Thermal Arc 400 GTSW AC/DC Manuale utente

INVERTER

ARC

WELDER

MODEL 400 GTSW AC/DC

CC/TIG

• Stick

• TIG - High Frequency

- Lift Start

Operating Manual

Manual No. 0-2430

First Edition • September 1994

Read and understand this entire Operating Manual and your

employer’s safety practices before installing, operating, or

servicing the equipment.

While the information contained in this manual represents our

best judgement, Thermal Dynamics Corporation assumes no

liability for its use.

Thermal Arc™ Model 400 GTSW Inverter Arc Welder

Operating Manual Number 0-2430

Published by:

Thermal Dynamics Corporation

Industrial Park No. 2

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

Thermal Dynamics Corporation

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™ Model 400 GTSW Inverter Arc

Welder Operating Manual, whether such error results from

negligence, accident, or any other cause.

First Edition

September 1994

WARNING

TABLE OF CONTENTS

Introduction

General Information

Installation

Operation

Service

Notes, Cautions, and Warnings ..........................................................i

Important Safety Precautions ............................................................ ii

Statement of Warranty .....................................................................xiv

1.1 Specifications................................................................................1

1.2 Duty Cycle....................................................................................2

2.1 Site Selection.................................................................................3

2.2 Transporting Methods ................................................................4

2.3 Weld Output Connections..........................................................5

2.4 Shielding Gas Connections ........................................................8

2.5 Remote 14 Connections ..............................................................9

2.6 Electrical Input Connections ....................................................10

3.1 Operator Controls......................................................................13

3.2 Sloper and Pulser Controls ......................................................19

3.3 Operating Precautions ..............................................................22

3.4 Sequence of Operation ..............................................................23

3.5 Electrode Preparation ...............................................................26

3.6 Electrode Selection ....................................................................27

4.1 General Maintenance ................................................................29

4.2 Troubleshooting Guide.............................................................30

INTRODUCTION

NOTES, CAUTIONS, AND WARNINGS

Throughout this manual, notes, cautions, and warnings are used

to highlight important information. These highlights are catego-

rized as follows:

An operation, procedure, or background information which

requires additional emphasis or is helpful in efficient operation of

the system.

A procedure which, if not properly followed, may cause damage

to the equipment.

A procedure which, if not properly followed, may cause injury

to the operator or others in the operating area.

NOTE

CAUTION

WARNING

INTRODUCTION

IMPORTANT SAFETY PRECAUTIONS

WARNING

Gases and Fumes

Operation and maintenance of arc welding equipment involves

potential hazards. Operators and all others in the operating area

should be alerted to possible hazards, and precautions should be

taken to prevent possible injury.

Read these safety precautions and the entire instruction manual

before operating.

Do not use this power supply to thaw frozen water pipes.

This equipment must be installed, operated, and serviced by

qualified personnel only.

GASES AND FUMES produced during arc welding can be

dangerous and hazardous to your health.

Keep all fumes and gases from the breathing area.

Different arc welding processes, electrodes, and fluxes can

produce different fumes, gases and radiation levels. Consult

Material Safety Data Sheets (MSDS's) and manufacturer's instruc-

tions for specific technical data and precautionary measures for

all fluxes, electrodes, and materials used.

Severe discomfort, illness or death can result from fumes, vapors,

heat, or oxygen enrichment or depletion that welding (or cutting)

may produce. Ventilation must be adequate to remove gases and

fumes during operation as described in ANSI Standard Z49.1.

Use a downdraft table or water table to capture fumes and gases.

Use an air-supplied respirator if ventilation is not adequate to

remove all fumes and gases.

When working in confined spaces provide adequate ventilation

or wear an air-supplied respirator if necessary.

Gas leaks in a confined space should be avoided. Leaked gas in

large quantities can change oxygen concentration dangerously.

Do not bring gas cylinders into a confined space.

When leaving confined space, shut off gas supply at source to

prevent possible accumulation of gases if downstream valves are

accidentally opened. Check that area is safe before re-entering.

Materials containing lead, cadmium, zinc, mercury, beryllium,

and similar materials may produce harmful concentrations of

toxic fumes when welded or cut. Adequate local exhaust ventila-

tion must be used, or operators and others in the operating area

must wear an air-supplied respirator. For beryllium, both must

be used.

iii

INTRODUCTION

Gases and Fumes

(continued)

Arc Rays

IMPORTANT SAFETY PRECAUTIONS (continued)

Metals coated with or containing materials that emit toxic fumes

should not be heated unless coating is removed from work

surface and work area is well ventilated. Wear an air-supplied

respirator if necessary.

Vapors from chlorinated solvents can be decomposed by the heat

of the arc or flame to form phosgene, a highly toxic gas, and other

lung and eye irritating products. The ultraviolet radiant energy

of the arc can also decompose trichloroethylene and perchloro-

ethylene vapors to form phosgene. Do not weld or cut where

solvent vapors may be drawn into the welding or cutting atmo-

sphere or where radiant energy may penetrate to atmospheres

containing even minute amounts of trichloroethylene or perchlo-

roethylene. Solvents, degreasers, and potential sources of these

vapors must be removed from the operating area.

Oil or grease in the presence of oxygen may ignite and burn

violently. Keep cylinders, valves, couplings, regulators, hoses,

and other apparatus clean and free from oil and grease. Oxygen

cylinders and apparatus should not be handled with oily hands

or gloves. Do not allow an oxygen stream to contact oily or

greasy surfaces.

Do not use oxygen as a substitute for compressed air.

NEVER ventilate with oxygen.

Generator engine exhaust must be vented to the outside air.

Carbon monoxide can kill.

ARC RAYS can injure eyes and burn skin.

Never look at an electric arc without protection. Protect eyes

from exposure to arc. Looking at an arc momentarily with

unprotected eyes (particularly a high intensity gas-shielded arc)

can cause permanent damage to vision.

Use a welding helmet or shield with proper filter (see chart on

page v). Place over face before striking arc.

Protect filter plate with a clear cover plate.

Do not use cracked or broken helmet or shield; radiation can pass

through to cause burns.

Replace any cracked, broken or loose filter plates immediately.

Replace clear cover plate when broken, pitted, or spattered.

Flash goggles with side shields must be worn under helmet to

protect eyes in case helmet is not in position before arc is struck.

Wear proper protective clothing. Arc rays can penetrate light-

weight clothing,

Welding arc rays can reflect from light-colored surfaces.

INTRODUCTION

IMPORTANT SAFETY PRECAUTIONS (continued)

Arc Rays

(continued) Make sure others in the operating area are protected from arc

rays.

For production welding, use separate room or enclosed bay. In

open areas, surround operation with low reflective non-combus-

tible screens or panels. Make sure that screen flaps or bay doors

are closed before welding. Allow for free air circulation, particu-

larly at floor level.

Provide face shields for all others viewing the weld.

Make sure others in the operating area are wearing flash goggles.

Welding or Cutting Operation Electrode Size Filter

Metal Thickness Shade

or Welding Current Number

Torch soldering - 2

Torch brazing - 3 or 4

Oxygen Cutting

Light Under 1 in (25 mm) 3 or 4

Medium 1-6 in (25-150 mm) 4 or 5

Heavy Over 6 in (150 mm) 5 or 6

Gas welding

Light Under 1/8 in (3 mm) 4 or 5

Medium 1/8-1/2 in (3-12 mm) 5 or 6

Heavy Over 1/2 in (12 mm) 6 or 8

Shielded metal arc welding

(stick) electrodes

Light Under 5/32 in (4 mm) 10

Medium 5/32-1/4 in (4-6.4 mm) 12

Heavy Over 1/4 in (6.4 mm) 14

Gas metal arc welding (MIG)

Non-ferrous base metal All 11

Ferrous base metal All 12

Gas tungsten arc welding (TIG) All 12

Atomic hydrogen welding All 12

Carbon arc welding All 12

Plasma arc welding All 12

Carbon arc air gouging

Light - 12

Heavy - 14

Plasma arc cutting

Light Under 300 amps 9

Medium 300-400 amps 12

Heavy Over 400 amps 14

Recommended Eye Protection for Welding and Cutting (Based on AWS A6.2-73)

INTRODUCTION

Electric Shock ELECTRIC SHOCK can kill.

Do not contact electrically live parts.

Install equipment according to safety precautions, instruction

manual, and all applicable codes.

Keep all panels, covers, and guards in place.

Disconnect all primary power before installing or servicing this

equipment.

Insulate operator and others from work and ground.

Replace any cracked or damaged insulating parts.

Shut down welding power source before touching electrode, wire

drive assembly, welding wire, wire reel, or any metal parts in

contact with the welding wire.

Exposed hot conductors or other bare metal in the welding circuit

or in ungrounded, electrically hot equipment can cause poten-

tially fatal electric shock. Do not contact a wet surface when

welding without suitable protection.

Wear dry insulating gloves and body protection. Keep body and

clothing dry. Never work in damp area without adequate insula-

tion against electrical shock. Stay on a dry duckboard, or rubber

mat when dampness or sweat cannot be avoided. Sweat, sea

water, or moisture between body and an electrically hot part or

grounded metal reduces electrical resistance and could cause

potentially fatal electric shock.

A voltage will exist between the electrode and any conducting

object in the work circuit. Examples of conducting objects in-

clude, but are not limited to, buildings, electrical tools, work

benches, welding power source cases, workpieces, etc. Never

touch electrode to any metal object unless the welding power

source is off.

Arc welding equipment must be grounded according to the

National Electrical Code, and the work must be grounded accord-

ing to ANSI Z49.1 “Safety in Welding and Cutting.”

When installing, connect the frames of each unit such as welding

power source, control, work table and water circulator to the

building ground. Conductors must be adequate to carry ground

currents safely. Equipment made electrically hot by stray current

may cause potentially fatal electric shock. Do not ground to

electrical conduit or to pipe carrying any gas or flammable liquid

such as oil or fuel.

Check phase requirements before installing. If only three-phase

power is available, connect single-phase equipment to only two

wires of the three-phase line. Do not connect the equipment

ground lead to the third (live) wire, or the equipment will be-

IMPORTANT SAFETY PRECAUTIONS (continued)

INTRODUCTION

come electrically hot - a dangerous condition that may cause

potentially fatal electric shock.

Before welding, check ground for continuity. Be sure conductors

are touching bare metal of equipment frames at connections.

If a line cord with a ground lead is provided with the equipment

for connection to a switchbox, connect the ground lead to the

grounded switchbox. If a three-prong plug is added for connec-

tion to a grounded mating receptacle, the ground lead must be

connected to the ground prong only. If the line cord comes with

a three-prong plug, connect to a grounded mating receptacle.

Never remove the ground prong from a plug, or use a plug with

a broken off ground plug.

Fully insulated electrode holders should be used. Do not use

holders with protruding screws.

Fully insulated lock-type connectors should be used to join

welding cable lengths.

Frequently inspect cables for wear, cracks and damage. Replace

those with excessively worn or damaged insulation to avoid

potentially fatal electric shock from bared cable. Cables with

damaged areas may be taped to give resistance equivalent to

original cable.

Keep cables dry, free of oil and grease, and protected from hot

metal and sparks.

Terminals and other exposed parts of electrical units should have

insulating covers secured before operation.

For equipment with output ON/OFF control (contactor): Weld-

ing power sources for use with gas metal arc welding (GMAW),

gas tungsten arc welding (GTAW) and similar processes nor-

mally are equipped with devices that permit ON-OFF control of

the welding power output. When so equipped the electrode wire

becomes electrically hot when the power source switch is ON and

welding gun switch is closed. Never touch electrode wire or any

conducting object in contact with electrode circuit unless the

welding power source is OFF.

For equipment without output ON/OFF control (no contactor):

Welding power sources used with shielded metal arc welding

(SMAW) and similar processes may not be equipped with weld-

ing power output ON-OFF control devices. With such equipment

the electrode is electrically hot when the power switch is turned

ON. Never touch the electrode unless the welding power source

is off.

Safety devices such as interlocks and circuit breakers should

never be disconnected or shunted out.

IMPORTANT SAFETY PRECAUTIONS (continued)

Electric Shock

(continued)

Electrode

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