Thermal Arc 400GTS CC/TIG User manual

INVERTER
ARC
WELDER
MODEL 400GTS CC/TIG
• STICK
• TIG - HIGH FREQUENCY
- LIFT START
OPERATING MANUAL
July 1, 1997 Manual No. 0-2512
TM
R

TABLE OF CONTENTS
1.0 GENERAL INFORMATION ........................................................2
1.01 Notes, Cautions and Warnings .................................................2
1.02 Important Safety Precautions....................................................3
1.03 Publications .................................................................................6
1.04 Note, Attention et Avertissement .............................................7
1.05 Precautions De Securite Importantes.......................................8
1.06 Documents De Reference......................................................... 11
1.07 Declaration of Conformity ......................................................12
1.08 Statement of Warranty .............................................................13
2.0 INTRODUCTION AND DESCRIPTION................................15
2.01 Description ................................................................................15
2.02 Functional Block Diagram.......................................................16
2.03 Transporting Methods..............................................................17
2.04 Electrical Input Connections ...................................................17
2.05 Specifications.............................................................................20
2.06 Duty Cycle .................................................................................21
3.0 OPERATOR CONTROLS ...........................................................22
3.01 Front and Rear operator controls ...........................................22
3.02 Setup for Operation ..................................................................24
Shielded Metal Arc Welding (SMAW) .........................................25
Gas Tungsten Arc Welding (GTAW)
High Frequency/Lift Start.............................................................26
Gas Tungsten Arc Welding-Pulsed (GTAW-P)
-Sloped (GTAW-S) -TIG Spot .........................................................28
4.0 BASIC TROUBLESHOOTING..................................................31
4.01 Common Welding Operation Faults......................................31
4.02 Specific Problems......................................................................31
4.03 Remote 8-Pin Connections ......................................................35
APPENDIX A – ACCESORIES.........................................................36
APPENDIX B – INTERCONNECTION DIAGRAMS.................39

1GENERALMANUAL 0-2512
WARNING Read and understand this entire Operating Manual and your
employer’s safety practices before installing, operating, or servicing
the equipment.
WARNING While the information contained in this Operating Manual represents
our best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
Thermal Arc Models 400GTS CC/TIG Welder
Operating Manual Number 0-2512
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 1997 by
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 this
Operating Manual, whether such error results from negligence,
accident, or any other cause.
Printed in the United States of America
July 1, 1997

2
GENERAL MANUAL 0-2512
1.0 GENERAL INFORMATION
1.01 NOTES, CAUTIONS AND WARNINGS
Throughout this manual, notes, cautions, and warnings are used to
highlight important information. These highlights are categorized as
follows:
NOTE An operation, procedure, or background information which requires
additional emphasis or is helpful in efficient operation of the system.
CAUTION A procedure which, if not properly followed, may cause damage to the
equipment.
WARNING A procedure which, if not properly followed, may cause injury to the
operator or others in the operating area.

3GENERALMANUAL 0-2512
WARNING
1.02 IMPORTANT SAFETY PRECAUTIONS
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT
CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.
To prevent possible injury, read, understand and follow all warnings, safety precautions and
instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any
questions.
GASES AND FUMES Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area. Keep your head out
of the welding fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove
all fumes and gases.
• The kinds of fumes and gases from the plasma arc depend on the kind
of metal being used, coatings on the metal, and the different
processes. You must be very careful when cutting or welding any
metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS) that should be
supplied with the material you are using. These MSDSs will give you
the information regarding the kind and amount of fumes and gases
that may be dangerous to your health.
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in the Publications Section in this manual.
• Use special equipment, such as water or down draft cutting tables, to
capture fumes and gases.
• Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated
solvents and cleansers. Remove all sources of these vapors.

4
GENERAL MANUAL 0-2512
IMPORTANT SAFETY PRECAUTIONS (CONTINUED)
ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc process uses and
produces high voltage electrical energy. This electric energy can cause
severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the work piece
or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or damp.
• Install and maintain equipment according to NEC code, refer to item 4
in the Publications section of this manual.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Be sure there is no combustible or flammable material in the
workplace. Any material that cannot be removed must be protected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire hazards may
exist.
• Hydrogen gas may be formed and trapped under aluminum
workpieces when they are cut underwater or while using a water
table. DO NOT cut aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. Trapped
hydrogen gas that is ignited will cause an explosion.
NOISE Noise can cause permanent hearing loss. Plasma arc processes can cause
noise levels to exceed safe limits. You must protect your ears from loud
noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs
and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do
not exceed safe levels.
• For information on how to test for noise, see item 1 in the Publications
section of this manual.

5GENERALMANUAL 0-2512
IMPORTANT SAFETY PRECAUTIONS (CONTINUED)
PLASMAARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma
arc process produces very bright ultra violet and infra red light. These
arc rays will damage your eyes and burn your skin if you are not
properly protected.
• To protect your eyes, always wear a welding helmet or shield. Also
always wear safety glasses with side shields, goggles or other
protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from
the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace lenses
when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective
booths, screens or shields.
• Use the shade of lens as recommended in the Operating Manual.

6GENERAL MANUAL 0-2512
1.03 PUBLICATIONS
Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDINGAND CUTTING, obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDINGAND CUTTING,
obtainable from the Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway,
New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING
PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York,
NY 10018
7. AWS StandardA6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126
8. NFPAStandard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED
PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
9. NFPAStandard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPAStandard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable
from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding
Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society StandardAWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE
HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from
American National Standards Institute, 1430 Broadway, New York, NY 10018

7GENERALMANUAL 0-2512
1.04 NOTE, ATTENTION ET AVERTISSEMENT
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont
utilisés pour mettre en relief des informations à caractère important. Ces
mises en relief sont classifiées comme suit :
NOTET oute opération, procédure ou renseignement général sur lequel il
importe d’insister davantage ou qui contribue à l’efficacité de
fonctionnement du système.
ATTENTION Toute procédure pouvant résulter l’endommagement du matériel en cas
de non-respect de la procédure en question.
AVERTISSEMENT Toute procédure pouvant provoquer des blessures de l’opérateur
ou des autres personnes se trouvant dans la zone de travail en cas de
non-respect de la procédure en question.

8
GENERAL MANUAL 0-2512
AVERTISSEMENT
1.05 PRECAUTIONS DE SECURITE IMPORTANTES
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE
À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER
DES RISQUES ET DES DANGERS DE SANTÉ.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de
sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre
distributeur local si vous avez des questions.
FUMÉE et GAZ La fumée et les gaz produits par le procédé de jet de plasma peuvent
présenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre
tête hors de la plume de fumée provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent
du genre de métal utilisé, des revêtements se trouvant sur le métal et
des différents procédés. Vous devez prendre soin lorsque vous coupez
ou soudez tout métal pouvant contenir un ou plusieurs des éléments
suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité des matières (sigle
américain “MSDS”); celles-ci devraient être fournies avec le matériel
que vous utilisez. Les MSDS contiennent des renseignements quant à
la quantité et la nature de la fumée et des gaz pouvant poser des
dangers de santé.
• Pour des informations sur la manière de tester la fumée et les gaz de
votre lieu de travail, consultez l’article 1 et les documents cités à la
page 11.
• Utilisez un équipement spécial tel que des tables de coupe à débit
d’eau ou à courant descendant pour capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée provenant des
solvants et des produits de nettoyage chlorés. Eliminez toute source
de telle fumée.