Thermal Arc 400 GTSW AC/DC Operating Manual
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Thermal Arc 400 GTSW AC/DC Operating Manual

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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

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Summary of Contents for Thermal Arc 400 GTSW AC/DC

  • Page 1 INVERTER WELDER MODEL 400 GTSW AC/DC CC/TIG • Stick • TIG - High Frequency - Lift Start Operating Manual Manual No. 0-2430 First Edition • September 1994...
  • Page 3 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Introduction Notes, Cautions, and Warnings ............i Important Safety Precautions ............ii Statement of Warranty ..............xiv General Information 1.1 Specifications ................1 1.2 Duty Cycle ..................2 Installation 2.1 Site Selection ................. 3 2.2 Transporting Methods ..............4 2.3 Weld Output Connections ............

  • Page 5: Notes, Cautions, And Warnings

    NOTES, CAUTIONS, AND WARNINGS Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are catego- rized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.

  • Page 6: Important Safety Precautions

    IMPORTANT SAFETY PRECAUTIONS Operation and maintenance of arc welding equipment involves potential hazards. Operators and all others in the operating area WARNING 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.
  • Page 7 IMPORTANT SAFETY PRECAUTIONS (continued) Metals coated with or containing materials that emit toxic fumes Gases and Fumes (continued) 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.
  • Page 8 IMPORTANT SAFETY PRECAUTIONS (continued) Arc Rays Make sure others in the operating area are protected from arc (continued) 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.
  • Page 9 IMPORTANT SAFETY PRECAUTIONS (continued) 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.
  • Page 10 IMPORTANT SAFETY PRECAUTIONS (continued) come electrically hot - a dangerous condition that may cause Electric Shock (continued) 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.
  • Page 11 IMPORTANT SAFETY PRECAUTIONS (continued) Before installating, inspecting, or servicing equipment, disconnect Electric Shock (continued) primary power and remove line fuses (or lock or red-tag switches) to prevent accidental electric shock. Disconnect all cables from welding power source and pull all 115V line-cord plugs.
  • Page 12 IMPORTANT SAFETY PRECAUTIONS (continued) Fire and Explosion A container with unknown contents should be cleaned (see (continued) preceding paragraph). Do not depend on smell or sight to determine if it is safe to weld or cut. Hollow castings or containers must be vented before welding or cutting to prevent explosion.
  • Page 13 IMPORTANT SAFETY PRECAUTIONS (continued) Flammable hair preparations should not be used by persons Fire and Explosion (continued) intending to weld or cut. Allow work and equipment to cool before handling. Noise NOISE can cause permanent hearing loss. Wear proper protective ear muffs or plugs. Make sure others in the operating area are protected from noise.
  • Page 14 IMPORTANT SAFETY PRECAUTIONS (continued) Locate or secure cylinders so they cannot be knocked over. High Pressure Gas Cylinders Keep cylinders clear of passageways and work areas where they (continued) may be struck. To transport cylinders with a crane, use a secure support such as a platform or cradle.
  • Page 15 IMPORTANT SAFETY PRECAUTIONS (continued) When assembling threaded connections, clean and smooth seats Proper Connections (continued) where necessary before tightening. If connection leaks, disas- semble, clean, and retighten using properly fitting wrench. Use a CGA adapter (available from supplier) between cylinder and regulator, if required.
  • Page 16 IMPORTANT SAFETY PRECAUTIONS (continued) Refer to the following standards or their latest revisions for more Publications information: 1. ANSI Standard Z49.1, SAFETY IN WELDING AND CUT- TING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 2.
  • Page 17 IMPORTANT SAFETY PRECAUTIONS (continued) 12. CSA Standard W117.2, CODE FOR SAFETY IN WELD- Publications (continued) ING 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 Associa- tion, 1900 Arch Street, Philadelphia, PA 19103 14.

  • Page 18: 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® Service Centers. No transportation costs of any kind will be paid under this warranty.

  • Page 19: Specifications

    1.1 SPECIFICATIONS Description The Thermal Arc™ 400 GTSW AC/DC is a three-phase or single- phase arc welding power source with Constant Current (CC) output characteristics. This unit has a built in TIG SLOPER and PULSER and is equipped with a gas control valve, lift arc starter, and high- frequency arc starter for use with Gas Tungsten Arc Welding (GTAW).

  • Page 20: Duty Cycle

    1.2 DUTY CYCLE The duty cycle of a welding power source is the percentage of a ten minute period that a welding power source can be operated at a given output without causing overheating and damaging of the unit. This unit is rated at 40 percent duty cycle when oper- ated at 400 amperes.

  • Page 21: Site Selection

    2.1 SITE SELECTION Select an installation site which provides the following: 1. Correct input power supply (see unit nameplate) 2. Shielding gas supply (if applicable) 3. Water supply (if applicable) 4. Adequate ventilation and fresh air supply 5. No flammables 6.

  • Page 22: Transporting Methods

    2.2 TRANSPORTING METHODS This unit is equipped with two eyelets 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 WARNING equipment damage.

  • Page 23: Weld Output Connections

    2.3 WELD OUTPUT CONNECTIONS To obtain full rated output from this unit, it is necessary to select, prepare, and install proper weld cables. Failure to comply in any of these areas may result in unsatisfactory welding performance. Weld Cable Selection Use the following guidelnes to select weld cables: 1.
  • Page 24 2.3 WELD OUTPUT CONNECTIONS (continued) Install the supplied male connectors onto proper cables as follows Connector Installation (refer to Figure 2-A below): 1. Obtain cable of desired length and proper size for installation (see Table A, page 5). 2. If the installation requires cable larger than 3/0 AWG, pre- pare one end of 3/0 AWG pigtail no longer than 2 ft (0.61 m) for connector installation.
  • Page 25 2.3 WELD OUTPUT CONNECTIONS (continued) A-00067 WORK ELECTRODE Figure 2-B Weld Output Connections - Lower Front Panel Refer to Figure 2-B and: Gas Tungsten Arc Welding a. Connect torch cable to the negative (-) weld output receptacle (DCEN) and (AC) as follows: align keyway, insert plug, and rotate plug clock- (Electrode Negative/ wise until it is securely seated in receptacle.

  • Page 26: Shielding Gas Connections

    2.4 SHIELDING GAS CONNECTIONS The gas valve (PROCESS SELECTOR switch in HF or LIFT TIG NOTE MODE) will not work unless the OUTPUT CONTACTOR switch is in the REMOTE position and a remote control device is con- nected to the REMOTE 14 receptacle. The gas input and gas output fittings have 5/8-18 right-hand threads.

  • Page 27: Remote 14 Connections

    2.5 REMOTE 14 CONNECTIONS The REMOTE 14 receptacle is used to connect any of the follow- REMOTE 14 ing equipment to the welding power source circuitry: • Remote Hand Pendant • Remote Foot Control • Remote Amperage Control • Wire Feeder (one which provides contactor control to welding power source).

  • Page 28: Electrical Input Connections

    2.6 ELECTRICAL INPUT CONNECTIONS ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE WARNING exists after removal of input power. • DO NOT TOUCH live electrical parts. • SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures, wait 60-80 seconds, and measure voltage on input capacitors before touching any parts.
  • Page 29 2.6 ELECTRICAL INPUT CONNECTIONS (continued) ELECTRIC SHOCK can kill. WARNING • Do not connect an input (white, red, or black) conductor to the ground terminal. • Do not connect the ground (green) conductor to an input line terminal. Refer to Figure 2-D (page 13) and: 1.
  • Page 30 2.6 ELECTRICAL INPUT CONNECTIONS (continued) Ground Conductor Ground Terminal METER WARNING AC POWER AMPERAGE/VOLTAGE LIFT PREVIEW START (PUSH) STICK START OUTPUT CONTACTOR OUTPUT SELECTOR REMOTE STICK AMPERAGE WAVE BALANCE NORMAL 5 DC Gouging 400 A REMOTE PANEL 10 AC CONTROL PENETRATION CLEANING 400GTSW...

  • Page 31: Operator Controls

    3.1 OPERATOR CONTROLS METER WARNING AC POWER AMPERAGE/VOLTAGE LIFT START PREVIEW (PUSH) STICK START OUTPUT CONTACTOR OUTPUT SELECTOR REMOTE STICK AMPERAGE WAVE BALANCE NORMAL 5 DC 400 A Gouging REMOTE PANEL 10 AC CONTROL PENETRATION CLEANING SLOPER PULSER HIGH 100AMPS UP SLOPE DOWN SLOPE % ON TIME...
  • Page 32 3.1 OPERATOR CONTROLS (continued) Placing the POWER switch (Circuit Breaker) located on the front AC POWER Indicator (1) panel in the ON position energizes the welding power source. The AC power lamp located on the front panel, comes on when the POWER switch is in the ON position, indicating that the unit is energized.
  • Page 33 3.1 OPERATOR CONTROLS (continued) Main Knob Arc Control 5-400A 19V 10V/100A Droop A-00328 100% 145A Arc Control Knob Main Knob = Arc Control Knob Figure 3-B Arc Control Characteristics The POSTFLOW TIME, PREFLOW TIME, and HOT START NOTE controls are located behind the hinged access door on the front panel.
  • Page 34 3.1 OPERATOR CONTROLS (continued) The HOT START control only works if the process selector switch HOT START is in the HF TIG position, the OUTPUT CONTACTOR switch is in Control(12) the REMOTE position and a remote control is connected to the REMOTE 14 receptacle.
  • Page 35 3.1 OPERATOR CONTROLS (continued) The unit will provide weld output for the Gas Tungsten Arc HF TIG Welding (GTAW) process. High frequency will be present from (GTAW With High the time the contactor is closed until a welding arc is established. Frequency Start) Once an arc is established, high frequency is no longer present.
  • Page 36 3.1 OPERATOR CONTROLS (continued) OUTPUT SELECT When the switch is in the AC mode, Alternating Current is SWITCH AC/DC(9) present at the output terminals. If DC mode is selected Direct Current is present at the output terminals. CLEANING When set to minimum, the AC wave form is made up largely of CONTROL(10) DCEN and offers only minimum cleaning of aluminum.

  • Page 37: Sloper And Pulser Controls

    3.2 SLOPER AND PULSER CONTROLS SLOPER and PULSER Controls Behind Front Panel Access Door SLOPER PULSER HIGH UP SLOPE DOWN SLOPE % ON TIME PULSE PER SECOND INITIAL AMPERAGE FINAL AMPERAGE BACKGROUND AMPERAGE PEAK AMPERAGE A-00329 Figure 3-D Sloper and Pulser Controls ON/OFF Placing the switch in the ON position energizes the sloper con- trols.
  • Page 38 3.2 SLOPER AND PULSER CONTROLS (continued) GAS TUNGSTEN 1. To start Slope sequence Close REMOTE switch. ARC WELDING WITH 2. In the HF mode, after Preflow time High Frequency is present SLOPE CONTROL at the torch. When the torch is positioned close to the work the welding current will transfer to the work and establish the arc to the initial current setting on the sloper.
  • Page 39 3.2 SLOPER AND PULSER CONTROLS (continued) The PEAK AMPERAGE control ADJUSTS THE PEAK AMPER- PEAK AMPERAGE CONTROL(10) AGE FOR PULSE TIG WELDING. If the welding power source is set at the 50% position, the PEAK AMPERAGE control will provide (from it’s minimum to maximum adjustment) amperage control of 50% of the welding power source output.

  • Page 40: Operating Precautions

    3.3 OPERATING PRECAUTIONS ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury; IMPROPER AIRFLOW AND EXPOSURE TO WARNING ENVIRONMENT can damage internal parts. • Do not touch live electrical parts. • Keep away from moving parts. • Keep all covers and panels in place while operating. Warranty is void if the welding power source is operated with any portion of the outer enclosure removed.

  • Page 41: Sequence Of Operation

    3.4 SEQUENCE OF OPERATION Read and follow all safety precautions on page 22 and at the front WARNING of this manual before proceeding with operation. 1. Install and connect unit according to section 2. GAS TUNGSTEN ARC WELDING (GTAW) 2. Select and obtain proper tungsten electrode (see table 3-B). 3.
  • Page 42 3.4 SEQUENCE OF OPERATION (continued) Read and follow all safety precautions on page 22 and at the WARNING front of this manual before proceeding with operation. Gas Tungsten Arc Select proper tungsten electrode. Welding - Pulsed Arc Prepare tungsten electrode and insert into torch. (GTAW-P) Wear dry, insulating gloves and clothing.
  • Page 43 3.4 SEQUENCE OF OPERATION (continued) Read and follow all safety precautions on page 22 and at the front WARNING of this manual before proceeding with operation. Install and connect unit PROPERLY. Shielded Metal Arc Wear dry insulating gloves and clothing. Welding (SMAW) Connect work clamp to clean, bare metal at workpiece.

  • Page 44: Electrode Preparation

    3.5 ELECTRODE PREPARATION Arc Wanders Stable Arc Flat End Electrode Ground to (Diameter determines Electrode a Point Amperage Capacity) Ground Straight A-00235 A-00236 Ground Radial Figure 3-E Figure 3-F Ideal Electrtode Preparation Incorrect Electrtode Preparation 1-1/2 Times 2 to 2-1/2 Times 2 to 2-1/2 Times Electrode Diameter Electrode Diameter...

  • Page 45: Electrode Selection

    3.6 ELECTRODE SELECTION ELECTRODE DIAMETER AMPERAGE RANGE PURE TUNGSTEN DC-ARGON ELECTRODE DC-ARGON ELECTRODE (GREEN BAND) NEGATIVE/STRAIGHT POLARITY POSITIVE/STRAIGHT POLARITY .010 in (0.25 mm) 1-15 .020 in (0.51 mm) 5-20 .040 in (1.02 mm) 15-80 1/16 in (1.59 mm) 70-150 10-20 3/32 in (2.38 mm) 125-225 15-30...
  • Page 46 NOTES OPERATION...

  • Page 47: General Maintenance

    4.1 GENERAL MAINTENANCE The only routine maintenance required for the Inverter Arc Routine Maintenance Welder thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. To clean the unit, first make sure that the power is disconnected. Blow out any accumulated dirt and dust with compressed air.

  • Page 48: Troubleshooting Guide

    4.2 TROUBLESHOOTING GUIDE Troubleshooting and repairing the this unit is a process which General should be undertaken only by those familiar with high voltage high power electronic equipment. There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you WARNING have had training in power electronics measurement and trouble- shooting techniques.
  • Page 49 4.2 TROUBLESHOOTING GUIDE (continued) How to use Guide The following information is a guide to help the Customer/ Operator determine the most likely causes for various symptoms. This guide is set up in the following manner: A. Symptom (Bold Type) Any Special Instructions (Text Type) 1.
  • Page 50 4.2 TROUBLESHOOTING GUIDE (continued) 2. Incorrect welding cable size a. Use proper size and type of cable (see Table 2-A, page 5) 3. Improper input connections a. Refer to Section 2.6 4. Electrode condition a. Replace electrode 5. Remote amperage control (when applicable) a.
  • Page 51 4.2 TROUBLESHOOTING GUIDE (continued) 3. Insufficient postflow time. a. Increase postflow time. 4. Loose gas fittings on regulator or gas line. This will draw air into the weld zone. a. Check and tighten all gas fittings. 5. Water in torch. a.
  • Page 52 4.3 REPACEMENT PARTS CATALOG NO. DESCRIPTION 230/460 380/415 460/575 10-2236 PL1, PL2 Pilot Lamp 10-2274 F1 Fuse 5A 600V 10-2206 F2, F3 Fuse 2A, 250V 10-2196 S1, S2, S3 Switch 1P3T 10-2124 VR1 10K Pot 10-2618 VR2 10K Pot 10-2135 CON1 14-Pin Receptacle 10-2133 CON2 17-Pin Receptacle...

This manual is also suitable for:

400 gtsw cc/tig

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