ESAB Inverter Arc Welder Model PS-3000 User manual

Brand: ESAB

Model: Inverter Arc Welder Model PS-3000

Category: Welding System

Type: User manual

Manual No. 0-2337

Instruction Manual

INVERTER

ARC

WELDER

MODEL PS-3000

• Plasma Arc Welding

October 23, 1998

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

Model PS-3000 Inverter Arc Welder

Instruction Manual Number 0-2337

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

Model PS-3000 Inverter Arc

Welder Instruction Manual, whether such error results from

negligence, accident, or any other cause.

October 23, 1998

WARNING

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................................i

Notes, Cautions and Warnings .................................................................................i

Important Safety Precautions ...................................................................................i

Publications .............................................................................................................ii

Note, Attention et Avertissement ............................................................................ iii

Precautions De Securite Importantes..................................................................... iii

Documents De Reference ...................................................................................... v

Declaration of Conformity .......................................................................................vi

Statement of Warranty........................................................................................... vii

SECTION 1: GENERAL INFORMATION ..................................................................................... 1

1.1 Specifications ................................................................................................... 1

1.2 Duty Cycle....................................................................................................... 2

SECTION 2: INSTALLATION ....................................................................................................... 3

2.1 Site Selection................................................................................................... 3

2.2 Transporting Methods ...................................................................................... 4

2.3 Weld Ooutput Connections .............................................................................. 5

2.4 Remote 14 Connections .................................................................................. 8

2.5 Electrical Input Connections .......................................................................... 10

SECTION 3: OPERATION ......................................................................................................... 13

3.1 Operator Controls .......................................................................................... 13

3.2 Operating Precautions................................................................................... 18

3.3 Troubleshooting ............................................................................................. 19

SECTION 4: PARTS LIST..........................................................................................................21

4.01 Introduction.................................................................................................. 21

4.02 Ordering Information.................................................................................... 21

4.03 Parts List ..................................................................................................... 22

i INTRODUCTION

INTRODUCTION

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.

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 Publications.

• 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 Publications.

• Disconnect power source before performing any ser-

vice or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

INTRODUCTION ii

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 Publications.

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 recommended in Publica-

tions, item 4.

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

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

iii INTRODUCTION

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

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.

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 v.

INTRODUCTION iv

• 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 v, 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.

• 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 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.

v INTRODUCTION

• Pour des renseignements sur la manière de tester le

bruit, consultez l’article 1, page v.

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

INTRODUCTION vi

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) 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. 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

process 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: David Ashworth

Vice President & Managing Director

Thermadyne Europe

Chorley England.

vii INTRODUCTION

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

INTRODUCTION viii

Manual 0-2337 1 GENERAL INFORMATION

SECTION 1: GENERAL INFORMATION

1.1 Specifications

The Model PS-3000 is a three-phase or single-phase (if derated)

DC arc welding power source with constant current output

characteristics. This unit is designed for use with the Plasma Arc

Welding (PAW) process. A digital meter displaying amperes and

voltage is standard.

Description

Table 1-A Unit Specifications

Figure 1-A Volt-Ampere Curve

The volt-ampere curve shows the voltage and amperage output

capabilities of the welding power source. Curves of other

settings will fall between the curves shown.

NOTE

Input Data At Rated Load No Load

50/60 Hz Output Output

Amps KVA KW Amps KVA KW

208 VAC 1-Phase 48 10 7 2.5 0.5 0.3

208 VAC 3-Phase 39 14 11 1.5 0.5 0.3

230 VAC 1-Phase 43 10 7 2.0 0.5 0.3

230 VAC 3-Phase 35 14 11 1.0 0.5 0.3

460 VAC 1-Phase 21 10 7 1.0 0.5 0.3

460 VAC 3-Phase 18 14 11 0.5 0.5 0.3

575 VAC 3-Phase 14 14 11 0.5 0.5 0.3

380 VAC 3-Phase 21 14 11 1.0 0.5 0.3

400 VAC 3-Phase 20 14 11 1.0 0.5 0.3

415 VAC 3-Phase 19 14 11 0.5 0.5 0.3

Rated Output Single-Phase Three-Phase

Amperes 210 300

Volts 28 32

Duty Cycle 60% 60%

Range (Min-Max):

Amperes 5-260 5-350

Volts 10-30 10-36

Maximum OCV: 70

Input Data 50/60 Hz

Width 10.88 in (276 mm)

Height 16.75 in (425 mm)

Length 18.31 in (465 mm)

Weight (with Cable) 82 lbs (37.2 kg)

OCV Less than 80V C.C.

AMPS

5 150 350

OLTS

GENERAL INFORMATION 2 Manual 0-2337

The duty cycle of a welding power source is defined as the

percentage of a ten minute period that the unit can be operated at

a given output without causing overheating and/or damage to

the unit. This unit is rated at 60 percent duty cycle when oper-

ated at 300 amperes from three-phase input power, or when

operated at 210 amperes from single-phase input power. If the

unit is operated from three-phase input power, the unit can be

operated at 300 amperes for six consecutive minutes, but it must

operate at no load for the remaining four minutes to allow proper

cooling. When the welding power source is operated from

single-phase input power, the unit can be operated at 210 am-

peres for six consecutive minutes, but it must operate at no load

for the remaining four minutes to allow proper cooling. If the

welding amperes decrease, the duty cycle increases. If the

welding amperes are increased beyond rated output, the duty

cycle will decrease.

EXCEEDING DUTY CYCLE RATINGS will cause thermal

overload protection circuit to become energized and shut down

output until unit has cooled to operating temperature.

CONTINUAL EXCEEDING OF DUTY CYCLE RATINGS can

cause damage to the welding power source.

• Do not exceed indicated duty cycles.

1.2 Duty Cycle

CAUTION

Manual 0-2337 3 INSTALLATION

SECTION 2: 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 over

combustible surfaces. RESTRICTED AIRFLOW can cause

overheating 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, 6

inches (152 mm) from rear, and open, unrestricted access to

ambient air at front of unit.

• Do not place any filtering device over the intake air passages

that provide airflow for cooling this equipment.

Warranty is subject to being voided if any type of filtering device

is used at intake air passages.

WARNING

NOTE

INSTALLATION 4 Manual 0-2337

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 supply

line before moving welding power source.

FALLING EQUIPMENT can cause serious personal injury and

equipment damage.

• 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 proper

skid before transporting.

WARNING

Manual 0-2337 5 INSTALLATION

2.3 Weld Ooutput Connections

To obtain full rated output from this unit, it is necessary to select,

prepare, and install proper weld cables. Failure to comply in any

of these areas may result in unsatisfactory welding performance.

Use the following guidelines to select weld cables:

1. Use the shortest possible cables, and place cables close

together. Excessive cable lengths may reduce or cause unit

overload due to added resistance.

2. Use weld cable with an insulation voltage rating equal to or

greater than the maximum open circuit voltage (OCV) of the

welding power source (see Table 2-A below).

3. Select weld cable size according to maximum weld output

and total length of connecting cables in weld circuit.

4. Do not use damaged or frayed cables.

1. Install terminal lugs of adequate amperage capacity and

correct stud size onto ends of cables that connect to the work

clamp and electrode holder or torch.

2. Install work clamp onto cable.

3. Install supplied male connectors onto remaining ends of both

cables (refer to Connector Installation, page 6).

Weld Cable Selection

Weld Cable Preparation

Table 2-A Weld Cable Sizes

Maximum Total Cable Length in Weld Circuit

Welding Under 100 ft 150 ft 200 ft 250 ft 300 ft 250 ft 400 ft

Amperes (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 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

INSTALLATION 6 Manual 0-2337

To install the supplied male connectors onto proper cables, refer

to Figure 2-A below and:

1. Obtain cable of desired length and proper size for installation

(refer to 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 is

connected to the main run of 3/0 AWG or larger weld cable.

3. Push weld cable through insulator as shown.

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 is

snug and against bottom of connector body.

7. Install and tighten set screw with supplied hex wrench to

secure connector body onto cable.

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

2.3 Weld Output Connections (continued)

Connector Installation

ELECTRIC SHOCK can kill. ARCING can burn skin or damage

electrical connections.

• Do not touch live electrical parts.

• Shut down unit before making any weld output connections.

• Do not change position of the welding cable connectors while

welding.

• Be sure the connectors are secure in receptacles before welding.

WARNING

Weld Cable Connections

Figure 2-A Connector Installation

Strip insulation approx. 1 in from end

Insulator Weld Cable

Sleeve

Set Screw

Connector Bod

(Male or Femal

Manual 0-2337 7 INSTALLATION

2.3 Weld Oouput Connections (continued)

Refer to Figure 2-B and:

a. Connect torch cable connector to NEGATIVE (-) weld output

receptacle as follows: align keyway, insert plug, and rotate

plug clockwise until it is securely seated in receptacle.

b. Connect work cable connector to POSITIVE (+) weld output

receptacle as follows: align keyway, insert plug, and rotate

plug clockwise until it is securely seated in receptacle.

Plasma Arc

Welding (PAW)

Electrode Negative/

Straight Polarity

Figure 2-B Weld Output Connections - Lower Front Panel

Positive Negative

INSTALLATION 8 Manual 0-2337

2.4 Remote 14 Connections

The REMOTE 14 receptacle on the lower front panel can connect

the following equipment to the welding power source circuitry:

• Remote Contactor Control

• Remote Amperage Control

To make connections, align keyway, insert plug, and rotate

threaded collar fully clockwise.

The following socket information (Table 2-B, page 9) is included

in case the supplied cord is not suitable, and it is necessary to

wire a plug or cord to interface with REMOTE 14 receptacle.

Figure 2-C 14-Pin Socket Receptacle with Socket Locations (Lower Front Panel)

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ESAB Inverter Arc Welder Model PS-3000 User manual

Brand: ESAB

Model: Inverter Arc Welder Model PS-3000

Category: Welding System

Type: User manual

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