Thermal Arc Viking 210GM User manual

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

i
WARNING
Read and understand this entire Operating Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
WARNING
While the information contained in this manual represents our best judgement, Thermal Dynamics
Corporation assumes no liability for its use.
Thermal Arc™ Viking Welder Model Operating Manual
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 1996
Thermal Dynamics Corporation
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 the Thermal Arc™ Viking Welder
Operating Manual, whether such error results from negligence, accident, or any other
cause.

Viking 210GM, 250GM
TABLE OF CONTENTS
Page
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1. INTRODUCTION ..................................................................................................................1
1.1 Notes, Cautions and Warnings...................................................................................................................1
1.2 Important Safety Precautions.....................................................................................................................1
1.3 Publications................................................................................................................................................3
1.4 Note, Attention et Avertissement...............................................................................................................4
1.5 Precautions De Securite Importantes .........................................................................................................4
1.6 Documents De Reference...........................................................................................................................7
1.7 Statement of Warranty ...............................................................................................................................8
2. GENERAL INFORMATION................................................................................................9
2.1 Safety .........................................................................................................................................................9
2.2 Protective Filter Lenses..............................................................................................................................9
2.3 Welding Protection ..................................................................................................................................10
2.4 User Responsibility..................................................................................................................................10
2.5 Duty Cycle ...............................................................................................................................................10
3. SPECIFICATIONS ..............................................................................................................10
3.1 MIG Torch Specifications........................................................................................................................10
3.2 Machine Specifications............................................................................................................................11
3.3 Wire Drive Specifications........................................................................................................................12
3.4 Power Supply Contents............................................................................................................................12
3.5 Optional Accessories ...............................................................................................................................13
4. INSTALLATION RECOMMENDATIONS .....................................................................13
4.1 Environment.............................................................................................................................................13
4.2 Location ...................................................................................................................................................13
4.3 Ventilation ...............................................................................................................................................14
4.4 Mains Supply Voltage Requirements ......................................................................................................14
4.5 Alternative Mains Supply Voltages.........................................................................................................14
5. SET UP FOR COMPACT VIKINGS.................................................................................15
6. WELDING GUIDE VIKING 210GM ................................................................................16
7. WELDING GUIDE VIKING 250GM. ...............................................................................17
8. POWER SOURCE CONTROLS, INDICATORS AND FEATURES............................18
8.1 Indicator Light .........................................................................................................................................18
8.2 Standby/Coarse Voltage Control Switch and Fine Voltage Control Switch............................................18
8.3 Digital Ammeter and Voltmeter (Optional).............................................................................................18
8.4 Torch Polarity Lead (Compact Models Only) .........................................................................................19
8.5 Positive and Negative Welding Terminals...............................................................................................19
8.6 Wirefeeder Control Socket (Remote Wirefeeder Models Only)..............................................................19
8.7 Thermal Overload ....................................................................................................................................19
8.8 Choice of Inductance Setting (Viking 210GM & 250GM Only) ............................................................19
8.9 Wirespeed Control (Compact Models Only) ...........................................................................................19
8.10 Spot Timer (Compact Models Only) .....................................................................................................20

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8.11 Dwell Timer (Compact Models Only)...................................................................................................20
8.12 Mode Selector Switch (Compact Models Only)....................................................................................20
8.13 Wirefeeder Drive Roller Pressure Adjustment (Compact Models Only) ..............................................20
8.14 Wire Reel Brake (Compact Models Only).............................................................................................20
9. TWECO MIG TORCH (Cat No: 10-6105 where supplied)............................................. 21
9.1 Introduction..............................................................................................................................................21
9.2 MIG Torch Components..........................................................................................................................21
9.3 Torch Consumable Parts..........................................................................................................................22
9.4 Installing A New Wire Conduit...............................................................................................................23
9.5 MIG Torch Maintenance .........................................................................................................................24
10. BASIC WELDING TECHNIQUE ................................................................................... 24
10.1 Setting of the Power Source...................................................................................................................24
10.2 Position of MIG Torch...........................................................................................................................24
10.3 Distance from the MIG Torch Nozzle to the Work Piece......................................................................24
10.4 Travel Speed ..........................................................................................................................................24
10.5 Electrode Wire Size Selection ...............................................................................................................24
10.6 Stitch Welding Operation ......................................................................................................................25
10.7 Spot Welding Operation ........................................................................................................................26
11. ROUTINE MAINTENANCE & INSPECTION ............................................................. 26
11.1 Improved Current Accuracy Calibration Procedure for the Digital Meter ............................................27
12. BASIC TROUBLESHOOTING ....................................................................................... 28
12.1 Solving Problems Beyond the Welding Terminals................................................................................28
12.2 Welding Problems .................................................................................................................................30
12.3 Power Source Problems.........................................................................................................................31
12.4 Key Spare Parts......................................................................................................................................33
13. VOLT/AMP GRAPHS ...................................................................................................... 34
14. VIKING 210GM CIRCUIT DIAGRAM ......................................................................... 35
15. VIKING 250GM CIRCUIT DIAGRAM ......................................................................... 36
16. PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM (CAT NO: 10-6100) ............... 37

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TABLES
Page
Table 1 - Filter lens size verses welding current...................................................................................10
Table 2 - Factory fitted Mains supply leads fitted to the Viking Power Sources .................................14
Table 3 - Mains supply lead sizes for alternative Mains supply voltages.............................................14
Table 4 - Mig Torch components..........................................................................................................21
Table 5 - Mig torch gas diffusers ..........................................................................................................22
Table 6 - Mig torch contact tips ............................................................................................................22
Table 7 - Mig torch nozzles...................................................................................................................22
Table 8 - Mig torch conduits................................................................................................................. 22
Table 9 - 0.9mm (.035”)/1.2mm (.045”) wire deposition rate ..............................................................25
FIGURES
Figure 1 - Viking duty cycle curves...................................................................................................... 10
Figure 2 - Voltage settings for Viking 210GM & 250GM. .................................................................. 15
Figure 3 - Compact Viking controls......................................................................................................18
Figure 4 - Remote Viking controls........................................................................................................18
Figure 5 - Examples of the digital read outs ......................................................................................... 18
Figure 6 - Exploded view of MIG torch................................................................................................21
Figure 7 - Conduit trim length...............................................................................................................23
Figure 8 - MIG Torch angle .................................................................................................................. 24
Figure 9 - Wire penetration comparison ...............................................................................................25
Figure 10 - Volt/Amp curves of the Viking 210 ...................................................................................34
Figure 11 - Volt/Amp curves of the Viking 250 ...................................................................................34

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1. INTRODUCTION
1.1 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important
information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in
efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.
1.2 Important Safety Precautions
WARNING
OPERATION AND MAINTENANCE OF WELDING ARC EQUIPMENT CAN BE DANGEROUS
AND HAZARDOUS TO YOUR HEALTH.
To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions
before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the welding process can be dangerous and hazardous to your
health.
•Keep all fumes and gases from the breathing area. Keep your head out of the welding fume
plume.
•Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
•The kinds of fumes and gases from the welding arc depend on the kind of metal being used,
coatings on the metal, and the different processes. You must be very careful when cutting or
welding any metals which may contain one or more of the following:
Antimony Beryllium Cobalt Manganese Selenium
Arsenic Cadmium Copper Mercury Silver
Barium Chromium Lead Nickel Vanadium
•Always read the Material Safety Data Sheets (MSD’s) that should be supplied with the material
you are using. These MSDS’s will give you the information regarding the kind and amount of
fumes and gases that may be dangerous to your health.
•For information on how to test for fumes and gases in your workplace, refer to item 1 in
Subsection 1.3, Publications in this manual.
•Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
•Do not use the welding torch in an area where combustible or explosive gases or materials are
located.
•Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers.
Remove all sources of these vapors.

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ELECTRIC SHOCK
Electric Shock can injure or kill. The welding arc process uses and produces high voltage
electrical energy. This electric energy can cause severe or fatal shock to the operator or others in
the workplace.
•Never touch any parts that are electrically “live” or “hot.”
•Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the
welding circuit.
•Repair or replace all worn or damaged parts.
•Extra care must be taken when the workplace is moist or damp.
•Install and maintain equipment according to NEC code, refer to item 4 in Subsection 1.3,
Publications.
•Disconnect power source before performing any service or repairs.
•Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the welding arc.
•Be sure there is no combustible or flammable material in the workplace. Any material that
cannot be removed must be protected.
•Ventilate all flammable or explosive vapors from the workplace.
•Do not cut or weld on containers that may have held combustibles.
•Provide a fire watch when working in an area where fire hazards may exist.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed
safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
•To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect
others in the workplace.
•Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
•For information on how to test for noise, see item 1 in Subsection 1.3, Publications, in this
manual.
ARC RAYS
Arc Rays can injure your eyes and burn your skin. The welding arc process produces very bright
ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are
not properly protected.
•To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses
with side shields, goggles or other protective eye wear.
•Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
•Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or
dirty.
•Protect others in the work area from the arc rays. Use protective booths, screens or shields.
•Use the shade of lens as recommended in the Operating Manual.

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1.3 Publications
Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the
Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND
CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL
EYE AND FACE PROTECTION, obtainable from American National Standards Institute,
1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable
from the American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING
PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New
York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND
ALLIED PROCESSES, obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
10.NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the
National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11.CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS,
obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12.CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable
from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
13.NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14.American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR
THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING
THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15.ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from
American National Standards Institute, 1430 Broadway, New York, NY 10018

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1.4 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief
des informations à caractère important. Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui
contribue à l’efficacité de fonctionnement du système.
ATTENTION
Toute procédure pouvant résulter l’endommagement du matériel en cas de non-respect de la procédure en
question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la
zone de travail en cas de non-respect de la procédure en question.
1.5 Precautions De Securite Importantes
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE
PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures
possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les
consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez
des questions.

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FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des
dangers de santé.
•Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de
fumée provenant du chalumeau.
•Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas
d’éliminer la fumée et les gaz.
•Les sortes de gaz et de fumée provenant de l’arc de soudage dépendent du genre de métal
utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre
soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments
suivants:
antimoine baryum chrome manganèse plomb
argent béryllium cobalt mercure sélénium
arsenic cadmium cuivre nickel vanadium
•Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”);
celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des
renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers
de santé.
•Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail,
consultez l’article 1 et les documents cités à la page 7
•Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant
descendant pour capter la fumée et les gaz.
•N’utilisez pas le chalumeau au jet de soudage dans une zone où se trouvent des matières ou des
gaz combustibles ou explosifs.
•Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de
nettoyage chlorés. Eliminez toute source de telle fumée.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de soudage requiert et
produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs
graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
•Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
•Réparez ou remplacez toute pièce usée ou endommagée.
•Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
•Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis.
(Voir la page v, article 9.)
•Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
•Lisez et respectez toutes les consignes du Manuel de consignes.