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GENERAL

MANUAL 0-2510

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.

WARNING

A procedure which, if not properly followed, may cause injury to the
operator or others in the operating area.

Содержание Thermal Arc 400GMS CC

Страница 1: ...INVERTER ARC WELDER MODEL 400GMS CC CV STICK TIG LIFT START MIG SHORT ARC GLOBULAR SPRAY OPERATING MANUAL July 1 1997 Manual No 0 2510 TM R...

Страница 2: ...nal 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 Front and Rear operator controls 22 3 02...

Страница 3: ...ual Number 0 2510 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 Re...

Страница 4: ...e 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...

Страница 5: ...ed 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...

Страница 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...

Страница 7: ...rotected 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...

Страница 8: ...ty 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 Quin...

Страница 9: ...ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me ATTENTION Toute proc dure pouvant r sulter l endommageme...

Страница 10: ...a d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieu...

Страница 11: ...de consignes INCENDIE ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du m tal des tincelles de...

Страница 12: ...bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des cra...

Страница 13: ...can Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE...

Страница 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 Laborato...

Страница 15: ...se 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 I...

Страница 16: ...14 MANUAL 0 2510...

Страница 17: ...panel meter The 400GMS unit is equipped with selectable Constant Current CC or Constant Voltage CV output characteristics It is designed for use with Shielded Metal Arc Welding SMAW Gas Metal Arc Weld...

Страница 18: ...de Output Diodes Output Inductor Input Power Inrush Current Suppresor IGBT Inverter Module Thermal Sensor Output Transformers Current Transformer CT 1 Capacitor Thermal Sensor Circuit Current Adjustme...

Страница 19: ...rocedures 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 d...

Страница 20: ...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 Cod...

Страница 21: ...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...

Страница 22: ...t 16 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 Out...

Страница 23: ...uty 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 du...

Страница 24: ...s Input voltage is too low Input voltage is 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 in...

Страница 25: ...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 weldin...

Страница 26: ...de functions as a inductance control allowing for the adjustment of the dynamic properties of the arc enhancing the weld puddle control when operated in the Gas Metal Arc GMAW and Flux Cored Arc FCAW...

Страница 27: ...Socket B is used to determine remote output the REMOTE 17 receptacle commands the full range of the welding power source output independent of the front panel AMPERAGE VOLTAGE setting Determining whic...

Страница 28: ...trode 5 Refer to Operator Control section page 22 and set the controls per the following a PROCESS SELECTOR switch 4 to STICK position b Rotate the AMPERAGE control 1 to output current level desired c...

Страница 29: ...ity of electrodes in use the electrode is connected to the NEGATIVE output terminal 4 Wear dry insulating gloves and clothing 5 Connect TIG torch 6 Connect remote control device to 14 Pin receptacle N...

Страница 30: ...es 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 9 Turn on shielding gas 10...

Страница 31: ...t work clamp to clean bare metal on workpiece For the majority of electrodes in use the work clamp is connected to the NEGATIVE output terminal 5 Place the PROCESS SELECTOR switch 4 in MIG position 6...

Страница 32: ...SHIELDING GAS can impair health or kill Shut off gas supply when not in use Shutting Down 14 Stop welding 15 Move the PRIMARY POWER switch 18 to the OFF position 16 Turn off the shielding gas and wat...

Страница 33: ...ngsten 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...

Страница 34: ...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 In...

Страница 35: ...re 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 le...

Страница 36: ...pen conductor in input power line a Check continuity and replace if necessary F Red WARNING Indicator ON No Weld Output 1 Thermal sensor TH1 open thermal shutdown a Allow the unit to cool for five min...

Страница 37: ...Improper Weld Output 1 Loose welding cable connections a Tighten all welding cable connections 2 Improper setup a Check for proper connection of input power 3 Faulty Remote Device a Check all remote d...

Страница 38: ...y circuit breaker MCB3 Input to energize the solid state contactor 24 VAC contact closure is provided between Sockets A and B to energize the solid state contactor Amperage remote control MAXIMUM inpu...

Страница 39: ...ulse controls Amperage voltage remote control input command signal 10 volts for machine maximum Not used Solid state contactor remote control command signal 24 volts operates above 13 volts turns cont...

Страница 40: ...X 15 4 6m 14 Pin Male N A Extension Cables for Remote Controls Ext Cable 10 2030 X X 3 9m 14 Pin Male 14 Pin Female N A Ext Cable 10 2031 X X 15 4 6m 14 Pin Male 14 Pin Female N A Ext Cable 10 2032 X...

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

Страница 42: ...Drive E1 Black IGBT Gate Drive 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 The...

Страница 43: ...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...

Страница 44: ...ive 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 Thermal Detect Black Thermal D...

Страница 45: ...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...

Страница 46: ...T Gate 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 B...

Страница 47: ...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...

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