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Thermadyne THERMAL ARC 250 GTS CC/TIG Operating Manual

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A THERMADYNE
Company
®
INVERTER
ARC
WELDER
MODEL 250 GTS CC/TIG
• STICK
• TIG - HIGH FREQUENCY
- LIFT START
OPERATING MANUAL
September 1,1999
Manual No. 430429-462

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Summary of Contents for Thermadyne THERMAL ARC 250 GTS CC/TIG

  • Page 1 A THERMADYNE Company ® INVERTER WELDER MODEL 250 GTS CC/TIG • STICK • TIG - HIGH FREQUENCY - LIFT START OPERATING MANUAL September 1,1999 Manual No. 430429-462...

  • Page 3: 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 Avertissemen ..........7 1.05 Precautions De Securite Importantes ........8 1.06 Documents De Reference .............11 1.08 Statement of Warranty ............13 2.0 INTRODUCTION AND DESCRIPTION ......15 2.01 Description ................15 2.02 Functional Block Diagrams ..........16...
  • Page 5 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 Arc INC. assumes no liability for its use. Thermal Arc Models 200 GTS CC/TIG Welder Operating Manual Number 430429-462 Published by:...

  • Page 6: 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: 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.

  • Page 7: 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 1-937-440-0100 or your local distributor if you have any questions.
  • Page 8 IMPORTANT SAFETY PRECAUTIONS (CONTINUED) ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc welding 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 9 IMPORTANT SAFETY PRECAUTIONS (CONTINUED) NOISE Noise can cause permanent hearing loss. Plasma arc welding 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.

  • Page 10: 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 11: Note, Attention Et Avertissemen

    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 ute opération, procédure ou renseignement général sur lequel il iraporte d'insister davantage ou qui contribue à...

  • Page 12: 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 aut 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 13 PRECAUTIONS DE SECURITE IMPORTANTES CHOC ELECTRIQUE Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l'énergie electrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l'opérateur et les autres persormes sur le lieu de travail. •...
  • Page 14 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'rarc de plasma produit une lumière in&a-rouge et des rayons ultra-violets très forts. Ces rayons d'arc nuiront à...

  • Page 15: 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: 1. 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 16 PAGE LEFT INTENTIONALLY BLANK GENERAL MANUAL 430429-462...

  • Page 17: Statement Of Warranty

    1.08 STATEMENT OF WARRANTY LIMITED WARRANTY: Thermal Arc ® , Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of its authorized distributors hereafter “Thermal; Arc” 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 Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry...
  • Page 18 PAGE LEFT INTENTIONALLY BLANK MANUAL 430429-462...

  • Page 19: Introduction And Description

    2.0 INTRODUCTION AND DESCRIPTION 2.01 Description The Thermal Arc™ Model 250 GTS is 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 20: Functional Block Diagrams

    2.02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of 250 GTS power supply. Input Coupling Main Current IGBT Output Output Input Circuit Inverter Diodes Inductor Diode Coil Breaker Power Transformer Thermal (CT-1) Detector High Frequency Unit Thermal Drive Capacitor Voltage...

  • Page 21: 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. WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage.

  • Page 22: Electrical Input Connections

    2.4 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 23 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). Input Power Smart Link®- Each unit incorporates art INRUSH circuit and input voltage sensing circuit.

  • Page 24: Specifications

    2.05 Specifications Parameter/Model Model 250 GTS CC/TIG Rated Output @ 230 V @460V Amperes Volts Duty Cycle @ 230 V Input 20% at 250 A / 18 V 20% at 140 A / 25.6 V @ 460 V Input 15% at 250 A / 20 V 15% at 160 A / 26.4 V Range (Min.

  • Page 25: 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 26: Operator Controls

    3.0 OPERATOR CONTROLS 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. Pulse Frequency Control - The Pulse Frequency control provides a means of selecting the pulse frequency when the Pulse switch is in the H (HIGH)
  • Page 27 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 28: Gts - Setup For Operation

    3.02 GTS - Setup for Operation Shielded Metal Arc Welding (SMAW) WARNING Read and follow all safety precautions on pages 2-5 of this manual before proceeding with operation. 1. Install and connect unit according to the installation instructions in section 2.4, page 18, of this manual. 2.

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

    3.02 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 proceeding 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 remote device must be used for TIG operation. NOTES a. In LIFT TIC, mode, touch electrode to work and lift to start arc. 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

    3.02 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 proceeding with operation. 1. Install and connect unit according to the installation instructions in section 2.04, page 18, of this manual.

  • Page 32: Shutting Down

    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 Table 2. Fuse Size Selection Input Power/Input Voltage Fuse Size (Amperes) Single-Phase Model 250GTS 208-230 VAC 460 VAC 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 34 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 35: Basic Troubleshooting

    4.0 BASIC TROUBLESHOOTING General Troubleshooting and repairing this unit is a process which should be 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 training in power electronics measurement and troubleshooting techniques.
  • Page 36 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. Linefuse(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 37 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 38: Remote 8-Pin Connections

    4.03 REMOTE 8-Pin Connections The REMOTE 8-Pin receptacle 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 39: Jumper Setting For "Ok-To-Move

    4.04 JUMPER SETTING FOR "OK–TO–MOVE" Three jumpers plugs are on the front logic PC Board. Factory Shipped-All jumpers in position "A". This is for normal semi- automatic operation with a remote device, such as a foot control. The 8 pin remote operates as described in the operating manual.

  • Page 40: Appendix A - Accessories

    APPENDIX A - ACCESSORIES APPENDIX A MANUAL 430429-462 ACCESSORIES...

  • Page 41: Appendix B - Interconnection Diagrams

    APPENDIX B – INTERCONNECTION DIAGRAMS The following pages contain the interconnection diagrams for all 250 GTS models in current production, to aid in the identification of replacement parts.   MANUAL 430429-462 APPENDIX B INTERCONNECTION DIAGRAMS...
  • Page 42 250GTS Interconnection Diagram CN 101 CN 102 Black THY1 Black CN 201 CN 202 PCB5 THY Gate Circuit Board [WK4231] PCB6 IGBT Gate Circuit Board MCB1 [WK4232] Line1 ZNR1 Line2 (Green) Ground PCB1 Main 1 Circuit Board [WK4220] CN 123 CN 122 CN 121 E2 C1...
  • Page 43 Black Black +Output Terminal Green Black PCB7 Filter Circuit Board [WK4309] C.C. U.S. +12VDC Supply (Brown) -12VDC Supply (Red) +Output 0 to -12VDC Current Output Detect (Orange) Terminal GND (Yellow) Europe HF-UNIT PCB3 Log ic Circuit Board 1 2 3 4 5 6 7 8 [WK4213] CON1 (Front View)

  • Page 44: Appendix C - Parts List

    APPENDIX C – PARTS LIST Table 5. 250GTS Parts List DV. No. Description Type & Rating Code No. Order No. Coupling Coil F2A192100 F2A192100 10-6541 CON1 Receptacle 206433-1 8P 26301112900 10-6338 Current HC-TN200V4B15M 11251003000 10-5003 Transformer 200A 4V Diode DD55F-160 454030160 10-6542 Diode...

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