Thermal Arc 400 GTSW AC/DC User manual

INVERTER
ARC
WELDER
MODEL 400 GTSW AC/DC
CC/TIG
• Stick
• TIG - High Frequency
- Lift Start
Operating Manual
Manual No. 0-2430
First Edition • September 1994

Read and understand this entire Operating Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this manual represents our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
Thermal Arc™ Model 400 GTSW Inverter Arc Welder
Operating Manual Number 0-2430
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 1994
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 400 GTSW Inverter Arc
Welder Operating Manual, whether such error results from
negligence, accident, or any other cause.
First Edition
September 1994
WARNING
WARNING

TABLE OF CONTENTS
Introduction
General Information
Installation
Operation
Service
Notes, Cautions, and Warnings ..........................................................i
Important Safety Precautions ............................................................ ii
Statement of Warranty .....................................................................xiv
1.1 Specifications................................................................................1
1.2 Duty Cycle....................................................................................2
2.1 Site Selection.................................................................................3
2.2 Transporting Methods ................................................................4
2.3 Weld Output Connections..........................................................5
2.4 Shielding Gas Connections ........................................................8
2.5 Remote 14 Connections ..............................................................9
2.6 Electrical Input Connections ....................................................10
3.1 Operator Controls......................................................................13
3.2 Sloper and Pulser Controls ......................................................19
3.3 Operating Precautions ..............................................................22
3.4 Sequence of Operation ..............................................................23
3.5 Electrode Preparation ...............................................................26
3.6 Electrode Selection ....................................................................27
4.1 General Maintenance ................................................................29
4.2 Troubleshooting Guide.............................................................30

i INTRODUCTION
NOTES, CAUTIONS, AND WARNINGS
Throughout this manual, notes, cautions, and warnings are used
to highlight important information. These highlights are catego-
rized as follows:
An operation, procedure, or background information which
requires additional emphasis or is helpful in efficient operation of
the system.
A procedure which, if not properly followed, may cause damage
to the equipment.
A procedure which, if not properly followed, may cause injury
to the operator or others in the operating area.
NOTE
CAUTION
WARNING

INTRODUCTION ii
IMPORTANT SAFETY PRECAUTIONS
WARNING
Gases and Fumes
Operation and maintenance of arc welding equipment 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.
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 can
produce different fumes, gases and radiation levels. Consult
Material Safety Data Sheets (MSDS's) and manufacturer's instruc-
tions 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 adequate to
remove all fumes and gases.
When working in confined spaces provide adequate ventilation
or wear an air-supplied respirator if necessary.
Gas leaks in 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 downstream valves are
accidentally opened. Check that area is safe before re-entering.
Materials containing lead, cadmium, zinc, mercury, beryllium,
and similar materials may produce harmful concentrations of
toxic fumes when welded or cut. Adequate local exhaust ventila-
tion must be used, or operators and others in the operating area
must wear an air-supplied respirator. For beryllium, both must
be used.

iii INTRODUCTION
Gases and Fumes
(continued)
Arc Rays
IMPORTANT SAFETY PRECAUTIONS (continued)
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 perchloro-
ethylene vapors to form phosgene. Do not weld or cut where
solvent vapors may be drawn into the welding or cutting atmo-
sphere or where radiant energy may penetrate to atmospheres
containing even minute amounts of trichloroethylene or perchlo-
roethylene. Solvents, degreasers, and potential sources of these
vapors must be removed from the operating area.
Oil or grease in the presence of oxygen may ignite and burn
violently. Keep cylinders, valves, couplings, regulators, hoses,
and other apparatus clean and free from oil 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.
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 momentarily with
unprotected eyes (particularly a high intensity gas-shielded arc)
can cause permanent damage to vision.
Use a welding helmet or shield with proper filter (see chart on
page v). Place over face before striking arc.
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 immediately.
Replace clear cover plate when broken, pitted, or spattered.
Flash goggles with side shields must be worn under helmet to
protect eyes in case helmet is not in position before arc is struck.
Wear proper protective clothing. Arc rays can penetrate light-
weight clothing,
Welding arc rays can reflect from light-colored surfaces.

INTRODUCTION iv
IMPORTANT SAFETY PRECAUTIONS (continued)
Arc Rays
(continued) 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 reflective non-combus-
tible screens or panels. Make sure that screen flaps or bay doors
are closed before welding. Allow for free air circulation, particu-
larly at floor level.
Provide face shields for all others viewing the weld.
Make sure others in the operating area are wearing flash goggles.
Welding or Cutting Operation Electrode Size Filter
Metal Thickness Shade
or Welding Current Number
Torch soldering - 2
Torch brazing - 3 or 4
Oxygen Cutting
Light Under 1 in (25 mm) 3 or 4
Medium 1-6 in (25-150 mm) 4 or 5
Heavy Over 6 in (150 mm) 5 or 6
Gas welding
Light Under 1/8 in (3 mm) 4 or 5
Medium 1/8-1/2 in (3-12 mm) 5 or 6
Heavy Over 1/2 in (12 mm) 6 or 8
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
Recommended Eye Protection for Welding and Cutting (Based on AWS A6.2-73)

v INTRODUCTION
Electric Shock ELECTRIC SHOCK can kill.
Do not contact electrically live parts.
Install equipment according to safety precautions, instruction
manual, and all applicable codes.
Keep all panels, covers, and guards in place.
Disconnect all primary power before installing or servicing this
equipment.
Insulate operator and others from work and ground.
Replace any cracked or damaged insulating parts.
Shut down welding power source before touching electrode, 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 welding circuit
or in ungrounded, electrically hot equipment can cause poten-
tially 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 without adequate insula-
tion 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 reduces electrical resistance and could cause
potentially fatal electric shock.
A voltage will exist between the electrode and any conducting
object in the work circuit. Examples of conducting objects in-
clude, but are not limited to, buildings, electrical tools, work
benches, welding power source cases, workpieces, etc. Never
touch electrode to any metal object 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 accord-
ing 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 circulator to the
building ground. Conductors must be adequate 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 be-
IMPORTANT SAFETY PRECAUTIONS (continued)

INTRODUCTION vi
come 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 connec-
tion to a grounded mating receptacle, 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 insulation 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.
For equipment with output ON/OFF control (contactor): Weld-
ing power sources for use with gas metal arc welding (GMAW),
gas tungsten arc welding (GTAW) and similar processes nor-
mally are equipped with devices that permit ON-OFF control of
the welding power output. When so equipped the electrode wire
becomes electrically hot when the power source switch is ON and
welding 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 weld-
ing power output ON-OFF control devices. With such equipment
the electrode is electrically 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.
IMPORTANT SAFETY PRECAUTIONS (continued)
Electric Shock
(continued)
Electrode