ESAB Weld Sequencer User manual

Brand: ESAB

Model: Weld Sequencer

Category: Welding System

Type: User manual

Manual No. 0-2023

Instruction Manual

WELD SEQUENCER

December 16, 2005

A-02401

Read and understand this entire Manual and your employer’s

safety practices before installing, operating, or servicing the

equipment.

While the information contained in this manual represents our

best judgement, Thermal Arc Corporation assumes no liability

for its use.

Thermal Arc

Weld Sequencer

Instruction Manual Number 0-2023

Published by:

Thermal Dynamics Corporation

Industrial Park No. 2

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

Thermal Dynamics Corporation

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 liabil-

ity to any party for any loss or damage caused by any error or

omission in the Thermal Arc

Weld Sequencer Instruction

Manual, whether such error results from negligence, accident, or

any other cause.

Revised on December 16, 2005

WARNING

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ................................................................................................... 1

1.01 Notes, Cautions and Warnings ........................................................................ 1

1.02 Important Safety Precautions ........................................................................ 1

1.03 Publications ................................................................................................... 2

1.04 Note, Attention et Avertissement ................................................................... 3

1.05 Precautions De Securite Importantes............................................................. 3

1.06 Documents De Reference .............................................................................. 5

1.07 Declaration of Conformity ............................................................................... 6

1.08 Statement of Warranty .................................................................................... 7

SECTION 2:

INTRODUCTION & DESCRIPTION ...................................................................................... 9

2.01 Scope of Manual ............................................................................................ 9

2.02 General Description ........................................................................................ 9

2.03 Specifications & Design Features .................................................................10

SECTION 3:

INSTALLATION PROCEDURES .......................................................................................... 11

3.01 Introduction ................................................................................................... 11

3.02 Site Selection ...............................................................................................11

3.03 Unpacking .....................................................................................................11

3.04 Equipment Installation - General ................................................................... 11

3.05 WT1 Weld Timer ............................................................................................13

3.06 GS1 Gas Slope .............................................................................................15

3.07 CS1 Current Slope ........................................................................................ 17

3.08 CP1 Pulser ................................................................................................... 17

3.09 Automatic Voltage Control (AVC) Lockout .....................................................17

3.10 Auxiliary Connections For Interfacing External Controls ................................ 17

SECTION 4:

OPERATION ........................................................................................................................19

4.01 Introduction ................................................................................................... 19

4.02 Functional Overview .................................................................................... 19

4.03 Weld Sequencer Enclosure Control Descriptions ..........................................19

4.04 RP1 Control Descriptions ..............................................................................20

4.05 WT1 Weld Timer Control Descriptions............................................................ 20

4.06 CS1 Current Slope Control Descriptions ........................................................21

4.07 CP1 Pulser Control Descriptions ...................................................................22

4.08 GS1 Gas Slope Control Descriptions ............................................................23

4.09 Pre-Operation Setup...................................................................................... 24

4.10 System Operation .........................................................................................27

TABLE OF CONTENTS (continued)

SECTION 5:

CUSTOMER/OPERATOR SERVICE .................................................................................... 29

5.01 Introduction ...................................................................................................29

5.02 Transformer Connections ...............................................................................29

5.03 Troubleshooting Guide - General Information ................................................. 29

5.04 Test Procedures ............................................................................................33

5.05 WT1 Weld Timer Parts Replacement Procedures .......................................... 34

SECTION 6:

PARTS LIST ........................................................................................................................39

6.01 Introduction ...................................................................................................39

6.02 Ordering Information......................................................................................39

6.03 Weld Sequencer Enclosure ........................................................................... 40

6.04 GS1 Gas Slope (Front Panel) ........................................................................42

6.05 GS1 Gas Slope (Rear Panel) .........................................................................43

6.06 CS1 Current Slope ........................................................................................ 44

6.07 CP1 Pulser ...................................................................................................45

6.08 WT1 Weld Timer ............................................................................................46

6.09 RP1 Remote Pendant Control ........................................................................47

APPENDIX I: MOTION CONTROL & WIRE FEED INTERFACE DIAGRAM ................................49

APPENDIX II: WELD SEQUENCER TERMINAL STRIP DIAGRAM ............................................50

APPENDIX III: AUXILIARY INTERFACE CONNECTION DIAGRAM ...........................................51

APPENDIX IV: NECESSARY CONNECTIONS - RP-1 NOT USED WITH CS-1 WITH OR WITHOUT GS-1,

WT-1 OR CP-1 ..................................................................................................................... 52

APPENDIX V: NECESSARY CONNECTIONS - RP-1 NOT USED WITH CP-1, WT-1 SYSTEM ... 53

APPENDIX VI: TIMING AND SEQUENCE OF OPERATION FOR WELD SEQUENCER (ALL MODELS)

APPENDIX VII: TIMING AND SEQUENCE OF OPERATION FOR GS1 GAS SLOPE ONLY ......55

APPENDIX VIII: SYSTEM SCHEMATIC .....................................................................................56

Special TA 2/25/99 1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting

process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.

Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS)

that should be supplied with the material you are

using. These MSDSs will give you the information

regarding the kind and amount of fumes and gases

that may be dangerous to your health.

• For information on how to test for fumes and gases

in your workplace, refer to item 1 in Subsection

1.03, Publications in this manual.

• Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator 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 cir-

cuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.03, Publica-

tions.

• Disconnect power source before performing any ser-

vice or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

GENERAL INFORMATION 2 Special TA 2/25/99

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable mate-

rial in the workplace. Any material that cannot be

removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have held

combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the deci-

bels (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.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.

The plasma arc process produces very bright ultra violet

and infra red light. These arc rays will damage your

eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly

seen. Experience has shown that lighter filters

may be used when the arc is hidden by the work-

piece.

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, Wash-

ington, 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 WELD-

ING AND GAS WELDING AND CUTTING, obtain-

able from the Superintendent of Documents, U.S.

Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-

CUPATION AND EDUCATIONAL EYE AND FACE

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the

American National Standards Institute, 1430 Broad-

way, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES,

obtainable from American National Standards Insti-

tute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS-

TIBLES, obtainable from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, obtainable from the National Fire Protec-

tion 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

Special TA 2/25/99 3 GENERAL INFORMATION

10. NFPA Standard 51B, CUTTING AND WELDING

PROCESSES, obtainable from the National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from

the Compressed Gas Association, 1235 Jefferson

Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING, obtainable from the Ca-

nadian Standards Association, Standards Sales, 178

Rexdale Boulevard, Rexdale, Ontario, Canada M9W

1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRA-

PHY obtainable from the National Welding Supply

Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, REC-

OMMENDED SAFE PRACTICES FOR THE PREPA-

RATION FOR WELDING AND CUTTING OF CON-

TAINERS AND PIPING THAT HAVE HELD

HAZARDOUS SUBSTANCES, obtainable from the

American Welding Society, 550 N.W. LeJeune Rd,

Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-

TORY PROTECTION, obtainable from American

National Standards Institute, 1430 Broadway, New

York, NY 10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des

informations à caractère important. Ces mises en relief

sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement

général sur lequel il importe d’insister davantage

ou qui contribue à l’efficacité de fonctionnement

du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENT

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de

sécurité et toutes les consignes avant d’utiliser le

matériel. Composez le + 603-298-5711 ou votre

distributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de

plasma peuvent présenter des risques et des dangers de

santé.

• Eloignez toute fumée et gaz de votre zone de respi-

ration. Gardez votre tête hors de la plume de fumée

provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en

air si l’aération fournie ne permet pas d’éliminer la

fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de

plasma dépendent du genre de métal utilisé, des

revêtements se trouvant sur le métal et des différents

procédés. Vous devez prendre soin lorsque vous

coupez ou soudez tout métal pouvant contenir un

ou plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité

des matières (sigle américain “MSDS”); celles-ci

devraient être fournies avec le matériel que vous

utilisez. Les MSDS contiennent des renseignements

quant à la quantité et la nature de la fumée et des

gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la

fumée et les gaz de votre lieu de travail, consultez

l’article 1 et les documents cités à la page 5.

GENERAL INFORMATION 4 Special TA 2/25/99

• Utilisez un équipement spécial tel que des tables de

coupe à débit d’eau ou à courant descendant pour

capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans

une zone où se trouvent des matières ou des gaz

combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée

provenant des solvants et des produits de nettoyage

chlorés. Eliminez toute source de telle fumée.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le

procédé au jet de plasma requiert et produit de l’énergie

électrique haute 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 pièce “sous tension” ou

“vive”; portez des gants et des vêtements secs.

Isolez-vous de la pièce de travail ou des autres par-

ties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone de tra-

vail est humide ou moite.

• Montez et maintenez le matériel conformément au

Code électrique national des Etats-Unis. (Voir la

page 5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-

vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel

de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories

chaudes, des étincelles ou de l’arc de plasma. Le procédé

à l’arc de plasma produit du métal, des étincelles, des

scories chaudes pouvant mettre le feu aux matières com-

bustibles ou provoquer l’explosion de fumées

inflammables.

• Soyez certain qu’aucune matière combustible ou in-

flammable ne se trouve sur le lieu de travail.

Protégez toute telle matière qu’il est impossible de

retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées

inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail

dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler

sous les pièces de travail en aluminium lorsqu’elles

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 gas hydrogène

peut s’échapper ou se dissiper. Le gas hydrogène

accumulé explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de plasma

produit une lumière infra-rouge et des rayons ultra-vio-

lets très forts. Ces rayons d’arc nuiront à vos yeux et

brûleront votre peau si vous ne vous protégez pas

correctement.

• Pour protéger vos yeux, portez toujours un casque

ou un écran de soudeur. Portez toujours des lunettes

de sécurité munies de parois latérales ou des lu-

nettes de protection ou une autre sorte de protec-

tion oculaire.

• Portez des gants de soudeur et un vêtement

protecteur approprié pour protéger votre peau

contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protec-

tion en bon état. Remplacez toute lentille sale ou

comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone

de travail contre les rayons de l’arc en fournissant

des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans

le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé

clairement. L’experience a démontrer que les filtres

moins foncés peuvent être utilisés quand l’arc est

caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.

Les procédés de soudage à l’arc de plasma peuvent

provoquer des niveaux sonores supérieurs aux limites

Special TA 2/25/99 5 GENERAL INFORMATION

normalement acceptables. Vous dú4ez 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 tampons protecteurs et/ou des protections

auriculaires. Protégez également les autres

personnes se trouvant sur le lieu de travail.

• Il faut mesurer 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 Documents De Reference

Consultez les normes suivantes 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 PROTECTION DE LA SANTÉ, 29CFR 1910,

disponible auprès du Superintendent of Docu-

ments, U.S. Government Printing Office, Washing-

ton, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES

OPÉRATIONS DE COUPE ET DE SOUDAGE,

disponible auprès de la Société Américaine 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 À

L’ARC ET AU GAZ, disponible auprès du Superin-

tendent of Documents, U.S. Government Printing

Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA

PROTECTION DES YEUX ET DU VISAGE AU

TRAVAIL ET DANS LES ECOLES, disponible de

l’Institut Américain des Normes Nationales (Ameri-

can National Standards 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 10018

6. Norme ANSI Z49.2, PRÉVENTION DES

INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS

DE COUPE ET DE SOUDAGE, disponible auprès

de l’American National Standards 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

PRODUITS COMBUSTIBLES, disponible auprès de

la American Welding Society, 550 N.W. LeJeune Rd.,

Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Pro-

tection contre les Incendies (NFPA), LES SYSTEMES

À GAZ AVEC ALIMENTATION EN OXYGENE

POUR LE SOUDAGE, LA 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 NA-

TIONAL, disponible auprès de la National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE

COUPE ET DE SOUDAGE, disponible auprès de

la National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,

disponible auprès de l’Association des Gaz

Comprimés (Compressed Gas Association), 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR

LE SOUDAGE ET LA COUPE, disponible auprès

de l’Association des Normes Canadiennes, Stan-

dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3

13. ivret 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 À LA COUPE ET

AU SOUDAGE DE CONTENEURS ET TUYAUX

AYANT RENFERMÉ DES PRODUITS

DANGEREUX , disponible auprès de la American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-

TION RESPIRATOIRE, disponible auprès de

l’American National Standards Institute, 1430

Broadway, New York, NY 10018

GENERAL INFORMATION 6 Special TA 2/25/99

1.07 Declaration of Conformity

Manufacturer:

Thermal Arc, Inc.

Address: 2200 Corporate Drive

Troy, Ohio 45373-1085

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc-

tive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National leg-

islation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture

a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and

manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and

related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing pro-

cess to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our

area of manufacture.

Manufacturers responsible representative: Steve Ward

Director of Operations

Thermadyne UK

Chorley England

Special TA 2/25/99 7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Arc

, Inc., A Thermadyne 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, Thermal Arc shall, upon notification thereof and substantiation that the product has been

stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and

recognized standard industry practice, and not subject to misuse, repair, neglect, 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 determined 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 as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter

“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal

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 representative of Thermal Arc is authorized to

change this warranty in any way or grant any other warranty.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THER-

MAL ARC’S SOLE JUDEGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

Except with regards to the products listed below, this warranty shall remain effective three (3) years 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 forego-

ing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered

the product to the authorized distributor.

PLASMA WELDING/

POWER SUPPLIES VIKING/GENERATORS 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 1 YEAR 1 YEAR 1 YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS,

SOLENOIDS, PUMPS, POWER SWITCHING SEMI-CONDUCTORS

ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE

ENGINE MANUFACTURER. SEE THE ENGINE MANUFACTORS WARRANTY FOR DETAILS.

CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR 1 YEAR

EXCHANGES, AND ACCESSORY EQUIPMENT

TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS

REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Ther-

mal Arc® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this war-

ranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the cus-

tomer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal Arc

warranties.

Thermal Arc® is a Registered Trademark of Thermadyne.

Effective May 1, 1997

GENERAL INFORMATION 8 Special TA 2/25/99

Manual 0-2023 9 INTRODUCTION & DESCRIPTION

SECTION 2:

INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions

and maintenance procedures for the Thermal Arc Weld

Sequencer. Service of this equipment is restricted to prop-

erly trained personnel; unqualified personnel are strictly

cautioned against attempting repairs or adjustments not

covered in this manual, at the risk of voiding the War-

ranty.

Read this manual thoroughly. A complete understand-

ing of the characteristics and capabilities of this equip-

ment will assure the dependable operation for which it

was designed.

2.02 General Description

The Thermal Arc Weld Sequencer is an accessory pack-

age designed to automatically control the output of most

solid-state power supplies. The Weld Sequencer gives the

operator more accurate control of the variables within a

welding operation. Once the Weld Sequencer is pro-

grammed for a particular welding operation, the weld

can be reproduced with minimal fluctuations. Four sepa-

rate solid-state control modules, a Weld Sequencer En-

closure and a RP1 Control remote pendant make up the

Weld Sequencer. Any combination of the four modules

can be used with the Weld Sequencer Enclosure to be a

stand-alone unit.

A-02401

Figure 2-1 Weld Sequencer Assembly

• Weld Sequencer Enclosure

Housing for combinations of the four modules.

Contains interface wiring and power for each unit.

Provides relay contacts for interfacing with exter-

nal controls (wire feeders, motion controls, etc).

• RP1 Control

Offers remote control for activating main contac-

tor, starting weld sequencer, starting downslope

manually, starting spot weld sequence, and adjust-

ing welding current.

• CS1 Current Slope

Allows welding current to be automatically ad-

justed from an initial current setting to a peak cur-

rent setting (upslope) and decreased automatically

to a final current setting (downslope) when sig-

naled manually or by the WT1 Weld Timer.

Upslope changes the current linearly from initial

current value to weld (peal) current value.

Downslope changes the current linearly from peak

value down to final value.

• GS1 Gas Slope (Plasma Gas)

Allows linear change in the plasma gas flow rate

(upslope and downslope) between two variable

settings. The control can be manual or automatic

when used with CS1 Current Slope

• CP1 Pulser

Reduces the amount of heat input into the weld

by pulsing the current between peak level and a

background level. The CP1 offers complete con-

trol of the pulse frequency rate and the percent-

age of 'on' time at peak current versus background

current. The CP1 also offers the capability of a lin-

ear upslope and downslope on each pulse.

• WT1 Weld Timer

Allows weld time to be set from 0.1 to 999.9 sec-

onds. When used with CS1 Current Slope the WT1

times the weld from the start of upslope to the end

of peak (weld) current at which time it provides a

signal for initiating the downslope sequence. WT1

can also be used independently as a spot weld

timer.

INTRODUCTION & DESCRIPTION 10 Manual 0-2023

2.03 Specifications & Design

Features

A. Weld Sequencer Enclosure

1. Input Power

115/230VAC, 1 Amp, 50/60 Hz

2. Control Circuit Output

28 VAC

3. Current Control

Up to 24 VDC using RP1 Control remote pendant

or some other external device.

4. Contactor Control

28 V control circuit using RP1 Control remote pen-

dant or some other external device.

5. Control Console or Power Supply Control

Control is via 10' control cable.

6. Auxiliary Connections

Relay contacts and terminal connector provided

for auxiliary input/output signals (wire feeders,

motion controls, etc.).

7. Housing Capabilities

WT1 and/or GS1; WT1 and/or CS1 and/or CP1

NOTE

For a complete Sequencer Assembly, the Enclosure

Expansion must be added on top of the Weld Se-

quencer Enclosure to accommodate CS1 and CP1

modules. Also, the enclosure expansion is required

when WT1 or GS1 is used with either CS1 or CP1.

8. Dimensions (W x H xD)

15 inches (381 mm) x 11 inches (279 mm) x 16-3/4

inches (425 mm)

With Enclosure Expansion height dimension is 18

inches (457 mm)

9. Weight

24.5 lbs (11.62 kg).

With Enclosure Expansion weight is 30 lbs

(14.23kg)

B. GS1 Gas Slope (Plasma)

1. Input Power

28 VAC from Weld Sequencer Enclosure

2. Plasma Gas Range

Min 0.5 - 3 scfh (0.25 - 1.4 lpm)

Max 2 - 7 scfh (1 - 3.3 lpm) @ 30 psi (2 bar)

3. Weight

9 lbs (4.05 kg)

C. CS1 Current Slope

1. Input Power

28 VAC from Weld Sequencer Enclosure

2. Weight

4 lbs (1.8 kg)

D. CP1 Pulser

1. Input Power

28 VAC from Weld Sequencer Enclosure

2. Pulse Rate

0.5 - 20 pulses/sec

3. Weight

3.5 lbs (1.58 kg)

E. WT1 Weld Timer

1. Input Power

28 VAC from Weld Sequencer Enclosure

2. Timing Control

Adjustable from 0.1 to 999.9 seconds

3. Weight

2.5 lbs (1.12 kg)

CAUTION

When using CS1 or CP1 with a power source other

than the Thermal Arc PS30A, the remote control

circuit must be 0 to +24 vdc and of a solid state

design.

Manual 0-2023 11 INSTALLATION PROCEDURES

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

This section describes installation of the Weld Sequencer.

These instructions apply to the Weld Sequencer only; in-

stallation procedures for the Power Supply, Welding Con-

sole, Torch, Options, and Accessories are given in Manu-

als specifically provided for those units.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Weld Sequencer

4. Operator training

3.02 Site Selection

The Weld Sequencer Enclosure should be located either

next to or on top of the Welding Console (GS1 connec-

tions must be installed in Welding Console before mount-

ing on top). A source of 115 or 230 VAC power must also

be available.

NOTE

Review Important Safety Precautions (page 1) to

be sure that the selected location meets all safety

requirements.

3.03 Unpacking

Each component of the system is packaged and protected

with a carton and packing material to prevent damage

during shipping.

1. Unpack each item and remove all packing material.

2. Locate the packing list(s) and use the list to identify

and account for each item.

3. Inspect each item for possible shipping damage. If

damage is evident, contact your distributor and/or

shipping company before proceeding with system

installation.

3.04 Equipment Installation -

General

WARNING

Make sure that all power to the welding system is

shut off at the incoming source. Do not turn ON

the power until all components are connected.

A. Voltage Selection

The Weld Sequencer Enclosure is factory-wired for 230V,

60Hz operation. If 230V primary power is available, con-

nect the end of the input power cord to the 230V primary

power source.

If 115V primary power is to be used change TB4 connec-

tions as follows:

1. Locate TB4 terminal strip on the rear panel of the En-

closure. Remove the two jumpers from each side of

terminals 5 and 6.

230 Volt Jumpers

TB4 Terminal Strip

A-02404

1 2 3 4 5 6 7

Figure 3-1 Jumper Installation For 230 VAC Input

2. Connect one jumper across terminals 4 and 5 and the

other across 6 and 7.

115 Volt Jumpers

TB4 Terminal Strip

A-02405

1 2 3 4 5 6 7

Figure 3-2 Jumper Installation For 115 VAC Input

INSTALLATION PROCEDURES 12 Manual 0-2023

3. Connect plug (supplied) to the end of the input power

cord per the following:

a. Feed the free end of the input power cable through

the small section of the rubber plug housing.

b. Connect the ground lead to the green terminal on

the plug.

c. Connect the other two leads to the two terminals

on the plug.

d. Press the plug into the rubber housing until the

plastic disk is captured by the rubber housing.

e. Tighten cord grip to secure input cable.

B. Cable Connections

1. Connect RP1 Control pendant to the connector on the

end of the 20 foot (6.1 m) Remote Control Cable. Con-

nect the other end of the cable to the back of the Weld

Sequencer Enclosure marked REMOTE CONTROL.

REMOTE

CONTROL

CONSOLE/POWER SUPPLY

CONTROL

A-02406

Control Cable Console/Power Supply

Control Cable

Figure 3-3 Weld Sequencer Enclosure Rear Panel

Connections

If a different remote control device is to used refer to

the Wiring Diagram supplied with the Weld Se-

quencer. The current control potentiometer must be

rated for 10k ohm at 2 watts.

Plasma Gas

Shield Gas

A-02407

Weld

Sequencer

Optional Remote

Control

Torch

Welding

Console

DC Power

Supply

Coolant Recirculator

Figure 3-4 WC100B Connections

Manual 0-2023 13 INSTALLATION PROCEDURES

2. Connect the mating plug of the 10 foot (3 m) Control

Cable to the receptacle on the rear panel of the Weld

Sequencer Enclosure marked CONSOLE/POWER

SUPPLY CONTROL.

3. The connection on the other end of the cable depends

on the welding console, power supply or current con-

trol device. Connect as follows (refer to Figure 3-4):

• Thermal Arc WC100B Welding Console

a. Connect Control Cable plug to the receptacle on

the front panel of the WC100B marked REMOTE

CONTROL. Move REMOTE ON/OFF switch to

ON position.

• Thermal Arc WC100A and WC122A (and earlier

models) Welding Consoles

b. Cut the Control Cable plug off and strip cable jacket

back approximately 2 inches.

c. Locate the cable from the welding console CON-

TROL receptacle. Measure enough cable to con-

nect with the Control Cable from the Weld Se-

quencer Enclosure and cut.

d. Connect the white/brown (J5-3) and black (J5-4)

wires of the Weld Sequencer Enclosure Control

Cable to the two leads of the cable from the weld-

ing console CONTROL. The order of connection

is unimportant. This connection gives contactor

control to the Sequencer.

e. Connect a cable to the Remote Amperage Control

of the power supply. Connect the other end to the

Weld Sequencer Enclosure Control Cable (see Fig-

ure 3-E):

Power Supply Amperage Control maximum lead

to orange wire (J5-1)

Power Supply Amperage Control variable (wiper)

lead to red wire (J5-7)

Power Supply Amperage Control minimum lead

to blue wire (J5-13)

Contactor

Control

AMP Control

(Wiper)

AMP Control

(Min)

AMP Control

(Max)

Contactor

Control

Ground

A-02408

Figure 3-5 Back View of Control Cable Plug

f. Tape back the wires not used.

• Other Welding Consoles and Power Supplies

WARNING

The remote control circuit of the welding console

or power supply must not exceed 28 volts AC or

DC.

a. Cut the cable plug off. Strip the cable jacket back

approximately 2 inches.

b. Connect the white/brown (J5-3) and black (J5-4)

wires of the Weld Sequencer Enclosure Control

Cable to the contactor control of the welding unit.

This gives contactor control to the Sequencer.

c. Connect a cable to the Remote Amperage Control

of the power supply. Connect the other end to the

Weld Sequencer Enclosure Control Cable (refer to

Figure 3-5):

Power Supply Amperage Control maximum lead

to orange wire (J5-1)

Power Supply Amperage Control variable (wiper)

lead to red wire (J5-7)

Power Supply Amperage Control minimum lead

to blue wire (J5-13)

d. Tape back the wires not used.

e. Check input power connections on the terminal

strip TB4, located on the rear panel of the Weld

Sequencer Enclosure, to be sure that they are set

up for the available voltage. Provisions are made

for primary inputs of 115 or 230 volts AC (refer to

Section 4.2) and 50 or 60 Hz power may be used.

3.05 WT1 Weld Timer

CAUTION

The WT1 Weld Timer is factory set for 60 Hz op-

eration. If 50 Hz power is used or WT1 doesn’t

time properly remove the cover from WT1 and check

the position of the switch mounted in the middle of

the PC board. Move the handle to the proper posi-

tion printed on the PC board (50 or 60).

1. Install WT1 into the bottom of the opening in the Weld

Sequencer Enclosure (refer to Figure 3-6). Secure with

screws provided.

2. Connect WT1 to the Weld Sequencer Enclosure wiring

harness with the J4 connectors.

INSTALLATION PROCEDURES 14 Manual 0-2023

Enclosure Expansion

CP1 Pulser

CS1 Current Slope

WT1 Weld Timer

RP1 Control

GS1 Gas Slope

Weld Sequencer

Enclosure

A-02409

Figure 3-6 Weld Sequencer Assembly

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ESAB Weld Sequencer User manual

Brand: ESAB

Model: Weld Sequencer

Category: Welding System

Type: User manual

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ESAB Weld Sequencer User manual

ESAB Weld Sequencer User manual

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