Thermal Arc 260S CC STICK Operating Instructions Manual
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Thermal Arc 260S CC STICK Operating Instructions Manual

Thermal Arc 260S CC STICK Operating Instructions Manual

Inverter arc welder
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A THERMADYNE
Company
®
INVERTER
ARC
WELDER
MODEL 260S CC
• STICK
OPERATING MANUAL
September 1,1999
Manual No. 430429-447

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Summary of Contents for Thermal Arc 260S CC STICK

  • Page 1 A THERMADYNE Company ® INVERTER WELDER MODEL 260S CC • STICK OPERATING MANUAL September 1,1999 Manual No. 430429-447...

  • 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 1.07 Declaration of Conformity ...........12 1.08 Statement of Warranty ............13 2.0 INTRODUCTION AND DESCRIPTION ......15 2.01 Description ................15...
  • Page 5 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 260S CC Welder Operating Manual Number 430429-447...

  • 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 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) PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and bum your skin if you are not properly protected •...

  • 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 oute opération, procédure ou renseignement général sur lequel il importe 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 ampies 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: Declaration Of Conformity

    Thermal Arc INC 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.

  • Page 17: 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 18 MANUAL 430429-447...

  • Page 19: Introduction And Description

    2.0 INTRODUCTION AND DESCRIPTION 2.01 Description The Thermal Arc™ Model 260S is a single or three-phase DC arc welding power sources with Constant Current (CC) output characteristics. The 260S unit is designed for use with Shielded Metal Arc Welding (SMAW).

  • Page 20: Functional Block Diagrams

    2.02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of the 260S power supply. Input Main Current Current Input Inrush Current Inrush Current IGBT Inverter Output Output Circuit Capacitor Diode Suppressor Suppressor Module Transformers Diodes Breaker Power Transformer Transformer (CT-2) (CT-1)

  • Page 21: 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 22 • To operate signal-phase, do not connect the RED input conductor. • Do not connect an input (WHITE or BLACK) conductor to the ground terminal. • Do not connect the ground (GREEN) conductor to an input line terminal. Refer to figure 3 and: 1.
  • Page 23 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. 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 24: Specifications

    2.05 Specifications 260S Models Parameter Rated Output 40% duty cycle Three-phase Amperes Volts Single-phase Amperes Volts 60% duty cycle Three-phase Amperes Volts Single-phase Amperes Volts Output Range (Min.- MAX.) STICK Amperes 5-260 Volts 10-30 Open Circuit Voltage 230 V/460 V 64 V Dimensions/Weight Width...

  • 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 3.01 260S Front & Rear Panels 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 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 tum on and the warning indicator will be...

  • Page 28: Setup For Operation

    3.02 Setup for Operation Arc Control The ARC CONTROL provides a suitable short circuit amperage to suit individual welding situations when operating in the STICK welding (SMAW) mode. The Arc Control current is set to 45 Amperes (30%) in factory. If you want to change Arc Control current, it will be necessary to change dip switch [9] (DSW1) on the front panel PC Board (PCB7 [WK-4224 ] ).

  • Page 29: Shielded Metal Arc Welding (Smaw)

    3.02 Setup for Operation Shielded Metal Arc Welding (SMAW) WARNING Read and follow all safety precautions on pages 2-5 of this manual before preceding with operation. 1. Install and connect unit according to the installation instructions in section 2.04, page 17, of this manual. 2.
  • Page 30 3.02 Setup for Operation Table 2. 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...

  • Page 31: 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 32 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 33 E. Red WARNING Indicator-ON; No Weld Output 1. Input voltage fluctuation causing protection circuits to activate a. Monitor input power for spikes and high voltage condition. Most power utilities will monitor and verify line voltage. 2. Thermal sensor TH1 open (thermal shutdown) a.
  • Page 34 MANUAL 430429-447...

  • Page 35: Appendix A - Interconnection Diagrams

    APPENDIX A – INTERCONNECTION DIAGRAMS The following pages contain the interconnection diagrams for all 260S, models in current production, to aid in the identification of replacement parts. MANUAL 430429-447 APPENDIX A INTERCONNECTION DIAGRAMS...
  • Page 36 260S - 230/460V Interconnection Diagram C21E1 C21E1 PCB4 PCB5 IG BT C2E1 C2E1 IGBT Inverter Inverter (Q1) (Q2) E1 G2 G1 E1 G2 PCB3 PCB2 Input Diode Black Bridge (D1) TI 1 MCB1 Black Line1 White White Orange Line2 Line3 (Bus Bar) Ground TB1 TB2...
  • Page 37 TO 1 Output Filter Network TO 2 FAN1 1 2 3 1 2 3 4 CN10 (Brown) (Red) (Orange) (Yellow) (Yellow) (Pink) (White) (Black) DSW1 DSW1 CN 22 1 2 3 4 1 2 3 4 +5V DC (Brown) Warning Signal (Red) AC Power Signal (Orange) +5V DC (Yellow) Amperage Control Signal (Blue)
  • Page 38 260S - 380/415V Interconnection Diagram C21E1 C21E1 PCB5 PCB4 C2E1 IG BT IG BT C2E1 Inverter Inverter (Q2) (Q1) E1 G2 G1 E1 G2 PCB2 PCB3 Input Diode Black Bridge (D1) MCB1 Black White Line1 White Orange Line2 Line3 (Bus Bar) Ground TB1 TB2 Line 3 (Black)
  • Page 39 TO 1 Output Filter Network TO 2 FAN1 1 2 3 4 1 2 3 CN10 (Brown) (Red) (Orange) (Yellow) (Yellow) (Pink) DSW1 DSW1 CN 22 1 2 3 4 1 2 3 4 +5V DC (Brown) Warning Signal (Red) AC Power Signal (Orange) +5V DC (Yellow) Amperage Control Signal (Blue)
  • Page 40 260S - 460/575V Interconnection Diagram C21E1 C21E1 PCB4 PCB5 C2E1 IGBT C2E1 IG BT Inverter Inverter (Q2) (Q1) E1 G2 G1 E1 G2 PCB2 PCB3 Input Diode Black Bridge (D1) MCB1 Black White Line1 White Orange Line2 Line3 (Bus Bar) Ground TB1 TB2 Line 3 (Black)
  • Page 41 Output Filter Network FAN1 1 2 3 4 1 2 3 CN10 (Brown) (Red) (Orange) (Yellow) (Yellow) (Pink) DSW1 DSW1 CN 22 1 2 3 1 2 3 +5V DC (Brown) Warning Signal (Red) AC Power Signal (Orange) +5V DC (Yellow) Amperage Control Signal (Blue) PCB Common 0V (Purple) ARC Control Signal (Gray)

  • Page 42: Appendix B - Parts List

    APPENDIX B – PARTS LIST Table 3. 260S - 230/460V Parts List DV. No. Description Type & Rating Code No. Order No. Capacitor ECQE12104MZ 42422137100 10-2270 DC1250V 0.1µF C2,3 Capacitor ECW-H10H103JR 42421138400 10-5014 C6,7 Capacitor ECKATS103MF 10000F 42442007100 10-2219 Capacitor ECW-H10H683JR 42421138500 10-5013...

  • Page 43: Parts List

    APPENDIX B – PARTS LIST Table 4. 260S – 380/415V Parts List No. DV. No. Description Type & Rating Code No. Order No. Capacitor ECQE12104MZ 42422137100 10-2270 DC1250V 0.1µF C2,3 Capacitor ECW-H10H103JR 42421138400 10-5014 C6,7 Capacitor ECKATS103MF 42442007100 10-2219 10000PF Capacitor ECW-H10H683JR 42421138500...
  • Page 44 APPENDIX B – PARTS LIST Table 5. 260S – 460/575V Parts List DV. No. Description Type & Rating Code No. Order No. Capacitor ECQE12104MZ 42422137100 10-2270 DC1250V 0.1µF C2,3 Capacitor ECW-H10H103JR 42421138400 10-5014 C6,7 Capacitor ECKATS103MF 42442007100 10-2219 10000PF Capacitor ECW-H10H683JR 42421138500 10-5013...

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