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R
INVERTER
ARC
WELDER
MODEL 300GMS CC/CV
• Stick
• TIG - Lift Start
• MIG - Short Circuit
- Globular
- Spray
THERMADYNE
Manual No. 0-2371
Thermal Dynamics
WARNING
Read and understand this entire instruction manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
WARNING
While the information contained in this instruction manual
represents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
Thermal Arc™ Model 300GMS Inverter Arc Welder
Instruction Manual Number 0-2371
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1993
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability
to any party for any loss or damage caused by any error or
omission in the Thermal Arc™ Model 300GMS Inverter Arc
Welder Instruction Manual, whether such error results from
negligence, accident, or any other cause.
First Edition
March 31, 1993
TABLE OF CONTENTS
Introduction
Notes, Cautions, and Warnings ........................................................ ii
Important Safety Precautions ........................................................... iii
Statement of Warranty ...................................................................... xv
General Information
1.1 Specifications ................................................................................ 1
1.2 Duty Cycle .................................................................................... 2
Installation
2.1
2.2
2.3
2.4
2.5
2.6
Site Selection ................................................................................. 3
Transporting Methods ................................................................ 4
Weld Output Connections .......................................................... 5
Remote 14 Connections .............................................................. 8
Remote 17 Connections ............................................................ 10
Electrical Input Connections .................................................... 12
Operation
3.1
3.2
3.3
3.4
3.5
Operator Controls ...................................................................... 15
Operating Precautions .............................................................. 22
Sequence of Operation .............................................................. 23
Operation Troubleshooting ...................................................... 27
Electrode Selection .................................................................... 29
Service
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Opening the Enclosure ............................................................. 30
Service Troubleshooting ........................................................... 31
Input Rectifier Testing and Replacement ............................... 34
Power IGBT Module Testing and Replacement .................... 35
PC Board Testing ....................................................................... 36
Channel Connections on PCB1 ................................................ 37
Test Points on PCB1 .................................................................. 39
Parts List
5.1 Parts List ..................................................................................... 40
i
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
CAUTION
WARNING
INTRODUCTION
An operation, procedure, or background information which
requires additional emphasis or is helpful in efficient operation of
the system.
A procedure which, if not properly followed, may cause damage
to the equipment.
A procedure which, if not properly followed, may cause injury
to the operator or others in the operating area.
ii
IMPORTANT SAFETY PRECAUTIONS
WARNING
Operation and maintenance of arc welding equipment involves
potential hazards. Operators and all others in the operating area
should be alerted to possible hazards, and precautions should be
taken to prevent possible injury.
Read these safety precautions and the entire instruction manual
before operating.
Do not use this power supply to thaw frozen water pipes.
This equipment must be installed, operated, and serviced by
qualified personnel only.
Gases and Fumes
GASES AND FUMES produced during arc welding can be
dangerous and hazardous to your health.
Keep all fumes and gases from the breathing area.
Different arc welding processes, electrodes, and fluxes can
produce different fumes, gases and radiation levels. Consult
Material Safety Data Sheets (MSDS's) and manufacturer's instructions for specific technical data and precautionary measures for
all fluxes, electrodes, and materials used.
Severe discomfort, illness or death can result from fumes, vapors,
heat, or oxygen enrichment or depletion that welding (or cutting)
may produce. Ventilation must be adequate to remove gases and
fumes during operation as described in ANSI Standard Z49.1.
Use a downdraft table or water table to capture fumes and gases.
Use an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases.
When working in confined spaces provide adequate ventilation
or wear an air-supplied respirator if necessary.
Gas leaks in a confined space should be avoided. Leaked gas in
large quantities can change oxygen concentration dangerously.
Do not bring gas cylinders into a confined space.
When leaving confined space, shut off gas supply at source to
prevent possible accumulation of gases if downstream valves are
accidentally opened. Check that area is safe before re-entering.
Materials containing lead, cadmium, zinc, mercury, beryllium,
and similar materials may produce harmful concentrations of
toxic fumes when welded or cut. Adequate local exhaust ventilation must be used, or operators and others in the operating area
must wear an air-supplied respirator. For beryllium, both must
be used.
iii
INTRODUCTION
IMPORTANT SAFETY PRECAUTIONS (continued)
Gases and Fumes
(continued)
Metals coated with or containing materials that emit toxic fumes
should not be heated unless coating is removed from work
surface and work area is well ventilated. Wear an air-supplied
respirator if necessary.
Vapors from chlorinated solvents can be decomposed by the heat
of the arc or flame to form phosgene, a highly toxic gas, and other
lung and eye irritating products. The ultraviolet radiant energy
of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene. Do not weld or cut where
solvent vapors may be drawn into the welding or cutting atmosphere or where radiant energy may penetrate to atmospheres
containing even minute amounts of trichloroethylene or perchloroethylene. Solvents, degreasers, and potential sources of these
vapors must be removed from the operating area.
Oil or grease in the presence of oxygen may ignite and burn
violently. Keep cylinders, valves, couplings, regulators, hoses,
and other apparatus clean and free from oil and grease. Oxygen
cylinders and apparatus should not be handled with oily hands
or gloves. Do not allow an oxygen stream to contact oily or
greasy surfaces.
Do not use oxygen as a substitute for compressed air.
NEVER ventilate with oxygen.
Generator engine exhaust must be vented to the outside air.
Carbon monoxide can kill.
Arc Rays
ARC RAYS can injure eyes and burn skin.
Never look at an electric arc without protection. Protect eyes
from exposure to arc. Looking at an arc momentarily with
unprotected eyes (particularly a high intensity gas-shielded arc)
can cause permanent damage to vision.
Use a welding helmet or shield with proper filter (see chart on
page v). Place over face before striking arc.
Protect filter plate with a clear cover plate.
Do not use cracked or broken helmet or shield; radiation can pass
through to cause burns.
Replace any cracked, broken or loose filter plates immediately.
Replace clear cover plate when broken, pitted, or spattered.
Flash goggles with side shields must be worn under helmet to
protect eyes in case helmet is not in position before arc is struck.
Wear proper protective clothing. Arc rays can penetrate lightweight clothing,
Welding arc rays can reflect from light-colored surfaces.
INTRODUCTION
iv
IMPORTANT SAFETY PRECAUTIONS (continued)
Arc Rays
(continued)
Make sure others in the operating area are protected from arc
rays.
For production welding, use separate room or enclosed bay. In
open areas, surround operation with low reflective non-combustible screens or panels. Make sure that screen flaps or bay doors
are closed before welding. Allow for free air circulation, particularly at floor level.
Provide face shields for all others viewing the weld.
Make sure others in the operating area are wearing flash goggles.
Welding or Cutting Operation
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal arc welding
(stick) electrodes
Light
Medium
Heavy
Gas metal arc welding (MIG)
Non-ferrous base metal
Ferrous base metal
Gas tungsten arc welding (TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode Size
Metal Thickness
or Welding Current
Filter
Shade
Number
-
2
3 or 4
Under 1 in (25 mm)
1-6 in (25-150 mm)
Over 6 in (150 mm)
3 or 4
4 or 5
5 or 6
Under 1/8 in (3 mm)
1/8-1/2 in (3-12 mm)
Over 1/2 in (12 mm)
4 or 5
5 or 6
6 or 8
Under 5/32 in (4 mm)
5/32-1/4 in (4-6.4 mm)
Over 1/4 in (6.4 mm)
10
12
14
All
All
All
All
All
All
11
12
12
12
12
12
-
12
14
Under 300 amps
300-400 amps
Over 400 amps
9
12
14
Recommended Eye Protection for Welding and Cutting (Based on AWS A6.2-73)
v
INTRODUCTION
IMPORTANT SAFETY PRECAUTIONS (continued)
Electric Shock
ELECTRIC SHOCK can kill.
Do not contact electrically live parts.
Install equipment according to safety precautions, instruction
manual, and all applicable codes.
Keep all panels, covers, and guards in place.
Disconnect all primary power before installing or servicing this
equipment.
Insulate operator and others from work and ground.
Replace any cracked or damaged insulating parts.
Shut down welding power source before touching electrode, wire
drive assembly, welding wire, wire reel, or any metal parts in
contact with the welding wire.
Exposed hot conductors or other bare metal in the welding circuit
or in ungrounded, electrically hot equipment can cause potentially fatal electric shock. Do not contact a wet surface when
welding without suitable protection.
Wear dry insulating gloves and body protection. Keep body and
clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber
mat when dampness or sweat cannot be avoided. Sweat, sea
water, or moisture between body and an electrically hot part or
grounded metal reduces electrical resistance and could cause
potentially fatal electric shock.
A voltage will exist between the electrode and any conducting
object in the work circuit. Examples of conducting objects include, but are not limited to, buildings, electrical tools, work
benches, welding power source cases, workpieces, etc. Never
touch electrode to any metal object unless the welding power
source is off.
Arc welding equipment must be grounded according to the
National Electrical Code, and the work must be grounded according to ANSI Z49.1 “Safety in Welding and Cutting.”
When installing, connect the frames of each unit such as welding
power source, control, work table and water circulator to the
building ground. Conductors must be adequate to carry ground
currents safely. Equipment made electrically hot by stray current
may cause potentially fatal electric shock. Do not ground to
electrical conduit or to pipe carrying any gas or flammable liquid
such as oil or fuel.
Check phase requirements before installing. If only three-phase
power is available, connect single-phase equipment to only two
wires of the three-phase line. Do not connect the equipment
ground lead to the third (live) wire, or the equipment will be-
INTRODUCTION
vi
IMPORTANT SAFETY PRECAUTIONS (continued)
Electric Shock
(continued)
come electrically hot - a dangerous condition that may cause
potentially fatal electric shock.
Before welding, check ground for continuity. Be sure conductors
are touching bare metal of equipment frames at connections.
If a line cord with a ground lead is provided with the equipment
for connection to a switchbox, connect the ground lead to the
grounded switchbox. If a three-prong plug is added for connection to a grounded mating receptacle, the ground lead must be
connected to the ground prong only. If the line cord comes with
a three-prong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a plug with
a broken off ground plug.
Fully insulated electrode holders should be used. Do not use
holders with protruding screws.
Fully insulated lock-type connectors should be used to join
welding cable lengths.
Frequently inspect cables for wear, cracks and damage. Replace
those with excessively worn or damaged insulation to avoid
potentially fatal electric shock from bared cable. Cables with
damaged areas may be taped to give resistance equivalent to
original cable.
Keep cables dry, free of oil and grease, and protected from hot
metal and sparks.
Terminals and other exposed parts of electrical units should have
insulating covers secured before operation.
Electrode
For equipment with output ON/OFF control (contactor): Welding power sources for use with gas metal arc welding (GMAW),
gas tungsten arc welding (GTAW) and similar processes normally are equipped with devices that permit ON-OFF control of
the welding power output. When so equipped the electrode wire
becomes electrically hot when the power source switch is ON and
welding gun switch is closed. Never touch electrode wire or any
conducting object in contact with electrode circuit unless the
welding power source is OFF.
For equipment without output ON/OFF control (no contactor):
Welding power sources used with shielded metal arc welding
(SMAW) and similar processes may not be equipped with welding power output ON-OFF control devices. With such equipment
the electrode is electrically hot when the power switch is turned
ON. Never touch the electrode unless the welding power source
is off.
Safety devices such as interlocks and circuit breakers should
never be disconnected or shunted out.
vii
INTRODUCTION
IMPORTANT SAFETY PRECAUTIONS (continued)
Electric Shock
(continued)
Before installating, inspecting, or servicing equipment, disconnect
primary power and remove line fuses (or lock or red-tag
switches) to prevent accidental electric shock. Disconnect all
cables from welding power source and pull all 115V line-cord
plugs.
Do not open power circuit or change polarity while welding. If it
must be disconnected in an emergency, guard against shock
burns and flash from switch arcing.
Always shut off and disconnect all primary power when leaving
equipment unattended.
Primary power disconnect switch must be available near the
welding power source.
Fire and Explosion
FIRE AND EXPLOSION can be caused by hot slag, spatter,
sparks, extreme heat, misuse of compressed gases and cylinders,
and electrical short circuits.
Remove all combustibles from working area or provide a fire
watch. Avoid paint spray rooms, dip tanks, storage areas, ventilators. Move work to an area free of combustibles if possible. If
work cannot be moved, move combustibles at least 35 ft (10.7 m)
away from sparks and heat or protect against ignition with
suitable and snug-fitting, fire-resistant covers or shields.
Walls having combustibles on opposite sides should not be
welded on or cut. Walls, ceilings, and floor near work should be
protected by heat-resistant covers or shields.
A fire watch with suitable fire extinguishing equipment must be
provided during and after welding or cutting if combustibles
(including building construction) are within 35 ft (10.7 m), if
combustibles are further than 35 ft but may be ignited by flying
sparks, or if openings (concealed or visible) in floors or walls
within 35 ft may expose combustibles to sparks.
Combustibles adjacent to walls, ceilings, roofs, or metal partitions
can be ignited by radiant or conducted heat.
A hot work permit should be obtained before operation to ensure
supervisor’s approval that adequate precautions have been taken.
Do not weld or cut an empty container that has held combustibles, or that can produce flammable or toxic vapors when
heated, unless container has first been cleaned as described in
AWS Standard A6.0. This includes a thorough steam or caustic
cleaning (or a solvent or water washing, depending on the
combustible’s solubility) followed by purging and inerting with
nitrogen or carbon dioxide, and using protective equipment as
recommended in A6.0. Waterfilling just below working level
may substitute for inerting.
INTRODUCTION
viii
IMPORTANT SAFETY PRECAUTIONS (continued)
Fire and Explosion
(continued)
A container with unknown contents should be cleaned (see
preceding paragraph). Do not depend on smell or sight to
determine if it is safe to weld or cut.
Hollow castings or containers must be vented before welding or
cutting to prevent explosion.
Never weld or cut in potentially explosive atmospheres containing flammable dust, gas, or liquid vapor (such as gasoline).
Do not mount this equipment over combustible surfaces.
Flying sparks or falling slag can fly up to 35 ft (10.7 m) and pass
through cracks, along pipes, through windows or doors, and
through wall or floor openings, out of sight of the operator.
Keep equipment clean and operable, free of oil, grease, and
metallic particles that can cause short circuits in electrical parts.
Overloading arc welding equipment beyond rated capacity may
overheat cables and cause fire.
Loose cable connections may overheat or flash and cause fire.
Never strike an arc on a cylinder or other pressure vessel. It
creates a brittle area that can cause a violent rupture or lead to
rupture under rough handling.
After work is done, check that area is free of sparks, glowing
embers, and flames.
Burn Prevention - Wear protective clothing including gauntlet
welding gloves, hat, and high safety toe shoes. Button shirt collar
to protect chest and neck, button pocket flaps, and wear cuffless
trousers to avoid entry of sparks and slag. Wear dark colored,
substantial long-sleeve clothing (particularly for gas-shielded
arc). As necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-resistant
leggings. Avoid outer garments of untreated cotton.
Wear helmet with safety goggles and glasses with side shields
underneath, appropriate filter lenses or plates (protected by clear
cover glass) for welding or cutting (and chipping) to protect the
eyes from radiant energy and flying metal. Replace cover glass
when broken, pitted, or spattered.
Avoid oily or greasy clothing which may be ignited by sparks.
Do not handle hot metal such as electrode stubs and workpieces
without gloves.
Medical first aid and eye treatment facilities and personnel
should be available for each shift unless medical facilities are
close by for immediate treatment of flash burns of the eyes and
skin burns.
ix
INTRODUCTION
IMPORTANT SAFETY PRECAUTIONS (continued)
Fire and Explosion
(continued)
Flammable hair preparations should not be used by persons
intending to weld or cut.
Allow work and equipment to cool before handling.
Noise
NOISE can cause permanent hearing loss.
Wear proper protective ear muffs or plugs.
Make sure others in the operating area are protected from noise.
High Pressure
Gas Cylinders
Comply with the precautions in this manual and those detailed in
CGA Standard P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS.
Pressure Regulators:
Regulator relief valve is designed to protect only the regulator
from overpressure and not intended to protect any downstream
equipment. Provide such protection with one or more relief
devices.
Never connect a regulator to a cylinder containing gas other than
that for which the regulator was designed.
Remove faulty regulator from service immediately for repair
(first close cylinder valve) if gas leaks externally, if delivery
pressure continues to rise with downstream valve closed, or if
gauge pointer does not move off stop pin when pressurized, nor
returns to stop pin after pressure release.
Do not attempt to repair faulty regulators. Send to manufacturer’s authorized repair center where special techniques and tools
are used by trained personnel.
Cylinders must be handled carefully to prevent leaks and damage to walls, valves, or safety devices.
Contact with electrical circuits including third rails, electrical
wires, or welding circuits can product short circuit arcs that may
lead to a serious accident.
ICC or DOT markings must be on each cylinder as an assurance
of safety when the cylinder is properly handled.
Use only cylinders with name of gas clearly marked on them; do
not rely on color to identify gas content. Notify supplier if
unmarked. Never deface or alter name, number or other markings on a cylinder.
Keep valves closed on empty cylinders, replace caps securely,
mark MT, keep separate from full cylinders and return promply.
Never use a cylinder or contents for other than intended use.
Never use as a support or roller.
INTRODUCTION
x
IMPORTANT SAFETY PRECAUTIONS (continued)
High Pressure
Gas Cylinders
(continued)
Locate or secure cylinders so they cannot be knocked over.
Keep cylinders clear of passageways and work areas where they
may be struck.
To transport cylinders with a crane, use a secure support such as
a platform or cradle. Do not lift cylinders by valves or caps, or by
chains, slings, or magnets.
Do not expose cylinders to excessive heat, sparks, slag, or flame
which may cause rupture. Do not allow contents to exceed
1300°F. Cool with water spray where such exposure exists.
Protect cylinders and valves from bumps, falls, falling objects,
and weather. Replace caps securely when moving cylinders.
Do not use hammer or wrench to open a cylinder lock valve
which cannot be opened by hand. Notify supplier.
Never mix gases in a cylinder.
Never refill any cylinder.
Do not modify or exchange cylinder fittings.
Hose
Never use hose unless appropriate for specified gas. General hose
identification is: red for fuel gas, green for oxygen, and black for
inert gases.
Use ferrules or clamps designed for hose (not ordinary wire or
other substitute) as a binding to connect hoses to fittings.
Do not use copper tubing splices. Use only standard brass
fittings to splice hose.
Avoid long runs to prevent kinks and abuse. Coil excess hose to
prevent kinks and tangles. Suspend hose off ground to protect
from damage. Protect hose from damage by sharp edges, sparks,
slag, excessive heat, and open flame.
Examine hose regularly for leaks, wear, and loose connections.
Immerse pressured hose in soapy water; bubbles indicate leaks.
Repair leaky or worn hose by cutting area out and splicing. Do
not tape.
Proper Connections
Keep cylinder valve outlet free of impurities which may clog
orifices and damage seats before connecting regulator. Except for
hydrogen, crack valve momentarily and point outlet away from
people and sources of ignition. Wipe clean with a lintless cloth.
Match regulator to cylinder. Before connecting, check that
regulator label and cylinder marking area match and that regulator inlet and cylinder outlet match. Never connect a regulator
designed for one type of gas to a cylinder containing another gas.
xi
INTRODUCTION
IMPORTANT SAFETY PRECAUTIONS (continued)
Proper Connections
(continued)
When assembling threaded connections, clean and smooth seats
where necessary before tightening. If connection leaks, disassemble, clean, and retighten using properly fitting wrench.
Use a CGA adapter (available from supplier) between cylinder
and regulator, if required. Use two wrenches to tighten adapter
marked RIGHT and LEFT HAND threads.
Regulator outlet (or hose) connections may be identified by right
hand threads for oxygen and left hand threads (with grooved hex
on nut or shank) for fuel gas.
Pressurizing Steps
Drain regulator of residual gas through suitable vent before
opening cylinder (or manifold valve) by turning adjusting screw
clockwise. Draining prevents excessive compression heat at high
pressure seat by allowing seat to open on pressurization. Leave
adjusting screw engaged slightly on single-stage regulators.
Do not stand in front of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure increases
slowly. When gauge is pressurized (gauge reaches regulator
maximum) open cylinder valve fully to seal stem against possible
leak when using oxygen and inert gases. For fuel gas, open less
than one turn to permit quick emergency shutoff.
Use pressure charts (available from supplier) for safe and efficient, recommended pressure settings on regulators.
Check for leaks on first pressurization and regularly thereafter.
Brush with soapy solution (one capful of liquid detergent per
gallon of water); bubbles indicate leak Clean off soapy water
after test; dried soap is combustible.
Remove leaky or defective equipment immediately for repair.
Close gas supply at source and drain gas when leaving equipment unattended.
Do not use rope staging support for welding or cutting operation;
rope may burn.
Electronic Life Support
Devices (Pacemakers)
INTRODUCTION
Magnetic fields from high currents can affect pacemaker operation. Persons wearing electronic life support equipment (pacemakers) should consult with doctor before going near arc welding, gouging, or spot welding operations.
xii
IMPORTANT SAFETY PRECAUTIONS (continued)
Publications
Refer to the following standards or their latest revisions for more
information:
1. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550
N.W. LeJeune Rd, Miami, FL 33126
2. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND
GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
3. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
obtainable from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETYTOE 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 Standards 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
xiii
INTRODUCTION
IMPORTANT SAFETY PRECAUTIONS (continued)
Publications
(continued)
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 Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION
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
INTRODUCTION
xiv
STATEMENT OF WARRANTY
LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter “Thermal”) 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 products as stated below, Thermal shall,
upon notification thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal’s specifications, instructions, recommen dations 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’s sole option, of any components or parts of the
product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal 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 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 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.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED
WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows: A maximum of three (3) years
from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such
distributor to the Purchaser, and with the following further limitations on such two (2) year period:
PAK UNITS, POWER SUPPLIES
PARTS
LABOR
MAIN POWER MAGNETICS ....................................................... 2 YEARS ..................... 1 YEAR
ORIGINAL MAIN POWER RECTIFIER ..................................... 2 YEARS ..................... 1 YEAR
CONTROL PC BOARD .................................................................. 2 YEARS ..................... 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS ......................... 1 YEAR ...................... 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT ........................... 1 YEAR ...................... 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS ..................................................................... 180 DAYS .................. 180 DAYS
REPAIR/REPLACEMENT PARTS ................................................. 90 DAYS .................... 90 DAYS
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized
Thermal Arc® repair facility within thirty (30) days of the repair. Authorized Thermal Arc® repair
facilities are authorized distributors and authorized Thermal Arc® Service Centers. 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 warranties.
Thermal Arc® is a Registered Trademark of Thermal Dynamics.
Effective January 18, 1991
xv
INTRODUCTION
1.1 SPECIFICATIONS
Description
OCV Less than 80V
The Thermal Arc™ 300GMS is a three-phase or single-phase (if
derated) DC arc welding power source with selectable Constant
Current (CC) and Constant Voltage (CV) output characteristics.
This unit is designed for use with Shielded Metal Arc Welding
(SMAW), Gas Metal Arc Welding (GMAW), and Gas Tungsten
Arc Welding - Lift Start (GTAW) processes. A digital amperage/
voltage meter is standard.
OCV Less Than 80V
C.C.
Arc Characteristics
"CURRENT" Control
C.V.
36V
19V
10V
5
150
375 410
25A
AMPS
410A
Output Current Limit 410A
Figure 1-A Volt-Ampere Curves
NOTE
Rated Output
Amperes
Volts
Duty Cycle
Range (Min-Max):
Amperes
Volts
Maximum OCV:
Input Data
Width
Height
Length
Weight (with Cable)
Volt-ampere curves show the voltage and amperage output
capabilities of the welding power source. Curves of other
settings will fall between the curves shown.
Single-Phase
210
28
60%
Three-Phase
300
32
60%
5-260
10-30
5-375
10-36
70
50/60 Hz
12 in
(305 mm)
20 in
(510 mm)
18.5 in
(470 mm)
230/460 380/415 460/575
88.7 lb 82.1 lb
83.8 lb
40.3 kg 37.3 kg 38.1 kg
Input Data
50/60 Hz
At Rated Load
No Load
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
230 VAC 1-Phase
39
43
14
10
11
7
1.5
2.0
0.5
0.5
0.3
0.3
230 VAC 3-Phase
460 VAC 1-Phase
35
21
14
10
11
7
1.0
1.0
0.5
0.5
0.3
0.3
460 VAC 3-Phase
575 VAC 3-Phase
18
14
14
14
11
11
0.5
0.5
0.5
0.5
0.3
0.3
380 VAC 3-Phase
400 VAC 3-Phase
21
20
14
14
11
11
1.0
1.0
0.5
0.5
0.3
0.3
415 VAC 3-Phase
19
14
11
0.5
0.5
0.3
Table 1-A Unit Specifications
1
GENERAL INFORMATION
1.2 DUTY CYCLE
The duty cycle of a welding power source is the percentage of a
ten minute period that a welding power source can be operated
at a given output without causing overheating and damaging of
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 the thermal
overload protection circuit to become energized and shut down
output until the unit cools to normal operating temperature.
CAUTION
CONTINUAL EXCEEDING OF DUTY CYCLE RATINGS can
cause damage to the welding power source.
• Do not exceed indicated duty cycles.
GENERAL INFORMATION
2
2.1 SITE SELECTION
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
WARNING
FIRE OR EXPLOSION can result from placing unit on or over
combustible surfaces; RESTRICTED AIRFLOW can cause
overheating and possible damage to internal parts.
• 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.
NOTE
Warranty is subject to being voided if any type of filtering device
is used at intake air passages.
3
INSTALLATION
2.2 TRANSPORTING 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.
WARNING
FALLING EQUIPMENT can cause serious personal injury and
equipment damage.
• Lift unit with handles on top ends of case.
• 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.
• This unit has built-in handles on top ends of case for lifting. Be
sure unit is lifted and transported safely and securely.
• Do not lift unit by one handle.
INSTALLATION
4
2.3 WELD OUTPUT 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
Use the following guidelnes 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 welding cable size according to maximum weld output
and total length of connecting cables in weld circuit. For
example, if a 25 foot (7.5 m) electrode holder or torch cable is
used with a 25 foot (7.5 m) work cable, select the cable size
recommended in Table 2-A for 50 feet (15 m).
4. Do not use damaged or frayed cables.
Weld Cable Preparation
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. If installing electrode holder, follow manufacturer’s installation instructions. Always use an insulated electrode holder to
ensure operator safety.
3. Install work clamp onto cable.
4. Install supplied male connectors onto remaining ends of both
cables (refer to Connector Installation, page 6).
Maximum Total Cable Length in Weld Circuit
Welding
Amperes
100
150
200
250
300
400
Under 100 ft
(Under 30 m)
10-60%
Duty Cycle
60-100%
Duty Cycle
4
3
3
2
1
1/0
4
3
2
1
1/0
2/0
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
250 ft
(105 m)
400 ft
(120 m)
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
10-100%
Duty Cycle
4
2
1
1/0
2/0
3/0
3
1
1/0
2/0
3/0
4/0
2
1/0
2/0
3/0
4/0
2-2/0
1
2/0
3/0
4/0
2-2/0
2-3/0
Table 2-A Weld Cable Sizes
5
INSTALLATION
2.3 WELD OUTPUT CONNECTIONS (continued)
Connector Installation
Install the supplied male connectors onto proper cables as follows
(refer to Figure 2-A below):
1. Obtain cable of desired length and proper size for installation
(see 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 in Figure 2-A.
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
Strip insulation approx. 1 in from end
Insulator
Weld Cable
Sleeve
Connector Body
(Male or Female)
Figure 2-A Connector Installation
WARNING
Weld Cable Connections
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.
INSTALLATION
6
2.3 WELD OUTPUT CONNECTIONS (continued)
Positive
Negative
Figure 2-B Weld Output Connections - Lower Front Panel
Shielded Metal Arc
Welding (SMAW)
(Electrode Positive/
Reverse Polarity)
Refer to Figure 2-B and:
a. Connect end of electrode holder cable to the positive (+) 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 the negative (-) weld output
receptacle as follows: align keyway, insert plug, and rotate
plug clockwise until it is securely seated in receptacle.
NOTE
Gas Metal Arc
(GMAW) and
Flux Cored Arc
(FCAW) Welding
(Electrode Positive/
Reverse Polarity)
NOTE
Gas Tungsten Arc
Welding (GTAW)
(Electrode Negative/
Straight Polarity,
Lift-Start)
For Electrode Negative/Straight Polarity connections, reverse
cable connections to weld output receptacles; electrode (torch)
becomes negative.
a. Connect end of electrode holder cable to the positive (+) weld
output receptacle as follows: align keyway, insert plug, and
rotate plug clockwise until it is securely seated in receptacle.
Cremaining end to terminal connection located on drive
housing of wire feeder (see wire feeder manual for location).
b. Connect work cable connector to the negative (-) weld output
receptacle as follows: align keyway, insert plug, and rotate
plug clockwise until it is securely seated in receptacle.
For Electrode Negative/Straight Polarity connections, reverse
cable connections to weld output receptacles; electrode (torch)
becomes negative.
a. Connect torch cable connector to the 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 the positive (+) weld output
receptacle as follows: align keyway, insert plug, and rotate
plug clockwise until it is securely seated in receptacle.
7
INSTALLATION
2.4 REMOTE 14 CONNECTIONS
14
A
B
C
J
K
I
L
D
N
M
H
G
E
F
Figure 2-C Front View of 14-Pin Socket Receptacle with Socket Locations
The REMOTE 14 receptacle is used to connect any of the following equipment to the welding power source circuitry:
• Remote Contactor Control
• Remote Amperage Control
• Wire Feeder (one which provides contactor control to welding
power source)
• Combination of the above.
To make connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
The following socket information 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.
INSTALLATION
8
2.4 REMOTE 14 CONNECTIONS (continued)
Socket A
Up to 10 amps of 24 VAC, 60Hz, with respect to Socket G
(circuit common); protected by circuit breaker MCB3
Socket B
Input to energize the solid-state contactor; 24 VAC (contact
closure is provided between Sockets A and B to energize the
solid-state contactor
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) in CC or CV mode
Socket F
Not used
Socket G
24 and 115 VAC circuit common; also connected to welding
power source chassis
Socket H
100 VAC with respect to Socket L (see note below)
Socket I
Up to 1.5 amperes of 115 VAC, 60Hz, with respect to Socket G
(circuit common); protected by circuit breaker MCB2
Socket J
115 VAC input control to energize solid state contactor (contact
closure is provided between Sockets I and J)
Socket K
Chassis common
Socket L
100 VAC circuit common (see note below)
Socket M
Current sensing contactor with respect to Socket N (N/O)
Socket N
Current sensing contactor with respect to Socket M (N/O)
NOTE: The voltage referenced on Sockets H and L is to be used for
applications requiring 100 VAC
Table 2-B Remote 14 Socket Information
9
INSTALLATION
2.5 REMOTE 17 CONNECTIONS
17
A
M
B
C
L
N
T
P
D
K
R
E
S
J
F
H
G
Figure 2-D Front View of 17-Socket Receptacle with Socket Locations
The 17-socket REMOTE receptacle provides a junction point for
connecting various remote controls to the welding power source.
The functions available from this receptacle are:
• Remote MIG synergic pulse control
• Robot control
• Weld current and voltage signals for remote metering
To make connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
The following socket information is included in case the supplied
cord is not suitable, and it is necessary to wire a plug or cord to
interface with REMOTE 17 receptacle.
INSTALLATION
10
2.5 REMOTE 17 CONNECTIONS (continued)
Socket A
Amperage/voltage reference output signal; +10 volts; for use
with pulse controls
Socket B
Amperage/voltage remote control input command signal; +10
volts for machine maximum
Socket C
Not Used
Socket D
Solid-state contactor remote control command signal; +24 volts
(operates above 13 volts) turns contactor on; 0 volts (open or
ground) turns contactor off
Socket E
Actual weld current signal; +1 volt per 100 amperes of output
current
Socket F
PC board common; use as return for remote control inputs/
outputs only from terminals A, B, C, D, E, J, and K
Socket G
Not Used
Socket H
+24 volts unregulated; fused for 1/2 ampere
Socket J
Not Used
Socket K
Remote amperage/voltage reference signal; 0 to +10 volts (set
by main rheostat) in CC and CV mode
Socket L
-24 volts unregulated; fused for 1/2 ampere
Socket M
Load voltage output signal; +1 volt per 10 volts of load voltage
Socket N
Not Used
Socket P
Circuit common (PC board common and internal chassis
ground) use as return (+/-) 18 volts logic supply only
(pins H and L)
Socket R
Not Used
Socket S
Chassis ground
Socket T
Not Used
Table 2-C Remote 17 Socket Information
11
INSTALLATION
2.6 ELECTRICAL INPUT CONNECTIONS
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE
exists 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 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 red-tagging circuit breaker or other
disconnecting device.
Electrical Input
Requirements
Operate the welding power source from a three-phase, or single
phase 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
INSTALLATION
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.
12
2.6 ELECTRICAL INPUT CONNECTIONS (continued)
WARNING
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-E (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
deenergized line disconnect switch.
3. For single-phase electrical input power: connect ends of red
(line 1), white (line 2), input conductors to a de-energized line
disconnect switch. Insulate and isolate the black (line 3)
conductor.
4. Use Table 2-D (below) as a guide to select line fuses for the
disconnect switch.
INPUT
POWER
INPUT
VOLTAGE
FUSE SIZE
(AMPERES)
SINGLE
PHASE
208-230 VAC
460 VAC
60
30
THREE
PHASE
208-230 VAC
380-460 VAC
575 VAC
60
30
25
Table 2-D 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).
13
INSTALLATION
2.6 ELECTRICAL INPUT CONNECTIONS (continued)
Ground
Terminal
Ground
Conductor
Line
Disconnect
Switch
Line Fuse
Welding Power Supply
Primary Power Cable
Figure 2-E 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.
• The surge current prevention circuit becomes activated when
the PRIMARY 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.
INSTALLATION
14
3.1 OPERATOR CONTROLS
9
2
1
5
WARNING AC POWER
METER
AMPERAGE/VOLTAGE
A
8
V
MIG
PREVIEW
A/V
20
40
20
80
REMOTE
ON
300
100
7
14
250
30
15
4
200
150
60
OUTPUT CONTACTOR
25
CB (24V)
LIFT
TIG
STICK
(PUSH)
350
50
CB (115V)
17
AMPERAGE/VOLTAGE
14
0
% 100
ARC CONTROL
/INDUCTANCE
5
375 A
A
10
R
PANEL
REMOTE
36V
17
6
300 GMS
DC INVERTER ARC WELDER
3
WEST LEBANON, NH USA
17
14
AMPERAGE
/VOLTAGE
A/V
FEEDER
OUTPUT
1. AC POWER Indicator
2. WARNING Indicator
3. AMPERAGE/VOLTAGE Control
4. ARC CONTROL/INDUCTANCE Control
5. Process Selector Switch
6. AMPERAGE/VOLTAGE Switch
7. OUTPUT CONTACTOR Switch
8. Digital AMPERAGE/VOLTAGE Meter (Optional)
9. METER Switch and PREVIEW (Optional)
Figure 3-A Front Panel Controls
15
OPERATION
3.1 OPERATOR CONTROLS (continued)
Primary Power
Switch
PRIMARY POWER
OFF
ON
Figure 3-B Rear Panel Controls
OPERATION
16
3.1 OPERATOR CONTROLS (continued)
PRIMARY POWER
Switch and
AC POWER Indicator
NOTE
WARNING Indicator
The PRIMARY POWER switch (circuit breaker) located on the
rear panel energizes the welding power source when placed in
the ON position. The AC POWER indicator on the front panel
comes on when the PRIMARY POWER switch is in ON position,
indicating that the unit is energized. Placing the PRIMARY
POWER switch in OFF position shuts down the welding power
source and turns off the AC power indicator.
When the PRIMARY 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 lit during the pre-charge time delay.
The WARNING indicator located on the front panel will become
activated if the unit witnesses the following:
• Input voltage too low
• Thermal overload
AMPERAGE/VOLTAGE
Control
A
AMPERAGE
V
VOLTAGE
NOTE
ARC CONTROL/
INDUCTANCE Control
ARC CONTROL For
STICK (CC) Mode
STICK
The AMPERAGE/VOLTAGE control selects the desired amperage within the entire range of the welding power source. Rotating the control in a clockwise direction increases the amperage
output. The scale surrounding the AMPERAGE/VOLTAGE
control represents approximate actual amperage and voltage
values and is read according to the selected mode: Constant
Voltage (CV) or Constant Current (CC). The amperage scale (CC)
is for SMAW and GTAW. The voltage scale (CV) is for GMAW
and FCAW.
The AMPERAGE/VOLTAGE control may be adjusted while
welding.
The ARC CONTROL/INDUCTANCE control may be adjusted
while welding. Operations of this control depends on the welding mode selected.
In STICK welding mode, the ARC CONTROL/INDUCTANCE
control functions as an arc control, providing a variable selection
of short circuit amperage to suit individual welding situations
when operating in the STICK (SMAW) mode. Rotating the
control clockwise causes amperage to increase as a short circuit
condition is approached.
When the control is set at 100, short circuit amperage is considerably higher than normal welding amperage. This provides extra
amperage for arc starting in out-of-position welds as well as
momentary over amperage necessary for certain electrode types.
When the control is set at 0 (zero), short circuit amperage above
normal welding amperage is minimal.
17
OPERATION
3.1 OPERATOR CONTROLS (continued)
ARC CONTROL For
STICK (CC) Mode
(continued)
When the control is set at 50, short circuit amperage is approximately half that of the 100 position, but still higher than normal
welding amperage. The 50 position provides a moderate amperage increase for arc starting necessary for certain type of electrodes and applications.
Select a setting best suited for the application and electrode type.
Main Knob
5-375A
0
Arc Control
19V 10V/100A Droop
25%
50%
75%
100%
145A
Arc Control Knob
Main Knob = Arc Control Knob
= Less Than 410A Output Current Limit
Figure 3-C Arc Control/Inductance Characteristics
INDUCTANCE For
MIG (CV) Mode
MIG
In the MIG (CV) mode, the ARC CONTROL/INDUCTANCE
control functions as an inductance control, allowing for the
adjustment of the dynamic properties of the arc enhancing the
weld puddle control when operated in the Gas Metal Arc
(GMAW) and Flux Cored Arc (FCAW) welding processes.
The 0 (zero) setting provides a minimum inductance, i.e., a stiff,
fast-responding arc, and a small fast-freezing weld puddle.
The 100 setting provides maximum inductance characteristics,
i.e., a soft , slower-responding, low spatter arc, and high weld
puddle fluidity.
As the inductance is increased, it may be required to reduce the
arc voltage at the AMPERAGE/VOLTAGE control to achieve the
desired weld characteristics.
Select a setting best suited for the application and electrode type.
OPERATION
18
3.1 OPERATOR CONTROLS (continued)
Process Selector Switch
The process selector switch allows the operator to select the
STICK welding (SMAW) process, the MIG welding (GMAW)
process, or the SCRATCH TIG welding (GTAW) process.
STICK Welding
(SMAW)
In STICK welding mode, the unit provides weld output characteristics specifically designed for the Shielded Metal Arc Welding
(SMAW) process. When the process selector switch is in this
position, the arc control function of the ARC CONTROL/INDUCTANCE control is active, and the amperage scale of the
AMPERAGE/VOLTAGE control is applicable.
STICK
MIG Welding
(GMAW and FCAW)
In MIG welding mode, the unit provides weld output characteristics specifically designed for the Gas Metal Arc (GMAW) and
Flux Cored Arc (FCAW) welding processes. When the process
selector switch is in this position, the inductance function of the
ARC CONTROL/INDUCTANCE control is active, the voltage
scale of the AMPERAGE/VOLTAGE control is applicable.
MIG
LIFT TIG
(GTAW without
High Frequency)
In this mode, the unit provides weld output for the gas tungsten
arc welding (GTAW) process. High frequency will not be
present. When the process selector switch is in this position, the
POST FLOW control will function and the ARC CONTROL will
not function. The unit will provide a low open circuit voltage
and approximately 15 amps (for 1.0 ms) to the tungsten electrode
when touched to the work and lifted away from surface. After
the welding arc becomes established, the output current will be
regulated at determined current level.
LIFT
TIG
Output Characteristics of LIFT TIG
5V
15A
Short Circuit Current
Figure 3-D Output Characteristics of Lift TIG
19
OPERATION
3.1 OPERATOR CONTROLS (continued)
AMPERAGE/VOLTAGE
Switch
PANEL
This switch determines whether the amperage/voltage is adjusted by the front panel AMPERAGE/VOLTAGE control or by a
remote control device. If remote control function is not desired,
place this switch in PANEL position.
For remote amperage/voltage control, place the AMPERAGE/
VOLTAGE switch in REMOTE 14 position if remote control
connections are made to the REMOTE 14 receptacle, or to the
REMOTE 17 position if remote control connections are made to
the REMOTE 17 receptacle.
14
REMOTE
17
WARNING
When using the REMOTE 14 receptacle, remote control is a
percentage of the value set by the front panel AMPERAGE/
VOLTAGE control. For example, if the AMPERAGE/VOLTAGE
control is set at half maximum output, the maximum output
available from the remote control will be half the welding power
source maximum output.
When using the REMOTE 17 receptacle, two possibilities exist.
If Socket K is used to determine remote output, the REMOTE 17
receptacle functions the same as the REMOTE 14 (remote control
is a percentage of the value set by the front panel AMPERAGE/
VOLTAGE control). If Socket B is used to determine remote
output, the REMOTE 17 receptacle commands the full range of
the welding power source output, independent of the front panel
AMPERAGE/VOLTAGE setting. Determining which socket to
use depends on the remote control device used in the application.
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.
OUTPUT CONTACTOR
Switch
If the OUTPUT CONTACTOR switch is in ON position, open
circuit voltage will be present at the output receptacles whenever
the PRIMARY POWER switch is in ON position.
NOTE
Although the term CONTACTOR is used on the nameplate and
throughout this manual, the output is not switched on or off by a
physical contactor; rather, the unit uses solid-state output control.
OPERATION
20
3.1 OPERATOR CONTROLS (continued)
OUTPUT CONTACTOR
Switch (continued)
14
REMOTE
17
For remote contactor control, place the OUTPUT CONTACTOR
switch in REMOTE 14 position if remote contactor connections
are made to the REMOTE 14 receptacle, or to the REMOTE 17
position if remote contactor connections are made to the REMOTE 17 receptacle. Open circuit voltage will be present at the
weld output receptacles whenever the torch switch or remote
device is closed.
If remote contactor control is not desired, place the OUTPUT
CONTACTOR switch in ON position. Open circuit voltage will
be available whenever the PRIMARY POWER switch is in ON
position.
ON
Digital AMPERAGE/
VOLTAGE Meter and
Switch (Optional)
A
AMPERAGE
V
VOLTAGE
AMP
AMP
VOLT
VOLT
The LED 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
SWITCH SETTING
METER
INDICATOR
OFF
ON
OFF
ON
PRESET
PRESET
PRESET
ACTUAL
Table 3-A Values Displayed for Meter Switch Setting and Parameters Selected
21
OPERATION
3.2 OPERATING PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill; MOVING PARTS can cause
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.
Warranty is void if the welding power source is operated with
any portion of the outer enclosure removed.
WARNING
ARC RAYS, SPARKS, AND HOT SURFACES can burn eyes
and skin; NOISE can damage hearing.
• Wear correct eye, ear and body protection.
WARNING
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.
WARNING
HOT MEAL, SPATTER, AND SLAG can cause fire and burns.
• Watch for fire.
• 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.
WARNING
MAGNETIC FIELDS FROM HIGH CURRENTS can affect
pacemaker operation.
• Wearers should consult their doctor before going near arc
welding, gouging, or spot welding operations.
OPERATION
22
3.3 SEQUENCE OF OPERATION
WARNING
Shielded Metal Arc
Welding (SMAW)
Read and follow all safety precautions on page 22 and at the front
of this manual before proceeding with operation.
1. Install and connect unit according to the Installation section
(pages 3-14).
2. Wear dry insulating gloves and clothing.
3. Connect work clamp to clean, bare metal at workpiece.
4. Select proper electrode (see Table 3-B, page 29).
Refer to Operating Controls (pages 15-21) and:
5. Place the process selector switch in STICK position.
6. Place the OUTPUT CONTACTOR switch in ON position.
7. If remote amperage control is not used, place the AMPERAGE/VOLTAGE switch in PANEL position. If remote
amperage control is to be used, place the AMPERAGE/
VOLTAGE switch in REMOTE 14 position.
8. Rotate the amperage/voltage control, or remote amperage
control if applicable, to desired position.
9. Rotate the ARC CONTROL/INDUCTANCE control to
desired position.
10. Insert electrode into electrode holder.
11. Wear welding helmet with proper filter lens according to
ANSI Z49.1.
12. Place the PRIMARY POWER switch in ON position.
13. Begin welding.
23
OPERATION
3.3 SEQUENCE OF OPERATION (continued)
WARNING
Gas Tungsten Arc
Welding (GTAW)
Lift Start Only
Read and follow all safety precautions on page 22 and at the front
of this manual before proceeding with operation.
1. Install and connect unit according to the Installation section
(pages 3-14).
2. Select and obtain proper tungsten electrode (see Table 3-B
page 29).
3. Prepare tungsten electrode and insert into torch.
4. Wear dry insulating gloves and clothing.
5. Connect work clamp to clean, bare metal at workpiece.
Refer to Operating Controls (pages 15-21) and:
6. Place the process selector switch in LIFT TIG position.
7. Place the OUTPUT CONTACTOR switch in desired position.
8. Place the AMPERAGE/VOLTAGE switch in desired position.
9. Rotate amperage/voltage control to desired position.
10. Turn on shielding gas and water supplies as applicable.
11. Wear welding helmet with proper filter lens according to
ANSI Z49.1.
12. Place the PRIMARY POWER switch in ON position.
13. Activate the remote control device (foot control or remote
pendant).
14. Touch electrode to work and lift to start arc.
15. Begin welding.
WARNING
HIGH CONCENTRATION OF SHIELDING GAS can harm
health or kill.
• Shut off gas supply when not in use.
OPERATION
24
3.3 SEQUENCE OF OPERATION (continued)
WARNING
Gas Metal Arc Welding
(SMAW)
Read and follow all safety precautions on page 22 and at the front
of this manual before proceeding with operation.
1. Install and connect unit according to the Installation section
(pages 3-14).
2. Install and connect wire feed system according to its Owners
Manual.
3. Wear dry insulating gloves and clothing.
4. Connect work clamp to clean, bare metal at workpiece.
Refer to Operating Controls (pages 15-21) and:
5. Place the process selector switch in MIG position.
6. Place the OUTPUT CONTACTOR switch in REMOTE position.
7. Place the AMPERAGE/VOLTAGE switch in the desired
position.
8. Rotate AMPERAGE/VOLTAGE control to desired position.
9. Rotate ARC CONTROL/INDUCTANCE control to desired
position.
10. Turn on shielding gas supplyand set desired flow rate.
11. Wear welding helmet with proper filter lens according to
ANSI Z49.1.
12. Place PRIMARY POWER switch in ON position.
13. Begin welding.
25
OPERATION
3.3 SEQUENCE OF OPERATION (continued)
WARNING
Flux Cored Arc Welding
(FCAW)
Read and follow all safety precautions on page 22 and at the front
of this manual before proceeding with operation.
1. Install and connect unit according to the Installation section
(pages 3-14).
2. Install and connect wire feeding system according to its
Owners Manual.
3. Wear dry insulating gloves and clothing.
4. Connect work clamp to clean, bare metal at workpiece.
Refer to Operating Controls (pages 15-21) and:
5. Place the process selector switch in MIG position.
6. Place the OUTPUT CONTACTOR switch in REMOTE position.
7. Place the AMPERAGE/VOLTAGE switch in the desired
position.
8. Rotate the AMPERAGE/VOLTAGE control to the desired
position.
9. Rotate the ARC CONTROL/INDUCTANCE control to
desired position.
10. Wear welding helmet with proper filter lens according to
ANSI Z49.1.
11. Place PRIMARY POWER switch in ON position.
12. Begin welding.
Shutting Down
1. Stop welding.
2. Place the PRIMARY POWER switch in OFF position.
3. Turn off the shielding gas and water supplies if applicable.
OPERATION
26
3.4 OPERATION TROUBLESHOOTING
TROUBLE
A. No weld output; unit
completely inoperative
B. No weld output; fan motor
running and AC POWER
indicator on
C. Erratic or improper weld
output
D. Remote device completely
inoperative
POSSIBLE CAUSE
REMEDY
1. Line disconnect switch in
OFF position
1. Place line disconnect
switch in ON position
2. Line fuse(s) open
2. Check and replace line
fuse(s)
3. Improper electrical input
connections
3. See Installation section
(pages 3-14) for proper
input connections
4. Primary power switch
MCB in OFF position
4. Check and reset MCB if
necessary
1. OUTPUT CONTACTOR
switch S2 in REMOTE 14
position; no remote
contactor control connected to REMOTE 14
receptacle
1. Place S2 in ON position or
connect remote contactor
control to REMOTE 14
receptacle
2. Defective remote control
device
2. Check and replace remote
control device if necessary
3. Warning indicator on.
Thermostat THS 1,THS 2
open (thermal shutdown)
3. Allow cooling period of
approximately five minutes
1. Loose welding cable
connections
1. Tighten all welding cable
connections
2. Incorrect welding cable
size
2. Use proper size and type
of cable (see Table 2-A,
page 5)
3. Improper input and/or
output connections
3. Use proper size and cable
size (see Table 2-A)
4. Improper input and/or
output connections
4. Check for proper input
and output connections
5. Electrode condition
5. Replace electrode
6. Remote amperage control
(when applicable)
6. Check remote amperage
control potentiometer and
connections. Repair or
replace if necessary
1. Remote control not connected or connected
improperly to REMOTE 14
receptacle
1. Connect remote control to
REMOTE 14 receptacle
27
OPERATION
3.4 OPERATION TROUBLESHOOTING (continued)
TROUBLE
E. Wandering arc; poor
control of arc direction
OPERATION
POSSIBLE CAUSE
REMEDY
1. Use of tungsten considerably larger than recommended
1. Use proper size tungsten
(see Table 3-B, page 29)
2. Improperly prepared
tungsten
2. Prepare tungsten per
instruction manual
3. Gas flow rate too high
3. Reduce flow rate
4. Drafts blowing shielding
gas away from tungsten
electrode
4. Shield weld zone from
drafts
5. Loose gas fittings on
regulator or gas line
drawing air into weld
zone
5. Check and tighten all gas
fittings
6. Water in torch
6. Refer to torch parts list for
part(s) requiring replacement and repair torch as
necessary
28
3.5 ELECTRODE SELECTION
ELECTRODE DIAMETER
PURE TUNGSTEN
(GREEN BAND)
.010 in
.020 in
.040 in
1/16 in
3/32 in
1/8 in
5/32 in
3/16 in
1/4 in
(0.25 mm)
(0.51 mm)
(1.02 mm)
(1.59 mm)
(2.38 mm)
(3.18 mm)
(3.97 mm)
(4.76 mm)
(6.35 mm)
AMPERAGE RANGE
DC-ARGON ELECTRODE
NEGATIVE/STRAIGHT POLARITY
1-15
5-20
15-80
70-150
125-225
225-360
DC-ARGON ELECTRODE
POSITIVE/STRAIGHT POLARITY
450-720
720-950
10-20
15-30
25-40
360-450 40-55
55-80
80-125
1-25
15-40
25-85
50-160
135-235
250-400
400-500
500-750
750-1000
10-20
15-30
25-40
40-55
55-80
80-125
2% THORIUM ALLOYED
TUNGSTEN
(RED BAND)
.010 in
.020 in
.040 in
1/16 in
3/32 in
1/8 in
5/32 in
3/16 in
1/4 in
(0.25 mm)
(0.51 mm)
(1.02 mm)
(1.59 mm)
(2.38 mm)
(3.18 mm)
(3.97 mm)
(4.76 mm)
(6.35 mm)
Table 3-B Electrode Selection
29
OPERATION
4.1 OPENING THE ENCLOSURE
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE
exists after removal of input power.
1. Turn off MCB1 of power source and open wall disconnect
switch or circuit breaker.
2. Wait at least 100 seconds to allow discharge of primary
capacitors.
3. Open the enclosure.
SERVICE
30
4.2 SERVICE TROUBLESHOOTING
Troubleshooting
Preparation
1. Set the PROCESS SELECTOR switch to STICK position.
2. Set the CONTACTOR SELECTOR switch to PANEL position.
3. Disconnect remote options from the 14 pin receptacle.
4. Close the wall disconnect switch or circuit breaker.
5. Turn on MCB1 of power source.
TROUBLE
A. MCB trips without running (contactor off)
B. Green power indicator
does not light (no fan)
C. Red trouble warning
indicator on
POSSIBLE CAUSE
REMEDY
1. Input voltage over rated
limit
1. Connect to proper line
voltage.
2. Shorted primary lines or
devices
2. Check surge absorber
PCB10, Check primary
lines for shorts.
3. Faulty control PCB1
3. Check PCB1 (see page 36)
1. Line disconnect switch in
OFF position
1. Place line disconnect
switch in ON position
2. Line fuses open
2. Check and replace fuses if
necessary
3. Fuse F1 open or loose
contact
3. Check F1 and replace if
necessary
4. Power switch S1
4. Check F1 contacts. Check
and replace MCB if necessary
5. Control transformer T2
5. Check T2 connections on
CN14 - CN17, CN21 on
PCB1 (see page 38)
1. Line voltage below rated
limit
1. Connect to proper line
voltage
2. Thermostat THS or THS2
open (thermal shutdown)
2. Allow to cool 5 minutes
before turning on power
supply. If problem still
occurs check THS and
THS2 for continuity and
replace if necessary. Check
contact of plug CN8 (see
page 38)
31
SERVICE
4.2 SERVICE TROUBLESHOOTING (continued)
TROUBLE
D. No weld output (fan
motor running, warning
indicator off)
E. Low weld output with no
control
SERVICE
POSSIBLE CAUSE
REMEDY
1. Output contactor switch
S2 in REMOTE position
with no remote contactor
connected
1. Place S2 in ON position or
connect remote contactor
control to remote receptacle
2. Faulty remote control
device
2. Check and replace remote
control device if necessary.
3. Input contactor MC1, R1
not closing
3. Check and replace MC,
points and coil for open
circuit if necessary.
4. Faulty input rectifier D1
4. Check for open circuit in
D1 rectifier.
5. Faulty IGBT modules Q1
and Q2
5. Check Q1 and Q2 and
replace if necessary (see
page 35). Check wiring
from CN9-CN12 on PCB1
to CN1-CN2 on PCB 8, 9.
Replace if necessary
6. Secondary diode D6 or D7
open
6. Check D6 and D7 and
replace if necessary
7. Faulty control board PCB1
7. Check all connections on
PC board. Check PCB1
and replace if necessary
1. Amperage/voltage control
switch S2 in REMOTE
position with no remote
control device connected
1. Place S2 in PANEL position or connect remote
control remote receptacle
2. Amp/volt control potentiometer VR1
2. Check VR1 for proper
connections and values.
Wire voltage is adjustable
from 0 to 10 VDC. Replace
if necessary. TP9 on logic
PCB to GND (see page 39)
3. Current feedback device
CT2
3. Check continuity and
signal at CN25. Replace if
necessary. Check all
connections on board (see
page 38)
4. Contact PCB1
4. Replace PCB1 if all channel connections are correct
(see page 37)
32
4.2 SERVICE TROUBLESHOOTING (continued)
TROUBLE
F. Maximum weld output
with no control
G. Limited weld output
H. Erratic or improper weld
output
POSSIBLE CAUSE
REMEDY
1. Amp/volt control potentiometer VR1
1. Check VR1 for proper
connections and values.
Wiper voltage is adjustable from 0 to 10 VDC.
Replace VR1 if necessary
2. Current feedback device
CT2
2. Check continuity and
signal at CN25. Replace if
necessary
3. Control board PCB1
3. Replace PCB1 if all channel connections are correct
(see page 37)
1. Poor input or output
connections
1. Check input and output
connections
2. Amp/volt control potentiometer VR1
2. Check VR1 for proper
connections and values.
Wiper voltage is adjustable from 0 to 10 VDC.
Replace VR1 if necessary
3. Current feedback device
CT2
3. Check continuity and
signal at CN25
4. Contact PCB1
4. Check all connections.
Check PCB1 and replace if
necessary
1. Loose welding cable
connection
1. Tighten all welding cable
connections
2. Improper setup
2. See instructions on wire
feeder
3. Amp/volt control VR1
3. Check CR1 for proper
connections. Wiper voltage is adjustable from 0 to
100 VDC. Replace if
necessary
4. Current feedback device
CT2
4. Check continuity and
signal at CN 25. Check all
connections on PCB1
5. Control PCB1
5. Check PCB1
33
SERVICE
4.3 INPUT RECTIFIER TESTING AND REPLACEMENT
NOTE
This test requires a digital volt meter with a diode test scale.
1. Perform a visual inspection of input rectifier D1. Visible
evidence of a fracture in the plastic case could indicate a
faulty rectifier.
2. Disconnect wire #8 or #9.
3. Set meter on diode test scale.
4. D1 contains six standard diodes. Three are common to the
negative terminal and three are common to the the positive
terminal. Test each diode in the forward and reverse direction. A properly functioning diode conducts in the forward
direction and blocks in the reverse direction.
5. If any diode section does not check properly, replace input
rectifier D1.
NOTE
SERVICE
Apply heatsink compound (Dow Corning #340 or equivalent) to
mounting surface
34
4.4 POWER IGBT MODULE TESTING AND REPLACEMENT
NOTE
This test requires a digital volt meter with a diode test scale.
1. Perform a careful inspection of Q1 and Q2 IGBT modules.
Failures are usually identified by evidence of a fracture in the
plastic case.
2. Locate and disconnect all leads from C2, E1 terminals on
IGBT module.
3. The IGBT module has two diode sections. Test each diode
section in the forward and reverse direction by connecting
and then reversing the meter leads across the appropriate set
of terminals C2, E1 and C1, C2, E1 and E2.
4. If any diode section does not check properly (open or
shorted) replace the IGBT module.
NOTE
To replace IGBT module remove and work all leads. Clean
surface of heatsink and apply a thin layer of heatsink compound
(Dow Corning #340 or equivalent) to mounting surface before
mounting IGBT module to heatsink.
35
SERVICE
4.5 PC BOARD TESTING
System I
MCB Trip
1. With power off, disconnect wires 8 and 9 on input rectifier.
Turn on power if MCB trips, unplug trip coil CN20. If MCB
still trips replace MCB. If MCB does not trip replace PCB.
System II
Check Voltages of PC
Board Power Supply
1. Test point (TP1) circuit common:
Test point (TP2) +15 VDC
Test point (TP3) -15 VDC
Test point (TP5) -24 VDC
Test point (TP6) +24 VDC
If voltages are not present replace PCB. If voltages are
present then check signals at TP16 and TP17 with respect to
common TP1.
Check TP16 and TP17 (with contactor on). If voltages are not
present replace PCB1. If voltages are present check wire
harness from PCB to IGBT modules.
System III
Check Voltages of PC
Board Power Supply
SERVICE
1. Check signal at CN2 connector:
Pin 1 0 V
Pin 2 0 to 10 VDC
36
4.6 CHANNEL CONNECTIONS ON PCB1
CONNECTOR
PIN
VALUE
MEANING
CN2
1
2
3
4
0V
0 to +10 VDC
+10 VDC
CN3
1
2
0V
0V
+24 VDC
CN4
1
2
4
0V
0 to +10 VDC
CN5
1
2
3
4
5
6
+15 VDC
+15 VDC
+15 VDC
+15 VDC
+15 VDC
+15 VDC
CN6
1
2
3
4
5
6
7
+15 VDC
0V
-15 VDC
0 to +15 VDC
0 to +10 VDC
0 to +4 VDC
CN7
1
2
3
4
5
6
+10 VDC
0 to +8 VDC
0 to +4 VDC
0V
-24 VDC
+24 VDC
CN8
1-2
Continuity
CN9
1-2
+18 V peak
Gate pulse output
CN10
1-2
3
+18 V peak
Not used
Not used
CN11
1-2
+18 V peak
Gate pulse output
CN12
1-2
3
+18 V peak
Gate pulse output
Not used
Minimum level of amp/volt signal
Reference signal of amp/volt from amp/volt adjuster (VR1)
Maximum level of amp/volt signal
Not used
Circuit common and chassis common
Contactor OFF
CONTACTOR, signal when PANEL position
PCB common
Remote amperage control input command signal
Not used
When select NIG process
When select SCRATCH TIG process
When select HF TIG process
When select LIFT TIG process
When select STICK process
Process selection signal
PCB common
Amp/volt preset signal
Amp/volt preset signal
+1 VDC per 10 VDC of output
+1 VDC per 100 A of output
Not used
Amp/volt reference signal for use with pulse control
+1 VDC per 10 volt output
+1 VDC per 100 amps output
PCB common
Unregulated
Unregulated
Dry contact when output current is detected
NOTE - All values with respect to test point TP-1 on main PCB1 logic board.
37
SERVICE
4.6 CHANNEL CONNECTIONS ON PCB1 (continued)
CONNECTOR
PIN
CN13
1
2
3
4
5
CN14
1-2
CN15
1
2
3
4
5
250 VAC
1
2
3
100 VAC
100 VAC
Normal open of CR2 on PCB1
Not used
Common of CR2 onf PCB1
CN17
1
0V
+10 VDC
MC2 off
MC2 off or no contact of MC2
CN18
1-2
CN20
1
2
+24 VDC
0V
1
2
3
18 VAC
0V
18 VAC
CN22
1-2
70 V peak
CN23
1-2
70 VDC
CN25
1
2
3
4
-15 VDC
0V
0 to 4 VDC
+15 VDC
1
2
3
4
0V
+24 VDC
CN27
1
2
0V
0V
CN28
1
2
3
0V
0 to 10 VDC
+10 VDC
CN16
CN21
CN26
VALUE
MEANING
Connect with C4 (-)
Not used
Connect with cross point of R2 and R3
Not used
Connect with C5 (+)
Dry contact as drive MC1
100 VAC
Not used
100 VAC
Normal close of CR5 on PCB1
Not used
Normal open of CR5 on PCB1
Common of CR5 on PCB1
Current waveform of IGBT,1V peak of 24 A peak
If trip else (or normally) +24 VDC
Circuit common
Pulse waveform of T1 secondary
Approximately at no load
PCB common
Current signal 1 VDC per 100 amp output current
If warning then +24 VDC normally
PCB common
+24 VDC
PCB common
If temperature over +24 VDC normally
Minimum level of arc (inductor) signal
Reference signal of arc (Inductor) control
Maximum level arc (inductor) control signal.
NOTE - All values with respect to test point TP-1 on main PCB1 logic board.
SERVICE
38
4.7 TEST POINTS ON PCB1
CONNECTOR
VALUE
TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8
Common
+15 VDC
-15 VDC
+24 VDC
-24 VDC
+24 VDC
TP9
TP10
TP11
TP12
TP13
TP14
TP15
TP16
TP17
TP18
TP19
TP20
TP21
TP22
TP23
TP24
TP25
TP26
TP27
TP28
TP29
TP30
TP31
TP32
TP34
TP35
TP36
TP37
TP38
TP41
TP42
TP43
TP 45
TP47
-15 VDC
+15 VDC
0 to +10 VDC
0 to +10 VDC
0 to +4 VDC
0 to +7 VDC
0V
+14 VDC
0/+15 VDC
0/+15 VDC
+15 VDC
+15 VDC
+15 VDC
+24 VDC
0 VDC
0 VDC
0/+15 VDC
+15 VDC
+15 VDC
+15 VDC
+15 VDC
0/+15 VDC
0/+15 VDC
MEANING
Circuit common
Regulated Vcc of control circuit
Regulated Cee of control circuit
Unregulated. Use for relays drive and detect point of over voltage.
Unregulated. Not used in PCB1. Output to 17-pin receptacle
Unregulated. Use for SMART LINK or MINI LINK
Common line of SMART LINK circuit
Normally
When input voltage is low (approximately -25% of rated).
Amp/volt output reference signal
Amp/volt reference signal
Arc/inductor control reference signal
Output current signal. 1 VDC per 100 A of output current
Output voltage signal. 1 VDC per 10 V of output voltage
Inverter running
Inverter stop
Saw tooth waveform .32 KHz basic clock of PWM
Square pulse waveform. Pulse appear at CONTACTOR on
Same as TP16
Wave form of pulse trans drive
Same as TP18
Same as TP18
Same as TP18
+15 VDC normally, but if less than 10 VDC then unbarance voltage of
C4 and C5
Same as TP22
Normally
Normally
Normally
Normally
Normally, but if error then +15 VDC
Normally, but +15 VDC in period of initial charge
O V at CONTACTOR on, else +15 VDC
When place PROCESS selector in STICK
When place PROCESS selector in STICK
When place PROCESS selector in STICK
When place PROCESS selector in MIG
Control signal for MIG
Current detect signal +15 VDC when output current detected
Short detect signal +15 VDC when output is shorted
“L” in MIG mode, else “H”
“H” in MIG mode, else “L”
“H” if output is short, else “L”
“H” if output is short in LIFT TIG mode, else “L”
“L” if output is short in LIFT TIG mode, else “H"
NOTE - All values with respect to test point TP-1 on main PCB1 logic board.
39
SERVICE
5.1 PARTS LIST
CATALOG NO.
10-2160
10-2161
10-2117
10-2115
10-2116
10-2113
10-2114
10-2156
10-2157
10-2158
10-2111
10-2112
10-2110
10-2159
10-2148
10-2150
10-2151
10-2153
10-2099
10-2100
PARTS LIST
DESCRIPTION
PL1 & 2 Pilot Lamp
Fuse 3A
Fuse 2A
CT 1 Current Transformer
CT2 Current Transformer
S1 & 2 & 3 Switch 1P3T
MC1 Magnetic Contactor
THS 1 & 2 Thermal Switch
MCB1 Molded Case C.B
MCB1 Molded Case C.B
MCB2 Molded Case C.B
MCB3 Molded Case C.B
VR1 & 2 10K Pot
R1 30 W 20 r
R1 30W 400r
R2, 3 30 W 10K r
R2, 3 30 W 15K r
R4, 5 20W 10r
R6, 9 3W 100K r
C10, 13 1200v .0068 uf
C10, 13 1200v .0047 uf
C14, 15 12200v .022 uf
C17 1000v dc .1 uf
C18, 19 .01 uf
Q1, 2 600v 100A
Q1, 2 1200v 100A
C20 AC250v 1 uf
D1 Diode
D1 Diode
D1 Diode
D2, 3 10A 600v
D4, 5 10A 600v
D6, 7 Diode
SA 6 Surge Supressor
Fan Coding Fan
T1 Transformer
T1 Transformer
T1 Transformer
T2 Transformer
T2 Transformer
T3 Transformer
T3 Transformer
FCH DC Reactor
COM, Receptacle
LON2 Receptacle
PCB1 Printed Circuit Card
PCB, Printed Circuit Card
40
230/460
380/415
460/575
X
X
X
X
X
X
X
X
O
X
X
X
X
X
O
X
O
X
X
X
O
X
X
X
X
O
X
O
O
X
X
X
X
X
X
O
O
X
O
X
O
X
X
X
X
O
X
X
X
X
X
X
X
X
X
X
O
X
X
X
X
O
X
O
X
X
X
O
X
X
X
X
O
O
X
O
O
X
X
X
X
X
X
O
O
X
O
X
O
X
X
X
X
O
X
X
X
X
X
X
X
X
X
O
X
X
X
O
X
O
X
X
X
O
X
X
X
X
O
X
O
O
X
O
X
X
X
X
X
O
X
O
O
X
O
X
X
X
X
O
O
5.1 PARTS LIST (continued)
CATALOG NO.
10-2101
10-2146
10-2147
10-2145
10-2165
10-2164
10-2120
10-2121
10-2119
DESCRIPTION
PCB, Printed Circuit Card
PCB2, Printed Circuit Card
PCB7, Printed Circuit Card
PCB8, 9 Printed Circuit Card
PCB, O Printed Circuit Card
PCB, O Printed Circut Card
PCB, 0 Printed Circuit Card
TI Input Terminal
TI Input Terminal
TI Input Terminal
TO Output Terminal
Case Left & Right Side
R10-13 Resistor 20u 10 r
R14-15 Resistor 3w 22r
R17 Resistor 3w 6.8K r
C4-5 400 VDC 1800 uf
C4-5 500 VDC 1200 u.f.
C6-9 350 VDC 20 uf
41
230/460
380/415
460/575
X
X
X
O
O
O
X
O
O
X
X
X
X
X
X
X
O
X
O
X
X
X
X
O
O
X
O
O
X
X
X
X
X
X
O
X
O
X
X
O
O
X
O
O
X
O
X
X
X
X
X
O
X
X
PARTS LIST
8
D2
D1
MCB
L2
5
~
2
6
~
3
L3
7
~
4
G
+
1
R2
MC2
2
F1
V
18
14
13
G
_
R7
C7
R8
C8
D4
93
W
R2
Surge Absorber
PCB10
A
12
R4
C4
94
U
C6
R1
MC2
11
R3
E
R4
94
D3
93
4
9
T1 (S)
(A)
MC1
F 15
R19 C20
1 3 5
4
MC2
R3
3
C5
16
G
63 64
MC2
R9
D5
0V
PL1-1
PL1-2
POWER WARNING
18V
33
32 0V
97
150
1
3 CN15
5
FAN
141
18V
95
31
200V
96
250V
0V
100V
T2
98
SA7
1
34
35
36
37
230V
0V
230V
24 VAC
115 VAC
4
0 VAC
0V
230V
10
T3
C9
G3
E3
53 54
2 4 6
G2
E2
62 61
19
17
R5
G1
E1
MC2
+
MC2
R1
G4
E4
L1
R6
T1(S)
(B) F
+
1
2
CN21
2 1
CN9
4 3 2 1
CN26
3
2 1 2 1 2 1
CN11 CN10 CN12
100
A1
MC2
A2
1
CN16
3
1
CN17
2
99
101
71
MCB2
72
MC2
MCB3
A1
MC1
A2
102
1
CN14
3
CN8
1 3
96
103
CN4
1 3
SA6
142
63
61
62
143
2
75
66
4
3
PANEL
Input RMT. Signal
Output Ref. Signal
4
PCB Common
Contactor (Remote 14)
24 VAC
115 VAC
2 5
REMOTE 17
CN1
64
REMOTE 14
76
F3
PCB6-3
AMPERAGE/VOLTAGE
S3
L H
M N
7
3 1 2
CN7
Filter PCB4
A G
14 Pin Receptacle
Art #A-00331a
J
I
114
115
CN3
3 2 1
113
118
112
119
K B
117
CN1
3 1
CN2
4 3 2 1
116
74
75
97
160
5
5 1 3 4
CN6
111
6
C E D
Q1
R10
C1
PCB8
G1
G2
C14
R14
C2E1
1
CN2
2
E2
C10
E1
20
C11
G2
T1
A C
E2
+
D6
23
R11
E2
27
22
CT2
24
B
CT1
D
G1
G3
2
1 CN1
E3
G4
E4
A
4
40 41 42 43
C12
23
C19
24
28
FCH
38 39
24
E1
C2E1
1
CN2
2
C17
_
R12
C1
PCB9
To
R17
25
(A)
Q2
C18
1 3 4 2
21
C13
G2
27 28
(B)
E2
R13
E2
C15
R15
25
B
E 26
D7
Digital Panel Meter
PCB7
CN1
1 2 3 4 6 5
27
28
44
26
24
40
41
42
43
38
39
93
11
94
26 24
1 2
13 5 1 2 4 321 4 1
CN13 CN18 CN25 CN22 CN23
50
E1
48
49
2
CN1
1
46
47
G1
1 2 3 4 5 6 7
CN8
PWM Control PCB1
144
145
146
CN2
3 2 1
77
78 79
CN28
3 2 1
80
81 82
CN20
1
2
86
87
CN27
1
2
89
88
161
MCB
3
2
1
3
2
1
24 V
10 V
Trip Coil
-24 V
MIG
PCB6-1
S1
1 6
3
SCRATCH
4
STICK
Output Ref. Signal
REMOTE 17
PCB6-2
OUTPUT CONTACTOR
Amperage Signal
REMOTE 14
3
2 5
Contactor (Remote 17)
4
ON
2 5
CN1
151
147
150
CN1
148
71 72 74 73
1 V/100 Amp
61
149
68
1 V/10 V
4
CN7
2 3 5
4
Process Selector
VR1
A/V
THS1
THS2
VR2
ARC CONTROL/
INDUCTANCE
S2
3 2
1 4
CN9
5
6 5 4 3 2 1
CN8
CN4
6 5 4 3 2 1
CN5
5 4 3 2 1
H A
L E M F
K B
130
129
123
122
125
128
124
127
121
126
Connection Diagram
131
67
CN5
6 5 1 2
PCB Common
CN3
2 1 3
O P S
300GMS (230U) T/D
42B794
17 Pin Receptacle
Art #A-00331a
8
D2
D1
MCB
6
~
3
7
~
4
C4
13
G
_
R7
C7
Surge Absorber
PCB10
11
R8
C8
93
E
93
D3
9
T1 (S)
(A)
MC1
F 15
1 3 5
+
2 4 6
G3
16
G4
G
R9
32
33
1
2
CN21
2 1 2 1 2 1 2 1
CN9 CN11 CN10 CN12
4 3 2 1
CN26
3
98
MCB3
MC1
A2
1
CN14
3
96
103
SA6
CN8
1 3
CN4
1 3
63
61
62
143
CN3
2 1 3
2
67
4
68
75
66
4
3
PANEL
Output Ref. Signal
Input RMT. Signal
4
PCB Common
Contactor (Remote 14)
24 VAC
115 VAC
2 5
REMOTE 17
CN1
64
REMOTE 14
76
F3
CN1
5 1 3 4
CN6
7
S2
3 1 2
CN7
Filter PCB4
L H
M N
A G
K B
14 Pin Receptacle
J
I
114
115
CN3
3 2 1
113
117
118
112
119
116
111
75
74
97
160
5
CN1
3 1
CN2
4 3 2 1
C E D
3
OUTPUT CONTACTOR
S3
6
4
PCB6-2
PCB6-3
AMPERAGE/VOLTAGE
2 5
ON
A1
Art #A-00332a
G4
E4
G1
E1
34
35
36
37
0V
31
96
95
142
1
CN2
2
E4
18 V
18 V
0V
100 V
200 V
T2
0 VAC
24 VAC
115 VAC
0V
400 V
0V
400 V
PL1-1
PL1-2
POWER WARNING
FAN
MCB2
C9
D5
10
97
2
1 CN1
E3
R5
C5
R3
PCB9
19
17
R1
141
1
CN2
2
D4
4
4
G2
E2
W
A
T3
2
1 CN1
G3
E3
F1
V
E1
18
14
93
U
G1
12
R4
REMOTE 17
G
+
R2
REMOTE 14
L3
~
2
PCB8
C6
G2
E2
L1
L2
5
R6
T1(S)
(B) F
+
1
Q1
R10
C1
G1
C10
C14
R14
E1
C2E1
20
C11
G2
T1
A C
E2
+
D6
23
R11
E2
27
22
CT2
24
B
CT1
D
G1
C17
4
40 41 42 43
C19
_
R12
C1
To
R17
25
(A)
Q2
C18
1 3 4 2
A
C12
23
24
28
FCH
38 39
24
E1
21
27 28
(B) E 26
E2
R13
D7
Digital Panel Meter
PCB7
44
1 2
13 5 1 2 4 321 4 1
CN13 CN18 CN25 CN22 CN23
50
CN1
1 2 3 4 6 5
27
28
26
24
40
41
42
43
38
39
93
11
94
26 24
48
49
E2
C15
R15
25
B
C13
G2
46
47
C2E1
1 2 3 4 5 6 7
CN8
PWM Control PCB1
3 2
144
145
146
CN2
3 2 1
77
78 79
CN28
3 2 1
80
81 82
S1 Process Selector
CN20
1
2
86
87
CN27
1
2
89
88
161
MCB
3
5
2
1
3
2
1
24 V
10 V
Trip Coil
-24 V
1 V/100 Amp
MIG
PCB6-1
1 4
CN9
1 6
3
1 V/10 V
4
STICK
Output Ref. Signal
Amperage Signal
Contactor (Remote 17)
2 5
SCRATCH
151
148
CN1
149
71 72 74 73
PCB Common
61
150
CN7
2 3 5
4
147
CN5
6 5 1 2
VR1
A/V
THS1
THS2
VR2
ARC CONTROL/
INDUCTANCE
6 5 4 3 2 1
CN8
CN4
6 5 4 3 2 1
CN5
5 4 3 2 1
H A
L E M F
K B
130
129
123
122
131
125
128
124
127
121
126
Connection Diagram
O P S
300GMS (380E) T/D
42B796
17 Pin Receptacle
Art #A-00332a
8
D2
D1
MCB
5
6
~
3
7
~
~
4
R2
F1
V
13
G
_
R7
C7
Surge Absorber
PCB10
11
R8
C8
93
E
93
D3
T1 (S)
(A)
MC1
F 15
1 3 5
+
16
G
2
R9
0V
G4
E4
1
CN2
2
32
34
35
36
37
0V
31
18 V
18 V
200 V
100 V
0V
C9
PL1-1
PL1-2
POWER WARNING
T2
0 VAC
24 VAC
115 VAC
460 V
0V
460 V
575 V
2
1 CN1
D5
10
33
96
97
95
1
3 CN15
5
FAN
141
E3
R5
C5
R3
G3
G1
E1
MC2
MC2
2 4 6
PCB9
19
17
R1
1
4
1
CN2
2
D4
9
T3
G2
E2
R4
C4
4
62
2
1 CN1
W
A
61
E1
18
14
93
U
G1
12
G4
E4
G
+
G3
E3
L2
L3
1
2
PCB8
C6
G2
E2
L1
R6
T1(S)
(B) F
+
98
SA7
1
2
CN21
2 1 2 1 2 1 2 1
CN9 CN11 CN10 CN12
4 3 2 1
CN26
3
100
A2
1
CN16
3
99
101
102
MC2
MCB3
A1
MC1
A2
1
CN14
3
CN8
1 3
96
103
CN4
1 3
SA6
142
63
61
62
143
CN3
2 1 3
2
67
66
68
4
3
PANEL
Output Ref. Signal
Input RMT. Signal
115 VAC
4
PCB Common
Contactor (Remote 14)
24 VAC
2 5
REMOTE 17
CN1
64
REMOTE 14
76
F3
PCB6-3
AMPERAGE/VOLTAGE
S3
6
5 1 3 4
CN6
7
3 1 2
CN7
Filter PCB4
L H
M N
K B
14 Pin Receptacle
J
I
114
115
CN3
3 2 1
113
118
112
119
116
A G
117
CN1
3 1
CN2
4 3 2 1
111
75
74
97
160
5
Art #A-00333a
4
75
C E D
CN1
2 5
4
3
ON
MCB2
PWM Control PCB1
1
CN17
2
72
71
REMOTE 17
MC2
REMOTE 14
A1
PCB6-2
OUTPUT CONTACTOR
S2
Q1
R10
C1
G1
C10
C14
R14
E1
C2E1
20
C11
G2
T1
A C
E2
+
D6
23
R11
E2
27
22
CT2
24
B
CT1
D
G1
C17
4
40 41 42 43
C19
_
R12
C1
To
R17
25
(A)
Q2
C18
1 3 4 2
A
C12
23
24
28
FCH
38 39
24
E1
21
C13
27 28
(B)
E2
R13
D7
Digital Panel Meter
PCB7
CN1
1 2 3 4 6 5
27
28
44
26
24
40
41
42
43
38
39
93
11
94
26 24
1 2
13 5 1 2 4 321 4 1
CN13 CN18 CN25 CN22 CN23
1 4
CN9
144
145
146
148
CN2
3 2 1
77
78 79
CN28
3 2 1
80
81 82
CN20
1
2
86
87
CN27
1
2
89
88
161
MCB
24 V
10 V
Process Selector
5
2
1
3
2
1
Trip Coil
-24 V
1 V/100 Amp
3
1 V/10 V
PCB6-1
S1
1 6
3
SCRATCH
MIG
STICK
Output Ref. Signal
Amperage Signal
Contactor (Remote 17)
3 2
4
149
CN1
2 5
CN7
2 3 5
4
71 72 74 73
151
CN8
PCB Common
61
150
1 2 3 4 5 6 7
147
CN5
6 5 1 2
50
E2
E 26
48
49
G2
C15
R15
25
B
46
47
C2E1
VR1
A/V
THS1
THS2
VR2
ARC CONTROL/
INDUCTANCE
6 5 4 3 2 1
CN8
CN4
6 5 4 3 2 1
CN5
5 4 3 2 1
H A
L E M F
K B
130
129
123
122
131
125
128
124
127
121
126
Connection Diagram
O P S
300GMS (575C) T/D
42B795
17 Pin Receptacle
Art #A-00333a