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Thermal Arc 300GTSW Pro-Wave User Manual

Thermal Arc 300GTSW Pro-Wave
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PRO-WAVE
INVERTER ARC WELDER
300GTSW
Service Manual
Version No: AB Issue Date: June 21, 2012 Manual No.: 0-2515
Operating Features:
Art # A-06102

Table of Contents

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Thermal Arc 300GTSW Pro-Wave Specifications

General IconGeneral
Input Voltage208/230/460 V
Input Frequency50/60 Hz
Output Current Range5-300 A
Output Voltage Range10-32 V
Duty Cycle60% at 300 A
Welding ProcessesGTAW (TIG), SMAW (Stick)
Rated Output300 A at 32 VDC
Input PhaseSingle/Three Phase

Summary

Section 1: Safety Instructions and Warnings

Arc Welding Hazards

Details potential dangers and precautions for arc welding operations.

Principal Safety Standards

Lists applicable industry standards and safety regulations for welding.

Declaration of Conformity

States compliance with relevant European Directives and National legislation.

Limited Warranty

Outlines the terms and conditions of the product warranty.

Section 2: Introduction

How To Use This Manual

Guidance on navigating and utilizing the service manual effectively.

Equipment Identification

Information on locating unit identification numbers for reference.

General Description

Overview of the Thermal Arc 300GTSW welding power source.

Specifications

Detailed technical specifications including output, input, and dimensions.

Duty Cycle

Explanation of duty cycle and its impact on operation and performance.

Section 3: Installation

Electrical Input Connections

Instructions for proper electrical hookup and input voltage requirements.

Section 4: Operation

Operator Controls

Description of front panel controls for operating the welding unit.

Rear Panel Controls

Identification and function of controls located on the rear panel.

Section 5: Service

Routine Maintenance

Guidelines for regular cleaning and inspection of the unit.

Basic Troubleshooting

Initial steps to diagnose and resolve common operational problems.

Specific Problems

Detailed troubleshooting guide for various unit symptoms and faults.

Section 6: Advanced Troubleshooting

System-Level Fault Isolation

Procedure for isolating defective subsystems within the power supply.

Opening the Enclosure

Steps for safely accessing the internal components of the unit.

Power Supply Voltage Test

Procedure to verify input and internal voltages for diagnostics.

Main Circuit Board (PCB1) Replacement Procedure

Detailed instructions for removing and replacing the main circuit board.

PCA IGBT Inverter Test Procedure

Steps to test the function of the IGBT inverter assemblies.

PCA Output Diodes (D2 - D5) Replacement Procedure

Procedure for accessing and replacing output diodes.

Section 7: Parts List

Equipment Identification

Information required for identifying the unit when ordering parts.

How To Use This Parts List

Guidance on navigating and understanding the parts list.

Parts List

Comprehensive list of all replaceable parts with catalog numbers.

Parts Pictures

Illustrations of key components and their locations within the unit.

Appendix 1: General Information

Appendix 2: 208/230VAC Single-Voltage Single-/Three-Phase

Appendix 3: 208/230/460VAC Single-/Three-Phase

Appendix 4: 380/415VAC Single-Voltage Three-Phase

Appendix 5: Wire Chart Main Board PCB1

Appendix 6: Wire Chart Front Panel PCB6

Appendix 7: Wire Chart AC IGBT Gate Drive PCB8

Appendix 8: Bottom Wiring Placement Diagram

Appendix 9: Diode Testing Basics

Appendix 10: Meter Calibration Procedure

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