Thermal Arc 260S CC STICK Operating Instructions Manual Download Page 1

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A THERMADYNE

Company

INVERTER

ARC

WELDER

MODEL 260S CC

• STICK

OPERATING MANUAL

September 1,1999

Manual No. 430429-447

Summary of Contents for 260S CC STICK

Page 1: ...A THERMADYNE Company INVERTER ARC WELDER MODEL 260S CC STICK OPERATING MANUAL September 1 1999 Manual No 430429 447 ...

Page 2: ......

Page 3: ... Warranty 13 2 0 INTRODUCTION AND DESCRIPTION 15 2 01 Description 15 2 02 Functional Block Diagrams 16 2 03 Transporting Methods 17 2 04 Electrical Input Connections 17 2 05 Specifications 20 2 06 Duty Cycle 21 3 0 OPERATOR CONTROLS 22 3 01 260S Front Rear Pan 22 3 02 Setup for Operation 24 Arc Control 24 Shielded Metal Arc Welding SMAW 25 4 0 BASIC TROUBLESHOOTING 27 4 01 Common Welding Operation...

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Page 5: ...Operating Manual Number 430429 447 Published by Thermal Arc INC Corporation TROY OHIO 45373 1085 USA 937 440 0100 Copyright 1999 by Thermal Arc INC All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omis...

Page 6: ...hese 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 WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area ...

Page 7: ...ich may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information regarding the kind and mount of fumes and gases that may be dangerous to your health For...

Page 8: ...no combustible or flammable material in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles Provide a fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwa...

Page 9: ... protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use pr...

Page 10: ...ciety 550 N W LeJeune Rd Miami FL 33126 8 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 9 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 10 NFPA Standard 5lB CUTTING AND WELDING PROCESSES...

Page 11: ...opération procédure ou renseignement général sur lequel il importe d insister davantage ou qui contribue à l efficacité de fonctionnement du système ATTENTION Toute procédure pouvant résulter l endommagement du matériel en cas de non respect de la procédure en question AVERTISSEMENT Toute procédure pouvant provoquer des blessures de l opérateur ou des autres personnes se trouvant dans la zone de t...

Page 12: ...a dépendent du genre de métaI utillsé des revêtements se trouvant sur le métal et des différents procédés Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium Lisez toujours les fiches de donn es sur la sécurité d...

Page 13: ...el de consignes INCENDIE ET EXPLOSION Les incendies et les explosions peuvent résulter des scories chaudes des étincelles ou de l arc de plasma Le procédé à l arc de plasma prodult du métal des étincelles des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l explosion de fumées inflammables Soyez certain qu aucune matière combustible ou inflammable ne se trouve sur le ...

Page 14: ...n en bon état Remplacez toute lentille sale ou comportant fissure ou rognure Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en foumissant des cablnes ou des écrans de protection Respectez le teint de lentille recommandé dans le manuel de consignes BRUIT Le bruit peut provoquer une perte permanente de l ouYe Les procédés de soudage à l arc de plasma peuv...

Page 15: ...e la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Assoclahon Améncaine pour la Protechon contre les Incendms NFPA LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROCÉDIÉS ASSOCIÉS disponible auprès de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr...

Page 16: ...factured to a number of standards and technical requirements among them are CSA Canadian Standards Association standard C22 2 number 60 M1990 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment March 1995 IEC 974 1 BS 638 PT10 EM 60 974 1 applicable to welding equipm...

Page 17: ...strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS The limited warranty period...

Page 18: ...14 MANUAL 430429 447 ...

Page 19: ... designed for use with Shielded Metal Arc Welding SMAW Figure 1 260S model Volt Ampere curve NOTE Volt Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source Curves of other settings will fall between the curves shown The ARC CONTROL is set 30 45A in factory But Output Current is less than 270 amperes Output Current Limit VOLTS AMPS Arc Characteristics ...

Page 20: ... IGBT Inverter Module Thermal Sensor Output Transformers Output Diodes Transformer CT 1 Current Control Transformer c Config Primary Current Sensor Thermal Sensor Circuit Drive Circuit Voltage Sensor Output Inductor DC power Supply for Control Circuit To each control circuit 12VDC 20VDC 24VDC 5VDC Trouble Sensing Circuit Sequence Control Arc control current Adjustment DIP switch Current Adjustment...

Page 21: ... 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 Electrical Input Operate the welding power source from a single phase 50 60 Hz AC Requirements power supply The input voltage must match one of the electrical i...

Page 22: ...thod that complies with all applicable electrical codes 2 Connect ends of line 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch 3 Use Table 1 below as a guide to select line fuses for the disconnect switch Table 1 Fuse Size Selection Input Power Input Voltage Fuse Size Amperes Three Phase Single Phase 208 230 VAC 380 415VAC 460VAC 50 30 25 60 N A 30 NOTE Fuse size...

Page 23: ...R s in the Power Control Assembly PCA will turn on after the input capacitors have charged to full operating voltage after approximately 5 seconds NOTE Note the available input power Damage to the PCA could occur if 575VAC is applied with the INPUT SELECT switch in the 208 230V position 208VAC 50 60Hz three phase single phase 230VAC 50 60Hz three phase single phase 460VAC 50 60Hz three phase singl...

Page 24: ...V 575V 8 3 in 210 mm 16 9 in 430 mm 16 5 in 420 mm 46 3Ib 21 0 kg 45 0Ib 20 4kg 51 1Ib 23 2kg Output at No Load 208 V 230 V 380 V 400 V 415 V 460 V 575 V KVA KW Three phase Input 1 0A 0 9A 0 6A 0 6A 0 6A 0 5A 0 4A Single phase Input 1 7A 1 5A 0 8A 0 15 0 1 Output at Rated Load 40 Duty Cycle 208 V 230 V 380 V 400 V 415 V 460 V 575 V KVA KW 60 Duty Cycle 208 V 230 V 380 V 400 V 415 V 460 V 575 V KVA...

Page 25: ...NING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature Continually exceeding the duty cycle ratings can cause damage to the welding power source To calculate duty cycle cycle duty desired cycle duty rated current rated current 2 i e At the 260A rated output curre...

Page 26: ...esents approximate actual amperage values Warning Indicator The Warning Indicator located on the front panel will become activated under the following conditions Input voltage is too low Input voltage too high Thermal overload AC Power Indicator The AC Power Indicator located on the front panel lights when the Primary Power Switch is in the ON position indicating the unit is energized Positive Ter...

Page 27: ...urce 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 illuminated Not installed in 460V 575V units Input Cable 10 feet Figure 5 Rear panel operator controls ...

Page 28: ...rent 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 The Dip Switch setting for the Arc Control current is classified as follows Dip Switch Arc Control 1 2 3 4 Amperes Percentage Factory Shipping ON OFF OFF OFF 15A 10 OFF ON OFF OFF 30A 20 OFF OFF ON OFF 45A 30 OFF OFF OFF ON 60A ...

Page 29: ...r the majority of electrodes in use the work clamp is connected to the GROUND or NEGATIVE terminal 4 Select proper electrode 5 Refer to the Operator Control section page 22 and set the controls per the following Rotate the AMPERAGE control 1 to output current level desired 6 Insert electrode into electrode holder For the majority of electrodes in use the electrode holder is connected to the POSITI...

Page 30: ...er 100 ft Under 30m 150 ft 45m 200 ft 60m 250 ft 70m 300 ft 90m 350 ft 105m 400 ft 120m Duty Cycle 100 60 60 100 10 100 Welding Amperes 100 150 200 250 300 400 4 3 3 2 1 1 0 4 3 2 1 1 0 2 0 4 2 1 1 0 2 0 3 0 3 1 1 0 2 0 3 0 4 0 2 1 0 2 0 3 0 4 0 2 2 0 1 2 0 3 0 4 0 2 2 0 2 3 0 1 0 3 0 4 0 2 2 0 2 3 0 2 4 0 1 0 3 0 4 0 2 2 0 2 3 0 2 4 0 ...

Page 31: ...h in wrong position B Poor Weld Wrong polarity Wrong electrode used Electrode not properly prepared Incorrect welding amperage setting Speed too slow or too fast Incorrect switch settings for intended operation Poor weld output connection s If the problem is not resolved after checking the above the following guide may suggest more specific items to check given the faulty operating symptom s you a...

Page 32: ...condition Most power utilities will monitor and verify line voltage b Measure input voltage and verify that it matches the INPUT SELECTOR Easy Link switch setting The length of the input power cable must be considered as there will be a considerable voltage drop along its length C Erratic or Improper Weld Output 1 Loose welding cable connections a Tighten all welding cable connections 2 Incorrect ...

Page 33: ...Output Fan Operating WARNING Indicator OFF 1 Line voltage is too high a Verify that input voltage matches setting on rear panel INPUT SELECTOR switch G Limited Weld Output 1 Poor primary input voltage a Check primary input voltage is within 10 of nominal voltage i e 230VAC 10 H Erratic or Improper Weld Output 1 Loose welding cable connections a Tighten all welding cable connections 2 Improper setu...

Page 34: ...30 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 ...

Page 36: ... G2 White IGBT Gate Drive E4 Black IGBT Gate Drive G4 White IGBT Gate Drive G3 White Line 3 Black Line 2 White Line 1 Red Main Circuit Board PCB1 E2 C1 E1 G2 C2E1 E2 C21E1 PCB4 E2 C1 PCB2 5 4 2 1 IGBT Inverter Q1 PCB3 5 4 2 1 C2E1 C1 E2 G1 E1 G2 E2 PCB5 C21E1 C1 E2 IGBT Inverter Q2 Orange Black White R2 R S T G Input Diode Bridge D1 C1 MCB1 Black White Red Line1 Line2 Line3 Ground Bus Bar Bus Bar ...

Page 37: ...mon 0V 7 8 5 CN7 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 ARC Control Signal White 1 2 CN1 CN15 CN15 CN16 CN16 CN 22 1 2 3 4 5 6 8 9 10 11 12 13 14 15 7 Input Changeover Control Torch Switch Control Output Short Circuit Control Input 1 3 Phase Detect 12V DC Input Changeover Control PWM Gate Drive In...

Page 38: ...hyristor Gate White Thyristor Anode Orange Output Voltage Detect Black Line 3 Black Line 2 White Line 1 Red Main Circuit Board PCB1 E2 C1 E1 G2 C2E1 E2 C21E1 PCB4 E2 C1 PCB2 5 4 2 1 IGBT Inverter Q1 PCB3 5 4 2 1 C2E1 C1 E2 G1 E1 G2 E2 PCB5 C21E1 C1 E2 IGBT Inverter Q2 Orange Black White R2 R S T G Input Diode Bridge D1 C1 MCB1 Black White Red Line1 Line2 Line3 Ground Bus Bar Bus Bar Black Bus Bar ...

Page 39: ... Red AC Power Signal Orange 5V DC Yellow Amperage Control Signal Blue PCB Common 0V Purple ARC Control Signal Gray ARC Control Signal White 1 2 CN1 CN15 CN15 CN16 CN16 CN 22 1 2 3 4 5 6 8 9 7 Input Changeover Control Torch Switch Control Output Short Circuit Control Input 1 3 Phase Detect 12V DC Input Changeover Control PWM Gate Drive Input Changeover Control PCB Common 0V Primary Current Detect P...

Page 40: ... G2 White IGBT Gate Drive E3 Orange Line 3 Black Line 2 White Line 1 Red Main Circuit Board PCB1 E2 C1 E1 G2 C2E1 E2 C21E1 PCB4 E2 C1 PCB2 5 4 2 1 IGBT Inverter Q1 PCB3 5 4 2 1 C2E1 C1 E2 G1 E1 G2 E2 PCB5 C21E1 C1 E2 IGBT Inverter Q2 Orange Black White R2 R S T G Input Diode Bridge D1 C1 MCB1 Black White Red Line1 Line2 Line3 Ground L1 Bus Bar Bus Bar Black Bus Bar Bus Bar Bus Bar Black Input Curr...

Page 41: ... Red AC Power Signal Orange 5V DC Yellow Amperage Control Signal Blue PCB Common 0V Purple ARC Control Signal Gray ARC Control Signal White PCB Common 0V 1 2 CN1 CN15 CN15 CN16 CN16 CN 22 1 2 3 4 5 6 8 9 10 11 12 13 14 15 7 Input Changeover Control Torch Switch Control Output Short Circuit Control Input 1 3 Phase Detect 12V DC Input Changeover Control PWM Gate Drive Input Changeover Control Primar...

Page 42: ... breaker DBE53B 3P 480V 50AT 1 25850001500 10 5224 13 PCB1 Printed circuit board WK 3448 U21 MAIN 1 P0A344821 10 6521 14 PCB1 1 Printed circuit board WK 4182 260S CNTL 1 P0A418200 10 6522 15 PCB1 2 Printed circuit board WK 3363 1 P0A336300 10 5119 16 PCB1 3 Printed circuit bard WK 3449 DRIVER 1 P0A344900 10 6523 17 PCB2 3 Printed circuit board WK 3367 IGBT GATE 2 P0A336700 10 5120 18 PCB4 5 Printe...

Page 43: ... 47 15 27H 1 479531341 10 2290 12 MCB1 Molded case circuit breaker DBE53B 3P 480V 50AT 1 25850001500 10 5224 13 PCB1 Printed circuit board WK 3448 U23 MAIN 1 P0A344823 10 6527 14 PCB1 1 Printed circuit board WK 4182 CNTL 1 P0A418200 10 6522 15 PCB1 3 Printed circuit board WK 3449 S02 DRIVER 1 P0A344902 10 6528 16 PCB2 3 Printed circuit board WK 3367 IGBT GATE 2 P0A336700 10 5120 17 PCB4 5 Printed ...

Page 44: ...1 25303006400 9 1076 12 PCB1 Printed circuit board WK 3448 U22 MAIN PCB 1 P0A344822 10 6530 13 PCB1 1 Printed circuit board WK 4182 CNTL 1 P0A418200 10 6522 14 PCB1 3 Printed circuit board WK 3449 S01 DRIVER 1 P0A344901 10 6531 15 PCB2 3 Printed circuit board WK 3367 IGBT GATE 2 P0A336700 10 5120 16 PCB4 5 Printed circuit board WK 3366 S01 2 P0A336601 10 5122 17 PCB6 Printed circuit Board WK 4224 ...

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