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thermal arc inc., troy, ohio 45373-1085, usa

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3. 5 1 High Frequency Considerations 5 1 MAINTENANCE 6 Lubri ation ix she ape mm BUR oap x oe e on Lt e 6 1 Inspection and Cleaning 6 1 TROUBLESHOOTING 7 PARTS LIST 8 Equipment Identification 8 1 How To Use This Parts 8 1 DIAGRAMS December 1 1997 Revised 430429 125 INTRODUCTION INTRODUCTION How To Use This Manual This Owners Manual usually applies to just the underlined specification or part numbers listed on the cover If none are underlined they are all cov ered by this manual To ensure safe operation read the entire manual including the chapter on Safety Instructions and Warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily rec ognized as follows WARNING gives information re garding possible personal in jury Warnings will be enclosed in a box such as this CAUTION refers to possible equipment damage Cautions will be shown in bold type NOTE offers helpful information concerning certain operating procedures Notes will be shown in italics Equipment Identification The unit s identification number specification or part number model and serial numb
4. H 18 5 2 A 15345 3SIMH SS3INN wes 1195808 EXER SAH O0 2H 11155 39VllOA RERO GOD SENI ROBES Lms s 7 195985 i ECCO QE m OS ALULNVOO neu 032v143uU 2 914 17914 51104 005 G XUVH OL S110A 566 Q3NuVW TvNIWE31 OL ans cE 3 14 1330009 38 14 6 123NNO2 ON 55322 3NON 3A1L9310bd NNOD 5801123 02 225050 aras a 1041405 4 1 1941105 1 3384 Y0 amp a LD 31 15 89 AD 301 311H4 1M 3339 TEL T 371d4NA 13701A 1 18 5 NYL NL NHOSS 374722 X2v18 xat _ jt 775 3002 80109 oO Q3 4VW 13NVd NOLU3INI NO M3N2S 01 H31SAS YIMOd 123NNO2 ANIT ONITONVH 380438 340 51 1102812 NIVINJ 38 NOIINVI TIVANVW 30 1235 4NOLIVITAVISN 350 5151 3 53002 ON 31 30 31V1d3WVN NC NMOHS 1N388NI 304 3215 381M 3 11 334034 303 53003 19507 YNOA 923H9 39V110A 3NI1 333034 PHL 404 318V2lddV SV 1
5. ot z t 1 qua plomo M VAS ay jo order oq v pur ONO lai ner DES 23 DRE a PE d ry ava emu uius m Ria OvM3M2S mvs9YiO EA c i mm loses om e om RARE MEERN 42 2 HE 2 n MOLIVALNOO 30v110A Wine Tant pA MN HOLIMS 2061409 3504 BOLIVINOI 1 es is 41015 ti ISVALEZJNI amp 3 04 0 214340 IWEISOHMIKI 95 8 3i0d3t 1WOC 3061829 3212WiNC2 TKILEMS 55 281802 1 H211AS PONYIN BONNE MOIS 25 430 k0 H211 165140 001901909 10 15 1 1 7584 50 X27 13041802 14015152 Soin 5 SWO IS 01 54 SAN Pec 004 802 313 011 3106 MININ iive Duy ani 104 tu 3971004 335 fiw was 7590 OS OVEN 7 304244502 Nie 9 0261822 310933 23725142934 Ale Sevag 7274 13999109390 ar SU 7276 302r 302 ir 2 dM 7
6. BEAM Pw m rra m Der Q wvuovia IHON 1014 1169 OVA MOLOVINOO su BUVLIOA 154 33 310343 1907 l XS ES EEG ILIMS ki i 0199109 MOLDVINOO 4 i as azz is Jro 940 ex us i 1 1081802 95 1041 03 L I t 1835402 H 5 2215 i aum i ___ A sna PR EE M 1 Sx vx 95 i us mal M3NHOJSNVUL L ISVHANIINI i re 1001002 32404 v i i H 81815 Vis a H i 3 ve3b31NI 5 zi i 324025981 u t 2 X u 911 95 49 i 80016340 58 BOLW3U 1314 31033 39291 101802 801271109 HJ IMS 5 i 310435214201 19519402 1538575 HILIMS 5 i AOT HDIH HILIAS 15 H 430 0 HOLIMS 19 NOI WOLIVINOD 1 is Si SHHO 005 2 144280 39v 304 780151538 6 81 ALYA 2 1 Su Q 9975 IOBINCI 80151538 na H S11VM S SHHO OS 30 51533 01 5 INAS 4 Z WhO 5 1031409 1N38822 313 0 83104 fu L XS JEW gt 83439 11 31 09 zu d3A039NVM2 11v 501 O 051 346 580151534 ta 39V110 335 S
7. insi Y 0 __ AVES 45 ETI IYYOIA IA Nil ___ on _______8005 80702 __ _______ Su vwW3H5S VIG NOIL23NNO2 35unos 10684 IS 0 2 a vo8 24 01 8 1545 319901 211 5 08 804 ML WHO 5005 831301183104 Nunl HHO XS u313H0118N310d Nid 11 YOL93NNOD Nid S 30N3HdMY YOLI3NNOD Nid 01 3ON3HdHY UO123NNO2 9N1411H3 1H511 30010 STATEMENT OF WARRANTY LIMITED WARRANTY Thermal Thermadyne Company warrants that its products will be free of defects workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations 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 Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF
8. NES Figure 8 2 and Lifting Yoke Group 8 4 December 1 1997 Revised 430429 125 6 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty No Number per Assy 1 12CW 2170 Grommet Top 1 2 403091 4 Plug Hole Plastic 8 3 369652 Panel Top 1 4 369651 Panel Sides 2 5 369683 Panel Rear 1 6 369650 Shroud Fan 1 7 8RT 609 Blade Fan 1 8 12TW 595 1 Motor Fan 1 9 369640 Bracket Motor 2 10 369653 Base Assembly 1 369638 3 Rectifier Output Assembly 1 11 369639 Heat Sink Rect 1 12 367634 3 Suppressor Surge Assembly 2 13 405157 Label Fuse 1 14 404044 3 Thermostat Overload 1 15 369642 Heat Sink SCR 6 16 405139 Rectifier Silicon 6 17 16DA 954 12 Spring 6 18 405140 1 Clamp Mounting 6 19 367732 Shunt 1 20 369641 Insulator Mtg Rect 2 21 369703 Bar Bus Output Term to Shunt 1 22 200155 Thermostat Fan Turn On Optional 1 200157 Kit Cover OSHA Optional 1 23 200280 Cover 1 369826 Kit Side Panel W Access Door Optional 1 24 369827 Panel Side 1 25 369210 Door Access 1 26 200297 Transformer Power 1 27 200770 Brace V C Board 2 28 405129 1 Block Fuse 1 29 367170 5 Board V C Assembly 1 30 CW 811 Link Voltage Changeover 6 31 368084 5 Transformer Interface 1 32 367718 2 Reactor Filter 1 33 367579 Insulator Fuse Block 1 34 W 11166 9 Fuse 1 Amp 6 369630 5 Yoke Lifting Assembly 1 35 369631 Yoke
9. Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders asso ciated equipment and CGA publication P 1 listed in Safety Standards ENGINES can be hazardous 1 2 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes 2 2 May 8 1996 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning jo
10. 1281802 ISAI us 1083 CUYOS 1081503 3504 l 84 SISVHA TW nes 73503 WAOE 009 H OOP U T JVAO I OOf M OO2 M 1 3 139 Cs E gt WON 059 21 3 40 4 BOLI INET eu 77044 142 80156249445 WOLLJVAVI 5 15 V3AUO4SMYML 3 3404 T LI 34 repe Pos Serena t veo ay ta dec FUMIO ism maj AT PAQ WAWMOSSNVUL ASVHAHILNI HOLIMS 39NVH MOT HILIME 72081409 HOLIVINOD n a C HILIMS 5 9 ex HOLIMS 2 5 3504 40199105 Anant 9 __ 3304 0 1217 30 til 1M Lj NO Q31NnON 4 2014 ma s tal 3015 1431 08906 HOSS3Hdd S 9NIOV 5 5 w x o le FE WVHDVIO N3AO39NYHO 39v170A 335 3015 1331 92018 ISNI ONIDWS uod BL apaya Somo poene B prunpesdes va B ou PEP AVE reams jrywepynee pus naase TWLINIOINOD d
11. 30 1 1 1 9NI2v4 NOLOYiNOO YOLIVINOD vus 4 T T e M Ta i JI1VN3HOS JINVA H3A039NVHO 39V110A 9 A ANUT 2SVHA 39 L10NONIJVS Lee an Es a OP Nr Wi i Mm 9 L OLOY OM 8 ppm 22552 22000 J od 20 UI 04 jou pue 220008 5 Apedoid uspajawi 2 Dcum del dos 00 LE _______ ___ ____ v Y M H3AOSONVHO SOVLIOA MVEOVIO suu on men pe esu 7 Aus wes 9 8 f 4 55345 18 22 3 92900 assvuxan sivo xsow oN S110A OFZ Q3 xuvW 1VNIWN31 01 38 14 123NNO2 NOT123NNOD W3WHO4SNYUl 1044405 S110A S6t Q3 uvW TVNIWE31 OL 38 14 656 123NNOJ SNO1123NNO2 5 7031802 1104 09 IVNIWNAL 01 38 14 123802 1 SNO1123NNO2 M3
12. Figure 7 2 To Calibrate Force Gauge force Loosen both nuts and start over Never adjust force by back ing off the nuts Friction will produce a false reading Al ways start from Step 1 Ifthe gauge is suspected of being out of calibration due to wear or damage check it on a flat surface as shown below True flat surface or straight edge If the calibration edges do not line up calibrate the gauge by filing the bottom contact points Figure 7 4 7 6 December 1 1997 Revised 430429 125 TROUBLESHOOTING Detailed Setting and Troubleshooting of Printed Circuit Board PC Board 369511 Test Points There are several test points on the PC Board which will aid in determining if the defect is in the board First be certain that all the wiring to the board is in good shape and input leads X1 X3 are in place The voltage checks shown in Table 7 2 should be made in sequence 4 5 6 7 9 10 11 21 12 13 20 19 18 17 16 15 Figure 7 5 Printed Circuit Board Test Test Points Voltage Conditions Remarks 1 6 TP4 to or 11 8 16 15 V DC 596 Open circuit Checks output of regulator 2 7 TP5 to TP6 or 11 8 16 15 V DC 5 Open circuit Checks output of regulator 3 3 TP2 to TP6 or 11 8 or 16 22 V DC 10 Open circuit Checks solid state contactor control 4 4 to TP6 or 11 8 or 16 9
13. m gt PU NOLLO23NNO2 49 AT An AT p 3513 dws p AOS NOWWOD 2 8 NM a 09 03103NNOO NMOHS 9NI5Y3 1041402 RO 7300 170A OFZ SNOMLJINNOD 13NVd es basg 39VLIOA gt o o wi lt 2 mio HIWNOJSNVUL rit U3MOd olx 30 SIIBVWIHA 2 TA c 5 215 JUS ME A o LINN JO 5 2 9NI2V4 1 ES ERN d HOLOV1NOO YOLOVINOS d i MOTI3A 39NvuO 89 annoys E 5 8 0113 6b 1NOM4 WOH4 73NVd H3AO39NVHO B9VLIOA ONIYI 3SvHd DILVW3HOS ININ 3SvHd gt ESNHOJSNVEI 70H1N09 AOZZ A00Z 3NI13SvHd 3A08 HVUDVIO NI SY TIWANVW 3H1 30 011235 31V1d3HVN NMOHS C 3N11 ONIIONVH 380438 N340 SI 1 8012Y1N02 830138 30 401 WNOLIVIIVISNI 2 JHL ISN 15 5 EL M07113A 39NYHO Sb 3NON 3411031084 0Nn0u5 73NVd 40149141 NO M3UJS 3H 01 ONNOYI W31SAS W3MOd 123NNO0 102812 1NdNI WIv1U3 38 10ny2 O1 04 3SYHd f 1238029 151 3 3002 ON 31 803 3215 3UIM 3NI 334084 04 53002 1 AOA 2 OL
14. 430429 125 2 PARTS LIST EW Nw lt NES 7 Figure 8 2 and Lifting Yoke Group 8 4 December 1 1997 Revised 430429 125 2 PARTS LIST Parts List for Figure 8 2 Item No 11 12 13 14 15 16 18 19 Part Number 12CW 2170 403091 4 369652 369652 1 369651 369651 1 369683 369683 1 369650 369650 1 8RT 609 12TW 595 1 369640 369640 1 369653 369653 1 369638 2 369638 12 369639 367634 3 405157 404044 1 369642 405139 405140 1 16DA 954 12 367687 201073 369641 369703 Not Illustrated Description Grommet Top Plug Hole Plastic Panel Top Panel Top Panel Sides Panel Sides Panel Rear Panel Rear Shroud Fan Shroud Fan Blade Fan Motor Fan Bracket Motor Bracket Motor Base Mounting Assembly Base Mounting Assembly Rectifier Output Assembly Rectifier Output Assembly Heat Sink Rect Suppressor Surge Assembly Label Fuse Thermostat Overload Heat Sink SCR Rectifier Silicon Clamp Mounting Pin Spring Shunt Shunt Insulator Mtg Rect Bar Bus Output Term to Shunt Qty Application per Code Assy 1 8 1 ND All All ABCD EFGH JK ABCD EFGH JK ABCD EFGH JK ABCD EFGH JK All All ABCD EFGH JK ABCD EFGH JK ABCD EFJK GH All All All All All
15. All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed exceptfor commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded to another part The part descriptions may be indented to show part relationships Todetermine the part number description quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item inthe Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manu
16. Resistor 1 2 Watt Assembly 1 All 26 405365 2 Switch Toggle SPDT 2 All 27 400758 Receptacle 6 Pin Amphenol 1 All 28 401937 5 Block Terminal 1 All 402037 8 Grommet Rubber 1 All 402037 13 Grommet Rubber 1 All Illustrated December 1 1997 Revised 8 3 430429 125 1 PARTS LIST Figure 8 2 Base and Lifting Yoke Group December 1 1997 Revised 8 4 430429 125 1 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 1 12CW 2170 Grommet Top 1 All 2 403091 4 Plug Hole Plastic 8 All 3 369652 Panel Top 1 All 4 369651 Panel Sides 2 All 5 369683 Panel Rear 1 6 369650 Shroud Fan 1 All 7 8RT 609 Blade Fan 1 All 8 12TW 595 1 Motor Fan 1 All 9 369640 Bracket Motor 2 All 10 369653 Base Mounting Assembly 1 All 369638 1 Rectifier Output Assembly 1 ABCDEF 369638 1 1 Rectifier Output Assembly 1 GH 11 369639 Heat Sink Rect 1 All 12 367634A 3 Suppressor Surge Assembly 2 All 405157 Label Fuse 1 All 13 404044 1 Thermostat Overload 1 14 369642 Heat Sink SCR 6 All 15 405139 Rectifier Silicon 6 All 16 405140 1 Clamp Mounting 6 All 16DA 954 12 Spring 6 All 17 367731 Shunt 1 ABCDEF 201072 Shunt 1 GH 18 369641 Insulator Mtg Rect 2 All 19 369703 Bar Bus Output Term to Shunt 1 20 200155 Thermostat Fan Turn On Opti
17. Rubber tire mounted equipment shall be grounded to conform to local and national codes The grounding assists in provide protection against line voltage electrical shock and static shock The grounding serves to discharge the static electric charge which tends to build up on rubber tire mounted equipment This static charge can cause painful shock and lead to the erroneous conclusion that an electrical fault exists in the equipment December 1 1997 Revised 4 1 430429 125 INSTALLATION 20 30 Ibs 9 1 13 6 kg Soil Treating Material copper sulphate magnesium sulphate or rock salt placed in circular trench and covered with earth INI MANI AIS Approx Ft 305 mm 18 Inches 457 mm Not less than 8 Ft 2438 mm Approx Ground T a Grounding Conductor asten Grounding Conductor to the rod with an approved ground clamp 6 Inches 152 mm Approx Fasten Grounding Conductor Grounding to the rod with an approved Conductor ground clamp Removable Not less than B Ft 2438 mm Soil Figure 4 1 If a system ground is not available consult the electrical code enforcement body for instructions The welding machine should be connected to an adequate driven ground rod or to a water pipe that enters the ground not more than 10 feet 30 meters from the machine The equipment grounding conductor size is listed in Table 4 2
18. The Mega Arc machines are solid state welding machines The method of troubleshooting is differ ent but is not more difficult than troubleshooting a conventional unit Do not overlook the obvious As the case of all electrical equipment loose connec tions are the primary cause of malfunction both internal and external to the power source Do not overlook bad grounds shorted control cables wrong settings blown fuses worn contactors mis connections from auxiliary equipment misapplica tions etc The only equipment needed to properly detect a problem on this power source is a simple voltohmmeter although an oscilloscope is the best method to quickly see the problem Voltages Refer to Diagram 1 Across the secondary on all three phases 120 V AC 10 200 5 R 300 S 130 V 10 R 400 S R 500 S R 600 S 2 From the center bus bar on secondaries to the top or bottom of the secondary 60 V AC 10 R 200 S R 300 S 65 V AC 10 R 400 S 500 R 600 S 3 X4 X5 on B phase 115 V AC 10 4 Control transformer 115 V AC 10 See Volt age Changeover Diagram 5 X1 X3 on fuse block 33 V AC 10 6 X1 X2 and X2 to from fuse block to output rectifier 16 5 V AC 10 NOTE The 10 value indicates the pos sibility of having a high or low voltage on the input line Symptoms PC Board Failure If a board failure occurs the following situations will probably happen 1 Loss of weldi
19. WARNING Disconnect line volt age from the unit before attempt ing any servicing inside unit Turn off fused disconnect switch that supplies power to welding machine and remove its fuses CAUTION The flow of air through the welding machine is carefully directed by baffles Never operate the welding ma chine with any of the side or top panels removed or open as serious damage to the rectifiers might result December 1 1997 Revised 6 1 430429 125 MAINTENANCE This page intentionally left blank 6 2 December 1 1997 Revised 430429 125 TROUBLESHOOTING TROUBLESHOOTING The following chart contains information which can be used to diagnose and correct unsatisfactory operation or failure of various components of the welding machine Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem In addition to the chart detailed instructions for checking and adjusting and or setting components on the Printed Circuit Board and SCRs are given Troubleshooting Guide Welding machine will not start Power switch OFF Place power switch in ON position Power lines dead Check voltage Broken power lead Repair Wrong line voltage Check power supply Incorrect input power connections at welding machine Check connections against wiring diagram Open circuit to power switch or control transformer Repair Check for broken wire or loose connections at te
20. gt rommoo December 1 1997 Revised 8 1 430429 125 1 PARTS LIST Figure 8 1 Control Panel Group 8 2 December 1 1997 Revised 430429 125 1 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number per Code Assy 367845 1 Kit Meter Optional 1 All 1 400641 6 Ammeter DC 1 All 2 400642 4 Voltmeter DC 1 All 3 CW 1142A Shunt 1 369685 1 Panel Control Assembly 1 All 4 369684 1 Panel Control 1 All 5 No Number Screw 46 32 x 3 16 Rd MH ST 2 All 6 351505 Screw 1 2 13 x 1 3 4 HHC Drilled for Item 5 2 All 7 No Number Washer LK ST 1 2 4 All 8 No Number Washer 1 2 FL ST 2 9 5CW 976A Washer Insulating 4 All 10 5CW 975 Bushing Insulator Stud 2 11 5CW 974 Bus Cable Stud 2 12 No Number Nut 1 2 13 Hex Flanged ST 2 13 No Number Washer 1 2 Flat ST 2 All 14 No Number Screw 1 2 13 x 1 1 4 HHC ST 2 All 15 405982 1 Cover Meter Hole 2 All 16 406161 Knob Red 1 406162 Knob Control 1 All 17 402663 Nut Pot Lock 2 All 18 402658 Fuseholder 1 All 19 11166 10 Fuse Amp AGC 1 All 20 402421 2 Light Pilot Red 1 21 402900 Terminal Quick Connect Tab Male 2 All 22 368705 8 Capacitor W Lead amp Term 2 All 369686 Harness Wire Assembly 1 All 23 405365 1 Switch Toggle SPST 2 All 24 401428 8 Potentiometer 2 Watt 5 2 All 25 367703 1
21. tached items which are soldered riveted or welded SPECIFICATION NUMBER 6033A 1 6034A 1 6035A 1 6036A 1 6037A 1 6033A 3 6036A 2 6037A 2 6034B 1 6035B 1 to another part The part descriptions may be indented to show part relationships Todetermine the part number description quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item inthe Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual APPLICATION CODE crcrtommoo December 1 1997 Revised 8 1 430429 125 2 PARTS LIST Figure 8 1 Control Panel Group 8 2 December 1 1997 Revised 430429 125 2 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number per Code Assy 367845 1 Kit Meter Optional 1 All 1 400641 6 Ammeter DC 1 All 2 400642 4 Voltmeter DC 1 All 3 CW 1142A Shunt 1 All
22. 1155 1 Wd xi43ud YVO EHI u Gas a AOD IVNIHBIL OL 38 14 6 6 1238802 AOZZ O3JYYW OL 8 7 6 1238502 137014 A N01123MN02 W3HMOJSNVMI 1041802 5H011238K0 83490358741 3051N02 038 QW xoig 3002 010 4O0NnOu5 QIXUVH 13 4 UOIU3IN 3H NO M3U2S 01 ONNOUN W31SAS WSMOd J23NNO 76 ONTIONVH 300438 8340 51 1102812 1ndN NIvJU3O 38 0110 2 HVUDVIO NI SV YOLIVINOD 3 11 830138 30 401 01 3N 1 u3MOd 3SVHd 123NNO JHI 30 11535 4NOIIVITISNI NI 18VH 350 5151 3 3002 ON 41 u3013M 30 31v1d3HYN NO NMOHS 1838802 INIT 803 3215 3UIM 3 11 433084 YOS 53002 1 201 YNOA 23H29 39Y110A INII 834084 404 318v lddv Sv 1331 t ONV 75 914 NMOHS SY z 4123NNO2 HSIM HOIHA 01 39V110A 3N11 03 91530 51 11 2 38 01 83013M 40 31V1d3HYN 23 2 71 NOLIODMISNI NOLIVHUGANI 335 057 3417 83 04 9NI123NNO2 ONY 13NVd 39V110A ONI1 3S VOA 580112041581 1 702 501591402 A SI 30 NO Q31vOQ1 2 ne ou 3NIT 110A 09 8034 SHNIT 3NI1 110A OEZ 803 SANTI ions RI NUNTII NCA 88 NWvubovia
23. 44 60 60 91 50 70 90 125 48 8 8 6 8 8 8 10 10 8 8 500 28 5 36 5 50 50 76 40 50 70 110 8 8 8 6 10 8 8 10 10 10 8 6031A 2 6036A 2 6041 2 6046A 2 ee 6622 2 35 duty cycle 6032A 2 6037A 2 6042A 2 6047A 2 6623 2 V 40 duty cycle 6597 1 6633 1 A Conductor size shall be modified as required for line voltage drop and ambient temperature Sizes listed for conduit installation are based on 90 C conductor insulation designated as FEP FEPB RHH and THHN Table 4 3 Recommended Wire and Fuse Size Table 4 4 December 1 1997 Revised 430429 125 INSTALLATION WELDING LEADS TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS Welding ELECTRODE LEAD PLUS WORK LEAD Current 50 100 Feet 150 Feet 200 Feet 250 Feet Amperes 15 2 M 30 5 M 45 7 M 61 0 M 76 2 M 100 4 4 2 1 1 150 4 2 1 1 0 2 0 200 2 1 1 0 2 0 3 0 250 1 1 2 0 3 0 4 0 300 1 0 1 0 3 0 4 0 350 1 0 2 0 3 0 4 0 400 2 0 2 0 4 0 450 2 0 2 0 4 0 Table shows welding lead sizes recommended for various lengths of leads Footage shown includes complete welding Secondary circuit both electrode and work leads Lead size shown is for 90 C insulation 30 C 86 F ambient and not over 4 5 volts lead drop Table 4 4 December 1 1997 Revised 4 5 430429 125
24. 500 40 85 144 40 Table 3 1 Part 1 No Spec Load Load PU No Amps Volts Volts kW Cycle Model No 7 R 600 S 6046A 2 750 44 85 33 40 6047A 2 750 44 85 33 40 Model No 500 R 500 S 6619 1 500 40 85 20 60 6620 1 500 40 85 20 60 6621 1 500 40 85 20 60 6622 1 500 40 85 20 60 6623 1 500 40 85 20 60 Model No Mega Arc 6 R 500 S 6622 2 625 44 85 27 5 40 6623 2 625 44 85 27 5 40 Table 3 1 Part 2 Controls and Connections Input Connector ON Pilot Light Indicates when the connector is closed for power ON mode of the unit Input Connector Control ON OFF Switch This toggle switch is the master power switch for the welding machine and must be in the ON position before any other section will operate The primary circuit of the control transformer is energized when ever line voltage is present at the input terminals This switch closes the secondary circuit of the con trol transformer energizing the connector which energizes the power transformer See DANGER located in Safety Warning chapter Remote Amperage Control Local Remote Switch Selects either the LOCAL panel mounted current control or some control device to control welding curren
25. AB December 1 1997 Revised 8 5 430429 125 7 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 369630 6 Yoke Lifting Assembly 1 CDE 29 369631 Yoke Lifting 1 30 405362 1 Bushing Snap 2 All 31 405362 2 Bushing Snap 1 All 32 405793 Label Warning 1 406484 Label Fuse Control Trans 1 33 406358 2 Resistor 50 Ohms 1 34 405402 Contactor 1 35 402037 27 Grommet Rubber 1 All 36 W 11166 11 Fuse 1 2 Amp 1 All 37 406392 1 Transformer Control 1 AB 406392 2 Transformer Control 1 CDE 38 367803 Reactor Filter 1 All 39 368084 4 Transformer Interphase 1 All 40 367579 Insulator Fuse Block 1 All 41 W 11166 9 Fuse 1 Amp 6 All 405362 2 Bushing Snap 1 All 42 CW 811 Link Voltage Changeover 6 ABCD CW 811 Link Voltage Changeover 3 E 43 201273 Transformer Power 1 A 201274 Transformer Power 1 B 201275 Transformer Power 1 C 201276 Transformer Power 1 D 201277 Transformer Power 1 E 44 200770 Brace V C Board 2 All 45 405129 1 Block Fuse 1 All 46 367170 5 Board Voltage Changeover 1 A 367229 6 Board Voltage Changeover 1 B 367229 7 Board Voltage Changeover 1 C 367229 9 Board Voltage Changeover 1 D 367229 8 Board Voltage Changeover 1 E 47 204036 Label Precautionary 1 All Not Illustrated 8 6 December 1 1997 Revised 430429 125 DIAGRAMS DIAGRAMS Note the mod
26. ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal Arc 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 Arc 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 Arc whether arising out of contract negligence strike 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 No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS Except with regards to the products listed below this warranty shall remain effective three 3 years from the d
27. Check the following table for typical values NOTE The above values in Table 7 1 were recorded at nominal line voltage MAX OCV All One Two Three SCRs Not Not Not Firing Firing Firing Firing Mega Arc 200 80V 73V 66V 53V DC DC DC DC Mega Arc 300 80V 73V 66V 53V DC DC DC DC Mega Arc 400 85V 77V 69V 61V DC DC DC DC Mega Arc 500 85V 77V 69V 61V DC DC DC DC Mega Arc 600 85V 77V 69V 61V DC DC DC DC Table 7 1 Isolating Malfunctioning SCR This is best done by trial and error method Use Connection Diagram as reference while inspecting the unit On the output rectifier heat sink there are two surge suppressor boards each having three terminals The leads connected to these terminal strips are providing the gate signal to the SCRs The wires from the other side of the terminal strips to the SCRs are white wires in all cases Turn the Current Control to maximum position fully clockwise and begin disconnecting the leads from the terminals one at a time As the first lead is disconnected observe the open circuit voltage of the machine If the OCV drops to a lower value it will indicate that this particular SCR is working properly Reconnect this lead and proceed to do the same with the remaining five leads until you discover which disconnection does not cause the to drop to a lower level
28. This will be the SCR which should be changed See Mounting Procedure for SCRs December 1 1997 Revised 7 5 430429 125 TROUBLESHOOTING Mounting Procedure for SCRs 1 Thoroughly clean heat sink surface to eliminate any dirt or contamination 2 Apply a thin coat of Alcoa 2 compound to cleaned surface Alcoa 2 is available from Thermal Arc part number 903870 3 Positively locate the SCR in place in the heat sink A small spring pin in the extruded heat sink will locate the SCR 4 Placethe clamp in position with the bolts through the holes in the heat sink and proceed in following manner 5 Tighten the nuts evenly until finger tight 6 Tighten each bolt in 1 4 turn increments using correct size hex key 7 Placethe Force Indicator Gauge 903878 firmly against the springs as shown Be sure both ends and the center are in firm contact with the springs The gauge notch location will indicate the spring deflection or force Correct mounting force is indi cated as shown below 8 Spring deflection over 2 1 4 inches of spring is 037 002 for all clamps 9 Allclamps to be set at 4 mark This corresponds to the VE3000 VE2500 section on the gauge label Force Gage shown in position 905878 Figure 7 3 Examples than Less rated force Tighten nuts al ternately 1 4 at a time until points co incide Top edges lined up 488 Correct rated Excessive force
29. and place it on pins 2 and 3 3 Replace side panel December 1 1997 Revised 5 1 430429 125 OPERATION This page intentionally left blank 5 2 December 1 1997 Revised 430429 125 MAINTENANCE MAINTENANCE Lubrication The fan motor incorporates sleeve bearings You can expect the life of this motor to exceed 50 000 hours without relubrication Periodically cleaning the motor and lubricating the bearings will extend the life of the motor The following table will furnish a recommended guide to the frequency of this lubri cation if desired Lubrication Interval Every 12 months Every 6 months Every 3 months Type of Duty Light up to 6 hrs day Moderate 7 to 15 hrs day Heavy 16 to 24 hrs day NOTE Apply 1 12 drops of 20W non deter gent oil at each end of bearing Inspection and Cleaning For uninterrupted satisfactory service from this welding machine it is necessary to keep the ma chine clean dry and well ventilated At least every three months or more often as necessary wipe and blow out all dirt from the machine s internal compo nents with air pressure of not over 25 psi 172 kPa Be sure to wipe the fan blades clean Check and tighten all electrical connections as necessary to eliminate unnecessary losses and to avoid subsequent trouble from overheating or open circuits Check for broken wiring or damaged insu lation on wiring
30. 1 V 1096 Open circuit Checks reference voltage 5 12 TPNto TP6 or 11 8 16 10 V DC Open circuit Checks reference voltage 6 21 TPAtoTP6or11 80r16 2 7 V DC 10 Open circuit Checks timer operation 17 TPE to TP6 or 11 8 or 16 2 7 V DC 1096 Open circuit 18 TPJ to TP6 or 11 8or 16 2 7 V DC 1096 Open circuit 7 1 TP1 to TP6 or 11 8 16 12 5 V DC 10 Open circuit Checks timer operation 20 TP7 to TP6 or 11 8 16 2 5 V DC 1096 Current control set 50 19 TP10 to TP6 or 11 8 16 2 5 V DC 10 Current control set 50 8 5 TP8 to TP6 or 11 8 or 16 1 6 V DC 1096 Minimum output Checks summing Op Amp High range 11 TP9 to TP6 or 11 8 16 0 4 V DC 10 Short circuit Checks feedback circuit 10 0 V DC Checks zero calibration 11 TP9 to TP6 or 11 Bor 16 Open circuit NOTE Locate numbers in parens on PC Board by callout numbers It will be necessary to scrape varnish from component lead test points and post test points to get a voltmeter reading If any of the above tests fail there is a high probability of a defective P C Board Table 7 2 December 1 1997 Revised 7 7 430429 125 TROUBLESHOOTING CAUTION The open circuit voltage is set on the PC Board This setting is sensitive to line voltage Do not connect a machine to a line in which the voltage varies more than 1096 of nominal line voltage For example on a 460 volt line
31. 369685 2 Panel Control Assembly 1 ABCD EFGH 369685 14 Panel Control Assembly 1 JK 4 369684 2 Panel Control 1 ABCD EFGH 369684 8 Panel Control 1 JK 5 No Number Screw 46 32 x 3 16 Rd Hd MH ST 2 6 351505 Screw 1 2 13 x 1 3 4 HHC Drilled for tem 5 2 All 7 No Number Washer LK ST 1 2 4 All 8 No Number Washer 1 2 FL ST 2 All 9 5CW 976A Washer Insulating 4 All 10 5CW 975 Bushing Insulator Stud 2 11 5CW 974 Bus Cable Stud 2 All 12 No Number Nut 1 2 13 Hex Flanged ST 2 13 No Number Washer 1 2 Flat ST 2 All 14 No Number Screw 1 2 13 x 1 1 4 HHC ST 2 All 15 AW 113 3 Cover Meter Hole 2 ABCD EFGH AW 113 9 Cover Meter Hole 2 JK 16 406806 3 Knob 1 408850 5 Knob Control 1 All 17 402663 Nut Pot Lock 2 All 18 402658 Fuseholder 1 All 19 W 11166 10 Fuse Amp AGC 1 All 20 402421 2 Light Pilot Red 1 All 21 402900 Terminal Quick Connect Tab Male 2 All 22 368705 8 Capacitor W Lead amp Term 2 All 369686 Harness Wire Assembly 1 All 23 405365 1 Switch Toggle SPST 2 All 24 401428 8 Potentiometer 2 Watt 5 K 2 All 25 367703 1 Resistor 1 2 Watt Assembly 1 All 26 405365 2 Switch Toggle SPDT 2 All 27 400758 Receptacle 6 Pin Amphenol 1 28 401937 5 Block Terminal 1 All 402037 8 Grommet Rubber 1 All 402037 13 Grommet Rubber 1 All Not Illustrated December 1 1997 Revised 8 3
32. 6 16 405139 Rectifier Silicon 6 17 16DA 954 12 Spring 6 18 405140 1 Clamp Mounting 6 19 367687 Shunt 1 20 369641 Insulator Mtg Rect 2 21 369703 Bar Bus Output Term to Shunt 1 22 200155 Thermostat Fan Turn On Optional 1 200157 Kit Cover OSHA Optional 1 23 200280 Cover 1 369826 Kit Side Panel W Access Door Optional 1 24 369827 Panel Side 1 25 369210 Door Access 1 26 200292 Transformer Power 1 27 367690 Brace V C Board 2 28 405129 1 Block Fuse 1 29 367170 5 Board V C Assembly 1 30 CW 811 Link Voltage Changeover 6 31 369672 Transformer Interface 1 32 367696 2 Reactor Filter 1 33 367579 Insulator Fuse Block 1 34 W 11166 9 Fuse 1 Amp 6 369630 1 Yoke Lifting Assembly 1 35 369631 Yoke Lifting 1 December 1 1997 Revised 8 5 OM 193 5 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty No Number per Assy 36 405362 1 Bushing Snap 2 37 405362 2 Bushing Snap 1 38 405793 Label Warning 1 406484 Label Fuse Control Trans 1 39 406358 2 Resistor 50 Ohms 1 40 405479 Contactor 1 41 402037 27 Grommet Rubber 1 42 W 11166 11 Fuse 1 2 Amp 1 43 406392 1 Transformer Control 1 402549 2 Tag Line Voltage 1 44 200114 Spacer PC Panel 1 402687 2 Terminal Trans 6 201161 1 Panel PC Board Assembly 1 45 201162 Box PC Board 1 46 404915 1 Spacer PC Board 6 47 369511 Board PC 1 48 16D
33. All All All ABCD EFJK GH All All December 1 1997 Revised 8 5 430429 125 2 PARTS LIST This page intentionally left blank 8 6 December 1 1997 Revised 430429 125 2 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 20 200155A Thermostat Fan Turn On Optional 1 All 200157A Kit Cover OSHA Optional 1 All 21 200280 1 Cover 1 22 Deleted 23 Deleted 369669 2 Panel PC Board Assembly 1 ABCD EFGH 369669 10 Panel PC Board Assembly 1 JK 24 369670 Panel PC Board 1 ABCD EFGH 369670 1 Panel PC Board 1 JK 25 404915 1 Spacer PC Board 6 26 369511 Board PC Assembly 1 27 200114 Spacer PC Panel 1 All 369630 1 Yoke Lifting Assembly 1 ABF 369630 10 Yoke Lifting Assembly 1 J 369630 2 Yoke Lifting Assembly 1 CDEGH 369630 11 Yoke Lifting Assembly 1 K 28 369631 Yoke Lifting 1 ABCD EFGH 369631 2 Yoke Lifting 1 JK 29 405362 1 Bushing Snap 2 All 30 405362 2 Bushing Snap 1 All 31 405793 Label Warning 1 All 406484 Label Fuse Control Trans 1 All 32 406358 2 Resistor 50 Ohms 1 All 33 405479 Contactor 1 All 34 402037 27 Grommet Rubber 1 All 35 W 11166 11 Fuse 1 2 Amp 1 All 36 406392 1 Transformer Control 1 ABFJ 406392 2 Transformer Control 1 CDEGHK 37 367696 2 Reactor Filter 1 38 369672 Transformer Interface 1 All 39 367579 Insulator Fuse Block 1 All 40
34. Figure 8 2 Part Number 12CW 2170 403091 4 369652 369651 369683 369650 8RT 609 12TW 595 1 369640 369653 369638 10 369639 367634 3 405157 404044 4 369642 405139 405140 1 16DA 954 12 367733 369641 369703 200155 200157 369826 369827 369210 402549 2 402549 1 369669 2 369670 404915 1 369511 200114 369630 5 Not Illustrated Description Grommet Top Plug Hole Plastic Panel Top Panel Side Left amp Right Panel Rear Shroud Fan Blade Fan Motor Fan Bracket Mtg Fan Motor Base Assembly Rectifier Output Assembly Heat Sink Suppressor Surge Assembly Label Fuse Thermostat Overload Heat Sink SCR Rectifier Silicon Clamp Mounting Pin Spring Shunt Insulator Mtg Rect Bar Bus Output Term to Shunt Thermostat Fan Turn On Optional Kit Cover OSHA Optional Kit Side Panel W Access Door Optional Panel Side Door Access Tag Line Voltage Tag Line Voltage Panel PC Board Assembly Panel PC Board Spacer PC Board Board PC Assembly Spacer PC Panel Yoke Lifting Assembly Qty Application per Code Assy S Ss Ss DH HS All All All All All All All All All All All All All All All All All All All All All All All All All All All AB CDE All All All All All
35. Lifting 1 36 405362 1 Bushing Snap 2 December 1 1997 Revised 8 5 430429 125 6 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty No Number per Assy 37 405362 2 Bushing Snap 1 38 405793 Label Warning 1 406484 Label Fuse Control Trans 1 39 406358 2 Resistor 50 Ohms 1 40 405402 Contactor 1 41 402037 27 Grommet Rubber 1 42 W 11166 11 Fuse 1 2 Amp 1 43 406392 1 Transformer Control 1 402549 2 Tag Line Voltage 1 44 200114 Spacer PC Panel 1 402687 2 Terminal Trans 6 201161 1 Panel PC Board Assembly 1 45 201162 Box PC Board 1 46 404915 1 Spacer PC Board 6 47 369511 Board PC 1 48 16DA 4029 Bracket Mtg Relay 1 49 16DA 4052 1 Socket Relay 1 50 16DA 4004A 7 Relay 1 51 16DA 4253 1 Retainer Spring Relay 1 52 402037 13 Grommet Rubber 1 406008 4 Housing Receptacle 1 406008 6 Housing Receptacle 1 406009 1 Plug Keying 1 402037 8 Grommet Rubber 1 53 204036 Label Precautionary 1 These parts and their quantities are shown in relationship to their location in the machine but they are components of Wire Harness Assembly 201164 Not Illustrated 8 6 December 1 1997 Revised 430429 125 7 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found
36. No Number Washer 1 2 FL ST 2 10 5CW 976A Washer Insulating 4 11 5CW 975 Bushing Insulator Stud 2 12 5CW 974 Bus Cable Stud 2 13 No Number Nut 1 2 13 Hex Flanged ST 2 14 No Number Washer 1 2 Flat ST 2 15 No Number Screw 1 2 13 x 1 1 4 HHC ST 2 16 405982 1 Cover Meter Hole 2 17 406806 Knob Red 1 18 406808 1 Knob Control 1 19 90391 4 1 Cap Connector 1 20 402658 Fuseholder 1 21 11166 10 Fuse Amp AGC 1 22 402421 2 Light Pilot Red 1 23 368705 8 Capacitor W Lead amp Term 2 24 402900 Terminal Quick Connect Tab Male 2 25 402882 2 Valve Gas 1 26 W 10892 1 Elbow Street 90 Brs 2 27 370447 Adapter Gas Right Hand 2 28 401937 3 Block Terminal 12 Positions 1 29 401533 Receptacle 10 Pin Amphenol 1 30 405365 1 Switch Toggle SPST 2 31 405365 2 Switch Toggle SPDT 1 32 400400 Switch Toggle DPDT 2 33 367703 1 Resistor 1 2 Watt Assembly 1 34 401428 8 Potentiometer 2 Watt 5 2 201170 1 Board Voltage Dropping 1 35 201169 Bracket Mtg Assembly 1 36 W 9746 7 Resistor Fixed Type 1 37 406473 10 Capacitor 2 These parts and their quantities are shown in relationship to their location in the machine but they are components of Wire Harness Assembly 201164 December 1 1997 Revised 8 3 430429 125 6 PARTS LIST RI ES Nw lt
37. Un quipement inad quatement N utilisez qu une bonne prise de masse pour la mise la terre install ou inad quatement mis la terre est dangereux de la pi ce souder Ne touchez pas des pi ces sous tension Ne touchez pas l lectrode lorsqu en contact avec le circuit de Portez des gants et des v tements isolants secs et non trou s soudage terre Isolez vous de la pi ce souder et de la mise la terre au moyen N utilisez que des quipements en bon tat R parez ou rem de tapis isolants ou autres placez aussit t les pi ces endommag es D connectez la prise d alimentation de l quipement ou arr tez Dans des espaces confin s ou mouill s n utilisez pas de source le moteur avant de l installer ou d en faire l entretien Bloquez le de courant alternatif moins qu il soit muni d un r ducteur de commutateur en circuit ouvert ou enlevez les fusibles de l alimen tension Utilisez plut t une source de courant continu tation afin d viter une mise en marche accidentelle Portez un harnais de s curit si vous travaillez en hauteur Veuillez installer cet quipement et le mettre la terre selon Fermez solidement tous les panneaux et les capots le manuel d utilisation et les codes nationaux provinciaux et locaux applicables pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv
38. authorized Thermal repair facility within thirty 30 days of the repair No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc Thermal Arc Inc Effective January 4 1999 Troy Ohio 45373 830538
39. d ter compl tement le bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Pro tection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 2 4 8 V 96 430429 125 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT General The Mega Arc welding machines are constant current transformer type DC units that provi
40. d air Les gaz protec teurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respiration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur adduction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage 2 2 8 V 96 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN IN CENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati
41. es Des crans lat raux LE RAYONNEMENT DE L ARC PEUT BRULER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE is bap Entourez l aire de soudage de rideaux ou de cloisons pour L arc de soudage produit une chaleur et des prot ger les autres des coups d arc ou de l blouissement rayons ultraviolets intenses susceptibles de avertissez les observateurs de ne pas regarder l arc br ler les yeux et la peau Le bruit caus par Portez des v tements en mat riaux ignifuges et durables laine certains proc d s peut endommager et cuir et des chaussures de s curit 1 Portez une casque de soudeur avec filtre oculaire de nuance Portez un casque antibruit ou des bouchons d oreille approuv s appropri e consultez la norme ANSI 749 indiqu e lorsque le niveau de bruit est lev 8 V 96 2 1 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE Op ration de Coupage ou soudage Brasage tendre au chalumeau Brasage fort au chalumeau Oxycoupage mince moyen pais Soudage aux gaz mince moyen pais Soudage l arc avec electrode enrob es SMAW Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux m taux ferreux Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydrog ne atomique AHW Soudage l arc avec lectro
42. o INOA 30 NO 9349307 ae 25 110A 022 ANII 3NIT 410A Sit 803 ANID 718 035 492 __ 209 HOLOVLNOD LIOA 51 HOLIMS 3407 NO Wvuovia 335 MH3NBHOJSNVHL LNO9 OASIS QADOS QAOSP QAE OAC QWOD HOS NOILO3NNOO NMOHS 1NOMJ H3NHOJSNVHI 1091405 B3AO3ONTHI 39V1 10A CT Li 39v 18 201 NO HOt EOL 200 5 009 2 91 5 SON QY31 71300 IVIS HO Sb HIVIB 0 HO Sb 30 uvas woud 301991405 YOLOVLNOOD 1 Ta Tannouo A sir 3NI1 3SVHd 9ILVW3HO9S TANVA H3AO3ONVHO SOVLIOA 9NIOV ISVHA 1 8t 90 000 MET i d mm ped ui vi PALOJIMIP 20 pe nposdei eq 04 you pue 0002 aut TROC i los jo ay jo padod id pue aAnnj2xe uo242q4 paute Buimesp 1Y 1 N30I3NOO TZ n Taa m E 5 282 EC VONVIS E SASL S1u v4 QINTISIO HOUN 37 1432x3 4 MOJ38 S3ONYH 3301 IIIS JON OQ SIMONI Sc 39
43. on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed exceptfor commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded to another part The part descriptions may be in dented to show part relationships To determine the part number description quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item in the Parts SPECIFICATION NUMBER 6619 1 6620 1 6621 1 6622 1 6623 1 List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does
44. res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long par cours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de LES ETINCELLES ET LES PROJEC TIONS BRULANTES PEUVENT CAUSER DES BLESSURES LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exp
45. the operating voltage range is 414 to 504 volts Potentiometer Settings The following is a brief description of the potentiometers and what parame ters they control Callout numbers from Figure 7 5 in parens NOTE All potentiometer operating values are preset at the factory and normally should not have to be reset in the field If a need arises that would indicate the need for field adjustments please contact the fac tory 1 Pot R80B 13 Adjusts the output of Feed back Amplifier U8 and eliminates offset voltage values 2 Pot R33 9 Adjusts the 10 volt DC reference voltage 3 Pots R8A and R8B 2 Adjusts the phase balance output of the SCR rectifier 4 Pot R48A 15 Adjusts the maximum open circuit voltage 5 Pot R48B 15 Adjusts the voltage point at which the current begins increasing in the arc force circuit 6 Pot R74 12 Adjusts the maximum short circuit current in the arc force circuit 7 Pot R80A 13 Adjusts the minimum output current 8 Pot R50 10 Adjusts the maximum output current 7 8 December 1 1997 Revised 430429 125 1 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers follow
46. 1 1 3H NI 18Y42 ISN SISIX3 53002 ON 4 7V3073M 40 NO NMOHS IN3UNT 3NII 503 3215 341 3NIT 3H 304 3002 1Y201 32342 6 78 B dal JI NI111 804 39V1104 gt 3811 334054 351 303 318v2llddY Sv 1331 AV 2 5 913 NI 5 SV SMNIT z 711 123NNO2 01 HSIM H2IH 39V110A 3NI1 303 03891530 517 1 2 38 01 93613 J 20 31Y1d3HYN 23H2 E nNvs NOI 12091591 5 01 2VHni0JNI 335 051 3 11 u3MOd 9N1123NNO2 ONY 13NVd U3A039NVH2 39 119 1135 503 580112081581 7109 MOLOVLNOD ASII ROLLOS SONA NO 031001 OVA lt NOLLIINNOD 32v18 3n18 338 AO22 A002 HINHOJSNVUL 9NI2V4 AO9 03193NNO9 NMOHS HAWHOISNVUL 2 5 8 4300n 110 095 063 2 sNOI193NNO9 TINVA 30v130A 4 5 009 5 5 006 5 5 E 5 32V 18 XO Sb v HO12V1NO2 9 d 1 HOLIVINOD E 3015 4 05 2 jme D OILVW3H2S 2v 18 EOI 3NI1 3SvHd 33NVd 39VLIOA 9NI2V4 t t 1 verse D 4 4 020929
47. 1 2 4 All 8 No Number Washer 1 2 FL ST 2 All 9 5CW 976A Washer Insulating 4 All 10 5CW 975 Bushing Insulator Stud 2 11 5CW 974 Bus Cable Stud 2 12 No Number Nut 1 2 13 Hex Flanged ST 2 13 No Number Washer 1 2 Flat ST 2 All 14 No Number Screw 1 2 13 x 1 1 4 HHC ST 2 15 405982 1 Cover Meter Hole 2 All 16 406161 Knob Red 1 All 17 406162 Knob Control 1 All 18 402658 Fuseholder 1 All 19 W 11166 10 Fuse 3 Amp AGC 1 All 20 402421 2 Light Pilot 1 All 21 402900 Terminal Quick Connect Tab Male 2 All 22 368705 8 Capacitor W Lead amp Term 2 All 90391 4 1 Cap Connector 1 369686 Harness Wire Assembly 1 23 405365 1 Switch Toggle SPST 2 24 401428 8 Potentiometer 2 Watt 5 2 25 367703 1 Resistor 1 2 Watt Assembly 1 All 26 405365 2 Switch Toggle SPDT 2 27 400758 Receptacle 6 Pin Amphenol 1 All 28 401937 5 Block Terminal 1 All 402037 8 Grommet Rubber 1 All 402037 13 Grommet Rubber 1 All Not Illustrated December 1 1997 Revised 8 3 430429 125 7 PARTS LIST KW lt SR 4 um 7 Figure 8 2 Base and Lifting Yoke Group 8 4 December 1 1997 Revised 430429 125 7 PARTS LIST Item No O1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Parts List for
48. 10 8 6 6 230 41 60 87 108 132 60 90 125 200 48 6 46 2 8 48 46 4 10 8 6 6 380 25 36 53 65 80 30 50 70 110 10 8 48 46 10 48 48 8 10 10 8 8 415 23 33 48 60 73 30 50 70 110 10 48 8 8 10 48 8 8 10 10 8 8 460 205 30 435 54 66 30 50 70 110 10 48 8 8 10 8 8 8 10 48 8 500 19 27 40 50 61 25 40 60 110 12 48 8 8 12 10 8 48 10 10 8 8 575 16 24 35 43 53 25 40 60 80 12 8 48 8 12 10 8 8 10 10 8 8 6028A 1 3 0 6033 1 3 6038A 1 3 e 6043A 1 6619 1 Wire size calculated for 6029A 1 6034A 1 6039A 1 6044 1 6620 1 60 duty cycle 6030 1 6034B 1 6040A 1 6045A 1 6621 1 6031A 1 6035A 1 6041 1 6046 1 6622 1 6032 1 6035B 1 6042A 1 6047A 1 6623 1 6036A 1 6633 1 6037A 1 6597 1 Table 4 2 Recommended Wire and Fuse Size Table Line Full Load Approx Line Copper Line Wire Size Copper Volts Amps Fuse Rating In Conduit Flexible Cable Conductor Min 46 5 7 3 4 5 7 30 40 7 39 40 7V 30 40 5 7 220 645 84 114 113 172 90 125 150 225 48 6 4 2 8 8 8 4 10 48 6 6 380 37 5 48 66 65 100 50 70 90 150 48 8 8 6 8 HO 8 8 10 10 8 8 415 345
49. 10892 1 Elbow Street 90 Brs 2 27 370447 Adapter Gas Right Hand 2 28 401937 3 Block Terminal 12 Positions 1 29 401533 Receptacle 10 Pin Amphenol 1 30 405365 1 Switch Toggle SPST 2 31 405365 2 Switch Toggle SPDT 1 32 400400 Switch Toggle DPDT 2 33 367703 1 Resistor 1 2 Watt Assembly 1 34 401428 8 Potentiometer 2 Watt 5 K 2 201170 1 Board Voltage Dropping 1 35 201169 Bracket Mtg Assembly 1 36 W 9746 7 Resistor Fixed Type 1 37 406473 10 Capacitor 2 These parts and their quantities are shown in relationship to their location in the machine but they are components of Wire Harness Assembly 201164 December 1 1997 Revised 8 3 OM 193 5 PARTS LIST SS ak AN SON 72 AS Fo yen 2 s d December 1 1997 Revised Figure 8 2 Base and Lifting Yoke Group 8 4 OM 193 5 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty No Number per Assy 1 12CW 2170 Grommet Top 1 2 403091 4 Plug Hole Plastic 8 3 369652 Panel Top 1 4 369651 Panel Sides 2 5 369683 Panel Rear 1 6 369650 Shroud Fan 1 7 8RT 609 Blade Fan 1 8 12TW 595 1 Motor Fan 1 9 369640 Bracket Motor 2 10 369653 Base Assembly 1 369638 2 Rectifier Output Assembly 1 11 369639 Heat Sink Rect 1 12 367634 3 Suppressor Surge Assembly 2 13 405157 Label Fuse 1 14 404044 1 Thermostat Overload 1 15 369642 Heat Sink SCR
50. 2812 ANANI 1935 38 N0110nv2 3H1 SY wOI2YINOO 3NI7 U3013 40 401 01 3NI1 5 193NN09 JH 30 NO1123 NOIIYYIVISNI LYVHD 350 5151 3 53002 ON 41 0 3 JHL 30 31Y143HYN NO NMOHS JNIBUNI INTI 3215 341 INI 834084 VOA 53002 7 201 NnOA 323H2 39v1104 ANT 304 7378 21144 SY 1331 1V ONY 75 913 NI NMOHS SY M LE Ped ot HSIM 01 39 170 03491530 1 11 NIVIN32 35 01 930134 40 31V143HYN 1 SNOLI20HISNI NOIIVWUOJNI 335 OSIY INTI ONILIINNOD ONY 13 9U3A039NYH2 39Y110A 9 11135 303 5401 LINUISNI 3904 9N11317 30 9 NO 0317207 803 ANTT HQLIVLNOD 130A SHON 10714 HOLIMS 01108 NOLLOSNNO m gt 340 NO HM 1 fet 335 A H3WHOJSNVML 2 3503 8 id TR eO al 18 DIEK OASIS d oos 9 ADOZ d CH TITI HOT NOIIS3NNOO NMOHE ANOUA NOUS U3NHOJSNVHI 1081805 HIMNOJSNVUL 9NI2V4 AOS i nur i RS 2 39v 110A LE P Ve pores Xv 18 1 118 0345 6 3 XIV IA 01 HO Sb O 0 ASH Q Q mM
51. 331 1v Z 75 913 NMOHS SV SONIT 123NNOO 11 123 02 01 HSIM NOA HIIHM OL 39 110 3 11 JHL 503 934915349 51 1 32 38 OL Y3073M JHL 30 31VId3WVN 523H2 1 5 3A08V NI SV 801271 02 3 11 u3013M 30 401 OL 3811 Y3MOd 3SVHd JHL 1234402 4 l o cha o 404 ANID 1vnNVW NOII20HISNI NI NOIIVWHOS3NI 335 0537 3 11 u3MOd 9NI123NNOO 13NYd 53A039NVH2 39V110A 9 1135 303 SNOI LINHISNI 390A 9N1L417 30 NO G31v907 1H911 1074 7102 MOLOVINOO 170A Sli HOLIMS 330 NO WVS9VIQ WOLLO8 NOILO3NNO9 H3NHOJSNVHI 335 7IOH1NOD 3513 dWvs 4718 3018 8 18 H 9 e 2 18 034 6 83 E MOVIE Iv 8 2 005 803 NOILO3NNOO NMOHS 11045 H3WHUOJSNVHI JONIN M3WHOJSNVHI JWHOJSNVUL HLNOQ H 7 0877 13NVd 55 2 Odd O 39VI 10 dus 4 Ld 201 80 vt 1017 01 201 5 009 A9V 18 15 118 034 eg 808 S 007 4 35v18 VOL 80 5 75 04 aval 1300n HOVE 0 Sb 30 Bv3H YOLSVLNOD 9NI2vd MEN YOLOVLNOD BOLOVINOO jm 3NI1 3SVHd T 18 St J9ILVW3H2S 3NI1 3SvHd I3NVd H
52. 369686 Harness Wire Assembly 1 All 23 405365 1 Switch Toggle SPST 2 All 24 401428 8 Potentiometer 2 Watt 5 2 All 25 367703 1 Resistor 1 2 Watt Assembly 1 All 26 405365 2 Switch Toggle SPDT 2 All 27 400758 Receptacle 6 Pin Amphenol 1 28 401937 5 Block Terminal 1 All 402037 8 Grommet Rubber 1 All 402037 13 Grommet Rubber 1 All Not Illustrated December 1 1997 Revised 8 3 430429 125 3 PARTS LIST js 4 NS 7 Figure 8 2 Base and Lifting Yoke Group 8 4 December 1 1997 Revised 430429 125 3 PARTS LIST Item No 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Parts List for Figure 8 2 Part Number 12CW 2170 403091 4 369652 369651 369683 369650 8RT 609 12TW 595 1 369640 369653 369638 3 369639 367634 3 405157 404044 3 369642 405139 405140 1 160 954 12 367732 369641 369703 200155 200157 200280 369826 369827 369210 402549 2 402549 1 369669 2 369670 404915 1 369511 200114 369630 5 369630 6 Not Illustrated Description Grommet Top Plug Hole Plastic Panel Top Panel Sides Panel Rear Shroud Fan Blade Fan Motor Fan Bracket Motor Base Mounting Assembly Rectifier Output Assembly Heat Sink Rect Suppressor Surge Assembly Label Fuse Thermos
53. 39V110A 3NI1 303 03N91530 51 11 NIVAU39 38 01 40 3 NO112041SN1 NI N 3N1 3 04 9N1123NNO2 ONY JINVA H3AOJONVHI 32V1I0A 9811 3013 30 201 UNDA 3232 72 71 193NN09 OL 1V1d3HYN 23H 011 02 1 33 057 135 404 SNOILINUISNI Aes X1430d 14911 1 X13384 131014 JA NVI Ni 039 Ou JINVUQ 31 1 49 339 NO 3n18 78 NMOUS ug 35v18 3002 80102 NOVIE Se MOSS NOS 33 3XOX 5Niidlido Ov8 0386 NO 0317201 W3NHOJSNVHI TOULNOD SNOI NNQ9 39VLIOA NOVIA saone AJM pied NIKE 4 pus Le 335 MI 39 joym uj soye 9 Pome rue STIOA 062 NOLISOd NMOO 104 09 504 dfi pe ra 1 3SvHd 105 ASIT 20 perdes oq Vou pue MU TIVIIMBOIANCI gt gt gt D 173 Fede oiim ee 0777 xx ii o on we ae ia ted vi 29 ojo A in 0 peso on 10
54. 3AO039NVHO 9NIOV3 A wotstiused ped 20 sjouA gt Jo peidos eq jou ME Yate de Apodosd gt eArnjoxe s uot suuojur jjo Suasip s4 lt eno Sal ol lema TTD SEDE ommum mos x ANS TVNOISNZWIQ 3NI1100 nuu 3 77 PES et Z CONSSSOOW ANYI NOUDRULSIQ _ 8 LT pd jos 439 43 1171 218138 871 68 q t sziovt Lm 6l gvi gl s 271 61 10169 JO 00 1 8 0111549 9 2811 2 1 575094 5 S8313WlTTIW P HS119N3 548 099 38 uve ms rad cn vw ug 5 001 8 5 006 1 40 696 HSI19N3 _ 094 38 544 00 53 4 E NOISN3WIQ SNIMVEG ki int l meqtopmmsod ideare Lind Uf 8401 30 gt 20 pernpesdes oq Jou 5 erqo EM je pue 9 vorituusejw TIVLIMZONANOO
55. 6 60 3 50 24 9 6042A 1 380 500 53 40 3 50 20 5 6042A 2 380 500 66 50 3 50 24 9 6633 1 230 460 87 43 5 3 60 20 5 6043A 1 230 460 132 66 3 60 35 6044A 1 200 230 460 152 132 66 3 60 35 6045A 1 230 460 575 132 66 53 3 60 35 6046A 1 220 380 415 138 80 73 3 50 35 6046A 2 220 380 415 172 100 91 3 50 38 6047A 1 380 500 80 61 3 50 35 6047A 2 380 500 100 76 3 50 38 6619 1 230 460 108 54 3 60 26 5 6620 1 200 208 230 460 124 108 54 3 60 26 5 6621 1 230 460 575 108 54 43 3 60 26 5 6622 1 220 380 415 113 65 60 3 50 26 5 6622 2 220 380 415 141 81 75 3 50 33 6623 1 380 500 65 50 3 50 26 5 6623 2 380 500 81 62 5 3 50 33 Table 4 1 December 1 1997 Revised 4 3 430429 125 INSTALLATION Line Full Load Approx Line Copper Line Wire Size Copper Volts Amps Fuse Rating In Conduit Flexible Cable Conductor Min 200 3000 400 500 600 200 300 400 600 200 300 400 600 200 300 400 600 200 300 400 600 200 47 69 100 124 152 60 901125 200 8 6 4 2 8 8 6 4 10 8 6 6 208 47 69 100 124 152 60 901125 200 48 6 4 2 8 8 6 4 10 8 6 6 220 43 63 91 113 138 60 90 125 200 48 6 46 2 8 48 6 4
56. A 4029 Bracket Mtg Relay 1 49 16DA 4052 1 Socket Relay 1 50 16DA 4004A 7 Relay 1 51 16DA 4253 1 Retainer Spring Relay 1 52 402037 13 Grommet Rubber 1 406008 4 Housing Receptacle 1 406008 6 Housing Receptacle 1 E 406009 1 Plug Keying 1 402037 8 Grommet Rubber 1 53 204036 Label Precautionary 1 These parts and their quantities are shown in relationship to their location in the machine but they are components of Wire Harness Assembly 201164 Not Illustrated 8 6 December 1 1997 Revised 430429 125 6 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed exceptfor commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded to another part The part descriptions may be indented to show part relationships Todetermine the part number descriptio
57. AU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives LA VAPEUR ET LE LIQUIDE DE RE FROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression Seules des personnes qualifi es doivent d monter des protec teurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative N approchez pas les mains ou les cheveux de pi ces en mou vement elles peuvent aussi accrocher des v tements amples et des outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule Utilisez la polarit correcte et de l accumulateur N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant
58. Amp 6 41 CW 811 Link Voltage Changeover 6 ABCDFGH CW 811 Link Voltage Changeover 3 EH 42 200297 Transformer Power Assembly 1 AF 200298 Transformer Power Assembly 1 B 200299 Transformer Power Assembly 1 C 200300 Transformer Power Assembly 1 DG 200301 Transformer Power Assembly 1 E 43 367690 Brace V C Board 2 All 44 405129 1 Block Fuse 1 All 45 367170 5 Board V C Assembly 1 A 367229 6 Board V C Assembly 1 B 367229 7 Board V C Assembly 1 C 367229 9 Board V C Assembly 1 DGH 367229 8 Board V C Assembly 1 E 200643 Box Voltage Changeover Assembly 1 F 46 365167 Box Voltage Changeover 1 F 47 405615 Switch VC 1 F 48 W 10862 1 Connector Cable 1 F 49 200418 Bracket Mtg Box 1 F 50 361692 Label V C 1 F W 10080 4 Connector Straight 1 F 51 204036 Label Precautionary 1 All Not Illustrated 8 6 December 1 1997 Revised 430429 125 4 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassem
59. CTIONS AND WARNINGS Instruction 830001 This page intentionally left blank 2 4 May 8 1996 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE A LARC MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme Z49 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitair
60. INSTALLATION 4 gt gt lt Mega Arc 200 300 400 MA 3 MA 4 MA 5 600 7 A 21 1 2 546 24 1 2in 616 26 1 2 673 26 1 2 673 mm 29 1 2 749 mm 29 1 2 749 mm D 19 3 4in 502 mm D 22 1 2in 572 mm E 21 3 8 543 mm 21 0 in 610 mm F 13 16 21 mm 3 4 19 mm G 14 9 16 370 mm G 16 3 16 411 mm H 14 3 4 in 375 mm H 19 3 4 in 502 mm J 7 3 16 183 mm J 7 3 16 183 mm 20 3 4 in 527 mm K 25 3 4 in 654 mm 4 3 16 in 106 mm 4 3 16 in 106 mm M 29 1 8 in 738 mm M 34 1 8 in 867 mm Figure 4 2 Outline Dimensions 4 6 December 1 1997 Revised 430429 125 OPERATION OPERATION Sequence of Operation 1 Set INPUT CONTACTOR CONTROL Switch to ON UP position The mechanical contactor should close and the red pilot light on the panel should be illuminated The mechanical contactor energizes the Main Power Transformer which energizes the fan motor 2 For LOCAL control setthe REMOTE CONTAC TOR CONTROL Switch and the REMOTE AM PERAGE CONTROL Switch to LOCAL DOWN position The REMOTE CONTACTOR CONTROL Switch energizes the SCRs see Connection Dia gram in Diagram chapter and open circuit voltage is applied to the output terminals The REMOTE AMPERAGE CONTRO
61. L Switch allows control by the CURRENT CONTROL potentiometer located in the center of the front panel 3 For REMOTE control set the above switches to REMOTE UP position For this mode of operation it will be necessary to use a REMOTE CONTROL PENDANT plugged into the REMOTE CONTROL RECEPTACLE in order to energize the SCRs control the current The two remote switches work independently of each other The following combi nations can be accomplished a Remote welding contactor control b Remote current control c Both of the above at the same time 4 The RANGE SWITCH setting will be determined by the work application considering characteristics of the workpiece and electrode LOW range is des ignated as number 1 and HIGH range is number 2 5 The ARC FORCE AMPERE CONTROL poten tiometer varies the dynamic slope of the volt amp curves It essentially changes the short circuit arc current Turning the potentiometer knob clockwise causes forceful arc initiation with a hard driving arc maintained Turning the knob counterclockwise cre ates a softer start with a smooth arc NOTE When using GTAW TIG and Plasma Processes it is recommended that the Arc Force Control be set to minimum setting The setting of the potentiometer is dependent up on the type of joint and the electrode being used See paragraph entitled Arc Force Ampere Control in Description of Equipment chapter High Frequency Considerations Whe
62. MEGA ARC Constant Current Welding Machine For the Following Specs 200 300 4 400 5 NL e 6029A 1 e 6034 1 e 6039A 1 e 6030A 1 e 6034B 1 6040A 1 e 6031A 1 2 e 6035A 1 e 6041A 1 2 e 6032A 1 2 e 6035B 1 e 6042A 1 2 e 6036A 1 2 e 6633 1 e 6037A 1 2 e 6597 1 600 Amp 7 500 Amp 6 e 6043A ee e 6619 1 6 e 6044A 1 e 6620 1 e 6045A 1 e 6621 1 e 6046A 1 2 e 6622 1 2 e 6047A 1 2 e 6623 1 2 IHERMAL A THERMADYNE Company OWNER S MANUAL Number 430429 125 Rev B Revised September 30 1998 THERMAL ARC INC TROY OHIO 45373 1085 U S A 430429 125 Table of Contents INTRODUCTION How Use This 1 1 Equipment Identification 1 1 Receipt Of Equipment 5 1 1 SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3 Generali PPS 3 1 Controls and Connections 3 1 Welding Current Ranges 3 2 INSTALLATION 4 LOCATION AS etd e d Re tet ss fr 4 1 Internal Wiring 4 1 Connecting Welding Machine to Line Voltage 4 1 Grounding a ue dude E RARE db dL esed dr our de 4 1 Welding Leads er ea o 4 4 OPERATION 5 Sequence of Operation
63. S 6044A 1 369704 200030 369707 2 6045A 1 369704 200031 369707 2 6046A 1 369704 200032 369707 2 MA 7 6046A 2 369704 200032 369707 2 Mega Arc 600 6047 1 369704 200033 369707 2 MA 7 6047A 2 369704 200033 369707 2 Mega Arc 300 6597 1 201167 369705 369707 1 201181 Mega Arc 400 6633 1 201167 369705 369707 1 201181 Mega Arc 500 6619 1 369704 369705 369707 1 R 500 S 6620 1 369704 200030 369707 1 6621 1 369704 200031 369707 1 6622 1 369704 200032 369707 1 6623 1 369704 200033 369707 1 MA 6 6622 2 369704 200032 369707 1 6623 2 369704 200033 369707 1 December 1 1997 Revised CERIS ri wt a 8 lt 2 u 5 e H E H NET TAT E 9 eq T C od Ot 6 wq Ws d Ld vd i Wei 5 wh TT 5 BE E 5 rx gt 2 BHO 8 M wea s EMIT 5 pes 1 tw s Get emea E mas E e LEE 1 10 11 12 ere 1 CCMPCENTIAL towing 21 inarmati on contained herean it the sad pro pariy of VILA AG sut of Troy Chio sad ta be copied repredused or delivered or diesiecnd o others la whole ar is part mapi with written
64. VD n H 331313 TELET zx CEE 1 01281802 77192 8 91 Nid 01 30u1N02 340438 31241933934 fr Nis i 7972 73194143334 20458 5 009 5 00 5 Nid Qevo 27d 73194143334 ir 30A08 00 8 5 002 div 57 1041502 73534 gs ESOVIOA 1 3815 5340 23 i OsvQ 1051400 13524 1 22 SASVHA Tv E 3523 2 009 u 5 00 OvAOZ S OOt H S OO2 u j 10744 201291402 27444 931501236 031102102 9 029 7802129302 9 58 04 3 2 115749 11 62 taa kie cr 207 00r 1001129492 BANDA 304m 008 501159442 9 12 su 22 4 80104 Quit abun dit Y 9 L VEJJIJA dero ped 20 ojoya U ueque pesas p s perder oq e jou fet ONO oi jo PESEL AI youuepyves pue eann ss yuos vo j euo pal uas SN TIUNTOUNDO ECCE ILE RSS TE 1 Y i ir Rene il ET i Ei i i E OUO93U 39NYHD 5 3A1123108d 52395 wo a om p pu pu E mr ELEME 90 0811 553207 NO LS de 4150
65. W 11166 9 Fuse 1 Amp 6 All Not Illustrated December 1 1997 Revised 8 7 430429 125 2 PARTS LIST This page intentionally left blank 8 8 December 1 1997 Revised 430429 125 2 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 41 CW 811 Link Voltage Changeover 6 ABCD FGHJK CW 811 Link Voltage Changeover 3 E 42 200292 Transformer Power Assembly 1 AF 200293 Transformer Power Assembly 1 BJ 200294 Transformer Power Assembly 1 CK 200295 Transformer Power Assembly 1 DG 200296 Transformer Power Assembly 1 EH 43 367690 Brace V C Board 2 All 44 405129 1 Block Fuse 1 All 45 367170 5 Board V C Assembly 1 AF 367229 6 Board V C Assembly 1 BJ 367229 7 Board V C Assembly 1 CK 367229 9 Board V C Assembly 1 DGH 367229 8 Board V C Assembly 1 E 200643 Box Voltage Changeover Assembly 1 F 46 365167 Box Voltage Changeover 1 F 47 405615 Switch VC 1 F 48 W 10862 1 Connector Cable 1 F 49 200418 Bracket Mtg Box 1 F 50 361692 Label V C 1 F x W 10080 4 Connector Straight 1 F 51 204036 Label Precautionary 1 Not Illustrated December 1 1997 Revised 8 9 430429 125 2 PARTS LIST This page intentionally left blank 8 10 December 1 1997 Revised 430429 125 3 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be fu
66. WHOASNVHI 1034405 GHOD3H JONVHO HSINIJ Q3SN 343HM 20 08 NOnanisiC x1338d 1H911 1 MO eise ASNTISOQIW 31VIS AVUD A9 E M ded 31dund 13101A 1A me 18 AVI Ni NMONS Veit tpi y 938 05 MOVIE Lic Wl ege Q3xuvW TINVA WO TN31NI NO 3425 01 080099 W31SAS HIMOd 123NN03 75 C 3811 DNIJONVH 340438 390 51 1102812 LNdNt NIVIN32 38 NOIINVI 73 08 IHL NI SV 301991403 ININ 830138 30 401 OL 3811 3SVHd f 1293NNO 7 30 NOI123S NOILVTTVISNI JHL AU9HD 350 SISIX3 9609 ON 31 H3013M 30 31V1d3W4VN NO NMOHS 1838802 3NI1 3215 34044 M03 53002 1 207 4004 3971 5 3NI1 834094 804 sv 1337 1v anv 4241 5 913 NMOHS SV SYNI7 L93NNOD 72 714 193NN09 01 HSIM NOA HOIHM OL 39 110 303 03091530 51 11 2 38 830138 30 31Vld3vNN 923H2 1vnNVH NOI120HISNI NI NOLIVWHOJNI 335 057 Y3MOd 9NI123NNOO 13NVd 39V110A DNI113S 304 5 5 o o
67. al If only the assembly or specification number is listed the use of an Application Code does not apply to this manual SPECIFICATION NUMBER 6597 1 December 1 1997 Revised 8 1 OM 193 5 PARTS LIST Figure 8 1 Control Panel Group Parts List for Figure 8 1 Item Part Description Qty No Number per Assy 367845 1 Kit Meter Optional 1 1 400641 6 Ammeter DC 1 2 400642 4 Voltmeter DC 1 3 CW 1142A Shunt 1 4 40201 Shim Rubber 22 201166 1 Panel Front Assembly 1 5 201165 Panel Control 1 6 No Number Screw 6 32 x 3 16 Rd Hd MH ST 2 7 No Number Screw 1 2 13 x 1 3 4 HHC Drilled for Item 6 2 8 2 December 1 1997 Revised OM 193 5 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty No Number per Assy 8 No Number Washer LK ST 1 2 4 9 No Number Washer 1 2 FL ST 2 10 5CW 976A Washer Insulating 4 11 5CW 975 Bushing Insulator Stud 2 12 5CW 974 Bus Cable Stud 2 13 No Number Nut 1 2 13 Hex Flanged ST 2 14 No Number Washer 1 2 Flat ST 2 15 No Number Screw 1 2 13 x 1 1 4 HHC ST 2 16 405982 1 Cover Meter Hole 2 17 406806 Knob Red 1 18 406808 1 Knob Control 1 19 90391 4 1 Cap Connector 1 20 402658 Fuseholder 1 21 11166 10 Fuse Amp AGC 1 22 402421 2 Light Pilot Red 1 23 368705 8 Capacitor W Lead amp Term 2 24 402900 Terminal Quick Connect Tab Male 2 25 402882 2 Valve Gas 1 26 W
68. ate Thermal Arc s authorized distributor delivers the product to Purchaser but in no event more than 4 years from the date Thermal Arc delivers the product to the authorized distributor Shorter warranty periods apply to the products listed below On these products the warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor ALL OTHER P WEE PRO LITE POWER SUPPLIES POWER SUPPLIES PRO PLUS PRO WAVE LABOR MAIN POWER MAGNETICS STATIC amp ROTATING 3 YEARS 2 YEARS 1 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR BUT NOT LIMITED TO CONTACTORS RELAYS SOLENOID PUMPS POWER SWITCHING SEMI CONDUCTORS ENGINES ENGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS CONSOLES CONTROL EQUIPMENT HEAT 1 YEAR 1 YEAR 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an
69. b Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Have only qualified people remove guards or covers for mainte nance and troubleshooting as necessary To prevent accidental starting during servicing disconnect nega tive battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT Do not remove radiator cap when engine is hot Allow engine to COOLANT can burn face eyes and cool skin Wear gloves and put a rag over cap area when removing cap The coolant in the radiator can be very hot and under Allow pressure to escape before completely removing cap pressure WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cas
70. blies and detail parts All parts of the equipment are listed exceptfor commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded SPECIFICATION NUMBER 6043A 1 6044A 1 6045A 1 6046A 1 6046A 2 6047A 1 6047A 2 to another part The part descriptions may be indented to show part relationships Todetermine the part number description quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item inthe Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual APPLICATION CODE gt December 1 1997 Revised 8 1 430429 125 4 PARTS LIST Figure 8 1 Control Panel 8 2 December 1 1997 Revised 430429 125 4 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number p
71. d by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual APPLICATION CODE gt rommoo December 1 1997 Revised 8 1 430429 125 3 PARTS LIST Figure 8 1 Control Panel Group 8 2 December 1 1997 Revised 430429 125 3 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number per Code Assy 367845 2 Kit Meter Optional 1 All 1 400641 8 Ammeter DC 1 All 2 400642 4 Voltmeter DC 1 All 3 4DW 77 Shunt 1 All 369685 3 Panel Control Assembly 1 All 4 369684 3 Panel Control 1 All 5 No Number Screw 6 32 x 3 16 Rd Hd MH ST 2 All 6 351505 Screw 1 2 13 x 1 3 4 HHC Drilled for Item 5 2 All 7 No Number Washer LK ST 1 2 4 All 8 No Number Washer 1 2 FL ST 2 All 9 5CW 976A Washer Insulating 4 All 10 5CW 975 Bushing Insulator Stud 2 11 5CW 974 Bus Cable Stud 2 All 12 No Number Nut 1 2 13 Hex Flanged ST 2 All 13 No Number Washer 1 2 Flat ST 2 All 14 No Number Screw 1 2 13 x 1 1 4 HHC ST 2 All 15 405982 1 Cover Meter Hole 2 All 16 406161 Knob Red 1 All 406162 Knob Control 1 All 17 402663 Nut Pot Lock 2 All 18 402658 Fuseholder 1 All 19 W 11166 10 Fuse Amp AGC 1 All 20 402421 2 Light Pilot Red 1 All 21 402900 Terminal Quick Connect Tab Male 2 All 22 368705 8 Capacitor W Lead amp Term 2 All
72. d when straight polarity is used Remote Amperage Control Switch Control Switch Input Contactor x Control itch emote Contactor Contactor ON Pilot Light Fuse Remote Control Receptacle Negative Terminal Remote Control Receptacle Serves as con nection point for the Remote Control Pendant Fuse 3A Voltage Changeover Switch Not on all models On Spec Numbers 6028A 3 6033A 3 and 6038A 3 units a voltage changeover switch will be installed on the rear panel The switch will permit selection of either 230 volt or 460 volt input line voltage without changing the position of the links To select voltage open door on switch box and place switch in desired position Refer to Voltage Changeover Diagram in Diagrams chapter Welding Current Ranges Model Range 1 Range 2 High Low Mega Arc 300 4 15t0 185A 30 to 400 A 400 5 2010 240A 4010500A Mega Arc 500 6 3010350A 60 to 750 600 7 30 to 350 A 60 to 750 A Table 3 2 Range Switch rc Force Ampere Control Voltmeter Optional Amrneter Optional Current Control Positive Termina See Addendum O 229 for Spec 6597 1 and Spec 6633 1 Figure 3 1 Control Panel 3 2 December 1 1997 Revised 430429 125 INSTALLATION INSTALLATION Location For best operating characteristics and longest unit life take care i
73. de de carbone CAW Soudage l arc Plasma PAW Gougeage Air Arc avec lectrode de carbone mince pais Coupage l arc Plasma PAC mince moyen pais selon AWS 8 2 73 Dimension d lectrode ou Epaisseur de m tal ou Intensit de courant toutes conditions toutes conditions moins de 1 po 25 mm de 1 po 25 150 mm plus de 6 po 150 mm moins de 1 8 po 3 mm de 1 8 1 2 po 3 12 mm plus de 1 2 po 12 mm moins de 5 32 po 4 mm de 5 32 1 4 po 4 6 4 mm plus de 1 4 po 6 4 mm toutes conditions toutes conditions toutes conditions toutes conditions toutes conditions toutes dimensions moins de 300 amp res de 300 400 amp res plus de 400 amp res Nuance de de filtre oculaire LES VAPEURS ET LES FUMEES SONT 5 Ne travaillez dans un espace confin que s il est bien ventil DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer 1 Eloignez la t te des fum es pour viter de les respirer l int rieur assurez vous que l aire de soudage est bien ven til e ou que les fum es et les vapeurs sont aspir es l arc Sila ventilation est inadequate portez un respirateur adduc tion d air approuv Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev te ments et aux produits nettoyants sinon portez un respirateur adduction
74. de volt ampere curves that are basically drooping with a slight slope See Table 3 1 for rated output of the models covered by this manual No Spec Load Load No Amps Volts Volts kW Cycle Model No 200 R 200 S 6028A 1 3 200 28 80 5 6 60 6029A 1 200 28 83 5 6 60 6030 1 200 28 80 56 60 6031 1 200 28 80 56 60 6032 1 200 28 80 56 60 Model No 300 R 300 S 6033 1 3 300 32 80 9 6 6096 6034 1 300 32 83 9 6 60 6034B 1 300 32 83 9 6 60 6035 1 300 32 80 9 6 60 6035B 1 300 32 80 9 6 60 6036 1 300 32 80 9 6 60 6037 1 300 32 80 9 6 60 6597 1 300 32 80 96 60 Model 400 R 400 S 6038 1 3 400 36 85 144 60 6039 1 400 36 88 144 60 6040A 1 400 36 85 144 60 6041A 1 400 36 85 144 60 6042A 1 400 36 85 144 60 6633 1 400 36 85 144 60 Model No Mega Arc 600 R 600 S 6043A 1 600 44 85 264 60 6044A 1 600 44 85 264 60 6045A 1 600 44 85 264 60 6046A 1 600 44 85 264 60 6047A 1 600 44 85 264 60 Model No Mega Arc 3 R 200 S 6031A 2 300 32 80 96 35 6032A 2 300 32 80 96 35 Model No Mega Arc 4 R 300 S 6036A 2 400 32 80 12 8 35 6037A 2 400 32 80 128 35 Model No Mega Arc 5 R 400 S 6041A 2 500 40 85 144 40 6042A 2
75. el and specification number shown on the equipment nameplate Locate these numbers in the model and specification number columns below Use only those diagrams and instructions that are applicable VOLTAGE CONNECTION CHANGEOVER OUTLINE PENDANT MODEL NO SPEC NO DIAGRAM DIAGRAM DIMENSION DIAGRAM Mega Arc 200 6028A 1 369704 369705 369707 1 220 5 6028A 3 369704 200361 369707 1 6029A 1 369704 200030 369707 1 6030A 1 369704 200031 369707 1 6031A 1 369704 200032 369707 1 MA 3 6031A 2 369704 200032 369707 1 Mega Arc 200 6032 1 369704 200033 369707 1 MA 3 6032A 2 369704 200033 369707 1 300 6033A 1 369704 369705 369707 1 300 S 6033A 3 369704 200361 369707 1 6034A 1 369704 200030 369707 1 6034B 1 369704 200030 369707 1 6035A 1 369704 200031 369707 1 6035B 1 369704 200031 369707 1 6036A 1 369704 200032 369707 1 MA 4 6036A 2 369704 200032 369707 1 Mega Arc 300 6037 1 369704 200033 369707 1 4 6037A 2 369704 200033 369707 1 Mega Arc 400 6038A 1 369704 369705 369707 1 400 S 6038A 3 369704 200361 369707 1 6039A 1 369704 200030 369707 1 6040A 1 369704 200031 369707 1 6041A 1 369704 200032 369707 1 MA 5 6041A 2 369704 200032 369707 1 Mega Arc 400 6042A 1 369704 200033 369707 1 5 6042A 2 369704 200033 369707 1 Mega Arc 600 6043 1 369704 369705 369707 2 R 600
76. ell ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded 5 Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Wear approved face shield or safety goggles Side shields rec ommended Wear proper body protection to protect skin
77. er Code Assy 200906 1 Control Panel Assembly 1 ABCDF 200906 2 Control Panel Assembly 1 EG 1 200854 1 Panel Control Front 1 All 2 405982 1 Cover Meter Hole 2 BCDFG AW 113 3 Cover Meter Hole 2 AE 3 406806 Knob Red 1 All 4 406808 1 Knob Control 1 All 5 402421 2 Light Pilot Red 1 6 402658 Fuseholder 1 All 7 11166 10 Fuse Amp AGC 1 All 8 402900 Terminal Quick Connect Tab Male 2 9 368705 8 Capacitor W Lead 4 Term 2 All 10 No Number Screw 6 32 x 3 16 Rd Hd MH ST 2 11 351505 Screw 1 2 13 x 1 3 4 Drilled for Item 10 2 All 12 No Number Washer 1 2 LK ST 4 13 No Number Washer 1 2 Flat ST 2 All 14 5CW 976A Washer Insulator Cable Stud 4 All 15 5CW 975 Bushing Insulator Stud 2 All 16 No Number Nut 1 2 13 Hex Flanged ST 2 All 17 5CW 974 Bus Cable Stud L Shaped 2 All 18 No Number Washer Flat ST 2 All 19 No Number Screw 1 2 13 x 1 1 4 HHC ST 2 All 200911 Harness Wire Assembly 1 All 20 401428 8 Potentiometer 2 Watt 5 K 2 All 21 401937 5 Block Terminal 1 All 22 405365 1 Switch Toggle SPST 2 All 23 405365 2 Switch Toggle SPDT 2 All 24 400758 Receptacle 6 Pin Amphenol 1 All 25 367703 1 Resistor 1 2 Watt Assembly 1 All 90391 4 1 Cap Connector 1 367845 2 Kit Meter Optional 1 26 4DW 77 Shunt 1 27 400641 8 Ammeter DC Single Scale 1 All 28 400642 4 Voltm
78. er usually appear on a nameplate attached to the control panel In some cases the nameplate may be at tached to the rear panel Equipment which does not have a control panel such as gun and cable assem blies are identified only by the specification or part number printed on the shipping container Record these numbers for future reference Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immedi ately to file a claim Furnish complete information concerning damage claims or shipping errors to Thermal Arc Order Department 2200 Corporate Drive Troy Ohio 45373 1085 Include all equip ment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before uncrating the unit A lifting handle on the top of the case has been provided so that the equipment may be carried or lifted with a crane or hoist Use care to avoid damaging the equipment when using bars hammers etc to uncrate the unit WARNING Falling machine due to lifting eye failure may cause death or serious injury e Lifting device may fail when overloaded This lifting device is designed to lift the power source ONLY If the machine is equipped with a trailer or accessories over 100 pounds DO NOT LIFT by li
79. es suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI L ELECTROCUTION PEUT ETRE 6 Arr tez tout quipement apr s usage Coupez l alimentation de MORTELLE l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode Une d charge lectrique peut tuer ou br ler grave ment L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimenta tion et les circuits internes de l quipement sont aussi sous tension d s la mise en marche En soudage automatique ou semi automatique avec EN b fil ce dernier le rouleau ou la bobine de fil le N utilisez pas de c bles lectriques us s endommag s mal logement des galets d entrainement et toutes les piss s ou de section trop petite pi ces m talliques en contact avec le fil de soudage N enroulez pas de c bles lectriques autour de votre corps sont sous tension
80. es cancer California Health amp Safety Code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 3 Do not coil or drape cables around the body 2 Arrange cables to one side and away from the operator 4 Keep welding power source and cables as far away from body as practical About Pacemakers The above procedures a
81. eter DC Single Scale 1 All Not Illustrated December 1 1997 Revised 8 3 430429 125 4 PARTS LIST lt nn 31 Figure 8 2 Base and Lifting Yoke Group 8 4 December 1 1997 Revised 430429 125 4 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 1 12CW 2170 Grommet Lifting Yoke 1 All 2 200791 Panel Top 1 All 3 403091 4 Plug Hole Plastic 8 4 200789 Panel Side 2 5 200793 Panel Rear 1 All 6 369650 Shroud Fan 1 All 7 8RT 609 Blade Fan 1 All 8 12TW 595 1 Motor Fan 1 All 9 369640 Bracket Motor 2 All 369638 10 Rectifier Assembly 1 All 10 369639 Heat Sink Rect 1 11 369641 Insulator Mtg Rect 2 12 367733 Shunt 1 13 369642 Heat Sink SCR 6 14 405140 1 Clamp Mounting 6 15 367634 3 Suppressor Surge Assembly 2 16 404044 3 Thermostat Overload 1 17 405139 Rectifier Silicon Controlled 6 All 18 16DA 954 12 Spring 6 All 19 405157 Label Fuse 1 20 W 9234 55 Cable Terminal to Shunt 2 21 200879 Base Assembly 1 All 22 200155 Kit Thermostat Fan Turn On Opt 1 23 201020 Side Panel PC Access Door Opt 1 All 24 201019 Cover OSHA 1 All 25 367579 Insulation Fuse Block 1 All 26 W 11166 9 Fuse 1 Amp 6 27 200114 Spacer PC Board 1 200890 1 Panel PC Board Assembly 1 Al
82. fting eyes Avoid sudden jerks drops or swinging e Check lifting device components visually for looseness and signs of metal fatigue Before changing any hardware check grade and size of bolts and replace with bolts of equal or higher size and grade Additional copies of this manual may be pur chased by contacting Thermal Arc at the address given above Include the Owner s Manual number and equipment identification numbers December 1 1997 Revised 1 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUC TION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to equipment connected to power lines other practices apply to engine driven eq
83. ing the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed exceptfor commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded SPECIFICATION NUMBER 6028A 1 6029A 1 6030A 1 6031A 1 6032A 1 6028A 3 6031A 2 6032A 2 to another part The part descriptions may be indented to show part relationships To determine the part number description quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item inthe Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual APPLICATION CODE
84. l 28 404915 1 Spacer PC Board 6 29 200891 Panel PC Board 1 30 369511 PC Board Assembly 1 31 367718 4 Reactor Filter Assembly 1 All 32 368084 6 Transformer Interphase 1 33 200924 Transformer Power 1 A 200872 Transformer Power 1 B 200925 Transformer Power 1 C 200926 Transformer Power 1 DE 200927 Transformer Power 1 FG December 1 1997 Revised 8 5 430429 125 4 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 34 367654 Brace Voltage Changeover Board 2 All 35 405129 1 Block Fuse 1 All 36 367170 5 Board Voltage Changeover 1 A 367229 6 Board Voltage Changeover 1 B 367229 7 Board Voltage Changeover 1 C 367229 9 Board Voltage Changeover 1 DE 367229 8 Board Voltage Changeover 1 FG 37 CW 811 Link Voltage Changeover 6 All 200909 1 Yoke Lifting Assembly 1 AB 200909 2 Yoke Lifting Assembly 1 CDEFG 38 200886 Yoke Lifting 1 All 39 406358 2 Resistor Fixed 1 All 41 405362 2 Bushing Snap 1 42 405793 Label Warning 1 All 43 405362 5 Bushing Snap 1 All 44 406392 1 Transformer Control 1 AB 406392 2 Transformer Control 1 CDEFG 45 W 11166 11 Fuse 5 Amp 1 All 406484 Label Fuse Trans 1 46 204036 Label Precautionary 1 All 402549 1 Tag Line Voltage 1 All Not Illustrated 8 6 December 1 1997 Revised OM 193 5 PARTS LIST PARTS LIST Equipment Identification
85. liver welding current and open circuit voltage is present at the output when gun switch is depressed No ground connections at work Make connections Welding leads not connected Make connections Current control does not control welding current Potentiometer burned out Contact factory 7 2 December 1 1997 Revised 430429 125 TROUBLESHOOTING Loose connections in voltage control circuit Check connections Control circuit board failure See Detailed Setting and Troubleshooting of PC Board Fan not operating also see causes and remedies under Welding machine will not start Motor failed Replace or repair Broken lead or connection to fan motor Repair wiring Blown fuse on front panel of welding machine Replace 115 volt circuit may be overloaded Operator gets shock when welding machine case is touched Case of welding machine not grounded Ground welding machine case Abnormal current fluctuation voltage nearly constant Loose cable connections Check for overheated connections and tighten Control board failure See Detailed Setting and Troubleshooting of PC Board Contactor fails to open Contactor contacts sticking Clean contacts Very noticeable rough sputtering arc Loss of control Minor starting problems Control circuit board failure See Detailed Setting and Troubleshooting of PC Board December 1 1997 Revised 7 3 430429 125 TROUBLESHOOTING Detailed Troubleshooting Instructions
86. loser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec soin Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage MISE EN GARDE LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs LE CARBURANT PEUR CAUSER UN IN CENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de faire le plein Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s Portez des v tements appropri s pour prot ger la peau Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consig
87. n quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item inthe Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual SPECIFICATION NUMBER 6633 1 December 1 1997 Revised 8 1 430429 125 6 PARTS LIST 35 36 27 37 Figure 8 1 Control Panel Group Parts List for Figure 8 1 Item Part Description Qty No Number per Assy 367845 2 Kit Meter Optional 1 1 400641 8 Ammeter DC 1 2 400642 4 Voltmeter DC 1 3 4DW 77 Shunt 1 4 40201 Shim Rubber 20 201166 2 Panel Front Assembly 1 5 201165 2 Panel Control 1 6 No Number Screw 6 32 x 3 16 Hd MH ST 2 8 2 December 1 1997 Revised 430429 125 6 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty No Number per Assy 7 No Number Screw 1 2 13 x 1 3 4 HHC Drilled for Item 2 8 No Number Washer LK ST 1 2 4 9
88. n operating the unit in a high frequency at mosphere or with a high frequency attachment the following guidelines should be adhered to to mini mize interference 1 Turn the high frequency intensity on machines or attachments to the lowest level which will not interfere with arc starting 2 Use the shortest possible TIG Torch cable and do not route it with other control cables and power cables 3 Make certain that all equipment cases are earth grounded A large ground wire between a high frequency attachment case and ground is helpful 4 Do not coil power cables on control cables It is best to route cables on the floor rather than over head and among other cables This minimizes antenna effects 5 The input power cable to a high frequency attachment should be as short as possible 6 The input leads to the power source should be contained in solid metal conduit whenever possible When TIG welding at very low current less than 30 amperes a jumper plug can be changed on the printed circuit board 369511 to insure that the open circuit voltage will stay at maximum value This will reduce the possibility of high frequency interference when operating at low reference volt ages In order to make this change follow this procedure 1 Remove the left side panel 2 At the bottom of the printed circuit board there is a plug labeled J6 See Figure 7 5 in Trou bleshooting chapter Remove this plug from pins 1 and 2
89. n selecting an installation site Avoid locations exposed to high humidity dust high am bient temperature or corrosive fumes Moisture can condense on electrical components causing corro sion or shorting of circuits Dirt on components helps retain this moisture Adequate air circulation is needed at all times in order to assure proper operation Provide a mini mum of 12 inches 305 mm of free air space at both front and rear of the unit Make sure that the venti lator openings are not obstructed Internal Wiring Check Refer to the product identification plate name plate on the welding machine s control panel to determine the power input voltages and frequency at which it will be operated Remove cabinet top for access Line Voltage Changeover circuitry Check line voltage connec tions against instructions on Voltage Changeover Diagram supplied with this manual If necessary rearrange internal wiring and or link connections Connecting Welding Machine to Line Voltage The input power should be connected to the unit through a fused disconnect switch or other suitable disconnecting means furnished by the used A hole is provided in the rear panel of the machine near to the input connections for the entry of the input conductors DANGER ELECTRIC SHOCK CAN KILL Open the discon nect switch or breaker and determine that no voltage is present before connecting wires between welding ma chine and power sup
90. nes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publica tion P 1 de la CGA identifi e dans la liste de documents ci dessous Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur 8 V 96 2 3 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 DES PIECES EN MOUVEMENT PEU VENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur DES ETINCELLES PEUVENT FAIRE EX PLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PE
91. ng arc completely 2 Rough sputtering arc very noticeable 3 Loss of welding arc control 4 Difficulty in starting arc Malfunction in SCRs The following conditions will probably exist 1 Blown line fuses in the case of a shorted SCR similar to a shorted diode 2 One SCR does not turn on either it is open or gate signal is not being received by the SCR gate circuit open and a very small change will occur at the welding arc and will be difficult to detect by the average welding operator Generally when this hap pens it will be necessary to adjust the current control on the front of the power source increasing the current to obtain the same welding current that was being produced before the SCR defect oc curred 3 Two SCRs do not turn on the welding arc becomes more erratic and unstable Open Circuit Voltage Test If the power source is suspected a very simple test can tell you a great deal about the power source Observe the open circuit voltage of the machine by placing a voltmeter across the output terminals The voltage reading should be approxi mately 80 V DC on the R 200 S and R 300 S 85 V DC on the R 400 S R 500 S and R 600 S If the voltage is not equal or close to this voltage there is something wrong with the power source Note that this voltage was observed at normal input line voltage 230 volts for example It will vary according to the line voltage If the 80 or 85 V DC is observed
92. not apply to this manual How To Select Recommended Spares The first two columns of the Parts List are used to show the recommended quantity of parts which are typically required for spares or replacement purposes The quantities under Class 1 are for parts that are consumed or that may need replace ment in two years or less depending on operating hours Class 2 quantities are for parts that may need replacement under unusual service condi tions or additional operating hours These are suggested quantities based on expected usage or the minimum package quantity Class 1 spares are repeated under Class 2 but the quantities may be larger to allow for additional operating hours Con tact your equipment dealer for assistance in estab lishing the spare parts program best suited for your needs APPLICATION CODE moou December 1 1997 Revised 8 1 430429 125 7 PARTS LIST Figure 8 1 Control Panel Group 8 2 December 1 1997 Revised 430429 125 7 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number per Code Assy 367845 2 Kit Meter Optional 1 All 1 400641 8 Ammeter DC 1 All 2 400642 4 Voltmeter DC 1 All 3 4DW 77 Shunt 1 369685 4 Panel Control Assembly 1 All 4 369684 Panel Control Assembly 1 All 5 No Number Screw 6 32 x 3 16 Rd Hd MH ST 2 All 6 351505 Screw 1 2 13 x 1 3 4 HHC Drilled for 5 2 All 7 No Number Washer LK ST
93. nsformer Power Assembly 1 C 200290 Transformer Power Assembly 1 DG 200291 Transformer Power Assembly 1 E 43 367690 Brace V C Board 2 All 44 405129 1 Block Fuse 1 All 45 367170 5 Board V C Assembly 1 AF 367229 6 Board V C Assembly 1 B 367229 7 Board V C Assembly 1 C 367229 9 Board V C Assembly 1 DGH 367229 8 Board V C Assembly 1 E 200643 Box Voltage Changeover Assembly 1 F 46 365167 Box Voltage Changeover 1 F 47 405615 Switch VC 1 F 48 W 10862 1 Connector Cable 1 F 49 200418 Bracket Mtg Box 1 F 50 361692 Label V C 1 F W 10080 4 Connector Straight 1 F 51 204036 Label Precautionary 1 All Not Illustrated 8 6 December 1 1997 Revised 430429 125 2 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed exceptfor commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at
94. onal 1 All 200157 Kit Cover OSHA Optional 1 21 200280 Cover 1 369826 Kit Side Panel W Access Door Optional 1 All 22 369827 Panel Side 1 All 23 369210 Door Access 1 All m 402549 2 Tag Line Voltage 1 AFB 402549 1 Tag Line Voltage 1 CDEGH 369669 2 Panel PC Board Assembly 1 24 369670 Panel PC Board 1 All 25 404915 1 Spacer PC Board 6 All 26 369511 Board PC Assembly 1 All 27 200114 Spacer PC Panel 1 All 369630 1 Yoke Lifting Assembly 1 ABF 369630 2 Yoke Lifting Assembly 1 CDEGH Not Illustrated December 1 1997 Revised 8 5 430429 125 1 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 28 369631 Yoke Lifting 1 29 405362 1 Bushing Snap 2 30 405362 2 Bushing Snap 1 31 405793 Label Warning 1 All m 406484 Label Fuse Control Trans 1 All 32 406358 2 Resistor 50 Ohms 1 All 33 405479 Contactor 1 All 34 402037 27 Grommet Rubber 1 All 35 W 11166 11 Fuse 1 2 Amp 1 All 36 406392 1 Transformer Control 1 ABF 406392 2 Transformer Control 1 CDEGH 37 367723 2 Reactor Filter 1 All 38 369672 Transformer Interface 1 All 39 367579 Insulator Fuse Block 1 40 W 11166 9 Fuse 1 Amp 6 All 41 CW 811 Link Voltage Changeover 6 ABCDFGH CW 811 Link Voltage Changeover 3 EH 42 200287 Transformer Power Assembly 1 AF 200288 Transformer Power Assembly 1 B 200289 Tra
95. or 4 3 as a guide if no local or national code is applicable Attach the equipment grounding conductor to the stud provided adjacent to the contactor Determine that the ground wire size is adequate before the machine is operated CAUTION Be sure to replace the cabi net top to assure adequate internal ven tilation and prevent component failure Welding Leads Use Table 4 4 for selection of the proper size copper welding leads 4 2 December 1 1997 Revised 430429 125 INSTALLATION INPUT VOLTAGE DATA Spec No Line Volts Line Amps Phase Hz kW 6028 1 3 230 460 41 20 5 3 60 9 0 6029A 1 200 208 230 460 47 41 20 5 3 60 9 0 6030A 1 230 460 575 41 20 5 16 4 3 60 9 0 6031 1 220 380 415 43 25 23 3 50 9 0 6031A 2 220 380 415 64 5 37 5 34 5 3 50 14 3 6032A 1 380 500 25 9 3 50 9 0 6032A 2 380 500 37 5 28 5 3 50 14 3 6033A 1 3 230 460 62 31 3 60 14 0 6034A 1 200 208 230 460 71 62 31 3 60 14 0 6034B 1 200 208 230 460 71 62 31 3 60 14 0 6035A 1 230 460 575 62 31 25 3 60 14 0 6035B 1 230 460 575 62 31 25 3 60 14 0 6036A 1 220 380 415 63 36 33 3 50 14 0 6036A 2 220 380 415 84 48 44 3 50 18 5 6037A 1 380 500 36 27 3 50 14 0 6037A 2 380 500 48 36 5 3 50 18 5 6597 1 230 460 62 31 3 60 14 0 6038 1 3 230 460 87 43 5 3 60 20 5 6039A 1 200 208 230 460 100 87 43 5 3 60 20 5 6040A 1 230 460 575 87 43 5 35 3 60 20 5 6041 1 220 380 415 91 53 48 3 50 20 5 6041A 2 220 380 415 114 6
96. parts at once covers In confined spaces or damp locations do not use a welder with Disconnect input power or stop engine before installing or serv AC output unless it is equipped with a voltage reducer Use icing this equipment Lock input power disconnect switch open equipment with DC output or remove line fuses so power cannot be turned on accidentally Wear a safety harness to prevent falling if working above floor Properly install and ground this equipment according to its level Owner s Manual and national state and local codes Keep all panels and covers securely in place Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input ARC RAYS can burn eyes and skin Wear a welding helmet fitted with a proper shade of filter see NOISE can damage hearing ANSI Z49 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended Arc rays from the welding process produce intense Use protective screens or barriers to protect others from flash heat and strong ultraviolet rays that can burn eyes and glare warn others not to watch the arc de pith Noise from some processes can damage Wear protective clothing made from durable flame resistant 9 material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level i
97. ply CAUTION The method of installation conductor size and overcurrent protec tion shall conform to the requirements of the local electrical code the National Electrical Code or other national codes as applicable installation wiring and machine reconnection shall be done by qualified persons Table 4 2 or 4 3 provides minimal information for selection of line conductors fuses and the equip ment grounding conductor This information is from the National Electrical Code NFPA 70 1981 Edition Install this equipment per the latest edition avail able from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 See CAU TION above Connect the three phase line leads to terminals L1 L2 and L3 on the line contactor inside the welding machine cabinet Grounding The frame of this welding machine should be grounded for personnel safety and to assure op eration of the overcurrent protection The grounding method and the equipment grounding conductor size and type shall conform to local and national codes For the National Electrical Code the equipment grounding conductor shall be green green with a yellow stripe or bare If flexible power cable is used use a cable assem bly which includes the equipment grounding con ductor If metallic armored cable or conduit is used the metal sheathing or conduit must be effectively grounded per local and national codes
98. re among those also normally recommended for pacemaker wearers Consult your doctor for complete information PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis High way Suite 501 Arlington VA 22202 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Practices for Occupation and Educational Eye and Face Pro tection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 8 1996 2 3 ARC WELDING SAFETY INSTRU
99. rks and hot metal weld spatter hot work piece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases Read the Material Safety Data Sheets MSDSs and the manu facturer s instruction for metals consumables coatings and cleaners Work in a confined space only if it is w
100. rminals Fuse on control transformer blown Remedy cause Replace fuse Line contactor fails to close Defective coil Replace Mechanical obstruction on contactor Remove Broken leads at line contactor Repair Contactor chatters Line leads too small Use larger leads Low line voltage Check line voltage December 1 1997 Revised 7 1 430429 125 TROUBLESHOOTING Contactor operates and blows link fuses Wrong line voltage Check nameplate of welding machine for line voltage to use check line voltage Links on voltage changeover board incorrectly connected Check wiring diagrams for link positions connect links correctly Line fuse too small Install proper size fuse SCR failure See Silicon Controlled Rectifier Testing Short circuit in primary connections Remove short circuit Transformer failed Replace transformer Unit delivers welding current but soon shuts down Welding machine overloaded Reduce load overload can be carried only for a short time Duty cycle too high Do not operate continually at overload currents Power leads too long or too small in cross section Replace with larger diameter cable Ambient temperature too high Operate at reduced loads when temperature exceeds 104 F 40 C Ventilation blocked Check air intake and exhaust openings to be unobstructed Fan not operating Check bearings disconnect leads and apply motor nameplate voltage to test Contactor operates but welding machine will not de
101. rnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed exceptfor commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded SPECIFICATION NUMBER 6038A 1 6039A 1 6040A 1 6041A 1 6042A 1 6038A 3 6041A 2 6042A 2 to another part The part descriptions may be indented to show part relationships Todetermine the part number description quan tity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item inthe Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Specifications or Assemblies covere
102. s high Eye protection filter shade selector for welding Electrode Size i Electrode Size Welding or Cutting Metal Thickness Welding or Cutting Metal Thickness Operation or Welding Current Operation or Welding Current Torch soldering Gas metal arc welding MIG Torch brazing Non ferrous base metal All Oxygen cutting Ferrous base metal All Light Under 1 in 25 mm Gas tungsten arc welding TIG Medium 110 in 25 150 mm Atomic hydrogen welding All Heavy Over 6 in 150 mm Carbon arc welding Gas welding Plasma arc welding All Light Under 1 8 in 3 mm Carbon arc air gouging Medium 1 8 to 1 2 in 3 12 mm Light Heavy Over 1 2 in 12 mm Heavy Shielded metal arc welding Under 5 32 in 4 mm Plasma arc cutting stick electrodes 5 32 to 1 4 in 4 to 6 4 mm Light Under 300 Amp Over 1 4 in 6 4 mm Medium 300 to 400 Amp Heavy Over 400 Amp May 8 1996 2 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying spa
103. t Remote Connector Control Local Remote Switch In LOCAL DOWN position the SCRs Silicon Controlled Rectifiers are energized and open circuit voltage OCV is applied to welding output terminals In REMOTE UP position a re mote switch must be used Range Switch Low High Range The welding current range suitable for the work application and electrode selection will be chosen by this switch See Table 3 2 for current ranges December 1 1997 Revised 3 1 430429 125 DESCRIPTION OF EQUIPMENT Arc Force Ampere Control Varies the short circuit welding arc current and produces an in crease of amperage when arc length is shortened such as a tight groove This control provides more arc force and eliminates the tendency of snuffing out the arc when using electrode manipulation The control is especially suited for use with E 6010 and E 7018 electrodes for pipe welding applications See NOTE in Operation chapter Current Control Adjusts the welding current See Table 3 2 for ranges of control Voltmeter Optional Indicates the OCV or welding voltage of the arc if welding arc is estab lished Ammeter Optional Indicates the amperage of the welding arc when an arc is established Positive Terminal 4 Serves as connection point for the welding lead to the workpiece when straight polarity is used Negative Terminal Serves as connection point for the electrode lea
104. tat Overload Heat Sink SCR Rectifier Silicon Clamp Mounting Pin Spring Shunt Insulator Mtg Rect Bar Bus Output Term to Shunt Thermostat Fan Turn On Optional Kit Cover OSHA Optional Cover Kit Side Panel W Access Door Optional Panel Side Door Access Tag Line Voltage Tag Line Voltage Panel PC Board Assembly Panel PC Board Spacer PC Board Board PC Assembly Spacer PC Panel Yoke Lifting Assembly Yoke Lifting Assembly Qty Application per Code Assy All All All All All All All All All All All All All All All All All All All All All All All All All All All All AFB CDEGH All All All All All ABF CDEGH December 1 1997 Revised 8 5 430429 125 3 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 28 369631 Yoke Lifting 1 29 405362 1 Bushing Snap 2 30 405362 2 Bushing Snap 1 All 31 405793 Label Warning 1 All 406484 Label Fuse Control Trans 1 32 406358 2 Resistor 50 Ohms 1 All 33 405402 Contactor 1 All 34 402037 27 Grommet Rubber 1 35 W 11166 11 Fuse 1 2 Amp 1 All 36 406392 1 Transformer Control 1 ABF 406392 2 Transformer Control 1 CDEGH 37 367718 2 Reactor Filter 1 All 38 368084 5 Transformer Interface 1 All 39 367579 Insulator Fuse Block 1 40 W 11166 9 Fuse 1
105. there is a very good chance that the power source is operating properly See cuit Voltage vs Line Voltage Curve Figure 7 1 for open circuit voltage variation as a function of line voltage NOTE It is important to note that in the LOW range see Table 3 2 at minimum setting on the Current Control the open cir cuit voltage will drop to a lower value and possibly appear to be unstable fluctuate This is not a malfunction but a normal situation Printed Circuit Board Testing The next step is to check the Printed Circuit Board inside the unit For complete details see Detailed Setting and Troubleshooting of Printed Circuit Board which follows the next section and also Figure 7 5 Silicon Controlled Rectifier SCR Testing In the case of a severe malfunction such as a shorted SCR do not turn the unit ON Disconnect the leads from the transformer to the heat sink assembly and check with for shorted SCRs An open gate or an open SCR cannot be checked with a VOM If an SCR is not firing the open circuit 7 4 December 1 1997 Revised 430429 125 TROUBLESHOOTING mom Circuit Voltage Line mom Open Circuit Voltage CNN Nominal Value 400 5 Mega Arc 600 Mega Arc 500 6 Mega Arc 300 4 Mega Arc 200 3 05 215 225 25 245 255 Line Voltage ABI Figure 7 1 voltage will shift down
106. uipment Safe practices are outlined in the American National Standard Z49 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE ELECTRIC SHOCK can kill Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not power circuit and machine internal circuits are also d dd live when poweris In semiautomatic or automatic 4 peop wire welding the wire wire reel drive roll housing Donotuse worn damaged undersized or poorly spliced cables and all metal parts touching the welding wire are Do not wrap cables around your body electrically live Incorrectly installed or improperly Ground the workpiece to a good electrical earth ground grounded equipment is a hazard Do not touch electrode while in contact with the work ground Do not touch live electrical parts circuit Wear dry hole free insulating gloves and body protection Useonly well maintained equipment Repair or replace damaged Insulate yourself from work and ground using dry insulating mats

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