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Thermal Arc ArcMaster 300, 400 S & TS Service Manual_(0

Contents

1. Input Main Input Capacitor IGBT Main Output Hall Current Circuit Diode gt gt Inverter Transformer Diodes Power DC Power PCB14 ransformer 3 Thermal T hemall HCT1 Filter 1 i Detecto Detecto e Output gt inductor 1 gt Coupling C each control circuit Drive Thermal HF UNIT Stick Mode Lift Tig Mode 5 18VDC lcicui Sensor gt Control VRD Output Short 424VDC 5VDC ircuit Circuit Circuit Sensing Sensing Circuit Circuit 4 High A gt Frequency frrouble Primary Unit Sensing Current Circuit 4 1 Sensor Fan Control Torch Control Sequence Circuit gt Fan pe Connection Control I 1 Circuit Solenoid Curent Reference Adjustment Adjustment amp circuit Mode select Switches Panel Circuit Board Figure 2 2 300 400TS Model Functional Block Diagram Input Main Input Capacitor IGBT Main Output Hall Current gt gt Diode gt gt I
2. ra AC i R6 ges onl ICT jesus ER oa FRON PANE 5 fe EL TH CN8 CN9 1 RYO l Hi o 1 2 _ Par SIDE CHASSIS 2 Panel CET Circuit Board Encoder R7 a WK 5527 WK 5528 1 1 UBD Tv a 2 319 e Hs 12 DAAM 5 CN1 gm T AE CN1 I Et GND 14 300 4008 INTERCONNECT DIAGRAM 300 400S ne 112 a C QI C 013 Di 219 10 OS gr i UE G e IK P 1 d TB15 E PCB8 2 1 IGBT IGBT C 01 Board Circuit K Circuit WK 5493 Board Boarde 015 TBI 5 o5 WK 5479 0 5 Lg E E 349 Q4 016 G G 1 1 1 05 1 pe EBAH 2 8 G OK Fae k E 4 E 06 018 G G Sb 1 a d ona ile ae Y Filter Link Q7 q 9n TCU AO MN MIL WK 5597 TB20 E 9
3. 11 7 Verification and Remedy to Failures without Indication Codes 11 7 3 1 Cooling Fan FAN1 Failure Fan is not 11 7 3 2 Gas Valve Failure No Gas flow through unit 300 400TS 11 8 3 9 fis cca e cx ah avid ertet peto Purse ec tel RR bonn REO Ratte AURA 11 8 3 4 Operating Panel Failure LED s do not light properly or welding setting cannot be established 11 9 3 5 High Frequency Output Failure Unit does not generate High Frequency 300 400TS only 11 9 Faultlsolation Tests en e Dice eR Oe AC us a E abd ec en en 11 10 4 1 Preparation eio p encore em ope EY oem ed BAUS es eio Brera 11 10 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 11 12 5 3 Verification of the Cooling Fan Drive 11 13 5 4 Verification of the Gas Valve SOL1 Drive Circuitry 11 14 5
4. mene etu d ond RC ERR E S RR 2 5 3 INSTALLATION T Environmient etr a nem exer e Rn oem tet dtes meet vate 3 1 2 lt E UC DUE OPEN A 3 1 3 Electrical Input Connections 4 ouem mee nere Ene Her Cen e Ne en ron o A ea RU ee 3 1 4 Electrical Input 3 1 5 Input POWEr TP 3 2 6 High Frequency Introduction 300 400 5 3 3 7 High Frequency Interference 300 400TS only 3 3 8 Duty Cycle TE 3 3 9 Specifications sisse RE Rm xe n eR EE EE Langue ee veneered RR ener es 3 4 4 OPERATOR CONTROLS 1 ARC MASTER 300 400TS and 300 4008 Controls 4 1 2 Weld Process selection for ARC MASTER 300 400 5 and 300 4005 4 2 3 Weld Parameter Descriptions for ARC MASTER 300 400TS and 300 4008 4 3 4 Weld Parameters for ARC MASTER 300 400TS and 300 4005 4 5 gt Power Source Features viv ane acti eh e nent Wale Deae ede UR Re VR RR 4 6 5 SET UP FOR SMAW STICK AND GTAW TIG 6 SEQUENCE OF OPERATION
5. 14 goggles or helmet from AWS A6 2 73 Filter 2 Ferrous base metal Al 12 Atomic hydrogen welding Plasma arc welding Carbon arc air gouging or 1 to 6 in 25 150 mm TIG Over 6 in 150 mm 300 to 400 Amp Over 400 Amp WARNING WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw
6. A a o a o ES by wo A a o N H a o ___ ee ee N131 CN132 CN130 A Contactor Control 24VDC B Contactor Control Contactor Clouser To A C 0 To 10Vdc Output To Remote Control 1 D Remote Control Circuit i E 0 To 10Vdc From Remote Control 2 F Not Used 3 G Chassis Ground i 7 H Not Used 5 Not Used poc Ci uit 5 d 7 L Not Used ircuit Bor M OK to Move Current Detect Signal d N OKto Detect signa poc WK 5549 r L105 EB CN8 Jlal 13 300 400TS INTERCONNECT DIAGRAM To Pos 7 DIODE Snubber Circuit Board WK 5606 y 5 TRANS Cre Board lt PCB14 IWK 5594 rgs mem RYH T o _ PCB20 RY 215 Filte Circuit S 31 WK 54g9 ISIDE CHASSIS 3 oe e 7 LLL H TREO MAL EE HF UNIT1
7. heme dirt RR Rh Re Ra c RR s e MOOR OR CLR RR ee 1 2 HowTo Use This Parts List 42 mr re Dv Re BOCA e e eer e xd qox em ante Sens 1 APPENDIX 2 CONNECTION WIRING GUIDE APPENDIX 3 INTERCONNECT DIAGRAM APPENDIX 4 DIODE TESTING BASICS ARCMASTER 400TS 400S 300TS 3005 SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUCTION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Some of these practices apply to equipment connected to power lines other practices apply to engine driven equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Safe practices are outlined in the American National Standard 249 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety
8. 19 WARNING E FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners 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 breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded Torch soldering Torch brazing 00000 y Under 1in 25mm Oxygen Cutting Under 1 in 25 mm Gas welding 1 8 to 1 2 in 3 12 mm EN pT 5 82 to 1 4in 12 Plasma arc cutting
9. 12 23 300 400TS and 300 4008 12 MAINTENANCE 3 Cutthe one snap band and disconnect the one connector CN11 on the PCB3 4 Remove the two screws and detach the Cooling Fan FAN1 Do not have the wrong direction of the fan when reinstalling ROTATION 3 23 Solenoid Valve SOL1 300 400TS only 1 Remove the Side Panel Reference page 11 1 2 Remove the Nylon Hose and two terminals Remove the four screws and open the Rear Panel 12 24 300 400TS and 300 4008 12 MAINTENANCE 3 Remove the C ring and detach the Solenoid Valve SOL1 When reinstalling make sure that the C ring seats in the Solenoid Valve groove 3 24 Main ON OFF Switch S1 1 Remove the Side Panel Reference page 11 1 2 Remove the six screws and six terminals 12 25 300 400TS and 300 4008 12 MAINTENANCE 3 25 Input Voltage Switch 52 1 Remove the Side Panel Reference page 11 1 2 Remove the six screws and six terminals 4 Disconnect the one connector CN4 on the PCBA Remove the two screws and two nuts and then remove the Input Voltage Switch S2 12 26 300 400TS and 300 4008 12 MAINTENANCE 3 26
10. No weld current is available Buzzer sounds constantly Switch machine off 300 400TS and 300 400S 10 Power Source Error Code Description Possible Cause Remedy Remarks 9 E82 error code displayed Rated voltage selection circuit abnormality The Primary supply input voltage fluctuates and is not stable Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage No weld current is available Buzzer sounds constantly Switch machine off then on to reset E82 error 10 E83 error code displayed CPU checks mains supply input voltage when the on off switch on rear panel of machine is turned ON The Primary supply input voltage fluctuates and is not stable Have an Accredited Thermal Arc Service Agent check connector plug on input PCB and the Mains voltage No weld current is available Buzzer sounds constantly Switch machine off then on to reset E83 error 11 E85 error code displayed Pre charge abnormality Due to malfunction inside the Welding Power Source primary capacitors are not charging correctly Have an Accredited Thermal Arc Service Agent service 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 A
11. 3 35 Reactor L102 1 Remove the Side Panel Reference page 9 1 2 Remove four screws and three terminals 12 36 300 400TS and 300 4008 12 MAINTENANCE 4 Remove two screws and remove the PCB22 unit AF E et a 3 36 Reactor L103 1 Remove the Side Panel Reference page 9 1 2 Remove one screw and two terminals 12 37 300 400TS and 300 4008 12 MAINTENANCE 3 Remove four screws and open the rear panel Remove one nut one washer and one terminal 12 38 APPENDIX 1 PARTS LIST 1 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Part or Assembly numbers 2 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a break down 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 descrip tions may be indented to show part relationships To determine th
12. 8 Duty Cycle The duty cycle of a welding power source is the percentage of a ten 10 minute period that it can be operated at a given output without causing over heating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become ener gized and shut down the output until the unit has cooled to normal operating temperature CAUTION Continually exceeding the duty cycle ratings can cause damage to the welding power source and Will void the manufactures warranty NOTE Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are approximate only Achievable capacities and ratings in use and operation will depend upon correct installation use applications maintenance and service 300 400TS and 300 4008 INSTALLATION 9 Specifications Parameter 300TS 3005 400TS 4008 Rated Output Amperes Volts Duty Cycle 400VAC 300 32 40 400VAC 400 36 25 TIG Duty Cycle 300A 22V 40 3ph 250A 20V 60 3ph 180A 18V 100 3ph 400A 26V 25 3ph 300A 22V 60 3ph 200A 18V 100 3ph STICK 300A 22V 40 3ph 250A
13. Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Primary voltage Weld current ceases Buzzer sounds constantly Error code E11 automatically will reset when the voltage reduces E14 error code displayed Under mains supply input voltage warning primary capacitors is reduced for one second Mains supply voltage is less than the nominal operating voltage less 10 Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Weld current available Buzzer sounds intermittently Error code E14 automatically will reset when the voltage increases E12 error code displayed Under mains supply input voltage primary capacitors is reduced for one second Mains supply voltage is down to a dangerously low level A Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Have an Accredited Thermal Arc Service Agent or a qualified electrician check the primary cable and fuses Weld current ceases Buzzer sounds constantly Error code E12 automatically will reset when the voltage increases E81 error code displayed Wrong Primary supply input voltage connected When 3 phase machine is first turned on with the wrong Primary supply input voltage connected Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage 10 1
14. This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSE is on PULSE FREQ This parameter sets the PULSE FREQUENCY when the PULSE is on DOWN SLOPE This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down after 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 300 400TS and 300 4008 4 OPERATOR CONTROLS Parameter Description POST FLOW This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished This control is used to dramatically reduce oxidation of the tungsten electrode SAUVEGARDER CHARGER The SAVE LOAD buttons are used to save and retrieve a total number of 5 programs into the 300 400TS and 300 4008 memory Table 4 3 Weld Parameter Descriptions for ARC MASTER 300 400TS Figure 4 4 ARCMASTER 300 4005 Front Panel with Parameter Description Parameter Description HOT START This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes e g low hydrogen
15. si 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI 249 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 3 Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer pm M H Eloignez la t te des fum es pour viter de les respirer A l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate portez un respirateur adduction d air approuv Lisez les fiches signal tiques et les consignes du fabricant rela tives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ve travaillez dans un espace confin que s il est bien ventil sinon portez
16. 1 Do not touch live electrical parts 15 Keep all panels and covers securely in place 2 Wear dry hole free insulating gloves and body protection 4h 3 Insulate yourself from work and ground using dry insulating mats or covers WARNING 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch ARC RAYS can burn eyes and skin NOISE can damage open or remove line fuses so power cannot be turned on hearing Arc rays from the welding process produce accidentally intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing 6 Turn off all equipment when not in use Disconnect power tO 1 Wear a welding helmet fitted with a proper shade of filter see equipment if it will be left unattended or out of service ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching 5 Properly install and ground this equipment according to its Owner s Manual and national state and local codes 2 Wear approved safety glasses Side shields recommended May 22 2006 1 1 ARCMASTER 400TS 400S 300TS 300S 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high
17. 20V 60 3ph 180A 18V 100 3ph 400A 26V 25 3ph 300A 22V 60 3ph 200A 18V 100 3ph Output Current Range 5 300 Amps 5 400 Amps Open Circuit Voltage 57V Dimensions Width Height Length 8 3 210mm 16 5 420mm Weight 52 9 Ib 24 kg 300 400TS 17 7 450mm 44 1 Ib 20 kg 300 4005 Output Rated Load Output Amperes Output Volts Duty Cycle KVA KW Three phase 300A 32V 4096 18 0 12 0 Three phase 400A 36V 2596 24 0 18 0 Output No Load KVA KW 0 5 0 13 Input Volts Three Phase 400V Amperage Draw Rated Load 24 0 7 No Load Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change improve or revise the specifica tions or design of this or any product without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes updates improve ments or replacement of such items The values specified in the table above 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 in manufac tured components installation location and condi tions and local power grid supply conditions Amperage Draw Rated Load 35 0 7 No Load 4
18. 7 Filter 1 Circuit Board 3 WK 5550 1 2 15 300 4008 INTERCONNECT DIAGRAM 5 PCBIS 7 DIODE Snubber Circuit Board WK 5606 UB2 afafa 5 CNI RYxIS 5 PCB20 Iter Circuit 12 RY 15V gt 7 Panel 1 i Circuit Board Encoder b R7 WK 5527 WK 5528 1 UBA b 258 Oe ved UE i 16 APPENDIX 4 DIODE TESTING BASICS Testing of diode modules requires a digital Volt Ohmmeter that has a diode test scale 1 2 Locate the diode module to be tested Remove cables from mounting studs on diodes to isolate them within the module Set the digital volt ohm meter to the diode test scale Using figure 1 and 2 check each diode in the module Each diode must be checked in both the forward bias positive to negative and reverse bias negative to positive direction To check the diode in the forward bias direc tion 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 13 1 A properly functioning diode will co
19. Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion ANSI Standard Z87 1 from American National Standards Insti tute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 22 2006 ARCMASTER 400TS 400S 300TS 300S 1 03 Precautions de Securite en Soudage l Arc A MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APP
20. Replace diode D1 if the calculated measurement is not within the core sponding range 260 360 580 720 VDC following the process in section 12 3 28 Figure 11 8 The check points 1 P and 2 N 11 ADVANCED TROUBLESHOOTING 6 Verify bus voltage the voltage of the electrolytic capacitor after rectification using a DC Voltmeter The capacity of the DVM should be more than 1000VDC Measure between the output studs C and E on PCB8 WK5479 PCB9 WK5479 PCB10 WK5479 and PCB11 WK5479 The measured voltage should be approximately 1 4 times larger than the input voltage measured in step 1 above except when running at 460V where the bus voltage will be shared across all boards i e each board receiving 0 7 times the input voltage measured in step 1 above Replace diode D1 if the calculated measurement is not within the corresponding range 260 360 580 720VDC Follow the process in 12 3 28 TB4 N TB1 P Figure 11 9 The check points TB1 P and TB2 N 7 After the replacement of D1 if the above volt age is still abnormal replace PCB1 WK 5493 5 2 Verification of the Power Sup ply Voltage 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 beginning of an above section 1 Preparation 1 Verify Power Supply voltage using an DC volt meter The capability
21. WK 5493 Cut two snap bands and remove the Current Trans CT2 3 32 Ring Core L1 1 Remove the Side Panel Reference page 11 1 2 Remove four screws and three terminals 12 32 300 400TS and 300 4008 12 MAINTENANCE 3 Cut off one snap band and disconnect one connector Remove the one screw 12 33 300 400TS and 300 4008 12 MAINTENANCE 6 Remove the two screws and three terminals Cut the snap band and remove the Ring Core L1 3 33 Ring Core L105 1 Remove the Side Panel Reference page 11 1 2 Remove the Protection Cover 12 34 300 400TS and 300 4008 12 MAINTENANCE 4 Cutthe snap band remove the Ring Core L105 3 34 Reactor L101 2 9 1 Remove the Side Panel Reference page 9 1 2 Remove four screws and three terminals 3 Remove four screws and open the rear panel Remove one nut one washer and one terminal Remove the Reactor L101 12 35 300 400TS and 300 4008 12 MAINTENANCE 4 Remove harness from the Reactor L101 The harness is rolled three times at the installation
22. current and duty cycle from this welding equip ment Primary Minimum Current amp Supply Primary Duty Cycle Lead Size Current Factory Circuit Size TIG STICK Fitted Vin Amps 300A 40016 AnG 40 MASTER 300TS S 400 24 4mm sq 4minimum 400 26 ARC MASTER 400T 400 35 Table 3 2 400V Primary Current Circuit sizes to achieve maximum current The ARC MASTER 300 400TS and 300 4008 is designed for use with a generator as an input power source Contact an accredited Thermal Arc service agent for the proper sizing and set up rec ommendations of a generator power source sys tem As a general rule depending on the type of generator used the generator capacity should be twice the maximum rating of the welder 300 400TS and 300 4008 INSTALLATION 6 High Frequency Introduc tion 300 400TS only The importance of correct installation of high fre quency welding equipment cannot be over empha sized Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation The following information is intended as a guide for personnel installing high frequency welding machines WARNING Explosives The high frequency section of this machine has an output similar to a radio transmitter The machine should NOT be used in the vicinity of blasting oper ations due to the danger of premature firing A WARNI
23. inad quatement install ou inad quatement mis la terre est dangereux pum uu 14 Portez un harnais de s curit si vous travaillez en hauteur 1 Ne touchez pas des pi ces sous tension 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables May 22 2006 1 5 ARCMASTER 40015 4005 30015 3005 ah 4 AVERTISSEMENT ele 5 LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE L arc de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager l ouie E P
24. 1 Stick Welding ciem ee RR aL eee WOME EES da eur EDS ae EE RA ROL eee LEE a 6 1 2 HF TIG Welding 800 400 5 only s a oe ee 6 2 3 Lift TIG Welding senec err Lae Cave CER 6 2 4 Slope Mode Sequence 300 400TS only 6 2 5 Slope Mode with repeat sequence 300 400TS 6 3 6 Pulse Controls 300 400 TS only esee nain sg Rr Cm ee 6 3 7 ROUTINE MAINTENANCE 8 BASIC TROUBLESHOOTING 1 2 3 TIG Welding Probleris xr Rm eee we tee eae us ee orate 8 1 Stick Welding Problems 8 3 PowerSource Problems rre eR MP ER eror Fo ee Gop lind 8 5 9 VOLTAGE REDUCTION DEVICE VRD 1 2 3 10 11 VRDBSpeCIfICatiOnis rer Re er M oe Mota enl rel eM phe erstes qe on etn s ooh 9 1 VRD M intenance gf pr Daten rote emm ag En ve bue be Ere wile dylan Cea Ed Rod ter ays 9 1 Switching VRD Or OlL ertt Redi RR UR AUN TUR 9 2 POWER SOURCE ERROR CODE ADVANCED TROUBLESHOOTING System Level Fault Isolation eda mace RR cer 11 1 1 1 Opening
25. 12 10 3 5 PCB5 5551 isicing pau kn teens ane nase UICE ROSA 12 11 3 6 PCBG WK 5549 o oo sd e ettet e e eher edi redo rece C RUNE Er es 12 11 CONTENTS 3 7 8 9 WK 5479 and Q1 Q12 Primary IGBT 12 12 3 8 PCB10 PCB11 WK 5479 Q13 Q24 Primary IGBT 12 12 3 9 PCB12 WK 5527 1x Lr te anses D eere te WC Fa en ld da Oe RUE Po RT pada ae rate on Rud edo 12 12 5528 05 e ci ptr rem ie dey ete ca te ata ae en ee 12 13 3 11 PCB14 WK 5594 T1 Main Transformer gt 5 12 14 3 12 PCB15 WK 5606 2 2 Le nae ae Sede ATE er Ru wae aid Wad ve canard ia ee D aha oon a anime 12 16 EN Beza sert dns vale tt at 12 16 3 14 PCB21 WK 4917 a he hr ret ropes ep oem sel men oon gw cpa Ade Ben ets 12 17 3 15 Current Limiting Resistor 6 71 7 1 12 18 3 16 Resistor R7 ele ee xeu x E Ee nee Pe ERR ma Ce ex mer Ro ey S E ie 12 19 3 17 Coupling Coil CC1 300 400TS 12 20 918 ER EU 12 20 3 19 Primary Thermistor
26. 4008 4 OPERATOR CONTROLS 3 Positive Terminal Welding current flows from 2 Weld Process Selection for the P S ia h duty Di t terminal 50 mm Itis essential however ARC MASTER 300 400TS that the male plug is inserted and turned and 300 400S securely to achieve a sound electrical connec tion 4 Negative Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal 50 mm It is essential how ever that the male plug is inserted and turned securely to achieve a sound electrical connec Weld Mode HF LIFT TIG TIG Weld Process Selection STICK Description 2T operation in TIG Modes using Yes Yes Yes remote devices to tion control contactor amp current CAUTION 4T operation in TIG Modes with crater fill using a No Yes Yes remote contactor device to control Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal sequence 300 400TS only 4T operation in TIG Modes with repeat operation No Yes Yes and crater fill using a remote contactor device 300 400TS only 2T operation spot welding in HF TIG No Yes No using a remote contactor device 300 400TS only 5 Torch Gas Terminal Torch Gas Terminal is an all in one design of the Gas Outlet and the Negative Terminal Gas Outlet is a BSP 3 8 inch female gas fitt
27. 5 Verification of the primary Diode 01 11 14 5 6 Verification of the secondary Diode 2 7 11 15 5 7 Verification of the primary IGBT 01 024 11 15 5 8 Verification of the secondary IGBT Q25 Q26 11 16 5 9 Verification of No load Voltage 11 16 12 MAINTENANCE 1 2 Maintenance List 48 o RR Rem ER UAE RES ee ER EAE 12 1 Service Tools ce n te ten ae Y d ob lir de a ete 12 5 2 4 Tools AMG DANS pe is tst Dan E ee io ire able dde E fa sels d 12 5 2 2 Notes of disassembly and assembly 12 5 Replacement Procedure tm eie tec str Ro goce aha som EVER case DU Jan 12 6 3 1 PCB1 WK 5493 2 cet sean se guet make Re e Ree whee NE one Chee Gee SOR 12 6 3 2 2 5597 e n e n RR ERROR RR RUE uno E a ACH Aa 12 7 3 3 PCB3 WK 5548 PCB7 5550 12 9 3 4 PCBA WK 4819 cios t et EE Re nement toe ns Rome x
28. C T HCT1 Replacement Refer to section 12 3 27 d Replacement Refer to section 12 3 3 4 Operating Panel Failure LED s do not light properly or welding setting cannot be established Cause Occurs when there is a connection failure among PCB6 WK 5549 PCB12 WK 5527 and PCB6 or PCB12 are defective Verification Remedy a Verify the harness connection between CN21 on PCB6 WK 5549 and CN2 on PCB12 WK 5527 Confirm a secure connection of the harness and the connections between CN21 on PCB6 WK 5549 and CN2 on PCB12 WK 5527 Contact the manufacture if you find any bro ken connectors or damaged wiring har nesses b Verify the connection between PCB6 WK 5549 and PCB12 WK 5527 c Replace PCB6 WK 5549 and PCB12 WK 5527 Refer to section 12 3 6 12 3 9 d Verify the connection between PCB5 WK 5551 and PCB6 WK 5549 e Replace PCB5 WK 5551 and PCB6 WK 5549 Refer to section 12 3 5 12 3 6 3 5 High Frequency Output Fail ure Unit does not generate High Frequency 300 400TS only Cause Occurs when the HF unit HF UNIT1 is defective or blown Verification Remedy Caution Read and understand this entire section before proceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately The unit will generate a High Voltage component that can cause extreme personal harm and test equip
29. ERG3SJ220H 3W 220 MHS20A101KI 20W 1000 R7 8 MHS20A151JI 20W 1500HM 51 DCP 103SR100C 480V 3P 480V 35 52 SDKGA4 A 1 A SOL1 W7001604 Solenoid Valve gen 3 1 IPS 5505NBR1 5 DC24V 11VA 10W with Gas Inlet and PC4 02 ERTA53D203 20k0 25 CB 3950K 38 W7001472 Panel Front gen 3 1 IPS 00004801 39 W7001329 Panel Rear gen 3 1 IPS 00004901 40 7001330 Side gen 3 1 IPS 00005207 i41 W7001331_ Case Front gen 3 1 IPS E0C346000 42 W7001332 JEA496001 W7001656 Cover Rear gen 3 1 IPS JDA173300 110 6701 Encoder gen 3 1 IPS EBA514400 L 107001336 Cover PCB gen 3 1 IPS E1B547900 with Dustcover Sheet Label Name gen 3 1 IPS N4A933200 300TS W7001686 Label Name gen 3 1 IPS N4A933300 40015 48 7001338 Label Side gen 3 1 IPS N4A785200 7001339 Label 1 Warning gen 3 1 IPS N18029700 50 W7001340 Label 2 Warning gen 3 1 IPS N18029800 51 7001689 terminal output gen 3 1 IPS N4A670700 52 10 6733 Gas Input gen 3 1 IPS N4A040700 1 53 7001345 Switch gen 3 1 IPS 1 54 7001513 Label VRD gen 3 1 IPS 55 7001511 Label VRD gen 3 1 IPS N4A598700 56 W7001690 Outlet Gas gen 3 1 IPS E5A925600 with PC4 02 RAK BE35 70S Cable Input gen 3 1 IPS 07RN F 1600106 4 X L 3 9m 10 6795 Clamp Input ge
30. Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on 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 Arrange cables to one side and away from the operator Do not coil or drape cable around the body Es Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS M M 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 Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd
31. Intensit de courant Nuance de ou soudage filtre oculaire toutes conditions toutes conditions mince May 22 2006 Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur ad duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage W AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et ga
32. PCB WK 5479 U01 GATE PCB with IRGP20B60PD WK 5527 U14 PANEL PCB WK 5528 U01 ENCODER PCB WK 5594 U01 TRANS PCB WK 5606 U01 DIODE SNUBBER PCB WK 5499 001 FILTER PCB WK 4917 U04 INPUT FILTER PCB WK 5022 U01 INPUT FILTER PCB P 7001325 Resistor gen 3 1 IPS MHS20A151J1 20W 1500HM Switch gen 3 1 IPS DCP 103SR100C 480V 3P 480V ERTA53D203 20k0 25 CB 3950K E0D004901 0C346000 EA496001 DA173300 06299200 4 933000 3005 N4A785200 300 400 5 and 300 4008 PARTS LIST 300 400S No DWGNo PartNo Description Additiomalinformation QTY Label 2 Warning gen 3 1 IPS Switch gent IPS 0 10 6660 E wa abe input grt IPS ceres gen 31 FS fws Chassis 1 gen 3 1 IPS 45017500 wrootasa ees PS Knob Cap gen 31 7001356 Protector gen 3 1 IPS S P H 515 olo ele ala i hex uter gen 3 1 PS mE Bus Bar 1D gen EE Bus Bar 20 gen 1 IPS Bus Bar 3D 31 15 ER 0 6868 5 bus Bar gen 311 nsulation Sheet gen 3 1 IPS over Protector gen 3 1 IPS over Protector gen 3 1 IPS over CONT 7001377 Edge protect gen 3 1 IPS 0 202
33. TH1 2 2 lt hrs y RE E RR Ra Ra ds ei 12 21 3 20 Secondary Thermistor HAZ sade oreet rente aree re ue medi ehe Ge a Ire ete den 12 22 3 21 Cooling Fan EANT zx ee chee m gilet Abus e m RR 12 22 3 22 Solenoid Valve SOL1 300 400TS only 12 23 3 23 Main ON OFF Switch SI o ree et rere em Pee un rr red ee oa th egal ete bie eae 12 24 3 24 Input Voltage Switch 82 sisia us ee eh hem babe dea IUE pese ERE REG EE En 12 25 3 25 Remote Socket CONT seek Deer DR ER D ans GEOP ROME E eu ex o alte se sa d n e RR es 12 26 3 26 High Freguency Unit HF UNIT1 300 400TS 12 26 3 27 Hall Current Sensor 1 1 12 27 3 28 Primary Diode DT Reg hor d one er ea REPRE dla 12 28 3 29 Secondary Diode D2 D4 D5 7 12 28 3 30 Current Trans C T3 ne uei ua nexa ge Ka a dun pne 12 29 3 31 Ring Core re Eure a ead tatc tes i E tn a C RO PR Ce ERE c leen c abe 12 30 3 32 Ring Core 1105 Rene ode x ER ER ae eq T era alee De eue 12 30 APPENDIX 1 PARTS LIST 1 Eq ipment Identification
34. about 1 second The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Weld current ceases Buzzer sounds constantly Fan operates at max speed E02 resets when TH2 decreases to 70 C for about 30 seconds E03 error code displayed Transformer current too high Transformer current is too high because welding arc is too long Mains supply voltage is more than 10 below nominal voltage Reduce length of welding arc Have an Accredited Thermal Arc Service Agent or a qualified electrician check for low Mains voltage Weld current ceases Buzzer sounds constantly Switch machine off then on to reset E03 error E04 error code displayed Output voltage exceeds the secondary voltage 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 E11 error code displayed Over Primary supply input voltage at primary capacitors is exceeded for one second Primary supply voltage is greater than the nominal voltage plus 10
35. frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use a Light Under 300 Amp 9 May 22 2006 WARNING FLYING SPARKS AND HOT METAL can cause injury V Chipping and grinding cause flying metal As welds cool they can throw off slag 1 Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully 1 Protect compressed gas cylinders from excessive heat mechanical shocks and arcs 2 Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping 3 Keep cylinders away from any welding or other electrical circuits 4 Never allow a welding electrode to touch any cylinder 5 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition 6 Turn face away from valve outlet when opening cylinder valve 7 Keep protective cap in place over valve except when cylinder is in use or connected for use 8 Read and follow instructions on com
36. h 4 Hees cand manust saon parametar 1 To start Slope sequence Close remote switch Set PRE FLOW time contacts Once the welding arc is established e Set HOT START current the Power Source will maintain initial current Set POST FLOW time setting as long as the remote switch contacts Set WELD PEAK CUR current areclosed Set POST FLOW time a In the HF TIG mode after Preflow time High Frequency is present at the torch Slope Mode Parameters if required When the torch is positioned close to the Set INTIAL CUR current work the welding current will transfer to the e Set UP SLOPE time work and establish the arc at the initial cur rent setting Set WELD PEAK CUR current b Inthe Lift TIG mode after Preflow time Lift Set BASE t SE Start current is present at the torch When Set DOWN SLOPE time the electrode is touched to the work and Set CRATER CUR current lifted off the welding arc is established at Pulse Mode parameters if required the initial current setting e Set PULSE WIDTH for PEAK CURRENT 2 Open Remote Switch current increases to Set PEAK CURRENT weld current Once welding arc has reached weld current the power source will maintain Set PULSE FREQ weld current as long as the remote switch con Commence welding tacts are open 3 Close Remote Switch Welding current decreases to final current setting Once final 3 Lift TIG Welding weld
37. 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 11 12 2 On the PCB3 WK 5548 PCB6 WK 5549 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 indicated in Figure 11 10 11 11 TPO 2 2 Figure 11 10 Checkpoints TPO TP3 PCB6 Check Point PCB6 Reference PCB6 ACCEPTABLE VALUE TP1 TPO 45VDC TP2 TPO 15VDC TPO 15VDC Table 11 1 Checkpoints TPO TP3 on PCB6 Figure 11 11 Checkpoints CN18 on PCB3 Check Point PCB3 Reference PCB3 ACCEPTABLE VALUE Pin 1 on CN18 Pin 3 on CN18 24VDC Table 11 2 Checkpoints CN18 on PCB3 300 400TS and 300 4008 1 1 ADVANCED TROUBLESHOOTING 3 If any of these voltages are not present or are below a 10 tolerance replace the PCB3 WK 5548 Refer to section 12 3 3 5 3 Verification of the Cooling Fan Drive Circuitry 2 Using the measurement taken above follow the chart below for possible failure modes FAN1 Status Voltage measurement 1PIN 2PIN of CN11 on PCB3 Remedy CAUTION Case 1 Rotating DC 18 25V FAN1 drive circuit is normal Before performing any portion
38. out a For transportable equipment at least once every 3 months and b For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests NOTE A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated In addition to the above tests and specifically in relation to the VRD fitted to this machine the fol lowing periodic tests should also be conducted by an accredited Thermal Arc service agent Description VRD Open Circuit Voltage VRD Turn ON Resistance VRD Turn OFF Time IEC 60974 1 Requirements Less than 20V at Vin 400V Less than 200 ohms Less than 0 3 seconds Table 9 2 Periodic Tests If this equipment is used in a location or an envi ronment with a high risk of electrocution then the above tests should be carried out prior to entering this location The test of VRD is shown below 1 In STICK welding mode mark and then turn potentiometer VR1 on PCB6 WK 5549 all the way to the left and turn on the electric shock protector function Voltage Reduction 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 more than 100VDC 4 The normal no load voltage is approximately 18V 5
39. precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 01 Arc Welding Hazards 7 Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode 8 Do not use worn damaged undersized or poorly spliced cables WARNING 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground ELECTRIC SHOCK can kill 11 Do not touch electrode while in contact with the work ground circuit Touching live electrical parts can cause fatal shocks or 12 Use only well maintained equipment Repair or replace damaged severe burns The electrode and work circuit is electrically parts at once live whenever the output is on The input power circuit and machine internal circuits are also live when power 13 In confined spaces or damp locations do not use a welder with is on In semiautomatic or automatic wire welding the AC output unless it is equipped with a voltage reducer Use wire wire reel drive roll housing and all metal parts equipment with DC output touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard 14 Wear a safety harness to prevent falling if working above floor level
40. the Enclosur Ehre Re peg ehe e mex ta OR Een tere Qa ua 11 1 Verification and Remedy to the Indicated Error 11 3 2 1 E01 Over Temperature at the primary side 11 3 2 2 E02 Over Temperature at the secondary 1 11 4 2 3 E03 Transformer Over Current 11 4 2 4 E04 Torch Cable Failure ossa m mr rie eme UE adus 11 5 2 5 E11 Main Supply Over 11 5 2 6 E12 Main Supply Under 4 11 5 2 7 E81 Wrong Main Supply 11 5 2 8 E82 Rated Voltage Selection Circuit 11 6 2 9 E83 Abnormalities in Mains Supply Voltage 11 6 2 40 EB5 Pre charge abnormality i se tke e Rm ay E eh dre a E er Rea 11 6 2 4 E94 Thermistor malf rictior i 7 12 5 eet let ces Roe Nm ite Re lw P M n RC ce father d 11 7 2 12 E99 Initial Power 0
41. 0 Plug Output gen 3 1 IPS 300x4899 300x4900 Operating Manual gen 3 1 IPS 7001345 Label VRD gen 3 1 IPS w7001643 W7001373 EN EN EN EN 73 Es N 7001375 SSI Ijala lalalalala aolslsilslisls e olelelieleloe alslslsls sisls gl o Eu NNO EE EST PS EN sis E 75 77 MERGE 300 4008 PARTS LIST 300 400S 300 400S PARTS LIST 300 400S li s b 4 24 Ty lt ie t SE x E 24 7 amp 10 APPENDIX 2 CONNECTION WIRING GUIDE Destination IO m gt 12227 2 T ITITI K L M N R S T U V W X 300 400TS only 11 300 400TS and 300 4008 CONNECTION WIRING GUIDE gt MO PcB1s 12 APPENDIX 3 INTERCONNECT DIAGRAM 300 400TS _ O Sa D CE Mele AE eMe 1 Q1 TB10 c Q13 Bos sok 2 sok TBIS E E TB12 E E PCB1 PCB8 cA Q2 PCB10cx Q14 Mai IGBT IGB
42. 00 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 5 4 Verification of the Gas Valve 5 5 Verification of the primary 5011 Drive Circuitry Diode D1 CAUTION CAUTION Before performing any portion of the procedure Before performing any portion of the procedure below make certain the unit is placed in the initial below make certain the unit is placed in the initial set up condition as described at the beginning of set up condition as described at the beginning of section 11 4 1 Preparation on page 11 10 section 11 4 1 Preparation on page 11 10 1 Verify the voltage between the PIN 3 Positive 1 Verify the characteristic of the primary diode and PIN 4 Negative of connector CN11 D1 using a diode tester on PCB3 WK 5548 while you press the torch 2 Refer to Table 11 5 and Figure 11 14 for switch while in TIG Mode The capacity of the the checkpoints on D1 voltmeter should be more than 50VDC The location of connector CN11 of PCB3 WK COMPONENT TERMINALS ACCEPTABLE 5548 is indicated in Figure 11 13 When you TESTED Positive Negative VALUE measure the above voltage do not remove the i connector Conduct the measurement while Diode of D1 3 4 5 0 0 3 to 0 5V the connector plug and receptacle are still con B SUA 3 4 5 2 3 4 5 0 3 to 0 5V Open Open Gate of D1 52 43 x3ohms nected Diode of D1 Thyristor of D1 Figure 11 13 Verificat
43. 06 VAC of the rated voltage 208 230 460V verify the available power capacity at the installed site If the input voltage is within the operating range recheck the input voltage while welding as welding may cause the input voltage to decrease to a value below the oper ating range of the unit 11 11 3 gt 2 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 between the points V2 and W2 on the input switch S1 The location of points U2 V2 and W2 on switch S1are indicated in Figure 11 7 When using a single phase connection the voltage can be verified only between U2 and V2 If this voltage is out of the operating range which is 10 187 253 414 506 VAC of the rated voltage 208 230 460V replace S1 following the process in section 12 3 23 Verify the rectified output voltage of the input diode D1 using a DC voltmeter The capability of the voltmeter should be more than 1000VDC Using a DC voltmeter measure between the points 1 P and 2 N on Di Points 1 P and 2 N are on D1 See Figure 11 8 The measured voltage should be approxi mately 1 4 times larger than input voltage mea sured in 1 above
44. 2 Remove the PCB3 WK 5548 Reference page 12 9 3 Remove four screws and three terminals 12 29 300 400TS and 300 4008 12 MAINTENANCE 6 Remove the six screws and 14 terminals Remove the two screws and then detach the Primary Diode D1 Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 3 30 Secondary Diode D2 D4 D5 and 07 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB15 WK 5606 Reference page 12 17 3 Remove one screw and one nut Remove 20 screws and two terminals Remove the D Bus Bar D Bus Bart D Bus D Bus Bar3 and D Bus Bar4 4 Remove the eight screws and then detach the Secondary Diodes D2 D4 D5 D7 Do not have the wrong direction of the diodes when reinstalling Before installing a new diodes apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 300 400TS and 300 4008 12 MAINTENANCE 3 31 Current Trans CT2 CT3 1 Remove the Side Panel Reference page 11 1 2 Remove four screws and three terminals 12 31 300 400TS and 300 4008 12 MAINTENANCE 5 Remove the Nylon Hose and two terminals Remove the four screws and open the Rear Panel 6 Cut the three snap bands and remove the connector from the PCB3 WK 5548 Remove two screws and three terminals from the PCB1
45. 300 400TS and 300 4008 INSTALLATION Refer to figure 3 and 1 Connect end of ground GREEN YELLOW conductor to a suitable ground Use a ground ing method that complies with all applicable electrical codes 2 Connect ends of line 1 BROWN and line 2 BLUE and line 3 GRAY input conductors to a de energized line disconnect switch 3 Use Table 3 1 and Table 3 2 as a guide to select line fuses for the disconnect switch Input Voltage Fuse Size 400V 60 Amps Table 3 1 Electrical Input Connections NOTE Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code Weiding Power Supply Ww Ground Conductor Ground Terminal Line Disconnect Switch Line Fuse Primary Power Cable Figure 3 1 Electrical Input Connections 5 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit When the MAIN CIRCUIT SWITCH is turned on the inrush circuit provides a pre charging of the input capacitors At this point 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 3 2
46. 5 welding parameter pro grams 6 Control knob allows the operator to adjust the output amper age within the entire range of the power source and sets each parameter value 7 Process Button This button selects between STICK HF TIG and Lift 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 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 Contactor Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set HOT START Set WELD current Commence welding 300 400TS and 300 4008 6 SEQUENCE OF OPERATION 2 HF TIG Welding 4 Slope Mode Sequence 300 400TS only 300 400TS only Connect work lead to positive terminal Switch Switch EI Connect TIG torch to negative terminal Switch machine on HU Weld Current B Connect remote control device if required euren Use the Scroll Buttons to move to the parameter to Preflow Postflow be set The LED will show which function is being adjusted on the weld sequence graph Figure 6 3 Slope Mode Sequence th trol k t just
47. 8 9 EN z z RES wo wo gt WHO Ww ow NIN m ol dc o e zER co mn 3 o o o o y 6857 W7001329 ile 36 7001334 z s3 s s s s s s s 21212 Co Di 7001676 7001338 PCB6 7001733 CB 4008 gen 3 1 IPS P 7001732 3005 gen 3 1 IPS P WK5527 U14 GEN3 1 IPS 5228 Thermistor gen 3 1 IPS 001472 Front gen 3 1 IPS E0D004801 Panel Rear gen 3 1 IPS 7 Case Front gen 3 1 IPS Board Front gen 3 1 IPS 6 Cover Rear gen 3 1 IPS Cover Protector gen 3 1 IPS 0 6791 Cover Encoder gen 3 1 IPS EBA514400 001336 PCB gen 3 1 IPS E1B547900 with Dustcover Sheet abel Name gen 3 1 IPS L 3005 7001663 Label Name gen 3 1 IPS N4A933100 4005 abel Side gen 3 1 IPS PartNo Description Additional Information ransformer gen 3 1 IPS 628 6629 DBA200UA60 F2A503001 CT 1 40 09E5724H507 DC 24V 16 8W CH1 7001653 Inductor gen 3 1 IPS F3A285201 DC FCH 0 5003 Sensor Current gen 3 1 IPS HC TN200V4B15M 200A 4V 7001309 Reactor gen 3 1 IPS WK 5548 U01 DDC PCB WK 4819 U01 DETECT PCB WK 5551 001 CONNECT PCB WK 5549 U05 1 DC CTRL PCB WK 5550 U01 FILTER
48. 9 connectors 3 Remove the four screws Remove the PCB3 PCB4 PCB5 PCB6 and PCB7 unit Disconnect the three connectors 300 400TS and 300 4008 12 MAINTENANCE 4 Remove the six screws three terminals and three connectors 3 3 PCB3 WK 5548 PCB7 WK 5550 1 2 3 4 5 Remove the Side Panel Reference page 11 1 Remove the PCB4 WK 4819 Reference page 12 11 Remove the PCB6 WK 5549 Reference page 12 11 Remove the PCB5 WK 5551 Reference page 12 11 Disconnect the 11 connectors from the PCB3 WK 5548 300 400TS and 300 4008 12 MAINTENANCE 6 Remove the screw and then the four ground terminals Remove the four screws and then remove the WK 5550 PCB3 and PCB7 unit Disconnect the three connectors from the PCB7 and then remove the PCB7 WK 5550 from the PCB3 WK 5548 Remove one screw and one ground terminal from the PCB7 WK 5550 7 Disconnect the one connector and remove the two screws 8 Disconnect the two connectors from the PCB3 WK 5548 12 9 300 400TS and 300 4008 12 MAINTENANCE 3 4 PCB4 WK 4819 1 Remove the Side Panel Reference page 11 1 2 Disconnect the two connectors Remove the two screws and three connectors and remove the PCB4 WK 4819 from the PCB3 WK 5548 3 5 PCB5 WK 5551 1 R
49. E TB7 E PCB11E IGBT OZ IGBT OS Gate g 1 Gate Circuit OK Circuit oO 1 Boardc 9 021 WK 5479 C gt WK 5479 C 1 2 G7 z E 2 C 10E7 72 C 22 Hj usui 552 on 1 2 a S 316 PCB4 4 Detect di Circuit Board WK 4819 ens CNS CN4 2 T ena 27 EB 515 CN32 0 Ontro 316 5 1 d 4 Conect Circuit Board FRE 1121314151617 mE _ wes MSA E CN132 CN130 Contactor Control 24VDC IL 4 Contactor Control Contactor Clouser To A N131 ICN132 CN130 0 To 10Vde Output To Remote Control D Remote Control Circuit Common E 0 To 10Vdc Intput From Remote Control Not Used 1 1 1 Not Used 1 1 CN23 mp 1 2 3 G Chassis Ground 1 1 Not Used PCB6 O 5 K Not Used 1 Control 6 M OK to Detect Signal Circuit Board 1 OK to Move Current Detect Signal k ent lexis WK 5549 1 CNIS ar L105 2 1 o
50. IHERMAL ARC 40018 4008 ARCMASTER INVERTER ARC WELDERS 30015 07263 Service Manual Revision No AB Issue Date 22 2006 Manual No 0 4882B Operating Features INVERTER CE BEL Icd IHERMAL Al RC A WARNINGS Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Service Manual Number 0 4882B for ArcMaster 400TS CE Inverter Arc Welder Part Number 10 3091 ArcMaster 4005 CE Inverter Arc Welder Part Number 10 3095 ArcMaster 300TS CE Inverter Arc Welder Part Number 10 3097 ArcMaster 3005 CE Inverter Arc Welder Part Number 10 3094 Published by Thermadyne Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 2007 2008 by Thermadyne 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 accident or any other cause Publication Date May 22 2006 Revision AB Date January 28 2008 Record the following information for Warranty
51. 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 Contactor function is put into the state of ON pushing Function button Refer to section 6 WARNING Electric shock hazard The unit will generate OCV Open Circuit Voltage immediately when contactor function is put into the state of on pushing Function button enabling STICK mode 7 Verify the no load voltage OCV using a DC voltmeter The capability of the voltmeter should be more than 100VDC 8 The normal no load voltage is approximately 65V 300 400TS and 300 400S 9 Voltage Reduction Device VRD 3 Switching VRD On Off Switch the machine Off A Remove the clear plastic cover from the control panel see Figure 9 1 e Lift up the cover so it rests on the top of the unit Place a small flat bladed screw driver between the cover hinge on the front panel Gently lift the cover hinge out of the front cover mounting hole Remove the control s clear plastic cover Figure 9 1 VRD ON OFF Step A B Remove four mounting screws from the control panel see Figure 9 2 Figure 9 2 VRD ON OFF Step B C C Access the VRD control by gently prying back the front 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 bac
52. NG Computers It is also possible that operation close to computer installations may cause computer malfunction 7 High Frequency Interfer ence 300 400TS only Interference may be transmitted by a high fre quency initiated or stabilized arc welding machine in the following ways 1 Direct Radiation Radiation from the machine can occur if the case is metal and is not prop erly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded 2 Transmission via the Supply Lead Without adequate shielding and filtering high fre quency energy may be fed to the wiring within the installation mains by direct coupling The energy is then transmitted by both radiation and conduction 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 Metallic Objects A major factor contributing to interfer ence is re radiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent re radia tion in most cases
53. OPERATOR CONTROLS 1 ARC MASTER 300 400TS and 300 400S Controls 1 450 2 Figure 4 1 ARC MASTER Power Source 4 Control Knob This control sets the selected weld parameter rotating it clockwise increases the parameter that is indicated on the digital meter Pushing the knob inward displays the actual welding voltage Remote Control Socket The 14 pin Remote Control Socket is used to connect remote cur rent control devices to the welding Power Source To make connections align keyway insert plug and rotate threaded collar fully clockwise A B C DIE F GIH I J K L MIN o 2 5k ohms Front view of 14 Socket Receptacle vy Figure 4 2 14 Socket Receptacle Function Torch Switch Input 24V to connect pins A amp B to turn on welding current Torch Switch Input OV to energize weld current connect pins A amp B to turn on welding current 5k ohm maximum connection to 5k ohm remote control potentiometer Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control potentiometer Mains Earth Not Used OK to move current detect signal for robotics applications OK to move current detect signal for robotics applications Table 4 1 Socket Pin Functions 300 400TS and 300
54. ROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION QU LES INSTRUCTIONS AVANT D INSTALLER UTILISER QU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entra nement avant d utiliser l equipement Toute personne n ayant pas suivi un entra nement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 249 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 04 Dangers Relatifs au Soudage l Arc 6 Arr tez tout quipement apr s usage Cou
55. Remote Socket CON1 1 Remove the Side Panel Reference page 11 1 2 Remove the Ring Core L105 Reference page 12 36 3 Disconnect the three connectors CNB 15 on the PCB7 Remove the one screw and one ground terminals KA le E CN14 E 3 27 High Freguency Unit HF UNIT1 300 400TS only 1 Remove the Side Panel Reference page 11 1 2 Remove the high freguency gap Remove the four terminals ral ary TRE Or Z gt LR 2 PERS 12 27 300 400TS and 300 4008 12 MAINTENANCE 3 Remove the two screws and detach the High Freguency Unit HF UNIT1 Jo P Z 3 28 Hall Current Sensor HCT1 1 Remove the Side Panel Reference page 11 1 2 Remove one screw and one terminal Remove one bolt toothed washer washer and terminal Remove one screw nut and the Output Bus Bar Disconnect one connector from HCT1 3 Remove the one screw and detach the Hall Current Sensor HCT1 from the Output Bus Bar 12 28 300 400TS and 300 4008 12 MAINTENANCE 3 29 Primary Diode D1 1 Remove the Side Panel Reference page 11 1
56. T Circuit Gate GK K TB3 PCB2 MP ud ut T 1 Link i i circuit PCE Fiter cirouitBoard 00 07 0 019 Board Circuit Board WK 5597 I GK eK WK 4917 _ WK 5022 TB20QE E TB7 E QUE PCB9 26 Q8 PCB11 Q20 SIDE CHASSIS 1 S TB4 IGBT IGBT 6 gate GK ircuit ircuit E 2 bonn 2 Board 09 Board Q21 ik le D E 7531 1 2 4 CAE 2 5 ch G2 N i soJK sok EE CO Q12 4 CO Q24 Circuit Board G 2 2 ok sok ens 1 523 731 ONT d cns E 2 ensaf lense soLt 3438 l PCB5 4 dee Circuit Board onnect Circuit Board WK 5551 WK 5548
57. T1 correctly and completely Confirm there are no short circuits burnt or broken wires between AC1 and AC2 d Verify and replace the Gap GAP of the High Frequency HF UNIT1 Confirm that the GAP is connected to HF UNIT1 correctly and completely Confirm there is no dust or foreign debris between the space of the GAP If there are any abnormalities observed with the GAP replace the GAP A setup of a gap is 1 0mm In the case of a gap 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 on HF UNIT1 e f R6 is defective blown burnt cracked etc replace R6 Refer to section 12 3 15 f Replace the High Frequency HF UNIT1 Refer to section 12 3 26 g Replace PCB3 WK 5548 Refer to section 12 3 3 4 Fault Isolation Tests 4 1 Preparation The following initial conditions must be met prior to starting any of the procedures in this section 1 Connect the appropriate input voltage Check the name plate on the rear of the power supply for the proper input voltage NOTE Operate at all input voltages as noted on the name plate on the rear panel when testing the power sup ply 2 Remove the side covers Refer to the sec tion 11 01 3 Close primary power source wall discon nect switch or circuit breaker 4 P
58. Unit 12 29 300 400TS only L101 Reactor 12 37 L102 Reactor 12 38 51 Main ON OFF Switch 12 27 S2 Input Voltage Switch 12 28 o B 02 O 12 3 300 400TS and 300 4008 12 MAINTENANCE Pd o Parts name Reference page Note Coupling Coil 12 23 300 400TS only Current Trans 12 33 Current Trans 12 33 Cooling Fan 12 25 Reactor 12 23 Hall Current Sensor 12 30 Ring Core 12 34 Reactor 12 39 Ring Core 12 36 Current Limiting Resistor 12 20 300 400TS only Resistor 12 21 Resistor 12 21 Solenoid Valve 12 26 300 400TS only Primary Thermistor 12 24 N Secondary Thermistor 12 25 12 4 300 400TS and 300 4008 12 MAINTENANCE 2 Service Tools 2 1 Tools and parts The tools and parts to be used for maintenance are shown by icons Philips Head Long Nose y Z Silicon Screwdriver AY Pliers Bie Snap Band Compound 2 2 Notes of disassembly and assembly NOTE When removing the locking type connectors and board supporters disengage the locking mechanism first and then disconnect them Locking type connectors and board supporters are indicated in this manual using the following symbols black star marks for locking connectors and white star marks for locking board supports NOTE During
59. anada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District 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 Jin 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 Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters IHERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE 96 St Louis MO 63017 Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com
60. art of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermadyne has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX May 22 2006 1 9 2 INTRODUCTION 1 How To Use This Manual This Service Manual applies to just specification or part numbers listed on page i To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows WARNING A WARNING gives information regarding possible personal injury CAUTION A CAUTION refers to possible equipment damage NOTE A NOTE offers helpful information concerning cer tain operating procedures Additional copies of this manual may be purchased by contacting Thermal Arc at the add
61. as valve is faulty Gas valve jammed open D POST FLOW control is set to 60 sec Strike an arc to complete the weld cycle OR Switch machine off then on to reset solenoid valve sequence Have an Accredited Thermal Arc Service Agent repair or replace the gas valve Have an Accredited Thermal Arc Service Agent repair or replace the gas valve D Reduce POST FLOW time The TIG electrode has been contaminated due to the gas flow shutting off before the programmed POST FLOW time has elapsed The Weld Process Mode STICK HF TIG or LIFT TIG was changed before POST FLOW gas time had finished Table 8 3 Power Source Problems Do not change Weld Process Mode before the POST FLOW gas time had finished 300 400TS and 300 4008 8 BASIC TROUBLESHOOTING PAGE LEFT INTENTIONALLY BLANK 9 VOLTAGE REDUCTION DEVICE VRD 1 VRD Specification ARC MASTER 300 400TS 300 4008 Description Notes VRD Open Circuit Voltage Open circuit voltage 15 3 to 19 8V between welding terminals The required resistance VRD 148 to 193 between welding Resistance ohms terminals to turn ON the welding power The time taken to turn OFF the welding power once the welding current has stopped VRD Turn OFF Time 0 2 to 0 3 seconds Table 9 1 VRD Specification 2 VRD Maintenance Routine inspection and testing power source An inspection of the power source should be car ried
62. cable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC 50199 EMC Product Standard for Arc Welding Equipment e 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 conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as p
63. ccredited Thermal Arc Service Agent check the control PCB Weld current ceases Buzzer sounds constantly Switch machine off 13 E94 error code displayed Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit The Welding Power Source s temperature sensors have malfunctioned Have an Accredited Thermal Arc Service Agent check or replace the temperature sensors Weld current ceases Buzzer sounds constantly Switch machine off 14 E99 error code displayed Mains supply input voltage has been turned off but control circuit has power from the primary capacitors A Main on off switch on machine has been turned off Mains supply input voltage has been turned off A Turn on off switch on Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage and fuses Table 10 1 Power Source Error Codes 10 2 Weld current ceases Buzzer sounds constantly Must switch machine off then on to reset E99 error 11 ADVANCED TROUBLESHOOTING If you are here all of the troubleshooting sugges tions in Section 8 Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective This section provides the information needed to take live mea surements on the various subsystems within the power supply and replace those sub
64. crews and one ground terminal Remove the PCB21 WK 4917 12 17 300 400TS and 300 4008 12 MAINTENANCE 3 15 PCB22 WK 5022 1 Remove the Side Panel Reference page 11 1 2 Disconnect one connector Remove the four screws and one terminal Remove the PCB22 WK 5022 3 Remove three board supports 3 16 Current Limiting Resistor R6 1 Remove the Side Panel Reference page 11 1 2 Remove the HF UNIT1 Reference page 11 15 3 Cutthe cable Remove one screw and then remove the Current Limiting Resistor R6 12 18 300 400TS and 300 4008 12 MAINTENANCE 3 17 Resistor R7 R8 1 Remove the Side Panel Reference page 11 1 2 Remove four screws and three terminals 12 19 300 400TS and 300 4008 12 MAINTENANCE 5 Remove four screws and open the Rear Panel 4 12 20 300 400TS and 300 4008 12 MAINTENANCE 3 18 Coupling Coil 1 300 400TS only 1 Remove the Side Panel Reference page 11 1 2 Remove the Nylon Hose Remove the two bolts and one terminal Remove the four screws and open the Front Panel 3 Remove the two terminals Remove one screw one nut and two terminals Remove one screw and detach the Coupling Coil CC1 4 3 19 Rea
65. ctor FCH1 1 Remove the Side Panel Reference page 11 1 2 Remove the Nylon Hose Remove the two bolts and one terminal Remove the four screws and open the Front Panel 12 21 300 400TS and 300 4008 12 MAINTENANCE 3 Remove one screw one nut and two terminals Remove one screw one nut and one terminal 3 20 Primary Thermistor TH1 1 Remove the Side Panel Reference page 11 1 2 Disconnect the one connector CN8 on the PCB6 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 Dm 300 400TS and 300 4008 12 MAINTENANCE 3 21 Secondary Thermistor TH2 OMAR 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB16 WK 5569 Reference page 12 16 3 Cut the three snap bands and disconnect the one connector CN9 on the PCB6 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 22 Cooling Fan FAN1 1 Remove the Side Panel Reference page 11 1 2 Remove the Nylon Hose and two terminals Remove the four screws and open the Rear Panel
66. d 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 Lockout tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device 4 Electrical Input Require ment Operate the welding power source from a single phase 50 60 Hz AC power supply The input volt age must match one of the electrical input voltages shown on the input data label on the unit name plate Contact the local electric utility for informa tion about the type of electrical service available how proper connections should be made and any inspection required The line disconnect switch provides a safe and convenient means to completely remove all electri cal power from the welding power supply whenever necessary to inspect or service the unit NOTE These units are equipped with a three conductor with earth power cable that is connected at the welding power source end for single and three phase electrical input power Do not connect an input BROWN or BLUE or GRAY conductor to the ground terminal Do not connect the ground GREEN YELLOW conductor to an input line terminal
67. e quency TIG mode waRNING This welding mode produces high frequency and high voltage Extra care shall be taken to prevent electric shock 1 When in HF TIG mode the unit will gener ate high voltage To prevent personal harm and test equipment damage mark and then remove the indicated wire from the HF UNIT1 shown in Figure 11 18 To prevent electric shock always wrap the removed wire with electrical tape or other suitable insulation Figure 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 seconds after you depress the torch switch 4 The normal no load voltage is approxi mately 65V 5 Return the setting variable resister VR1 to the original position Return to the posi tion recorded by a 1 clause e fully clockwise VRD ON e fully counter clockwise VRD OFF 6 Return connection with HF UNIT1 to the original position 11 17 12 MAINTENANCE 1 Maintenance List z o Parts name D S LIT SN Reference page Print Circuit Board WK 5597 12 8 Prin
68. e please refer to Section 11 01 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 Blowing air into the unit can cause metal parti cles to interfere with sensitive electrical components and cause damage to the unit Maintain more often if used under severe conditions Warning Disconnect input power before maintaining Each Use Visual check of Visual check of torch regulator and pressure Consumable parts Weekly Visually inspect the torch body and consumables Visually inspect the cables and leads Replace as needed 3 Montlis Clean exterior of power supply Replace all broken parts 6 Months Bring the unit to an authorized Thermal Arc Service Center to remove any accumulated dirt and dust from the interior This may need to be done more frequently under exceptionally dirty conditions Art A 07331 7 2 8 BASIC TROUBLESHOOTING WARNING There are extremely dangerous voltages and power levels present inside this product Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques If major c
69. e ARC MASTER 300 400TS and 300 4008 is designed for use in adverse environments Examples of environments with increased adverse conditions are a In locations in which freedom of movement is restricted so that the operator is forced to per form the work in a cramped kneeling sitting or lying position with physical contact with con ductive parts In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator or In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insula tion properties of accessories Environments with adverse conditions do not include places where electrically conductive parts are in the near vicinity of the operator which can cause increased hazard have been insulated 2 Location Be sure to locate the welder according to the fol lowing guidelines n areas free from moisture and dust Ambient temperature between degrees C to 40 degrees C n areas free from oil steam and corrosive gases n areas not subjected to abnormal vibration or shock n areas not exposed to direct sunlight or rain Place at a distance of 12 304 79mm or more from walls or similar boundaries that could restrict natural airflow for cooling WARNING Thermal Arc advises that this equipment be electri cally connecte
70. e Confirm the layout of the TIG torch gas hose and that the hose adapters are properly con nected C Verify the wiring harness and connection of gas valve SOL1 and CN11 on PCB3 WK 5548 d Verify the drive circuitry of the gas valve SOL1 Verify the drive circuitry of the gas valve SOL1 Refer to section 11 5 4 Replace PCB3 when abnormal Refer to section 12 3 3 e Replace the PCB6 WK 5549 Refer to section 12 3 6 3 3 No Weld Output When in High Frequency TIG HF TIG mode if the High Frequency is not generated present refer to High Frequency Output Failure Refer to the page 11 9 Cause Occurs when the remote connector CON1 or associated circuitry is defective damaged or the TIG torch cable is defective Verification Remedy Caution Head and understand this entire section before proceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately a Verify the remote connector CON1 Applies to LIFT TIG and High Frequency TIG HF TIG mode Confirm a secure between the remote con nector CON1 and the TIG torch cable Confirm a secure connection of the harness and the connections between the remote connector CON1 and PCB7 WK 5550 are all correct and there are no open circuits Contact the manufacture if you find any bro ken connectors or damaged wiring har nesses Confir
71. e or Weld Process Mode until after POST FLOW time has finished TN 28 Figure 5 2 300 4005 Set up 300 400TS and 300 4008 5 SET UP FOR SMAW STICK AND GTAW TIG PAGE LEFT INTENTIONALLY BLANK 6 SEQUENCE OF OPERATION NOTE Scroll Buttons are used to select the parameters to be set The LED s show which function is being adjusted on the weld sequence graph Refer to the Symbols Table located in the front of the manual for Symbol descriptions Figure 6 1 300 40TS Front Panel eo 9 M gt Figure 6 2 300 400S Front Panel 1 Pulse function Pressing this button enables the TIG current pulse functions 2 Remote Current function Pressing this button enables remote current functions 3 TIG Mode Functions Pressing this button scrolls through the output TIG function modes Standard Slope Slope w repeat Spot 4 Digital LED display Welding amperage and parameter values are displayed in this window Internal warnings such as over temperature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen 5 Save Load Buttons by using the Save amp Load buttons the operator can easily save up to
72. e part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item num ber in the corresponding Parts List PART NUMBERS ARC MASTER 300TS 10 3097 ARC MASTER 400TS 10 3091 ARC MASTER 3005 10 3094 ARC MASTER 400S 10 3095 300 400TS DWG No PartNo Description Additional Information 1 cci W7001382 Coupling Coil gen 3 1 IPS F3A073800 300A AC CC EE EJ CON1 W7001666 Connector remote gen 3 1 IPS MS3102A20 27S NIC 14P with Wiring Assembl 3 _ CT2 3 W7001304 Transformer gen 3 1 IPS F2A503001 CT 1 40 2 6 FANT W7001307 Fan gen 3 1 IPS 109 5724 507 DC 24V16 8W 1 8 10 503 Sensor Current gen 3 1 IPS HC TN200V4B15M 200A 4V 1 9 007001399 HF Unit gen 3 1 IPS HF UNIT WK 4840 U04 1 10 10 6633 _ Gap gen 3 1 IPS UOA6000 1 11 t1 W7001309 Reactor gen 3 1 1PS GP 7 1 12 L101 W7001670 Reactor gen 3 1 IPS JDFR47ZMD 13 L102 7001672 Reactor gen 3 1 IPS F2A73400 1 22 PCB7 W7001423 gen 3 1 IPS WK 5550 U01 FILTER PCB 1 PCB8 11 W7001318 PCB gen 3 1 IPS WK 5479 001 GATE PCB with IRGP20B60PD 300 400TS PARTS LIST 300 400TS No DWG PartNo Description Additional Information QTY 1 WK 4917 U04 INPUT FILTER PCB WK 5022 B 001 FILTER2 1 2
73. e wire or damaged connectors Replace wiring harnesses if you find any bro ken connectors or damaged wiring harnesses Replace the fan if there are any broken cracked or missing fan blades Refer to section 12 3 21 b Verify the wiring harness between the cooling fan FAN1 and CN11 on PCB3 WK 5548 Confirm a secure connection of the harness to CN11 on PCB3 c Verify the drive circuitry of the cooling fan FAN1 on PCB3 Verify the drive circuitry of the cooling fan FAN1 on Refer to section 11 5 3 Replace PCB3 if necessary Refer to section 12 3 3 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 3 2 Gas Valve Failure No Gas flow through unit 300 400TS only Cause Occurs when the gas valve SOL1 is defective damaged or the driving voltage is incorrect Verification Remedy a Confirm that TIG welding is selected on the welding mode Do not change welding modes while welding Only change welding modes when the unit is idle torch switch OFF Verify the setting of Pre flow and Post flow on the front panel If the Pre flow or Post flow time is set to O seconds change them to higher setting b Verify the layout the of the gas hose Confirm that the hose is securely connected into the fitting at the inlet and the outlet Con firm the layout of the gas hose so that it is not bent or kinked Confirm there are no breaks burns or holes in the hose
74. efer to tsection 11 04 1 Check whether there are any abnormalities on the appearance of PCB17 2 Verify the characteristic of the secondary IGBT Q25 Q26 using a diode tester 3 Refer bellow Table 11 8 and Figure 11 17 for the checkpoints on Q25 Q26 TERMINALS COMPONENT TESTED ACCEPTABLE VALUE Positive Negative lead lead Collector Emitter of Q25 C1 C2E1 Open By PCB18 C2E1 C1 connection 0 2 to 0 5V Collector Emitter of Q26 Open By PCB19 0 2 to 0 5V connection Table 11 8 Tester checkpoints for Q25 Q26 Figure 11 17 Tester checkpoints in the Q25 Q26 a Verify the no load voltage in STICK mode 1 In STICK welding mode mark and then turn potentiometer VR1 on PCB6 WK 5549 all the way to the right and 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 WARNING Electric shock hazard The unit will generate OCV immediately when contactor function is put into the state of on pushing Function button at STICK mode 3 Verify the no load voltage using a DC volt meter The capability of the voltmeter should be more than 100VDC 4 The normal no load voltage is approxi mately 65V 11 16 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING b Verify the no load voltage OCV in High Fr
75. electrodes It sets the peak start current on top of the WELD current A Weld Current Amperage sets the STICK and TIG WELD current EN ARC CONTROL This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability Table 4 4 Weld Parameter Descriptions 300 400S 300 400TS and 300 4005 4 OPERATOR CONTROLS 4 Weld Parameters for ARC MASTER 300 400TS and 300 400S Weld Mode Weld Parameter Parameter Range Factory Setting Incremental Unit HF TIG LIFT TIG PRE FLOW 0 0 to 1 0 sec 0 sec 0 1 sec Yes Yes HOT START to 70A 20A 1A Yes No 5 to 300A INITIAL CUR 5 to 400A 30A 1A Yes UP SLOPE 0 to 15 sec 1 sec 0 1 sec Yes 5 to 300A PEAK CUR 5 to 400A 120A 1A Yes WELD CUR 5 to 300A TIG 5 to 400A 80A 1A Yes WELD CUR 5 to 300A STICK 5 to 400A 80A 1A No SPOT TIME 0 5 to 5 0 sec 2 sec 0 1 sec PULSE WIDTH 15 to 80 50 1 PULSE FREQ 0 5 to 500Hz 100 0Hz See Table 4 6 DOWN SLOPE 0 to 25 sec 3 sec 0 1 sec CRATER CUR 5 to 40A 30A 1A POST FLOW 0 0 to 60 sec 10 sec 0 1 sec Table 4 5 Weld Parameters for ARC MASTER 300 400TS PULSE FREQ Range 0 5 to 20Hz 20 to 100Hz 100 to 500Hz Incremental U
76. emove 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 from the PCB3 WK 5548 3 6 PCB6 WK 5549 1 Remove the Side Panel Reference page 11 1 2 Disconnect the six connectors 300 400TS and 300 4008 12 MAINTENANCE 3 Remove the three screws and five connectors Remove the PCB6 WK 5549 from the PCB5 WK 5551 and PCB7 WK 5550 3 7 PCB8 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 where silicone compound Shinetsu silicone G 747 or equivalent was spread when reinstalling the PCB8 and PCB9 Spread the silicone compound on IGBT 12 11 300 400TS and 300 4008 12 MAINTENANCE 3 8 PCB10 PCB11 WK 5479 and Q13 Q24 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 PCB10 WK 5479 and PCB11 WK 5479 Remember to install Silicone Rubber Sheets where silicone compound Shinetsu silicone G 747 or equiv alent was spread when reinstalling the PCB10 and PCB11 Spread the silicone compound on IGBT CN1 2 1 e prt r
77. en 3 1 IPS 1070500 20 with String i W7001377 Edge protect gen 3 1 IPS EHIBU 2 i E 10 6681 Hose Nylon gen 3 1 IPS T0425B Nylon Hose L 0 5m 10 2020 Plug Output gen 341 15 TRAK SK50 1 300X4901 Operating Manual gen 3 1 IPS Operating Manual 30079 1 __ 300X4902 Operating Manual gen 3 1 IPS Operating Manual 40015 1 W7001334 Protector gen 3 1 IPS E0c299200 1 300 400TS PARTS LIST 300 400TS 300 400TS PARTS LIST 300 400TS 300 400TS and 300 4008 PARTS LIST 300 400S T2 3 7001304 5 5 eise 2 4 5 7 AN1 7001307 an gen 3 1 IPS HCT1 L101 L102 L103 L105 PCB1 PCB2 eactor gen 3 1 IPS eactor gen 3 1 IPS eactor gen 3 1 IPS eactor gen 3 1 IPS PCB gen 3 1 IPS PCB gen 3 1 IPS PCB3 7001314 PCB gen 3 1 IPS PCB4 0 6635 PCB gen 3 1 IPS PCB5 7001417 gen 3 1 IPS R R R R 51515151515 kd bd d olwlelololo He PCB6 PCB7 PCB8 11 PCB12 PCB gen 3 1 IPS PCB gen 3 1 IPS PCB gen 3 1 IPS PCB gen 3 1 IPS 26 PCB gen 3 1 IPS 22 7 PCB22 CB gen 3 1 IPS 7001423 CB gen 3 1 IPS PCB gen 3 1 IPS No 5 7
78. f the internal subassemblies that may be defective CAUTION Perform all steps in each procedure in sequence Skipping portions of procedures or performing steps out of sequence can result in damage to the unit and possible injury or worse to the operator 1 1 Opening the Enclosure 1 Confirm that the switch of power supply and the switch on switchboard distribution panel are all OFF Figure 11 1 Switch OFF CAUTION The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box dis tribution panel Wait at least 5 minutes for the dis charge to complete 11 1 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 2 Remove all screws and nuts on the side cov 4 Pull the front panel slightly forward and pull the ers rear panel slightly backward The interlocking hooks of the side case covers can now be dis engaged from the front and rear panels Figure 11 2 Remove screws 3 Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW Figure 11 4 Loosen front and rear panels 5 Remove the side covers Figure 11 3 Loosen screws NOTE DO NOT remove the screws completely Figure 11 5 Remove Side covers 11 2 300 400TS and 300 4008 1 1 ADVANCED TROUBLESHOOTING 6 Remove protection cover sheet by removing the pla
79. fety in Welding and Cutting norme ANSI 249 1 American Weld ing 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 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Pro tection Association Batterymarch Park Quincy MA 02269 May 22 2006 ARCMASTER 400TS 400S 300TS 300S 1 06 Declaration Of Conformity Manufacturer Thermadyne Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all appli
80. for the checkpoints on D2 D7 Collector Emitter of Q13 Q24 with E pen E CE 0 2 to 0 5V PCB10 and PCB11 COMPONENT TERMINALS ACCEPTABLE TESTED en 2 VALUE Table 11 7 Tester checkpoints in the Q1 Q24 ea ea Diode 1 of Anode Cathode 0 2 to 0 3V D2 D7 Cathode Anode Open Diode 2 of Anode Cathode 0 2 to 0 3V D2 D7 Cathode Table 11 6 Tester checkpoints for D2 D7 5098 PCB10 PCB Es ARR Figure 11 15 Tester checkpoints for D2 D7 5 7 Verification of the primary IGBT Q1 Q24 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 beginning of an above section 1 Preparation Refer to section 11 04 Figure 11 16 Tester checkpoints for Q1 Q24 11 15 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 5 8 Verification of the secondary IGBT Q25 Q26 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 beginning of section 11 4 1 Preparation on page 11 10 5 9 Verification of No load Volt age OCV 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 beginning of an above section 1 Preparation R
81. ge selection circuit inside the Welding Power Source is not functioning properly Verification Remedy a Verify the wiring harness and connection of CN4 on PCB4 WK 4819 Re install the harness with a secure connec tion Contact the manufacturer if you find any bro ken connectors or damaged wiring harness When the PCB fixed screw is loosening it fastens certainly b 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 9 E83 Abnormalities in Mains Supply Voltage Detection Cause Abnormalities such as an input voltage detection circuit 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 Confirm a secure connection of the harness wired between CN2 on PCB3 WK 5548 and CN1 on PCB21 WK 4917 Re install the harness with a secure connec tion Contact the manufacturer if you find any bro ken connectors or damaged wiring harness 11 6 C Verify PCB4 WK 4819 and replace it if neces sary Check whether there are any abnormalities on the appearance of PCB4 Replace Refer to section 12 3 4 2 10 E85 Pre charge abnormality Cause Due to a malfunction inside the Welding Power Source primary capacitors are not char
82. ging cor rectly Verification Remedy a Verify the connection PCB2 WK 5597 the rectified output voltage of the rectifier Verify the connection between CN2 on PCB2 and CN3 on PCB3 e Confirm whether there is any breakage blown burnt cracked etc of R18 on PCB2 Perform what is described in a section of Verification of the Power Supply Voltage Refer to section 11 5 2 b Verify the primary diode D1 Verify D1 Refer to section 11 5 5 Replace D1 Refer to section 12 3 28 c Verify the primary IGBT Q1 Q24 Verify IGBT Refer to section 11 5 7 Replace IGBT Refer to section 12 3 7 12 3 8 d Replace PCB2 WK 5597 and PCB4 WK 4819 Replace PCB2 and PCB4 when abnormalities occur even if you carry out the above mentioned verifications Refer to section 12 3 2 12 3 4 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 2 11 E94 Thermistor malfunction Cause Thermistors for detecting temperature of internal components have malfunctioned Verification Remedy a Confirm a secure connection of the harness wired between CN8 9 on PCB6 WK 5549 and Thermistors TH1 TH2 Re install the harness with a secure connec tion Contact the manufacturer if you find any bro ken connectors or damaged wiring harness b Replace thermistors TH1 TH2 Refer to section 12 3 19 12 3 20 c Replace PCB6 WK 5549 Refer to section 12 3 6 2 12 E99 In
83. ing 300 400TS only 6 ON OFF Switch This switch connects the Pri mary supply voltage 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 maybe at 240V potential with respect to earth Pulse operation No Yes Yes in TIG Modes 300 400TS only 7 Input Cable The input cable connects the Pri mary supply voltage to the equipment 8 SMART Logic Switch Manual slide switch mounted on the back panel selects the proper input voltage If this slide is not set to the posi tion that matches the input voltage from the electrical source the Smart Logic circuit will inhibit welding power source output The digi tal meter will show primary input error code 9 Gas Inlet The Gas Inlet is a BSP 3 8 inch female gas fitting 300 400TS only Contactor Yes No Yes operation in Stick Mode Selects mode of Yes Yes Yes Operation Panel or Remote Operation PANEL REMOTE Table 4 2 Weld Process selection verses Weld Mode for ARC MASTER 300 400TS and 300 400S 300 400TS and 300 4008 4 OPERATOR CONTROLS 3 Weld Parameter Descriptions for ARC MASTER 300 400TS and 300 400S Figure 4 3 ARC MASTER 300 400TS Front Panel with Parameter Description Parameter Description WE PRE FLOW This parameter operates in TIG modes on
84. ing 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 ventilation pur poses Verify 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 dusty environments will require more frequent cleanings C Verify the operation of the cooling fan FAN1 and replace it if necessary Verify the condition of FAN1 Verify that there are no broken or cracked fan blades and that is not producing any abnormal 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 21 for the replacement of FAN1 Refer to section 11 5 3 for addition FAN1 tests d Replace PCB6 WK 5549 Refer to section 12 3 6 for the replacement of PCB6 11 4 Over Current Failure Cause Occurs when excessive current is detected flow ing into the primary side of the main transformer Verification Remedy a Confirm the operation of the machine within the rated specification Refer to the specification data sheet in Sec tion 3 9 b Verify the secondary diode D2 D4 D5 and D7 Refer to section 11 5 6 for
85. ing current is reached the power source will maintain final current setting as long as the Connect work lead to positive terminal remote switch contacts are closed Connect TIG torch to negative terminal 4 Open Remote Switch Welding arc stops and Switch machine on post flow begins Set weld current Connect remote control device Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter e Set WELD current Commence welding 300 400TS and 300 4008 6 SEQUENCE OF OPERATION 5 Slope Mode with repeat increase and decrease the welding current on a regular basis The faster you move the foot rheo seq uence stat up and down the faster the frequency 300 400TS only The repeat function is operated during the down slope cycle of the 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 Once final cur rent setting is reached opening the Remote Switch again will turn off the welding arc and post flow begins 6 Pulse Controls 300 400TS only f Pul
86. ing the equipment when using bars hammers etc to un crate the unit 300 400TS and 300 400S 2 INTRODUCTION 4 Symbol Chart Note that only some of these symbols will appear on your model Amperage STICK Shielded Metal Arc SMAW Voltage Pulse Current Function Hertz frequency Spot Time GTAW Seconds Remote Control Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current Gas Post Flow Standard Function Gas Pre Flow Slope Function Voltage Reduction Device Circuit Slope W Repeat Function Negative Spot Function Positive Impulse Starting High Frequency GTAW Gas Input Touch Start Lift Start TIG circuit GTAW Gas Output 300 400TS and 300 4008 2 INTRODUCTION 5 Description The Thermal Arc Model ARC MASTER 300TS and 400TS is a single three phase DC arc welding power source with Constant Current CC output characteristics This unit is equipped with a Digital Volt Amperage Meter gas control valve built in Sloper and Pulser lift arc starter and high frequency arc starter for use with Gas Tungsten Arc Welding GTAW Gas Tungsten Arc Welding Pulse GTAW P Gas Tungsten Arc Weld ing Sloped GTSW S and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resistant flame resistant and non conductive plastic case The Thermal A
87. ion of the SOL1 2 Using the measurement taken above follow the chart below for possible failure modes Voltage measurement PIN 1 PIN 2 of CN11 on PCB3 Remedy Replace PCB1 Below 18 Refer to the page 12 23 1 Replace SOL1 DC 18 25 Refer to the page 12 23 Table 11 4 Verification of the 5011 4 3 When verifying the voltage confirm that the AC input voltage remain within the operating range of the unit 2 The AC input does not drop below 180VAC Figure 11 14 Tester checkpoints for D1 showing the interconnection diagrams 11 14 300 400TS and 300 4008 1 1 ADVANCED TROUBLESHOOTING 5 6 Verification of the secondary 1 Check whether there are any abnormalities on Diode D2 D7 the appearance of PCB8 PCB11 2 Verify the characteristic of the primary IGBT CAUTION Q1 Q24 using a diode tester Before performing any portion of the procedure 3 Refer to Table 11 7 and Figure 11 16 for below make certain the unit is placed in the initial the checkpoints on PCB8 PCB11 set up condition as described at the beginning of 2 TERMINALS section 11 4 1 Preparation on page 11 10 COMPONENT ACCEPTABLE TESTED Positive Negative VALUE lead lead 1 Verify the characteristic of the secondary Collector Emitter diode D2 D7 using a diode tester of Q1 Q12 with 2 and CE 0 2 to 0 5V 2 Refer to Table 11 6 and Figure 11 15
88. ions established in the owners manual 3 Installation not in accordance 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 2005 3005 4005 200TS 300TS 400TS 400 MST 200AC DC 300AC DC PowerMaster 320SP 400SP 500SP Fabricator 200 Ultrafeed VA4000 Portafeed VS212 3 Years 150SE 155SE 250SE 400SE 250TE 400TE 180AC DC 250AC DC 400AC DC Fabricator 250 Fabricator 330 Fabricator 400 Fabricator 450 220GMS 2 Years Options and Accessories 6 Months Repair and Replacement Parts 3 Months Torch Consumables None Cutting Equipment Limited Warranty Period Product Period CutMaster 38 51 81 101 151 3 Years PakMaster 150XL Drag Gun Plus 2 Years CutSkill C 35A C 70A C 100A Drag Gun 1 Year 1TorchTM SureLokTM Torches and PCH 120 1 Year Other Torches 6 Months Repair Parts 3 Months Arc Accessories Limited Warranty Period Product Period All Products 1 Month Consumables None Torch Consumables None IHERMAL ARC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne C
89. itial Power Receiving Cause Occurs when the initial AC power received signal has not reached the CPU This error occurs nor mally during the power OFF sequence of the unit Verification Remedy a Confirm a secure connection of the harness wired between CN1 on PCB21 WK 4917 and CN2 on PCB3 WK 5548 Re install the harness with a secure connec tion Contact the manufacturer if you find any bro ken connectors or damaged wiring harness b Verify PCB4 WK 4819 and replace it if neces sary e Confirm a secure connection of all the har nesses wired to PCB3 and PCBA Replace PCB4 Refer to section 12 3 4 c Replace PCB6 WK 5549 Refer to section 12 3 6 11 7 3 1 3 Verification and Remedy to Failures without Indication Codes 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 peripheral parts Clean the fan blades and all peripheral parts if covered with dust Clean ing and removing dust from the fan blades once every 6 months in a normal environ ment is recommended Extremely dusty environments will require more frequent cleanings Verify that there are no wiring harnesses entangled inside the fan confirm that the har nesses do not have any brakes in th
90. k into the front panel controls can only be achieved by removing the side covers Figure 9 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 PCB fully clockwise When VRD is turned ON check that it operates as per VRD Specifications on section 9 1 To turn VRD OFF rotate the trim potentiometer VR1 on the display PCB fully counter clock wise WARNING The VRD ON OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the VRD function will be unknown for every other position 10 POWER SOURCE ERROR CODE Description Possible Cause Remedy Remarks E01 error code displayed Temperature sensor TH1 protects IGBTs is greater than 80 C for about 1 second The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Weld current ceases Buzzer sounds constantly Fan operates at max speed E01 resets when TH1 decreases to 70 C for about 30 seconds E02 error code displayed Temperature sensor TH2 protects secondary diodes is greater than 80 C for
91. lace power supply MAIN CIRCUIT SWITCH S1 on rear of the unit in the ON position WARNING Dangerous voltage and power levels are present inside this unit Be sure the operator is equipped with proper gloves clothing and eye and ear pro tection Make sure no part of the operator s body comes into contact with the work piece or any inter nal components while the unit is activated 11 10 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 5 Verification 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 at the beginning of section 11 4 1 Preparation on page 11 10 5 1 Verification of the AC Input Voltage using an AC voltmeter 1 Verify input voltage Phase to Phase using an AC voltmeter The capability of the voltmeter should be more than 600VAC Measure the point between lines U1 and V1 on the input switch S1 Measure the point between lines U1 and W1 on the input switch S1 Measure the point between lines V1 and W1 on the input switch S1 The location of points U1 V1 and Won switch S1 are indicated in Figure 11 7 When using a single phase connection the voltage can be verified only between U1 and V1 W1 Figure 11 7 Check points U1 U2 V1 V2 W1 and W2 2 Ifthe input voltage is out of the operating range of the unit which is 10 187 253 414 5
92. lieve weld joint of soon after solidification Severe stresses or use crack commences resistance electrodes B Insufficient throat thickness B Travel slightly slower to allow greater build up in throat C Cooling rate is too high C Preheat plate and cool slowly A gap is left by failure of the weld A Welding current is too low A Increase welding current metal to fill the root of the weld Electrode too large for joint B Use smaller diameter electrode C Insufficient gap C Allow wider gap D Incorrect sequence D Use correct build up sequence Table8 2 a STICK Welding Problems Incorrect sequence Insufficient gap Figure 8 1 Example of insufficient gap or incorrect sequence Description Possible Cause Remedy 4 Portions of the weld run do not A Small electrodes used on heavy cold Use larger electrodes and preheat fuse to the surface of the metal plate the plate or edge of the joint Welding current is too low Increase welding current Wrong electrode angle Adjust angle so the welding arc is directed more into the base metal Travel speed of electrode is too high Reduce travel speed of electrode Scale or dirt on joint surface Clean surface before welding Table 8 2 6 STICK Welding Problems continued Lack of fusion caused by dirt 2 electrode angle incorrect rate of travel too high gt lt 2 Lack of inter run Fusion Lack of side fusio
93. ly and is used to provide gas to the weld zone prior to striking the arc once the torch trigger switch has been pressed This control is used to dramatically reduce weld porosity at the start of a weld HOT START This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes e g low hydrogen electrodes It sets the peak start current on top of the BASE WELD current e g HOT START current 130 amps when BASE WELD 100 amps amp HOT START 30 amps INITIAL CUR This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the start current for TIG The Start Current remains on 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 current when in PULSE mode WELD This parameter sets the TIG WELD current in STD SLOPE REPEAT and SPOT modes when PULSE is off This parameter also sets the STICK weld current BASE Background Current This parameter sets the Background current when in Pulse TIG mode SPOT TIME This parameter sets the duration of the SPOT TIME in HF TIG mode only PULSE WIDTH
94. m the proper pin outs of the remote connector at the TIG Torch side Refer to the Operating Manual e Confirm that there is no open circuit on the remote connector at TIG Torch side In equipment for remote control use confirm the pin specification of a connector Refer to the Operating Manual b Verify the condition and connections of the welding cable the stick rod holders and the ground clamp Applies to all welding modes Confirm a secure connection of the welding cable stick rod holders ground clamp and dense connectors and there are no open cir cuits 11 8 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING Verify the no load voltage OCV Applies to STICK High Frequency TIG HF TIG mode Refer to the section Verification of No load voltage OCV in section 11 5 9 e If performing the No Load Voltage Failure procedure does not rectify the failure per form the following tests in the sequence below Replace any defective components found 1 Secondary diode D2 D4 D5 and D7 Verification Refer to section 11 5 6 Replacement Refer to section 12 3 29 2 Coupling coil CC1 300 400TS only Replacement Refer to section 12 3 17 3 Reactor FCH1 Replacement Refer to section 12 3 18 4 PCB14 T1 Replacement Refer to section 12 3 11 5 PCB8 PCB11 Q1 Q24 Verification Refer to section 11 5 7 Replacement Refer to section 12 3 7 12 3 8 7 Hall
95. ment damage Capac itors installed inside the Welding Power Source are electrically charged for a while after the Mains ON OFF switch or distribution panel switch has been turned off Before inspecting the inside of the Weld ing Power Source leave it for about 5 min after switching off power for discharging the capacitors and then remove the top and side panels a Verify the connection between High Frequency HF UNIT1 and Coupling Coil CC1 Verify the connection between the HF UNIT1 and CC1 confirm that the quick disconnect terminals are inserted onto the terminals of HF UNIT1 TB5 TB6 correctly and com pletely Confirm there are no short circuits burnt or broken wires at CC1 Replace CC1 Refer to section 12 3 17 11 9 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING b Verify the connection between High Frequency HF UNIT1 and the current limiting resistor R2 Verify the connection between HF UNIT1 and the current limiting resistor R2 confirm that the quick disconnect terminals are inserted onto the terminals of HF UNIT1 TB3 TB4 correctly and completely Confirm there are no short circuits burnt or broken wires between the HF UNIT1 and the current limiting resistor R2 C Verify the connection between the terminals between AC1 AC2 TB1 TB2 Verify the connection between AC1 AC2 confirm that the quick disconnect terminals are inserted onto the terminals of HF UNI
96. n scale dirt small electrode amperage too low ES Lack of Root Fusion Figure 8 2 Example of lack of fusion 8 3 300 400TS and 300 4008 8 BASIC TROUBLESHOOTING Description Possible Cause Remedy 5 Non metallic particles are trapped in the weld metal slag inclusion Non metallic particles may be trapped in undercut from previous run Joint preparation too restricted Irregular deposits allow slag to be trapped Lack of penetration with slag trapped beneath weld bead Rust or mill scale is preventing full fusion Wrong electrode for position in which welding is done Not cleaned or incorrect electrode undercut gt Slag trapped in root Figure 8 3 Examples of slag inclusion Slag trapped in If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode Allow for adequate penetration and room for cleaning out the slag If very bad chip or grind out irregularities Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from corners Clean joint before welding Use electrodes designed for position in which welding is done otherwise proper control of slag is difficult 300 400TS and 300 4008 8 BASIC TROUBLESHOOTING 3 Power Source Problems Description Possible Cause Remedy The welding arc cannot be establi
97. n 3 1 IPS BA156800 18895000 18870100 63 7001351 Spring Clip IGBT gen 3 1 IPS E1B850100 64 7001352 PCB1 gen 3 1 IPS J5B017500 65 W7001353 Chassis gen 341 16 J3C356600 Z 1 66 1 10 6665 Knob gen3 1 IPS 26216080 1 67 10 6666 KnobCap gen3 1 IPS 3021104 1 68 1 W7001685 Cover Protector gen 3 1 IPS N1B036500 3007 1 300 400TS PARTS LIST 300 400TS No DWG No PartNo Description Additional Information QTY 69 7 7001357 Sheet rubber gen 3 1 IPS EDA227700 4 70 7 W7001358 Post M5 gen 3 1 IPS EBA643600 M5 M5 3 71 7 17001645 Bus Bar D gen 3 1 IPS ECA903300 1 72 7 17001360 Bus Bar T D gen 3 1 IPS EDAO0380 CT 73 17001361 Bus Bar 1 D gen 3 1 IPS EDA046900 74 17001362 Bus Bar 2 D gen 3 1 IPS EDAO4700 75 7 7001363 Bus Bar 3 D gen 3 1 IPS EDAO47100 W7001364 Bus Bar S1 gen 3 1 IPS Bus Bar Output gen 3 1 IPS 83 7 17001369 insulated Board gen 3 1 IPS E1B872000 84 7 7001370 Insulation Sheet gen 3 1 IPS E18859700 85 7 W7001371 Insulation Sheet gen 3 1 IPS EDAO79800 1 86 7 17001643 Protector gen 3 1 IPS E16933000 1 87 W7001373 Protector gen 3 1 IPS E18933100 88 17001374 Clip gen3 1 IPS_ f 4NATURAL 4 89 17001375 CON g
98. nduct in the forward bias direction and will indicate between 0 3 and 0 9 volts 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 flow in the reverse bias direction and depending on the meter function will indicate an open or OL If any diode in the module tests as faulty replace the diode module Reconnect all cables to the proper terminals Forward Bias Diode Conducting Anode Cathode Figure 13 1 Forward bias diode test Reverse Bias Diode Not Conducting Cathode Anode Figure 13 2 Reverse bias diode test 17 LIMITED WARRANTY AND SCHEDULE This information applies to Thermadyne products that were purchased in the United Kingdom April 2006 Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in the owner s manual supplied with the machine Thermadyne welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment Thermadyne warranty will not apply to 1 Equipment that has been modified by any other party other than Thermadyne s own service personnel or with prior written consent obtained from Thermadyne service department UK 2 Equipment that has been used beyond the specificat
99. nfin les fum es d chappement doivent amp tre envoy es l ext rieur loin des prises d air du b timent 7 AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein 2 Nefaites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue 3 Sic est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage 4 Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N a
100. nit 0 1Hz 1Hz 5Hz Table 4 6 PULSE FREQ Range and Incremental Units Weld Mode STICK LIFT TIG Yes No Weld Parameter HOT START Parameter Range 5 to 70A 5 to 300A DC 5 to 400A DC 0 to 100 Factory Setting Incremental Unit 20A 1A 3005 4005 WELD CUR 80A 1A Yes ARC CONTROL 10 Yes Table 4 7 Weld Parameters for ARC MASTER 300 400S 300 400TS and 300 4008 4 OPERATOR CONTROLS 5 Power Source Features Feature Description New Digital Control e Almost all welding parameters are adjustable Touch Panel Switches Touch switches eliminate mechanical damage Front Control Cover Protects front panel controls Digital Meter Displays selected weld parame ter value Displays weld current when weld ing Displays weld current for 20 sec onds after weld has been com pleted selected weld parameter value can be adjusted at any time even while welding Intelligent Fan Control The intelligent cooling system is designed to reduce dust and for eign material build up whilst pro viding optimum cooling speed reduces approximately 30 seconds after machine is turned on speed increases when inter nal components reach operat ing temperature Primary voltage Supply ON OFF Switch located on rear panel Voltage Reducti
101. nverter P gt Transformer gt Diodes DC Power PCB14 Themal 1 Filter 1 Primary Detecto Detecto Voltage Output Sensor 1 gt inductor 1 each control circuit Drive Therma StickMode Lift Tig Mode 15VDC 18VDC Circuit Sensor VRD Output Short 24VDC 5VDC rcu Circuit Sensing Sensing Circuit Circuit m Vv Trouble j Primary Sensing Curent Circuit 4 1 Sensor Torch Control Sequence Fan Control Connection Control Circuit ri ran CON1 1 Current Reference Adjustmen Adjustment amp Circuit Mode select Switches Panel Circuit Board Figure 2 3 300 400S Model Functional Block Diagram 300 400TS and 300 4008 2 INTRODUCTION 7 Transporting Methods These units are equipped with a handle for carrying purposes A WARNING ELECTRIC SHOCK can kill DO NOT TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving the welding power source A 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 fork lift vehicle place and secure unit on a proper skid before transporting 300 400TS and 300 4008 2 INTRODUCTION PAGE LEFT INTENTIONALLY BLANK 3 INSTALLATION 1 Environment Th
102. of the procedure below make certain the unit is placed in the initial Case 2 Rotating Below DC 18V Replace PCB3 Refer to section 12 3 3 set up condition as described at the beginning of section 11 4 1 Preparation on page 11 10 1 Verify the condition of the cooling fan FAN1 using a DC voltmeter The capability of the voltmeter should be more than 50VDC Using a DC voltmeter measure between PIN 1 Posi tive and PIN 2 Negative of CN11 on PCB3 WK 5548 The location of connector Case 3 Inactive Below DC 18V Replace PCB3 Refer to section 12 3 3 l Perform Verification of the Power Supply Voltage Refer to section 11 5 2 CN11 of PCB3 is indicated in Figure 11 12 When you measure the above voltage do not remove the connector Conduct the measure ment while the connector plug and receptacle are still connected Figure 11 12 Verification of the FAN1 11 13 Case 4 Inactive DC 18 25V Replace the FAN1 Refer to section 12 3 21 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 abnormalities When verifying the voltage confirm that the AC input voltage remain within the operating range of the unit drop below 180VAC The AC input does not 3
103. ols away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine 5 WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries ARCMASTER 400TS 400S 300TS 300S FA P WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure 1 Do not remove radiator cap when engine is hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological
104. omplex subassemblies are faulty then the Welding Power Source must be returned to an Accred ited Thermal Arc Service Agent for repair The basic level of troubleshooting is that which can be performed without special equipment or knowledge 1 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables maintenance of equipment and proper welding technique Description Possible Cause Remedy 1 Excessive bead build up or poor Welding current is too low Increase weld current and or faulty joint penetration or poor fusion at edges preparation of weld 2 Weld bead too wide and flat or Welding current is too high Decrease weld current undercut at edges of weld or excessive burn through 3 Weld bead too small or insufficient Travel speed too fast Reduce travel speed penetration or ripples in bead are widely spaced apart 4 Weld bead too wide or excessive Travel speed too slow Increase travel speed bead build up or excessive penetration in butt joint 5 Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts when arc is struck Electrode is connected to the A Connect the electrode to the terminal terminal B WAVE BALANCE is greater than B Reduced WAVE BALANCE to below 50 50 or increase the electrode size 7 Dirty weld pool A Electrode contaminated through A Clean the electrode by grinding off c
105. on Device VRD Reduces the OCV when the power supply is not in use Eliminates the need for add on voltage reducers and has no effect on arc starting VRD fully complies to IEC 60974 1 When Stick mode is selected the green VRD light 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 selected weld parameter value can be adjusted at any time even while welding Pushing the knob in displays actual arc voltage Feature Description Self An error code is displayed on the Diagnosis Digital Meter when a problem Using Error occurs with Primary supply volt Codes age or internal component prob lems Refer to troubleshooting guide Save Load total number of 5 programs can function be saved into the 300 400TS 300 400TS memory only SAVE the Current Weld Parameters into Memory e Press the SAVE button e Select a memory location by rotat ing the control knob 1 to 5 is dis played on the meter e After selecting the desired mem ory location ie 1 to 5 press the right scroll button and the machine will give a beep to con firm the weld parameters from the control panel are saved LOAD retrieve a Program to Control Panel e Press the LOAD button e Select a memory loca
106. ont normalement partie du proc d de soudage traitez les avec soin M M M ni Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci dessous AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs ARCMASTER 400TS 400S 300TS 300S 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es 2 Si vous utilisez ces quipements dans un endroit co
107. ontact with work piece or filler the contaminates rod material B Check gas lines for cuts and loose B Gas contaminated with air fitting or change gas cylinder 8 Electrode melts or oxidizes when an A No gas flowing to welding region A Check the gas lines for kinks or arc is struck breaks and gas cylinder contents B Torch is clogged with dust B Clean torch C Gas hose is cut C Replace gas hose D Gas passage contains impurities D Disconnect gas hose from torch then raise gas pressure and blow out impurities E Gas regulator turned off E Turn on F Torch valve is turned off F Turn on G The electrode is too small for the G Increase electrode diameter or welding current reduce the welding current H WAVE BALANCE is set above H Reduced WAVE BALANCE to below 50 50 or increase the electrode size 300 400TS and 300 4008 8 BASIC TROUBLESHOOTING Description Possible Cause Remedy 9 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for gas flow problems 10 Arc flutters during TIG welding A Tungsten electrode is too large for the welding current B Absence of oxides in the weld pool A Selectthe right size electrode Refer to Basic TIG Welding guide B Refer Basic TIG Welding Guide for ways to reduce arc flutter 11 Welding arc can not be established Work clamp is not connected to the work piece or the work torch leads are n
108. ot connected to the right welding terminals Torch lead is disconnecte Gas flow incorrectly set 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 Connect it to the terminal Select the right flow rate change cylinders or turn torch valve on 12 Arc start is not smooth Tungsten electrode is too large for the welding current The wrong electrode is being used for the welding job Gas flow rate is too high Incorrect shielding gas is being used Poor work clamp connection to work piece Table 8 1 TIG Welding Problems Selectthe right size electrode Refer to Basic TIG Welding Guide Select the right electrode type Refer to Basic TIG Welding Guide Select the correct rate for the welding job Refer to Basic TIG Welding Guide Select the right shielding gas Refer to Basic TIG Welding Guide Improve connection to work piece 300 400TS and 300 4008 8 BASIC TROUBLESHOOTING 2 Stick Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in weld A Electrodes are damp A Dry electrodes before use metal Porosity B Welding current is too high B Reduce welding current C Surface impurities such as oil C Clean joint before welding grease paint etc 2 Crack occurring in weld metal A Rigidity of joint A Redesign to re
109. ottom Remove the two screws and then drags out the PCB14 WK 5594 and D Bus D Bus Bar2 D Bus Bar3 D Bus and Dust Cover Sheet Rear Remove the four screws and then remove the D Bus Bar1 D Bus Bar2 D Bus Bar3 D Bus Bar4 and Dust Cover Sheet Rear form PCB14 3 12 PCB15 WK 5606 1 Remove the Side Panel Reference page 11 1 2 Remove the Nylon Hose and two terminals of SOL1 3 Open the Dust sheet Remove the eight screws Remove the two PCB supporters and remove the PCB15 WK 5606 300 400TS and 300 4008 12 MAINTENANCE 3 13 PCB20 WK 5499 1 Remove the Side Panel Reference page 11 1 2 Remove one screw and one terminal Remove one bolt toothed washer washer and terminal Remove one screw nut and the Output Bus Bar Disconnect one connector from HCT1 3 Disconnect the two connectors Remove the four PCB board supporters and then remove the PCB20 WK 5499 H 3 14 PCB21 WK 4917 1 Remove the Side Panel Reference page 11 1 2 Remove the six screws from the S1 and remove the six terminals 12 16 300 400TS and 300 4008 12 MAINTENANCE 3 Remove the four screws and then open the Rear Board 4 Disconnect the one connector Remove the two s
110. pez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilisez pas de c bles lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT ETRE MORTELLE 9 N enroulez pas de c bles lectriques autour de votre corps 10 N utilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique peut tuer ou br ler gravement ee la pi ce souder L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de circuits internes de l quipement sont aussi sous ten soudage terre sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou 12 N utilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement
111. pprochez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur Wa P AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression M 1 W tez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant d ter compl tement le bouchon 1 05 Principales Normes de Securite Sa
112. pressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards Engines can be dangerous 9 WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Use equipment outside in open well ventilated areas May 22 2006 ARCMASTER 400TS 400S 300TS 300S 2 f used in a closed area vent engine exhaust outside and away from any building air intakes Vt 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 check and add fuel to cold engine before beginning job 4 Do not overfill tank allow room for fuel to expand 5 Do not spill fuel If fuel is spilled clean up before starting engine p we WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before 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 to
113. purposes Where Purchased Purchase Date Equipment Serial CONTENTS 1 SAFETY INSTRUCTIONS AND WARNINGS 1 Arc Welding Hazards ee ERR doin tree du re eer RS e als 1 1 2 PRINGIPAE SAEETY STANDARDS a rene n gratia tan va ae 280 a a RR Re ian UN 1 6 3 PRECAUTIONS DE SECURITE EN SOUNDAGE 1 6 4 Dangers relatifs au soudage 1 7 5 PRINCIPAL SAFETY STANDARDS 1 oe ay be Ber beer er eese ea eed e e e A Eon eme Rm 1 11 6S TATEMENT OF WARRANTY iu litt mn UNIT XS cR Rl ee a RED 1 12 7 DECLARATION OF CONFORMIITY 1 13 2 INTRODUCTION 1 How To Use This Manuali ns e o ao e ea EA Ree ee ees 2 1 2 Equipment Identification siaii aip ae pude ver eie bee 2 1 3 Recept OD EquiptTient cree PT Te ARR AR eter ks 2 1 4 lt UL XN Eq EM E UTE Eu beer eti a RET RATE 2 2 b D sCrplion cs ss Soo coos on RC NEU M sun MN D Et Leur rre tac hs 2 3 6 Functional Block Diagrams savin rope E Ron rice e va ete bee BS wel dere p t Rue E e Ue 2 4 7 _ Transporting Methods
114. r 3 9 PCB12 WK 5527 1 Remove the Side Panel Reference page 11 1 2 Remove the PCB13 WK 5528 Reference page 12 15 3 Remove the three latches of Front Control Cover and then the PCB12 WK 5527 12 12 300 400TS and 300 4008 12 MAINTENANCE 3 10 PCB13 WK 5528 1 Remove the Side Panel Reference page 11 1 2 Remove the Protection Cover 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 12 13 300 400TS and 300 4008 12 MAINTENANCE 5 Remove the one connector and two screws Remove the PCB13 WK 5528 and Encoder Cover 3 11 PCB14 WK 5594 T1 Main Transformer Remove the Side Panel Reference page 11 1 Remove the Coupling Coil CC1 Reference page 12 23 Remove the PCB20 WK 5499 Reference page 12 18 Remove the Reactor FCH1 Reference page 12 23 Remove the two screws and the T CC Bus Bar from the front side 300 400TS and 300 4008 12 MAINTENANCE 7 Remove the four screws from the PCB1 WK 5477 Remove the seven terminals The cables is drawn out 8 Remove the four screws and then two cables from b
115. rc Model ARCMASTER 3005 and 4005 is a self contained single three phase DC arc weld ing power source with Constant Current CC output characteristics This unit is equipped with a Digital Volt Amperage Meter and lift arc starter for use with Gas Tungsten Arc Welding GTAW and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resistant flame resistant and non conductive plastic case V V V OCV 300TS 10V 5A 300A 25A 300A 5A 300A 4 STICK Process LIFT TIG Process HF TIG Process V V V OCV ocv 400TS 10V 5A 400A A 25A 400A A 5A 400A A STICK Process LIFT TIG Process HF TIG Process V V OCV 3005 1 18V 10V 5A 300A 320A A 25A 300A STICK Process LIFT TIG Process V OCV 4005 1 300 4005 18V F 10V 5A 400A 420A A 25A 400A STICK Process LIFT TIG Process Figure 2 1 300 400TS Volt Ampere curve N 3 300 400TS and 300 400S 2 INTRODUCTION 6 Functional Block Diagrams Figure 2 2 illustrates the functional block diagram of the 300TS and 400TS power supply Figure 2 3 illus trates the functional block diagram of the 3005 and 4005 power supply
116. rdez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage 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 casque May 22 2006 ARCMASTER 400TS 400S 300TS 300S 4h gt 4 AVERTISSEMENT 22 LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau 2 LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles f
117. ress and phone number in your area listed in the inside back cover of this manual Include the manual number and equipment identification numbers Electronic copies of this manual can also be down loaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed 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 identified only by the specification or part number printed on the shipping container Record these numbers on the bottom of page i for future reference 3 Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to ship ping If there is any damage notify the carrier immediately to file a claim Furnish complete infor mation concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before uncrating the unit Use care to avoid damag
118. rify 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 occur even if carries out the above mentioned veri fications Refer to section 12 3 4 2 7 E81 Wrong Main Supply Voltage Cause The detection circuitry of main supply voltage is abnormality Verification Remedy 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 Confirm a secure connection of the harness wired between CN2 on PCB3 WK 5548 and CN1 on PCB21 WK 4917 Re install the harness with a secure connec tion Contact the manufacturer if you find any bro ken connectors or damaged wiring harness When the PCB fixed screw is loosening it fastens certainly 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 11 5 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 2 8 E82 Rated Voltage Selection Circuit abnormality Cause Rated volta
119. se Pulse Frequency Peak Current Base Background Current The Pulse controls are used primarily to control heat input Pulse offers a number of advantages as follows 1 Control puddle size and fluidity especially out of position 2 Increase penetration 3 Travel speed control 4 Better consistent quality 5 Decreased distortion on lighter or thinner materials Pulse current provides a system in which the weld ing current continuously changes between two lev els During the periods of Peak current heating and fusion takes place and during the background base current periods cooling and solidification take place Pulse Width is the time in one cycle the current remains at the peak current setting Pulse Frequency measured in Hertz is the number of cycles per second the current travels between peak and background current settings It is as if the foot rheostat were moved up and down to 300 400TS and 300 4008 6 SEQUENCE OF OPERATION PAGE LEFT INTENTIONALLY BLANK 7 ROUTINE MAINTENANCE The only routine maintenance required for the power supply is a thorough cleaning and inspec tion with the frequency depending on the usage and the operating environment WARNING Disconnect primary power at the source before opening the enclosure Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosur
120. shed A The Primary supply voltage has not been switched ON B The Welding Power Source switch is switched OFF C Loose connections internally Switch ON the Primary supply voltage Switch ON the Welding Power Source C Have an Accredited Thermal Arc Service Agent repair the connection Maximum output welding current can not be achieved with nominal Mains supply voltage Defective control circuit Have an Accredited Thermal Arc Service Agent repair the connection Welding current reduces when welding Loose welding cable connections Incorrect welding cable size Improper input connections Poor electrode condition Wrong welding polarity A Tighten all welding cable connections Use proper size and type of cable Refer to Section 2 05 Electrical Input Requirements Replace electrode Verify output torch connections No gas flow when the torch trigger switch is depressed Gas hose is cut Gas passage contains impurities Gas regulator turned off Torch trigger switch lead is disconnected or switch cable is faulty Replace gas hose Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities Turn gas regulator on Reconnect lead or repair faulty switch cable Gas flow won t shut off Weld Mode STD SLOPE REPEAT or SPOT was changed before POST FLOW gas time had finished G
121. stic tabs Figure 11 6 Remove PCB cover NOTE When you re assemble the parts conduct the above process backwards 2 Verification and Remedy to the Indicated Error Codes NOTE The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box dis tribution panel Wait at least 5 minutes for the dis charge to complete and then remove the cases to continue your inspection and repair or mainte nance inside the power supply As for the removal and installation of the case refer to section 11 1 1 NOTE During the Verification Remedy procedures below follow the alphabetical sequence a b and proceed with your verification and confirma tion NOTE After you confirm and replace all spare parts and components confirm that there are no damaged harnesses or connectors uninstalled or loose Screws 11 3 2 1 E01 Over Temperature at the primary side Cause Occurs when an over temperature condition of the primary IGBT is detected Verification Remedy a Unit may be in thermal shutdown mode e 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 e Maintain a clear and unobstructed distance of more than 30cm in the fron
122. systems that prove faulty CAUTION Troubleshooting and repairing this unit is a pro cess which should be undertaken only by those familiar with high voltage high power electronic equipment WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have training in power electronics measurement and troubleshoot ing techniques Under no circumstances are field repairs to be attempted on printed circuit boards or other subas semblies of this unit Evidence of unauthorized repairs will void the factory warranty If a subas sembly is found to be defective by executing any of the procedures in this Service Manual the subas 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 the operator s body comes into con tact with the work piece or any internal components while the unit is activated 1 System Level Fault Isola tion If none of the suggestions provided in Section 8 have solved the problem or corrected the faulty operation the next step is to isolate one or more o
123. t Circuit Board WK 5548 12 9 Print Circuit Board WK 4819 12 11 Print Circuit Board WK 5551 12 11 12 9 Print Circuit Board WK 5527 12 14 Print Circuit Board WK 5528 12 15 Print Circuit Board WK 5594 12 16 AJOJN Print Circuit Board WK 5550 Print Circuit Board WK 4917 12 1 12 18 300 400TS and 300 4008 12 MAINTENANCE DWG No Parts name Reference page PCB1 Print Circuit Board WK 5493 12 6 PCB6 Print Circuit Board WK 5549 12 11 PCB8 Q1 Q6 Print Circuit Board WK 5479 Primary IGBT 12 12 PCB9 Q7 Q12 Print Circuit Board WK 5479 Primary IGBT 12 12 PCB10 Q13Q18 Print Circuit Board WK 5479 Primary IGBT 12 14 PCB11 Q19 Q24 Print Circuit Board WK 5479 Primary IGBT PCB15 Print Circuit Board WK 5606 PCB20 Print Circuit Board WK 5499 PCB22 Print Circuit Board WK 5022 12 2 300 400TS and 300 4008 12 MAINTENANCE AU 2 2 gt cu Sy Gy 2 Reference page Remote Socket 12 29 D1 Primary Diode 12 31 D2 Secondary Diode 12 32 D4 Secondary Diode 12 32 D5 Secondary Diode 12 32 D7 Secondary Diode 12 32 HF UNIT1 High Frequency
124. t and more that 50cm in the rear of the unit for ventilation pur poses Verify 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 dusty environments will require more frequent cleanings c Verify the operation of the cooling fan FAN1 and replace it if necessary Verify the condition of FAN1 Verify that there are no broken or cracked fan blades and that is not producing any abnormal sounds f 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 is inactive Follow the instruction in section Refer to section 12 3 21 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 of PCB6 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 2 2 E02 Over Temperature at 2 3 E03 Transformer the secondary side Cause Occurs when an over temperature condition of the secondary IGBT and diode are detected Verification Remedy a Unit 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 b Verify the ventilat
125. the test and replacement of D2 D4 D5 and D7 c Replace the Hall CT HCT1 Refer to section 12 3 29 for the replacement of HE UNIT 1 NOTE Pay special attention to installed direction of HCT1 The Hall CT will not function properly if installed in the incorrect direction Refer to section 12 3 27 for the replacement of HCT1 d Verify the H F unit HF UNIT1 Refer to section 12 3 26 for the replacement of HF UNIT 1 300 400TS only 300 400TS and 300 4008 11 ADVANCED TROUBLESHOOTING 2 4 E04 Torch Cable Failure Cause The combined length of the torch cable and the work cable is too long Verification Remedy a Verify the rated duty cycle of the torch work cable and the power supply e Only use appropriate sized torch cables length and capacity The recommended total combined length of the torch and work cable is 50 feet Torch and work cable should not be coiled during welding operations Maintain the duty cycle of the power supply Refer to section 3 8 for the recommended duty cycle b Replace PCB6 WK 5549 Refer to section 12 3 6 for the replacement of PCB6 2 5 E11 Main Supply Over Volt age Cause Main supply voltage occurs in about 275V or more Verification Remedy Verify main supply voltage Perform what is described in a section of Verification of the Power Supply Voltage Refer section 11 5 2 b Replace PCB4 WK 4819 Ve
126. tion by rotat ing the control knob 1 to 5 is dis played on the meter After selecting the desired memory location ie 1 to 5 press the right scroll button and the machine will give a beep to confirm the weld parameters are loaded onto the control panel Table 4 8 Power Source Features 9 SET UP FOR SMAW STICK AND GTAW TIG Conventional operating procedures apply when using the Welding Power Source i e connect work lead directly to work piece and electrode lead is used to hold electrode Wide safety margins pro vided by the coil design ensure that the Welding Power Source will withstand short term overload without adverse effects The welding current range values should be used as a guide only Current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator 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 holder make sure the Primary power supply is switched off CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear or sides of the Welding Power Source CAUTION DO NOT change the Weld Mod
127. 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 que l air est propre la respi ration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Brassage terdre toutes conditions 2 au chalumeau Brassage fort toutes conditions 30u4 au chalumeau moins de 1 po 25 mm 30u4 moyen de 46 po 254150 mm 4005 plus de 6 150 mm 50u6 moins de 1 8 po 3 mm 40u5 de 1 8 1 2 3412 mm 5ou6 pais plus de 1 2 po 12 mm 60u8 Soudage l arc avec lectrode enrobees SMAW Nuance de filtre oculaire Op ration de coupage ou soudage moins de 5 32 po 4 mm o 5 32 amp 1A po 4 46 4 mm 12 plus de 1 4 po 6 4 mm 14 1 6 Op ration de coupage Soudage l arc sous gaz avec fil plein GMAW Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydrog ne atomique AHW Soudage l arc avec toutes conditions 12 Gougeage Air Arc avec lectrode de carbone Dimension d lectrode ou Epiasseur de m tal ou
128. 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 power supply will slowly discharged after you turn off the switch of the power sup ply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete 12 5 300 400TS and 300 4008 12 MAINTENANCE 3 Replacement Procedure 3 1 PCB1 WK 5493 SONDE 1 Remove the Side Panel Reference page 11 1 Remove the PCB2 WK 5597 Reference page 12 8 Remove the Primary Diode D1 Reference page 12 31 Remove the Current Trans CT2 CT3 Reference page 12 33 Remove the Nylon Hose Remove the two bolts and one terminal Remove the four screws and open the front cabinet 7 Remove the Reactor L1 Reference page 12 34 12 6 300 400TS and 300 4008 12 MAINTENANCE 8 Remove the 18 screws and remove the PCB1 WK 5493 4 M SO N 6 M 3 2 2 WK 5597 1 Remove the Side Panel Reference page 11 1 2 Remove the screw and then disconnect the four ground terminals Disconnect the 1

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