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Thermal Arc Viking 210GM User Manual

Thermal Arc Viking 210GM
42 pages
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VIKING WELDER
Manual No. 0-2538
First Edition
July 1996
Operating Manual
Models 210/250GM CV/DC
MIG Power Supplies

Table of Contents

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Thermal Arc Viking 210GM Specifications

General IconGeneral
BrandThermal Arc
ModelViking 210GM
CategoryWelding System
LanguageEnglish

Summary

1. INTRODUCTION

1.1 Notes, Cautions and Warnings

Explains how notes, cautions, and warnings are categorized in the manual.

1.2 Important Safety Precautions

General safety precautions for operating welding arc equipment.

1.3 Publications

Lists standards and publications for further safety and welding information.

1.7 Statement of Warranty

Details the limited warranty terms, limitations, and exclusions for the welding equipment.

2. GENERAL INFORMATION

2.1 Safety

Outlines basic safety rules that should always be followed during operation.

2.2 Protective Filter Lenses

Explains the function of protective filter lenses and their importance for eye safety.

2.3 Welding Protection

Recommends using a welding helmet with the correct filter lens for electric arc welding.

2.4 User Responsibility

Defines user responsibilities for proper installation, operation, maintenance, and modification of the equipment.

2.5 Duty Cycle

Explains the concept of duty cycle for welding power sources and its implications for operation.

3. SPECIFICATIONS

3.1 MIG Torch Specifications

Lists the specifications for the TWECO MIG torch, including part numbers and cable length.

3.2 Machine Specifications

Provides detailed specifications for Viking 210GM/RGM and 250GM/RGM models, including dimensions, voltage, and current ratings.

3.3 Wire Drive Specifications

Details specifications related to the wire drive system, including wire speed, diameter, and spool size.

3.4 Power Supply Contents

Lists the standard items included in the Viking 210 and 250 power supply packages.

3.5 Optional Accessories

Lists optional accessories available for the Viking 210GM and 250GM models, with catalogue numbers.

4. INSTALLATION RECOMMENDATIONS

4.1 Environment

Describes suitable environmental conditions and hazards to avoid during installation.

4.2 Location

Provides guidelines for selecting an appropriate location for the power source, considering airflow and safety.

4.3 Ventilation

Emphasizes the need for effective ventilation due to potentially harmful welding fumes.

4.4 Mains Supply Voltage Requirements

Details mains supply voltage requirements and potential issues with incorrect voltages.

4.5 Alternative Mains Supply Voltages

Lists alternative mains supply voltages and corresponding lead sizes and fuse requirements.

5. SET UP FOR COMPACT VIKINGS

6. WELDING GUIDE VIKING 210GM

7. WELDING GUIDE VIKING 250GM.

8. POWER SOURCE CONTROLS, INDICATORS AND FEATURES

8.1 Indicator Light

Describes the function of the indicator light and its connection to the mains supply voltage.

8.2 Standby/Coarse Voltage Control Switch and Fine Voltage Control Switch

Explains the operation of coarse and fine voltage control switches for setting welding voltage.

8.3 Digital Ammeter and Voltmeter (Optional)

Details the optional digital ammeter and voltmeter for monitoring welding current and voltage.

8.4 Torch Polarity Lead (Compact Models Only)

Explains how to use the torch polarity lead to select the welding voltage polarity.

8.5 Positive and Negative Welding Terminals

Describes the function of the heavy-duty bayonet type welding terminals for current flow.

8.6 Wirefeeder Control Socket (Remote Wirefeeder Models Only)

Explains the use of the wirefeeder control socket for connecting the wirefeeder control cable.

8.7 Thermal Overload

Describes the thermal overload protection mechanism and procedure for cooling the machine.

8.8 Choice of Inductance Setting (Viking 210GM & 250GM Only)

Explains the selection of inductance taps for controlling spatter and penetration.

8.9 Wirespeed Control (Compact Models Only)

Details the wirespeed control knob for adjusting welding current via wire feed rate.

8.10 Spot Timer (Compact Models Only)

Explains the function of the spot timer knob for controlling single spot weld duration.

8.11 Dwell Timer (Compact Models Only)

Describes the dwell timer knob for controlling the interval or 'OFF' time in stitch welding.

8.12 Mode Selector Switch (Compact Models Only)

Explains how the mode selector switch is used to choose between SPOT, CONTINUOUS, and STITCH welding modes.

8.13 Wirefeeder Drive Roller Pressure Adjustment (Compact Models Only)

Details how to adjust the wirefeeder drive roller pressure for optimal wire feeding.

8.14 Wire Reel Brake (Compact Models Only)

Explains the adjustment of the wire reel brake for proper wire tension during feeding.

9. TWECO MIG TORCH

9.1 Introduction

Introduces the TWECO MIG torch and its benefits for Viking welders.

9.2 MIG Torch Components

Lists and identifies the various components of the TWECO MIG torch.

9.3 Torch Consumable Parts

Details consumable parts for TWECO MIG torches, including gas diffusers, contact tips, nozzles, and conduits.

9.4 Installing A New Wire Conduit

Provides step-by-step instructions for installing a new wire conduit in the MIG torch cable.

10. BASIC WELDING TECHNIQUE

10.1 Setting of the Power Source

Explains how to set welding current and voltage using Wirespeed and Voltage Control switches.

10.2 Position of MIG Torch

Discusses the effect of MIG torch angle on weld width.

10.3 Distance from the MIG Torch Nozzle to the Work Piece

Specifies the recommended electrode stick-out distance from the MIG torch nozzle.

10.4 Travel Speed

Explains how travel speed influences weld width and penetration.

10.5 Electrode Wire Size Selection

Lists factors influencing the choice of electrode wire size and shielding gas.

10.6 Stitch Welding Operation

Guides on setting controls for stitch welding to bridge gaps or weld thin material.

10.7 Spot Welding Operation

Details how to set controls for spot welding operations using the MIG torch.

11. ROUTINE MAINTENANCE & INSPECTION

11.1 Improved Current Accuracy Calibration Procedure for the Digital Meter

Provides a procedure for calibrating the digital meter for improved current accuracy.

12. BASIC TROUBLESHOOTING

12.1 Solving Problems Beyond the Welding Terminals

Offers troubleshooting steps for common GMAW problems like porosity and inconsistent wire feed.

12.2 Welding Problems

Lists common welding faults, their causes, and recommended remedies.

12.3 Power Source Problems

Identifies common power source issues, their causes, and solutions.

12.4 Key Spare Parts

Lists key spare parts for Viking 210GM and 250GM models with part numbers.

13. VOLT/AMP GRAPHS

14. VIKING 210GM CIRCUIT DIAGRAM

15. VIKING 250GM CIRCUIT DIAGRAM

16. PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM (CAT NO: 10-6100)

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