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Thermadyne THERMAL ARC 130 GTS & S CC/TIG Operating Manual

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TM
R
INVERTER
ARC
WELDER
MODEL 130 GTS & S CC/TIG
• STICK
• TIG - HIGH FREQUENCY
- LIFT START
OPERATING MANUAL
July 1, 1997
Manual No. 0-2620

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Summary of Contents for Thermadyne THERMAL ARC 130 GTS & S CC/TIG

  • Page 1 INVERTER WELDER MODEL 130 GTS & S CC/TIG • STICK • TIG - HIGH FREQUENCY - LIFT START OPERATING MANUAL July 1, 1997 Manual No. 0-2620...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1.0 GENERAL INFORMATION ............2 1.01 Notes, Cautions and Warnings ..........2 1.02 Important Safety Precautions ............ 3 1.03 Publications ................. 6 1.04 Note, Attention et Avertissement ..........7 1.05 Precautions De Securite Importantes........8 1.06 Documents De Reference ............11 1.07 Declaration of Conformity ............
  • Page 3 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 Operating Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. Thermal Arc Models 130 GTS &...

  • Page 4: General Information

    1.0 GENERAL INFORMATION 1.01 NOTES, CAUTIONS AND WARNINGS Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: An operation, procedure, or background information which requires NOTE additional emphasis or is helpful in efficient operation of the system. A procedure which, if not properly followed, may cause damage to the CAUTION equipment.

  • Page 5: Important Safety Precautions

    WARNING 1.02 IMPORTANT SAFETY PRECAUTIONS OPERATION AND MAINTENANCE OF PLASMA 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.
  • Page 6 IMPORTANT SAFETY PRECAUTIONS (CONTINUED) ELECTRIC SHOCK Electric Shock can injure or kill. The plasma 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. •...
  • Page 7 IMPORTANT SAFETY PRECAUTIONS (CONTINUED) Plasma Arc Rays can injure your eyes and burn your skin. The plasma PLASMA ARC RAYS 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.

  • Page 8: Publications

    1.03 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.

  • Page 9: Note, Attention Et Avertissement

    1.04 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 : NOTET oute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à...

  • Page 10: Precautions De Securite Importantes

    AVERTISSEMENT 1.05 PRECAUTIONS DE SECURITE IMPORTANTES 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...
  • Page 11 PRECAUTIONS DE SECURITE IMPORTANTES Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet CHOC ELECTRIQUE de plasma 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. •...
  • Page 12 PRECAUTIONS DE SECURITE IMPORTANTES RAYONS D’ARC DE PLASMA Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à...

  • Page 13: Documents De Reference

    1.06 DOCUMENTS DE REFERENCE Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 14: Declaration Of Conformity

    Thermal Dynamics has been manufacturing products that perform in a safe manner for more than 30 years and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: David Ashworth Vice President & Managing Director Thermadyne Europe Chorley England. MANUAL 0-2620 GENERAL...

  • Page 15: Statement Of Warranty

    1.08 STATEMENT OF WARRANTY LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommen dations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident,...
  • Page 16 MANUAL 0-2620...

  • Page 17: Introduction And Description

    2.0 INTRODUCTION AND DESCRIPTION 2.01 Description ™ The Thermal Arc Model 130 GTS and S are single-phase DC arc welding power sources with Constant Current (CC) output characteristics. Each GTS unit is equipped with a built-in Sloper, Pulser, gas control solenoid, Lift Start TIG, and a High-Frequency arc starter for use with Gas Tungsten Arc Welding (GTAW).

  • Page 18: Functional Block Diagrams

    2.02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of both the GTS and S models within the 100 Series power supplies. The shaded areas show the common subsystems discussed in this section. Thermal Detector Power Module (IPM) Input Main Coupling...

  • Page 19: Transporting Methods

    2.03 Transporting Methods These units are equipped with one handle and a shoulder strap for carrying purposes. WARNING ELECTRIC SHOCK can kill. • DO NOT TOUCH live electrical parts. • Disconnect input power conductors from de-energized supply line before moving welding power source. FALLING EQUIPMENT can cause serious personal injury and equipment WARNING damage.

  • Page 20: Electrical Input Connections

    2.04 Electrical Input Connections WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. • DO NOT TOUCH live electrical parts. • SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red- tagging circuit breaker or other disconnecting device.
  • Page 21 NOTE Continuous output on 115VAC/20 Amp circuit breaker for fuse: 92 Amps/ 13 Vdc (TIG), 51 Amps/23 Vdc (STICK). NOTE Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code).

  • Page 22: Specifications

    2.05 Specifications Parameter/Model Model 130 GTS/S CC/TIG Rated Output @ 230 V @115V Amperes Volts Duty Cycle @ 230 V Input 40% at 130 A/15 V 25% at 100 A/25 V @ 115 V Input 40% at 85 A/13 V 25% at 85 A/23 V Range (Min.

  • Page 23: Duty Cycle

    2.06 Duty Cycle The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases.

  • Page 24: Operator Controls

    3.0 OPERATOR CONTROLS 3.01 GTS Models Amperage Control - The Amperage Control selects the desired amperage within the entire range of the welding power source. Rotating this control in a clockwise direction increases the amperage output. The scale surrounding the amperage control represents approximate actual amperage values.
  • Page 25 Positive Terminal - 25mm DIN-style female receptacle. Negative Terminal - 25mm DIN-style female receptacle. Main Circuit Breaker - Placing the Main Circuit Breaker located on the rear panel to the ON position energizes the welding power source. Input Cable - 10 feet; size 12/3 cable Input Gas Fitting - The input gas connection is located on the bottom center of the rear panel.

  • Page 26: S Models

    3.0 OPERATOR CONTROLS (CON'T) 3.02 S Models Amperage Control - The Amperage Control selects the desired amperage within the entire range of the welding power source. Rotating this control in a clockwise direction increases the amperage output. The scale surrounding the amperage control represents approximate actual amperage values.
  • Page 27 Main Circuit Breaker - Placing the Main Circuit Breaker located on the rear panel to the ON position energizes the welding power source. Input Cable - 10 feet; size 12/3 cable Figure 5b. S model rear panel operator controls MANUAL 0-2620 OPERATOR CONTROLS...

  • Page 28: Gts - Setup For Operation

    3.03 GTS – Setup for Operation Shielded Metal Arc Welding (SMAW) WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceeding with operation. Install and connect unit according to the installation instructions in section 2.04, page 18, of this manual. Wear dry insulating gloves and clothing.

  • Page 29: Gas Tungsten Arc Welding (Gtaw) High Frequency/Lift Start

    3.03 GTS – Setup for Operation Gas Tungsten Arc Welding (GTAW) High Frequency/Lift Start WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceeding with operation. 1. Install and connect unit according to the installation instructions in section 2.04, page18, of this manual.
  • Page 30 11. Activate remote control device. a. In LIFT TIG mode, touch electrode to work and lift to start arc. NOTES b. In HF TIG mode, high frequency will start, followed by welding arc. The distance between the tungsten to the plate where the arc will be established will vary with the setting of the HOT START control.

  • Page 31: Gas Tungsten Arc Welding -Pulsed (Gtaw-P) -Sloped (Gtaw-S) -Tig Spot

    3.03 GTS – Setup for Operation Gas Tungsten Arc Welding -Pulsed (GTAW-P) -Sloped (GTAW-S) -TIG Spot WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceeding with operation. 1. Install and connect unit according to the installation instructions in section 2.04, page 18, of this manual.
  • Page 32 C. SPOT TIG welding 1. SLOPER switch [3] to SPOT position. 2. Rotate AMPERAGE control [1] to desired spot welding current level. 3. Rotate SPOT TIME UP/DOWN SLOPE control [6] to desired SPOT welding time. Note: The SPOT TIMER is disabled in the LIFT TIG mode. To use the SPOT TIMER, use the HF START mode.

  • Page 33: S - Setup For Operation

    3.04 S – Setup for Operation Shielded Metal Arc Welding (SMAW) WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceeding with operation. 1. Install and connect unit according to the installation instructions in section 2.04, page 18, of this manual. 2.

  • Page 34: Gas Tungsten Arc Welding (Gtaw) Lift Start

    3.04 S – Setup for Operation Gas Tungsten Arc Welding (GTAW) Lift Start WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceeding with operation. Install and connect unit according to the installation instructions in section 2.04, page 18, of this manual.
  • Page 35 10. Place the PRIMARY POWER switch [9] to ON. 11. Activate remote control device. NOTES a. In LIFT TIG mode, touch electrode to work and lift to start arc. 12. Begin welding. HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill. WARNING Shut off gas supply when not in use.
  • Page 36 Table 2. Fuse Size Selection Input Power/Input Voltage Fuse Size (Amperes) Single-Phase Model 130GTS Model 130S 208-230 VAC 115 VAC NOTE Continuous output on 115VAC/20 Amp circuit breaker for fuse: 92 Amps/ 13 Vdc (TIG), 51 Amps/23 Vdc (Stick). Fuse size is based on not more than 200 percent of the rated input NOTE amperage of the welding power source (Based on Article 630, National Electrical Code).
  • Page 37 Table 4. Weld Cable Size Maximum Total Cable Length in Weld Circuit Under 100 ft. 150 ft. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft. (Under 30m) (45m) (60m) (70m) (90m) (105m) (120m) Duty Cycle 100-60% 60-100% 10-100% Welding Amperes 2-2/0 2-2/0...

  • Page 38: Basic Troubleshooting

    4.0 BASIC TROUBLESHOOTING Troubleshooting and repairing this unit is a process which should be General undertaken only by those familiar with high voltage, high power electronic equipment. WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had train– ing in power electronics measurement and troubleshooting techniques.
  • Page 39 A. No Weld Output; Unit is Completely Inoperative 1. Line disconnect switch is in OFF position a. Place line disconnect switch in ON position. 2. Line fuse(s) open a. Check and replace line fuse(s). 3. Improper electrical input connections a. See Section 2.04 Electrical Input Connections, page 18, for proper input connections.
  • Page 40 3. Insufficient postflow time a. Increase postflow time. 4. Loose gas fitting on regulator or gas line drawing air into weld zone a. Check and tighten all gas fittings. 5. Water in torch a. Refer to torch parts list for part(s) requiring replacement and repair torch as necessary.

  • Page 41: Remote 8-Pin Connections

    4.03 REMOTE 8-Pin Connections The REMOTE 8-Pin receptable is used to connect any of the following equipment to the welding power source circuitry: • Remote Hand Pendant • Remote Foot Control • Remote Contactor Control • Remote Amperage Control To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
  • Page 42 MANUAL 0-2620...

  • Page 43: Appendix A - Accessories

    APPENDIX A - ACCESSORIES APPENDIX A MANUAL 0-2620 ACCESSORIES...
  • Page 44 MANUAL 0-2620...

  • Page 45: Appendix B - Interconnection Diagrams

    APPENDIX B – INTERCONNECTION DIAGRAMS The following pages contain the interconnection diagrams for all 130 GTS and S models in current production, to aid in the identification of replacement parts. MANUAL 0-2620 APPENDIX B INTERCONNECTION DIAGRAMS...
  • Page 46 GTS Model White Strap White Strap Black White White Line 1 Black MCB1 DOUT Black Line 2 P (TB3) Q (TB4) Single Pole R (TB2) C (TB5) Line 1 Line 2 S (TB1) N (TB6) Double Pole TH2 TH1 Green PCB1 [WK3310] Green +12VDC Supply (Brown)
  • Page 47 Black Black + Output Terminal Output Filter Network Black +12VDC Supply (Brown) -12VDC Supply (Red) 0 to -12VDC Current Output Detect (Orange) GND (Yellow) U.S. – Output Terminal Europe HF Unit PCB3 Logic Circuit Board [WK3406] 1 2 3 4 5 6 7 8 CON1 (Front View) PCB4...
  • Page 48 S Model White Strap White Strap Black White White Line 1 Black MCB1 DOUT Black Line 2 P (TB3) Q (TB4) Single Pole R (TB2) C (TB5) Line 1 Line 2 S (TB1) N (TB6) Double Pole Green PCB1 [WK3310] Green +12VDC Supply (Brown) -12VDC Supply (Red)
  • Page 49 Black Black + Output Terminal Output Filter Network Black +12VDC Supply (Brown) -12VDC Supply (Red) 0 to -12VDC Current Output Detect (Orange) GND (Yellow) U.S. – Output Terminal 1 2 3 4 5 6 7 8 CON1 (Front View) Contactor Control 1 / GND (Brown) Contactor Control 2 / +24VDC (Red) Case Ground PCB3...

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