Thermal Arc ARCMASTER 200 TS Service Manual Download Page 34

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200TS

ROUTINE MAINTENANCE

7 – 2

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Summary of Contents for ARCMASTER 200 TS

Page 1: ...INVERTER ARC WELDER Revision No AB Issue Date May 7 2008 Manual No 0 4941B Operating Features 200 TS Service Manual Art A 06912 ARCMASTER...

Page 2: ......

Page 3: ...www thermalarc com Copyright 2006 2007 2008 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The...

Page 4: ...Input Connections 3 1 4 Electrical Input Requirements 3 1 5 Input Power 3 2 6 High Frequency Introduction 3 2 7 High Frequency Interference 3 3 8 Duty Cycle 3 3 9 Specifications 3 4 4 OPERATOR CONTROL...

Page 5: ...of the Cooling Fan FAN1 Drive Circuitry 11 10 5 4 Verification of the Gas Valve SOL1 Drive Circuitry 11 11 5 5 Verification of the primary Diode D1 11 11 5 6 Verification of the secondary Diode D2 D3...

Page 6: ...CONTENTS APPENDIX 1 PARTS LIST 1 Equipment Identification 13 1 2 How To Use This Parts List 13 1 APPENDIX 2 CONNECTION WIRING GUIDE APPENDIX 3 INTERCONNECT DIAGRAM APPENDIX 4 DIODE TESTING BASICS...

Page 7: ...ectrically 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 f...

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: ...ce 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 q...

Page 13: ...oupez 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 u...

Page 14: ...AU 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...

Page 15: ...t 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 TS...

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: ...ernating 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 Posit...

Page 19: ...rc Welding GTAW Gas Tungsten Arc Welding Pulsed GTAW P Gas Tungsten Arc Welding Sloped GTAW S and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resistant...

Page 20: ...r device of adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting To each control circuit Main Circuit Switch Filter Input Diode Capacitor DC Power...

Page 21: ...e electri 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 el...

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

Page 23: ...ded where possible 4 Re radiation from Unearthed Metallic Objects A major factor contributing to interference is re radiation from unearthed metallic objects close to the welding leads Effective groun...

Page 24: ...e of the following variations or changes in manufac tured components installation location and condi tions and local power grid supply conditions Parameter 200TS Rated Output 115VAC 230VAC Amperes 85A...

Page 25: ...tacle 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 0V to en...

Page 26: ...imary supply volt age to the inverter when in the ON position This enables the Power Supply WARNING When the welder is connected to the Primary sup ply voltage the internal electrical components may b...

Page 27: ...and is used to set the time for the weld current to ramp up after the torch trigger switch has been pressed then released from INITIAL CUR to PEAK or BASE current PEAK CUR This parameter sets the PEA...

Page 28: ...LOAD Weld Parameter Parameter Range Factory Setting Incremental Unit Weld Mode STICK MIG LIFT TIG PRE FLOW 0 0 to 1 0 sec 0 1 sec 0 1 sec No Yes Yes HOT START 0 to 70A 20A 1A Yes Yes No INITIAL CUR 1...

Page 29: ...ameters 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 5 is displayed on the meter After sel...

Page 30: ...oltage 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 wel...

Page 31: ...8 Save Load Button by using the Save Load buttons the operator can easily save up to 5 welding parameter program 1 Stick Welding Connect work lead to negative terminal Connect electrode lead to positi...

Page 32: ...e Switch contacts the current will increase back to weld cur rent Within the Down Slope period the repeat func tion can operated as many times as desired To continue slope cycle and end slope sequence...

Page 33: ...ure to allow the primary capacitors to discharge To clean the unit open the enclosure please refer to Section 11 1 1 Opening the Enclosure 200TS Service Manual P N and use a vacuum cleaner to remove a...

Page 34: ...200TS 7 ROUTINE MAINTENANCE 7 2 PAGE LEFT INTENTIONALLY BLANK...

Page 35: ...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 36: ...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 37: ...revious 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...

Page 38: ...ut torch connections 4 No gas flow when the torch trigger switch is depressed A Gas hose is cut B Gas passage contains impurities C Gas regulator turned off D Torch trigger switch lead is disconnected...

Page 39: ...Device 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...

Page 40: ...t panel 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...

Page 41: ...Air flow is restricted by vents being blocked investigate tt 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 be...

Page 42: ...200TS 10 POWER SOURCE ERROR CODE 10 2 PAGE LEFT INTENTIONALLY BLANK...

Page 43: ...new 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 r...

Page 44: ...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 45: ...ify and maintain clean dust free 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...

Page 46: ...alled direction of CT1 The Hall CT will not function properly if installed in the incorrect direction Refer to section 12 3 10 for the replacement of CT1 2 4 E94 Thermistor malfunction Cause Thermisto...

Page 47: ...Verify the drive circuitry of the cooling fan FAN1 on PCB3 Refer to section 11 5 3 Replace PCB1 if necessary Refer to section 12 3 1 3 2 Gas Valve Failure No Gas flow through unit Cause Occurs when th...

Page 48: ...the welding cable the stick rod holders and the ground clamp Applies to all welding modes Verify a secure connection of the welding cable stick rod holders ground clamp and dense connectors and there...

Page 49: ...UNIT1 and C C Verify that the quick disconnect ter minals are inserted onto the terminals of HF UNIT1 TB5 TB6 correctly and completely Verify there are no short circuits burnt or bro ken wires at C C...

Page 50: ...fication of the Power Input Circuitry CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described in section 11 4 1 Prepar...

Page 51: ...B1 P and TB3 N on PCB1 WK 5713 Points TB1 P and TB2 N can be found on the parts side of PCB2 See Figure 11 9 The mea sured voltage should be approximately 1 4 times larger than input voltage measured...

Page 52: ...a DC voltmeter measure between PIN 1 Posi tive and PIN 2 Negative of CN11 on PCB3 WK 5548 The location of connector CN11 of PCB3 is indicated in Figure 11 12 When you measure the above voltage do not...

Page 53: ...ge do not remove the connector Conduct the measurement while the connector plug and receptacle are still con nected Figure 11 13 Verification of the SOL1 2 Using the measurement taken above follow the...

Page 54: ...D3 5 7 Verification of the primary IGBT Q1A Q4C CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described at the beginni...

Page 55: ...fy the no load voltage using a DC volt meter The capability of the voltmeter should be more than 100VDC 3 The normal no load voltage is approxi mately 65V b Verify the no load voltage OCV in High Fre...

Page 56: ...n 100VDC The check point with a tester is the voltage between output termi nal and In TIG mode the OCV ceases 3 seconds after you depress the torch switch 4 The normal no load voltage is approxi matel...

Page 57: ...cal damage overheating and loose connections 1 2 Test and Replacement Parts List NO DWG NO PARTS NAME REFERENCE PAGE PARTNO 1 PCB1 Printed Circuit Board WK 5713 12 5 W7001626 2 PCB2 Printed Circuit Bo...

Page 58: ...01621 4 C2 Capacitor 12 25 W7001620 5 C C Coupling Coil 12 15 W7001384 6 FCH1 Reactor 12 15 W7001502 7 HF UNIT High Freguency Unit 12 19 W7001399 8 L101 Ring Core 12 21 W7001623 9 L102 Reactor 12 24 W...

Page 59: ...27 2 CT1 Hall Current Trans 12 17 10 5003 3 D1 Primary Diode 12 5 W7001481 4 D2 Secondary Diode 12 15 10 6629 5 D3 Secondary Diode 12 15 10 6629 6 FAN1 Cooling Fan 12 18 10 5227 7 S1 Switch 12 21 W700...

Page 60: ...intenance 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 nance o...

Page 61: ...ry Diode D1 1 Remove the Side Panel See section 11 1 1 2 Remove the L102 See section 12 3 18 3 Remove the screw and three cables Cut the snap band 4 Remove the terminal and Disconnect the three connec...

Page 62: ...AINTENANCE 12 6 6 Remove the Gas Tube Remove the two bolts two toothed washers and the terminal 7 Remove the four screws and the Front Panel 8 Remove the Gas Tube and the two cables 1 2 2 2 1 1 1 1 1...

Page 63: ...the four screws and the Rear Panel 10 Remove the four screws and the two cables Disconnect the eight connectors CN1 8 on the PCB1 11 Remove the four screws and Remove the PCB1 unit 1 1 1 1 2 1 2 2 CN2...

Page 64: ...e apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 3 2 PCB2 WK 5417 Capacitor C1 and Resistor R1 1 Remove the Side Panel See section 11 1 1 2 Remove the PCB1...

Page 65: ...NCE 12 9 5 Remove the eight screws and the PCB2 unit 6 Remove the screw and Remove the Capacitor C1 and Resistor R1 from the PCB2 Remove the two edge holders and the PCB2 Insulation Sheet from PCB2 1...

Page 66: ...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 t...

Page 67: ...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 68: ...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...

Page 69: ...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 Q1A Q2C Remember to install new Silicone Rubber Sheets where silicone comp...

Page 70: ...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 71: ...h 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 747 or equivalent on the bas...

Page 72: ...NCE 12 16 3 Remove the four screws and the Front Panel 4 Remove the screw and then remove the cable Remove the two terminals from HF UNIT Remove the terminal from PCB3 5 Remove the C C and FCH1 1 1 1...

Page 73: ...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 Disconnect...

Page 74: ...the Side Panel See section 11 1 1 2 Remove the Gas Tube Remove the two terminals and Cut the three snap bands 3 Disconnect the connector CN2 on the PCB1 and Cut the snap band 4 Remove the four screws...

Page 75: ...the wrong direction of the fan when reinstalling 3 12 HF UNIT1 High Frequency Unit 1 Remove the Side Panel See section 11 1 1 2 Remove the high frequency gap Remove the four terminals 3 Remove the tw...

Page 76: ...1 Solenoid GAS Valve 1 Remove the Side Panel See section 11 1 1 2 Remove the Gas Tube and two terminals 3 Remove the C ring and then detach the SOL1 When reinstalling make sure that the C ring seats i...

Page 77: ...h 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 78: ...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...

Page 79: ...orm coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 3 17 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 80: ...screws six terminals Remove the C103 and L102 Note When C103 is installed again it is a thing fixed to former place on PCB3 by RTV silicon rubber 3 19 L103 Reactor 1 Remove the Side Panel See section...

Page 81: ...r screws and open the Rear Control Cover 5 Remove one nut one washer and two terminals Remove the L103 3 20 C2 Capacitor and R2 Resistor 1 Remove the Side Panel See section 11 1 1 2 Remove the Gas Tub...

Page 82: ...10 5 Cut the snap band and remove the cables Disconnect the three connectors CN1 3 on the PCB3 Remove the three screws and the three cables Remove the terminal 6 Remove the 11 screws and PCB3 unit Ta...

Page 83: ...200TS 12 MAINTENANCE 12 27 7 Remove the screw and C2 unit 8 Remove the C2 with the soldering iron from the R2 1 2 1 1 2 2...

Page 84: ...il 1 6 CON1 10 6627 Socket Remote gen 3 1 IPS 206433 1 8P with Wiring Assembly Remote Receptacle 1 7 CT1 10 5003 Sensor Current gen 3 1 IPS HC TN200V4B15M 200A 4V Hall Current Trans 1 8 D1 W7001481 Di...

Page 85: ...gen 3 1 IPS 2 53 10 6660 Terminal Output gen 3 1 IPS TRAK BE35 70S 2 54 N A Cable Input gen 3 1 IPS VCT 2 5 3XC L 3 2m 1 55 W7001484 Clamp Input gen 3 1 IPS SCLB14A 1 56 W7001489 Heatsink gen 3 1 IPS...

Page 86: ...200TS PARTS LIST 3 79 36 43 43 37 33 11 38 38 50 42 15 17 16 63 70 55 39 61 22 41 21 32 2 45 60 6 59 40 52 47 51 65 44 46 45 44 52 48 53 53 54 49 65...

Page 87: ...200TS PARTS LIST 4 56 62 62 62 73 74 58 30 4 58 72 72 72 72 62 57 75 75 18 3 8 19 23 71 24 12 5 34 77 1 29 20 7 69 67 68 66 76 10 9 35 35 13 64 31 14 71 78 78 78...

Page 88: ...CONNECTION WIRING GUIDE Destination Destination A PCB1 CN1 CON1 B PCB1 CN2 FAN1 SOL1 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 PCB7 CN1 I PCB1 CN1...

Page 89: ...0TS CONNECTION WIRING GUIDE 6 PCB6 PCB4 CON1 TH1 TH2 PCB7 SOL1 R1 R2 ACT1 ACT2 PCB1 FAN1 CT1 PCB3 CN1 CN1 CN3 CN1 CN2 HF UNIT CN3 CN1 CN7 CN3 CN4 CN2 CN101 CN103 CN1 CN5 CN6 CN8 B H J A F E C D K L I...

Page 90: ...rage 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 5 CN7 6 1 SOL1 Q1A Q1B Q1C C G E PCB6 IGBT Gate Circuit Board WK 5460 PCB...

Page 91: ...Output Terminal TO1 TO2 TB5 1 2 4 12 12 IS GND T1 D2 D3 TB6 CT1 1 2 3 CN2 1 2 3 HF UNIT CC2 CC1 R1 R2 AC1 AC2 TB2 TB4 TB3 TB1 CN2 CN2 PCB4 Control Circuit Board WK 5449 PCB5 Panel Circuit Board WK 54...

Page 92: ...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 93: ......

Page 94: ...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 95: ...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 96: ...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...

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