THERMAL ARC 300 GMS NOT 124-r02

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THERMAL ARC 300 GMS

USER’S MANUAL

The machine you have just acquired has taken advantages, in its production, of THERMADYNE INDUSTRIES 's wide experience in the manufacturing of welding machines, along with the latest technology strides in power electronics.

It will give you entire satisfaction for years if you respect all the operating and maintenance instructions given in this manual.

We strongly suggest to read very carefully chapters concerning security and individual protection before using this machine.

We thank you in advance for your co-operation.

THERMADYNE INDUSTRIES reserve the right to make changes without previous notification. Illustrations, descriptions and characteristics are not contractually binding and do not engage the responsability of the manufacturer.

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TABLE OF CONTENTS

WARRANTY POLICY STATEMENT .................................................... Erreur ! Signet non défini.

SAFETY....................................................................................................................................... 5

1.

ELECTROMAGNETIC COMPATIBILITY ................................................................................................................6

1.1.

DECLARATION OF CONFORMITY ......................................................................................................................6

1.2.

INSTALLATION AND USE.....................................................................................................................................7

1.2.1.

ASSESSMENT OF AREA ...................................................................................................................................................7

1.2.2.

METHODS OF REDUCING EMISSIONS..........................................................................................................................8

1.2.2.1.

Public supply system.........................................................................................................................................................8

1.2.2.2.

Maintenance of the arc welding equipment.......................................................................................................................8

1.2.2.3.

Welding cables..................................................................................................................................................................8

1.2.2.4.

Equipotential bonding .......................................................................................................................................................8

1.2.2.5.

Earthing of the workpiece .................................................................................................................................................8

1.2.2.6.

Screening and shielding ....................................................................................................................................................8

2.

ELECTRIC SECURITY..................................................................................................................................................9

2.1.

CONNECTION OF THE WELDING POWER SOURCE TO THE NETWORK ....................................................9

2.2.

WORKING AREA.....................................................................................................................................................9

2.3.

INTERVENING.........................................................................................................................................................9

2.4.

MAINTENANCE.....................................................................................................................................................10

2.5.

RISKS OF FIRE AND EXPLOSION ......................................................................................................................10

3.

INDIVIDUAL PROTECTION......................................................................................................................................10

3.1.

RISK OF EXTERNAL INJURIES...........................................................................................................................10

3.1.1.

THE WHOLE BODY .........................................................................................................................................................10

3.1.2.

FACE AND EYES..............................................................................................................................................................11

3.2.

RISK OF INTERNAL INJURIES............................................................................................................................11

3.3.

SAFETY IN THE USE OF GASES (welding with TIG or MIG inert gases) .........................................................12

3.3.1.

COMPRESSED GAS CYLINDERS ..................................................................................................................................12

3.3.2.

PRESSURE RELIEF VALVE ............................................................................................................................................12

3.3.3.

DETAILS ABOUT GASES................................................................................................................................................12

DESCRIPTION .......................................................................................................................... 13

4.

GENERAL CHARACTERISTICS...............................................................................................................................13

5.

TECHNICAL CHARACTERISTICS ..........................................................................................................................14

SETTING UP ............................................................................................................................. 15

6.

CONNECTION TO THE MAIN SUPPLY...................................................................................................................15

7.

CONNECTION TO THE GROUND ............................................................................................................................15

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TABLE OF CONTENTS

8.

PRELIMINARY PRECAUTIONS ...............................................................................................................................15

USING........................................................................................................................................ 16

9.

DESCRIPTION OF THE FRONT PANEL..................................................................................................................16

10.

DESCRIPTION OF THE BACK PANEL ................................................................................................................17

11.

MMA (

STICK

) WELDING..........................................................................................................................................18

12.

TIG WELDING ..........................................................................................................................................................18

13.

MIG WELDING .........................................................................................................................................................21

13.1.

PREPARATION ..................................................................................................................................................21

13.2.

ADJUSTMENT OF THE PARAMETERS..........................................................................................................21

14.

SPOT MIG WELDING..............................................................................................................................................23

15.

INTERMITTENT MIG WELDING.........................................................................................................................23

16.

« SAVE »

AND

« LOAD » MENU .............................................................................................................................24

MAINTENANCE ........................................................................................................................ 25

17.

MAINTENANCE .......................................................................................................................................................25

18.

SPARE PARTS ...........................................................................................................................................................25

19.

TROUBLE SHOOTING ............................................................................................................................................30

20.

WIRING DIAGRAM .................................................................................................................................................31

APPENDICE .............................................................................................................................. 32

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WARRANTY POLICE STATEMENT

In accordance with the warranty periods stated below, Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in this operating manual.

Thermadyne welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment.

Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the warranty period. The warranty period begins on the date of sale to the end user.

Thermal Arc 300 GMS

Component Warranty Period

Power Source 2 Years

Optional Remote Controls 6 Months

If warranty is being sought, Please contact your Thermadyne product supplier for the warranty repair procedure.

Thermadyne warranty will not apply to:

Equipment that has been modified by any other party other than Thermadyne’s own service personnel or with prior written consent obtained from Thermadyne Service Department.

Equipment that has been used beyond the specifications established in the operating manual.

Installation not in accordance with the installation/operating manual.

Any product that has been subjected to abuse, misuse, negligence or accident.

Failure to clean and maintain (including lack of lubrication, maintenance and protection), the machine as set forth in the operating, installation or service manual.

Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation.

This manual also offers basic troubleshooting, operational and technical details including application usage.

You may also wish to visit our web site www.thermadyne.com select your product class and then select literature.

Here you will find documentation including:

Operator manuals

Service manuals

Product guides

Alternatively please contact your Thermadyne distributor and speak with a technical representative.

NOTE

Warranty repairs must be performed by either a Thermadyne Service Centre, a Thermadyne distributor or an

Authorised Service Agent approved by the Company.

September 2009

The equipment you have just acquired will give you entire satisfaction if you respect the operating and maintenance instructions.

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SAFETY

Its design, the specification of the components and its manufacture are in accordance with the existing rules, French standards (NF), ISO and CEI international injunctions, EEC general lines and CEN/CENELEC standards.

In this chapter, you will find safety rules in the use of electric arc welding power sources with coated electrodes.

We give you hereunder a list of recommandations and obligations you have to respect.

Safety rules must be observed, and particulary those relating to Decree 88.1056 dated November 14., 1988 concerning protective measures against electric currents.

1.

ELECTROMAGNETIC COMPATIBILITY

1.1.

DECLARATION OF CONFORMITY

THERMADYNE INDUSTRIES hereby declare that the machine object of this manual complies with the following

European regulations :

Electromagnetic compatibility :

Rule 89/336-EEC of 3/05/89 modified by rules 92/31-EEC of 28/04/1992 and 93/68-EEC of 22/07/1993.

Low voltage :

Rule 73/23-EEC of 19/02/1973 modified by rule 93/68-EEC of 22/07/1993. and with the national legislation transposing them.

THERMADYNE INDUSTRIES also declare that following harmonised standards have been applied :

EN 60974-10 (2003): Electromagnetic compatibility (CEM) – Product norm for arc welding material.

EN 50060 (1990): Current source for arc manual welding with limited service.

EN 60974-1: Security rules for electric welding material.

Part 1: welding current sources.

EN 50192 (1995): Arc welding material – plasma cutting systems.

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SAFETY

1.2.

INSTALLATION AND USE

The machine object of this manual complies with the European regulations about electromagnetic compatibility

89/336 CEE. It also complies with EN 60974-10 standard: Electromagnetic compatibility, product standard for welding machines.

The user is responsible for installing and using the arc welding equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected, then it shall be the responsibility of the user of the arc welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see Note. In other cases it could involve constructing an electromagnetic screen enclosing the welding power source and the work complete with associated input filters. In all cases electromagnetic disturbances shall be reduced to the point, where they are no longer troublesome.

NOTE - The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths, which may damage the earth circuits of other equipment.

Further guidance is given in IEC 62081 "Arc welding equipment - Installation and use" (under consideration).

1.2.1.

ASSESSMENT OF AREA

Before installing arc welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account : a) other supply cables, control cables, signalling and telephone cables, above, below and adjacent to the arc welding equipment; b) radio and television transmitters and receivers; c) computer and other control equipment; d) safety critical equipment, e.g. guarding of industrial equipment, e) the health of the people around, e.g. the use of pacemakers and hearing aids; f)equipment used for calibration or measurement; g) the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; h) the time of day that welding or other activities are to be carried out.

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SAFETY

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

1.2.2.

METHODS OF REDUCING EMISSIONS

1.2.2.1. Public supply system

Arc welding equipment should be connected to the public supply system according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the public supply system. Consideration should be given to shielding the supply cable of permanently installed arc welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

1.2.2.2. Maintenance of the arc welding equipment

The arc welding equipment should be routinely maintained according to the manufacturers recommendations. All access and service doors and covers should be closed and properly fastened when the arc welding equipment is in operation. The arc welding equipment should not be modified in any way, except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilising devices should be adjusted and maintained according to the manufacturer’s recommendations.

1.2.2.3. Welding cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

1.2.2.4. Equipotential bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.

However, metallic components bonded to the work piece will increase the risk that the operator could receive an electric shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

1.2.2.5. Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

1.2.2.6. Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.

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SAFETY

2.

ELECTRIC SECURITY

2.1.

CONNECTION OF THE WELDING POWER SOURCE TO THE NETWORK

Before connecting your equipment, you must check that:

-The meter, the safety device against over-currents, and the electric installation are compatible with the maximum power and the supply voltage of the welding power source (refer to the instructions plates).

-The connection, either single-phase, or three-phase with earth can be effected on a socket compatible with the welding power source cable plug.

If the cable is connected to a fixed post, the earth, if provided, will never be cut by the safety device against electric shocks.

-The ON/OFF switch (if exists) situated on the welding power source, is turned off.

2.2.

WORKING AREA

The use of arc welding implies a strict respect of safety conditions with regard to electric currents (Decree dated

14.12.1988).

It is necessary to check that no metal piece accessible to the operators and to their assistants can come into direct contact with a phase conductor and the neutral of the network. In case of uncertainty, this metal part will be connected to the earth with a conductor of at least equivalent section to the largest phase conductor.

Make sure that all metal pieces that the operator could touch with a non insulated part of his body (head, hands without gloves on, naked arms ...) is properly grounded with a conductor of at least equivalent section to the biggest supply cable of the ground clamp or welding torch. If more than one metal ground are concerned, they need to be all interlinked in one, which must be grounded in the same conditions.

Unless very special care have been taken, do not proceed to any arc welding or cutting in conductive enclosures, whether it is a confined space or the welding machine has to be left outside. Be even more prudent when welding in humid or not ventilated areas, and if the power source is placed inside (Decree dated

14.12.1988, Art. 4).

2.3.

INTERVENING

-Before carrying out any internal checking or repair work, check that the power source has been separated from the electrical installation by locking and guard devices.

-The current plug has to be taken out. Provisions have to be taken to prevent an accidental connection of the plug to a socket.

-Cut-off through a fixed connecting device has to be omnipolar (phases and neutral). It is in the "OFF" position and cannot be accidentally put into operation.

-Maintenance works of electrical equipment must be entrusted to qualified people (Section VI, Art. 46).

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SAFETY

2.4.

MAINTENANCE

Check the good state, insulation and connection of all the equipment and electrical accessories: plugs and flexible supply cables, cables (NF A 32-510), conduits, connectors, extension cables (NF A 85-610 and CENELEC HD

433), sockets on the power source, ground and electrode-holder clamps (NF A 85-600).

These connections and mobile accessories are marked according to standards, if consistent with the safety rules.

They can either be controlled by you or by accredited firms.

- Maintenance and repair works of conduits and liners have to be properly carried out (Section VI, Art. 47).

-Repair or replace all defective accessories

-Check periodically that the electrical connections are tightened and do not heat.

2.5.

RISKS OF FIRE AND EXPLOSION

Welding can occur risks of fire or explosion. You have to pay attention to fire safety regulation

- Remove flammable or explosive materials from welding area.

- Always have sufficient fire fighting equipment

- Fire can break out from sparks even several hours after the welding work has been finished.

3.

INDIVIDUAL PROTECTION

3.1.

RISK OF EXTERNAL INJURIES

3.1.1.

THE WHOLE BODY

Arc rays produce very bright ultra violet and infra red light. They will damage yours eyes and burn your skin if you are not properly protected

-The welder is dressed and protected according to the constraints his works impose him.

-Insulate yourself from the workpiece and the ground. Make sure that no metal piece, especially those connected to the network, can come into contact with the operator.

-The welder must always wear an individual insulating protection (decree of 14/12/1988, article 3-3).

Protective clothing : gloves, aprons, safety shoes offer the additional advantage to protect the operator against burns caused by hot pieces, spatters ...

Check the good state of these equipment and replace them before you are not protected any more.

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SAFETY

3.1.2.

FACE AND EYES

-.It is absolutely necessary to protect your eyes against arc rays.

- Protect your hair and your face against sparks

The welding shield, with or without headset, is always equipped with a proper filter according to the arc welding current (NS S 77-104 / A 88-221 / A 88.222 standards).

In order to protect shaded filter from impacts and sparks, you have to add a plain glass in front of the shield.

The helmet provided with your equipment (if requested) is equipped with a protective filter. When you want to replace it, precise the reference and number of opacity degree of the filter. Use the shade of lens as recommended in the instruction manual (opacity graduation number)

Protect others in the work area from arc rays by using protective booths, UV protective goggles, and if necessary, a welding shield with appropriate protective filter on (NF S 77-104 - by A 1.5).

Opacity gradation numbers and recommended use for arc welding

Welding process or

connected techniques

Coated electrodes

MIG on heavy metals

MIG on light alloys

TIG on all metals

MAG

Air/Arc gouging

Plasma cutting

Current intensity in Amps

0.5 2.5 10 20 40 80 125 175 225 275 350 450

1 5 15 30 60 100 150 200 250 300 400 500

9

9 10

10

11

10

10

11

11

11

12

12

13

12

12

13

14

13

13

14

14

14

15

10 11 12

10 11

13

12 13

14

14

9 10 11 12 13

15

15

Depending on the conditions of use, the next highest or lowest category number may be used.

The expression “heavy metals” covers steels, alloyed steels, copper and its alloys.

The shaded areas represent applications where the welding processes are not normally used at present.

CARE : Use a higher degree of filters if welding is performed in premises which are not well lighted.

3.2.

RISK OF INTERNAL INJURIES

GASES AND FUMES

Gases fumes produced during the welding process can be dangerous and hazardous to your health. Arc welding works have to be carried out in suitable ventilated areas.

Ventilation must be adequate to remove gases and fumes during operation. All fumes produced during welding have to be removed as soon as they are given off, and as close as possible from the place they are produced to be the most efficient.

Vapors of chlorinated solvents can form the toxic gas phosgene when exposed to ultraviolet radiation from an electric arc.

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SAFETY

3.3.

SAFETY IN THE USE OF GASES (WELDING WITH TIG OR MIG INERT GASES)

3.3.1.

COMPRESSED GAS CYLINDERS

Compressed gas cylinders are potentially dangerous. Refer to suppliers for proper handling procedures.

- No impact: secure the cylinders and keep them away from impacts.

- No excess heat (over 50°C)

3.3.2.

PRESSURE RELIEF VALVE

Check that the pressure relief screw is slackened off before connecting to the cylinder.

Check that the union is tight before opening the valve of the cylinder. Open it slowly a fraction of a turn.

If there is a leak, NEVER tighten a union which is under pressure, but first close the valve on the cylinder.

Always check that hoses are in good condition.

3.3.3.

DETAILS ABOUT GASES

Gas and gaseous mixtures containing less than 20% of CO

2

:

If these gases or mixtures take the place of the oxygen in the air, there is a danger of asphyxia. An atmosphere containing less than 17% oxygen is dangerous. hydrogen and hydrogen-based combustible gaseous mixtures

These are very light gases. In the case of leaks, they collect under the ceiling.

Provide for ventilation at ceiling level.

These are also inflammable gases. The flame of hydrogen is almost invisible. There is therefore a risk of burns.

Air/hydrogen and oxygen/hydrogen mixtures are explosive in the following proportions:

- 4 to 74.5 % of hydrogen in air.

- 4 to 94 % of hydrogen in oxygen.

Store the bottles in the open or in a well-ventilated place.

Avoid any leakage by limiting the number of connections or couplings to a minimum.

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DESCRIPTION

4.

GENERAL CHARACTERISTICS

The three phase power source THERMAL ARC 300 GMS has been designed as integrated and portable units using the latest techniques in power electronics, based on an IGBT controlled inverter process, which enables the following:

a considerable reduction of weight and volume

the dynamic control of the welding current

a high power in a small space at a very low power consumption

With their innovative design, these machines are both robust (plastic front and back panel, new internal conception) and ergonomic.

The THERMAL ARC 300 GMS units are multiprocess DC inverters which allow:

-

MMA welding (stick welding) : with coated electrodes up to 5 mm

TIG welding : with infusible electrodes . Ignition made with lift arc process.

2 stroke or 4 stroke mode

Post gas adjustment

Down-slope time adjustment

Gas purge

-

MIG welding : wire feeder built in

15 kgs spools steel wire, stainless steel wire of diameter 0.6 mm to 1.2 mm direct or reverse polarity of the wire

2 stroke or 4 stroke mode

Post gas adjustment

Cold wire inch

Burn-back adjustment

Inductor linear adjustment

Spot MIG welding :

with adjustment of the spot’s time

Intermittent MIG welding : with adjustment of the spot’s time and of their frequency.

Program :

Possibility to save and load welding parameters

This power source offers exceptional arc stability.

Easy to use, it can be adjusted exactly to your need :

- It has a linear electronic inductor, which allows the arc adjustment (soft or hard) and limits the amount of spatter.

- It has an adjustable burn-back which allows to adjust the wire’s length on the torch’s head at the end of the welding.

(All parameters adjustment p.18 to 24)

It’s perfectly suited to the MIG welding with aluminium wire.

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DESCRIPTION

5.

TECHNICAL CHARACTERISTICS

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400 +/-10%

50 / 60

TIG

10.8

7.4

0.98

16

TIG

50-60

3 - 300

300

250

210

PRIMARY

three phased power supply

Frequency

Maximum primary current

Maximum power consumption

Power factor (cos Ø)

Primary protection

DIMENSIONS ( in mm )

V

Hz

A kVA

A

MMA

13

9.1

SECONDARY

Off load voltage

Welding current range

Welding current at

40°C

Welding current at 40 %

Welding current at 60 %

Welding current at 100 %

V

A

A

A

A

MMA

50-60

3 - 250

250

230

190

Protection degree

Insulation class

Standards

Weight

Dimensions L x W x H kg mm

IP 23

H

EN 60974-1 / EN 60974-10

25

570 x 279 x 460

MIG

13.2

9.3

MIG

50-60

3-280

280

250

210

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SETTING UP

6.

CONNECTION TO THE MAIN SUPPLY

The power source must be connected to a three-phase 400V - 50 Hz/60 Hz mains + ground

It has built-in over voltage protection which allows engine driven generator supply

Main supply must be protected by fuses or circuit-breaker according to the value I1 eff

written on the specifications of the power source. it is strongly suggested to use a differential protection for the operator’s safety.

7.

CONNECTION TO THE GROUND

For the operator's protection, the power source must be correctly grounded (according to the International

Protections Norms).

It is absolutely necessary to set a good ground connection installation with the green/yellow leading of the power cable. This will avoid discharges caused by accidental contacts with grounded pieces.

If no earth connection has been set, a high risk of electric shock through the chassis of the unit remains possible.

8.

PRELIMINARY PRECAUTIONS

For the good operation of your welding power source, make sure that the air flow produced by the fan inside the unit is not obstructed.

Also try to operate in a non-dusty area.

Avoid all impacts, exposure to damp areas or excessive temperatures.

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USING

9.

DESCRIPTION OF THE FRONT PANEL

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USING

ITEM

F1

F2

F3

F4

F5

F6

F7

F8

F9

Power terminal +

Power terminal -

Torch’s polarity connection

Torch’s EURO connector

DESCRIPTION

Setting key for “LOAD” program

Setting key for “SAVE” program

F13 adjustment knob

«second» indicator on F13 display

Setting key for “SET UP” program

F10

“SET UP” program indictor

F11

«Volt» indicator on F13 display

F12

«%» indicator on F13 display

F13

Digital display

F14

Digital display

F15

«Amps» indicator on F14 display

F16

Power supply fault indicator

F17

« Water colling fault » indicator

F18

«m/min» indicator on F14 display

F19

« TIG welding » indicator

F20

F14 adjustment knob

F21

« MIG welding » indicator

F22

Setting key for selecting welding mode

F23

Setting key for selecting 2 strokes or 4 strokes welding mode

F24

« MMA welding » indicator

F25

Indicator « 4 strokes welding »

10.

DESCRIPTION OF THE BACK PANEL

ITEM

B1

B2

DESCRIPTION

Switch ON/OFF

Gas input

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USING

NOTE : *FP = Factory parameter

11.

MMA (STICK) WELDING

Connect the power source to the main supply and the ground as explained in the chapter « Setting up » (as

6 and 7 section).

Connect the ground cable and the electrode-holder to the appropriate power connections + F1 and – F2 according to the electrode polarity being used (refer to the electrodes manufacturer’s datasheets).

The “torch’s polarity connection” F3 is not connected.

Start up the power source with the main switch ON/OFF B1.

Select MMA(stick) welding mode with the setting key F22, the indicator F24 illuminates.

Adjust welding current with knob F20.

Place the electrode on the piece you have to weld in order to strike the arc.

Arc force control

FP*: OFF

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “DYN” function on F14 display.

With knob F7, adjust the arc force between 1 and 99% on display F13.

To exit this function, select “SET UP”. The indictor F10 is off.

HOT START control

FP*: OFF

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “HOT” function on F14 display.

With knob F7, adjust the HOT START between 0.1 and 3 sec. on display F13.

To exit this function, select “SET UP”. The indictor F10 is off.

Off load voltage control

FP*: OFF

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “URD” function on F14 display.

With knob F7, choose the output load voltage on display F13 between:

- “OFF” (standard off load voltage)

- “ON” 20 V (limited to 20V)

To exit this function, select “SET UP”. The indictor F10 is off.

12.

TIG WELDING

Connect the unit

Connect the power source to the main supply and the ground as explained in the chapter « Setting up » (as

6 and 7 section).

Connect the ground cable to the power terminal + F1 and the torch’s polarity connection F3 to the – F2.

Connect the torch in the EURO connector F4 and do it up to the end of the threads.

Connect the gas supply

Open the valve of the bottle for a moment to remove any impurities.

Fit the flow-control valve (flow from 5 to 8 l/mn) to the output of the bottle and its pipe.

Connect the gas pipe at the rear of the machine, to the gas input B2.

Open the bottle.

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Set TIG parameters

Start up the power source with the main switch ON/OFF B1.

-

- TIG welding mode choice

Select TIG welding mode with the setting key F22, the indicator F19 illuminates.

2 strokes or 4 strokes mode

-

If the indicator F25 is OFF, 2 stroke mode is selected.

Select 4 stroke mode with the setting key F23, the indicator F25 illuminates.

Post gas

FP* : Auto

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “tPo” function on F14 display.

With knob F7, control and adjust the post gas between 3 and 25 sec. on display F13 or select “AUTO

-

function (post gas is automatically regulated).

To exit this function, select “SET UP”.F9 The indictor F10 is off

Down-slope time

Adjust the down-slope time from 0 to 16s with the knob F7.

- Welding current

Adjust the welding current with the knob F20.

- Pre gas

FP : 0.5 sec

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “tPR” function on F14 display.

With knob F7, adjust the pre gas between 0.1 to 5.0 sec on display F13.

To exit this function, select “SET UPF9 The indictor F10 is off

Initial current control

FP*: 50%

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “IS” function on F14 display.

With knob F7, control and adjust the initial current (percentage of welding current) between 30% and 200%.

To exit this function, select “SET UPF9. The indictor F10 is off

Time of progressive start current

FP*: 1 sec

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “tUP” function on F14 display.

With knob F7, adjust the time between 0.1 and 10 sec or select “OFF”.

To exit this function, select “SET UP F9 The indictor F10 is off

Time of up-current (up slope)

FP* : 0.1

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “TIG” function on F14 display.

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With knob F7, adjust the post gas between 0.01 and 0.2 sec. on display F13 or select “OFF” function.

To exit this function, select “SET UP”.F9 The indictor F10 is off

Final current control

FP*: 30%

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “IF” function on F14 display.

With knob F7, adjust the parameter between 30% and 100% of welding current.

To exit this function, select “SET UP”. The indictor F10 is off

Spot welding control

FP*: OFF

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “SPt” function on F14 display.

With knob F7, adjust the time spot between 0.1 and 25 second. To stop Spot welding, select “OFF” .

To exit this function, select “SET UP”. The indictor F10 is off

Welding

Put the tungsten electrode in direct contact with the workpiece. Push on the trigger.

Raise the torch slowly. The arc strike start according to the cycle described hereunder.

NOTE :

When the tungsten electrode comes into contact with the workpiece, the current is

maintained at a low value till the electrode lifts up in order to avoid tungstens penetration

Purge the gas and wire test

Press the purge gas knob or test gas knob inside the wire feeder

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13.

MIG WELDING

13.1.

PREPARATION

Connect the unit

Connect the power source to the main supply and the ground as explained in the chapter « Setting up » (as para 6 and 7).

Connect the ground cable and the torch’s polarity connection F3 to the power connection + F1 and – F2, regarding to the type of wire used.

Connect the gas supply

Open the valve of the bottle for a moment to remove any impurities.

Fit the flow-control valve (flow from 5 to 8 l/mn) to the output of the bottle and its pipe.

Connect the gas pipe at the rear of the machine, to the gas input B2.

Open the bottle.

Fitting the feed rolls

Place the fitted feed rolls in the wire feeding unit according to the instructions given in chapter 17.

It is essential that the spool be fitted with the appropriate feed rolls, to provide the best welding and

spooling conditions.

Install the wire in the spool

(please see the spare parts lists of the machine in chapter 17)

You can use wire’s type : steel, stainless steel, aluminium wire from 0.6 mm to 1.0 mm.

Undo the retaining screw of the spool (screw on Item. 22) .

Engage the spool on its support, (Item. 22), taking care to position the rod of the spool brake correctly. The spool must be mounted so that the wire is spooled from below.

The firmness of the spool brake can be adjusted using the central screw located behind the screw (Item. 22).

This system allows the motion of the spool to be stopped at the end of spooling, preventing it from rotating further. This is vital when one is spooling at high speeds. Nevertheless, the spool should not be braked

excessively, in order not to overload the motor.

Re-fit the retaining screw (screw on Item. 22).

Engage the wire in the wire feeding unit according to the instruction given chapter 17 and let it go out the

EURO connector F4.

13.2.

ADJUSTMENT OF THE PARAMETERS

MIG welding mode

Select MIG welding mode with the setting key F22, the indicator F21 illuminates.

2 strokes or 4 strokes mode

If the indicator F25 is OFF, 2 stroke mode is selected.

Select 4 strokes mode with the setting key F23, the indicator F25 illuminates.

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Pre gas

FP*: 0.5 sec

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “tPr” function on F14 display.

With knob F7, adjust the pre-gas between 0.1 à 5 sec. or “OFF” on display F13.

To exit this function, select “SET UP”. The indictor F10 is off

Inductance control (spatter limitation)

FP*: 60%

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “Ind” function on F14 display.

With knob F7, control and adjust the inductance between 0 and 100%

To exit this function, select “SET UPF9. The indictor F10 is off

BURN BACK control

FP : 0.4 sec

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “bb” function on F14 display.

With knob F7, control and adjust the BURN BACK between 0.1 and 1.0 second.

To exit this function, select “SET UP”. The indictor F10 is off

Post gas

FP* : 3 sec

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “tPo” function on F14 display.

With knob F7, control and adjust the post between 0.1 and 10 sec.

To exit this function, select F9SET UP”. The indictor F10 is off (post gas is automatically regulated).

HOT START control

FP* : 35%

Select “SET UP” menu with the setting key F9, the indicator F10 illuminates.

With the knob F20, select “Hot” function on F14 display.

With knob F7, control and adjust the HOT START between 0 to 100% on display F13.

To exit this function, select F9SET UP”. The indictor F10 is off.

Wire speed

Adjust the wire speed from 1 to 15 m/min with knob F20 on F14 display

Arc voltage

Adjust the arc voltage from 14V to 28V with the knob F7 on F13 display

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14.

SPOT MIG WELDING

Read the instructions for the preparation of the generator given in 13.1 section

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “SPt” function on F14 display.

With knob F7, adjust the time spot between 0.1 and 2.5 second. To stop Spot welding, select “OFF”.

To exit this function, select “SET UPF9. The indictor F10 is off

Welding

Depress the torch’s trigger in order to start welding. The arc stops after the spot time.

Release and depress the trigger to start a new spot time.

15.

INTERMITTENT MIG WELDING

Read the instructions for the preparation of the generator given in 13.1

Spot time

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “SPt” function on F14 display.

With knob F7, adjust the time spot between 0.1 and 2.5 sec on F13 display. To stop Spot welding, select

“OFF”.

To exit this function, select F13SET UP”. The indictor F10 is off

Time adjustment between spots

Select “SET UP” menu with the setting key F9, the indicator F10 flashes.

With the knob F20, select “Int” function on F14 display.

With knob F7, adjust the time spot between 0.4 and 25 sec on F13 display. To stop intermittent welding, select “OFF”.

To exit this function, select “SET UP”. The indictor F10 is off

Welding

Depress the torch’s trigger in order to start welding. When holding on the trigger, you will do the welding cycles defined with parameters adjusted above. Release the trigger to stop the cycle.

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16.

« SAVE » AND « LOAD » MENU

« SAVE » to save welding parameters (1 to 15 programs)

1) Press “SAVE” key for SAVE menu – “SAU” is flashing = SAVE

2) Choice a program number from 1 to 15 with the knob F7 in the right display F13

3) Press SAVE key during 3 seconds to memorise the parameters program. The right display shows « yES »

=YES flashing

4) Press SAVE key to exit the SAVE mode

« LOAD » loading registered parameters

5) Press “LOAD” key for SAVE menu – “Ld” is flashing = SAVE

6) Choice a program number from 1 to 15 with the knob F7 in the right display F13

7) Press LOAD key during 3 seconds to load registered programs. The right display shows « yES » =YES flashing

8) Press LOAD key to exit the SAVE mode

After loading saved program, it’s possible to adjust all parameters but they won’t be automatically saved

« LOAD » Loading factory parameters

9) Press “LOAD key for SAVE menu – “Ld” is flashing = SAVE

10) Select “FAC” with the knob F7 in the right display F13

11) Press LOAD key during 3 seconds to load factory preset. The right display shows « FAC » =YES flashing

12) Press SAVE key to exit the SAVE mode

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MAINTENANCE

17.

MAINTENANCE

CAUTION : BEFORE OPENING the unit, disconnect the power source from the mains. Voltages are high and dangerous inside the machine.

In spite of their robustness, THERMADYNE INDUSTRIES’ power sources require some regular maintenance.

Once every 6 months (more often in dusty surroundings) :

the machine must be blown through with dry, oilfree compressed air

check for continuity all electrical connections.

-

Check the connection of cables and flat top.

18.

SPARE PARTS

SPARE PARTS OF THE POWER SOURCE

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8

9

10

11

12

13

14

15

ITEM

1

2

3

4

5

6

7

16

17

18

19

20

21

22

23

24

25

26

27

28

29

REFERENCE

I06002

060153

B06050

C60438

B01062

B00022/TH

I06013

E32420

E92280

E32418

T18119

T18120

V01008

G02011

F04002

F18008

I06021/MIG

C02107

I06034/P3005

I06099/P3005

Chassis

DESCRIPTION

Power terminal 35/50 mm²

Cable anchorage

EURO connector

Knob diam. 23

Front fascia

Black front frame

Display and control PCB

Secondary PCB

Primary PCB

Inductor

Power transformer

Fan

ON/OFF commutator

Gas valve 230 Vac

Adaptor F12/100 –M 3/8 BSP

Black back frame

Female socket 7 pins

Painted cover

Painted handle’s support

J15021-4/P9005

Painted handle

L93821

T18122

EMI PCB

Supply transformer

U20030

E32419

Spool support with screw

Wire feeder PCB

B05001

U21033

U45801

U21033-1

I06036/P3005

I06035/P3005

A20002

Black push button

Complete wire feeder unit

Wire feeding unit without motor

Motor without wire feeding unit

Painted door

Painted left panel

Lock for door

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COMPLETE WIRE FEEDING UNIT U21033

9

10

11

12

3

4

5

6

7

8

REP REF

1

2

DESCRIPTION

U46001

Fixing cap

U45807

Feed roll diam 0.8 / 1.0 - « V » groove

U45810

Feed roll diam 1.0 / 1.2 - « V » groove

U45823

Feed roll diam 0.8 / 1.0 - « U » groove

U45820

Feed roll diam 1.0 / 1.2 - « U » groove

U46002

Gear Wheel

U45435

Parallel key 4x4x8

U46009

shaft

U46003

Complete wire inlet guide

U45850

Fixing shaft

U46005

Complete pressure arm

U46006-D2 Intermediate wire guide

U46007

Gear wheel

U46008

Aluminium support

U21033-1

Motor 42V without wire feeding unit

U45801

Wire feeding unit without motor

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MAINTENANCE

The wire feeding unit consists of one pressure feed roll at the top, usable for all the wires, and one grooved feed roll (Rep. 2) at the lower, which have to be adapted to the nature of the wire and to its diameter.

It is essential that the spool be fitted with the appropriate feed rolls, so as to provide the best welding

and spooling conditions.

Each grooved feed roll is designed to weld 2 different diameters. To change diameter, the feed roll is just turned round. The feed rolls mounted as standard on delivery are designed to weld steel/stainless steel wire

(triangular groove in « V ») 0.6 or 0.8 mm in diameter (by turning the feed roll). Another feed roll is supplied for steel wire of 0.8 or 1.0 mm in diameter.

Spooling of aluminium wires :

For aluminium wire, semicircular grooved (in « U ») feed rolls are available as options in diameters 0.6/0.8 mm and 0.8/1.0 mm.

These type of feed rolls are recommended for spooling of aluminium wires, since they prevent deformation or crushing of the wire.

Replacing the feed rolls

Release the pressure of the upper feed roll, using knob of the fixing shaft (Rep. 7).

Undo the fixing cap (Rep. 1) of the lower feed roll.

Remove the lower feed roll (Rep. 2), and turn it or fit a different feed roll in its place.

Engage the feed roll well down onto the gear wheel (Rep. 3).

Refit the fixing cap (Rep. 1).

Refit the pressure of the upper feed roll, using knob of the fixing shaft (Rep. 7).

Place the wire in the wire feeding unit

Release the pressure of the upper feed roll, using knob of the fixing shaft (Rep. 7).

Engage the wire in the inlet guide (Rep. 6), then in the groove of the feed roll, finally in the wire inlet of the EURO connector F14 until the wire comes out of the connector

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19.

TROUBLE SHOOTING

CAUTION : BEFORE ANY INTERNAL CHECKS ARE MADE, disconnect the power source from the power supply. Internals voltages are high and dangerous

POSSIBLE CAUSES CHECKING / REMEDY

ON/OFF main switch is OFF

Power supply cable is cut

No main supply

Defective ON/OFF main switch

FRONT PANEL OFF = NO SUPPLY

Put the switch ON

Check cable and connections

Check circuit breaker and fuses

Replace the switch

DIGITAL DISPLAY OFF AND INDICATOR F16 ON = INPUT VOLTAGE DEFAULT

Input voltage too low Check supply voltage

Lack of one phase Check the supply

DIGITAL DISPLAY F13 FLASHES AND SHOWS « tPb » = PRIMARY WARMING UP

Primary temperature over rated The machine doesn’t stop but the welding current is limited to 0A

DIGITAL DISPLAY F13 FLICKERS AND SHOWS « tSb » AND INDICATOR F13 ON

= SECONDARY WARMING UP

Secondary temperature over rated The machine doesn’t stop but the welding current is limited to 0A

DIGITAL DISPLAY F13 FLASHES AND SHOWS « tH » = WARMING UP

Duty cycle over rated (particulary if ambient t° is > Let the machine cool, it will automatically start again

40°C)

Insufficient cooling air

Very dusty machine

Fan doesn’t start

Clean the air inlets

Open the machine and blow it through

Replace the fan

DIGITAL DISPLAY F13 FLASHES AND SHOWS « coL » AND INDICATOR F17 ON = COOLING UNIT FAULT

The machine stops until repair of the default

Lack of water

Water circuit blocked up

Check the water level

Check the torch

Wrong electrode polarity

STICK WELDING - IMPROPER WELDING

Use the right polarity according to the indications of electrode’s manufacturer

TIG - IGNITION FAILURE

Wrong polarity

Pre gas time selected

Check the connection

Torch to power terminal

Ground to power terminal +

You must wait for the end of the pre gas flow or cancel it

DIGITAL DISPLAY F13 FLASHES AND SHOWS « C_O » = OVER LOAD

Over load indication Press the MIG GUN switch

DIGITAL DISPLAY F13 FLICKERS ANS SHOWS « FEd » = WIRE FEEDER DEFAULT

Wire feeding fault Check the wire feeder motor

No gas arrives to the machine

No gas goes out of the machine

Initial current too low

OTHER FAILURES

Check the gas supply

Check the gas valve

Check the value of initial current (see chapter 12)

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20.

WIRING DIAGRAM

21.

APPENDICE

Stick welding

Welding current range

Arc force control

Hot Start

Off low voltage

TIG Welding

Welding current range

Post gas

Down slope

Pre gas

Start current

Progressive time of start current

Time of over-current start

Final current

MIG Welding

Arc voltage

Wire speed

Post gas

Inductor

Burn back

Spot’s length

Time between 2 spots

Unit

% s s

%

A s s s

A

%

S

V

THERMAL ARC 300 GMS

3 - 250

OFF – 1 to 99%

OFF - 0.1 to 3

20 or 50/60

3 - 300

AUTO - 3 to 25

0 - 16

0.1 – 5.0

30% - 200%

0.01 – 10

0.01 – 0.20

30 - 100

V m/min s

% s s s

14 - 28

1 - 15

1 - 10

0 - 100

0.1- 1

0.1 - 2.5

0.4 - 2.5

NOTES

NOTES

NOTES

Thermadyne Industries, Ltd

.

U.K

Chorley, England

Tel : (44) 01257 261 755

Fax : (44) 01257 224 802

Thermadyne Industries, Ltd

.

Netherlands

Hoofddorp, Holland

Tel : (31) 23 561 4182

Fax : (31) 23 565 5074

Thermadyne Industries, Ltd

.

Italia

Milan, Italy

Tel : (39) 039 204 991

Fax : (39) 039 204 9922

PTA Plasmatechnik.

Germany

Westerburg, Germany

Tel : (49) 2663 915666

Fax : (49) 2663 915667

THERMADYNE INDUSTRIES reserve the right to make changes without previous notification. Illustrations, descriptions and characteristics are not contractually binding and do not engage the responsability of the manufacturer.

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