Thermal Arc ARCMASTER 300 AC/DC Service Manual Download Page 1

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400

INVERTER

Service Manual

ARCMASTER

Version No:

AA.01

Issue Date:

May 22, 2006

Manual No.:

0-4942B

Operating Features:

INVERTER ARC WELDER

300 AC/DC

Art # A-07238

Summary of Contents for ARCMASTER 300 AC/DC

Page 1: ...400 V 3 50 60 Hz INVERTER Service Manual ARCMASTER Version No AA 01 Issue Date May 22 2006 Manual No 0 4942B Operating Features INVERTER ARC WELDER 300 AC DC Art A 07238 ...

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Page 3: ...03784 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 publisher 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 in this Manual whether such error results from negligence acc...

Page 4: ...ical Input Connections 3 1 4 Electrical Input Requirement 3 1 5 Input Power 3 2 6 High Frequency Introduction 3 3 7 High Frequency Interference 3 3 8 Duty Cycle 3 3 9 Specifications 3 4 4 OPERATOR CONTROLS 1 ARC MASTER 300ACDC Controls 4 1 2 Weld Process selection for ARC MASTER 300ACDC 4 2 3 Weld Parameter Descriptions for ARC MASTER 300ACDC 4 3 4 Weld Parameters for ARC MASTER 300ACDC 4 5 5 Powe...

Page 5: ...welding setting cannot be establish 11 9 3 5 High Frequency Output Failure Unit does not generate High Frequency 11 9 4 Fault Isolation Tests 11 10 4 1 Preparation 11 10 5 Verification of the Power Input Circuitry 11 11 5 1 Verification of the AC Input Voltage using an AC Voltmeter 11 11 5 2 Verification of the Power Supply Voltage 11 12 5 3 Verification of the Cooling Fan FAN1 Drive Circuitry 11 ...

Page 6: ... 3 27 Main ON OFF Switch S1 12 27 3 28 Remote Socket CON1 12 28 3 29 High Freguency Unit HF UNIT1 12 28 3 30 Hall Current Sensor HCT1 12 29 3 31 Primary Diode D1 12 30 3 32 Secondary Diode D2 D7 12 31 3 33 Secondary IGBT Q25 Q26 and PCB18 PCB19 12 32 3 34 Current Trans CT2 CT3 12 33 3 35 Ring Core L1 12 34 3 36 Ring Core L105 12 36 3 37 Reactor L101 12 37 3 38 Reactor L102 12 38 3 39 Reactor L103 ...

Page 7: ...lly 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 from work and ground using dry insulating mats or covers 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch open or remove line fuses so p...

Page 8: ... 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 flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be alert that welding sparks an...

Page 9: ...se 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 Engine fuel is highly flammable 1 Stop engine before checking or adding fuel 2 Do not add fuel while smoking or if unit is near any sparks or open flames 3 Allow engine to cool before fueling If possible che...

Page 10: ...rategies 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 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 tho...

Page 11: ...e 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 pièces métalliques en contact avec le fil de soudage sont sous tension Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux 1 Ne touchez pas à des pièces sous tension 2 Portez des gants et des vêtements isolants secs et ...

Page 12: ... bien ventilé sinon portez un respirateur à adduction d air Les gaz protecteurs de soudage peuvent déplacer l oxygène de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre à la respi ration 6 Ne soudez pas à proximité d opérations de dégraissage de nettoyage ou de pulvérisation La chaleur et les rayons de l arc peuvent réagir avec des vapeurs et former des gaz hautemen...

Page 13: ...le fil au tube con tact lorsqu inutilisé après le soudage 11 Portez des vêtements protecteurs non huileux tels des gants en cuir une chemise épaisse un pantalon revers des bottines de sécurité et un casque AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules métalliques volantes En refroidissant la soudure peut pr...

Page 14: ... ET LES YEUX Les accumulateurs contiennent de l électrolyte acide et dégagent des vapeurs explosives 1 Portez toujours un écran facial en travaillant sur un accumu lateur 2 Arrêtez le moteur avant de connecter ou de déconnecter des câbles d accumulateur 3 N utilisez que des outils anti étincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un ...

Page 15: ...derwriters 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 when used in...

Page 16: ... 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 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 is identifi...

Page 17: ...lternating 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 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 TIG circuit GTAW ...

Page 18: ...e curve 6 Functional Block Diagrams Figure 2 1 illustrates the functional block diagram of the 300ACDC power supply Figure2 2 300ACDC Model Functional Block Diagram 300A 5A A V OCV 300A 25A A V OCV 10V 300A A V OCV 5A STICK Process LIFT TIG Process HF TIG Process Main Circuit Switch Filter Input Diode Primary Capacitor DC Power Voltage Sensor IGBT Inverter Thermal Detector To each control circuit ...

Page 19: ...al 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 unit with handle on top of case Use handcart or similar device of adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting ...

Page 20: ...uld restrict natural airflow for cooling WARNING Thermal Arc advises that this equipment be 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 electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lock...

Page 21: ...t the Bus Voltages are checked and the welder is enabled after the input capacitors have charged to full operating voltage after approximately 5 seconds NOTE Note the available input power Damage to the welder could occur if 575VAC or higher is applied The following 400V Primary Current recommenda tions are required to obtain the maximum welding current and duty cycle from this welding equip ment ...

Page 22: ...on Adequate shielding and filter ing is provided in the Power Source 3 Radiation from Welding Leads Radiated interference from welding leads although pro nounced in the vicinity of the leads diminishes rapidly with distance Keeping leads as short as possible will minimize this type of interfer ence Looping and suspending of leads should be avoided where possible 4 Re radiation from Unearthed Metal...

Page 23: ...ively to any one or more of the following variations or changes in manufac tured components installation location and condi tions and local power grid supply conditions Parameter 300ACDC Rated Output Amperes 300 Volts 22 Duty Cycle 25 Duty Cycle TIG 300A 22V 25 190A 17V 60 150A 16V 100 STICK 300A 32V 25 190A 27V 60 150A 26V 100 Output Current Range TIG 5 300 DC 5 300 AC 60Hz 50 Cleaning STICK 5 30...

Page 24: ...ockwise Figure4 2 14 Socket Receptacle Table 4 1 Socket Pin Functions 450 210 435 1 3 5 8 2 7 6 4 Socket Pin Function A Torch Switch Input 24V to connect pins A B to turn on welding current B Torch Switch Input 0V to energize weld current connect pins A B to turn on welding current C 5k ohm maximum connection to 5k ohm remote control potentiometer D Zero ohm minimum connection to 5k ohm remote con...

Page 25: ...en the welder is connected to the Primary sup ply voltage the internal electrical components may be at 720V potential with respect to earth 7 Input Cable The input cable connects the Pri mary supply voltage to the equipment 8 Gas Inlet The Gas Inlet is a BSP 3 8 inch female gas fitting 2 Weld Process selection for ARC MASTER 300ACDC Table4 2 Weld Process selection verses Weld Mode for ARC MASTER 3...

Page 26: ...is used to set the start current for TIG The Start Current remains on until the torch trigger switch is released after it has been depressed UP SLOPE This parameter operates in TIG modes only 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 PEAK weld cu...

Page 27: ...the torch trigger switch has been pressed to CRATER CUR This control is used to eliminate the crater that can form at the completion of a weld CRATER CUR This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the finish current for TIG The CRATER Current remains on until the torch trigger switch is released after it has been depressed POST FLOW This parameter operates in T...

Page 28: ... sec 1 sec 0 1 sec No Yes Yes PULSE PEAK CUR 5 to 300A 120A 1A No Yes Yes PULSE BASE CUR 5 to 300A 80A 1A No Yes Yes WELD CUR 5 to 300A 80A 1A Yes Yes Yes SPOT TIME 0 5 to 5 0 sec 2 sec 0 1 sec No Yes Yes PULSE WIDTH 15 to 80 50 1 No Yes Yes PULSE FREQ 0 5 to 500Hz 100 0Hz See Table Table 4 5 No Yes Yes AC FREQUENCY 15 to 150Hz 60Hz 1Hz Yes Yes Yes WAVE BALANCE 10 to 65 50 1 Yes Yes Yes DOWN SLOPE...

Page 29: ...ht is ON when not welding and red when welding When in TIG modes VRD is off Control Knob For the selected weld parameter rotating the knob clockwise increases the parameter Rotating the knob counter clock wise decreases the parameter A selected weld parameter value can be adjusted at any time even while welding Pushing the knob in displays actual arc voltage Self Diagnosis Using Error Codes An err...

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 welding current range values as a guide then finally adjust the current setting to suit the application WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode h...

Page 31: ...300ACDC 5 SET UP FOR SMAW STICK AND GTAW TIG 5 2 PAGE LEFT INTENTIONALLY BLANK ...

Page 32: ... TIG mode 8 Scroll Buttons used to select the parameters to be set The LED s show which function is being adjusted on the Sequence Graph 9 AC DC Button Selects between AC or DC welding output 10 Contactor function Pressing this button enables Contactor func tions 1 Stick Welding Connect work lead to negative terminal Connect electrode lead to positive terminal Switch machine on Set AC or DC weld c...

Page 33: ...Slope Sequence and is active through the down slope period only During the down slope period by opening the Remote Switch contacts the current will increase back to weld cur rent Within the Down Slope period the repeat function can operated as many times as desired To continue slope cycle and end slope sequence close remote switch contacts and allow weld cur rent to reach final current setting Onc...

Page 34: ...ening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure refer to to Section 11 1 1 Opening the Enclosure and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean if necessary with solvents that are recommended for cleaning electrical apparatus CAUTION Do not blow air into the power supply during clean ing Blo...

Page 35: ...300ACDC 7 ROUTINE MAINTENANCE 7 2 PAGE LEFT INTENTIONALLY BLANK ...

Page 36: ...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 placement of filler rod Re position filler rod 6 Electrode melts when arc is struck A Electrode is connected to the terminal B WAVE BALANCE is greater than 50 A Connect the electrode to the terminal B Re...

Page 37: ...cylinder empty or the torch valve is off A Connect the work clamp to the work piece or connect the work torch leads to the right welding terminals B Connect it to the terminal C Select the right flow rate change cylinders or turn torch valve on 12 Arc start is not smooth A Tungsten electrode is too large for the welding current B The wrong electrode is being used for the welding job C Gas flow rat...

Page 38: ...l slowly 3 A gap is left by failure of the weld metal to fill the root of the weld A Welding current is too low B Electrode too large for joint C Insufficient gap D Incorrect sequence A Increase welding current B Use smaller diameter electrode C Allow wider gap D Use correct build up sequence Incorrect sequence Insufficient gap Description Possible Cause Remedy 4 Portions of the weld run do not fu...

Page 39: ...cale is preventing full fusion F Wrong electrode for position in which welding is done A If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode B Allow for adequate penetration and room for cleaning out the slag C If very bad chip or grind out irregularities D Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to ...

Page 40: ...nections 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 or switch cable is faulty A Replace gas hose B Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities C Turn gas regulator on D Reconnect lead or repair faulty switch c...

Page 41: ...300ACDC 8 BASIC TROUBLESHOOTING 8 6 PAGE LEFT INTENTIONALLY BLANK ...

Page 42: ...vice VRD 2 Contactor function is put into the state of ON by 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 more than 100VDC 4 The normal no load voltage is approximately 18V 5 In STICK welding mode mark and then turn potentiometer VR1 on PCB6 WK 5549 all the way to the right and turn off the VRD 6 Contacto...

Page 43: ...l 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 front panel controls can only be achieved by removing the Side Panel Figure9 3 VRD ON OFF Step D D Turning the VRD ON OFF see Figure 9 3 To turn VRD ON rotate the trim potentiometer VR1 on the display P...

Page 44: ...tage specification TIG torch cable and or work lead are too long or leads are coiled Reduce the length of the TIG torch cable and or work lead or un coiled leads Weld current ceases Buzzer sounds constantly Switch machine off then on to reset E04 error 5 E11 error code displayed Over Primary supply input voltage at primary capacitors is exceeded for one second Primary supply voltage is greater tha...

Page 45: ...the machine No weld current is available Buzzer sounds constantly Switch machine off then on to reset E85 error 12 E93 error code displayed Memory chip EEPROM on control PCB can not read write weld parameters Memory chip EEPROM error Have an Accredited Thermal Arc Service Agent check the control PCB Weld current ceases Buzzer sounds constantly Switch machine off 13 E94 error code displayed Tempera...

Page 46: ...ubas sembly should be replaced with a 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 review the Important Safety Precautions in section 1 02 Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of...

Page 47: ...ning them approximately two turns CCW Figure11 3 Loosen screws NOTE DO NOT remove the screws completely 4 Pull the front panel slightly forward and pull the rear panel slightly backward The interlocking hooks of the side case covers can now be dis engaged from the front and rear panels Figure11 4 Loosen front and rear panels 5 Remove the Side Panel Figure11 5 Remove Side Panel ...

Page 48: ...ted Verification Remedy a Unit may be in thermal shutdown mode Review the rated duty cycle of the unit per section 3 8 Exceeding the duty cycle can damage the unit and void the warranty Refer also to section 1 6 for additional information b Verify the ventilating condition Maintain a clear and unobstructed distance of more than 30cm in the front and more that 50cm in the rear of the unit for venti...

Page 49: ...ormal sounds If broken or cracked FAN1 blades or abnor mal sounds are emanating from FAN1 replace FAN1 Verify the operation of the cooling fan and replace it if the condition of FAN1 is inactive Follow the instruction in section Refer to section 12 3 24 for the replacement of FAN1 Refer to section 11 5 3 for additional FAN1 tests d Replace PCB6 WK 5549 Refer to section 12 3 6 for the replacement o...

Page 50: ... 2 b Replace PCB4 WK 4819 Verify PCB4 WK 4819 and replace it if nec essary Refer to section 12 3 4 2 6 E12 Main Supply Under Volt age Cause Main supply voltage occurs at about 150V or less Verification Remedy a Verify main supply voltage Perform what is described in a section of Verification of the Power Supply Voltage Refer to section 11 5 2 b Replace PCB4 WK 4819 Replace PCB4 when abnormalities ...

Page 51: ...all the harness with a secure connec tion Contact the manufacturer if you find any bro ken connectors or damaged wiring harness c Verify PCB4 WK 4819 and replace it if neces sary Check whether there are any abnormalities on the appearance of PCB4 Replace PCB4 Refer to section 12 3 4 2 10 E85 Pre charge abnormality Cause Due to malfunction inside the Welding Power Source primary capacitors are not ...

Page 52: ...ion 12 3 4 c Replace PCB6 WK 5549 Refer to section 12 3 6 3 Verification and Remedy to Failures without Indication Codes Refer to Note on Section 11 02 3 1 Cooling Fan FAN1 Failure Fan is not rotating Cause Occurs when the cooling fan FAN1 is defective damaged or the driving voltage is incorrect Verification Remedy a Verify the cooling fan FAN1 Inspect the condition of the fan blades and all perip...

Page 53: ...TIG HF TIG mode if the High Frequency is not generated present refer to High Frequency Output Failure Refer to section 11 3 5 Cause 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 proceeding Extreme personal harm and test equipment damage will occur if t...

Page 54: ...527 Contact the manufacturer if you find any bro ken connectors or a damaged wiring har nesses b Verify the connection between PCB5 WK 5551 and PCB6 WK 5549 c Replace PCB5 WK 5551 and PCB6 WK 5549 Refer to section 12 3 5 12 3 6 d Verify the connection between PCB6 WK 5549 and PCB12 WK 5527 e Replace PCB6 WK 5549 and PCB12 WK 5527 Refer to section 12 3 6 12 3 9 3 5 High Frequency Output Fail ure Un...

Page 55: ...1 0mm or more high fre quency voltage and a period increase In the case of a gap 1 0mm or less high fre quency voltage and a period decrease e Verify and replace the Current limiting Resistor R6 on HF UNIT1 If R6 is defective blown burnt cracked etc replace R6 Refer to section 12 3 17 f Replace the High Frequency Unit HF UNIT1 Refer to section 12 3 29 g Replace PCB3 WK 5548 Refer to section 12 3 3...

Page 56: ...put voltage to decrease to a value below the oper ating range of the unit 3 Verify input voltage after the input switch S1 using an AC voltmeter The capability of the voltmeter should be more than 600VAC Using an AC voltmeter measure between the points U2 and V2 on the input switch S1 Using an AC voltmeter measure between the points U2 and W2 on the input switch S1 Using an AC voltmeter measure be...

Page 57: ... 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 Preparation 1 Verify Power Supply voltage using an DC volt meter The capability of the voltmeter should be more than 50VDC Operate at all input volt ages as noted on the nameplate on the rear panel when testing the power supply 2 On the PCB3 WK 5548 a...

Page 58: ... connector plug and receptacle are still connected Figure11 12 Verification of the FAN1 2 Using the measurement taken above follow the chart 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 becomes impossible Perform the check of voltage in the state of...

Page 59: ...1 3 When verifying the voltage confirm that the AC input voltage remain within the operating range of the unit The AC input does not drop below 180VAC 5 5 Verification of the primary Diode D1 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 Preparation 1 Verify the characteristic of the prima...

Page 60: ...11 4 1 Preparation 1 Check whether there are any abnormalities on the appearance of PCB8 PCB11 2 Verify the characteristic of the primary IGBT Q1 Q24 using a diode tester 3 Refer below Table 11 7 and Figure 11 16 for the checkpoints on PCB8 PCB11 Table11 7 Tester checkpoints in the Q1 Q24 Figure 11 16 Tester checkpoints in the Q1 Q24 COMPONENT TESTED TERMINALS ACCEPTABLE VALUE Positive lead Negati...

Page 61: ...n as described in section 11 4 1 Preparation a Verify the no load voltage in STICK mode 1 In STICK welding mode mark and then turn potentiometer VR1 on PCB6 WK 5549 fully counterclockwise to turn off the electric shock protector function Volt age Reduction Device VRD 2 Contactor function is put into the state of ON pushing Function button Refer to sec tion 6 WARNING Electric shock hazard The unit ...

Page 62: ...11 18 Removal and installation from the HF UNIT1 To disable the operation of the HF unit 2 Press the Welding mode selection button to select HF TIG welding mode 3 While depressing the Torch switch verify the OCV using a DC voltmeter The capa bility of the voltmeter should be more than 100VDC The check point with a tester is the voltage between output terminal and In TIG mode the OCV ceases 3 secon...

Page 63: ...001314 3 PCB4 Print Circuit Board WK 4819 12 10 10 6635 4 PCB5 Print Circuit Board WK 5551 12 11 W7001417 5 PCB7 Print Circuit Board WK 5550 12 9 W7001423 6 PCB12 Print Circuit Board WK 5527 12 12 W7001319 7 PCB13 Print Circuit Board WK 5528 12 13 W7001320 8 PCB14 Print Circuit Board WK 5594 12 14 W7001435 9 PCB16 Print Circuit Board WK 5569 12 16 W7001433 10 PCB21 Print Circuit Board WK 4917 12 1...

Page 64: ...cuit Board WK 5479 Primary IGBT 12 12 W7001318 4 PCB9 Q7 Q12 Print Circuit Board WK 5479 Primary IGBT 12 12 W7001318 5 PCB10 Q13Q18 Print Circuit Board WK 5479 Primary IGBT 12 12 W7001318 6 PCB11 Q19 Q24 Print Circuit Board WK 5479 Primary IGBT 12 12 W7001318 7 PCB15 Print Circuit Board WK 5606 12 16 W7001321 8 PCB17 Print Circuit Board WK 5570 12 17 W7001434 9 PCB20 Print Circuit Board WK 5499 12...

Page 65: ...629 4 D3 Secondary Diode 12 30 10 6629 5 D4 Secondary Diode 12 30 10 6629 6 D5 Secondary Diode 12 30 10 6629 7 D6 Secondary Diode 12 30 10 6629 8 D7 Secondary Diode 12 30 10 6629 9 HF UNIT1 High Frequency Unit 12 28 W7001399 10 Q25 PCB18 Secondary IGBT WK 3367 12 31 10 6643 11 Q26 PCB19 Secondary IGBT WK 3367 12 31 10 6643 12 S1 Main ON OFF Switch 12 26 10 6857 13 S2 Input Voltage Switch 12 27 10 ...

Page 66: ...ng Fan 12 24 W7001307 5 FCH1 Reactor 12 22 W7001681 6 HCT1 Hall Current Sensor 12 29 10 5003 7 L1 Ring Core 12 33 W7001309 8 L105 Ring Core 12 33 W7001309 9 R3 Discharge Resistor 12 20 10 5137 10 R6 Current Limiting Resistor 12 19 W7001451 11 R7 Resistor 12 21 W7001325 12 R8 Resistor 12 21 W7001325 13 SOL1 Solenoid Valve 12 25 10 6645 14 TH1 Primary Thermistor 12 23 10 5228 15 TH2 Secondary Thermi...

Page 67: ...pports NOTE During 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 nance or repair CAUTION Please note that you remove each connector grasp and pull out by the connector part only Do not pull the harness cable part WARNING The capacitors inside the...

Page 68: ... page 12 7 3 Remove the diode D1 Reference page 12 30 4 Remove the current trans CT2 CT3 Reference page 12 33 5 Remove the gas tube Remove the two bolts and one terminal Remove the four screws and open the front cabinet 6 Remove the four screws and six terminals from the PCB1 WK 5477 7 Remove the reactor L1 Reference page 12 34 3 3 3 3 4 2 1 1 2 2 ...

Page 69: ...rence page 11 1 2 Remove the screw and then disconnect the four ground terminals Disconnect the 19 connectors 3 Remove the four screws Remove the PCB3 PCB4 PCB5 PCB6 and PCB7 unit Disconnect the three connectors 2 1 1 1 2 2 CN1 CN3 CN2 CN17 CN21 CN9 CN8 CN7 CN7 CN4 CN21 CN8 CN22 CN23 CN1 CN11 CN19 CN20CN9 1 2 CN15 CN14 CN13 ...

Page 70: ...2 WK 5597 and insulation sheet 3 3 PCB3 WK 5548 PCB7 WK 5550 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB4 WK 4819 Reference page 12 10 3 Remove the PCB6 WK 5549 Reference page 12 11 4 Remove the PCB5 WK 5551 Reference page 12 10 5 Disconnect the 11 connectors from the PCB3 WK 5548 CN2 CN1 CN3 CN23 CN19 CN11 CN8 CN3 CN2 CN1 CN9 CN22 CN21 CN20 ...

Page 71: ...d PCB7 unit Disconnect the three connectors from the PCB7 WK 5550 7 Disconnect the one connector and remove the two screws and then remove the PCB7 WK 5550 from the PCB3 WK 5548 Remove one screw and one ground terminal from the PCB7 WK 5550 8 Disconnect the two connectors from the PCB3 WK 5548 3 1 CN14 CN15 CN13 2 1 2 CN20 CN33 CN18 ...

Page 72: ...the two connectors Remove the two screws and three connectors and remove the PCB4 WK 4819 3 5 PCB5 WK 5551 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB6 WK 5549 Reference page 12 11 3 Remove the two screws and three connectors Remove the PCB5 WK 5551 2 1 CN6 CN5 CN4 CN4 CN7 CN32 CN31 CN30 ...

Page 73: ...B8 PCB9 WK 5479 and Q1 Q12 Primary IGBT 1 Remove the Side Panel Reference page 11 1 2 Remove the eight screws and four device clips Remove the four connectors and six screws Remove the PCB8 WK 5479 and PCB9 WK 5479 Remember to install silicone rubber sheets when reinstalling the print circuit boards CN21 CN20 CN8 CN9 CN17 CN1 CN27 CN30 CN31 CN32 CN18 CN2 CN2 CN1 CN1 1 2 2 3 Silicone rubber sheets ...

Page 74: ...screws Remove the PCB10 WK 5479 and PCB11 WK 5479 Remember to install silicone rubber sheets when reinstalling the print circuit boards 3 9 PCB12 WK 5527 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB13 WK 5528 Reference page 12 13 3 Remove the three latches and then the PCB12 WK 5527 When reinstalling the PCB12 engage two latches first CN2 CN2 CN1 CN1 1 2 3 Silicone rubber sheets 1 ...

Page 75: ...e operation cover 3 Remove the jog dial cap Holding the jog dial down loosen the screw and remove the jog dial 4 Disconnect the one connector from the PCB12 WK 5527 Remove the nut washer and terminal Remove the four screws Pull out the operation panel and bring it down 1 2 2 3 1 2 3 1mm 3 3 3 3 4 CN2 1 2 ...

Page 76: ...1 2 Remove the coupling coil CC1 Reference page 12 23 3 Remove the PCB16 WK 5569 Reference page 12 16 4 Remove the PCB20 WK 5499 Reference page 12 17 5 Remove the inductor FCH1 Reference page 12 23 6 Remove the two screws from the front side and remove the bus bar 7 Remove the gas tube and two terminals Remove the four screws and open the rear cabinet 1 2 3 CN1 4 2 1 1 2 3 3 3 3 4 ...

Page 77: ...rminals from the bottom Remove the two screws from the rear side and pull out the PCB14 WK 5594 Remove the four screws and then remove the bus bar 3 12 PCB15 WK 5606 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB16 WK 5569 Reference page 12 16 3 Remove the eight screws Remove the two PCB supporters and remove the PCB15 WK 5606 2 2 1 1 2 3 1 1 2 2 3 ...

Page 78: ...x connectors two screws and two terminals 3 Remove the four screws and then the PCB16 WK 5569 3 14 PCB17 WK 5570 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB20 WK 5499 Reference page 12 17 3 Remove the five screws and three terminals Remove the PCB17 WK 5570 and insulation sheet CN1 CN6 CN3 CN4 CN2 CN5 2 1 3 4 1 1 1 1 1 2 2 2 3 3 ...

Page 79: ...supporters from the PCB17 WK 5570 3 15 PCB20 WK 5499 1 Remove the Side Panel Reference page 11 1 2 Remove the gas tube from the front side 3 Disconnect the two connectors Remove the three print circuit board supporters and then remove the PCB20 WK 5499 2 1 CN3 1 1 CN1 2 ...

Page 80: ...ference page 11 1 2 Remove the six screws from the switch S1 and remove the six terminals 3 Remove the four screws and then open the rear plate 4 Disconnect the one connector Remove the two screws and one ground terminal Remove the PCB21 WK 4917 1 1 2 2 1 1 1 1 2 1 2 2 3 CN1 ...

Page 81: ...three screws and the bus bar from the PCB21 WK 4917 3 17 PCB22 WK 5022 1 Remove the Side Panel Reference page 11 1 2 Disconnect one connector Remove four screws and one terminal Remove the PCB19 WK 5022 3 Remove three board supports CN1 2 1 2 3 ...

Page 82: ... the current limiting resistor R6 3 19 Discharge Resistor R3 1 Remove the Side Panel Reference page 11 1 2 Remove the coupling coil CC1 Reference page 12 23 3 Remove the PCB16 WK 5569 Reference page 12 16 4 Remove the PCB20 WK 5499 Reference page 12 17 5 Remove the inductor FCH1 Reference page 12 23 6 Cut the snap band and remove the connector 7 Remove the two screws and the discharge resistor R3 ...

Page 83: ...Resistor R7 R8 1 Remove the Side Panel Referance page 11 1 2 Remove four screws and three terminals 3 Cut off one snap band and disconnect one connector Remove the one screw 4 Remove two screws and remove the PCB22 unit CN1 1 2 3 1 1 2 ...

Page 84: ...300ACDC 12 MAINTENANCE 12 22 5 Remove four screws and open the rear panel 6 Remove four screws and six terminals Remove the resistors R7 and R8 1 1 1 1 2 1 1 1 1 2 2 ...

Page 85: ...move one screw four terminals and one nut Remove one screw and detach the coupling coil CC1 3 22 Inductor FCH1 1 Remove the Side Panel Reference page 11 1 2 Remove the high frequency unit HF UNIT1 Reference page 12 28 3 Remove the coupling coil CC1 Reference page 12 23 4 Remove the PCB16 WK 5569 Reference page 12 16 5 Remove the PCB20 WK 5499 Reference page 12 17 6 Remove the three screws and thre...

Page 86: ...1 3 23 Primary Thermistor TH1 1 Remove the Side Panel Reference page 11 1 2 Disconnect the one connector Remove the one screw and then detach the primary thermistor TH1 Before installing a new therminstor apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 1 2 CN8 1 2 3 ...

Page 87: ...nect the one connector Remove the one screw and secondary thermister TH2 Before installing a new therminstor apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 3 25 Cooling Fan FAN1 1 Remove the Side Panel Reference page 11 1 2 Remove the gas tube and two terminals Remove the four screws and open the rear cabinet CN9 2 1 1 1 3 4 2 1 1 2 3 3 3 3 4 ...

Page 88: ...wo screws and detach the cooling fan FAN1 Do not have the wrong direction of the fan when reinstalling 3 26 Solenoid Valve SOL1 1 Remove the Side Panel Reference page 11 1 2 Remove the gas tube and two terminals Remove the four screws and open the rear cabinet CN11 AIR FLOW ROTATION 2 1 1 2 3 3 3 3 4 ...

Page 89: ...en reinstalling make sure that the C ring seats in the solenoid valve groove 3 27 Main ON OFF Switch S1 1 Remove the Side Panel Reference page 11 1 2 Remove the six screws and six terminals 3 Remove the two screws and detach the main ON OFF switch S1 Remove the three posts u 1 2 1 1 2 2 ...

Page 90: ...Reference page 12 36 3 Disconnect the three connectors Remove the one screw and four ground terminals 4 Remove the two screws and disconnect the remote socket CON1 3 29 High Freguency Unit HF UNIT1 1 Remove the Side Panel Reference page 11 1 2 Remove the high freguency gap Remove the six terminals 2 1 1 1 CN15 CN14 CN13 1 2 ...

Page 91: ...1 1 2 Remove the PCB16 WK 5569 Reference page 12 16 3 Remove the PCB20 WK 5499 Reference page 12 17 4 Remove the PCB17 WK 5570 Reference page 12 16 5 Remove the gas tube Remove the two bolts and one terminal Remove the four screws and open the front cabinet 6 Remove the one post and one screw Remove the one screw one terminal and bus bar 2 1 1 3 3 3 3 4 2 1 1 2 2 1 2 ...

Page 92: ... the bus bar Remove the hall current sensor HCT1 3 31 Primary Diode D1 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB3 WK 5548 Reference page 12 8 3 Remove four screws and three terminals 4 Cut off one snap band and disconnect one connector Remove the one screw 1 2 CN1 1 2 3 ...

Page 93: ...iode D1 Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 3 32 Secondary Diode D2 D7 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB16 WK 5569 Reference page 12 16 3 Remove the PCB15 WK 5606 Reference page 12 15 4 Remove the 30 screws and four terminals Remove the bus bar 1 1 2 1 1 2 ...

Page 94: ...emove the Side Panel Reference page 11 1 2 Remove the PCB16 WK 5569 Reference page 12 16 3 Remove the PCB20 WK 5499 Reference page 12 17 4 Remove the PCB17 WK 5570 Reference page 12 16 5 Remove the hall current sensor HCT1 Reference page 12 29 6 Remove the one screw and one post remove the bus bar 7 Remove the two connectors and four screws Remove the two secondary IGBT Q25 Q26 Before installing a...

Page 95: ...rent Trans CT2 CT3 1 Remove the Side Panel Reference page 11 1 2 Remove four screws and three terminals 3 Cut off one snap band and disconnect one connector Remove the one screw 4 Remove two screws and remove the PCB22 unit CN1 1 2 3 1 1 2 ...

Page 96: ...the three snap bands and remove the connector from the PCB3 WK 5548 Remove two screws and three terminals from the PCB1 WK 5493 Cut two snap bands and remove the current trans CT2 CT3 3 35 Ring Core L1 1 Remove the Side Panel Reference page 11 1 2 Remove four screws and three terminals 2 1 1 2 3 3 3 3 4 1 1 2 3 3 4 5 5 1 CN7 ...

Page 97: ...off one snap band and disconnect one connector Remove the one screw 4 Remove two screws and remove the PCB22 unit 5 Remove the gas tube and two terminals Remove the four screws and open the rear cabinet CN1 1 2 3 1 1 2 2 1 1 2 3 3 3 3 4 ...

Page 98: ...nd three terminals Cut the snap band and remove the ring core L1 3 36 Ring Core L105 1 Remove the Side Panel Reference page 11 1 2 Remove the operation cover 3 Remove the four screws Pull out the operation panel and bring it down 2 3 1 1 1 2 2 3 1 1 1 1 2 ...

Page 99: ...E 12 37 4 Remove the ring core L105 3 37 Reactor L101 1 Remove the Side Panel Reference page 11 1 2 Remove four screws and remove the three ground cables 3 Disconnect the connector CN1 on the PCB22 Remove the screw CN1 1 2 ...

Page 100: ...MAINTENANCE 12 38 4 Remove the PCB22 unit 5 Cut the snap band Remove the reactor L101 from the Input cable 3 38 Reactor L102 1 Remove the Side Panel Reference page 11 1 2 Remove four screws and three terminals 1 2 ...

Page 101: ...ENANCE 12 39 3 Cut off one snap band and disconnect one connector Remove the one screw 4 Remove two screws and remove the PCB22 unit 5 Remove six screws nine terminals and remove the reactor L102 CN1 1 2 3 1 1 2 1 2 3 ...

Page 102: ...or L103 1 Remove the Side Panel Reference page 11 1 2 Remove one screw and two terminals 3 Remove four screws and open the rear panel Remove one nut one washer and one terminal 4 Cut off one snap band Remove the reactor L103 1 1 1 1 2 3 1 2 ...

Page 103: ...666 Socket Remote gen 3 1 IPS MS3102A20 27S NIC 14P with Wiring Assembly Remote Socket 1 3 CT1 W7001304 Transformer gen 3 1 IPS F2A503001 CT 1 40 2 4 D1 10 6628 Diode gen 3 1 IPS DFA50BA160 Primary Diode 1 5 D2 7 10 6629 Diode gen 3 1 IPS DBA200UA60 Secondary Diode 6 6 FAN1 W7001307 Fan gen 3 1 IPS 109E5724H507 DC 24V 16 8W 1 7 FCH1 W7001681 Inductor gen 3 1 IPS F3A040701 300A AC FCH 1 8 HCT1 10 5...

Page 104: ...VA 10W with Gas Inlet and PC4 02 1 40 TH1 2 10 5228 Thermistor gen 3 1 IPS ERTA53D203 20kΩ 25 C B 3950K 2 41 W7001472 Panel Front gen 3 1 IPS E0D004801 1 42 W7001329 Panel Rear gen 3 1 IPS E0D004901 1 43 W7001330 Label Side gen 3 1 IPS E0D005207 2 44 W7001331 Case Front gen 3 1 IPS E0C346000 1 45 W7001332 Board Front gen 3 1 IPS JEA496001 1 46 W7001699 Cover Rear gen 3 1 IPS JCA911200 1 47 W700133...

Page 105: ...1 IPS EDA047100 1 79 W7001364 Bus Bar 4 D gen 3 1 IPS EDA047200 1 80 10 6868 Bus Bar S1 gen 3 1 IPS ECA321000 3 81 W7001692 Bus Bar Output gen 3 1 IPS EDA046600 1 82 W7001691 Bus Bar 1 L Q gen 3 1 IPS EEA158800 1 83 W7001695 Bus Bar 2 L Q gen 3 1 IPS EEA158900 1 83 W7001367 Bus Bar T CC gen 3 1 IPS EDA047300 1 84 W7001671 Bus Bar input gen 3 1 IPS EDA069200 1 85 W7001673 Chassis PCB22 gen 3 1 IPS ...

Page 106: ...300ACDC PARTS LIST 4 46 38 71 71 61 93 49 43 51 52 80 80 60 42 56 58 12 14 39 53 43 54 94 87 55 59 57 58 95 2 15 41 50 47 68 67 69 44 24 48 45 25 59 87 50 51 6 31 ...

Page 107: ...LIST 5 3 3 4 96 96 89 65 62 70 23 64 64 23 62 40 26 70 23 66 63 88 88 66 9 36 79 78 77 76 74 8 73 72 30 91 81 82 83 29 40 10 27 34 28 92 75 75 5 5 23 64 64 16 11 5 33 84 1 7 35 90 17 85 22 18 19 20 21 37 37 86 32 13 ...

Page 108: ...CN2 H SOL1 U PCB7 CN13 CON1 I PCB3 CN20 PCB8 CN1 V CN14 J PCB3 CN21 PCB8 CN2 W CN15 K PCB3 CN22 PCB11 CN1 X PCB12 CN1 PCB13 CN1 L PCB3 CN23 PCB11 CN2 Y PCB16 CN6 Q25 M PCB3 CN18 PCB7 CN20 Q26 CN6 CN4 CN1 CN1 PCB16 Q25 Q26 O PCB2 PCB3 PCB7 PCB4 D1 PCB8 PCB9 PCB21 PCB11 PCB10 PCB12 K X F P B L A D CN20 CN22 CN7 CN4 CN33 CN7 CN3 CN1 CN2 CN1 CN20 CN21 CN23 CN3 CN2 CN1 CN2 CN1 CN1 CN2 CN1 CN2 CN1 CN2 C...

Page 109: ...THIS PAGE LEFT INTENTIONALLY BLANK ...

Page 110: ...G E Q24 C G E PCB11 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 PCB5 Conect Circuit Board WK 5551 CN30 CN31 CN31 CN30 CN32 CN32 PCB7 Filter Circuit Board WK 5550 CN1 1 2 3 CN7 1 2 3 CT4 CT3 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 TB15 TB10...

Page 111: ... 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 Board WK 5569 G11 E11 G12 E12 1 2 3 4 15 15 IS GND HCT1 Output Terminal TO1 FCH1 PCB18 IGBT Gate Circuit Board WK 3367 G1 E1 E2 G2 G1 E1 G2 E2 PCB17 IGBT Snubber Circuit Board WK 5570 TB1 TB2 SH DET CN1 1 2 3 4 5 G10 ...

Page 112: ...hm 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 direction and will indicate between 0 3 and 0 9 volts 6 To check the diode in the reverse bias direc tion reverse the meter leads refer to Figure 13 1 A properly functioning diode will block current f...

Page 113: ......

Page 114: ...ce 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 warranty department for a warranty authorization returns form Welding Equipment Limited Warranty Period Product Period 200S 300S 400S 200TS 300TS 400TS 400 MST 200AC DC 300AC DC PowerMaster 320SP 400S...

Page 115: ...strict 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 Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L V...

Page 116: ...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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