Thermal Arc 400 GTSW AC/DC Operating Manual Download | Manualshive

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SERVICE

30

4.2 TROUBLESHOOTING GUIDE

Troubleshooting and repairing the this unit is a process which
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
have had training in power electronics measurement and trouble-
shooting techniques.

This manual covers a basic level of troubleshooting that requires
limited dissasembly and measurements. It is helpful for solving
many of the common problems that can arise with the Inverter
Arc Welder system.

If major complex subassemblies are faulty, the unit must be
returned to an authorized service center for repair.

Follow all instructions as listed and complete each section in the
order presented.

General

WARNING

Basic Troubleshooting

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Summary of Contents for 400 GTSW AC/DC

Page 1: ...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 ...

Page 2: ......

Page 3: ... Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1994 Thermal Dynamics Corporation 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 omission in the...

Page 4: ...e 2 2 1 Site Selection 3 2 2 Transporting Methods 4 2 3 Weld Output Connections 5 2 4 Shielding Gas Connections 8 2 5 Remote 14 Connections 9 2 6 Electrical Input Connections 10 3 1 Operator Controls 13 3 2 Sloper and Pulser Controls 19 3 3 Operating Precautions 22 3 4 Sequence of Operation 23 3 5 Electrode Preparation 26 3 6 Electrode Selection 27 4 1 General Maintenance 29 4 2 Troubleshooting Gu...

Page 5: ...tego rized as follows An operation procedure or background information which requires additional emphasis or is helpful in efficient operation of the system A procedure which if not properly followed may cause damage to the equipment A procedure which if not properly followed may cause injury to the operator or others in the operating area NOTE CAUTION WARNING ...

Page 6: ...ss or death can result from fumes vapors heat or oxygen enrichment or depletion that welding or cutting may produce Ventilation must be adequate to remove gases and fumes during operation as described in ANSI Standard Z49 1 Use a downdraft table or water table to capture fumes and gases Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases When working in conf...

Page 7: ... apparatus clean and free from oil and grease Oxygen cylinders and apparatus should not be handled with oily hands or gloves Do not allow an oxygen stream to contact oily or greasy surfaces Do not use oxygen as a substitute for compressed air NEVER ventilate with oxygen Generator engine exhaust must be vented to the outside air Carbon monoxide can kill ARC RAYS can injure eyes and burn skin Never ...

Page 8: ... Welding Current Number Torch soldering 2 Torch brazing 3 or 4 Oxygen Cutting Light Under 1 in 25 mm 3 or 4 Medium 1 6 in 25 150 mm 4 or 5 Heavy Over 6 in 150 mm 5 or 6 Gas welding Light Under 1 8 in 3 mm 4 or 5 Medium 1 8 1 2 in 3 12 mm 5 or 6 Heavy Over 1 2 in 12 mm 6 or 8 Shielded metal arc welding stick electrodes Light Under 5 32 in 4 mm 10 Medium 5 32 1 4 in 4 6 4 mm 12 Heavy Over 1 4 in 6 4...

Page 9: ...lly hot part or grounded metal reduces electrical resistance and could cause potentially fatal electric shock A voltage will exist between the electrode and any conducting object in the work circuit Examples of conducting objects in clude but are not limited to buildings electrical tools work benches welding power source cases workpieces etc Never touch electrode to any metal object unless the wel...

Page 10: ...esistance equivalent to original cable Keep cables dry free of oil and grease and protected from hot metal and sparks Terminals and other exposed parts of electrical units should have insulating covers secured before operation For equipment with output ON OFF control contactor Weld ing power sources for use with gas metal arc welding GMAW gas tungsten arc welding GTAW and similar processes nor mal...

Page 11: ...vers or shields Walls having combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields A fire watch with suitable fire extinguishing equipment must be provided during and after welding or cutting if combustibles including building construction are within 35 ft 10 7 m if combustibles are further than 35 f...

Page 12: ...ter work is done check that area is free of sparks glowing embers and flames Burn Prevention Wear protective clothing including gauntlet welding gloves hat and high safety toe shoes Button shirt collar to protect chest and neck button pocket flaps and wear cuffless trousers to avoid entry of sparks and slag Wear dark colored substantial long sleeve clothing particularly for gas shielded arc As nec...

Page 13: ...inter does not move off stop pin when pressurized nor returns to stop pin after pressure release Do not attempt to repair faulty regulators Send to manufactur er s authorized repair center where special techniques and tools are used by trained personnel Cylinders must be handled carefully to prevent leaks and dam age to walls valves or safety devices Contact with electrical circuits including thir...

Page 14: ... for hose not ordinary wire or other substitute as a binding to connect hoses to fittings Do not use copper tubing splices Use only standard brass fittings to splice hose Avoid long runs to prevent kinks and abuse Coil excess hose to prevent kinks and tangles Suspend hose off ground to protect from damage Protect hose from damage by sharp edges sparks slag excessive heat and open flame Examine hos...

Page 15: ...eases slowly When gauge is pressurized gauge reaches regulator maximum open cylinder valve fully to seal stem against possible leak when using oxygen and inert gases For fuel gas open less than one turn to permit quick emergency shutoff Use pressure charts available from supplier for safe and effi cient recommended pressure settings on regulators Check for leaks on first pressurization and regular...

Page 16: ...itute 1430 Broadway New York NY 10018 6 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAIN ERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 NFPA Standard 51 OXYGEN FUEL GAS SYS...

Page 17: ...ing Supply Associa tion 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from Ameri...

Page 18: ...all 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 periods for Thermal products shall be as follows A maxi...

Page 19: ...er source Curves of other set tings will fall between the curves shown Description NOTE Table 1 A Unit Specifications Input Data At Rated Load No Load 50 60 Hz Output Output Amps KVA KW Amps KVA KW 208 VAC 1 Phase 84 17 12 3 7 0 8 0 4 208 VAC 3 Phase 46 17 12 2 9 0 8 0 4 230 VAC 1 Phase 76 17 12 3 3 0 8 0 4 230 VAC 3 Phase 41 17 12 2 6 0 8 0 4 460 VAC 1 Phase 38 17 12 1 7 0 8 0 4 460 VAC 3 Phase 2...

Page 20: ...four consecutive minutes but it must operate at no load for the remaining six minutes to allow proper cooling If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond rated output the duty cycle will decrease EXCEEDING DUTY CYCLE RATINGS will cause the thermal overload protection circuit to become energized and shut down output until the unit cools to no...

Page 21: ...t FIRE OR EXPLOSION can result from placing unit on or over combustible surfaces RESTRICTED AIRFLOW can cause overheating and possible damage to internal parts Do not locate unit over combustible surfaces Maintain at least 3 inches 76 mm of space from sides of unit 6 inches 152 mm from rear and open unrestricted access to ambient air at front of unit Do not place any filtering device over the inta...

Page 22: ...LLING EQUIPMENT can cause serious personal injury and equipment damage Do not hang unit from eyelets Have two persons of adequate physical strength lift unit Use hand cart or similar device of adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting This unit has two eyelets on top ends of case for lifting Be sure unit is lifted and transported safe...

Page 23: ... the cable size recommended in Table 2 A for 50 feet 15 m 4 Do not use damaged or frayed cables 1 Install terminal lugs of adequate amperage capacity and correct stud size onto ends of cables that connect to the work clamp and electrode holder or torch 2 If installing electrode holder follow manufacturer s installa tion instructions Always use an insulated electrode holder to ensure operator safet...

Page 24: ...plied sleeve on stripped end of cable 6 Insert cable with sleeve into connector body so that cable is snug and against bottom of connector body 7 Install and tighten set screw with supplied hex wrench to secure connector body onto cable 8 Push insulator onto connector body to cover set screw Connector Installation ELECTRIC SHOCK can kill ARCING can burn skin or damage electrical connections Do not...

Page 25: ...hen Gas Tungsten Arc Welding in the AC mode a Connect end of electrode holder cable to the positive weld output receptacle as follows align keyway insert plug and rotate plug clockwise until it is securely seated in receptacle b Connect work cable connector to the negative weld output receptacle as follows align keyway insert plug and rotate plug clockwise until it is securely seated in receptacle...

Page 26: ...te and connect a hose of suitable length and construction from the shielding gas supply to the GAS INPUT fitting on rear of unit 2 Connect the torch gas hose to the GAS OUTPUT fitting on front of unit The gas flow must be accurately controlled with a regulator and flowmeter Recommendations for rate of gas flow should be obtained from the torch manufacturer It is recommended to use a nylon or synfl...

Page 27: ...o interface with REMOTE 14 receptacle Table 2 B Remote 14 Socket Information Figure 2 C Front View of 14 Pin Socket with Locations Socket A Remote solid state contactor control when contact closure is provided between Sockets A and B Socket B Remote solid state contactor control when contact closure is provided between Sockets A and B to energize the solid state contactor Socket C Remote amperage ...

Page 28: ...hase or single phase if derated 50 60 Hz AC power supply The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service avail able how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means ...

Page 29: ...ors to a deenergized line disconnect switch 3 For single phase electrical input power connect ends of red line 1 white line 2 input conductors to a de energized line disconnect switch Insulate and isolate the black line 3 conductor 4 Use Table 2 C below as a guide to select line fuses for the disconnect switch 2 6 ELECTRICAL INPUT CONNECTIONS continued INPUT INPUT FUSE SIZE POWER VOLTAGE AMPERES S...

Page 30: ...ns and Components The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate This power source incorporates the Smart Link circuit which automatically links the power source to primary input voltage and adjusts it to allow for operation of unit within input rating on data tag It is not necessary to manually switch terminals or links if uni...

Page 31: ...AGE 0 3 2 4 6 8 10S 0 3 2 6 10S 0 20 80 40 60 100 INITIAL AMPERAGE 0 20 40 60 80 100 ON TIME L H PULSE PER SECOND PEAK AMPERAGE 15 30 50 70 0 20 80 40 60 100 BACKGROUND AMPERAGE 0 20 40 60 80 100 SLOPER PULSER OFF ON OFF LOW HIGH 8 4 85 0 20 40 60 1 0 0 30 0 5 0 0 1 2 3 5 10 2 5 2 1 8 9 10 11 12 13 14 7 6 5 4 3 Primary Power Switch Controls Behind Access Door A 00327 3 1 OPERATOR CONTROLS 8 DIGITA...

Page 32: ... source Rotating this control in a clockwise direction increases the amperage output The scale surrounding the AMPERAGE control is calibrated in actual amperage values The AMPERAGE control may be adjusted while welding The ARC CONTROL provides a variable selection of short circuit amperage to suit individual welding situations when operating in the STICK Welding SMAW mode Rotating this control clo...

Page 33: ...ds Rotating the control clockwise increases postflow time The POSTFLOW TIME control and gas valve only work if the Process Selector switch is in one of the Gas Tungsten Arc Weld ing positions the OUTPUT CONTACTOR switch is in the RE MOTE position and a remote control is connected to the RE MOTE 14 receptacle The PREFLOW TIME control only works if the PROCESS SELEC TOR switch is in the LIFT TIG or ...

Page 34: ...process the LIFT TIG GTAW process without high frequency and the HF TIG GTAW process with high frequency start only The unit will provide weld output for the Shielded Metal Arc Welding SMAW process When the Process Selector switch is in this position the ARC CONTROL will function and the POSTFLOW TIME control will not function The unit will provide weld output for the Gas Tungsten Arc Welding GTAW...

Page 35: ...aximum output the maximum output available from the remote control will be half the welding power source maximum output ELECTRIC SHOCK CAN KILL Do not touch live electrical parts Do not touch the weld output receptacles when the contactor is energized Do not touch electrode and work clamp at the same time If the OUTPUT CONTACTOR switch is in the ON position open circuit voltage will be present at ...

Page 36: ...utput frequency is 60 Hz The frequency can be adjusted from 20 to 100 Hz The LED meter displays either an amperage or voltage value The selected preview amperage value is displayed when welding is not taking place The meter is not intended for exact amperage CC or voltage measurements The amperage display indicates amperage output of the welding power source and is driven by circuitry on control b...

Page 37: ...gizes the sloper con trols Placing the switch in the OFF position turns off the sloper controls When the sloper switch is in the ON position the output current control on the front panel of the welding power source is invalid Initial Amperage Control 4 allows the desired starting current to be set from which upslope will begin Adjustable for the full range of the power supply Final Amperage contro...

Page 38: ...ond switch func tion to the existing sequence of Operation USE PIN B PIN M FOR REPEAT FUNTION To use the repeat function start the Slope sequence as normal Maintaining the REMOTE switch CONNECTED TO PINS A B OF THE 14 PIN RECPT in the closed posistion starts the se quence for initial current setting Opening the REMOTE switch contacts will start the upslope sequence to weld current and will stay in...

Page 39: ... when the PULSER switch in the ON position Rotating the control clockwise increases the pulse frequency The two scales surrounding the control are calibrated in pulses per second The inner scale is calibrated from 0 5 to 25 pulses per second The outer scale is calibrated from 10 to 500 pulses per second The desired scale is selected by pulse switch 6 on panel THE PULSES PER SECOND CONTROL MAYBE AD...

Page 40: ...SURFACES can burn eyes and skin NOISE can damage hearing Wear correct eye ear and body protection FUMES AND GASES can seriously harm your health Keep your head out of the fumes Ventilate to keep from breathing fumes and gases If ventilation is inadequate use approved breathing device HOT METAL SPATTER AND SLAG can cause fire and burns Watch for fire Keep a fire extinguisher nearby and know how to ...

Page 41: ...operation see section 3 9 Place AMPERAGE CONTROL switch in desired position see section 3 10 Rotate AMPERAGE CONTROL to desired position see section 3 11 Rotate POSTFLOW TIME CONTROL to desired position see section 3 12 Rotate PREFLOW TIME CONTROL to desired position see section 3 13 Rotate HOT START CONTROL to desired position see section 3 14 Turn on shielding gas and water supplies as applicabl...

Page 42: ...UND AMPERAGE control in the desired position 11 Place the PULSES PER SECOND control in the desired position 12 Place the ON TIME control in the desired position 13 Place the AMPERAGE switch in the desired position 14 Place the OUTPUT CONTACTOR switch in the desired position 15 Place the PULSER switch in the ON position 16 Turn on shielding gas and water supplies as applicable 17 Wear welding helme...

Page 43: ...AC OR DC OPERATION 8 If remote amperage control is not used place the AMPER AGE Control switch in the PANEL position If remote amperage control is to be used place the AMPERAGE Control switch in the REMOTE 14 position 9 Rotate AMPERAGE control or remoted amperage control if applicable to desired position see Section 3 10 Rotate ARC CONTROL to desired position see Section 3 11 Wear welding helmet w...

Page 44: ... used on tungsten in the AC mode when the CLEANING balance control is set at 20 or less Grind the end of the tungsten electrode to a taper for a distance of 2 to 2 1 2 electrode diameter in length HOT FLYING METAL PARTICALS CAN INJURE PERSONNEL START FIRES AND DAMAGE EQUIPMENT HIGH CONCENTRATION OF SHIELDING GAS can harm health or kill Shut off gas supply when not in use Ground to a Point Ground R...

Page 45: ...30 1 8 in 3 18 mm 225 360 25 40 5 32 in 3 97 mm 360 450 40 55 3 16 in 4 76 mm 450 720 55 80 1 4 in 6 35 mm 720 950 80 125 2 THORIUM ALLOYED TUNGSTEN RED BAND 010 in 0 25 mm 1 25 020 in 0 51 mm 15 40 040 in 1 02 mm 25 85 1 16 in 1 59 mm 50 160 10 20 3 32 in 2 38 mm 135 235 15 30 1 8 in 3 18 mm 250 400 25 40 5 32 in 3 97 mm 400 500 40 55 3 16 in 4 76 mm 500 750 55 80 1 4 in 6 35 mm 750 1000 80 125 3...

Page 46: ...OPERATION 28 NOTES ...

Page 47: ...g environment To clean the unit first make sure that the power is disconnected Blow out any accumulated dirt and dust with compressed air The unit should also be wiped clean If necessary solvents that are recommended for cleaning electrical apparatus may be used Inspect all external wiring on the unit Look for any frayed wires or loose connections that should be corrected Routine Maintenance ...

Page 48: ... have had training in power electronics measurement and trouble shooting techniques This manual covers a basic level of troubleshooting that requires limited dissasembly and measurements It is helpful for solving many of the common problems that can arise with the Inverter Arc Welder system If major complex subassemblies are faulty the unit must be returned to an authorized service center for repa...

Page 49: ...heck and replace line fuse s 3 Improper electrical input connections a See Installation section pages 3 14 for proper input connections 4 Primary power switch MCB in OFF position a Check and reset MCB if necessary B No weld output fan motor running and AC POWER indicator on 1 OUTPUT CONTACTOR switch S2 in REMOTE 14 position no remote contactor control connected to REMOTE 14 receptacle a Place S2 i...

Page 50: ...E 14 receptacle 2 Remote control defective a Replace with known good device E Wandering arc poor control of arc direction 1 Use of tungsten considerably larger than recommended a Use proper size tungsten Refer toSection 3 5 2 Improperly prepared tungsten a Prepare tungsten 3 Gas flow rate too high a Reduce flow rate 4 Drafts blowing shielding gas away from tungsten electrode a Shield weld zone fro...

Page 51: ...efer to torch parts list for part s requiring replacement and repair torch as necessary G Lack of high frequency difficulty establishing an arc 1 Dissipation of high frequency from torch cable or conductive gas hose a Be sure that torch cable is not near any grounded metal Do not use conductive gas hose 2 Weld cable leakage a Check cables and torch for cracked or deteriorated insulation or bad con...

Page 52: ... Fuse 5A 600V X X X 10 2206 F2 F3 Fuse 2A 250V X X X 10 2196 S1 S2 S3 Switch 1P3T X X X 10 2124 VR1 10K Pot X X X 10 2618 VR2 10K Pot X X X 10 2135 CON1 14 Pin Receptacle X X X 10 2133 CON2 17 Pin Receptacle X X X 10 2227 TO Output Terminal X X X 10 2202 Case Left Right Side X X X 4 3 REPACEMENT PARTS ...

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