB)
OC Header Pin Pin function signal
1 Current transformer secondary
2 Current transformer secondary
Table 6-22: OC Header pin function (connects to transformer primary current transformer)
SD Header Pin Pin function signal
1 +24 VDC 24 VDC
2 Soft Start Relay drive signal (0V = relay on)
Table 6-23: SD Header pin function (connects to SS header on control PCB)
DCOUT Header Pin Pin function signal
1 +336V 336VDC
2 0V 0 VDC
Table 6-24: DC OUT Header pin function (connects to DCIN header on control PCB)
8 AC/DC Output PCB
TR1
POSITIVE OUTPUT
OF WELDING
RECTIFIER
TR2
1 NEGATIVE OUTPUT
1
OF WELDING
RECTIFIER
JP3
A-11428_AC
POSITIVE SIDE IGBT’S POSITIVE OUTPUT NEGATIVE SIDE IGBT’S

OUT1 Positive welding output VDC
Table 6-25: Header pin function (connects to main inverter transformer)
ACOUT Header Pin Pin function signal
1 enable
2 control signal 1
3 control signal 2
4 No connection
5 +15 VDC 15 VDC
6 0 VDC 0 VDC
Table 6-26: ACOUT Header pin function (connects to DR & ACPOUT header on control PCB)

9 Main Control PCB
GUN LED/SF SOU OT QF/HF
1 1 1
WV
1
TEST
POINTS
1
SS
1 JB
1
POWER
1
JB
1
DRIVE
1 1
WA ACPOUT A-11429_AC
GUN Header Pin Pin function signal

1 0 VDC 0 VDC
2 trigger
3 Remote pot maximum
4 Remote pot wiper
5 0 VDC 0 VDC
Table 6-27: GUN Header pin function (connects to 8 pin remote socket)

LED/SF Header Pin Pin function signal
1 +24 VDC 24 VDC
2 No connection
3 No connection
4 No connection
Table 6-28: LED/SF Header pin function
SOU Header Pin Pin function signal
1 +24 VDC 24 VDC
2 0 VDC 0 VDC
Table 6-29: SOU Header pin function(connects to DY2 header on power supply PCB)
OT Header Pin Pin function signal
1 +24 VDC 24 VDC
2 Thermal switch input (switch closed = 0VDC) 0 VDC
3 0 VDC 0 VDC
Table 6-30: OT Header pin function (connects to DY2 thermostats)
QF/HF Header Pin Pin function signal
1 +24 VDC 24 VDC
2 Solenoid coil, 0V = solenoid ON 0 VDC
3 HF on / off
4 0 VDC 0 VDC
Table 6-31: QF/HF Header pin function (connects to solenoid and HF PCB)
WV Header Pin Pin function signal
1 Negative welding terminal 0VDC
2 Positive welding terminal 67 VDC
Table 6-32: WV Header pin function (connects to welding DINSE terminals)
J2 Header Pin Pin function signal
1 +5 VDC 5 VDC
2 Serial interface
3 Serial interface
4 Serial interface
5 Serial interface
6 Serial interface
7 Serial interface
8 Serial interface
9 Serial interface
10 0 VDC 0 VDC
Table 6-33: J2 Header pin function (connects to J1 header on display PCB))
DCIN Header Pin Pin function signal
1 +336 VDC +336 VDC
2 0 VDC 0 VDC
Table 6-34: DCIN Header pin function (connects to DCOUT header on primary inverter PCB)
ACPOUT Header Pin Pin function signal
1 enable
2 control signal 1
3 control signal 2
Table 6-35: ACPOUT Header pin function (connects to ACOUT header on AC/DC output PCB)

WA Header Pin Pin function signal
1 +15 VDC +15 VDC
2 -15 VDC -15 VDC
3 Current signal +/- 4 VDC
4 0 VDC 0 VDC
Table 6-36: WA Header pin function (connects to Hall Effect Current Transformer)
DRIVE Header Pin Pin function signal
1 +15 VDC 15 VDC
2 PWM signal 1
3 PWM signal 2
4 PWM signal 2
5 PWM signal 1
6 Current Transformer Signal
6 0 VDC 0 VDC
7 +15 VDC 15 VDC
Table 6-37: DRIVE Header pin function (connects to DRIVE header on primary inverter PCB)
DR Header Pin Pin function signal
1 +15 VDC 15 VDC
2 0 VDC 0 VDC
Table 6-38: DR Header pin function (connects to ACOUT header on AC?DC output PCB)
POWER Header Pin Pin function signal
1 +24 VDC 24 VDC
2 0 VDC 0 VDC
3 -24 VDC -24 VDC
Table 6-39: POWER Header pin function (connects to POWER/fJ header on power supply PCB)
SS Header Pin Pin function signal
1 +24 VDC 24 VDC
2 Soft Start Relay drive signal (0V = relay on)
Table 6-40: SS Header pin function (connects to SD header on primary inverter PCB)
6.10 DIP switch settings, Control PCB

1 DIP Switch SW0, control PCB
SW1 position Function
1 Set to ON for Weldskill 200AC/DC
2 Set to OFF for Weldskill 200AC/DC
Table 6-41: SW0 Dip Switch functions

6.11 Calibration
1 Calibration
R68
WVF
0V
IMAX
A-11430
Set SW0 position 4 to OFF while the power source is turned off, to allow calibration of output volts & amps.

2 Output Current Calibration
Select STICK process and DC mode on the front panel.
Measure no load output welding voltage and adjust WVF potentiometer so Volts display reads within 0.1V of the
measured value.
Select TIG process and DC mode on the front panel.
Connect a load to the output terminals. The load should be of a resistance to give 18V at 200A.
Set front panel AMPS potentiometer to maximum.
Adjust Imax trimpot until output amps is 200A +/-0 2A
Set front panel AMPS potentiometer to minimum.
Adjust 0V (SW100) trimpot until output amps is 5A +/- 0.2A
Repeat the minimum & maximum calibration until both are within tolerance
Set front panel AMPS potentiometer to maximum.
Adjust A potentiometer so Amps display reads within 0.5A of the measured value.
6.12 Main Circuit Description
! WARNING
Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow
two minutes for capacitors to discharge after disconnection from mains supply voltage.
The mains supply voltage is connected via a double pole switch to the input rectifiers on the main inverter board
through an EMC filter. Overvoltage protection is provided by varistor CY1.
The rectifier output charges the main capacitor bank (C5, C6, C7, C8, C9 and C10) to high voltage. Inrush current
limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds.
The primary igbt transistors (T3, T4, T5, and T6) switch the transformer primary at high frequency and varying
duty cycle. The transformer return wire is taken from the terminal ZBQY1 (the voltage at this point is approximately
half the DC bus voltage).
Secondary output voltage from the transformer is rectified by the output diodes (D1, and D2) to DC. This DC is
controlled by the PWM of the primary side igbt transistors, and is filtered by an inductor before connecting to
the welding output terminals. IGBT1 to IGBT8 control whether AC or DC output is sent to the welding terminals.
A thermal overload device (thermal switch) is fixed to the rectifier heatsink. When an over temperature occurs,
the control circuit inhibits the trigger, gas solenoid, and the welding output. The thermal overload indicator LED
on the front panel is illuminated.
The current transformer CT1 provides a signal to the control circuit to indicate both transformer primary current,
and also detect transformer saturation. The Hall effect current sensor CT2 is powered from regulated + & - 15VDC
supplies and provides a voltage signal proportional to the output welding current to allow the control circuit to
regulate welding current.

Manual 0-5240
POSITIVE
SOFT
START
R1 Q1
C1 D1 D2
C3 G1
240VAC R3 Q3
G3 C7
SW1
A T1 HALL EFFECT WELD POSITIVE
INPUT
RECTIFIER CT2 POSITIVE
C5
R1
TROUBLESHOOTING
6.13 Circuit Diagram
N R4
CT1
Q2
R2 G2
E C2 Q4
0VAC C4
D3 D4 C6 G4 C8
OC
WELDING TERMINALS
NEGATIVE
DRIVER
WELD NEGATIVE
AC
SS DRIVE
DC
L1
DC BOARD
T2 NEGATIVE
DC-IN
POWER
POWER/FJ
WA
HFOUT
6-17
GD1
MAIN CONTROL BOARD HF BOARD

240VAC
ACOUT
WELD POSITIVE
ACPOUT
AC DRIVE BOARD
220VAC
SOLENOID
GD2
POWER SUPPLY BOARD

0VAC
ACOUT
JB
WELD NEGATIVE
DY2
DY3
SOU
FAN 24VDC HF SOUIN
NTCS DY1
QF/HF
MOD
WELD POSITIVE
WV
WELD NEGATIVE
TH1 TH2
OT
DISPLAY BOARD
J2 (10)
JB (10)
8 PIN REMOTE
GUN
A-11227_AC
Troubleshooting
202 AC/DC
Notes

DISASSEMBLY PROCEDURE 202 AC/DC
SECTION 7:
DISASSEMBLY PROCEDURE
7.01 Safety Precautions for Disassembly
!
Unplug unit before beginning Disassembly procedure.
7.02 Case Removal
! Read and follow safety information in Section 6.02 before proceeding with disassembly
1. Remove Screws on front panel.
2. Remove Screws on rear panel.
3. Remove Screws on side panel.
4. Remove ground screw.
1 2
A-11596_AD
Manual 0-5240 7-1 Disassembly Procedure

202 AC/DC DISASSEMBLY PROCEDURE
7.03 Control Board Removal
Remove case (refer to 6.04) before remove control board.
1. M4 Screw. Remove 4 screws from control panel.
2 Disconnect DRIVE harness from DRIVE connector.
3. Disconnect J8 harness from J8 connector
4. Disconnect SOURCE harness from SOURCE connector.
5. Disconnect SS harness from SS connector.
6. Disconnect GUN harness from GUN connector.
7. Disconnect SOU harness from Sou connector.
8. Disconnect IGBT OT harness from IGBT OT connector.
9. Disconnect QF/HF harness from QF/HF connector.
10. Disconnect WVIN harness from WVIN connector.
11 Disconnect JB harness from JB connector.
12. Disconnect ACP OUT harness from ACPOUT connector.
13. Disconnect WA harness from WA connector.
Ensure to unplug all harness from the main control PCB.
2 3 4 5
1 6
8
13
12
9
A-11432
11 10
Disassembly Procedure 7-2 Manual 0-5240

7.04 Auxiliary Power Supply PCB2 Removal
1. Disconnect DCIN harness from DCIN Connector.
2 Disconnect DY2 harness from DY2 connector.
3. Disconnect DY1 harness from DY1 connector
4. Disconnect SOURCE/FJ harness from SOURCE/FJ connector.
5. Remove glue then pull out board.
5
A-11433

7.05 PCB3 Removal
1. Remove screw.
2. Disconnect output harness from output Connector.
3 Disconnect input harness from input connector.
4. Disconnect SOU harness from SOU connector
5. Disconnect HF harness from HF connector.
6. Remove glue then pull out board.
6
3 2 A-11434
1

7.06 PCB4 Removal
1. Remove 6 screws.
2. Disconnect wire from terminals.
1
A-11435
7.07 PCB5 Removal
1. Remove 5 screws.
1
A-11436

7.08 Front Panel assembly Removal
1. Remove front panel screws.
2. Remove Positive Output Terminal Bolt.
3. Remove Negative Output Terminal Bolt.
4. Remove ground wire from front panel.
5. Disconnect hose from outlet.
A-11621_AC
2 4 3 5

7.09 Front Panel (operator Interface) Circuit Board PCB Removal
1. Remove Control Panel Screws.
2. Disconnect JB harness from JB connector.
3. Remove ground wire.
A-11622_AC
2 3

7.10 Back Panel Removal
1. Remove 6 screws on rear panel.
2. Remove ground screw and input wire screw.
3. Remove gas inlet.
4. Back of rear panel.
4
1 3
A-11439_AC

7.11 Main Power PCB1 Removal
1. Remove 5 screws.
2. Remove wire screws.
3. Disconnect harness from connectors.
1
2
3
A-11440
1

7.12 Main Power PCB2 Removal
1. Remove 4 screws.
2. Remove 5 screws.
3. Remove wire screws
4. Disconnect harness from connectors.
1
2
3
2

7.13 Power Switch S1, Fan and Power Cord Removal
1. Remove 3 switch screws.
2. Remove power cord screw.
3. Disconnect wire from switch terminals.
4. Remove magnetic from ground wire.
5. Remove fan.
6. Pull out power cord.
3 5
A-11442

Notes

ASSEMBLY PROCEDURE 202 AC/DC
SECTION 8:
ASSEMBLY PROCEDURES
8.01 Installing Main Power PCB1
1. Install main PCB1 assembly screws
2. Install wire screws.
3. Plug harness into connectors.
1
2
3
A-11440
1
Manual 0-5240 8-1 Assembly Procedures

202 AC/DC ASSEMBLY PROCEDURES
8.02 Installing Main Power PCB2
1. Install 5 screws.
2. Install wire screws.
3. Plug harness into connectors.
4. Install base plate.
1
2
2
Assembly Procedures 8-2 Manual -5240

8.03 Installing Front Panel
1. Reinstall positive output terminals on front panel with 17mm wrench.
2. Reinstall negative output terminals on front panel with 17mm wrench.
3. Reinstall ground wire.
4. Reinstall hose for gas outlet.
5. Reinstall 6 screws.
1 3 2 4
A-11623_AC

8.04 Installing Rear Panel
1. Reinstall ON/OFF Switch. install 3 screws.
2 Plug power supply cable to swtich connector.
3. Reinstall ferrite core into ground wire.
4. Reinstall fan.
5. Reinstall power cord and screw.
6. Reinstall gas inlet.
7. Reinstall screws.
1
2 4
A-11445

8.05 Installing PCB5
1. Install wire to terminals , tighten screws.
1
A-11436

2. install wire to terminals and tighten.
3. Reconnect 2 yellow wires.
A-11446
2
3

1. Insert plastic stud onto PCB3 board.
2. install screw.
3. Plug harness into HF connector.
4. Plug harness into SOU connector.
5. Plug harness into INPUT connector.
6. Plug harness into OUTPUT connector.
1
5 6 2
8.08 Installing Auxiliary Power Supply PCB2

1. Install four studs to PCB2.
2. Plug harness into the DY2 connector.
3. Plug harness into the DY1 connector.
4. Plug harness into the Power/FJ connector.
5. Plug harness into the DCIN connector.
6. Put glue on four Stud.
1
5
4

8.09 Installing Control Board
2. Plug harness into DRIVE connector.
3. Plug harness into J8 connector.
4. Plug harness into POWER connector.
5. Plug harness into SS connector.
6. Plug harness into GUN connector.
7. Plug harness into SOU connector.
8. Plug harness into OT connector.
9. Plug harness into QF/HF connector.
10. Plug harness into WV connector.
11. Plug harness into JB connector.
12. Plug harness into ACPOUT connector.
13. Plug harness into WA connector.

2 3 4 5
1 6
8
13
12
9
A-11432
11 10

8.10 Installing Case
1. Install ground screw.
2. Install side panel screws.
3. Install front panel screws.
4. Install rear panel screws.
3 4
A-11597_AD

SPARE PARTS 202 AC/DC
SECTION 9:
KEY SPARE PARTS
9.01 Power Source
25
22
15
7 8
5
28
6
2 21
3 11 23
10
4
1 26
24
12 13 17 28
12 18
14
9
20 16
A-11408
19
Figure 9-1
Manual 0-5240 9-1 KEY SPARE PARTS

202 AC/DC SPARE PARTS
202 AC/DC Spare Parts
Item Part Number Description
1 W7005500 PCB display
2 W7005503 PCB aux power supply
3 W7005502 PCB HF
4 W7005504 PCB primary inverter
5 W7005505 PCB AC output drive
6 W7005506 PCB control
7 W7005507 PCB secondary rectifier
8 W7005508 PCB EMC filter
9 W7005509 Coil coupling HF
10 W7005512 Fan assembly
11 W7003033 Gas solenoid assembly
12 W7005513 Dinse Socket 50mm²
13 W7005568 Control socket 8 pin
14 W7005514 Gas outlet, front panel
15 W7005515 Switch, On/Off
16 W7003076 CT, output
17 W7005511 Transformer 202AC/DC
18 W7005510 Inductor 202AC/DC
19 W7005534 Base Panel
20 W7005531 Front panel
21 W7005532 Rear panel
22 W7005535 Panel, Top Cover
23 W7005605 Gas inlet fitting
24 W7005537 Control knob, (25mm2 OD)
25 W7005536 Handle
26 W7004952 CT, primary
27 W7004930 Shielding gas hose assembly
28 W7005538 Side Panel
Table 9-1
KEY SPARE PARTS 9-2 Manual 0-5240

LIMITED WARRANTY & WARRANTY SCHEDULE
In accordance with the warranty periods stated below, Victor Technologies guarantees the proposed product
to be free from defects in material or workmanship when operated in accordance with the written instructions
as defined in this operating manual.
Victor Technologies welding products are manufactured for use by commercial and industrial users and trained
personnel with experience in the use and maintenance of electrical welding and cutting equipment.
Victor Technologies will repair or replace, at its discretion, any warranted parts or components that fail due
to defects in material or workmanship within the warranty period. The warranty period begins on the date of
sale to the end user.
Welding Equipment - Limited Warranty Period

Product Period
Thermal Arc 202AC/DC 2 Years
TIG Torch, Electrode Holder & Work Lead 30 Days
If warranty is being sought Victor Technologies must be notified in writing within 30 days of the failure and
at such time we will make arrangements to fulfil the warranty claim. Please contact your Victor Technologies
product supplier for the warranty repair procedure.
Victor Technologies warranty will not apply to:
• Equipment that has been modified by any other party other than Victor Technologies’s own service person-
nel or with prior written consent obtained from Victor Technologies Service Department (UK).
• Equipment that has been used beyond the specifications established in the operating manual.
• Installation not in accordance with the installation/operating manual.
• Any product that has been subjected to abuse, misuse, negligence or accident, improper care and/or
maintenance including lack of lubrication, maintenance and protection, will be refused warranty.
• Failure to clean and maintain the machine as set forth in the operating, installation or service manual.
Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation.
This manual also offers basic troubleshooting, operational and technical details including application usage.
Using this manual correctly will ensure the quickest time possible for resolving any technical questions, ap-
plication issues or defects with your Victor Technologies product.
You may also wish to visit our web site www.victortechnologies.com select your product class and then select
literature. Here you will find documentation including:
• Operator manuals
• Service manuals
• Product guides
Alternatively please contact your Victor Technologies distributor and speak with a technical representative.
NOTE
Warranty repairs must be performed by either a Victor Technologies Service Centre, a Victor Technologies
distributor or an Authorised Service Agent approved by the Company.
THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph: 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph: 1-940-381-1212
Fax: 1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph: 1-954-727-8371
Fax: 1-954-727-8376
Oakville, Ontario, Canada

Canada Customer Care
Ph: 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph: +44 1257-261755
Fax: +44 1257-224800
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: +603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph: 1300-654-674 (tollfree)
Ph: 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph: 61-3-9474-7508
Fax: 61-3-9474-7488
Shanghai, China
Sales Office
Ph: +86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph: +65 6832-8066
Fax: +65 6763-5812
TECHNOLOGIES™ I N N O VAT I O N T O S H A P E T H E W O R L D ™
U.S. Customer Care: 800-426-1888 • Canada Customer Care: 905-827-4515 • International Customer Care: 940-381-1212
Form No. 0-5240 (10/31/12) © 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in China

Ac DC Inverter

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Ac DC Inverter

Hochgeladen von

Copyright:

Verfügbare Formate

202 AC/DC

Revision: AD Issue Date: August 3, 2015 Manual No.: 0-5240

We have made every effort to provide you with accurate instructions,

YOU ARE IN GOOD COMPANY!

We distinguish ourselves from our competition through market-leading,

Above all, we are committed to develop technologically advanced products

Welding Power Supply

Thermal Arc 202 AC/DC Part Number W1006305

Copyright 2012, 2013, 2014, 2015 by

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the

Publication Date: November 2, 2012

Record the following information for Warranty purposes:

Where Purchased: _____________________________________

Purchase Date: _____________________________________

Equipment Serial #: _____________________________________

12. Use only well-maintained equipment. Repair or replace

Safety Instructions and Warnings 1-2 Manual 0-5240

Manual 0-5240 1-3 Safety Instructions and Warnings

Safety Instructions and Warnings 1-4 Manual 0-5240

ON Single Phase Wire Feed Function

Wire Feed Towards

Increase/Decrease Remote Purging Of Gas

AC Auxiliary Power % Percentage Spot Weld Mode

Fuse Panel/Local Spot Time

Gas Metal Arc

Gas Tungsten Arc 2 Step Trigger

Negative Constant Current 4 Step Trigger

Direct Current (DC) High Temperature

Line Arc Force

Line Connection Touch Start (GTAW)

Auxiliary Power Variable Inductance See Note

115V 15A Receptacle Rating- Pulse Welding

Manual 0-5240 1-5 Safety Instructions and Warnings

• Do not touch hot parts bare handed.

Safety Instructions and Warnings 1-6 Manual 0-5240

Manual 0-5240 1-7 Safety Instructions and Warnings

Safety Instructions and Warnings 1-8 Manual 0-5240

Gives information regarding possible per- 2.04 Description

! Disconnect input power

Manual 0-5240 2-1 Introduction

Introduction 2-2 Manual 0-5240

30 SAFE OPERATING REGION

Welding Current (AMPS) A-11402

Figure 3-1: 202 AC/DC Duty Cycle

Manual 0-5240 3-1 Safety and Installation

Note 2: Generator Requirements at the Maximum Output Duty Cycle.

Safety and Installation 3-2 Manual 0-5240

3.05 High Frequency Introduction

Manual 0-5240 3-3 Safety and Installation

Manual 0-5240 3-5 Safety and Installation

Figure 3-2: 202 AC/DC Volt-Ampere Curves

Safety and Installation 3-6 Manual 0-5240

Figure 4-2: Rear Panel

Manual 0-5240 4-1 INSTALLATION, OPERATION AND SETUP

Socket Pin Part Number / Description

Table 4-1: 8 Pin Interconnection Control Plug Configuration

INSTALLATION, OPERATION AND SETUP 4-2 Manual 0-5240

Press & hold Release Press & hold Release

Manual 0-5240 4-3 INSTALLATION, OPERATION AND SETUP

12. Back Programming Button

4.02 202 AC/DC - STICK Programming Mode

Adjust programming parameter Press to go forward / go back