Thermal Arc ARCMASTER 200 S Service Manual Download Page 1

Page: 1 / 88

Version No:

AA.0

Issue Date:

May 22, 2006

Manual No.:

0-4940B

Operating Features:

200 S

Service Manual

INVERTER ARC WELDER

Art # A-06795

ARCMASTER

Summary of Contents for ARCMASTER 200 S

Page 1: ...Version No AA 01 Issue Date May 22 2006 Manual No 0 4940B Operating Features 200 S Service Manual INVERTER ARC WELDER Art A 06795 ARCMASTER...

Page 2: ......

Page 3: ...84 603 298 5711 www thermalarc com Copyright 2006 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibi...

Page 4: ...ent 3 1 2 Location 3 1 3 Electrical Input Connections 3 1 4 Electrical Input Requirements 3 1 5 Input Power 3 2 6 Duty Cycle 3 2 7 Specifications 3 3 4 OPERATOR CONTROL 1 ARC MASTER 200S Controls 4 1...

Page 5: ...5 6 Verification of the primary IGBT Q1A Q4C 11 11 5 7 Verification of No load Voltage OCV 11 12 12 MAINTENANCE 1 Subsystem Test and Replacement Procedures 12 1 1 1 Preparation 12 1 1 2 Test and Repla...

Page 6: ......

Page 7: ...ctrically live Incorrectly installed or improperly grounded equipment is a hazard 1 Do not touch live electrical parts 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself fr...

Page 8: ...ires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where...

Page 9: ...es 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes WARNING ENGINE FUEL can cause fire or explosion E...

Page 10: ...n strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to on...

Page 11: ...la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pi ces m talliques en contact avec...

Page 12: ...e confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous qu...

Page 13: ...upez le fil au tube con tact lorsqu inutilis apr s le soudage 11 Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un...

Page 14: ...U ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives 1 Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de c...

Page 15: ...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...

Page 16: ...1 10 May 22 2006 ARCMASTER 200 S...

Page 17: ...ted below and clicking on the Literature Library link http www thermalarc com 2 Equipment Identification The unit s identification number specification or part number model and serial number usually a...

Page 18: ...rnating Current Standard Function Slope Function Slope W Repeat Function Spot Function Pulse Current Function Spot Time GTAW Remote Function Arc Control SMAW Gas Post Flow Gas Pre Flow Negative Positi...

Page 19: ...l fall between the curves shown 6 Functional Block Diagrams Figure 2 2 illustrates the functional block diagram of the 200S power supply Figure2 2 200S Model Functional Block Diagram 200A 25A A V OCV...

Page 20: ...parts Disconnect input power conductors from de energized supply line before moving the welding power source WARNING FALLING EQUIPMENT can cause serious per sonal injury and equipment damage Lift uni...

Page 21: ...ectri cally connected by a qualified electrician 3 Electrical Input Connec tions WARNING ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power DO NOT TOUCH live electr...

Page 22: ...imary Current Circuit sizes to achieve maximum current The ARC MASTER 200S is designed for use with a generator as an input power source Contact an accredited Thermal Arc service agent for the proper...

Page 23: ...are optimal values your values may differ Individual equip ment may differ from the above specifications due to in part but not exclusively to any one or more of the following variations or changes i...

Page 24: ...200S 3 INSTALLATION 3 4 PAGE LEFT INTENTIONALLY BLANK...

Page 25: ...et Receptacle Table 4 1 Socket Pin Functions 320 130 260 15 1 3 6 2 5 4 Socket Pin Function 1 Earth Ground 2 Torch Switch Input 24V to connect pins 2 3 to turn on welding current 3 Torch Switch Input...

Page 26: ...up ply voltage the internal electrical components maybe at 240V potential with respect to earth 6 Input Cable The input cable connects the Primary supply voltage to the equipment 2 Weld Parameter Desc...

Page 27: ...eld has been completed A selected weld parameter value can be adjusted at any time even while welding ON OFF switch Primary voltage Supply ON OFF switch located on rear panel Voltage Reduction Device...

Page 28: ...200S 4 OPERATOR CONTROL 4 4...

Page 29: ...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 should use the we...

Page 30: ...voltage 4 Process Button This button selects between STICK or Lift TIG mode 8 pin remote control receptacle for connecting remote devices A remote control device is required for use during LIFT TIG op...

Page 31: ...pening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure refer to Section 11 1 1 Opening the Enclosure and use a vacuum cleaner to remove any accumulated...

Page 32: ...les Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply 6 Months Replace all broken parts Bring the unit to an authorized Thermal Arc Service Center to remo...

Page 33: ...ast Reduce travel speed 4 Weld bead too wide or excessive bead build up or excessive penetration in butt joint Travel speed too slow Increase travel speed 5 Uneven leg length in fillet joint Wrong pla...

Page 34: ...Incorrect shielding gas is being used E Poor work clamp connection to work piece A Select the right size electrode Refer to Basic TIG Welding Guide B Select the right electrode type Refer to Basic TI...

Page 35: ...evious run B Joint preparation too restricted C Irregular deposits allow slag to be trapped D Lack of penetration with slag trapped beneath weld bead E Rust or mill scale is preventing full fusion F W...

Page 36: ...t inspect then repair the welder 3 Welding current reduces when welding A Loose welding cable connections B Incorrect welding cable size C Improper input connections D Poor electrode condition E Wrong...

Page 37: ...evice VRD 2 Contactor function is put into the state of on pushing Function button Refer to section 6 3 Verify the no load voltage OCV using a DC voltmeter The capability of the voltmeter should be mo...

Page 38: ...anel controls to reveal the VRD on off potentiometer see Figure 9 3 CAUTION Do not pull back the front panel with excessive force as this will unplug control PCB Plugging the control PCB back into the...

Page 39: ...flow is restricted by vents being blocked C Agent investigateUnblock vents then let Power Source cool down 3 E03 error code displayed Primary input current too high A Primary current is too high beca...

Page 40: ...200S 10 POWER SOURCE ERROR CODE 10 2 PAGE LEFT INTENTIONALLY BLANK...

Page 41: ...ew one The faulty subassembly should then be returned to Thermal Arc through established procedures WARNING Disconnect primary power at the source before dis assembling the power supply Frequently rev...

Page 42: ...t panel slightly forward and pull the rear panel slightly backward The interlocking hooks of the side case covers can now be disengaged from the front and rear panels Figure11 4 Loosen front and rear...

Page 43: ...e front and rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working envi ronment is recommended Extremely dusty environments will require...

Page 44: ...nction properly if installed in the incorrect direction Refer to section 12 3 10 for the replacement of CT1 2 4 E94 Thermistor malfunction Cause Thermistors for detecting temperature of internal compo...

Page 45: ...Occurs when the remote connector CON1 or associated circuitry is defective damaged or the TIG torch cable is defective Verification Remedy CAUTION Read and understand this entire section before proce...

Page 46: ...ectors or damaged wiring harnesses b Verify the connection between PCB5 WK 5448 and PCB4 WK 5449 Verify that there is no omission of a loosening screws and connected harness between the PCB1 and PCB5...

Page 47: ...ints U2 and V2 on the input switch S1 The location of points U2 and V2 on switch S1are indicated in Figure 11 7 4 If this voltage is out of the operating range which is 10 207 253VAC of the rated volt...

Page 48: ...PCB5 WK 5448 and PCB4 WK 5449 measure the voltages according to the following table The check points and the refer ence are obtainable on the solder side of PCB4 WK 4819 The locations of points are i...

Page 49: ...art below for possible failure modes Table 11 3 Verification of the FAN1 At the time of a low output and standby as for this equipment rotation of a fan becomes slow Therefore exact voltage measuring...

Page 50: ...on on page 11 6 1 Verify the characteristic of the primary diode D1 using a diode tester 2 Refer to Table 11 4 and Figure 11 14 for the checkpoints on D1 Table11 4 Tester checkpoints in the D1 Figure1...

Page 51: ...dition as described in section 11 4 1 Preparation on page 11 6 1 Check whether there are any abnormalities on the appearance of PCB6 and PCB7 2 Verify the characteristic of the primary IGBT Q1A Q4C us...

Page 52: ...ICK mode 1 In STICK welding mode mark and then turn potentiometer VR1 on PCB4 WK 5449 all the way to the right and turn off the electric shock protector function Volt age Reduction Device VRD Refer to...

Page 53: ...cal damage overheating and loose connections 1 2 Test and Replacement Parts List NO DWG NO PARTS NAME REFERENCE PAGE PART NO 1 PCB1 Printed Circuit Board WK 5713 12 5 W7001626 2 PCB2 Printed Circuit B...

Page 54: ...or 12 17 W7001622 3 C103 Capacitor 12 20 W7001621 4 C2 Capacitor 12 21 W7001620 5 FCH1 Reactor 12 14 W7001502 6 L101 Ring Core 12 20 10 5230 7 L102 Reactor 12 20 W7001625 8 L103 Reactor 12 20 W7001624...

Page 55: ...eptacle 12 18 10 6627 2 CT1 Hall Current Trans 12 15 10 5003 3 D1 Primary Diode 12 5 W7001481 4 D2 Secondary Diode 12 14 10 6629 5 D3 Secondary Diode 12 14 10 6629 6 FAN1 Cooling Fan 12 16 10 5227 7 S...

Page 56: ...your maintenance or repair please cut any tie wraps necessary However after your maintenance or repair please reassemble and tie wrap all components and wiring in the same manner as before the mainte...

Page 57: ...Diode D1 1 Remove the Side Panel See section 11 1 1 2 Remove the L102 See section 12 3 16 3 Remove the screw and three cables Cut the snap band 4 Remove the terminal and Disconnect the three connecto...

Page 58: ...the four screws and the Front Panel 7 Remove the four screws and the Rear Panel 8 Remove the four screws and the two cables Disconnect the eight connectors CN1 8 on the PCB1 1 1 1 1 2 1 1 1 1 2 1 2 2...

Page 59: ...our screws and Remove the PCB1 unit 10 Remove the Primary Diode D1 with the soldering iron from the PCB1 Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G 747...

Page 60: ...B1 and D1 See section 12 3 1 3 Remove the PCB6 and PCB7 See section 12 3 6 3 7 4 Remove the screw and the cable 5 Remove the eight screws and the PCB2 unit 6 Remove the screw and Remove the Capacitor...

Page 61: ...CN1 3 on the PCB3 Remove the three screws and the three cables Remove the terminal 4 Remove the 11 screws and PCB3 unit Take care about the shape of the screw when you replace PCB3 5 Remove the two ta...

Page 62: ...on 11 1 1 2 Remove the Protection Cover 3 Remove the Knob Cap Holding the Knob down loosen the screw and remove the Knob 4 Disconnect the two connectors CN1 3 on the PCB4 Remove the four screws Pull o...

Page 63: ...3 5 PCB5 WK 5448 1 Remove the Side Panel See section 11 1 1 2 Remove the PCB4 See section 12 3 4 3 Remove the three latches of Front Control Cover and then remove the PCB5 When reinstalling the PCB5 e...

Page 64: ...and two IGBT Spring Clips Remove the cables from edge holder 3 Disconnect the connector CN1 on the PCB6 Cut the lead of the Q1A Q2C Remember to install new Silicone Rubber Sheets where silicone compo...

Page 65: ...s and two IGBT Spring Clips Remove the cables from edge holder 3 Disconnect the connector CN1 on the PCB6 Cut the lead of the Q3 Q4C Remember to install new Silicone Rubber Sheets where silicone compo...

Page 66: ...ve six screws and then detach the D2 and D3 Do not have the wrong direction of the diodes when reinstalling Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G...

Page 67: ...e FCH1 3 10 CT1 Hole Current Trans 1 Remove the Side Panel See section 11 1 1 2 Remove the bolts the spring and the washer Remove the three screws and then remove the Output Bus Bar 3 Remove the CT1 D...

Page 68: ...ove the Side Panel See section 11 1 1 2 Disconnect the connector CN2 on the PCB1 and Cut the snap band 3 Remove the four screws and then open the Rear Panel 4 Remove the FAN1 Do not have the wrong dir...

Page 69: ...1 Remove the Side Panel See section 11 1 1 2 Remove the four screws and the six cables Remove the one nut and one terminal Remove the C101 C102 3 Cut off the snap band Remove the L101 from the Input...

Page 70: ...Remove the Side Panel See section 11 1 1 2 Remove the screw and then three ground cables Cut the two snap bands 3 Cut the snap band and disconnect connector CN1 on the PCB1 4 Open the Panel Protects R...

Page 71: ...rm coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 3 15 TH2 Secondary Thermistor 1 Remove the Side Panel See section 11 1 1 2 Remove PCB3 unit See section 12 3 3 3 Cut the...

Page 72: ...e the Side Panel See section 11 1 1 2 Remove four screws six terminals Remove the C103 and L102 3 17 L103 Reactor 1 Remove the Side Panel See section 11 1 1 2 Remove the L102 See section 12 3 18 3 Cut...

Page 73: ...ews and open the Rear Control Cover 5 Remove one nut one washer and two terminals Remove the L103 3 18 C2 Capacitor and R2 Resistor 1 Remove the Side Panel See section 11 1 1 2 Remove the four screws...

Page 74: ...e cables Disconnect the three connectors CN1 3 on the PCB3 Remove the three screws and the three cables Remove the terminal 5 Remove the 11 screws and PCB3 unit Take care about the shape of the screw...

Page 75: ...200S 12 MAINTENANCE 12 23 7 Remove the C2 with the soldering iron from the R2 1 1 2 2...

Page 76: ...apacitor gen 3 1 IPS ECWH12H102JR 1200V 0 0010uF 1 5 CON1 10 6627 Socket Remote gen 3 1 IPS 206433 1 8P with Wiring Assembly Remote Receptacle 1 6 CT1 10 5003 Sensor Current gen 3 1 IPS HC TN200V4B15M...

Page 77: ...Input gen 3 1 IPS VCT 2 5 3XC L 3 2m 1 47 W7001484 Clamp Input gen 3 1 IPS SCLB14A 1 48 W7001489 Heatsink gen 3 1 IPS E1B834200 2 49 W7001490 Heatsink gen 3 1 IPS E1B836800 1 50 W7001488 Insulated Boa...

Page 78: ...200S PARTS LIST 3 31 39 39 32 63 10 33 33 38 12 55 62 47 34 53 19 37 18 13 14 2 28 52 5 51 36 43 57 40 42 41 40 45 63 45 46 35 44...

Page 79: ...200S PARTS LIST 4 48 54 54 54 66 67 50 50 65 27 4 65 65 65 54 49 15 3 7 16 20 64 21 11 29 69 1 26 17 6 61 59 60 58 68 9 8 30 30 56 64 70 70 70...

Page 80: ...nnection Wiring Guide CONNECTION WIRING GUIDE Destination Destination A PCB1 CN1 CON1 B PCB1 CN2 FAN1 C PCB1 CN3 PCB3 CN1 D PCB1 CN4 CT1 E PCB1 CN5 TH1 F PCB1 CN6 TH2 G PCB1 CN7 PCB6 CN1 H PCB1 CN8 PC...

Page 81: ...200S CONNECTION WIRING GUIDE 6 APPENDIX 3 Interconnect Diagram PCB6 PCB4 CON1 TH1 TH2 PCB7 PCB1 FAN1 CT1 PCB3 CN1 CN1 CN3 CN1 CN1 CN7 CN3 CN4 CN2 CN101 CN103 CN1 CN5 CN6 CN8 B H J A F E C D I G...

Page 82: ...imum GND 7 Amperage Control Wiper 0 10VDC 8 Remote Installed 12VDC CN5 CN1 TH1 TH2 S1 TB12 Ground TB9 TB11 TB10 TB1 TB2 TB3 TB1 TB2 TB3 6 1 2 3 4 5 CN1 6 1 2 3 4 5 CN7 6 1 2 3 4 5 CN7 6 1 Q1A Q1B Q1C...

Page 83: ...WK 5609 Output Terminal Output Terminal TO1 TO2 TB5 1 2 3 4 12 12 IS GND C1 R1 T1 D2 D3 TB6 CT1 CN2 CN2 PCB4 Control Circuit Board WK 5449 PCB5 Panel Circuit Board WK 5448 1 2 3 4 5 6 7 CN3 SIDE CHAS...

Page 84: ...m meter positive lead to the anode positive of the diode and the negative lead to the cathode negative of the diode refer to Figure 13 1 A properly functioning diode will conduct in the forward bias d...

Page 85: ......

Page 86: ...e with the installation service manual 4 Failure to clean and maintain the machine as set forth in the owner installation or service manual If warranty is being sought please contact Thermadyne s UK w...

Page 87: ...trict Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Eh...

Page 88: ...World Headquarters Thermadyne Holdings Corporation Suite 300 16052 Swingley Ridge Road St Louis MO 63017 Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com...

Search results

Summary of Contents for ARCMASTER 200 S

Reviews:

Related manuals for ARCMASTER 200 S

Brands by name

Popular brands

Thermal Arc ARCMASTER 200 S, Service Manual

Search results

Summary of Contents for ARCMASTER 200 S

Reviews:

Related manuals for ARCMASTER 200 S

Brands by name

Popular brands