Thermal Arc TA-8/300-KAT User manual

MODEL TA-8/300-KAT
DC CC/CV
Welding Generator
INSTRUCTION MANUAL
•STICK
•MIG
•Auxiliary Power
October 27 ,2003 Manual No. 430429-484
MI146-06-00-04

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ref. FT8300KAT.TIF

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Proposition 65
WARNING: This product, when used for welding or cutting,
produces fumes or gases which contain chemicals known to the
State of California to cause birth defects and, in some cases,
cancer. (California Health & Safety Code Sec.25249.5 et seq.)

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WARNING
Read and understand this entire Instruction Manual and your employer’s safety practices before
installing, operating, or servicing the equipment.
WARNING
While the information contained in this Instruction Manual represent our best judgement, Thermal
Arc assumes no liability for its use.
Thermal Arc DC CC/CV Welding Generator Model TA-8/300-KAT
Instruction Manual Number 11-1010
Published by:
Thermal Arc
2200 Corporate Drive
Troy OH
USA 45373
Ph: (1) 937 440 0100
Copyright 1997 by
Thermal Arc
All right 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 part for any loss or damage
caused by any error or omission in the Thermal Arc DC CC/CV Welding Generator Model
TA-8/300-KAT Instruction Manual, whether such error results from negligence, accidental, or any
other cause.
August 1, 1997

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TABLE OF CONTENTS
1. GENERAL INFORMATION.....................................................................................................6
1.01 Notes, Cautions and Warnings.........................................................................................................................6
1.02 Important Safety Precautions ...........................................................................................................................6
1.03 Publications......................................................................................................................................................8
1.04 Note, Attentions et Avertissement....................................................................................................................9
1.05 Precations De Securite Importantes .................................................................................................................9
1.06 Publications....................................................................................................................................................11
2. STATEMENT OF WARRANTY.............................................................................................13
3. TECHNICAL SPECIFICATIONS ..........................................................................................15
4. FRONT PANEL DESCRIPTION............................................................................................16
5. OVERALL DIMENSIONS WEIGHT BASE MOUNTING .................................................19
6. SPECIFICATIONS ...................................................................................................................20
7. INSTALLING WELDING GENERATOR.............................................................................21
8. WARNING .................................................................................................................................22
9. GENERATOR AUXILIARY POWER SYSTEM..................................................................23
9.01 SELECTING EQUIPMENT..........................................................................................................................23
10. WIRING OPTIONAL 230 VOLT PLUG................................................................................24
11. GROUNDING THE GENERATOR TO A TRUCK OR A TRAILER FRAME................25
12. GROUNDING THE GENERATOR WHEN CONNECTING TO HOME, SHOP, OR
FARM WIRING ........................................................................................................................25
13. SELECTING AND PREPARING WELD OUTPUT CABLES............................................26
14. TYPICAL PROCESS CONNECTIONS .................................................................................27
15. POWER REQUIRED TO START MOTOR..........................................................................27
16. SELECTING WELD CABLES SIZES ...................................................................................28
17. WELD OUTPUT CONNECTION...........................................................................................29
18. SEQUENCE OF OPERATION................................................................................................30
18.01 SHELDED METAL ARC WELDING (SMAW) ..........................................................................................30
18.02 GAS METAL ARC WELDING (GMAW)....................................................................................................30
19. ROUTINE MAINTENANCE...................................................................................................31
20. PARTS LIST ..............................................................................................................................34
STATOR PARTS.........................................................................................................................................................34
FRONT PANEL AND INSTRUMENT PARTS .........................................................................................................36
20.03 SHEET PARTS..............................................................................................................................................38
21. WIRING DIAGRAM ................................................................................................................41

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1. GENERAL INFORMATION
GASES AND FUMES
1.01 Notes, Cautions and Warnings
Gases and fumes produced during the Arc
welding/cutting process can be dangerous and
hazardous to your healt.
Throughout this manual,notes,cautions,and
warnings are used to highlight important
information. These highlights are categorized as
follows:
•Keep all fumes and gases from the breathing
area. Keep your head out of the welding fume
plume.
NOTE
•Use an air-supplied respirator if ventilation is
not adeguate to remove all fumes and gases.
An operation, procedure, or background
information wich requires additional emphasis or
is helpful in efficent operation of the system.
•The kinds of fumes and gases from the arc
welding/cutting depend on the kind of metal
being used coatings on the metal, and the
different process. You must be very careful
when cutting or welding any metals which may
contain one or more of the following:
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the
operating area.
•Always read the Material Safety data Sheets
(MSDS) that should be supplied with the
material you are using. These MSDS will give
you the information regarding the kind and
amount of fumes and gases that may dangerous
to your healt.
1.02 Important Safety Precautions
•For information on how to test for fumes and
gases in your workplace, refer to item 1 in
Subsection 1.03, Publication in this manual.
WARNING
•Use special equipment, such as water or down
draft welding/cutting tables, to capture fumes
and gases.
OPERATION AND MAINTENANCE OF
WELDING EQUIPMENT CAN BE DANGEROUS
AND HAZARDOUS TO YOUR HEALT.
•Do not use the welding torch in an area where
combustible or explosive gases or materials
are located.
To prevent possible injury, read, understand, and
follow all warnings, safety precautions and
instructions bedore using the equipment. Call 1-
603-298-5711 or your local distributor if you have
any questions.
•Phosgene, a toxic gas, is generated from the
vapors of chlorinated solvents and cleansers.
Remove all sources of these vapors.
GENERAL INFORMATION

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ELECTRIC SHOCK
Electric Shock can injure or kill. The arc welding
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 ar damage parts.
•Extra care must be taken when the workplace
is moist or damp.
•Install and mantain equipment according to
NEC code, refer to item 4 in Subsection 1.03,
Publications.
•Disconnect power source before performing
any service or repairs.
•Read and follow all the instruction in the
Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag,
sparks or the arc weld.
•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 aluminium workpieces when they
are cut underwater or while using a water
table. DO NOT cut aluminium 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. Arc
welding/cutting processes can cause noise levels
to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of
hering.
•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 Subsection 1.03, Publications,
in this manual.
ARC WELDING RAYS
Arc Welding/Cutting Rays can injure your
eyes and burn your skin. The arc welding
cutting 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
GENERAL INFORMATION

8
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 raccomanded in
Subsection 1.03, item 4.
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
WELDING AND 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 WELDING AND
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 Standard 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 1018.
6. ANSI Standard Z49.2, FIRE PREVENTION
IN THE USE OF CUTTING AND WELDING
PROCESSES, Obtainable from American
National Standard Institute, 1430 Broadway,
New York, NY 10018.
7. AWS Standard A6.0, WELDING AND
CUTTING CONTAINERS WICH HAVE
HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. Lejeune
Rd, Miami, FL33126.
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 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 Standard
AWSF4.1, RECOMMENDED SAFE
PRACTICES FOR THE PREPARATION
FOR WELDING AND CUTING OF
CONTAINERS AND PIPING THAT HAVE
HELD HAZARDOUS SUBSTANCES
obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL
33126.
GENERAL INFORMATION

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15.
ANSI Standard Z88.2, PRACTICE FOR
RESPIRATORY PROTECTION, obtainable
from American National Standards Instiute,
1430 Broadway, New York, NY 10018.
1.04 Note, Attentions et
Avertissement
Dans ce manuel les mots “note”, “attention”, et
“avertissement” sont utilises pour mettre en relief
des informations à caractère important
NOTE
Toute opération, procedure ou reseignement
général sur lequel il importe d’insister davantage
ou qui ciìontribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de
nonrespect 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.
1.05 Precations De Securite
Importantes
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE A 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 lisez,
comprenez et suivez tous les avertissement, toutes
les précautions de sécurité et toutes les consignes
avant d’utilizer le materiel. Composez le +603-
298-5711 ou votre distributeur local si avez des
questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procede de jet
de plasma peuvent présenter des risques et des
dangers de saté.
•Eloignez toute fumée et gaz de votre zone de
respiration. gardez votre tête hors de la plume
de fumée proventant du chalumeau.
•Utilisez un appareil respiratoire à alimentation
en air si l’aération fournie ne permet pas
d’éliminerla dumée et les gaz.
•Les sortes de gaz et de fumée provenant de
l’arc de plasma dépendent de genre de métal
utilisé, des revêtements se trouvant sur le
métal et des differents procédés. Vous devez
prendre soin lorque vous coupez ou soudez
tout métal pouvant contenir un ou plusieurs
des éléments suivants :
Antimoine Cadmium Mercury
Argent Chrome Nickel
Arsenic Cobalt Plomb
Baryum Cuivre Sélénium
Béryllium Manganése
Vanadium
•Lisez toujours les fiches de données sur la
sécurité des matéries (sigle américain
“MSDS”); celle-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 maniere de tester
la fumés et les gaz de votre lieu de travail,
ccnsultez l’article 1 et les documents cités à la
page 5.
GENERAL INFORMATION

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•Utilisez un équipment 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 oú se trouvent des matiéres ou
des gaz combustibles ou explosifs.
•Le phosgène, un gaz toxique, est généré par la
fumée proventant des solvants et des produits
de nettoyage chlorés. Eliminez toute. Source
de telle fumée.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même
tuer. Le procédé au jet de plasma requiert et
produit de l’énergie électrique haube tension.
Cette énergie électrique peut produire des chocs
graves, voire mortels, pour l’opérateur et les
autres personnes sur le lieu de travail.
•Ne touchez jamais une piéce “sous tension” ou
“vive”; portez des gants et des vêtemets secs.
Isolez-vous de la pièce de travail ou des autre
parties du circuit de soudage.
•Rérarez ou remplacez toute pièce usée ou
endommagée.
•Prenez des soins particuliers lorsque la zone de
travail est humide ou moite.
•Montez et maintenez le matériel au Code
électrique national des Etats-Unis. (Voir la
page 5, article 9).
•Débranchez l’alimentation électrique avant
tout tarvail d’entretien ou de réparation.
•Lisez et respectez toutes les consignes du
Manuel de consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosion peuvent résulter
des scories chaudes, des étincelles ou de l’arc de
plasma. Le procédè à l’arc de plasma produit du
métal, des étincelles, des scories chaudes pouvant
mettre le feu aux matieres combustibles ou
provoquer l’explosion de fumées inflammables.
•Soyez certain qu’aucune matière combustible
ou inflammable ne se trouve sur le lieu de
travail. Protéges toute telle matière qu’il est
impossible de retirer de la zone de travail.
•Procurez une bonne aeration de toutes les
fumées inflammable ou explosives.
•Ne coupez pas et ne soudez pas les conteneurs
ayant pu renfermer des matieres combustibles.
•Prévoyez une veille d’incendie lors de tout
travail dans une zone présentant des dangers
d’incendie.
•Le gaz Hydrogène peut se former ou
s’accumuler sous les pièces de travail en
aluminium lorsqu’elle sont coupées sous l’eau
ou sur une table d’eau. NE PAS couper les
alliages en aluminium sous l’eau ou sur une
table d’eau à moins que le ga shydrogène peut
s’echapper ou se dissipier. Le gaz hydrogène
accunulé explosera si enflammé.
RAYONS D’ARC DE PLASMA
Les rayons provenent del’arc de plasma peuvent
blesser vous yeux et brûler votre peau. Le procédé
à l’arc de plasma produit une lumière infra-rouge
et des rayons ultra-violets très forts. Ces rayon
d’arc nuirontà vos yeux et brûleront votre peau si
vous ne vous proteges pas correctment.
•Pour protéger vos yeux, portez toujours un
casque ou un écran de soudeur. Portez toujours
des lunettes de sécurité minies de parois
latérales ou des lunettes de protection ou une
autre sorte de protection oculaire.
•Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayon de l’arc.
•Maintenez votre casque et vos lunettes de
protection en bon état. Remplacez toute
lentille sale ou comportant fissure ou rognure.
•Protegez les autrez personnes se trouvent sur
la zone de travail contre les rayons de l’arc en
fournissant del cabines ou del écrans de
protection.
•Respectez le teint de lentille racommandé dans
le article4, page 5.
GENERAL INFORMATION

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BRUIT
Le bruit peut provoquer une perte permanente de
l’ouie. Les procédés de soudage à l’arc de plasma
peuvent provoquer des niveaux sonores
supérieures aux limites normalement acceptables.
Vous dùvez vous protéger les oreilles contre les
bruits forts afin d’éviter une perte permanente de
l’ouïe.
•Pour protéger votre ouïe contre les bruits forts,
portez des taòpons protecteurs st/ou des
protections auriculaires. Protégez également
les autres personnes se trouvant sur le lieu de
travail.
•Il faut measurer les niveaux sonores afin
d’assurer que les décibels (le bruit) ne
dépassent pas les niveaux sûrs.
•Pour des renseignements sur la manière de
tester le bruit, consultez l’article 1, page 5.
1.06 Publications
Consultez les normes suivents ou les révisions les
plus récentes ayant été faites à celles-ci pour de
plus amples renseignements:
1. OSHA, NORMES DE SÉCURITÉ DU
TRAVAIL ET DE LA PROTECTION DE LA
SANTÉ, 29CFR 1910, disponible auprès du
Superintenent of documents, U.S. Government
Printing Office, Washington, D.C. 20402.
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE
SOUDAGE, disponible auprésde la Société
Americaine de Soudage (American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL
33126.
3. NIOSH LA SÉCURITÉ ET LA SANTÉ LORS
DES OPÉRATIONS DE COUPE ET DE
SOUDAGE A L’ARC ET AU GAZ,
disponible auprès du Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
4. Norme ANSI Z87.1, PARTIQUES SURES
POUR LA PROTECTION DES YEUX ET
DU VISAGE AU TRAVAIL ET DANS LES
ECOLES, disponible de l’ Institute Américain,
des Normes Nationales (American National
Standard Institute), 1430 Broadway, New
York, NY 10018.
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible
auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY
1018.
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L’EMPLOI DE
PROCÉDÉS DE COUPE ET DE SOUDAGE,
disponible aupres de l’American National
Standard Institute, 1430 Broadway, New York,
NY 10018.
7. Norme A6.0 de l’Association Américaine du
Soudage (AWS), LE SOUDAGE ET LA
COUPE DE CONTENEURS AYANT
RENFERMÉ DES PORDUITS
COMBUSTIBLES disponible auprès de la
American Welding Society, 550 N.W. Lejeune
Rd, Miami, FL33126.
8. Norme 51 de l’Association Américaine pour la
Protection contre les Incendies (NFPA), LES
SYSTEMS A GAZ AVEC ALIMENTATION
EN COUPE ET LES PROCÉDÉS ASSOCIÉS,
disponible auprès de la National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.
9. Norme 70 de la NFPA,CODE ELECTRIQUE
NATIONAL, disponible aupres de la National
Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10.Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible aupres
de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
11.Brochure CGA P-1, LA MANIPULATION
SANS RISQUE DES GAZ COMPRIMÉS EN
CYLINDRES, disponible aupres de
l’Association des Gaz Comprimes
(Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501 Arlington, VA
22202.
GENERAL INFORMATION

12
12.Norme CSA W117.2, CODE DE SÉCURITÉ
POUR LE SOUDAGE ET LA COUPE,
disponible aupres de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W
1R3.
13.Invret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible
auprès de l’Association Nationale de
Fournitures de Soudage (National Welding
Supply Association), 1900 Arch Street,
Philadelphia PA 19103.
14.Norme AWSF4.1 de l’Association Américaine
de soudage , RECOMMANDATIONS DE
PRATIQUES SURES POUR LA
PRÉPARATION A LA COUPE ET AU
SOUDAGE DE CONTENEURS ET
TUYAUX AYANT RENFERMÉ DES
PRODUITS DANGEREUX, disponible auprès
de l’American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126.
15.Norme ANSI Z88.2, PRATIQUES DE
PROTECTION RESPIRATOIRE, disponible
auprès de l’American National Standards
Instiute, 1430 Broadway, New York, NY
10018.
GENERAL INFORMATION

13
2. STATEMENT OF WARRANTY
LIMITED WARRANTY: Thermal Arcâ, Inc. A Thermadine Company, 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 Arc products as stated below, Thernal Arc shall, upon notification thereof and substantiation
that the product has been stored, installed, operated, and manteined in accordance with Thermal Arc’s specifications,
instructions, recomandations and recognized standard industry practice, and not subjet to misuse, repair, neglet,
alteration, or accident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of any
components or parts of the product determinated by Thermal Arc to be defective.
THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS
EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special or consequential
damages, such us, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of
distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are
exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as
the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or
furnished by Thermal Arc whether arising out of contract, negligence, 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. No
employee, agent, or rapresentative of Thermal Arc is authorized to change this warranty in any way or grant any other
warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR
ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE JUDGEMENT MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO
PURCHASER CY NONAUTHORIZED PERSONS.
Except with regards to the products listed below, this warranty shall remain effective there (3) years from from the date
Thermal Arc’s authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date
Thermal Arc delivers the product to the authorized distributor.
Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time
stated below beginning on the date that the authorized distributor delivers the products to the Purchaser.
Notwithstanding the foregoing, in no event shall the warranty period extend more that the time stated plus one year from
the date Thermal Arc delivered the product to the authorized distributor.
ALL OTHER P-WEE, PRO-LITE
POWER SUPPLIES POWER SUPPLIES INVERTERS LABOR
MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 2 YEARS 1 YEAR
ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR
CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING
BUT NOT LIMITED TO, CONTACTORS, RELAYS,
SOLENOIDS, PUMPS, POWER SWITCHING SEMI-
CONDUCTORS.
1 YEAR 1 YEAR 1 YEAR
ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE
WARRANTED BY THE ENGINE MANUFACTURER. SEE THE ENGINE MANUFACTURES WARRANTY
FOR THE DETAILS.
CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR 1 YEAR
EXCANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS
REPAIR/ REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS
GENERAL INFORMATION

14
Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized
Thermal Arcârepair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under
this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the
responsability of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes
all previous Thermal Arc warranties.
Thermal Arcâis a Registred trademark of Thermadyne Industries Inc.
Effective January 1,1998
GENERAL INFORMATION

15
3. TECHNICAL SPECIFICATIONS
WELDING GENERATOR DC
DC amperage range 30÷300A of continuous control
DC welding current 300A 60% duty cycle
DC welding current 210A 100% duty cycle
CC Mode / CV Mode
VOLTAGE
CC 70 OCV
CV 15 to 30 Load Volt
AUXILIARY POWER
60 Hz Single Phase 115 V 3,5 kVA - 230 V 8,5 kVA
ENGINE
Make/Type KUBOTA Diesel
Model series D722-E
Number of cylinders 3
Displacement 719 cc.
Power 19 HP
Engine speed 3600 r.p.m.
Cooling system Water
Oil capacity 3.1 l. - 0,8 gl.
Fuel capacity 37,5 l. - 10 gl.
Fuel consumption 4,2 l/h - 1,1 gl./h
Battery 12 V 44 Ah

16
4. FRONT PANEL DESCRIPTION
1 Amperage / Voltage control - The Amperage / Voltage control selects the desired Amperage
or voltage (depending on mode) withing the entire range of the welding generator. Rotating
this control in a clockwise direction increases the amperage or voltage output. The scale
surrounding the control represents approximate actual amperage or voltage values.
2 Battery Charge Lamp - When the RUN/STOP Switch is turned on the Battery Charge Lamp
will Glow. For normal operation when the engine is running the Battery Carge Lamp will be
off. Should the Charging circuit at Battery fail the Battery Warning Lamp will Turn-on and
the engine will shut off.
3 Oil Pressure Lamp - When the RUN/STOP Switch is turned on the Oil Pressure Lamp will
Not Glow. Should the oil sensor in the engine detect a low oil condition the Oil Pressure
Lamp will turn-on and the engine will shut off.
4 Water Temperature Lamp - Lamp turns on when engine temperature reaches degrees.
5 Fuel reserve Lamp.
6 Arc Control Switch.
7 Process Selector switch : CC/CV - Allows the operator to select the CC (Constant Current)
process or CV (Constant Voltage) process.
ref. T8300KAT.DWG
++
,+
EXPLORER
CIRCUIT
BREAKER
115V 3A
+8


"
REMOTE
TM
PROCESS SELECTOR
ENGINE WARNING SYSTEM
&
DC CURRENT/VOLTAGE REGULATION

!
$
VOLTS
AMPERES
# !
%
 #
$

AMPERE/VOLT
PANEL
!
%
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OFF
ARC CONTROL
ON CV
CC
1RC
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HERMAL)
4
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17
8 Remote Control AMPERAGE / VOLTAGE Switch - This selector switch determines the
adjustment of Amperage/Voltage. In the PANEL position, Amperage/Voltage is controlled
by the front panel control knob. For remote Amperage/Voltage control, set the switch to
REMOTE 14 for control through the 14 pin receptacle with a remote Amperage/Voltage
device.
9 Serial number
10 Welding Receptacle Electrode: Positive output welding connection for CC (Constant
Current) and CV (Constant Voltage).
11 115V 3A Circuit breaker - Push to reset. Controls 115V power source for wire feeders
controlled through 14 pin receptacle.
12 14 Pin receptacle - Used for remote Contactor , amperage controls wire feeder control.
13 Welding receptacle Work: Negative output welding connection for CV (Constant Voltage)
MIG.
14 Welding Receptacle Work: Negative output welding connection for CC (Constant Current)
STICK.

18
FRONT PANEL DESCRIPTION
1 115V 20A Circuit Breakers - Push to reset. Controls 115V power source for the 115V duplex
GFCI receptacles.
2 GFCI 115V Duplex receptacles - Ground fault interrupt protection receptacle for 115V 60Hz
power source.
3 230/115V 40A Circuit breakers - Push to reset. Controls 230/115V power source for the
230/115V receptacle.
4 230/115V Single Phase Receptacle – Supplies 60 Hz single-phase power at weld/power
5 Engine : Auto/High switch - When in Auto the unit will idle until a load is applied. In High
position the engine will operate above idle RPM.
6 Engine RUN/STOP Switch - Place the switch in the RUN position to operate generator. Use
the START button to start the engine. To shut off engine place switch in STOP position.
7 Glow Plug push button - push and wait until Glow Lamp turns off before starting engine.
8 START button- Used to start the engine. Set the RUN/START switch to RUN, wait for glow
plug light to turn off, push START button to start engine. When engine starts release button.
9 Glow Lamp - Indicates glow plug is active.
10 Hour meter - Monitors Time in hours when the engine is on.
11 Fuel Gauge - Monitors fuel level. Low fuel shuth-down circuits stops engine before fuel tank
is empty.
12 Earth connection - used to earth ground the generator for auxiliary power.
ref. T300KT1.DWG
AUXILIARY POWER
CIRCUIT
115V 20A
BREAKER 115V AC
BREAKER
CIRCUIT
115/230V 40A
ENGINE
230V AC
HIGH
AUTO
STOP
RUN GLOW PLUG START

19
5. OVERALL DIMENSIONS WEIGHT BASE
MOUNTING
OVERALL DIMENSION
MAXIMUM WELDING GENERATOR OPERATING ANGLES
Do not exceed operating amgles while running or engine damage will occur.
Errore. Il collegamento non è valido.
Base mounting hole layout
Dimensions
Height 850 mm 33,46 in
Width 530 mm 20,86 in
Lenght 1330 mm 52,36 in
A 15 mm 0,59 in
B 1300 mm 51,18 in
C 34 mm 1,38 in
D 462 mm 18,18 in
E 10,5 mm Dia 0,41 in
Weight 302 Kg 665,8 lb
ref. TA300K2.TIF
ref. TA300K1.TIF

20
6. SPECIFICATIONS
DESCRIPTION
The Thermal Arc TA-8/300-KAT is Diesel
engine driven DC welding generator with
selectable Constant Current (CC) and
Constant Voltage (CV) output characteristics.
This unit is designed for use with Shielded
Metal Arc Welding (SMAW), Gas Metal Arc
Welding (GMAW).
NOTE
Volt-Ampere curves show the voltage and
amperage output capabilities of the welding
power source. Curves of other settings will
fall between the curves shown.
DUTY CYCLE
The duty cycle of a welding generator is the
percentage of a ten minute period that welding
generator can be operated at a given output
without causing overheating and damaging og
the unit. This unit is rated at 60 percent duty
cycle when operated at 300 amperes. The unit
can be operated at 300 amperes for six
consecutives minutes, but it must operate at
no load for the remaining four minutes to
allow proper cooling. If the welding amperes
decrease, the duty cycle increases. If the
welding amperes are increased beyond rated
output, the duty cycle will decrease.
CAUTION
EXCEEDING DUTY CYCLE RATINGS
will cause the thermal overload protection
circuit to become energized and shut down
output until the cools to normal operating
temperature.
CAUTION
CONTINUAL EXCEEDING OF DUTY
CYCLE RATINGS can cause damage to the
welding power source.
•Do not exceed indicated duty cycles.
Volt-Am
p
ere Curves
NOTE: Full output may not be
achived before Engine break-in time.
Engine break-in time is Approx. 80
hours.
ref. TA300K.TIF