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Thermal Arc 400GTS CC/TIG, Operating Manual

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19

MANUAL 0-2512

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).

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/single-phase
575VAC 50/60Hz three-phase

INTRODUCTION

Summary of Contents for 400GTS CC/TIG

Page 1: ...INVERTER ARC WELDER MODEL 400GTS CC TIG STICK TIG HIGH FREQUENCY LIFT START OPERATING MANUAL July 1 1997 Manual No 0 2512 TM R ...

Page 2: ...ctional Block Diagram 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 Front and Rear operator controls 22 3 02 Setup for Operation 24 Shielded Metal Arc Welding SMAW 25 Gas Tungsten Arc Welding GTAW High Frequency Lift Start 26 Gas Tungsten Arc Welding Pulsed GTAW P Sloped GTAW S TIG Spot 28 4 0 BASIC TROU...

Page 3: ...nual Number 0 2512 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1997 by 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 dam...

Page 4: ...se 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 5: ...sed coatings on the metal and the different processes You must be very careful when cutting or welding any metals which 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 wi...

Page 6: ... 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 underwate...

Page 7: ...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 pro...

Page 8: ...ety 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 51B CUTTING AND WELDING PROCESSES o...

Page 9: ...ération 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 tra...

Page 10: ...dépendent du genre de métal utilisé 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 données sur la sécurité des...

Page 11: ... 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 produit 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 li...

Page 12: ...n 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 fournissant des cabines 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 ouïe Les procédés de soudage à l arc de plasma peuven...

Page 13: ...merican Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Américaine pour la Protection contre les Incendies NFPA LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROCÉDÉS ASSOCIÉS disponible auprès de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible auprès ...

Page 14: ... and manufactured 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 EN 60 974 1 applicable to weldi...

Page 15: ...ise 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 OFANY 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...

Page 16: ...14 MANUAL 0 2512 ...

Page 17: ...enoid lift arc starter and a high frequency arc starter for use with Gas Tungsten Arc Welding GTAW Gas Tungsten Arc Welding Pulsed GTAW P Gas Tungsten Arc Welding Sloped GTAW S Gas Tungsten Arc Welding TIG Spot GTAW TIG and Shielded Metal Arc Welding SMAW processes 19V 400 5 AMPS VOLTS Arc Characteristics CURRENT Control 410 145 OCV Less than 70V C C Figure 1 400GTS model Volt Ampere curve NOTE Vo...

Page 18: ... Diodes Output Inductor Input Power Inrush Current Suppresor IGBT Inverter Module Thermal Sensor Output Transformers High Frequency Unit Current Transformer CT 1 Capacitor Thermal Sensor Circuit Current Adjustment Circuit Reference Adjustments Control Switches Torch Control Connection CON1 Control Transformer c Config Gas Control Circuit Trouble Sensing Circuit Sequence Control To each control cir...

Page 19: ...procedures Lockout tag out 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 Requirements Operate the welding power source from a single or three phase 50 60 Hz AC power supply The input voltage must match one of the electrical input voltages shown on t...

Page 20: ...8 230VAC 70 80 380 415 VAC 40 N A 460 VAC 30 40 NOTE Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code THERMADYNE OFF ON 208 230V 460V INPUT SELECT SWITCH PRIMARY POWER PRIMARY CABLE TURN OFF YOUR MAIN POWER SOURCE AND CIRCUIT BREAKER OF THIS WELDER BEFORE MAINTENANCE OR INSPECTION 5A 10V 400A 36V 4...

Page 21: ...r 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 single phase 575VAC ...

Page 22: ...6 9 in 430 mm Length 16 5 in 420 mm Weight 41 8 lb 19 kg Output At Rated Load Input data 50 60 Hz Duty Cycle OutputAmperes 400 300 Output Volts 36 32 Duty Cycle 25 60 KVA 21 9 11 3 KW 16 9 11 3 Output At No Load Input data 50 60 Hz Duty Cycle KVA 0 5 KW 0 3 Input Volts Amperage Draw Rated Load No Load Three Phase 208 61 40 1 4 230 55 37 1 3 380 33 32 0 8 400 32 21 0 7 415 30 20 0 7 460 27 18 0 6 5...

Page 23: ...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 rated current 2 x rated duty cycle desired duty cycle current i e At the 400A rated output current and 25 rated d...

Page 24: ...he short circuit current available to control the welding arc LCD Display Amperage Voltage Selector Switch selects digital meter display of output amperage on voltage Preview Pushbutton Switch Allows digital meter to be used to set amperage in HF Start Mode or amperage in TIG or STICK modes prior to welding 12 17 15 16 Gas Solenoid The pre flow is fixed at 150 ms Post flow is automatically adjuste...

Page 25: ...his 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 turn on and the warning indicator will be illuminated Input Cable 10 feet Input Gas Fitting The input gas connection is located on the bottom center of the rear panel Size 5 8 18 unf female European Fitting 3 8 BSP male GTS Model only 19 20 21 18 F...

Page 26: ...rt circuit amperage to suit individual welding situations when operating in the STICK welding SMAW mode 5 400A 75 0 145A Main Knob Arc Control 100 25 50 19V 10V 100A Droop Arc Control Knob Main Knob Arc Control Knob Less Than 410 Output Current Limit Figure 6 Arc Control Characteristics SETUP FOR OPERATION ...

Page 27: ...IVE output terminal 4 Select proper electrode 5 Refer to Operator Control section page 22 and set the controls per the following a PROCESS SELECTOR switch 5 to STICK position b Rotate the AMPERAGE control 1 to output current level desired 1 5 6 Insert electrode into electrode holder For the majority of electrodes in use the electrode holder is connected to the POSITIVE output terminal 7 Wear weldi...

Page 28: ...insulating gloves and clothing 5 Connect shielding gas supply to gas fitting on back panel 6 Connect TIG torch gas fitting to output 3 8 BSP or 5 8 18 UNF fitting where applicable 7 Connect remote control device to 8 Pin receptacle NOTE The maximum output that can be obtained using the remote control is set by the main current knob 1 5 8 Connect work clamp to clean bare metal on workpiece For the ...

Page 29: ...rovide a low open circuit voltage and approximately 15 amps to the tungsten electrode when touched to the work After the Tungsten Electrode is lifted away and the welding arc becomes established the output current will be regulated at the current level determined by the AMPERAGE control 1 b Rotate the AMPERAGE control 1 to output current level desired 10 Turn on shielding gas 11 Wear welding helme...

Page 30: ...plicable 7 Connect remote control device to 8 Pin receptacle 8 Connect work clamp to clean bare metal on workpiece For the majority of electrodes in use the work clamp is connected to the POSITIVE output terminal 9 Refer to the Operator Control section page 22 and set the controls per the following 10 PROCESS SELECTOR switch 5 to desired gas tungsten arc welding position LIFT or HF TIG A PULSE TIG...

Page 31: ...13 Place the PRIMARY POWER switch 18 to ON 14 Activate the remote control device NOTES a In the LIFT TIG mode touch electrode to work and lift to start arc b In the HF TIG mode the high frequency will start followed by welding arc The distance between the tungsten to the plate where the arc will be established will vary with the setting of the HOT START control 15 Begin welding WARNING HIGH CONCEN...

Page 32: ...ungsten Red Band 0 010 in 0 25mm 1 25 0 020 in 0 51mm 15 40 0 040 in 1 02mm 25 85 1 16 in 1 59mm 50 160 10 20 3 32 in 2 38mm 135 235 15 30 1 8 in 3 18mm 250 400 25 40 5 32 in 3 97mm 400 500 40 55 3 16 in 4 76mm 500 750 55 80 1 4 in 6 35mm 750 1 000 80 125 Table 3 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 ...

Page 33: ...e 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 C Remote Operation Incorrect contactor switch settings Remote not connected If the problem is not resolved after checking the above the following guide may suggest more specific items to check given the faulty operating ...

Page 34: ...ure 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 welding cable size a Use proper size and type of cable see Table 2 page 30...

Page 35: ...rode 3 Loose gas fitting on regulator or gas line drawing air into weld zone a Check and tighten all gas fittings 4 Water in torch a Refer to torch parts list for part s requiring replacement and repair torch as necessary 5 Tungsten condition is poor a Replace electrode 6 Electrode too high off metal a Reduce stand off F Lack of High Frequency Difficulty in Establishing an Arc 1 Dissipation of hig...

Page 36: ...etting on rear panel INPUT SELECTOR switch J Low or Maximum Weld Output With No Control 1 Faulty remote control device a Connect a jumper between pins 2 and 3 of the REMOTE 8 receptacle for contactor closure If amperage and voltage can be adjusted with front panel controls repair or replace remote control device K Limited Weld Output 1 Poor primary input voltage a Check primary input voltage is wi...

Page 37: ...Chassis common 2 Remote contactor control when contact closure is provided between sockets 2 and 3 GND Function 3 4 5 6 7 8 8 1 3 Remote contactor control when contact closure is provided between sockets 2 and 3 24 V DC 4 Remote amperage control when contact closure is provided between sockets 4 and 8 12 V DC 8 Remote amperage control when contact closure is provided between sockets 4 and 8 SIGNAL...

Page 38: ...le 7 8 1 1 8 22mm 29mm Torch Switch 10 4010 X X 15 4 6m 8 Pin Male 1 1 8 1 3 8 29mm 35mm Torch Switch 10 4011 X X 25 7 6m 8 Pin Male 5 8 7 8 16mm 22mm Torch Switch 10 4012 X X 25 7 6m 8 Pin Male 7 8 1 1 8 22mm 29mm Torch Switch 10 4013 X X 25 7 6m 8 Pin Male 1 1 8 1 3 8 29mm 35mm Hand Pendant 10 4014 X X 25 7 6m 8 Pin Male N A Foot Control 10 4015 X X 15 4 6m 8 Pin Male N A Foot Control 10 4016 X ...

Page 39: ...Torch w accessory kit Victor HRF1425 580 regulator Ground lapm w 12ft cable and 50mm Dinse Connector attached STICK Kit 10 4082 Includes Electrode Holder w 15ft cable and Dinse style Connector attached Ground Clamp w 12ft cable and Dinse style Connector attached Dinse Connector 10 2020 50mm Male for additional torches electrode holders Adapter 10 4003 8 Pin Male to 14 Pin Female ...

Page 40: ...38 MANUAL 0 2512 ...

Page 41: ...2 APPENDIX B INTERCONNECTION DIAGRAMS APPENDIX B INTERCONNECTION DIAGRAMS The following pages contain the interconnection diagrams for all 400GTS in current production to aid in the identification of replacement parts ...

Page 42: ... G1 White IGBT Gate Drive G3 White IGBT Gate Drive E3 Orange IGBT Gate Drive E4 Black IGBT Gate Drive G4 White Output Voltage Detect White Output Voltage Detect Black HF Unit ON OFF Gray Thermal Detect Black Thermal Detect Black Bus Bar Bus Bar Bus Bar Bus Bar Black Black Black Black Black Black L1 FAN1 5 4 2 1 CN9 1 2 3 4 CN1 1 3 5 CN5 5 3 1 CN7 2 1 TH1 CN10 MCB Input Diode Bridge D1 1 2 4 5 PCB2...

Page 43: ...l Output Voltage Detect Output Voltage Detect Output Current Detect PCB Common 0V 12VDC 5VDC 5VDC PCB Common 0V 12VDC 11 10 9 8 7 6 5 4 3 2 1 CN7 Torch Control Pink Torch Control Yellow 2 1 CN4 Case Ground Green Output Short Detect Black Output Short Detect White Ground Yellow Output Current Detect 0V to 4V Orange 12VDC Red 12VDC Brown T1 A C D E B A C D E B T2 1 2 3 4 D2 R2 C2 CT1 FCH C6 C7 C8 Ou...

Page 44: ...te Drive E3 Orange IGBT Gate Drive E4 Black IGBT Gate Drive G4 White Output Voltage Detect White Output Voltage Detect Black Thermal Detect Black Thermal Detect Black Bus Bar Bus Bar Bus Bar Bus Bar Black Black L1 FAN1 5 4 2 1 CN9 1 2 3 4 CN1 1 3 5 CN5 5 3 1 CN7 2 1 TH1 CN10 1 3 CN24 MCB Input Diode Bridge D1 1 2 4 5 PCB2 PCB4 E2 C2E1 C1 G1 E1 G2 E2 E2 C1 1 2 4 5 PCB3 PCB5 E2 C2E1 C1 IGBT Inverter...

Page 45: ...l Output Voltage Detect Output Voltage Detect Output Current Detect PCB Common 0V 12VDC 5VDC 5VDC PCB Common 0V 12VDC 11 10 9 8 7 6 5 4 3 2 1 CN7 Torch Control Pink Torch Control Yellow 2 1 CN4 Case Ground Green Output Short Detect Black Output Short Detect White Ground Yellow Output Current Detect 0V to 4V Orange 12VDC Red 12VDC Brown T1 A C D E B A C D E B T2 1 2 3 4 D2 R2 C2 CT1 FCH C6 C7 C8 Ou...

Page 46: ...e Drive E3 Orange IGBT Gate Drive E4 Black IGBT Gate Drive G4 White Output Voltage Detect White Output Voltage Detect Black Thermal Detect Black Thermal Detect Black Bus Bar Bus Bar Bus Bar Bus Bar Black Black L1 FAN1 SOL1 5 4 2 1 CN9 1 2 3 4 CN1 1 3 5 CN5 3 1 CN7 2 1 TH1 CR1 CN10 1 4 CN25 1 3 CN1 MCB Input Diode Bridge D1 1 2 4 5 PCB2 PCB4 E2 C2E1 C1 G1 E1 G2 E2 E2 C1 1 2 4 5 PCB3 PCB5 E2 C2E1 C1...

Page 47: ...l Output Voltage Detect Output Voltage Detect Output Current Detect PCB Common 0V 12VDC 5VDC 5VDC PCB Common 0V 12VDC 11 10 9 8 7 6 5 4 3 2 1 CN7 Torch Control Pink Torch Control Yellow Blue Gray 2 1 CN4 Case Ground Green Output Short Detect Black Output Short Detect White Ground Yellow Output Current Detect 0V to 4V Orange 12VDC Red 12VDC Brown T1 A C D E B A C D E B T2 1 2 3 4 D2 R2 C2 CT1 FCH C...

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