ESAB Inverter Arc Welder Model 600 GMS CC/CV User manual

Brand: ESAB

Model: Inverter Arc Welder Model 600 GMS CC/CV

Category: Welding System

Type: User manual

MODEL 600 GMS

CC/CV

Inverter Arc Welder

• STICK

• TIG - Lift Start

• MIG - Short Circuit

- Globular

- Spray

SERVICE MANUAL

3/23/98 Manual No. 0-2446

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 Dynamics Corporation assumes no

liability for its use.

Thermal Arc ® Model 600GMS CC/CV Inverter Arc Welder

Service Manual

Number 0-2446

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 liability

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

omission in the Thermal Arc ® Model 600GMS CC/CV Inverter

Arc Welder Service Manual whether such error results from

negligence, accident, or any other cause.

Printed in the United States of America

March 1998

WARNING

Purchase Date

Power Supply

Torch

RECORD SERIAL NUMBERS FOR WARRANTY PURPOSES

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 ................................................................................................................. 9

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

2.02 General Service Philosophy ........................................................................... 9

2.03 Service Responsibilities ................................................................................. 9

SECTION 3:

DESCRIPTION .................................................................................................................. 11

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

3.02 General Description ..................................................................................... 11

3.03 Specifications/Design Features.................................................................... 11

SECTION 4:

SERVICE TROUBLESHOOTING DIAGNOSTICS ............................................................ 15

4.01 Introduction .................................................................................................. 15

4.02 Periodic Inspection & Procedures ................................................................ 15

4.03 MIG Welding Common Operating Faults...................................................... 15

4.04 Circuit Fault Isolation..................................................................................... 15

4.05 Troubleshooting Guide ................................................................................. 17

4.06 Troubleshooting Specific Problems .............................................................. 18

4.07 Test Procedures ........................................................................................... 20

4.08 Control/Logic Board (PCB1) Adjustments.................................................... 28

4.09 SMART LINK Circuit Descriptions ............................................................... 31

SECTION 5:

REPAIRS & REPLACEMENT PROCEDURES.................................................................. 33

5.01 Introduction .................................................................................................. 33

5.02 Anti-Static Handling Procedures .................................................................. 33

5.03 Disassembly & Replacement ........................................................................ 33

SECTION 6:

PARTS LISTS .................................................................................................................... 35

6.01 Introduction .................................................................................................. 35

6.02 Ordering Information .................................................................................... 35

6.03 Complete Systems....................................................................................... 35

6.04 Replacement Parts ...................................................................................... 36

APPENDIX I: CONTROL/LOGIC BOARD (PCB1) CONNECTOR REFERENCE..................... 39

APPENDIX II: CONTROL/LOGIC BOARD (PCB1) CONNECTOR SIGNALS .......................... 40

APPENDIX III: CONTROL/LOGIC BOARD (PCB1) TEST POINT SIGNALS ........................... 42

APPENDIX IV: SYSTEM BLOCK DIAGRAM ............................................................................ 44

APPENDIX V: INTERCONNECTION DIAGRAM (230V).......................................................... 45

APPENDIX VI: INTERCONNECTION DIAGRAM (380V) ........................................................ 46

APPENDIX VII: FILTER PC BOARD (PCB4) DIAGRAM........................................................... 47

APPENDIX VIII: EYE PROTECTION CHART ........................................................................... 48

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 op-

erating 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 va-

pors of chlorinated solvents and cleansers. Re-

move all sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc pro-

cess uses and produces high voltage electrical energy.

This electric energy can cause severe or fatal shock to

the operator or others in the workplace.

• Never touch any parts that are electrically “live”

or “hot.”

• Wear dry gloves and clothing. Insulate yourself

from the work piece or other parts of the welding

circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

code, refer to item 4 in Subsection 1.03, Publica-

tions.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

GENERAL INFORMATION 2

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 ma-

terial 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

processes can cause noise levels to exceed safe limits.

You must protect your ears from loud noise to prevent

permanent loss of hearing.

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

tra violet and infra red light. These arc rays will dam-

age your eyes and burn your skin if you are not prop-

erly 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 recommended in Subsec-

tion 1.03, item 4.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS,

29CFR 1910, obtainable from the Superintendent of

Documents, U.S. Government Printing Office, 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 Asso-

ciation, Batterymarch Park, Quincy, MA 02269

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

3 GENERAL INFORMATION

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

• 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

travail 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 combustibles ou provoquer l’explosion de

fumées inflammables.

• Soyez certain qu’aucune matière combustible ou

inflammable 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-violets 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 lu-

nettes de sécurité munies de parois latérales ou des

lunettes de protection ou une autre sorte de pro-

tection 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.

• Respectez le teint de lentille recommandé dans le

article 4, page 5.

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

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 protec-

tions 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.

5 GENERAL INFORMATION

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 Super-

intendent of Documents, U.S. Government Print-

ing 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

(American 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 PRA-

TIQUES 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

1.07 Declaration of Conformity

Manufacturer:

Thermal Arc

An unicorporated division of Thermal Dynamics Corp

A Thermadyne Company

Address: Industrial Park #2

West Lebanon, New Hampshire 03784

USA

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

Directive’ (European Council Directive 73/23/EU, as recently changed in Directive 93/63/EU) and to the National

legislation for the enforcement of this Directive.

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

ture 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-M1990 for Arc welding equipment.

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

* IEC 974-1 (BS 638-PT10) (EN 60 974-1) applicable to welding equipment and associated accessories.

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

manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated

into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Arc has been manufacturing products that perform in a safe manner for more than 30 years and will continue to

achieve excellence in our area of manufacture.

Manufacturers responsible representative: David Ashworth

Vice President & Managing Director

Thermadyne Europe

Chorley England.

7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Arc, an unicorporated division of Thermal Dynamics Corp., 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 (hereinaf-

ter “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 PROD-

UCT.

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

foregoing, 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

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

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

customer. 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

Manual 0-2446 9 SECTION 2: GENERAL INFORMATION

SECTION 2:

INTRODUCTION

2.01 Scope of Manual

This manual provides service instructions for Thermal

Arc® Model 600GMS Inverter Arc Welder.

Refer to the Operating Manual (0-2367) for individual op-

erating procedures. Information in this edition is par-

ticularly applicable to the troubleshooting and repair of

equipment, and is intended for useby properly trained

service technicians familiar with this equipment.

Read this manual and the Operating Manual thoroughly.

A complete understanding of the capabilities and func-

tions of the equipment will assure the dependable op-

eration and performance for which it was designed.

2.02 General Service Philosophy

Several key points are essential to properly support the

application and operation of this equipment.

A. Application

The equipment should satisfy the customer’s require-

ments as supplied and as described in Section 3 of this

manual. Be sure to confirm that the equipment is capable

of the application desired.

B. Modifications

No physical or electrical modifications other than selec-

tion of standard options and Accessories are to be made

to this equipment.

C. Customer/Operator Responsibilities

It is the customer/operators’ responsibility to maintain

the equipment and peripheral accessories provided by

Thermal Arc in good operating order in accordance with

the procedures outlined in the Operating Manual, and to

protect the equipment from accidental or malicious dam-

age.

D. Repair Restrictions

The electronics consists of Printed Circuit Board Assem-

blies which must be carefully handled, and must be re-

placed as units. No replacement of printed circuit sol-

der-mounted components is allowed except as noted in

this manual.

If to be returned, the replaced Printed Circuit Board As-

semblies must be properly packaged in protective mate-

rial and returned intact per normal procedures.

2.03 Service Responsibilities

The Service Technician should be familiar with the equip-

ment and its capabilities. He should be prepared to rec-

ommend arrangements of components which will pro-

vide the most efficient layout, utilizing the equipment to

its best possible advantage.

Maintenance work should be accomplished in a timely

manner. If problems are encountered, or the equipment

does not function as specified, contact Technical Services

Department at West Lebanon for assistance.

SECTION 2: GENERAL INFORMATION 10 Manual 0-2446

Manual 0-2446 11 SECTION 3: DESCRIPTION

SECTION 3:

DESCRIPTION

3.01 Introduction

The information in this section has two purposes: To fa-

miliarize the Service Technician with the capabilities

and limitations of the equipment, and to provide him with

an overall understanding which will allow him, in turn,

to properly train the customer’s operating personnel.

3.02 General Description

The 600 GMS unit is a three-phase DC, arc welding power

source with selectable constant current (CC) and constant

voltage (CV) output characteristics. This unit is designed

for use with Shielded Metal Arc (SMAW), Gas Metal Arc

(GMAW) in the spray and short circuit mode, and Lift

Start Gas Tungsten Arc Welding (GTAW) processes. A

digital Amp and Volt Meter is standard. The models

available are listed below:

10-1016 380/415 VAC MODEL (3 Phase Only)

10-1020 230/460 VAC MODEL (3 Phase Only)

3.03 Specifications/Design Features

A. Front Panel Controls/Indicators

1. AC POWER Indicator

The AC POWER indicator on the front panel comes

on when the PRIMARY POWER switch is in ON po-

sition, indicating that the unit is energized.

2. WARNING Indicator

The WARNING indicator located on the front panel

will turn ON if the unit detects one of the

followingconditions:

• Input voltage too low

• Thermal overload

3. AMPERAGE/VOLTAGE Control

NOTE

The AMPERAGE/VOLTAGE control may be ad-

justed while welding.

The AMPERAGE/VOLTAGE control selects the de-

sired amperage within the entire range of the weld-

ing power source. Rotating the control clockwise in-

creases the amperage output. The scale surrounding

the AMPERAGE/VOLTAGE control represents the

approximate amperage (A) and voltage (V) values and

is read according to the selected mode: Constant Volt-

age (CV) or Constant Current (CC). The amperage

scale (CC) is for SMAW and GTAW. The voltage scale

(CV) is for GMAW and FCAW.

4. ARC CONTROL/INDUCTANCE Control

NOTE

The ARC CONTROL/INDUCTANCE control

may be adjusted while welding.

Operation of this control depends on the welding

mode selected as follows:

a. ARC CONTROL For STICK (CC) Mode

STICK

In STICK welding mode, the ARC CONTROL/

INDUCTANCE control functions as an arc con-

trol, providing a variable selection of short circuit

amperage to suit individual welding situations

when operating in the STICK (SMAW) mode.

Rotating the control clockwise causes amperage

to increase as a short circuit condition is ap-

proached.

When the control is set at 100, short circuit am-

perage is considerably higher than normal weld-

ing amperage. This provides extra amperage for

arc starting in out-of-position welds as well as

momentary over amperage necessary for certain

electrode types.

When the control is set at 0 (zero), short circuit

amperage above normal welding amperage is

minimal.

When the control is set at 50, short circuit amper-

age is approximately half that of the 100 position,

but still higher than normal welding amperage.

The 50 position provides a moderate amperage

increase for arc starting necessary for certain type

of electrodes and applications.

Select a setting best suited for the application and

electrode type.

b. INDUCTANCE For MIG (CV) Mode

MIG

In the MIG (CV) mode, the ARC CONTROL/IN-

DUCTANCE control functions as an inductance

control, allowing for the adjustment of the dy-

namic properties of the arc enhancing the weld

puddle control when operated in the Gas Metal

Arc (GMAW) and Flux Cored Arc (FCAW) weld-

ing processes.

The inductance circuit will give acceptable welds

for most any application when set at the 50% set-

ting.

SECTION 3: DESCRIPTION 12 Manual 0-2446

The 0 (zero) setting provides a minimum induc-

tance, 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 weld puddle fluidity.

Two further suggestions to improve performance

are as follows:

Reducing inductance setting but keep wire IPM

the same

As the inductance is reduced the voltage at the

AMPERAGE/VOLTAGE control may need to be

reduced to achieve the desired weld characteris-

tics and to provide a more "crisp" sound . If volt-

age and IPM remain the same at a lower induc-

tance setting spatter may occur.

Increasing inductance setting but keep wire IPM

the same

As the inductance is increased the voltage at the

AMPERAGE/VOLTAGE control may need to be

increased to achieve the desired weld character-

istics and provide a more "fluid" puddle. If volt-

age and IPM remain the same at a higher induc-

tance may result in unflatten welds.

Select a setting best suited for the application and

electrode type.

5. Process Selector Switch

The process selector toggle switch allows the opera-

tor to select the type of process to be used. There are

three settings for the switch. When to the left it se-

lects the STICK welding (SMAW) process; center se-

lects the MIG welding (GMAW) process; to the right

selects the LIFT TIG welding (GTAW) process.

a. STICK Welding (SMAW)

STICK

The unit provides weld output characteristics spe-

cifically designed for the Shielded Metal Arc Weld-

ing (SMAW) process. The arc control function of

the ARC CONTROL/INDUCTANCE control is

active, and the amperage scale of the AMPER-

AGE/VOLTAGE control is applicable.

b. MIG Welding (GMAW and FCAW)

MIG

The unit provides weld output characteristics spe-

cifically designed for the Gas Metal Arc (GMAW)

and Flux Cored Arc (FCAW) welding processes.

The inductance function of the ARC CONTROL/

INDUCTANCE control is active, the voltage scale

of the AMPERAGE/VOLTAGE control is appli-

cable.

c. LIFT TIG (GTAW without High Frequency)

LIFT

TIG

The unit provides weld output for the gas tung-

sten arc welding (GTAW) process. High frequency

will not be present. POST FLOW control will func-

tion and the ARC CONTROL will not function.

The unit will provide a low open circuit voltage

and approximately 15 amps (for 1.0 ms) to the

tungsten electrode when touched to the work and

lifted away from surface. After the welding arc

becomes established, the output current will be

regulated at determined current level.

6. AMPERAGE/VOLTAGE Switch

This switch determines whether the amperage/volt-

age is adjusted by the front panel AMPERAGE/

VOLTAGE control or by a remote control device. If

remote control function is not desired, place this

switch in PANEL position.

a. PANEL Position

PANEL

For remote amperage/voltage control, place the

AMPERAGE/VOLTAGE switch in REMOTE 14

position if remote control connections are made

to the REMOTE 14 receptacle, or to the REMOTE

17 position if remote control connections are made

to the REMOTE 17 receptacle.

b. REMOTE 14 Position

REMOTE

Remote control is a percentage of the value set by

the front panel AMPERAGE/VOLTAGE control.

For example, if the AMPERAGE/VOLTAGE con-

trol is set at half maximum output, the maximum

output available from the remote control will be

half the welding power source maximum output.

c. REMOTE 17 Position

Two possibilities exist when using the REMOTE

17 receptacle. If Socket K is used to determine

remote output, the REMOTE 17 receptacle func-

tions the same as the REMOTE 14 (remote control

is a percentage of the value set by the front panel

AMPERAGE/VOLTAGE control). If Socket B is

used to determine remote output, the REMOTE

17 receptacle commands the full range of the weld-

ing power source output, independent of the front

panel AMPERAGE/VOLTAGE setting. Deter-

mining which socket to use depends on the re-

mote control device used in the application.

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ESAB Inverter Arc Welder Model 600 GMS CC/CV User manual

Brand: ESAB

Model: Inverter Arc Welder Model 600 GMS CC/CV

Category: Welding System

Type: User manual

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ESAB Inverter Arc Welder Model 600 GMS CC/CV User manual

ESAB Inverter Arc Welder Model 600 GMS CC/CV User manual

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