INVERTER ARC WELDER - Victor Technologies
Contents
1. HOT START WARNING POWER THERMAL Arc 130GTS LIFT START 6 Insert electrode into electrode holder 7 Wear welding helmet with proper filter lens according to ANSI 249 1 8 Place the PRIMARY POWER switch 13 to ON 9 Begin welding 17 OPERATION 2 2 SETUP FOR OPERATION Gas Tungsten Arc Welding GTAW High Frequency Lift Start A WARNING Read and follow all safety precautions on pages 2 3 of this manual before preceeding with operation 1 Install and connect unit according to the installation instructions in section 1 3 of this manual 2 Connect TIG torch to proper output receptacle 3 Select proper tungsten electrode refer to Electrode Selection Table 2 Page 22 4 Prepare tungsten electrode and insert into torch 5 Wear dry insulating gloves and clothing 6 Connect remote control device to 8 Pin receptacle 7 Connect work clamp to clean bare metal at workpiece 8 Refer to Operator Control section and set the controls per the following a PROCESS SELECTOR switch 5 to desired Gas Tungsten Arc Welding position LIFT or HF Start b Rotate the AMPERAGE control 1 to output current level desired STICK TIG E HOT START GWN SLOPE x2 WARNING B POWER 07o THERMAL Arc 130GTS 9 Turn on shielding gas 10 Wear welding helmet with proper filter lens according to ANSI ZA9 1 OPERATION 182. 11 Place the PRIMARY POWER switch 13 to 12 Activate remote control device NOTES a In LIFT TIG mode touch electrode to work and lift to start arc b In HF TIG mode high frequency will start followed by welding arc 13 Begin welding kill Shut off gas supply when not in use WARNING HIGH CONCENTRATION OF SHIELDING GAS can impair health or 19 OPERATION 2 2 SETUP FOR OPERATION Gas Tungsten Arc Welding Pulsed GTAW P Sloped GTAW S TIG Spot preceeding with operation WARNING Read and follow all safety precautions on pages 2 3 of this manual before 1 Install and connect unit according to the installation instructions in section 1 3 of this manual 2 Select proper tungsten electrode refer to Electrode Selection Table 2 Page 22 3 Prepare tungsten electrode and insert into torch 4 Wear dry insulating gloves and clothing 5 Connect remote control device to 8 Pin receptacle 6 Connect work clamp to clean bare metal at workpiece 7 Refer to Operator Control section and set the controls per the following I PROCESS SELECTOR switch 5 to desired gas tungsten arc welding position LIFT or HF TIG A PULSE TIG welding 1 PULSER SELECTOR switch 4 to desired frequency pulse of high or low 2 Rotate the AMPERAGE control 1 to desired output current level 3 Rotate PULSE FREQUENCY control 2 to desired frequency position B SLOPE TIG welding 1 SLOPER switch 3 t
3. 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 8 pin Receptacle Used for remote contactor and amperage controls Output Gas Fitting European Model Gas output fitting size 3 8 BSP for Monocable TIG Torch All other models have 5 8 18 unf female Figure 5a Operator Controls Front Panel 15 OPERATION 2 1 OPERATOR CONTROLS Positive Terminal 25mm DIN style female receptacle Negative Terminal 25mm DIN style female receptacle Primary Power Switch Placing the Primary Power Switch circuit breaker located on the rear panel to the ON position energizes the welding power source Input Cable 10 feet size 12 3 cable Input Gas Fitting The input gas connection is located on the bottom center of the rear panel European models have 3 8 BSP fitting all others have 5 8 18 unf female Hot Start Control The Hot Start Control operates in the STICK and HF TIG modes The Hot Start time is approximately 0 01 seconds in TIG and 0 06 seconds in STICK The current value is adjusted from 0 to 100 Amps over the determined weld current set by the Amperage Control Rotating the control clockwise increases Hot Start current Gas Solenoid The pre flow is fixed at 150 ms Post flow is automatically adjusted from 1 to 15 seconds by the position of the welding Am
4. Remote Hand Pendant Remote Foot Control Remote Contactor Control Remote Amperage Control To make connections align keyway insert plug and rotate threaded collar fully clockwise The socket information is included in the event the suplied cord is not suitable and it is necessary to wire a plug or cord to interface with the REMOTE 8 Pin receptacle 8 amp o Socket Function 1 Chassis common 2 Remote contactor control when contact closure is provided between sockets 2 and 3 GND 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 5 Amperage remote control MINIMUM C board common use as return for remote control inputs outputs 6 Amperage remote control MAXIMUM input command signal 4 volts for maximum 7 Remote amperage reference signal WIPER 0 volts to 4 volts peak current set by main rheostat 8 Remote amperage control when contact closure iS provided between sockets 4 and 8 SIGNAL Figure 6 REMOTE 8 Pin Connections APPENDIX 26
5. 7 Ib 8 5 kg 40 at 150 A 16 V 21 5A 4 5 KVA 2 8KV 25 at 120 25 27 0A 5 6KVA 3 5 KV 40 at 150 A 16 V 19 5A 4 5 KVA 2 8 25 at 120 25 27 0A 5 6KVA 3 5 KV 40 at 85 18 0A 2 1 KVA 1 3 25 at 85 A 23 V 32 0A 3 6 KVA 2 3 KV 40 at 150 A 16 V 25 0 5KVA 0 3 KV 25 at 120 A 25 V 25 0 5KVA 0 3 KV 40 at 150 A 16 V 20 0 5KVA 0 3 KV 25 at 120 A 25 V 1 0A 0 5 KVA 0 3 KV 40 at 85 A 13 V 1 0A 0 5 KVA 0 3 KV 25 at 85 A 23 V 1 0A 0 5 KVA 0 3 KV Model 190 GTS CC TIG 230V 115V 190 95 18 13 25 at 190 A 17 V 25 at 150 A 26V 40 at 95 A 14 V 25 at 95 A 24 V 5 190 5 95 10 28 64V 50 60 Hz 5 1 in 130mm 9 5 in 240mm 11 8 in 300mm 18 7 Ib 8 5 kg 40 at 150A 17V 29 0 A 6 0 3 8KV 25 at 150 A 26 V 35 0A 7 3 KVA 3 5 KV 40 at 150A 17V 26 0A 6 0KVA 2 8KV 25 150 A 26 V 32 0A 7 3KVA 4 6KV 40 at 85 A 14 V 21 5A 2 5 1 6KV 25 at95 A 24 V 37 0A 4 2 KVA 2 7 KV 40 at 150 A 17 V 25 0 5KVA 0 3 KV 25 at 150 A 26 V 25 0 5KVA 0 3 40 at 150 A17 V 1 0A 0 5 KVA 0 3 KV 25 at 150 A 26 V 1 0A 0 5 KVA 0 3 KV 40 at 85 A 14 V 1 0A 0 5 KVA 0 3 KV 25 at 95 A 24 V 1 0A 0 5 KVA 0 3 KV 1 2 TRANSPORTING METHODS These units are equipped with one handle and a shoulder strap for carrying purposes A WARNING ELE
6. too high a Reduce flow rate 4 Drafts blowing shielding gas away from tungsten electrode a Shield weld zone from drafts 5 Loose gas fitting on regulator or gas line drawing air into weld zone a Check and tighten all gas fittings 6 Water in torch a Refer to torch parts list in Service Manual for part s requiring replacement and repair torch as necessary E No high frequency 1 PROCESS SELECTOR switch is not in the HF TIG position a Place switch in HF TIG position 2 Drafts blowing shielding gas away from tungsten electrode a Shield weld zone from drafts 3 Insufficient postflow time a Increase postflow time 4 Loose gas fitting on regulator or gas line drawing air into weld zone a Check and tighten all gas fittings 5 Water in torch a Refer to torch parts list in Service Manual for part s requiring replacement and repair torch as necessary 6 Tungsten condition is poor a Replace electrode F Lack of high frequency difficulty in establishing an arc 1 Dissipation of high frequency from torch cable or conductive gas hose a Be sure that the torch cable is not near any grounded metal Do not use conductive gas hose 2 Weld cable leakage a Check cables and torch fro cracked or deteriorated insulation or bad connections Repair or replace necessary parts 25 OPERATION 2 4 REMOTE 8 PIN CONNECTIONS The REMOTE 8 Pin receptable is used to connect any of the following equipment to the welding power source circuitry
7. 0 1 0 2 0 3 0 2 4 0 2 4 0 23 OPERATION 2 3 OPERATION TROUBLESHOOTING General WARNING Troubleshooting and repairing 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 train Basic Troubleshooting NOTE How to Use This Guide Specific Problems OPERATION ing in power electronics measurement and troubleshooting techniques This manual covers a basic level of troubleshooting that requires limited disassembly 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 sevice center for repair Follow all instructions as listed and complete each section in the order presented For major troubleshooting and parts replacement procedures please refer to the appropriate Inverter Arc Welder Service Manual Model 130GTS CC TIG Service Manual 0 2493 Model 150GTS CC TIG Service Manual 0 2493 Model 190GTS CC TIG Service Manual 0 2493 The following information is a guide to help you determine the most likely causes for various symptoms This guide is set up in the following manner A Symptom Bold Type Any special instructions Text Type 1 Cause Itali
8. 0 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOMMENDED 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 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 INTRODUCTION 6 DECLARATION OF CO ATE OR I Manufacturer Thermal Dynamics Corporation Address Industrial Park 2 West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EU as recently changed in Directive 93 63 EU and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the Directive European Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are CSA Canadian Standards Association stan
9. CTRIC SHOCK can kill DO NOT TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving welding power source damage WARNING FALLING EQUIPMENT can cause serious personal injury and equipment e Lift unit with handle or shoulder strap on top of case 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 a built in handle and shoulder strap on top of case for lifting Be sure unit is lifted and transported safely and securly 11 OPERATION 1 3 ELECTRICAL INPUT CONNECTIONS ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present afte removal of input power T WARNING Electrical Input Requirements OPERATION NOTE DO NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures wait 60 80 seconds and measure voltage on input capacitors according to instruction manual before touching any parts 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 Operate the welding power source from a single phase 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
10. IHERMAL ARC A THERMADYNE Company INVERTER ARC WELDER MODEL 130 150 190 GTS CC TIG e STICK e TIG HIGH FREQUENCY LIFT START Operating Manual February 15 1996 Manual No 0 2491 TABLE OF CONTENTS Introduction Notes Cautions and Warnings eese 2 Important Safety Precautions sese 3 Publications nain ette Hemp Dee terae 6 Declaration of Conformity essen 7 Statement of Warranty i eie tbe eere ete ret cines 8 General Information 1 1 Specificationsz a use eee bere er P D n d den 9 Operation 1 2 Transporting Methods sees 11 1 3 Electrical Input Connections esee 12 2 1 Operator Controls nce eerie tete db 15 2 2 Setup For Operation eee heretice tts 17 2 3 Operation Troubleshooting eene 24 Appendix 3 0 Remote 8 Pin Connections esee 26 Thermal Arc Model 130GTS CC TIG Model 150GTS CC TIG and Model 190GTS CC TIG Inverter Arc Welders Instruction Manual Number 0 2491 Published by Thermal Dynamics Corporation Industrial Park 2 West Lebanon New Hampshire USA 03784 Copyright 1995 Thermal Dynamics Corporation rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited While the information contained in this instruction manual represents our best judgement Thermal Dynamics Cor
11. S Model 150GTS Model 190GTS 208 230 VAC 30 30 40 115 VAC 25 25 30 NOTE Continuous output on 115VAC 20 Amp circuit breaker for fuse 92 Amps 13 Vdc TIG 51 Amps 23 Vdc Stick 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 Table 2 Electrode Selection Table Electrode Diameter Amperage Range DC Argon Electrode DC Argon Electrode Negative Straight Polarity Positive ReversePolarity Pure Tungsten Green Band 0 010in 0 25mm 1 15 0 020in 0 51mm 5 20 0 040 in 1 02mm 15 80 1 16in 1 59mm 70 150 10 20 3 32 in 2 38mm 125 225 15 20 1 8in 3 18mm 225 360 25 40 5 32 in 3 97mm 360 450 40 55 3 16 in 4 76mm 450 720 55 80 1 4 in 6 35mm 720 950 80 125 2 Thorium Alloyed Tungsten Red Band 0 010 in 0 25mm 1 25 0 020 in 0 51mm 15 40 0 040 in 1 02mm 25 85 1 16in 1 59mm 50 160 10 20 3 32 in 2 38 135 235 15 30 1 8in 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 OPERATION 22 Table 3 Weld Cable Size Maximum Total Cable Length in Weld Circuit Under 30m 45m 60m 70m 90m 105m 120m Duty 1006076 601002 1919 Welding Amperes 100 4 4 4 1 0 1 0 150 3 3 2 3 0 3 0 200 3 2 1 4 0 4 0 250 2 1 1 0 2 2 0 2 2 0 300 1 1 0 2 0 2 3 0 2 3 0 40
12. c Type a Check Remedy Text Type Locate your symptom check the cause s the simplest or most likely is listed first then perform the remedy given Repair as needed being sure to verify that the unit is fully operational after any repairs 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 1 3 Electrical Input Requirements for proper input connections 4 PRIMARY POWER switch Main Circuit Breaker in OFF position a Check and reset Main Circuit Breaker if necessary 24 2 3 OPERATION TROUBLESHOOTING B WARNING indicator is ON 1 Unit is in thermal shutdown mode a Allow cooling period of approximately five 5 minutes 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 3 Page 23 3 Improper input connections a Refer to Section 1 3 Electrical Input Requirements 4 Poor electrode condition a Replace electrode D Wandering arc poor control of arc direction 1 Wrong size tungsten electrode typically larger than recommended a Use proper size electrode for amperage selected see Table 2 Page 22 2 Improperly prepared tungsten electrode a Prepare tungsten properly 3 Gas flow rate
13. dard 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 EC 974 1 BS 638 PT10 EN 60 974 1 applicable to welding equipment and associated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process to ensure the product is safe and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermal Dynamics 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 Manufacturers responsible representative David Ashworth Vice President amp Managing Director Thermadyne Europe C 4 Chorley England 7 INTRODUCTION STATEMENT OF WARRANTY LIMITED WARRANTY Thermal Dynamics Corporation hereinafter Thermal warrants that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below Thermal shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal s spec
14. ds Institute 1430 Broadway New York NY 10018 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 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 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 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 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 190
15. epair facility shall be the responsibility of the customer returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal warranties Thermal Axc is a Registered Trademark of ThermapDynamics Effective January 18 1991 INFORMATION 1 1 SPECIFICATIONS Description The Thermal Arc Model 130GTS Model 150GTS and Model 190GTS are single phase DC arc welding power sources with Constant Current CC output charactaeristics Each unit is equipped with a gas control solenoid lift start TIG and high frequency arc starter for use with Gas Tungsten Arc Welding GTAW These units are designed for use with Shielded Metal Arc Welding SMAW Gas Tungsten Arc Welding Lift Start GTAW LS and Gas Tungsten Arc Welding Pulsed GTAW P Sloped GTAW S processes Arc Characteristics CURRENT Control 1 1 n 5 130 00032 5 Figure 1 Model 130 GTS CC TIG Volt Ampere Curves Arc Characteristics CURRENT Control I I 5 150 A 00032 AMPS Figure 2 Model 150 GTS CC TIG Volt Ampere Curves Arc Characteristics CURRENT Control 5 A 00032 AMPS Figure 3 Model 190 GTS CC TIG Volt Ampere Curves NOTE Volt Ampere curves show the voltage and Amperage output capabilities of the welding power source Curves of other settings will fall between the curves shown 9 GENERAL INFORMATION 1 1 SPECIFICATIONS Parameter Model Rated Output Amper
16. es Volts Duty Cycle 230 V Input 9 115 V Input Range Min Max Amperes 9 230 V Input 9 115 V Input Volts Over Current Voltage Maximum OCV Input Data Dimensions Weight Width Height Length Weight with Cable Output At Rated Load Input data 50 60 Hz Duty Cycle 208 VAC 1 Phase 230 VAC 1 Phase 115 VAC 1 Phase Output At No Load Input data 50 60 Hz Duty Cycle 208 VAC 1 Phase 230 VAC 1 Phase 115 VAC 1 Phase Model 130 GTS CC TIG 230V 115V 130 85 15 13 40 at 130 A 15 V 25 at 100 A 25 V 40 at 85 A 13 V 25 at 85 A 23 V 5 130 5 85 10 25 64V 64V 50 60 Hz 50 60 Hz 5 1 in 130mm 9 5in balana 11 8 in 300mm 18 7 Ib 8 5 kg 40 at 130 A 15 V 17 5A 3 6KVA 2 3KV 25 at 100 A 24 V 21 5A 4 5 KVA 2 8KV 40 at 130 A 15 V 16 0A 3 6 KVA 2 3KV 25 at 100 A 24 V 19 5A 4 5KVA 2 8KV 40 at 85 A 13 V 18 0A 2 1 KVA 1 3KV 25 at 85 A 23 V 32 0A 3 6 KVA 2 3 KV 40 at 130 A 15 V 25A 0 5KVA 0 3 25 at 100 A 24 V 25A 0 5KVA 0 3 40 at 130 A 15 V 20 0 5 0 3KV 25 at 100 A 24 V 20 0 5 0 3 40 at 85 A 13 V 1 0A 0 5KVA 0 3 KV 25 at 85 A 23 V 1 0A 0 5 KVA 0 3 KV GENERAL INFORMATION 10 Model 150 GTS CC TIG 230V 115V 150 85 16 18 40 at 150 A 16 V 25 at 200 A 25 V 40 at 85 A 13 V 25 at 85 A 23 V 5 150 5 85 10 26 5 1 in 130mm 9 5in bla 11 8 in 300mm 18
17. f the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code see page iv item 9 Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operators Manual Fire and Explosions can be caused by hot slag sparks or the plasma arc The plasma arc process produces hot sparks slag and metal which can ignite combustible material or cause flammable vapors to explode Be sure there is 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 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 burn your skin if you are not properly 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
18. frequency The two scales surrounding the control represent approximate actual values The pulse frequency is adjustable from 0 5 to 25 Hz in LOW and 10 to 500 Hz in HIGH Sloper Switch When in the OFF position the Sloper is inactive Selecting the ON position activates the Sloper Selecting the SPOT position activates the spot welding timer The Slope sequence and spot modes are activated by a remote ON OFFswitch connected to the 8 pin receptacle See the section on Slope sequence Pulser Switch When in the OFF position the Pulser is inactive Selecting H HIGH or L LOW will activate the TIG pulser The Pulse Frequency can be adjusted by the Pulse Frequency control Pulse width is fixed at 50 Background current is fixed at 1 5th of the peak current Process Selector Switch The Process Selector Switch allows the operator to select the STICK welding SMAW process LIFT TIG GTAW or HF TIG GTAW process Spot Time Up Down Slope Control This control provides Spot Up and Down slope time control Rotating the control clockwise increases the time The scale surrounding the control represents approximate actual values The Spot and Up slope time is adjustable from 0 5 to 5 seconds The Down slope time is twice the Up slope time at 0 5 to 10 seconds 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
19. ifications instructions recommen dations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal s sole option of any components or parts of the product determined by Thermal to be defective THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal whether arising out of contract negligence 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 warra
20. nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or sevice the unit These units are equipped with a two conductor with earth power cable that is connected at the welding power source end for single phase electrical input power Do not connect an input conductor to the ground terminal European models have brown line 1 and blue line 2 conductors all others have white line 2 and black line 1 Do not connect the ground conductor to an input line terminal European models have yellow green ground conductor all others have green Refer to Figure 4 and 1 Connect end of ground conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 and line 2 input conductors to a de energized line disconnect switch W Use Table 1 on Page 20 as a guide to select line fuses for the disconnect switch 12 Earth Conductor Ground Terminal Line Fuse Disconnect Switch Line 1 Line 2 Ground Primary Power Cable Welding Power Supply a Figure 4 Electrical Input Connections 13 OPERATION Voltage Selection OPERATION The inp
21. nty periods for Thermal products shall be as follows A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of sale by such distributor to the Purchaser and with the following further limitations on such two 2 year period PAK UNITS POWER SUPPLIES PARTS LABOR MAIN POWER MAGNETICS sse 2 YEARS 1 YEAR ORIGINAL MAIN POWER RECTIFIER 2 YEARS 1 YEAR CONTROL PC BOARD eene 2 YEARS 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS TILAR uen 1 YEAR INCLUDING BUT NOT LIMITED TO STARTING CIRCUIT CONTACTORS RELAYS SOLENOIDS PUMPS POWER SWITCHING SEMI CONDUCTORS CONSOLES CONTROL EQUIPMENT HEAT 1 YEAR 1YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS eme 180 DAYS 180 DAYS REPAIR REPLACEMENT 90 90 DAYS 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 Transportation charges to send products to an authorized warranty r
22. o SLOPE position 2 Rotate AMPERAGE control 1 to desire welding current level 3 Rotate SPOT TIME UP DOWN SLOPE control 6 to desired UP DOWN slope time NOTE Use a remote ON OFF switch to control SLOPE sequence See Operator Control section page 15 C SPOT TIG welding 1 SLOPER switch 3 to SPOT position 2 Rotate AMPERAGE control 1 to desired spot welding current level 3 Rotate SPOT TIME UP DOWN SLOPE control 6 to desired SPOT welding time OPERATION 20 2 2 SETUP FOR OPERATION NOTES N WARNING STICK TIG HOT START PE SPOT TIME DOWN SLOPE x2 WARNING B POWER THERMAL Arc 130GTS 8 Turn on shielding gas and water supplies as applicable 9 Wear welding helmet with proper filter lens according to ANSI 7491 10 Place the PRIMARY POWER switch 13 to ON 11 Activate remote control device a In LIFT TIG mode touch electrode to work and lift to start arc b In HF TIG mode high frequency will start followed by welding arc 12 Begin welding HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill Shut off gas supply when not in use Shutting Down 13 Stop welding 14 Move the PRIMARY POWER switch 13 to the OFF position 15 Turn off the shielding gas and water supplies if applicable 21 OPERATION Table 1 Fuse Size Selection Input Power Input Voltage Fuse Size Amperes Single Phase Model 130GT
23. or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as recommended in the operators manual IMPORTANT SAFETY PRECAUTIONS CONTINUED NOISE Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For information on how to test for noise see item 1 page 6 5 INTRODUCTION PUBLICATIONS Refer to the following standards or their latest revisions for more information 1 10 11 12 13 14 15 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standar
24. perage Control ol Sloper Sequence A Remote ON OFF switch closed Pre flow starts to flow In HF TIG mode HF and initial current is present after pre flow In LIFT TIG mode HF is not present Initial current is 1 5th of the welding current IMARY CABLE e Ng B Remote ON OFF switch opened Current increases to welding current at the rate set by the UP DOWN Slope control Welding current is set by the Amperage Control C Remote ON OFF switch closed Current decreases to final current at twice the rate set for UP Slope Final current is 1 5th of welding current D Remote ON OFF switch opened Arc shuts off and post flow time initiated GAS INPUT Figure 5b Operator Controls Rear Panel OPERATION 16 2 2 SETUP FOR OPERATION Shielded Metal Arc Welding SMAW preceeding with operation WARNING Read and follow all safety precautions on pages 2 3 of this manual before 1 Install and connect unit according to the installation instructions in section 1 3 of this manual 2 Wear dry insulating gloves and clothing 3 Connect work clamp to clean bare metal at workpiece 4 Select propor electrode 5 Refer to Operator Control section 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 STICK TIG UP SLOPE SP DOWN SLOPE x2 ws
25. poration assumes no liability for its use 1 INTRODUCTION 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 A procedure which if not properly followed may cause damage to the equipment operator or others in the operating area A WARNING procedure which if not properly followed may cause injury to the INTRODUCTION 2 WARNING IMPORTANT SAFETY PRECAUTIONS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH Operators and personnel should be alerted to ALL possible hazards To prevent possible injury read understand and follow all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions FUMES and GASES amp Fumes and Gases produced from the plasma process can be dangerous and hazardous to your health Keep all fumes and gases from your breathing area Keep your head out of the welding fume plume Use an air supplied respirator if available ventilation cannot remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coating
26. s 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 MSDS s will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 and related publictions on page 6 Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where combustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors 3 INTRODUCTION IMPORTANT SAFETY PRECUATIONS CONTINUED ELECRTIC SHOCK A FIRE AND EXPLOSION PLASMA ARC RAYS INTRODUCTION 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 Never touch any parts that are electrically live or hot wear dry gloves and clothing Insulate yourself from the work piece or other parts o
27. ut voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate This power source incorporates a control circuit which automatically links the power source to the primary input voltage and adjusts it to allow for operation of the unit within the input rating on the input data tag It is not necessary to manually switch terminals or links if the unit is moved to a new location and a different input power is selected The surge current prevention circuit becomes activated when the PRIMARY POWER switch is turned ON About two seconds after power on the control circuit detects the input voltage and automatically selects the correct circuits for operation The welding power source is ready for operation within five seconds after power is turned on 14 2 1 OPERATOR CONTROLS NA J SCT HOT START APOT TIME GOWN SLOPE x2 a iN European Models 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 Pulse Frequency Control The Pulse Frequency control provides a means of selecting the pulse frequency when the Pulse switch is in the H HIGH or L LOW position Rotating the control clockwise increases the pulse
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