Tweco Weld Sequencer User Manual

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WELD SEQUENCER

A-02401

Instruction Manual

December 16, 2005

Manual No. 0-2023

WARNING

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this manual represents our best judgement, Thermal Arc Corporation assumes no liability for its use.

Thermal Arc

Weld Sequencer

Instruction Manual Number 0-2023 Published by:

Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711

permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liabil-

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

omission in the Thermal Arc

Weld Sequencer Instruction Manual, whether such error results from negligence, accident, or any other cause.

Revised on December 16, 2005

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ................................................................................................... 1

1.01 Notes, Cautions and Warnings ........................................................................ 1

1.02 Important Safety Precautions ........................................................................ 1

1.03 Publications ................................................................................................... 2

1.04 Note, Attention et Avertissement ................................................................... 3

1.05 Precautions De Securite Importantes ............................................................. 3

1.06 Documents De Reference .............................................................................. 5

1.07 Declaration of Conformity ............................................................................... 6

1.08 Statement of Warranty .................................................................................... 7

SECTION 2:

INTRODUCTION & DESCRIPTION ...................................................................................... 9

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

2.02 General Description ........................................................................................ 9

2.03 Specifications & Design Features ................................................................. 10

SECTION 3:

INSTALLATION PROCEDURES .......................................................................................... 11

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

3.02 Site Selection ...............................................................................................11

3.03 Unpacking .....................................................................................................11

3.04 Equipment Installation - General ................................................................... 11

3.05 WT1 Weld Timer ............................................................................................13

3.06 GS1 Gas Slope .............................................................................................15

3.07 CS1 Current Slope ........................................................................................ 17

3.08 CP1 Pulser ...................................................................................................17

3.09 Automatic Voltage Control (AVC) Lockout .....................................................17

3.10 Auxiliary Connections For Interfacing External Controls ................................ 17

SECTION 4:

OPERATION ........................................................................................................................ 19

4.01 Introduction ................................................................................................... 19

4.02 Functional Overview ....................................................................................19

4.03 Weld Sequencer Enclosure Control Descriptions ..........................................19

4.04 RP1 Control Descriptions ..............................................................................20

4.05 WT1 Weld Timer Control Descriptions............................................................ 20

4.06 CS1 Current Slope Control Descriptions ........................................................ 21

4.07 CP1 Pulser Control Descriptions ...................................................................22

4.08 GS1 Gas Slope Control Descriptions ............................................................ 23

4.09 Pre-Operation Setup...................................................................................... 24

4.10 System Operation ......................................................................................... 27

TABLE OF CONTENTS (continued)

SECTION 5:

CUSTOMER/OPERATOR SERVICE .................................................................................... 29

5.01 Introduction ...................................................................................................29

5.02 Transformer Connections ...............................................................................29

5.03 Troubleshooting Guide - General Information ................................................. 29

5.04 Test Procedures ............................................................................................ 33

5.05 WT1 Weld Timer Parts Replacement Procedures ..........................................34

SECTION 6:

PARTS LIST ........................................................................................................................ 39

6.01 Introduction ...................................................................................................39

6.02 Ordering Information...................................................................................... 39

6.03 Weld Sequencer Enclosure ...........................................................................40

6.04 GS1 Gas Slope (Front Panel) ........................................................................ 42

6.05 GS1 Gas Slope (Rear Panel)......................................................................... 43

6.06 CS1 Current Slope ........................................................................................ 44

6.07 CP1 Pulser ...................................................................................................45

6.08 WT1 Weld Timer ............................................................................................46

6.09 RP1 Remote Pendant Control........................................................................47

APPENDIX I: MOTION CONTROL & WIRE FEED INTERFACE DIAGRAM ................................49

APPENDIX II: WELD SEQUENCER TERMINAL STRIP DIAGRAM ............................................50

APPENDIX III: AUXILIARY INTERFACE CONNECTION DIAGRAM ...........................................51

APPENDIX IV: NECESSARY CONNECTIONS - RP-1 NOT USED WITH CS-1 WITH OR WITHOUT GS-1,

WT-1 OR CP-1 ..................................................................................................................... 52

APPENDIX V: NECESSARY CONNECTIONS - RP-1 NOT USED WITH CP-1, WT-1 SYSTEM ... 53

APPENDIX VI: TIMING AND SEQUENCE OF OPERATION FOR WELD SEQUENCER (ALL MODELS)

APPENDIX VII: TIMING AND SEQUENCE OF OPERATION FOR GS1 GAS SLOPE ONLY ......55

APPENDIX VIII: SYSTEM SCHEMATIC .....................................................................................56

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection

1.03, Publications in this manual.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

WARNING

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

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FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

• Provide a fire watch when working in an area where fire hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

GENERAL INFORMATION 2 Special TA 2/25/99

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

1.05 Precautions De Securite Importantes

AVERTISSEMENT

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

Special TA 2/25/99 3 GENERAL INFORMATION

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites

GENERAL INFORMATION 4 Special TA 2/25/99

normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

Special TA 2/25/99 5 GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Address: 2200 Corporate Drive

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

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

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

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

manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Arc, Inc.

Troy, Ohio 45373-1085 USA

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative: Steve Ward

Director of Operations Thermadyne UK Chorley England

GENERAL INFORMATION 6 Special TA 2/25/99

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special or consequential damages,

such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE JUDEGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

Except with regards to the products listed below, this warranty shall remain effective three (3) years from the date Thermal Arc’s authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date Thermal Arc delivers the product to the authorized distributor.

Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.

PLASMA WELDING/

POWER SUPPLIES VIKING/GENERATORS INVERTERS LABOR

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 2 YEARS 1 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS, SOLENOIDS, PUMPS, POWER SWITCHING SEMI-CONDUCTORS

ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER. SEE THE ENGINE MANUFACTORS WARRANTY FOR DETAILS.

CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR 1 YEAR

EXCHANGES, AND ACCESSORY EQUIPMENT TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal Arc warranties.

Thermal Arc® is a Registered Trademark of Thermadyne.

Effective May 1, 1997

Special TA 2/25/99 7 GENERAL INFORMATION

GENERAL INFORMATION 8 Special TA 2/25/99

SECTION 2:

INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the Thermal Arc Weld Sequencer. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2.02 General Description

• Weld Sequencer Enclosure

Housing for combinations of the four modules. Contains interface wiring and power for each unit. Provides relay contacts for interfacing with external controls (wire feeders, motion controls, etc).

• RP1 Control

Offers remote control for activating main contactor, starting weld sequencer, starting downslope manually, starting spot weld sequence, and adjusting welding current.

• CS1 Current Slope

Allows welding current to be automatically adjusted from an initial current setting to a peak current setting (upslope) and decreased automatically to a final current setting (downslope) when signaled manually or by the WT1 Weld Timer. Upslope changes the current linearly from initial current value to weld (peal) current value. Downslope changes the current linearly from peak value down to final value.

The Thermal Arc Weld Sequencer is an accessory package designed to automatically control the output of most solid-state power supplies. The Weld Sequencer gives the operator more accurate control of the variables within a welding operation. Once the Weld Sequencer is programmed for a particular welding operation, the weld can be reproduced with minimal fluctuations. Four separate solid-state control modules, a Weld Sequencer Enclosure and a RP1 Control remote pendant make up the Weld Sequencer. Any combination of the four modules can be used with the Weld Sequencer Enclosure to be a stand-alone unit.

• GS1 Gas Slope (Plasma Gas)

Allows linear change in the plasma gas flow rate (upslope and downslope) between two variable settings. The control can be manual or automatic when used with CS1 Current Slope

• CP1 Pulser

Reduces the amount of heat input into the weld by pulsing the current between peak level and a background level. The CP1 offers complete control of the pulse frequency rate and the percentage of 'on' time at peak current versus background current. The CP1 also offers the capability of a linear upslope and downslope on each pulse.

• WT1 Weld Timer

Allows weld time to be set from 0.1 to 999.9 seconds. When used with CS1 Current Slope the WT1 times the weld from the start of upslope to the end of peak (weld) current at which time it provides a signal for initiating the downslope sequence. WT1 can also be used independently as a spot weld timer.

A-02401

Figure 2-1 Weld Sequencer Assembly

Manual 0-2023 9 INTRODUCTION & DESCRIPTION

2.03 Specifications & Design Features

B. GS1 Gas Slope (Plasma)

1. Input Power

A. Weld Sequencer Enclosure

1. Input Power

115/230VAC, 1 Amp, 50/60 Hz

2. Control Circuit Output

28 VAC

3. Current Control

Up to 24 VDC using RP1 Control remote pendant or some other external device.

4. Contactor Control

28 V control circuit using RP1 Control remote pendant or some other external device.

5. Control Console or Power Supply Control

Control is via 10' control cable.

6. Auxiliary Connections

Relay contacts and terminal connector provided for auxiliary input/output signals (wire feeders, motion controls, etc.).

7. Housing Capabilities

WT1 and/or GS1; WT1 and/or CS1 and/or CP1

NOTE

For a complete Sequencer Assembly, the Enclosure Expansion must be added on top of the Weld Sequencer Enclosure to accommodate CS1 and CP1 modules. Also, the enclosure expansion is required when WT1 or GS1 is used with either CS1 or CP1.

28 VAC from Weld Sequencer Enclosure

2. Plasma Gas Range

Min 0.5 - 3 scfh (0.25 - 1.4 lpm)

Max 2 - 7 scfh (1 - 3.3 lpm) @ 30 psi (2 bar)

3. Weight

9 lbs (4.05 kg)

C. CS1 Current Slope

1. Input Power

28 VAC from Weld Sequencer Enclosure

2. Weight

4 lbs (1.8 kg)

D. CP1 Pulser

1. Input Power

28 VAC from Weld Sequencer Enclosure

2. Pulse Rate

0.5 - 20 pulses/sec

3. Weight

3.5 lbs (1.58 kg)

E. WT1 Weld Timer

1. Input Power

28 VAC from Weld Sequencer Enclosure

2. Timing Control

8. Dimensions (W x H xD)

15 inches (381 mm) x 11 inches (279 mm) x 16-3/4 inches (425 mm)

With Enclosure Expansion height dimension is 18 inches (457 mm)

9. Weight

24.5 lbs (11.62 kg).

With Enclosure Expansion weight is 30 lbs (14.23kg)

INTRODUCTION & DESCRIPTION 10 Manual 0-2023

Adjustable from 0.1 to 999.9 seconds

3. Weight

2.5 lbs (1.12 kg)

CAUTION

When using CS1 or CP1 with a power source other than the Thermal Arc PS30A, the remote control circuit must be 0 to +24 vdc and of a solid state design.

SECTION 3:

INSTALLATION

PROCEDURES

3.04 Equipment Installation General

WARNING

3.01 Introduction

This section describes installation of the Weld Sequencer. These instructions apply to the Weld Sequencer only; installation procedures for the Power Supply, Welding Console, Torch, Options, and Accessories are given in Manuals specifically provided for those units.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Weld Sequencer

4. Operator training

3.02 Site Selection

The Weld Sequencer Enclosure should be located either next to or on top of the Welding Console (GS1 connections must be installed in Welding Console before mounting on top). A source of 115 or 230 VAC power must also be available.

NOTE

Review Important Safety Precautions (page 1) to be sure that the selected location meets all safety requirements.

3.03 Unpacking

Make sure that all power to the welding system is shut off at the incoming source. Do not turn ON the power until all components are connected.

A. Voltage Selection

The Weld Sequencer Enclosure is factory-wired for 230V, 60Hz operation. If 230V primary power is available, connect the end of the input power cord to the 230V primary power source.

If 115V primary power is to be used change TB4 connections as follows:

1. Locate TB4 terminal strip on the rear panel of the En-

closure. Remove the two jumpers from each side of terminals 5 and 6.

230 Volt Jumpers

1 2 3 4 5 6 7

TB4 Terminal Strip

A-02404

Each component of the system is packaged and protected with a carton and packing material to prevent damage during shipping.

1. Unpack each item and remove all packing material.

2. Locate the packing list(s) and use the list to identify and account for each item.

3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and/or shipping company before proceeding with system installation.

Manual 0-2023 11 INSTALLATION PROCEDURES

Figure 3-1 Jumper Installation For 230 VAC Input

2. Connect one jumper across terminals 4 and 5 and the other across 6 and 7.

115 Volt Jumpers

1 2 3 4 5 6 7

TB4 Terminal Strip

Figure 3-2 Jumper Installation For 115 VAC Input

A-02405

3. Connect plug (supplied) to the end of the input power cord per the following:

a. Feed the free end of the input power cable through

the small section of the rubber plug housing.

b. Connect the ground lead to the green terminal on

the plug.

c. Connect the other two leads to the two terminals

on the plug.

d. Press the plug into the rubber housing until the

plastic disk is captured by the rubber housing.

e. Tighten cord grip to secure input cable.

A-02406

REMOTE

CONTROL

Control Cable Console/Power Supply

CONSOLE/POWER SUPPLY

CONTROL

Control Cable

Figure 3-3 Weld Sequencer Enclosure Rear Panel

Connections

B. Cable Connections

1. Connect RP1 Control pendant to the connector on the end of the 20 foot (6.1 m) Remote Control Cable. Connect the other end of the cable to the back of the Weld Sequencer Enclosure marked REMOTE CONTROL.

Plasma Gas

If a different remote control device is to used refer to the Wiring Diagram supplied with the Weld Sequencer. The current control potentiometer must be rated for 10k ohm at 2 watts.

Coolant Recirculator

DC Power

Supply

Welding Console

Weld Sequencer

Shield Gas

Optional Remote

Control

A-02407

Torch

Figure 3-4 WC100B Connections

INSTALLATION PROCEDURES 12 Manual 0-2023

2. Connect the mating plug of the 10 foot (3 m) Control Cable to the receptacle on the rear panel of the Weld Sequencer Enclosure marked CONSOLE/POWER SUPPLY CONTROL.

3. The connection on the other end of the cable depends on the welding console, power supply or current control device. Connect as follows (refer to Figure 3-4):

• Thermal Arc WC100B Welding Console

• Other Welding Consoles and Power Supplies

WARNING

The remote control circuit of the welding console or power supply must not exceed 28 volts AC or DC.

a. Connect Control Cable plug to the receptacle on

the front panel of the WC100B marked REMOTE CONTROL. Move REMOTE ON/OFF switch to ON position.

• Thermal Arc WC100A and WC122A (and earlier

models) Welding Consoles

b. Cut the Control Cable plug off and strip cable jacket

back approximately 2 inches.

c. Locate the cable from the welding console CON-

TROL receptacle. Measure enough cable to connect with the Control Cable from the Weld Sequencer Enclosure and cut.

d. Connect the white/brown (J5-3) and black (J5-4)

wires of the Weld Sequencer Enclosure Control Cable to the two leads of the cable from the welding console CONTROL. The order of connection is unimportant. This connection gives contactor control to the Sequencer.

e. Connect a cable to the Remote Amperage Control

of the power supply. Connect the other end to the Weld Sequencer Enclosure Control Cable (see Figure 3-E):

Power Supply Amperage Control maximum lead to orange wire (J5-1)

a. Cut the cable plug off. Strip the cable jacket back

approximately 2 inches.

b. Connect the white/brown (J5-3) and black (J5-4)

wires of the Weld Sequencer Enclosure Control Cable to the contactor control of the welding unit. This gives contactor control to the Sequencer.

c. Connect a cable to the Remote Amperage Control

of the power supply. Connect the other end to the Weld Sequencer Enclosure Control Cable (refer to Figure 3-5):

Power Supply Amperage Control maximum lead to orange wire (J5-1)

Power Supply Amperage Control variable (wiper) lead to red wire (J5-7)

Power Supply Amperage Control minimum lead to blue wire (J5-13)

d. Tape back the wires not used.

e. Check input power connections on the terminal

strip TB4, located on the rear panel of the Weld Sequencer Enclosure, to be sure that they are set up for the available voltage. Provisions are made for primary inputs of 115 or 230 volts AC (refer to Section 4.2) and 50 or 60 Hz power may be used.

Power Supply Amperage Control variable (wiper) lead to red wire (J5-7)

Power Supply Amperage Control minimum lead to blue wire (J5-13)

Contactor

Control

AMP Control

(Wiper)

A-02408

AMP Control

(Max)

Contactor

Control

Ground

(Min)

Figure 3-5 Back View of Control Cable Plug

3.05 WT1 Weld Timer

CAUTION

The WT1 Weld Timer is factory set for 60 Hz operation. If 50 Hz power is used or WT1 doesn’t time properly remove the cover from WT1 and check the position of the switch mounted in the middle of the PC board. Move the handle to the proper position printed on the PC board (50 or 60).

1. Install WT1 into the bottom of the opening in the Weld Sequencer Enclosure (refer to Figure 3-6). Secure with screws provided.

2. Connect WT1 to the Weld Sequencer Enclosure wiring

f. Tape back the wires not used.

harness with the J4 connectors.

Manual 0-2023 13 INSTALLATION PROCEDURES

A-02409

Enclosure Expansion

CP1 Pulser

CS1 Current Slope

Weld Sequencer

Enclosure

GS1 Gas Slope

RP1 Control

WT1 Weld Timer

Figure 3-6 Weld Sequencer Assembly

INSTALLATION PROCEDURES 14 Manual 0-2023

3.06 GS1 Gas Slope

1. Install PLASMA IN and OUT fittings from the back of GS1 through the opening in the front of the Weld Sequencer Enclosure and secure to the rear of the Enclosure.

PLASMA

Gas IN

2. Install GS1 into upper opening of the Enclosure (refer to Figure 3-6) and secure with screws provided.

3. Connect GS1 to the Weld Sequencer Enclosure wiring harness with the J3 connectors.

NOTE

If CS1 and/or CP1 are not used then the jumper connectors must be installed in wire harness connector J8 (CS1) and/or connector J7 (CP1). If this is not done the current control will not function properly.

4. Install GS1 adapter fitting assembly into the welding console between the flowmeter and the plasma gas torch connection. For installation in Welding Consoles WC100A, WC100B and WC122A (refer to Figures 3-8, 3-9, and 3-10).

PLASMA

Gas OUT

A-02410

Figure 3-7 GS1 Plasma Connections

To To r ch

Remove

Disconnect this tube and move up and out of the way. Reconnect after assembly is complete.

this fitting.

5. Feed plasma gas hoses from the adapter fitting assembly through the plastic bushing on the rear panel of the welding console.

6. Open plasma gas flow valve on the welding console all the way.

Disconnect Tube

From Plasma Gas Metering Valve

Add sealant to threads and screw in assembly to position shown.

From Source

Remove this nut.

Reconnect plasma gas supply hose.

Bold arrows indicate direction of flow

A-02411

From GS1

To GS1

Figure 3-8 GS1 Connections to WC100A and WC122A (with copper tubing)

Manual 0-2023 15 INSTALLATION PROCEDURES

To To r c h

Remove these two fittings.

Apply sealant to these threads and screw in assembly to position shown.

Bold arrows indicate direction of flow

Cut tubing off at end of fittings.

From Plasma Gas Metering Valve

Push tubing into fitting and hand tighten, then 3/4 turn more.

If tubing in step 1 is too short, use the one supplied with the assembly.

Push insert into tubing.

From Source

A-02412

Figure 3-9 GS1 Connections to WC122A (with plastic tubing)

To To r ch

Remove these two fittings.

Cut tubing off at end of fittings.

Apply sealant to these threads and screw in assembly to position shown.

From Plasma Gas Metering Valve

Push tubing into fitting and hand tighten, then 3/4 turn more.

From GS1

If tubing in step 1 is too short, use the one supplied with the assembly.

Push insert into tubing.

To GS1

From Source

Bold arrows indicate direction of flow

A-02413

From GS1

To GS1

Figure 3-10 GS1 Connections to WC100B

INSTALLATION PROCEDURES 16 Manual 0-2023

3.07 CS1 Current Slope

1. Install CS1 into the bottom of either the Weld Sequencer Enclosure or the Enclosure Expansion (see NOTE) and secure with screws provided.

NOTE

If CP1 and/or CS1 are used without GS1 they are mounted in the Weld Sequencer Enclosure. When either or both are used with the Gas Slope the Enclosure Expansion must be mounted to the top of the Weld Sequencer Enclosure (refer to Figure 3-6). CP1 and CS1 are then mounted in the Enclosure Expansion.

2. Connect CS1 to the Weld Sequencer Enclosure wiring harness with the J8 connectors.

3.08 CP1 Pulser

1. Install CP1 into Weld Sequencer Enclosure or Enclosure Expansion above CS1 (if included) and secure with screws provided.

2. Connect CP1 to the Weld Sequencer Enclosure wiring harness with the J7 connectors.

NOTE

When spot welding using automated control devices (and only if RP1 Remote Pendant is used) the jumper across TB3-2 to TB3-3 must be removed (refer to Appendix III).

3.09 Automatic Voltage Control

(AVC) Lockout

When using CP1 on systems having Automatic Voltage Control (AVC) it is necessary to inhibit AVC when CP1 is not at peak voltage so that the AVC does not try to track the voltage change due to pulsing. Since it is possible that the power supply ground of the AVC unit will not be common to that of the Weld Sequencer the circuit to supply the 'inhibit' signal is electrically isolated from CP1 by an optoisolator.

The ground and supply voltage for the isolation circuit must be supplied from the AVC (refer to Appendix III). Supply voltage can be from +5 to +15 vdc. The AVC 'inhibit' signal is low, or not inhibited, when the CP1 is at peak voltage, and high, or inhibited (equal to supply voltage), during the rest of the cycle.

3.10 Auxiliary Connections For

Interfacing External Controls

There are three terminal strips provided on the base of the Weld Sequencer Enclosure for interfacing the Sequencer with other components or controls(refer to Appendix I and III for available locations and signals). Relay AL de-energizes at the end of upslope and re-energizes at the start of downslope. The CC relay signals contactor closure and de-energizes during welding sequence.

Manual 0-2023 17 INSTALLATION PROCEDURES

INSTALLATION PROCEDURES 18 Manual 0-2023

SECTION 4:

OPERATION

4.01 Introduction

4.03 Weld Sequencer Enclosure Control Descriptions

This section provides a description of the Power Supply operating controls and procedures. Identification of the Front and Rear Panel components is followed by operating procedures.

4.02 Functional Overview

The Weld Sequencer is designed to automatically control the output of most solid-state power supplies. The Weld Sequencer gives the operator more accurate control of the variables within a welding operation. Once the Weld Sequencer is programmed for a particular welding operation, the weld can be reproduced with minimal fluctuations. Four separate solid-state control modules, a Weld Sequencer Enclosure and a RP1 Control remote pendant make up the Weld Sequencer. Any combination of the four modules can be used with the Weld Sequencer Enclosure to be a stand-alone unit.

CP1

PULSE RATE

CS1

INITIAL

CURRENT TIME

GS1

MIN

PULSER

PERCENT ON TIME

CURRENT SLOPE

UPSLOPE RATE

0 - 10 sec.

GAS SLOPE

GAS FLOW

SLOPING

MAX

PULSE SLOPE

BACKGROUND CURRENT

weld time

DOWNSLOPE

DELAY RATE

0 - 10 sec.

DOWN

(pull for display)

CURRENT TIME

0 - 10 sec.

MANUAL

FINAL

AUTO

ONOFF

OFF

A-02415

Figure 4-2 Weld Sequencer Enclosure

1. ON/OFF Switch

Activates Weld Sequencer Enclosure power circuits and supplies AC power to all Sequencer Controls in ON position. In the OFF position deactivates all Sequencer Control circuits.

2. Red AC Power Light

Indicates that AC power is being supplied to the Sequencer control modules.

DOWNSLOPE

RATE

DELAY

(0 - 10 sec.)

ONOFF

AC POWER

A-02414

MAX

GAS FLOW

2 - 7 SCFH 1 - 3.3 lpm

WT 1

SECONDS

UPSLOPE

RATE

WELD TIMER

TENTHS

MIN

GAS FLOW

.5 - 3 SCFH

.25 - 1.4 lpm

OFF

Figure 4-1 Control Modules Assembled In Weld

Sequencer Enclosure

Manual 0-2023 19 OPERATION

4.04 RP1 Control Descriptions

Start of

downslope

Start of upslope

Weld Time

(0.1 - 999.9 sec)

A-02421

4.05 WT1 Weld Timer Control Descriptions

CONTACTOR

OFF

SPOTWELD

RP 1

CONTROL

WELD

CURRENT

START

SEQUENCE

START

DOWNSLOPE

A-02416

Figure 4-3 RP1 Control

1. Contactor ON/OFF Switch

Activates main contactor closure in power supply to prepare for start of weld sequence. Must be in the OFF position before turning sequencer to OFF position.

WT 1

SECONDS

WELD TIMER

ONOFF

TENTHS

A-02417

Figure 4-4 WT1 Weld Timer

1. ON/OFF Switch

In OFF position WT1 is disabled. The ON position energizes timing circuits.

2. SECONDS-TENTHS Dial

Allows weld time to be set in seconds to the tenth of a second up to 999.9. When WT1 is used with CS1 timing starts with start of upslope and times out to automatically initiate downslope sequence.

2. Weld Current

Allows welding current to be adjusted within the range set on the power supply. Can be used to set CS1 and CP1.

3. START SEQUENCE Switch

Activates sequence of CS1 and GS1 only. When GS1 is used independently, pressing switch will start plasma gas 'upslope' sequence.

4. START DOWNSLOPE Switch

Allows manual start of plasma gas and current 'downslope' sequence.

5. SPOTWELD Switch

Allows contactor closure to be initiated at operators discretion after the first spot weld sequence has been completed (if the CONTACTOR ON/OFF switch is left in ON position).

CAUTION

WT1 is set for operation on 60Hz power. For 50Hz operation the timer must be reset (refer to Section

3.05 for 50Hz).

OPERATION 20 Manual 0-2023

4.06 CS1 Current Slope Control Descriptions

A-02418

CS1

INITIAL

CURRENT TIME

0 - 10 sec.

CURRENT SLOPE

UPSLOPE RATE

weld time

DOWNSLOPE

DELAY RATE

0 - 10 sec.

FINAL

CURRENT TIME

0 - 10 sec.

23 4 5

ONOFF

3. UPSLOPE RATE Control

Peak Current

Initial

Current

Upslope

Distance

(Amps)

Figure 4-5 CS1 Current Slope

1. ON/OFF Switch

In OFF position CS1 is taken out of the welding operation. The ON position energizes the circuitry.

2. INITIAL CURRENT/TIME Control (Dual Control

Pot)

INITIAL CURRENT Control (inner knob) allows setting of desired starting current from which upslope will begin. This setting is the percentage of the difference between MAX (determined by RP1 weld current setting) and MIN of the Power Supply current range. Add the value of this percentage to the MIN current to determine actual current level.

MIN

Current

Initial Current

A-02423

Time

(seconds)

Determines rate at which current slopes up from initial setting to MAX setting. The numbers are reference points and have no predetermined value. Zero setting reflects the slowest slope rate for a particular current range and ten relects the fastest (refer to Figure 4-8 for details).

4. DOWNSLOPE DELAY/RATE Control

Delay Start Downslope

Start Downslope

Signal

Distance

(Amps)

(0 - 10 sec)

Downslope

Initial Current

A-02422

Time

EXAMPLE

A Power Supply set at a range of 25 to 125 amps has a difference of 125 - 25 = 100 amps. A 50% setting is equal to 100 X 50% = 50 amps, + 25 amps min = 75 amps initial current.

A-02424

A dual control potentiometer that controls the Downslope Delay and the Rate. The RATE control (outer knob) determines the rate at which the current slopes down from MAX setting to final current setting. The numbers are reference points and have no

Time

(seconds)

predetermined value. Zero (0) setting reflects the

TIME control (outer knob) sets the desired initial current time before activating the upslope sequence. It is variable between 0-10 seconds as represented by the numbers around the knob.

slowest slope rate for a particular current range while ten (10) reflects the fastest rate (refer to Figure 4-8 for details). The DELAY control (inner knob) allows the actual start of downslope current to be delayed from 0-10 seconds after the downslope is initiated.

Manual 0-2023 21 OPERATION

5. FINAL CURRENT/TIME Control

Final Current

Time

A-02425

One Pulse

Time

A-02426

EXAMPLE

Ten pulses in one second means that the distance from point A to point B is traveled ten times in one second (10 pulses/second or 600 pulses/minute)

A dual control potentiometer that controls the Final Current and the Time. The FINAL CURRENT control (inner knob) sets welding current at the finish of the weld. Like the INITIAL CURRENT it is a percentage of the set operating current range of the Power Supply (maximum current setting determined by RP1) and is added to the minimum current to arrive at a amperage value.

The FINAL TIME control (outer knob) sets the length of time that the final current will be maintained before signaling the contactor to open, ending the weld. The numbers around the knob refer to seconds.

4.07 CP1 Pulser Control Descriptions

A-02419

CP1

PULSER

PULSE RATE

PERCENT ON TIME

PULSE SLOPE

BACKGROUND CURRENT

(pull for display)

234 5

ONOFF

3. PERCENT ON TIME Control

Percent ON

Time Setting

75% 25%

One Pulse

Peak Current

Background

Current

A-02427

Sets the amount of time the peak current is on relative to the amount of time background current is on, in any one pulse. Settings are in percent, not actual time. A setting of 50% means peak current is on the same amount of time as the background current. A setting of 75% means peak current is on three times longer than background current.

4. PULSE SLOPE Control

Gradual Change

Peak Current

Figure 4-6 CP1 Pulser

A-02428

1. ON/OFF Switch

Background Current

In OFF position CP1 is disabled. In the ON position its circuitry is energized.

Allows gradual change in current between background current and peak current levels during puls-

2. PULSE RATE Control

Regulates the number of pulses (time taken to go from point A to point B) in a given time period. Numbers

ing.

5. BACKGROUND CURRENT Control (pull for display)

are for reference only and do not indicate pulses per second.

Adjusts lower level of current. Can be adjusted while pulsing by turning the knob. Numbers around knob refer to the percentage of Power Supply output current range and should not be taken as an amperage value.

OPERATION 22 Manual 0-2023

EXAMPLE

NOTE

A Power Supply set in a range of 50 - 150 amps with a background current of 30% would be 150 50 = 100 amps total range 100 amps x 30% = 30 amps 30 amps + 50 amps min = 80 amps background.

A-02429

Background Current

To adjust background current with an ammeter while doing a test weld, pull the knob out. CP1 will cease to pulse and will maintain weld current at background current level. Adjust to new background current by turning knob (checking ammeter on console or power (supply). Push back in to resume pulsing operation.

NOTE

An auxiliary connection is available to start or stop the CP1 without stopping the weld sequence (see AVC LOCKOUT, refer to Section 3.09).

4.08 GS1 Gas Slope Control Descriptions

CS1 will not operate with GS1 in MANUAL position. In AUTO position the gas slope sequence will automatically be controlled by signals from the CS1 Control circuitry only.

3. UP/DOWN Switch

With the MANUAL/AUTO switch in MANUAL position the UP/DOWN switch (see NOTE) is used to start upslope (UP) and downslope (DOWN) of gas flow. The rate of slope is determined by the sloping control settings. In AUTO position, the UP/DOWN switch is disabled.

NOTE

Refer to Section 4.04, RP1 Control, for Remote Up/Down Control.

4. GAS FLOW MIN/SLOPING/MAX LED

These three LEDs light to indicate the status of gas flow during a weld.

5. MIN GAS FLOW Control

Adjusts minimum gas flow rate, 0.5 - 3 scfh (0.25 - 1.4 lpm). The numbers surrounding the knob are reference points only and have no set value.

6. MAX GAS FLOW Control

234

GS1 GAS SLOPE

.25 - 1.4 lpm

MIN

GAS FLOW

.5 - 3 SCFH

GAS FLOW

SLOPING

MAX

GAS FLOW

2 - 7 SCFH 1 - 3.3 lpm

DOWN

UPSLOPE

RATE

MANUAL

AUTO

DOWNSLOPE

RATE

OFF

DOWNSLOPE

DELAY

(0 - 10 sec.)

A-02420

98765

Figure 4-7 GS1 Gas Slope

1. ON/OFF Switch

In OFF position GS1 is disabled and gas flow remains at its last setting. The ON position energizes its circuitry.

2. MANUAL/AUTO Switch

MANUAL position allows the operator to manually control gas slope sequence for setup and also during the welding operation.

Adjusts maximum gas flow rate, 2 - 7 scfh (1 - 3.3 lpm). The numbers surrounding the knob are reference points only and have no set value.

7. UPSLOPE RATE Control

Controls the rate (time) for gas flow to increase from minimum flow to maximum. This is done by trial and error in pre-setup. The numbers surrounding the knob are reference points only and do not indicate time (0 slowest, 10 fastest). Refer to Figure 4-10 for details.

8. DOWNSLOPE RATE Control

Controls rate (time) for gas flow to decrease from maximum flow to minimum. This is done by trial and error in pre-setup. Numbers surrounding the knob are reference points only and do not indicate time (0 slowest, 10 fastest). Refer to Figure 4-10 for details.

9. DOWNSLOPE DELAY Control

Allows the start of gas downslope to be delayed for a predetermined amount of time (0 to 10 seconds) after downslope is initiated either manually or by WT1. Numbers surrounding the knob correspond to seconds.

Manual 0-2023 23 OPERATION

4.09 Pre-Operation Setup

A. General

1. Follow all pre-operation set-up procedures required

in the Welding Console and Power Supply instruction manuals.

2. Move the ON/OFF switch on the Weld Sequencer En-

closure to the ON position.

WARNING

The RP1 Control CONTACTOR ON/OFF switch must be in the OFF position before the Weld Sequencer Enclosure or any control module is shut off. If this is not done and the torch is close enough to the workpiece (or ground) when the system is energized an arc transfer can take place.

CAUTION

Pre-operation setup of each module can be done independently from the others but it must be kept in mind that when actual welding sequence begins some controls depend on others for proper operation. For instance, the rate of plasma gas flow must correspond to the current level at any given time or tip damage could occur.

NOTE

Initial current must be within the range selected on the power supply.

EXAMPLE

A. The power supply is set in a range of 25 to 125

amps and the desired initial current is 30 amps. This value is 5 amps above the MIN range of 25 amps (30-25 min = 5).

B. Full current range is 125 amps MAX - 25 amps

MIN = 100 amps.

C. The 5 amps above MIN (25 amp) setting di-

vided by the 100 amp range equals the percentage setting of the INITIAL CURRENT (inner) knod (5 ÷ 100 = 0.05 or (5%). Set knob on 5 (5%).

3. Set initial current time from 0 to 10 seconds using the outer knob on the INITIAL CURRENT/TIME control. The numbers correspond directly to the time in seconds.

4. Set final current at which downslope will end. Final current value is determined the same as in Step 2 above and is set using the inner FINAL CURRENT knob.

5. Adjust UPSLOPE RATE control while test welding until the desired upslope is obtained or use Figure 4-8. Note the number corresponding to the knob position for future reference.

3. If GS1 is installed but not being used, set gas flow with GS1 first then turn GS1 OFF.

4. CS1 and CP1 controls are adjusted within the current range selected on the power supply (determined in Step 1). Some control settings can be made only by trial and error during sample welding operations.

B. CS1 Current Slope

CAUTION

The sloping current must stay within the acceptable range of plasma gas flow rate to prevent tip damage (current too high) or insufficient penetration (current too low).

1. Move the ON/OFF switch to the ON position.

2. Set the starting current from which upslope will begin and the percentage of difference between adjusted MAX (as set on RP1 WELD CURRENT) and MIN of the power supply range and adjust the inner knob (INITIAL CURRENT) to obtain the desired current level.

6. Adjust DOWNSLOPE RATE control while test welding until the desired downslope is obtained (or use Figure 4-8). Record the number corresponding to the knob position for future reference.

7. Set final current time from 0 to 10 seconds using the outer knob on the FINAL CURRENT/TIME control. The numbers correspond directly to the time in seconds.

Final Current

Time

A-02425

8. Adjust DOWNSLOPE DELAY (inner) knob to the desired delay 0 to 10 seconds as indicated by the numbers.

OPERATION 24 Manual 0-2023

Downslope Delay

(0 - 10 sec)

A-02431

3. Determine the relationship required of peak current on time versus background current on-time in percent. Set the PERCENT ON TIME knob to the appropriate number (1 = 10%, 5 = 50%, etc).

Downslope Signal

Initiated

C. CP1 Current Pulser

1. Move ON/OFF switch to the ON position.

2. Adjust the PULSE RATE control knob to set desired pulses per second (clockwise rotation increases pulse rate).

A-02432

One Pulse

50%

Peak ON

50%

Background ON

75%

Peak ON

25%

Background ON

A-02433

NOTE

When sloping the pulse, PERCENT ON TIME of peak current is not proportional to background current on-time.

A-02430

vs. Slope Time For Different Slope Rates

(Same Upslope and Downslope)

Initial and Final Current Control Settings

Rate = 10

Rate = 9

Rate = 8

Rate = 7

Rate = 6

Rate = 5

Rate = 4

Rate = 3

Rate = 2

Rate = 1

Rate = 0

Initial or Final Current Control Setting

0 5 10 15 20 25 30 35

Slope Time (seconds)

Figure 4-8 Upslope and Downslope Rates for Initial or Final Current Settings and Slope Times

Manual 0-2023 25 OPERATION

SLOPE

Time

By Increa sing

PULSE RATE Decreases Unchanged Decreases Decreases

PERCENT ON TIME I ncreases Unchanged Decreases Unchanged

PULSE SLOPE Unchanged Decreases Unchanged Decreases

BACKGROUND CURRENT Unchanged Decreases Unchanged Decreases *

* = No change when Slope Rate set at MAX

ON Time

(Peak Current)

Peak Current

Background Current

Minimum Current

Total Pulse Time

On-Time

(Peak)

Slope Time

SLOPE

Time

ON Time

(Background Current)

On-Time

(Background)

A-02434

Total Pulse

Time

Figure 4-9 Adjusting CP1 Controls

D. WT1 Weld Timer

WT1 controls weld time from the start of upslope to the start of the downslope (timed out) sequence when CS1 is used. Calculate or determine the time by timing the sequence during a test weld.

When WT1 is used to time spot welds determine the 'time on' of the weld. Contactor closure will activate the timer for each spot weld. Make sure to shut CS1 off when spot welding.

1. Set the SECONDS-TENTHS dial to the required weld time.

2. Move the ON/OFF switch to the ON position to activate the timer.

3. Activate the RP1 CONTACTOR ON switch. One spot weld sequence will be completed.

4. Press the RP1 SPOTWELD switch as required for additional welds.

4. Determine necessary background current and calculate the percent of the power supply range setting as done for CS1 INITIAL CURRENT. If the welding console has an ammeter, while welding, set by pulling the BACKGROUND CURRENT knob out and rotate the knob until the desired amperage is read on the ammeter. Push the knob back in.

5. While making a sample weld, adjust the PULSE SLOPE control knob until the desired rate of change between background and peak current is achieved.

Peak Current

Background Current

Pulse Slope

A-02435

WARNING

The RP1 Control CONTACTOR ON/OFF switch must be in the OFF position before the Weld Sequencer Enclosure or any control module is shut OFF. If this is not done and the torch is close enough to the workpiece (or ground) when the welding system is energized an arc transfer can occur.

E. GS1 Gas Slope

1. Make sure plasma gas supply is turned on.

2. Make sure the welding console is in SET mode and power is ON.

3. Move the GS1 ON/OFF switch to ON position.

4. Move the GS1 MANUAL/AUTO switch to MANUAL position.

5. Move the GS1 UP/DOWN switch to DOWN position (momentary)

CAUTION

Minimum sloping and maximum gas flow rates must stay within the acceptable range of the current at each point to prevent tip damage (gas flow too low) or cutting action (gas flow too high).

6. Adjust the MIN GAS FLOW knob until the required minimum plasma gas flow rate is shown on the welding console flowmeter.

7. Move the GS1 UP/DOWN switch to UP position (momentary).

8. Adjust the MAX GAS FLOW knob until the required maximum plasma gas flow rate is shown on the welding console flowmeter.

9. Adjust GS1 UPSLOPE RATE to correspond to current upslope rate (if CS1 is used) or to achieve the desired rate refer to Figure 4-10.

OPERATION 26 Manual 0-2023

Max - Min Gas Flow (scfh)

Rate = 10

Rate = 9

Rate = 8

Rate = 6

Rate = 7

Rate = 5

Rate = 4

Rate = 2

Rate = 3

Rate = 1

Rate = 0

Time (Seconds)

Figure 4-10 GS1 Upslope and Downslope Rate Selection

10. Adjust GS1 DOWNSLOPE RATE to correspond to current downslope rate (if CS1 is used) or to achieve the desired rate refer to Figure 4-10.

11. Adjust delay time for the start of downslope using the GS1 DOWNSLOPE DELAY knob. The numbers specify delay time in seconds (from 0 to 10 seconds).

4.10 System Operation

NOTES

Refer to Appendix VI for timing and detailed sequence of operation for all Weld Sequencer Models.

A-02436

70 80 90 100

5. Move the RP1 Control CONTACTOR ON/OFF switch to ON position to close the main contactor.

6. Push the RP1 Control START SEQUENCE switch to start the welding sequence (see NOTES).

NOTES

1. If spot welding, once the CONTACTOR switch is moved to ON position only the SPOTWELD switch must be pressed to continue.

2. If GS1 is not used the entire weld sequence will start with contactor closure and pressing the START SEQUENCE switch. If GS1 is set in to MANUAL, CS1 (if used) will not operate.

Refer to Appendix VII for timing and detailed sequence of operation for GS1 Gas Slope Only.

1. Position torch for start of weld.

2. Turn on gas supplies.

3. If CS1 is not used and GS1 is set to MANUAL, start gas upslope by pressing the RP1 Control START SEQUENCE switch. Start gas downslope by pressing the RP1 Control START DOWNSLOPE switch.

3. Activate welding console, coolant recirculator, power supply, weld sequencer and any accessory control circuits.

4. Turn on all control modules in the weld sequencer that are to be used.

Manual 0-2023 27 OPERATION

OPERATION 28 Manual 0-2023

SECTION 5:

CUSTOMER/OPERATOR

SERVICE

5.03 Troubleshooting Guide General Information

WARNING

5.01 Introduction

This Section provides service diagnostics for the Weld Sequencer, allowing the Technician to isolate any faulty Subassemblies. Refer to Subsection 5.05, Parts Replacement Procedures, for parts replacement instructions.

Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other Subassemblies of this unit. Evidence of unauthorized repairs will void the factory warranty.

NOTE

The troubleshooting contained in this manual is for the Weld Sequencer only. Troubleshooting other parts of the system is covered in the separate manuals for that product.

5.02 Transformer Connections

The main transformer in the Weld Sequencer Enclosure is compatible with input voltages of 115 and 230VAC. Selection is made on the terminal strip on the rear panel of the Enclosure using two jumper terminals. Figure 5-1 shows the jumper locations for the different voltages.

230 Volt Jumpers

1 2 3 4 5 6 7

TB4 Terminal Strip

115 Volt Jumpers

1 2 3 4 5 6 7

TB4 Terminal Strip

Figure 5-1 Input Voltage Terminal Locations

A-02404

A-02405

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

A. Troubleshooting

This manual provides troubleshooting and parts replacement. In most cases, it requires Weld Sequencer disassembly and live measurements.

Troubleshooting and repair of this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment.

If major complex subassemblies are faulty, the faulty subassembly must be returned for repair.

NOTE

Follow all instructions as listed and complete each in the order presented.

Malfunctions may be due to faulty connections rather than a faulty component. Check all connections to the components that appear to be malfunctioning. The troubleshooting guide is arranged in the normal operating sequence of the Weld Sequencer (refer to Appendix VI or VII) for easy reference. Before troubleshooting is started, the Weld Sequencer should be isolated from the system to confirm that the problem exists in the Weld Sequencer and not another part of the system. If a problem is in the power supply, welding console, or other component of the system, check their respective Manuals supplied with that product.

The Weld Sequencer contains accessory components of the welding system and consists of individual modules. It is important to isolate the area of the trouble should problems occur. The quickest way to identify whether the problem is in the Weld Sequencer or one of the other components of the welding system is to take the Weld Sequencer out of the system by running GS1 GAS FLOW up to the maximum flow desired, then shutting the GS1 module OFF. If CS1 and/or CP1 are connected they also must be turned OFF. Try a weld. If the problem is corrected the fault is in the Weld Sequencer. If it doesn’t correct the problem, the fault is probably in the welding console, power supply or RP1 Remote Control. RP1 can be isolated by switching the welding console and power supply out.

Manual 0-2023 29 Section Name

Subsection 5.04 includes specific test procedures, as referenced by the troubleshooting guide, for any specific test(s) to be performed.

B. How to Use the Troubleshooting Guide

The following information is a guide to help the Service Technician determine the most likely causes for various symptoms. This guide is set up in the following manner:

B. Cannot set desired plasma gas flow rate (GS1 in

use)

1. GS1 not turned on

a. Turn on

2. Gas supply not turned on

a. Turn on

1. Perform operational check(s) on the equipment to isolate problem to possible circuit(s).

2. Determine symptom and isolate to defective assembly using the following format:

System normal operational sequence and condition(s)

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

3. Locate your symptom in the appropriate.

4. Check the causes (easiest listed first) for the symptom.

5. Check the remedies listed for each cause.

6. Repair as needed being sure to verify that unit is fully operational after any repairs.

NOTES

While troubleshooting visually inspect the internal components for signs of overheating, fractures and damage.

With all components of the welding system ready for operation, move the Weld Sequencer Enclosure ON/OFF switch to the ON position. The red AC POWER light comes ON.

A. No red AC POWER light

1. No input power

a. Check input power connections and fuses

2. Fuse 1FU blown

a. Check and replace

3. ON/OFF switch faulty

a. Check and replace

4. AC POWER light

a. Replace

3. GS1 set in AUTO using current slope

a. Switch to manual, adjust flow rates and switch

to AUTO sequence

4. Plasma gas metering valve in Welding Console not completely opened

a. Open valve completely

5. Incorrect gas supply pressure to console

a. Reset or replace regulator, check for gas leaks

6. Faulty GS1 PC board

a. Replace

7. GS1 motor/valve assembly out of calibration

a. Recalibrate, refer to Section 5.05-F

8. Blockage in hoses, console, or torch, restricting flow

a. Locate and repair

If CS1 is not on when the RP1 CONTACTOR switch is moved to “ON” the power supply contactor closes and the welding arc should transfer. If CS1 is used then the welding arc is established when RP1 START SEQUENCE is pressed.

C. No welding arc transfer:

CS1 and WT1 not used, RP1 only used

1. CC Relay faulty or missing

a. Check and replace

2. RP1 contactor switch faulty

a. Check and replace

WT1 and RP1 used

3. WT1 faulty

a. Turn WT1 off, if arc transfers replace WT1 PC

Board. If not, refer to Section 5.04-B

CS1 and RP1 used

4. RP1 contactor switch not on before start sequence is pressed

a. Switch to ON

Section Name 30 Manual 0-2023

5. CS1 faulty

CS1 used, Initial or Final Current incorrect

a. Disconnect J8, connect to jumper plug, if arc

transfers replace CS1 PC Board. If no transfer, refer to Section 5.04-C

GS1, CS1 & RP1 used

6. GS1 (if used) in MANUAL position

a. Switch to AUTO

D. Contactor stays on

CS1 and WT1 not used, GS1 and CP1 on or off

1. Console or power supply not switched to remote contactor control

a. Check & correct

2. RP1 contactor switch faulty

a. Replace

WT1 used. Contactor does not shut off at end of timing period but shuts off with RP1 contactor switch

3. Faulty CC relay

a. Check & replace; Refer to Setion 5.04-B

5. Improper setting or faulty CS1

a. Correct setting or replace CS1 PC Board

CP1 used, Welds at background current only (no pulse)

6. BACKGROUND CURRENT knob (pull for display) is pulled out

a. Push knob in

7. Faulty CP1 PC board

a. Replace

CS1 used, Welds at peak only

8. Background current set to same as peak

a. Set properly

9. Stop pulse signal applied at wrong time (J7-13, TB2-3 wire #22 connected to signal common wire #11 TB1-1, 2, 3, 4)

a. Remove stop pulse signal (refer to Appendix)

10. Faulty CP1 PC Board

4. Faulty WT1

a. Check per Section 5.04-A and replace WT1 PC

Board if necessary

CS1 used. Transfer occurs as soon as RP1 contactor switch turned on, prior to start sequence

5. Faulty CC relay

a. Check replace

6. Faulty CS1

a. Replace CS1 PC board

E. No current control or incorrect current level

CS1 & CP1 not used

1. Power supply on wrong range

a. Set to proper range

2. Power supply or console not set to remote current

a. Set to remote

3. RP1 current control faulty

a. Check & replace (refer to Section 5.04-C)

4. If CS1 or CP1 not installed, J7 or J8 not plugged into jumper plugs

a. Replace

F. At end of set initial current time current does not

start to increase

1. Initial current set same as weld current

a. Reset

2. CS1 faulty

a. Replace CS1 PC Board

G. Gas does not start to increase at end of set initial

current time

1. GS1 not ON

a. Turn GS1 to ON

2. Gas supply not on

a. Open supply valve

3. MIN gas flow set to close to MAX flow

a. Check MIN flow setting

4. Plasma gas control valve in welding console not opened all the way

a. Open valve completely

5. Faulty GS1 valve

a. Install jumper(s)

Manual 0-2023 31 Section Name

a. Replace (refer to Section 5.05-F)

6. Faulty GS1 PC Board

3. WT1 timer faulty

a. Replace

H. Torch tip blows during upslope sequence

1. Current slope too fast or gas slope too slow to maintain proper arc characteristics

a. Check CS1 (refer to Section 4.06) and GS1 (refer

to Section 4.08) for proper adjustment

2. Gas leaks in system

a. Check and correct

3. Incorrect gas flow

a. Adjust

I. Welding arc cuts instead of maintaining keyhole

1. Current or gas flow too high to maintain proper keyhole

a. Adjust properly

J. Current doesn’t reach proper peak level (also see

Symptom 'D')

1. RP1 Weld Current set too low

a. Adjust RP1 to desired peak current

K. Plasma gas flow doesn’t reach desired maximum

rate

1. Plasma gas control valve in welding console not opened all the way

a. Open valve completely

2. Plasma gas pressure incorrect

a. Adjust pressure check for leaks replace regula-

tor

a. Check and replace

4. CS1 PC Board faulty

a. Replace

M. Gas flow does not start to decrease

1. GS1 set for delay of downslope

a. Check GS1 DOWNSLOPE DELAY setting

2. GS1 PC Board faulty

a. Replace

N. GS1 or CS1 downslope not delayed when set for

delay

1. DOWNSLOPE DELAY circuit faulty

a. Replace PC Board in faulty module GS1 or CS1

At the end of the downslope sequence the current is at the CS1 FINAL CURRENT set level and the gas flow at the GS1 MIN flow setting. The CS1 FINAL TIME starts timing. If keyhole welding the keyhole should be closed at this point.

O. Keyhole weld not closing

1. MIN gas flow too high

a. Reduce flow rated

P. Current doesn’t reach final current level or goes

lower

1. CS1 FINAL CURRENT at wrong setting

a. Check and adjust

2. Faulty CS1 PC board

3. Faulty GS1 PC Board

a. Replace

4. GS1 Motor/Valve Assembly out of calibration

a. Recalibrate (refer to Section 5.05-F)

As the weld time set on WT1 times out, the start of CS1 and GS1 downslope is signaled. The AL relay is also energized.

L. Current does not start to decrease

1. CS1 set for delay of downslope

a. Check CS1 DOWNSLOPE DELAY setting

2. WT1 not ON

a. Turn WT1 to ON

Section Name 32 Manual 0-2023

a. Replace

Q. Minimum gas flow too high or too low

1. GS1 MIN flow at a wrong setting

a. Check and adjust

2. Gas pressure incorrect

a. Reset or replace regulator or check for leaks

3. GS1 PC Board faulty

a. Replace

4. GS1 Motor/Valve Assembly out of calibration

a. Recalibrate (refer to Section 5.05-F

5. Blockage in hoses, console or torch restricting flow

a. Find and repair

R. Using RP1 and CP1, spot welds are erratic with

varying penetration

1. CP1 on during spot welding

a. Turn CP1 to OFF

When the CS1 FINAL TIME times out the CC relay is energized, opening the circuit to the main contactor in the power supply. Welding arc is extinguished.

S. Welding arc does not extinguish

1. CC relay faulty

a. Replace relay

2. CS1 PC Board faulty

a. Replace

B. Checking Contactor Control

With the Weld Sequencer in OFF position and the RP1 CONTACTOR switch ON. Use an ohmmeter to check for continuity from black to white/brown wires on the console P/S cable J5-4 and J5-5. If there is no continuity, check each component and wire in the contactor control circuit diagram.

Console/Power

Supply Control

Cable

Black

J5-4

Weld

Sequencer

Enclosure

2627

J6-4

Remote

Control

Cable

J9-4

RP1

Contactor

OFF

At the end of the weld the RP1 CONTACTOR switch is moved to the OFF position first to open the main contactor in the power supply. Then the Weld Sequencer Enclosure is turned OFF along with the other components of the system.

T. Welding arc transfers when CS1, WT1 or Weld

Sequencer is turned OFF

1. RP1 CONTACTOR switch not OFF

a. Move RP1 to OFF

5.04 Test Procedures

WARNING

Some tests involve voltage measurements made with power ON. Tests requiring voltage measurements are marked with this warning symbol. All other tests are to be made with the primary system power turned OFF.

White/Brown

J5-3

J6-3

J9-3

2828

A-02438

Figure 5-2 Contactor Control Circuit Diagram

C. Checking Current Control

With CS1 and CP1 turned OFF or J8 and J7 connected to the jumper plugs and RP1 CURRENT CONTROL set to minimum, check for continuity (approximately zero ohms) from J5-7 (red wire) to J5-13 (blue wire), (refer to Figure 5-3) with an ohmmeter set on “times 1000” scale. Check for 10K (10,000) ohms from J5-7 to J5-1. Setting RP1 CURRENT CONTROL to maximum will reverse the readings (zero ohms between J5-7 and J5-1, and 10K ohms between J5-7 and J5-13). If proper readings are not obtained check individual wire connections and components to identify the fault.

The following tests are suggested for specific problems listed in the troubleshooting guide. Letter designations correspond to those listed in the remedy area of the guide.

A. Checking WT1

To test WT1 move the torch to about 1 inch (25.4 mm) above the workpiece. Arc will not transfer but the gas should go through the upslope sequence to max flow and start to downslope at the end of set weld time (or at end of downslope delay time). If this does not happen WT1 is faulty and must be replaced.

Manual 0-2023 33 Section Name

Weld Sequencer Enclosure

CS1 or Jumper CP1 or Jumper

A-02439

Console/Power

Supply Control

High

Wiper

Low

Cable

Orange

J5-1

Red

J5-7

Blue

J5-13

OFF

J8-5 J8-6 J7-5 J7-6

20 20

TB3-4

21 23

1 2 3 4

TB1

Figure 5-3 Current Control Diagram

5.05 WT1 Weld Timer Parts Replacement Procedures

NOTE

Refer to Section 6.08 for parts list and overall detail drawing.

A. WT1 Timer Thumbwheel Switch

Replacement

1. Remove WT1 from Weld Sequencer Enclosure by re-

moving the four (4) outside button head screws on the front panel (see Parts List)

2. Remove the WT1 cover.

3. Remove the four (4) screws that hold the timer switch

to the front panel. Use 3/64" hex wrench for the screw head and 3/16" driver for the hex nut.

4. To remove the switch, press down on the large PC

board beside the two blue rectangular resistor assemblies while pulling up on the switch assembly until it clears the white connector.

J6-1

J6-7

Remote

Control

Cable

J9-1

J9-7

J9-13

RP1

Max

Current Control

(10K ohms)

Min

OFF

J6-13

2. Remove the ON/OFF switch knob by pulling straight out. Remove the hex nut that secures the switch to the front panel.

3. Remove the two screws securing the front of the PC board to the two spacers.

4. Press each locking tab of the two plastic PC board supports inward and slide the PC board off.

5. Install the new PC board by reversing these steps.

C. CP1, CS1 & GS1 PC Board Removal

NOTE

Refer to Sections 6.05, 6.06 and 6.06 for parts list and overall detail drawing.

1. Remove cover from the module

2. Disconnect the plug from the PC board.

3. Remove all the single knobs from the switches mounted on the PC board by pulling straight out. Remove all the concentric (dual) knobs (CS1 only) by loosening the set screws securing each knob to the switch shaft.

5. Install the new switch by reversing the above steps.

B. WT1 PC Board Replacement

NOTE

Refer to Section 6.08 for parts list and overall detail drawing.

1. Remove the Timer Thumbwheel Switch per Section

5.05-A.

Section Name 34 Manual 0-2023

Cover

PC Board

Connector

A-02440

Washer

Hex Nut

Knob

D. GS1 Motor/Valve/Pot Assembly

Replacement

NOTE

Refer to Sections 6.04 and 6.05 for parts list and overall detail drawing.

The main components of the Motor/Valve/Pot Assembly are replaceable. These include the motor assembly, valve assembly, pot assembly, pinion gear, and coupling. The assembly can also be purchased complete. Replacement of the components require that GS1 be removed from the Weld Sequencer. Proceed as follows:

1. Disconnect all power to the welding system.

2. Remove cover or side panels (enclosure extension).

3. Remove the two welding console plasma gas hoses from the rear of the Weld Sequencer Enclosure. Remove the four screws holding the GS1 gas hose connectors to the Enclosure rear panel.

4. Remove connector from the rear of GS1.

5. Remove the four screws securing GS1 to the front of the Weld Sequencer Enclosure.

Figure 5-4 Typical PC Board Removal

4. Remove all the hex nuts securing Figure 4-D Typical PC Board Removal (CP1, CS1 and GS1)

5. Press the locking tab on each PC board support and raise the board past the locking position to allow removal of the board.

6. Install the PC board (component side up) into the switch mounting holes in the front panel. Press the board down onto the supports until it snaps into the locking tabs.

7. Secure the switches to the front panel with supplied hex nuts.

8. Position knobs on the flats of the switch shafts and push on.

9. Connect plug(s) to connector(s).

10. Replace module cover and secure.

6. Slide GS1 out of the Weld Sequencer Enclosure.

7. Remove the cover from GS1.

8. Disconnect the two connectors (motor and pot) on the Motor/ Valve/Pot Assembly.

9. Remove the four screws securing the Assembly to the GS1 rear panel.

If the complete Motor/Valve/Pot Assembly is to be replaced go to Section 5.05-H.

E. Coupling, Pinion Gear, Pot Assembly and

Motor Assembly Replacement

NOTE

Refer to Section 6.05 for parts list and overall detail drawing.

1. If the motor assembly is to be replaced loosen the two 1/16" hex set screws securing the coupling to the motor assembly. If the coupling or pinion gear is to be replaced loosen the two 1/16" hex set screws securing the coupling to the pinion gear.

2. Remove the four screws from the motor assembly and remove the motor and coupling, leaving the pinion gear in place

Manual 0-2023 35 Section Name

NOTES

11. Slide the valve assembly out of the slot in the bracket.

If the pinion gear is left engaged with the two other gears the assembly will not require calibrating after assembly.

If the pinion gear is to be replaced try to keep both gears from rotating until the new gear is installed.

3. Remove the pinion gear by pulling straight out (see NOTE above).

4. Slide new pinion gear into teeth of valve and pot gears (not rotating more than one tooth) and into bushing on valve/pot bracket.

5. Slide the new coupling onto the motor shaft. Do not tighten.

6. Guide the coupling end of the motor through the hole in the motor mounting bracket. Align the motor and pinion shafts and slide coupling onto the pinion gear shaft until both shafts are engaged in the coupling.

7. Secure the new motor assembly to the bracket with the connector toward the lower inside corner of the mounting bracket.

8. Slide the coupling up against the pinion gear and secure all four set screws.

12. Disconnect the two hoses from the valve assembly. Use a wrench to hold the elbow fitting.

13. Add pipe sealant to the two hose fittings and install on the new valve assembly. Make sure hoses are through the holes in the GS1 rear panel.

14. Back GS1 up to the right side of the Weld Sequencer Enclosure and

a. Connect the Weld Sequencer Enclosure J3 plug to

the rear of GS1.

b. Connect the upper gas hose from the valve assem-

bly to the PLASMA IN hose from the Welding Console

c. Connect the lower gas hose from the valve assem-

bly to the PLASMA OUT hose from the Welding Console.

d. Reconnect the motor assembly and pot assembly

plugs to the GS1 wiring harness.

15. Turn on the power to the system.

16. Put Welding Console in SET position.

17. Turn Weld Sequencer Enclosure to ON position.

F. Valve Assembly Replacement

NOTE

Refer to Section 6.05 for parts list and overall detail drawing.

1. Disconnect all power to the welding system.

2. Remove cover or side panels (enclosure extension).

3. Remove the two welding console plasma gas hoses from the rear of the Weld Sequencer Enclosure. Remove the four screws holding the GS1 gas hose connectors to the Enclosure rear panel.

4. Remove connector from the rear of GS1.

5. Remove the four screws securing GS1 to the front of the Weld Sequencer Enclosure.

6. Slide GS1 out of the Weld Sequencer Enclosure.

7. Remove the cover from GS1.

8. Disconnect the two connectors (motor and pot) on the Motor/ Valve/Pot Assembly.

9. Remove the four screws securing the Assembly to the GS1 rear panel.

18. Turn GS1 to ON position. Set for MANUAL operation. Set MIN GAS FLOW to 0 (min). Move UP/ DOWN switch to DOWN. GAS FLOW MIN light should be on when motor stops.

19. Rotate gear on valve assembly until gas flow reaches minimum (0.4 scfh on flowmeter).

20. Slide the new valve assembly into the slot in the valve/pot mounting bracket and engage the gear with the pinion gear. Slide the valve clamp between the valve and the bracket.

21. Secure valve clamp to bracket with the two screws provided.

22. With the valve gear firmly engaged with the pinion gear, tighten the large hex nut on the gear side of the bracket.

23. Slope the gas flow up and down with the UP/DOWN switch and check the accuracy on the Welding Console flowmeter.

If the calibration is off loosen the valve assembly from the mounting bracket and disengage the valve and pinion gears, then repeat to steps 18 - 23 above.

10. Remove the two screws securing the valve clamp to the valve/pot mounting bracket. Loosen the hex nut securing the valve to the bracket.

Section Name 36 Manual 0-2023

G. Potentiometer Assembly Replacement

H. Reinstalling the Motor/Valve/Pot Assembly

NOTE

Refer to Section 6.05 for parts list and overall detail drawing.

1. Disconnect all power to the welding system.

2. Remove cover or side panels (enclosure extension).

3. Remove the two welding console plasma gas hoses from the rear of the Weld Sequencer Enclosure. Remove the four screws holding the GS1 gas hose connectors to the Enclosure rear panel.

4. Remove connector from the rear of GS1.

5. Remove the four screws securing GS1 to the front of the Weld Sequencer Enclosure.

6. Slide GS1 out of the Weld Sequencer Enclosure.

7. Remove the cover from GS1.

8. Disconnect the two connectors (motor and pot) on the Motor/ Valve/Pot Assembly.

9. Remove the four screws securing the Assembly to the GS1 rear panel. If the complete Motor/Valve/Pot Assembly is to be replaced go to Section 5.05-H.

10. Remove the two screws securing the pot clamp to the mounting bracket. Loosen the hex nut securing the pot assembly to the mounting bracket.

1. Make sure the two plasma gas hoses are through the holes designated on the GS1 rear panel. Add pipe sealant to the two hose fittings and install “plasma out” hose in the bottom of the gas valve assembly. Install “plasma in” hose in the top of the gas valve assembly.

2. Secure Motor/Valve/Pot Assembly to the rear panel of GS1 with the four screws provided (through the four grommets).

3. Connect the motor assembly and pot assembly plugs to the GS1 wiring harness.

4. Replace GS1 cover

5. Feed the GS1 plasma gas hose through the Weld Sequencer Enclosure front panel opening and secure to the Enclosure rear panel in the proper holes.

6. Connect the Enclosure wiring harness plug J3 to the rear connector on the GS1.

7. Position GS1 into the Enclosure front panel opening and secure with the four button head screws.

8. Connect the plasma gas hoses from the Welding Console to the appropriate fittings on the Enclosure rear panel.

9. Replace either Enclosure cover or side panels as required.

11. Slide the pot assembly out of the mounting bracket slot.

12. Plug the new pot assembly into the connector in the GS1 wiring harness.

13. Plug in the Weld Sequencer Enclosure to a power source and turn to ON.

14. Move MIN GAS FLOW switch to MIN (0) position.

15. Move UP/DOWN switch momentarily to DOWN position.

16. Adjust the pot clockwise until the SLOPING light goes out and the MIN light stays on continuously. This is about 1-1/2 turns from max clockwise rotation.

17. Move GS1 to “OFF” and unplug the Weld Sequencer Enclosure

18. Keeping the pot in this position install in the mounting bracket slot and engage the gear teeth with the pinion gear teeth.

19. Install the pot clamp on the outside of the mounting bracket and secure with the two screws provided.

20. With the pot gear firmly engaged with the pinion gear, tighten the large hex nut on the gear side of the bracket.

Manual 0-2023 37 Section Name

Section Name 38 Manual 0-2023

SECTION 6:

PARTS LIST

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all basic replaceable parts. The parts lists are arranged as follows:

Section 6.03 Weld Sequencer Enclosure

Section 6.04 GS1 Gas Slope (Front Panel)

Section 6.05 GS1 Gas Slope (Rear Panel)

Section 6.06 CS1 Current Slope

Section 6.07 CP1 Pulser

Section 6.08 WT1 Weld Timer

Section 6.09 RP1 Remote Pendant Control

NOTE

Parts listed without item numbers are not illustrated, but may be ordered by the catalog number shown.

B. Returns

If a Thermal Arc product must be returned for service, contact your Thermal Arc distributor. Materials returned to Thermal Arc without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the description column of the Parts List. Also, include the model and serial number of the machine as shown on the data tag attached to the unit. Address any inquiries to your authorized Thermal Arc distributor.

Manual 0-2023 39 Section Name

6.03 Weld Sequencer Enclosure

Item # Qty Description Reference Catalog #

1 Weld Sequencer Enclosure 7-3104 1 1 Chassis Assembly 2 1 Cover 9-4152 3 2 Chassis Brace 4 2 Relay Socket 9-2731 5 1 Relay- 3PDT, 12VDC CC 9-5167 6 1 Relay- DPDT, 12VDC US 9-5164 7 1 Transformer- 115/230V Primary, 28V Secondary T1 9-4128 8 1 Fuse Holder 9-2936 9 1 Fuse- 250V, 1A 1FU 9-5530

10 1 Strain Relief 9-2179 11 1 Plastic Bushing 8-0228 12 2 Terminal Strip- 7 Section TB1 & TB4 9-4067 13 2 Terminal Strip- 15 Section TB2 & TB3 9-3589 14 1 Toggle Switch SW1 9-3325 15 1 Receptacle- 16 Circuit J5 9-5218 16 6 Pin B 9-3296 17 1 Receptacle- 14 Circuit J6 9-3293 18 12 Socket 9-3297 19 1 Light- Red, 115VAC LT1 8-1885 20 4 Rubber Foot 8-0381 21 1 Enclosure Expansion Chassis 9-4151 22 2 Side Panel 9-4153

Section Name 40 Manual 0-2023

8, 9

15, 16

17, 18

A-02441

Manual 0-2023 41 Section Name

6.04 GS1 Gas Slope (Front Panel)

Item # Qty Description Reference Catalog #

1 GS1 Gas Slope 7-3101 1 1 GS1 Chassis Assembly 2 1 GS1 Cover 3 1 GS1 PC Board Assembly 9-4135 4 1 LED Assembly D139,140,141 9-4139 5 1 Toggle Switch- SPDT, Mom. On SW102 9-5212 6 2 Toggle Switch- 3PDT SW101, SW103 8-1778 7 3 PC Board Support 9-5333 8 1 GS1 Front Panel 9-4147 9 5 Control Knob 9-4144

A-02442

Section Name 42 Manual 0-2023

6.05 GS1 Gas Slope (Rear Panel)

Item # Qty Description Reference Catalog #

10 2 Resistor- 15 ohm, 25w R142 & R143 9-4127 11 1 Motor Assembly M101 9-4138 12 1 Potentiometer Assembly R147 9-4140 13 1 Valve Assembly 14 1 Pinion Gear 9-4126 15 1 Coupling 9-4143 16 1 Gearbox Side- Motor 17 4 Gearbox Spacer 18 1 Gearbox Side- Pot & Valve 19 1 Potentiometer Clamp 21 2 Gas Hose Assembly 9-4131 22 1 Receptacle- 16 Circuit J3 9-5218 23 10 Pin 9-3296 24 4 Grommet

A-02443

Manual 0-2023 43 Section Name

6.06 CS1 Current Slope

Item # Qty Description Catalog #

1 CS1 Current Slope 7-3102 1 1 CS1 Chassis Assembly 2 1 CS1 Cover 3 1 CS1 PC Board Assembly 9-4136 4 3 PC Board Support 9-5333 5 1 CS1 Front Panel 9-4148 6 2 Control Knob 9-4144 7 3 Control Knob- Outer 9-4145 8 3 Control Knob- Inner 9-4146

A-02444

Section Name 44 Manual 0-2023

6.07 CP1 Pulser

Item # Qty Description Catalog #

1 CP1 Pulser 7-3103 1 1 CP1 Chassis Assembly 2 1 CP1 Cover 3 1 CP1 PC Board Assembly 9-4137 4 3 PC Board Support 9-5333 5 1 CP1 Front Panel 9-4149 6 5 Control Knob 9-4144

A-02445

Manual 0-2023 45 Section Name

6.08 WT1 Weld Timer

Item # Qty Description Reference Catalog #

1 WT1 Weld Timer 7-3100 1 1 WT1 Chassis Assembly 2 1 WT1 Cover 3 1 Thumbwheel Switch Assembly SW2 9-4134 4 1 WT1 PC Board Assembly 9-4133 5 2 PC Board Support 9-5333 6 2 Threaded Spacer 9-5543 7 1 WT1 Front Panel 9-4150 8 1 Control Knob 9-4144

A-02446

Section Name 46 Manual 0-2023

6.09 RP1 Remote Pendant Control

Item # Qty Description Reference Catalog #

1 RP1 Remote Pendant Control 7-3106 1 1 RP1 Enclosure 2 1 RP1 Front Panel 9-4160 3 1 Dial- 10 Turn 9-4159 4 2 Handle 9-4158 5 1 Eyebolt 9-5553 6 3 Pushbutton Switch, Mom., SPDT SW 9-4156 7 1 Potentiometer- 10 Turn, 10K ohm 9-4157 8 1 Toggle Switch- DPDT SW 9-3405 9 1 Receptacle- 16 Circuit J12 9-5218

10 11 Pin 9-3296

A-02447

Manual 0-2023 47 Section Name

Section Name 48 Manual 0-2023

APPENDIX I: MOTION CONTROL & WIRE FEED

INTERFACE DIAGRAM

Start Of

Sequence

Initial

Current

AL Deenergized

CC Energized

NOTE: TD1 and TD3 are customer supplied adjustable time delay relays used to delay the start of motion or wire feed controls at any point during the Initial Current, Upslope, or Peak Current sequence.

TD2 is a customer supplied adjustable time delay relay used to stop the wire feed control at any point during the Downslope or Final Current sequence.

TD1 or TD3

AL Energized

Peak Weld

Current

Upslope

AL Deenergized

CC Deenergized

TD2

Downslope

Final

Current

AL Energized

CC Relay operates only with CS1 or WT1. AL Relay operates only with CS1. TD1 - Wire Feed Start TD2 - Wire Feed Stop TD3 - Motion Start

End Of

Sequence

AL Deenergized

CC Energized

Weld Sequencer

Enclosure

Input Power For TD Relays

Customer Supplied

TD1

TD3

TD2

Input Power For Motion Control Device

And Wire Feed

TD3

Motion Device

Motion

TD2

Wire

TD1

Wire Feed

TD1, TD2 and TD3 are customer supplied adjustable 115 VAC time delay relays (delay on operate). Latch Relay, LR, is necessary to provide proper sequence of time delay relays TD1, TD2 and TD3.

A-02448

Manual 0-2023 49 APPENDIX

APPENDIX II: WELD SEQUENCER TERMINAL STRIP

DIAGRAM

TB4

TB1 TB3Wire #

TB1-1

TB1-2

TB1-3

TB1-4

TB1-5

TB1-6

TB1-7

TB2-1

TB2-2

TB2-3

TB2-4

TB2-5

TB2-6

TB2-7

TB2-8

TB2-9

TB2-10

TB2-11

TB2-12

TB2-13

TB2-14

TB2-15

11 11 64 65 66

13 15 22 29 30 31

32 33 34 35 36 37 38 39 40

TB4-1

TB4-2

TB3-1

TB3-2

TB3-3

TB3-4

TB3-5

TB3-6

TB3-7

TB3-8

TB3-9

TB3-10

TB3-11

TB3-12

TB3-13

TB3-14

TB3-15

TB4-3

TB4-4

TB4-5

TB4-6

6 7 8 9

Wire #

Rear Panel

Wire #

TB4-7

44 43 42 24 20 16

15 14 13

3 3

2 2 1 1

TB2

Base

A-02449

APPENDIX 50 Manual 0-2023

APPENDIX III: AUXILIARY INTERFACE CONNECTION

DIAGRAM

Weld Sequencer

Jumper

System Control

TB3-5

TB3-4

TB1-2

TB3-3

TB3-2

TB2-1

TB2-2

TB3-6

TB1-1

TB4-1

TB4-2

TB2-3

TB1-4

Customer Supplied

Pot High

Wiper

Pot Low

10k, 2W Potentiometer For Remote Current Control

If NC Switch Used, Open Momentarily, Then Close. If NO Switch Used to Start Sequence, This Must Remain Closed Until WT-1 Times Out. NOTE: If This Set Of Contacts Used For Spotweld Application, Then Jumper Must Be Removed.

Spotweld - Spotweld Will Occur When This Line Is Opened, Then Closed (Open Then Close To Start).

Start Downslope (Momentary Closure)

Start Sequence (Momentary Closure)

Contactor ON/OFF - Resets Control Logic (Second Pole Of Replay)

Contactor ON/OFF (1st Pole Of Relay) - See Warning

Disable Pulser When Closed System Will Weld At Peak Current

Either One Of These Sets May Be Used For Spotweld Applications

TB1-5

TB1-6

TB1-7

External Common

Pulser At Peak Signal

Externally Supplied Voltage

Use For AVC Lockout To Disable An Automatic Voltage Control While Pulser Is Not At Peak

(+5 to +15.5 VAC)

TB2-10

TB2-11

TB2-12

TB2-13

TB2-14

TB2-15

TB2-7

TB2-8

TB2-9

TB2-4

TB2-5

TB2-6

Unplug Unit Before Making Any Connections On TB4.

NOTE

Refer to Appendix I for Relay Timing

WARNING

TB4 Pins 4 - 7 Carry High Voltage.

A-02450

Manual 0-2023 51 APPENDIX

APPENDIX IV: NECESSARY CONNECTIONS - RP-1 NOT

USED WITH CS-1 WITH OR WITHOUT GS-1, WT-1 OR CP-1

TB3-1

TB3-4

TB1-1

TB3-6

TB2-1

TB2-2

Pot High

Pot Low

Resets Control Logic

Wiper

10k, 2 Watt Potentiometer Should Be Used For Remote Current Control (See Note 4)

Contactor Control (See Note 3) Contactor ON/OFF Relay Resets Control Logic

Start Downslope (Momentary Closure) Active When Closed (See Note 2)

Start Sequence (Momentary Closure) Active When Closed (See Note 1)

Contactor Control (See Note 3) Contactor ON/OFF Used To Control The Contactor. When Open The Contactor Cannot Be Energized.

Chassis Ground

Not System Common

A-02451

NOTES

1. Contacts Must Be Open Prior To Downslope Signal.

2. Downslope Signal Not Required If WT-1 Is Used.

3. Contacts Are Off The Same Double Pole Relay

4. Wire #11 Is System Common Not Chassis Ground.

APPENDIX 52 Manual 0-2023

APPENDIX V: NECESSARY CONNECTIONS - RP-1 NOT

USED WITH CP-1, WT-1 SYSTEM

TB3-1

TB3-4

TB1-1

TB1-2

TB3-6

TB3-2

Pot High

Pot Low

Resets Control Logic

Wiper

10k, 2 Watt Potentiometer Should Be Used For Remote Current Control (See Note 2)

Contactor Control (See Note 1) Contactor ON/OFF Relay Resets Control Logic

Spot Weld Closed Contacts Open Then Close To Actuate (Actuate Upon Closure). These Contacts Must Remain Closed Until Spot Weld Is Finished.

Contactor Control (See Note 1) Contactor ON/OFF Used To Control The Contactor. When Open The Contactor Cannot Be Energized.

Chassis Ground

Not System Common

A-02452

NOTES

1. Contacts Are Off The Same Double Pole Relay

2. Wire #11 Is System Common Not Chassis Ground.

Manual 0-2023 53 APPENDIX

APPENDIX VI: TIMING AND SEQUENCE OF OPERATION

FOR WELD SEQUENCER (ALL MODELS)

A-02437

• Power Supply to ON

• Weld Console in RUN position

• Coolant Recirculator to ON

• Gases on

• Torch positioned

• Weld Sequencer Enclosure to ON

• RP1 Control CONTACTOR to ON

• All other control modules to ON

• RP1 START SEQUENCE pressed

• CP1 starts pulsing current

• CS1 INITIAL CURRENT starts timing

• CC Relay de-energized

• AL Relay energized

• CS1 INITIAL CURRENT times out and Signals: CS1 UPSLOPE to start GS1 UPSLOPE to start WT1 to start timing

•Peak current is reached

• Peak plasma gas flow is reached

• AL Relay de-energized

• WT1 times out and Signals: CS1 to start downslope GS1 to start downslope AL Relay energized

• CS1 downslope delayed X seconds

• GS1 downslope delayed X seconds

G and G

• Current reaches FINAL level

• Gas flow reaches MIN flow level

• FINAL CURRENT starts timing

H and H

• FINAL CURRENT times out

• CC Relay energized

• Main Contactor opens

• Welding Arc extinguishes

I and I

• RP1 CONTACTOR to OFF

• All control modules to OFF

• Weld Sequencer Enclosure to OFF

• Welding Console to OFF

• Power Supply to OFF

• Coolant recirculator to OFF

• Gases shut off

APPENDIX 54 Manual 0-2023

APPENDIX VII: TIMING AND SEQUENCE OF OPERATION

FOR GS1 GAS SLOPE ONLY

A-02437

• Power Supply to ON

• Welding Console in RUN position

• Coolant Recirculator to ON

• Gases on

• Torch positioned

• Weld Sequencer Enclosure to ON

• GS1 to ON

• GS1 to MANUAL

• RP1 Control CONTACTOR to ON

• Welding Arc transfers

• Gas at MIN flow

• RP1 START SEQUENCE pressed

• GS1 UPSLOPE starts

• MAX plasma gas flow is reached

E and E

• RP1 DOWNSLOPE pressed

If GS1 DOWNSLOPE DELAY is set at 0 downslope of gas starts

If not set at 0, downslope starts X seconds later at E

G and G

• Gas flow reaches MIN flow level

H and H

• RP1 CONTACTOR to OFF

• Welding Arc extinguishes

I and I

• Weld Sequencer Enclosure to OFF

• Welding Console to OFF

• Power Supply to OFF

• Coolant recirculator to OFF

• Gases shut off

Manual 0-2023 55 APPENDIX

APPENDIX VIII: SYSTEM SCHEMATIC

Art # A-04050

APPENDIX 56 Manual 0-2023

Art # A-04050

Manual 0-2023 57 APPENDIX

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 Victor Brasil

Avenida Brasil 13629-Cordovil Rio de Janeiro, Brazil 21012-351 Telephone: 55-21-2485-8998 Fax: 55-21-2-485-8735

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

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 Chile

Piloto Lazo #90 Cerrillos Santiago, Chile 7278-654 Telephone: 56-2-557-2465 Fax: 56-2-557-5349

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne South Africa

209 Risi Ave. Linmeyer Johannesberg, 2197 South Africa Tel: (27) 11-917 3600 Fax: (27) 11-917 8580

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

Corporate Headquarters

82 Benning Street West Lebanon, NH 03784 USA Telephone: (603) 298-5711 800-752-7621 Fascimile: Email: sales@thermalarc.com

800-221-4401

www.thermalarc.com

Tweco Weld Sequencer User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.05 Precautions De Securite Importantes

1.04 Note, Attention et Avertissement

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

2.01 Scope of Manual

2.02 General Description

2.03 Specifications & Design Features

3.01 Introduction

3.02 Site Selection

3.03 Unpacking

3.05 WT1 Weld Timer

3.06 GS1 Gas Slope

3.07 CS1 Current Slope

3.08 CP1 Pulser

4.01 Introduction

4.03 Weld Sequencer Enclosure Control Descriptions

4.02 Functional Overview

4.04 RP1 Control Descriptions

4.05 WT1 Weld Timer Control Descriptions

4.06 CS1 Current Slope Control Descriptions

4.07 CP1 Pulser Control Descriptions

4.08 GS1 Gas Slope Control Descriptions

4.09 Pre-Operation Setup

4.10 System Operation

5.01 Introduction

5.02 Transformer Connections

5.04 Test Procedures

5.05 WT1 Weld Timer Parts Replacement Procedures

6.01 Introduction

6.02 Ordering Information

6.03 Weld Sequencer Enclosure

6.04 GS1 Gas Slope (Front Panel)

6.05 GS1 Gas Slope (Rear Panel)

6.06 CS1 Current Slope

6.07 CP1 Pulser

6.08 WT1 Weld Timer

6.09 RP1 Remote Pendant Control

APPENDIX VIII: SYSTEM SCHEMATIC