Thermal Arc ARCMASTER 400TS, ARCMASTER 400S, ARCMASTER 300TS Service Manual

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400TS

400S

300TS

300S

ARCMASTER

INVERTER ARC WELDERS

Service Manual

ersion No:ersion No:

ersion No: AA.03

ersion No:ersion No:

Operating FeaturesOperating Features

Operating Features:

Operating FeaturesOperating Features

Issue Date:Issue Date:

Issue Date: May 22, 2006

Issue Date:Issue Date:

Art # A-07263

Manual NoManual No

Manual No: 0-4895B

Manual NoManual No

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Service Manual Number 0-4895B for: ArcMaster 400TS Inverter Arc Welder Part Number 10-3071 ArcMaster 400S Inverter Arc Welder Part Number 10-3070 ArcMaster 300TS Inverter Arc Welder Part Number 10-3096 ArcMaster 300S Inverter Arc Welder Part Number 10-3093

Published by: Thermadyne Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: May 22, 2006

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

CONTENTS

1 SAFETY INSTRUCTIONS AND WARNINGS

1 Arc Welding H a z a rd s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

2 PRINCIPAL SAFETY STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6

3 PRECAUTIONS DE SECURITE EN SOUNDAGE A L'ARC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6

4 Dangers relatifs au soudage à l’arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7

5 PRINCIPLE S

AFETY STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11

2 INTRODUCTION

1 How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2 Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

3 S

ymbol Cha rt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

4 Descriptio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

5 Functional Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2– 4

6 Transpor t i n g M e th o ds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

3 INSTALLATION

1 Environme n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3 Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

4 Electrical Input Requirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

5 Input Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

6 High Frequency Introduction (300/400TS only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

7 High Frequency Interference (300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

8 Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

9 Specifica t io n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 –4

4 OPERATO R CONTROLS

1 ARC MASTER 300/400TS and 300/400S Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

2 Weld Process selection for ARC MASTER 300/400TS and 300/400S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

3 Weld Parameter Descriptions for ARC MASTER 300/400TS and 300/400S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

4 Weld Parameters for ARC MASTER 300/400TS and 300/400S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5

5 Power Sour ce Fe atures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6

5 SET-UP FOR SMAW (STICK) AND GTAW (TIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 SEQUENCE OF OPERATION

1 Stick Weldi n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

2 HF TIG Welding (300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

3 Lift TIG Wel d in g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

4 Slope Mode Sequence(300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6– 2

5 Slope Mode with repeat sequence (300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

6 Pulse Controls (300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

7 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 BASIC TROUBLESHOOTING

1 TIG Welding Pro b l e ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

2 Stick Weldi n g Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

3 Power Sourc e Pr o b l e ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5

9 VOLTAGE REDUCTION DEVICE (VRD)

1 VRD Specific a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

2 VRD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

3 Switching VR D On /Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –2

10 POWER SOURCE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11 ADVANCED TROUBLESHOOTING

1 System-Level Fault Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

1.1 Opening the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

2 Verification and Remedy to the Indicated Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3

2. 1 E01 "Over-Temperature at the primary side" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3

2.2 E02 "Over-Temperature at the secondary side" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4

2. 3 E03 "Transformer Over-Current Failure". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4

2. 4 E04 "Torch Cable Failure". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1–5

2.5 E11 "Main Supply Over Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1–5

2.6 E12 "Main Supply Under Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5

2.7 E81 "Wrong Main Supply Voltage". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 5

2.8 E82 "Rated Voltage Selection Circuit abnormality" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6

2.9 E83 "Abnormalities in Mains Supply Voltage Detection" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 6

2.10 E85 "Pre-charge abnormality" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 –6

2.11 E94 "Thermistor malfunction". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

2.12 E99 "Initial Power Receiving". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

3 Verification and Remedy to Failures without Indication Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

3.1 "Cooling Fan (FAN1) Failure" (Fan is not rotating.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

3.2 "Gas Valve Failure" (No Gas flow through unit)(300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8

3.3 "No Weld Out p u t". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8

3.4 "Operating Panel Failure" (LED's do not light properly or welding setting cannot be established.) . . . . . . . . . . . . . .1

1–9

5 "High Frequency Output Failure" (Unit does not generate High Frequency.) (300/400TS only) . . . . . . . . . . . . . . . . 11–9

4 Fault Isola t io n Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10

4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10

5 Verification of the Power Input Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1–11

5.1 Verification of the AC input voltage using an AC voltmeter.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11

5.2 Verification of the Power Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–12

5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–13

5.4 Verification of the Gas Valve, SOL1, Drive Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–14

5.5 Verification of the primary Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–14

5.6 Verification of the secondary Diode (D2-D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15

5.7 Verificat io n o f the primary IGBT (Q1 - Q 2 4 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1–15

5.8 Verification of the secondary IGBT (Q25-Q26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16

5.9 Verification of No-load Voltage (OCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16

12 MAINTENANCE

1 Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1

2 Service Too l s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5

2.1 Tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5

2.2 Notes of disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5

3 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6

3.1 PCB1 (WK-5493) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6

3.2 PCB2 (WK-5597) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7

3.3 PCB3 (WK-5548), PCB7 (WK-5550) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9

3.4 PCB4 (WK-4819) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10

3.5 PCB5 (WK-5551) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11

3.6 PCB6 (WK-5549) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11

CONTENTS

3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12

3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12

3.9 PCB12 (W K-5527) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12

3.10 PC B13 (W K-5528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13

3.11 PCB14 (WK-5594) <T1 “Main Transformer”>

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1 4

12 PCB15 (WK-5606) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16

3.13 PC B20 (W K-5499) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16

3.14 PC B21 (W K-4917) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17

3. 15 Current Limiting Resistor (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18

3.16 Resistor ( R 7 , R8 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 1 9

3.17 Coupling Coil (CC1) * 300/400TS only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12–20

3.18 Reactor (FCH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20

3. 19 Primary Thermistor (TH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21

3.20 Sec ondary Thermistor (TH2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –22

3.21 Cooling Fan ( F AN 1 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–22

3.22 Solenoid Valve (S OL1) * 300/400TS only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–23

3. 23 Main ON/OFF Switch (S1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24

3. 24 Input Voltage Switch (S2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–25

3. 25 Remote Socket (CON1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2–26

3.26 High Freguency Unit (HF.UNIT1) * 300/400TS only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–26

3.27 Hall Current Sensor (HCT1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –27

3.28 Pr imary Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28

3.29 Secondary Diode (D2, D4, D5 and D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –28

3. 30 Current Trans (CT2, CT3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–29

3.31 Ring Core (L 1 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–30

3.32 Ring Core (L105) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –30

APPENDIX 1 PARTS LIST

1 Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1

2 How To Use This Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1

APPENDIX 2 CONNECTION WIRING GUIDE APPENDIX 3 INTERCONNECT DIAGRAM APPENDIX 4 DIODE TESTING BASICS

ARCMASTER 400TS, 400S, 300TS, 300S

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 products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.

Safe practices are outlined in the American National Standard Z49.1 entitled: 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.

SAFETY IN WELDING AND CUTTING.

1.01 Arc Welding Hazards

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

May 22, 2006

9. Do not wrap cables around your body.

10.Ground the workpiece to a good electrical (earth) ground.

1-1

ARCMASTER 400TS, 400S, 300TS, 300S

11.Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13.In 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.

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.

4. Wear protective clothing made from durable, flameresistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

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.

1. 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.

3. If ventilation is poor, use an approved air-supplied respirator.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 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.

Eye p rotecti on fi lter shade selector for wel ding or cu t t ing

(g oggles or h elmet), f rom AWS A6.2-73.

Weldi ng or cut ting Electrode Size Filter Welding or c utting Elec trode Size F ilter

Torch soldering 2

Tor c h br azing 3 or 4 Non-ferr ous base met a l A l l 11

Oxyg en Cutting

Light Under 1 in. , 25 mm 3 or 4 Gas tungsten arc welding All 12

Heavy 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Medium Over 6 in., 150 mm 5 or 6 Atomic hy d r oge n we lding All 12

G as welding

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Heavy 1/ 8 to 1/2 in., 3-12 mm 5 or 6

Medium Over 1/2 in. , 12 mm 6 or 8 Light 12

Sh ielded metal-ar c

Under 5/ 3 2 in. , 4 mm 10 Heavy 14

5/32 to 1/4 in., 12

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. 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.

Gas metal - ar c

Fer r ous base met al All 12

Carbon ar c welding All 12

C arbon a rc air gouging

Plasma arc cutting

Heavy 300 to 400 Amp 12

Medium Over 40 0 Amp 14

1-2

May 22, 2006

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

WARNING

WELDING can cause fire or explosion.

ARCMASTER 400TS, 400S, 300TS, 300S

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. Wear proper body protection to protect skin.

WARNING

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. 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.

9. Do not use welder to thaw frozen pipes.

CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

10.Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

May 22, 2006

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ARCMASTER 400TS, 400S, 300TS, 300S

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

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

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

WARNING

ENGINE FUEL can cause fire or explosion. Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

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.

1-4

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

May 22, 2006

ARCMASTER 400TS, 400S, 300TS, 300S

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 & 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, Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

Biological Effects of Power

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, 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 Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, 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.

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.

May 22, 2006

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ARCMASTER 400TS, 400S, 300TS, 300S

1.03 Precautions de Securite en Soudage à L’Arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’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 procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

1.04 Dangers Relatifs au Soudage à l’Arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

3 Isolez-vous de la pièce à souder et de la mise à la

terre au moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez 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’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

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May 22, 2006

ARCMASTER 400TS, 400S, 300TS, 300S

9. N’enroulez pas de câbles électriques autour de votre corps.

10.N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11.Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12.N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13.Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15.Fermez solidement tous les panneaux et les capots.

AVERTISSEMENT

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

DANGEREUSES POUR LA SANTE. Le soudage dégage des vapeurs et des fumées

dangereuses à respirer.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

SELECTION DES NUANCES DE FILTRES OCULAIRS PO UR LA PROTECTION

DES YEUX EN COUPA G E ET SOUDAGE (selon AWS á 6.

Opération de coupage

ou soudage

Brassage t endr e au chalumeau Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

moyen de 1 á 6 po. ( 25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

moyen de 1/8 á 1/2 po. ( 3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

May 22, 2006

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

tout es condit ions 3 ou 4 métaux non- ferreux tout es condit ions 11

mince moins de 1 po. (25 mm) 3 ou 4

épais plus de 6 po. (150 mm) 5 ou 6

mince moins de 1/8 po. (3 mm) 4 ou 5

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. ( 4 mm) 10 Coupage á l'arc P lasma (PAC)

5/32 á 1/ 4 po. ( 4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

fi l tre oculai re

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec f il plein (GMAW)

Soudage á l'arc sous gaz avec élect r ode de t ungstène (GTAW)

Soudage á l'hydrogène at omique (AHW ) Soudage á l'arc avec élect r ode de carbone ( CAW)

Gougeage A i r - Arc avec élect r ode de carbone

2-73)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 am pe rès 14

Nuance de

fi l tre oculai re

1-7

ARCMASTER 400TS, 400S, 300TS, 300S

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10.Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.

11.Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1-8

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

May 22, 2006

ARCMASTER 400TS, 400S, 300TS, 300S

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D’ECHAPPEMENT DES MOTEURS

PEUVENT ETRE MORTELS.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

Les moteurs produisent des gaz d’échappement nocifs.

May 22, 2006

1-9

ARCMASTER 400TS, 400S, 300TS, 300S

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer 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’électrolyte acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

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 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 M9W 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.

1-10

May 22, 2006

2 INTRODUCTION

How To Use This Manual

Equipment Identification

This Service Manual applies to just specification or part numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

The unit's identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i future reference.

for

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual. 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

2 – 1

Symbol Chart

Note that only some of these symbols will appear on your model.

300/400TS and 300/400S 2 INTRODUCTION

SEC

Amperage

Voltage

Hertz (frequency)

Seconds

Percent

DC (Direct Current)

AC (Alternating Current)

STICK (Shielded Metal Arc SMAW)

Pulse Current Function

Spot Time (GTAW)

Remote Control (Panel/Remote)

Remote Function

Arc Control (SMAW)

Gas Post-Flow

Standard Function

Slope Function

Slope W/Repeat Function

Spot Function

Impulse Starting (High Frequency GTAW)

Touch Start (Lift Start TIG circuit GTAW)

2 – 2

VRD

Gas Pre-Flow

Voltage Reduction Device Circuit

Negative

Positive

Gas Input

Gas Output

300/400TS and 300 /400S 2 INTRODUCTION

2 – 3

Description

The Thermal ArcTM Model ARC MAST ER 300TS and 400T S is a si ngle/thr ee-phase DC arc weldin g power source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas control valve, built in Sloper and Pulser, lift arc starter, and high-frequency arc starter for use with Gas Tungsten Ar c W el din g ( GTA W) , G as Tungsten Arc Welding-Pulse (G TAW - P) , G as T ung sten Arc Welding-Sloped (GTSW-S ), and Shielded Metal Arc Weld ing (SMAW) processes. The power s ource is totally enclosed in an impact resistant, flame resistant and non-conductive plastic case.

The Thermal Arc

Model ARCMASTER 300S and 400S is a self contained single/three-phase DC arc welding power source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/ Amperage Meter and li ft ar c starter for use with Gas Tungsten Arc We ldi ng ( GT AW ) and Shi el ded Meta l A rc Welding (SMAW) process es. The power source is totally enclosed in an impa ct resistant, flame resistant and non-conductive plastic case.

Figure2-1: 300/400TS and 300/400S Volt-Ampere Curves

300A5A (A)

(V)

OCV

STICK Process

300A25A (A)

(V)

OCV

10V

LIFT TIG Process

300A (A)

(V)

OCV

HF TIG Process

[ 300TS ]

400A5A (A)

(V)

OCV

STICK Process

400A (A)

(V)

OCV

HF TIG Process

400A25A (A)

(V)

OCV

10V

LIFT TIG Process

[ 400TS ]

[ 300S ]

300A25A (A)

(V)

OCV

10V

LIFT TIG Process

300A 320A

160A

18V

5A (A)

(V)

OCV

STICK Process

400A25A (A)

(V)

OCV

10V

LIFT TIG Process

400A 420A

160A

18V

5A (A)

(V)

OCV

STICK Process

[ 400S ]

300/400TS and 300/400S 2 INTRODUCTION

2 – 4

Functional Block Diagrams

Figure 2-2 illust rates the functi onal block diagram of the 300TS and 400TS power sup ply. Figure 2-3 il lustrates the functional block diagram of the 300S and 400S power supply.

Figure 2-2: 300/400TS Model Functional Block Diagram

Figure 2-3: 300/400S Model Functional Block Diagram

Main

Circuit Switch

Filter

Input

Diode

Primary

Capacitor DC Power

Voltage Sensor

IGBT

Inverter

Thermal Detector

To each control circuit

+/-15VDC +18VDC

+24VDC +5VDC

Trouble Sensing

Circuit

Drive

Circuit

Torch Control

Connection

(CON1)

circuit

Current

Adjustment

Reference

Adjust ment &

Mode select Switches

Panel Circuit Board

Sequence

Control

Thermal Sensor

Circuit

Mai n

Transformer

(PCB14)

Output Diodes

HF-UNIT

Control

Circuit

Stick Mode

VRD

Sensing

Circuit

Lift Tig Mode

Output Short

Sensing

Circuit

Coupling

High

Coil

Frequency

Unit

Fan Control

Circuit

Gas Co ntrol

Circuit

Fan

Solenoid

Hall Current Transformer

(HCT1)

Output

Inductor

Thermal Detector

Input

Power

Primary Current Sensor

Main

Circuit Switch

Filter

Input

Diode

Primary

Capacitor

DC Power Voltage

Sensor

IGBT

Inverter

Thermal Detector

To each control circuit

+/-15VDC +18VDC

+24VDC +5VDC

Trouble Sensing

Circuit

Drive

Circuit

Torch Control

Connection

(CON1)

circuit

Current

Adjustment

Reference

Adjust ment &

Mode select Switches

Panel Circuit Board

Sequence

Control

Thermal Sensor

Circuit

Mai n

Transformer

(PCB14)

Output

Diodes

Stick Mode

VRD

Sensing

Circuit

Lift Tig Mode

Output Short

Sensing

Circuit

Fan Control

Circuit

Fan

Hall Current Transformer

(HCT1)

Output

Inductor

Thermal Detector

Input

Power

Primary Current Sensor

300/400TS and 300 /400S 2 INTRODUCTION

2 – 5

Transporting Methods

These units are equipped with a handle for carrying purposes.

WARNING

ELECTRIC SHOCK can kill.

 DO NOT TOUCH live electrical parts.  Disconnect input power conductors from de-

energized supply li ne befo re mo vi ng t he we ld ing power source.

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

 Lift unit with handle on top of case.  Use handcart or similar device of adequate

capacity.

 If usin g a fork lift veh icle, place and sec ure unit

on a proper skid before transporting.

300/400TS and 300/400S 2 INTRODUCTION

2 – 6

PAGE LEFT INTENTIONALLY BLANK

3 INSTALLATION

3 – 1

INSTALLATION

Environment

The ARC MASTER 300/400TS and 300/400S are designed for use in adverse environments.

Examples of environme nts with increased adv erse conditions are:

a. In locations in which freedom of movement is

restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts;

b. In locations which are fully or partially limited

by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator, or

c. In wet or damp hot locations where humidity or

perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

Environments with adverse conditions do not include places where electrically conductive parts are in the near vicinity of th e operator, which can cause increased hazard, have been insulated.

Location

Be sure to locate th e welder according to the following guidelines:

 In areas, free from moisture and dust.  Ambient temperature between 0 degrees C to

40 degrees C.

 In areas, free from oil, steam and corrosive

gases.

 In areas, not su bjected to abnormal vibration or

shock.

 In areas, not exposed to direct sunlight or rain.  Place at a distance of 12

” (304.79mm) or more

from walls or similar boundaries that could restrict natural airflow for cooling.

WARNING

Thermal Arc advises that thi s equip men t be el ec trically connected by a qualified electrician.

Electrical Input Connections

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect

input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Electrical Input Requirement

Operate the welding power source from a singlephase 50/60 Hz, AC power su pply. The input voltage must match one of the elect rica l in put volt ages 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 connection s should be ma de, and any inspection required.

The line disconnect switch provides a safe and convenient mean s to co mpl ete ly r em ov e a ll e lec trical power from the welding power supply whenever necessary to inspect or service the unit.

NOTE

These units are equipped with a three-conductor with earth power cable that is connected at the welding power source end for single and three phase electrical input power.

Do not connect an input (WHITE or BLACK or RED) conductor to the ground terminal.

Do not connect the ground (GREEN) conductor to an input line terminal.

300/400TS and 300/400S 3 INSTALLATION

Refer to figure 3 and:

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) and line 2 (WHITE) and line 3 (RED) input conductors to a de-energized line disconnect switch.

3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.

Input Voltage Fuse Size

208V 100 Amps 230V 90 Amps 460V 30 Amps

Table3-1: Electrical Input Connections

NOTE

Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code).

The following 208-230/460V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment:

Current & Duty

Cycle

TIG STICK

300A

@ 40%

300A

@ 40%

250A

@ 40%

250A

@ 40%

400A

@ 25%

400A

@ 25%

300A

@ 25%

300A

@ 25%

−

Model

ARC

MASTER

300TS

300S

ARC

MASTER

400TS

400S

Primary

Supply

Lead Size

(Factory

Fitted)

8/4 AWG minimum

8/3 AWG minimum

8/4 AWG minimum

8/3 AWG minimum

Minimum

Primary

Current Circuit Size (Vin/Amps)

208/31 230/28 − 460/14 −

3φ

208/45 − 230/41 − 460/21 − 208/51 230/46 −

1φ

208/76 − 230/68 − 208/49 230/44 − 460/22 −

3φ

208/67 − 230/61 − 460/31 − 208/67 230/60 −

1φ

208/97 − 230/87 −

Figure3-1: Electrical Input Connections

Input Power

Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors. At this point, the Bus Voltages are checked and the welder is enabled after the input capacitors have charged to full operating voltage (after approximately 5 seconds).

NOTE

Note the available input power. Damage to the welder could occur if 575VAC or higher is applied.

208-230/460V Primary Current Circuit sizes

Table3-2:

to achieve maximum current

The ARC MASTER 300/400TS and 300/400S are designed for use with a generator as an input power source. Contact an accredited Thermal Arc service agent for the proper sizing and set-up recommendations of a generator power source system. As a general rule, depending on the type of generator used, the generator capacity should be twice the maximum rating of the welder.

3 – 2

300/400TS and 300 /400S 3 INSTALLATION

3 – 3

High Frequency Introduction (300/400TS only)

The importance of correct installation of high frequency welding equipmen t cannot be over-e mphasized. Interferenc e due to high fr equency initia ted or stabilized arc is almost invariably traced to improper installa tion. The following information is intended as a guide for personnel installing high frequency welding mach ine s.

WARNING: Explosives

The high frequency se ction of thi s machin e has an output similar to a radio tran smitter. The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing.

WARNING: Computers

It is also possible t hat operation close to com puter installations may cause com puter malfunction.

High Frequency Interference (300/400TS only)

Interference may be transmitted by a high frequency initiated or stabilized arc we lding machine in the following ways:

1. Direct Radiation: Radiation from the machine can occur if the case is metal and is not properly grounded. It can occur through apertures such as open access panels. The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded.

2. Transmission via the Supply Lead: Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction. Adequate shielding and filtering is provided in the Power Source.

3. Radiation from Welding Leads: Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with distance. Keeping leads as short as possible will minimize this type of interference. Looping and suspending of leads should be avoided where possible.

4. Re-radiation from Unearthed Metallic Objects: A major factor contributing to interference is re-radiation from unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent re-radiation in most cases.

Duty Cycle

The duty cycle of a welding power source is the percentage of a ten (10) minut e period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decreas e, the duty cycle in crease s. If the welding amperes are increased beyond the rated output, the duty cycle will decrease.

WARNING

Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature.

CAUTION

Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty.

NOTE

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct in stallati on, use, applicati ons, maintenance and service.

300/400TS and 300/400S 3 INSTALLATION

3 – 4

Specifications

Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or an y product without prior notice. Such updates or cha nge s do not entitl e the buyer of equipment previously sold or sh ipped to the corresponding changes, updates, improvements or replacement of such items.

The values specifi ed in the tabl e abo ve are optim al values, your values may differ. Individual equipment may differ from th e above specifications due to in part, but not exclusively, to any one or more of

the following; variations or changes in manufactured components, installation location and conditions and local power grid supply conditions .

Parameter 300TS / 300S 400TS / 400S

Rated Output 208-230/460VAC 208-230/460VAC

Amperes 300 400 Volts 32 36 Duty Cycle 40% 25%

Duty Cycle 300A / 32V @ 40% (3ph) 400A / 36V @ 25% (3ph)

200A / 28V @ 60% (3ph) 300A / 32V @ 60% (3ph)

250A / 30V @ 40% (1ph) 300A / 32V @ 25% (1ph) Output Current Range 5 - 300 Amps 5 - 400 Amps Open Circuit Voltage 65V

Dimensions

Width 8.3” (210mm) Height 16.5” (420mm) Length 17.7” (450mm)

Weight 52.9 lb. 24 kg (300/400TS)

44.1 lb. 20 kg (300/400S)

Output @ Rated Load Three-phase Single-phase Three-phase Single-phase

Output Amperes 300A 250A 400A 300A Output Volts 32V 30V 36V 32V Duty Cycle 40% 40% 25% 25% KVA 18.0 15.7 24.0 20.0 KW 12.0 9.4 18.0 12.0

Output @ No Load

KVA 0.5 KW 0.13

Input Volts Three Phase

Amperage Draw @

Rated Load

No Load

Amperage Draw @

Rated Load

No Load

208V 45 1.4 67 1.4 230V 41 1.3 61 1.3 460V 21 0.7 31 0.7

Input Volts Single Phase

208V 76 2.5 97 2.5

230V 68 2.2 87 2.2

4 OPERATOR CONTROLS

4 – 1

OPERATOR CONTROLS

ARC MASTER 300/400TS and 300/400S Controls

Figure 4-1: ARC MASTER Power Source

1. Control Knob: This control sets the selected weld parameter, rotating it clockwise increases the parameter that is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage.

2. Remote Control Socket: The 14 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Figure 4-2: 14-Socket Receptacle

Table 4-1: Socket Pin Functions

450

210

435

Socket

Function

Torch Switch Input (24V) to connect pins A & B to turn on the welding current.

Torch Switch Input (0V) to energize weld current (connect pins A & B to tu rn o n wel din g current).

5k ohm (maximum) connection to 5k ohm remote control potentiometer.

Zero ohm (minimum) connection to 5k ohm remote control potentiometer.

Wiper arm connection to 5k ohm remote control potentiometer.

G Mains Earth.

F,H,I,J,

K,L

Not Used.

OK to move current detect signal for robotics applications.

BKI

CLNH

DMG

ABCDEFGHIJKLMN

Front view of 14 Socket Receptacle

5k ohms

300/400TS and 300/400S 4 OPERATOR CONTROLS

4 – 2

3. Positive Terminal: Welding current flows from the Power Source via heavy duty Dinse type terminal (50 mm). It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

4. Negative Terminal: Wel di ng cu rren t flows from the Power Source via heavy duty Dinse type terminal (50 mm). It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

5. Gas Outlet: The Gas Outlet is a 5/8 18 UNF female gas fitting. (300/400TS only)

6. ON/OFF Switch: This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Supply.

WARNING

When the welder is conne cted to the Primary su pply voltage, the internal electrical components maybe at 240V potential with respect to earth.

7. Input Cable: The input cable connects the Primary supply voltage to the equipment.

8. SMART Logic Switch: Manual slide switch mounted on the back panel selects the pr

oper

nput voltage. If this slide is not set to the position that matches the input voltage from the electrical source the Smart Logic circuit will inhibit welding power source output. The digital meter will show primary input error code.

9. Gas Inlet: The Gas Inlet is a 5/8 18 UNF female gas fitting. (300/400TS only)

Weld Process selection for ARC MASTER 300/400TS and 300/400S

Table4-2:

Weld Process selection verses Weld Mode for

ARC MASTER 300/400TS and 300/400S

Weld Mode

Weld Process

Selection

STICK

TIG

LIFT

TIG

Description

Yes Yes Yes

2T operation in TIG Modes using remote device s to control contactor & current.

No Yes Yes

4T operation in TIG Modes with crater fill using a remote contactor device to control sequence.

(300/400TS only)

No Yes Yes

4T operation in TIG Modes with repeat operation and crater fill using a remote contactor device.

(300/400TS only)

No Yes No

2T operation spot welding in HF TIG using a remote contactor device.

(300/400TS only)

No Yes Yes

Pulse operation in TIG Modes.

(300/400TS only)

Yes No Yes

Contactor operation in Stick Mode

Yes Yes Yes

Selects mode of operation: Panel or Remote

STD

SLOPE

REPEAT

SPOT

PULSE ON/OFF

Contactor ON/OFF

Operation

PANEL /REMOTE

300/400TS and 300 /400S 4 OPERATOR CONTROLS

4 – 3

Weld Parameter Descriptions for ARC MASTER 300/400TS and 300/400S

Figure 4-3:

ARC MASTER 300/400TS

Front Panel with Param e ter Descriptio n

Parameter Description

PRE-FLOW

This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc, once th e torch trigg er swi tch has be en press ed. This control is used to dra matic ally reduce weld porosity at the start of a weld.

HOT START

This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the BASE (WELD) current. e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps & HOT START = 30 amps

INITIAL CUR.

This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the start current for TIG. The Start Current remains on until the torch trigger switch is released after it has been depressed.

UP SLOPE

This parameter operate s in TIG modes only and is used to set the time for the weld curre nt to ramp up, after the torch trigger switch has been pressed then released, from INITIAL CUR to PEAK or BASE current.

PEAK CUR. This parameter sets the PEAK weld current when in PULSE mode.

WELD

This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and SPOT modes when PULSE is off. This parameter also sets the STICK weld current.

BASE

(Background

Current)

This parameter sets the Background current when in Pulse TIG mode.

SPOT TIME This parameter sets the duration of the SPOT TIME in HF TIG mode only.

PULSE WIDTH

This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSE is on.

PULSE FREQ. This parameter sets the PULSE FREQUENCY when the PULSE is on.

DOWN SLOPE

This parameter operate s in TIG modes only and is used to set the time for the weld curre nt to ramp down, after the torch trigger switch has been pressed, to CRATER CUR. This control is used to eliminate the crater that can form at the completion of a weld.

CRATER CUR.

This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the finish current for TIG. The CRATER Current remains on until the torch trigger switch is released after it has been depressed.

300/400TS and 300/400S 4 OPERATOR CONTROLS

4 – 4

Table4-3: Weld Parameter Descriptions for ARC MASTER 300/400TS

Figure 4-4:

ARCMASTER 300/400S

Front Panel with Param e ter Descriptio n

Table4-4: Weld Parameter Descriptions 300/400S

POST-FLOW

This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished. This control is used to dramatically reduce oxidation of the tungsten electrode.

The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into the 300/ 400TS and 300/400S memory.

Parameter Description

SAUVEGARDER CHARGER

SAVE LOAD

Parameter Description

HOT START This parameter operates in STICK weld mode and is used to improve the start characteristics for

stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the WELD current.

Weld Current (Amperage)- sets the STICK and TIG WELD current.

ARC CONTROL - This parameter pr ovides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability.

300/400TS and 300 /400S 4 OPERATOR CONTROLS

4 – 5

Weld Parameters for ARC MASTER 300/400TS and 300/400S

Table4-5: Weld Parameters for ARC MASTER 300/4 00TS

Table4-6: PULSE FREQ. Range and Incremental Units

Table4-7: Weld Parameters for ARC MASTER 300/400S

Weld Mode

Weld Parameter

Parameter

Range

Factory Setting Incremental Unit STICK HF TIG LIFT TIG

PRE-FLOW 0.0 to 1.0 sec 0 sec 0.1 sec No Yes Yes HOT START 0 to 70A 20A 1A Yes Yes No

INITIAL CUR.

300TS 5 to 300A

30A 1A No Yes Yes

400TS 5 to 400A

UP SLOPE 0 to 15 sec 1 sec 0.1 sec No Yes Yes PEAK CUR.

300TS 5 to 300A

120A 1A No Yes Yes

400TS 5 to 400A

WELD CUR. (TIG)

300TS 5 to 300A

80A 1A No Yes Yes

400TS 5 to 400A

WELD CUR. (STICK)

300TS 5 to 300A

80A 1A Yes No No

400TS 5 to 400A SPOT TIME 0.5 to 5.0 sec 2 sec 0.1 sec No Yes Yes PULSE WIDTH 15 to 80% 50% 1% No Yes Yes PULSE FREQ. 0.5 to 500Hz 100.0Hz See Table 4-6 No Yes Yes DOWN SLOPE 0 to 25 sec 3 sec 0.1 sec No Yes Yes CRATER CUR. 5 to 40A 30A 1A No Yes Yes POST-FLOW 0.0 to 60 sec 10 sec 0.1 sec No Yes Yes

PULSE FREQ. Range Incremental Unit

0.5 to 20Hz 0.1Hz

20 to 100Hz 1Hz

100 to 500Hz 5Hz

Weld Mode

Weld Parameter Parameter Range Factory Setting Incremental Unit STICK LIFT TIG

HOT START 5 to 70A 20A 1A Yes No WELD CUR.

300S 5 to 300A DC

80A 1A Yes Yes

400S 5 to 400A DC

ARC CONTROL 0 to 100% 10% 1% Yes No

300/400TS and 300/400S 4 OPERATOR CONTROLS

4 – 6

Power Source Features

Table4-8: Power Source Features

Feature Description

New Digital Control

 Almost all welding parameters are

adjustable.

Touch Panel Switches

 Touch switches eliminate

mechanical damage.

Front Control Cover

 Protects front panel controls.

Digital Me ter

 Displays selected weld parame-

ter value.

 Displays weld current when weld-

ing.

 Displays weld current for 20 sec-

onds after weld has been completed.

 A selected weld parameter value

can be adjusted at any time even while welding.

Intelligent Fan Control

 The intelligent cooling system is

designed to reduce dust and foreign material build-up, while providing optimum cooling.

 Fan speed reduces approximately

30 seconds after machine is turned on.

 Fan speed increases when inter-

nal components reaches operating temperature.

ON/OFF switch

 Primary voltage Supply ON/OFF

switch located on rear panel.

Voltage Reduction Device (VRD)

Reduces the OCV when the power supply is not in use. Eliminates the need for add on voltage reducers and has no effect on arc starting.

 VRD fully complies to IEC 60974-1  When Stick mode is selected the

green VRD light is ON when not welding and red when welding.

 When in TIG modes VRD is off.

Control Knob

 For the selected weld parameter,

rotating the knob clockwise increases the parameter.

 Rotating the knob counter-clock-

wise decreases the parameter.

 A selected weld parameter value

can be adjusted at any time even while welding.

 Pushing the knob in displays

actual arc voltage.

Self Diagnosis Using Error Codes

 An error code is displayed on the

Digital Meter when a problem occurs with Primary supply voltage or internal component problems. Refer to troubleshooting guide.

Save/Load function

(300/400TS only)

 A total number of 5 programs can

be saved into the 300/400TS memory.

SAVE the Current Weld Parameters into Memory.

 Press the SAVE button.  Select a memory location by rotat-

ing the control knob, 1 to 5 is d isplayed on the meter.

 After selecting the desired mem-

ory location (ie 1 to 5), press the right scroll button and the machine will give a beep to confirm the weld parameters from the control panel are saved.

LOAD (retrieve) a Program to Control Panel.

 Press the LOAD button.  Select a memory location by rotat-

ing the control knob, 1 to 5 is d isplayed on the meter.

After selecting the desired memory location (ie 1 to 5), press the rig ht scrol l button and the machin e will give a beep to confirm the weld parameters are loaded onto the control panel.

Feature Description

5 SET-UP FOR SMAW (STICK) AND GTAW (TIG)

Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects. Current delivered to the arc

is dependent on the welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding current at any one setting

would vary according to the type of electrode in use.

The operator should use the welding current range

values as a guide, then finally adjust the current

setting to suit the application.

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear or

sides of the Welding Power Source.

CAUTION

DO NOT change the Weld Mode or Weld Process Mode until after POST-FLOW time has finished.

Figure5-1: 300/400TS Set-up

Figure5-2: 300/400S Set-up

5 – 1

300/400TS and 300/400S 5 SET-UP FOR SMAW (STICK) AND GTAW (TIG)

5 – 2

PAGE LEFT INTENTIONALLY BLANK

6 SEQUENCE OF OPERATION

6 – 1

SEQUENCE OF OPERATION

NOTE

Scroll Buttons are used to s elec t the pa ra mete rs to be set. The LED's show which function is being adjusted on the weld sequence graph. Refer to the Symbols Table loc ated in the front of the manual for Symbol descriptions.

Figure 6-1: 300/40TS Front Panel

Figure 6-2: 300/400S Front Panel

1. Pulse function: Pressing this button enables the TIG current pulse functions.

2. Remote Current function: Pressing this button enables remote current functions.

3. TIG Mode Functions: Pressing this button scrolls through the output TIG function modes (Standard, Slope, Slope w/repeat, Spot).

4. Digital LED display: Welding amperage and parameter values are displayed in this window. Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen.

5. Save/Load Buttons: By using the Save & Load buttons the operator can easily save up to 5 welding parameter programs.

6. Control knob: Allows the operator to adjust the output amperage within the entire range of the power source and sets each parameter value.

7. Process Button: This button selects between STICK, HF TIG and Lift TIG mode.

8. Scroll Buttons: Used to select the parameters to be set. The LED's show which function is being adjusted on the Sequence Graph.

9. Contactor function: Pressing this button enables Contactor functions.

Stick Welding

 Connect work lead to negative terminal.  Connect electrode lead to positive terminal.  Switch machine on.  Set Contactor.  Connect remote control device if required.

Use the Scroll Buttons to move to th e pa ra met er to be set. The LED will show which function is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

 Set HOT START.  Set WELD current.

Commence welding.

300/400TS and 300/400S 6 SEQUENCE OF OPERATION

6 – 2

HF TIG Welding (300/400TS only)

 Connect work lead to positive terminal.  Connect TIG torch to negative terminal.  Switch machine on.  Connect remote control device if required.

Use the Scroll Buttons to move to the parameter to be set. The LED will show which functi on is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

 Set PRE-FLOW time.  Set HOT START current.  Set POST-FLOW time.  Set (WELD) PEAK CUR current.  Set POST-FLOW time.

Slope Mode Parameters if required.

 Set INTIAL CUR current.  Set UP SLOPE time.  Set (WELD) PEAK CUR current.  Set BASE current.  Set DOWN SLOPE time.  Set CRATER CUR current.

Pulse Mode parameters if required.

 Set PULSE WIDTH % for PEAK CURRENT.  Set PEAK CURRENT.  Set PULSE FREQ.

Commence welding.

Lift TIG Welding

 Connect work lead to positive terminal.  Connect TIG torch to negative terminal.  Switch machine on.  Set weld current.  Connect remote control device.

Use the Scroll Buttons to move to the parameter to be set. The LED will show which functi on is being adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

 Set WELD current

Commence welding

Slope Mode Sequence (300/400TS only)

Figure 6-3: Slope Mode Sequence

1. To start Slope sequence Close remote switch contacts. Once the welding arc is established the Power Source will maintain initial current setting as long as the remote switch contacts are closed.

a. In the HF TIG mode, after Preflow time,

High Frequency is present at the torch. When the torch is positioned close to the work the welding current will transfer to the work and establish the arc at the initial current setting.

b. In the Lift TIG mode, after Preflow time, Lift

Start current is present at the torch. When the electrode is touched to the work and lifted off, the welding arc is established at the initial current setting.

2. Open Remote Switch

– current increases to

weld current. Once welding arc has reached weld current the power source will maintain weld current as long as the remote switch contacts are open.

3. Close Remote Switch

– Welding current

decreases to final current setting. Once final welding current is reached the power source will maintain final current setting as long as the remote switch contacts are closed.

4. Open Remote Switch

– Welding arc stops and

post flow begins.

Weld Current

Down Slope

Up Slope

Initial Current

Switch Closed

Switch Open

Switch Closed

Switch Open

Preflow

Final Current

Postflow

300/400TS and 300 /400S 6 SEQUENCE OF OPERATION

6 – 3

Slope Mode with repeat sequence (300/400TS only)

The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the down slope period only. During the down slope period by op ening the Remote Switch contacts the current will increase bac k to weld current. Within the Down Slope period the repeat function can operated as many times as desired. To continue slope cy cle and end slo pe sequence close remote switc h contacts and allow weld current to reach final current setting. Once fina l current setting is reached openi ng the Remote Swi tch again will turn off the welding arc and post flow begins.

Pulse Controls (300/400TS only)

The Pulse controls are used primarily to control heat input. Pulse o ffers a number of advantages as follows:

1) Control puddle

– size and fluidity (especially

out of position).

2) Increase penetration.

3) Travel speed control.

4) Better consistent quali ty.

5) Decreased distortion on lighter or thinner materials.

Pulse-current prov ide s a syst em in which the wel ding current continuousl y changes betw een two levels. During the periods of Peak current, heating and fusion takes place, and during the background (base) current periods, cooling and solidification take place. Pulse Width is the time in one cycle the current remains at the peak current setting. Pulse Frequency, measured in Hertz, is the number of cycles per second the current travels between peak and background current settings. It is as if the foot rheostat were moved up and down to

increase and decrease the welding current on a regular basis. The faster you move the foot rheostat up and down, the faster the frequency.

(Peak Current)

(Base)

Background

Current

(Pulse Width) (Pulse Frequency)

300/400TS and 300/400S 6 SEQUENCE OF OPERATION

6 – 4

PAGE LEFT INTENTIONALLY BLANK

7 ROUTINE MAINTENANCE

7 – 1

ROUTINE MAINTENANCE

The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

WARNING

Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enc losure to allow the primary capacitors to discharge.

To clean the unit, op en the enclosu re (pl ease ref er to Section 11.01.1, Opening the Enclosure) and use a vacuum cl eaner to rem ove any acc umulated dirt and dust. The unit s hould also be wiped clean , if necessary; with solvents that are rec ommended for cleaning electrical apparatus.

CAUTION

Do not blow air into the pow er su ppl y d urin g c lea ning. Blowing air into the unit ca n cause m etal pa rticles to interfere with sensitive electrical components and cause damage to the unit.

Warning! Disconnect input power before maintaining.

Each Use

Maintain more often if used under severe conditions

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Replace all broken parts

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

7-2

6 Months

Bring the unit to an authorized Thermal Arc Service Center to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

Art # A-07331

8 BASIC TROUBLESHOOTING

8 – 1

BASIC TROUBLESHOOTING

WARNING

There are extremel y dangerous voltages and power levels present ins ide this product. Do not a ttempt to open or repair unless you ar e an Accr edite d Thermal Arc S ervice Age nt and you have had tr aini ng in power measurements and troubleshooting techniques.

If major complex subassemblies are fa ulty, then the Weldi ng Power Source m ust be returned to an Accr edited Thermal Arc Service Agent for repair.

The basic level of troubleshooting is that which can be performed without special equipment or knowledge.

TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.

Description Possible Cause Remedy

1. Excessive bead build-up or poor penetration or poor fusion at edges of weld.

Welding current is too low. Increase weld current and/or faulty joint

preparation.

2. Weld bead too wide and flat or undercut at edges of weld or excessive burn through.

Welding current is too high. Decrease weld current.

3. Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart.

Travel speed too fast. Reduce travel speed.

4. Weld bead too wide or excessive bead build up or excessive penetration in butt joint.

Travel speed too slow. Increase travel speed.

5. Uneven leg length in fillet joint. Wrong placement of filler rod. Re-position filler rod.

6. Electrode melts when arc is struck. A. Electrode is connected to the '+' terminal.

B. WAVE BALANCE is greater than

50%.

A. Connect the electrode to the '–'

terminal.

B. Reduced WAVE BALANCE to below

50% or increase the electrode size.

7. Dirty weld pool. A. Electrode contaminated through contact with work piece or filler rod material.

B. Gas contaminated with air.

A. Clean the electrode by grinding off

the contaminates.

B. Check gas lines for cuts and loose

fitting or change gas cylinder.

8. Electrode melts or oxidizes when an

arc is struck.

A. No gas flowing to welding region.

B. Torch is clogged with dust. C. Gas hose is cut. D. Gas passage contains impurities.

E. Gas regulator turned off. F. Torch valve is turned off. G. The electrode is too small for the

welding current.

H. WAVE BALANCE is set above

50%.

A. Check the gas lines for kinks or

breaks and gas cylinder contents. B. Clean torch. C. Replace gas hose. D. Disconnect gas hose from torch the n

raise gas pressure and blow out

impurities. E. Turn on. F. Turn on. G. Increase electrode diameter or

reduce the welding current. H. Reduced WAVE BALANCE to below

50% or increase the electrode size.

300/400TS and 300/400S 8 BASIC TROUBLESHOOTING

ydemeResuaC elbissoPnoitpircseD

9. Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems.

10.Arc flutters during TIG welding. A. Tungsten electrode is too large

for the welding current.

B. Absence of oxides in the weld

pool.

11.Welding arc can not be established. A. Work clamp is not connected to

the work piece or the work/torch leads are not connected to the

right welding terminals. B. Torch lead is disconnecte. C. Gas flow incorrectly set, cylinder

empty or the torch valve is off.

12.Arc start is not smooth. A. Tungsten electrode is too large for the welding current.

B. The wrong electrode is being

used for the welding job.

C. Gas flow rate is too high.

D. Incorrect shielding gas is being

used.

E. Poor work clamp connection to

work piece.

F. Contaminated electrode. F. Re-prep tungsten. G. Improper electrode preparation. G. Sharpen to a symetrical point.

A. Select the right size electrode. Refer

to Basic TIG Welding guide.

B. Refer Basic TIG Welding Guide for

ways to reduce arc flutter.

A. Connect the work clamp to the work

piece or connect the work/torch leads to the right welding terminals.

B. Connect it to the '–' terminal. C. Select the right flow rate, change

cylinders or turn torch valve on.

A. Select the right size electrode. Refer

to Basic TIG Welding Guide.

B. Select the right electrode type.

Refer to Basic TIG Welding Guide.

C. Select the correct rate for the

welding job. Refer to Basic TIG Welding Guide.

D. Select the right shielding gas.

Refer to Basic TIG Welding Guide.

E. Improve connection to work piece.

Table8-1: TIG Welding Problems

8 – 2

300/400TS and 300 /400S 8 BASIC TROUBLESHOOTING

8 – 3

Stick Welding Problems

Table8-2-a: STICK Welding Prob lems

Figure 8-1: Example of insufficient gap

or incorrect sequen ce

Table8-2-b: STICK Weld in g Pro b lem s (con tin ue d)

Figure8-2: Example of lack of fusion

Description Possible Cause Remedy

1. Gas pockets or voids in weld metal (Porosity).

A. Electrodes are damp. B. Welding current is too high. C. Surface impurities such as oil,

grease, paint, etc.

A. Dry electrodes before use. B. Reduce welding current. C. Clean joint before welding.

2. Crack occurring in weld metal soon after solidification commences.

A. Rigidity of joint.

B. Insufficient throat thickness.

C. Cooling rate is too high.

A. Redesign to relieve weld joint of

severe stresses or use crack resistance electrodes.

B. Travel slightly slower to allow

greater build up in throat.

C. Preheat plate and cool slowly.

3. A gap is left by failure of the weld metal to fill the root of the weld.

A. Welding current is too low. B. Electrode too large for joint. C. Insufficient gap. D. Incorrect sequence.

A. Increase welding current. B. Use smaller diameter electrode. C. Allow wider gap. D. Use correct build-up sequence.

Incorrect sequence Insufficient gap

Description Possible Cause Remedy

4. Portions of the weld run do not

fuse to the surface of the metal or edge of the joint.

A. Small electrodes used on heavy cold

plate. B. Welding current is too low. C. Wrong electrode angle.

D. Travel speed of electrode is too high. E. Scale or dirt on joint surface.

A. Use larger electrodes and preheat

the plate. B. Increase welding current. C. Adjust angle so the welding arc is

directed more into the base metal. D. Reduce travel speed of electrode. E. Clean surface before welding.

Lack of Root Fusion

Lack of inter-run Fusion

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

Lack of side fusion, scale dirt, small electrode, amperage too low

300/400TS and 300/400S 8 BASIC TROUBLESHOOTING

8 – 4

Table 8-2-c: STICK Welding Problems (continued)

Figure8-3: Examples of slag inclusion

Description Possible Cause Remedy

5. Non-metallic particles are trapped in the weld metal (slag inclusion).

A. Non-metallic particles may be

trapped in undercut from previous run.

B. Joint preparation too restricted.

C. Irregular deposits allow slag to be

trapped.

D. Lack of penetration with slag

trapped beneath weld bead.

E. Rust or mill scale is preventing full

fusion.

F. Wrong electrode for position in

which welding is done.

A. If bad undercut is present, clean

slag out and cover w ith a ru n from a smaller diameter electrode.

B. Allow for adequate penetration and

room for cleaning out the slag.

C. If very bad, chip or grind out

irregularities.

D. Use smaller electrode with

sufficient current to give adequate penetration. Use suitable tools to remove all slag from corners.

E. Clean joint before welding.

F. Use electrodes designed for

position in which welding is done, otherwise proper control of slag is difficult.

Not cleaned, or incorrect electrode

Slag trapped in undercut

Slag trapped in root

300/400TS and 300 /400S 8 BASIC TROUBLESHOOTING

8 – 5

Power Source Problems

Table8-3: Power Source Problems

Description Possible Cause Remedy

1. The welding arc cannot be established.

A. The Primary supply voltage has not

been switched ON.

B. The Welding Power Source switch

is switched OFF.

C. Loose connections intern al ly.

A. Switch ON the Primary supply

voltage.

B. Switch ON the Welding Power

Source.

C. Have an Ac credited Thermal Ar c

Service Agent repair the connection.

2. Maximum output welding current can not be achieved with nominal Mains supply voltage.

Defective control circuit. Have an Accredited Thermal Arc

Service Agent repair the connection.

3. Welding current reduces when welding.

A. Loose welding cable connections.

B. Incorrect welding cable size. C. Improper input connections.

D. Poor electrode condition. E. Wrong welding polarity.

A. Tighten all welding cable

connections. B. Use proper size and type of cable. C. Refer to Section 2.05 Elec trical Input

Requirements. D. Replace electrode. E. Verify output torch connections.

4. No gas flow when the torch trigger switch is depressed.

A. Gas hose is cut. B. Gas passage contains impurities.

C. Gas regulator turned off. D. Torch trigger switch lead is

disconnected or switch/cable is faulty.

A. Replace gas hose. B. Disconnect gas hose from the rear of

Power Source then raise gas

pressure and blow out impurities. C. Turn gas regulator on. D. Reconnect lead or repair faulty

switch/cable.

5. Gas flow won't shut off. A. Weld Mode (STD, SLOPE, REPEAT or SPOT) was changed before POST-FLOW gas time had finished.

B. Gas valve is faulty.

C. Gas valve jammed open.

D. POST-FLOW control is set to 60

sec.

A. Strike an arc to complete the weld

cycle. OR Switch machine off then on to reset solenoid valve sequence.

B. Have an Accredited Ther mal Arc

Service Agent repair or replace the gas valve.

C. Have an Ac credited Thermal Ar c

Service Agent repair or replace the gas valve.

D. Reduce POST-FLOW time.

6. The TIG electrode has been

contaminated due to the gas flow shutting off before the pro grammed POST-FLOW time has elapsed.

The Weld Process Mode (STICK, HF TIG or LIFT TIG) was changed before POST-FLOW gas time had finished.

Do not change Weld Process Mode before the POST-FLOW gas time had finished.

300/400TS and 300/400S 8 BASIC TROUBLESHOOTING

8 – 6

PAGE LEFT INTENTIONALLY BLANK

9 VOLTAGE REDUCTION DEVICE (VRD)

VRD Specification

Description Range Notes

VRD Open Circuit Voltage

VRD Resistance

VRD Turn OFF Time

VRD Maintenance

Routine inspection and testing (power source): An inspection of the power source should be car-

ried out.

a. For transportable equipment, at least once

every 3 months; and

b. For fixed equipment, at least once every 12

months.

The owners of the equipment shall keep a suitable record of the periodic tests. Please refer to Table 9-2 for the tests.

15.3 to

19.8V

148 to 193

ohms

0.2 to 0.3 seconds

Table9-1: VRD Specification

Open circuit voltage between welding terminals.

The required resistance between welding terminals to turn ON the welding power.

The time taken to turn OFF the welding power once the welding current has stopped.

Voltage Reduction Device (VRD)

NOTE

A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated.

If this equipment is used in a location or an environment with a high risk of electrocution then the above tests should be carried out prior to entering this location.

The test of VRD is shown below:

1) In STICK welding mode, mark and then turn potentiometer VR1 on PCB6 (WK-5549) fully clockwise and turn on the electric shock protector function (Voltage-Reduction-Device, VRD).

2) Contactor function is put into the state of “ON” pushing Function button. Refer to section 6.

3) Verify the no-load voltage (OCV) using a DC voltmeter. (The capability of the voltmeter should be more than 100VDC.)

4) The normal no-load voltage is approximately 18V.

5) In STICK welding mode, mark and then turn potentiometer VR1 on PCB6 (WK-5549) fully counter-clockwise and turn off the VRD.

6) Contactor function is put into the state of “ON” pushing Function button. Refer to section 6.

WARNING

Electric shock hazard. The unit will generate OCV (Open Circuit Voltage) immediately when contactor function is put into the state of on pushing Function button enabling STICK mode.

7) Verify the no-load voltage (OCV) using a DC voltmeter. (The capability of the voltmeter should be more than 100VDC.)

8) The normal no-load voltage is approximately 65V.

In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should also be conducted by an accredited Thermal Arc service agent.

Description IEC 60974-1 Requirements

VRD Open Circuit Voltage

VRD Turn ON Resistance

VRD Turn OFF Time

Less than 20V; at Vin=230V or 460V

Less than 200 ohms

Less than 0.3 seconds

Table9-2: Periodic Tests

9 – 1

300/400TS and 300/400S 9 Voltage Reduction Device (VRD)

9 – 2

Switching VRD On/Off

Switch the machine Off.

A) Remove the clear plastic cover from the control

panel (see Figure 9-1).

 Lift up the cover so it rests on the top of the

unit.

 Place a small flat bladed screw driver between

the cover hinge on the front panel.

 Gently lift the cover hinge out of the front cover

mounting hole.

 Remove the control's clear plastic cover.

Figure 9-1: VRD ON/OFF Step A

B) Remove four mounting screws from the control

panel (see Figure 9-2).

Figure9-2: VRD ON/OFF Step B,C

C) Access the VRD control by gently prying back

the front panel controls to reveal the VRD on/ off potentiometer (see Figure 9-3).

CAUTION

Do not pull back the front panel with excessive force as this will un plug the control PCB . Plugging

the control PCB back into the front panel controls can only be achieved by removing the side covers.

Figure9-3: VRD ON/OFF Step D

D) Turning the VRD ON/OFF (see Figure 9-3).

 To turn VRD ON: rotate the trim potentiometer

(VR1) on the display PCB fully clockwise. When VRD is turned ON check that it operates as per VRD Specifications on section 9.1.

 To turn VRD OFF: ro tate the trim potenti ometer

(VR1) on the display PCB fully counter clockwise.

WARNING

The VRD ON/OFF t r i m po t en t io m ete r MUS T ONLY be positioned fully clockwise OR fully counter clockwise as the VRD functi on will be unknown for every other position.

VR1

10 POWER SOURCE ERROR CODE

10 – 1

Power Source Error Code

Description Possible Cause Remedy Remarks

1. E01 error code displayed Temperature sensor TH1 (protects IGBT s) is greater than 80°C for about 1 second.

A. The Welding Power

Source's duty cycle has been exceeded.

B. Fan ceases to operate.

C. Air flow is restricted by

vents being blocked.

A. Let Power Source cool

down then keep within its duty cycle.

B. Have an Accredited

Thermal Arc Service Agent investigate.

C. Unblock vents then let

Power Source cool down.

Weld current ceases. Buzzer sounds constantly. Fan operates at max speed. E01 resets when TH1 decreases to 70°C for about 30 seconds.

2. E02 error code displayed Temperature sensor TH2 (protects secondary diodes) is greater than 80°C for about 1 second.

A. The Welding Power

Source's duty cycle has been exceeded.

B. Fan ceases to operate.

C. Air flow is restricted by

vents being blocked.

A. Let Power Source cool

down then keep within its duty cycle.

B. Have an Accredited

Thermal Arc Service Agent investigate

C. Unblock vents then let

Power Source cool down.

Weld current ceases. Buzzer sounds constantly. Fan operates at max speed. E02 resets when TH2 decreases to 70°C for about 30 seconds.

3. E03 error code displayed Transformer current too high.

A. Transformer current is

too high becaus e welding arc is too long.

B. Mains supply voltage is

more than 10% below nominal voltage .

A. Reduce length of welding

arc.

B. Have an Accredited

Thermal Arc Service Agent or a qualified electrician check for low Mains voltage.

Weld current ceases. Buzzer sounds constantly. Switch machine off then on to reset E03 error.

4. E04 error code displayed Output voltage exceeds the secondary voltage specification.

TIG torch cable and/or work lead are too long or leads are coiled.

Reduce the length of the TIG torch cable and/or work lead or un-coiled leads.

Weld current ceases. Buzzer sounds constantly. Switch machine off then on to reset E04 error.

5. E11 error code displayed Over Primary supply (input) voltage at prim ar y capacitors is exceeded for one second.

Primary supply voltage is greater than the nominal voltage plus 10%.

Have an Accredited Therm al Arc Service Agent or a qualified electrician check the Primary voltage.

Weld current ceases. Buzzer sounds constantly. Error code E11 automatically will res et when the voltage reduces.

6. E14 error code displayed Under mains supply (input) voltage warning primary capacitor s is reduced for one second.

Mains supply voltage is less than the nominal operating voltage less 10%.

Have an Accredited Therm al Arc Service Agent or a qualified electrician check the Mains voltage.

Weld current available. Buzzer sounds intermittently./Error code E14 automatically will reset when the voltage increases.

7. E12 error code displayed Under mains supply (input) voltage primary capacitors is reduced for one second.

Mains supply voltage is down to a dangerously low level.

A. Have an Accredited

Thermal Arc Service Agent or a qualified electrician check the Mains voltage.

B. Have an Accredited

Thermal Arc Service Agent or a qualified electrician check the primary cable and fuses.

Weld current ceases. Buzzer sounds constantly. Error code E12 automatically will res et when the voltage increases.

8. E81 error code displayed Wrong Primary supply (input) voltage connected.

When 3 phase machine is first turned on with the wrong Primary supply (i nput) voltage connected.

Have an Accredited Therm al Arc Service Agent or a qualified electrician check the Mains voltage.

No weld current is available. Buzzer sounds constantly. Switch machine off.

300/400TS and 30 0/400S 10 Power Source Error Code

10 – 2

Table10-1: Power Source Erro r Co des

9. E82 error code displayed Rated voltage selection circuit abnormality.

The Primary supply (input) voltage fluctuates and is not stable.

Have an Accredited Therm al Arc Service Agent or a qualified electrician check the Mains voltage.

No weld current is available. Buzzer sounds constantly. Switch machine off then on to reset E82 error.

10.E83 error code displayed CPU checks mains supply (input) voltage when the on/off switch on rear panel of machine is turned ON.

The Primary supply (input) voltage fluctuates and is not stable.

Have an Accredited Therm al Arc Servi ce Agent check connector plug on inpu t PCB and the Mains voltage.

No weld current is available. Buzzer sounds constantly. Switch machine off then on to reset E83 error.

11.E85 error code displayed Pre-charge abnormality.

Due to malfunction inside the Welding Power Source, primary capacitors are not charging correctly.

Have an Accredited Therm al Arc Service Agent service the machine.

No weld current is available. Buzzer sounds constantly. Switch machine off then on to reset E85 error.

12.E93 error code displayed Memory chip (EEPROM) on control PCB can not read/write weld parameters.

Memory chip (EEPROM) error.

Have an Accredited Therm al Arc Service Agent chec k t he control PCB.

Weld current ceases. Buzzer sounds constantly. Switch machine off.

13.E94 error code displayed Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit.

The Welding Power Source's temperature sensors have malf unc tioned.

Have an Accredited Therm al Arc Servi ce Agent check or replace the temperature sensors.

Weld current ceases. Buzzer sounds constantly. Switch machine off.

14.E99 error code displayed Mains supply (input) voltage has been turned off but control circuit has power from the primary capacitors.

A. Main on/off switch on

machine has been turned off

B. Mains supply (input)

voltage has been turned off.

A. Turn on/off switch on.

B. Have an Accredited

Thermal Arc Service Agent or a qualified electrician check the Mains voltage and fuses.

Weld current ceases. Buzzer sounds constantly. Must switch machine off then on to reset E99 error.

Description Possible Cause Remedy Remarks

11 ADVANCED TROUBLESHOOTING

11 – 1

ADVANCED TROUBLESHOOTING

If you are here, all of the troubles hooting suggestions in Section 8 Basic Troubleshooting have either failed to reso lve the faulty operation or ha ve indicated that one or more of the subsystems within the power s upply are d efective . This se ction provides the informa tion needed to take live meas- urements on the various subsystems within the power supply, and re place 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.

WARNING

There are extremely d angero us volt age and pow er levels present inside this unit. Do not attempt to diagnose or repair unless you have training in power electronics, mea su remen t and tro ubl es hoo ting techniques.

Under no circumstances are field repairs to be attempted on printed circ uit boar ds or oth er subas semblies of this unit. Evidence of unauthorized repairs will void the factory warranty. If a subassembly is fo und t o be de fe ct iv e b y ex ecuting any of the procedures in this Service Manual, the subassembly should be replaced with a new one. The faulty subassembly should then be returned to Thermal Arc through established procedures.

WARNING

Disconnect primary power at the source before disassembling the power supply. Frequently review the "Prinicpal Safety Standards" in secti on 1.02. Be sure the operator is equipped with proper gloves, clothing and eye a nd ear protection. Make sure no part of the operator's body comes into contact with the work piece or any internal components while the unit is activated.

System-Level Fault Isolation

If none of the suggestions provided in Section 8 have solved the problem or corrected the faulty operation, the next step is to isolate one or more of the internal subassemblies that may be defective.

CAUTION

Perform all steps in each pr ocedure in sequence. Skipping portions of procedures or performing steps out of seque nce can res ult in damage to the unit and possible injury, or worse, to the operator.

1.1 Opening the Enclosure

1) Confirm that the switch in the power supply and the switch in switchboard (distribution panel) are all OFF.

Figure 11-1: Switch OFF

CAUTION

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

11 – 2

2 ) Remove all s crews and nuts on the side cov-

ers.

Figure11-2: Remove s crews

3 ) L oosen the screws on the f ront panel and the

rear panel by turning the m approximately two turns CCW.

Figure11-3: Loosen screw s

NOTE

DO NOT remove the screws completely.

4) Pull the front panel slightly forward and pull the rear panel slightly backward. The interlocking hooks of the side case cov ers can now be disengaged from the front and rear panels.

Figure 11-4: Loosen front and rear panels

5) Remove the side covers.

Figure11-5: Remove Si de covers

300/400TS and 300 /400S 11 ADVANCED TROUBLESHOOTING

11 – 3

6) Remove protection cover sheet by removing the plastic tabs.

Figure 11-6: Remove PCB cover

NOTE

When you re-assemble the parts, conduct the above process backwards.

Verification and Remedy to the Indicated Error Codes

NOTE

The capacitors inside the power supply will s lowly discharged after you turn off the switch of the power supply or the s witch at th e breake r box (dis tribution panel). Wait at least 5 minutes for the discharge to complete and then remove the c ases to continue your inspection and repair (or maintenance) inside the po wer s uppl y. Refer to section

11.1.1 for the removal and installation of the case.

NOTE

During the "Verification/Remedy" procedures below, follow the alphabetical sequen ce (a, b, c...) and proceed with your verification and confirmation.

NOTE

After you confirm and replace all spare par ts and components, confirm that there are no damaged harnesses or connectors, and no uninstalled or loose screws.

2.1 E01 "Over-Temperature at the primary side"

Cause

Occurs when a n o ve r- t em pe ra t ur e co nd i ti o n of the primary IGBT is detected.

Verification/Remedy

a) Unit may be in thermal shutdown mode.

 Review the rated duty cycle of the unit per

section 3.8. Exceeding the duty cycle can damage the unit and void the warranty. Refer to Limited Warranty at the end of the manual.

b) Verify the ventilating condition.

 Maintain a clear and unobstructed distance

of more than 12 in. in

the front and more that 20 in. in the rear of the unit for ventilation purpos

es.

 Verify and maintain clean, dust free, front and

rear airflow paths. Cleaning and removing dust from the front and rear panels once every six months in a normal working environment is recommended. Extremely dusty environments will require more frequent cleanings.

c) Verify the operation of the cooling fan, FAN1,

and replace it if necessary.

 Verify the condition of FAN1. Verify that there

are no broken or crack ed fan bla des and that FAN1 is not producing any abnormal sounds.

 If brok en or cracked FAN1 blade s, or abnor-

mal sounds are emanating from FAN1, replace FAN1.

 Verify the operation of the cooling fan and

replace it if the condition of FAN1 is inactive.

 Refe

r to section 12.3.21 for th e replacement

of FAN1.

 Refer to section 11.5.3 for additional FAN1

tests.

d) Replace PCB6 (WK-5549).

 Refer to s ection 12.3.6 for the repl acement of

PCB6.

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

11 – 4

2.2 E02 "Over-Temperature at the secondary side"

Cause

Occurs when an over-temperature condition of the secondary IGBT and diode are detected.

Verification/Remedy

a) Unit may be in thermal shutdown mode.

 Review the rated duty cycle of the unit per

section 3.8. Exceeding the duty cycle can damage the unit and void the warranty.

b) Verify the ventilating condition.

 Maintain a clear and unobstructed distance

of more than 12 in. in the fr ont an d more tha t 20 in. i

n the rear of the unit for ventilation pur-

ses.

 Verify and maintain clean, dust free, front and

c) Verify the operation of the cooling fan, FAN1,

and replace it if necessary.

 Verify the condition of FAN1. Verify that there

are no broken or crac ke d fa n bl ad es and tha t FAN1 is not producing any abnormal sounds.

 If brok en or cracked FAN1 blades, or ab nor-

mal sounds are emanating from FAN1, replace FAN1.

 Verify the operation of the cooling fan and

replace it if th e cond ition o f FAN1 is inacti ve. Follow the instruction in section.

 Refer to sectio n 12.3.21 for the replacement

of FAN1.

 Refer to section 11.5.3 for addition FAN1

tests.

d) Replace PCB6 (WK-5549).

 Refer to se ction 12.3.6 fo r the replacement of

PCB6.

2.3 E03 "Transformer Over-Current Failure"

Cause

Occurs when excessive curren t is detected flowing into the primary side of the main transformer.

Verification/Remedy

a) Confirm the operation of the machine within

the rated specificatio n.

 Refer to the specification data sheet in Se c-

tion 3.9.

b) Verify the secondary diode (D2, D4, D5 and

D7).

 Refer to section 11.5.6 for the test

of D2, D4, D5 and D7.

c) Replace the Hall CT, HCT1.

 Refer to section 12.3.29 for the replac ement

of HF.UNIT 1.

NOTE

Pay special attention to installed direction of HCT1. The Hall CT will not fu nction proper ly if install ed in the incorrect direction.

 Refer to section 12.3.27 for the replac ement

of HCT1.

d) Verify the High Frequency Un

it (HF. UNIT1).

 Refe

r to section 12.3.26 for th e replacement

of HF.UNIT 1.

(300/400TS only)

300/400TS and 300 /400S 11 ADVANCED TROUBLESHOOTING

11 – 5

2.4 E04 "Torch Cable Failure"

Cause

The combined length of the torch cable and the work cable is too long.

Verification/Remedy

a) Verify the rated duty cycle of the torch/work

cable and the power supply.

 Only use appropriate sized torch cables

(length and capacity). The recommended total combined le ngth of the torch and work cable is 50 feet.

 Torch an d work cable should not be "coile d"

during welding operations.

 Maintai n the duty cycle of the power supply.

Refer to section 3.8 for the recommended duty cycle.

b) Replace PCB6 (WK-5549)

 Refer to section 12.3.6 for the replacement of

PCB6.

2.5 E11 "Main Supply Over Voltage"

Cause

Main supply voltage occurs in about 275V or more.

Verification/Remedy

a) Verify main supply voltage.

 Perform what is described in a section of

"Verification of the Power Supply Voltage". Refer section 11.5.2.

b) Replace PCB4 (WK-4819)

 Verify PCB4 (WK-4819) and replace it if nec-

essary. Refer to section 12.3.4.

2.6 E12 "Main Supply Under Voltage"

Cause

Main supply voltage occurs at ab

out 150V or less.

Verification/Remedy

a) Verify main supply voltage.

 Perform what is described in a section of

"Verification of the Power Supply Voltage". Refer to section 11.5.2

b) Replace PCB4 (WK-4819)

 Replace PCB4 when abnormalities occur,

even if it carries out the above-menti oned verifications. Refer to section 12.3.4.

2.7 E81 "Wrong Main Supply Voltage"

Cause

The detection circuitry of main supply voltage is abnormal.

Verification/Remedy

a) Verify main supply voltage.

 Perform what is described in the section

"Verification of the Power Supply Voltage". Refer to section 11.5.2.

b) Confirm a secure connection of the harness

wired between CN2 on PCB3 (WK-5548) and CN1 on PCB21 (WK-4917)

 Re-in stall the harness with a secur e connec-

tion.

 Contac t the manufactu rer if you find an y bro-

ken connectors or damaged wiring harnesses.

) Verify PCB4 (WK-4819) and replace it if neces-

sary

 Check whether there are any abnormalities

in the appearance of PCB4.

 Replace PCB4. Refer to section 12.3.4.

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

11 – 6

2.8 E82 "Rated Voltage Selection Circuit abnormality"

Cause

Rated voltage s election circ uit inside the Welding Power Source is not functioning properly.

Verification/Remedy

a) Verify the wiring harness and connection of

CN4 on PCB4 (WK-4819).

 Re-instal l the harness with a secure connec-

tion.

 Contact the manufacturer if you find any br o-

ken connectors or a damaged wiring harness.

b) Verify PCB4 (WK-4819) and replace it if neces-

sary.

 Check whether there are any abnormalities

in the appearance of PCB4.

 Replace PCB4. Refer to section 12.3.4.

2.9 E83 "Abnormalities in Mains Supply Voltage Detection"

Cause

Abnormalities, s uch as an inp ut voltage dete ction circuit.

Verification/Remedy

a) Verify main supply voltage.

 Perform what is described in the sec

tion

Verification of the Power Supply Voltage".

Refer to section 11.5.2.

b) Confirm a secure connection of the harness

wired between CN2 on PCB3 (WK-5548) and CN1 on PCB21 (WK-4917).

 Re-instal l the harness with a secure connec-

tion.

 Contact the manufacturer if you find any br o-

ken connectors or damaged wiring harness.

c) Verify PCB4 (WK-4819) and replace it if neces-

sary.

 Check whether there are any abnormalities

in the appearance of PCB4.

 Replace PCB4. Refer to section 12.3.4.

2.10E85 "Pre-charge abnor mality"

Cause

Due to a malfunction inside the Welding Power Source, primary capacitors are not charging co rrectly.

Verification/Remedy

a) Verify the connection of PCB2 (WK-5597) and

the rectified output voltage of the rectifier.

 Veri fy the co nne ction between CN2 on PCB2

and CN3 on PCB3.

 Confirm whether there is any breakage

(blown, burnt, cracked, etc.) of R18 on PCB2.

 Perform what is described in the section

"Verification of the Power Supply Voltage". Refer to section 11.5.2.

b) Verify the primary diode (D1).

 Verify D1. Refer to section 11.5.5.  Replace D1. Refer to section 12.3.28.

c) Verify the primary IGBT (Q1-Q24).

 Verify IGBT. Refer to section 11.5.7.



Replace IGBT. Refer to section 12.3.7, 12.3.8.

d) Replace PCB2 (WK-5597) and PCB4

(WK-4819).

 Repl ac e P CB2 an d P CB 4 w h en abno rma lit ies

occur, even if you ca

rry out the above-mentioned

erifications. Refer to

sections 12.3.2 and 12.3.4.

300/400TS and 300 /400S 11 ADVANCED TROUBLESHOOTING

11 – 7

2.11E94 "Thermistor malfunction"

Cause

Thermistors for detecting temperature of internal components have malfunctioned.

Verification/Remedy

a) Confirm a secure connection of the harness

wired between CN8-9 on PCB6 (WK-5549) and Thermistors (TH1, TH2).

 Re-instal l the harness with a secure connec-

tion.

 Contact the manufacturer if you find any br o-

ken connectors or a damaged wiring harness.

b) Replace thermistors (TH1, TH2).

 Refer to

section 12.3.19, 12.3.20.

c) Replace PCB6 (WK-5549).

 Refer to

section 12.3.6.

2.12E99 "Initial Power Receiving"

Cause

Occurs when the initial AC powe r received s ignal has not reached the CPU. This error occurs normally during the power "OFF" sequence of the unit.

Verification/Remedy

a) Confirm a secure connection of the harness

wired between CN1 on PCB21 (WK-4917) and CN2 on PCB3 (WK-5548).

 Re-instal l the harness with a secure connec-

tion.

 Contact the manufacturer if you find any br o-

ken connectors or a damaged wiring harness.

b) Verify PCB4 (WK-4819) and replace it if neces-

sary.

 Confirm a secure connection of all the har-

nesses wi

red to PCB3 and PCB4.

 R

eplace PCB4. Refer to

section 12.3.4.

c) Replace PCB6 (WK-5549).

 Refer to

section 12.3.6.

Verification and Remedy to Failures without Indication Codes

3.1 "Cooling Fan (FAN1) Failure" (Fan is not rotating.)

Cause

Occurs when the cooling fan (FAN1 ) is defective, damaged or the driving voltage is incorrect.

Verification/Remedy

a) Veri fy the cooli ng fan (FA N1) .

 Inspect the condition of the fan blades and all

peripheral parts. Clean the fan blades and all peripheral parts if cove red with dust. Cleaning and removing dust from the fan blades once every 6 months in a normal environment is recommended. Extremely dusty environments will require more frequent cleanings.

 Verify that there are no wiring harnesses

entangled inside the fan.

Confirm that the har-

nes

ses do not have any breaks

in the wire or

dam

aged connectors.



Replace wiring harnesses if you find any broken connectors or damaged wiring harnesses.

 Replace the fan if there are any broken,

cracked or missing fan blades.

 Refer to

section 12.3.21.

b) Verify the wiring harness between the cooling

fan (FAN1) and CN11 on PCB3 (WK-5548).

 Conf irm a secure connection of the harness

to CN11 on PCB3.

c) Verify the drive circuitry of the cooling fan

(FAN1) on PCB3.

 Verify the drive circuitry of the cooling fan

(FAN1) on PCB3.

 Refer to

section 11.5.3.

 Replace PCB3 if necessary.  Refer to

section 12.3.3.

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

11 – 8

3.2 "Gas Valve Failure" (No Gas flow through unit) (300/400TS only)

Cause

Occurs when the gas valve (SOL1) is defective, damaged or the driving voltage is incorrect.

Verification/Remedy

a) Confirm that TIG welding is selected on the

welding mode.

 Do not chan ge weldi ng mo des while we ldi ng .

Only change welding modes when the unit is idle (torch switch OFF).

 Verify the setting of Pre-flow and Post-flow

on the front panel. If the Pre-flow or Post-flow time is set to 0 seconds, change them to a higher setting.

b) Verify the layout of the gas hose.

 Confirm that the hose is securely connec ted

into the fitting at the in let and t he o utl et. Co nfirm the layout of the gas hose so that i t is not bent or kinked. Confirm there are no breaks, burns or holes in the hose.

 Confirm the layou t of th e TIG torc h gas ho se

and that the hose adapters are properl y connected.

c) Verify the wiring harness and connection of the

gas valve (SOL1) and CN11 on PCB3 (WK-5548).

d) Verify the drive circuitry of the gas valve

(SOL1).

 Verify the drive circuitry of the gas valve

(SOL1).

 Refer to

section 11.5.4.

 Replace PCB3, when abnormal.  Refer to

section 12.3.3.

e) Replace the PCB6 (WK-5549).

 Refer to

section 12.3.6.

3.3 "No We ld Ou tput"

When in High Frequency TIG (HF TIG) mode, if the High Frequency is not generat ed ( pres ent) , refer to "High Frequency Output Failure" section 11.3.5.

Cause

Occurs when the remote connector (CON1) or associated circu itry is defective, damage d, or the TIG torch cable is defective.

Verification/Remedy

Caution

Read and understand this entire section before proceeding. Extreme personal harm and test equipment damage will o ccur if the pro cedures are not performed accurately.

a) Verify the remote connector (CON1).

(Applies to LIFT TIG and High Frequency TIG [HF TIG]

mode.)

 Conf

irm a secure connection b

etween the

remote connector (CON1) and the TIG torch cable.

 Conf

irm a secure connec tion of the harness and the connections between the remote connector (CON1) and PCB7 (WK-55 50) and that the

re are no open circuits.

 Cont

act the manufacturer i

f you find any br o-

n connectors or damaged wiring har-

nesses.

 Confirm the proper pin-outs of the remote

connector at the TIG Torch side. (Refer to section 4.1.2.)

 Confirm that there is no open circuit on the

remote connector at TIG Torch side.

 In equi pment for remote control is used,

confirm

the p

in specification of the con nector . (Ref er to

section 4.1.2.)

b) Verify the condition and connections of the

welding cable, the stick rod holders and the ground clamp. (Applies to all welding modes.)

 Conf irm a secure connection of t he welding

cable, stick rod holders, ground clamp and dinse connectors and that there are no o pen

cir

cuits.

300/400TS and 300 /400S 11 ADVANCED TROUBLESHOOTING

11 – 9

c) Verify the no-load voltage (OCV).

(Applies to STICK, High Frequency TIG [H

IG] mo

de.)

 Re

fer to the section "Verification of No-load

voltage (OCV)" in

section 11.5.9.

 If performing the "No-Load Voltage Failure"

procedure does not rectify the failure, perform the following tests in the sequence below. Replace any defective components found.

1. Secondary diode (D2, D4, D5 and D7).  Verification. Refer to

section 11.5.6.

 Replacement. Refer to

section 12.3.29.

2. Coupling coil (CC1)

(300/400TS only)

 Replacement. Refer to

section 12.3.17.

3. Reactor (FCH1)  Replacement. Refer to

section 12.3.18.

4. PCB14 (T1)  Replacement. Refer to

section 12.3.11.

5. PCB8-PCB11 (Q1~Q24)

 Verification. Refer to section 11.5.7.  Replacement.

Refer to section 12.3.7,

12.3.8.

7. Hall C.T. (HCT1)  Replacement. Refer to section 12.3.27.

3.4 "Operating Panel Failure" (LED's do not light properly or welding setting cannot be established.)

Cause

Occurs when there is a connecti on failure among PCB6 (WK-5549), PCB12 (WK-5527) and PCB6 or PCB12 are defective.

Verification/Remedy

a) Verify the harnes s co nnec tion between CN21

on PCB6 (WK-5549) and CN2 on PCB12 (WK-5527).

 Confirm a secure connection of the harness

and the connections between CN21 on PCB6 (WK-5549) and CN2 on PCB12 (WK-5527).

 Contact the manufacturer if you find any bro-

ken connectors or damaged wiring harnesses.

b) Verify the conne cti on betwe en PCB 6

(WK-5549) and PCB12 (WK-5527).

c) Replace PCB6 (WK-5549) and PCB12

(WK-5527).

 Refer to section 12.3.6, 12.3.9.

d) Verify the conne cti on betwe en PCB 5

(WK-5551) and PCB6 (WK-5549).

e) Replace PCB5 (WK-5551) and PCB6

(WK-5549).

 Refer to section 12.3.5, 12.3.6.

3.5 "High Frequency Output Failure" (Unit does not generate High Frequency.) (300/400TS only)

Cause

Occurs when the High Frequency Unit (HF UNIT1) is defective

or blown.

Verification/Remedy

Caution

Read and understand this entire section before proceeding. Extreme personal harm and test equipment damage will o ccur if the pro cedures are not performed accu rately. The unit will gener ate a High Voltage component that can cause extreme personal harm and test equipment damage.Capacitors installed inside the Welding Power Source are electrically charge d for a whil e after the Mains O N/ OFF switch or distribution panel switch has been turned off. Before inspecting the inside of the Welding Power Source, leave it for about 5 min. after switching off power fo r discharging the cap acitors, and then remove the top and side panels.

a) Verify the connection between High Frequency

(HF UNIT1) and Coupling Coil (CC1).

 Veri fy the c onnect ion be tween th e HF UN IT1

and CC1; confirm that the quick-disconnect terminals are inserted onto the terminals of HF UNIT1 (TB5-TB6) correctly and completely.

 Confir m there are no short circuits, burnt or

broken wires at CC1.

 Replace CC1.  Refer to section 12.3.17.

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

11 – 10

b) Verify the connection between High Frequency

Unit (HF UNIT1) and the current limiting resistor (R2).

 Verify the connection between HF UNIT1 and

the current limiting resistor (R2). Co

nfirm that

e quick-disconnect terminals are inserted onto the terminals of HF UNIT1 (TB3-TB4) correctly and compl etely.

 Confirm there are no short circuits, burnt or

broken wires between the HF UNIT1 and the current limiting resistor (R2).

c) Verify the connection between the terminals

between AC1-AC2 (TB1-TB2).

 Verify the connection between AC1-AC2.

onfirm that the quick-disconnect terminals

e inserted onto the terminals of HF UNIT1

correctly and compl etely.

 Confirm there are no short circuits, burnt or

broken wires between AC1 and AC2.

d) Verify and replace the Gap (GAP) of the High

Frequency (HF UNIT1).

 Confirm that the GAP is connected to HF

UNIT1 correctly and completely.

 Confirm there is no dust or foreign debris

between the space of the GAP.

 If the re are any abnormalit ies observed with

the GAP, replace the GAP.

 A setup of a gap is 1.0mm.

In the case of a gap 1.0mm or more, high frequency voltage and period increases. In the case of a gap 1.0mm or les s, high frequency voltage and period decreases.

e) Verify and repl ace th e Curre nt L i

miting Re sistor

(R6) o

n HF UNIT1.

 If R6 is defective (blown, burnt, cracked,

etc.), replace R6.

 Refer to section 12.3.15.

f) Replace the High Frequency (HF UNIT1).

 Refer to section 12.3.26.

g) Replace PCB3 (WK-5548).

 Refer to section 12.3.3.

Fault Isolation Tests

4.1 Preparation

The following initial conditions must be met prior to starting any of the procedures in this section.

1) Connect the appropriate input voltage. (Check the name plate on th

e rear of the

ower 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.

2 ) Remove the side covers. Refe r to section

tion 11.1.1.

3) Close primary power source wall disconnect switch or circuit breaker.

4) Place power supply MAIN CIRCUIT SWITCH (S1) on rear of the unit in the "ON" position.

WARNING

Dangerous voltage and power levels are present inside this unit. Be sure the operator is equipped with proper gloves, cl othing and eye and ear protection. Make su re no part of the operator's body comes into contact with the work piece or any internal components while the unit is activated.

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

Verification of the Power Input Circuitry

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 11.4.1

"Preparation".

5.1 Verification of the AC Input Voltage using an AC voltmeter.

1) Verify input voltage (Phase-to Phase) using an AC voltmeter. (The capability of the voltmeter should be more than 600VAC). Measure the point between lines U1 and V1 on the input switch, S1. M and W1 on the input switch, S1. Measure the point between lines V1 and W1 on the input switch, S1. The location of points U1, V1 and W1 o

n switch S1 are indicated in Figure 11-7. When using a single-phase connection, the voltage can be verified only between U1 and V1.

easure the point between lines U1

U2 V2

3) Verify input voltage after the input switch (S1) using an AC voltmeter. (The capability of the voltmeter should be more than 600VAC.)

• U

sing an AC voltmeter, measure between

the points U2 and V2 on the input switch, S1.

sing an AC voltmeter, measure between

• U the points U2 and W2 on the input switch, S1.

sing an AC voltmeter, measure between

• U the points V2 and W2 on the input switch, S1.

The location of points U2, V2 and W2 on switch S1 are indicated in Figure 11-7. When using a single-phase connection, the voltage can be verified only between U2 and V2.

4) If this voltage is out of the operating range, which is the rated voltage (208, 230/460V), replace S1 following the process in section 12.3.23.

5) Verify the rectified output voltage of the input diode, D1 using a DC voltmeter. (The capability of the voltmeter should be more than 1000VDC.) Using a DC voltmeter, measure between the points 1 (P) [+] and 2(N) [-] on D1. Points 1 (P) and 2 (N) are on D1. See Figure 11-8. The measured voltage should be approximately 1.4 times larger than the i sured in #1 above. Replace diode D1 if the calculated measurement is not within the corresponding range (260 following the process in section 12.3.28.

±10% (187 ∼ 253/414 ∼ 506 VAC) of

nput voltage mea-

60/580

~ 3

∼

720 VDC)

Figure11-7: Check points U1, U2, V1, V2, W1 and W2

2) If the input voltage is out of the operating range of the unit, which is VAC) of the rated voltage (208, 230/460V), verify the available power capacity at the installed site. If the input voltage is within the operating range, recheck the input voltage while welding, as welding may cause the input voltage to decrease to a value below the operating range of the unit.

±10% (187∼ 253/414 ~ 506

Figure11-8: The check points 1 (P) and 2(N)

11 – 11

11 ADVANCED TROUBLESHOOTING

6) Verify bus voltage (the voltage of the electrolytic capacitor after rectification) using a DC Voltmeter. The capacity of the DVM should be more than 1000VDC. Measure between the output studs C and E on PCB8 (WK5479), PCB9 (WK5479), PCB10 (WK5479) and PCB11 (WK5479). The measured voltage should be approximately

1.4 times larger than the input voltage measured in step 1 (above), except when running at 460V where the bus voltage will be shared across all boards, i.e., each board receiving 0.7 times the input voltage measured in step 1 (above). Replace diode D1 if the calculated measurement is not within the corresponding range (260 ~ 360/580 ~ 720VDC). Follow the process in

12.3.28.

TB4(N) TB1(P)

PCB2

2) On the PCB3 (WK-5548) and PCB6 (WK-

5549), measure the voltages according to the following table. The check points and the reference are obtainable on the solder side of PCB4 (WK-4819). The locations of points are indicated in Figure 11-10, 11-11.

TP3

TP1

TP0

TP2

PCB6

Figure11-10: Checkpoints TP0-TP3 on PCB6

Check Point

PCB6

TP1 TP0 +5VDC TP2 TP0 +15VDC TP3 TP0 -15VDC

Reference

PCB6

ACCEPTABLE

VALUE

Figure11-9: The check points TB1(P) and TB2(N)

7) After the replacement of D1, if the above voltage is still abnormal, replace PCB1 (WK-5493).

5.2 Verification of the Power Supply Voltage

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 11.4.1

"Preparation"

1) Verify Power Supply voltage using an DC voltmeter. The capability of the voltmeter should be more than 50VDC. Operate at all input voltages as noted on the nameplate on the rear panel when testing the power supply.

11 – 12

Table11-1: Checkpoints TP0-TP3 on PCB6

pin 1

pin 3

PCB3

CN18

Figure11-11: Checkpoints CN18 on PCB3

Check Point

PCB3

Pin 1 on CN18 Pin 3 on CN18 +24VDC

Table11-2: Checkpoints CN18 on PCB3

Reference

PCB3

ACCEPTABLE

VALUE

300/400TS and 300 /400S 11 ADVANCED TROUBLESHOOTING

11 – 13

3 ) If any of these voltage s are not present or

are below a 10% tolerance, replace the PCB3 (WK-5548). Refer to section 12.3.3.

5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 11.4.1 "Preparation".

1 ) Verify the conditi on of the cooling fan, FAN1,

using a DC voltmeter. (The capability of the voltmeter should be more th an 50VDC.) Using a DC voltmeter, measu re be tween PIN1 ( Positive [+]) and PIN2 (

Negative [-]) of CN11 on

CB3 (WK-5548). The location of connector CN11 of PCB3 is indicated in Figure 11-12. When you measure the above vo ltage, do not remove the connector. Co nduct the measurement while the connector plug and recep tacle are still connected.

Figure 11-12: Verification of the FAN1

2) Using the measurement taken above, follow the chart below for possible failure mod es .

Table 11-3: Verification of the FAN1

 At the time of a low output and standby ,

fan rotation becomes slow, which makes exact voltage measuring impossible.

 When v erifying the voltage, confirm that the

AC input voltage remain within the operating range of the unit. (The AC input does not drop below 180VAC).

PCB3

CN11

pin1

pin2

FAN1

Status

Voltage measurement. (PIN1-PIN2 of

CN11 on PCB3)

Remedy

Case 1 Rotating

DC 18 ∼ 25V

FAN1 drive circuit is normal.

Case 2 Rotating Below DC 18V

Replace PCB3. Refer to section

12.3.3.

Case 3 Inactive Below DC 18V

Replace PCB3. Refer to section

12.3.3.

Perform "Verification of the Power Supply Voltage". Refer to section

11.5.2.

Case 4 Inactive

DC 18 ∼ 25V

Replace the FAN1. Refer to section

12.3.21.

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

11 – 14

5.4 Verification of the Gas Valve, SOL1, Drive Circuitry

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 11.4.1 "Preparation".

1 ) Verify the v oltage between t

he PIN 3 (Positive [+]) and PIN 4 (Negative [-]) of connecto r CN11 on PCB3 (WK-5548 ) while y ou press the torch switch while in TIG Mode. (The capacity of the voltmeter should be more than 50VDC.) The location of connector CN11 of PCB3 (WK-

5548) is indicated in Figure 11-13. When you measure the above voltage , do not remov e the connector. Conduct the measurement while the connector plug and receptacle are still connected.

Figure 11-13: Verification of the SOL1

2) Using the measurement taken above, follow the chart below for possible failure modes.

Table11-4: Verification of the SOL1

3) When verifying the voltage, confirm that the AC input voltage remain within the operating range of the unit. (The AC input does not drop below 180VAC).

5.5 Verification of the primary Diode (D1)

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the ini tial set up condition as described in section 11.4.1 "Preparation".

1) Verify the characteristic of the primary diode, D1, using a diode tester.

2 ) Refer

to Table 11-5 and Figu re 11-14 for

the checkpoints on D1.

Table11-5: Tester checkpoints in D1

Figure11-14: Tester chec kpoints for D

1 showing

the interconnection diagram s

Voltage

measurement.

(PIN 3-PIN 4 of

CN11 on PCB3)

Remedy

Case 1 Below DC 18V

Replace PCB1.

Refer to section 12.3.1

Case 2

DC 18 ∼ 25V

Replace SOL1.

Refer to section 12.3.22

PCB3

CN11

pin 3

pin 4

COMPONENT

TESTED

TERMINALS

ACCEPTABLE

VALUE

Positive

lead

Negative

lead

Diode of D1

3, 4, 5

0.3 to 0.5V Open

Diode of D1

3, 4, 5

Open

0.3 to 0.5V

Thyristor of D1

0 1

1 0

Open Open

Gate of D1 6 7 52 +3, ±3ohm

067

5 4 3

300/400TS and 300 /400S 11 ADVANCED TROUBLESHOOTING

11 – 15

5.6 Verification of the secondary Diode (D2-D7)

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 11.4.1 "Preparation".

1) Verify the characteristic of the secondary diode, D2-D7, using a diode tester.

2 ) Re fer

to Table 11 - 6 and Figure 1 1-15 for

the checkpoints on D2-D7.

Table11-6: Tester checkp oints for D2-D7

Figure 11-15: Tester checkpoints in the D2-D7

5.7 Verification of the primary IGBT (Q1-Q24)

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 11.4.1

"Preparation".

1 ) Check whether ther e are any abnormalities in

the appearance of PCB8-PCB11.

2) Verify the characteristic of the primary IGBT (Q1-Q24), using a diode tester.

3 ) Refer to T

able 11 - 7 and Figure 11-16 for

the ch

eckpoints on PCB8-PCB11.

Table11-7: Tester checkpoints in the Q1-Q24

Figure 11-16: Tester checkpoints for Q1-Q24

COMPONENT

TESTED

TERMINALS

ACCEPTABLE

VALUE

Positive

lead

Negative

lead

Diode 1 of

D2-D7

Anode

Cathode

Anode

0.2 to 0.3V Open

Diode 2 of

D2-D7

Anode

Cathode

Anode

0.2 to 0.3V Open

Anode

Diode 1 Diode 2

Anode

Cathode

COMPONENT

TESTED

TERMINALS

ACCEPTABLE

VALUE

Positive

lead

Negative

lead

Collector-Emitter of Q1∼Q12 with PCB8 and PCB9

Open

0.2 to 0.5V

Collector-Emitter of Q13∼Q24 with PCB10 and PCB11

Open

0.2 to 0.5V

TRO_0031

C CE E

TRO_0031

C CE E

PCB10

PCB11

PCB8

PCB9

C CE E

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

11 – 16

5.8 Verification of the secondary IGBT (Q25-Q26)

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 11.4.1 "Preparation".

1 ) Check whether there are any abnormalities in

the appearance of PCB17.

2) Verify the characteristic of the secondary IGBT (Q25-Q26), using a diode tester.

3 ) Re fer

to Table 11 - 8 and Figure 1 1-17 for

the checkpoints on Q25-Q26.

Table11-8: Tester checkpoints in the Q25-Q26

Figure11-17: Tester checkpoints in Q25-Q26

5.9 Verification of No-load Voltage (OCV)

CAUTION

Before performing any portion of the procedure below, make certain the unit is placed in the ini tial set up condition as described in section 11.4.1 "Preparation".

a. Verify the no-load voltage in STICK mode.

1) In STICK welding mode, mark and then turn potentiometer VR1 on PCB6 (WK-

5549) fully counter-clockwise to turn off the electric shock protector function (Voltage-Reduction-Device, VRD).

2) Contactor function is put into the state of "ON" pushing the Funct ion button. _

WARNING

Electric shock haz ard. The unit will gener ate OCV immediately when con tactor fun ction is put into t he state of "ON" pushing Function button enabling STICK mode.

3 ) Verif y the no-l oad volt age usin g a DC vo lt-

meter. (The capability of the voltmeter should be more than 100VDC.)

4) The normal no-load voltage is approximately 65V.

COMPONENT

TESTED

TERMINALS

ACCEPTABLE

VALUE

Positive

lead

Negative

lead

Collector-Emitter of Q25 (By PCB18 connection)

C2E1

Open

0.2 to 0.5V

Collector-Emitter of Q26 (By PCB19 connection)

C2E1

Open

0.2 to 0.5V

Q25

Q26

C2E1

300/400TS and 300/400S 11 ADVANCED TROUBLESHOOTING

b. Verify the no-load voltage (OCV) in High Fre-

quency TIG mode.

WARNING

This welding mode produces high frequency and high voltage. Extra care should electric shock.

1) When in HF TIG mode, the unit will generate high voltage. To prevent personal harm and test equipment damage, mark and then remove the indicated wire from the HF UNIT1 shown in Figure 11-18. To prevent electric shock, always wrap the removed wire with electrical tape or other suitable insulation.

HF. UNIT1

be taken to prevent

Figure11-18: Removal and installation (To disable the operation of the HF unit.)

from the HF UNIT1

2) Press the Welding Mode selection button to select HF TIG welding mode.

3) While depressing the Torch switch, verify the OCV using a DC voltmeter. (The capability of the voltmeter should be more than 100VDC.) The check point with a tester is the voltage between output terminal + and

-. In TIG mode, the OCV ceases 3 seconds after you depress the torch switch.

4) The normal no-load voltage is approximately 65V.

5) Return the setting variable resistor

(VR1)

to the original position.

• f

ully clockwise: VRD ON

• fully counter-clockwise: VRD OFF

6) Return connection with HF UNIT1 to the original position.

11 – 17

12 MAINTENANCE

12 – 1

MAINTENANCE

Maintenance List

2 4

5 6

No. DWG No. Parts name Reference page Part No.

1 PCB2 Printed Circuit Board (WK-5597)

- 7 W7001313

PCB3 Printed Circuit Board (WK-5548)

12- 9 W7001314

3 PCB4 Printed Circuit Board (WK-4819)

-10 10-6635

PCB5 Printed Cir

cuit Board (WK-5551)

12-11 W7001417

PCB7 Printed Circuit Board (WK-5550)

12- 9 W7001423

6 PCB12 Printed Circuit Board (WK-5527)

-12 W7001319

PCB13 Printed Cir

cuit Board (WK-5528)

12-13 W7001320

PCB14 Printed Circuit Board (WK-5594)

-14 W7001321

PCB21 Printed Cir

cuit Board (WK-4917)

12-17 10-6740

300/400TS and 300/400S 12 MAINTENANCE

2 6

No DWG No. Parts name Reference page Part No.

1 2 2 2

2 3

6 7

PCB1 PCB6

PCB6 PCB6 PCB6

PCB8 (Q1-Q6)

PCB9 (Q7-Q12)

PCB10 (Q13Q18)

PCB11 (Q19-Q24)

PCB15 PCB20

Printed Circuit Board (WK-5493) Printed Circuit Board (WK-5549) 300S

Printed Circuit Board (WK-5549) 400S Printed Circuit Board (WK-5549) 300TS Printed Circuit Board (WK-5549) 400TS

Printed Circuit Board (WK-5479) (Primary IGBT)

Printed Circuit Board (WK-5606) Printed Circuit Board (WK-5499)

12- 6 W7001312 12-11 12-11

12-11 12-11

12-12

12-16 12-16

W7001730 W7001731

W7001734 W7001735

W7001318

W7001322 W7001324

12 – 2

300/400TS and 300 /400S 12 MAINTENANCE

12 – 3

No. DWG No. Parts name Reference page Part No.

1 CON1 Remote Socket

12-26 W7001666

2D1 Primary Diode

12-28 10-6769

3 D2 Secondary Dio de

12-28 10-6629

4 D4 Secondary Dio de

12-28 10-6629

5 D5 Secondary Dio de

12-28 10-6629

6 D7 Secondary Dio de

12-28 10-6629

7* HF.UNIT1 High Frequency Unit 1

-26 W7001399

S1 Main ON/OFF Switch

12-24 10-6857

9 S2 Input Voltage Switch

12-25 10-5222

* 300/400TS/ only

300/400TS and 300/400S 12 MAINTENANCE

6 1

12 13 14

No. DWG No. Parts name Reference page Part No.

CC1 Coupling Coil 2 CT2 Current Trans 3 CT3 Current Trans 4 FAN1 Cooling Fan 5 FCH1 Reactor 6 HCT1 Hall Current Sensor 7 L1 Ring Core 8 L105 Ring Core

R6 Current Limiting Resistor

10 R7 Resistor 11 R8 Resistor

SOL1 Solenoid Valve

12*

13 TH1 Primary Thermistor 14 TH2 Secondary Thermistor

12-20 12-29 12-29 12-22 12-20 12-27 12-30 12-30 12-18

12-23 12-21 12-22

W7001382 W7001304 W7001304 W7001307

W7001681 10-5003 W7001309

W7001400

W7001451

W7001325

10-6645

10-5228

* 300/400TS only

12 – 4

300/400TS and 300 /400S 12 MAINTENANCE

12 – 5

Service Tools

2.1 Tools and parts

The tools and parts to be used for maintenance are shown by icons.

2.2 Notes of disassembly and assembly

NOTE

When removing the l ocking type connectors and board supporters, dise ngage the locking mech anism first and then disconnect them.

Locking type connectors and board supporters are indicated in this manual using the following symbols; black star marks for locking connectors and white star marks for locking board supports.

NOTE

During your maintenance or repair, please cut any tie-wraps necessary. However, after your maintenance or repair, please reassemble and tie-wrap all components and wiring in the same manner as before the maintenance or repair.

CAUTION

Please note that when you re move each c onnector, gr asp and pull out by the c onnector pa rt only. D o not pull the harness (cable) part.

WARNING

C-Ring Pliers

Long Nose Pliers

Philips Head Screwdriver

Spanner

Snap Band

Silicon Compound

300/400TS and 300/400S 12 MAINTENANCE

12 – 6

Replacement Procedure

3.1 PCB1 (WK-5493) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the PCB2 (WK-5597). [Reference page : 12-7]

3) Remove the Primary Diode (D1). [Reference page : 12-28]

4) Remove the Current Trans (CT2/CT3). [Reference page : 12-29]

5) Remove the Nylon Hose. Remove the two bolts, and one terminal. Remove the four screws and open the front cabinet.

6) Remove the two screws and three terminals from the PCB1 (WK-5493).

7) Remove the Reactor (L1). [Reference page : 12-30]

300/400TS and 300 /400S 12 MAINTENANCE

12 – 7

8) Remove the 18 screws and remove the PCB1 (WK-5493).

3.2 PCB2 (WK-5597) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the screw and then disconnect the four ground terminals. Disconnect the 19 connectors.

3) Loosen two screws. Rotate the Resistor (R7 and R8) to expose two screws on PCB3 (WK-5548).

CN1

CN3

CN2

CN17

CN21

CN9

CN8

CN7

CN4

CN21

CN8

CN22

CN23

CN1

CN11

CN19

CN20

CN9

300/400TS and 300/400S 12 MAINTENANCE

12 – 8

4) Remove the four screws. Remove the PCB3, PCB4, PCB5, PCB6, and PCB7 unit. Disconnect the three connectors.

5) Remove the six screws, three terminals and three connectors.

6) Remove the two PCB supporters and then the PCB2 (WK-5597) and insulation sheet.

CN15

CN14

CN13

CN2

CN1

CN3

300/400TS and 300 /400S 12 MAINTENANCE

12 – 9

3.3 PCB3 (WK-5548), PCB7 (WK-5550) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the PCB4 (WK-4819). [Reference page : 12-10]

3) Remove the PCB6 (WK-5549). [Reference page : 12-11]

4) Remove the PCB5 (WK-5551). [Reference page : 12-11]

5) Disconnect the 11 connectors from the PCB3 (WK-5548).

6) Loosen two screws. Rotate the Resistor (R7 and R8) to expose two screws on PCB3 (WK-5548).

7) Remove the screw and then the four ground terminals. Remove the four screws and then remove the PCB3 and PCB7 unit. Disconnect the three connectors from the PCB7 (WK-5550).

CN23

CN19

CN11

CN8

CN3

CN2

CN1

CN9

CN22

CN21

CN20

CN14

CN15

CN13

300/400TS and 300/400S 12 MAINTENANCE

12 – 10

8) Disconnect the one conne ctor and re move the two screws, and then remov e the PCB7 (WK-55 50) from the PCB3 (WK-5548). Remove one screw and one ground terminal from the PCB7 (WK-5550).

9) Disconnect the two connectors from the PCB3 (WK-5548).

3.4 PCB4 (WK-4819) 

1) Remove the side cover. [Reference page : 11-1]

2 ) Discon nect the two connectors. Remov e the two screws and three connectors and remove the PCB4

(WK-4819) from the PCB3 (WK-5548).

CN20

CN33

CN18

CN6

CN5

CN4

CN7

300/400TS and 300 /400S 12 MAINTENANCE

12 – 11

3.5 PCB5 (WK-5551) 

1) Remove the side cover. [Reference page : 11-1]

2) Remove the PCB6 (WK-5549). [Reference page : 12-11]

3) Remove the two screws and three connectors. Remove the PCB5 (WK-5551) from the PCB3 (WK-

5548).

3.6 PCB6 (WK-5549) 

1) Remove the side cover. [Reference page :11-1]

2) Disconnect the six connectors.

3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549) from the PCB5 (WK-5551) and PCB7 (WK-5550).

CN32

CN31

CN30

CN21

CN20

CN8

CN9

CN17

CN1

CN27

CN30

CN31

CN32

CN18

300/400TS and 300/400S 12 MAINTENANCE

12 – 12

3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” 

1) Remove the side cover. [Reference page : 11-1]

2) Remove the eight screws and four device clips. Remove the four connectors and six screws. Remove the PCB8 (WK-5479) and PCB9 (WK-5479).

 Remember to install Silicone Rubber Sheets where silicone compound (Shinetsu silicone G-747 or

equivalent) was spread when reinstalling the PCB8 and PCB9. Spread the silicone compound on IGBT.

3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” 

1) Remove the side cover. [Reference page : 11-1]

2) Remove the eight screws and four device clips. Remove the four connectors and six screws. Remove the PCB10 (WK-5479) and PCB11 (WK-5479).



Remember to install Silicone Ru bber Sh eets whe re silic one co mpo und (Sh inets u silicon e G- 747 or equ ivalent)

was spread when reinstalling the PCB10 and PCB11. Spread the silicone compound on IGBT.

3.9 PCB12 (WK-5527) 

1) Remove the side cover. [Reference page : 11-1]

2) Remove the PCB13 (WK-5528). [Reference page :12-13]

3) Remove the three latches of Front Control Cover and then the PCB12 (WK-5527).

CN2

CN1

Silicone rubber sheets

CN2

CN1

Silicone rubber sheets

300/400TS and 300 /400S 12 MAINTENANCE

12 – 13

 When reinstalling the PCB12 (WK-5527), engage two latches of Front Control Cover first.

3.10 PCB13 (WK-5528) 

1) Remove the side cover. [Reference page : 11-1]

2) Remove the Protection Cover.

3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob.

1mm

300/400TS and 300/400S 12 MAINTENANCE

12 – 14

4) Disconnect the one connector from the PCB12 (WK-5527). Remove the nut, washer and terminal. Remove the four screws. Pull out the Operation Panel and bring it down.

5) Remove the one connector and two screws. Remove the PCB13 (WK-5528) and Encoder Cover.

3.11 PCB14 (WK-5594) <T1 “Main Transformer”> 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Coupling Coil (CC1). [Reference page : 12-20]

3) Remove the PCB20 (WK-5499). [Reference page : 12-16]

4) Remove the Reactor (FCH1). [Reference page : 12-20]

5) Remove the two screws and the T-CC Bus Bar from the front side.

CN2

CN1

300/400TS and 300 /400S 12 MAINTENANCE

12 – 15

6) Remove the Nylon Hose and two terminals of SOL1. Remove the four screws and open the Rear Panel.

7) Remove the four screws from the PCB1 (WK-5477). Remove the seven terminals. The cables are dr

awn out.

) Remove t he four scr ews and the n two cable s from bottom . Remove th e two screws and then remove

the PCB14 (WK-5594) and D Bus Bar1, D Bus Bar2, D Bus Bar3, D Bus Bar4 and Dust Cover Sheet (Rear). Remove the four screws and then remove the D Bus Bar1, D Bus Bar2, D Bus Bar3, D Bus Bar4 and Dust Cover Sheet (Rear) from PCB14.

300/400TS and 300/400S 12 MAINTENANCE

12 – 16

3.12 PCB15 (WK-5606) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Nylon Hose and two terminals of SOL1.

3) Open the Dust sheet. Remove the eight screws. Remove the two PCB supporters and remove the PCB15 (WK-5606).

3.13 PCB20 (WK-5499) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove one sc rew and one terminal . Remov e one b olt, toot hed was her, wash er and terminal . Remove one screw, nut and the Output Bus Bar. Disconnect one connector from HCT1.

3) Disconnect the two connectors. Remove the four PCB board supporters and then remove the PCB20 (WK-5499).

CN1

CN3

300/400TS and 300 /400S 12 MAINTENANCE

12 – 17

3.14 PCB21 (WK-4917) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the six screws from the S1 and remove the six terminals.

3) Remove the four screws and then open the Rear Board.

4) Disconnect the one connector. Remove the two screws and one ground terminal. Remove the PCB21 (WK-4917).

CN1

300/400TS and 300/400S 12 MAINTENANCE

12 – 18

5) Remove the three screws and the S1 Bus Bar from the PCB21 (WK-4917).

3.15 Current Limiting Resistor (R6) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the HF.UNIT1. [Reference page : 12-26]

3) Cut the cable. Remove one screw and then remove the Current Limiting Resistor (R6).

300/400TS and 300 /400S 12 MAINTENANCE

12 – 19

3.16 Resistor (R7, R8) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the main ON/OFF switch (S1). [Reference page : 12-24]

3) Remove the four screws and four terminals.

4) Remove two screws and the Resistor (R7, R8)

300/400TS and 300/400S 12 MAINTENANCE

12 – 20

3.17 Coupling Coil (CC1)  *300/400TS only

1) Remove the side cover. [Reference page : 11-1]

2) Remove the Nylon Hose. Remove the two bolts, and one terminal. Remove the four screws and open the Front Panel.

3) Remove the two terminals. Remove one screw, one nut and two terminals. Remove one screw and detach the Coupling Coil (CC1).

3.18 Reactor (FCH1) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Nylon Hose. Remove the two bolts, and one terminal. Remove the four screws and open the Front Panel.

300/400TS and 300 /400S 12 MAINTENANCE

12 – 21

3) Remove one screw, one nut and two terminals. Remove one screw, one nut and one terminal.

4) Remove four screws and remove the Reactor (FCH1).

3.19 Primary Thermistor (TH1)

1) Remove the Side Panel. [Reference page : 11-1]

2 ) Disconnect the one conne ctor CN8 on PCB6. Rem ove the one screw and then de tach the Primary

Thermistor (TH1).

 Before installing a new th erminstor, apply a u niform coat of silic one compound (Sh inetsu Silicone G-

747 or equivalent) on the base.

CN8

300/400TS and 300/400S 12 MAINTENANCE

12 – 22

3.20 Secondary Thermistor (TH2) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the PCB16 (WK-5569). [Reference page : 12-16]

3) Cut the three s nap ban ds an d disco nnect t he one conne ctor CN9 o n the P CB6. Re move t he one screw and Secondary Thermister (TH2).

 Before installing a new th erminstor, apply a u niform coat of silic one compound (Sh inetsu Silicone G-

747 or equivalent) on the base.

3.21 Cooling Fan (FAN1) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.

CN9

300/400TS and 300 /400S 12 MAINTENANCE

12 – 23

3) Cut the one snap band and disconnect the one connector CN11 on the PCB3.

4) Remove the two screws and detach the Cooling Fan (FAN1).

Be sure that the fan is in the correct direction whe

n reinstalling.

3.22 Solenoid Valve (SOL1) *300/400TS only

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.

CN11

AIR FLOW

ROTATION

300/400TS and 300/400S 12 MAINTENANCE

12 – 24

3) Remove the C-ring and detach the Solenoid Valve (SOL1).

 When reinstalling, make sure that the C-ring seats in the Solenoid Valve groove.

3.23 Main ON/OFF Switch (S1)

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the six screws and six terminals.

3) Remove the two screws and detach the Main ON/OFF Switch (S1). Remove the three posts.

300/400TS and 300 /400S 12 MAINTENANCE

12 – 25

3.24 Input Voltage Switch (S2) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the six screws and six terminals.

3) Remove the four screws, and open the Rear Board.

4) Disconnect the one connector CN4 on the PCB4. Remove the two screws and two nuts and then remove the Input Voltage Switch (S2).

CN4

300/400TS and 300/400S 12 MAINTENANCE

12 – 26

3.25 Remote Socket (CON1) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Ring Core (L105). [Reference page : 12-30]

Disconnect the three connectors CNB-15 on the PCB7. Remove the one screw and one ground terminals.

4) Remove the two screws and remove the Remote Socket (CON1).

3.26 High Frequency Unit (HF.UNIT1) *300/400TS only

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the high freguency gap. Remove the four terminals.

CN15

CN14

CN13

300/400TS and 300 /400S 12 MAINTENANCE

12 – 27

3) Remove the two screws and detach the High Frequency Unit (HF. UNIT1).

3.27 Hall Current Sensor (HCT1) 

1) Remove the Side cover. [Reference page : 11-1]

2) Remove one sc rew and one terminal . Remov e one b olt, toot

hed washer, washer and terminal. Rem ove

ne screw, nut and the Output Bus Bar. Disconnect one connector from HCT1.

3) Remove the one screw and detach the Hall Current Sensor (HCT1) from the Output Bus Bar.

CN1

300/400TS and 300/400S 12 MAINTENANCE

12 – 28

3.28 Primary Diode (D1)

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the PCB3 (WK-5548). [Reference page : 12-9]

3 ) Remove the six screws and 1 3 terminals. Remove the two screws and then detach th e Primary Diode

(D1).

 Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or

equivalent) on the base.

3.29 Secondary Diode (D2, D4 , D5 and D7)

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the PCB15 (WK-5606). [Reference page : 12-16]

3 ) Remove one s crew and one nu t. Remove 20 screws and two ter minals. Rem ove the D Bus Ba r, D Bus

Bar1, D Bus Bar2, D Bus Bar3 and D Bus Bar4.

300/400TS and 300 /400S 12 MAINTENANCE

12 – 29

4) Remove the eight screws and then detach the Secondary Diodes (D2, D4, D5, D7).

Be sure that the diodes are placed in the correct direction when reinstalling.  Before installing a new diodes, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or

equivalent) on the base.

3.30 Current Trans (CT2, CT3) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.

3 ) Cut the snap band and remo ve the connecto r from the PCB3 (WK-55 48). Remove two screws and two

terminals from the PCB1 (WK-5493). Cut two snap bands and remove the Current Trans (CT2, CT3).

CN7

300/400TS and 300/400S 12 MAINTENANCE

12 – 30

3.31 Ring Core (L1) 

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.

3) Remove the two screws and two terminals. Cut the snap band and remove the Ring Core (L1).

3.32 Ring Core (L105)

1) Remove the Side Panel. [Reference page : 11-1]

2) Remove the Protection Cover.

300/400TS and 300 /400S 12 MAINTENANCE

12 – 31

3) Remove the four screws. Pull out the Operation Panel and bring it down.

4) Cut the snap band remove the Ring Core (L105).

THIS PAGE LEFT INTENTIONALLY BLANK

APPENDIX 1 PARTS LIST

Equipment Identification

All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Part o

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.

PART NUMBERS: ARC MASTER 300TS 10-3096 ARC MASTER 400TS 10-3071

ARC MASTER 300S 10-3093 ARC MASTER 400S 10-3070

300/400TS

r Assembly numbers.

No. DWG No. Part No. Description Additional Information QTY.

1 CC1 2 CON1 3 CT2-3 4 D1 5 D2,4,5,7 6 FAN1 7 FCH1 8 HCT1 9 HF.UNIT1 10

10-6633 HF, Gap, gen 3.1, IPS 11 L1 12 L105 13 PCB1 14 PCB2 15 PCB3 16 PCB4 17 PCB5

18 PCB6 W7001735 PCB, 400TS, gen 3.1, IPS WK-5549 U05-8 DC CTRL PCB 1 18 PCB6 W7001734 PCB, 300TS, gen 3.1, IPS WK-5549 U05-7 DC CTRL PCB 1 19 PCB7 20 PCB8-11 21 PCB12 22 PCB13 23 PCB14 24 PCB15 25 PCB20 26 PCB21 27 R2

W7001382 Coupling Coil, gen 3.1, IPS W7001666 Socket, Remote+D32, gen 3.1, IPS W7001304 Transformer, gen 3.1, IPS 10-6769 Diode, gen 3.1, IPS 10-6629 Diode, gen 3.1, IPS W7001307 Fan, gen 3.1, IPS W7001681 Inductor, gen 3.1, IPS 10-5003 Sensor, Current, gen 3.1, IPS W7001399 HF, Unit, gen 3.1, IPS

W7001309 Reactor, gen 3.1, IPS W7001400 Reactor, gen 3.1, IPS W7001312 PCB, gen 3.1, IPS W7001313 PCB, gen 3.1, IPS W7001314 PCB, gen 3.1, IPS 10-6635 PCB, gen 3.1, IPS W7001417 PCB, gen 3.1, IPS

W7001423 PCB, gen 3.1, IPS W7001318 PCB, gen 3.1, IPS W7001319 PCB, gen 3.1, IPS W7001320 PCB, gen 3.1, IPS W7001321 PCB, gen 3.1, IPS W7001322 PCB, gen 3.1, IPS W7001324 PCB, gen 3.1, IPS 10-6740 PCB, gen 3.1, IPS W7001449 Resistor, gen 3.1, IPS

F3A073800 300A AC CC 1 MS3102A20-27S (NIC) 14P (with Wiring Assembly) 1 F2A503001 CT 1:40 2 DFA100BA160 1 DBA200UA60 4 109E5724H507 DC 24V 16.8W 1 F3A040701 300A AC FCH 1 HC-TN200V4B15M 200A 4V 1 HF.UNIT (WK-4840 U04) 1 U0A601100 1 GP-7 1 ZCAT-3035-1330 1 WK-5493 U01 MAIN PCB 1 WK-5597 U01 LINK PCB 1 WK-5548 U01 DDC PCB 1 WK-4819 U01 DETECT PCB 1 WK-5551 U01 CONECT PCB 1

WK-5550 U01 FILTER PCB 1 WK-5479 U01 GATE PCB (with IRGP20B60PD) 4 WK-5527 U05 PANEL PCB 1 WK-5528 U01 ENCODER PCB 1 WK-5594 U01 TRANS PCB 1 WK-5606 U01 DIODE SNUBBER PCB 1 WK-5499 U01 FILTER PCB 1 WK-4917 U04 INPUT FILTER PCB 1 ERG3SJ220H 3W 22Ω 2

Thermal Arc ARCMASTER 400TS, ARCMASTER 400S, ARCMASTER 300TS Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual