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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