Thermal Arc PS-3000 Instruction Manual

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INVERTER

ARC

WELDER

MODEL PS-3000

• Plasma Arc W elding

Instruction Manual

October 23, 1998

Manual No. 0-2337

WARNING

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 our best judgement, Thermal Arc Corporation assumes no liability for its use.

Thermal Arc

Model PS-3000 Inverter Arc Welder

Instruction Manual Number 0-2337 Published by:

Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711

permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liabil-

ity to any party for any loss or damage caused by any error or

omission in the Thermal Arc

Model PS-3000 Inverter Arc Welder Instruction Manual, whether such error results from negligence, accident, or any other cause.

October 23, 1998

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................................i

Notes, Cautions and Warnings .................................................................................i

Important Safety Precautions ...................................................................................i

Publications .............................................................................................................ii

Note, Attention et Avertissement ............................................................................ iii

Precautions De Securite Importantes.....................................................................iii

Documents De Reference ...................................................................................... v

Declaration of Conformity .......................................................................................vi

St atement of W arranty........................................................................................... vii

SECTION 1: GENERAL INFORMATION ..................................................................................... 1

1.1 Specifications ................................................................................................... 1

1.2 Duty Cycle....................................................................................................... 2

SECTION 2: INST ALLATION ....................................................................................................... 3

2.1 Site Selection................................................................................................... 3

2.2 Transporting Methods...................................................................................... 4

2.3 Weld Ooutput Connections .............................................................................. 5

2.4 Remote 14 Connections .................................................................................. 8

2.5 Electrical Input Connections .......................................................................... 10

SECTION 3: OPERA TION ......................................................................................................... 13

3.1 Operator Controls .......................................................................................... 13

3.2 Operating Precautions................................................................................... 18

3.3 Troubleshooting ............................................................................................. 19

SECTION 4: P ARTS LIST..........................................................................................................21

4.01 Introduction.................................................................................................. 21

4.02 Ordering Information.................................................................................... 21

4.03 Parts List ..................................................................................................... 22

INTRODUCTION

Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. Y ou must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Publications.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEAL TH.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• W ear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

i INTRODUCTION

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

• Provide a fire watch when working in an area wher e fire hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. T rapped hydr ogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• T o pr otect your hearing fr om loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Publications.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly pr otected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as recommended in Publications, item 4.

Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, W ashington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, W ashington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standar ds Institute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

INTRODUCTION ii

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARA TION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

Precautions De Securite Importantes

AVERTISSEMENT

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédur e en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différ ents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page v.

iii INTRODUCTION

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE P AS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’éner gie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page v, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Respectez le teint de lentille recommandé dans le article 4, page 5.

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

INTRODUCTION iv

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page v.

Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAV AIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L ’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRA TIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (A WS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American W elding Society, 550 N.W . LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFP A), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W1 17.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRA TIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUY AUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork, NY 10018

v INTRODUCTION

Declaration of Conformity

Manufacturer: Address: 2200 Corporate Drive

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requir ements among them are:

* CSA (Canadian Standar ds Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) applicable to welding equipment and associated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and

manufacturing process. This is to ensure the product is safe, when used accor ding to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Arc, Inc.

T roy, Ohio 45373-1085 USA

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative: David Ashworth

Vice President & Managing Dir ector Thermadyne Europe Chorley England.

INTRODUCTION vi

Statement of Warranty

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the pr oduct has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, r ecommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS W ARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY W ARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special or consequential damages,

such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE JUDEGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

Except with regards to the products listed below, this warranty shall remain effective three (3) years from the date Thermal Ar c’s authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date Thermal Arc delivers the product to the authorized distributor.

Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser . Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.

PLASMA WELDING/

POWER SUPPLIES VIKING/GENERATORS INVERTERS LABOR

MAIN POWER MAGNETICS (ST ATIC & ROTATING) 3 YEARS 2 YEARS 1 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS, SOLENOIDS, PUMPS, POWER SWITCHING SEMI-CONDUCTORS

ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER. SEE THE ENGINE MANUFACTORS WARRANTY FOR DETAILS.

CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR 1 YEAR EXCHANGES, AND ACCESSORY EQUIPMENT TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer ’s risk and expense. This warranty supersedes all previous Thermal Arc warranties.

Thermal Arc® is a Registered Trademark of Thermadyne.

Effective May 1, 1997

vii INTRODUCTION

INTRODUCTION viii

SECTION 1: GENERAL INFORMATION

1.1 Specifications

Description

OLTS

The Model PS-3000 is a three-phase or single-phase (if derated) DC arc welding power source with constant current output characteristics. This unit is designed for use with the Plasma Arc Welding (PAW) process. A digital meter displaying amperes and voltage is standard.

OCV Less than 80V C.C.

5 150 350

AMPS

Figure 1-A Volt-Ampere Curve

NOTE

The volt-ampere curve shows the voltage and amperage output capabilities of the welding power source. Curves of other settings will fall between the curves shown.

Rated Output Single-Phase Three-Phase

Amperes 210 300 Volts 28 32 Duty Cycle 60% 60%

Range (Min-Max):

Amperes 5-260 5-350

Volts 10-30 10-36 Maximum OCV: 70 Input Data 50/60 Hz Width 10.88 in (276 mm) Height 16.75 in (425 mm) Length 18.31 in (465 mm)

Weight (with Cable) 82 lbs (37.2 kg)

Input Data At Rated Load No Load 50/60 Hz Output Output

Amps KVA KW Amps KVA KW

208 VAC 1-Phase 48 10 7 2.5 0.5 0.3 208 VAC 3-Phase 39 14 11 1.5 0.5 0.3 230 VAC 1-Phase 43 10 7 2.0 0.5 0.3 230 VAC 3-Phase 35 14 11 1.0 0.5 0.3 460 VAC 1-Phase 21 10 7 1.0 0.5 0.3 460 VAC 3-Phase 18 14 11 0.5 0.5 0.3 575 VAC 3-Phase 14 14 11 0.5 0.5 0.3 380 VAC 3-Phase 21 14 11 1.0 0.5 0.3 400 VAC 3-Phase 20 14 11 1.0 0.5 0.3 415 VAC 3-Phase 19 14 11 0.5 0.5 0.3

Table 1-A Unit Specifications

Manual 0-2337 1 GENERAL INFORMA TION

1.2 Duty Cycle

The duty cycle of a welding power source is defined as the percentage of a ten minute period that the unit can be operated at a given output without causing overheating and/or damage to the unit. This unit is rated at 60 percent duty cycle when operated at 300 amperes from three-phase input power, or when operated at 210 amperes from single-phase input power. If the unit is operated from three-phase input power, the unit can be operated at 300 amperes for six consecutive minutes, but it must operate at no load for the remaining four minutes to allow proper cooling. When the welding power source is operated from single-phase input power, the unit can be operated at 210 amperes for six consecutive minutes, but it must operate at no load for the remaining four minutes to allow proper cooling. If the welding amperes decrease, the duty cycle increases. If the welding amperes are increased beyond rated output, the duty cycle will decrease.

CAUTION

EXCEEDING DUTY CYCLE RATINGS will cause thermal overload protection circuit to become energized and shut down output until unit has cooled to operating temperature.

CONTINUAL EXCEEDING OF DUTY CYCLE RATINGS can cause damage to the welding power source.

• Do not exceed indicated duty cycles.

GENERAL INFORMA TION 2 Manual 0-2337

SECTION 2: INSTALLATION

2.1 Site Selection

WARNING

Select an installation site which provides the following:

1. Correct input power supply (see unit nameplate)

2. Shielding gas supply (if applicable)

3. Water supply (if applicable)

4. Adequate ventilation and fresh air supply

5. No flammables

6. A clean and dry area

7. Proper temperature that avoids extremes of heat or cold

8. Proper airflow around unit

FIRE OR EXPLOSION can result from placing unit on or over combustible surfaces. RESTRICTED AIRFLOW can cause overheating and possible damage to internal parts.

NOTE

• Do not locate unit over combustible surfaces.

• Maintain at least 3 inches (76 mm) of space from sides of unit, 6 inches (152 mm) from rear, and open, unrestricted access to ambient air at front of unit.

• Do not place any filtering device over the intake air passages that provide airflow for cooling this equipment.

Warranty is subject to being voided if any type of filtering device is used at intake air passages.

Manual 0-2337 3 INST ALLATION

2.2 T ransporting Methods

This unit is equipped with two handles for carrying purposes.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power conductors from de-energized supply line before moving welding power source.

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

• Have two persons of adequate physical strength lift unit.

• Use hand cart or similar device of adequate capacity.

• If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

INST ALLATION 4 Manual 0-2337

2.3 Weld Ooutput Connections

To obtain full rated output from this unit, it is necessary to select, prepare, and install proper weld cables. Failure to comply in any of these areas may result in unsatisfactory welding performance.

Weld Cable Selection

Weld Cable Preparation

Use the following guidelines to select weld cables:

1. Use the shortest possible cables, and place cables close together. Excessive cable lengths may reduce or cause unit overload due to added resistance.

2. Use weld cable with an insulation voltage rating equal to or greater than the maximum open circuit voltage (OCV) of the welding power source (see Table 2-A below).

3. Select weld cable size according to maximum weld output and total length of connecting cables in weld circuit.

4. Do not use damaged or frayed cables.

1. Install terminal lugs of adequate amperage capacity and correct stud size onto ends of cables that connect to the work clamp and electrode holder or torch.

2. Install work clamp onto cable.

3. Install supplied male connectors onto remaining ends of both cables (refer to Connector Installation, page 6).

Welding Under 100 ft 150 ft 200 ft 250 ft 300 ft 250 ft 400 ft

Amperes (Under 30 m) (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)

10-60% 60-100% 10-100%

Duty Cycle Duty Cycle Duty Cycle

100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

Manual 0-2337 5 INST ALLATION

Maximum Total Cable Length in Weld Circuit

Table 2-A Weld Cable Sizes

2.3 Weld Output Connections (continued)

Connector Installation

Strip insulation approx. 1 in from end

To install the supplied male connectors onto proper cables, refer to Figure 2-A below and:

1. Obtain cable of desired length and proper size for installation (refer to Table A, page 5).

2. If the installation requires cable larger than 3/0 AWG, prepare one end of 3/0 AWG pigtail no longer than 2 ft (0.61 m) for connector installation. The remaining end of the pigtail is connected to the main run of 3/0 AWG or larger weld cable.

3. Push weld cable through insulator as shown.

4. Remove 1 in (25 mm) of insulation from end of cable.

5. Install supplied sleeve on stripped end of cable.

6. Insert cable with sleeve into connector body so that cable is snug and against bottom of connector body.

7. Install and tighten set screw with supplied hex wrench to secure connector body onto cable.

8. Push insulator onto connector body to cover set screw.

Set Screw

Insulator Weld Cable

WARNING

Weld Cable Connections

INST ALLATION 6 Manual 0-2337

Sleeve

Connector Bod

(Male or Femal

Figure 2-A Connector Installation

ELECTRIC SHOCK can kill. ARCING can burn skin or damage

electrical connections.

• Do not touch live electrical parts.

• Shut down unit before making any weld output connections.

• Do not change position of the welding cable connectors while welding.

• Be sure the connectors are secure in receptacles before welding.

2.3 Weld Oouput Connections (continued)

Positive Negative

Figure 2-B Weld Output Connections - Lower Front Panel

Plasma Arc

Welding (PAW)

Electrode Negative/

Straight Polarity

Refer to Figure 2-B and:

a. Connect torch cable connector to NEGATIVE (-) weld output

receptacle as follows: align keyway, insert plug, and rotate plug clockwise until it is securely seated in receptacle.

b. Connect work cable connector to POSITIVE (+) weld output

receptacle as follows: align keyway, insert plug, and rotate plug clockwise until it is securely seated in receptacle.

Manual 0-2337 7 INST ALLATION

2.4 Remote 14 Connections

Figure 2-C 14-Pin Socket Receptacle with Socket Locations (Lower Front Panel)

The REMOTE 14 receptacle on the lower front panel can connect the following equipment to the welding power source circuitry:

• Remote Contactor Control

• Remote Amperage Control

To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

INST ALLATION 8 Manual 0-2337

The following socket information (Table 2-B, page 9) is included in case the supplied cord is not suitable, and it is necessary to wire a plug or cord to interface with REMOTE 14 receptacle.

2.4 Remote 14 Connections (continued)

Socket A Remote contactor control when contact closure is provided

between Sockets A and B (24 VAC available)

Socket B Remote contactor control when contact closure is provided

between Sockets A and B (24 VAC available)

Socket C Amperage remote control (MAXIMUM) input command signal;

+10 volts for maximum

Socket D Amperage remote control (MINIMUM); PC board common; use

as return for remote control inputs/outputs

Socket E Remote amperage reference signal (WIPER); 0 to +10 volts

(peak current set by main rheostat)

Socket F Not used

Socket G 24 volts AC common, power source chassis

Socket H 100 volts AC with respect to Socket L

Socket I Not used

Socket J Not used

Socket K Chassis common

Socket L 100 volts AC

Socket M Current sensing contactor

Socket N Current sensing contactor

Table 2-B Remote 14 Socket Information

Manual 0-2337 9 INST ALLATION

2.5 Electrical Input Connections

WARNING

Electrical Input

Requirements

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, wait 60-80 seconds, and measure voltage on input capacitors according to instruction manual before touching any parts. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and redtagging circuit breaker or other disconnecting device.

Operate the welding power source from a three-phase, or singlephase if derated, 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required.

The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.

NOTE

This unit is equipped with a three-conductor with ground power cable that is connected at the welding power source end for threephase electrical input power.

INST ALLATION 10 Manual 0-2337

2.5 Electrical Input Connections (continued)

WARNING

Electrical Input

Connections

ELECTRIC SHOCK can kill.

• Do not connect an input (white, red, or black) conductor to the ground terminal.

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

Refer to Figure 2-D (page 12) and:

1. Connect end of green ground conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes.

2. For three-phase electrical input power: connect ends of red (line 1), white (line 2), and black (line 3) input conductors to a de-energized line disconnect switch.

3. For single-phase electrical input power: connect ends of red (line 1) and white (line 2), input conductors to a de-energized line disconnect switch. Insulate and isolate the black (line 3) conductor.

4. Use Table 2-C below as a guide to select line fuses for the disconnect switch.

INPUT INPUT FUSE SIZE

POWER VOLTAGE (AMPERES)

SINGLE 208-230 VAC 60

PHASE 460 VAC 30

THREE 208-230 VAC 60 PHASE 380-460 VAC 30

575 VAC 25

Table 2-C Fuse Sizes

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).

Manual 0-2337 11 INST ALLATION

2.5 Electrical Input Connections (continued)

WARNING

AC POWER

Ground Terminal

Ground Conductor

AMPERAGE/VOLTAGE

METER

WARNING

AC POWER

PREVIEW

A/V

(PUSH)

100

REMOTE14PANEL

AMPERAGE

Welding Power Supply Primary Power Cable

Figure 2-D Electrical Input Connections and Components

Voltage Selection

The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate.

This power source incorporates the Smart Link™ circuit, which automatically links the power source to primary input voltage and adjusts it to allow for operation of unit within input rating on data tag. It is not necessary to manually switch (terminals or links) if unit is moved to a new location and a different input power is selected.

Line Disconnec Switch

Line Fuse

INST ALLATION 12 Manual 0-2337

• The surge current prevention circuit becomes activated when the POWER switch is turned ON.

• About two seconds after power on, the Smart Link™ circuit detects input voltage and automatically selects the correct circuits for operation.

• The welding machine is ready for operation in five seconds after turn-on.

SECTION 3: OPERATION

3.1 Operator Controls

AMPERAGE/VOLTAGE

METER

A/V

PREVIEW

(PUSH)

AMPERAGE

100

AC POWER

WARNING

REMOTE14PANEL

AMPERAGE

Front Panel

Operating Controls

Manual 0-2337 13 OPERATION

1. AC POWER Indicator

2. WARNING Indicator

3. AMPERAGE Control

4. AMPERAGE Switch

5. Digital AMPERAGE/VOLTAGE Meter

6. METER Switch and PREVIEW

7. Internal Maximum Current Limiter

Figure 3-A Front Panel Controls

3.1 Operator Controls (continued)

P S

rimary Power witch

PRIMARY POWER

ONOFF

Figure 3-B Rear Panel Controls

OPERATION 14 Manual 0-2337

3.1 Operator Controls (continued)

PRIMARY POWER

Switch and

AC POWER Indicator

NOTE

WARNING Indicator

AMPERAGE Control

AMPERAGE

NOTE

Place the PRIMARY POWER switch (circuit breaker) on the rear panel in ON position to energize the welding power source. The green AC POWER indicator on the front panel comes on when the AC POWER switch is in ON position, indicating that the unit is energized. Moving the AC POWER switch to OFF position shuts down the unit and turns off the AC POWER indicator.

When the AC POWER switch is placed in ON position, there is a pre-charge time delay of approximately 4-5 seconds before the unit is ready to weld. The AC POWER indicator will be on during the pre-charge time delay.

The red WARNING indicator located on the front panel will become activated if the unit witnesses the following:

• Input voltage too low

• Thermal overload

The AMPERAGE control selects the desired amperage within the entire range of the welding power source. Rotating this control in a clockwise direction increases the amperage output. The scale surrounding the AMPERAGE control represents 0-100 percent of the actual current output.

The AMPERAGE control may be adjusted while welding.

Manual 0-2337 15 OPERATION

3.1 Operator Controls (continued)

AMPERAGE

Switch

WARNING

Maximum Current

Limiter Control

This switch determines whether the amperage is adjusted by the front panel amperage control or by a remote control device. If remote amperage control function is not desired, place this switch in PANEL position.

If remote amperage control is desired, place the AMPERAGE switch in REMOTE 14 position. Remote amperage is a percentage of the value set by the front panel amperage control. For example, if the amperage control is set at half maximum output, the maximum output available from the remote control will be half the welding power source maximum output.

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Do not touch the weld output receptacles when the contactor is energized.

• Do not touch electrode and work clamp at the same time.

This control limits the maximum output current of the power source. The current limit prevents damage to the welding torch or consumables and can also provide more precise current control. For example, with the maximum current limiter set to 150 amps, the maximum setting (10) on the front panel current control would represent 150 amps, and the minimum setting (0) would represent approximately 5 amps.

If current is controlled with a remote device, the remote current will be 0-100% of the setting of front panel control and the front panel control will be 0-100% of the maximum current limiter setting. For example, with the remote control set at 50%, the front panel control set at 5, and current limiter set at 150 amps, approximately 40 amps weld current will be provided.

NOTE

OPERATION 16 Manual 0-2337

Remote control can be defined as follows:

• Remote Pendant Control (RP-1)

• Remote Foot Control

• Microprocessor Controls

• Other Control Devices

Remove the front panel hole plug and insert a screwdriver into the slot of the control pot. Turn the control counter clockwise to reduce the maximum current output. By setting the remote AMPERAGE switch to PANEL position, the maximum current can be displayed in preview mode of amp meter.

3.1 Operator Controls (continued)

Digital AMPERAGE/

VOLTAGE Meter,

METER Switch,

and PREVIEW

AMPERAGE

VOLTAGE

The AMPERAGE/VOLTAGE meter displays either an amperage or voltage value. The selected (PREVIEW) amperage value is displayed when welding is not taking place. Refer to Table 3-A below for the values displayed for each meter switch setting and parameters selected.

The meter is not intended for exact amperage or voltage measurements. The amperage display indicates amperage output of the welding power source and is driven by circuitry on control board PC1. The voltage sensing circuitry is internally connected to the welding power source output terminals. The voltage display indicates the voltage at the weld output terminals, but does not necessarily indicate the actual voltage at the welding arc (due to cable resistance, poor connections, etc.).

CONTACTOR METER

SWITCH SETTING INDICATOR

AMP OFF PRESET

AMP ON PRESET VOLT OFF PRESET VOLT ON ACTUAL

Table 3-A Values Displayed for Meter Switch Setting and Parameters Selected

Manual 0-2337 17 OPERATION

3.2 Operating Precautions

ELECTRIC SHOCK can kill; MOVING PARTS can cause

WARNING

serious injury; IMPROPER AIRFLOW AND EXPOSURE TO ENVIRONMENT can damage internal parts.

• Do not touch live electrical parts.

• Keep away from moving parts.

• Keep all covers and panels in place while operating.

NOTE

WARNING

Warranty is void if the welding power source is operated with any portion of the outer enclosure removed.

ARC RAYS, SPARKS, AND HOT SURFACES can burn eyes and skin; NOISE can damage hearing.

• Wear correct eye, ear and body protection.

FUMES AND GASES can seriously harm your health.

• Keep your head out of the fumes.

• Ventilate to keep from breathing fumes and gases.

• If ventilation is inadequate, use approved breathing device.

HOT MEAL, SPATTER, AND SLAG can cause fire and burns.

• Watch for fire.

WARNING

OPERATION 18 Manual 0-2337

• Keep a fire extinguisher nearby, and know how to use it.

• Do not use near flammable material.

• Allow work and equipment to cool before handling.

MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.

• Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

3.3 T roubleshooting

TROUBLE POSSIBLE CAUSE REMEDY

A. No weld output; unit

completely inoperative

B. No weld output; fan

motor running and AC POWER lamp on

C. Erratic or improper weld

output

1. Line disconnect switch in the OFF position

2. Line fuse(s) open

3. Improper electrical input connections

4. Power switch MCB in OFF position

1. Defective remote control device

2. WARNING indicator on. Thermostat THS 1,THS 2 open (thermal shutdown)

1. Loose welding cable connections

2. Incorrect welding cable size

3. Improper input and/or output connections

1. Place line disconnect switch in ON position

2. Check and replace line fuse(s)

3. Check for proper input connections

4. Check and reset MCB if necessary

1. Check and replace remote control device if necessary

2. Allow cooling period of approximately five minutes

1. Tighten all welding cable connections

2. Use proper size and type of cable (see Table 2-A, page 5)

3. Use proper size and cable size (see Table 2-A)

D. Remote device completely

inoperative

4. Improper input and/or output connections

5. Electrode condition

6. Remote amperage control (when applicable)

1. Remote control not connected or connected improperly to REMOTE 14 receptacle

4. See Installation (pages 5-

12) for proper input and output connections

5. Replace electrode

6. Check remote amperage control potentiometer and connections. Repair or replace if necessary

1. Connect remote control to REMOTE 14 receptacle

Manual 0-2337 19 OPERATION

OPERATION 20 Manual 0-2337

SECTION 4: PARTS LIST

4.01 Introduction

A. Parts List Breakdown

The parts list provides a list of all replaceable components.

B. Returns

If a Thermal Arc® pr oduct must be returned for service, contact your Thermal Arc® distributor. Materials r eturned to Thermal Arc® without proper authorization will not be accepted.

4.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the description column of the Parts List. Also include the model and serial number of the machine as shown on the plate attached to the front panel of the unit. Address all inquiries to your authorized Thermal Arc® distributor.

21 P ARTS LIST

4.03 Parts List

Catalog # Description 230/460 380/415 460/575

9-6136 Base Assembly X X X 10-2120 C4 & C5 400v 1800uf X X O 10-2121 C4 & C5 300v 1200uf O O X 10-2119 C6 - C9 350v 20uf X X X 10-2215 C10 & C13 1200v .0068uf X X X 10-2216 C10 & C13 1200v .0047uf O O X 10-2217 C14 & C15 1200v .022uf X X X 10-2241 C17 1000v .1uf X X X 10-2219 C18 & C19 .01uf X X X 10-2220 C20 250v .0luf X O O 10-2135 CON1 14 Pin Receptacle X X X 10-2160 CT1 Current Transformer X X X 10-2161 CT2 Current Transformer X X X

9-6137 Cover X X X

9-6134 Cover Insulator X X X 10-2158 D1 Diode X O O 10-2156 D1 Diode O X O 10-2157 D1 Diode O O X 10-2111 D2 & D3 Diode X X X 10-2112 D4 & D5 Diode X X X 10-2110 D6 & D7 Diode X X X 10-2050 Digital Meter Kit X X X 10-2020 DIN Style Male Adapter X X X 10-2237 F1 Fuse 3A 600V X X X 10-2206 F2 & F3 Fuse 2A, 250V X X X 10-2159 F AN Cooling X X X 10-2232 FCH DC Reactor X X X

9-6135 Hole Plug X X X 10-2117 MC1 Mag. Contactor X X X 10-2118 MC2 Mag. Contactor X O X 10-2242 MC2 Mag. Contactor O O X 10-2116 MCB1 Circuit Breaker X O O 10-2115 MCB1 Circuit Breaker O X X 10-2107 PCB1 Printed Circuit Board X O O 10-2105 PCB1 Printed Circuit Board O X O 10-2106 PCB1 Printed Circuit Board O O X 10-2163 PCB4 Filter Bd. (14 pin) X X X 10-2146 PCB7 Meter PC Bd. X X X 10-2147 PCB8 & PCB9 IGBT Gate Board X X X 10-2164 PCB10 Printed Circuit Board X O O

P ARTS LIST 22

Catalog # Description 230/460 380/415 460/575

10-2145 PCB10 Printed Circuit Board O X O 10-2165 PCB10 Printed Circuit Board O O X 10-2236 PL1, PL2 Pilot Lamp X X X

9-6138 Pot Support Bracket X X X 10-2113 Q1 & Q2 IGBT X X O 10-2114 Q1 & Q2 IGBT O O X 10-2207 R1 30w 200 ohms X X O 10-2208 R1 30w 400 ohms O O X 10-2209 R2 & R3 30w 10k ohms X X O 10-2210 R2 & R3 30w 15k ohms O O X 10-2211 R4, R5, & R10 - R13 20w 10 ohms X X X 10-2212 R6 - R9 3w 100k ohms X X X 10-2213 R14 & R15 3w 22 ohms X X X 10-2231 R17 3w 6.8k ohms X X X 10-2239 S3 Switch 1P2T X X X 10-2221 SA6 & SA7 Surge Absorber X X X 10-2224 T1 T ransformer X O O 10-2222 T1 T ransformer O X O 10-2223 T1 T ransformer O O X 10-2149 T2 T ransformer X O O 10-2148 T2 T ransformer O X O 10-2155 T2 T ransformer O O X 10-2238 THS1 & THS2 Thermal Switch X X X 10-2227 TO Output Terminal X X X 10-2472 VR1 1/3w 100k ohms Potentiometer X X X 10-2124 VR2 3w 10k ohms Potentiometer X X X

T1 Input Terminal X O O T1 Input Terminal O X O T1 Input Terminal O O X

23 P ARTS LIST