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Thermal Arc
Welding System
ARCMASTER 300TS
Thermal Arc ARCMASTER 300TS User Manual
120 pages
Manual
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400TS
400S
ARCMASTER
®
INVER
TER ARC WELDERS
Art # A-07263
Service
Manual
V
V
V
V
V
ersion No:
ersion No:
ersion No:
ersion No:
ersion No:
AA.0
3
Issue Date:
Issue Date:
Issue Date:
Issue Date:
Issue Date:
May 22, 2006
Manual No
Manual No
Manual No
Manual No
Manual No
:
0-4895B
Operating Features
Operating Features
Operating Features
Operating Features
Operating Features
:
300TS
300S
2
Table of Contents
Default Chapter
4
Table of Contents
4
Safety Instructions and Warnings
7
Arc Welding Hazards
7
Principal Safety Standards
11
Precautions de Securite en Soundage a L'arc
12
Dangers Relatifs Au Soudage À L'arc
12
Principales Normes de Securite
16
Introduction
17
How to Use this Manual
17
Equipment Identification
17
Symbol Chart
18
Description
19
Functional Block Diagrams
20
Transporting Methods
21
Installation
23
Environment
23
Location
23
Electrical Input Connections
23
Electrical Input Requirement
23
Input Power
24
High Frequency Introduction (300/400TS Only)
25
High Frequency Interference (300/400TS Only)
25
Duty Cycle
25
Specifications
26
Operator Controls
27
ARC MASTER 300/400TS and 300/400S Controls
27
Weld Parameter Descriptions for ARC MASTER 300/400TS and 300/400S
29
Weld Parameters for ARC MASTER 300/400TS and 300/400S
31
Power Source Features
32
Set-Up for Smaw (Stick) and Gtaw (Tig)
33
Sequence of Operation
35
Stick Welding
35
HF TIG Welding (300/400TS Only)
36
Lift TIG Welding
36
Slope Mode Sequence(300/400TS Only)
36
Slope Mode with Repeat Sequence (300/400TS Only)
37
Pulse Controls (300/400TS Only)
37
Routine Maintenance
39
Basic Troubleshooting
41
TIG Welding Problems
41
Stick Welding Problems
43
Power Source Problems
45
Voltage Reduction Device (Vrd)
47
VRD Specification
47
VRD Maintenance
47
Switching VRD On/Off
48
Power Source Error Code
49
Advanced Troubleshooting
51
System-Level Fault Isolation
51
Opening the Enclosure
51
Verification and Remedy to the Indicated Error Codes
53
E01 "Over-Temperature at the Primary Side
53
E02 "Over-Temperature at the Secondary Side
54
E03 "Transformer Over-Current Failure
54
E04 "Torch Cable Failure
55
E11 "Main Supply over Voltage
55
E12 "Main Supply under Voltage
55
E81 "Wrong Main Supply Voltage
55
E82 "Rated Voltage Selection Circuit Abnormality
56
E83 "Abnormalities in Mains Supply Voltage Detection
56
E85 "Pre-Charge Abnormality
56
E94 "Thermistor Malfunction
57
E99 "Initial Power Receiving
57
Verification and Remedy to Failures Without Indication Codes
57
Cooling Fan (FAN1) Failure" (Fan Is Not Rotating.)
57
Gas Valve Failure" (no Gas Flow through Unit)(300/400TS Only)
58
No Weld Output
58
Operating Panel Failure" (Led's Do Not Light Properly or Welding Setting Cannot be Established.)
59
High Frequency Output Failure" (Unit Does Not Generate High Frequency.) (300/400TS Only)
59
Fault Isolation Tests
60
Preparation
60
Verification of the Power Input Circuitry
61
Verification of the AC Input Voltage Using an AC Voltmeter
61
Verification of the Power Supply Voltage
62
Verification of the Cooling Fan, FAN1, Drive Circuitry
63
Verification of the Gas Valve, SOL1, Drive Circuitry
64
Verification of the Primary Diode (D1)
64
Verification of the Secondary Diode (D2-D7)
65
Verification of the Primary IGBT (Q1-Q24)
65
Verification of the Secondary IGBT (Q25-Q26)
66
Verification of No-Load Voltage (OCV)
66
Maintenance
68
Maintenance List
68
Service Tools
72
Tools and Parts
72
Notes of Disassembly and Assembly
72
Replacement Procedure
73
Pcb1 (Wk-5493)
73
Pcb2 (Wk-5597)
74
Pcb3 (Wk-5548), Pcb7 (Wk-5550)
76
Pcb4 (Wk-4819)
77
Pcb5 (Wk-5551)
78
Pcb6 (Wk-5549)
78
PCB8, PCB9 (WK-5479) and Q1-Q12 "Primary IGBT
79
PCB10, PCB11 (WK-5479) and Q13-Q24 "Primary IGBT
79
Pcb12 (Wk-5527)
79
Pcb13 (Wk-5528)
80
PCB14 (WK-5594) <T1 "Main Transformer
81
Pcb15 (Wk-5606)
83
Pcb20 (Wk-5499)
83
Pcb21 (Wk-4917)
84
Current Limiting Resistor (R6)
85
Resistor (R7, R8)
86
Coupling Coil (CC1) * 300/400TS Only
87
Reactor (FCH1)
87
Primary Thermistor (TH1)
88
Secondary Thermistor (TH2)
89
Cooling Fan (FAN1)
89
Solenoid Valve (SOL1) * 300/400TS Only
90
Main ON/OFF Switch (S1)
91
Input Voltage Switch (S2)
92
Remote Socket (CON1)
93
High Freguency Unit (HF.UNIT1) * 300/400TS Only
93
Hall Current Sensor (HCT1)
94
Primary Diode (D1)
95
Secondary Diode (D2, D4, D5 and D7)
95
Current Trans (CT2, CT3)
96
Ring Core (L1)
97
Ring Core (L105)
97
Appendix 1 Parts List
100
Equipment Identification
100
How to Use this Parts List
100
Appendix 2 Connection Wiring Guide
108
Appendix 3 Interconnect Diagram
110
Appendix 4 Diode Testing Basics
114
Limited Warranty
116
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Thermal Arc ARCMASTER 300TS Specifications
General
Brand
Thermal Arc
Model
ARCMASTER 300TS
Category
Welding System
Language
English
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