300 gms inverter arc welder operators manual (0-2419)

INVERTERARC

WELDER

MODEL 300GMS CC/CV

Stick TIG - Lift Start MIG - Short Circuit

- Globular- Spray

Manual No. 0-2419First EditionJune 1994

This Operating Manual Applies to the Following Units:230/460V - Serial No. C301001R188204 and Up380/415V - Serial No. T401001A188205A and Up460/575V - Serial No. T402001A188206A and Up

Operating Manual

jma gamerHighlight

Read and understand this entire Operating Manual and youremployers safety practices before installing, operating, orservicing the equipment.

While the information contained in this manual represents ourbest judgement, Thermal Dynamics Corporation assumes noliability for its use.

Thermal Arc Model 300GMS Inverter Arc Welder OperatingManual Number 0-2419

Published by:Thermal Dynamics CorporationIndustrial Park No. 2West Lebanon, New Hampshire, USA 03784(603) 298-5711

Copyright 1994Thermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without writtenpermission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liabilityto any party for any loss or damage caused by any error oromission in the Thermal Arc Model 300GMS Inverter ArcWelder Operating Manual, whether such error results fromnegligence, accident, or any other cause.

First EditionJune 1994

WARNING

WARNING

TABLE OF CONTENTS

Introduction

General Information

Installation

Operation

Service

Notes, Cautions, and Warnings .......................................................... iImportant Safety Precautions ............................................................ iiStatement of Warranty .....................................................................xiv

1.1 Specifications................................................................................ 11.2 Duty Cycle .................................................................................... 2

2.1 Site Selection................................................................................. 32.2 Transporting Methods ................................................................ 42.3 Weld Output Connections.......................................................... 52.4 Remote 14 Connections .............................................................. 82.5 Remote 17 Connections ............................................................ 102.6 Electrical Input Connections .................................................... 12

3.1 Operator Controls ...................................................................... 153.2 Operating Precautions .............................................................. 223.3 Sequence of Operation .............................................................. 233.4 Electrode Selection .................................................................... 27

4.1 General Maintenance ................................................................ 294.2 Troubleshooting Guide ............................................................. 304.3 Parts Replacement ..................................................................... 33

i INTRODUCTION

NOTES, CAUTIONS, AND WARNINGS

Throughout this manual, notes, cautions, and warnings are usedto highlight important information. These highlights are catego-rized as follows:

An operation, procedure, or background information whichrequires additional emphasis or is helpful in efficient operation ofthe system.

A procedure which, if not properly followed, may cause damageto the equipment.

A procedure which, if not properly followed, may cause injuryto 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 involvespotential hazards. Operators and all others in the operating areashould be alerted to possible hazards, and precautions should betaken to prevent possible injury.

Read these safety precautions and the entire instruction manualbefore operating.

Do not use this power supply to thaw frozen water pipes.

This equipment must be installed, operated, and serviced byqualified personnel only.

GASES AND FUMES produced during arc welding can bedangerous and hazardous to your health.

Keep all fumes and gases from the breathing area.

Different arc welding processes, electrodes, and fluxes canproduce different fumes, gases and radiation levels. ConsultMaterial Safety Data Sheets (MSDS's) and manufacturer's instruc-tions for specific technical data and precautionary measures forall 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 andfumes 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 toremove all fumes and gases.

When working in confined spaces provide adequate ventilationor wear an air-supplied respirator if necessary.

Gas leaks in a confined space should be avoided. Leaked gas inlarge 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 toprevent possible accumulation of gases if downstream valves areaccidentally opened. Check that area is safe before re-entering.

Materials containing lead, cadmium, zinc, mercury, beryllium,and similar materials may produce harmful concentrations oftoxic fumes when welded or cut. Adequate local exhaust ventila-tion must be used, or operators and others in the operating areamust wear an air-supplied respirator. For beryllium, both mustbe used.

iii INTRODUCTION

Gases and Fumes(continued)

Arc Rays

IMPORTANT SAFETY PRECAUTIONS (continued)

Metals coated with or containing materials that emit toxic fumesshould not be heated unless coating is removed from worksurface and work area is well ventilated. Wear an air-suppliedrespirator if necessary.

Vapors from chlorinated solvents can be decomposed by the heatof the arc or flame to form phosgene, a highly toxic gas, and otherlung and eye irritating products. The ultraviolet radiant energyof the arc can also decompose trichloroethylene and perchloro-ethylene vapors to form phosgene. Do not weld or cut wheresolvent vapors may be drawn into the welding or cutting atmo-sphere or where radiant energy may penetrate to atmospherescontaining even minute amounts of trichloroethylene or perchlo-roethylene. Solvents, degreasers, and potential sources of thesevapors must be removed from the operating area.

Oil or grease in the presence of oxygen may ignite and burnviolently. Keep cylinders, valves, couplings, regulators, hoses,and other apparatus clean and free from oil and grease. Oxygencylinders and apparatus should not be handled with oily handsor gloves. Do not allow an oxygen stream to contact oily orgreasy 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 eyesfrom exposure to arc. Looking at an arc momentarily withunprotected 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 onpage 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 passthrough 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 toprotect 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


Arc Rays(continued)

Make sure others in the operating area are protected from arcrays.

For production welding, use separate room or enclosed bay. Inopen areas, surround operation with low reflective non-combus-tible screens or panels. Make sure that screen flaps or bay doorsare 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 FilterMetal Thickness Shade

or Welding Current Number

Torch soldering - 2Torch brazing - 3 or 4Oxygen Cutting

Light Under 1 in (25 mm) 3 or 4Medium 1-6 in (25-150 mm) 4 or 5Heavy Over 6 in (150 mm) 5 or 6

Gas weldingLight Under 1/8 in (3 mm) 4 or 5Medium 1/8-1/2 in (3-12 mm) 5 or 6Heavy Over 1/2 in (12 mm) 6 or 8

Shielded metal arc welding(stick) electrodes

Light Under 5/32 in (4 mm) 10Medium 5/32-1/4 in (4-6.4 mm) 12Heavy Over 1/4 in (6.4 mm) 14

Gas metal arc welding (MIG)Non-ferrous base metal All 11Ferrous base metal All 12

Gas tungsten arc welding (TIG) All 12Atomic hydrogen welding All 12Carbon arc welding All 12Plasma arc welding All 12Carbon arc air gouging

Light - 12Heavy - 14

Plasma arc cuttingLight Under 300 amps 9Medium 300-400 amps 12Heavy 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, instructionmanual, and all applicable codes.

Keep all panels, covers, and guards in place.

Disconnect all primary power before installing or servicing thisequipment.

Insulate operator and others from work and ground.

Replace any cracked or damaged insulating parts.

Shut down welding power source before touching electrode, wiredrive assembly, welding wire, wire reel, or any metal parts incontact with the welding wire.

Exposed hot conductors or other bare metal in the welding circuitor in ungrounded, electrically hot equipment can cause poten-tially fatal electric shock. Do not contact a wet surface whenwelding without suitable protection.

Wear dry insulating gloves and body protection. Keep body andclothing dry. Never work in damp area without adequate insula-tion against electrical shock. Stay on a dry duckboard, or rubbermat when dampness or sweat cannot be avoided. Sweat, seawater, or moisture between body and an electrically hot part orgrounded metal reduces electrical resistance and could causepotentially fatal electric shock.

A voltage will exist between the electrode and any conductingobject in the work circuit. Examples of conducting objects in-clude, but are not limited to, buildings, electrical tools, workbenches, welding power source cases, workpieces, etc. Nevertouch electrode to any metal object unless the welding powersource is off.

Arc welding equipment must be grounded according to theNational 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 weldingpower source, control, work table and water circulator to thebuilding ground. Conductors must be adequate to carry groundcurrents safely. Equipment made electrically hot by stray currentmay cause potentially fatal electric shock. Do not ground toelectrical conduit or to pipe carrying any gas or flammable liquidsuch as oil or fuel.

Check phase requirements before installing. If only three-phasepower is available, connect single-phase equipment to only twowires of the three-phase line. Do not connect the equipmentground lead to the third (live) wire, or the equipment will be-


INTRODUCTION vi

come electrically hot - a dangerous condition that may causepotentially fatal electric shock.

Before welding, check ground for continuity. Be sure conductorsare touching bare metal of equipment frames at connections.

If a line cord with a ground lead is provided with the equipmentfor connection to a switchbox, connect the ground lead to thegrounded switchbox. If a three-prong plug is added for connec-tion to a grounded mating receptacle, the ground lead must beconnected to the ground prong only. If the line cord comes witha three-prong plug, connect to a grounded mating receptacle.Never remove the ground prong from a plug, or use a plug witha broken off ground plug.

Fully insulated electrode holders should be used. Do not useholders with protruding screws.

Fully insulated lock-type connectors should be used to joinwelding cable lengths.

Frequently inspect cables for wear, cracks and damage. Replacethose with excessively worn or damaged insulation to avoidpotentially fatal electric shock from bared cable. Cables withdamaged areas may be taped to give resistance equivalent tooriginal cable.

Keep cables dry, free of oil and grease, and protected from hotmetal and sparks.

Terminals and other exposed parts of electrical units should haveinsulating 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 ofthe welding power output. When so equipped the electrode wirebecomes electrically hot when the power source switch is ON andwelding gun switch is closed. Never touch electrode wire or anyconducting object in contact with electrode circuit unless thewelding 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 equipmentthe electrode is electrically hot when the power switch is turnedON. Never touch the electrode unless the welding power sourceis off.

Safety devices such as interlocks and circuit breakers shouldnever be disconnected or shunted out.


Electric Shock(continued)

Electrode

vii INTRODUCTION

Electric Shock(continued)

Fire and Explosion

Before installating, inspecting, or servicing equipment, disconnectprimary power and remove line fuses (or lock or red-tagswitches) to prevent accidental electric shock. Disconnect allcables from welding power source and pull all 115V line-cordplugs.

Do not open power circuit or change polarity while welding. If itmust be disconnected in an emergency, guard against shockburns and flash from switch arcing.

Always shut off and disconnect all primary power when leavingequipment unattended.

Primary power disconnect switch must be available near thewelding power source.

FIRE AND EXPLOSION can be caused by hot slag, spatter,sparks, extreme heat, misuse of compressed gases and cylinders,and electrical short circuits.

Remove all combustibles from working area or provide a firewatch. Avoid paint spray rooms, dip tanks, storage areas, venti-lators. Move work to an area free of combustibles if possible. Ifwork cannot be moved, move combustibles at least 35 ft (10.7 m)away from sparks and heat or protect against ignition withsuitable and snug-fitting, fire-resistant covers or shields.

Walls having combustibles on opposite sides should not bewelded on or cut. Walls, ceilings, and floor near work should beprotected by heat-resistant covers or shields.

A fire watch with suitable fire extinguishing equipment must beprovided during and after welding or cutting if combustibles(including building construction) are within 35 ft (10.7 m), ifcombustibles are further than 35 ft but may be ignited by flyingsparks, or if openings (concealed or visible) in floors or wallswithin 35 ft may expose combustibles to sparks.

Combustibles adjacent to walls, ceilings, roofs, or metal partitionscan be ignited by radiant or conducted heat.

A hot work permit should be obtained before operation to ensuresupervisors approval that adequate precautions have been taken.

Do not weld or cut an empty container that has held combus-tibles, or that can produce flammable or toxic vapors whenheated, unless container has first been cleaned as described inAWS Standard A6.0. This includes a thorough steam or causticcleaning (or a solvent or water washing, depending on thecombustibles solubility) followed by purging and inerting withnitrogen or carbon dioxide, and using protective equipment asrecommended in A6.0. Waterfilling just below working levelmay substitute for inerting.


INTRODUCTION viii

A container with unknown contents should be cleaned (seepreceding paragraph). Do not depend on smell or sight todetermine if it is safe to weld or cut.

Hollow castings or containers must be vented before welding orcutting to prevent explosion.

Never weld or cut in potentially explosive atmospheres contain-ing 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 passthrough cracks, along pipes, through windows or doors, andthrough wall or floor openings, out of sight of the operator.

Keep equipment clean and operable, free of oil, grease, andmetallic particles that can cause short circuits in electrical parts.

Overloading arc welding equipment beyond rated capacity mayoverheat cables and cause fire.

Loose cable connections may overheat or flash and cause fire.

Never strike an arc on a cylinder or other pressure vessel. Itcreates a brittle area that can cause a violent rupture or lead torupture under rough handling.

After work is done, check that area is free of sparks, glowingembers, and flames.

Burn Prevention - Wear protective clothing including gauntletwelding gloves, hat, and high safety toe shoes. Button shirt collarto protect chest and neck, button pocket flaps, and wear cufflesstrousers to avoid entry of sparks and slag. Wear dark colored,substantial long-sleeve clothing (particularly for gas-shieldedarc). As necessary, use additional protective clothing such asleather jacket or sleeves, flame-proof apron, and fire-resistantleggings. Avoid outer garments of untreated cotton.

Wear helmet with safety goggles and glasses with side shieldsunderneath, appropriate filter lenses or plates (protected by clearcover glass) for welding or cutting (and chipping) to protect theeyes from radiant energy and flying metal. Replace cover glasswhen broken, pitted, or spattered.

Avoid oily or greasy clothing which may be ignited by sparks.

Do not handle hot metal such as electrode stubs and workpieceswithout gloves.

Medical first aid and eye treatment facilities and personnelshould be available for each shift unless medical facilities areclose by for immediate treatment of flash burns of the eyes andskin burns.

Fire and Explosion(continued)


ix INTRODUCTION

Flammable hair preparations should not be used by personsintending 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.

Comply with the precautions in this manual and those detailed inCGA Standard P-1, SAFE HANDLING OF COMPRESSEDGASES IN CYLINDERS.

Pressure Regulators:

Regulator relief valve is designed to protect only the regulatorfrom overpressure and not intended to protect any downstreamequipment. Provide such protection with one or more reliefdevices.

Never connect a regulator to a cylinder containing gas other thanthat for which the regulator was designed.

Remove faulty regulator from service immediately for repair(first close cylinder valve) if gas leaks externally, if deliverypressure continues to rise with downstream valve closed, or ifgauge pointer does not move off stop pin when pressurized, norreturns to stop pin after pressure release.

Do not attempt to repair faulty regulators. Send to manufactur-ers authorized repair center where special techniques and toolsare used by trained personnel.

Cylinders must be handled carefully to prevent leaks and dam-age to walls, valves, or safety devices.

Contact with electrical circuits including third rails, electricalwires, or welding circuits can product short circuit arcs that maylead to a serious accident.

ICC or DOT markings must be on each cylinder as an assuranceof safety when the cylinder is properly handled.

Use only cylinders with name of gas clearly marked on them; donot rely on color to identify gas content. Notify supplier ifunmarked. Never deface or alter name, number or other mark-ings on a cylinder.

Keep valves closed on empty cylinders, replace caps securely,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.


Fire and Explosion(continued)

Noise

High PressureGas Cylinders

INTRODUCTION x

Locate or secure cylinders so they cannot be knocked over.

Keep cylinders clear of passageways and work areas where theymay be struck.

To transport cylinders with a crane, use a secure support such asa platform or cradle. Do not lift cylinders by valves or caps, or bychains, slings, or magnets.

Do not expose cylinders to excessive heat, sparks, slag, or flamewhich may cause rupture. Do not allow contents to exceed1300F. Cool with water spray where such exposure exists.

Protect cylinders and valves from bumps, falls, falling objects,and weather. Replace caps securely when moving cylinders.

Do not use hammer or wrench to open a cylinder lock valvewhich cannot be opened by hand. Notify supplier.

Never mix gases in a cylinder.

Never refill any cylinder.

Do not modify or exchange cylinder fittings.

Never use hose unless appropriate for specified gas. General hoseidentification is: red for fuel gas, green for oxygen, and black forinert gases.

Use ferrules or clamps designed for hose (not ordinary wire orother substitute) as a binding to connect hoses to fittings.

Do not use copper tubing splices. Use only standard brassfittings to splice hose.

Avoid long runs to prevent kinks and abuse. Coil excess hose toprevent kinks and tangles. Suspend hose off ground to protectfrom damage. Protect hose from damage by sharp edges, sparks,slag, excessive heat, and open flame.

Examine hose regularly for leaks, wear, and loose connections.Immerse pressured hose in soapy water; bubbles indicate leaks.

Repair leaky or worn hose by cutting area out and splicing. Donot tape.

Keep cylinder valve outlet free of impurities which may clogorifices and damage seats before connecting regulator. Except forhydrogen, crack valve momentarily and point outlet away frompeople and sources of ignition. Wipe clean with a lintless cloth.

Match regulator to cylinder. Before connecting, check thatregulator label and cylinder marking area match and that regula-tor inlet and cylinder outlet match. Never connect a regulatordesigned for one type of gas to a cylinder containing another gas.

High PressureGas Cylinders

(continued)

Hose

Proper Connections


xi INTRODUCTION

When assembling threaded connections, clean and smooth seatswhere necessary before tightening. If connection leaks, disas-semble, clean, and retighten using properly fitting wrench.

Use a CGA adapter (available from supplier) between cylinderand regulator, if required. Use two wrenches to tighten adaptermarked RIGHT and LEFT HAND threads.

Regulator outlet (or hose) connections may be identified by righthand threads for oxygen and left hand threads (with grooved hexon nut or shank) for fuel gas.

Drain regulator of residual gas through suitable vent beforeopening cylinder (or manifold valve) by turning adjusting screwclockwise. Draining prevents excessive compression heat at highpressure seat by allowing seat to open on pressurization. Leaveadjusting screw engaged slightly on single-stage regulators.

Do not stand in front of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure increasesslowly. When gauge is pressurized (gauge reaches regulatormaximum) open cylinder valve fully to seal stem against possibleleak when using oxygen and inert gases. For fuel gas, open lessthan one turn to permit quick emergency shutoff.

Use pressure charts (available from supplier) for safe and effi-cient, recommended pressure settings on regulators.

Check for leaks on first pressurization and regularly thereafter.Brush with soapy solution (one capful of liquid detergent pergallon of water); bubbles indicate leak Clean off soapy waterafter test; dried soap is combustible.

Remove leaky or defective equipment immediately for repair.

Close gas supply at source and drain gas when leaving equip-ment unattended.

Do not use rope staging support for welding or cutting operation;rope may burn.

Magnetic fields from high currents can affect pacemaker opera-tion. Persons wearing electronic life support equipment (pace-makers) should consult with doctor before going near arc weld-ing, gouging, or spot welding operations.

Proper Connections(continued)

Pressurizing Steps

Electronic Life SupportDevices (Pacemakers)


INTRODUCTION xii

Refer to the following standards or their latest revisions for moreinformation:

1. ANSI Standard Z49.1, SAFETY IN WELDING AND CUT-TING, obtainable from the American Welding Society, 550N.W. LeJeune Rd, Miami, FL 33126

2. NIOSH, SAFETY AND HEALTH IN ARC WELDING ANDGAS WELDING AND CUTTING, obtainable from the Super-intendent 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

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPA-TION AND EDUCATIONAL EYE AND FACE PROTEC-TION, obtainable from American National Standards Insti-tute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MENS SAFETY-TOE FOOTWEAR, obtainable from the American NationalStandards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OFCUTTING AND WELDING PROCESSES, obtainable fromAmerican National Standards Institute, 1430 Broadway, NewYork, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-ERS WHICH HAVE HELD COMBUSTIBLES, obtainablefrom American Welding Society, 550 N.W. LeJeune Rd,Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FORWELDING, CUTTING AND ALLIED PROCESSES, obtain-able 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 PRO-CESSES, obtainable from the National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSEDGASES IN CYLINDERS, obtainable from the CompressedGas Association, 1235 Jefferson Davis Highway, Suite 501,Arlington, VA 22202

Publications


xiii INTRODUCTION

Publications(continued)

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-ING AND CUTTING, obtainable from the CanadianStandards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHYobtainable from the National Welding Supply Associa-tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-MENDED SAFE PRACTICES FOR THE PREPARATIONFOR WELDING AND CUTTING OF CONTAINERSAND PIPING THAT HAVE HELD HAZARDOUSSUBSTANCES, obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORYPROTECTION, obtainable from American NationalStandards Institute, 1430 Broadway, New York, NY10018


INTRODUCTION xiv

STATEMENT OF WARRANTY

LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter Thermal) warrants that itsproducts will be free of defects in workmanship or material. Should any failure to conform to this war-ranty 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, andmaintained in accordance with Thermals specifications, instructions, recommen dations and recognizedstandard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct suchdefects by suitable repair or replacement, at Thermals sole option, of any components or parts of theproduct determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITYOR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or conse-quential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claimsof customers of distributor (hereinafter Purchaser) for service interruption. The remedies of the Pur-chaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anythingdone 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 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 USEDWHICH 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) yearsfrom date of sale to an authorized distributor and a maximum of two (2) years from date of sale by suchdistributor to the Purchaser, and with the following further limitations on such two (2) year period:

PAK UNITS, POWER SUPPLIES PARTS LABOR

MAIN POWER MAGNETICS ....................................................... 2 YEARS ..................... 1 YEAR

ORIGINAL MAIN POWER RECTIFIER ..................................... 2 YEARS ..................... 1 YEAR

CONTROL PC BOARD.................................................................. 2 YEARS ..................... 1 YEAR

ALL OTHER CIRCUITS AND COMPONENTS ......................... 1 YEAR ...................... 1 YEARINCLUDING, BUT NOT LIMITED TO, STARTINGCIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,POWER SWITCHING SEMI-CONDUCTORS

CONSOLES, CONTROL EQUIPMENT, HEAT ........................... 1 YEAR ...................... 1 YEAREXCHANGES, AND ACCESSORY EQUIPMENT

TORCH AND LEADS ..................................................................... 180 DAYS .................. 180 DAYS

REPAIR/REPLACEMENT PARTS ................................................. 90 DAYS .................... 90 DAYS

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorizedThermal Arc repair facility within thirty (30) days of the repair. Authorized Thermal Arc repairfacilities are authorized distributors and authorized Thermal Arc Service Centers. No transportationcosts of any kind will be paid under this warranty. Transportation charges to send products to an autho-rized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at thecustomer's risk and expense. This warranty supersedes all previous Thermal warranties.

Thermal Arc is a Registered Trademark of Thermal Dynamics.

Effective January 18, 1991

1 GENERAL INFORMATION

1.1 SPECIFICATIONS

The Thermal Arc 300GMS is a three-phase or single-phase (ifderated) DC arc welding power source with selectable ConstantCurrent (CC) and Constant Voltage (CV) output characteristics.This unit is designed for use with Shielded Metal Arc Welding(SMAW), Gas Metal Arc Welding (GMAW), and Gas TungstenArc Welding - Lift Start (GTAW) processes. A digital amperage/voltage meter is standard.

Description

Table 1-A Unit Specifications

Figure 1-A Volt-Ampere Curves

Volt-ampere curves show the voltage and amperage outputcapabilities of the welding power source. Curves of other set-tings will fall between the curves shown.

NOTE

Input Data At Rated Load No Load50/60 Hz Output Output

Amps KVA KW Amps KVA KW

208 VAC 1-Phase 48 10 7 2.5 0.5 0.3208 VAC 3-Phase 39 14 11 1.5 0.5 0.3230 VAC 1-Phase 43 10 7 2.0 0.5 0.3230 VAC 3-Phase 35 14 11 1.0 0.5 0.3460 VAC 1-Phase 21 10 7 1.0 0.5 0.3460 VAC 3-Phase 18 14 11 0.5 0.5 0.3575 VAC 3-Phase 14 14 11 0.5 0.5 0.3380 VAC 3-Phase 21 14 11 1.0 0.5 0.3400 VAC 3-Phase 18 14 11 1.0 0.5 0.3415 VAC 3-Phase 19 14 11 0.5 0.5 0.3

Rated Output Single-Phase Three-PhaseAmperes 210 300Volts 28 32Duty Cycle 60% 60%

Range (Min-Max):Amperes 5-260 5-375Volts 10-30 10-36

Maximum OCV: 70Input Data 50/60 HzWidth 12 in (305 mm)Height 20 in (510 mm)Length 18.5 in (470 mm)Weight (with Cable) 230/460 380/415 460/575

88.7 lb 82.1 lb 83.8 lb40.3 kg 37.3 kg 38.1 kg

OCV Less than 80V C.C.

Arc Characteristics "CURRENT" Control

19V

AMPS5 150 375 410

VOLTS

A-00032

OCV Less Than 80V C.V.

36V

10V

25A 410AOutput Current Limit 410A

A-00041

GENERAL INFORMATION 2

The duty cycle of a welding power source is the percentage of aten minute period that a welding power source can be operatedat a given output without causing overheating and damaging ofthe unit. This unit is rated at 60 percent duty cycle when oper-ated at 300 amperes from three-phase input power, or whenoperated at 210 amperes from single-phase input power. If theunit is operated from three-phase input power, the unit can beoperated at 300 amperes for six consecutive minutes, but it mustoperate at no load for the remaining four minutes to allow propercooling. When the welding power source is operated fromsingle-phase input power, the unit can be operated at 210 am-peres for six consecutive minutes, but it must operate at no loadfor the remaining four minutes to allow proper cooling. If thewelding amperes decrease, the duty cycle increases. If thewelding amperes are increased beyond rated output, the dutycycle will decrease.

EXCEEDING DUTY CYCLE RATINGS will cause the thermaloverload protection circuit to become energized and shut downoutput until the unit cools to normal operating temperature.

CONTINUAL EXCEEDING OF DUTY CYCLE RATINGS cancause damage to the welding power source.

Do not exceed indicated duty cycles.

1.2 DUTY CYCLE

CAUTION

CAUTION

3 INSTALLATION

2.1 SITE SELECTION

Select an installation site which provides the following:

1. Correct input power supply (see unit nameplate)

2. Shielding gas supply (if applicable)

3. Water supply (if applicable)

4. Adequate ventilation and fresh air supply

5. No flammables

6. A clean and dry area

7. Proper temperature that avoids extremes of heat or cold

8. Proper airflow around unit

FIRE OR EXPLOSION can result from placing unit on or overcombustible surfaces; RESTRICTED AIRFLOW can causeoverheating and possible damage to internal parts.

Do not locate unit over combustible surfaces.

Maintain at least 3 inches (76 mm) of space from sides of unit, 6inches (152 mm) from rear, and open, unrestricted access toambient air at front of unit.

Do not place any filtering device over the intake air passagesthat provide airflow for cooling this equipment.

Warranty is subject to being voided if any type of filtering deviceis used at intake air passages.

WARNING

NOTE

INSTALLATION 4

2.2 TRANSPORTING METHODS

This unit is equipped with two handles for carrying purposes.

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Disconnect input power conductors from de-energized supplyline before moving welding power source.

FALLING EQUIPMENT can cause serious personal injury andequipment damage.

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 capacity.

If using a fork lift vehicle, place and secure unit on a properskid before transporting.

This unit has built-in handles on top ends of case for handlifting only. Be sure unit is lifted and transported safely andsecurely.

Do not lift unit by one handle.

WARNING

WARNING

WARNING HANDLES are not for mechanical lifting.

5 INSTALLATION

2.3 WELD OUTPUT CONNECTIONS

To obtain full rated output from this unit, it is necessary to select,prepare, and install proper weld cables. Failure to comply in anyof these areas may result in unsatisfactory welding performance.

Use the following guidelnes to select weld cables:

1. Use the shortest possible cables, and place cables closetogether. Excessive cable lengths may reduce or cause unitoverload due to added resistance.

2. Use weld cable with an insulation voltage rating equal to orgreater than the maximum open circuit voltage (OCV) of thewelding power source (see Table 2-A below).

3. Select welding cable size according to maximum weld outputand total length of connecting cables in weld circuit. Forexample, if a 25 foot (7.5 m) electrode holder or torch cable isused with a 25 foot (7.5 m) work cable, select the cable sizerecommended in Table 2-A for 50 feet (15 m).

4. Do not use damaged or frayed cables.

1. Install terminal lugs of adequate amperage capacity andcorrect stud size onto ends of cables that connect to the workclamp and electrode holder or torch.

2. If installing electrode holder, follow manufacturers installa-tion instructions. Always use an insulated electrode holder toensure operator safety.

3. Install work clamp onto cable.

4. Install supplied male connectors onto remaining ends of bothcables (refer to Connector Installation, page 6).

Weld Cable Selection

Weld Cable Preparation

Table 2-A Weld Cable Sizes

Maximum Total Cable Length in Weld CircuitWelding Under 100 ft 150 ft 200 ft 250 ft 300 ft 250 ft 400 ftAmperes (Under 30 m) (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)

10-60% 60-100% 10-100%Duty Cycle Duty Cycle Duty Cycle

100 4 4 4 3 2 1 1/0 1/0150 3 3 2 1 1/0 2/0 3/0 3/0200 3 2 1 1/0 2/0 3/0 4/0 4/0250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

INSTALLATION 6

2.3 WELD OUTPUT CONNECTIONS (continued)

Install the supplied male connectors onto proper cables as follows(refer to Figure 2-A below):

1. Obtain cable of desired length and proper size for installation(see Table A, page 5).

2. If the installation requires cable larger than 3/0 AWG, pre-pare one end of 3/0 AWG pigtail no longer than 2 ft (0.61 m)for connector installation. The remaining end of the pigtail isconnected to the main run of 3/0 AWG or larger weld cable.

3. Push weld cable through insulator as shown in Figure 2-A.

4. Remove 1 in (25 mm) of insulation from end of cable.

5. Install supplied sleeve on stripped end of cable.

6. Insert cable with sleeve into connector body so that cable issnug and against bottom of connector body.

7. Install and tighten set screw with supplied hex wrench tosecure connector body onto cable.

8. Push insulator onto connector body to cover set screw.

Connector Installation

ELECTRIC SHOCK can kill. ARCING can burn skin or damageelectrical connections.


Shut down unit before making any weld output connections.

Do not change position of the welding cable connectors whilewelding.

Be sure the connectors are secure in receptacles before welding.

WARNING

Weld Cable Connections

Figure 2-A Connector Installation

Strip insulationapprox. 1 in from end

Insulator Weld Cable

SleeveSet Screw

Connector Body(Male or Female)

A-00033

7 INSTALLATION

2.3 WELD OUTPUT CONNECTIONS (continued)

Refer to Figure 2-B and:

a. Connect end of electrode holder cable to the positive (+) weldoutput receptacle as follows: align keyway, insert plug, androtate plug clockwise until it is securely seated in receptacle.

b. Connect work cable connector to the negative (-) weld outputreceptacle as follows: align keyway, insert plug, and rotateplug clockwise until it is securely seated in receptacle.

For Electrode Negative/Straight Polarity connections, reversecable connections to weld output receptacles; electrode (torch)becomes negative.

a. Connect end of electrode holder cable to the positive (+) weldoutput receptacle as follows: align keyway, insert plug, androtate plug clockwise until it is securely seated in receptacle.Connect remaining end to terminal connection located ondrive housing of wire feeder (see wire feeder manual forlocation).

b. Connect work cable connector to the negative (-) weld outputreceptacle as follows: align keyway, insert plug, and rotateplug clockwise until it is securely seated in receptacle.

For Electrode Negative/Straight Polarity connections, reversecable connections to weld output receptacles; electrode (torch)becomes negative.

a. Connect torch cable connector to the negative (-) weld outputreceptacle as follows: align keyway, insert plug, and rotateplug clockwise until it is securely seated in receptacle.

b. Connect work cable connector to the positive (+) weld outputreceptacle as follows: align keyway, insert plug, and rotateplug clockwise until it is securely seated in receptacle.

Shielded Metal ArcWelding (SMAW)

(Electrode Positive/Reverse Polarity)

NOTE

Gas Metal Arc(GMAW) and

Flux Cored Arc(FCAW) Welding

(Electrode Positive/Reverse Polarity)

NOTE

Gas Tungsten ArcWelding (GTAW)

(Electrode Negative/Straight Polarity,

Lift-Start)

Figure 2-B Weld Output Connections - Lower Front Panel

Positive NegativeA-00034

Work CableConnection

Electrode HolderCable Connection

INSTALLATION 8

2.4 REMOTE 14 CONNECTIONS

The REMOTE 14 receptacle is used to connect any of the follow-ing equipment to the welding power source circuitry:

Remote Contactor Control

Remote Amperage Control

Wire Feeder (one which provides contactor control to weldingpower source)

Combination of the above.

To make connections, align keyway, insert plug, and rotatethreaded collar fully clockwise.

The following socket information is included in case the suppliedcord is not suitable, and it is necessary to wire a plug or cord tointerface with REMOTE 14 receptacle.

Figure 2-C Front View of 14-Pin Socket Receptacle with Socket Locations

14

A

B

C

D

E

J

I

L

K

N H

M G

F

A-00035

9 INSTALLATION

Socket A Up to 10 amps of 24 VAC, 60Hz, with respect to Socket G(circuit common); protected by circuit breaker MCB3

Socket B Input to energize the solid-state contactor; 24 VAC (contactclosure is provided between Sockets A and B to energize thesolid-state contactor

Socket C Amperage remote control (MAXIMUM) input command signal;+10 volts for maximum

Socket D Amperage remote control (MINIMUM); PC board common; useas return for remote control inputs/outputs

Socket E Remote amperage reference signal (WIPER); 0 to +10 volts(peak current set by main rheostat) in CC or CV mode

Socket F Not used

Socket G 24 and 115 VAC circuit common; also connected to weldingpower source chassis

Socket H 100 VAC with respect to Socket L (see note below)

Socket I Up to 1.5 amperes of 115 VAC, 60Hz, with respect to Socket G(circuit common); protected by circuit breaker MCB2

Socket J 115 VAC input control to energize solid state contactor (contactclosure is provided between Sockets I and J)

Socket K Chassis common

Socket L 100 VAC circuit common (see note below)

Socket M Current sensing contactor with respect to Socket N (N/O)

Socket N Current sensing contactor with respect to Socket M (N/O)

NOTE: The voltage referenced on Sockets H and L is to be used forapplications requiring 100 VAC

2.4 REMOTE 14 CONNECTIONS (continued)

Table 2-B Remote 14 Socket Information

INSTALLATION 10

2.5 REMOTE 17 CONNECTIONS

The 17-socket REMOTE receptacle provides a junction point forconnecting various remote controls to the welding power source.The functions available from this receptacle are:

Remote MIG synergic pulse control

Robot control

Weld current and voltage signals for remote metering

To make connections, align keyway, insert plug, and rotatethreaded collar fully clockwise.

The following socket information is included in case the suppliedcord is not suitable, and it is necessary to wire a plug or cord tointerface with REMOTE 17 receptacle.

Figure 2-D Front View of 17-Socket Receptacle with Socket Locations

17

AB

C

D

F

E

G H

J

K

L

M

NP T

R S

A-00042

11 INSTALLATION

2.5 REMOTE 17 CONNECTIONS (continued)

Socket A Amperage/voltage reference output signal; +10 volts; for usewith pulse controls

Socket B Amperage/voltage remote control input command signal; +10volts for machine maximum

Socket C Not Used

Socket D Solid-state contactor remote control command signal; +24 volts(operates above 13 volts) turns contactor on; 0 volts (open orground) turns contactor off

Socket E Actual weld current signal; +1 volt per 100 amperes of outputcurrent

Socket F PC board common; use as return for remote control inputs/outputs only from terminals A, B, D, E and K

Socket G Not Used

Socket H +24 volts unregulated; fused for 1/2 ampere

Socket J Not Used

Socket K Remote amperage/voltage reference signal; 0 to +10 volts (setby main rheostat) in CC and CV mode

Socket L -24 volts unregulated; fused for 1/2 ampere

Socket M Load voltage output signal; +1 volt per 10 volts of load voltage

Socket N Not Used

Socket P Circuit common (PC board common and internal chassisground) use as return (+/-) 24 volts logic supply only(pins H and L)

Socket R Not Used

Socket S Chassis ground

Socket T Not Used

Table 2-C Remote 17 Socket Information

INSTALLATION 12

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGEexists after removal of input power.

DO NOT TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input poweremploying lockout/tagging procedures, wait 60-80 seconds,and measure voltage on input capacitors before touching anyparts. Lockout/tagging procedures consist of padlocking linedisconnect switch in open position, removing fuses from fusebox, or shutting off and red-tagging circuit breaker or otherdisconnecting device.

Operate the welding power source from a three-phase, or singlephase if derated, 50/60 Hz, AC power supply. The input voltagemust match one of the electrical input voltages shown on theinput data label on the unit nameplate. Contact the local electricutility for information about the type of electrical service avail-able, how proper connections should be made, and inspectionrequired.

The line disconnect switch provides a safe and convenient meansto completely remove all electrical power from the weldingpower supply whenever necessary to inspect or service the unit.

This unit is equipped with a three-conductor with ground powercable that is connected at the welding power source end for three-phase electrical input power.

2.6 ELECTRICAL INPUT CONNECTIONS

WARNING

Electrical InputRequirements

NOTE

13 INSTALLATION

ELECTRIC SHOCK can kill.

Do not connect an input (white, red, or black) conductor to theground terminal.

Do not connect the ground (green) conductor to an input lineterminal.

Refer to Figure 2-E (page 12) and:

1. Connect end of green ground conductor to a suitable ground.Use a grounding method that complies with all applicableelectrical codes.

2. For three-phase electrical input power: connect ends of red(line 1), white (line 2), and black (line 3) input conductors to adeenergized line disconnect switch.

3. For single-phase electrical input power: connect ends of red(line 1), white (line 2), input conductors to a de-energized linedisconnect switch. Insulate and isolate the black (line 3)conductor.

4. Use Table 2-D (below) as a guide to select line fuses for thedisconnect switch.

2.6 ELECTRICAL INPUT CONNECTIONS (continued)

Table 2-D Fuse Sizes

Fuse size is based on not more than 200 percent of the rated inputamperage of the welding power source (Based on Article 630,National Electrical Code).

NOTE

INPUT INPUT FUSE SIZE POWER VOLTAGE (AMPERES)

SINGLE 208-230 VAC 60PHASE 460 VAC 30

THREE 208-230 VAC 60PHASE 380-460 VAC 30

575 VAC 25

WARNING

INSTALLATION 14

2.6 ELECTRICAL INPUT CONNECTIONS (continued)

Figure 2-E Electrical Input Connections and Components

The input voltage must match one of the electrical input voltagesshown on the input data label on the unit nameplate.

This power source incorporates the Smart Link circuit, whichautomatically links the power source to primary input voltageand adjusts it to allow for operation of unit within input rating ondata tag. It is not necessary to manually switch (terminals orlinks) if unit is moved to a new location and a different inputpower is selected.

The surge current prevention circuit becomes activated whenthe PRIMARY POWER switch is turned ON.

About two seconds after power on, the Smart Link circuitdetects input voltage and automatically selects the correctcircuits for operation.

The welding machine is ready for operation in five secondsafter turn-on.

Voltage Selection

Welding Power Supply Primary Power Cable

Ground Conductor

Line Disconnect Switch

Ground Terminal

Line Fuse

A-00036

15 OPERATION

The AC POWER indicator on the front panel comes on when thePRIMARY POWER switch is in ON position, indicating that theunit is energized.

The WARNING indicator located on the front panel will turn onif the unit detects one of the followingconditions:

Input voltage too low Thermal overload

The AMPERAGE/VOLTAGE control selects the desired amper-age within the entire range of the welding power source. Rotat-ing the control clockwise increases the amperage output. Thescale surrounding the AMPERAGE/VOLTAGE control repre-sents the approximate amperage (A) and voltage (V) values and

Figure 3-A Front Panel Controls

AC POWER Indicator (1)

WARNING Indicator(2)

AMPERAGE/VOLTAGEControl(3)

3.1 OPERATOR CONTROLS

AMPERAGE/VOLTAGE

A/V

METER

PREVIEW

(PUSH)

A V

WARNING AC POWER

STICK

OUTPUT CONTACTOR

REMOTE

0

ON

AMPERAGE/VOLTAGE

REMOTE14

PANEL

14

10

2 8

4 6

5

50

100

150200

250

300

350

375 A

A/VARC CONTROL /

INDUCTANCE

R 300 GMSDC INVERTER ARC WELDER

WEST LEBANON, NH USA

14

MIG

LIFT TIG

17

17

15

20 25

30

36V10

CB (24V)

CB (115V)

17 A/VAMPERAGE/VOLTAGE

FEEDER

OUTPUT

129

4

5

7

6

3

8

1

3

5

7

9

TIG

STICK

MIG

ARCGOUGING

A-00043

jma gamerHighlight

OPERATION 16

3.1 OPERATOR CONTROLS (continued)

is read according to the selected mode: Constant Voltage (CV)or Constant Current (CC). The amperage scale (CC) is forSMAW and GTAW. The voltage scale (CV) is for GMAW andFCAW.

The AMPERAGE/VOLTAGE control may be adjusted whilewelding.

The ARC CONTROL/INDUCTANCE control may be adjustedwhile welding. Operations of this control depends on thewelding mode selected.

Figure 3-B Arc Control/Inductance Characteristics

In STICK welding mode, the ARC CONTROL/INDUCTANCEcontrol functions as an arc control, providing a variable selec-tion of short circuit amperage to suit individual welding situa-tions when operating in the STICK (SMAW) mode. Rotatingthe control clockwise causes amperage to increase as a shortcircuit condition is approached.

When the control is set at 100, short circuit amperage is consid-erably higher than normal welding amperage. This providesextra amperage for arc starting in out-of-position welds as wellas momentary over amperage necessary for certain electrodetypes.

When the control is set at 0 (zero), short circuit amperage abovenormal welding amperage is minimal.

When the control is set at 50, short circuit amperage is approxi-mately half that of the 100 position, but still higher than normalwelding amperage. The 50 position provides a moderate

NOTE

ARC CONTROL/INDUCTANCE Control(4)

ARC CONTROL ForSTICK (CC) Mode

Arc Control

Arc Control KnobMain Knob = Arc Control Knob

= Less Than 410A Output Current Limit

Main Knob5-375A 19V 10V/100A Droop

0 25% 50% 75% 100%145A

A-00039

STICK

17 OPERATION


amperage increase for arc starting necessary for certain type ofelectrodes and applications.

Select a setting best suited for the application and electrode type.

In the MIG (CV) mode, the ARC CONTROL/INDUCTANCEcontrol functions as an inductance control, allowing for theadjustment of the dynamic properties of the arc enhancing theweld puddle control when operated in the Gas Metal Arc(GMAW) and Flux Cored Arc (FCAW) welding processes.

The inductance circuit will give acceptable welds for most anyapplication when set at the 50% setting. The following chart listsspecific settings that will tend to optimize performance withvarious gases:

Inductance Setting ofGases (% of each) Setting Amps/VoltsCO2 30% As RequiredArg (75%) - CO2 (25%) 40% As RequiredArg (90%) - CO2 (10%) 50% As RequiredHe (90%) - Arg (7.5%) - CO2 (2.5%) 70% As Required

The 0 (zero) setting provides a minimum inductance, i.e., a stiff,fast-responding arc, and a small fast-freezing weld puddle.

The 100 setting provides maximum inductance characteristics,i.e., a soft , slower-responding, low spatter arc, and high weldpuddle fluidity.

Two further suggestions to improve performance are as follows:

Reducing inductance setting but keep wire IPM the sameAs the inductance is reduced the voltage at the AMPERAGE/VOLTAGE control may need to be reduced to achieve the de-sired weld characteristics and to provide a more "crisp" sound - .If voltage and IPM remain the same at a lower inductancesetting spatter may occur.

Increasing inductance setting but keep wire IPM the sameAs the inductance is increased the voltage at the AMPERAGE/VOLTAGE control may need to be increased to achieve thedesired weld characteristics and provide a more "fluid" puddle.If voltage and IPM remain the same at a higher inductance mayresult in unflatten welds.

Select a setting best suited for the application and electrode type.

The process selector toggle switch allows the operator to selectthe type of process to be used. There are three settings for theswitch. When to the left it selects the STICK welding (SMAW)process; center selects the MIG welding (GMAW) process; to theright selects the LIFT TIG welding (GTAW) process.

INDUCTANCE ForMIG (CV) Mode

Process SelectorSwitch(5)

MIG

OPERATION 18

In STICK welding mode, the unit provides weld output charac-teristics specifically designed for the Shielded Metal Arc Weld-ing (SMAW) process. When the process selector switch is inthis position, the arc control function of the ARC CONTROL/INDUCTANCE control is active, and the amperage scale of theAMPERAGE/VOLTAGE control is applicable.

In MIG welding mode, the unit provides weld output character-istics specifically designed for the Gas Metal Arc (GMAW) andFlux Cored Arc (FCAW) welding processes. When the processselector switch is in this position, the inductance function of theARC CONTROL/INDUCTANCE control is active, the voltagescale of the AMPERAGE/VOLTAGE control is applicable.

In this mode, the unit provides weld output for the gas tungstenarc welding (GTAW) process. High frequency will not bepresent. When the process selector switch is in this position, thePOST FLOW control will function and the ARC CONTROL willnot function. The unit will provide a low open circuit voltageand approximately 15 amps (for 1.0 ms) to the tungsten elec-trode when touched to the work and lifted away from surface.After the welding arc becomes established, the output currentwill be regulated at determined current level.

Figure 3-C Output Characteristics of LIFT TIG

This switch determines whether the amperage/voltage isadjusted by the front panel AMPERAGE/VOLTAGE control orby a remote control device. If remote control function is notdesired, place this switch in PANEL position.

For remote amperage/voltage control, place the AMPERAGE/VOLTAGE switch in REMOTE 14 position if remote controlconnections are made to the REMOTE 14 receptacle, or to theREMOTE 17 position if remote control connections are made tothe REMOTE 17 receptacle.

STICK Welding (SMAW)

MIG Welding (GMAWand FCAW)

LIFT TIG (GTAW withoutHigh Frequency)

AMPERAGE/VOLTAGESwitch(6)


STICK

MIG

LIFTTIG

PANEL

5V

15AShort Circuit Current

A-00040

19 OPERATION

WARNING

OUTPUT CONTACTORSwitch(7)

NOTE

When using the REMOTE 14 receptacle, remote control is apercentage of the value set by the front panel AMPERAGE/VOLTAGE control. For example, if the AMPERAGE/VOLTAGEcontrol is set at half maximum output, the maximum outputavailable from the remote control will be half the welding powersource maximum output.

When using the REMOTE 17 receptacle, two possibilities exist.If Socket K is used to determine remote output, the REMOTE 17receptacle functions the same as the REMOTE 14 (remote controlis a percentage of the value set by the front panel AMPERAGE/VOLTAGE control). If Socket B is used to determine remoteoutput, the REMOTE 17 receptacle commands the full range ofthe welding power source output, independent of the front panelAMPERAGE/VOLTAGE setting. Determining which socket touse depends on the remote control device used in the applica-tion.

ELECTRIC SHOCK CAN KILL.


Do not touch the weld output receptacles when the contactor isenergized.

Do not touch electrode and work clamp at the same time.

If the OUTPUT CONTACTOR switch is in ON position, opencircuit voltage will be present at the output receptacles wheneverthe PRIMARY POWER switch is in ON position.

Although the term CONTACTOR is used on the nameplate andthroughout this manual, the output is not switched on or off by aphysical contactor; rather, the unit uses solid-state output con-trol.

For remote contactor control, place the OUTPUT CONTACTORswitch in REMOTE 14 position if remote contactor connectionsare made to the REMOTE 14 receptacle, or to the REMOTE 17position if remote contactor connections are made to the RE-MOTE 17 receptacle. Open circuit voltage will be present at theweld output receptacles whenever the torch switch or remotedevice is closed.

If remote contactor control is not desired, place the OUTPUTCONTACTOR switch in ON position. Open circuit voltage willbe available whenever the PRIMARY POWER switch is in ONposition.


REMOTE14

17

REMOTE14

17

ON

OPERATION 20


DigitalAMPERAGE/VOLTAGE Meter (8) and

Switch (9)The LED AMPERAGE/VOLTAGE meter displays either anamperage (A) or voltage (V) value. The selected (preview)amperage value is displayed when welding is not taking place.Refer to Table 3-A below for the values displayed for each meterswitch setting and parameters selected.

The meter is not intended for exact amperage or voltage mea-surements. The amperage display indicates amperage output ofthe welding power source and is driven by circuitry on controlboard PC1. The voltage sensing circuitry is internally connectedto the welding power source output terminals. The voltagedisplay indicates the voltage at the weld output terminals, butdoes not necessarily indicate the actual voltage at the welding arc(due to cable resistance, poor connections, etc.).

CONTACTOR METERSWITCH SETTING INDICATOR

AMP OFF PRESETAMP ON PRESETVOLT OFF PRESETVOLT ON ACTUAL

Table 3-A Values Displayed for Meter Switch Setting andParameters Selected

21 OPERATION

The PRIMARY POWER switch (circuit breaker) located on therear panel energizes the welding power source when placed inthe ON position. Placing the PRIMARY POWER switch in OFFposition shuts down the welding power source and turns off theAC POWER indicator.

When the PRIMARY POWER switch is in the ON position, thereis a pre-charge time delay of approximately 4-5 seconds beforethe unit is ready to weld. The AC POWER indicator will be onduring the pre-charge time delay.


PRIMARY POWERSwitch

NOTE

Figure 3-D Rear Panel Controls

A-00038

Gas Input

PrimaryCable

PRIMARY POWER

ONOFF

3

1

2

OPERATION 22

WARNING

WARNING

WARNING

WARNING

WARNING

ELECTRIC SHOCK can kill; MOVING PARTS can causeserious injury; IMPROPER AIRFLOW AND EXPOSURE TOENVIRONMENT can damage internal parts.


Keep away from moving parts.

Keep all covers and panels in place while operating.

Warranty is void if the welding power source is operated withany portion of the outer enclosure removed.

ARC RAYS, SPARKS, AND HOT SURFACES can burn eyesand skin; NOISE can damage hearing.

Wear correct eye, ear and body protection.

FUMES AND GASES can seriously harm your health.

Keep your head out of the fumes.

Ventilate to keep from breathing fumes and gases.

If ventilation is inadequate, use approved breathing device.

HOT METAL, SPATTER, AND SLAG can cause fire and burns.

Watch for fire.

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.

MAGNETIC FIELDS FROM HIGH CURRENTS can affectpacemaker operation.

Wearers should consult their doctor before going near arcwelding, gouging, or spot welding operations.

3.2 OPERATING PRECAUTIONS

23 OPERATION

Read and follow all safety precautions on page 22 and at thefront of this manual before proceeding with operation.

1. Install and connect unit according to the Installation section(pages 3-14).

2. Wear dry insulating gloves and clothing.

3. Connect work clamp to clean, bare metal at workpiece.

4. Select proper electrode (see Table 3-B, page 29).

5. Refer to Figure 3-E and set the controls per the following: :

a. Process Selector Switch (1) to STICK position.

b. OUTPUT CONTACTOR Switch (2) to ON position.

c. AMPERAGE/VOLTAGE switch (3) to PANEL position,if remote amperage control is not used . If remote amper-age control is to be used, then set AMPERAGE/VOLT-AGE switch to REMOTE 14 position.

d. Rotate the amperage/voltage control (4), or remoteamperage control if applicable, to desired position.

e. Rotate the ARC CONTROL/INDUCTANCE control (5)to desired position.

3.3 SEQUENCE OF OPERATION

WARNING

Shielded Metal ArcWelding (SMAW)

6. Insert electrode into electrode holder.

7. Wear welding helmet with proper filter lens according toANSI Z49.1.

8. Place the PRIMARY POWER switch in ON position.

9. Begin welding.

Figure 3-E STICK Set Up

AMPERAGE/VOLTAGE

A/V

METER

PREVIEW

(PUSH)

A V

WARNING AC POWER

STICK

OUTPUT CONTACTOR

REMOTE

0

ON

AMPERAGE/VOLTAGE

REMOTE14

PANEL

14

10

2 8

4 6

5

50

100

150200

250

300

350

375 A

A/VARC CONTROL /

INDUCTANCE

MIG

LIFT TIG

17

17

15

20 25

30

36V10

CB (24V)

CB (115V)1

3

5

7

9

TIG

STICK

MIG

ARCGOUGING

21 01

2

345

A-00044

OPERATION 24

3.3 SEQUENCE OF OPERATION (continued)



2. Select and obtain proper tungsten electrode (see Table 3-Bpage 29).

3. Prepare tungsten electrode and insert into torch.



6. Refer to Figure 3-F and set the controls per the following:

a. Process Selector Switch(1) to LIFT TIG position.

b. OUTPUT CONTACTOR Switch(2) to desired position.

c. AMPERAGE/VOLTAGE Switch(3) to desired position.

d. Rotate amperage/voltage control (4) to desired position.

7. Turn on shielding gas and water supplies as applicable.


9. Place the PRIMARY POWER switch in ON position.

10. Activate the remote control device (foot control or remotependant).

11. Touch electrode to work and lift to start arc.

12. Begin welding.

HIGH CONCENTRATION OF SHIELDING GAS can harmhealth or kill.

Shut off gas supply when not in use.

WARNING

Gas Tungsten ArcWelding (GTAW)

Lift Start Only

WARNING

Figure 3-F LIFT TIG Set Up

AMPERAGE/VOLTAGE

A/V

METER

PREVIEW

(PUSH)

A V

WARNING AC POWER

STICK

OUTPUT CONTACTOR

REMOTE

0

ON

AMPERAGE/VOLTAGE

REMOTE14

PANEL

14

10

2 8

4 6

5

50

100

150200

250

300

350

375 A

A/VARC CONTROL /

INDUCTANCE

MIG

LIFT TIG

17

17

15

20 25

30

36V10

CB (24V)

CB (115V)1

3

5

7

9

TIG

STICK

MIG

ARCGOUGING

1

2

3

1 2 0

4A-00045

25 OPERATION




2. Install and connect wire feed system according to its OwnersManual.



5. Refer to Figure 3-G and set the controls per the following:

a. Process Selector Switch(1) to MIG position.

b. OUTPUT CONTACTOR Switch(2) to REMOTE J14position.



e. Rotate ARC CONTROL/INDUCTANCE control (5) todesired position.

WARNING

Gas Metal Arc Welding(SMAW)

6. Turn on shielding gas supply and set desired flow rate.


8. Place PRIMARY POWER switch in ON position.

9. Begin welding.

Figure 3-G MIG Set Up (SMAW)

AMPERAGE/VOLTAGE

A/V

METER

PREVIEW

(PUSH)

A V

WARNING AC POWER

STICK

OUTPUT CONTACTOR

REMOTE

0

ON

AMPERAGE/VOLTAGE

REMOTE14

PANEL

14

10

2 8

4 6

5

50

100

150200

250

300

350

375 A

A/VARC CONTROL /

INDUCTANCE

MIG

LIFT TIG

17

17

15

20 25

30

36V10

CB (24V)

CB (115V)1

3

5

7

9

TIG

STICK

MIG

ARCGOUGING

1

2

3

1 8

5 4A-00046

OPERATION 26



2. Install and connect wire feeding system according to itsOwners Manual.



5. Refer to Figure 3-H and set the controls per the following:

a. Process Selector Switch(1) to MIG position.

b. OUTPUT CONTACTOR Switch(2) to REMOTE J14position.



e. Rotate ARC CONTROL/INDUCTANCE control (5) todesired position.

WARNING

Flux Cored Arc Welding(FCAW)


6. Turn on shielding gas and set flow rate.


8. Place PRIMARY POWER switch in ON position.

9. Begin welding.

1. Stop welding.

2. Move the PRIMARY POWER switch to OFF position.

3. Turn off the shielding gas and water supplies if applicable.

Figure 3-H MIG Set Up (FCAW)

Shutting Down

AMPERAGE/VOLTAGE

A/V

METER

PREVIEW

(PUSH)

A V

WARNING AC POWER

STICK

OUTPUT CONTACTOR

REMOTE

0

ON

AMPERAGE/VOLTAGE

REMOTE14

PANEL

14

10

2 8

4 6

5

50

100

150200

250

300

350

375 A

A/VARC CONTROL /

INDUCTANCE

MIG

LIFT TIG

17

17

15

20 25

30

36V10

CB (24V)

CB (115V)1

3

5

7

9

TIG

STICK

MIG

ARCGOUGING

1

2

3

1 8

5 4A-00046

27 OPERATION

3.4 ELECTRODE SELECTION

ELECTRODE DIAMETER AMPERAGE RANGE

PURE TUNGSTEN DC-ARGON ELECTRODE DC-ARGON ELECTRODE(GREEN BAND) NEGATIVE/STRAIGHT POLARITY POSITIVE/STRAIGHT POLARITY

.010 in (0.25 mm) 1-15 -

.020 in (0.51 mm) 5-20 -

.040 in (1.02 mm) 15-80 -1/16 in (1.59 mm) 70-150 10-203/32 in (2.38 mm) 125-225 15-301/8 in (3.18 mm) 225-360 25-40

5/32 in (3.97 mm) 360-450 40-553/16 in (4.76 mm) 450-720 55-801/4 in (6.35 mm) 720-950 80-125

2% THORIUM ALLOYEDTUNGSTEN(RED BAND)

.010 in (0.25 mm) 1-25 -

.020 in (0.51 mm) 15-40 -

.040 in (1.02 mm) 25-85 -1/16 in (1.59 mm) 50-160 10-203/32 in (2.38 mm) 135-235 15-301/8 in (3.18 mm) 250-400 25-40

5/32 in (3.97 mm) 400-500 40-553/16 in (4.76 mm) 500-750 55-801/4 in (6.35 mm) 750-1000 80-125

OPERATION 28

NOTES

29 SERVICE

4.1 GENERAL MAINTENANCE

The only routine maintenance required for the Inverter ArcWelder thorough cleaning and inspection, with the frequencydepending on the usage and the operating environment.

To clean the unit, first make sure that the power is disconnected.Blow out any accumulated dirt and dust with compressed air.The unit should also be wiped clean. If necessary, solvents thatare recommended for cleaning electrical apparatus may be used.

Inspect all external wiring on the unit. Look for any frayed wiresor loose connections that should be corrected.

Routine Maintenance

SERVICE 30

4.2 TROUBLESHOOTING GUIDE

For major troubleshooting and parts replacementprocedures refer to Inverter Arc Welder 300GMSService Manual 0-2429.

Troubleshooting and repairing the this unit is a process whichshould be undertaken only by those familiar with high voltage highpower electronic equipment.

There are extremely dangerous voltage and power levels presentinside this unit. Do not attempt to diagnose or repair unless youhave had training in power electronics measurement andtroubleshooting techniques.

This manual covers a basic level of troubleshooting that requireslimited dissasembly and measurements. It is helpful for solvingmany of the common problems that can arise with the InverterArc Welder system.

If major complex subassemblies are faulty, the unit must bereturned to an authorized service center for repair.Follow all instructions as listed and complete each section in theorder presented.

General

WARNING

Basic Troubleshooting

31 SERVICE

4.2 TROUBLESHOOTING GUIDE (continued)

The following information is a guide to help the Customer/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) thenremedies. Repair as needed being sure to verify that unit is fullyoperational after any repairs.

A. No weld output; unit completely inoperative

1. Line disconnect switch in OFF position

a. Place line disconnect switch in ON position

2. Line fuse(s) open

a. Check and replace line fuse(s)

3. Improper electrical input connections

a. See Installation section (pages 3-14) for proper inputconnections

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 indicatoron

1. OUTPUT CONTACTOR switch S2 in REMOTE 14 position; noremote contactor control connected to REMOTE 14 receptacle

a. Place S2 in ON position or connect remote contactorcontrol to REMOTE 14 receptacle

2. Defective remote control device

a. Check and replace remote control device if necessary

C. WARNING indicator on

1. Thermostat THS 1,THS 2 open (thermal shutdown)

a. Allow cooling period of approximately five minutes

D. Erratic or improper weld output

1. Loose welding cable connections

a. Tighten all welding cable connections

How to use Guide

Specific Problems

SERVICE 32

4.2 TROUBLESHOOTING GUIDE (continued)

2. Incorrect welding cable size

a. Use proper size and type of cable (see Table 2-A, page 5)

3. Improper input connections

a. Refer to Section 2.6

4. Electrode condition

a. Replace electrode

5. Remote amperage control (when applicable)

a. Check remote amperage control potentiometer andconnections. Repair or replace if necessary

E. Remote device completely inoperative

1. Remote control not connected or connected improperly to RE-MOTE 14 receptacle

a. Connect remote control to REMOTE 14 receptacle

2. Remote control defective

a. Replace with known good device

F. Wandering arc; poor control of arc direction

1. Use of tungsten considerably larger than recommended

a. Use proper size tungsten (Refer toSection 3.4)

2. Improperly prepared tungsten

a. Prepare tungsten

3. Gas flow rate too high

a. Reduce flow rate

4. Drafts blowing shielding gas away from tungsten electrode

a. Shield weld zone from drafts

5. Loose gas fittings on regulator or gas line drawing air into weldzone

a. Check and tighten all gas fittings

33 SERVICE

4.3 REPLACEMENT PARTS

CATALOG NO. DESCRIPTION 230/460 380/415 460/575

10-2236 PL1, PL2 Pilot Lamp X X X10-2274 F1 Fuse 5A 600V X X X10-2206 F2, F3 Fuse 2A, 250V X X X10-2196 S1, S2, S3 Switch 1P3T X X X10-2124 VR1 10K Pot X X X10-2618 VR2 10K Pot X X X10-2135 CON1 14-Pin Receptacle X X X10-2133 CON2 17-Pin Receptacle X X X10-2227 TO Output Terminal X X X10-2202 Case Left & Right Side X X X

SERVICE 34

NOTES

300 gms inverter arc welder operators manual (0-2419)

Documents

entire operating manual

operating precautions

thermal arc model

gms inverter arcwelder

up460575v serial

up380415v serial

weld output connections

electrical input connections