Thermal Arc PS-3000 Instruction Manual
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Thermal Arc PS-3000 Instruction Manual

Thermal Arc PS-3000 Instruction Manual

Plasma arc welder
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INVERTER
ARC
WELDER
MODEL PS-3000
• Plasma Arc Welding
Instruction Manual
Manual No. 0-2337
October 23, 1998

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Summary of Contents for Thermal Arc PS-3000

  • Page 1 INVERTER WELDER MODEL PS-3000 • Plasma Arc Welding Instruction Manual Manual No. 0-2337 October 23, 1998...
  • Page 3 Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the WARNING equipment. While the information contained in this manual represents our best judgement, Thermal Arc Corporation assumes no liability WARNING for its use. Thermal Arc ®...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..........................i Notes, Cautions and Warnings ................. i Important Safety Precautions ...................i Publications ......................ii Note, Attention et Avertissement ................iii Precautions De Securite Importantes ..............iii Documents De Reference ..................v Declaration of Conformity ..................vi Statement of Warranty ...................

  • Page 5: Introduction

    • The kinds of fumes and gases from the plasma arc INTRODUCTION depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any met- Notes, Cautions and Warnings als which may contain one or more of the follow- ing: Throughout this manual, notes, cautions, and warnings...

  • Page 6: Publications

    • Protect others in the work area from the arc rays. Use protective booths, screens or shields. FIRE AND EXPLOSION • Use the shade of lens as recommended in Publica- tions, item 4. Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

  • Page 7: Note, Attention Et Avertissement

    12. CSA Standard W117.2, CODE FOR SAFETY IN Precautions De Securite Importantes WELDING AND CUTTING, obtainable from the Ca- nadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W AVERTISSEMENT 13. NWSA booklet, WELDING SAFETY BIBLIOGRA- PHY obtainable from the National Welding Supply L’OPÉRATION ET LA MAINTENANCE DU Association, 1900 Arch Street, Philadelphia, PA 19103 MATÉRIEL DE SOUDAGE À...
  • Page 8 • Utilisez un équipement spécial tel que des tables de • Prévoyez une veille d’incendie lors de tout travail coupe à débit d’eau ou à courant descendant pour dans une zone présentant des dangers d’incendie. capter la fumée et les gaz. •...

  • Page 9: Documents De Reference

    • Pour des renseignements sur la manière de tester le 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- bruit, consultez l’article 1, page v. TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA Documents De Reference 02269 10.

  • Page 10: Declaration Of Conformity

    Declaration of Conformity Manufacturer: Thermal Arc, Inc. Address: 2200 Corporate Drive Troy, Ohio 45373-1085 The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc- tive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National leg- islation for the enforcement of this Directive.

  • Page 11: Statement Of Warranty

    Purchaser. Notwithstanding the forego- ing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.
  • Page 12 INTRODUCTION viii...

  • Page 13: Section 1: General Information

    SECTION 1: GENERAL INFORMATION 1.1 Specifications Description The Model PS-3000 is a three-phase or single-phase (if derated) DC arc welding power source with constant current output characteristics. This unit is designed for use with the Plasma Arc Welding (PAW) process. A digital meter displaying amperes and voltage is standard.

  • Page 14: Duty Cycle

    1.2 Duty Cycle The duty cycle of a welding power source is defined as the percentage of a ten minute period that the unit can be operated at a given output without causing overheating and/or damage to the unit. This unit is rated at 60 percent duty cycle when oper- ated at 300 amperes from three-phase input power, or when operated at 210 amperes from single-phase input power.

  • Page 15: Section 2: Installation

    SECTION 2: INSTALLATION 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.

  • Page 16: Transporting Methods

    2.2 Transporting Methods This unit is equipped with two handles 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 17: Weld Ooutput Connections

    2.3 Weld Ooutput 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 guidelines to select weld cables: 1.
  • Page 18 2.3 Weld Output Connections (continued) To install the supplied male connectors onto proper cables, refer Connector Installation to Figure 2-A below and: 1. Obtain cable of desired length and proper size for installation (refer to 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 19 2.3 Weld Oouput Connections (continued) Positive Negative Figure 2-B Weld Output Connections - Lower Front Panel Plasma Arc Refer to Figure 2-B and: Welding (PAW) a. Connect torch cable connector to NEGATIVE (-) weld output Electrode Negative/ receptacle as follows: align keyway, insert plug, and rotate Straight Polarity plug clockwise until it is securely seated in receptacle.

  • Page 20: Remote 14 Connections

    2.4 Remote 14 Connections Figure 2-C 14-Pin Socket Receptacle with Socket Locations (Lower Front Panel) The REMOTE 14 receptacle on the lower front panel can connect the following equipment to the welding power source circuitry: • Remote Contactor Control • Remote Amperage Control To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
  • Page 21 2.4 Remote 14 Connections (continued) Socket A Remote contactor control when contact closure is provided between Sockets A and B (24 VAC available) Socket B Remote contactor control when contact closure is provided between Sockets A and B (24 VAC available) Socket C Amperage remote control (MAXIMUM) input command signal;...

  • Page 22: Electrical Input Connections

    2.5 Electrical Input Connections ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is WARNING present 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 according to instruc- tion manual before touching any parts.
  • Page 23 2.5 Electrical Input Connections (continued) WARNING ELECTRIC SHOCK can kill. Electrical Input • Do not connect an input (white, red, or black) conductor to the Connections ground terminal. • Do not connect the ground (green) conductor to an input line terminal.
  • Page 24 2.5 Electrical Input Connections (continued) Ground Conductor Ground Terminal METER AMPERAGE/VOLTAGE WARNING WARNING AC POWER AC POWER PREVIEW (PUSH) REMOTE PANEL AMPERAGE AMPERAGE Line Disconnect Switch Line Fuse Welding Power Supply Primary Power Cable Figure 2-D Electrical Input Connections and Components Voltage Selection The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate.

  • Page 25: Section 3: Operation

    SECTION 3: OPERATION 3.1 Operator Controls 1, 2 METER AMPERAGE/VOLTAGE WARNING AC POWER PREVIEW (PUSH) REMOTE PANEL AMPERAGE AMPERAGE 1. AC POWER Indicator Front Panel 2. WARNING Indicator Operating Controls 3. AMPERAGE Control 4. AMPERAGE Switch 5. Digital AMPERAGE/VOLTAGE Meter 6.
  • Page 26 3.1 Operator Controls (continued) Primary Power Switch PRIMARY POWER Figure 3-B Rear Panel Controls OPERATION Manual 0-2337...
  • Page 27 3.1 Operator Controls (continued) Place the PRIMARY POWER switch (circuit breaker) on the rear PRIMARY POWER panel in ON position to energize the welding power source. The Switch and AC POWER Indicator green AC POWER indicator on the front panel comes on when the AC POWER switch is in ON position, indicating that the unit is energized.
  • Page 28 3.1 Operator Controls (continued) This switch determines whether the amperage is adjusted by the AMPERAGE Switch front panel amperage control or by a remote control device. If remote amperage control function is not desired, place this switch in PANEL position. If remote amperage control is desired, place the AMPERAGE switch in REMOTE 14 position.
  • Page 29 3.1 Operator Controls (continued) The AMPERAGE/VOLTAGE meter displays either an amperage Digital AMPERAGE/ VOLTAGE Meter, or voltage value. The selected (PREVIEW) amperage value is METER Switch, displayed when welding is not taking place. Refer to Table 3-A and PREVIEW below for the values displayed for each meter switch setting and parameters selected.

  • Page 30: Operating Precautions

    3.2 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 NOTE any portion of the outer enclosure removed.

  • Page 31: Troubleshooting

    3.3 Troubleshooting TROUBLE POSSIBLE CAUSE REMEDY 1. Line disconnect switch in 1. Place line disconnect A. No weld output; unit the OFF position switch in ON position completely inoperative 2. Line fuse(s) open 2. Check and replace line fuse(s) 3. Improper electrical input 3.
  • Page 32 OPERATION Manual 0-2337...

  • Page 33: Section 4: Parts List

    The parts list provides a list of all replaceable components. B. Returns If a Thermal Arc® product must be returned for service, contact your Thermal Arc® distributor. Materials returned to Thermal Arc® without proper authorization will not be accepted. 4.02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly, as listed in the de- scription column of the Parts List.

  • Page 34: Parts List

    4.03 Parts List Catalog # Description 230/460 380/415 460/575 9-6136 Base Assembly 10-2120 C4 & C5 400v 1800uf 10-2121 C4 & C5 300v 1200uf 10-2119 C6 - C9 350v 20uf 10-2215 C10 & C13 1200v .0068uf 10-2216 C10 & C13 1200v .0047uf 10-2217 C14 &...
  • Page 35 Catalog # Description 230/460 380/415 460/575 10-2145 PCB10 Printed Circuit Board 10-2165 PCB10 Printed Circuit Board 10-2236 PL1, PL2 Pilot Lamp 9-6138 Pot Support Bracket 10-2113 Q1 & Q2 IGBT 10-2114 Q1 & Q2 IGBT 10-2207 R1 30w 200 ohms 10-2208 R1 30w 400 ohms 10-2209...
  • Page 36 SYSTEM SCHEMATIC, 230/460V UNITS Art # A-04053...
  • Page 37 PS-3000 POWER SUPPLY 230 / 460V SYSTEM DIAGRAM Art # A-04053...
  • Page 38 SYSTEM SCHEMATIC, 380/415V UNITS Art # A-04054...
  • Page 39 PS-3000 POWER SUPPLY 380/415V SYSTEM DIAGRAM Art # A-04054...
  • Page 40 SYSTEM SCHEMATIC, 460/575V UNITS Art # A-04055...
  • Page 41 PS-3000 POWER SUPPLY 460/575V SYSTEM DIAGRAM Art # A-04055...

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