SanRex IA-3000TP-U3E Operator'S Manual Download

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6.01.02 Stick Welding Sequence with Voltage Reduction Device Enabled...................................... 59

6.02 AC or DC HF TIG Welding....................................................................................................... 60

6.03 LIFT TIG Sequence ................................................................................................................... 61

6.03.01 Standard Mode ...................................................................................................................... 61

6.03.02 Slope Mode ........................................................................................................................... 61

6.03.03 Repeat Mode ......................................................................................................................... 61

6.04 HF TIG Sequence ...................................................................................................................... 62

6.04.01 Standard Mode ...................................................................................................................... 62

6.04.02 Slope Mode ........................................................................................................................... 62

6.04.03 Repeat Mode ......................................................................................................................... 62

6.04.04 Spot Mode ............................................................................................................................. 63

6.05 Waveform Options ..................................................................................................................... 63

6.05.01 VR-Current ........................................................................................................................... 63

6.05.02 AC-SOFT Mode.................................................................................................................... 64

6.06 Slope Function ........................................................................................................................... 65

6.06.01 2T Slope Function ................................................................................................................. 65

6.06.02 4TS Mode Setting ................................................................................................................. 65

7.0 VOLTAGE REDUCTION DEVICE (VRD) ............................................................................... 66

7.01 VRD Spectifications .................................................................................................................. 66

7.02 Enabling/Disabling VRD ........................................................................................................... 66

8.0 TROUBLE SHOOTING .............................................................................................................. 69

8.01 Power Source Problems ............................................................................................................. 69

8.02 Power Source Error Codes ......................................................................................................... 71

9.0 ROUTINE MAINTENANCE ...................................................................................................... 75

9.01 Opening the Enclosure ............................................................................................................... 76

10.0 PARTS LIST 300AP ................................................................................................................. 79

10.01 Interconnect Diagram 300AP .................................................................................................. 88

10.02 Exploded View 300AP ............................................................................................................ 90

APPENDIX A ..................................................................................................................................... 92

Summary of Contents for IA-3000TP-U3E

Page 1: ...SanRex SANARG 300AP WITH COOLING WATER PRESSURE SENSOR AC DC AC SOFT INVERTER ARC WELDER Operators Manual Version No AD Issue Date MAR 15 2021 Manual No K00A0316500 ...

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Page 3: ...ions that are dedicated solely to the safety of you and others in the work area It is highly recommended that this information be reviewed and that this manual be kept in a secure but accessible location for reference of these import safety and well being notices Remember the number one requirement in performing any job is safety Sansha Electric of Osaka Japan and its SanRex brand name of products...

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Page 5: ... the functional lock diagram of the product SECTION 3 INSTALLATION RECOMMENDATIONS Describing the transportation working environment electrical hook up with consideration for grounding and high frequency interference Also input power connections and specifications SECTION 4 OPERATOR CONTROLS DIMENSIONS AND OUTLINE Included in this section is a sequence of operation welding process selection 300AP ...

Page 6: ...l Block Diagram 31 3 0 INSTALLATION RECOMMENDATIONS 33 3 01 Transportation Methods 33 3 02 Environment 34 3 03 Machine Grounding High Frequency Interference 34 3 03 01 Grounding 34 3 03 02 High Frequency Introduction 34 3 03 03 High Frequency Interference 35 3 04 Location 36 3 05 Electrical Input Connections Requirements 36 3 05 01 Input Power 36 3 05 02 Fusing 37 3 05 03 Electrical Input Connecti...

Page 7: ...pot Mode 63 6 05 Waveform Options 63 6 05 01 VR Current 63 6 05 02 AC SOFT Mode 64 6 06 Slope Function 65 6 06 01 2T Slope Function 65 6 06 02 4TS Mode Setting 65 7 0 VOLTAGE REDUCTION DEVICE VRD 66 7 01 VRD Spectifications 66 7 02 Enabling Disabling VRD 66 8 0 TROUBLE SHOOTING 69 8 01 Power Source Problems 69 8 02 Power Source Error Codes 71 9 0 ROUTINE MAINTENANCE 75 9 01 Opening the Enclosure 7...

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Page 9: ...tion 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 DANGER Procedures which if not properly followed may lead to death or serious injury Please read this operating m...

Page 10: ...iety the Welding Engineering Society and the headquarters or branch offices of societies or associations concerned For the purpose of safety it is recommended that this welding equipment should be operated by persons who have sufficient knowledge and skill to understand all safety precautions and instructions in the Operating Manual and to be able handle the equipment safely After reading this Ope...

Page 11: ...hielding used Follow recommended procedures in AWS F2 1 Engine Fuel Fire Develop adequate procedures and use proper equipment to do the job safely When required obtain a Hot Work Permit See NFPA 51B If relocation is not possible protect combustibles with fire resistant covers Welding Fumes and Gases Fumes and Gases Keep your head out of the fumes Do not breathe the fumes Use enough ventilation or ...

Page 12: ...Hazardous Air Contaminants Determine if special training or a permit is required to enter the space Open all covers and secure them from closing Test atmosphere for 1 suitable oxygen content 2 combustibles or reactives 3 toxics Sparks Radiation Hot Metal Slag Heat Electrical Thermal Wear a helmet with filter lens and cover plate that complies with ANSI Z87 1 for protection from radiant energy flyi...

Page 13: ...at hazardous materials are present or might be given off by the coating when it is exposed to the arc of high temperatures Reactive Force from Tools Tool Jammed or Coming Loose Mechanical Wear proper head eye and hand protection Use face shields safety glasses and goggles as appropriate Inspect tools before use Never use a tool that is in poor or faulty condition Keep all tools in good condition E...

Page 14: ...ion Failure Mechanical Thermal Electrical Gloves should be Dry and moisture resistant In good condition no holes or tears Flame resistant Electrically and thermally insulated to suit the process Coating of Steel Fumes and Gases Obtain the Material Safety Data Sheets MSDSs for all materials used Read and understand the specification for coating type and coating weights Find out what hazardous mater...

Page 15: ...at hazardous materials are present or might be given off by the coating when it is exposed to the arc of high temperatures Reactive Force from Tools Tool Jammed or Coming Loose Mechanical Wear proper head eye and hand protection Use face shields safety glasses and goggles as appropriate Inspect tools before use Never use a tool that is in poor or faulty condition Keep all tools in good condition E...

Page 16: ...a Welding Cutting Toxic Fumes Electric Shock Be alert aware and focused on the job and the work area notice any changing conditions Wear and use only the correct approved equipment for the specific job be sure it is properly installed and used Welding or its Allied Processes Pneumatic Electrical Gases Liquid Employers must develop a written lockout tagout program and procedure Employees must be tr...

Page 17: ...rrent Slope Function Spot Function Slope with Repeat Function f Pulse Current Function Spot Time GTAW Remote Function Arc Control SMAW Gas Post Flow Gas Pre Flow Negative Positive Gas Input Gas Output Impulse Starting High Frequency GTAW STICK Shielded Metal Arc SMAW Remote Control Panel Remote Voltage Reduction Device Circuit Touch Start Lift Start GTAW Protective Ground ...

Page 18: ...ating Manual such damages are classified into two ranks by combination of attention attracting symbols and signal for the purpose of warning indications These attention attracting symbols and signal terms have the same meanings as those for warning labels on the equipment PROCEDURES NOT PROPERLY FOLLOWED MAY CAUSE A RISK TO OPERATORS RESULTING IN MEDIUM OR SLIGHT INJURY AND OR DAMAGE Serious or li...

Page 19: ... Not doing so may cause fatal injury to the operator or others resulting in death or serious injury Do not use this welding equipment for applications other than welding Those who use heart pacemakers should not enter the surrounding area of this welding equipment in operation or the welding area without permission of the doctor Welding equipment during energizing produces a magnetic field in the ...

Page 20: ...ch Capacitors built in may be electrically charged even after the power has been switched off Before performing works make sure that no charging voltage should be applied to such parts Do not use cables which have insufficient capacity are damaged or in which any conductor is exposed Tighten cable connections securely and insulate properly Do not operate with welding equipment with its cover or en...

Page 21: ...ng operations Doing so may cause harmful gases To prevent gas poisoning or suffocation use local ventilating facilities set forth in legislations or Regulations Industrial Safety and Health Law and Ordinance on Prevention of Hazards Due to Dusts and or Fumes or wear a respirator When welding in confined spaces ensure that the welding area is adequately ventilated wear a respirator and perform the ...

Page 22: ...soline Rupture can be caused by welding enclosed tanks or pipes Keep combustibles away from scattered welding spatter Cover combustibles that cannot be removed with incombustible shields Do not weld in the vicinity of flammable gases Keep hot base metals immediately after the welding processes away from combustibles When welding ceilings floors or walls remove combustibles hidden adjacent to them ...

Page 23: ...tector with filter lenses providing sufficient scale number or a welding face shield To protect your eyes from spatter or slag wear goggles Wear safeguards including gauntlet type of welding safety gloves long sleeved clothing leggings and spats and leather aprons etc Prevent gas cylinders from being exposed to welding arc and spatter generated from the welding torch To protect others eyes from ar...

Page 24: ...ons or regulations and your company s standards Use a gas flow regulator of the proper size and is suited for the shielding gas type being used Read and follow all warnings safety precautions and instructions in the Operating Manual which is supplied with the gas flow regulator prior to use Fix the gas cylinder on a special purpose holder or rack Gas cylinder shall not be exposed to high temperatu...

Page 25: ... from American Welding Society 8669 NW 36th Street Miami FL 33166 6672 8 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02169 9 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association 1 Batterymarch Park Quincy MA 02169 10 NFPA Standar...

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Page 27: ...or use with Shielded Metal Arc Welding SMAW process The unit is equipped with a digital Amperage Voltage meter and Output Contactor and Output Control functions that that are conveniently located on the front control panel The 300AP incorporates a high performance microcontroller to achieve complete digital control The 300AP is designed with a flame and impact resistant non conductive plastic case...

Page 28: ...ating the knob clockwise increases the parameter Rotating the knob counter clockwise decreases the parameter A selected weld parameter value can be adjusted at any time even while welding Pressing the Control Knob while welding will display the arc voltage Self Diagnostic Error Codes An error code is displayed on the Digital Meter when a problem occurs with Mains supply voltage or internal compone...

Page 29: ...ED is illuminated the water cooling pressure switch circuitry is enabled No output current will be available if there is insufficient cooling water pressure detected The cooling water pressure switch circuitry is operational in all welding modes To disable the cooling water pressure switch circuitry Press the WATER COOLING button Once the LED is extinguished the water cooling pressure switch circu...

Page 30: ...rms shown in figure 2 1 are the maximum Voltage Amperage output capabilities of the 300AP Curves for actual welding setting will fall within the curves shown STICK PROCESS LIFT TIG PROCESS HF TIG PROCESS FIGURE 2 1 300AP Voltage Ampere Curves 300A 5A A V OCV 300A A V OCV 5A 300A 25A A V OCV 10V ...

Page 31: ...31 2 05 Functional Block Diagram Figure 2 2 shows the functional block diagram of the 300AP FIGURE 2 2 300AP Functional Block Diagram ...

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Page 33: ...l parts Disconnect input power conductors from de energized supply lines before moving the welding power source WARNING If stacking units DO NOT stack units more than two units high Stacked units must be supported in an appropriate way such that the units cannot fall and cause damage WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage Always lift the unit utilizing the...

Page 34: ...ion properties of accessories Environments with adverse conditions do not include places where electrically conductive parts are in the near vicinity of the operator which can cause increased hazard have been insulated 3 03 Machine Grounding High Frequency Interference 3 03 01 Grounding The welder must be properly grounded Check the local codes and the National Electric Code NEC book for proper gr...

Page 35: ...uivalent shielding The metal conduit should have a good common ground to the welder ground Transmission via the Supply Lead Without adequate shielding and filtering high frequency energy may be fed back into the wiring within the installation mains by direct coupling The energy is then transmitted by both radiation and conduction Remedy Keep the work and torch leads as short as possible and as clo...

Page 36: ...t voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and any inspection required 3 05 01 Input Power The 300AP incorporates an INRUSH circuit and input voltage sensing circuit When the MAIN CIRCUIT SWITCH is turned on the inrush circuit provides a pre ch...

Page 37: ...is the responsibility of the user to provide proper fuse protection for the welding power source Failure to do so will void the warranty NOTE Maximum fuse size should be such that the fuse value not be more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code ...

Page 38: ...with a three conductor with earth power cable that is connected at the welding power source end for single and three phase electrical input power For Single Phase operation connect the GREEN BLACK and WHITE input conductors Insulate the RED conductor it is not used for single phase operation The welding power source will not operate properly if the BLACK or WHITE wire is exchanged for the RED wire...

Page 39: ...HITE input conductors to a de energized line disconnect switch Insulate the end of line 3 RED conductor as it is not used for single phase operation 3 Use Table 3 1 and section 3 5 2 as a guide to select proper line fuses for the disconnect switch Figure 3 1 Electrical Input Connections ...

Page 40: ...32 Input at No Load KVA 16 20 0 5 KW 12 12 0 13 Input Input Voltage 208 230 460 VAC 3 Phase 208 230 VAC 1 Phase Line Frequency 50 60 Hz Line Volts Compensation 10 Input Cable AWG 8 4 SOOW approximately 10 feet long Dimensions W 8 27 in 210 mm H 16 89 in 435 mm L 17 72 in 450mm Weight 53 lb 24 kg SanRex continuously strives to produce the best product possible and therefore reserves the right to ch...

Page 41: ...l Parameter Holds weld value for 8sec after weld current has stopped Value stops displaying if control knob is rotated LED Indicator Voltage Reduction Display Selected Function and Parameter GREEN VRD ON RED Others Both VRD light off in HF TIG LIFT TIG modes Contactor Functions Button Output On Off at STICK LIFT TIG mode Panel Remote Selections Button Panel or Remote chosen about a setup of weldin...

Page 42: ...d the rated output the duty cycle will decrease Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty Refer to the Input Output specifica...

Page 43: ...used to change the value of the selected weld parameter rotate it clockwise to increase the selected weld parameter and counter clockwise to decrease the value The value is indicated on the digital meter Pushing the knob in previews the actual welding voltage while welding 2 14 PIN Remote Control Receptacle The 14 PIN Remote Control Receptacle is used to connect a remote current control devices to...

Page 44: ...ion A loose or worn connection will cause excessive heat and may cause damage to the front frame or internal components of the welding unit Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal and or melting of the housing case and or internal components of the welding unit 5 GAS OUTLET The Gas Outlet is a 5 8 18 UNF right hand th...

Page 45: ...let is a 5 8 18 UNF left hand threaded female fitting 12 MANUFACTURES IDENTIFICATION DATA PLATE The Manufacturers Identification Data Plate label is located on the rear panel upper left hand side The layout of the data plate is based on IEC standard 60974 1 and indicates model type manufacturer load voltage rated output amperage duty cycle percentage primary input voltage input amperage and open c...

Page 46: ... to low side of 1k ohm remote control potentiometer E Input Wiper arm connection to 1k ohm remote control potentiometer 0 to 10VDC signal F N C Not used G GND Internally connected to chassis ground H N C Not used I N C Not used J N C Not used K N C Not used L N C Not used M Output OK TO MOVE current detect signal dry contact closure to pin N N Output OK TO MOVE current detect signal dry contact cl...

Page 47: ... up the weld zone in TIG modes or improve the start characteristics for stick electrodes e g low hydrogen electrodes It sets the peak start current on top of the PEAK WELD current e g HOT START current 130 amps when PEAK WELD 100 amps HOT START 30 amps INITIAL CUR This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the start current for TIG The Start Current remains on ...

Page 48: ...t WAVE BALANCE This parameter is used for aluminium AC TIG mode and is used to set the penetration to cleaning action for the AC weld current Generally WAVE BALANCE is set to 50 for AC STICK welding The WAVE BALANCE control changes the ratio of penetration to cleaning action of the AC TIG welding arc Maximum weld penetration is achieved when the WAVE BALANCE control is set to 10 Maximum cleaning o...

Page 49: ...is displayed on the meter After selecting the desired memory location ie 1 to 30 press the right scroll button and the machine will give a beep to confirm the weld parameters from the control panel are saved LOAD retrieve a Program to Control Panel Press the LOAD button Select a memory location by rotating the control knob 1 to 30 is displayed on the meter After selecting the desired memory locati...

Page 50: ...Sensor circuitry This circuitry operates in all welding modes i e STICK LIFT TIG and HF TIG If insufficient water pressure is detected when enabled the unit will display error code E33 produce an audible alarm and the welding current will cease Restoring water pressure or disabling the WATER COOLING circuitry by depressing the button to extinguish the LED will reset error code E33 and welding curr...

Page 51: ...actor device to control sequence REPEAT NO YES YES 4T operation in TIG Modes with repeat operation and crater fill using a remote contactor device SPOT NO NO YES 2T operation spot welding in HF TIG using a remote contactor device AC DC AC DC YES YES YES Selects AC DC or AC SOFT weld current AC SOFT NO YES YES PULSE ON OFF NO YES YES Enables Pulse operation in TIG Modes CONTACTOR ON OFF ON OFF YES ...

Page 52: ...ximum value in AC SOFT mode is 200A 4 The VR current cannot be set beyond the output current range The minimum output current is 10 A The maximum output current is 300A in AC mode and 200A in AC SOFT mode Process PARAMETER RANGE Default 1 Units STK LFT HF AC Frequency 15 to 150Hz 60Hz 1Hz YES YES YES Wave Balance 10 to 65 20 1 YES YES YES VR Current 99 to 100A 4 0A 1A YES YES YES Weld Current 5 to...

Page 53: ...ction 6 6 1 P20 4TS mode Setting OFF ON OFF See Section 6 6 2 P24 AC waveform Selection OFF ON OFF OFF Setting Sinusoidal wave ON Setting Triangular wave P26 OK to Move current detect signal output logic inversion OFF ON OFF OFF Setting CON1_M N short circuited at current detection ON Setting CON1_M N is open when current is detected P31 Operation panel lock password setting OFF ON OFF When the en...

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Page 55: ... Welding Power Source will withstand short term overload without adverse effects The welding current range values should be used as a guide only Welding current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator sho...

Page 56: ...Buttons are used to select the parameters to be set An illuminated LED indicates which function is being adjusted on the weld sequence graph Refer to Symbols Table located in the front of the manual for Symbol descriptions Figure 6 1 300AP Front Panel 8 3 7 2 10 1 9 4 5 6 11 ...

Page 57: ...ects between STICK Lift TIG or HF TIG welding processes 8 Scroll Buttons Used to scroll through the available welding functions to be set as shown on the on the welding sequence graph The LEDs in the graphical representation will illuminate indicating which function has been selected and available for adjustment Once the desired function has been selected use the Encoder Knob to adjust the functio...

Page 58: ...gital Display Set AC or DC weld current If AC is selected then set AC FREQ to 60Hz WAVE BALANCE to 50 Disable the WATER COOLING function of the welding power source in STICK mode Set Contactor Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set An illuminated LED indicates which function is being adjusted on the weld sequence graph Use the control kn...

Page 59: ...e Disabled 6 01 02 Stick Welding Sequence with Voltage Reduction Device Enabled Hotstart Iw Hotcur Arccontrol Arccontrollevel about18V Output Current Output Voltage OCV Hotstart Iw Hotcur Arccontrol Arccontrollevel about18V I_DET Output Current Output Voltage Vrd ...

Page 60: ...rol Receptacle for complete details of the remote device Enable the WATER COOLING function of the welding power source when utilizing water cooled TIG torches Use the Scroll Buttons to move to the parameter to be set An illuminated LED indicates which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set PRE FLOW time Set HOT START current Set POST...

Page 61: ... Pulsewidth Basecur Pulsefrequency short short ON ON Electrode Solenoid Output current Postflow tim e Peakcur Contactor short short ON ON Electrode Solenoid Output current ON Iw Initialcur Cratercur Upslopetim e Downslopetim e ON Contactor ON ON Electrode Solenoid Output current ON Peak Cur Initialcur Cratercur Upslopetim e Downslopetim e short ...

Page 62: ...low tim e Pulse width Basecur Pulsefrequency ON ON HF Solenoid Output current ON Preflowtim e Hotcur Peak cur Contactor ON ON HF Solenoid Output current ON Iw Initialcur Cratercur Upslopetim e Downslopetim e ON Contactor ON ON HF Solenoid Output current ON Peak Cur Initialcur Cratercur Upslopetim e Downslopetim e ...

Page 63: ...leaning action VR Current along with AC Wave Balance dramatically effects the RP cleaning action By reducing VR Current will reduce the heat input to the TIG Torch and reduce electrode geometry degradation and increases heat input to the work piece for increased travel speeds By increasing VR Current will enhance cleaning when welding on a dirty work piece Note Increased VR Current and increased W...

Page 64: ... Triangular Wave Set Internal parameters P24 to ON See Section 4 7 in the Owner s Manual for instructions on how to switch from AC Soft sinusoidal to AC SOFT triangular waveform Set Internal Parameter 24 to ON for Triangle Wave Turn Internal Parameter 24 to OFF for Soft AC A CF re q u e n cy W a ve B a l a n ce AC sinusoidal wave includes all the benefits of AC square wave with the addition of max...

Page 65: ... Factory setting is P20 OFF In the 4TS mode setting when a torch switch is turned off during downslope choose whether or not to weld exiting from down slope to the crater current 4TS mode setting is OFF P20 to OFF 4TS mode setting is ON P20 to ON ON Contactor Output current Iw Hot cur Hot start Output current Initial cur Up slope time Down slope time Iw Iw Crater cur Hot cur ON Contactor Welding e...

Page 66: ... VRD Open Circuit Voltage 15 3 to 19 8V Open circuit voltage between welding terminals VRD Resistance 148 to 193 ohms The required resistance between welding terminals to turn ON the welding power VRD Turn OFF Time 0 2 to 0 3 seconds The time taken to turn OFF the welding power once the welding current has stopped 7 02 Enabling Disabling VRD Switch the machine OFF A Remove the clear plastic protec...

Page 67: ...ometer see Figure 7 2 Do not pull back the front panel with excessive force as this may unplug cable from the control or main PCB Plugging the cable back into the main PCB from the front panel control PCB can only be achieved by removing the side covers Figure 7 2 VRD Enable Disable Step B The VRD Enable Disable potentiometer MUST ONLY be positioned fully clockwise OR fully counterclockwise as the...

Page 68: ...otate the trim potentiometer VR1 on the display PCB fully clockwise When VRD is ENABLED verify that it operates as per the VRD specification To DISABLE the VRD function rotate the trim potentiometer VR1 on the display PCB fully counterclockwise Figure 7 3 VRD ENABLE DISABLE Step C ...

Page 69: ... Defective control circuit Have an Accredited Service Agent repair the connection 3 Welding current reduces when welding A B C D E Loose welding cable connections Incorrect welding cable size Improper input connections Poor electrode condition Wrong welding polarity A B C D E Tighten all welding cable connections Use proper size and type of cable Refer to Section 3 5 Electrical Input Connections R...

Page 70: ...ted Service Agent repair or replace the gas valve C Gas valve jammed open C Have an Accredited Service Agent repair or replace the gas valve D POST FLOW control is set to 60 sec D Reduce POST FLOW time 6 The TIG electrode has been contaminated due to the gas flow shutting off before the programmed POST FLOW time has elapsed The Weld Process Mode STICK HF TIG or LIFT TIG was changed before POST FLO...

Page 71: ...erates at max speed When the detection temperature of TH2 falls and the Control Knob is pressed E02 is reset B Fan ceases to operate B Have an Accredited SanRex Service Agent investigate C Air flow is restricted by vents being blocked C Unblock vents then let Power Source cool down 3 E03 error code displayed Primary input current too high A Primary current is too high because welding arc is too lo...

Page 72: ...esets when the voltage reduces and the Control Knob is pressed 8 E12 error code displayed Under mains supply input voltage primary capacitors is reduced for one second Mains supply voltage is down to a dangerously low level Have an Accredited SanRex Service Agent or a qualified electrician check the Mains voltage Weld current available Buzzer sounds intermittently Error code E12 is reset when the ...

Page 73: ...d then switch on to reset E85 error 14 E86 error code displayed There is an abnormality in the voltage balance of the input capacitor when the input voltage is set to AC460V When starting up with an input voltage of AC460V there is a voltage difference between the primary capacitors of the two main circuits Have an Accredited SanRex Service Agent or a qualified electrician check the Mains voltage ...

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Page 75: ...spection with the frequency depending on the usage and the operating environment WARNING Disconnect Primary power at the source before opening the enclosure Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure see Section 9 01 Opening the Enclosure and use a vacuum cleaner to remove any accumulated dirt and dust Th...

Page 76: ... inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete a Remove all screws and nuts on the side covers Figure 9 2 Remove screws b Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW ...

Page 77: ... the front and rear panels completely c Pull the front panel slightly forward while pulling the rear panel slightly backward The interlocking hooks of the side case covers can now be disengaged from the front and rear panel Figure 9 4 Loosen front and rear panels ...

Page 78: ... side covers Figure 9 5 Remove Side covers e Remove protection cover sheet by removing the four plastic clips Figure 9 6 Remove PCB cover NOTE When you re assemble the parts conduct the above process in reverse order ...

Page 79: ... CC1 CON1 CT2 3 D1 D2 7 FAN1 FCH1 HCT1 HF UNIT1 L1 L105 QTY 1 1 2 1 6 1 1 1 1 1 1 1 TYPE RATING F3A073802 300A AC CC N MS3102A20 27S NIC 14PIN with Wiring Assembly F2A503001 CT 1 40 DFA100BA160R DBA200UA60R 109E5724H507 DC 24V 16 8W with wiring assembly F3A040702 300A AC FCH HC TN200V4B15M 200A 4V HF UNIT with gap NO RESISTORS U0A601101 GP 7 ZCAT 3035 1330 DESCRIPTION Coupling Coil Remote Socket C...

Page 80: ... 1 1 1 1 1 1 1 2 TYPE RATING WK 5493 U05 MAIN PCB or WK 5493 WK 5597 U09 LINK PCB or WK 5597 WK 5548 U13 DDC PCB or WK 5548 WK 4819 U12 DETECT PCB or WK 4819 U01 WK 5551 U03 CONNECT PCB or WK 5551 WK 7615 U01 AC CTRL PCB or WK 7615 WK 7618 U01 FILTER PCB or WK 7618 WK 5479 U07 U01 GATE PCB Kit with IGBT IGBT Spring Clip Silicon Rubber Sheet DESCRIPTION Printed Circuit Board Printed Circuit Board P...

Page 81: ...TY 1 1 1 1 1 1 1 1 1 TYPE RATING WK 5527 U46 ACDC PANEL PCB or WK 5527 U45 WK 5528 U03 ENCODER PCB or WK 5528 WK 5594 U09 TRANSFORMER PCB or WK 5594 U08 WK 5606 U03 DIODE SNUBBER PCB or WK 5606 WK 5569 U03 GATE IMPOSE PCB or WK 5569 WK 5570 U03 IGBT SNUBBER PCB or WK 5570 WK 5499 U06 FILTER PCB or WK 5499 WK 4917 U15 AC INPUT FILTER PCB or WK 4917 U12 ST S6 PB R 4 DESCRIPTION Printed Circuit Board...

Page 82: ...1JT TYPE 1 68W 100Ω MHS20A101KI 20W 100Ω MHS20A151JI 20W 150Ω DCP 103SR100C 480V 3P 480V SDKGA4 A 1 A SLIDE SWITCH 5505NBR1 5 DC24V 11VA 10W with Gas Inlet and PC4 02 PTP 46F S1 Wiring Assembly PTP 46F S1 Wiring Assembly E0D004801 with water E0D004901 with water E0D005209 E0C346000 JEA496003 JDA173302 E0C299200 Assembly with E2B058500 No name label DESCRIPTION Transistor Resistor on HF UNIT1 Resis...

Page 83: ... 2 1 1 2 1 TYPE RATING EBA514400 E00B0195001 with Dustcover Sheet N4A084800 N4A009300 N1B029700 Safety Instructions N1B029800 Two Warnings N4A095200 N4A095100 N4A146500 EBA619700 with PC4 02 EBA580600 with PC4 02 TRAK BE35 70S SOOW AWG8X4C L 3 4m EBA156800 E1B895000 IGBT E1B870100 Output Diode DESCRIPTION Encoder Cover PCB Cover Name Label 300AP Side Label AC DC Warning Label 1 Warning Label 2 Out...

Page 84: ...1 73 2 INTERCONNECT DIAGRAM REFERENCE QTY 8 1 1 set 1 1 1 1 1 1 4 TYPE RATING E1B850100 J5B017502 J3C356600 Two piece set JDA210600 JDA250300 JDA210700 2621603 3021104 N00B0358400 EDA227700 DESCRIPTION IGBT Q1 Q24 Spring Clips PCB1 Chassis Chassis main support GAS WATER Outlet Chassis 1 GAS WATER Outlet Chassis 2 Water INLET Chassis Knob Knob Cap Control Cover Sheet Mylar Silicone Rubber Sheet ...

Page 85: ...6 2 87 2 89 1 INTERCONNECT DIAGRAM REFERENCE QTY 3 3 1 1 4 1 1 1 1 3 1 1 1 1 2 TYPE RATING EAA502500 M5 M5 EBA643600 M5 M5 EDA046700 EDA046800 EDA003800 EDA046902 EDA047002 EDA047102 EDA047202 ECA321000 EDA046600 EEA158802 EEA158902 EDA047302 ECA867900 DESCRIPTION Post1 M5 Post11 M5 For S1 D L Bus Bar 1 D L Bus Bar 2 T D Bus Bar D Bus Bar 1 D Bus Bar 2 D Bus Bar 3 D Bus Bar 4 S1 Bus Bar Q Output B...

Page 86: ...1 1 1 4 2 1 2 1 1 2 1 2 TYPE RATING E1B872000 E1B859700 EDA079801 E1B933000 E1B933100 74 NATURAL C30SG20A 0250468000 with String Clip EH18U T0425B Nylon Hose L 0 5m PN4 6X4 Nylon Hose L 0 5m N00A0712000 EEA405300 EBA580700 with PC4 02 TRAK SK50 DESCRIPTION Heatsink Insulated Board PCB1 Insulated Sheet PCB2 Insulated Sheet Dust Cover Sheet Front Dust Cover Sheet Rear Clip Rubber Grommet for PCB1 CO...

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Page 88: ...Circuit Bord WK 5479 CN2 1 2 3 4 CN1 1 2 CN2 1 2 3 4 G3 E3 G4 E4 G8 E8 G7 E7 3 CN1 1 2 3 G1 E1 G2 E2 G7 E7 G8 E8 G3 E3 Line3 PCB5 Conect Circuit Bord WK 5551 CN30 CN31 CN31 CN30 CN32 CN32 PCB7 Filter Circuit Bd WK 7618 CN1 1 2 3 CN7 1 2 3 CT4 CT3 S2 CN3 1 2 3 4 5 CN2 1 2 3 CN1 1 2 3 4 5 6 CN11 1 2 3 4 CN20 1 2 3 4 5 6 CN21 1 2 3 4 5 6 7 CN22 1 2 3 4 5 6 CN23 1 2 3 4 5 6 7 1 2 CN7 3 4 TB13 TB14 TB1...

Page 89: ...IT1 CC2 CC1 R1 R2 AC1 AC3 CC1 AC1 AC3 R2 R6 TB1 TB2 CN1 1 2 3 4 P N CN2 1 2 P 21V PGND CN3 1 2 3 S 15V SG CN4 1 2 3 4 5 6 7 1 2 CN6 3 4 5 6 7 8 G9 E9 G10 E10 RY_ON R3 PCB16 Super Inpose Circuit Bord WK 5569 G11 E11 G12 E12 15 15 IS GND HCT1 Output Terminal TO1 FCH1 PCB18 IGBT Gate Circuit Bord WK 3367 G1 E1 E2 G2 G1 E1 G2 E2 PCB17 IGBT Snubber Circuit Bord WK 5570 TB1 TB2 SH DET CN1 1 2 3 4 5 G10 ...

Page 90: ... 10 02 Exploded View 300AP 45 36 55 101 35 75 75 61 95 48 42 50 51 83 83 60 41 54 58 58 103 69 37 52 42 99 102 100 100 89 53 59 58 40 49 46 71 70 72 43 21 47 44 22 59 68 57 56 89 67 49 102 50 6 28 97 2 12 ...

Page 91: ...3 4 96 96 91 65 62 73 20 64 64 20 34 62 38 23 73 20 66 98 63 90 90 98 66 9 33 82 81 80 79 77 76 74 27 93 86 85 8 84 26 38 10 24 31 25 94 78 78 5 5 20 29 34 64 64 13 11 5 30 87 1 7 32 92 14 19 88 15 16 17 18 ...

Page 92: ...device to step through weld the sequence Sequences include Initial Current Up Slope Weld Current Down Slope Final Current SLOPE w REPEAT Additional Slope function for current control while in the Weld Current sequence activated through the remote ON OFF device For a detailed description of the Slope Slope w Repeat functions see your owner s manual under the Slope Mode Sequence section NOTE All Slo...

Page 93: ...quence Graph Pushing the knob inward displays the actual welding voltage The welding voltage is for reference purposes only and is not a machine adjustable value Detailed description of each parameter can be found in the Owner s Manual SANARG 300AP SETTINGS The settings shown below should be used as guidelines for a first set up The welder should adjust these setting to achieve optimal weld perfor...

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Page 95: ...to step through weld the sequence Sequences include Initial Current Up Slope Weld Current Down Slope Final Current SLOPE w REPEAT Additional Slope function for current control while in the Weld Current sequence activated through the remote ON OFF device For a detailed description of the Slope Slope w Repeat functions see your owner s manual under the Slope Mode Sequence section NOTE All Slope func...

Page 96: ...ence Graph Pushing the knob inward displays the actual welding voltage The welding voltage is for reference purposes only and is not a machine adjustable value Detailed description of each parameter can be found in the Owner s Manual SANARG 300AP SETTINGS The settings shown below should be used as guidelines for a first set up The welder should adjust these setting to achieve optimal weld performa...

Page 97: ...PAGE LEFT INTENTIONALLY BLANK ...

Page 98: ...SanRex SANREX CORPORATION USA 50 Seaview Blvd Port Washington NY 11050 SANSHA ELECTRIC MFG CO LTD Japan 301056 Nishi Awaji Higashiyodogawa Osaka Japan 533 0031 ...

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SanRex IA-3000TP-U3E, Operator'S Manual

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