0-2411 250 GTSW (O)
 THERMADYNE
Thermal Dynamics
INVERTER
ARC
WELDER
MODEL 250GTSWSE AC/DC CC/TIG
With Sloper and Repeat Functions
e Stick
e TIG - High Frequency
- Lift Start
Operating Manual
First Edition
February 1995 Manual No. 0-2411
SECTION 1:
SECTION 2:
SECTION 3:
SECTION 4:
SECTION 5:
TABLE OF CONTENTS
GENERAL INFORMATION ...............ee.eeeemeirececirr ceo ene ener Dee eee. 1
1.01 Notes, Cautions, and Warnings ..........................mecviiererrer e RR OI III AIDA 1
1.02 Important Safety Precautions ....................e.e.e.eereee RR O RI IR RO e RD 1
1.03 Publications ..........................e.edireee eee e De ee 6
1.04 Statement Of Warranty ................e.... mr... eeerecri DD DDD e ee eee errores 7
INTRODUCTION 8: DESCRIPTIÓN ............. een en eenennennaria rare nene rreccees 9
2.01 Scope of Manual ...................e.. eee eee eee eee eee eee eee eee ees 9
2.02 General DescriptiON een eee er area a eee es 9
2.03 Specifications & Design Features esse EEE ee 9
INSTALLATION PROCEDURES .................... eercrneanercarereaeareece cen aeee corea tara 11
3.01 Introduction ........................eeeeeerererrecercon ree e e eee ear ren cerros 11
3.02 Site Selection ..................... eee 11
3.03 Unpacking .........................eeeeceeriiere ren enana reee een rarenene racer ee eee eens 11
3.04 Lifting Options .......................22... eee cere esses eee e eee areata eevee ee ans 11
3.05 Input Power Connections ...................... e... eee reee eee eee eee eee eee 12
3.06 Weld Output Cables .......................2. eee 13
3.07 Remote 14 Receptale.....................eeeceei ere eee eee eres 15
OPERATION Loess eres eee. 17
4.01 Introduction Lovee eee eee eee eee eee eee eee es 17
4.02 Functional Overview.….….….….......…...reerenesinre ce esen ren sanar rene an anne naa rare near 17
4.03 Operating CONtrOIS …............….……crcsésseassrcarrenrererear raser ar ra can een ana cannes 17
4.04 Operating Precautions……..…….……………….…erenassenirrerrr rare eee eee IRA RR Re 21
4.05 Electrode Selection .......................2...miiee DIR een rene renace 21
4.06 Tungsten Preparation ......................e eme rare rene ne nanas aan ere ee 22
4.07 Operating Procedures ………..….....….…nerrrrererrrcacrrrr racer aa rare ane nananaa naar ass ee 23
CUSTOMER/OPERATOR SERVICE …….……ccrcrccrerrerreneenenr RER RER 29
5.01 Introduction ....................... eee. rene eee eee eee eran ana care 29
5.02 General Maintenance ...................... e... ere eres 29
5.03 Troubleshooting Guide .................reee E RR e ares 29
5.04 Replacement Parts ...................ve....eeeeeeerener e reee e areas 31
5.05 Parts List oon ee enero ar reee recae ereeaeeeameneeoos 31
A WARNING
Read and understand this entire Operating Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
A WARNING
While the information contained in this manual represents our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
Thermal Arc™ Model 250GTSWSE Inverter Arc Welder Operat-
ing Manual Number 0-2411
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1995
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability
to any party for any loss or damage caused by any error or
omission in the Thermal Arc™ Model 250GTSWSE Inverter Arc
Welder Operating Manual, whether such error results from
negligence, accident, or any other cause.
First Edition
February 1995
GENERAL INFORMATION
1.01 Notes, Cautions, and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high-
lights are categorized as follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful in efficient operation of the system.
mm CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
A WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the oper-
ating area.
1.02 Important Safety Precautions
A WARNING
Operation and maintenance of arc welding equip-
ment involves potential hazards. Operators and
all others in the operating area should be alerted to
possible hazards, and precautions should be taken
to prevent possible injury.
Read these safety precautions and the entire instruction
manual before operating.
Do not use this power supply to thaw frozen water pipes.
This equipment must be installed, operated, and serviced
by qualified personnel only.
A GASES AND FUMES
Gases and fumes produced during arc welding can be
dangerous and hazardous to your health.
Keep all fumes and gases from the breathing area.
Different arc welding processes, electrodes, and fluxes
SECTION 1:
can produce different fumes, gases and radiation levels.
Consult Material Safety Data Sheets (MSDS's) and
manufacturers instructions for specific technical data and
precautionary measures for all fluxes, electrodes, and
materials used.
Severe discomfort, illness or death can result from fumes,
vapors, heat, or oxygen enrichment or depletion that
welding (or cutting) may produce. Ventilation must be
adequate to remove gases and fumes during operation
as described in ANSI Standard Z49.1.
Use a downdraft table or water table to capture fumes
and gases.
Use an air-supplied respirator if ventilation is not ad-
equate to remove all fumes and gases.
When working in confined spaces provide adequate ven-
tilation or wear an air-supplied respirator if necessary.
Gas leaksin a confined space should be avoided. Leaked
gas in large quantities can change oxygen concentration
dangerously. Do not bring gas cylinders into a confined
space.
When leaving confined space, shut off gas supply at
source to prevent possible accumulation of gases if down-
stream valves are accidentally opened. Check that area
is safe before re-entering.
Materials containing lead, cadmium, zinc, mercury, be-
ryllium, and similar materials may produce harmful con-
centrations of toxic fumes when welded or cut. Adequate
local exhaust ventilation must be used, or operators and
others in the operating area must wear an air-supplied
respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit toxic
fumes should not be heated unless coating is removed
from work surface and work area is well ventilated. Wear
an air-supplied respirator if necessary.
Vapors from chlorinated solvents can be decomposed by
the heat of the arc or flame to form phosgene, a highly
toxic gas, and other lung and eye irritating products. The
ultraviolet radiant energy of the arc can also decompose
trichloroethylene and perchloroethylene vapors to form
phosgene. Do not weld or cut where solvent vapors may
be drawn into the welding or cutting atmosphere or
where radiant energy may penetrate to atmospheres con-
taining even minute amounts of trichloroethylene or per-
chloroethylene. Solvents, degreasers, and potential
sources of these vapors must be removed from the oper-
ating area.
Oil or grease in the presence of oxygen may ignite and
burn violently. Keep cylinders, valves, couplings, regu-
lators, hoses, and other apparatus clean and free from oil
1 GENERAL INFORMATION
and grease. Oxygen cylinders and apparatus should not
be handled with oily hands or gloves. Do not allow an
oxygen stream to contact oily or greasy surfaces.
Do not use oxygen as a substitute for compressed air.
NEVER ventilate with oxygen.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
m
12 ARC RAYS
Arc rays can injure eyes and burn skin.
Never look at an electric arc without protection. Protect
eyes from exposure to arc. Looking at an arc momen-
tarily with unprotected eyes (particularly a high inten-
sity gas-shielded arc) can cause permanent damage to
vision.
Use a welding helmet or shield with proper filter (refer
to the following chart). Place over face before striking
arc.
Welding or Electrode Size Filter
Cutting Operation Metal Thickness Shade
or Welding Current Number
Torch soldering - 2
Torch brazing - Зог4
Oxygen Cutting
Light Under 1 in (25 mm) Зог 4
Medium 1-6 in (25-150 mm) 4or5
Heavy Over 6 in (150 mm) bor6
Gas welding
Light Under 1/8 in (3 mm) 4or5
Medium 1/8-1/2 in (3-12 mm) B5or6
Heavy Over 1/2 in (12 mm) бог8
Shielded metal arc welding (stick) electrodes
Light Under 5/32 in (4 mm) 10
Medium 5/32-1/4 in (4-6.4 mm) 12
Heavy Over 1/4 in (6.4 mm) 14
Gas metal arc welding (MIG)
Non-ferrous base metal All 11
Ferrous base metal All 12
Gas tungsten arc welding (TIG) All 12
Atomic hydrogen welding All 12
Carbon arc welding All 12
Plasma arc welding All 12
Carbon arc air gouging
Light - 12
Heavy - 14
Plasma arc cutting
Light Under 300 amps 9
Medium 300-400 amps 12
Heavy Over 400 amps 14
GENERAL INFORMATION
Protect filter plate with a clear cover plate.
Do not use cracked or broken helmet or shield; radiation
can pass through to cause burns.
Replace any cracked, broken or loose filter plates imme-
diately. Replace clear cover plate when broken, pitted,
or spattered.
Flash goggles with side shields must be worn under hel-
met to protect eyes in case helmet is not in position be-
fore arc is struck.
Wear proper protective clothing. Arc rays can penetrate
lightweight clothing,
Welding arc rays can reflect from light-colored surfaces.
Make sure others in the operating area are protected from
arc rays.
For production welding, use separate room or enclosed
bay. In open areas, surround operation with low reflec-
tive non-combustible screens or panels. Make sure that
screen flaps or bay doors are closed before welding. Al-
low for free air circulation, particularly at floor level.
Provide face shields for all others viewing the weld.
Make sure others in the operating area are wearing flash
goggles.
Recommended Eye Protection for Welding and Cutting
(Based on AWS A6.2-73) is as follows:
A ELECTRIC SHOCK
Electric shock can kill.
Do not contact electrically live parts.
Install equipment according to safety precautions, instruc-
tion manual, and all applicable codes.
Keep all panels, covers, and guards in place.
Disconnect all primary power before installing or servic-
ing this equipment.
Insulate operator and others from work and ground.
Replace any cracked or damaged insulating parts.
Shut down welding power source before touching elec-
trode, wire drive assembly, welding wire, wire reel, or
any metal parts in contact with the welding wire.
Exposed hot conductors or other bare metal in the weld-
ing circuit or in ungrounded, electrically hot equipment
can cause potentially fatal electric shock. Do not contact
a wet surface when welding without suitable protection.
Wear dry insulating gloves and body protection. Keep
body and clothing dry. Never work in damp area with-
out adequate insulation against electrical shock. Stay on
a dry duckboard, or rubber mat when dampness or sweat
cannot be avoided. Sweat, sea water, or moisture between
body and an electrically hot part or grounded metal re-
duces electrical resistance and could cause potentially
fatal electric shock. | |
A voltage will exist between the electrode and any con-
ducting object in the work circuit. Examples of conduct-
ing objects include, but are not limited to, buildings, elec-
trical tools, work benches, welding power source cases,
workpieces, etc. Never touch electrode to any metal ob-
ject unless the welding power source is off.
Arc welding equipment must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 “Safety in Welding
and Cutting.”
When installing, connect the frames of each unit such as
welding power source, control, work table and water cir-
culator to the building ground. Conductors must be ad-
equate to carry ground currents safely. Equipment made
electrically hot by stray current may cause potentially
fatal electric shock. Do not ground to electrical conduit
or to pipe carrying any gas or flammable liquid such as
oil or fuel.
Check phase requirements before installing. If only three-
phase power is available, connect single-phase equipment
to only two wires of the three-phase line. Do not connect
the equipment ground lead to the third (live) wire, or the
equipment will become electrically hot - a dangerous
condition that may cause potentially fatal electric shock.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment frames
at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-prong
plug is added for connection to a grounded mating re-
ceptacle, the ground lead must be connected to the
ground prong only. If the line cord comes with a three-
prong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a
plug with a broken off ground plug.
Fully insulated electrode holders should be used. Do not
use holders with protruding screws.
Fully insulated lock-type connectors should be used to
join welding cable lengths.
Frequently inspect cables for wear, cracks and damage.
Replace those with excessively worn or damaged insula-
tion to avoid potentially fatal electric shock from bared
cable. Cables with damaged areas may be taped to give
resistance equivalent to original cable.
Keep cables dry, free of oil and grease, and protected from
hot metal and sparks.
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
Electrode
For equipment with output ON/OFF control (contactor):
Welding power sources for use with gas metal arc weld-
ing (GMAW), gas tungsten arc welding (GTAW) and simi-
lar processes normally are equipped with devices that
permit ON-OFF control of the welding power output.
When so equipped the electrode wire becomes electri-
cally hot when the power source switch is ON and weld-
ing gun switch is closed. Never touch electrode wire or
any conducting object in contact with electrode circuit
unless the welding power source is OFF.
For equipment without output ON/OFF control (no
contactor): Welding power sources used with shielded
metal arc welding (SMAW) and similar processes may
not be equipped with welding power output ON-OFF
control devices. With such equipment the electrode is elec-
trically hot when the power switch is turned ON. Never
touch the electrode unless the welding power source is
off.
Safety devices such as interlocks and circuit breakers
should never be disconnected or shunted out.
Before installating, inspecting, or servicing equipment,
disconnect primary power and remove line fuses (or lock
or red-tag switches) to prevent accidental electric shock.
Disconnect all cables from welding power source and pull
all 115V line-cord plugs.
Do not open power circuit or change polarity while weld-
ing. If it must be disconnected in an emergency, guard
against shock burns and flash from switch arcing.
Always shut off and disconnect all primary power when
leaving equipment unattended.
Primary power disconnect switch must be available near
the welding power source.
A FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, spatter,
sparks, extreme heat, misuse of compressed gases and
cylinders, and electrical short circuits.
3 GENERAL INFORMATION
Remove all combustibles from working area or provide
a fire watch. Avoid paint spray rooms, dip tanks, stor-
age areas, ventilators. Move work to an area free of com-
bustibles if possible. If work cannot be moved, move
combustibles at least 35 ft (10.7 m) away from sparks and
heat or protect against ignition with suitable and snug-
fitting, fire-resistant covers or shields.
Walls having combustibles on opposite sides should not
be welded on or cut. Walls, ceilings, and floor near work
should be protected by heat-resistant covers or shields.
A fire watch with suitable fire extinguishing equipment
must be provided during and after welding or cutting if
combustibles (including building construction) are within
35 ft (10.7 m), if combustibles are further than 35 ft but
may be ignited by flying sparks, or if openings (concealed
or visible) in floors or walls within 35 ft may expose com-
bustibles to sparks.
Combustibles adjacent to walls, ceilings, roofs, or metal
partitions can be ignited by radiant or conducted heat.
A hot work permit should be obtained before operation
to ensure supervisor’s approval that adequate precau-
tions have been taken.
Do not weld or cut an empty container that has held com-
bustibles, or that can produce flammable or toxic vapors
when heated, unless container has first been cleaned as
described in AWS Standard A6.0. This includes a thor-
ough steam or caustic cleaning (or a solvent or water
washing, depending on the combustibles solubility) fol-
lowed by purging and inerting with nitrogen or carbon
dioxide, and using protective equipment as recom-
mended in A6.0. Waterfilling just below working level
may substitute for inerting.
A container with unknown contents should be cleaned
(see preceding paragraph). Do not depend on smell or
sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting to prevent explosion.
Never weld or cut in potentially explosive atmospheres
containing flammable dust, gas, or liquid vapor (such as
gasoline).
Do not mount this equipment over combustible surfaces.
Flying sparks or falling slag can fly up to 35 ft (10.7 m)
and pass through cracks, along pipes, through windows
or doors, and through wall or floor openings, out of sight
of the operator.
Keep equipment clean and operable, free of oil, grease,
and metallic particles that can cause short circuits in elec-
trical parts.
Overloading arc welding equipment beyond rated capac-
ity may overheat cables and cause fire.
GENERAL INFORMATION
Loose cable connections may overheat or flash and cause
fire.
Never strike an arc on a cylinder or other pressure ves-
sel. It creates a brittle area that can cause a violent rup-
ture or lead to rupture under rough handling.
After work is done, check that area is free of sparks, glow-
ing embers, and flames.
Burn Prevention - Wear protective clothing including
gauntlet welding gloves, hat, and high safety toe shoes.
Button shirt collar to protect chest and neck, button pocket
flaps, and wear cuffless trousers to avoid entry of sparks
and slag. Wear dark colored, substantial long-sleeve
clothing (particularly for gas-shielded arc). As necessary,
use additional protective clothing such as leather jacket
or sleeves, flame-proof apron, and fire-resistant leggings.
Avoid outer garments of untreated cotton.
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass) for welding or cutting
(and chipping) to protect the eyes from radiant energy
and flying metal. Replace cover glass when broken, pit-
ted, or spattered.
Avoid oily or greasy clothing which may be ignited by
sparks.
Do not handle hot metal such as electrode stubs and
workpieces without gloves.
Medical first aid and eye treatment facilities and person-
nel should be available for each shift unless medical fa-
cilities are close by for immediate treatment of flash burns
of the eyes and skin burns.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
Allow work and equipment to cool before handling.
Noise can cause permanent hearing loss.
Wear proper protective ear muffs or plugs.
Make sure others in the operating area are protected from
noise.
A HIGH PRESSURE GAS CYLINDERS
Comply with the precautions in this manual and those
detailed in CGA Standard P-1, SAFE HANDLING OF
COMPRESSED GASES IN CYLINDERS.
Pressure Regulators:
Regulator relief valve is designed to protect only the regu-
lator from overpressure and not intended to protect any
downstream equipment. Provide such protection with
one or more relief devices.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Remove faulty regulator from service immediately for
repair (first close cylinder valve) if gas leaks externally, if
delivery pressure continues to rise with downstream
valve closed, or if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after pres-
sure release.
Do not attempt to repair faulty regulators. Send to
manufacturer’s authorized repair center where special
techniques and tools are used by trained personnel.
Cylinders must be handled carefully to prevent leaks and
damage to walls, valves, or safety devices.
Contact with electrical circuits including third rails, elec-
trical wires, or welding circuits can product short circuit
arcs that may lead to a serious accident.
ICC or DOT markings must be on each cylinder as an
assurance of safety when the cylinder is properly handled.
Use only cylinders with name of gas clearly marked on
them; do not rely on color to identify gas content. Notify
supplier if unmarked. Never deface or alter name, num-
ber or other markings on a cylinder.
Keep valves closed on empty cylinders, replace caps se-
curely, mark MT, keep separate from full cylinders and
return promply.
Never use a cylinder or contents for other than intended
use. Never use as a support or roller.
Locate or secure cylinders so they cannot be knocked over.
Keep cylinders clear of passageways and work areas
where they may be struck.
To transport cylinders with a crane, use a secure support
such as a platform or cradle. Do not lift cylinders by
valves or caps, or by chains, slings, or magnets.
Do not expose cylinders to excessive heat, sparks, slag,
or flame which may cause rupture. Do not allow con-
tents to exceed 1300°F. Cool with water spray where such
exposure exists.
Protect cylinders and valves from bumps, falls, falling
objects, and weather. Replace caps securely when mov-
ing cylinders.
Do not use hammer or wrench to open a cylinder lock
valve which cannot be opened by hand. Notify supplier.
Never mix gases in a cylinder.
Never refill any cylinder.
Do not modify or exchange cylinder fittings.
Hose
Never use hose unless appropriate for specified gas. Gen-
eral hose identification is: red for fuel gas, green for oxy-
gen, and black for inert gases.
Use ferrules or clamps designed for hose (not ordinary
wire or other substitute) as a binding to connect hoses to
fittings.
Do not use copper tubing splices. Use only standard brass
fittings to splice hose.
Avoid long runs to prevent kinks and abuse. Coil excess
hose to prevent kinks and tangles. Suspend hose off
ground to protect from damage. Protect hose from dam-
age by sharp edges, sparks, slag, excessive heat, and open
flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in soapy water;
bubbles indicate leaks.
Repair leaky or worn hose by cutting area out and splic-
ing. Do not tape.
Proper Connections
Keep cylinder valve outlet free of impurities which may
clog orifices and damage seats before connecting regula-
tor. Except for hydrogen, crack valve momentarily and
point outlet away from people and sources of ignition.
Wipe clean with a lintless cloth.
Match regulator to cylinder. Before connecting, check
that regulator label and cylinder marking area match and
that regulator inlet and cylinder outlet match. Never
connect a regulator designed for one type of gas to a cyl-
inder containing another gas.
When assembling threaded connections, clean and
smooth seats where necessary before tightening. If con-
nection leaks, disassemble, clean, and retighten using
properly fitting wrench.
Use a CGA adapter (available from supplier) between
cylinder and regulator, if required. Use two wrenches to
tighten adapter marked RIGHT and LEFT HAND
threads.
Regulator outlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
5 GENERAL INFORMATION
Pressurizing Steps
Drain regulator of residual gas through suitable vent be-
fore opening cylinder (or manifold valve} by turning
adjusting screw clockwise. Draining prevents excessive
compression heat at high pressure seat by allowing seat
to open on pressurization. Leave adjusting screw en-
~ gaged slightly on single-stage regulators.
Do not stand in front of regulator while opening cylin-
der valve.
Open cylinder valve slowly so that regulator pressure
increases slowly. When gauge is pressurized (gauge
reaches regulator maximum) open cylinder valve fully
to seal stem against possible leak when using oxygen and
inert gases. For fuel gas, open less than one turn to per-
mit quick emergency shutoff.
Use pressure charts (available from supplier) for safe and
efficient, recommended pressure settings on regulators.
Check for leaks on first pressurization and regularly there-
after. Brush with soapy solution (one capful of liquid
detergent per gallon of water); bubbles indicate leak
Clean off soapy water after test; dried soap is combus-
tible.
Remove leaky or defective equipment immediately for
repair.
Close gas supply at source and drain gas when leaving
equipment unattended.
Do not use rope staging support for welding or cutting
operation; rope may burn.
Electronic Life Support Devices (Pacemakers)
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support equip-
ment (pacemakers) should consult with doctor before
going near arc welding, gouging, or spot welding opera-
tions.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. ANSI Standard 749.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Soci-
ety, 550 N.W. LeJeune Rd, Miami, FL. 33126
2. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable from
the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C. 20402
GENERAL INFORMATION
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR, obtainable from the Ameri-
can National Standards Institute, 1430 Broadway, New
York, NY 10018
6. ANSI Standard 749.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES, ob-
tainable from American National Standards Institute,
1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES,
obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL. 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Cana-
dian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-
PHY obtainable from the National Welding Supply As-
sociation, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, REC-
OMMENDED SAFE PRACTICES FOR THE PREPARA-
TION FOR WELDING AND CUTTING OF CONTAIN-
ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-
TORY PROTECTION, obtainable from American Na-
tional Standards Institute, 1430 Broadway, New York, NY
10018
A
LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter “Thermal”) warrants that its products
will be free of defects in workmanship or material. Should any failure to conform to this warranty appear
within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance
with Thermal's specifications, instructions, recommen dations and recognized standard industry practice, and
not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replace-
ment, at Thermal's sole option, of any components or parts of the product determined by Thermal to be
defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequen-
tial damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of
customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set
forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connec-
tion therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use
of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or
under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods
upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED
WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
~The limited warranty periods for Thermal products shall be as follows: A maximum of three (3) years from
date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor
to the Purchaser, and with the following further limitations on such two (2) year period:
PAK UNITS, POWER SUPPLIES PARTS LABOR
MAIN POWER MAGNETICS ..................m.emeserecienenere reee 2 YEARS coc 1 YEAR
ORIGINAL MAIN POWER RECTIFIER ..................e.mercrencees 2 YEARS ..................... 1 YEAR
CONTROL PC BOARD ..................ee.cemcenercacenen eee enero 2 YEARS ..................... 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS -..............e.cenece... 1 YEAR -...........e......... 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT .................e2eeee... 1 YEAR -................... 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS ......................ere0cerecn o e DD 180 DAYS .................. 180 DAYS
REPAIR/REPLACEMENT PARTS ..............e.ee.ceoceciorenroereeneen cen. 90 DAYS .........e..m....... 90 DAYS
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized
Thermal Arc® repair facility within thirty (30) days of the repair. Authorized Thermal Arc® repair facilities are
authorized distributors and authorized Thermal Arc® Service Centers. No transportation costs of any kind will
be paid under this warranty. Transportation charges to send products to an authorized warranty 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 warranties.
Thermal Arc® is a Registered Trademark of Thermal Dynamics.
Effective January 18, 1991
7 GENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION &
DESCRIPTION
SECTION 2:
2.01 Scope of Manual
This manual contains installation, operating and first ech-
elon maintenance procedures for the Model 250 GTSWSE
AC/DC Inverter Arc Welders. Service to this equipment
is restricted to properly trained personnel; unqualified
personnel are strictly cautioned against attempting re-
pairs, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understand-
ing of the characteristics and capabilities of this equip-
ment will assure the dependable operation for which it
was designed.
2.02 General Description
The Thermal Arc¢™ 250 GTSWSE is an AC/DC arc weld-
ing power source with Constant Current (CC) output
characteristics. The unit is equipped with a built-in sloper
control, gas control valve, lift arc starter, and high-fre-
quency arc starter for use with Gas Tungsten Arc Weld-
ing (GTAW). This unit is designed for use with Gas Tung-
sten Arc Welding (GTAW), Gas Tungsten Arc Welding -
Pulsed (GTAW-P), Gas Tungsten Arc Welding - Sloped
(GTAW-5), and Shielded Metal Arc Welding (SMAW)
processes. A front panel digital amperage/ voltage meter
is optional.
o . -
2s Or ” ” O me
"= ы Ma.
O O 5
ы O En pa
ADC MOURNE WAVE SYR TER ANC WELDEN
O uma. 250 GTSWSEO
yd Ny 2 >
É NS >
L NZ x
L NZ A
ZE NZ uy
г NZ >
É A Sy
É NN A Sy
„ 4 2 x
Zz NZ x
„ à 2 À
pd Ny Ny,
E NS Sy
Figure 2-A 250 GTSWSE Arc Welder
Manual 0-2411
Features
A. Models Available
The 250 GTSWSE AC/DC Inverter Arc Welder is avail-
able in the following model:
Model
10-1035
2.03 Specifications & Design
380/415 VAC Three Phase Only
B. Technical Characteristics
The following table defines the technical characteristics
of this equipment:
Table 2-A Technical Characteristics
Characteristic
Model 10-1035
Three-Phase
Rated Output
Amperes
Volts
Duty Cycle
Range (Min-Max):
Amperes (DC)
Amperes (AC)
Volts
Maximum OCV:
Input Frequency
Width
Height
Length
Weight with Cable
250
30
40%
5-300
10-300
10-32
70
50/60 Hz
11" (280 mm)
16.5" (420 mm)
18.5" (470 mm)
79 Ib (35.9 kg)
OCV Less than 80V
\
C.C.
|
Arc Characteristics
"CURRENT" Control
VOLTS
19V
5 145 300
A-00226 AMPS
Figure 2-B: Volt-Ampere Curves
NOTE
Volt-ampere curves show the voltage and amper-
age output capabilities of the welding power source.
Curves of other settings will fall between the curves
shown.
INTRODUCTION & DESCRIPTION
C. Output Characteristics
The following table defines the output characteristics of
this equipment at it's rated input power:
Table 2-B Output Characteristics
At Rated Load No Load
Input Power Output Output
50/60 Hz Amps KVA KW | Amps KVA KW
380/415 VAC 16 | 11 | 9 | 0.75 | 0.54} 0.14
3-Phase
D. Duty Cycle
The duty cycle of a welding power source is the percent-
age of a ten minute period that a welding power source
can be operated at a given output without causing over-
heating and damaging of the unit. This unit is rated at
40 percent duty cycle when operated at 250 amperes. The
unit can be operated at 250 amperes for four consecutive
minutes, but it must operate at no load for the remaining
six minutes to allow proper cooling. If the welding am-
peres decrease, the duty cycle increases. If the welding
amperes are increased beyond rated output, the duty
cycle will decrease.
mm CAUTIONS
EXCEEDING DUTY CYCLE RATINGS will
cause the thermal overload protection circuit to
become energized and shut down output until the
unit cools to normal operating temperature.
CONTINUAL EXCEEDING OF DUTY
CYCLE RATINGS can cause damage to the weld-
ing power source.
Do not exceed indicated duty cycles.
INTRODUCTION & DESCRIPTION
10
Manual 0-2411
SECTION 3:
INSTALLATION
PROCEDURES
3.01 Introduction
This Section describes installation of the Power Supply
and Welding Cables.
These instructions apply to the Power Supply and Weld-
ing Cables only; installation procedures for Accessories
are given in Manuals specifically provided for those units.
The complete installation consists of:
1. Unpacking
2. Site selection
3. Connections to Power Supply
a. Input power
b. Gas
¢. Work and welding cables
4. Grounding
5. Operator training
3.02 Site Selection
Select an installation site which provides the following:
. Correct input power supply (see unit nameplate)
. Shielding gas supply (if applicable)
. Water supply (if applicable)
. Adequate ventilation and fresh air supply
No flammables
A clean and dry area
Proper temperature that avoids extremes of heat or
cold
8. Proper airflow around unit
WARNING
Fire or explosion can result from placing unit on
or over combustible surfaces; Restricted Airflow
can cause overheating and possible damage to in-
ternal parts.
A
Manual 0-2411
* Do not locate unit over combustible surfaces.
* Maintain at least 3 inches (76 mm) of space from
sides of unit, 6 inches (152 mm) from rear, and open,
unrestricted access to ambient air at front of unit.
* Do not place any filtering device over the intake air
passages that provide airflow for cooling this equip-
ment.
NOTE
Warranty is subject to being voided if any type of
filtering device is used at intake air passages.
3.03 Unpacking
Each component of the system is packaged separately
and protected with a carton and packing material to pre-
vent damage during shipping.
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system in-
stallation.
3.04 Lifting Options
This unit is equipped with two handles for manually car-
rying the units.
WARNING
Electric shock can kill.
|
e Do not touch live electrical parts.
e Disconnect input power conductors from de-ener-
gized supply line before moving welding power
source.
WARNING
Falling equipment can cause serious personal in-
jury and equipment damage.
—————m——m—m——
* Lift unit with handles on top ends of case.
* Have two persons of adequate physical strength lift
unit.
* Use hand cart or similar device of adequate capac-
ity.
11 INSTALLATION PROCEDURES
* If using a fork lift vehicle, place and secure unit on
a proper skid before transporting.
* This unit has built-in handles on top ends of case
for hand lifting only. Be sure unit is lifted and trans-
ported safely and securely.
* Do not lift unit by one handle.
WARNING
Handles are not for mechanical lifting.
3.05 Input Power Connections
A WARNING
Electric shock can kill; significant DC voltage
exists after removal of input power.
* DO NOT TOUCH live electrical parts.
* SHUT DOWN welding power source, disconnect
input power employing lockout/ tagging proce-
dures, wait 60-80 seconds, and measure voltage on
input capacitors before touching any parts. Lock-
out/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging cir-
cuit breaker or other disconnecting device.
A. Electrical Input Requirements
Operate the welding power source from a three-phase,
50/60 Hz, AC power supply. The input voltage must
match the electrical input voltage shown on the input
data label on the unit nameplate. Contact the local elec-
tric utility for information about the type of electrical ser-
vice available, how proper connections should be made,
and inspection required.
— The line disconnect switch provides a safe and conve-
nient means to completely remove all electrical power
from the welding power supply whenever necessary to
inspect or service the unit.
NOTE
The unit is supplied with a 13feet of three-conduc-
tor power cable with ground that is connected at
the welding power source end for three-phase elec-
trical input power.
INSTALLATION PROCEDURES
12
WARNING
Electric shock can kill.
FE]
* Do not connect an input (white, red, or black) con-
ductor to the ground terminal.
* Do not connect the ground (green) conductor to an
input line terminal.
Connect the input power cable per the following proce-
dure:
Ground
Conductor
Ground
Terminal
Line
Disconnect
Switch
Line Fuse
> Primary Power
Cable
00
Welding Power
А-00489
Supply
Figure 3-A Electrical Input Connections and
Components
1. Connect end of green ground conductor to a suitable
ground. Use a grounding method that complies with
all applicable electrical codes.
2. Connect ends of the red (line 1), white (line 2), and
black (line 3) input conductors to a deenergized line
disconnect switch.
3. Use the following table as a guide to select line fuses
for the disconnect switch:
Manual 0-2411
Table 3-A Fuse Size
Fuse Size
Input Power | Input Voltage (Amperes)
Three Phase | 380/415 VAC 30
NOTE
Fuse size is based on not more than 200 percent of
the rated input amperage of the welding power
source (Based on Article 630, National Electrical
Code).
B. Voltage Selection
The input voltage must match one of the electrical input
voltages shown on the input data label on the unit name-
plate.
* The surge current prevention circuit becomes acti-
vated when the PRIMARY POWER switch is turned
ON.
* The welding machine is ready for operation in five
seconds after power-on.
3.06 Weld Output Cables
To obtain full rated output from this unit, it is necessary
to select, prepare, and install proper weld cables. Failure
to comply in any of these areas may result in unsatisfac-
tory welding performance.
A. Weld Cable Selection
Use the following guidelnes to select weld cables:
1. Use the shortest possible cables, and place cables close
together. Excessive cable lengths may reduce or cause
unit overload due to added resistance.
2. Use weld cable with an insulation voltage rating equal
to or greater than the maximum open circuit voltage
(OCV) of the welding power source (refer to Section
2.03-C, Table 2-B).
3. Select welding cable size according to maximum weld
output and total length of connecting cables in weld
circuit. For example, if a 25 foot (7.5 m) electrode
holder or torch cable is used with a 25 foot (7.5 m)
work cable, select the cable size recommended in Table
3-A for 50 feet (15 m).
4. Do not use damaged or frayed cables.
B. Weld Cable Preparation
1. Install terminal lugs of adequate amperage capacity
and correct stud size onto ends of cables that connect
to the work clamp and electrode holder or torch.
2. If installing electrode holder, follow manufacturer’s
installation instructions. Always use an insulated elec-
trode holder to ensure operator safety.
3. Install work clamp onto cable.
C. Connector Installation
Install the supplied male connectors onto proper cables
as follows (refer to Figure 3-B):
1. Obtain cable of desired length and proper size for in-
stallation (refer to Table 3-B).
2. If the installation requires cable larger than 3/0 AWG,
prepare one end of 3/0 AWG pigtail no longer than 2
ft (0.61 m) for connector installation. The remaining
end of the pigtail is connected to the main run of 3/0
AWG or larger weld cable.
3. Push weld cable through insulator as shown in Figure
3-B.
Table 3-B Weld Cable Sizes
Maximum Total Cable Length in Weld Circuit
Under 100 ft 150 ft 200 ft 250 ft 300 ft 250 ft 400 ft
(Under 30 m) (45 m) | (60 m) | (70 m) | (90 m) | (105 m) | (120 т)
Welding 10-60% 60-100% 10-100%
Amperes Duty Cycle |Duty Cycle Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
Manual 0-2411 13 INSTALLATION PROCEDURES
Sleeve
Strip insulation Set Screw
approx. 1 in from end |
Connector Body
Insulator (Male or Female)
Weld Cable
A-00033
Figure 3-B Connector Installation
4. Remove 1 in (25 mm) of insulation from end of cable.
9. Install supplied sleeve on stripped end of cable.
6. Insert cable with sleeve into connector body so that
cable is snug and against bottom of connector body.
7. Install and tighten set screw with supplied hex wrench
to secure connector body onto cable.
8. Push insulator onto connector body to cover set screw.
WARNING
Electric shock can kill. Arcing can burn skin or
damage electrical connections.
BA
D. Weld Cable Connections
Do not touch live electrical parts.
Shut down unit before making any weld output con-
nections.
Do not change position of the welding cable con-
nectors while welding.
Be sure the connectors are secure in receptacles be-
fore welding.
Shielded Metal Arc Welding (DCEP) (Electrode Posi-
tive/Reverse Polarity)
1. Connect end of electrode holder cable to the positive
(+) weld output receptacle as follows: align keyway,
insert plug, and rotate plug clockwise until it is se-
curely seated in receptacle.
INSTALLATION PROCEDURES
Electrode Holder
) Work Cable
Cable Connection Connection
Positive Negative
Not Used A-00497
Figure 3-C Electrode Positive /Reverse Polarity
Weld Output Connections - Lower Front Panel
2. Connect work cable connector to the negative (-) weld
output receptacle as follows: align keyway, insert
plug, and rotate plug clockwise until it is securely
seated in receptacle.
NOTE
For AC OR DCEN Electrode Negative/Straight
Polarity connections, reverse cable connections to
weld output receptacles; electrode (torch) becomes
negative.
Gas Tungsten Arc Welding (GTAW) (Electrode Nega-
tive/ Straight Polarity, High Frequency, Lift TIG or AC
- Alternating Current)
mm CAUTION
Do not connect torch cable to positive (+) output
post on power supply when gas tungsten arc weld-
ing in the AC mode.
1. Connect torch cable connector to the 3/8 BSP
monocable negative (-) weld output receptacle as fol-
lows: align keyway, insert plug, and rotate plug clock-
wise until it is securely seated in receptacle.
Manual 0-2411
Torch Cable Connection
3/8 BSP Monocable Work Cable
Connection
Negative Positive $
Not Used
A-00498
Figure 3-D Electrode Negative/Straight Polarity
Weld Output Connections - Lower Front Panel
2. Connect work cable connector to the positive (+) weld
output receptacle as follows: align keyway, insert
plug, and rotate plug clockwise until it is securely
seated in receptacle.
3. Route and connect a hose of suitable length and con-
struction from shielding gas supply to the torch gas
hose connection.
4. The gas flow must be accurately controlled with a regu-
lator and flowmeter. Recommendations for rate of
gas flow should be obtained from the torch manufac-
turer.
NOTES
For DCEN Electrode Positive/Reverse Polarity
connections, reverse cable connections to weld out-
put receptacles; electrode (torch) becomes positive.
It is recommended to use a nylon or non-conduc-
tive type hose to supply the shielding gas to the
unit. The use of rubber can result in potential con-
tamination of weld surface.
E. Shielding Gas Connections
The gas valve will not work unless the OUTPUT
CONTACTOR switch is in REMOTE position and a re-
mote control device is connected to the REMOTE 14 re-
ceptacie.
The GAS INPUT and gas output fittings have 3/8 BSP
monocable fittings. To make gas connections, proceed
as follows:
1. Route and connect a hose of suitable length and con-
struction from the shielding gas supply to the GAS
INPUT fitting on lower rear panel of unit.
2. Connect the torch cable to the 3/8 BSP monocable gas
output fitting on lower front panel of unit.
Manual 0-2411
The gas flow must be accurately controlled with a regu-
lator and flowmeter. Recommendations for rate of gas
flow should be obtained from the torch manufacturer.
NOTE
It is recommended to use a nylon or non-conduc-
tive type hose to supply the shielding gas to the
unit. The use of rubber can result in potential con-
tamination of weld surface.
3.07 Remote 14 Receptacle
The REMOTE 14 receptacle is used to connect any of the
following equipment to the welding power source cir-
cuitry:
e Remote Hand Pendant
es Remote Foot Control
* Remote TIG Pulser
* Remote Contactor Control
Remote Amperage Control
Wire Feeder - Must be voltage sensing (one which
provides contactor control to welding power
source)
* Combination of the above.
To make connections, align keyway, insert plug, and ro-
tate threaded collar fully clockwise.
The following socket information is included in case the
supplied cord is not suitable, anditis necessary to wirea
plug or cord to interface with REMOTE 14 receptacle.
7
14
ÓN
A-00035
Figure 3-E Front View of REMOTE 14 Receptacle
15 INSTALLATION PROCEDURES
Table 3-C Remote 14 Socket Information
Socket A
Up to 2 amps of 24 VAC, 60Hz, with
respect to Socket G (circuit common);
protected by Fuse F2
Socket B
Input to energize the solid-state contactor;
24 VAC (contact closure is provided ~~
between Sockets A and B to energize the
solid-state contactor
Socket C
Amperage remote control (MAXIMUM)
input command signal; +10 volts for
maximum
Socket D
Amperage remote control (MINIMUM); PC
board common; use as return for remote
control inputs/outputs
Remote amperage reference signal
Socket E (WIPER); 0 to +10 volts (peak current set
by main rheostat) in CC mode
Socket F Not used
Socket G 24 VAC circuit common; also connected to
welding power source chassis
Socket H
100 VAC with respect to Socket L (see
note below); 2 amps protected by Fuse
F3.
Socket! Not used
Up to 2 amps of 24 VAC, 60Hz, with
Socket J respect to Socket G (circuit common)
Socket K Chassis common
Socket L 100 VAC circuit common (see note below);
| 2 amps protected by Fuse F3.
Socket M Contact for repeat function with respect to
Socket B
Socket N Not used
NOTE
The voltage referenced on Sockets H and L is to be
used for applications requiring 100 VAC for Pulser
applications. Not for use in high current appli-
cations.
INSTALLATION PROCEDURES
16
Manual 0-2411
SECTION 4:
OPERATION
4.01 Introduction
This Section provides a description of the Power Supply
operating controls and procedures. Identification of the
Front and Rear Panel Controls is followed by operationg
procedures.
4.02 Functional Overview
The 250 GTSWSE AC/DC Inverter Arc Welders are ca-
pable of providing a great degree of operating flexibility.
4.03 Operating Controls
This subsection provides specfic functional descriptions
of the Power Supply operating controls and indicators.
A. Upper Front Panel
En ce
E sn WAVE VENER ARC WELDER
50 GTSWSE ©
A-00490
Figure 4-A Front Panel Operating Controls
1. AC POWER Indicator (Green)
The AC POWER indicator on the front panel comes on
when the PRIMARY POWER switch is in ON position,
indicating that the unit is energized.
2. WARNING Indicator (Red)
The WARNING indicator located on the front panel will
turn on if the unit detects one of the followingconditions:
* Input voltage too low
* Thermal overload
* Voltage too high
Manual 0-2411
3. AMPERAGE Control
The AMPERACE control selects the desired amperage
Within the entire range of the welding power source. Ro-
tating the control clockwise increases the amperage out-
put. The scale surrounding the AMPERAGE control rep-
resents the approximate amperage (A) values.
NOTE
The AMPERAGE control may be adjusted while
welding.
4. ARC CONTROL Control [1
The ARC CONTROL control provides a variable selec-
tion of short circuit amperage to suit individual welding
situations when operating in the STICK (SMAW) mode.
Rotating the control clockwise causes amperage to in-
crease as a short circuit condition is approached.
Main Knob
5-375A
Arc Control
19V 10V/100A Droop
~~
A-00039
0 25% 50% 75% 100%
че 145А ——
Arc Control Knob
Main Knob = Arc Control Knob
= Less Than 410A Output Current Limit
Figure 4-B Arc Control Characteristics
When the control is set at 100, short circuit amperage is
considerably higher than normal welding amperage. This
provides extra amperage for arc starting in out-of-posi-
tion welds as well as momentary over amperage neces-
sary for certain electrode types.
When the control is set at (zero), short circuit amperage
above normal welding amperage is minimal.
When the control is set at 50, short circuit amperage is
approximately half that of the 100 position, but still higher
than normal welding amperage. The 50 position pro-
vides a moderate amperage increase for arc starting nec-
essary for certain type of electrodes and applications.
Select a setting best suited for the application and elec-
trode type.
17 OPERATION
5. Process Selector Switch
The process selector toggle switch allows the operator to
select the type of process to be used. There are three set-
tings for the switch. When to the left it selects the STICK
welding (SMAW) process; to the center selects the LIFT
TIG (GTAW) process without high frequency; to the right
selects the HF TIG (GTAW) process with high frequency
start.
STICK Welding (SMAW) crak
In STICK welding mode, the unit provides weld output
characteristics specifically designed for the Shielded
Metal Arc Welding (SMAW) process. When the process
selector switch is in this position, the ARC CONTROL
control is active and the POSTFLOW TIME will not func-
tion.
10
~~
HF TIG (GTAW with High Frequency Start) HE TIG
In this position, the unit provides weld output for the
Gas Tungsten Arc Welding (GTAW) process. High fre-
quency will be present from the time the contactor is
closed until a welding arc is established. Once an arc is
established, high frequency is no longer present. High
frequency is present any time the arc is broken to aid in
restarting the arc as long as the contactor is energized.
When the process selector switch is in this position, the
POST FLOW, PREFLOW and HOT START controls will
function and the ARC CONTROL will not function.
NOTE
For this function to operate must have remote con-
trol connected.
LIFT TIG (GTAW without High Frequency)
ZA
In this mode, the unit provides weld output for the Gas
Tungsten Arc Welding (GTAW) process. High frequency
will not be present. When the process selector switch is
in this position, the PREFLOW and POST FLOW con-
trols will function and the ARC CONTROL and HOT
START controls will not function. The unit will provide
a low open circuit voltage and approximately 15 amps to
the tungsten electrode when touched to the work and
lifted away from surface. After the welding arc becomes
established, the output current will be regulated at de-
termined current level.
OPERATION
—
La===—7
15A
Short Circuit Current
Figure 4-C Output Characteristics of LIFT TIG
6. AMPERAGE Switch
This switch determines whether the amperage is adjusted
by the front panel AMPERAGE control or by a remote
control device. If remote control function is not desired,
O
. . . P 141 .
place this switch in PANEL position PANEL
For remote amperage control, place the AMPERAGE
switch in REMOTE 14 position. Zh
When using the REMOTE 14 receptacle, remote control
is a percentage of the value set by the front panel AM-
PERAGE control. For example, if the AMPERAGE con-
trol is set at half maximum output, the maximum output
available from the remote control will be half the weld-
ing power source maximum output.
7. OUTPUT CONTACTOR Switch
WARNING
ELECTRIC SHOCK CAN KILL.
(UN
* Do not touch live electrical parts.
* Do not touch the weld output receptacles when the
contactor is energized.
* Do not touch electrode and work clamp at the same
time.
If the OUTPUT CONTACTOR switch is in ON position,
open circuit voltage will be present at the output recep-
tacles whenever the PRIMARY POWER switch is in ON
position.
18 | Manual 0-2411
NOTE
Although the term CONTACTOR is used on the
nameplate and throughout this manual, the out-
put is not switched on or off by a physical contactor;
rather, the unit uses solid-state output control.
For remote contactor control, place the OUTPUT
CONTACTOR switch in REMOTE 14 position
A] 14
REMOTE
tions to the REMOTE 14 receptacle. Open circuit voltage
will be present at the weld output receptacles whenever
the torch switch or remote device is closed.
and connect the remote contactor connec-
If remote contactor control is not desired, place the OUT-
PUT CONTACTOR switch in ON 1
Open circuit voltage will be available whenever the PRI-
MARY POWER switch is in ON position.
8. POST FLOW Control
position.
The POST FLOW control sets the length of time gas flows
after the arcis extinguished. Post flow time begins when
the arc is broken and the contactor opens. When post
flow time ends, the gas valve closes, shutting off shield-
ing gas flow to the torch.
POST FLOW time can be adjusted from 1-50 seconds. Ro-
tating the control clockwise increases post flow time.
NOTE
The POST FLOW contro! and gas valve only work
if the process selector switch is in one of the gas
tungsten arc welding positions, the OUTPUT
CONTACTOR switch is in REMOTE position,
and a remote control is connected to the REMOTE
14 receptacle.
9. PRE FLOW Control
The PRE FLOW control only works if the process selec-
tor switch is in HF TIG position, the OUTPUT
CONTACTOR switch is in REMOTE position and a re-
mote control is connected to the REMOTE 14 receptacle.
The PRE FLOW time can be adjusted from 0.5 to 15 sec-
onds. The welding arc and high frequency will not be-
come established until the PRE FLOW control completes
timing. Rotating the control clockwise increases the PRE
FLOW time.
10. HOT START Control
The HOT START control only works if the process selec-
tor switch is in HF TIG position, the OUTPUT
CONTACTOR switch is in REMOTE position and a re-
mote control is connected to the REMOTE 14 receptacle.
Manual 0-2411
The HOT START time is approximately 0.2 seconds and
the HOT START current value is adjusted from 0 to 100%
over the determined weld current set at AMPERAGE
control. Rotating the control clockwise increases HOT
START current.
Example: Weld current set at AMPERAGE control is 100
amps and HOT START is set at 50%. The arc will initiate
at 150 amps for 0.2 seconds and then resume at 100 amps.
11. Optional Digital AMPERAGE/VOLTAGE Meter
The AMPERAGE /VOTAGE meter displays either an am-
perage (A) or voltage (V) value. The meter is not intended
for exact amperage or voltage measurements. The am-
perage display indicates amperage output of the weld-
ing power source and is driven by circuitry on control
board PC1. The voltage sensing circuitry is internally
connected to the welding power source output terminals.
The voltage display indicates the voltage at the weld
output terminals, but does not necessarily indicate the
actual voltage at the welding arc (due to cable resistance,
poor connections, etc.).
12. PREVIEW and METER Switches
These switches are supplied with the optional AMPER-
AGE/VOLTAGE meter (11). The METER switch selects
what is to be displayed on the meter. Place the toggle
switch to "A" to indicate amperage or "V" for voltage.
Push PREVIEW switch to display the amperage value
when welding is not taking place. Refer to Table 3-A
below for the values displayed for each meter switch set-
ting and parameters selected.
The following table shows the what value is displayed
for selected meter switch setting and parameters selected:
Table 4-A Meter Value Displayed
Value Contactor Meter
Displayed Switch Setting Indicator
Amperage OFF Preset
Amperage ON Preset
Volts OFF Preset
Volts ON Actual
13. Output Select Switch AC/DC
Selects the type of output to be present at the output ter-
minals. In the AC mode, square wave Alternating Cur-
rent is present at the output terminals. In the DC mode,
Direct Current is present at the output terminals.
14. CLEANING Control (AC Operation)
This feature adjusts (balances) the amount of time that
the AC square wave output is used for cleaning (DC Elec-
trode Positive - DCEP) and welding (DC Electrode Nega-
tive - DCEN).
19 OPERATION
Normal electrical power is 50% DCEP and 50% DCEN.
The DCEP part of each cycle "scrubs" oxides off the plate
and the DCEN portion increases the penetration. Increas-
ing the DCEN portion of the cycle improves penetration
by increasing the heat input into the base metal. Weld
quality and performance can be improved if this ratio is
adjusted.
When set to minimum, the AC waveform is made up of
5% DCEP and 95% DCEN which offers only minimum
cleaning of aluminum. As the CLEANING control is
moved toward 100%, the waveform changes to increase
time spent on DCEP. At the maximum setting the out-
put AC waveform is made up of 50% DCEP and 50%
DCEN. This results in aggressive scrubbing of alumi-
num.
Conventional square wave power supplies can increase
current draw as much as 50% or more if set to maximum
cleaning. A unique and very valuable feature of the Ther-
mal Arc 250 GTSWSE is that current draw is not effected
by where the cleaning knob is set.
14. SLOPER ON/OFF Switch
This switch turns the sloper control functions ON and
OFF. In the OFF position, the sloper controls are deacti-
vated. In the ON position the sloper UP/DOWN
SLOPER control and the INIT./FINAL AMP control are
activated.
15. UP/DOWN SLOPER Control
Controls the slope time from initial amperage up to the
welding amperage and from the welding amperage down
to the final amperage. The control can be set from 0.3 to
10 seconds.
16. INIT/FINAL AMP Control
Controls the setting of the desired starting amperage for
when the up-slope is to begin and the final current at the
completion of the down-slope cycle to finish the weld.
The control can be set from 0 to 100% of the full range of
the unit.
B. Lower Front Panel
1. 3/8 BSP monocable negative (-) output connection for
shielding gas and torch cable. Used in gas tungsten
operations only..
2. Positive (+) weld output receptacle for work cable.
3. Negative (-) weld output receptacle for use in shielded
metal arc welding operations .
4. REMOTE 14 receptacle used to connect various re-
mote equipment to the welding power supply.
OPERATION
A-00499
Figure 4-D Lower Front Panel Connections
C. Rear Panel
q
Os
‘ll
di
NAAA
WANA AA
NISSAN NN NN
©
EJ
{
+ AAA
|
|
|
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A-00059
Figure 4-E Rear Panel Controls
1. PRIMARY POWER Switch
The PRIMARY POWER switch (circuit breaker) located
on the rear panel energizes the welding power source
when placed in the ON position. Placing the PRIMARY
POWER switch in OFF position shuts down the welding
power source and turns off the AC POWER indicator.
NOTE
When the PRIMARY POWER switch is in the ON
position, there is a pre-charge time delay of approxi-
mately 4-5 seconds before the unit is ready to weld.
The AC POWER indicator will be on during the
pre-charge time delay.
2. Primary Power Cable
The unit is supplied with a primary power input cable
capable of handling the input voltage for the model used.
Manual 0-2411
3. GAS Input Connection
3/8 BSP input connection for shielding gas.
4.04 Operating Precautions
A WARNING
Electric shock can kill; Moving parts can cause
serious injury; Improper airflow and exposure
to environment can damage internal parts.
* Do not touch live electrical parts.
* Keep away from moving parts.
* Keep all covers and panels in place while operat-
mg.
Warranty is void if the welding power source is oper-
ated with any portion of the outer enclosure removed.
WARNING
Arc rays, sparks, and hot surfaces can burn eyes
and skin; Noise can damage hearing.
* Wear correct eye, ear and body protection.
A WARNING
Fumes and gases can seriously harm your health.
* Keep your head out of the fumes.
e Ventilate to keep from breathing fumes and gases.
* If ventilation is inadequate, use approved breath-
ing device.
WARNING
Hot metal, spatter, and slag can cause fire and
burns.
BT
e Watch for fire.
e Keep a fire extinguisher nearby, and know how to
use it.
* Do not use near flammable material.
Allow work and equipment to cool before handling.
Manual 0-2411
WARNING
Magnetic fields from high currents can affect
pacemaker operation.
ATT ООН
e Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
4.05 Electrode Selection
The proper electrode must be used depending on the
operation and the desired results. Refer to Table 4-B and
select the proper electrode. In the table an asterisk (*)
means that this type electrode is not recommended. The
table is intended as a guide and are a composite of rec-
ommendations from the American Welding Society
(AWS) and various electrode manufacturers.
21 OPERATION
Table 4-B Electrode Selection
Diameter Amperage Range - Polarity - Gas Type
Pure DC - Argon Electrode] DC - Argon Electrode : AC - Argon Balanced
Tungsten Negative/Straight Positive/Reverse High Froquenos” Wave Using
Green Band) Polarity Polarity High Frequency
.010" Up to 15 * Up to 15 Up to 10
020" 5-20 * 5-20 10-20
040" 15-80 * 10-60 20 - 30
1/16" 70-150 10-20 50-100 30-80
3/32" 125 - 225 15 - 30 100 - 160 60 - 130
1/8" 225 - 360 25 - 40 150 - 210 100 - 180
5/32" 360 - 450 40 -55 200 - 275 160 - 240
3/16" 450 - 720 55 - 80 250 - 350 190 - 300
1/4" 720 - 950 80 - 125 325 - 450 250 - 400
2 % Thorium
Alloyed
Tungsten
(Red Band) = Ses
.010" Up to 25 * Up to 25 Up to 15
020" 15-40 * 15-35 5-20
.040" 25 - 85 * 20 - 80 20-60
1/16" 50-160 10-20 50-150 60 - 120
3/32" 135 - 235 15-30 130 - 250 100 - 180
1/8" 250 - 400 25 - 40 225 - 360 160 - 250
5/32" 400 - 500 40 - 55 300 - 450 200 - 320
3/16" 500 - 750 55 - 80 400 - 500 290 - 390
1/4" 750 - 1000 80 - 125 600 - 800 340 - 525
Zirconium
Alloyed
Tungsten
(Brown Band) :
010" * * Up to 25 Upto 15
020" * * 15-35 5-20
.040" * * 20 - 80 20-60
1/16" * * 50 - 150 60 - 120
3/32" * * 130 - 250 100 - 180
1/8" * x 225 - 360 160 - 250
5/32" * * 300 - 450 200 - 320
3/16" * * 400 - 550 290 - 390
1/4" * * 600 - 800 340 - 525
than 1-1/2 times. A point can be used on tungsten in the
AC mode when the CLEANING (balance) control is set
at 20% or less.
4.06 Tungsten Preparation
Refer to Section 4.05, Table 4-B to select the correct size
and type tungsten electrode. Prepare the tungsten elec-
trode using the following guidelines.
A. For AC or DC Electrode Positive Welding
Ball the end of tungsten electrode used for AC or DC elec-
trode positive welding before beginning the welding
operation. Weld amperage causes the tungsten electrode
to form the ball end. The diameter of the end should not
exceed the diameter of the tungsten electrode by more
OPERATION 22 Manual 0-2411
Stable Arc
\
° 4
Ground Straight
Flat End
(Diameter determines
Amperage Capacity)
A-00235 O
Figure 4-F Ideal Tungsten Electrode Preparation
Arc Wanders
a) Т <
M
Ground to
a Point Electrode
- 2
А-00236
Ground Radial
Figure 4-G Incorrect Tungsten Electrode
Preparation
Grind the end of the tungsten electrode to a taper for a
distance of 2 to 2-1/2 electrode diameter in length.
Manual 0-2411
1-1/2 Times
Electrode Diameter
AC and DC
Electrode Positive
Electrode
2 to 2-1/2 Times
Electrode Diameter
а
DC Electrode
Negative
Electrode
2 to 2-1/2 Times
Electrode Diameter
Electrode Pe T=
AC Electrode
A-00237 Cleaning Control 20% or Less
Figure 4-H Properly Prepared Tungsten Electrodes
CAUTION
Hot flying metal particles can injure personnel,
start fires and damage equipment.
4.07 Operating Procedures
This Section describes various operating procedures on
the Thermal Arc Model 250 GTSWSE Inverter Arc Welder.
The Section has the following parts:
A. Shielded Metal Arc Welding (SMAW)
B. Gas Tungsten Arc Welding (GTAW) High Fre-
quency/Lift Start
C. Gas Tungsten Arc Welding (GTAW) High Fre-
quency/Lift Start With Slope Controls
D. Gas Tungsten Arc Welding (GTAW) High Fre-
quency/Lift Start With Slope Controls and Re-
peat Function
E. Gas Tungsten Arc Welding - Pulsed (GTAW-P)
FE. Shutting Down
Refer to the appropriate operation per the lettered para-
graph above (A, B, C, D, E or F) and follow the instruc-
tions as given.
23 OPERATION
A. Shielded Metal Arc Welding (SMAW)
WARNING
Read and follow all safety precautions in Section
4.04 and at the front of this manual before pro-
ceeding with operation.
|
1. Install and connect unit according to the instruc-
tions in Section 3, Installation Procedures.
2. Wear dry insulating gloves and clothing.
3. Connect work clamp to clean, bare metal at
workpiece.
4. Select proper electrode.
5. Refer to Figure 4-1 and set the controls per the fol-
lowing: :
a. Process Selector Switch (1) to STICK position.
b. OUTPUT CONTACTOR Switch (2) to ON po-
sition if remote contactor is used..
c. AC/DC Selector Switch (3) to desired opera-
tion.
d. AMPERAGE switch (4) to PANEL position, if
remote amperage control is not used . If re-
mote amperage control is to be used, then set
AMPERAGE switch to REMOTE 14 position.
e. Rotate the amperage control (5), or remote am-
perage control if applicable, to desired output
level.
f. Rotate the ARC CONTROL control (6) to de-
sired position.
x. =Q)= O: =@t| 2
TO e ==
* AC/DC SQUARE WAVE INVERER ARG WELDER
O TenmarZise. 250 GTSWSEO
— ID
A-00491 NXT
6
Figure 4-1 STICK Mode Set Up
OPERATION 24
. Insert electrode into electrode holder.
. Wear welding helmet with proper filter lens ac-
cording to ANSI 749.1.
. Place the PRIMARY POWER switch to ON posi-
tion.
9. Begin welding.
. Gas Tungsten Arc Welding (GTAW) High
Frequency/Lift Start
A WARNING
Read and follow all safety precautions in Section
4.04 and at the front of this manual before pro-
ceeding with operation.
A.
. Install and connect unit according to the instruc-
tions in Section 3, Installation Procedures.
. Select proper tungsten electrode (refer to Section
4.05).
. Prepare tungsten electrode per Section 4.06 and
insert into torch.
. Wear dry insulating gloves and clothing.
Connect work clamp to clean, bare metal at
workpiece.
. Refer to Figure 4-J and set the controls per the fol-
lowing:
a. Process Selector Switch(1) to desired gas arc
welding position.
b. OUTPUT CONTACTOR Switch(2) to REMOTE
14 position.
c. AC/DC Selector Switch (3) to desired opera-
tion.
d. AMPERAGE Switch(4) to desired position.
e. Rotate amperage contro! (5) to desired posi-
tion.
Rotate the POST FLOW (6), PRE FLOW (7) and
HOT START (8) controls to the desired posi-
tions.
>
Manual 0-2411
8 3 5
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sn =| | СЕВ”).
120 AN "o | a >"
CF sr?
TACA A
= AUDE SQUARE WAVE INVERTER ARC WELDER
О Tærmaëlike\ 250 GTSWSEO
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A-00492
6 7
Figure 4-J TIG Mode Set Up
L |
se A NL
7. Turn on shielding gas and water supplies as appli-
cable.
A WARNING
High concentration of shielding gas can harm
health or kill. Shut off gas supply when not in use.
ZOO ;z LN
8. Wear welding helmet with proper filter lens ac-
cording to ANSI 749.1.
9. Place the PRIMARY POWER switch to ON posi-
tion.
10. Activate the remote control device (foot control
or remote pendant).
NOTE
Gas controls and high frequency must have a re-
mote device for operation.
11. Touch electrode to work and lift to start arc (refer
to the following notes).
NOTES
In LIFT TIG mode, touch electrode to work and
lift to start arc.
In HF TIG mode, high frequency will start, fol-
lowed by welding arc.
12. Begin welding.
Manual 0-2411
25
C. Gas Tungsten Arc Welding (GTAW) High
Frequency/Lift Start With Slope Controls
WARNING
Read and follow all safety precautions in Section
4.04 and at the front of this manual before pro-
ceeding with operation.
ро)
1. Install and connect unit according to the instruc-
tions in Section 3, Installation Procedures.
2. Select proper tungsten electrode (refer to Section
4.05).
3. Prepare tungsten electrode per Section 4.06 and
insert into torch.
>
. Wear dry insulating gloves and clothing.
5. Connect work clamp to clean, bare metal at
workpiece.
6. Refer to Figure 4-K and set the controls per the
following:
a. Process Selector Switch(1) to desired gas arc
welding position.
b. OUTPUT CONTACTOR Switch(2) to REMOTE
14 position.
c. AC/DC Selector Switch (3) to desired opera-
tion.
d. AMPERAGE Switch(4) to REMOTE 14 posi-
tion.
e. Rotate amperage control (5) to maximum posi-
tion.
f. Rotate the POST FLOW (6), PRE FLOW (7) and
HOT START (8) controls to the desired posi-
tions.
g. SLOPE ON/OFF Switch (9) to ON.
h. Rotate UP/DOWN (10) and INIT./FINAL AMP
(11) controls to the desired positions.
OPERATION
? *
»
- {Hw
LY
%
En cara
ОНИ 7
„
ANDC SQUARE WAVE INVERTER ARC WELDER
== 250 GTSWSEO
L \
\ № N
A-00494
11 10 6 7
Figure 4-K TIG Mode Set Up With Slope
7. Turn on shielding gas and water supplies as appli-
cable.
A WARNING
High concentration of shielding gas can harm
health or kill. Shut off gas supply when not in use.
8. Wear welding helmet with proper filter lens ac-
cording to ANSI Z49.1.
9. Place the PRIMARY POWER switch to ON posi-
tion.
10. Activate the remote control device (foot control
or remote pendant).
NOTE
Gas controls and high frequency must have a re-
mote device for operation.
11. Touch electrode to work and lift to start arc (refer
to the following notes).
NOTES
In LIFT TIG mode, touch electrode to work and
lift to start arc.
In HF TIG mode, high frequency will start, fol-
lowed by welding arc.
12. Begin welding.
13. The following describes the operational sequence
of the Slope Panel Controls:
a. When the remote (torch) switch is closed pre-
flow starts, initial current and high frequency
are present at the torch.
OPERATION
NOTE
High frequence will be present only in HF TIG
mode.
b. After arc initiation unit will stay in initial am-
perage until remote (torch) switch is released
(opened).
c¢. The amperage will ramp up to the welding
amperage set at the UP/DOWN control. The
unit will stay in this mode until the remote
(torch) switch is closed again.
d. The unit will then ramp down to final amper-
age set at the UP/DOWN control. The unit
will stay in this mode until the remote (torch)
switch is released (opened) again.
e. The arc will stop and post-flow will start and
continue as set by the POST FLOW control.
D. Gas Tungsten Arc Welding (GTAW) High
Frequency/Lift Start With Slope Controls
and Repeat Function
A WARNING
Read and follow all safety precautions in Section
4.04 and at the front of this manual before pro-
ceeding with operation.
р
To use the Repeat Function requires that a second
switch be added to the existing slope sequence. This
switch must be wired across pins 'B' and 'M' on the
REMOTE 14 connector.
1. Install and connect unit according to the instruc-
tions in Section 3, Installation Procedures.
2. Select proper tungsten electrode (refer to Section
4.05).
3. Prepare tungsten electrode per Section 4.06 and
insert into torch.
4. Wear dry insulating gloves and clothing.
5. Connect work clamp to clean, bare metal at
workpiece.
6. Refer to Figure 4-L and set the controls per the
following:
a. Process Selector Switch(1) to desired gas arc
welding position.
b. OUTPUT CONTACTOR Switch(2) to REMOTE
14 position.
c. AC/DC Selector Switch (3) to desired opera-
tion.
26 Manual 0-2411
d. AMPERAGE Switch(4) to desired position.
e. Rotate amperage control (5) to desired posi-
tion.
f. Rotate the POST FLOW (6), PRE FLOW (7) and
HOT START (8) controls to the desired posi-
tions.
g. SLOPE ON/OFF Switch (9) to ON.
h. Rotate UP/DOWN (10) and INIT./FINAL AMP
(11) controls to the desired positions.
DAN
ADC SQUARE WAVE INVERTER ARC WELDER
= 250 GTSWSEO
1 | \ М
EY в
11 10 6 7
Figure 4-L TIG Mode Set Up With Slope and Repeat
Function
7. Turn on shielding gas and water supplies as appli-
cable.
A WARNING
High concentration of shielding gas can harm
health or kill. Shut off gas supply when not in use.
8. Wear welding helmet with proper filter lens ac-
cording to ANSI 749.1.
9. Place the PRIMARY POWER switch to ON posi-
tion.
10. Activate the remote control device (foot control
or remote pendant).
NOTE
Gas controls and high frequency must have a re-
mote device for operation.
11. Touch electrode to work and lift to start arc (refer
to the following notes).
Manual 0-2411
27
NOTES
In LIFT TIG mode, touch electrode to work and
lift to start arc.
In HF TIG mode, high frequency will start, fol-
lowed by welding arc.
12. Begin welding.
13. The following describes the operational sequence
of the Slope Panel Controls and the added Repeat
Function:
d.
When the remote (torch) switch is closed pre-
flow starts, initial current and high frequency
are present at the torch.
NOTE
High frequence will be present only in HF TIG
mode.
b.
After arc initiation unit will stay in initial am-
perage until remote (torch) switch is released
(opened).
The amperage will ramp up to the welding
amperage set at the UP/DOWN control. The
unit will stay in this mode until the Repeat
Function switch is closed.
. The welding current will slope down to the
initial current and stay in this mode until the
Repeat Function switch is released (opened).
. The unit will then up-slope to weld and stay in
this mode until the Repeat Function switch is
closed again.
To stop the operation close the remote (torch)
switch.
. The unit will then ramp down to final amper-
age set at the UP/DOWN control. The unit
will stay in this mode until the remote (torch)
switch is released (opened) again.
The arc will stop and post-flow will start and
continue as set by the POST FLOW control.
E. Gas Tungsten Arc Welding ~ Pulsed
(GTAW-P)
A WARNING
Read and follow all safety precautions in Section
4.04 and at the front of this manual before pro-
ceeding with operation.
OPERATION
1. Install and connect unit according to the instruc-
tions in Section 3, Installation Procedures.
2. Install and connect TIG pulser control according
to its owner's manual.
3. Select and proper tungsten electrode (refer to Sec-
tion 4.05).
4. Prepare tungsten electrode per Section 4.06 and
insert into torch.
5. Wear dry insulating gloves and clothing.
6. Connect work clamp to clean, bare metal at
workpiece.
7. Refer to Figure 4-M and set the controls per the
following:
a. Process Selector Switch(1) to desired gas tung-
sten arc welding position.
b. OUTPUTCONTACTOR Switch(2) to REMOTE
14 position.
c. AC/DC Selector Switch (3) to desired opera-
tion.
d. AMPERAGE Switch(4) to desired position.
e. Rotate amperage control (5) to maximum posi-
tion.
f. Rotate the POST FLOW (6), PRE FLOW (7) and
HOT START (8) controls to the desired posi-
tions.
ADC SQUARE WAVE INVERTER ARC WELDER
o EN 250 GTSWSEO
К
6 7
Figure 4-M GTAW-P Set-Up
ren]
A-00493
8. Adjust TIG pulser contro! according to its owners
manual.
9. Turn on shielding gas and water supplies as appli-
cable.
OPERATION
28
A, WARNING
High concentration of shielding gas can harm
health or kill. Shut off gas supply when not in use.
HET
10. Wear welding helmet with proper filter accord-
ing to ANSI 749.1.
11. Place PRIMARY POWER switch to ON position.
12. Activate remote control device (foot control or
remote pendant).
NOTES
In LIFT TIG mode, touch electrode to work and
lift to start arc.
In HF TIG mode, high frequency will start, fol-
lowed by welding arc.
13. Begin welding.
Shutting Down
1. Stop welding.
2. Move the PRIMARY POWER switch to OFF posi-
tion.
3. Turn off the shielding gas and water supplies if
applicable.
A WARNING
High concentration of shielding gas can harm
health or kill. Shut off gas supply when not in use.
HT
Manual 0-2411
SECTION 5:
CUSTOMER/OPERATOR
SERVICE
5.01 Introduction
This Section describes first-echelon maintenance proce-
dures performable by operating personnel. No other
adjustments or repairs are to be attempted by other than
Thermal Dynamics Trained personnel.
5.02 General Maintenance
4 WARNING
Disconnect primary power to the system before
opening the unit.
DE
A. Routine Maintenance
The only routine maintenance required for the Inverter
Arc Welder thorough cleaning and inspection, with the
frequency depending on the usage and the operating en-
vironment.
B. Cleaning
mE CAUTION
Do not blow air into the power supply during
Cleaning. Blowing air into the unit can cause metal
particles to interfere with sensitive electrical com-
ponents and cause damage to the unit.
To clean the unit, first make sure that the power is dis-
connected. Open the enclosure and use a vacuum cleaner
to remove any accumulated dirt and dust. Blow out any
accumulated dirt and dust with compressed air.
The unit should also be wiped clean. If necessary, sol-
vents that are recommended for cleaning electrical ap-
paratus may be used.
C. Inspection
Inspect all external wiring on the unit. Look for any
frayed wires or loose connections that should be cor-
rected.
Manual 0-2411
5.03 Troubleshooting Guide
General
Troubleshooting and repairing the this unit is a process
which should be undertaken only by those familiar with
high voltage high power electronic equipment.
4 À WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot-
ing techniques.
|
Basic Troubleshooting
This manual covers a basic level of troubleshooting that
requires limited dissasembly and measurements. It is
helpful for solving many of the common problems that
can arise with the Inverter Arc Welder system.
If major complex subassemblies are faulty, the unit must
be returned to an authorized service center for repair.
Follow all instructions as listed and complete each sec-
tion in the order presented.
NOTE
For major troubleshooting and parts replace-
ment procedures refer to Inverter Arc Welder
250GTSWSE Service Manual 0-2466.
How to use Guide
The following information is a guide to help the Cus-
tomer/ Operator determine the most likely causes for
various symptoms.
This guide is set up in the following manner:
A. Symptom (Bold Type)
Any Special Instructions (Text Type)
1. Cause (Italic Type)
a. Check/Remedy (Text Type)
Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
unitis fully operational after any repairs.
Specific Problems
A. No weld output; unit completely inoperative
1. Line disconnect switch in OFF position
a. Place line disconnect switch to ON position
29 SERVICE
2. Line fuse(s) open
a. Check and replace line fuse(s)
3. Improper electrical input connections
a. Refer to Section 3.05, Input Power Connections
for proper connections
4. Primary power switch MCB in OFF position
a. Check and reset MCB if necessary
B. No weld output; fan motor running and AC
POWER indicator ON
1. OUTPUT CONTACTOR switch S2 in REMOTE 14
position; no remote contactor control connected to RE-
MOTE 14 receptacle
a. Place 52 in ON position or connect remote
contactor control to REMOTE 14 receptacle
2. Defective remote control device
a. Check and replace remote control device if nec-
essary
C. WARNING indicator ON
1. Thermostat THS 1,THS 2 open (thermal shutdown)
a. Allow cooling period of approximately five
minutes
. Erratic or improper weld output
1. Loose welding cable connections
a. Tighten all welding cable connections
2. Incorrect welding cable size
a. Use proper size and type of cable (refer to Sec-
tion 3.06, Weld Output Cable, Table 3-A)
3. Improper input or outputconnections
a. Refer to Sections 3.05 and 3.06
4. Electrode condition
a. Replace electrode
5. Remote amperage control (when applicable)
a. Check remote amperage control potentiometer
and connections. Repair or replace if necessary
E. Remote device completely inoperative
1. Remote control not connected or connected improperly
to REMOTE 14 receptacle
a. Connect remote control to REMOTE 14 recep-
tacle
SERVICE
30
2. Remote control defective
a. Replace with known good device
Е. Wandering arc; poor control of arc direction
1. Use of tungsten considerably larger than recommended
a. Use proper size tungsten (refer to Sections 4.05
and 4.06)
2. Improperly prepared tungsten
a. Prepare tungsten per Section 4.06
3. Gas flow rate too high
a. Reduce flow rate
4. Drafts blowing shielding gas away from tungsten elec-
trode
a. Shield weld zone from drafts
5. Loose gas fittings on regulator or gas line drawing air
into weld zone
a. Check and tighten all gas fittings
6. Water in torch
a. Refer to torch parts list for part(s) requiring re-
placement and repair torch as necessary
. No high frequency
1. Process selector switch not in HF TIG position
a. Place switch in HF TIG position
2. Drafts blowing shielding gas away from tungsten elec-
trode
a. Shield weld zone from drafts
3. Insufficient postflow time
a. Increase post flow time
4. Loose gas fittings on regulator or gas line drawing air
into weld zone
a. Check and tighten all gas fittings
5. Water in torch
a. Refer to torch parts list for part(s) requiring re-
placement and repair torch as necessary
H. Lack of high frequency; difficulty in establishing
an arc
1. Dissipation of high frequency from torch cable or con-
ducive gas hose
a. Be sure that torch cable is not near any grounded
metal. Do not use conductive gas hose
Manual 0-2411
2. Weld cable leakage
a. Check cables and torch for cracked or deterio-
rated insulation or bad connections. Repair or
replace necessary parts
5.04 Replacement Parts
A. Parts List Breakdown
The parts list provides a breakdown of replaceable com-
ponents.
NOTE
For major troubleshooting and parts replace-
ment procedures refer to Inverter Arc Welder
Model 250GTSWSE Service Manual 0-2466.
Parts listed without item numbers are not illustrated, but
may be ordered by the catalog numbers shown.
B. Returns
If a Thermal Dynamics product must be returned for ser-
vice, contact your Thermal Dynamics distributor. Mate-
rials returned to Thermal Dynamics without proper au-
thorization will not be accepted.
C. Ordering Information
Order replacement parts by catalog number and com-
plete description of the part or assembly, as listed in the
description column of the Parts List. Also include the
model and serial number of the machine as shown on
the plate attached to the front panel of the unit. Address
all inquiries to your authorized Thermal Dynamics dis-
tributor.
5.05 Parts List
Catalog
No. Description
10-2236 PL1, PL2 Pilot Lamp
10-2274 F1 Fuse 5A 600V
10-2206 F2, F3 Fuse 24, 250V
10-2196 51 Switch 1P3T
10-2252 52, 53, 54, & 55 Switch 1P2T
10-2124 УК1, VR2, VR3, VR6 & VR7 10K 0.3w Pot
10-2125 VR4, VRS, & VRE 100K 0.25w Pot
10-2135 CONT 14-Pin Receptacle
10-2227 ТО 1 & TO 2 Output Terminal
10-2490 TO 3 Output Terminal With Gas Fitting
10-2202 Case Left & Right Side
10-2244 Rubber Foot
Manual 0-2411
31
SERVICE
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