Thermal Arc 300GTSW Pro-Wave Service Manual Download

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I N N O V A T I O N T O S H A P E T H E W O R L D

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T E C H N O L O G I E S

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Summary of Contents for 300GTSW Pro-Wave

Page 1: ...pro wave Inverter arc welder 300GTSW Service Manual Version No AB Issue Date June 21 2012 Manual No 0 2515 Operating Features Art A 06102 ...

Page 2: ...ally the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is the Global Brand of Arc Welding Products for Thermadyne Industries Inc We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction M...

Page 3: ...oration 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2001 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission ...

Page 4: ...Description 2 3 2 06 Functional Block Diagram 2 4 2 07 Transporting Methods 2 5 2 08 Specifications 2 6 2 09 Duty Cycle 2 7 SECTION 3 INSTALLATION 3 1 3 01 Electrical Input Connections 3 1 SECTION 4 OPERATION 4 1 4 01 Operator Controls 4 1 SECTION 5 SERVICE 5 1 5 01 Routine Maintenance 5 1 5 02 Basic Troubleshooting 5 1 5 03 Common Welding Operation Faults 5 1 5 04 Specific Problems 5 2 SECTION 6 ...

Page 5: ...26 6 27 PCA IGBT Inverters Q1 and Q2 Replacement Procedure 6 28 6 28 PCA IGBT Inverter Q3 Q4 Replacement Procedure 6 30 6 29 PCA Output Diodes D2 D5 Test Procedure 6 32 6 30 PCA Output Diodes D2 D5 Replacement Procedure 6 33 6 31 PCA Thermal Sensor TH1 Test Procedure 6 36 6 32 Thermal Sensor TH1 Replacement 6 37 6 33 Auxiliary Transformer T3 Test Procedure 6 38 6 34 Auxiliary Transformer T3 Replac...

Page 6: ...INGLE THREE PHASE A 4 APPENDIX 4 380 415VAC SINGLE VOLTAGE THREE PHASE A 6 APPENDIX 5 WIRE CHART MAIN BOARD PCB1 A 8 APPENDIX 6 WIRE CHART FRONT PANEL PCB6 A 12 APPENDIX 7 WIRE CHART AC IGBT GATE DRIVE PCB8 A 14 APPENDIX 8 BOTTOM WIRING PLACEMENT DIAGRAM A 15 APPENDIX 9 DIODE TESTING BASICS A 16 APPENDIX 10 METER CALIBRATION PROCEDURE A 18 ...

Page 7: ...r or electrode 8 Do not use worn damaged undersized or poorly spliced cables 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHER...

Page 8: ...welding fumes and gases 3 If ventilation is poor use an approved air supplied respirator 4 Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners 5 Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the...

Page 9: ...ding current from traveling long possibly unknown paths and causing electric shock and fire hazards 9 Do not use welder to thaw frozen pipes 10 Remove stick electrode from holder or cut off welding wire at contact tip when not in use WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag 1 Wear approved face shield or saf...

Page 10: ...ore installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine WA...

Page 11: ...wisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 1 02 PRINCIPAL SAFETY STANDARDS Safety in Welding and C...

Page 12: ...relatifs au soudage à l arc AVERTISSEMENT L ELECTROCUTION PEUT ETRE MORTELLE Une décharge électrique peut tuer ou brûler gravement L électrode et le circuit de soudage sont sous tension dès la mise en circuit Le circuit d alimentation et les circuits internes de l équipement sont aussi sous tension dès la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou l...

Page 13: ...aux ignifuges et du rables laine et cuir et des chaussures de sécurité 5 Portez un casque antibruit ou des bouchons d oreille approuvés lorsque le niveau de bruit est élevé Opération de coupage ou soudage Dimension d électrode ou Epiasseur de métal ou Intensité de courant Nuance de filtre oculaire Opération de coupage ou soudage Dimension d électrode ou Epiasseur de métal ou Intensité de courant N...

Page 14: ...vent causer un incendie et des brûlures Le contact accidentel de l électrode ou du fil électrode avec un objet métallique peut provoquer des étincelles un échauffe ment ou un incendie 1 Protégez vous ainsi que les autres contre les étin celles et du métal chaud 2 Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables 3 Enlevez toute...

Page 15: ...appement nocifs 1 Utilisez l équipement à l extérieur dans des aires ou vertes et bien ventilées 2 Si vous utilisez ces équipements dans un endroit con finé les fumées d échappement doivent être envoyées à l extérieur loin des prises d air du bâtiment AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arrêtez le moteur avant de vérifier le ...

Page 16: ...gants et posez un torchon sur le bouchon pour l ôter 3 Laissez la pression s échapper avant d ôter complète ment le bouchon 1 05 PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommend...

Page 17: ...ment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 wh...

Page 18: ... representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHOR...

Page 19: ... listed below and clicking on the Literature Library link http www thermalarc com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies i...

Page 20: ...urrent DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Time Postflow Time Spot Time Spot Weld Mode Continuous Weld Mode Press to initiate wirefeed and welding release to stop Purging Of Gas Inches Per Minute Meters Per M...

Page 21: ...and high frequency arc starter for use with Gas Tungsten Arc Welding GTAW Gas Tungsten Arc Welding Pulsed GTAW P Gas Tungsten Arc Welding Sloped GTAW S and Shielded Metal Arc Welding SMAW processes 19V 300 5 AMPS VOLTS Arc Characteristics CURRENT Control 310 145 OCV Less than 70V C C Art A 06103 Figure 2 1 300GTSW volt ampere curve NOTE Volt Ampere curves show the maximum Voltage and Amperage outp...

Page 22: ... Sensor Circuit Current Adjustment Circuit Reference Adjustments Control Switches Torch Control Connection CON1 Gas Control Circuit Trouble Sensing Circuit Sequence Control To each control circuit 12VDC 20VDC 24VDC 5VDC Output Inductor Art A 06104 Figure 2 2 Block Diagram WARNING Disconnect primary power at the source before disassembling the power supply Frequently review the Important Safety Pre...

Page 23: ...lectrical parts Disconnect input power conductors from de energized supply line before moving welding power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift unit with handle on top of case Use hand cart or similar device of adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting ...

Page 24: ...250 300 250 Volts 32 30 32 30 Duty Cycle 25 40 25 40 KVA 15 7 12 3 19 8 15 5 0 5 KW 12 2 9 5 12 5 9 8 0 3 Output at No Load Input data 50 60 Hz Duty Cycle KVA KW Input Volts Three Phase Single Phase No Load 208 95 74 2 2 230 86 67 2 2 460 43 34 1 1 208 44 34 1 4 230 40 31 1 3 380 24 19 0 8 400 23 18 0 7 415 22 17 0 7 460 20 15 0 6 10 32 Volts 208V 230V 460V 64 V 50 60 Hz Three Phase Single Phase T...

Page 25: ...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 To calculate duty cycle Art A 06105 rated current 2 x rated duty cycle desired duty cycle current i e At the 300A rated output curren...

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Page 27: ...t match one of the electrical input 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 inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply wheneve...

Page 28: ...rcuit and input voltage sensing circuit When the Main Circuit Breaker is turned on the inrush circuit provides a pre charging of the input capacitors SCR s in the Power Control Assembly PCA will turn on after the input capacitors have charged to full operating voltage after approximately 5 seconds THERMADYNE OFF ON 208 230V 460V INPUT SELECT SWITCH PRIMARY POWER PRIMARY CABLE TURN OFF YOUR MAIN PO...

Page 29: ...G GTAW or HF TIG GTAW process 5 Warning Indicator The Warning Indicator located on the front panel will become activated under the following conditions Input voltage is too low Input voltage too high Thermal overload 6 AC Power Indicator The AC Power Indicator located on the front panel lights when the Primary Power Switch is in the ON position indicating the unit is energized 7 Output Selector Sw...

Page 30: ...le receptacle 17 8 Pin Receptacle Used for remote contactor and amperage controls 18 Output Gas Fitting Gas output fitting size 5 8 18 unf female 18 Output Gas Fitting European model European model gas output Accommodates 3 8 BSP monocable TIG torch NOTE F and G revisions refer to the letter at the end of the serial number for this product Gas Solenoid The pre flow is fixed at 150ms On F revision ...

Page 31: ...ly 3 Input Cable 10 feet 4 Input Gas Fitting The input gas connection is located on the bottom center of the rear panel Size 5 8 18 unf female European Fitting 3 8 BSP male GTS Model only If this slide switch is not set to the position that matches the input voltage from the electrical source the warning indicator will be illuminated and the unit will not operate Not installed in single voltage un...

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Page 33: ...fixaproblemusing this section first This section on basic troubleshooting will help you isolate faults and problems that are easily remedied without requiring that the power supply be opened or requiring specialized test equipment and procedures If the problem or fault cannot be corrected by following the recommendations in this section then proceed to Section 6 0 on Advanced Troubleshooting 5 03 ...

Page 34: ...N 1 Unit is in thermal shutdown mode a Allow cooling period of approximately five 5 minutes with the power ON Duty cycle should be reviewed To reset the WARNING indicator the power supply must be turned OFF then ON again 2 Input voltage is low a Measure input voltage and verify that it matches the INPUT SELECTOR Easy Link switch setting The length of the input power cable must be considered as the...

Page 35: ... in torch a Refer to torch parts list for part s requiring replacement and repair torch as necessary 5 Tungsten condition is poor a Replace electrode 6 Electrode too high off metal a Reduce stand off 7 Faulty Main Circuit Board PCB1 a Refer to the Main Circuit Board section 6 11 page 6 10 8 Faulty Current Transformer CT1 a With no welding arc established measure for 0VDC between CN1 pins 3 and 4 o...

Page 36: ...Perform the Easy Link test section 6 04 page 6 3 3 Thermal sensor TH1 open thermal shutdown a Allow the unit to cool for five minutes before turning the power supply ON If the problem still occurs perform the PCA Thermal Sensor TH1 test section 6 31 page 6 36 4 Warning Indicator ON when output energized a Check Q1 Q2 and Q3 Q4 Section 6 26 J Power Supply Works When in DC output mode But Not in AC ...

Page 37: ...e 6 22 5 Tungsten condition is poor causing discoloration of workpiece a Replace electrode O No Weld Output Fan Not Operating WARNING Indicator OFF 1 Line voltage too low a Verify that input voltage matches setting on rear panel INPUT SELECTOR switch b Verify the INPUT SELECTOR Easy Link switch is functioning properly by performing test in section 6 05 page 6 3 2 Loose connection on Main Circuit B...

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Page 39: ...bly is found to be defective by executing any of the procedures in this Manual the subassembly should be replaced with a new one The faulty subassembly should then be returned to Thermal Dynamics through established procedures WARNING Disconnect primary power at the source before disassembling the power supply Frequently review the Important Safety Precautions page ii Be sure the operator is equip...

Page 40: ...tic retaining plugs are in the correct position 2 Insert the white plastic retaining plugs into the holes in the heatsink through the matching holes in the plastic shield 3 Place the power supply into an enclosure half taking care that the front and rear panel edges are seated properly into the matching grooves inside the enclosure Repeat for the second enclosure half 4 When the two enclosure halv...

Page 41: ...ation under both input power conditions 1 Disconnect primary power at the source Make sure the MAIN CIRCUIT BREAKER MCB is in the OFF position 2 Set the INPUT SELECTOR switch on the rear panel to the low voltage 208 230VAC range position 3 Using an Ohmmeter at CN13 on the Main Circuit Board between pins 1 BLUE and 3 GREEN should measure a short and an open between CN13 pins 2 GRAY and 3 GREEN 4 Se...

Page 42: ...o the unit 8 On the ribbon cable measure for the following voltages between pins Pins 2 and 1 12VDC Pins 2 and 5 12VDC Pins 2 and 3 5VDC Pins 2 and 4 5VDC If voltages are correct with CN 7 disconnected but not with it connected then the front panel PCB is defective 9 Turn the unit OFF 10 Reconnect the ribbon cable to connector CN7 on the Front Panel Circuit Board 11 Reapply power to the unit 12 On...

Page 43: ...pro wave 300gtsw June 21 2012 6 5 CN7 CN13 CN7 PCB6 CN8 PCB6 CN9 PCB6 CN10 CN1 CN2 CN4 CN5 Art A 06111 Figure 6 2 Power supply voltage connector locations ...

Page 44: ...o the various test procedures in this section to isolate the problem If the results are as expected then the power supply is giving the proper output 6 07 LIFT START Circuit Test This test verifies proper operation of the LIFT START circuit A clamp type amperage meter or equivalent meter capable of reading approximately 20A full scale and a digital voltmeter capable of indicating 20VDC full scale ...

Page 45: ...ake sure the MAIN CIRCUIT BREAKER MCB is turned OFF 2 Set the PROCESS SELECTOR switch to HF START mode 3 Connect TIG torch and shielding gas 4 Connect a remote control or jumper between pins 2 and 3 of the REMOTE 8 receptacle for contactor closure If a remote switch is installed close it 5 Place the power supply MCB on the rear of the unit to the ON position After PRE FLOW of 150 ms the HF START c...

Page 46: ... protection Make sure no part of the operator s body comes into contact with the workpiece or any internal components while the unit is activated This section provides specific procedures for verifying the operation and replacement of each subsystem within the power supply Before undertaking any of these procedures eliminate the obvious first visually inspect the suspect subsystem for physical dam...

Page 47: ... Retaining Screws Art A 06112 Figure 6 3 Main Circuit Breaker White S R Black Art A 06113 Figure 6 4 Main Circuit Breaker connections single phase R S T Black White Red Art A 06114 Figure 6 5 Main Circuit Breaker connection three phase ...

Page 48: ...r on the Main Circuit Board PCB1 measure the voltage between Q2 signal pairs Pin 1 and 2 Pin 4 and 5 4 Using a voltmeter measure the voltage between signal pins 1 and 2 and pins 4 and 5 at connector CN8 The voltage between each pair of pins should be 5VDC Switch the PROCESS SELECTOR switch to the TIG LIFT START position The voltage between both pair of pins should drop to 4VDC 5 Return the PROCESS...

Page 49: ...pro wave 300gtsw June 21 2012 6 11 CN24 CN16 CN9 CN8 Art A 06115 Figure 6 6 Main Circuit Board 4 0V 11 0V 4 0V CH1 CH2 11 0V 10 0µs div Art A 06116 Figure 6 7 Gate drive enable waveform ...

Page 50: ...emote control device from the REMOTE 8 receptacle 1 Measure for 24VDC between pins 3 and 4 on CN2 on the Main Circuit Board PCB1 Replace the Main Circuit Board PCB1 if the voltage is low or not present 2 Measure for 24VDC between CN7 1 and CN7 2 If no voltage is present check and replace wires between CN7 1 PCB4 and CN4 1 PCB2 or between CN7 2 PCB4 and CN4 2 PCB2 With a remote control device conne...

Page 51: ...t the top edge of the Front Panel Circuit Board 2 Gently pull up on the retainer bar on each side of each connector to release the ribbon cable in the connectors 3 Remove the ribbon cable by gently pulling straight up on the ribbon cable CN7 CN13 CN7 PCB6 CN8 PCB6 CN9 PCB6 CN10 CN1 CN2 CN4 CN5 Art A 06111 Figure 6 8 Power supply voltage connector locations ...

Page 52: ...t board 5 Remove all connectors from the left side and front of the Main Circuit Board CN1 CN2 CN4 CN5 CN7 CN10 CN13 and CN26 not shown CN7 CN13 CN7 PCB6 CN8 PCB6 CN9 PCB6 CN10 CN1 CN2 CN4 CN5 Art A 06111 Figure 6 10 Connectors to be removed from left side and front of main circuit board 6 Cut any cable ties securing wire harnesses to TB1 or TB2 leads 7 Move the wiring harness aside clear of the M...

Page 53: ...N14 from the rear of the Main Circuit Board 10 Remove screws associated hardware and wire lugs from TB1 through TB6 Straighten the lugged wires that were removed from TB1 and TB2 so they stand vertically This will allow the wires to pass through the current sensors when the Main Circuit Board is lifted away from the chassis in a later step CN24 CN16 CN9 CN8 Art A 06115 Figure 6 12 Connectors to be...

Page 54: ...nt sensors and connectors CN8 and CN9 through the hole in the board 3 As you lower the Main Circuit Board onto the chassis replace the connectors on the rear end of the board at locations CN5 CN8 CN9 and CN14 4 Continue lowering the board so the vertical bus bars pass through the slots in the boards and line up with TB3 4 and TB5 6 The board is properly seated when the holes in the vertical bus ba...

Page 55: ...pro wave 300gtsw June 21 2012 6 17 TB3 TB1 TB5 TB6 TB2 TB4 Art A 06118 Figure 6 14 TB1 through TB6 reconnections ...

Page 56: ...d it is necessary to remove the front panel of the power supply unit To accomplish this do the following 1 Locate and remove the six screws securing the Front Panel to the front of the power supply Allow the front panel to drop down to allow free access to the test points on the Front Panel Circuit Board PCB6 Art A 06120 Figure 6 15 Front panel retaining screws ...

Page 57: ... 5VDC 5 Set up the contactor closure circuit by removing the jumper from the REMOTE 8 receptacle 6 Measure the voltage between test points TP8 and TP0 to be 3 5VDC 7 Measure the voltage between test points TP4 and TP0 to be 0VDC 8 Measure the voltage between test points TP5 and TP0 to be 0VDC 9 Measure between TP0 and the test points below to verify the voltages given TP0 0V Circuit Common TP1 5VD...

Page 58: ...ent Procedure Refer to Figures 6 17 and 6 18 To remove the Front Panel Circuit Board 1 Remove the Main Circuit Board referring to page 6 13 2 Locate and remove five 5 screws from the Front Panel Circuit Board Shield securing them to the inside of the front panel of the unit Art A 06122 Figure 6 17 Front panel circuit board retaining screws 3 Pull the Front Panel Circuit Board back toward the rear ...

Page 59: ...2 6 21 CN3 CN5 CN9 CN6 CN4 CN8 CN7 Art A 06123 Figure 6 18 Component side of front panel circuit board 5 Remove the Front Panel Circuit Board from the power supply To replace the Front Panel Circuit Board reverse the removal steps ...

Page 60: ...E OUTPUT TERMINAL bend the Output Bus Bar sufficiently to allow the CT to slide off the end of the bus bar To replace the Current Transformer 1 Slide the new CT onto the Output Bus Bar in the same orientation as the one removed 2 Return the end of the Output Bus Bar to a right angle 90 bend The next step makes it much easier to complete the replacement due to interference with the Coupling Coil 3 ...

Page 61: ... Lead Auxiliary Transformer T3 IGBT Inverter Q2 TB2 Primary Lead Art A 06125 Figure 6 20 Top of power control assembly main circuit board removed 6 23 Power Control Assembly PCA Test Procedures WARNING Disconnect primary power at the source before performing these procedures This procedure requires a digital Volt Ohm meter that has a diode test scale This procedure will give a general indication o...

Page 62: ...5 PCA Input Diode Bridge D1 Replacement Procedure Refer to figure 6 21 To remove the Input Diode Bridge D1 do the following 1 Remove the Main Circuit Board PCB1 per page 6 13 2 Remove the input power and sensing lugged wires from the input terminals R and two RED S and two White RED input line and BLACK 3 Remove screws from all terminals with lugged wires and the corner bus bar 4 Remove the two sc...

Page 63: ...pro wave 300gtsw June 21 2012 6 25 R2 Junction Diode Anode Thyristor Gate Thyristor Cathode C1 T Red Input Line S R Art A 06126 Figure 6 21 Power control assembly input diode bridge D1 ...

Page 64: ... Q4 These can be tested with the power OFF to verify their proper function Input Diode Bridge D1 IGBT Inverter Q1 IGBT Inverter Q3 Driver Board PCB8 TB1 Primary Lead Auxiliary Transformer T3 IGBT Inverter Q2 TB2 Primary Lead Art A 06125 Figure 6 22 Top of power control assembly HF Unit Coupling Coil Leads IGBT s Inverter Q3 Q4 Art A 06127 Figure 6 23 Power control assembly IGBT inverters ...

Page 65: ...the POSITIVE OUTPUT TERMINAL 6 If a component on the Q3 Q4 gate board PCB9 is damaged then the Driver PCB PCB8 should be checked A Disconnect CN2 from PCB8 B Check the gate resistance on PCB9 between E1 to G1 and E2 to G2 Reading should be 1 1kW C Check gate drive on PCB8 at CN2 between CN2 1 to CN2 2 and CN2 4 to CN2 5 Reading should be 1kW Pin 1 White Black Pin 2 Pin 4 Pin 5 White Red CN8 PCB1 O...

Page 66: ... board is to remain with the Inverter being removed PCB4 on Q1 or PCB5 on Q2 Be sure the screw goes through only the hole in the bus bar connected to the printed circuit board PCB4 or PCB5 4 Remove the two 2 screws securing the Inverter to the main chassis frame To replace either Inverter Q1 or Q2 do the following 1 Spread a light coating of thermal compound on the bottom surface of the Inverter 2...

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Page 68: ...gged wires at terminals AC1 and AC2 on the HF Unit 4 Disconnect connector CN1 on IGBT Inverter Q3 Q4 5 Remove the four 4 screws securing Q3 Q4 to the chassis To replace either Inverter Q3 Q4 do the following 1 Spread a light coating of thermal compound on the bottom surface of the Inverters 2 Reverse the remaining removal steps above When replacing the screws that secure the Inverter to the chassi...

Page 69: ...pro wave 300gtsw June 21 2012 6 31 HF Unit Coupling Coil Leads IGBT s Inverter Q3 Q4 Art A 06127 Figure 6 28 IGBT Inverter Q3 Q4 ...

Page 70: ...Note that these measurements can be accomplished without removing the main transformers The transformers were removed in figure 6 29 to aid in identifying the diodes To check for shorted diodes without dismantling the power supply take a voltmeter set on the diode scale from the GRAY wire and the BROWN on the FCH to the NEGATIVE weld terminal A good reading will be 2V D3 D5 D5 K D5 A D3 A D4 D2 A ...

Page 71: ...is 1 Remove the Output Inductor Assembly refer to section 6 37 page 6 42 2 Remove hardware at T1 T2 secondary lead junctions C D and E Figure 6 30 T1 T2 Secondary Lead Junction E Blue Wire to HF Unit AC1 T1 T2 Secondary Lead Junction D center tap leads bent upward two black lugged leads to CN7 1 and CN5 3 White Wire to CN7 3 T1 T2 Secondary Lead Junction C Art A 06131 Figure 6 30 Output inductor T...

Page 72: ...e the bus bar s and filter network s attached to the terminals of the output diode s to be replaced Output Diodes shown in Figure 6 33 8 Remove the two 2 screws securing the output diode to the chassis To replace the Output Diodes D2 D5 do the following 1 Spread a light coating of thermal compound on the bottom surface of the Diode Assembly 2 Reverse the remaining removal steps above When replacin...

Page 73: ...wave 300gtsw June 21 2012 6 35 D5 D4 D3 IGBT Inverter Q3 D2 T1 T2 Mounting Brackets Art A 06133 Figure 6 32 Output diodes and T1 T2 mounting brackets D3 D5 D4 D2 Art A 06134 Figure 6 33 Output diodes D2 D5 ...

Page 74: ...nector at CN10 on the Main Circuit Board PCB1 3 The resistance of a good sensor measured between pins 1 and 2 on the connector should be in the 10KOhm to 21 6KOhm range with the reading decreasing as the temperature of the power supply increases A shorted reading indicates a bad sensor and it should be replaced CN7 CN13 CN7 PCB6 CN8 PCB6 CN9 PCB6 CN10 CN1 CN2 CN4 CN5 Art A 06111 Figure 6 34 Therma...

Page 75: ...Q2 3 Using a magnetic or split screwdriver remove the screw that secures the sensor to the chassis frame 4 Cut cable ties as appropriate to free the BLACK BLACK wire harness that connects the Thermal Sensor to connector CN10 plug To replace the Thermal Sensor TH1 do the following 1 Spread a light coating of thermal compound on the bottom surface of the Thermal Sensor 2 Reverse the removal steps ab...

Page 76: ...edure 1 Select the Ohms scale on the digital meter 2 With the Main Circuit Breaker ON verify continuity between LINE1 on the MCB and CN19 pin 3 on PCB1 1 3 Measure the primary winding resistance between LINE 2 on the MCB and CN19 pin 1 to be 74 Ohms 208 230V or pin 5 460V to be 14 8 Ohms If there is no continuity or the resistance measurement yields an open circuit replace the auxiliary transforme...

Page 77: ...T3 do the following 1 Remove Main Circuit Board per page 6 13 2 Remove connector CN1 from PCB8 3 Remove the RED and WHITE lugged wires from the R and S terminals of the Input Diode Bridge D1 4 Remove the two 2 screws securing the Auxiliary Transformer to the chassis To replace the Auxiliary Transformer reverse the removal steps above ...

Page 78: ...n any of the windings or if there is evidence of overheating Art A 06138 Figure 6 38 T1 T2 primary lead routing through ferrite ring Q1 C2E2 T1 Primary Lead Green Mark Q2 C2E2 T2 Primary Lead Green Mark TB2 T2 Primary Lead TB1 T1 Primary Lead Art A 06137 Figure 6 37 Preparation for removal of main transformers T1 T2 right side of unit from front 6 35 Main Transformer Assembly T1 and T2 Test Proced...

Page 79: ...g the transformer s 8 Remove the Output Inductor Assembly section 6 37 page 6 42 9 Bend the secondary center tap leads of both transformers T1 and T2 D up to expose the C and E secondary lead junctions See Figure 6 39 10 Remove the hardware from the C and E secondary leads 11 Remove the two 2 screws securing the transformer plastic frame to the metal mounting bracket To replace Main Transformers T...

Page 80: ...mbly junctions at W X Y and Z 2 Cut the middle cable tie securing the BLACK gas hose wire harness to the Output Inductor Assembly lead Y 3 Remove the compression nut on the gas inlet on the rear panel Move the gas hose wire harness to clear the Output Inductor Assembly 4 Cut two 2 cable ties that form an X which secure the Coupling Coil to the frame of the Output Inductor Assembly Figure 6 41 5 Re...

Page 81: ...pro wave 300gtsw June 21 2012 6 43 Cable ties to cut Art A 06139 Figure 6 41 Coupling coil cable ties ...

Page 82: ...ring R6 to the front panel to allow R6 to rotate downward 6 Remove the compression nut on both ends of the black gas hose 7 Remove the YELLOW and VIOLET lugged wires from the gas solenoid 8 Disconnect CN1 from IGBT Inverter Q3 Q4 9 Disconnect the lugged BLUE and GRAY wires from the HF Unit 10 Follow the RED BLACK twisted wire pair from the fan through the hole in the chassis Cut cable ties as need...

Page 83: ...ardware Bolt Positive Output Current Transformer Output Bus Bar Art A 06124 Figure 6 42 Output bus bar CT assembly R6 Topscrew Fan Retaining Screw R6 Fan Assembly IGBT Inverter Q3 Q4 Driver Board CN1 Art A 06140 Figure 6 43 Cable ties and R6 on right side of unit ...

Page 84: ...UTPUT TERMINAL and the two screws holding the bus bar to Q3 Q4 Remove the connector from CT1 3 Remove the Coupling Coil by removing the bolt inside the NEGATIVE OUTPUT TERMINAL and hardware from the bus bar T1 T2 center tap junction 4 Disconnect BLACK wires to the HF Unit 5 Remove the lugged wires from the AC1 and AC2 terminals 6 Remove the two 2 screws that secure the HF Unit to the chassis To re...

Page 85: ...pro wave 300gtsw June 21 2012 6 47 HF Unit Coupling Coil Connections AC1 AC2 Art A 06141 Figure 6 44 HF Unit replacement ...

Page 86: ...cement Procedure Refer to figure 6 45 To remove the HF Coupling Coil 1 Remove the Output Inductor Assembly per section 6 37 page 6 42 2 Remove the bolt from the inside of the NEGATIVE OUTPUT TERMINAL 3 Remove the bolt from the inside of the POSITIVE OUTPUT TERMINAL 4 Disconnect the connector on CT1 5 Remove the hardware securing the Output Bus Bar to IGBT Inverter Q3 Remove the Output Bus Bar CT A...

Page 87: ...BT Inverter Q3 Junction Hardware Bolt Positive Output Current Transformer Output Bus Bar Art A 06124 Figure 6 45 Output bus bar CT assembly HF Unit Coupling Coil Leads IGBT s Inverter Q3 Q4 Art A 06127 Figure 6 46 Coupling coil replacement ...

Page 88: ...s on the solenoid valve 2 Remove the compression nut securing the black gas line to the solenoid valve 3 Remove the C retaining ring from the gas input fitting on the exterior of the Front Panel 4 Remove the gas solenoid valve from the unit To replace the gas solenoid valve reverse the above steps Yellow Top Violet Bottom C Ring Solenoid Art A 06142 Figure 6 47 Gas solenoid valve ...

Page 89: ...ove connector CN1 on the IGBT Inverter Q3 Q4 2 Using a digital meter on the diode scale test for diodes on the CN1 connector plug between pin pairs 1 2 and 4 5 Shorted readings indicate that the IGBT inverter Q3 Q4 Driver Circuit Board PCB8 should be replaced CN1 Art A 06143 Figure 6 48 Location of CN1 on IGBT inverter Q3 Q4 driver board ...

Page 90: ...able ties securing ribbon cable at CN3 to GREEN ground wires 4 Remove the four 4 screws securing PCB8 to the chassis As the board is lifted off the chassis disconnect connector CN5 To replace PCB8 reverse the removal steps above It may be helpful to connect CN2 and CN5 before seating the board fully back onto the chassis CN1 CN4 CN5 CN2 CN3 Retaining Screw Retaining Screw Retaining Screw Retaining...

Page 91: ...tput Current Shielding Gas Art A 06145 Figure 6 50 HF TIG mode timing Lift TIG Mode Figure 6 51 shows the LIFT TIG timing waveforms with the SLOPE control ON and OFF Output Contactor SLOPE OFF mode SLOPE ON mode On Short Release On Off Off On Off On Off Output Current Shielding Gas Electrode Art A 06146 Figure 6 51 LIFT TIG mode timing Current Waveform on PULSE ON mode Art A 06147 Figure 6 52 LIFT...

Page 92: ...re 6 53 shows the SPOT timing waveforms with the SLOPE control OFF and ON Output Contactor SLOPE OFF mode Works only in HF TIG mode SLOPE ON mode On On Off Off On Off On Off Output Current Shielding Gas Art A 06148 Figure 6 53 SPOT HF TIG mode timing ...

Page 93: ...ns a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted or welded to other parts The part descriptions may be indented to show part relationships To determine the part number description q...

Page 94: ...55000100 not shown Switch toggle 2 pos WK 3369 AC DC 1 10 5057 10 5057 10 5057 24703128000 not shown Switch toggle 2 pos WK 3988 AC DC 1 10 6364 10 6364 10 6364 24655000200 10 Label Warning Explanation 1 10 5496 10 5496 10 5496 N0B476400 not shown Label Warning Illustration 1 10 5497 10 5497 10 5497 N0B476500 0 0 0 7 7 4 B 0 N 9 9 4 5 0 1 9 9 4 5 0 1 9 9 4 5 0 1 2 e d i S l e b a L 1 1 0 0 2 1 8 1...

Page 95: ... N A 10 5469 N A F1A540900 38 IGBT Kit Q1 Q2 2 10 6320 10 6320 N A Z000348300 38 IGBT Kit Q1 Q2 2 N A N A 10 6320 Z000348300 39 Input Rectifier D1 1 10 2653 N A 10 2653 45707016000 39 Input Rectifier D1 1 N A 10 5088 N A 45704016000 40 Capacitor C1 1 10 2270 10 2270 10 2270 42422137100 41 Thermal Sensor TH1 1 10 5228 10 5228 10 5228 46965000900 42 AC Driver PCB PCB8 1 10 5149 10 5149 10 5149 P0A33...

Page 96: ...653400A 78 PCB 11 PCB11 1 10 6345 10 6345 10 6345 P0A353600 0 0 6 7 4 7 B 2 J 2 8 4 5 0 1 2 8 4 5 0 1 2 8 4 5 0 1 s i s s a h C n w o h s t o n not shown Acrylic board under main pcb 1 10 5431 10 5431 10 5431 E6A652800 not shown R1 on main pcb 1 10 6684 10 6684 10 6684 not shown PCB CE PCB101 1 N A 10 5517 N A P0A347500 not shown Filter L1 1 10 2290 10 2290 10 2290 47953134100 not shown Filter CE ...

Page 97: ... 2613 10 2613 10 2613 N A not shown CN6 Plug 2pos PCB6 10 2662 10 2662 10 2662 N A not shown CN1 Plug 3pos PCB8 10 2613 10 2613 10 2613 N A not shown CN2 Plug 5pos PCB8 10 2663 10 2663 10 2663 N A not shown CN4 Plug 5pos PCB8 10 2663 10 2663 10 2663 N A not shown CN5 Plug 2pos PCB8 10 2662 10 2662 10 2662 N A A N 1 7 6 2 0 1 1 7 6 2 0 1 1 7 6 2 0 1 s g u l P r o f s n i P n w o h s t o n Last lett...

Page 98: ...pro wave 300gtsw 7 6 June 21 2012 7 04 Parts Pictures 8 6 5 7 1 2 3 Art A 06149 Figure 7 1 Front Panel ...

Page 99: ...pro wave 300gtsw June 21 2012 7 7 14 15 11 12 10 5 Places 4 Places 13 4 places Art A 06150 Figure 7 2 Enclosure ...

Page 100: ...pro wave 300gtsw 7 8 June 21 2012 6 16 17 Art A 06151 Figure 7 3 Rear Panel ...

Page 101: ...21 2012 7 9 Main Transformer Current Transformer Fan HF Unit Output Inductor Coupling Coil Main Circuit Breaker Heat Sink Main Circuit Board Figure 7 5 Art A 06152 Figure 7 4 Left Side Parts 78 Art A 06153 Figure 7 5 PCB 11 ...

Page 102: ...pro wave 300gtsw 7 10 June 21 2012 31 25 32 30 29 27 23 24 16 Art A 06154 Figure 7 6 Right Side Parts 31 24 Art A 06155 Figure 7 7 Top View Parts ...

Page 103: ...pro wave 300gtsw June 21 2012 7 11 36 26 29 30 20 27 Art A 06156 Figure 7 8 Bottom View Parts 37 42 41 39 40 38 38 Art A 06157 Figure 7 9 Internal Parts ...

Page 104: ...pro wave 300gtsw 7 12 June 21 2012 66 65 69 67 68 Art A 06158 Figure 7 10 Primary IGBT assembly ...

Page 105: ...pro wave 300gtsw June 21 2012 7 13 77 26 36 1 36 Art A 06159 Figure 7 11 Output diode bus bar ...

Page 106: ...pro wave 300gtsw 7 14 June 21 2012 76 Art A 06160 Figure 7 12 Main Transformer ...

Page 107: ...pro wave 300gtsw June 21 2012 7 15 38 44 45 D2 45 D4 45 D3 45 D5 Art A 06161 Figure 7 13 Internal Parts continued ...

Page 108: ...pro wave 300gtsw 7 16 June 21 2012 71 72 73 71 45 74 53 Art A 06162 Figure 7 14 Output diode assembly ...

Page 109: ...pro wave 300gtsw June 21 2012 7 17 28 43 46 27 25 32 Art A 06163 Figure 7 15 Internal Parts continued 69 70 76 75 43 46 Art A 06164 Figure 7 16 Q3 Q4 assembly ...

Page 110: ...pro wave 300gtsw 7 18 June 21 2012 This page left blank intentially ...

Page 111: ...ameplate Locate these numbers in the model and specification number columns below Use only those diagrams and instructions that are applicable Specification Number Model Appendix Location 103024 208 230VAC Single Voltage Single Three Phase 2 103025 208 230 460VAC Single Three Phase 3 103038 380 415VAC Single Voltgae Three Phase 4 ...

Page 112: ...Black HF Unit ON OFF Gray Thermal Detect Black Thermal Detect Black 12VDC Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary Overvoltage Signal PCB Common 0V Bus Bar Bus Bar Bus Bar Bus Bar Black Black White White L1 FAN1 SOL1 1 2 3 4 CN1 1 3 5 CN5 5 3 1 CN7 2 1 TH1 CN10 1 4 CN26 3 1 CN1 MCB Single Phase Input Diode Bridge D1 1 2 4 5 PCB2 PCB4 E2 C2E1 C1 G1 E1 ...

Page 113: ...ommon 0V 12VDC 5VDC 5VDC PCB Common 0V 12VDC 11 10 9 8 7 6 5 4 3 2 1 CN7 Torch Control Pink Torch Control Yellow Blue Gray Blue Gray 2 1 CN4 Output Short Detect White Output Short Detect Black Case Ground Green 12VDC Brown 12VDC Red Output Current Detect 0V to 4V Orange Ground Yellow Black Yellow Gray T1 A C D E B A C D E B T2 1 2 3 4 CT1 C6 C7 C8 Output Filter Network R7 CC FCH1 W X AC1 AC2 CC2 C...

Page 114: ...ck 12VDC Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary Overvoltage Signal PCB Common 0V Bus Bar Bus Bar Bus Bar Bus Bar Black Black White White L1 FAN1 SOL1 5 4 2 1 CN9 1 2 3 4 CN1 1 3 5 CN5 5 3 1 CN7 2 1 TH1 CN10 1 4 CN26 3 1 CN1 MCB Single Phase Input Diode Bridge D1 1 2 4 5 PCB2 PCB4 E2 C2E1 C1 G1 E1 G2 E2 E2 C1 1 2 4 5 PCB3 PCB5 E2 C2E1 C1 IGBT Inverte...

Page 115: ...ommon 0V 12VDC 5VDC 5VDC PCB Common 0V 12VDC 11 10 9 8 7 6 5 4 3 2 1 CN7 Torch Control Pink Torch Control Yellow Blue Gray Blue Gray 2 1 CN4 Output Short Detect White Output Short Detect Black Case Ground Green 12VDC Brown 12VDC Red Output Current Detect 0V to 4V Orange Ground Yellow Black Yellow Gray T1 A C D E B A C D E B T2 1 2 3 4 CT1 C6 C7 C8 Output Filter Network R7 CC FCH1 W X AC1 AC2 CC2 C...

Page 116: ...ray Thermal Detect Black Thermal Detect Black 12VDC Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary Overvoltage Signal PCB Common 0V Bus Bar Bus Bar Bus Bar Bus Bar Black Black White White L1 FAN1 SOL1 5 4 2 1 CN9 1 2 3 4 CN1 1 3 5 CN5 5 3 1 CN7 2 1 TH1 CN10 1 4 CN26 3 1 CN1 Input Diode Bridge D1 1 2 4 5 PCB2 PCB4 E2 C2E1 C1 G1 E1 G2 E2 E2 C1 1 2 4 5 PCB3 PC...

Page 117: ...ommon 0V 12VDC 5VDC 5VDC PCB Common 0V 12VDC 11 10 9 8 7 6 5 4 3 2 1 CN7 Torch Control Pink Torch Control Yellow Blue Gray Blue Gray 2 1 CN4 Output Short Detect White Output Short Detect Black Case Ground Green 12VDC Brown 12VDC Red Output Current Detect 0V to 4V Orange Ground Yellow Black Yellow Gray T1 A C D E B A C D E B T2 1 2 3 4 CT1 C6 C7 C8 Output Filter Network R7 CC FCH1 W X AC1 AC2 CC2 C...

Page 118: ...7 N C e t i h W t c e t e d e g a t l o v t u p t u O 3 7 N C y a r G O N y a l e r l a n g i s n o F H 5 7 N C CN8 1 5Vdc on 4Vdc off G1 Gate drive ref To E1 Black e t i h W 1 E n o m m o c 2 8 N C CN8 4 5Vdc on 4Vdc off G2 Gate drive ref To E2 White d e R 2 E n o m m o c 5 8 N C CN9 1 5Vdc on 4Vdc off G3 Gate drive ref To E3 Black e t i h W 3 E n o m m o c 2 9 N C CN9 4 5Vdc on 4Vdc off G4 Gate ...

Page 119: ...460V input Easylink switch Ribbon CN22 10 5V 230V input 0V 460V input Easylink switch Ribbon CN22 11 12 off 11 on PWM Gate drive squarewave Ribbon CN22 12 12 off 11 on PWM Gate drive squarewave Ribbon n o b b i R c d V 2 1 3 1 2 2 N C CN22 14 12V 230V input 0V 460V input Input changeover circuit Ribbon n o b b i R t c e t e d e s a h p e e r h T e l g n i S 5 1 2 2 N C CN23 1 0V 230V input 5V 460V...

Page 120: ...2012 Connector Number Meter Reading Comments Wire color CN26 1 15V squarewave Super impose gate drive CN26 2 common d e s u t o n 3 6 2 N C CN30 1 12Vdc PCB11 d e s u t o n 2 0 3 N C l o r t n o c y a l e r g n i p p i r T 3 0 3 N C ...

Page 121: ...pro wave 300gtsw June 21 2012 A 11 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 122: ... n o c e S 5 5 N C n o b b i R n o m m o c 6 5 N C n w o r B 1 n i P s i s s a h c 1 6 N C n w o r B 1 n i P s i s s a h c 2 6 N C n o b b i R y l p p u s r e w o P c d V 2 1 1 7 N C n o b b i R n o m m o c 2 7 N C n o b b i R y l p p u s r e w o P c d V 5 3 7 N C n o b b i R y l p p u s r e w o P c d V 5 4 7 N C n o b b i R y l p p u s r e w o P c d V 2 1 5 7 N C n o b b i R n o m m o c 6 7 N C C...

Page 123: ...voltage detect Ribbon n o b b i R n o m m o c 2 9 N C n o b b i R y l p p u s r e w o P c d V 2 1 3 9 N C n o b b i R l a n g i s t e s e R 4 9 N C CN9 5 0V OVR detected 5V no OVR Overvoltage detect Ribbon CN9 6 0V UVR detected 5V no UVR Undervoltage detect Ribbon n o b b i R n o m m o c 7 9 N C n o b b i R l o r t n o c e g r a h c e r P 8 9 N C n o b b i R e v i r d e t a g r o t s i r y h T 9 9...

Page 124: ... White n o b b i R y l p p u s r e w o P c d V 2 1 1 3 N C CN3 2 squarewave Straight polarity gate drive Ribbon CN3 3 squarewave Reverse polarity gate drive Ribbon CN3 4 squarewave Super impose gate drive Ribbon n o b b i R l a n g i s e g a t l o v r e v o y r a d n o c e S 5 3 N C n o b b i R n o m m o c 6 3 N C CN4 1 80Vpk Weld volts from FCH Brown d e s u t o n 2 4 N C CN4 3 300Vpk pulse Super...

Page 125: ...RING PLACEMENT DIAGRAM Black Black and Blue Wires White on lower diode bus bar rear of unit 2 black to top center bus bar Blue on front lower diode bus bar Brown to outside FCH connection White to outside FCH connection Gray to bus bar in center Art A 06168 ...

Page 126: ...rward bias direction connect the volt ohm meter positive lead to the anode positive of the diode and the negative lead to the cathode negative of the diode refer to figure A 6 A properly functioning diode will conduct in the forward bias direction and will indicate between 0 3 and 0 9 volts 6 To check the diode in the reverse bias direction reverse the meter leads refer to figure A 6 A properly fu...

Page 127: ...pro wave 300gtsw June 21 2012 A 17 Art A 06016 VR COM A Reverse Bias Diode Not Conducting Anode Cathode Reverse Bias Diode Test ...

Page 128: ...ybe 5 dependent on the arc length and the combines length of the negative and positive welding leads Preset voltage is used for MIG operation and is valid on the LM300 and 400GMS AMPERAGE TEST 1 Set the controls for STICK mode ARC CONTROL minimum HOT START minimum 2 Connect the negative and positive output terminals to a load capable of the maximum current of the power supply 3 Turn on the power s...

Page 129: ...This page left blank intentially ...

Page 130: ...CIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 806...

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