Why does the electrode melt when the arc is struck on my Thermal Arc ARCMASTER 200 TS?
If the electrode melts when the arc is struck with your Thermal Arc Welding System, it could be because the electrode is connected to the '+' terminal or the WAVE BALANCE is greater than 50%. To solve this, connect the electrode to the '-' terminal and reduce the WAVE BALANCE to below 50% or increase the electrode size.
How to prevent gas pockets or voids (porosity) in welds with my Thermal Arc ARCMASTER 200 TS?
If you're experiencing gas pockets or voids (porosity) in the weld metal when using your Thermal Arc Welding System, it could be due to damp electrodes, welding current that is too high, or surface impurities like oil, grease, or paint. To fix this, ensure you dry the electrodes before use, reduce the welding current, and thoroughly clean the joint before welding.
What to do if the welding arc cannot be established on my Thermal Arc ARCMASTER 200 TS?
If the welding arc cannot be established with your Thermal Arc Welding System, it could be due to several reasons: A) The primary supply voltage is not switched ON. B) The Welding Power Source switch is switched OFF. C) There are loose connections internally. To resolve this: A) Switch ON the Primary supply voltage. B) Switch ON the Welding Power Source. C) Have an Accredited Thermal Arc Service Agent repair the connection.
How to improve poor weld finish with my Thermal Arc ARCMASTER 200 TS Welding System?
If you notice a poor weld finish with your Thermal Arc Welding System, it's likely due to inadequate shielding gas. Increase the gas flow or check the gas line for any problems that might be restricting gas flow.
How to fix excessive beard build-up or poor penetration in my Thermal Arc ARCMASTER 200 TS?
If you experience excessive beard build-up, poor penetration, or poor fusion at the edges of the weld with your Thermal Arc Welding System, it's likely because the welding current is too low. To fix this, increase the weld current and ensure proper joint preparation.
Why are cracks appearing in the weld metal after solidification on my Thermal Arc ARCMASTER 200 TS Welding System?
If a crack occurs in the weld metal soon after solidification commences with your Thermal Arc Welding System, it could be due to the rigidity of the joint, insufficient throat thickness, or a cooling rate that is too high. To address this, redesign the joint to relieve severe stresses or use crack resistance electrodes, travel slightly slower to allow greater build up in the throat, and preheat the plate and cool slowly.
Why is there a gap in the weld root with my Thermal Arc ARCMASTER 200 TS Welding System?
If a gap is left because the weld metal fails to fill the root of the weld when using your Thermal Arc Welding System, it could be due to several reasons: the welding current is too low, the electrode is too large for the joint, there is insufficient gap, or an incorrect sequence is being used. To fix this, increase the welding current, use a smaller diameter electrode, allow a wider gap, and use the correct build-up sequence.
Why aren't portions of the weld fusing to the metal surface with my Thermal Arc ARCMASTER 200 TS Welding System?
If portions of the weld run do not fuse to the surface of the metal or edge of the joint when using your Thermal Arc Welding System, it could be due to several reasons: small electrodes used on heavy cold plate, welding current is too low, wrong electrode angle, travel speed of electrode is too high, or scale or dirt on joint surface. To resolve this, use larger electrodes and pre-heat the plate, increase welding current, adjust the electrode angle, reduce travel speed of electrode, and clean the surface before welding.
Why is there uneven leg length in fillet joint when using my Thermal Arc ARCMASTER 200 TS Welding System?
If you observe uneven leg length in a fillet joint with your Thermal Arc Welding System, it's likely due to incorrect placement of the filler rod. Re-position the filler rod to ensure even leg length.
Why does the welding current reduce while welding with my Thermal Arc ARCMASTER 200 TS Welding System?
If the welding current reduces while welding with your Thermal Arc Welding System, several factors could be responsible: loose welding cable connections, incorrect welding cable size, improper input connections, poor electrode condition or wrong welding polarity. To address this, tighten all welding cable connections, use the proper size and type of cable, refer to Section 2.05 Electrical Input Requirements, replace the electrode, and verify output torch connections.
Details electrical shock, arc ray hazards, and safety measures.
Covers hazardous fumes, gases, fire/explosion risks from welding.
Explains manual structure, annotations (WARNING, CAUTION, NOTE), and how to get more copies.
Details the single-phase AC power supply requirements.
Procedures for safely connecting the welder to the power supply.
Explains the inrush circuit, voltage sensing, and generator use for input power.
Defines duty cycle and its impact on welder operation and potential damage.
Identifies and describes the front panel controls, including the digital meter and knob.
Explains how to select different welding processes (STICK, MIG, TIG) and modes.
Details the function of each adjustable parameter on the front panel.
Lists the available weld parameters, their ranges, factory settings, and applicable weld modes.
Step-by-step guide for setting up and performing stick welding.
Instructions for setting up and performing HF TIG and Lift TIG welding.
Lists common TIG welding quality issues and their causes/remedies.
Identifies common stick welding defects and provides troubleshooting steps.
Troubleshooting guide for common power source operational failures.
Explains common error codes displayed by the power source and provides troubleshooting steps.
Guides on isolating faults to subsystems and safely opening the unit.
Procedures for verifying and resolving specific error codes (E01, E02, E03, E94, E99).
Steps for issues not indicated by codes (fan, gas valve).
Troubleshooting steps for no weld output and operating panel failures.
Steps to troubleshoot when the unit does not generate High Frequency output.
Initial conditions and preparation steps for performing fault isolation tests.
Steps to verify AC input voltage.
General| Input Voltage | 230 V |
|---|---|
| Input Frequency | 50/60 Hz |
| Rated Input Current | 16 A |
| Output Current Range (TIG) | 10 - 200 A |
| Duty Cycle (TIG) | 60% at 200 A |
| Duty Cycle (MMA) | 60% at 200 A |
| Input Phase | Single Phase |
| Rated Output | 200 A |
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