Thermal Arc 400GTS CC/TIG Operating Manual
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Thermal Arc 400GTS CC/TIG Operating Manual

Thermal Arc 400GTS CC/TIG Operating Manual

Inverter arc welder
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TM
R
INVERTER
ARC
WELDER
MODEL 400GTS CC/TIG
• STICK
• TIG - HIGH FREQUENCY
- LIFT START
OPERATING MANUAL
July 1, 1997
Manual No. 0-2512

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Summary of Contents for Thermal Arc 400GTS CC/TIG

  • Page 1 INVERTER WELDER MODEL 400GTS CC/TIG • STICK • TIG - HIGH FREQUENCY - LIFT START OPERATING MANUAL July 1, 1997 Manual No. 0-2512...

  • 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 While the information contained in this Operating Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. Thermal Arc Models 400GTS CC/TIG Welder Operating Manual Number 0-2512 Published by: Thermal Dynamics Corporation Industrial Park No. 2...

  • 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

    1.07 DECLARATION OF CONFORMITY Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 West Lebanon, New Hampshire 03784 The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EU, as recently changed in Directive 93/63/EU) and to the National legislation for the enforcement of this Directive.

  • Page 15: Statement Of Warranty

    Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized ® ® Thermal Arc repair facility within thirty (30) days of the repair. Authorized Thermal Arc repair facilities are authorized distributors and authorized Thermal Arc ®...
  • Page 16 MANUAL 0-2512...

  • Page 17: Introduction And Description

    2.0 INTRODUCTION AND DESCRIPTION 2.01 Description ™ The Thermal Arc Model 400GTS are single or three-phase DC arc welding power sources with Constant Current (CC) output characteristics. They are available with an optional digital AMPERAGE/VOLTAGE panel meter (standard in European models).

  • Page 18: Functional Block Diagram

    2.02 Functional Block Diagram Figure 2 illustrates the functional block diagram of the 400GTS power supplies. Input Main Current Coupling Input Output Inrush Current IGBT Inverter Output Capacitor Circuit Diode Suppresor Module Transformers Diodes Power Breaker Transformer Coil (CT-1) Thermal Sensor Control Transformer...

  • Page 19: Transporting Methods

    2.03 Transporting Methods These units are equipped with a handle 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 20 • To operate single-phase, do not connect the RED input conductor. • Do not connect an input (WHITE, BLACK or RED) conductor to the ground terminal. • Do not connect the ground (GREEN) conductor to an input line terminal. Refer to Figure 3 and: Connect end of ground (GREEN) conductor to a suitable ground.
  • Page 21 Each unit incorporates an INRUSH circuit and input voltage sensing circuit. Input Power When the MAIN CIRCUIT BREAKER is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).

  • Page 22: Specifications

    2.05 Specifications Parameter 400GTS Rated Output Amperes Volts Duty Cycle Output Range (Min. - Max.) TIG/STICK Amperes 5-400 Volts 10-32 Open Circuit Voltage Maximum OCV 64 V Input Data Dimensions/Weight Width 8.3 in (210 mm) Height 16.9 in (430 mm) Length 16.5 in (420 mm) Weight...

  • 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 Front and Rear operator controls Amperage Control - The Amperage Control selects Process Selector Switch - The Process Selector the desired amperage within the entire range of the Switch allows the operator to select the STICK welding power source.
  • Page 25 Primary Power Switch - Placing the Primary Power Switch (circuit breaker) located on the rear panel to the ON position energizes the welding power source. Voltage Selector - Manual slide switch selects the proper input voltage range. If this slide switch is not set to the position that matches the input voltage from the electrical source the Smart Logic will inhibit welding power source turn on and the warning indicator will be illuminated.

  • Page 26: Setup For Operation

    3.02 Setup for Operation Arc Control The ARC CONTROL provides a variable selection of short circuit amperage to suit individual welding situations when operating in the STICK welding (SMAW) mode. Main Knob Arc Control 5 - 400A 19V 10V/100A Droop 100% 145A Arc Control Knob...

  • Page 27: Shielded Metal Arc Welding (Smaw)

    3.02 Setup for Operation Shielded Metal Arc Welding (SMAW) Read and follow all safety precautions on pages 2-5 of this manual before WARNING preceding with operation. Install and connect unit according to the installation instructions in section 2.04, page 17, of this manual. Wear dry insulating gloves and clothing.

  • Page 28: Gas Tungsten Arc Welding (Gtaw) High Frequency/Lift Start

    3.02 Setup for Operation Gas Tungsten Arc Welding (GTAW) High Frequency/Lift Start Read and follow all safety precautions on pages 2-5 of this manual before WARNING preceding with operation. Install and connect unit according to the installation instructions in section 2.04, page 17, of this manual. Select proper tungsten electrode (refer to Electrode Selection Table 2, page 30).
  • Page 29 Tungsten Arc Welding (GTAW) process. High frequency will be HF START present from the time the contactor is closed until a welding arc is (GTAW with High established. Once an arc is established, high frequency is no longer Frequency Start) present.

  • Page 30: Gas Tungsten Arc Welding-Pulsed (Gtaw-P) -Sloped (Gtaw-S) -Tig Spot

    3.02 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 preceding with operation. Install and connect unit according to the installation instructions in section 2.04, page 17, of this manual.
  • Page 31 C. SPOT TIG welding 1. Set 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 32 3.02 Setup for Operation Table 2. Electrode Selection Table Electrode/Diameter Amperage Range DC-Argon Electrode DC-Argon Electrode Negative/Straight Polarity Positive/Reverse Polarity Pure Tungsten (Green Band) 0.010 in. (0.25mm) 1-15 — 0.020 in. (0.51mm) 5-20 — 0.040 in. (1.02mm) 15-80 — 1/16 in. (1.59mm) 70-150 10-20 3/32 in.

  • Page 33: 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 34 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 Requirements, page 17, for proper input connections.
  • Page 35 D. Wandering Arc, Poor Control of Arc Direction 1. Wrong size tungsten electrode, typically larger than recommended a. Use proper size electrode for amperage selected (see Table 2, page 30). 2. Improperly prepared tungsten electrode a. Prepare tungsten properly. 3. Gas flow rate too high a.
  • Page 36 NOTE Verify that for single-phase operation, the RED input line is not connected. 4. Open conductor in input power line a. Check continuity and replace if necessary. H. Red WARNING Indicator ON; No Weld Output 1. Thermal sensor TH1 open (thermal shutdown) a.

  • Page 37: 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 38: Appendix A - Accesories

    APPENDIX A – ACCESORIES APPENDIX A MANUAL 0-2512 ACCESSORIES...
  • Page 39 MANUAL 0-2512 APPENDIX A ACCESSORIES...
  • Page 40 MANUAL 0-2512...

  • Page 41: Appendix B - Interconnection Diagrams

    APPENDIX B – INTERCONNECTION DIAGRAMS The following pages contain the interconnection diagrams for all 400GTS in current production, to aid in the identification of replacement parts. MANUAL 0-2512 APPENDIX B INTERCONNECTION DIAGRAMS...
  • Page 42 400GTS 230/460V Interconnection Diagram PCB4 PCB5 C21E1 C21E1 IGBT IGBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Black Line 1 White Orange Line 3 White Line 2 – (Bus Bar) Ground PCB1-2 CN20 CN20 Line 3 (Black) Line 2 (White) Line 1 (Red)
  • Page 43 Output Filter Network – (Blue) (Gray) HF Unit 1 2 3 4 5 6 7 8 CON1 (Front View) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor Gate Drive Pre-charge Control PCB Common - 0V Undervoltage Overvoltage Reset Signal +12VDC PCB Common - 0V Input Voltage Detect...
  • Page 44 400GTS 380V Interconnection Diagram PCB4 PCB5 C21E1 C21E1 IGBT IGBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) Ground Line 3 (Black) Line 2 (White) Line 1 (Red) (Red)
  • Page 45 Output Filter Network – (Blue) (Gray) HF Unit 1 2 3 4 5 6 7 8 CON1 (Front View) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor Gate Drive Pre-charge Control PCB Common - 0V Undervoltage Overvoltage Reset Signal +12VDC PCB Common - 0V Input Voltage Detect...
  • Page 46 400GTS 460/575V Interconnection Diagram PCB4 PCB5 C21E1 C21E1 IGBT IGBT C2E1 C2E1 Inverter Inverter (Q1) (Q2) PCB2 PCB3 Input Diode Black Bridge (D1) Line 1 Black White Orange Line 3 White Line 2 – (Bus Bar) Ground Line 3 (Black) Line 2 (White) Line 1 (Red) (Red)
  • Page 47 Output Filter Network – (Blue) (Gray) HF Unit 1 2 3 4 5 6 7 8 CON1 (Front View) Tripping Relay Control Input Changeover Switch Input Changeover Switch Thyristor Gate Drive Pre-charge Control PCB Common - 0V Undervoltage Overvoltage Reset Signal +12VDC PCB Common - 0V Input Voltage Detect...

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