Thermal arc 170-220 GMS notice technique NOT077-r04
Contents
1. 18 13 1 PREPARATION FOR WELDING WITH 00000000000000000000005050150 3 18 15 22 PREPARATION FOR WELDING WITH 5 2 56 19 13 3 ADIUSTMENT OF THE PARAMETER S D M 19 14 SPOT MIG L Co 20 15 INTERMITTENT WELDING to nnde be cena eoo Ie nap 20 MAINTENANCE 16 22 17 5 tc 22 18 TROUBLESHOOTING H S 26 19 rc RR 27 APPENDICE 20 APPENDICE ADJUSTABLE VALUES FOR WELDING PARAMETERS 29 USER S MANUAL Page 4 30 THERMAL ARC 170 GMS THERMAL AIRC Arc 220 5875 lt In accordance with the warranty periods stated below Thermadyne guarantees the proposed product be free from defects in material or workmanship when operated in accordance with the written instructions as defined in this operating manual Thermadyne welding products are manufactured for use by commercial and industrial users and trained personnel with experience2. PLATINE AUTOMATISME 7 CONTROL L93341 4 ALIMENTATION 230U AC MAIN SUPPLY 2300 L93281 PONT REOR 15 MAIN RECT TRANSFORMER 2 RANSF ORMATEUR gt T Ew ar EE UENT 24UDC 24UDC FANS lt of B motor s moteur gt 18090 NO CLAVIER FRONT KEYPAD 00012 ou BOOD12 TH 12e position PLATINE PRINCIPALE 193012 MAIN Couleurs des fils SORTIE Noir gt POWER TERM Marrom gt 1 Rouge gt 2 iE POLARITE Orange gt 3 TERM POLARITY SELF INDUCTOR Jaune gt Vert gt 5 THERMAL ARC 170 GMS REV 104 Bleu gt 6 Violet gt 7 Gris gt 8 Blanc gt 9 Dated 03 09 2004 A 7 ELECTROVANNE 230V 8 Bas VALUE gt 7 1 T02002 FACADE FRONT PANEL PCB 93282 PLATINE INTERFACE CONTROL PCB 193342 DE 4 ALIMENTATION 238U AQ AIN SUPPLY 238U AQ 24UDC FANS VENT 24UDC 2 2 LL a 5 z 8 2 e LJ T 18 moteur 2 5 THT 2 100 C NO 47k position 47k PLATINE PRINCIPALE 93373 MAIN PCB 00012 ou BOBOL2 TH Couleurs des fils m SORTIE Noir gt B POWER TERM Marron gt 1 Dudes gt SORTIE POLARITE Drange gt 3 POWER TERM POLARITY SELF ZINDUCTOR Jaune gt 4 Vert gt 5 THERMAL ARC 22 GMS WIRING DIAGRAM TITRE T
3. USER S MANUAL THERMAL ARC 170 GMS THERMAL AIRC 220 DK Date 15 10 2009 10 DESCRIPTION OF THE BACK PANEL ITEM DESCRIPTION Switch ON OFF 11 MMA STICK WELDING Connect the power source to the main supply and the ground as explained in the chapter Setting up as para 6 and 7 Connect the ground cable and the electrode holder to the appropriate power connections F15 and F16 according to the electrode polarity being used refer to the electrodes manufacturer s datasheets The torch s polarity connection F17 is not connected Start up the power source with the main switch ON OFF B1 Select MMA stick welding mode with the setting key F6 the indicator F14 illuminates Adjust welding current with potentiometer F1 Note For THERMAL ARC 170 GMS unit the welding current can be adjusted until 150A maximum The graduation between 150A to 200A is not available Place the electrode on the piece you have to weld in order to strike the arc Arc force control Arc force control is not adjustable but it is optimised for welding with a large range of rutile and basic electrodes USER S MANUAL Page 16 30 THERMAL ARC 170 GMS THERMAL THERMAL ARC 220 GMS DK Date 15 10 2009 12 TIG WELDING Connect the unit Connect the power source to the main supply and the ground as explained in the chapter Setting up as para 6 and 7 Connect the
4. Make sure that all metal pieces that the operator could touch with a non insulated part of his body head hands without gloves on naked arms is properly grounded with a conductor of at least equivalent section to the biggest supply cable of the ground clamp or welding torch If more than one metal ground are concerned they need to be all interlinked in one which must be grounded in the same conditions Unless very special care has been taken do not proceed with any arc welding or cutting in USER S MANUAL Page 8 30 THERMAL ARC 170 GMS THERMAL AIRC arc 220 GMs 5875 DK minii conductive enclosures whether it is a confined space or the welding machine has to be left outside Be even more prudent when welding in humid or non ventilated areas and if the power source 15 placed inside Decree dated 14 12 1988 Art 4 2 3 INTERVENING Before carrying out any internal checking or repair work check that the power source has been separated from the electrical installation by locking and guard devices The current plug has to be taken out Provisions have to be taken to prevent an accidental connection of the plug to a socket Cut off through a fixed connecting device has to be omnipolar phases and neutral It is in the OFF position and cannot be accidentally put into operation Maintenance works of electrical equipment must be entrusted to qualified people Section VI Art 46 2 4 MAINTENANC
5. THERMAL ARC 170 GMS THERMAL AIRC 220 DK 4 GENERAL CHARACTERISTICS The single phase power sources THERMAL ARC 170 GMS and 220 GMS have been designed as integrated and portable units using the latest techniques in power electronics based on an IGBT controlled inverter process which enables the following aconsiderable reduction of weight and volume the dynamic control of the welding current ahigh power in a small space at a very low power consumption With their innovative design these machines are both robust plastic front and back panel new internal conception and ergonomic The THERMAL ARC 170 GMS and 220 GMS units are multiprocess DC inverters wich allow MMA welding stick welding with coated electrodes until 4 mm 170 GMS or 5 mm 220 GMS TIG welding with infusible electrodes Ignition made with PAE lift arc process 2 stroke or 4 stroke mode Post gas adjustment Down slope time adjustment Gas purge MIG welding wire feeder built in 15 kgs spools steel wire stainless steel wire of diameter 0 6 mm to 1 0 mm 170 GMS or 1 2 mm 220 GMS direct or reverse polarity of the wire 2 stroke or 4 stroke mode Post gas adjustment Cold wire inch Burn back adjustment Inductor linear adjustment Spot MIG welding with adjustment of the spot s time Intermittent MIG welding with adjustment of the spot s time and of thei
6. __ 9 14 U10000 _ Wire feeding unit without motor _____ The wire feeding unit consists of one pressure feed roll at the top usable for all the wires and one grooved feed roll Item 2 at the lower which have to be adapted to the nature of the wire and to its diameter It is essential that the spool be fitted with the appropriate feed rolls so as to provide the best welding and spooling conditions Each grooved feed roll is designed to weld 2 different diameters To change diameter the feed roll is just turned round The feed roll mounted as standard on delivery are designed to weld steel stainless steel wire triangular groove in V 0 6 or 0 8 mm in diameter by turning the feed roll Another feed roll is supplied for steel wire of 0 8 or 1 0 mm in diameter opooling of aluminium wires For aluminium wire semicircular grooved in U feed rolls are available as options in diameters 0 6 0 8 mm and 0 8 1 0 mm These type of feed rolls are recommended for spooling of aluminium wires since they prevent deformation or crushing of the wire Heplacing the feed rolls Release the pressure of the upper feed roll using knob of the fixing shaft Item 6 Undo the fixing cap Item 1 of the lower feed roll Remove the lower feed roll Item 2 and turn it or fit a different feed roll in its place Engage the feed roll well down onto the gear wheel Item 3 Refit the fixing cap Item 1 Refit the pressure of
7. connected to the network can come into contact with the operator The welder must always wear an individual insulating protection decree of 14 12 1988 article 3 3 Protective clothing gloves aprons safety shoes offer the additional advantage to protect the operator against burns caused by hot pieces and spatter This protective equipment should be kept in good order and checked on a regular basis USER S MANUAL Page 9 30 Notice NOT 077 THERMAL ARC 170 GMS IHERMAL SAFETY 3 1 2 FACE AND EYES It is absolutely necessary to protect your eyes against arc rays Protect your hair and your face against sparks The welding shield with or without headset is always equipped with a proper filter according to the arc welding current NS S 77 104 88 221 A 88 222 standards In order to protect shaded filter from impacts and sparks you have to add a plain glass in front of the shield The helmet provided with your equipment if requested is equipped with a protective filter When you want to replace it precise the reference and number of opacity degree of the filter Use the shade of lens as recommended in the instruction manual opacity graduation number Protect others in the work area from arc rays by using protective booths UV protective goggles and if necessary a welding shield with appropriate protective filter on NF S 77 104 by A 1 5 Opacity gradation numbers and recommended use for arc we
8. 13 110000 Wirefeeding unit without motor ______ U2100 Complete wirefeederunt 14 TO200 Transformer 100VA 48V 16 J15021 4 P9005 18 F0401 X F1808 AdaptatoF12 100 M3 8BBSP 6000 X CommutatnrONOFF 02 20 1600 21 7815 lIHnductor 7 106021 MIG 02 V01003 Fan 120 120 220 Vac THERMAL ARC 170GMS V01008 Fan 120 120 12 THERMAL ARC 220GMS 1209 MainPCB THERMAL 1700 5 Eti2204 THERMALARC2200MS 26 120030 9 Spoolsuppotwihhscrew Panel 28 106036 3005 29 A2002 Lockfodor 390 C604227 WieinletforEUROconnectr 32 _ 0502 Site 060154 Male plug 35 50 mm 61221 USER S MANUAL THERMAL ARC 170 GMS THERMAL RC THERMAL ARC 220 GMS lt ET UNITE DE DEVIDAGE 121030 COMPLETE WIRE FEEDING UNIT U21030 USER S MANUAL THERMAL ARC 170 GMS THERMAL AIRC THERMAL arc 220 5 DK MAINTENANCE DESCRIPTION U45854 E 045806 Feedroll diam 0 6 0 8 groove V gt niet wre gue 5 045853 _ Stainless steel bearing 6 030000 jFiingshat 5 5 8 045417 jWirguidetbe
9. Push on the trigger Raise the torch slowly The arc strikes according to the cycle described hereunder NOTE When the tungsten electrode comes into contact with the workpiece the current is maintained in a low value till the electrode lifts up in order to avoid tungstens penetration Purge the gas If necessary connect the TIG torch on the EURO connector F18 and do it up to the end of the threads and start up the power source with the main switch ON OFF B1 Depress the setting key F4 the indicator F8 illuminates This operation evacuates the air wich is still in the pipes inside the machine Depress the key F4 to stop this operation USER S MANUAL Page 17 30 THERMAL ARC 170 GMS THERMAL THERMAL ARC 220 GMS DK Date 15 10 2009 13 MIG WELDING 13 1 PREPARATION FOR WELDING WITH THE MIG TORCH Connect the unit Connect the power source to the main supply and the ground as explained in the chapter Setting up as para 6 and 7 Connect the ground cable and the torch s polarity connection F17 to the power connection F15 and F16 regarding to the type of wire used Connect the gas supply Open the valve of the bottle for a moment to remove any impurities Fit the flow control valve flow from 5 to 8 to the output of the bottle and its pipe Connect the gas pipe at the rear of the machine at the gas input B2 Open the bottle Choose the wire feeding unit Open the door Put the s
10. ground cable to the power connection F15 and the torch s polarity connection F17 to the F16 Connect the torch in the EURO connector F18 and do it up to the end of the threads Connect the gas supply Open the valve of the bottle for a moment to remove any impurities Fit the flow control valve flow from 5 to 8 to the output of the bottle and its pipe Connect the gas pipe at the rear of the machine at the gas input B2 Open the bottle Set TIG parameters Start up the power source with the main switch ON OFF B1 TIG welding mode Select TIG welding mode with the setting key F6 the indicator F12 illuminates Adjust welding current with potentiometer F1 2 stroke or 4 stroke mode If the indicator F11 is OFF 2 stroke mode is selected Select 4 stroke mode with the setting key F5 the indicator F11 illuminates Post gas Depress the setting key F6 for more than 3 seconds the indicator F12 flickers and adjust the post gas with the potentiometer F1 The post gas can be adjusted from 0 to 10s Release the key when setting is finished Down slope time Adjust the down slope time from 0 to 16s with the potentiometer F2 Welding current Adjust the welding current with the potentiometer F1 Note For THERMAL ARC 170 GMS unit the welding current can be adjusted until 150A maximum The graduation between 150A to 200A is not available Welding Put the tungsten electrode in direct contact with the workpiece
11. in the use and maintenance of electrical welding and cutting equipment Thermadyne will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the warranty period The warranty period begins on the date of sale to the end user Thermal Arc 170 220 GMS Component Warranty Period Power Source 2 Years Optional Remote Controls 6 Months warranty is being sought Please contact your Thermadyne product supplier for the warranty repair procedure Thermadyne warranty will not apply to e Equipment that has been modified by any other party other than Thermadyne s own service personnel or with prior written consent obtained from Thermadyne Service Department Equipment that has been used beyond the specifications established in the operating manual Installation not in accordance with the installation operating manual Any product that has been subjected to abuse misuse negligence or accident Failure to clean and maintain including lack of lubrication maintenance and protection the machine as set forth in the operating installation or service manual Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation This manual also offers basic troubleshooting operational and technical details including application usage You may also wish to visit our web site www thermadyne com select your product class and the
12. the upper feed roll using knob of the fixing shaft Item 6 Place the wire in the wire feeding unit Release the pressure of the upper feed roll using knob of the fixing shaft Item 6 Engage the wire in the inlet guide Item 4 then in the groove of the feed roll finally in the wire inlet of the EURO connector F16 until the wire comes out of the connector USER S MANUAL Page 25 30 THERMAL ARC 170 GMS THERMAL AIRC 220 DK 18 TROUBLE SHOOTING BEWARE BEFORE ANY INTERNAL INTERVENTION disconnect the power source from the power supply Internal voltages are high and dangerous ALL INDICATORS OFF SUPPLY Defective ON OFF main switch INDICATOR F7 WARMING UP Duty cycle over rated particulary if Let the machine cool it will automatically start again ambient t is gt 256 Wrong electrode or wire polarity Use the right polarity according to the indications of electrode s manufacturer Check the torch s connection No ignition Check the TIG torch s trigger Check that the torch s connection output is connected to the power terminal No wire feeding Check the MIG torch s trigger No gas present at machine inlet Check the gas supply No gas supply at machine outlet Check the gas valve USER S MANUAL Page 26 30 19 WIRING DIAGRAMS sea Cae bs ELECTROVANNE GAS VALVE Ed 2 I 702002 4 1 PLATINE DE FACADE FRONT PANEL PCB
13. 2 Maintenance of the arc weldine equipments 7 1 22 Me ITE S CODO S 7 224 Eguimoten adL E A A 7 122232 Of the 8 12252502 5crcenmo and SHICICING ui eene actio corre v 8 ZEN DE D E 4 Or YE DU dep E E 8 2 1 CONNECTION OF THE WELDING POWER SOURCE TO THE NETWORK n 9 2e WORKING AREA auc ntu 9 IN DIA DET 9 9 2 95 na ERU 9 INDIVIDUAT PROTEC LION 9 Sale 555 99 dpt teer ptt pde gt EA 9 3 1 1 BOD E SE 9 3 1 2 ACE A INTE YE 10 3522 RISKOFINFERNALINJURIE 5 __ oath 10 3 3 SAFETY IN THE USE OF
14. E Check the good state insulation and connection of all the equipment and electrical accessories plugs and flexible supply cables cables NF A 32 510 conduits connectors extension cables NF A 85 610 and CENELEC HD 433 sockets on the power source ground and electrode holder clamps NF A 85 600 These connections and mobile accessories are marked according to standards if consistent with the safety rules They can either be controlled by you or by accredited firms Maintenance and repair works of conduits and liners have to be properly carried out Section VI Art 47 Repair or replace all defective accessories Check periodically that the electrical connections are tightened and do not heat 2 5 RISKS OF FIRE AND EXPLOSION Welding can occur risks of fire or explosion You have to pay attention to fire safety regulation Remove flammable or explosive materials from welding area Always have sufficient fire fighting equipment Fire can break out from sparks even several hours after the welding work has been finished 3 INDIVIDUAL PROTECTION 3 1 RISK OF EXTERNAL INJURIES 3 1 1 THE WHOLE BODY Arc rays produce very bright ultra violet and infra red light They will damage yours eyes and burn your skin if you are not properly protected The welder is dressed and protected according to the constraints his works impose him Insulate yourself from the workpiece and the ground Make sure that no metal piece especially those
15. GASES welding with TIG inert gases 11 3 3 1 COMPRESSED GAS CYLINDERS eb e uer Gba ow cu 11 332 PRESSUBE BBLIEE VIS bin vd qued ud Boe bea t ed aus 11 3 3 3 POE TEATS ABOUT GASE 11 DESCRIPTION 12 5 TECHNICAL CHARACTERISTICS 13 SETTING UP 6 CONNEC HON TO THE SUPPLE Y 14 USER S MANUAL Page 3 30 THERMAL ARC 170 GMS THERMAL AIRC arc 220 GMs 8879 DK Te 14 5 lt 552 14 9 DESCRIPTION OF THE FRONT PANEL 2522224 e cH e eara epa 15 10 DESCRIPTION OF THE BACK PANEL ioi 5 16 CD 16 12 rec 17 19 5 2
16. HERMAL ARC 22 GMS Indice Document REV 102 Date 16 11 2005 08 48 18 ELEKTROSTA S fi 225 69515 UnULX VELIN Cedex FRANCE Bleu gt 6 Violet gt 7 Gris gt 5 Blanc gt 8 20 APPENDICE ADJUSTABLE VALUES FOR WELDING PARAMETERS THERMAL ARC 170GMS THERMAL ARC 220GMS stick welding Welding current range 310150 3 to 200 TIGweldng AA A Welding current range 7 30150 7 359000 Postgas Otoio 000 O Downsoe 868 006 006 2 l Arc voltage 14 to 28 14 to 28 1to 15 1 to 15 tO 008 Burnback m 00400 0040 Spo slegh 70025 0025 Time between 2 spots s 0025 0025 IHERMAL RC THERMADYNE INDUSTRIES reserve the right to make changes without previous notification Illustrations descriptions and Thermadyne Industries Ltd U K Chorley England Tel 44 01257 261 755 Fax 44 01257 224 802 Thermadyne Industries Ltd Netherlands Hoofddorp Holland Tel 31 23 561 4182 Fax 31 23 565 5074 Thermadyne Industries Ltd Italia Milan Italy Tel 39 039 204 991 Fax 39 039 204 9922 PTA Plasmatechnik Germany Westerburg Germany Tel 49 2663 915666 Fax 49 2663 915667 characteristics are not contractually binding and do not engage the responsability of the manufacturer
17. THERMAL ARC 170 GMS THERMAL ARC 220 GMS USER S MANUAL The machine you have just acquired taken aduautages ta ito production of Thermal wide experience ia the manufacturing of welding machines aloug with the latest technology 90442 ta power electronics 72 ull give you entire satisfaction for years amp you respect all the operating aud maintenance tartructions given ta this manual We strongly suggest you read very carefully chapters concerning safety aud individuaal We thank you tu advance your co operation THERMADYNE INDUSTRIES reserve the right to make changes without previous notification Illustrations descriptions and characteristics are not contractually binding and do not engage the responsability of the manufacturer USER S MANUAL Page 2 30 THERMAL ARC 170 GMS THERMAL THERMAL ARC 220 GMS Rev 04 DK WARRANTY POLICY STATEMENT SAFETY 50 EENEN 6 LI DECLARATION OOPCONEORMIEDY 6 k2 es 6 24 IVT INO ABER 5 255 5 1 2 2 METHODS OF REDUCING EMISSIONS 2 122221 Pubie supply syste Meere 7 1 2 2
18. cording to national regulations 1 2 2 6 Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applications 2 ELECTRIC SAFETY 21 CONNECTION OF THE WELDING POWER SOURCE TO THE NETWORK Before connecting your equipment you must check that The meter the safety device against over currents and the electric installation are compatible with the maximum power and the supply voltage of the welding power source refer to the instructions plates The connection either single phase or three phase with earth can be effected on a socket compatible with the welding power source cable plug If the cable is connected to a fixed post the earth if provided will never be cut by the safety device against electric shocks The ON OFF switch if exists situated on the welding power source is turned off 2 2 WORKING AREA The use of arc welding implies a strict respect of safety conditions with regard to electric currents Decree dated 14 12 1988 It is necessary to check that no metal piece accessible to the operators and to their assistants can come into direct contact with a phase conductor and the neutral of the network In case of uncertainty this metal part will be connected to the earth with a conductor of at least equivalent section to the largest phase conductor
19. dditional protection measures h The time of day that welding or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises 1 2 2 METHODS OF REDUCING EMISSIONS 1 2 2 1 Public supply system Arc welding equipment should be connected to the public supply system according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the public supply system Consideration should be given to shielding the supply cable of permanently installed arc welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure 1 2 2 2 Maintenance of the arc welding equipment The arc welding equipment should be routinely maintained according to the manufacturers recommendations All access and service doors and covers should be closed and properly fastened when the arc welding equipment is in operation The arc welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc str
20. ding mode Welding CAUTION Before welding check that the intermittent MIG welding is selected indicator F9 ON Depress the torch s trigger in order to start welding When holding on the trigger you will do the welding cycles defined with parameters adjusted above Release the trigger to stop the cycle USER S MANUAL Page 21 30 THERMAL ARC 170 GMS THERMAL AIRC 220 DK 16 MAINTENANCE CAUTION BEFORE OPENING the unit disconnect the power source from the mains Voltages are high and dangerous inside the machine In spite of their robustness THERMAL ARC power sources require some regular maintenance Once every 6 months more often in dusty surroundings the machine must be blown through with dry oilfree compressed air check all connections for electrical continuity Check all cable connections including ribbon cables 17 SPARE PARTS USER S MANUAL THERMAL ARC 170 GMS THERMAL AIRC 220 MAINTENANCE REFERENCE DESCRIPTION 106002 Chassis Bottom of the front face Power terminal 35 50 WE 060153 4 B0600 Cable anchorage 5 6048 EURO connector 6 Knob diam 14 Knob diam 23 8 B00012 TH Front fascia 4106013 Black front frame Front face 328 170GMS Front face 328 220GMS Ene 12 02103031 Motorwithout wire feeding unit
21. essed gas cylinders are potentially dangerous Refer to suppliers for proper handling procedures No impact secure the cylinders and keep them away from impacts No excess heat over 50 C 3 3 2 PRESSURE RELIEF VALVE Check that the pressure relief screw is slackened off before connecting to the cylinder Check that the union is tight before opening the valve of the cylinder Open it slowly a fraction of a turn If there is a leak NEVER tighten a union which is under pressure but first close the valve on the cylinder Always check that hoses are in good condition 3 3 3 DETAILS ABOUT GASES Gas and gaseous mixtures containing less than 20 of If these gases or mixtures take the place of the oxygen in the air there is a danger of asphyxia An atmosphere containing less than 1796 oxygen is dangerous hydrogen and hydrogen based combustible gaseous mixtures These are very light gases In the case of leaks they collect under the ceiling Provide for ventilation at ceiling level These are also inflammable gases The flame of hydrogen is almost invisible There is therefore a risk of burns Air hydrogen and oxygen hydrogen mixtures are explosive in the following proportions 4 to 74 5 96 of hydrogen in air 4 to 94 96 of hydrogen in oxygen Store the bottles in the open or in a well ventilated place Avoid any leakage by limiting the number of connections or couplings to a minimum USER S MANUAL Page 11 30
22. et a high risk of electric shock through the chassis of the unit remains possible 8 PRELIMINARY PRECAUTIONS For the good operation of your welding power source make sure that the air flow produced by the fan inside the unit is not obstructed Also try to operate in a non dusty area Avoid all impacts exposure to damp areas or excessive temperatures USER S MANUAL Page 14 30 THERMAL ARC 170 GMS THERMAL AIRC 220 DK Date 15 10 2009 9 DESCRIPTION OF THE FRONT PANEL 5 DESCRIPTION ITEM DESCRIPTION Knob for intensity wire soeed and TIG welding indicator or TIG post gaz parameters in adjustment indicator Knob for voltage and down slope time MIG welding indicator or MIG post gaz in adjustment indicator Knob for linear inductor 14 _ welding indicator T gaz purge cold wire inch Burn back adjustment stroke welding mode intermittent MIG welding or spot MIG welding F6 Setting key for selecting welding mode Torch s polarity connection Overheat indicator Torch s EURO connector bli 53d Burn back adjustment indicator gun intermittent MIG welding indicator or Switch wire feeder built in or spool time between two spots in adjustment gun indicator eee time adjustment indicator SSS SS SS SSS Indicator 4 stroke welding
23. iking and stabilising devices should be adjusted and maintained according to the manufacturer s recommendations 1 2 2 9 Welding cables The welding cables should be kept as short as possible and should be positioned close together running at or close to the floor level 1 2 2 4 Equipotential bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered USER S MANUAL Page 7 30 Notice NOT 077 THERMAL ARC 170 GMS IHERMAL SAFETY However metallic components bonded to the work piece will increase the risk that the operator could receive an electric shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components 1 2 2 5 Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected ac
24. lding Current intensity in Amps Welding process or OS 222 10 20 40 80 125 175 225 215 350 450 connected techniques 1 5 15 30 60 100 150 200 250 300 400 500 L9 fio 1 Poo u 12 13 _ Depending on the conditions of use the next highest lowest category number may be used The expression heavy metals covers steels alloyed steels copper and its alloys The shaded areas represent applications where the welding processes are not normally used at present CARE Use a higher degree of filters if welding is performed in premises which are not well lighted 3 2 RISK OF INTERNAL INJURIES GASES AND FUMES Gases fumes produced during the welding process can be dangerous and hazardous to your health Arc welding works have to be carried out in suitable ventilated areas Ventilation must be adequate to remove gases and fumes during operation All fumes produced during welding have to be removed as soon as they are given off and as close as possible from the place they are produced to be the most efficient Vapors of chlorinated solvents can form the toxic gas phosgene when exposed to ultraviolet radiation from an electric arc USER S MANUAL Page 10 30 THERMAL ARC 170 GMS THERMAL THERMAL ARC 220 GMS DK SAFETY LE 3 3 SAFETY IN THE USE OF GASES WELDING WITH TIG OR MIG INERT GASES 3 3 1 COMPRESSED GAS CYLINDERS Compr
25. n select literature Here you will find documentation including e Operator manuals e Service manuals e Product guides Alternatively please contact your Thermadyne distributor and speak with a technical representative NOTE Warranty repairs must be performed by either Thermadyne Service Centre a Thermadyne distributor or an Authorised Service Agent approved by the Company September 2009 USER S MANUAL Page 5 30 THERMAL ARC 170 GMS THERMAL THERMAL ARC 220 GMS Rev 04 DK minii The equipment you have just acquired will give you entire satisfaction if you respect the operating and maintenance instructions Its design the specification of the components and its manufacture are in accordance with the existing rules French standards NF ISO and international injunctions EEC general lines CEN CENELEC standards In this chapter you will find safety rules in the use of electric arc welding power sources with coated electrodes We give you hereunder a list of recommendations and obligations you have to respect Safety rules must be observed and particularly those relating to Decree 88 1056 dated November 14 1988 concerning protective measures against electrical currents 1 ELECTROMAGNETIC COMPATIBILITY 11 DECLARATION OF CONFORMITY THERMADYNE Industries hereby declare that the machine object of this manual complies with the following European regulations Electromagnetic compatibili
26. ng an electromagnetic screen enclosing the welding power source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome NOTE The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorised by a person who 15 competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Further guidance 15 given in IEC 62081 Arc welding equipment Installation and use under consideration 1 2 1 ASSESSMENT OF AREA Before installing arc welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the arc welding equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment e g guarding of industrial equipment e The health of the people around e g the use of pacemakers and hearing aids f Equipment used for calibration or measurement g The immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require a
27. r frequency These power sources offer exceptional arc stability Easy to use they can be adjusted exactly to your need They have a linear electronic inductor wich allows total variation of the arc soft or hard and limits the amount of spatter They have adjustable burn back wich allows the adjustment of the wire s length after the torch s head at the end of the welding They are perfectly suited to the MIG welding with aluminium wire USER S MANUAL Page 12 30 THERMAL ARC 170 GMS THERMAL AIRC 220 DK 5 TECHNICAL CHARACTERISTICS DIMENSIONS in mm EJEEJETEJEJETETETETETETETETETETET X Loa 5 4 PRIMARY THERMAL ARC 170 GMS THERMAL ARC 220 GMS 5 2 2 Single phased power supply Frequency Maximum primary current Maximum power consumption Power factor cos Primary protection SECONDARY 50 60 15 80 1 3 150 3 200 Off load voltage Welding cu
28. ress the setting key F4 the indicator F8 illuminates This operation inches the wire Depress the key F4 to stop this operation USER S MANUAL Page 18 30 THERMAL 170 GMS Notice 077 THERMAL AIRC 220 DK Date 15 10 2009 13 2 PREPARATION FOR WELDING WITH THE SPOOL GUN Connect the unit Connect the power source to the main supply and the ground as explained in the chapter Setting up as para 6 and 7 Connect the ground cable and the torch s polarity connection F17 to the power connection F15 and F16 regarding to the type of wire used Connect the gas supply Open the valve of the bottle for a moment to remove any impurities Fit the flow control valve flow from 5 to 8 to the output of the bottle and its pipe Connect the gas pipe at the rear of the machine at the gas input B2 Open the bottle Choose the wire feeding unit Open the door Put the switch F20 on position spool gun Connect the spool gun Connect the spool gun on the female socket F19 13 3 ADJUSTMENT OF THE PARAMETERS MIG welding mode Select MIG welding mode with the setting key F6 the indicator F13 illuminates 2 stroke or 4 stroke mode If the indicator 11 is OFF 2 stroke mode is selected Select 4 stroke mode with the setting key F5 the indicator F11 illuminates Post gas Depress the setting key F6 for more than 3 seconds the indicator F13 flickers and adju
29. rrent range 1 Welding current at 40 C Welding current at 15 Welding current at 20 Welding current at 35 Welding current at 60 Welding current at 100 Eos i __ 220 150 L4 doom _ EE ONES 200 105 170 95 150 Welding currentat 15 A Weldingcurrentat 20 A 150 Welding currentat 35 A Welding currentat 60 A 105 Weldingcurrentat 100 A 9 Welding current at 25 C Welding current 60 96 Welding current 100 eee Proectiondegree IPB Insulation class _____ ________ Standards 12 EN 60974 1 EN 50199 USER S MANUAL THERMAL ARC 170 GMS THERMAL AIRC 220 DK gt 6 CONNECTION TO THE MAIN SUPPLY The power source must be connected to a single phase 230V 50 Hz 60 Hz mains ground Main supply must be protected by fuses or circuit breaker according to the value written on the specifications of the power source It is strongly suggested to use a differential protection for the operator s safety 7 CONNECTION TO THE GROUND For the operator s protection the power source must be correctly grounded according to the International Protections Norms It is absolutely necessary to provide a good ground connection installation with the green yellow lead of the power cable This will avoid discharges caused by accidental contact with grounded pieces If no earth connection has been s
30. st the post gas with the potentiometer The post gas can be adjusted from 0 to 8s Release the key when setting is finished Wire speed Adjust the wire speed from 1 to 15 m min with potentiometer Arc voltage Adjust the arc voltage from 14V to 28V with the potentiometer F2 Inductance Adjust the inductance value with the potentiometer F4 in order to adapt it to the arc you need and to limit the spatter Burn back This parameter adjusts the wire length after the torch s head at the end of the welding Depress the setting key F4 for more than 3 seconds the indicator F8 flickers and adjust the burn back with the potentiometer F1 The burn back can be adjusted from 0 to 400 ms Release the key when setting is finished USER S MANUAL Page 19 30 THERMAL ARC 170 GMS THERMAL THERMAL ARC 220 GMS DK Date 15 10 2009 14 SPOT MIG WELDING Read the instructions for the preparation of the generator given in para 13 1 Adjustment of the parameters Spot MIG welding mode Select MIG welding mode with the setting key F6 the indicator F13 illuminates Select MIG spot welding mode with the setting key F5 the indicator F10 illuminates Spot time Depress the setting key F5 for more than 3 seconds the indicator F10 flickers and adjust the spot time with the potentiometer F1 The spot time can be adjusted from 0 to 2 5s Release the key when setting is finished Others parame
31. ters Adjust the others parameters as described in para 13 2 except 2 stroke 4 stroke mode not available in this type of welding mode Welding Depress the torch s trigger in order to start welding The arc dies out after the spot time Relax and depress the trigger to start a new spot time 15 INTERMITTENT MIG WELDING Read the instructions for the preparation of the generator given in para 13 1 Adjustment of the parameters Spot time Select MIG spot welding mode with the setting key F5 the indicator F10 illuminates Depress the setting key F5 for more than 3 seconds the indicator F10 flickers and adjust the spot time with the potentiometer F1 The spot time can be adjusted from 0 to 2 5s Release the key when setting is finished Intermittent MIG welding mode Select MIG welding mode with the setting key F6 the indicator F13 illuminates Select Intermittent MIG welding mode with the setting key F5 the indicator F9 illuminates Time between 2 spots Depress the setting key F5 for more than 3 seconds the indicator F9 flickers and adjust the spot time with the potentiometer F1 The spot time be adjusted from 0 to 2 5s Release the key when setting is finished USER S MANUAL Page 20 30 THERMAL ARC 220 GMS THERMAL ARC 170 GMS IHERMAL Others parameters Adjust the others parameters as described in para 13 2 except 2 stroke 4 stroke mode not avalaible in this type of wel
32. ty Rule 89 336 EEC of 3 05 89 modified by rules 92 31 EEC of 28 04 1992 and 93 68 EEC of 22 07 1993 Low voltage Rule 73 23 EEC of 19 02 1973 modified by rule 93 68 of 22 07 1993 and with the national legislation transposing them THERMADYNE Industries also declare that following harmonised standards have been applied EN 50199 1995 Electromagnetic compatibility CEM Product norm for arc welding material EN 50060 1990 Current source for arc manual welding with limited service EN 60974 1 Security rules for electric welding material Part 1 welding current sources EN 50192 1995 Arc welding material plasma cutting systems 1 22 INSTALLATION AND USE The machine object of this manual complies with the European regulations about electromagnetic compatibility 89 336 CEE It also complies with 50199 standard Electromagnetic compatibility product standard for welding machines The user is responsible for installing and using the arc welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the arc welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the welding circuit see Note In other cases it could involve USER S MANUAL Page 6 30 THERMAL ARC 170 GMS IHERMAL SAFETY constructi
33. witch F20 on position MIG torch Fitting the feed rolls Place the fitted feed rolls in the wire feeding unit according to the instructions given chapter 17 It is essential that the spool be fitted with the appropriate feed rolls so as to provide the best welding and spooling conditions Setting up of the wire in the spool please see the spare parts lists of the machine in chapter 1 7 You can use wire s type steel stainless steel aluminium wire of diameters from 0 6 mm to 1 0 mm Undo the retaining screw of the spool screw on Item 26 Engage the spool on its support Item 26 taking care to position the rod of the spool brake correctly The spool must be mounted so that the wire is spooled from below The firmness of the spool brake can be adjusted using the central screw located behind the screw Item 26 This system allows the motion of the spool to be stopped at the end of spooling preventing it from rotating further This is vital when one is spooling at high speeds Nevertheless the spool should not be braked excessively in order not to overload the motor Re fit the retaining screw screw on Item 26 Engage the wire in the wire feeding unit according to the instruction given chapter 17 and let it go out the EURO connector F18 Inch the wire If necessary connect the MIG torch on the EURO connector F18 and do it up to the end of the threads and start up the power source with the main switch ON OFF B1 Dep
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