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pro-wave 300GtSw Service Manual

1. gt P gt 10 Brown 2 2 1 1 Output RT Network A Networ 045 ll rm White 5 0 Black K A 54 White R5 C5 L I FCH2 Black Yellow emp 2 WMA Gray D5 Blue N gt Gray gt 12VDC Brown gt 12VDC Red Output Current Detect OV to 4V Orange gt Ground Yellow gt Blue cc2 cC1 gt Output Short Detect White Output Short Detect Black 2 Ground Green gt HF Unit Tripping Relay Control AC2 12 gt Input Changeover Switch 41 Gray Input Changeover Switch olo R2 R1 gt 5 10 2 Thyristor Gate Drive lt SIS 9 gt Pre charge Control 8 a gt PCB Common 0V 7 9 555 gt Undervoltage 6 R1 gt Overvoltage 5 pl gt Reset Signal 4 M gt 2 3 gt Input Volt Detect 2 gt Voltage 1 gt Input 1 3 Phase Detect 15 Contactor Control 2 24VDC Orange gt Input Changeover Control 14 6 Contactor Control 1 GND Red gt 12VDC 13
2. gt gt 2 10 Brown e C2E1 R2 C2 MAN em gt lt N 1 whe X af R7 Filter A 52 i Network R3 UT l ANNE 8 8 9 gt a 5 APT 5 0 03 i 1 IGBT IGBT A i os Q4 T 1 B 1 D 1 4 amp 1 R4 C4 n White 1 Blue ari T Black T 54 White 5 5 1 NVE WA FCH2 Black Yellow R6 15 gt K A VVV Gray 05 Blue N gt Gray gt 12VDC Brown gt 12VDC Red Output Current Detect to 4V Orange gt Ground Yellow gt Blue 2 CC1 gt Output Short Detect White Output Short Detect Black gt gt 4 HF Unit gt Tripping Relay Control 12 LL AC2 gt Input Changeover Switch IA Gray Input Changeover Switch olo R2 R1 gt 10 2 2 gt Thyristor Gate Drive lt 9 gt Pre charge Control lt 8 gt 7 gt 6 9 R1 gt 5 535 gt Reset Signal 4 S gt Input Volt Detect 2 gt Voltage Detec 1 Input 1 3 Phase D
3. Single Phase NN Input Diode Bridge D1 5 Line 1 Black R R R i Line 3 White 1 gt s s gt e s 9 Line 2 Red gt gt AT Three Phase 3 3 NN 55 alole 2 2 6 fo fo o o D 0 amp Line 1 Black 22 lt lt 5 Line 3 White 5859535953682 TeS 8 28 5 2 219 S 5 6 1 5 65 jojo O gt Bless s ES gt X 5 2 Red 21218 Ci Ci o 2 wer 8 gt 3 l2 Z 18 2 5 4 gt 0 515 2151850 9 amp 9 E Ta Wall lal Wa Vl Vl Wl CN20 2 E CN20 e 2 3 m gt 5 gt 3 9g 4 o SS gt A 1 gt 9 gt gt 5 olo m 2 c 1 w gt gt alle gt CRE 4 gt Line 3 Black Line 2 White T 4 2 3 Line 1 Red 1 o 5 m gt 115V T3 115V 8 8 gt W 24VDC Red gt FAN1 X gt Common OV Black 2 5 m 115V 115V z o 4 5 Gas ON OFF Control Yellow 5 5 ov ov SOL1 Gas ON OFF Control Violet gt Black 4 7 gt 2125
4. Figure 6 7 Gate drive enable waveform June 21 2012 6 11 PRO WAVE 300GTSW 6 12 Lift Start Test 1 Disconnect primary power at the source Make sure the MAIN CIRCUIT BREAKER is in the OFF position 2 Measure the continuity between the front panel NEGATIVE OUTPUT TERMINAL to CN5 3 on the Main Circuit Board PCB1 and from the front panel POSITIVE OUTPUT TERMINAL to CN5 1 on the Main Circuit Board PCB1 Both should be zero Ohms Replace wire if continuity is broken 3 Reapply power to the unit by turning the MAIN CIRCUIT BREAKER to the ON position 4 Disconnect connectors CN8 and on the Main Circuit Board PCB1 Measure the voltage between CN22 5 and CN22 4 for OVDC Install a jumper between the POSITIVE and NEGATIVE OUTPUT TERMINALS on the front panel The voltage between CN22 5 and CN22 4 should increase to 5 0 If the voltage does not increase in step 4 above replace the Main Circuit Board PCB1 6 13 Gas Control Test Disconnect the remote control device from the REMOTE 8 receptacle 1 Measure for 24 0 between pins 3 and 4 on CN2 on the Main Circuit Board PCB1 Replace the Main Circuit Board PCB1 if the voltage is low or not present 2 Measure for 24 0 between CN7 1 and CN7 2 If no voltage is present check and replace wires between CN7 1 PCB4 and CN4 1 PCB2 or between CN7 2 PCB4 and CN4 2 PCB2 With a remote
5. 6 13 6 16 Gaining Access to Front Panel Circuit Board PCB6 WK 3988 6 18 6 17 Front Panel PCB6 WK 3988 Test Point 6 19 6 18 Input Power Selector Switch uae t cient totes 6 20 6 19 Front Panel Circuit Board PCB6 Replacement Procedure 6 20 6 20 Current Transformer Test 6 22 6 21 Current Transformer Replacement 6 22 5 22 POWER Control ne nn 6 23 6 23 Power Control Assembly PCA Test 6 23 6 24 Input Diode Bridge D1 Test Procedure 6 24 6 25 PCA Input Diode Bridge D1 Replacement Procedure 6 24 6 26 IGBT Inverter Test 6 26 6 27 IGBT Inverters Q1 and Q2 Replacement 6 28 6 28 IGBT Inverter 03 04 Replacement 6 30 6 29 PCA Output Diodes 02 05 Test 6 32 6 30 PCA Output Diodes D2 05 Replacement
6. Shielding Gas Output Current Figure 6 53 SPOT HF TIG mode timing Art A 06148 June 21 2012 SECTION 7 PARTS LIST 7 01 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 Specification or Assembly numbers 7 02 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted or welded to other parts The part descriptions may be indented to show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List SPEC NUMBERS 208 230VAC Single Voltage Single Three Phase 208 230 460VAC Single Three Phase 380 415VAC Single Voltage Three Phase June 21 2012 103024 103025 103038 PRO WAVE 300GTSW 7
7. 6 33 6 31 Thermal Sensor TH1 Test 6 36 6 32 Thermal Sensor EH T ununi dr tanen 6 37 6 33 Auxiliary Transformer T3 Test Procedure 6 38 6 34 Auxiliary Transformer T3 6 39 6 35 Main Transformer Assembly T1 and T2 Test Procedure 6 40 6 36 Main Transformer T1 and T2 Assembly Replacement Procedure 6 41 6 37 Output Inductor Assembly Test and Replacement Procedures 6 42 6 38 Fan Assembly Replacement 6 44 6 39 HF Unit Test and Replacement Procedures 6 46 6 40 HF Coupling Coil Test and Replacement Procedures 6 48 6 41 Gas Solenoid Valve Replacement 6 50 6 42 IGBT Inverter 03 04 Driver Circuit Board PCB8 Test Procedure 6 51 6 43 IGBT Inverter 03 04 Driver Circuit Board PCB8 Replacement Procedure 6 52 6 44 Sequence Timing BIGOESITIS espe sd dece odes 6 53 SECTION 7 PARTS m 1 1 PR a 7 1 7 02 MOW TO U
8. 14 LighiUnderS00Amp 9 ES WARNING 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 2 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 4 Readthe 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 6 Do not weld in locations near degreasing cleaning spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Medium 30010400 Amp 12 Over 400 Amp June 21 2012 9 Do not weld 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 EN WELDING cause fire or explosion WARNING Sparks and spatter
9. 14 _ moins de 5 32 po 4 Coupage l arc Plasma 5 32 1 4 po 446 4 mm mince moins de 300 amperes plus de 1 4 po 6 4 mm de 300 400 amper s June 21 2012 plus de 400 1 7 PRO WAVE 300GTSW EZ AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DAN GEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer Eloignez la t te des fum es pour viter de les respirer 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 relatives aux m taux aux produits consum mables aux rev tements et aux produits nettoyants travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respiration Ne soudez pas proximit d op rations de d grais sage 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 Ne soudez des t les galvanis es ou plaqu es au plomb ou
10. 7 n WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing 1 Wear a welding helmet fitted with a proper shade of filter see ANSI 749 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc 4 Wear protective clothing made from durable flame resistant material wool and leather and foot protection 5 Use approved ear plugs or ear muffs if noise level is high Oxygen Cutting Gas welding goggles or helmet from AWS A6 2 73 Torch soldering __________ Gasmetarare f Tochbrzng ___________ Sr Nonfemousbasemeta 3i Femouspasemeta A 12 ________ Under Tin 26mm Gas tungsten arc welding 12 Medium 110 617 25 150 4ors 09 r Heavy 150mm 50 6 Atomic hydrogen welding ___ _____12 ________________ Ai _______ UnderiBin 3mm 2075 Plasmaarcwelding Over iin 12 Shielded metal arc Under 5 32in 4mm 10 14 12 Plasmaarcuting
11. Ed Label Warning Illustration Label Side Case Half Screws Rubber Foot Screws Main Circuit Breaker Easylink Switch Input Cable Clamp Input Power Cable Gas Inlet Fitting Gas Inlet Fitting CE Rear Plastic Frame Rear Upper Metal Panel E6A181600 25850001800 10 5409 10 5409 10 5409 4 449800 not shown not shown 10 5239 10 5239 10 5239 52026000500 10 5075 5 925600 6 586600 10 5525 446900 10 5390 444400 10 5391 444600 444700 444400 10 5455 E0B869600 20 not shown not shown not shown not shown not shown a Rear Upper Metal Panel Rear Upper Metal Panel CE Rear Upper Metal Panel Heatsink Main PCB PCB1 Main PCB PCB1 Main PCB PCB1 1 10 6317 POA344816 10 6350 P0A344815 10 6318 P0A344817 not shown not shown not shown 5 z utto Ls not shown not shown not shown 20 not shown not shown not shown not shown not shown a La 7 2 21 2012 PRO WAVE 300GTSW 208 230 380 415 230 460 ITEM DESCRIPTION LOCATION QTY MODEL MODEL MODEL VENDOR 25 331112360 25 before 9 29 95 3311119700 26 27 0 1 10504 10504 10 5024 0 329100 04
12. 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 entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement 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 749 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pra tiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez connaitre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE 1 Ne touchez pas des pi ces sous tension DES TRAVAUX D INSTALLATION DE REPARATION 2 Portez d TORE vat een t D ENTRETIEN ET D ESSAI Portez des gants et des v tements isolants secs e non trou s 1 04 Dangers relatifs au soudage l arG 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 a 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 AVERTISSEMENT une mise en marche accidentelle L ELECTROCUTION PEUT E
13. 7 A L TB1 T1 Primary Lead emoval of main transformers T1 T2 right side of unit from front D Figure 6 38 T1 T2 primary lead routing through ferrite ring June 21 2012 6 36 Main Transformer T1 and T2 Assembly Replacement Procedure To remove Main Transformer T1 or T2 1 2 Remove the Main Circuit Board page 6 13 Remove MAIN CIRCUIT BREAKER and shield per page 24 Cut cable ties securing T1 or T2 primary leads WHITE to ferrite ring L1 See Figure 6 37 Cut cable ties securing insulating sheath on T1 or TB2 T2 at the BLACK WHITE lead junction Remove the hardware from the BLACK WHITE primary lead junction and remove the lead from the ferrite ring Remove the WHITE primary lead from the terminal 01 1 or 02 2 Turn the unit on its side and feed the two WHITE primary leads down through the hole in the chassis in preparation for removing the transformer s White Wire to CN7 3 Blue Wire to HF Unit AC1 T1 T2 Secondary Lead Junction E PRO WAVE 300GTSW 8 Remove the Output Inductor Assembly section 6 37 page 6 42 9 Bend the secondary center tap leads of both transformers 1 and T2 D up to expose the C and E secondary lead junctions See Figure 6 39 10 Remove the hardware from the C and E secondary leads 11 Remove the two 2 screws securing the transformer plastic frame to the metal mountin
14. White 1 Blue T White Yellow 12VDC Brown 4 12VDC Red Output Current Detect to 4V Orange gt Ground Yellow gt cca CC1 Output Short Detect White Output Short Detect Black Lo ACI Case Ground Green 1 HF Unit Tripping Relay Control 45 1 AC2 12 gt Input Changeover Switch 11 Gray Input Changeover Switch olo R2 R1 gt 10 212 gt Thyristor Gate Drive 9 g SJS gt Pre charge Control lt 8 gt 7 9 555 gt Undervoltage E 95 R1 gt Overvoltage 5 5 Reset Signal 4 gt 12VDC 3 3 lolo PCB Common OV 2 gt Input Voltage Detect 1 gt Input 1 3 Phase Detect 15 Contactor Control 2 24VDC Orange Changeover Control 14 5 Contactor Control 1 GND Red gt 12VDC 13 5 PWM Gate Drive lt Faz Amperage Control Wiper 0 4VDC Gray gt Drive A 11 n 5 2 Amperage Maximum Violet gt Changeover Control S 38 GND Blue gt
15. Art A 06117 TB12 Figure 6 9 Location of TB12 on main circuit board 5 Remove all connectors from the left side and front of the Main Circuit Board CN1 CN2 CN4 CN10 CN13 and CN26 not shown CN9 PCB6 CN8 PCB6 Art A 06111 CN7 PCB6 Figure 6 10 Connectors to be removed from left side and front of main circuit board 6 Cut any cable ties securing wire harnesses to TB1 or TB2 leads 7 Move the wiring harness aside clear of the Main Circuit Board 6 14 June 21 2012 PRO WAVE 300GTSW Figure 6 11 Location of TB1 through TB6 on main circuit board 8 Remove the screws securing the MAIN CIRCUIT BREAKER to the rear panel 9 Remove connectors CN6 CN8 CN9 and CN14 from the rear of the Main Circuit Board 10 Remove screws associated hardware and wire lugs from TB1 through TB6 Straighten the lugged wires that were removed from TB1 and TB2 so they stand vertically This will allow the wires to pass through the current sensors when the Main Circuit Board is lifted away from the chassis in a later step 4 9r Art 06115 _ CN 8 CN9 CN24 Figure 6 12 Connectors to be removed from rear end of main circuit board June 21 2012 6 15 PRO WAVE 300GTSW 11 Cut the cable tie securing the CN18 to CN24 ORANGE GRAY wire pair to the BLACK lead attached to TB1 12 Remove the four 4 mounting screws from the corners of the Main Circuit Board Art 06119 Figure 6 13 Main circ
16. 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 shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information 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 un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 1 PRO WAVE 300GTSW 2 04 Symbol Chart Note that only some of these symbols will appear on your model __ o Dangerous Voltage AC Auxiliary Power rw e RICE Hertz cycles sec Frequency Sa HI Direct Current DC Ground D D lt Auxiliary Power Receptacle Rating Auxiliary Power Wire Feed Function Wire Feed Towards O Workpiece With Output Voltage Off Welding Gun Purging Of Gas Continuous Weld a Spot Weld Mode Preflow Time Gas Metal Arc Welding GMAW ne Postflow Time 2 Step Trigger tt Operation Press to initiate wirefeed and welding release to stop Three Phase Static Frequency Converter Transformer Rectifier
17. 3 Faulty PCB a Replace PCB1 Refer to page 6 13 5 3 PRO WAVE 300GTSW H 5 4 Green AC POWER Indicator OFF Fan Not Operating 7 Input line disconnect switch in OFF position a Place input line disconnect switch to ON position 2 Power supply MAIN CIRCUIT BREAKER MCB in OFF position a Place MCB to ON position 3 Input line breaker tripped tuses blown a Reset MCB check primary supply breaker or fuses and replace if necessary Refer to letter 4 Power supply MCB faulty a Check external connections to the circuit breaker and continuity Replace if necessary NOTE Verity that for single phase operation the RED input line is not connected 2 Open conductor in input power line a Check continuity and replace if necessary 6 Faulty Main Circuit Board PCB1 a Check the Main Circuit Board PCB1 supply voltages Refer to section 6 05 page 6 4 Replace the Main Circuit Board PCB1 if any of the voltages are not present page 6 13 7 Faulty auxiliary transformer 73 a Check auxiliary transformer T3 primary and secondary windings for shorts or open circuits and replace if necessary Refer to section 6 33 page 6 38 Red WARNING Indicator ON No Weld Output 7 Input voltage fluctuation causing protection circuits to activate a Monitor input power for spikes and high voltage conditions Most power utilities will monitor and verify line voltage 2 Easy Link not operating correc
18. 9 99 1891 indino indino 5 E gt 5 o o 9 S 5 la 8129 10181 1 3 Line 2 White Line 1 Red T3 115V 24VDC Red ov Gray Common 0V Black peog 115V Gas ON OFF Control Yellow Gas ON OFF Control Violet Black 125V ov Black 250VAC Brown 250VAC Orange Thermal Detect Black IGBT Gate Drive G6 White Thermal Detect Black IGBT Gate Drive E6 Black IGBT Gate Drive G5 Blue IGBT Gate Drive E5 White From Brown 300Vpk Pulse Yellow 300VDC Supply Common 0 412VDC Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary Overvoltage Signal 15V Pulse Red PCB Common 0V Common Blue Art A 06167 8804 YO O 1 1991 A 6 June 21 2012 PRO WAVE 300GTSW
19. Case Ground Green PWM Gate Drive lt Amperage Control Wiper 0 4VDC Gray gt 12 4 gt PWM Gate Drive 11 5 Amperage Maximum Violet gt Input Changeover Control 10 o 58 2 GND Blue gt Input Changeover Control 9 95 Amperage Control 12VDC Yellow gt Torch Switch Control 8 25 9 Case Ground Brown gt Output Short Circuit Detect 5 gt gt Primary Current Detect 3 gt Primary Current Detect 2 Case Ground Brown Primary Current Detect 2 gt 1 5 1 te gt Thermal Control 11 gt Thermal Control 10 gt Output Voltage Detect 9 gt Output Voltage Detect 8 gt Output Current Detect 7 Front View gt PCB Common 0V 6 9 gt 12VDC 5 gt 5VDC 4 gt 5VDC 3 gt PCB Common 0V 2 gt 12VDC 1 PCB8 S Art 06167 gt Torch Control Pink F3 gt Torch Control Yellow 1 June 21 2012 PRO WAVE 300GTSW APPENDIX 5 WIRE CHART MAIN BOARD PCB1 Cromer Commens 2 PowertoCT1 24Vac Fan supply voltage Red C22 06050 1 C25 notused C26 notused 9Vde p common Outputshortdetect CNS S C61 Inputline voltage CN67 voltage Black Output voltage Black Output v
20. 1254 gt ov Black g 230v 1 250VAC Brown INPUT SELECT 52 1 3 Z gt 250VAC Orange ssov o _ _2 gt Thermal Detect Black 2710 2 IGBT Gate Drive G6 White EX Thermal Detect Black o gt i gt PX IGBT Gate Drive E6 Black THI IS IGBT Gate Drive G5 Blue 2 gt i i gt IGBT Gate Drive E5 White A White lt gt gt 05 80Vpk From Brown 298 gt a gt Parcs Secondary IGBT Gate Drive 292 Pulse Yellow 5 FL Secondary Gate Drive b Boz 300VDC Supply Common N m 3 A i 75 gt ONE Secondary IGBT Gate Drive 4 8 lt T Secondary Overvoltage Signal 5 15V Pulse Red 1 gt 6 4 Art 06165 2 June 21 2012 PRO WAVE 300GTSW
21. 6 31 Thermal Sensor TH1 Test Procedure A WARNING Disconnect primary power at the source before performing this procedure Refer to figure 6 34 1 Select the Ohms scale on the digital meter 2 Disconnect the connector at CN10 on the Main Circuit Board PCB1 3 The resistance of a good sensor measured between pins 1 and 2 on the connector should be in the 10KOhm to 21 6KOhm range with the reading decreasing as the temperature of the power supply increases A shorted reading indicates a bad sensor and it should be replaced CN9 PCB6 CN8 PCB6 Art A 06111 CN7 PCB6 i Figure 6 34 Thermal sensor connector on main circuit board PCB1 6 36 June 21 2012 PRO WAVE 300GTSW 4 Cut cable ties as appropriate to free the BLACK BLACK wire harness that connects the Thermal Refer to figure 6 35 Sensor to connector CN10 plug To remove the Thermal Sensor TH1 do the To replace the Thermal Sensor TH1 do the following following 1 Remove the Main Circuit Board per section 6 15 1 Spread a light coating of thermal compound on page 6 13 the bottom surface of the Thermal Sensor 2 Locate the sensor mounted on the main chassis 2 Reverse the removal steps above between the circuit boards PCB4 and PCB5 that connect to IGBT Inverters Q1 and Q2 3 Using a magnetic or split screwdriver remove the screw that secures the sensor to the chassis frame IGBT Inverter Q2 Input Diode Bridge D1
22. ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine 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 tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine 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 battery 2 Stop engine before disconnecting or connecting battery cables 3 Do not allow tools to cause sparks when working on a battery
23. Shielded Metal Arc Welding SMAW Gas Tungsten Arc Welding GTAW Air Carbon Arc Cutting CAC A Constant Current Constant Voltage Or Constant Potential High Temperature Fault Indication NES La Touch Start GTAW 4 Step Trigger Operation Press and hold for preflow release to start arc Press to stop arc and hold for preflow Burnback Time Mt Inches Per Minute LJ Meters Per Minute Variable Inductance Voltage Input Note For environments with increased hazard of electrical shock Power Supplier bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed tips if equipped with properly installed standoff guides Cannot be disposed with household garbage 2 0 June 21 2012 2 05 General Description The Thermal Arc Model 300GTSW is a three phase or single phase if derated AC DC arc welding power source with Constant Current CC output characteristics The unit is equipped with a 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 Pulsed GTAW P Gas Tungsten Arc Welding Sloped GTAW S and Shielded Metal Arc Welding SMAW processes OCV Less than 70V C C Art A 06103 Arc Characteristics VOLTS CURRENT Control Serge eae eee tare 145 AMPS 300 310 Figure 2 1 300GTSW vol
24. and correctly configure the internal power circuits for proper operation under both input power conditions 1 Disconnect primary power at the source Make sure the MAIN CIRCUIT BREAKER MCB is in the OFF position Setthe INPUT SELECTOR switch on the rear panel to the low voltage 208 230VAC range position Using an Ohmmeter at CN13 on the Main Circuit Board between pins 1 BLUE and 3 GREEN should measure a short and an open between CN13 pins 2 GRAY and 3 GREEN Set the INPUT SELECTOR switch to the high voltage 460VAC range Using an Ohmmeter at CN13 on the Main Circuit Board between pins 1 BLUE and 3 GREEN should measure an open and a short between CN13 pins 2 GRAY and 3 GREEN June 21 2012 PRO WAVE 300GTSW 6 3 PRO WAVE 300GTSW 6 05 Power Supply Voltage Test Refer to figure 6 2 For location of ribbon cables 1 Connect the power supply to a source of either 208 230VAC or 460VAC 2 Set the Input Select switch to match the input voltage 3 Apply power to the unit and place the MAIN CIRCUIT BREAKER on the power supply to the ON position 4 The voltage at CN 7 as listed in Step 9 If any voltages are incorrect then proceed to Step 6 If all readings are correct the proceed to Step 12 5 Turn the unit OFF 6 At the Front Panel Circuit Board disconnect the ribbon cable at connector CN7 Pull up on the retaining bar to release the ribbon cable from the connector bod
25. rifier le niveau e carburant ou de faire le plein Ne faites pas le plein fumant ou proche d une source d tincelles ou d une flamme nue Si c 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 Nefaites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Net toyez tout carburant renvers avant de faire d marrer le moteur AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventila teurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s Avant d installer ou de connecter un syst me arr tez le moteur Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils PRO WAVE 300GTSW 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire
26. 06122 3 Pull the Front Panel Circuit Board back toward the rear of the power supply and then up to free the controls from their respective holes in the front panel Fold the Front Panel Circuit Board down to expose the component side of the board 4 Remove all connectors from the Front Panel Circuit Board 6 20 June 21 2012 PRO WAVE 300GTSW Art A 06123 Figure 6 18 Component side of front panel circuit board 5 Remove the Front Panel Circuit Board from the power supply To replace the Front Panel Circuit Board reverse the removal steps June 21 2012 6 21 PRO WAVE 300GTSW 6 20 Current Transformer Test Procedure 1 Disconnect connector CN1 from the Main Circuit Board PCB1 2 With an Ohmmeter set the Rx10 scale measure between the pins on the CN1 plug as follows Pin 4 YELLOW and Pin 1 BROWN gt 120KOhms Pin 4 YELLOW and Pin 2 RED 20KOhms 6 21 Current Transformer Replacement Procedure Refer to figure 6 19 To remove the Current Transformer CT 1 Remove the Output Inductor Assembly per section 6 370n page 6 42 2 Remove hardware from Output Bus Bar IGBT Inverter Q3 Q4 Bus Bar junction 3 Remove the bolt and associated hardware from the inside of the POSITIVE OUTPUT TERMINAL 4 Remove the connector with the RED YELLOW ORANGE BROWN twisted wiring harness from the CT 5 Remove the Output Bus Bar CT 6 At the end removed from the POSITIVE OUTPUT TERMINAL bend the
27. 1 PRO WAVE 300GTSW 7 03 Parts List 208 230 380 415 230 460 DESCRIPTION LOCATION MODEL MODEL CAT VENDOR Front Upper Metal Panel 10 5341 A3A439400 Front Upper Metal Panel a 10 6346 600019 Knob large 10 5233 50551002900 Poteniometer 10 6363 41114001000 Knob small 10 5232 50551002100 Poteniometer 10 5056 41114001100 10 6324 004397400 U0A397800 10 5462 A3A441900 10 5073 E6A475200 E6A967700 10 5184 53003000600 10 5131 2699901 0100 N NS not shown not shown not shown 29 emote Receptacle w harness 1 emote Receptacle w harness Front Plastic Frame Gas Outlet Fitting Gas Outlet Fitting C C Ring Gas Vavle Female Output Terminal Switch toggle 3 pos WK pulse slope not shown 3369 process 3 B N 10 5570 10 5570 10 5570 24703128400 10 6365 10 6365 10 6365 24655000100 Switch toggle 2 pos WK 3092 not shown 3369 AC DC 1 Switch toggle 2 pos WK res not shown 3988 AC DC 1 10 not shown 10 5057 10 5057 10 5057 24703128000 10 6364 10 6364 10 6364 24655000200 10 5496 10 5496 10 5496 0 476400 10 5497 10 5497 10 5497 108476500 10 5499 10 5499 10 5499 108477000 10 5461 10 5461 10 5461 E0C 181200 10 5411 10 5411 10 5411 10 6321 10 5224 10 5224 10 5222 24704531400 Switch toggle pos WK pulse slope not shown 3988 process 3 Label Warning Explanation
28. 4 Do not use welder to charge batteries or jump start vehicles 5 Observe correct polarity and on batteries E 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 June 21 2012 WARNING 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 Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office 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 and interact with and produce changes in biological systems While most of this work is of very high quality the results
29. D PCB4 E Retaining Screw L 5 5 Thermal Sensor TH1 Figure 6 35 Thermal sensor TH1 June 21 2012 6 37 PRO WAVE 300GTSW 6 33 Auxiliary Transformer T3 Test Power OFF Test Procedure The auxiliary transformer can be checked with either a power OFF or power ON test Do the power OFF test first Locate the auxiliary transformer in the bottom front of performing this procedure the power supply WARNING Disconnect primary power at the source before 1 Select the Ohms scale on the digital meter 2 With the MAIN CIRCUIT BREAKER ON verify continuity between LINE1 on the MCB and CN19 pin 3 on PCB1 1 3 Measure the primary winding resistance between LINE 2 on the MCB and CN19 pin 1 to be 74 Ohms 208 230V or pin 5 460V to be 14 8 Ohms If there is no continuity or the resistance measurement yields an open circuit replace the auxiliary transformer T3 Red and White Leads to Input Diode Bridge D1 Retaining Screw CN2 f Art A 06136 Auxiliary Transformer L Retaining Screw Figure 6 36 Auxiliary transformer June 21 2012 PRO WAVE 300GTSW 6 34 Auxiliary Transformer T3 Replacement Refer to figure 6 36 To remove the Auxiliary Transformer T3 do the following 1 Remove Main Circuit Board per page 6 13 2 Remove connector CN1 from PCB8 3 Remove the RED and WHITE lugged wires from the R and S terminals of the Input Diode
30. E6A653100 10 5434 E6A653300 10 5432 E6A52900A 10 5420 E6A558900 10 5421 E6A559000A 10 5429 E6A652500 10 5435 E6A653400A 10 6345 P0A353600 10 5482 J2B747600 10 5431 E6A652800 10 6684 N A 10 5517 P0A347500 10 2290 N A 10 5176 795300550 795301450 795301460 355001160 10 5249 10 2663 10 5249 10 5249 369211890 10 2663 10 2665 10 2662 10 2664 10 2666 10 2665 10 2662 10 2664 10 2666 10 2664 10 2664 10 2664 10 2664 10 2664 10 2662 10 2613 10 2663 10 2663 10 2613 10 2664 10 2613 10 2613 10 2613 10 2613 10 2613 10 2613 21 2012 PRO WAVE 300GTSW 208 230 MODEL 380 415 MODEL 230 460 MODEL ITEM DESCRIPTION LOCATION QTY CAT CAT CAT VENDOR not shown not shown not shown not shown NA notshown Plug 5pos not shown Last letter in S N is m 10 2663 10 2663 10 2663 10 2662 10 2662 10 2662 10 2671 10 2671 10 2671 notshown Plug 5pos PeBe 10 2663 10 2663 10 2663 21 2012 7 5 PRO WAVE 300GTSW 7 04 Parts Pictures Art A 06149 8 Figure 7 1 Front Panel 7 6 June 21 2012 June 21 2012 PRO WAVE 300GTSW THERMAL D Dynamics THERMAL ARC DC INVERTER ARC WELDER 13 Art A 06150 15 14 5 Places 4 Places Figure 7 2 Enclosure 7 7 PRO
31. Input Changeover Control 9 95 Amperage Control 12VDC Yellow gt Torch Switch Control 8 2 98 1 Case Ground Brown Output Short Circuit Detect 5 2 8 4 Common 4 Primary Current Detect 3 gt Primary Current Detect 2 Case Ground Brown Primary Current Detect 2 gt 1 Thermal Control gt 11 gt Thermal Control 10 gt Output Voltage Detect 9 gt Output Voltage Detect 8 Output Current Detect 7 Front View gt PCB Common 6 9 gt 12VDC 5 5VDC 4 4 5VDC 3 PCB Common gt 2 gt 12VDC 1 pope Art A 06166 gt Torch Control Pink 2 gt Torch Control Yellow 1 21 2012 5 PRO WAVE 300GTSW APPENDIX 4 380 415VAC SINGLE VOLTAGE THREE PHASE 380 415VAC Single Voltage Three Phase IGBT IGBT Inverter Inverter Q1 Q2 Ground PE gt Input Diode Black Bridge D1 i Line 1 Black B G White Line 3 White 5 R2 Orange Line 2 Red C1 Bus Bar sng TB6 TB1 TB2 e ug 229 1491 440 NO HUN e g 10 SUAUL 19 eie 1891 L3 229 1991 peu eua 8129 1891 GIUM 1991 ELUM 1891 opelg 1991 ELUM
32. January 20 1997 Revision AB Date June 21 2012 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 Arc Welding hea QR aa da 1 1 1 02 PRINCIPAL SAFETY STANDARDS 1 5 1 03 PRECAUTIONS DE SECURITE SOUDAGE A 1 6 1 04 Dangers relatifs au soudage 1 6 1 05 PRINCIPALES NORMES DE SECURITE 1 10 1 06 DECLARATION OF 1 11 1 07 LIMITED WARRANTY 1 12 SECTION 2 INTRODUCTION gt 2 1 2 01 To Use This MANUAL sentais 2 1 2 02 Equipment Os 2 1 2 03 2 1 2 04 Symbol 2 2 2 05 General Description 2 3 2 06 Functional Block Diagram sse 2 4 2 07 Transporting Methods 2 5 2 08 2 6 eee a nn 2 7 SECTION 3 INSTALLATION ne eme 3 1 3 01 Electrical CONTIG INOS na 3 1 SECTION 4 OPERATION sentence 4 1 4 01 Operator Controls 4 1 SECTION 5 SERVICE aT 5 1 5 01 Routine uiuis mai
33. Output Bus Bar sufficiently to allow the CT to slide off the end of the bus bar To replace the Current Transformer 1 Slide the new CT onto the Output Bus Bar in the same orientation as the one removed 2 Return the end of the Output Bus Bar to a right angle 90 bend The next step makes it much easier to complete the replacement due to interference with the Coupling Coil 3 On IGBT Inverter Q3 Q4 remove the two screws securing the bus bar that was attached to the Output Bus Bar CT Assembly 4 Replace the hardware to joint the bus bar removed from Q3 Q4 and the Output Bus Bar CT Assembly Finger tighten 5 Replace the bus bar onto Q3 Q4 Securing the two screws through the bus bar into Q3 Q4 may require using a Screwdriver at an angle or a right angle screwdriver if available 6 Reverse the remaining removal steps Output Junction Hardware Bolt Positive Las Transformer 2 Ton Output Bus Bar Art A 06124 IGBT Inverter 03 Figure 6 19 Current transformer and output bus bar June 21 2012 PRO WAVE 300GTSW 6 22 Power Control Assembly The Power Control Assembly PCA consists of input diode D1 IGBT Inverters Q1 Q4 output diodes D2 D5 heat sinks main and auxiliary transformers output inductors and high frequency coupling coil Perform a careful inspection of all components of the PCA first Failure may be identified by burned
34. Procedure 1 Visually inspect coil primary and secondary for 2 overheating other damage Check connections of coil wires on HF Unit terminals CC1 and CC2 3 Verify continuity through the coils Replace the HF Coupling Coil if damaged or continuity is broken HF Coupling Coil Replacement Procedure Refer to figure 6 45 To remove the HF Coupling Coil 1 Remove the Output Inductor Assembly per section 6 37 page 6 42 Remove the bolt from the inside of the NEGATIVE OUTPUT TERMINAL Remove the bolt from the inside of the POSITIVE OUTPUT TERMINAL Disconnect the connector on CT1 Remove the hardware securing the Output Bus Bar to IGBT Inverter Q3 Remove the Output Bus Bar CT Assembly Remove the Coupling Coil from the unit disconnecting the BLACK lugged wires from the HF Unit as the Coupling Coil is removed To replace the HF Coupling Coil reverse the removal steps June 21 2012 PRO WAVE 300GTSW Bolt Positive Output Current Transformer Output Bus Bar Art 06124 Junction Hardware IGBT Inverter Q3 Figure 6 45 Output bus bar CT assembly Art 06127 HF Unit IGBT s Coupling Coil Leads Inverter 03 04 Figure 6 46 Coupling coil replacement June 21 2012 6 49 PRO WAVE 300GTSW 6 41 Gas Solenoid Valve Replacement Procedure Refer to figure 6 47 To remove the gas solenoid valve 1 Remove the YELLOW VIOLET wires from the lugs on the sol
35. Safety Precautions page ii Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure part of the operators body comes into contact with the workpiece or any internal components while the unit is activated Wait at least two minutes for the input capacitors to discharge before opening the enclosure June 21 2012 PRO WAVE 300GTSW 2 07 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 welding power Source A WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage e Lift unit with handle on top of case Use hand cart or similar device of adequate capacity f using a fork lift vehicle place and secure unit on a proper skid before transporting June 21 2012 2 5 PRO WAVE 300GTSW 2 08 Specifications Volt a 3 3 10 32 Voli then Circuit Yota Dimensions Ang 260 300 20 ws 2 woe ae pon 95 125 98 Output at Load data Le ______ Vols Amperage Draw __________________ Single Phase No Load ___ __ __ 5 22 Table 2 2 Specifications 2 6 June 21 2012 2 09 Duty Cycle The
36. WAVE 300GTSW 7 8 Ex m Art A 06151 6 Figure 7 3 Rear Panel June 21 2012 21 2012 2 57668 DANGER Main Circuit Breaker PRO WAVE 300GTSW Main Circuit Board Art 06152 Figure 7 5 Fan Main Transformer Output HF Coupling Unit Coil Current Inductor Transformer Figure 7 4 Left Side Parts UOA329100A 980304 Figure 7 5 PCB 11 Art A 06153 7 9 PRO WAVE 300GTSW Art A 06154 25 32 27 29 23 30 Figure 7 6 Right Side Parts Art 06155 Figure 7 7 Top View Parts 7 10 June 21 2012 PRO WAVE 300GTSW 36 27 29 20 37 38 39 40 Figure 7 9 Internal Parts June 21 2012 T PRO WAVE 300GTSW Art 06158 68 7 Figure 7 10 Primary IGBT assembly 7 12 June 21 2012 June 21 2012 Figure 7 11 Output diode bus bar PRO WAVE 300GTSW Art 06159 PRO WAVE 300GTSW 76 Art A 06160 Figure 7 12 Main Transformer 7 14 21 2012 PRO WAVE 300GTSW Art 06161 45 05 45 D3 Figure 7 13 Internal Parts continued June 21 2012 7 15 PRO WAVE 300GTSW Art A 06162 14 Output diode assembly Figure 7 June 21 2012 7 16 PRO WAVE 300GTSW 28 43 46 27 25 Art A 06163 69 8 46 EX 70 43 76 75 Art 06164 Figure 7 16 03 04 assembly June 21 2012 7 17 PRO WA
37. and power levels present inside this unit Do not attempt to diagnose or repair unless you have training in power electronics measurement and troubleshooting techniques Sa Under no circumstances are field repairs to be attempted on printed circuit boards or other subassemblies of this unit Evidence of unauthorized repairs will void the factory warranty If a subassembly is found to be defective by executing any of the procedures in this Manual the subassembly should be replaced with a new one The faulty subassembly should then be returned to Thermal Dynamics through established procedures A WARNING ee ee Disconnect primary power at the source before disassembling the power supply Frequently review the Important Safety Precautions page 1 Be sure the operator 15 equipped with proper gloves clothing eye and ear protection Make sure no part of the operators body comes into contact with the workpiece or any internal components while the unit is activated EU c il June 21 2012 PRO WAVE 300GTSW 6 01 System Level Fault Isolation If none of the suggestions provided in Section 5 have solved the problem or corrected the faulty operation the next step is to isolate one or more of the internal subassemblies that may be defective WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had traini
38. 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 adduction 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 AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des tincellies et des projec tions 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 chauffe ment ou un incendie 9 Prot gez vous ainsi que les autres contre les tin celles 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 soi gneusement 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 gardez 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 te
39. 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 Arr tez le moteur avant de connecter ou de d con necter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule Utilisez la polarit correcte et de l accumulateur E AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSE MENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl te ment le bouchon 1 10 1 05 PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for
40. 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 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 frozen pipes 10 Remove stick electrode from holder or cut off welding wire at contact tip when not in use June 21 2012 PRO WAVE 300GTSW gt 2 4 WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag 1 Wear approved face shield or safety goggles Side shields recommended 2 Wea
41. if necessary 2 INPUT SELECTOR Easy Link switch is set to incorrect position for applied input voltage 208 230 460 model only a Verify primary source voltage and set INPUT SELECT switch to correct setting 5 2 WARNING Indicator is ON 7 Unit js in thermal shutdown mode a Allow cooling period of approximately five 5 minutes with the power ON Duty cycle should be reviewed To reset the WARNING indicator the power supply must be turned OFF then ON again 2 Input voltage is low a Measure input voltage and verify that it matches the INPUT SELECTOR Easy Link switch setting The length of the input power cable must be considered as there will be a considerable voltage drop along its length 3 Erratic input voltage spikes over tolerance will cause the warning light to come on for protection a Turn MCB off then on to reset the warning light Erratic or Improper Weld Output 7 Loose welding cable connections a Tighten all welding cable connections 2 Incorrect welding cable size a Use proper size and type of cable see Operating Manual 0 2514 3 Improper input connections a Refer to Section 3 1 Electrical Input Requirements page 3 1 4 Poor electrode condition a Replace electrode 2 If in GIAW mode check the condition of the tungsten electrode a Use the recommended 2 Thoriated tungsten 6 In GIAW mode incorrect argon gas flow a Verify that argon gas flow is correct ap
42. if a digital meter is not present in the unit CAUTION Before performing any portion of the procedure below make certain the unit 15 placed in the initial setup condition as described at the beginning of this section page 6 2 1 Place the AMPERAGE control in its minimum fully counterclockwise position 2 Connect the POSITIVE and NEGATIVE OUTPUT TERMINALS to a piece of metal separated by approximately three feet one meter 3 Connect the clamp on amperage meter or equivalent to the output loop between the POSITIVE and NEGATIVE OUTPUT TERMINALS 4 Place the power supply MAIN CIRCUIT BREAKER on the rear of the unit to the ON position After five 5 seconds the amperage meter will indicate approximately 5 Amps 5 Slowly turn the AMPERAGE control clockwise to the maximum of the power supply then counterclockwise back to 5 Amps as the control returns to its minimum position The amperage meter should indicate a continuous range of Amperes between the 5 Amps minimum and the 300 Amps maximum of the power supply 6 Place the power supply MAIN CIRCUIT BREAKER on the rear of the unit to the OFF position 7 Remove the dead short between the OUTPUT TERMINALS This completes the output load test If the results of any step differ from those above then refer to the various test procedures in this section to isolate the problem If the results are as expected then the power supply is giving th
43. insulation or other physical symptoms If there are no signs of physical damage conduct the procedure that follows i IGBT Inverter Q2 Auxiliary Transformer T3 TB2 Primary Lead IGBT Inverter 03 Input Diode Bridge D1 Driver Board PCB8 TB1 Primary Lead Art 06125 IGBT Inverter Q1 Figure 6 20 Top of power control assembly main circuit board removed 6 23 Power Control Assembly PCA Test Procedures WARNING Disconnect primary power at the source before performing these procedures This procedure requires a digital Volt Ohm meter that has a diode test scale This procedure will give a general indication of the condition of the PCA components a more conclusive test requires specialized equipment Therefore even if the results of these procedures check out as good one or more components may still be faulty If there is any doubt replace the faulty PCA component It is assumed that you are familiar with diode testing basics If not please refer to the Appendix June 21 2012 6 23 PRO WAVE 300GTSW 6 24 PCA Input Diode Bridge D1 Test Procedure Refer to figure 6 21 1 Select the Ohms scale the digital meter 2 Check CN14 on Main Circuit Board between pins 1 and 2 The resistance should read 44 Ohms Select the diode test setting on the digital meter Check the diodes between the following MAIN CIRCUIT BREAKER MCB wire R and TB6 on the Main Circuit Board MCB wire S
44. 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 June 21 2012 1 11 PRO WAVE 300GTSW 1 07 LIMITED WARRANTY LIMITED WARRANTY Thermal Arc Inc A Thermadyne Company hereafter Thermal Arc warrants to customers of itsauthorized distributors hereafter Purchaser that its products will be free of defects in workmanship or material Should anyfailure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PAR
45. 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 Association canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada 1R3 Safe Practices for Occupation and Educational Eye and Face Protection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 June 21 2012 PRO WAVE 300GTSW 1 06 DECLARATION OF CONFORMITY Manufacturer Victor Technologies Address 16052 Swingley Ridge Road Suite 300 Chersterfiedl 63017 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Direc tive 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 th
46. torch a Refer to torch parts list for part s requiring replacement and repair torch as necessary 2 Tungsten condition 15 poor a Replace electrode 6 Electrode too high off metal June 21 2012 PRO WAVE 300GTSW a Reduce stand off 7 Faulty Main Circuit Board 1 a Refer to the Main Circuit Board section 6 11 page 6 10 8 Faulty Current Transformer CT1 a With no welding arc established measure for OVDC between CN1 pins and 4 on PCB1 Replace CT1 if voltage is greater than 0 1VDC 9 Faulty High Frequency Unit a Refer to section 6 39 page 6 46 70 Faulty TIG Torch a Replace TIG torch 77 Work lead not connected a Verify all connections to torch and workpiece Lack of High Frequency Difficulty in Establishing an Arc 7 Dissipation of high frequency from torch cable or conductive gas hose a Be sure that the torch cable is not near any grounded metal Do not use conductive gas hose 2 Weld cable leakage a Check cables and torch for cracked or deteriorated insulation or bad connections Repair or replace necessary parts 3 Poor ground connection to power supply a Verify ground by trying to strike arc within one inch 2 54 of ground clamp Wall Fuse Circuit Breaker Trips When Turned ON 7 Input voltage over rated limit a Connect to proper line voltage 2 Shorted primary inverter components a Perform the PCA Input Diode Bridge Test section 6 24 page 6 24
47. 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 con us 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 1 Utilisez l quipement l ext rieur dans des aires ou vertes et bien ventil es June 21 2012 PRO WAVE 300GTSW 2 Sivous utilisez ces quipements dans un endroit con fin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable Arr tez le moteur avant de v
48. 3 White 2 oT TB1 3 3Y 1891 UUM 59 99 1891 eNUM LO 9129 1991 L3 1891 peu 23 BD 1491 HUM 99 1891 UUM PD 99 1891 belg v3 99 1991 921a indino NUM indino 4JO NO 9814 4o1su U L E HE als NE 818 oja 218 EIE 8 5 Line 3 Black Line 2 White Line 1 Red 24VDC Red 115V T3 115 PCB Common OV Black peog ov ov Gray Gas ON OFF Control Yellow 115V Gas ON OFF Control Violet ov Black 125V ov Black 250VAC Brown 250VAC Orange Thermal Detect Black IGBT Gate Drive G6 White Thermal Detect Black IGBT Gate Drive E6 Black IGBT Gate Drive G5 Blue IGBT Gate Drive E5 White jojn 80 From Brown 300Vpx Pulse Yellow 300VDC Supply Common o 12VDC Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary IGBT Gate Drive Secondary Overvoltage Signal 15V Pulse Red PCB Common PCB Common OV Blue Art A 06166 N 8809 1991 4 21 2012 PRO WAVE 300GTSW Brown VV aja 1
49. 418000 F1A541300 F1A611600 F1A611600 ront 10 6347 10 6347 0 398800 28 29 30 30 31 32 Front Panel 10 6347 10 5137 10 5137 10 5137 _ 4051100020 10 5236 10 5236 5200300070 10 5236 15 Pin Ribbon Cable 105234 10 5234 52003000500 12 Ribbon Cable 1 105235 10 5235 52003000600 36 10 5007 10 5007 10 5007 34910000400 36 1 10 5316 10 5316 10 5316 6784211290 10 5143 N A F1A540800 VA 10 5469 F1A540900 N A 10 5469 F1A540900 10 6320 10 6320 7000348300 10 2653 39 10 5088 570401600 40 C1 10 2270 10 2270 10 2270 4242213710 4 gt gt 515 oio 25 25 gt 3 5 37 37 37 38 gt 41 10 5228 10 5228 696500090 42 10 5149 10 5149 39100 43 10 5140 10 5140 10 5140 43460002101 44 45 46 PCBS 1 P0A339200 E6A490100 not shown Clip PCB Cover 6060242200 not shown Sheild 1 10 5484 10 5484 10 5484 J2B748200 Shield CE 1 N A 10 5488 N A J2B858600 53 206434 1 206062 745229 7 not shown 10 5080 10 5080 10 5080 _ 40511000600 gt gt 515 5 5 olo oio o o oio a a 6 olo oio o o 5 5 5 5 5 5 21 2012 7 3 PRO WAVE 300GTSW ITEM DESCRIPTION LOCATION not shown Digital Meter opt Screws 65 Snubber Circuit us Ba 0 67 Bus
50. 4VDC for 26 5 and the ON level of 11VDC for 21115 There is a 2 5 5 dead time before and after the ON time of each channel before the other goes through its OFF ON transition Refer to figure 6 7 1 Apply power to the unit and turn the MAIN CIRCUIT BREAKER MCB ON 2 Using an oscilloscope at the CN8 connector on the Main Circuit Board PCB1 measure the voltage between Q1 signal pairs Pin 1 and 2 Pin 4 and 5 3 Using oscilloscope at the CN9 connector on the Main Circuit Board PCB1 measure the voltage between Q2 signal pairs Pin 1 and 2 Pin 4 and 5 4 Using a voltmeter measure the voltage between signal pins 1 and 2 and pins 4 and 5 at connector CN8 The voltage between each pair of pins should 5 0 Switch the PROCESS SELECTOR switch to the TIG LIFT START position The voltage between both pair of pins should drop to 4VDC 5 Return the PROCESS SELECTOR switch to the STICK position 6 Using a voltmeter measure the voltage between signal pins 1 and 2 and pins 4 and 5 at connector CN9 The voltage between each pair of pins should be 5 0 Switch the PROCESS SELECTOR switch to the TIG LIFT START position The voltage between both pair of pins should drop to 4VDC If the results of any of these tests are incorrect replace the Main Circuit Board PCB1 June 21 2012 PRO WAVE 300GTSW c Art A 06115 Figure 6 6 Main Circuit Board Art A 06116 0
51. Bar Q1 Q2 to PCB 70 Bus Bar Q3 Q4 to FCH 1 Bus Bar Output Diodes 2 Bus Bar Output Diodes 3 Bus Bar Output Diodes 74 Bus Bar Output Diodes 75 Bus Bar 03 0410 FCH 6 ransformer to 7 Bus Bar 03 04 to output stud 8 PCB 11 PCB11 not shown Chassis not shown Acrylic board not shown R1 on main pcb not shown PCB CE PCB101 not shown Filter L1 not shown Filter CE L106 L107 not shown Filter CE L104 not shown Filter CE L102 L103 not shown Filter CE L104 L105 notshown Female Union CE not shown not shown not shown not shown not shown CN5 Plug 5pos not shown CN6 Plug 7pos not shown CN7 Plug 5pos not shown CN8 Plug 5pos CN9 Plug 5pos CN10 Plug 2pos CN13 Plug 3pos CN14 Plug 4pos CN18 Plug 3pos CN19 Plug 5pos PCB1 CN24 Plug 3pos PCB1 CN26 Plug 3pos PCB1 NNN NNN under main pcb PCB1 PCB1 PCB1 PCB1 PCB1 PCB1 PCB1 PCB1 PCB1 PCB1 PCB1 PCB1 ot shown E m 7 e 7 not shown not shown not shown not show not shown not shown not shown not shown not shown an not shown 7 4 0 1 1 2 1 1 4 5 1 2 2 1 1 1 1 1 1 208 230 380 415 230 460 37500 4244200710 4242113850 40305147200 300102820 3001026300 36600 10 5413 10 5413 10 5413 E6A419400 10 5414 10 5414 10 5414 E6A419500 10 5415 E6A419600 10 5447 E6A930600 10 5433
52. Bridge D1 4 Remove the two 2 screws securing the Auxiliary Transformer to the chassis To replace the Auxiliary Transformer reverse the removal steps above June 21 2012 6 39 PRO WAVE 300GTSW 6 35 Main Transformer Assembly 1 and 2 Test Procedure A WARNING Disconnect primary power at the source before performing this procedure Inspect the primary winding wires on both Main Transformers for breaks in the insulation signs of overheating or loose connections Check for continuity across the primary windings of both transformers To do this do the following 1 Remove the lugged leads from TB1 and TB2 See Figure 6 37 Q2 C2E2 T2 Primary Lead Green Mark Art A 06137 Q1 C2E2 T1 Primary Lead Green Mark Figure 6 37 Preparation f Art A 06138 2 To test the primary of T1 measure the continuity between Main Circuit Board connector CN8 pin 2 and the lugged transformer lead removed from 1 3 To test the primary of 2 measure the continuity between Main Circuit Board connector CN9 pin 2 and the lugged transformer lead removed from TB2 The secondaries of T1 and T2 cannot be isolated To test the parallel combination of secondaries 4 Measure the continuity between the connector CN7 pin 3 and CN5 pin 3 Replace the Main Transformer Inductor Assembly if no continuity is found in any of the windings or if there is evidence of overheating TB2 T2 Primary Lead
53. IHERMAL K OGTSW PRO WAVE Art A 06102 Version Issue Date June 21 2012 Manual No 0 2515 Operating Features 300 AC 460 LX p JHERMAL ARC K WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Arc product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 752 7621 or visit us on the web at www Thermalarc com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN 6000 COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is the Global Brand of Arc Welding Products for Thermadyne Industries Inc We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction Mining Automotive Engineering Rural and DIY Hobbysit We distinguish ourselves from our competition through market leading dependable b
54. OTE 8 receptacle Measure the voltage between test points TP8 and TPO to be 12VDC Measure the voltage between test points TP4 and TPO to be 5VDC Measure the voltage between test points TP5 and TPO to be 5VDC Set up the contactor closure circuit by removing the jumper from the REMOTE 8 receptacle Measure the voltage between test points TP8 and TPO to be 3 5VDC Measure the voltage between test points TP4 and TPO to be OVDC Measure the voltage between test points TP5 and TPO to be OVDC Measure between TPO and the test points below to verify the voltages given Art 06121 TP9 Figure 6 16 Front panel voltage test points PRO WAVE 300GTSW 1 Using ohmmeter check continuity from CN13 Pini and Pin with the input voltage selector switch in the 208 230 volt position 2 Using an ohmmeter check continuity from CN13 Pin 2 and Pin 3 with the input voltage selector switch in the 460 volt position 3 If any of the tests fail replace easylink switch on rear panel Panel Circuit Board PCB6 Replacement Refer to Figures 6 17 and 6 18 To remove the Front Panel Circuit Board 1 Remove the Main Circuit Board referring to page 6 13 2 Locate and remove five 5 screws from the Front Panel Circuit Board Shield securing them to the inside of the front panel of the unit gt FT 4 Figure 6 17 Front panel circuit board retaining screws BD Art A
55. Pint Brown chassis Pint Brown 12Vdc Power supply Ribbon common Ribbon 5Vdc Power supply Ribbon 5Vdc Power supply Ribbon 12Vdc Power supply Ribbon CN7 6 common Ribbon CN7 7 1 50 Output current detect Ribbon CN7 8 squarewave Output voltage detect Ribbon squarewave Ribbon 5Vdc Ribbon variable Ribbon squarewave Primary current detect Ribbon squarewave Ribbon squarewave Ribbon common Ribbon 5V on OV off Ribbon 0 12 HF on off Ribbon 0 12 Gas valve on off Ribbon 12 OV off torch switch Ribbon Ribbon CN8 10 Ribbon June 21 2012 PRO WAVE 300GTSW qe Ribbon Ribbon CN92 common Ribbon 09844 Resetsignal Ribbon CN97 common _ Pre charge control Ribbon CN99 Thyristor gate drive SV 230V input OV 460V input Tripping relay control Ribbon CN9 5 detected 5V Overvoltage detect June 21 2012 A 13 PRO WAVE 300GTSW APPENDIX 7 WIRE CHART AC IGBT GATE DRIVE PCB8 Connector Number CN1 1 CN1 2 CN1 3 250Vac CN2 1 CN2 2 not used CN2 4 CN2 5 CN3 1 squarewave common __ ________ ___ 80Vpk 300Vpk pulse 300Vpk common CN5 1 squarewave 15V pulse to fire super impose voltage CN5 2 common Meter Reading Comments 250Vac not used A 14 White Black hite Ribbon Ribbon Ribbon Ribbon Ribbon ibbon own Ye
56. RNING 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 ESS ME To clean the unit open the enclosure please refer to Section 6 3 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 E CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit June 21 2012 PRO WAVE 300GTSW 5 02 Basic Troubleshooting You should always attempt to isolate and fix a problem using this section first This section on basic troubleshooting will help you isolate faults and problems that are easily remedied without requiring that the power supply be opened or requiring specialized test equipment and procedures If the problem or fault cannot be corrected by following the recommendations in this section then proceed to Section 6 0 on Advanced Troubleshooting 5 03 Common Welding Operation Faults The following are some of the more common operating faults that occur during welding operations A Power Main power not connected Main power not turned on MAIN CIRCUIT BREAKER set of OFF position INPUT SELECTOR Easy Link Switch in wrong
57. Rotating the control clockwise increases the pulse frequency The two scales surrounding the control represent approximate actual values The pulse frequency is adjustable from 0 5 to 25 Hz in LOW and 10 to 500 Hz in HIGH 14 LED Voltage Amperage Display optional 15 Positive Terminal 50mm DIN style female receptacle 16 Negative Terminal 50mm DIN style female receptacle 17 8 Pin Receptacle Used for remote contactor and amperage controls 18 Output Gas Fitting Gas output fitting size 5 8 18 unf female 18 Output Gas Fitting European model European model gas output Accommodates 3 8 BSP monocable TIG torch NOTE revisions refer to the letter at the end of the serial number for this product Gas Solenoid The pre flow is fixed at 150ms On F revision and earlier units the post flow is automatically adjusted from 1 to 30 seconds by the position of the welding Amperage Control On G revision and later the unit has a separate post flow adjustment from 0 60 seconds independent of current setting 4 2 Sloper Sequence A Remote ON OFF switch closed Pre flow starts to flow In HF TIG mode HF and initial current is present after pre flow In LIFT TIG mode HF is not present Initial current is 1 5th of the welding current B Remote switch opened Current increases to welding current at the rate set by the UP DOWN Slope control Welding current is set by the A
58. SE This Parts nus 7 1 TOS RINS Se ue 7 2 7 04 Parts Pictures 000 7 6 TABLE OF CONTENTS APPENDIX 1 GENERAL INFORMATION A 1 APPENDIX 2 208 230VAC SINGLE VOLTAGE SINGLE THREE PHASE A 2 APPENDIX 3 208 230 460VAC 5110 4 APPENDIX 4 380 415VAC SINGLE VOLTAGE THREE PHASE A 6 APPENDIX 5 WIRE CHART MAIN BOARD PCB1 A 8 APPENDIX 6 WIRE CHART FRONT PANEL A 12 APPENDIX 7 WIRE CHART IGBT GATE DRIVE 8 A 14 APPENDIX 8 BOTTOM WIRING PLACEMENT A 15 APPENDIX 9 DIODE TESTING BASICS 1 mn dixe A 16 APPENDIX 10 METER CALIBRATION PROCEDURE A 18 PRO WAVE 300GTSW SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS WARNING 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 pr
59. TICULAR PURPOSE LIMITATION OF LIABILITY THERMAL ARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the pr
60. TRE MORTELLE 5 Veuillez installer cet quipement et le mettre la s il terre selon le manuel d utilisation et les codes nation Une d charge lectrique peut tuer ou br ler aux provinciaux et locaux applicables gravement L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le 6 Arr tez tout quipement apr s usage Coupez circuit d alimentation et les circuits internes l alimentation de l quipement s il est hors d usage de l quipement sont aussi sous tension d s ou inutilis la mise en marche En soudage automatique 7 N utilisez que des porte lectrodes bien isol s Ne ou semi automatique avec ce dernier le jamais plonger les porte lectrodes dans l eau pour rouleau ou la bobine de fil le logement des les refroidir Ne jamais les laisser trainer par terre ou galets d entrainement et toutes les pi ces sur les pi ces souder Ne touchez pas aux porte m talliques en contact avec le fil de soudage lectrodes raccord s deux sources de courant en Sont sous tension Un quipement inad quate m me temps Ne jamais toucher quelqu un d autre ment install ou inad quatement mis la terre avec l lectrode ou le porte lectrode est dangereux 8 N utilisez pas de c bles lectriques us s endomma 06 mal piss s ou de section trop petite 1 6 June 21 2012 9 N enroulez pas de c bles lectriques autour de votre corps 10 N utilisez qu un
61. VE 300GTSW This page left blank intentially 7 18 June 21 2012 PRO WAVE 300GTSW APPENDIX 1 GENERAL INFORMATION Note the model and specification number shown on the equipment nameplate Locate these numbers in the model and specification number columns below Useonly those diagrams and instructions that are applicable Specification Number Appendix Location 103024 208 230VAC Single Voltage Single Three Phase 2 103025 08 230 460VAC Single Three Phase 103038 80 415VAC Single Voltgae Three Phase June 21 2012 1 PRO WAVE 300GTSW APPENDIX 2 208 230VAC SINGLE VOLTAGE SINGLE THREE PHASE Wy 208 230 460VAC PCB4 PCBS Single Three Phase CIE E2 Gi C21E1 a Ground purs
62. ad capable of the maximum current of the power supply 3 Turn on the power supply 4 To verify perform the following tests a Set the preset to minimum amps Load voltage under this test should be approximately 1 to 2 volt b Set the preset to 150 amps Load voltage under this test should be approximately 20 to 25 volts Set the preset to 300 amps Load voltage under this test should be approximately 25 to 30 volts Panel Meter amperage versus measured amperage reading maybe 5 depending on the load and length of cables A 18 June 21 2012 This page left blank intentially THE AMERICAS Denton TX USA U S Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Miami FL USA ales Office Latin America 1 954 727 8371 1 954 727 8376 Ontario Canada Customer Care 1 905 827 4515 1 800 588 1714 tollfree 1700 EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 awang Malaysia ustomer Care 603 6092 2988 603 6092 1085 10002 Melbourne Australia ustralia Customer Care 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 Internation
63. age 6 3 2 Loose connection on Main Circuit Board 1 a Verify all connections 3 Faulty Main Circuit Board PCB1 a Verify gate drive signals from Main Circuit Board by performing Gate Drive Enable Signal test in section 6 11 page 6 10 4 Faulty output diodes a Perform PCA Output Diode test in section 6 29 page 6 32 2 Faulty IGBT Inverter Module s a If there is weld output in AC output mode but not DC perform PCA IGBT Inverter test on Q3 section 6 26 page 6 26 Unit will not change polarity from AC to DC or DC to AC a Turn the post flow control to minimum and try again The post flow circuit must be timed out before the unit will recognize a change in status 5 5 PRO WAVE 300GTSW This page left blank intentially 5 6 June 21 2012 SECTION 6 ADVANCED TROUBLESHOOTING If you are here all of the troubleshooting suggestions in Section 5 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 measurements on the various subsystems within the power supply and replace those subsystems that prove faulty CAUTION Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment A WARNING There are extremely dangerous voltage
64. al Ph 61 3 9474 7508 Fax 61 3 9474 7488 UP hanghai China ales Office 486 21 64072626 86 21 64483032 ingapore ales Office 65 6832 8066 65 6763 5812 179 C0 cn VICTOR TECHNOLOGIES INNOVATION TO SHAPE THE WORLD U S Customer Care 800 426 1888 Canada Customer Care 905 827 4515 International Customer Care 940 381 1212 2012 Victor Technologies International Inc www victortechnologies com Printed in U S A
65. and TB6 on the Main Circuit Board MCB wire T and TB6 on the Main Circuit Board MCB wire R and CN14 pin 4 on the Main Circuit Board MCB wire S and CN14 pin 4 on the Main Circuit Board MCB wire and CN14 pin 4 on the Main Circuit Board 6 25 PCA Input Diode Bridge D1 Replacement Procedure Refer to figure 6 21 To remove the Input Diode Bridge D1 do the following 1 Remove the Main Circuit Board PCB1 per page 6 13 Remove the input power and sensing lugged wires from the input terminals R and two RED S and two WHITE RED input line and BLACK Remove screws from all terminals with lugged wires and the corner bus bar Remove the two screws that secure the Input Diode Bridge to the main chassis frame 5 Slide the Bridge out from under the bus bar To replace the Input Diode Bridge D1 do the following 1 Spread a light coating of thermal compound on the bottom surface of the Bridge Slide the Bridge under the bus bar Reverse the remaining removal steps above When replacing the screws that secure the Bridge to the chassis make sure both screws are started before tightening them June 21 2012 21 2012 PRO WAVE 300GTSW Red Input Line T 5 aE 2 E 2 j 4 Y C s bom Junction Thyristor dd Thyristor Cathode Diode Anode Art A 06126 Figure 6 21 Power control assembly input diode brid
66. 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 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information June 21 2012 PRO WAVE 300GTSW 1 02 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard 749 1 from American Welding Society 550 N W LeJeune Rd 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 American 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 Associa
67. ay be helpful to connect CN2 and CN5 before seating the board fully back onto the chassis Retaining Screw CN3 Retaining Screw CN2 gt E Retaining Screw Retaining Figure 6 49 AC waveform circuit board PCB8 June 21 2012 PRO WAVE 300GTSW 6 44 Sequence Timing Diagrams HF TIG Mode Figure 6 50 shows the HF TIG timing waveforms with the SLOPE control ON and OFF SLOPE OFF mode SLOPE ON mode On Off On Off On Off On Off Output Contactor Shielding Gas Output Current Art A 06145 Figure 6 50 HF TIG mode timing Lift TIG Mode Figure 6 51 shows the LIFT TIG timing waveforms with the SLOPE control ON and OFF SLOPE OFF mode SLOPE ON mode On Off On Off On Off On Off Output Contactor Short Release Electrode Shielding Gas Output Current Art A 06146 Figure 6 51 LIFT TIG mode timing Current Waveform on PULSE ON mode 5 Art 06147 Figure 6 52 LIFT TIG mode pulse on current waveform June 21 2012 6 53 PRO WAVE 300GTSW SPOT Mode Figure 6 53 shows the SPOT timing waveforms with the SLOPE control OFF and ON Works only in HF TIG mode SLOPE OFF mode SLOPE ON mode On Off On Off On Off On Off Output Contactor
68. control device connected to the REMOTE 8 receptacle and contact closure between pins 2 and 3 measure the voltage between the gas solenoid valve terminals If the voltage is 24VDC and the solenoid does not operate replace the solenoid valve If the voltage is low or not present replace the Main Circuit Board PCB1 There is a 150ms delay built into the circuit before the voltage will be there 6 14 High Frequency Test 1 Place the PROCESS SELECTOR Switch in the STICK position 2 Jumper pins 1 and 5 on the CN7 plug Apply power to the unit 3 If the high frequency buzz is heard coming from the HF Unit the Main Circuit Board PCB1 should be replaced If no sound is heard coming from the HF Unit the HF Unit should be replaced June 21 2012 PRO WAVE 300GTSW 6 15 Main Circuit Board PCB1 Replacement Procedure To remove the Main Circuit Board 1 Locate connectors CN7 CN8 and CN9 at the top edge of the Front Panel Circuit Board 2 Gently pull up on the retainer bar on each side of each connector to release the ribbon cable in the connectors 3 Remove the ribbon cable by gently pulling straight up on the ribbon cable 9 PCB6 CN8 PCB6 Art 06111 CN7 PCB6 CN13 d Figure 6 8 Power supply voltage connector locations June 21 2012 6 13 PRO WAVE 300GTSW 4 On the Main Circuit Board remove the screw from TB12 and remove the GREEN ground wire lug from the terminal figure 6 9
69. crew if the printed circuit board is to remain with the IGBT Inverter being removed PCB4 Q1 PCB5 02 Remove the screw from the terminal with the double bus bar Again replace this screw if the printed circuit board is to remain with the Inverter being removed PCB4 on Q1 or PCB5 on Q2 Be sure the screw goes through only the hole in the bus bar connected to the printed circuit board PCB4 or PCBS Auxiliary Transformer T3 IGBT Inverter Q3 Driver Board PCB8 IGBT Inverter Q1 4 Remove the two 2 screws securing the Inverter to the main chassis frame To replace either Inverter Q1 or Q2 do the following 1 Spread a light coating of thermal compound on the bottom surface of the Inverter 2 Slide the Inverter in place under the bus bar coming from the Input Diode Bridge 3 Reverse the remaining removal steps above When replacing the screws that secure the Inverter to the chassis make sure both screws are started before tightening them IGBT Inverter Q2 TB2 Primary Lead Rout Diode Bridge D1 TB1 Primary Lead Art 06125 Figure 6 26 IGBT Inverters Q1 and Q2 June 21 2012 PRO WAVE 300GTSW THIS PAGE INTENTIONALLY LEFT BLANK June 21 2012 6 29 PRO WAVE 300GTSW 6 28 PCA IGBT Inverter 03 04 Replacement Procedure Refer to figure 6 27 To remove IGBT Inverters Q3 Q4 do the following 1 Remove the Output Inductor Assembly refer to the section further
70. djusted with front panel controls repair or replace remote control device 2 Faulty Front Panel Circuit Board PCB6 a Replace PCB6 Refer to section 6 16 page 6 18 June 21 2012 M Limited Weld Output 7 Poor primary voltage a Check primary input voltageis within 10 of nominal voltage i e 230 10 2 Faulty Current Transformer CTT a Check continuity and signals to current transformer CT Refer to tests in section 6 05 page 6 4 and section 6 20 page 6 22 Erratic or Improper Weld Output 7 Loose welding cable connections a Tighten all welding cable connections 2 Improper setup a Check for proper connection of input power b Perform Front Panel Test Point Voltage procedure section 6 17 page 6 19 3 Faulty Remote Device a Check all remote devices and repair or replace if necessary 4 Faulty Current Transformer a Check continuity and signals to current transformer CT Refer to section 6 05 page 6 4 measuring between pins 3 and 4 and section 6 20 page 6 22 5 Tungsten condition is poor causing discoloration of workpiece a Replace electrode June 21 2012 PRO WAVE 300GTSW 0 No Weld Output Fan Not Operating WARNING Indicator OFF 7 Line voltage too low a Verify that input voltage matches setting on rear panel INPUT SELECTOR switch b Verify the INPUT SELECTOR Easy Link switch is functioning properly by performing test in section 6 05 p
71. 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 overheating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperage are increased beyond the rated output the duty cycle will decrease A Exceeding the Duty Cycle Ratings will cause the Thermal Overload Protection Circuit to become energized and shut down the output until the unit has cooled to normal operating temperature WARNING Continually exceeding the Duty Cycle Ratings can cause damage to the welding power source To calculate duty cycle current rated current x rated duty cycle Art 06105 desired duty cycle i e At the 300A rated output current and 25 rated duty cycle the operator wants to work on a 50 duty cycle The maximum allowable current draw is 300A x 25 50 current current 90 000 x 0 5 current 45 000 Art A 06106 current 212 1A June 21 2012 PRO WAVE 300GTSW 2 7 PRO WAVE 300GTSW This page left blank intentially 2 8 June 21 2012 SECTION 3 INSTALLATION 3 01 Electrical Input Connections A 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 tag out procedures Lockout
72. e 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 e 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 e CENELEC 50199 EMC Product Standard for Arc Welding Equipment e ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 50192 EN50078 applicable to plasma cutting equipment and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the 5 mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides e Extensive product design verification is conducted at the manufacturing facility as part 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
73. e black gas hose 7 Remove the YELLOW and VIOLET lugged wires from the gas solenoid 8 Disconnect CN1 from IGBT Inverter 03 04 9 Disconnect the lugged BLUE and GRAY wires from the HF Unit 10 Follow the RED BLACK twisted wire pair from the fan through the hole in the chassis Cut cable ties as needed to locate a section of the wire pair where it can be cut and spliced together easily when the fan assembly is replaced Cut the RED BLACK wire pair it connects to CN2 with the YELLOW and VIOLET pair from the gas solenoid 1 Remove the two 2 screws securing the fan assembly to the front panel Slide the fan assembly back slightly and out toward the left side of the unit away from the R6 assembly To replace the fan reverse the removal steps above June 21 2012 PRO WAVE 300GTSW Output Bolt Positive E is Transformer Output Bus Bar Art A 06124 Junction Hardware IGBT Inverter Q3 o Figure 6 42 Output bus bar CT assembly IGBT Inverter 03 04 Driver Board CN1 y Art 06140 86 Topscrew R6 Fan Assembly Fan Retaining Screw Figure 6 43 Cable ties and R6 on right side of unit June 21 2012 6 45 PRO WAVE 300GTSW 6 39 HF Unit Test and Replacement Procedures HF Unit Test Procedure 1 Place the PROCESS SELECTOR Switch in the STICK position Jumper pins 1 and 5 on the CN7 plug Apply power to the unit If the high frequency buzz is heard comin
74. e bonne prise de masse pour la mise la terre de la pi ce souder 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 12 V utilisez que des quipements en bon tat R parez ou remplacez aussit t les pi ces endommag es 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 14 Portez un harnais de s curit si vous travaillez en hauteur 15 Fermez solidement tous les panneaux et les capots PRO WAVE 300GTSW JE 4 AVERTISSEMENT LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX ET LA PEAU LE BRUIT PEUT EN DOMMAGER 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 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI 749 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 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s Entourez l aire de soudage de rideaux ou de cloi sons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc Portez des v tements en mat riaux
75. e proper output 6 6 6 07 LIFT START Circuit Test This test verifies proper operation of the LIFT START circuit A clamp type amperage meter or equivalent meter capable of reading approximately 20A full scale and a digital voltmeter capable of indicating 20VDC full scale will be needed for this test RS CAUTION Before performing any portion of the procedure below make certain the unit 15 placed in the initial setup condition previously described page 6 2 1 Make sure the MAIN CIRCUIT BREAKER MCB is turned OFF 2 Set the PROCESS SELECTOR switch to LIFT START TIG mode 3 Connect a digital voltmeter between the POSITIVE and NEGATIVE OUTPUT TERMINALS of the unit Set the meter to indicate Volts DC 4 Connect a jumper between pins 2 and 3 of the REMOTE 8 connector or if a remote contactor is connected close it Ensure that the remote device is not faulty 5 Place the power supply MCB on the rear of the unit to the ON position After five 5 seconds the voltmeter will indicate approximately 6 volts open circuit 6 Turn off the power supply MCB 7 Connect the POSITIVE and NEGATIVE OUTPUT TERMINALS to a piece of metal separated by approximately three feet one meter 8 Connect a jumper between pins 2 and 3 of the REMOTE 8 connector or if a remote contactor is connected close it 9 Place the power supply MCB on the rear of the unit to the ON position After five 5 seconds the
76. ead junctions June 21 2012 6 33 PRO WAVE 300GTSW 3 Remove hardware at Coupling Coil Bus Bar junction Remove bus bar Figure 6 31 Remove the compression nut from the gas inlet fitting on rear panel and move gas line away from Main Transformers Figure 6 31 Remove the two 2 screws that secure Main Transformer 1 and 2 to their metal mounting brackets Allow the transformers to rest on the work surface Figure 6 32 Remove the two metal mounting brackets to expose the output diodes Remove the bus bar s and filter network s attached to the terminals of the output diode s to be replaced Output Diodes shown in Figure 6 33 Art 06132 Brown Wire Gray Wire Y Cut cable tie 8 Remove the two 2 screws securing the output diode to the chassis To replace the Output Diodes D2 D5 do the following 1 Spread a light coating of thermal compound on the bottom surface of the Diode Assembly 2 Reverse the remaining removal steps above When replacing the screws that secure the Diode s to the chassis make sure both screws are started before tightening them Inductor Coupling Coil Junction Gas Inlet w Black Lugged Wires Figure 6 31 Preparation Main transformer lead junctions June 21 2012 PRO WAVE 300GTSW IGBT Inverter Q3 T1 T2 Mounting Brackets Art A 06133 Art A 06134 Figure 6 33 Output diodes D2 D5 June 21 2012 6 35 PRO WAVE 300GTSW
77. enoid valve 2 Remove the compression nut securing the black gas line to the solenoid valve 3 Remove the C retaining ring from the gas input fitting on the exterior of the Front Panel 4 Remove the gas solenoid valve from the unit To replace the gas solenoid valve reverse the above steps Ring Solenoid Yellow Top Violet SOU Art 06142 Figure 6 47 Gas solenoid valve June 21 2012 PRO WAVE 300GTSW 6 42 IGBT Inverter 03 04 Driver Circuit Board PCB8 Test Procedure Refer to figure 6 48 1 Locate and remove connector CN1 on the IGBT Inverter 03 04 2 Using a digital meter on the diode scale test for diodes on the CN1 connector plug between pin pairs 1 2 and 4 5 Shorted readings indicate that the IGBT inverter Q3 Q4 Driver Circuit Board PCB8 should be replaced CN1 Art 06143 Figure 6 48 Location of CN1 IGBT inverter 03 04 driver board June 21 2012 6 51 PRO WAVE 300GTSW 6 43 IGBT Inverter 03 04 Driver Circuit Board PCB8 Replacement Procedure Refer to figure 6 49 To remove do the following il 2 3 4 Remove the Main Circuit Board page 6 13 Remove connector CN1 CN2 and CN4 from PCB8 Cut cable ties securing ribbon cable at CN3 to GREEN ground wires Remove the four 4 screws securing PCB8 to the chassis As the board is lifted off the chassis disconnect connector CNE To replace PCB8 reverse the removal steps above It m
78. etect 15 Contactor Control 2 24VDC Orange 5 Input Changeover Control 14 Contactor Control 1 GND Red gt 12VDC 13 Case Ground Green gt PWM Gate Drive 12 Amperage Control Wiper 0 4VDC Gray gt Gate 11 Amperage Maximum Violet gt Changeover Control 10 o 38 GND Blue gt Input Changeover Control 9 2 95 Amperage Control 12VDC Yellow Torch Switch Control 8 Case Ground Brown Output Short Circuit Detect 5 2 gt 4 gt Primary Current Detect 3 gt Primary Current Detect 2 lo Case Ground Brown Primary Current Detect 2 gt 1 1 9 lt 977 gt Thermal Control 11 1 gt Thermal Control 10 Output Voltage Detect 2 gt 9 1 2 3 4 5 6 7 8 gt Output Voltage Detect 8 Output Current Detect 7 Front View gt PCB Common 6 9 gt 12VDC 5 gt 5VDC 4 gt 5VDC 3 PCB Common gt 12VDC 2 gt 1 G lt _H To pops Art A 06165 Torch Control Pink 2 lt T ch Control Yellow I K June 21 2012 PRO WAVE 300GTSW APPENDIX 3 208 230 460VAC SINGLE THREE PHASE 208 230VAC Single Voltage Single Three Phase Ground peu Single Phase Input Diode Black Bridge D1 a Line 1 Black R White Line 3 White s gt s 2 Orange Line 2 gt C1 Three Phase Bus Bar S MCB Line 1 Black ISR Line
79. everse 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 Art A 06015 Anode Cathode Forward Bias Diode Test June 21 2012 June 21 2012 PRO WAVE 300GTSW Reverse Bias Diode Not Conducting Art A 06016 Cathode Reverse Bias Diode Test A 17 PRO WAVE 300GTSW APPENDIX 10 METER CALIBRATION PROCEDURE The digital meter Cat 10 4000 calibration is controlled by a microprocessor inside the machine and adjusts for variations in calibration If you suspect a problem with the meter due to damage etc you can check the calibration of the meter by the following test procedure below Make sure the remote voltage and amperage meters are calibrated and can measure frequencies above 42K Hz AMPERAGE MEASUREMENT Stick mode Under load the preset voltage setting is arbitrary and is not adjustable Under load the Panel meter voltage reading versus the actual voltage reading maybe 5 dependent on the arc length and the combines length of the negative and positive welding leads Preset voltage is used for MIG operation and is valid on the LM300 and 400GMS AMPERAGE TEST 1 Set controls for STICK mode ARC CONTROL minimum HOT START minimum 2 Connect the negative and positive output terminals to a lo
80. g bracket To replace Main Transformers 1 or T2 reverse the removal steps NOTE For proper phase connections to 2 the primary leads marked with GREEN paint connect to the IGBT Inverter terminals Also note the lead routing through the ferrite ring 11 Refer to figure 6 38 T1 T2 Secondary Lead Junction Art A 06131 T1 T2 Secondary Lead Junction D center tap leads bent upward two black lugged leads to CN7 1 and CN5 3 Figure 6 39 Preparation for removal of main transformers T1 T2 June 21 2012 PRO WAVE 300GTSW 6 37 Output Inductor Assembly Test and Replacement Procedure Replacement Procedures Refer to Figures 6 40 and 6 41 Test Procedure To remove the Output Inductor Assembly 1 Inspect the Output Inductor Assembly for signs 1 Remove the four 4 bolts and hardware from the of overheating or loose connections Output Diode Inductor Assembly junctions at W X Y and Z 2 Check for continuity through the Inductors by measuring between pairs of test points W and 2 Cut the middle cable tie securing the BLACK and and 7 Refer to figure 6 40 gas hose wire harness to the Output Inductor Assembly lead Y Replace the Output Inductor Assembly if there is no continuity or if there is evidence of overheating 3 Remove the compression nut on the gas inlet on the rear panel Move the gas hose wire harness to clear the Output Inductor Assembly 4 Cut two 2 cab
81. g from the HF Unit the Main Circuit Board PCB1 should be replaced If no sound is heard coming from the HF Unit the HF Unit should be replaced HF Unit Replacement Procedure To remove the HF Unit 1 Remove the Output Inductor Assembly per section 6 37 page 6 42 Remove the Output Bus Bar CT Assembly by removing the bolt inside the POSITIVE OUTPUT TERMINAL and the two screws holding the bus bar to 03 04 Remove the connector from Remove the Coupling Coil by removing the bolt inside the NEGATIVE OUTPUT TERMINAL and hardware from the bus bar T1 T2 center tap junction Disconnect BLACK wires to the HF Unit Remove the lugged wires from the AC1 and AC2 terminals Remove the two 2 screws that secure the HF Unit to the chassis To replace the HF Unit 1 3 Apply a liberal amount of thermally conductive grease to the bottom of the new HF Unit Hold the new HF Unit against the chassis while you replace the two screws that hold the HF Unit onto the chassis Be sure to orient the new HF Unit similar manner to the one just removed with the AC1 AC2 terminals and resistor R1 toward the front of the unit Reverse the remaining removal steps June 21 2012 21 2012 HF Unit PRO WAVE 300GTSW E TEETE AC1 AC2 Coupling Coil Connections Figure 6 44 HF Unit replacement PRO WAVE 300GTSW 6 40 HF Coupling Coil Test and Replacement Procedures HF Coupling Coil Test
82. ge D1 PRO WAVE 300GTSW 6 26 IGBT Inverter Test Procedure Refer to figures 6 22 and 6 23 The IGBT Inverter sections contain four IGBT transistor diode assemblies Q1 Q2 Q3 and Q4 These can be tested with the power OFF to verify their proper function IGBT Inverter 02 Auxiliary Transformer T3 TB2 Primary Lead gt HS JE TRE IGBT Inverter Q3 Driver Board PCB8 1 Primary Lead Art A 06125 IGBT Inverter Q1 Figure 6 22 Top of power control assembly IGBT s Inverter 03 04 Art A 06127 HF Unit Coupling Coil Leads Figure 6 23 Power control assembly IGBT inverters June 21 2012 PRO WAVE 300GTSW Power OFF Test Procedure T Pin 5 1 Set diode test scale on the digital meter AREE 2 For Q1 check the diodes between did TB3 and TB1 4 and TB1 3 For Q2 check the diodes between Red CN8 PCB1 TB5 and TB2 Orange CN9 PCB1 TB6 and TB2 1 8 To check the gate drive resistances for 01 and Q2 unplug CN8 and CN9 from the MAIN PCB Should measure 2 18kW CN8 CN9 plug PIN 1 to PIN 2 CN8 CN9 plug PIN 4 to PINS Figure 6 24 Plug orientation for IGBT inverter power 4 For 03 04 check the diodes between OFF test White quick check can be made across the POSITIVE For 03 04 refer to figure 6 25 then and NEGATIVE output terminals Set the meter to ohms and check t
83. hapter 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 A WARNING gives information regarding possible personal injury CAUTION WARNING A CAUTION refers to possible equipment damage NOTE A NOTE offers helpful information concerning certain operating procedures Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number for your area given in the back cover Include the Service Manual number and equipment identification numbers Electronic copies of this manual can also be downloaded 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 June 21 2012 PRO WAVE 300GTSW 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container Record these numbers on the bottom of page 1 for future reference 2 03 Receipt Of Equipment
84. he resistance across the weld terminals and the reading should 7 With the digital meter on the diode test scale measure between bus bars A B and B C be 2 5kW 8 On PCB1 mounted to 03 04 there are 4 sets of F 4 check the di t points E1G1 22062 E3G3 E4G4 Check each of these with a meter diode scale short is bad Brown wire on the filter choke to the POSITIVE indication If a short is detected remove the bus OUTPUT TERMINAL bars and test individually to determine which is Gray wire on the filter choke to the POSITIVE bad 03 or 04 OUTPUT TERMINAL 6 component on the 03 04 gate board PCB9 is damaged then the Driver PCB PCB8 should be checked A Disconnect CN2 from PCB8 B Check the gate resistance on PCB9 between 1 to G1 and E2 to G2 Reading should be 1 1kW C Check gate drive on PCB8 at CN2 between CN2 1 to CN2 2 and CN2 4 to CN2 5 Reading should be 1kW Art A 06129 Figure 6 25 Q3 Q4 IGBT inverter measurement points June 21 2012 6 27 PRO WAVE 300GTSW 6 27 PCA IGBT Inverters 01 and 02 Replacement Procedure Refer to figure 6 26 To remove either of the IGBT Inverters Q1 or Q2 do the following 01 is located on the right side of the unit Q2 on the left as you face the front panel of the power supply i Remove the Main Circuit Board per page 29 2 Remove the T1A or T2A heavy lugged lead depending on which Inverter you are removing Replace this s
85. ignifuges et du rables laine et cuir et des chaussures de s curit Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev Dimension d lectrode ou Op ration de coupage Epiasseur m tal ou 222 filtre oculaire Intensit de courant Brassage ao toutes conditions SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE SOUDAGE selon AWS 8 2 73 Soudage l arc sous gaz au chalumeau avec fil plein GMAW Dimension d lectrode ou Op ration de coupage Nuance Epiasseur de m tal ou ie filtre oculaire Intensit de courant ou soudage Brassage fort au chalumeau Oxycoupage toutes conditions mince moins de 1 po 25 mm Soudage l arc sous gaz avec lectrode de tungst ne GTAW m taux non ferreux toutes conditions toutes conditions 1 6 po 25 150 mm pais plus de 6 po 150 mm Soudage l hydrog ne atomique AHW Soudage l arc avec lectrode de carbone CAW toutes conditions toutes conditions Soudage aux gaz pais Soudage l arc avec lectrode enrobees SMAW Soudage l arc Plasma PAW toutes dimensions moins de 1 8 po 3 mm 4015 Gougeage Ar Nc avec lectrode de carbone de 12 po 34 12mm pus de
86. in Advanced Troubleshooting Remove the Output Bus Bar CT Assembly by removing the bolt inside the POSITIVE OUTPUT TERMINAL and the two screws on the terminals of Q3 Q4 holding the Output Bus Bar IGBT Inverter bus bar to IGBT Inverter Disconnect the lugged wires at terminals AC1 and AC2 on the HF Unit Disconnect connector CN1 on IGBT Inverter 03 04 Remove the four 4 screws securing 03 04 to the chassis Bolt Positive Output Current Transformer To replace either Inverter 03 04 do the following 1 Spread a light coating of thermal compound on the bottom surface of the Inverters Reverse the remaining removal steps above When replacing the screws that secure the Inverter to the chassis make sure all screws are started before tightening them It may be helpful to connect CN2 and CN5 before seating the board fully onto the chassis Output Bus Bar Art A 06124 ET gt key 3 xL 151 gt IGBT Inverter 03 Junction Hardware Figure 6 27 IGBT Inverter Q3 June 21 2012 PRO WAVE 300GTSW Art A 06127 HF Unit IGBT s Coupling Coil Leads Inverter 03 04 Figure 6 28 IGBT Inverter Q3 Q4 June 21 2012 6 31 PRO WAVE 300GTSW 6 29 PCA Output Diodes D2 D5 Test Procedure A WARNING Disconnect primary power at the source before performing this procedure Refer to figure 6 29 below The output
87. is c a ds 5 1 5 02 Basic Troubleshooting 5 1 5 03 Common Welding Operation Faults 5 1 5 2 SECTION 6 ADVANCED TROUBLESHOOTING 6 1 6 01 System Level Fault 6 1 6 02 Opening the ECHO Me el d 6 2 Set p amp 6 2 6 04 Easy Link Fault Isolation Test 208 230 460VAC Model only 6 3 6 05 Power Supply Voltage names 6 4 6 00 Qutp t Lodd M RR E 6 6 6 07 LIFT START Circuit Test urnes 6 6 TABLE OF CONTENTS 6 08 High Frequency START Circuit Test i c etes 6 7 6 09 Subsystem Test Preparation 6 8 6 10 Main Circuit Breaker MCB Replacement 6 8 6 11 Main PCB1 Gate Drive Enable Signal 6 10 E RERO RENDERE 6 12 6 13 Gas di nur 6 12 p 14 High FREQUENCY Ru Rc ask 6 12 6 15 Main Circuit Board PCB1 Replacement
88. ks or severe burns The electrode and work circuit is electrically live whenever the output is The input power circuit 7 Use fully insulated electrode holders Never dip holder machine internal circuits are also live when in water to cool it or lay it down on the ground or the power is on In semiautomatic or automatic work surface Do not touch holders connected to two wire welding the wire wire reel drive roll welding machines at the same time or touch other housing and all metal parts touching the people with the holder or electrode weing are electrically live 8 Do not use worn damaged undersized poorly installed or improperly grounded equipment spliced cables 1 Do not touch live electrical parts 10 the workpiece a good electrical earth 2 Wear dry hole free insulating gloves and body ground protection 11 Do not touch electrode while in contact with the work 3 Insulate yourself from work and ground using dry ground circuit insulating mats or covers 12 Use only well maintained equipment Repair or replace damaged parts at once June 21 2012 1 1 PRO WAVE 300GTSW 13 confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place
89. l 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 10 0122 l lectrode du porte lectrode ou coupez le fil au tube contact lorsqu inutilis apr s le soudage 11 Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque tj 2 AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRU LANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des par ticules 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 recomman d s 2 Portez des v tements appropri s pour prot ger la peau June 21 2012 AVERTISSEMENT LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endomma g es peuvent exploser Comme 165 bouteilles font normalement partie du proc d de soud age traitez les avec soin 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
90. le ties that form an X which secure the Coupling Coil to the frame of the Output Inductor Assembly Figure 6 41 5 Remove the four 4 screws that secure the frame of the Output Inductor Assembly to the main chassis frame 6 Pull the Output Inductor Assembly out of power supply To replace the Output Inductor Assembly reverse the removal steps above Inductor Coupling Coil Junction Gas Inlet 7 Gray Wire Cut cable tie Black Lugged Wires Figure 6 40 Output inductor assembly test points 6 42 June 21 2012 PRO WAVE 300GTSW gt 0010 5 13 Cable ties to cut Art 06139 Figure 6 41 Coupling coil cable ties June 21 2012 PRO WAVE 300GTSW 6 38 Fan Assembly Replacement Procedure Refer to figures 6 42 and 6 43 To remove fan The 1 Remove the Output Inductor Assembly per section 6 37 page 6 42 2 Remove the bolt inside the POSITIVE OUTPUT TERMINAL and the hardware from the Output Bus Bar IGBT Inverter Q3 Q4 junction 3 Disconnect the connector from the Current Transformer and remove the Output Bus Bar CT Assembly 4 Cut the cable ties securing wiring harnesses to both screws that secure the fan assembly to the front panel next steps free the wiring harness gas hose to allow access to the fan retaining screws Figure 6 43 5 Loosen the top screw securing R6 to the front panel to allow R6 to rotate downward 6 Remove the compression nut on both ends of th
91. line 2 WHITE and line 3 RED input conductors to a de energized line disconnect switch 3 Use Table 3 1 below as a guide to select line fuses for the disconnect switch Voltage Amperes 4 Single Phase 208 280 208 230 60 1 5 208 230 460 208 230 60 125 23 460 75 Table 3 1 Fuse Size Selection NOTE Fuse size 15 based on not more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit When the MAIN CIRCUIT BREAKER is turned on the inrush circuit provides a pre charging of the input capacitors SCR s in the Power Control Assembly PCA will turn on after the input capacitors have charged to full operating voltage after approximately 5 seconds Ground Conductor Ground Terminal Line Fuse PRIMARY POWER Line Disconnect Switch IITTTTITTITITTITTTTTTITTTITITETITI Line Fuse Art A 06107 Welding Power Supply Power Cable Figure 3 1 Electrical input connections 3 2 June 21 2012 SECTION 4 OPERATION 4 01 Operator Controls 1 Amperage Control The Amperage Control selects the desired amperage within the entire range of the welding power source Rotating this control in a clockwise direction inc
92. llow Gray E White Black Bie Ribbon Ribbon Ribbon Ribbon Yellow Blue June 21 2012 June 21 2012 PRO WAVE 300GTSW APPENDIX 8 BOTTOM WIRING PLACEMENT DIAGRAM White on lower Gray to bus bar in center diode bus bar rear of unit Black Black and Blue Wires Art 06168 Brown to outside White to outside FCH connection FCH connection A 15 PRO WAVE 300GTSW APPENDIX 9 DIODE TESTING BASICS Testing of diode modules requires digital Volt Ohmmeter that has a diode test scale A 16 1 2 3 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 A 6 and A 7 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 direction connect the volt ohm meter positive lead to the anode positive of the diode and the negative lead to the cathode negative of the diode refer to figure A 6 A properly functioning diode will conduct in the forward bias direction and will indicate between 0 3 and 0 9 volts To check the diode in the reverse bias direction reverse the meter leads refer to figure A 6 A properly func tioning diode will block current flow in the r
93. mperage Control C Remote ON OFF switch closed Current decreases to final current at twice the rate set for UP Slope Final current is 1 5th of welding current D Remote ON OFF switch opened Arc shuts off and post flow time initiated Art A 06108 Figure 4 1 Front panel operator controls June 21 2012 PRO WAVE 300GTSW 1 Primary Power Switch Placing the Primary Power Switch circuit breaker located on the rear panel to the ON position energizes the welding power source 2 Voltage Selector Manual slide switch selects the proper input voltage range 208 230 460VAC Model only 3 Input Cable 10 feet 4 Input Gas Fitting The input gas connection is located on the bottom center of the rear panel Size 5 8 18 unf female European Fitting 3 8 BSP male GTS Model only f this slide switch is not set to the position that matches the input voltage from the electrical source the warning indicator will be illuminated and the unit will not operate Not installed in single voltage unit shown Art A 06109 Figure 4 2 Rear panel operator controls 208 230 model shown June 21 2012 4 3 PRO WAVE 300GTSW This page left blank intentially 4 4 June 21 2012 SECTION 5 SERVICE 5 01 Routine Maintenance The only routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency determined by the usage and the operating environment WA
94. n activates the spot welding timer The Slope sequence and spot modes are activated by a remote ON OFF switch connected to the 8 pin receptacle See the section on Slope sequence on next page 9 Pulser Switch When in the OFF position the Pulser is inactive Selecting H HIGH or L LOW will activate the TIG pulser The Pulse Frequency can be adjusted by the Pulse Frequency control Pulse width is fixed at 35 Background current is fixed at 1 5th of the peak current 10 AC Frequency Control When Output Selector Switch is in AC position controls frequency of AC waveform on output Art A 06108 Figure 4 1 Front panel operator controls 4 1 PRO WAVE 300GTSW 11 Wave Balance This controls the portion of each AC output cycle that has its polarity reversed The reverse polarity portion of the waveform is used to clean the oxides of aluminum as it is welded The control is variable from 5 to 50 12 Spot Time Up Down Slope Control This control provides Spot Up and Down slope time control Rotating the control clockwise increases the time The scale surrounding the control represents approximate actual values The Spot and Up slope time is adjustable from 0 5 to 5 seconds The Down slope time is twice the Up slope time at 0 5 to 10 seconds 13 Pulse Frequency Control The Pulse Frequency control provides a means of selecting the pulse frequency when the Pulse switch is inthe H HIGH or L LOW position
95. ng in power electronics measurement and troubleshooting techniques CAUTION Perform all steps each procedure 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 6 1 PRO WAVE 300GTSW 6 02 Opening the Enclosure To open the enclosure 1 Turn off the MAIN CIRCUIT BREAKER MCB on the rear of the power supply Wait at least two minutes to allow the input capacitors to discharge Remove the two screws on the top and three screws from bottom of the unit Remove the two screws from the middle of the case on both sides of the unit Pull the plastic enclosure halves open and away from the internal frame Remove the inner plastic shield by locating three 3 white plastic retaining plugs on the sides of the heatsink by pulling the plastic plug straight out of the hole in the heatsink For reassembly make a note of the relationship of the grounding screw and the fourth hole in the plastic shield that did not have a plastic plug To reassemble the enclosure 6 2 1 Place the inner plastic shroud over the power supply so the three holes that will accept the plastic retaining plugs are in the correct position Insert the white plastic retaining plugs into the holes in the heatsink through the matching holes in the plastic shield Place the power su
96. o 1 2 of the work lead arc transfer will occur After arc transfer the HF START circuit will turn OFF 6 Remove the jumper or open the remote control switch if installed The arc turns OFF 7 Turn off the power supply MCB This completes the HF START circuit test If the results of any step differ from those above perform the HF Unit test further in Advanced Troubleshooting If the HF Unit is good replace the Main Circuit Board 6 7 PRO WAVE 300GTSW 6 09 Subsystem Test Preparation The following initial conditions must be met prior to starting any of the procedures in the subsystem tests 1 Set the PROCESS SELECTOR switch to STICK mode 2 Set OUTPUT MODE to DC OUTPUT position Set AMPERAGE control to its minimum fully counterclockwise position 4 No connection should be made to the remote receptacle s 5 Connect appropriate input voltage Check the data tag on the rear of the power supply for the proper input voltage NOTE Operate at ALL input voltages as noted on the nameplate on the rear panel when testing the power supply 6 Close primary power source wall disconnect switch or circuit breaker 7 Place power supply MAIN CIRCUIT BREAKER MCB on rear of unit in the ON position A WARNING E SS SS Dangerous voltage and power levels are present inside this unit Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part
97. oduct to the authorized distributor ____ ____________ __________ _______ _ ALL OTHER CIRCUITS AND COMPONENTS INCLUDING BUT NOT LIMITED TO CONTACTORS RELAYS SOLENOIDS PUMPS 1 YEAR 1 YEAR POWER SWITCHING SEMI CONDUCTORS ENGINES ENGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER SEE THE ENGINE MANUFACTURE S 1 YEAR 1 YEAR WARRANTY FOR DETAILS CONSOLES CONTROL EQUIPMENT HEAT EXCHANGES ACCESSORY EQUIPMENT NOTE Dragster 8569 excluded from this policy Refer to Dragster 85 warranty in Dragster 85 Owner s Manual Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty 30 days of purchaser s notice of any Warranty Claim No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc September 27 2004 1 12 June 21 2012 SECTION 2 INTRODUCTION 2 01 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 c
98. oducts 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 749 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 precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 01 Arc Welding Hazards 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input ro power disconnect switch open or remove line fuses 50 power cannot be turned on accidentally 5 Properly install and ground this equipment according WARNING to its Owner s Manual and national state and local ELECTRIC SHOCK can kill 6 Turn off all equipment when not in use Disconnect Touching live electrical parts can cause fatal power to equipment if it will be left unattended or out Shoc
99. of the operator s body comes into contact with the workpiece or any internal components while the unit 15 activated This section provides specific procedures for verifying the operation and replacement of each subsystem within the power supply Before undertaking any of these procedures eliminate the obvious first visually inspect the suspect subsystem for physical damage overheating and loose connections 6 8 6 10 Main Circuit Breaker MCB Replacement Procedure A WARNING Disconnect primary power at the source before performing this procedure Refer to figure 6 3 on opposite page To remove the MAIN CIRCUIT BREAKER jn Remove the four screws from the rear panel that secure the MAIN CIRCUIT BREAKER assembly to the rear panel Remove the input power leads and output power leads marked and 5 in figures 6 4 and 6 5 from the MCB terminals Remove the MCB from the metal shield If the metal shield must be removed note that it is connected to a GREEN ground lead To replace the MCB reverse the above steps replacing the input and output leads in the same matching positions Refer to figure 6 4 or 6 5 June 21 2012 PRO WAVE 300GTSW Retaining Screws Art 06112 Figure 6 5 Main Circuit Breaker connection three phase June 21 2012 6 9 PRO WAVE 300GTSW 6 11 Main PCB1 Gate Drive Enable Signal Test The gate drive signals are 21 3kHz square wave signals with an OFF level of
100. oltage detect White C75 HFonsigna relay N O Gray CN8 5 common 268 Red OV 230V input 5V 460V input CN Black 0472 Thyristorcathode White 43 044 Thyristoranode Orange Thyristor gate drive relay contact Orange 0482 not used CN18 3 Thyristor gate drive relay contact A 8 June 21 2012 PRO WAVE 300GTSW Meter Reading 12Vdc common 5Vdc 5Vdc Number CN21 1 CN21 2 CN21 3 CN21 4 CN21 5 12Vdc CN21 6 common CN21 7 Output current detect CN21 8 Output voltage detect CN21 9 Output voltage detect CN21 10 power supply for thermal Ribbon CN21 11 thermal input Ribbon CN22 1 Ribbon CN22 2 Ribbon CN22 3 Primary current detect Ribbon CN22 4 Ribbon CN22 5 Output short detect Ribbon CN22 6 HF on off Ribbon CN22 7 Gas valve on off Ribbon CN22 8 torch switch Ribbon CN22 9 Easylink switch Ribbon CN22 10 Easylink switch Ribbon CN22 11 Ribbon CN22 12 Ribbon CN2213 Ribbon CN22 14 Ribbon CN22 5 phase detect Ribbon CN23 1 Input voltage detect Ribbon CN23 2 Ribbon CN23 3 Power supply Ribbon 6 23 4 Reset signal Ribbon CN23 5 Overvoltage detect Ribbon CN23 6 0 UVR detected 5V no UVR Undervoltage detect Ribbon CN23 7 Ribbon CN23 8 Pre charge control Ribbon 20 ibbon ibbon Ribbon Ribbon Ribbon Ribbon Ribbon Ribbon Ribbon Power supply J Power supply Power suppl
101. position B Poor Weld Wrong polarity Wrong electrode used Electrode not properly prepared Incorrect welding amperage setting Speed too slow or too fast Incorrect switch settings for intended operation Poor weld output connection s Remote Operation Incorrect contactor switch settings Remote not connected If the problem is not resolved after checking the above the following guide may suggest more specific items to check given the faulty operating symptom s you experiencing 5 1 PRO WAVE 300GTSW 5 04 Specific Problems How to Use This Guide The following information is a guide to help you determine the most likely causes for various symptoms This guide is set up in the following manner A Symptom Bold Type Any special instructions Text Type 7 Cause Italic Type a Check Remedy Text Type Locate your symptom check the cause s the simplest or most likely is listed first then perform the remedy given Repair as needed being sure to verify that the unit is fully operational after any repairs A No Weld Output Unit is Completely Inoperative 7 Line disconnect switch 18 in OFF position a Place line disconnect switch in ON position 2 Line fuse s open a Check and replace line fuse s 3 Improper electrical input connections a See Section 3 01 Electrical Input Requirements page 3 1 for proper input connections 4 MAIN CIRCUIT BREAKER in OFF position a Check and reset MAIN CIRCUIT BREAKER
102. pply into an enclosure half taking care that the front and rear panel edges are seated properly into the matching grooves inside the enclosure Repeat for the second enclosure half When the two enclosure halves are fully together secure the two halves together with the five screws and matching nuts Install the two screws in the middle of each enclosure half THERMAL 1 DYNAMICS IHERMAL A RC DC INVERTER ARC WELDER Art A 06110 THERMAL THERMAL DC INVERTER WELDER Figure 6 1 Screw locations on case 6 03 Initial Setup Conditions Before starting any of the system level troubleshooting procedures that follow set the front panel controls of the unit to the following If necessary refer to the Operator s Controls section 4 page 4 1 for the location of the various controls for the unit 1 Set the PROCESS SELECTOR switch to STICK mode 2 Set the OUTPUT MODE to DC OUTPUT position Set AMPERAGE control to its minimum fully counterclockwise position 4 No connection should be made to the remote receptacle s June 21 2012 6 04 Easy Link Fault Isolation Test 208 230 460VAC Model only The Easy Link circuit configures the internal power circuits to accept the input power This test verifies that the INPUT SELECT switch is functioning properly and the Easy Link circuit can detect both the maximum 460 and the minimum 208 230V input power
103. proximately 12 SCFH 7 Incorrectly set PROCESS SELECTOR switch a Verify the PROCESS SELECTOR switch is set to match the type of welding process being conducted 8 Wrong welding polarity a Verify output torch connections June 21 2012 D Wandering Arc Poor Control of Arc Direction 7 Wrong size tungsten electrode typically larger than recommended a Use proper size electrode for amperage selected see Operating Manual 0 2514 2 Improperly prepared tungsten electrode a Prepare tungsten properly 3 Gas How rate too high a Reduce flow rate to approximately 12 SCFH 4 Drafts blowing shielding gas away from tungsten electrode a Shield weld zone from drafts and check condition of tungsten electrode 2 Loose gas fitting on regulator or gas line drawing air into weld zone causing green blue discoloration of workpiece a Check and tighten all gas fittings 6 Water in torch a Refer to torch parts list for part s requiring replacement and repair torch as necessary No High Frequency at Torch When PROCESS SELECTOR Switch is in HF TIG Position 7 PROCESS SELECTOR switch is not in the HF TIG position a Place switch in HF TIG position 2 Drafts blowing shielding gas away from tungsten electrode a Shield weld zone from drafts and check condition of tungsten electrode 3 Loose gas fitting on regulator or gas line drawing alr into weld zone a Check and tighten all gas fittings 4 Water in
104. r proper body protection to protect skin ae a 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 Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards PRO WAVE 300GTSW WARNING Engines can be dangerous WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 2 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes WARNING
105. rands that have stood the test of time technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise We are committed to develop technologically advanced products to achieve a safer working environment within the welding industry WARNINGS EEE 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 Pro Wavel 300GTSW Inverter Arc Welder Service Manual Number 0 2515 for 208 230VAC Single Voltage Single Three Phase Spec Number 10 3024 208 230 460VAC Single Three Phase Spec Number 10 3025 380 415VAC Single Voltage Three Phase Spec Number 10 3038 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2001 by Thermal Dynamics Corporation rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date
106. reases the amperage output The scale surrounding the amperage control represents approximate actual amperage values 2 Hot Start Control The Hot Start Control provides a variable selection of start circuit current that operates in the STICK and HF TIG modes The Hot Start time is approximately 0 01 seconds in TIG and 0 06 seconds in STICK The current value is adjusted from 0 to 100 Amps over the determined weld current set by the Amperage Control Rotating the control clockwise increases Hot Start current ARC Control The Arc Control is in use in the SMAW mode only Rotate the control clockwise to increase the short circuit current available to control the welding arc Process Selector Switch The Process Selector Switch allows the operator to select the STICK welding SMAW process LIFT TIG GTAW or HF TIG GTAW process Warning Indicator The Warning Indicator located on the front panel will become activated under the following conditions Input voltage is too low Input voltage too high Thermal overload AC Power Indicator The AC Power Indicator located on the front panel lights when the Primary Power Switch is in the ON position indicating the unit is energized Output Selector Switch Selects between AC or DC output June 21 2012 PRO WAVE 300GTSW 8 Sloper Switch When in the OFF position the Sloper is inactive Selecting the ON position activates the Sloper Selecting the SPOT positio
107. section contains four diodes D2 through D5 Check each diode between its POSITIVE A and NEGATIVE K TERMINALS Refer to figure 6 29 Note that these measurements can be accomplished without removing the main transformers The transformers were removed in figure 6 29 to aid in identifying the diodes To check for shorted diodes without dismantling the power supply take a voltmeter set on the diode scale from the GRAY wire and the BROWN on the FCH to the NEGATIVE weld terminal A good reading will be 2V 4 gt 4 2 4 1 4 2 IT wy 5 Art A 06130 D5 A D3 A 05 D5 K 03 Figure 6 29 Power control assembly output diodes 02 05 Main transformers removed for clarity 6 32 June 21 2012 PRO WAVE 300GTSW 6 30 PCA Output Diodes D2 D5 Replacement Procedure To gain access to the Output Diodes The Main Transformers 1 and T2 and their metal mounting brackets must be removed from the chassis 1 Remove the Output Inductor Assembly refer to section 6 37 page 6 42 2 Remove hardware at T1 T2 secondary lead junctions C D and E Figure 6 30 White Wire T1 T2 Secondary Lead to CN7 3 Junction C Art A 06131 Blue Wire 1 12 Secondary Lead to HF Unit AC1 Junction D center tap leads 1 12 Secondary Lead bent upward two black lugged Junction E leads to CN7 1 and CN5 3 Figure 6 30 Output inductor T1 T2 l
108. t ampere curve NOTE Volt Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source Curves of other settings will fall between the curves shown June 21 2012 PRO WAVE 300GTSW 2 3 PRO WAVE 300GTSW 2 06 Functional Block Diagram Figure 2 2 illustrates the functional block diagram of the 300GTSW power supply Trouble Sequence Sume SO Torch Control Reference Connection Adjustments amp CON1 Control Switches Gas Current Control Adjustment Circuit ircuit Figure 2 2 Block Diagram WARNING requi nit Y Art A 06104 Inrush Current IGBT Inverter Output Output IGBT Inverter Current Suppresor Capacitor odule Diodes Module Vaga O t Thermal gl Drive Circuit Primal Drive Circuit Curren Lift Tig Mode Sensor Output Short Sensing Circuit DC Power Voltage Sensor Thermal Supply for Sensor Control Circuit Circul Coupling Coil each control circuit 12VDC 20VDC 24VDC 5VDC Disconnect primary power at the source before disassembling the power supply Frequently review the Important
109. tag out 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 Electrical Input Requirements Operate the welding power source from a single or three phase 50 60 Hz AC power supply The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit NOTE These units are equipped with a four conductor with earth power cable that is connected at the welding power source end for single or three phase electrical input power To operate single phase do not connect the RED input conductor Do not connect an input WHITE BLACK or RED conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal Refer to figure 3 1 and June 21 2012 PRO WAVE 300GTSW 3 1 PRO WAVE 300GTSW 1 Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 BLACK
110. tion 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 183 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard 287 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 PRO WAVE 300GTSW 1 03 PRECAUTIONS DE SECURITE EN SOUDAGE L ARC MISE EN GARDE LE SOUDAGE EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU 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
111. tly a Perform the Easy Link test section 6 04 page 6 3 9 Thermal sensor TH7 open thermal shutdown a Allow the unit to cool for five minutes before turning the power supply ON If the problem still occurs perform the PCA Thermal Sensor TH1 test section 6 31 page 6 36 4 Warning Indicator ON when output energized a Check Q1 Q2 and Q3 Q4 Section 6 26 Power Supply Works When in DC Output Mode But Not in AC Output Mode 7 Faulty IGBT modules Q3 04 a Check IGBT modules Q3 Q4 for shorted gate circuit or defective diodes per section 6 26 page 6 26 and replace if necessary No Weld or Output Fan Operating WARNING Indicator OFF 7 Faulty Remote Control Device a Connect a jumper between pins 2 and 3 of the REMOTE 8 receptacle for contactor closure amperage and voltage can be adjusted with front panel controls repair or replace remote control device 2 Faulty Front Panel PCB a Refer to section 6 16 page 6 18 Front Panel Test Point Voltages 3 Faulty Main Circuit Board PCB1 a Check all connections on the Main Circuit Board PCB1 Perform Power Supply Voltage tests section 6 05 page 6 4 b Check PWM waveforms from front panel PCB to Main PCB and from Main PCB to the IGBT s Low or Maximum Weld Output With No Control 7 Faulty remote control device a Connect a jumper between pins 2 and 3 of the REMOTE 8 receptacle for contactor closure If amperage and voltage can be a
112. uit board retaining screws 13 Lift the Main Circuit Board straight up passing the lugged wires removed from TB1 and TB2 through the cur rent sensors 14 As you remove the Main Circuit Board pass connectors CN8 and 9 through the hole in the board 15 Continue to pull the Main Circuit Board straight up and away from the chassis To replace the Main Circuit Board 1 Hold the Main Circuit Board over the chassis oriented so the three ribbon cables are toward the front panel of the power supply As you lower the Main Circuit Board onto the chassis pass the lugged wires that will attach to TB1 and TB2 through the current sensors and connectors CN8 and CN9 through the hole in the board As you lower the Main Circuit Board onto the chassis replace the connectors on the rear end of the board at locations CN5 CN8 CN9 and CN14 Continue lowering the board so the vertical bus bars pass through the slots in the boards and line up with TB3 4 TB5 6 The board is properly seated when the holes in the vertical bus bar and the terminals TB1 6 line up the board is seated on the black plastic spacers in the corners of the board and there is no interference with wire harnesses Carefully pull up through the current sensors the excess lead length of the two lugged wires that will connect to TB1 and TB2 Replace the hardware to secure the lugged wires to TB1 through TB6 The lugged wires that connect to TB1 and TB2 must be bent o
113. ver in loop Insert the screws and washers into the four corners of the Main Circuit Board Do not tighten until all four screws are Started in their holes Replace all connectors on the Main Circuit Board and the MAIN CIRCUIT BREAKER on the rear panel June 21 2012 PRO WAVE 300GTSW Figure 6 14 TB1 through TB6 reconnections June 21 2012 6 17 PRO WAVE 300GTSW 6 16 Gaining Access to Front Panel Circuit Board PCB6 WK 3988 To gain access to the test points on the Front Panel Circuit Board it is necessary to remove the front panel of the power supply unit To accomplish this do the following 1 Locate and remove the six screws securing the Front Panel to the front of the power supply Allow the front panel to drop down to allow free access to the test points on the Front Panel Circuit Board PCB6 Art A 06120 Figure 6 15 Front panel retaining screws 6 18 June 21 2012 6 17 Front Panel WK 3988 Test Point Voltages PRO WAVE 300GTSW The test point voltages on the Front Panel Circuit Board should be verified as follows N A TP1 TP2 TP3 TP6 June 21 2012 OV 5VDC 12VDC 12VDC 4VDC Circuit Common Regulated voltage of control circuit Regulated voltage of control circuit Regulated voltage of control circuit Regulated voltage of control circuit Set up the contactor closure circuit by installing jumper between pins 2 and 3 of the REM
114. voltmeter will indicate approximately 1 volt 10 Turn off the power supply MCB 11 Connect the clamp on the amperage meter or equivalent to the output loop between the POSITIVE and NEGATIVE OUTPUT TERMINALS June 21 2012 12 Place the power supply the rear of unit to the ON position After five 5 seconds the amperage meter will indicate approximately 17Amps 13 Turn off the power supply MCB 14 Remove the loop connected between the POSITIVE and NEGATIVE OUTPUT TERMINALS This completes the LIFT START circuit test If the results of any step differ from those above the Main Circuit Board should be replaced June 21 2012 PRO WAVE 300GTSW 6 08 High Frequency HF START Circuit Test This test verifies the operation of the HF START circuit CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial setup condition previously described page 6 2 1 Make sure the MAIN CIRCUIT BREAKER MCB is turned OFF 2 Setthe PROCESS SELECTOR switch to HF START mode 3 Connect TIG torch and shielding gas 4 Connect a remote control or jumper between pins 2 and 3 of the REMOTE 8 receptacle for contactor closure If a remote switch is installed close it 5 Place the power supply MCB on the rear of the unit to the ON position After PRE FLOW of 150 ms the HF START circuit will turn ON If the torch is brought to within 3 8 t
115. y 7 Reapply power to the unit 8 On the ribbon cable measure for the following voltages between pins Pins 2 and 1 12VDC Pins 2 and 5 12VDC Pins 2 and 3 5VDC Pins 2 and 4 5VDC If voltages are correct with CN 7 disconnected but not with it connected then the front panel PCB is defective 9 Turn the unit OFF 10 Reconnect the ribbon cable to connector CN7 on the Front Panel Circuit Board 11 Reapply power to the unit 6 4 12 the Main Circuit Board PCB1 measure the voltages between the following points CN1 Hall Effect Pin 1 and pin 4 12VDC Pin 2 and pin 4 12VDC Pin 3 and pin 4 OV to 12VDC varies with AMPERAGE output under load 50A V CN2 Pin 1 and pin 2 24VDC CN21 Pin 1 pin 2 12 0 3 2 5 0 4 2 5 0 5 2 12VDC CN22 Pin 13 and pin 4 12VDC CN23 Pin 3 and pin 2 12VDC If any of these voltages are not present or are below a 10 tolerance replace the Main Circuit Board PCB1 June 21 2012 PRO WAVE 300GTSW CN9 PCB6 CN8 PCB6 Art A 06111 CN7 PCB6 Figure 6 2 Power supply voltage connector locations June 21 2012 6 5 PRO WAVE 300GTSW 6 06 Output Load Test This test verifies that the output controls are functioning properly A clamp type amperage meter or equivalent meter capable of reading approximately 300A full scale will be needed for this test
116. y Power supply CN23 9 Thyristor gate drive Ribbon CN23 10 Easylink switch Ribbon CN23 11 5V 230V input OV 460V input Easylink switch Ribbon CN23 12 Tripping relay control Ribbon CN24 Thyristor gate drive relay contac Gray _ CN24 not used __CN21 1 CN21 2 21 4 CN21 5 CN21 6 CN21 7 CN21 8 LCN21 10 CN21 11 CN22 1 CN22 2 CN22 4 CN22 5 CN22 6 CN22 7 CN22 9 _CN22 10 _CN22 11 _CN22 12 _CN22 14 CN2215 CN28 1 CN28 2 CN23 4 CN23 5 CN23 6 CN23 7 CN23 9 CN23 10_ _CN23 11 CN23 12 June 21 2012 9 PRO WAVE 300GTSW ee CN26 1 15Vsquarewave Super impose gate drive common notused CN30 1 12Vdc PCB11 CN30 2 notused O ne Tripping relay control 10 June 21 2012 PRO WAVE 300GTSW THIS PAGE INTENTIONALLY LEFT BLANK June 21 2012 A 11 PRO WAVE 300GTSW A 12 APPENDIX 6 WIRE CHART FRONT PANEL PCB6 Emp mem for C2 Meter circiut Pin 4 Remote Reference Common Pin 6 OV to 4 or OV to 10V G CN3 4 OV to or OV to 10V C Remote reference in from remote Gray control Pin 7 CN3 5 12Vdc When remote plugged in Pin 8 switch Pin Red _ Torch switch Pin 3 ibbon ibbon Super impose gate drive ibbon Ribbon common Ribbon chassis

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