Tweco 95 S Thermal Arc(Nov2010) User Manual

60HzArt # A-09694THERMAL ARC®INVERTER ARC WELDER95 SOperating ManualRevision: AA Issue Date: November 1, 2010 Manual No.: 0-5175Operating

THERMAL ARC 95 S SAFETY INSTRUCTIONSManual 0-5175 1-4 Safety Instructinos WARNINGSTEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

SAFETY INSTRUCTIONS THERMAL ARC 95 SSafety Instructions 1-5 Manual 0-5175 1.03 Symbol ChartNote that only some of these symbols will appear on you

THERMAL ARC 95 S SAFETY INSTRUCTIONSManual 0-5175 1-6 Safety Instructinos1.04 Precautions De Securite En Soudage A L’arc! MISE EN GARDELE SOUDA

SAFETY INSTRUCTIONS THERMAL ARC 95 SSafety Instructions 1-7 Manual 0-5175 1. Portez une casque de soudeur avec filtre oculaire de nuance ap-proprié

THERMAL ARC 95 S SAFETY INSTRUCTIONSManual 0-5175 1-8 Safety Instructinos AVERTISSEMENTLE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSIONL’arc

SAFETY INSTRUCTIONS THERMAL ARC 95 SSafety Instructions 1-9 Manual 0-5175 2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles

THERMAL ARC 95 S SAFETY INSTRUCTIONSManual 0-5175 1-10 Safety InstructinosSoudage á L’arc AvecElectrode Non Fusible(GTAW)Decoupe Arc Carbone(CAC-

SAFETY INSTRUCTIONS THERMAL ARC 95 SSafety Instructions 1-11 Manual 0-5175 1.08 Declaration Of ConformityManufacturer: Thermadyne Corporation A

THERMAL ARC 95 S SAFETY INSTRUCTIONSManual 0-5175 1-12 Safety Instructinos

INTRODUCTION THERMAL ARC 95 SIntroduction 2-1 Manual 0-5175SECTION 2: INTRODUCTION2.01 How to Use This ManualThis Operating Manual usually applies

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 w

THERMAL ARC 95 S INTRODUCTIONManual 0-5175 2-2 Introduction2.07 SpecificationsPower Source Part Number W1003206Welding OutputWelding Current Range

INSTALLATION THERMAL ARC 95 SInstallation 3-1 Manual 0-51753.01 EnvironmentThese units are designed for use in environments with increased

THERMAL ARC 95 S INSTALLATIONManual 0-5175 3-2 InstallationRefer to Figure 3-1:1. Connect end of ground (GREEN or GREEN/YELLOW) conductor to a s

INSTALLATION THERMAL ARC 95 SInstallation 3-3 Manual 0-5175Input PowerEach unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is tur

THERMAL ARC 95 S INSTALLATIONManual 0-5175 3-4 Installation3.04 Electromagnetic Compatibility! WARNINGExtra precautions for Electromagnetic C

INSTALLATION THERMAL ARC 95 SInstallation 3-5 Manual 0-51755. Earthing of the Work Piece Where the work piece is not bonded to earth for electri-

THERMAL ARC 95 S INSTALLATIONManual 0-5175 3-6 InstallationFigure 3-2: Setup for SMAW (Stick) WeldingSMAW (Stick) Mode Sequence of Operation CA

INSTALLATION THERMAL ARC 95 SInstallation 3-7 Manual 0-51753.07 GTAW (Lift TIG) SetupFigure 3-3: Setup for GTAW (Lift TIG) WeldingGTAW (Lift TIG)

THERMAL ARC 95 S INSTALLATIONManual 0-5175 3-8 Installation9. Set the “Process Selection Switch” to GTAW (Lift TIG)10. Set the weld cur

OPERATION THERMAL ARC 95 SOperation 4-1 Manual 0-5175Figure 4-1: 95 S ControlsSECTION 4: OPERATIONConventional operating procedures apply when

! WARNINGSRead and understand this entire Manual and your employer’s safety practices before installing,operating, or servicing the equipment.While th

THERMAL ARC 95 S OPERATIONManual 0-5175 4-2 Operation4.02 SMAW Electrode PolarityStick electrodes are generally connected to the "+" P

OPERATION THERMAL ARC 95 SOperation 4-3 Manual 0-51754.08 Tungsten Electrode TypesElectrode Type (Ground Finish) Welding Application Features Co

THERMAL ARC 95 S OPERATIONManual 0-5175 4-4 Operation4.10 Arc Welding PracticeThe techniques used for arc welding are almost identical regardles

OPERATION THERMAL ARC 95 SOperation 4-5 Manual 0-5175Figure 4-10: Typical joint designs for arc weldingGap varies from1/16” (1.6mm) to 3/16” (4.8mm

THERMAL ARC 95 S OPERATIONManual 0-5175 4-6 Operation4.13 Arc Welding TechniqueA Word to BeginnersFor those who have not yet done any welding, t

OPERATION THERMAL ARC 95 SOperation 4-7 Manual 0-5175a 70° to 90° included angle. This allows full penetration of the weld metal to the root. Using

THERMAL ARC 95 S OPERATIONManual 0-5175 4-8 Operationof the fillet. The electrode needs to be about 10° from the horizontal to enable a good bead

OPERATION THERMAL ARC 95 SOperation 4-9 Manual 0-5175Art # A-07706Figure 4-21: Parent metal contraction4.21 Overcoming Distortion EffectsThere ar

THERMAL ARC 95 S OPERATIONManual 0-5175 4-10 OperationE. PreheatingSuitable preheating of parts of the structure other than the area to be welde

SERVICE THERMAL ARC 95 SService 5-1 Manual 0-51755.01 Maintenance and InspectionThe only routine maintenance required for the power supply i

TABLE OF CONTENTSSECTION 1:SAFETY INSTRUCTIONS AND WARNINGS ... 1-11.01 Arc Welding Hazards ...

THERMAL ARC 95 S SERVICEManual 0-5175 5-2 Service5.02 SMAW (Stick) Welding Problems Insufficient GapIncorrect SequenceArt # A-05866_ACNot cleaned

SERVICE THERMAL ARC 95 SService 5-3 Manual 0-51755.03 GTAW (Lift TIG) Welding Problems Weld quality is dependent on the selection of the correct c

THERMAL ARC 95 S SERVICEManual 0-5175 5-4 ServiceGTAW (Lift TIG) Welding Problems (Con-5.04 Power Source Problems Description Possible Cause Rem

APPENDIX THERMAL ARC 95 SAppendix A-1 Manual 0-5175APPENDIX 1: REPLACEMENT PARTSDescription Part No.Case Toolbox, 95S W4012801Fan, 24V DC, 95S W700

THERMAL ARC 95 S APPENDIXManual 0-5175 A-2 AppendixAPPENDIX 2: OPTIONS AND ACCESSORIESDescription Part Number17V style TIG Torch with 3m lead, ga

APPENDIX THERMAL ARC 95 SAppendix A-3 Manual 0-5175APPENDIX 3: SYSTEM SCHEMATICAC1AC3+2-4-24VL?TRANS2OCPr2OC1OC2Pr1DR1DR2DR5DR6DR3DR4DR7DR8DR1DR2DR

THERMAL ARC 95 S APPENDIXManual 0-5175 A-4 AppendixThis Page Intentionally Blank

LIMITED WARRANTYThis information applies to Thermal Arc products that were purchased in the USA and Canada.November 2007LIMITED WARRANTY: Thermal Arc

WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada.January 2009 SAFETY EQUIPMENT WARRANTY PE

TABLE OF CONTENTS4.17 Rate of Travel ... 4-64.18 Maki

W O R L D H E A D Q U A RT E R S : 1 6 0 5 2 S w i n g l e y Rid g e R o a d , S u i t e 3 0 0 • S t . L o u i s, M i s s o u

SAFETY INSTRUCTIONS THERMAL ARC 95 SSafety Instructions 1-1 Manual 0-5175 1.01 Arc Welding Hazards WARNING ELECTRIC SHOCK can kill.Touching live e

THERMAL ARC 95 S SAFETY INSTRUCTIONSManual 0-5175 1-2 Safety Instructinos WARNINGFUMES AND GASES can be hazardous to your health.Welding produce

SAFETY INSTRUCTIONS THERMAL ARC 95 SSafety Instructions 1-3 Manual 0-5175 WARNINGFLYING SPARKS AND HOT METAL can cause injury.Chipping and grindi