Page 1
SGI 100
ARCMASTER
SPOOL GUN INTERFACE
Instruction Manual
Revision: AA Issue Date: May 1, 2008 Manual No.: 0-5061
Operating Features:
Page 2
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud
to have you as our customer and will strive to provide you with
the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call
1-800-426-1888, or visit us on the web at www.Thermalarc.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
Page 3
!
WARNINGS
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 the Manufacturer’s best judgement,
the Manufacturer assumes no liability for its use.
ArcMaster SGI 100 Spool Gun Interface
Instruction Manual Number 0-5061 for:
Catalog Numbers: SGI 100 Interface Box W4009115
Tweco 90939 Spool Gun Package W3100100
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2008 by
Thermadyne Industries Inc.
All rights 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 party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident, or
any other cause.
Publication Date: May 1, 2008
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
i
Page 4
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 Principal Safety Standards .............................................................................. 1-4
1.03 Symbol Chart .................................................................................................. 1-5
1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6
1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6
1.06 Principales Normes De Securite ..................................................................... 1-9
1.07 Graphique de Symbole .................................................................................. 1-10
SECTION 2:
INTRODUCTION ..................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Symbol Chart .................................................................................................. 2-2
2.05 Description ..................................................................................................... 2-3
2.06 Specifications ................................................................................................. 2-3
2.07 Control Cable Amphenol Plug Pin-Out Diagram .............................................. 2-4
2.08 Dimensional View ........................................................................................... 2-4
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Connections .................................................................................................... 3-1
3.02 SGI 100 Mounting Bracket .............................................................................. 3-2
3.03 Mounting the Bracket to the SGI 100 .............................................................. 3-2
3.04 Mounting the SGI 100 Bracket Assembly to the Power Supply ....................... 3-3
SECTION 4:
OPERATION .......................................................................................... 4-1
4.01 Front Panel ...................................................................................................... 4-1
4.03 Rear Panel ....................................................................................................... 4-2
4.03 Prewelding Procedure ..................................................................................... 4-2
4.04 Welding Procedure ......................................................................................... 4-2
Page 5
TABLE OF CONTENTS (continued)TABLE OF CONTENTS
SECTION 5:
TROUBLESHOOTING ................................................................................ 5-1
5.01 Scope .............................................................................................................. 5-1
5.02 Safety .............................................................................................................. 5-1
5.03 Troubleshooting Hints ..................................................................................... 5-1
5.04 Troubleshooting Guide .................................................................................... 5-2
SECTION 6:
PARTS LIST ........................................................................................... 6-1
6.01 Equipment Identification ................................................................................. 6-1
6.02 How To Use This Parts List ............................................................................. 6-1
6.03 SGI 100 Relacement Parts .............................................................................. 6-2
APPENDIx 1: SYSTEM SCHEMATIC ...................................................................... A-1
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ........................... Inside Rear Cover
Page 6
Page 7
SAFETY INSTRUCTIONS ARCMASTER SGI 100
!
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power
circuit and machine internal circuits are also live when
power is on. In semi-automatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live.
Incorrectly installed or improperly grounded equipment
is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced
cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with AC
output unless it is equipped with a voltage reducer. Use equipment
with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
May 1, 2008 1-1 Manual 0-5061
Page 8
ARCMASTER SGI 100 SAFETY INSTRUCTIONS
WARNING
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSD Ss) and the
manufacturer’s instruction for metals, consumables, coatings,
and cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing
an air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or cutting
Operation
Torch soldering 2
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc
welding
(stick) electrodes
Electrode Size
Metal Thickness
Under 5/32 in., 4 mm 10 Heavy 14
Filter
Shade
Welding or cutting
Operation
Gas metal-arc
welding (MIG)
Non-ferrous base metal All 12
Carbon arc welding All 12
Carbon arc air gouging
Electrode Size
Metal Thickness
Filter
Shade
Manual 0-5061 1-2 May 1, 2008
Page 9
SAFETY INSTRUCTIONS ARCMASTER SGI 100
!
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to treat
them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to prevent
falling or tipping.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open
flames.
3. Allow engine to cool before fueling. If possible, check and add fuel
to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
WARNING
WARNING
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
May 1, 2008 1-3 Manual 0-5061
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
Page 10
ARCMASTER SGI 100 SAFETY INSTRUCTIONS
NOTE
Considerations About Welding And The Effects of Low
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn
face, eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
WARNING
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some
cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing
Office, May 1989): “...there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields and interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results
are complex. Current scientific understanding does not yet allow us
to interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
WARNING
Handling the brass parts of this product will expose you
to lead, a chemical known to the State of California to
cause birth defects and other reproductive harm. Wash
hands after handling.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Manual 0-5061 1-4 May 1, 2008
Page 11
SAFETY INSTRUCTIONS ARCMASTER SGI 100
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Dangerous Voltage
Off
On
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Remote
Duty Cycle
Percentage
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Receptacle RatingAuxiliary Power
Art # A-04130
115V 15A
t
t1
t2
%
X
IPM
MPM
t
V
Fuse
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Preflow Time
Postflow Time
Spot Time
Spot Weld Mode
Continuous Weld
Mode
Press to initiate wirefeed and
welding, release to stop.
Purging Of Gas
Inches Per Minute
Meters Per Minute
Welding Gun
Burnback Time
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
4 Step Trigger
Operation
2 Step Trigger
Operation
1.03 Symbol Chart
Note that only some of these symbols will appear on your model.
May 1, 2008 1-5 Manual 0-5061
Page 12
ARCMASTER SGI 100 SAFETY INSTRUCTIONS
!
1.04 Precautions De Securite En Soudage A L’arc
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUx
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions
de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.05 Dangers relatifs au soudage à l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension dès
la mise en circuit. Le circuit d’alimentation et les circuits
internes de l’équipement sont aussi sous tension dès
la mise en marche. En soudage automatique ou semiautomatique avec fil, ce dernier, le rouleau ou la bobine
de fil, le logement des galets d’entrainement et toutes les
pièces métalliques en contact avec le fil de soudage sont
sous tension. Un équipement inadéquatement installé ou
inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation
afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
Manual 0-5061 1-6 May 1, 2008
Page 13
SAFETY INSTRUCTIONS ARCMASTER SGI 100
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux
et la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives
aux métaux, aux produits consummables, aux revêtements et aux
produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz protecteurs
de soudage peuvent déplacer l’oxygène de l’air et ainsi causer
des malaises ou la mort. Assurez-vous que l’air est propre à la
respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent
réagir avec des vapeurs et former des gaz hautement toxiques et
irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que
si l’espace est bien ventilé; si nécessaire portez un respirateur à
adduction d’air. Car ces revêtements et tout métal qui contient
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
Opération de coupage
ou soudage
Brassage tendre
au chalumeau
Brassage fort
au chalumeau
Oxycoupage métaux ferreux toutes conditions 12
mince moins de 1 po. (25 mm) 2 ou 3
moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5
Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12
mince moins de 1/8 po. (3 mm) 4 ou 5
moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
épais plus de 6 po. (150 mm) 5 ou 6
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Nuance de
filtre oculaire
toutes conditions 2
toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Gougeage Air-Arc avec
électrode de carbone
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
toutes conditions 12
toutes conditions 12
toutes conditions 12
Nuance
de
filtre
épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14
May 1, 2008 1-7 Manual 0-5061
Page 14
ARCMASTER SGI 100 SAFETY INSTRUCTIONS
ces éléments peuvent dégager des fumées toxiques au moment
du soudage.
AVERTISSEMENT
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure
et l’équipement surchauffé peuvent causer un incendie
et des brûlures. Le contact accidentel de l’électrode ou
du fil-électrode avec un objet métallique peut provoquer
des étincelles, un échauffement ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et
d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact
lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
Manual 0-5061 1-8 May 1, 2008
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez l e moteur a v a n t d e vérifier l e niveau e
carburant ou de faire le plein.
Page 15
SAFETY INSTRUCTIONS ARCMASTER SGI 100
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
AVERTISSEMENT
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des
outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR
PEUT BRULER LA PEAU ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour
l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
1.06 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association
canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un
accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
May 1, 2008 1-9 Manual 0-5061
Page 16
ARCMASTER SGI 100 SAFETY INSTRUCTIONS
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Decoupe Arc Carbone
(CAC-A)
Courant Constant
Tension Constante
Ou Potentiel Constant
Haute Température
Force d'Arc
Amorçage de L’arc au
Contact (GTAW)
Inductance Variable
Tension
Mono Phasé
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur
Transformateur-Redresseur
Tension dangereuse
Hors Tension
Sous Tension
Panneau/Local
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Distant
Facteur de Marche
Pourcentage
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
Courant Continue (DC)
Terre de Protection
Ligne
Connexion de la Ligne
Source Auxiliaire
Classement de PriseSource Auxiliaire
Art # A-07639
115V 15A
t
t1
t2
%
X
IPM
MPM
t
Fusible
Déroulement du Fil
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Durée de Pré-Dèbit
Durée de Post-Dèbit
Duréc du Pulse
Soudure Par Point
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Purge Du Gaz
Mode Continu de
Soudure
Pouces Par Minute
Mètres Par Minute
Torch de
Soudage
Probléme de Terre
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
Détente à 4-Temps
Détente à 2-Temps
V
1.07 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Manual 0-5061 1-10 May 1, 2008
Page 17
INTRODUCTION ARCMASTER SGI 100
!
!
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or part
numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention
to the information provided under these headings.
These special annotations are easily recognized as
follows:
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on
a nameplate attached to the control panel. In some
cases, the nameplate may be attached to the rear panel.
Equipment which does not have a control panel such
as gun and cable assemblies is identified only by the
specification or part number printed on the shipping
container. Record these numbers on the bottom of page
i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there is
any damage, notify the carrier immediately to file a claim.
Furnish complete information concerning damage claims
or shipping errors to the location in your area listed in
the inside back cover of this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number
in your area listed in the inside back cover of this manual.
Include the Owner’s Manual number and equipment
identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
May 1, 2008 2-1 Manual 0-5061
Page 18
ARCMASTER SGI 100 INTRODUCTION
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Dangerous Voltage
Off
On
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Remote
Duty Cycle
Percentage
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Receptacle RatingAuxiliary Power
Art # A-04130
115V 15A
t
t1
t2
%
X
IPM
MPM
t
V
Fuse
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Preflow Time
Postflow Time
Spot Time
Spot Weld Mode
Continuous Weld
Mode
Press to initiate wirefeed and
welding, release to stop.
Purging Of Gas
Inches Per Minute
Meters Per Minute
Welding Gun
Burnback Time
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
4 Step Trigger
Operation
2 Step Trigger
Operation
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
Manual 0-5061 2-2 May 1, 2008
Page 19
INTRODUCTION ARCMASTER SGI 100
2.05 Description
The Thermal Arc SGI 100 is a small, portable, light weight, and simple to use interface box that is designed to connect
a Tweco spool gun to a Thermal Arc power supply. The SGI 100 includes a spot weld mode with time adjustment and
a burn-back mode with control adjustment.
The SGI 100 can also connect a Tweco spool gun to any of the constant voltage (CV) DC GMAW welding power sources
listed below. The SGI 100 provides a DC control circuit voltage to the gun/feeder through its 14 pin receptacle.
Welding Power Sources Compatible with the SGI 100
Thermal Arc ArcMaster LM 200
Thermal Arc ArcMaster 300 MST/ 300 MSTP
Thermal Arc ArcMaster 400 MST/ 400 MSTP
Thermal Arc Power Master 350/500
Thermal Arc Power Master 500P
2.06 Specifi cations
Input Voltage 24 VAC
Input Frequency 50/60 Hz
Input Voltage Tolerance +/- 10%
Maximum Input Current 1 A
Welding Current (I) 300 A/X = 60%
DC Control Circuit Voltage 24 vdc
Interface
Features
Dimensions
Weight 2 lb (0.9 kg)
3 ft. (1m) pigtail w/14 pin
Amphenol plug
Spot mode adjustment
Burn-back adjustment
8.75 in. (22 cm) - L
5.00 in. (13 cm) - W
2.38 in. (6 cm) - H
May 1, 2008 2-3 Manual 0-5061
Page 20
ARCMASTER SGI 100 INTRODUCTION
A
J
K B
I
C
L
NH
MG D
E
F
5.0 in. (13cm) 8.75 in. (22cm)
2.38 in.
(6cm)
2.07 Control Cable Amphenol Plug Pin-Out Diagram
Pin A – 24VAC auxiliary supply
Pin B – Input to energize solid state contactor (contact closure between pin A and pin B)
Pin G – 24VAC circuit common, also connected to chassis
2.08 Dimensional View
Manual 0-5061 2-4 May 1, 2008
Page 21
INSTALLATION ARCMASTER SGI 100
3
5
4
1
2
SECTION 3:
INSTALLATION
3.01 Connections
1. Connect a weld cable from the power source to the
work connection.
2. Connect the weld cable from the spool gun assembly
to the positive terminal of the power source.
3. Connect the control cable from the SGI 100 to the
power source
4. Make the proper gas line connection from the gas
supply to the spool gun's gas hose.
5. Attach the spool gun assembly control cable to the
SGI 100 front panel connection.
Figure 3-1: SGI 100 Connections in a Typical System
May 1, 2008 3-1 Manual 0-5061
Page 22
ARCMASTER SGI 100 INSTALLATION
3
1
2
Offset Mounting Tab
on the right
Flush Mounting Tab
on the left
Hanging Rail
facing down
FRONT
3.02 SGI 100 Mounting Bracket
The SGI 100 can be fitted with an optional mounting bracket that is ideally suited to mobile configurations. The bracket
is designed to permanently attach to the SGI 100 while providing a convenient hanging configuration to enable easy
and secure placement on and off the power supply's carrying handle as needed.
The catalog number for this bracket is W4009116. Contact your Thermal Arc dealer to acquire one.
3.03 Mounting the Bracket to the SGI 100
1. Using a philps #2 screwdriver, remove the two enclosure screws located at the bottom center of each side of the
SGI 100 and put aside for re-use.
2. Slide the SGI 100 into position on the bracket by aligning the two vacant enclosure holes with the mounting tabs
on the brackets.
NOTE
Ensure that the bracket's orientation is correct by noting the position of its hanging rails and mounting
tabs in relation to the front of the SGI 100. The bracket can be mounted on either side, but the SGI 100
control cable will only connect to the ArcMaster power source using the configuration as shown. Refer to
illustration below.
3. Insert one of the enclosure screws through the hole in one of the mounting tabs and into the enclosure. Tighten
securely with a philps screwdriver. Repeat this on the other side.
Figure 3-2: Installing the Optional Mounting Bracket
Manual 0-5061 3-2 May 1, 2008
Page 23
INSTALLATION ARCMASTER SGI 100
Spacer (2) Supplied
Supplied
Philips Screw (2)
3.04 Mounting the SGI 100 Bracket Assembly to the Power Supply
1. Remove the two philips head screws from the right side of the ArcMaster power supply as shown below.
2. Tilt the SGI 100 Bracket Assembly to allow the hanging rails to pass underneath the carrying handle of the power
supply. Rotate the assembly to loop the hanging rails around the carrying handle and let the assembly hang against
the right side of the power supply.
3. Lift the assembly slightly and take one of the supplied new screws and pass it through one of the two holes in the
mounting bracket. Place one of the supplied spacers on the screw as it passes through the bracket.
4. Repeat step 3 on the other side.
5. Thread the screws back into their holes in the power supply and tighten securely with a philps screwdriver.
Figure 3-3: Mounting the SGI 100 Bracket Assembly to the Power Supply
May 1, 2008 3-3 Manual 0-5061
Page 24
ARCMASTER SGI 100 INSTALLATION
Manual 0-5061 3-4 May 1, 2008
Page 25
OPERATION ARCMASTER SGI 100
SECTION 4:
OPERATION
4.01 Front Panel
Spot Time Control Burnback ControlSpool Gun Interface
Spot Mode Switch
Protective Cover
Figure 4-1: SGI 100 Front Panel and Controls
Spool Gun Interface
The Spool Gun Interface is a 14-pin amphenol connector
that is used to connect a spool gun to the SGI 100. Refer
to the spool gun manual for the pin confi guration.
Protective Cover
When the spool gun is not being used, thread this cover
on to the Spool Gun Interface to protect it from dust and
moisture.
Spot Mode Switch
This switch turns the spot mode on and off. Spot mode
is a condition in which the wire feeder and power supply
are automatically turned on and off for a predetermined
length of time, as set by the Spot Time Control knob.
Spot Time Control
The spot time welding time period is set by this control
knob. Turning this knob clockwise lengthens the duration
of a single spot weld and turning it counter-clockwise
shortens it.
Burnback Control
Burnback time is the difference between the wirefeed
motor stopping and the welding current ceasing. The
Burnback time allows the electrode wire to burn out of the
molten metal weld pool. Burnback time is adjusted by the
knob labeled "Burnback". Clockwise adjustment increases
the time for the wire to burn back.
Art # A-07466
Figure 4-2: Spot Weld Example
May 1, 2008 4-1 Manual 0-5061
Page 26
ARCMASTER SGI 100 OPERATION
!
4.03 Rear Panel
Circuit Breaker
Control Cable
Control Cable Plug
Figure 4-3: SGI 100 Rear Panel
Control Cable
The control cable connects the SGI 100 to the power
source. After depressing the gun switch on the spool
gun, an internal relay on the SGI 100 provides a closure
between the two wires of the control cable. This closure
is then used to energize the power source.
4.03 Prewelding Procedure
Follow all installation and operating instructions for the
power source and spool gun assembly before attempting
to operate the SGI 100.
1. Make sure all necessary connections have been made
(Refer to the Installation section of this manual).
2. Turn the power source ON.
3. Set the power source to Remote Mode (refer to your
power source manual).
4. Adjust the fl ow of shielding gas to the desired level.
NOTE
The gun switch trigger on the spool gun
assembly will have to be depressed to allow
gas fl ow.
5. Adjust the wire feed speed of the fi ller metal to the
desired value by means of the wire feed speed control
located in the handle of the spool gun assembly.
6. Adjust the voltage of the power source to the desired
value by means of the voltage control located on the
power source.
4.04 Welding Procedure
Control Cable Plug
This is a 14-pin male amphenol plug that connects to the
14-pin socket on the power supplies listed in Section 2.05.
Refer to Section 2.07 for the plug's pin confi guration.
NOTE
Be sure to align the keyways between the plug
and the socket before pushing the plug in.
Circuit Breaker
This 2 amp circuit breaker provides protection against
faults or over loads on the primary side of the circuit.
WARNING
In semi automatic or automatic wire welding,
the welding wire, wire reel (if used), input
guide, feed rolls, output guide, feedhead, and
welding gun metal parts are all ELECTRICALLY
“HOT”.
1. To start the weld, position the spool gun assembly
above the workpiece and depress the gun switch.
Depressing the gun switch enables the gas valve, wire
feed motor, and power source; the welding process
begins.
2. To end the weld, release the gun switch which disables
the gas valve, wire feed motor, and power source.
NOTE
At the end of the work day or when welding
has been completed, it is recommended that
the gas be SHUT OFF at the cylinder, and the
power source be turned OFF.
Manual 0-5061 4-2 May 1, 2008
Page 27
TROUBLESHOOTING ARCMASTER SGI 100
SECTION 5:
TROUBLESHOOTING
5.01 Scope
The troubleshooting guide is to be used by qualified
service technicians. The troubleshooting guide contains
information which can be used to diagnose and correct
unsatisfactory operation or failure of the various
components of the SGI 100. Each symptom of trouble is
followed by a list of probable causes and the procedure
necessary to correct the problem.
5.02 Safety
To ensure safe operation and service, read this entire
manual before attempting to service or repair this
machine. The service technician may be asked to check
voltage levels while the machine is turned ON. To assure
safety, use care and follow all instructions accordingly.
5.03 Troubleshooting Hints
Examine connections for proper assembly and contact
before replacing a component. Wire lugs should be in
tight contact with the lead’s conductor and should be
crimped to the lead’s insulation. The mating surfaces
of the connection should be clean and free of oxidation.
Faulty connections or wiring problems are often the cause
of an equipment malfunction.
Do not pull on wires to disassemble connections. Firmly
grasp each lug or connector when disconnecting. Pulling
on wires for disassembly can damage the integrity of the
connection and cause future malfunctions.
Prior to disassembly or servicing of the machine, note
the wiring and connections in the machine. When
reassembling, place the wires in the same location and
routing as received from the factory. Keep wires and leads
away from hot parts and sharp objects.
All signals referenced in the following troubleshooting
guide can be measured with a digital multimeter
(DMM).
May 1, 2008 5-1 Manual 0-5061
Page 28
ARCMASTER SGI 100 TROUBLESHOOTING
!
5.04 Troubleshooting Guide
WARNING
ELECTRIC SHOCK can kill.
• Follow all safety precautions.
• Do not touch live electrical parts.
• Turn OFF in put power before servicing the
machine unless otherwise noted.
• Only qualified technicians are to service the
machine.
NOTES:
(1) Refer to the Parts List Section and the
Connection/Schematic Diagram in the Appendix
of this manual for graphical assistance in
disassembling and troubleshooting the SGI
100.
A. Unit is completely inoperative - nothing functions.
1. Make sure all connections have been made to
the SGI 100, spool gun assembly, and power
source.
See section 3.01 “Connections” in this manual.
2. Make sure the power source has been turned
ON.
3. Check for damaged control lines that connect
between the SGI 100 and the spool gun
assembly.
4. Check for tripped circuit breaker (CB1) on the
SGI 100.
See Section 4.03 “Rear Panel" in this manual.
5. Check circuit breaker (CB1), amphenol
receptacle (J1), and PC board connectors (JA,
JB, JE) for loose or faulty connections.
B. Spool gun motor operates but wire does not feed
or feeds erratically.
1. Check for incorrect voltage and/or wire feed
speed settings.
2. Make sure all connections to the SGI 100, spool
gun assembly, and power source are tight.
(2) The accept able tolerance (in most cases)
on measurements made with the DMM is
+/- 10%.
(3) Use only genuine Thermal Arc replacement
parts.
3. Check for a restriction in the spool gun
assembly.
C. Wire does not feed with gun switch trigger
depressed.
1. Move the wire feed speed (WFS) control knob
on the spool gun assembly off the minimum
setting.
2. Check for tripped circuit breakers (CB1) on the
SGI 100.
See Section 4.03 “Rear Panel" in this manual.
3. Check for damaged control lines that connect
between the SGI 100 and the spool gun
assembly.
4. Check the functionality of the spool gun
assembly.
See the spool gun assembly owner’s manual.
5. Check all components for loose or faulty
connections.
Manual 0-5061 5-2 May 1, 2008
Page 29
TROUBLESHOOTING ARCMASTER SGI 100
D. Spool gun motor continues to run after gun switch
has been released.
1. Check the functionality of the spool gun
assembly.
See the spool gun assembly owner’s manual.
2. Check for a shorted amphenol receptacle
(J1).
E. Wire feeds but no gas fl ows.
1. Check to see if the gas cylinder is empty or the
valve closed.
2. Make sure the proper gas fl ow rate has been
set.
3. Check for a possible restriction in the gas lines
or gas valve.
4. Check to see if the spool gun assembly nozzle
is plugged.
F. Wire feeds but there is no arc.
1. Check for a damaged control cable (P2) that
connects between the SGI 100 and power
source.
5.05 Circuit Operation Of The Control
PCB 7978050
CONNECTOR JA
Terminal JA-1
trigger input=40VDC trigger open, approx 20VDC
trigger closed
reference JA-5
Terminal JA-2
trigger input=0VDC trigger open, approx 20VDCV
trigger closed
reference JA-5
Terminal JA-3
spot timer pot=12VDCV trigger closed 0VDC
trigger open
reference JA-5
Terminal JA-4
spot timer pot= ramps up to 12V from 0V when
trigger closed
2. Check to make sure that the ground clamp
is properly attached and making adequate
electrical contact.
0VDC when trigger open
reference JA-5
Terminal JA-5
PCB common
Terminal JA-7
over temperature switch=0VDC temp switch
closed, approx 15VDC switch open
reference JA-5
NOTE
These wires are connected by a jumper
May 1, 2008 5-3 Manual 0-5061
Page 30
ARCMASTER SGI 100 TROUBLESHOOTING
CONNECTOR JE
Burnback potentiometer
100k potentiometer between pins
Terminal JE-1
burnback potentiometer 0VDC
reference JA-5
Terminal JE-2
burnback potentiometer approx 13VDC when
trigger on
NOTE
Turn Burnback knob to full on (clockwise).
ramps down to zero after trigger is released
reference JA-5
CONNECTOR JB
Terminal JB-1
Terminal JB-6
Motor positive terminal 0VDC - 24VDC with speed
pot
reference JB-8
NOTE
Trigger switch must be pressed.
Terminal JB-7
negative welding output voltage
reference JB-9
Terminal JB-9
positive welding voltage
Terminal JB-11
relay contact to control SOL1 & W1
closes to complete circuit to JB-10
reference JB-4
wiper of wire speed control potentiometer, varies
between <2V to approximately 4.7VDC (pot
wiper)
reference JA-5 or JB-5
Terminal JB-2
wire speed control potentiometer minimum (pot
low) approximately 0.4 VDC
reference JA-5
Terminal JB-3
wire speed control potentiometer maximum
approximately 4.7VDC
reference JA-5
NOTE
Make sure you are not in spot weld mode.
Terminal JB-4
27VAC supply from auxiliary winding on fan
reference JA-5 or JB-5
Manual 0-5061 5-4 May 1, 2008
Page 31
PARTS LIST ARCMASTER SGI 100
SECTION 6:
PARTS LIST
6.01 Equipment Identification
All identification numbers as described in the Introduction
chapter must be furnished when ordering parts or making
inquiries. This information is usually found on the
nameplate attached to the equipment. Be sure to include
any dash numbers following the Specification or Assembly
numbers.
NOTE
This part list is for SGI 100 replacement parts
only. Refer to the spool gun and power supply
manuals for their respective replacement
parts.
6.02 How To Use This Parts List
The Parts List is a combination of an illustration and a
corresponding list of parts which contains a breakdown
of the equipment into assemblies, subassemblies, and
detail parts. All parts of the equipment are listed except
for commercially available hardware, bulk items such
as wire, cable, sleeving, tubing, etc., and permanently
attached items which are soldered, riveted, or welded to
other parts. The part descriptions may be indented to show
part relationships.
To determine the part number, description, quantity, or
application of an item, simply locate the item in question
from the illustration and refer to that item number in the
corresponding Parts List.
SGI 100 Catalog Number: W4009115
May 1, 2008 6-1 Manual 0-5061
Page 32
ARCMASTER SGI 100 PARTS LIST
6.03 SGI 100 Replacement Parts
Item Qty. Description Ref. Part Number
1 1 BASE COVER ASSY, SG BOX W71004300
2 1 PCB CONTROL, SG BOX PCB1 7978050PKD
3 2 CAP SCREW, 4mm SEE NOTE 1
4 10 #6-20 X 3/8” PH PAN HD THD CUT SEE NOTE 1
5 1 BRIDGE RECTIFIER BR1 7-3345
6 1 WASHER, # 10 SCREW BRASS SEE NOTE 1
7 1 #10-32 REGULAR NYLON LOCK NUT SEE NOTE 1
8 1 BREAKER, 2A ZE-800-2-O, 1.5 PNL MNT .630 DIA CB1 7978041
9 1 SWITCH, ROCKER, SINGLE POLE S1 870359
10 2 KNOB CONTROL 0.57 OD x 0.25 ID 870734
11 1 STRAIN RELIEF 8-4249
12 1 HARNESS CONTROL, SG BOX W7004301
13 1 CABLE INPUT ASSY, SG BOX P2 W7004302
14 1 COVER (AND CHAIN) FOR 14S SOCKET W7004303
15 1 CRIMP, BELL PB456686
16 2 TIE WRAP, NYLON SEE NOTE 1
17 1 POTENTIOMETER 100K, BURNBACK R1 7977949PKD
18 1 POTENTIOMETER 100K, SPOT R2 7977949PKD
19 1 SOCKET, PANEL MTG, 14S, SG BOX J1 7977750PKD
NOTE 1: This part is available at most hardware stores.
Manual 0-5061 6-2 May 1, 2008
Page 33
PARTS LIST ARCMASTER SGI 100
13
3
11
2
8
1
5
14
6
5
7
9
10
18
17
13
1
16
15
19
1
1
4
5
12
1
May 1, 2008 6-3 Manual 0-5061
Page 34
ARCMASTER SGI 100 APPENDIX
within [.010] .25mm TIR.
DO NOT SCALE DRAWING
UNLESS OTHERWISE SPECIFIED:
Dimensions are displayed as:
[
XX]
Decimal inch XX Millimeters
Decimal inch: Millimeters:
Min. mold radii [.010] .25mm
.X
.015 X. 0.4mm
.XX .010 X.X 0.25mm
.XXX .005 X.XX 0.1mm
Angular
30'
Deburr all sharp corners and edges.
All diameters on same axis to be concentric
DATE
BYREVISIONS
REV
G
B
15A
J2
14 PIN AMPHENOL
15C
A
CB-1
BREAKER
2 AMP
BR-1
35 AMP BRIDGE
33
15
21
15A
P2
14A
15B
14B
16B
14
14C
AA
ECO-B904
JCD
05/08/08
APPENDIx 1: SYSTEM SCHEMATIC
Manual 0-5061 A-1 May 1, 2008
Page 35
APPENDIX ARCMASTER SGI 100
871941
INTERFACE BOX, SPOOL GUN
MATERIAL
TITLE
Chk
Drawn
Date
sedecrepuS
e
lacS
Superceded By
Reference
OF
App
2:1
3/3/2007
JCD
1
1
SEE BOM
Information proprietary to Thermadyne Corporation.
Not for release, reproduction, or distribution.
C
PCB1
PC BOARD
7978050
E
JB
1 2 3 4 5 6 7 8 9 10 11
JA
1 2 3 4 5 6 7
D
1 2
JE
A
B
L
M
R1
BURN BACK
100 K POT
R2
SPOT
100 K POT
S1
SWITCH
J1
14 PIN AMPHENOL
SPOOL GUN
31 32
11 13
12 14
16
16A
18
11
18
12
1
2
3
4
5
5
1
2
13
22
21
14C
15B
15
16A16B
16
A GUN SWITCH
B GUN SWITCH
C POT
D POT
E POT CONTROL
L - MOTOR
M +MOTOR
May 1, 2008 A-2 Manual 0-5061
Page 36
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
November 2007
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company (“Thermal Arc”), warrants
to customers of authorized distributors (“Purchaser”) that its products will be free of defects
in workmanship or material. Should any failure to conform to this warranty appear within the
warranty period stated below, Thermal Arc shall, upon notication thereof and substantiation that
the product has been stored, installed, operated, and maintained in accordance with Thermal
Arc’s specications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or damage, 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.
This warranty is exclusive and in lieu of any warranty of merchantability,
tness for any particular purpose, or other warranty of quality, whether
express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special, indirect,
incidental, or consequential damages, including but not limited to lost prots and business
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, tort, including
negligence or strict liability, or under any warranty, or otherwise, shall not 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, and Thermal Arc shall not be bound by any such attempt.
Correction of non-conformities, in the manner and time provided herein, constitutes fulllment
of thermal’s obligations to purchaser with respect to the product.
This warranty is void, and seller bears no liability hereunder, if purchaser used replacement
parts or accessories which, in Thermal Arc’s sole judgment, impaired the safety or performance
of any Thermal Arc product. Purchaser’s rights under this warranty are void if the product is sold
to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the authorized
distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event
shall the warranty period extend more than the time stated plus one year from the date Thermal
Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of purchaser’s
discovery of any defect. Thermal Arc shall pay no transportation costs of any kind under this
warranty. Transportation charges to send products to an authorized warranty repair facility
shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s
risk and expense. This warranty dated July 1st 2007 supersedes all previous Thermal Arc
warranties. Thermal Arc
®
is a Registered Trademark of Thermal Arc, Inc.
Page 37
WARRANTY SCHEDULE
November 2007
SAFETY EQUIPMENT Warranty Period Labor
Auto-Darkening Welding Helmet (Electronic Lens)
Harness Assembly
2 year
1 month
2 year
1 month
ENGINE DRIVEN WELDERS Warranty Period Labor
Scout, Raider, Explorer
Original Main Power Stators and Inductors 3 years 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors
1 year 1 year
Engines and associated components are NOT warranted by Thermal Arc,
although most are warranted by the engine manufacturer
See the Engine Manufactures’ Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT Warranty Period Labor
Fabricator 131, 181; 140; 180; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor 5 years 3 years
Original Main Power Rectifiers, Control PC Boards, power switch semi-conductors 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors.
1 year 1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT Warranty Period Labor
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors.
1 year
1 year
PLASMA WELDING EQUIPMENT Warranty Period Labor
Ultima 150
Original Main Power Magnetics 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors 3 years 3 years
Welding Console, Weld Controller, Weld Timer 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator.
1 year 1 year
SMAW (Stick) WELDING EQUIPMENT Warranty Period Labor
Dragster 85
Original Main Power Magnetics 1 year 1 year
Original Main Power Rectifiers, Control P.C. Boards 1 year 1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors
1 year 1 year
160S, 300S, 400S
Original Main Power Magnetics 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors
1 year 1 year
GENERAL ARC EQUIPMENT Warranty Period Labor
Water Recirculators 1 year 1 year
Plasma Welding Torches 180 days 180 days
Gas Regulators (Supplied with power sources) 180 days Nil
MIG and TIG Torches (Supplied with power sources) 90 days Nil
Replacement repair parts 90 days Nil
MIG, TIG and Plasma welding torch consumable items Nil Nil
This information applies to Thermal Arc products that were purchased in the USA and Canada.
Page 38
Page 39
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Page 40
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
FAX:
(636) 728-3010
Email: sales@thermalarc.com
www.thermalarc.com
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