Beruflich Dokumente
Kultur Dokumente
ARC
WELDER
MODEL 300GTS CC/TIG
Stick
TIG - High Frequency
- Lift Start
Service Manual
First Edition
January 1995
WARNING
WARNING
Updated Pages
The following pages have been updated to this manual since the last printing:
Page Number(s)
37 & 39
Date
5/16/95
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION ...................................................................................... 1
1.01
1.02
1.03
1.04
1
1
6
8
15
15
15
15
17
18
20
28
31
Introduction .................................................................................................
Ordering Information ...................................................................................
Complete Systems ......................................................................................
Replacement Parts (Before January 1994) .................................................
Replacement Parts (January 1994 and After) .............................................
35
35
35
36
38
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions, and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
Manual 0-2433
GENERAL INFORMATION
Welding or
Cutting Operation
Electrode Size
Metal Thickness
or Welding Current
Filter
Shade
Number
Torch soldering
Torch brazing
3 or 4
Oxygen Cutting
ARC RAYS
Light
3 or 4
Medium
4 or 5
Heavy
5 or 6
Gas welding
Light
4 or 5
Medium
5 or 6
Heavy
6 or 8
Light
10
Medium
12
14
Heavy
All
Replace any cracked, broken or loose filter plates immediately. Replace clear cover plate when broken, pitted,
or spattered.
11
All
12
All
12
All
12
All
12
All
12
Light
12
Heavy
14
Flash goggles with side shields must be worn under helmet to protect eyes in case helmet is not in position before arc is struck.
Light
Medium
300-400 amps
12
Heavy
14
ELECTRIC SHOCK
GENERAL INFORMATION
Manual 0-2433
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 threephase 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 become 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.
Manual 0-2433
GENERAL INFORMATION
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.
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 combustibles 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.
Flammable hair preparations should not be used by persons intending to weld or cut.
NOISE
GENERAL INFORMATION
Manual 0-2433
Manual 0-2433
GENERAL INFORMATION
Pressurizing Steps
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
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.
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.
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
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
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
GENERAL INFORMATION
Manual 0-2433
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY
10018
Manual 0-2433
GENERAL INFORMATION
PARTS
LABOR
GENERAL INFORMATION
Manual 0-2433
SECTION 2:
INTRODUCTION
2.01 Scope Of Manual
This Manual provides Service Instructions for Thermal
Dynamics Model 300GTS Inverter Arc Welder.
Refer to Operating Manual (0-2425) for individual operating procedures. Information in this edition is therefore
particularly applicable to the Troubleshooting and Repair
of the equipment, and is intended for use by properlytrained Service Technicians familiar with this equipment.
A. Application
The equipment should satisfy the customers requirements as supplied and as described in Section 3 of this
manual. Be sure to confirm that the equipment is capable
of the application desired.
B. Modifications
No physical or electrical modifications other than selection of standard options and Accessories are to be made
to this equipment.
C. Customer/Operator Responsibilities
It is the customer/operators responsibility to maintain
the equipment and peripheral Accessories provided by
Thermal Dynamics in good operating order in accordance
with the procedures outlined in the Operating Manual,
and to protect the equipment from accidental or malicious damage.
D. Repair Restrictions
The electronics consists of Printed Circuit Board Assemblies which must be carefully handled, and must be replaced as units. No replacement of printed circuit solder-mounted components is allowed except as noted in
this manual.
Printed Circuit Board Assemblies to be returned must be
properly packaged in protective material and returned
intact per normal procedures.
Manual 0-2433
INTRODUCTION
INTRODUCTION
10
Manual 0-2433
SECTION 3:
DESCRIPTION
4.
NOTE
The ARC control may be adjusted while welding.
The ARC control provides 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.
3.01 Introduction
The information in this Section has two purposes: To familiarize the Service Technician with the capabilities and
limitations of the equipment, and to provide him with an
overall understanding which will allow him, in turn, to
properly train the customers operating personnel.
When the control is set at 0 (zero), short circuit amperage above normal welding amperage is minimal.
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.
5.
Thermal overload
1. AC POWER Indicator
ARC Control
STICK
The unit provides weld output characteristics specifically designed for the Shielded Metal Arc Welding (SMAW) process. The ARC control is active.
b. HF TIG (GTAW with High Frequency Start)
3. AMPERAGE Control
HF TIG
NOTE
Manual 0-2433
11
DESCRIPTION
LIFT
TIG
The unit provides weld output for the gas tungsten arc welding (GTAW) process. High frequency
will not be present. POST FLOW control will function. The ARC and HOT START controls 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.
6.
This switch determines whether the amperage/voltage is adjusted by the front panel AMPERAGE control or by a remote control device.
PANEL Position
AMPERAGE Switch
a.
ON
NOTE
The POST FLOW control and gas valve only work
if the process selector switch is in one of the gas
tungsten arc welding positions, the OUTPUT
CONTACTOR switch is in REMOTE position,
and a remote control is connected to the REMOTE
14 receptacle.
PANEL
9.
The PRE FLOW control only works if the process selector switch is in HF TIG position, the OUTPUT
CONTACTOR switch is in REMOTE position and a
remote control is connected to the REMOTE 14 receptacle.
For remote amperage control, place the AMPERAGE switch in REMOTE 14 position.
Remote control is a percentage of the value set by
the front panel AMPERAGE control. For example,
if the AMPERAGE control is set at half maximum
output, the maximum output available from the
remote control will be half the welding power
source maximum output.
7.
Although the term CONTACTOR is used the output is not switched on or off by a physical contactor; rather, the unit uses solid-state output control.
The switch has two functions:
14
a. REMOTE 14 PositionREMOTE
Contactor connections are made to the REMOTE
14 receptacle. Open circuit voltage will be present
at the weld output receptacles whenever the torch
switch or remote device is closed.
DESCRIPTION
12
Manual 0-2433
10.
2.
Example: Weld current set at AMPERAGE control is 100 amps and HOT START is set at 50%.
The arc will initiate at 150 amps for 0.1 seconds
and then resume at 100 amps.
The process selector switch allows the operator to select the STICK welding (SMAW) process, the LIFT
TIG (GTAW) process without high frequency, or the
HF TIG (GTAW) process with high frequency start.
11.
Single-Phase:
The LED AMPERAGE/VOLTAGE meter displays either an amperage (A) or voltage (V) value. The selected (preview) amperage value is displayed when
welding is not taking place.
Amperes
Volts
Duty Cycle
Range (Min-Max)
Amperes
Volts
Maximum OCV
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.).
210
28
60%
5-260
10-30
70
Three-Phase:
Amperes
Volts
Duty Cycle
Range (Min-Max)
Amperes
Volts
Maximum OCV
Input Power
4.
300
32
60%
5-375
10-36
70
D. Input Power
1.
Manual 0-2433
13
Output At
No Load Output
Rated Load
Amps KVA KW Amps KVA KW
48
10
7
2.5 0.5 0.3
39
14
11
1.5 0.5 0.3
43
10
7
2
0.5 0.3
35
14
11
1
0.5 0.3
21
14
11
1
0.5 0.3
18
14
11
1
0.5 0.3
19
14
11
0.5 0.5 0.3
21
10
7
1
0.5 0.3
18
14
11
0.5 0.5 0.3
14
14
11
0.5 0.5 0.3
DESCRIPTION
5.
Duty Cycle
E. Voltage/Amperage Curve
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.
NOTE
Voltage/Amperage curve shows the voltage and
amperage output capabilities of the welding power
source. Curves of other settings will fall between
the curve shown.
OCV Less than 80V
Arc Characteristics
"CURRENT" Control
VOLTS
19V
150
A-00032
CAUTIONS
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.
C.C.
AMPS
375 410
F. Physical Characteristics
1.
DESCRIPTION
14
Manual 0-2433
SECTION 4:
SERVICE
TROUBLESHOOTING
DIAGNOSTICS
4.01 Introduction
This Section provides service diagnostics for the Model
300GTS Inverter Arc Welding System, allowing the Technician to islolate any faulty Subassemblies. Refer to Section 5, Repairs & Replacement Procedures, for parts replacement instructions.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.
A. Power
Main power not connected
B. Poor Weld
Wrong electrode used
WARNINGS
C. Remote Operation
Incorrect switch settings
NOTE
Before beginning troubleshooting visually inspect
the internal components for signs of over heating,
fractures and damage.
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.
CAUTION
To clean the unit, open the enclosure (refer to Section 4.07B, Opening Enclosure) and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.
Sparks from the welding process can cause damage to coated, painted, and other surfaces such as
glass, plastic and metal.
This section is to help isolate the defect circuit before
troubleshooting, identify symptoms, and test the unit for
proper operation. Follow the instructions as given to identify the possible symptom(s) and the defective circuit.
After repairs are complete then run the following tests
again to verify that the unit is fully operational.
Manual 0-2433
15
SERVICE TROUBLESHOOTING
NOTE
B. SMART-LINK Test
1. Place METER selector on optional Digital Meter
to the V position to indicate volts. If the optional
Digital Meter is not installed then connect a digital voltmeter between the positive (+) and negative (-) output terminals of the unit. Set the digital voltmeter to indicate VDC.
2. Connect the unit to 460 volt, 3 phase input voltage. Connect the wires as follows:
a. Red to Line 1
b. White to Line 2
c. Black to Line 3
d. Green to earth ground.
2. Place OUTPUT CONTACTOR selector to ON position. The meter will indicate approximately 5
amperes.
5. Place OUTPUT CONTACTOR selector to ON position. The meter will indicate approximately
60vdc open circuit.
SERVICE TROUBLESHOOTING
Manual 0-2433
WARNING
Manual 0-2433
17
SERVICE TROUBLESHOOTING
B. Advanced Troubleshooting
NOTE
NOTE
SERVICE TROUBLESHOOTING
18
Manual 0-2433
Manual 0-2433
19
SERVICE TROUBLESHOOTING
WARNING
A. Safety Precautions
1. Significant DC Voltage exists after removal of input
power. Allow 2 minutes for discharge time. Voltage
measured on input capacitors must be zero before
performing service on the power supply.
2. Do Not touch electrical components with any part of
the human body when power is applied.
3. Keep away for any moving parts.
4. Hot surfaces can cause severe burns. Allow equipment to cool before servicing.
5. Electrostatic discharge can damage printed circuit
board assemblies. Transport printed circuit boards in
proper anti-static shielded packages. Use proper
grounding techniques with wrist strap before
handleing printed circuit boards.
6. Misaligned plugs can cause printed circuit board damage. Be sure plugs are properly aligned and completely seated.
7. Excessive pressure can damage printed circuit board.
Use only minimal pressure and gentle movement when
disconnecting or connecting printed circuit board plugs.
B. Opening Enclosure
1. Turn off MCB1 of power source and open wall disconnect switch or circuit breaker.
2. Wait at least two minutes to allow discharge time of
input capacitors.
3. Remove the two screws on the bottom of the unit securing the plastic enclosure to the metal framing of
the unit.
4. Remove the ten bolts securing the rest of the plastic
enclosure to the metal framing.
5. To remove the plastic enclosure pull it open, away
from the top of the frame, and slide it up from the
bottom.
6. Close the enclosure by reversing the above steps.
20
Manual 0-2433
Art # A-00306
OL
Reverse Bias
Diode Not Conducting
VR COM
_
+
Cathode
5. Connect the volt/ohm meter positive lead to the anode (+) of the diode and the negative lead to the cathode (-) of the diode for forward bias testing (refer to
Figure 4-A). A properly functioning diode will conduct in the forward bias direction and indicate between 0.3 to 0.9 volts.
Anode
0.75
Forward Bias
Diode Conducting
Anode
VR COM
_
+
Cathode
Manual 0-2433
21
SERVICE TROUBLESHOOTING
A-00308
A-00309
R S T
R2
Wire 9
Wire 9
+
Wire 8
Wire 8
+
G R2
D1
D1
+
SERVICE TROUBLESHOOTING
NOTE
This procedure requires a digital volt ohm meter
that has a diode test scale. A more conclusive test
requires specialized equipment. Therefore, even if
the IGBTpower module checks out good, it may
still be bad. If in doubt, replace the IGBT module.
Perform a careful inspection of each IGBT module (Q1 &
Q2). Most failures are identified by a fracture in the plastic case of the device. If there are no signs of physical
damage or failure then proceed with the following test
procedure:
22
Manual 0-2433
1. Disconnect all leads and bus bars from the IGBT module to be tested noting the location of each.
PCB8 or PCB9
G3
CN1
2
G1
E3
E1
G4
CN2
1
G2
E4
E2
Q1 or Q2
C1
A-00310
C2
E1
E2
Q2
C1
Cathode
CN2
PCB8
C2
Q1 E1
G1 E1
CN2
E2 G2
E2
E2
CN1
PCB9
G1 E1
CN1
C1
E2 G2
Anode
C2
E1
Type 2 Diode
A-00311
Manual 0-2433
23
SERVICE TROUBLESHOOTING
d. Check output DC voltage of power supply on control/logic board (PCB1) for the following:
TP2 to TP1
TP3 to TP1
TP4 to TP1
TP5 to TP1
I.
Vertical: 5 V/Div
Horizontal: 5 ms/Div
TP4
NOTE
TP2
0 Ref
A-00296
WARNING
Before disconnecting or connecting any connectors
or wiring turn the power supply OFF.
1.
Vertical: 5 V/Div
Horizontal: 5 ms/Div
0 Ref
TP3
TP5
CN21 pin 1 to 2
18 VAC
CN21 pin 3 to 2
18 VAC
A-00297
Pin 2 is common
SERVICE TROUBLESHOOTING
24
Manual 0-2433
4.
a. With power supply turned OFF, remove connector plug CN13 from the control/logic board
(PCB1). Check for resistance at CN13 receptacle
as follows:
3 ohms
b. Disconnect wire #8 from input diode (D1) on input rectifier and connector CN13 plug from control/logic board (PCB1).
f. Turn power supply OFF and reconnect input diode (D1) wire #8 and connector CN18 plug.
5.
NOTE
If voltage values are not correct, turn power supply OFF and replace control/logic board (PCB1).
d. Turn power supply OFF and Reconnect input diode (D1) wire #8 and connector CN20 plug.
Manual 0-2433
25
SERVICE TROUBLESHOOTING
6.
Vertical: 5 V/Div
Horizontal: 20 s/Div
TP10
0 Ref
TP12
0 Ref
A-00304
If voltage values are not correct, turn power supply OFF and replace control/logic board (PCB1).
SERVICE TROUBLESHOOTING
26
Manual 0-2433
TP13 Settings
Vertical: 2 V/Div
Horizontal: 20 s/Div
TP10
TP9 to TP1
0 Ref
0 to +10 VDC
Vertical: 5 V/Div
TP13
Horizontal: 20 s/Div
TP9
0 Ref
A-00305
0 Ref
0 Ref
d. Check the AMPERAGE reference signal on control/logic board (PCB1) for the following:
TP10 to TP1 0 to +7 VDC
Vertical: 5 V/Div
Horizontal: 20 s/Div
TP9
TP10 Settings
Vertical: 5 V/Div
Horizontal: 20 s/Div
0 Ref
TP13 Settings
Vertical: 2 V/Div
Horizontal: 20 s/Div
TP10
0 Ref
TP11
0 Ref
TP13
A-00303
0 Ref
A-00305
Manual 0-2433
27
SERVICE TROUBLESHOOTING
11.
If voltage values are not correct, turn power supply OFF and replace control/logic board (PCB1).
e. Check to verify output of IC1 pulse waveform per
the following:
Vertical: 10 V/Div
Horizontal: 20 s/Div
0 Ref
Vertical: 5 V/Div
Horizontal: 20 s/Div
TP20
0 Ref
A-00301
TP16
0 Ref
Vertical: 10 V/Div
Horizontal: 20 s/Div
TP17
TP18
0 Ref
0 Ref
A-00295
0 Ref
A-00300
SERVICE TROUBLESHOOTING
28
Manual 0-2433
To properly make the adjustments described in this Subsection requires the use of an oscilloscope and probes.
Do not attempt to make the adjustments with only a meter.
NOTE
All oscilloscope setting are for x1 probe.
A. Versions
These adjustments apply only to the following versions
or later of the Control/Logic printed circuit board (PCB1):
Model (Type)
PCB1 Number
208-230/460 VAC
WK-2611, U06
460/575 VAC
380/415 VAC
B. Adjustment References
The function of each adjustment and it's reference designation are as follows:
Reference
Description
VR1
VR2
VR3
VR4
Dead Time
VR5
Basic Oscillation
VR6
VR10
VR11
C. Special Adjustment
Models (type) 460/575 VAC sold in Canada must have
the MINI LINK adjusted properly as follows:
If the input voltage is to be less than 505 VAC then
adjust VR11 to turn ON the MINI LINK.
The Control/Logic printed circuit board (PCB1) has various adjustments on it. These adjustments must be properly set for the power supply to operate properly.
WARNING
D. Adjustments
1. Initial Setup
The unit must be set to the following conditions before making any adjustments:
These adjustments require that the unit be powered on. High voltages and currents will be present.
Use extreme caution when making adjustments.
Manual 0-2433
29
SERVICE TROUBLESHOOTING
Vertical: 5 V/Div
Horizontal: 5 s/Div
OUTPUT CONTACTOR to ON
f. No Remote Connection
TP16
0 Ref
Dead Time
TP17
0 Ref
Vertical: 1 V/Div
Horizontal: 10 s/Div
A-00313
TP15
0 Ref
A-00312
SERVICE TROUBLESHOOTING
30
Manual 0-2433
b. Short output by connecting negative and positive output terminal leads together.
TP10 Settings
Vertical: 5 V/Div
Horizontal: 20 s/Div
TP13 Settings
Vertical: 2 V/Div
Horizontal: 20 s/Div
TP10
0 Ref
TP13
0 Ref
b. Short output by connecting negative and positive output terminal leads together.
Manual 0-2433
31
SERVICE TROUBLESHOOTING
Vertical: 5 V/Div
Horizontal: 5 s/Div
TP16
0 Ref
A-00302
When MCB1 is turned on, the Logic Board samples incoming primary voltage between L1 & L2. With 460 volt
supplied, the Logic Board will send a signal to MC-2 to
close. A time delay of 3 to 4 second will be noticed before
MC-2 energizes. When MC-2 closes the control transformer will configure to 460 volt on the primary windings. This is referred to as Mini Link. The input Power
circuit remains in the same configuration for 460 & 575
volt input.
SERVICE TROUBLESHOOTING
32
Manual 0-2433
SECTION 5:
REPAIRS & REPLACEMENT
PROCEDURES
5.01 Introduction
This Section describes parts replacement procedures and
all cable repairs which may be performed on the Model
300GTS Inverter Arc Welder.
Under not circumstances are field repairs to be attempted
on Printed Circuit or other Subassemblies of this unit.
Evidence of unauthorized repairs may void the factory
warranty.
A. General
WARNINGS
Read and understand these instructions and the
instructions on the grounding wrist strap package
before opening the power supply enclosure or removing the replacement PC board from its protective enclosure.
Disconnect primary power to the system before disassembling the power supply enclosure.
Do not operate the power supply or test equipment
under power while wearing the grounding wrist
strap.
Disconnect primary power at the source before assembling or disassembling this unit.
A. Opening Enclosure
1. Turn off MCB1 of power source and open wall disconnect switch or circuit breaker.
2. Wait at least two minutes to allow discharge time of
input capacitors.
3. Remove the two screws on the bottom of the unit securing the plastic enclosure to the metal framing of
the unit.
4. Remove the ten bolts securing the rest of the plastic
enclosure to the metal framing.
5. To remove the plastic enclosure pull it open, away
from the top of the frame, and slide it up from the
bottom.
6. Close the enclosure by reversing the above steps.
B. Fuse Replacement
B. Procedure
1. Open the wrist strap and unwrap the first two folds
of the band. Wrap the adhesive side firmly around
your wrist.
2. Unroll the rest of the band and peel the liner from the
copper foil at the opposite end.
Manual 0-2433
33
REPLACEMENT PROCEDURES
NOTE
5. Reinstall the replacement Control/Logic PCB Assembly by reversing the above procedure and noting the
following:
6. Apply a thin layer of Dow Corning #340 or equivalent heatsink compound to the mounting surface of
the replacement input diode (D1) assembly.
Connector
CN1
CN2
AMPERAGE Potentiometer
CN3
Contactor Switch
CN4
CN5
CN6
CN8
CN9
G1/E1 of IGBT Q1
CN10
G1/E1 of IGBT Q2
CN11
G2/E2 of IGBT Q1
CN12
G2/E2 of IGBT Q2
CN13
CN14
CN15
CN16
CN17
CN19
CN18
CN20
Trip coil
CN21
CN22
CN23
DC output detect
8. Install the replacement IGBT module (Q1 or Q2) assembly onto the heatsink and secure in place with the
screws removed in Step 3 above.
CN25
CN26
CN27
Temperature sensors
CN28
Description of Cable
REPLACEMENT PROCEDURES
34
Manual 0-2433
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:
Section 6.03: Complete Systems
Section 6.04: Replacement Parts (Before January
1994)
Section 6.05: Replacement Parts (January 1994 and
After)
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.
B. Returns
If a Thermal Dynamics product must be returned for service, contact your Thermal Arc distributor. Materials returned to Thermal Dynamics without proper authorization will not be accepted.
Description
10-1004
10-1005
10-1006
Manual 0-2433
35
PARTS LISTS
PARTS LISTS
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
Description
Pilot Lamp Assembly
Fuse 3A 600V
Fuse 2A, 250V
Current Transformer
Current Transformer
Process Selector Switch
Amperage & Contactor Switches
Magnetic Contactor
Magnetic Contactor
Aux. Contacts for 10-2118
Thermal Switch
Molded Case C.B.
Amperage, Arc & Hot Level Controls
Pre & Post Flow Controls
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Transistor
Diode
Diode
Diode
Diode
Surge Surpressor
Cooling Fan
Transformer
Transformer
Transformer
DC Reactor
14-Pin Receptacle
Solenoid Valve
Control/Logic PCB
Gas Control PCB
High Frequency PCB
Filter PCB
Optional Digital Panel Meter PCB
IGBT Gate PCB
Surge Absorber PCB
Output Terminal
Case Left & Right Side
Rubber Foot
36
Model
230/460
Model
380/415
Model
460/575
10-2236
10-2237
10-2206
10-2160
10-2161
10-2240
10-2239
10-2117
10-2118
10-2287
10-2238
10-2116
10-2124
10-2125
10-2207
10-2209
10-2211
10-2212
10-2213
10-2214
10-2228
10-2120
10-2119
10-2215
10-2217
10-2241
10-2219
10-2220
10-2113
10-2158
10-2111
10-2112
10-2110
10-2221
10-2159
10-2224
10-2149
10-2153
10-2225
10-2135
10-2154
10-2104
10-2108
10-2109
10-2163
10-2146
10-2164
10-2227
10-2202
10-2244
10-2236
10-2237
10-2206
10-2160
10-2161
10-2240
10-2239
10-2117
10-2238
10-2115
10-2124
10-2125
10-2207
10-2209
10-2211
10-2212
10-2213
10-2214
10-2120
10-2119
10-2215
10-2217
10-2241
10-2219
10-2113
10-2156
10-2111
10-2112
10-2110
10-2221
10-2159
10-2222
10-2148
10-2151
10-2225
10-2135
10-2154
10-2102
10-2108
10-2109
10-2163
10-2146
10-2147
10-2145
10-2227
10-2202
10-2244
10-2236
10-2237
10-2206
10-2160
10-2161
10-2240
10-2239
10-2117
10-2242
10-2238
10-2115
10-2124
10-2125
10-2207
10-2210
10-2211
10-2212
10-2213
10-2214
10-2121
10-2119
10-2216
10-2217
10-2241
10-2219
10-2114
10-2157
10-2111
10-2112
10-2110
10-2221
10-2159
10-2223
10-2155
10-2153
10-2225
10-2135
10-2154
10-2103
10-2108
10-2109
10-2163
10-2146
10-2165
10-2227
10-2202
10-2244
Manual 0-2433
MCB
THS1
PCB4
T2
F1
& F3
PCB1
D6
PCB3
D1
T1
FAN
PCB10
D7
CT2
FCH R2
& THS3
CC
R3
THS2
R1
MC1
MC2
A-00467
C5
C4
R10
R11
R12
R13
R4
R5
C8
PCB9
CT1
A-00469
Manual 0-2433
37
C7
C9
Q2
Q1
C6
PCB8
PARTS LISTS
Qty
PL1/ PL2
F1
F2 & F3
CT1
CT2
S1
S2 &S3
MC2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PARTS LISTS
Description
Pilot Lamp Assembly
Fuse 5A 600V
Fuse 2A, 250V
Current Transformer
Current Transformer
Switch
Switch
Magnetic Contactor
Aux. Contacts for 10-2118
Thermal Switch
Molded Case C.B.
Solenoid Valve
Amperage & Arc Controls
Pre & Post Flow Controls
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Transistor
Transistor
Diode
Diode
Surge Surpressor
Cooling Fan
Transformer
Transformer
DC Reactor
14-Pin Receptacle
Control/Logic PCB
Gas Control PCB
High Frequency PCB
Filter PCB
Optional Digital Panel Meter PCB
IGBT Gate PCB
Surge Absorber PCB
Output Terminal
Coupling Coil
Case Left & Right Side
38
Model
230/460
Model
380/415
Model
460/575
10-2236
10-2274
10-2206
10-2160
10-2161
10-2196
10-2252
10-2118
10-2287
10-2238
10-2116
10-2154
10-2124
10-2125
10-2207
10-2209
10-2212
10-2211
10-2213
10-2275
10-2228
10-2120
10-2119
10-2215
10-2217
10-2241
10-2219
10-2220
10-2270
10-2637
10-2113
10-2653
10-2630
10-2221
10-2159
10-2650
10-2149
10-2632
10-2135
10-2648
10-2108
10-2109
10-2163
10-2146
10-2164
10-2227
10-2633
10-2202
10-2236
10-2274
10-2206
10-2160
10-2161
10-2196
10-2252
10-2238
10-2115
10-2154
10-2124
10-2125
10-2207
10-2209
10-2212
10-2211
10-2213
10-2275
10-2120
10-2119
10-2215
10-2217
10-2241
10-2219
10-2270
10-2637
10-2628
10-2629
10-2630
10-2221
10-2159
10-2631
10-2148
10-2632
10-2135
10-2647
10-2108
10-2109
10-2163
10-2146
10-2147
10-2145
10-2227
10-2633
10-2202
10-2236
10-2274
10-2206
10-2160
10-2161
10-2196
10-2252
10-2242
10-2238
10-2115
10-2154
10-2124
10-2125
10-2207
10-2210
10-2212
10-2211
10-2213
10-2275
10-2121
10-2119
10-2216
10-2217
10-2241
10-2219
10-2270
10-2637
10-2114
10-2629
10-2630
10-2221
10-2159
10-2655
10-2155
10-2632
10-2135
10-2649
10-2108
10-2109
10-2163
10-2146
10-2165
10-2227
10-2633
10-2202
Manual 0-2433
MCB
D6
THS1
PCB4
F1
& F3
PCB1
T2
PCB3
D1
T1
FAN
PCB10
D7
CT2
FCH R2
& THS3
CC
R3
THS2
A-00468
R1
MC1
C5
C4
R10
R11
R12
R13
R4
R5
C8
PCB9
CT1
A-00470
Manual 0-2433
39
C7
C9
Q2
Q1
C6
PCB8
PARTS LISTS
PARTS LISTS
40
Manual 0-2433
Reference
CN1
VR3
CN2
VR1
CN3
PCB 6-2
Contactor S witch
CN4
PCB 6-3
CN5
PCB 6-1
CN6
PCB 7
CN8
CN9
PCB 8
G1/E 1 of IGB T Q1
CN10
PCB 9
G1/E 1 of IGB T Q2
CN11
PCB 8
G2/E 2 of IGB T Q1
CN12
PCB 9
CN13
G2/E 2 of IGB T Q2
Input capacitor imbalance circuit
CN14
MC1
CN15
T2
CN16
MC2
CN17
MC2
CN18
CT 1
CN19
T IG S equencer controls
CN20
MCB 1
CN21
T2
CN22
T1
CN23
Manual 0-2433
Des cription
T rip coil
CN25
CT 2
CN26
PL1 /PL2
CN27
T HS 1/T HS 2
CN28
VR2
41
APPENDIX
Pin
1
2
3
4
5
Value
0V
0 to +10 VDC
0 to +10 VDC
Description
Mimimum level of hot current signal
Reference signal of hot current signal; Return from VR3
Amp/ volt reference signal for use with hot start current level
Not Used
Not Used
CN2
1
2
3
4
0V
0 to +10 VDC
+10 VDC
CN3
1
2
0V
0V
+24 VDC
CN4
1
2
3
0V
0 to +10 VDC
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
CN8
1-2
Continuity
CN9
1-2
+18 V peak
CN10
1-2
3
+18 V peak
Not used
Not used
CN11
1-2
+18 V peak
CN12
1-2
3
+18 V peak
CN13
1
2
3
4
5
CN14
APPENDIX
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
Dry contact when output current is detected
42
Manual 0-2433
Connector
CN15
CN16
CN17
CN18
CN19
Pin
1
2
3
4
5
1
2
3
1
CN22
CN23
CN25
CN26
CN27
CN28
Manual 0-2433
100 VAC
0V
+10 VDC
+15 VDC
0 to +7.5 VDC
CN21
100 VAC
Not used
100 VAC
100 VAC
1-2
1
2
3
CN20
Value
250 VAC
0V
Description
Normal close of CR5 on PCB1
Not used
Normal open of CR5 on PCB1
Common of CR5 on PCB1
Normal open of CR2 on PCB1
Not used
Common of CR2 onf PCB1
MC2 off
MC2 off or no contact of MC2
Current w aveform of IGBT,1V peak of 24 A peak
PCB common
Not used
0 to +15 VDC
0 to +15 VDC
7
+24 VDC
1
+24 VDC
2
0V
If trip else (or normally) +24 VDC
1
18 VAC
2
0V
Circuit common
3
18 VAC
1-2
70 V peak
Pulse w aveform of T1 secondary
1-2
70 VDC
Approximately at no load
1
-15 VDC
2
0V
PCB common
3
0 to 4 VDC
Current signal 1 VDC per 100 amp output current
4
+15 VDC
1
0V
If w arning then +24 VDC normally
2
+24 VDC
3
PCB common
4
+24 VDC
1
0V
PCB common
2
0V
If temperature over +24 VDC normally
1
0V
Minimum level of arc (inductor) signal
2
0 to 10 VDC Reference signal of arc (Inductor) control
3
+10 VDC
Maximum level arc (inductor) control signal.
NOTE - All values w ith respect to test point TP1 on main PCB1 logic board.
43
APPENDIX
Value
TP1
Common
Description
Circuit common
TP2
+15 VDC
TP3
-15 VDC
TP4
+24 VDC
Unregulated. Used for relays drive and detect point of over voltage.
TP5
-24 VDC
TP6
+24 VDC
TP7
TP8
Normally
+15 VDC
0 to +10 VDC
TP11
0 to +10 VDC
TP12
0 to +4 VDC
TP13
0 to +7 VDC
TP14
0V
Inverter on
+14 VDC
Inverter off
TP9
TP10
TP15
TP16
TP17
Same as TP16
TP18
TP19
Same as TP18
TP20
Same as TP18
TP21
Same as TP18
TP22
0/ +15 VDC
+15 VDC normally, but if less than 10 VDC then unbarance voltage of C4 and C5
TP23
0/ +15 VDC
Same as TP22
TP24
+15 VDC
Normally
TP25
+15 VDC
Normally
TP26
+15 VDC
Normally
TP27
+24 VDC
Normally
TP28
0 VDC
TP29
0 VDC
TP30
0/ +15 VDC
TP31
+15 VDC
TP32
+15 VDC
TP33
+15 VDC
TP37
0/ +15 VDC
TP38
0/ +15 VDC
TP43
TP 45
TP47
TP48
APPENDIX
44
Manual 0-2433
TP6
TP4
TP9
TP10
TP39
TP47
TP43
TP13
TP48
TP1
Circuit
Ground
TP12
TP7
TP45
TP38
TP33
TP37
TP2
TP5
TP28
TP11
TP32
TP31
TP30
TP8
TP3
TP27
TP29
TP26
TP25
TP24
TP17
TP23
TP22
TP19
TP20
TP21
TP16
TP18
A-00411
Manual 0-2433
45
APPENDIX
APPENDIX
Amperage &
Voltage Sensor
Input
Inrush Current
Surpressor
SMART-LINK
Circuit
Capacitor
Control
Transformer
Primary
Current Sensor
Drive
Circuit
DC Power
Supply For
Control Circuit
46
To Each
Control Circuit
+/-15VDC & +/-24 VDC
IGBT Inverter
Modules
(Q1 & Q2)
Inrush Current
Surpressor and
SMART-LINK
Control Circuit
Thermal
Sensor Circuit
Output
Transformer
Trouble
Sensing Circuit
Control/Logic
Control (PCB1)
Output
Diodes
Optional Digital
Meter Panel
High Frequency
(PCB3)
Output
Current Sensor
Reference
Current Adjustment
From
Coupling Coil
Stability
Reactor
+
+
REMOTE 14
Connector
Manual 0-2433
Options
Hand Controller
Foot Controller
TIG Sloper
TIG Pulser
Filter Board
(PCB4)
Remote/Local
Contactor
Switch
Sequence
Control
ARC Control
Circuit
Function
Switch
To High
Frequency
PCB
Coupling Coil
(CC)
Output
Voltage Sensor
Work
Reference
ARC Control
A-00406
Input
Diodes (D1)
Input Circuit
Breaker (MCB)
D2
D1
MCB
5
MC2
G1
12
18
14
2
1 CN1
E1
C4
13
R7
C7
G2
E2
C10
C2E1
1
CN2
2
94
E2
R11
24
R2
94
Q2
G1
F 15
R19 C20
1 3 5
R1
MC2
MC2
2 4 6
R3
G3
19
17
2
1 CN1
E3
C5
16
G4
C12
R9
C9
E4
27 28
(B) E 26
E2
R13
D7
Optional Digital
Panel Meter
PCB7
40
41
42
43
38
39
93
11
94
G4
E4
G3
E3
G1
E1
34
35
36
37
33
87
4 3 2 1
CN26
1 2
2 1 2 1 2 1 2 1 13 5 1 2 4 321 4 1
CN9 CN11 CN10 CN12 CN13 CN18 CN25 CN22 CN23
2
CN20
A2
1
CN16
3
1
CN17
2
99
101
71
72
MC2 102
A2
1
CN14
3
CN8
1 3
96
103
F2
CN4
1
SA6
62
65
3
61
CN3
2
CN2
3 2 1
CN5
6 5 4 3
67
63
68
71 72 73 74
77
78 79
CN28
3 2 1
80
81 82
CN1
3 2 1
84 85
83
75
CN1
3
5
CN1
6 1
Filter PCB4
L H
M N
1
3
CN19 4
5
6
7
CN27
1 2
89
88
S3
PCB6-2
OUTPUT CONTACTOR
S2
3
HF TIG
2 5
VR1
A
VR2
ARC CONTROL
VR3
52
GND
54
55
+15V
RUN/STOP
56
I. DET
57 CON. ON/OFF
+24V
58
1
3
CN4
1
3
4
CN1
5
6
7
TIG Sequencer
PCB2
107
1
CN2
SOL
108
2
CN3
THS1 THS2
14 Pin Receptacle
PCB6-1
Process Selector
S1
VR4
VR5
PRE FLOW
POST FLOW
114
115
113
C E D
HOT LEVEL
CN2
6 2 4 3
117
112
111
75
74
97
160
APPENDIX
PCB6-3
AMPERAGE
CN1
CN1
1
LIFT TIG
STICK
ON
PANEL
PCB Common
24 VAC
64
REMOTE 14
76
F3
R18
97
161
66
REMOTE 14
MC1
A1
98
MC2
104
CN6
100
A1
106
200 VAC
1 2 3 4 5 6
60
SA7
2
CN21
59
1
3 CN15
5
70
105
95
150
FAN
95
CN1
64
69
63
86
71
High Frequency
PCB3
CN1
1 2 3 4 6 5
18V
18V
31
32 0V
200V
250V
100V
0 VAC
95
0V
47
96
97
110
109
C13
G2
Trip Coil
G2
E2
0V
230V
0V
230V
CC
MCB
97
29
C15
R15
25
26 24
PL1-1
PL1-2
POWER WARNING
T2
24 VAC
38 39
D5
10
28
24
FCH
21
E2
23
24
C2E1
1
CN2
2
C19
PCB5
_
A
E1
R5
63 64
MC2
PCB9
C8
R8
T1 (S)
(A)
R12
C1
40 41 42 43
70
D3
MC1
53 54
69
R4
93
9
62 61
C17
1, 2
R3
E
4
MC2
To
4, 5
25
(A)
MC2
C18
1 3 4 2
CT1
R1
11
CT2
50
D4
93
D6
48
49
27
22
23
46
47
Surge Absorber
PCB10
T1
A C
20
C11
G2
E2
F1
C14
R14
E1
R4
44
R2
R10
C1
G1
27
28
L3
1
2
T1(S)
(B) F
PCB8
C6
26
24
L1
L2
Q1
R6
A-00407
Manual 0-2433
G1
12
18
14
2
1 CN1
E1
C4
13
R7
C7
G2
E2
C10
C2E1
1
CN2
2
E2
R11
24
D
Q2
G1
F 15
1 3 5
+
C5
R3
2
1 CN1
E3
16
G
R9
C9
G4
E4
C12
1
CN2
2
38 39
21
CC
27 28
(B) E 26
E2
R13
D7
Optional Digital
Panel Meter
PCB7
40
41
42
43
38
39
93
11
94
G4
E4
G2
E2
G1
E1
G3
E3
Trip Coil
44
34
35
36
37
33
87
2
CN20
A2
1
CN14
3
CN8
1 3
96
103
CN4
1
SA6
62
65
3
61
CN3
2
CN2
3 2 1
CN5
6 5 4 3
67
63
68
71 72 73 74
77
78 79
CN28
3 2 1
80
81 82
CN1
3 2 1
84 85
83
75
CN1
3
5
CN1
6 1
L H
M N
1
3
CN19 4
5
6
7
CN27
1 2
89
88
PCB6-2
OUTPUT CONTACTOR
S2
3
HF TIG
PANEL
S3
2 5
VR1
A
VR2
ARC CONTROL
VR3
52
GND
54
55
+15V
RUN/STOP
56
I. DET
57 CON. ON/OFF
+24V
58
1
3
CN4
1
3
4
CN1
5
6
7
TIG Sequencer
PCB2
107
1
CN2
SOL
108
2
CN3
THS1 THS2
14 Pin Receptacle
PCB6-1
Process Selector
S1
VR4
VR5
PRE FLOW
POST FLOW
114
115
113
C E D
HOT LEVEL
CN2
6 2 4 3
117
112
111
74
75
1
97
160
Manual 0-2433
Filter PCB4
PCB6-3
AMPERAGE
CN1
CN1
1
LIFT TIG
STICK
ON
1
REMOTE 14
PCB Common
24 VAC
64
REMOTE 14
76
F3
R18
97
161
66
MC1
A1
104
CN6
98
106
200 VAC
1 2 3 4 5 6
60
1 2
2 1 2 1 2 1 2 1 13 5 1 2 4 321 4 1
CN9 CN11 CN10 CN12 CN13 CN18 CN25 CN22 CN23
59
FAN
4 3 2 1
CN26
70
105
95
2
CN21
95
F2
CN1
64
69
63
86
71
High Frequency
PCB3
CN1
1 2 3 4 6 5
18V
18V
31
200V
32 0V
100V
0 VAC
95
0V
48
96
97
110
109
C13
G2
C15
R15
25
MCB
97
29
FCH
0V
T2
28
24
26 24
PL1-1
PL1-2
POWER WARNING
C19
PCB5
23
D5
10
40 41 42 43
24
C2E1
E2
380/415V
E1
R5
R1
2 4 6
G3
19
17
R12
C1
PCB9
C8
R8
T1 (S)
(A)
MC1
24 VAC
C17
1, 2
93
D3
To
4, 5
25
(A)
93
11
C18
1 3 4 2
CT1
CT2
Surge Absorber
PCB10
A
D6
46
47
27
22
23
D4
93
U
T1
A C
20
C11
G2
E2
F1
C14
R14
E1
R4
27
28
+
R2
70
50
L3
1
2
R10
C1
G1
26
24
L1
L2
T1(S)
(B) F
PCB8
C6
48
49
MCB
Q1
R6
69
D2
D1
A-00408
APPENDIX
13
R7
C7
G2
E2
1
CN2
2
E2
24
D
Q2
G1
F 15
1 3 5
2 4 6
16
G
R9
27 28
(B) E 26
E2
R13
D7
0V
Optional Digital
Panel Meter
PCB7
93
11
94
G4
E4
G2
E2
G1
E1
G3
E3
Trip Coil
CN1
1 2 3 4 6 5
18V
33
97
95
86
87
1
3 CN15
5
SA7
2
CN21
4 3 2 1
CN26
1 2
2 1 2 1 2 1 2 1 13 5 1 2 4 321 4 1
CN9 CN11 CN10 CN12 CN13 CN18 CN25 CN22 CN23
A2
1
CN16
3
1
CN17
2
99
101
71
72
MC2
A2
1
CN14
3
CN8
1 3
96
103
F2
CN4
1
SA6
62
65
3
61
CN3
2
67
63
CN2
3 2 1
CN5
6 5 4 3
3
68
71 72 73 74
77
78 79
CN28
3 2 1
80
81 82
CN1
3 2 1
84 85
83
75
CN1
3
5
CN1
6 1
Filter PCB4
L H
M N
89
88
S3
PCB6-2
OUTPUT CONTACTOR
S2
3
HF TIG
2 5
VR1
A
VR2
ARC CONTROL
VR3
52
GND
54
55
+15V
RUN/STOP
56
I. DET
57 CON. ON/OFF
+24V
58
14 Pin Receptacle
TIG Sequencer
PCB2
107
1
CN2
SOL
108
2
CN3
THS1 THS2
HOT LEVEL
PCB6-1
Process Selector
S1
VR4
VR5
PRE FLOW
POST FLOW
114
115
113
C E D
R18
1
3
CN4
1
3
4
CN1
5
6
7
CN2
6 2 4 3
117
112
111
74
75
APPENDIX
97
160
PCB6-3
AMPERAGE
CN1
CN1
1
LIFT TIG
STICK
ON
PANEL
PCB Common
24 VAC
64
REMOTE 14
76
F3
1
3
CN19 4
5
6
7
CN27
1 2
161
66
REMOTE 14
MC1
A1
102
98
MC2
104
97
CN6
100
A1
106
200 VAC
1 2 3 4 5 6
CN20
70
105
95
150
FAN
97
CN1
64
69
63
34
35
36
37
18V
31
32 0V
200V
95
250V
100V
96
0V
49
0 VAC
MCB
71
High Frequency
PCB3
60
460V
575V
T2
110
109
C13
G2
26 24
PL1-1
PL1-2
POWER WARNING
CC
C15
R15
25
D5
10
29
FCH
21
E2
92
28
24
24
C2E1
1
CN2
2
C19
PCB5
23
E1
91
24 VAC
C9
G4
E4
40 41 42 43
38 39
40
41
42
43
MC2
2
1 CN1
E3
38
39
R1
C5
R3
G3
19
17
C12
R5
R1
R12
C1
PCB9
C8
R8
T1 (S)
(A)
MC1
R2
C17
1, 2
93
D3
To
4, 5
25
(A)
93
11
C18
1 3 4 2
CT1
MC2
CT2
Surge Absorber
PCB10
A
23
R11
D6
59
27
22
D4
93
U
T1
A C
20
C11
G2
E2
F1
C14
R14
C2E1
R4
C4
C10
E1
46
47
2
1 CN1
E1
70
R2
18
14
44
L3
G1
12
50
27
28
L2
G1
48
49
R10
C1
PCB8
C6
26
24
L1
Q1
R6
T1(S)
(B) F
69
D2
D1
MCB
A-00409
Manual 0-2433
MCB
L1
L2
L3
103
R2
R1
S
T
R2
MC2
C4
C21
C22
D1
94
U
F1
93
R2
Surge Absorber
PCB10
A
R1
MC2
11
R3
R4
94
93
4
9
R19 C20
MC2
MC2
62 61
+
C5
63 64
0V
230V
150
1
3 CN15
5
FAN
SA7
18V
32 0V
33
2
CN21
L1
L2
L3
MC2
A2
101
MCB3
71
102
L3
6
7
R2
R1
460 V
0V
100 V
0V
0 VAC
32
1
3 CN15
5
MC2
FAN
C4
98
SA7
33
2
CN21
100
A1
93
MCB2
MC2
A2
99
MCB3
71
72
MC2 102
9
8
103
C5
R3
31
96
101
Surge Absorber
PCB10
A
97
C21
11
T2
95
141
R2
_
F1
S
T
24 VAC
103
G
T3
115 VAC
460 V
MC2
8
C22
D1
62
MCB
L2
+
C5
R3
10
61
575 V
93
1
CN14
3
8
103
11
MC2
L1
93
Surge Absorber
PCB10
1
CN17
2
72
C21
18 V
MCB2
C4
93
U
F1
1
CN16
3
99
R2
_
100
A1
+
R2
R1
103
G
R
S
18 V
98
141
18V
31
250V
200V
100V
95
C22
D1
MCB
97
96
T2
0V
0V
230V
24 VAC
115 VAC
T3
0 VAC
0V
230V
10
0V
MC2
0V
53 54
R3
200 V
MC2
1
CN16
3
1
CN17
2
1
CN14
3
97
0V
31
32
FAN
98
8
103
MCB2
33
96
95
141
18 V
18 V
200 V
100 V
T2
0V
0 VAC
24 VAC
115 VAC
T3
0V
400 V
0V
400 V
10
2
CN21
1
CN14
3
MCB3
A-00334
APPENDIX
50
Manual 0-2433
Filter PCB4
CN2
CN1
Ground
6
C4
C2
C3
G
14 Pin
Receptacle
C1
C5
Contactor
24VAC 2 Amp
R1
Reference
Signal
C
E
PCB Common
A-00405
Manual 0-2433
51
APPENDIX
APPENDIX
52
Manual 0-2433
INDEX
A
AC
Power Indicator 11
AMPERAGE
Control 11
Switch 12
Amperage Curve 14
AMPERAGE/VOLTAGE
Meter 13
Switch 13
PANEL Position 12
REMOTE 14 Position 12
Anti-Static Handling 33
General 33
Procedure 33
ARC Control
Circuit Test 17
Control 11
C
Circuit Descriptions 31
SMART-LINK 31
230/460 Volt Models 31
380-415 Volt Models 31
460-575 Volt Models 31
Circuit Fault Isolation 15
Arc Control 17
HF TIG 17
Initial Setup Conditions 16
LIFT TIG 17
Output Load Test 16
SMART-LINK Test 16
Control
AMPERAGE 11
ARC CONTROL/INDUCTANCE 11
Control/Logic PC Board
Adjustments 28, 29
Basic Oscillation (VR5) 29
Dead Time (VR4) 29
Initial Setup 29
Maximum Output Current (VR2) 30
Minimum Output Current (VR1) 30
Minimum Pulse Width For LIFT TIG (VR10) 31
Output Current Limit (VR3) 30
Output Detection Voltage (VR6) 30
References 29
Special 29
Connectors 34, 41, 42
Replacement 34
Test Points 44
Versions 28
Manual 0-2433
Curve
Voltage 14
Cycle
Duty 13
D
Descriptions, Circuit 31
SMART-LINK 230/460 Volt Model 31
SMART-LINK 380-415 Volt Model 31
SMART-LINK 460-575 Volt Model 31
Design
Feature
WARNING Indicator 11
Specifications 11
Load/No Load Outputs 13
Rated Output 13
Diagram
Interconnection
208/230/460 Volt Model 47
380/415 Volt Model 48
460/575 Volt Model 49
Solid State Inrush Circuit 50
System Block 46
Disassembly & Parts Replacement 33
Duty Cycle 13
E
Enclosure
Opening 33
F
Faults
Circuit Isolation 15
Common Operating 15
Features
Design 11
Fuse Replacement 33
G
General Information 1
Notes, Cautions, and Warnings 1
Safety Precautions 1
H
HF TIG
Circuit Test 17
I
IGBT Module (Q1 & Q2)
Replacement 34
53
INDEX
Indicator
AC Power 11
WARNING 11
PRIMARY POWER
Switch 13
Process Selector
Switch 11
Information
Ordering 35
Publications
Operating Manual 9
Safety References 6
R
Rated Output
Input Power 13
Repair
Restrictions 9
LIFT TIG
Circuit Test 17
Replacement Parts
Before November 1993 36
Complete Systems 35
November 1993 and Later 38
M
Maintenance
Routine 15
Responsibilities
Customer/Operator 9
Service 9
Manual
Operating 9
Return Parts 35
Meter
AMPERAGE/VOLTAGE 13
Routine Maintenance 15
Modifications
General 9
Safety Precautions
Arc Rays 2
Electric Shock 2
Fire and Explosion 4
Gases and Fumes 1
High Pressure Gas Cylinders 5
Noise 4
Pacemakers 6
O
Opening Enclosure 33
Operating Faults 15
Ordering Information 35
Output
Load Circuit Test 16
Load/No Load 13
SMART-LINK
Circuit Descriptions 31
Circuit Test 16
Input Power 13
OUTPUT CONTACTOR
Switch 12
ON Position 12
REMOTE 14 Position 12
Specifications
Design 11
Switch
AMPERAGE 12
AMPERAGE/VOLTAGE 13
PANEL Position 12
REMOTE 14 Position 12
OUTPUT CONTACTOR 12
ON Position 12
REMOTE 14 Position 12
PRIMARY POWER 13
Process Selector 11
HF TIG (GTAW) w/High Frequency 11
LIFT TIG (GTAW) w/o High Frequency 12
STICK Welding (SMAW) 11
P
Parts
Return 35
Parts Lists 35
Sections Breakdown 35
Parts Replacement
Control/Logic PCB 34
Fuse 33
IGBT Module (Q1 & Q2) 34
Input Diode (D1) 34
Physical Characteristics 14
Dimensions 14
Weight 14
INDEX
54
Manual 0-2433
T
Test Procedures 20
Control/Logic PC Board (PCB1) 24
AMP/VOLT Control 26
ARC Control 26
Close Loop Current Feedback (CT2) 25
Close Loop Voltage Feedback 26
IC1 & Gate Drive 27
Input Capacitor Balance 24
Inverter Balance Circuit (CT1) 25
LIFT TIG Circuit 25
MCB Trip Circuit 25
Power Supply Circuit 24
Precharge Circuit 25
Diode Testing Basics 21
Forward Bias 21
Reverse Bias 21
Input Capacitor (C4 & C5) 23
Input Diode (D1)
With Mechanical Inrush Circuit 21
With Solid State Inrush Circuit 22
Opening Enclosure 20
Output Diode 23
Power IGBT (Q1 & Q2) Module 22
Safety Precautions 20
Troubleshooting
Guide 17
Preparation 18
Specific Problems 18
V
Voltage Curve 14
W
WARNING
Indicator 11
Manual 0-2433
55
INDEX
INDEX
56
Manual 0-2433