MODEL TA-4/170-H DC Welding Generator

MODEL TA-4/170-H
DC
Welding Generator
•
•
•
STICK
TIG-Scratch Start
Auxiliary Power
INSTRUCTION MANUAL
August 2,2002
MI118-06-01-06
Manual No. 0-2625/CSA
1
ref. TAF4170.TIF
TA-4/170-H
DC
Welding generator
2
Proposition 65
WARNING: This product, when used for welding or cutting,
produces fumes or gases which contain chemicals known to the
State of California to cause birth defects and, in some cases,
cancer. (California Health & Safety Code Sec.25249.5 et seq.)
3
WARNING
Read and understand this entire Instruction Manual and your employer’s safety practices before
installing, operating, or servicing the equipment.
WARNING
While the information contained in this Instruction Manual represent our best judgement, Thermal
Arc assumes no liability for its use.
Thermal Arc DC Welding Generator Model TA-4/170-H
Instruction Manual Number 0-2625/CSA
Published by:
Thermal Arc
2200 Corporate Drive
Troy OH
USA 45373
Ph: (1) 937 440 0100
Copyright 1997 by
Thermal Arc
All right reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any part for any loss or damage
caused by any error or omission in the Thermal Arc DC Welding Generator Model TA-4/170-H
Instruction Manual, whether such error results from negligence, accidental, or any other cause.
August 1, 1997
4
TABLE OF CONTENTS
1. GENERAL INFORMATION.....................................................................................................6
1.01
1.02
1.03
1.04
1.05
1.06
2.
3.
4.
5.
6.
7.
8.
9.
Notes, Cautions and Warnings .........................................................................................................................6
Important Safety Precautions ...........................................................................................................................6
Publications......................................................................................................................................................8
Note, Attentions et Avertissement....................................................................................................................9
Precations De Securite Importantes .................................................................................................................9
Publications....................................................................................................................................................11
STATEMENT OF WARRANTY.............................................................................................13
TECHINICAL SPECIFICATIONS.........................................................................................15
FRONT PANEL DESCRIPTION ............................................................................................16
OVERAL DIMENSIONS WEIGHT BASE MOUNTING ....................................................18
SPECIFICATIONS ...................................................................................................................19
INSTALLING WELDING GENERATOR.............................................................................20
WARNING .................................................................................................................................21
GENERATOR AUXILIARY POWER SYSTEM..................................................................22
9.01
SELECTING EQUIPMENT..........................................................................................................................22
10. WIRING OPTIONAL 230 VOLT PLUG................................................................................23
11. GROUNDING THE GENERATOR TO A TRUCK OR A TRAILER FRAME ................24
12. GROUNDING THE GENERATOR WHEN CONNECTING TO HOME, SHOP, OR
FARM WIRING ........................................................................................................................24
13. SELECTING AND PREPARING WELD OUTPUT CABLES............................................25
14. TYPICAL PROCESS CONNECTIONS .................................................................................26
15. POWER REQUIRED TO START MOTOR ..........................................................................26
16. SELECTING WELD CABLES SIZES ...................................................................................27
17. WELD OUTPUT CONNECTION...........................................................................................28
18. SEQUENCE OF OPERATION................................................................................................29
18.01
18.02
18.03
STARTING....................................................................................................................................................29
SHELDED METAL ARC WELDING (SMAW) .......................................................................................... 30
STOPPING THE ENGINE............................................................................................................................31
19. ROUTINE MAINTENANCE ...................................................................................................32
20. PARTS LIST ..............................................................................................................................35
20.01
TROLLEY 4 : TWO WHEELS TROLLEY WITH HANDLES (Optional accessory) .................................38
21. WIRING DIAGRAM ................................................................................................................40
5
1. GENERAL INFORMATION
GASES AND FUMES
Gases and fumes produced during the Arc
welding/cutting process can be dangerous and
hazardous to your healt.
• Keep all fumes and gases from the breathing
area. Keep your head out of the welding fume
plume.
1.01 Notes, Cautions and Warnings
Throughout
this
manual,notes,cautions,and
warnings are used to highlight important
information. These highlights are categorized as
follows:
• Use an air-supplied respirator if ventilation is
not adeguate to remove all fumes and gases.
• The kinds of fumes and gases from the arc
welding/cutting depend on the kind of metal
being used coatings on the metal, and the
different process. You must be very careful
when cutting or welding any metals which may
contain one or more of the following:
NOTE
An operation, procedure, or background
information wich requires additional emphasis or
is helpful in efficent operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
Antimony
Arsenic
Barium
Beryllium
Cadmium
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
• Always read the Material Safety data Sheets
(MSDS) that should be supplied with the
material you are using. These MSDS will give
you the information regarding the kind and
amount of fumes and gases that may dangerous
to your healt.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the
operating area.
• For information on how to test for fumes and
gases in your workplace, refer to item 1 in
Subsection 1.03, Publication in this manual.
• Use special equipment, such as water or down
draft welding/cutting tables, to capture fumes
and gases.
1.02 Important Safety Precautions
WARNING
OPERATION
AND
MAINTENANCE
OF
WELDING EQUIPMENT CAN BE DANGEROUS
AND HAZARDOUS TO YOUR HEALT.
To prevent possible injury, read, understand, and
follow all warnings, safety precautions and
instructions bedore using the equipment. Call 1603-298-5711 or your local distributor if you have
any questions.
• Do not use the welding torch in an area where
combustible 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.
GENERAL INFORMATION
6
• Hydrogen gas may be formed and trapped
under aluminium workpieces when they
are cut underwater or while using a water
table. DO NOT cut aluminium alloys
underwater or on a water table unless the
hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is
ignited will cause an explosion.
ELECTRIC SHOCK
Electric Shock can injure or kill. The arc welding
process uses and produces high voltage electrical
energy. This electric energy can cause severe or
fatal shock to the operator or others in the
workplace
• Never touch any parts that are electrically
•
•
•
•
•
•
“live” or “hot”.
Wear dry gloves and clothing. Insulate
yourself from the work piece or other parts of
the welding circuit.
Repair or replace all worn ar damage parts.
Extra care must be taken when the workplace
is moist or damp.
Install and mantain equipment according to
NEC code, refer to item 4 in Subsection 1.03,
Publications.
Disconnect power source before performing
any service or repairs.
Read and follow all the instruction in the
Operating Manual.
NOISE
Noise can cause permanent hearing loss. Arc
welding/cutting processes can cause noise levels
to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of
hering.
• To protect your hearing from loud noise wear
protective ear plugs and/or ear muffs. Protect
others in the workplace.
• Noise levels should be measured to be sure the
decibels (sound) do not exceed safe levels.
• For information on how to test for noise,
see item 1 in Subsection 1.03, Publications,
in this manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag,
sparks or the arc weld.
• Be sure there is no combustible or flammable
material in the workplace. Any material that
cannot be removed must be protected.
• Ventilate all flammable or explosive vapors
from the workplace.
• Do not cut or weld on containers that may
have held combustibles.
• Provide a fire watch when working in an area
where fire hazards may exist.
ARC WELDING RAYS
Arc Welding/Cutting Rays can injure your
eyes and burn your skin. The arc welding
cutting process produces very bright ultra
violet and infra red light. These arc rays will
damage your eyes and burn your skin if you
are not properly protected.
• To protect your eyes, always wear a welding
helmet or shield. Also always wear safety
glasses with side shields goggles or other
protective eye wear.
• Wear welding gloves and suitable clothing to
protect your skin from the arc rays and sparks
GENERAL INFORMATION
7
Keep helmet and safety glasses in good condition.
replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc
rays. Use protective booths, screens or shields.
• Use the shade of lens as raccomanded in
Subsection 1.03, item 4.
7. AWS Standard A6.0, WELDING AND
CUTTING CONTAINERS WICH HAVE
HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. Lejeune
Rd, Miami, FL33126.
8. NFPA Standard 51, OXYGEN-FUEL GAS
SYSTEMS FOR WELDING, CUTTING AND
ALLIED PROCESSES, obtainable from the
National
Fire
Protection
Association,
Batterymarch Park, Quincy, MA 02269.
1.03 Publications
Refer to the following standards or their latest
revisions for more information:
9. NFPA
Standard
70,
NATIONAL
ELECTRICAL CODE; obtainable from the
National
Fire
Protection
Association,
Batterymarch Park, Quincy, MA 02269
1. OSHA,
SAFETY
AND
HEALTH
STANDARDS, 29CFR 1910, obtainable from
the Superintendent of Documents, U.S.
Government Printing Office, Washington,
D.C. 20402.
10. NFPA Standard 51B, CUTTING AND
WELDING PROCESSES, obtainable from the
National
Fire
Protection
Association,
Batterymarch Park, Quincy, MA 02269.
2. ANSI Standard Z49.1, SAFETY IN
WELDING AND CUTTING, obtainable from
the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126.
11. CGA Pamphlet P-1, SAFE HANDLING OF
COMPRESSED GASES IN CYLINDERS,
obtainable from the Compressed Gas
Association, 1235 Jefferson Davis Highway,
Suite 501 Arlington, VA 22202.
3. NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND
CUTTING,
Obtainable
from
the
Superintendent
of
Documents,
U.S.
Government Printing Office, Washington,
D.C. 20402.
12. CSA Standard W117.2, CODE FOR SAFETY
IN WELDING AND CUTTING, obtainable
from the Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
4. ANSI Standard Z87.1, SAFE PRACTICES
FOR OCCUPATION AND EDUCATIONAL
EYE AND FACE PROTECTION, Obtainable
from American National Standard Institute,
1430 Broadway, New York, NY 10018.
13. NWSA booklet, WELDING SAFETY
BIBLIOGRAPHY obtainable from the
National Welding Supply Association, 1900
Arch Street, Philadelphia PA 19103.
5. ANSI Standard Z41.1, STANDARD FOR
MEN’S
SAFETY-TOE
FOOTWEAR,
obtainable from the American National
Standards Institute, 1430 Broadway, New
York, NY 1018.
14. American
Welding
Society
Standard
AWSF4.1,
RECOMMENDED
SAFE
PRACTICES FOR THE PREPARATION
FOR WELDING AND CUTING OF
CONTAINERS AND PIPING THAT HAVE
HELD
HAZARDOUS
SUBSTANCES
obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL
33126.
6. ANSI Standard Z49.2, FIRE PREVENTION
IN THE USE OF CUTTING AND WELDING
PROCESSES, Obtainable from American
National Standard Institute, 1430 Broadway,
New York, NY 10018.
8
GENERAL INFORMATION
Il faut communiquer aux opérateurs et au
personnel TOUS les dangers possibles lisez,
comprenez et suivez tous les avertissement, toutes
les précautions de sécurité et toutes les consignes
avant d’utilizer le materiel. Composez le +603298-5711 ou votre distributeur local si avez des
questions.
15.ANSI Standard Z88.2, PRACTICE FOR
RESPIRATORY PROTECTION, obtainable
from American National Standards Instiute,
1430 Broadway, New York, NY 10018.
1.04 Note, Attentions et
Avertissement
FUMÉE et GAZ
Dans ce manuel les mots “note”, “attention”, et
“avertissement” sont utilises pour mettre en relief
des informations à caractère important
La fumée et les gaz produits par le procede de jet
de plasma peuvent présenter des risques et des
dangers de saté.
NOTE
• Eloignez toute fumée et gaz de votre zone de
respiration. gardez votre tête hors de la plume
de fumée proventant du chalumeau.
• Utilisez un appareil respiratoire à alimentation
en air si l’aération fournie ne permet pas
d’éliminerla dumée et les gaz.
• Les sortes de gaz et de fumée provenant de
l’arc de plasma dépendent de genre de métal
utilisé, des revêtements se trouvant sur le
métal et des differents procédés. Vous devez
prendre soin lorque vous coupez ou soudez
tout métal pouvant contenir un ou plusieurs
des éléments suivants :
Toute opération, procedure ou reseignement
général sur lequel il importe d’insister davantage
ou qui ciìontribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute
procédure
pouvant
résulter
l’endommagement du matériel en cas de
nonrespect de la procédure en question.
AVERTISSEMENT
Antimoine
Argent
Arsenic
Baryum
Béryllium
Vanadium
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se
trouvant dans la zone de travail en cas de nonrespect de la procédure en question.
Cadmium
Chrome
Cobalt
Cuivre
Manganése
Mercury
Nickel
Plomb
Sélénium
• Lisez toujours les fiches de données sur la
sécurité des matéries (sigle américain
“MSDS”); celle-ci devraient être fournies avec
le matériel que vous utilisez. Les MSDS
contiennent des renseignements quant à la
quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• Pour des informations sur la maniere de tester
la fumés et les gaz de votre lieu de travail,
ccnsultez l’article 1 et les documents cités à la
page 5.
•
1.05 Precations De Securite
Importantes
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE A L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
9
GENERAL INFORMATION
Utilisez un équipment spécial tel que des
tables de coupe à débit d’eau ou à courant
descendant pour capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma
dans une zone oú se trouvent des matiéres ou
des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la
fumée proventant des solvants et des produits
de nettoyage chlorés. Eliminez toute. Source
de telle fumée.
• Soyez certain qu’aucune matière combustible
ou inflammable ne se trouve sur le lieu de
travail. Protéges toute telle matière qu’il est
impossible de retirer de la zone de travail.
• Procurez une bonne aeration de toutes les
fumées inflammable ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs
ayant pu renfermer des matieres combustibles.
• Prévoyez une veille d’incendie lors de tout
travail dans une zone présentant des dangers
d’incendie.
• Le gaz Hydrogène peut se former ou
s’accumuler sous les pièces de travail en
aluminium lorsqu’elle sont coupées sous l’eau
ou sur une table d’eau. NE PAS couper les
alliages en aluminium sous l’eau ou sur une
table d’eau à moins que le ga shydrogène peut
s’echapper ou se dissipier. Le gaz hydrogène
accunulé explosera si enflammé.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même
tuer. Le procédé au jet de plasma requiert et
produit de l’énergie électrique haube tension.
Cette énergie électrique peut produire des chocs
graves, voire mortels, pour l’opérateur et les
autres personnes sur le lieu de travail.
• Ne touchez jamais une piéce “sous tension” ou
“vive”; portez des gants et des vêtemets secs.
Isolez-vous de la pièce de travail ou des autre
parties du circuit de soudage.
• Rérarez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de
travail est humide ou moite.
• Montez et maintenez le matériel au Code
électrique national des Etats-Unis. (Voir la
page 5, article 9).
• Débranchez l’alimentation électrique avant
tout tarvail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du
Manuel de consignes.
RAYONS D’ARC DE PLASMA
Les rayons provenent del’arc de plasma peuvent
blesser vous yeux et brûler votre peau. Le procédé
à l’arc de plasma produit une lumière infra-rouge
et des rayons ultra-violets très forts. Ces rayon
d’arc nuirontà vos yeux et brûleront votre peau si
vous ne vous proteges pas correctment.
• Pour protéger vos yeux, portez toujours un
casque ou un écran de soudeur. Portez toujours
des lunettes de sécurité minies de parois
latérales ou des lunettes de protection ou une
autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayon de l’arc.
• Maintenez votre casque et vos lunettes de
protection en bon état. Remplacez toute
lentille sale ou comportant fissure ou rognure.
• Protegez les autrez personnes se trouvent sur
la zone de travail contre les rayons de l’arc en
fournissant del cabines ou del écrans de
protection.
• Respectez le teint de lentille racommandé dans
le article4, page 5.
INCENDIE ET EXPLOSION
Les incendies et les explosion peuvent résulter
des scories chaudes, des étincelles ou de l’arc de
plasma. Le procédè à l’arc de plasma produit du
métal, des étincelles, des scories chaudes pouvant
mettre le feu aux matieres combustibles ou
provoquer l’explosion de fumées inflammables.
GENERAL INFORMATION
10
4. Norme ANSI Z87.1, PARTIQUES SURES
POUR LA PROTECTION DES YEUX ET
DU VISAGE AU TRAVAIL ET DANS LES
ECOLES, disponible de l’ Institute Américain,
des Normes Nationales (American National
Standard Institute), 1430 Broadway, New
York, NY 10018.
BRUIT
Le bruit peut provoquer une perte permanente de
l’ouie. Les procédés de soudage à l’arc de plasma
peuvent provoquer des niveaux sonores
supérieures aux limites normalement acceptables.
Vous dùvez vous protéger les oreilles contre les
bruits forts afin d’éviter une perte permanente de
l’ouïe.
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible
auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY
1018.
• Pour protéger votre ouïe contre les bruits forts,
portez des taòpons protecteurs st/ou des
protections auriculaires. Protégez également
les autres personnes se trouvant sur le lieu de
travail.
• Il faut measurer les niveaux sonores afin
d’assurer que les décibels (le bruit) ne
dépassent pas les niveaux sûrs.
• Pour des renseignements sur la manière de
tester le bruit, consultez l’article 1, page 5.
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L’EMPLOI DE
PROCÉDÉS DE COUPE ET DE SOUDAGE,
disponible aupres de l’American National
Standard Institute, 1430 Broadway, New York,
NY 10018.
7. Norme A6.0 de l’Association Américaine du
Soudage (AWS), LE SOUDAGE ET LA
COUPE DE CONTENEURS AYANT
RENFERMÉ DES PORDUITS
COMBUSTIBLES disponible auprès de la
American Welding Society, 550 N.W. Lejeune
Rd, Miami, FL33126.
1.06 Publications
Consultez les normes suivents ou les révisions les
plus récentes ayant été faites à celles-ci pour de
plus amples renseignements:
8. Norme 51 de l’Association Américaine pour la
Protection contre les Incendies (NFPA), LES
SYSTEMS A GAZ AVEC ALIMENTATION
EN COUPE ET LES PROCÉDÉS ASSOCIÉS,
disponible auprès de la National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.
1. OSHA, NORMES DE SÉCURITÉ DU
TRAVAIL ET DE LA PROTECTION DE LA
SANTÉ, 29CFR 1910, disponible auprès du
Superintenent of documents, U.S. Government
Printing Office, Washington, D.C. 20402.
9. Norme 70 de la NFPA,CODE ELECTRIQUE
NATIONAL, disponible aupres de la National
Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE
SOUDAGE, disponible auprésde la Société
Americaine de Soudage (American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL
33126.
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible aupres
de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
3. NIOSH LA SÉCURITÉ ET LA SANTÉ LORS
DES OPÉRATIONS DE COUPE ET DE
SOUDAGE A L’ARC ET AU GAZ,
disponible auprès du Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
11. Brochure CGA P-1, LA MANIPULATION
SANS RISQUE DES GAZ COMPRIMÉS EN
CYLINDRES,
disponible
aupres
de
l’Association
des
Gaz
Comprimes
(Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501 Arlington, VA
22202.
11
GENERAL INFORMATION
12. Norme CSA W117.2, CODE DE SÉCURITÉ
POUR LE SOUDAGE ET LA COUPE,
disponible aupres de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W
1R3.
13. Invret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible
auprès de l’Association Nationale de
Fournitures de Soudage (National Welding
Supply Association), 1900 Arch Street,
Philadelphia PA 19103.
14. Norme AWSF4.1 de l’Association Américaine
de soudage , RECOMMANDATIONS DE
PRATIQUES
SURES
POUR
LA
PRÉPARATION A LA COUPE ET AU
SOUDAGE
DE
CONTENEURS
ET
TUYAUX AYANT RENFERMÉ DES
PRODUITS DANGEREUX, disponible auprès
de l’American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126.
15.Norme
ANSI Z88.2, PRATIQUES DE
PROTECTION RESPIRATOIRE, disponible
auprès de l’American National Standards
Instiute, 1430 Broadway, New York, NY
10018.
12
GENERAL INFORMATION
2. STATEMENT OF WARRANTY
LIMITED WARRANTY: Thermal Arcâ, Inc. A Thermadine Company, warrants that its products will be free of
defects in workmanship or material. Should any failure to conform to this warranty appear within the time period
applicable to the Thermal Arc products as stated below, Thernal Arc shall, upon notification thereof and substantiation
that the product has been stored, installed, operated, and manteined in accordance with Thermal Arc’s specifications,
instructions, recomandations and recognized standard industry practice, and not subjet to misuse, repair, neglet,
alteration, or accident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of any
components or parts of the product determinated by Thermal Arc to be defective.
THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS
EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special or consequential
damages, such us, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of
distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are
exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as
the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or
furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise,
shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No
employee, agent, or rapresentative of Thermal Arc is authorized to change this warranty in any way or grant any other
warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR
ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE JUDGEMENT MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO
PURCHASER CY NONAUTHORIZED PERSONS.
Except with regards to the products listed below, this warranty shall remain effective there (3) years from from the date
Thermal Arc’s authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date
Thermal Arc delivers the product to the authorized distributor.
Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time
stated below beginning on the date that the authorized distributor delivers the products to the Purchaser.
Notwithstanding the foregoing, in no event shall the warranty period extend more that the time stated plus one year from
the date Thermal Arc delivered the product to the authorized distributor.
ALL OTHER
POWER SUPPLIES
POWER SUPPLIES
P-WEE, PRO-LITE
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
1 YEAR
1 YEAR
1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING
BUT NOT LIMITED TO, CONTACTORS, RELAYS,
SOLENOIDS, PUMPS, POWER SWITCHING SEMICONDUCTORS.
ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE
WARRANTED BY THE ENGINE MANUFACTURER. SEE THE ENGINE MANUFACTURES WARRANTY
FOR THE DETAILS.
1 YEAR
1 YEAR
1 YEAR
CONSOLES, CONTROL EQUIPMENT, HEAT
EXCANGES, AND ACCESSORY EQUIPMENT
180 DAYS
180 DAYS
180 DAYS
TORCH AND LEADS
90 DAYS
90 DAYS
90 DAYS
REPAIR/ REPLACEMENT PARTS
GENERAL INFORMATION
13
Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized
Thermal Arcâ 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
responsability of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes
all previous Thermal Arc warranties.
Thermal Arcâ is a Registred trademark of Thermadyne Industries Inc.
Effective January 1,1998
14
GENERAL INFORMATION
3. TECHINICAL SPECIFICATIONS
WELDING GENERATOR DC
DC amperage range
DC welding current
DC welding current
40÷170 of continuous control stepless
170A 60% duty cycle
140A 100% duty cycle
VOLTAGE
CC
90V OCV
AUXILIARY POWER
60Hz Single phase
115V 2kVA - 230 4kVA
ENGINE
Make/Type
Model series
Number of cylinders
Displacement
Power
Engine speed
Cooling system
Starting system
Oil capacity
Fuel capacity
Fuel consumption
HONDA
GX 270
1
270 cc.
9 HP
3600 r.p.m.
Air
Manual recoil
1,1 l. - 0,3 gl.
6 l. - 1,6 gl.
2,9 l/h - 0,76 gl./h
15
4. FRONT PANEL DESCRIPTION
ref. TA1170C1.DWG
1
2
3
4
5
GFCI 115V Duplex Receptacle - Ground fault interrupt protection receptacles for 115V 60Hz
power source
115V 20A Circuit Breakers - Push to reset. Controls 115V power source for the 115V duplex
GFCI receptacle.
230V 15A Circuit Breakers - Push to reset. Controls 230V power source for the 230V
receptacle.
230V/115V Single Phase Receptacle - Supplies 60Hz single-phase power at weld/power
speed
Hourmeter
16
FRONT PANEL DESCRIPTION
ref. TA41702C.DWG
1
2
3
4
5
6
7
Earth Ground connection
Welding socket : Work - Negative connection 120/170A
Welding socket : Work - Negative connection 80/130A
Fine adjustment - controls throttle for fine welding control of current CC. Rotating this
control in a clockwise direction increases the amperage or voltage output. The scale
surrounding the control represents approximate actual amperage.
Welding socket : Work - Negative connection 40/90A
Welding socket : Electrode - Positive connection
Serial number
17
5. OVERAL DIMENSIONS WEIGHT BASE
MOUNTING
OVERALL DIMENSION
Dimensions
Height
Width
Lenght
510 mm
490 mm
730 mm
20.07 in
19.29 in
28.74 in
Weight
93 Kg
205 lb
ref. T41701.TIF
MAXIMUM WELDING GENERATOR OPERATING ANGLES
Do not exceed operating amgles while running or engine damage will occur.
ref. TA41702.TIF
18
6. SPECIFICATIONS
CAUTION
DESCRIPTION
CONTINUAL EXCEEDING OF DUTY
CYCLE RATINGS can cause damage to the
welding power source.
The Thermal Arc TA-4/170 H is a gasoline
engine driven DC welding generator. This
unit is designed for use with Shielded Metal
Arc Welding (SMAW) processes.
• Do not exceed indicated duty cycles.
NOTE
Volt-ampere curves show the voltage and
amperage output capabilities of the welding
power source. Curves of other settings will
fall between the curves shown.
Volt-Ampere Curves
DUTY CYCLE
The duty cycle of a welding generator is the
percentage of a ten minute period that welding
generator can be operated at a given output
without causing overheating and damaging of
the unit. This unit is rated at 60 percent duty
cycle when operated at 170 amperes. The unit
can be operated at 170 amperes for six
consecutives minutes, but it must operate at
no load for the remaining four minutes to
allow proper cooling. If the welding amperes
decrease, the duty cycle increases. If the
welding amperes are increased beyond rated
output, the duty cycle will decrease.
Ref. TA4170.TIF
NOTE: Full output may not be
achived before Engine break-in time.
Engine break-in time is Approx. 80
hours.
CAUTION
EXCEEDING DUTY CYCLE RATINGS
will cause the thermal overload protection
circuit to become energized and shut down
output until the cools to normal operating
temperature.
19
7. INSTALLING WELDING GENERATOR
1. Lifting forks.
2. Trailer
Install unit on trailer according to trailer manufacturing.
Do not lift unit from
Movement
ref.TA41703.TIF
1
Airflow Clearance
Location
500mm 19.7 in
500mm 19.7 in
OR
OR
500mm 19.7 in
500mm 19.7 in
Ref. TA41704.TIF
2
Ref. TA41705.TIF
20
8. WARNING
ENGINE FUEL CAN CAUSE FIRE OR EXPLOSION.
- Stop engine before fueling.
- Do not fuel while smoking or near sparks or flames.
- Do not overfill tank-clean up any spilled fuel.
REMOVE FUEL CAP SLOWLY-FUEL SPRAY MAY CAUSE INJURY.
FUEL MAY BE UNDER PRESSURE.
Rotate fuel cap slowly and wait until hissing stops before removing cap.
Check all fluids daily. Engine must be cold and on a level surface.
Add fresh fuel starting engine the first time.
Wipe dipstick clean and check oil : if oil is not up to full mark, add oil.
Full
Gasoline only
Ref. TA41706.TIF
Full
ref. TA500D8.TIF
21
9. GENERATOR AUXILIARY POWER SYSTEM
9.01 SELECTING EQUIPMENT
WARNING
1. Auxiliary power receptacles.
- Neutral bonded to frame.
2. 3-Prong plug from case.
Grounded equipment.
3. 2-Prong plug from double insulated equipment.
Be sure equipment
has this symbol
and/or wording.
Double
insulation
ref. TA500D9.TIF
Proper equipment to use
Simultaneous welding and auxiliary power
(Fine Current Control set at Maximum)
Weld current DC
170 A / 26.8 V
120 A / 24.8 V
70 A / 22.8 V
0A/0V
Auxiliary power single phase 115/230V
0.5 kVA
2 kVA
3.5 kVA
4 KVA
22
10. WIRING OPTIONAL 230 VOLT PLUG
The plug can be wired for a 230V, 2-wire load or a 115/230V, 3-wire load.
White - Neutral terminal.
YYY - Load 1 terminal.
XXX - Load 2 terminal.
Green - Ground terminal.
ref. TA500D17.TIF
23
11. GROUNDING THE GENERATOR TO A
TRUCK OR A TRAILER FRAME
1.
2.
3.
4.
Generator base.
Metal vehicle frame.
Equipment grounding terminal.
Grounding cable.
Use #10 AWG or larger insulated copper wire.
Grounding methods
Electrically bond generator
frame to vehicle frame by
metal-to-metal contactor.
ref. TA41707.TIF
12. GROUNDING THE GENERATOR WHEN CONNECTING
TO HOME, SHOP, OR FARM WIRING
1. Equipment grounding terminal.
2. Grounding cable.
Use #10 AWG or larger insulated copper wire.
3. Water meter.
4. Metal water pipe.
5. Driven ground rod.
Ground generator to system earth ground if supplying
power to a permises (home,shop,farm) wiring system.
ref. TA500D11.TIF
Use metal water pipe or
driven ground rod or
other means as stated in
electrical codes
24
13. SELECTING AND PREPARING WELD OUTPUT
CABLES
1. Weld output cable.
Determine total cable lenght in weld circuit and maximum welding amperes.
Use shortest cables possible.
Do not use damaged cables.
2. Welding socket: Negative connection.
3. Welding socket: Positive connection.
Use lugs of proper amperage capacity and hole size for connecting to work clamp.
4. Insulated electrode holder.
5. Work clamp.
Install onto work cable.
ref. TA41708.TIF
25
14. TYPICAL PROCESS CONNECTIONS
ref. TA62153.DWG
15. POWER REQUIRED TO START MOTOR
1.
2.
3.
4.
Motor start code.
Running amperage.
Motor HP.
Motor voltage.
MOTOR START CODE
kVA/HP
AC MOTOR
VOLT
230
AMPS
COMPRESSOR HZ
HP
2.7
PHASE
VENTILATOR
4
2,5
60
1
COMPRESSOR
8
kVA/HPxHPx1000
= STARTING AMPERAGE
VOLTS
ref. TA500D13.TIF
EXAMPLE : Calculate the starting amperage required for a 230 V, 2.7 HP motor with a motor start code of 8 for
compressor.
Volts = 230 HP = 2.7 Using table, Code for compressor result in kVA/HP = 8
8x2.7x1000
230
= 93.9 A Starting the motor requires 93.9 amperes
26
16. SELECTING WELD CABLES SIZES
Welding
Amperes
100
150
200
250
300
350
400
500
600
Total Cable (Copper) Lenght in Weld circuit Not Exceeding
100 ft. (30 m)
150 ft.
200 ft.
250 ft.
300 ft.
350 ft.
(45
m)
(60
m)
(70
m)
(90
m)
(105
m)
or Less
10 To 60% 60 Thru 100%
10 Thru 100% Duty Cycle
Duty Cycle
Duty Cycle
4
4
4
3
2
1/0
1/0
3
3
2
1
1/0
2/0
3/0
3
2
1
1/0
2/0
3/0
4/0
2
1
1/0
2/0
3/0
4/0
2-2/0
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
400 ft.
(120 m)
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-4/0
Wels cables size (AWG) is based on either a 4 volts or less drop or a current density of more than
300 circular mils per ampere.
27
17. WELD OUTPUT CONNECTION
CONNECTOR INSTALLATION
Install the supplied male connectors onto proper cables.
1. Obtain cable of desired lenght and proper size for installation.
2. If the installation requires cable large than 3/0 AWG, prepare 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.
4. Remove 0.79 in (20 mm) of insulation from end of cable.
5. Install supplied sleeve on stripped end of cable.
6. Insert cable with sleeve into connector boby so that cable is snug and against bottom of connector
boby.
7. Install and tighten set screw with supplied hex wrench to secure connector boby onto cable.
8. Push insulator onto connector boby to cover set screw.
Set screw
Strip insulation approx. 0.79 in from end
ref. TA500D16.TIF
Connector body
Sleeve
Weld cable
Insulator
WARNING : electric shock can kill. Arcing can burn skin
or damage electrical connections.
WELD CABLE CONNECTIONS
1.
2.
3.
4.
Do not touch live electrical parts.
Shut down unit before making any weld output connections.
Do not charge position of the welding cable connectors while welding
Be sure that the connectors are secure in receptacle before welding.
28
18. SEQUENCE OF OPERATION
WARNING : Read and follow all safety precaution before proceding with operation.
18.01 STARTING
1. Turn the fuel valve to the On position.
ref. F5180LH.TIF
2. Move the choke lever to the CLOSE Position.
Note: Do not use the choke if the engine is warm or the air temperature is high.
ref. F5180LH1.TIF
3. Turn the throttle knob until half way round.
4. Start the engine.
-With recoil starter
5. Turn the engine switch to the ON position.
ref. F5180LH2.TIF
29
6. Pull the starter grip lightly until resistance is felt, them pull brisckly.
Caution: Do not allow the starter grip to snap back bagainst the engine.
Return it gently to prevent damage to the starter.
ref. F5180LH3.TIF
7. As the engine warms up, gradually move the choke leverto the open position.
ref. F5180LH4.TIF
18.02 SHELDED METAL ARC WELDING (SMAW)
1.
2.
3.
4.
5.
6.
7.
Install and connect unit according to the installation section.
Wear gloves and clothing.
Connect work clamp at workplace.
Select power electrode.
Select proper negative welding socket.
Rotate the Fine adjust control, to desired position.
Insert electrode into electrode holder.
30
18.03 STOPPING THE ENGINE
To stop the engine in an emergency turn the engine switch the OFF position. Under normal
condition, use the following procedure:
1. Disconnect the utilizers.
2. Turn the engine speed control to its lowest setting.
3. Turn the engine switch to the OFF position.
ref. F5180LH5.TIF
4. Turn the fuel valve to the OFF position.
ref. F5180LH6.TIF
31
19. ROUTINE MAINTENANCE
ATTENTION : STOP ENGINE BEFORE MAINTENANCE
ref. FILTER.TIF
ref. FLUIDSLE.TIF
ref. WELDTERM.TIF
ref. CHANGEOI.TIF
ref. CHANGEOF.TIF
32
ref. CLEANCS.TIF
ref. CLEANSAC.TIF
ref. REPLUL.TIF
ref. REPLFF.TIF
33
ref. CHECKVC.TIF
ref. CHECKSA.TIF
ref. CHECKSP.TIF
1000 HOURS: Blow out or vacuum inside.
DURING HEAVY SERVICE CLEAN MONTHLY.
34
20.PARTS LIST
35
SPARE PARTS LIST
Item N° Thermal Arc Ord. n°
1 11-3000
2 11-4106
3 11-3002
4 11-3003
5 11-4107
6 11-4108
7 11-3006
8 11-4036
9 11-3061
10 11-3375
11 11-3010
12 11-3011
13 11-3012
14 11-3013
15 11-3014
16 11-3015
17 11-3016
18 11-3017
19 11-3018
20 11-3019
21 11-3020
22 11-3021
23 11-3022
24 11-3023
25 11-3024
26 11-3732
27 11-3581
28 11-4065
29 11-3047
30 11-4060
31 11-3030
32 11-3031
33 11-3032
34 11-3033
35 11-3034
36 11-3035
37 11-3036
38 11-3037
39 11-3038
40 11-3039
41 11-3040
42 11-4130
43 11-3534
44 11-3043
45 11-3044
Denomination
Stator
Engine connecting flange
Tierod
Shaft with rotor
Tierod
Flange with bearing seat
Bearing 30/72/19 6306
Internal ring
12mm male insulator
115V 2x15A GFCI 5-15R single phase cover
Fan
Fan ring
Rectifier assembly
Fan cap
Frame
Shock absorber 40x40
Prisoner M5x27
Shock absorber 30x30
Shock absorberprotection
Engine support
Instrumental cover
Terminal board 6 poles
Shock absorber 15x30
Shock absorber 15x30
Capacitors support
Capacitors plate
50µF capacitor
Aluminium front plate
15A circuit breaker
Throttle knob
Throttle unit
Earth clamp
Welding outlet
Plug for welding outlet
Reactor
Spacer H18,5
Right side cover
Air deflector
Three phase reactor
Left side cover
Spring
Front cover
Closing plate
Top cover
Left protection grate
36
Item N°
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
Thermal Arc Ord. n°
11-3045
11-4124
11-3148
11-3048
11-3049
11-3050
11-3051
11-3052
11-4059
11-3054
11-3055
11-3056
11-3057
11-3058
11-3059
11-3060
11-4109
11-4110
11-4105
11-4131
Denomination
Hourmeter
230V 50A 14-50 single phase outlet
20A circuit breaker
Ring
Circuit breaker cover
115V 2x15A GFCI 5-15R single phase outlet
Resistance cover
Resistance support
Resistance
Resistance plate
Resistance
Resistance terminal
Resistance support
7mm insulating washer
22mm female female insulator
12mm insulating washer
Frame flange
Stator support
Plate
Self locking ring
37
20.01TROLLEY 4 : TWO WHEELS TROLLEY WITH HANDLES (Optional accessory)
38
SPARE PARTS LIST
Item N° Thermal Arc Ord. n°
- 11-2013
1 11-3063
2 11-3064
3 11-3065
4 11-3066
5 11-3067
6 11-3068
7 11-3069
8 11-3070
Denomination
Trolley 4 assembly
Rubber handle
Bracket
Handle
Support
Support
Axle support
Axle
Wheel
39
21.WIRING DIAGRAM
40