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SanRex SANARG 300AP WITH COOLING WATER PRESSURE SENSOR AC/DC/AC-SOFT INVERTER ARC WELDER Operators Manual Version No: AD Issue Date: MAR 15, 2021 Manual No: K00A0316500...
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Team! Dear Welding Professional, We would like to take this opportunity to thank you, and congratulate you on procuring a SanRex SANARG 300AP with cooling water pressure sensor AC/DC STICK Welding Machine. Welding Professional, now that is a term that we do not take lightly. The welding machine that you purchased is a full function, portable unit that was designed with the Welding Professional in mind.
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This manual has been prepared to present the safety, installation/operation and maintenance instructions for the SanRex SANARG 300AP with cooling water pressure sensor, hereby referred to as 300AP, an AC/DC Stick and TIG welding machine manufactured by the Sansha Corporation of Osaka, Japan. The manual contains the information necessary for the Professional Welder to correctly use and operate the 300AP.
SECTION 1- SAFETY REGULATIONS AND REQUIREMENTS Please read this operating manual thoroughly before utilizing the equipment. Wherever welding equipment is used, safety is always our concern. PROTECT yourself and others 1.0 SAFETY REGULATIONS AND REQUIREMENTS Throughout this manual, notes, cautions, danger, attention and warnings are used to highlight important information.
1.02 Safety Recommendations For the purpose of safety, it is recommended that this welding equipment be installed, maintained, inspected, and repaired by appropriable qualified person or persons who are well familiarized with welding equipment. As for safety training, it is recommended to avail yourselves of various seminars and qualifying examinations for welding engineers and welding technicians sponsored by the Welding Society, the Welding Engineering Society, and the headquarters or branch offices of societies or associations concerned.
1.03 Welding Symbols 1.03.01 Safety Symbol Legend SOURCE OF SYMBOL HAZARD HOW TO AVOID HAZARD Don’t weld on painted parts. Remove the surface coating Welding Electric Shock before you begin welding. Keep Electrode your face away from the welding plume. Protect welding cables from sparks, hot metal, open flames, sharp edges, oil, and grease.
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SOURCE OF SYMBOL HAZARD HOW TO AVOID HAZARD Do not breathe fumes and gases. Keep your head out of the fumes. Chromium and Welding Fumes Use enough ventilation or Nickel Fumes exhaust at the arc or both to keep fumes and gases from your breathing zone and general area Maintain proper distances from the Arc Ray.
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SOURCE OF SYMBOL HAZARD HOW TO AVOID HAZARD Establish a written policy documenting general safety Optical Radiation and requirements for the wearing of Thermal Arc Heat contact lenses. Conduct an eye hazard evaluation in the workplace Gloves should be: Dry and moisture resistant. Cuts, Scrapes, Heat, Mechanical, In good condition, no holes or...
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SOURCE OF SYMBOL HAZARD HOW TO AVOID HAZARD Use approved helmets or hand shields that provide protection for the face, neck, and ears, and wear a head covering. Hot Metal, Slag, Arc Thermal Wear approved safety goggles or Rays, Hot Work Piece safety glasses with side shields, even under your helmet.
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SOURCE OF SYMBOL HAZARD HOW TO AVOID HAZARD Establish a written policy documenting general safety Optical Radiation and requirements for the wearing of Thermal Arc Heat contact lenses. Conduct an eye hazard evaluation in the workplace Gloves should be: Dry and moisture resistant. Cuts, Scrapes, Heat, Mechanical, In good condition, no holes or...
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SOURCE OF SYMBOL HAZARD HOW TO AVOID HAZARD Keep your head out of the fumes. Do not breathe the fumes. Any Coatings on Base Fumes and Use enough ventilation or Metal, Weld Process Gases exhaust at the arc, or both, to keep fumes and gases from your breathing zone and general area Be alert, aware, and focused on...
1.03.02 Graphic Symbol Legend STICK Amperage (Shielded Metal Arc SMAW) Voltage Pulse Current Function Hertz (cycles per second) Spot Time (GTAW) Remote Control Frequency (Panel/Remote) Seconds Remote Function Percentage Arc Control (SMAW) DC (Direct Current) Gas Post-Flow AC (Alternating Current) Gas Pre-Flow Voltage Reduction Standard Function...
1.04 Safety Precautions NOTE: FOR PROPER USE, PLEASE READ THIS OPERATING MANUAL THOROUGHLY PRIOR TO UTILIZING THE WELDING MACHINE The safety precautions described in this Operating Manual will give you the information necessary for you to handle the equipment safely and prevent any hazard or damage to you or others.
1.05 Safe Operation of the Welder and Personal Protection 1.05.01 Important Safety Precautions To prevent serious injury to the operator or others, be sure to observe the following: Never allow unqualified Those who use heart pacemakers person to enter the surrounding should not enter the surrounding area of this welding equipment in area of this welding equipment or...
1.05.02 Electric Shock To prevent electric shock, be sure to observe the following precaution: Touching any parts that are Tighten cable connections electrically “live” or “hot” may securely and insulate properly. cause fatal electric shock or burns. Have a qualified electrician connect the Welding Power Do not operate with welding Source.
1.05.03 Gases and Fumes To protect you and others from fumes and gases produced during the welding processes, use safeguards. Inhalation of gases and fumes produced during the welding When welding in confined processes can be dangerous and spaces, ensure that the welding hazardous to your health.
1.05.04 Fire and Explosions To prevent fire, explosion, or rupture, be sure to observe the following precautions. Spatter or hot base metals Do not weld in the vicinity of produced during flammable gases. immediately after the welding processes may cause fire. Keep base metals...
1.05.05 Arc Welding Rays, Noise and Spatter or Slag To protect you and others from arc rays, scattered spatter or slag, and loud noise produced during the welding processes, use safeguards. Arc rays can cause your eyes To protect your eyes from irritation and burn your skin.
1.05.06 Gas Cylinders To prevent the turnover of gas cylinder or the rupture of gas flow regulator, be sure to observe the following precautions. Turnover, tipping or falling gas Read and follow all warnings, cylinder may cause injury to the safety precautions, operator or others.
1.06 Reference Publications Refer to the following standards or their latest revisions for more information: 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, 732 N. Capital St NW, Washington, D.C. 20402 2.
SECTION 2 - INTRODUCTION AND DESCRIPTION 2.0 INTRODUCTION AND DESCRIPTION 2.01 General Information This manual is intended to be a guide to the understanding of the 300AP welding machine and process requirements. The application outlined is typical and serves only to illustrate and explain the relationship of power source to the process.
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Intelligent Fan Control • The intelligent cooling system is designed to reduce dust and foreign material build-up, while still providing optimum cooling. • Fan speed reduces approximately 30 seconds after machine is turned on. • Fan speed increases when internal components reach operating temperature. ON/OFF Switch •...
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Water Cooled Torch Protection The 300AP is equipped with a cooling water pressure switch that will disable the welding output current if inadequate cooling water is flowing to the torch. To enable the cooling water pressure switch circuitry: • Press the WATER COOLING button. •...
2.04 Welding Output Voltage and Amperage Curves 2.04.01 300AP V/A Output Curves The waveforms shown in figure 2.1 are the maximum Voltage-Amperage output capabilities of the 300AP. Curves for actual welding setting will fall within the curves shown. 300A STICK PROCESS 300A 300A LIFT-TIG PROCESS...
SECTION 3 - INSTALLATION RECOMMENDATIONS 3.0 INSTALLATION RECOMMENDATIONS 3.01 Transportation Methods The case design of the 300AP incorporates a built-in handle for carrying purposes. The case design also allows for the units to be stacked where the feet on one unit aligns with the notches on the top of another unit.
3.02 Environment The 300AP is designed for use in adverse environments with an IP23S rating. Examples of environments with increased adverse conditions are - • With its small, lightweight and portable form factor, the 300AP is ideal for use in locations in which freedom of movement is restricted, so that the operator is forced to perform work in cramped (kneeling, sitting or lying) positions.
WARNING: Explosives: The high frequency section of this machine has an output similar to a radio transmitter. The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing. WARNING: Computers: It is also possible that operation close to computer installations may cause computer malfunction.
3.04 Location The location of the 300AP should be in accordance to the following guidelines: • In areas, free from moisture and dust. • In areas, free from oil, steam and corrosive gases. • In areas, not exposed to direct sunlight or rain. •...
3.05.02 Fusing The 300AP is equipped with an input switch and does not have and input circuit breaker for protection. It is the responsibility of the user to provide proper fuse protection for the welding power source. Failure to do so will void the warranty. NOTE: Maximum fuse size should be such that the fuse value not be more than 200 percent of the rated input amperage of the welding power source.
3.05.03 Electrical Input Connections DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. 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.
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b. For single-phase input connections: Connect the ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line disconnect switch. Insulate the end of line 3 (RED) conductor, as it is not used for single-phase operation. 3.
53 lb. (24 kg) SanRex continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
3.06.02 General Information Model IA-3000TP-U3E General Approval/Standard IEC60974-1, IP23S Language English Front Panel Front Panel Pot Welding Current / Parameters Adjustment Push to voltage display / Set / Error Release Function Select Button Process STICK / HF TIG / LIFT TIG OUTPUT STD / SLOPE / REPEAT / SPOT Mode...
3.07 Duty Cycle The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty cycle will decrease.
SECTION 4 - OPERATOR CONTROLS, DIMENSIONS & OUTLINE 4.0 OPERATOR CONTROLS, DIMENSIONS & OUTLINE 4.01 Dimensions and Outline The figure below shows the dimensions, in millimeters, and the outline of theSanRex model 300AP. FIGURE 4-1 : 300AP Dimensions and Controls 4.02 Operator Controls, Location and Functionality Refer to the figure above for the corresponding reference numbers.
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3. Positive Output Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. A loose or worn connection will cause excessive heat and may cause damage to the front frame or internal components of the welding unit.
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8. AC INPUT VOLTAGE SELECT SWITCH This manual slide, user selectable switch selects the proper AC input voltage range. If this slide switch is not set to the position that matches the input line voltage, the internal microcontroller will inhibit the welding power source from turning on and will display an error code on the front control display panel.
4.03 14-PIN Remote Control Receptacle FIGURE 4-2 : 14-PIN Remote Control Receptacle Layout. Socket Pin Function Input Torch Switch Input. To energize weld current, connect pins A & B. Input Torch Switch Input. To energize weld current, connect pins A & B. Output +10VDC signal connects to high side of 1k ohm remote control potentiometer.
4.04 Parameter Display Panel Figure 4-3 – 300AP Front Panel PARAMETER DESCRIPTION This parameter operates in TIG modes only and is used to get gas to the weld zone prior to striking the arc, once the torch trigger switch has been pressed.
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PARAMETER DESCRIPTION pressed then released, from INITIAL CUR to PEAK or BASE current PEAK CUR. This parameter sets the PEAK weld current when in PULSE mode This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and SPOT modes when PULSE is off. This parameter also sets the STICK (WELD) weld current.
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PARAMETER DESCRIPTION AC-SOFT mode. This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down, after the torch trigger switch has been DOWN SLOPE pressed, to CRATER CUR. This control is used to eliminate the crater that can form at the completion of a weld.
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PARAMETER DESCRIPTION LIFT TIG mode of operation. A remote control device may be used for use during LIFT TIG operation. See section 4 for the 14-Pin Remote Control Receptacle for complete details of the remote device. Depressing this button and illuminating the corresponding LED will enable the Cooling Water Pressure Sensor circuitry.
4.05 Function Selection The Table below provides information of the functions that are available using the front panel display. Function Selection STICK LIFT Description 2T operation in TIG Modes using remote devices to control contactor & current 4T operation in TIG Modes with crater fill using a remote contactor device to control SLOPE sequence.
4.06 Parameter Selection The Table below provides information of the parameters that are available for modification using the front panel display. The table also provides information on the ranges available for each parameter as well as to which weld process the parameter is available. Process PARAMETER RANGE...
4.07 Internal Parameter Selection Internal parameters can be set by pressing and holding the encoder button. Turn the encoder to display “End” and press the encoder to return to the standby screen. Code No. Items Setting area Default Remarks [ON Setting] The welding current is reduced to 25A Anti-Stick OFF / ON...
SECTION 5- SET-UP FOR BASIC STICK (SMAW) AND TIG (GTAW) WELDING 5.0 SET-UP FOR BASIC STICK (SMAW) AND TIG (GTAW) WELDING Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects.
SECTION 6 – SEQUENCE OF OPERATION 6.0 SEQUENCE OF OPERATION NOTE: Scroll Buttons are used to select the parameters to be set. An illuminated LED indicates which function is being adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions.
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1. Pulse Function – Pressing this button enables the TIG current pulse functions. 2. Remote Current Function – Pressing this buttons enables remote current functions. 3. TIG Mode Functions – Pressing this button scrolls through the output TIG function modes. The user can select between Standard, Slope, Slope w/repeat or Spot modes.
6.01 Stick Welding • Connect work lead to negative terminal. • Connect electrode lead to positive terminal. • Switch machine on. • Wait for machine to cycle thru the start-up sequence during which the software version, followed by the machine code is displayed on the front Panels Digital Display. •...
6.01.01 Stick Welding Sequence with Voltage Reduction Device Disabled Hot cur. Arc control Output Current Hot start Output Voltage Arc control level (about 18V ) 6.01.02 Stick Welding Sequence with Voltage Reduction Device Enabled I_DET Hot cur. Arc control Output Current Hot start Output Voltage Arc control level...
6.02 AC or DC HF TIG Welding • Connect work lead to positive terminal. • Connect TIG torch to negative terminal. • Switch machine on. • Wait for machine to cycle thru the start-up sequence during which the software version, followed by the machine code is displayed on the front Panels Digital Display.
6.03 LIFT TIG Sequence 6.03.01 Standard Mode Contactor short short Electrode Solenoid Post flow tim e Pulse width Post flow tim e Pre flow tim e Pulse frequency Output current Peak cur. Base cur. 25A (fixed) Lift only. 6.03.02 Slope Mode Contactor short short...
6.04 HF TIG Sequence 6.04.01 Standard Mode Contactor Solenoid Post flow tim e Pre flow tim e Pulse width Hot start Hot cur. Pulse frequency Output current Peak cur. Base cur. 6.04.02 Slope Mode Contactor Solenoid Output current Initial cur. Crater cur.
6.04.04 Spot Mode Contactor Solenoid Pre flow tim e Spot tim e Hot start Hot cur. Output current 6.05 Waveform Options The following references are used within this section. SP = Straight Polarity RP = Reverse Polarity VR-Current = Variable Reverse Polarity Current 6.05.01 VR-Current Variable of Reverse Polarity Current.
6.05.02 AC-SOFT Mode When AC-SOFT mode is selected, there are two waveform options, a sinusoidal waveform or a triangular waveform. When the internal parameter P24 is set to the "OFF" condition, the AC-SOFT mode will output a sinusoidal waveform. <Sinusoidal Wave (Set Internal parameters P24 to OFF) > AC-sinusoidal wave includes all the benefits of AC- square wave with the addition of maximum puddle control...
6.06 Slope Function 6.06.01 2T Slope Function (Set with internal parameter P19, Factory setting is P19 OFF) This is the function to control the slope operation under 2T mode. It is necessary to set the upslope time, down slope time, initial current and crater current. The current wave becomes as shown below when this function is valid and invalid (OFF).
SECTION 7 – VOLTAGE REDUCTION DEVICE 7.0 VOLTAGE REDUCTION DEVICE (VRD) The 300AP is equipped with a Voltage Reduction Device circuit that when enabled lowers the Open Circuit Voltage (OCV) in STICK mode. This function is used in applications where a high OCV in STICK mode is dangerous or applications where a lower OCV would be advantageous.
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B) Remove the front control cover assembly from the front panel (see Figure 7-2). • Remove the four mounting screws from the front control panel. • Access the VRD control by gently prying back the front panel controls to reveal the VRD enable/disable potentiometer (see Figure 7-2). Do not pull back the front panel with excessive force as this may unplug cable from the control or main PCB.
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C) ENABLE/DISABLE the VRD function (see Figure 7-3). • To ENABLE the VRD function: rotate the trim potentiometer (VR1) on the display PCB fully clockwise. When VRD is ENABLED, verify that it operates as per the VRD specification. • To DISABLE the VRD function: rotate the trim potentiometer (VR1) on the display PCB fully counterclockwise.
SECTION 8 – TROUBLE SHOOTING 8.0 TROUBLE SHOOTING 8.01 Power Source Problems Description Possible Cause Remedy 1. The welding arc The Primary supply voltage Switch ON the Primary cannot be has not been switched ON. supply voltage. established. The Welding Power Source Switch ON the Welding switch is switched OFF.
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Description Possible Cause Remedy 5. Gas flow won’t A Weld Mode (STD, SLOPE, A Strike an arc to complete the shut off. REPEAT or SPOT) was weld cycle. changed before POST-FLOW gas time had finished. Switch machine off then on to reset solenoid valve sequence.
When the detection temperature B. Fan ceases to operate. B. Have an Accredited SanRex of TH1 falls and the Control Service Agent investigate. Knob is pressed, E01 is reset. C. Air flow is restricted by C. Unblock vents then let Power vents being blocked.
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Description Possible Cause Remedy Remarks Output current detection E05 error code displayed Have an Accredited SanRex Weld current ceases. signal of main circuit Service Agent or a qualified Buzzer sounds constantly. No output current inverter has abnormality. electrician check for Current Switch machine off, wait 3 seconds, detection.
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When 3 phase machine is Have an Accredited No weld current is available. Wrong Primary supply first turned on with the SanRex Service Agent or a Buzzer sounds constantly. (input) voltage connected wrong Primary supply (input) qualified electrician check Switch machine off.
SECTION 9- ROUTINE MAINTENANCE 9.0 ROUTINE MAINTENANCE Routine inspection and testing (power source) An inspection of the power source, an insulation resistance test and an earth resistance test should be carried out. a) For transportable equipment, at least once every 3 months; and b) For fixed equipment, at least once every 12 months.
9.01 Opening the Enclosure a) Confirm that the switch of power supply and the switch on switchboard (distribution panel) are all OFF. Figure 9-1 Switch OFF WARNING: The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box (distribution panel).
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Figure 9-3 Loosen screws NOTE: DO NOT remove the screws from the front and rear panels completely. c) Pull the front panel slightly forward while pulling the rear panel slightly backward. The interlocking hooks of the side case covers can now be disengaged from the front and rear panel.
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d) Remove the side covers. Figure 9-5 Remove Side covers e) Remove protection cover sheet by removing the four plastic clips. Figure 9-6 Remove PCB cover NOTE: When you re-assemble the parts, conduct the above process in reverse order.
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APPENDIX A 300AP QUICK SET-UP GUIDE STICK SANARG 300AP Front Panel Description HF TIG Process Functions – Push the Process button to scroll through the three processes (STICK, LIFT TIG, HF TIG). The green LED will LIFT TIG light as the process is selected. When in STICK mode, the output contactor is activated.
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Detailed description of each parameter can be found in the Owner’s Manual. SANARG 300AP SETTINGS The settings shown below should be used as guidelines for a first set-up. The welder should adjust these setting to achieve optimal weld performance for the specific application.
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300AP QUICK SET-UP GUIDE SANARG 300AP Front Panel Description STICK Process Functions – Push the Process button to scroll through the HF TIG three processes (STICK, LIFT TIG, HF TIG). The green LED will light as the process is selected. When in STICK mode, the output LIFT TIG contactor is activated.
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Detailed description of each parameter can be found in the Owner’s Manual. SANARG 300AP SETTINGS The settings shown below should be used as guidelines for a first set-up. The welder should adjust these setting to achieve optimal weld performance for the specific application.
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SanRex SANREX CORPORATION (USA) SANSHA ELECTRIC MFG. CO. LTD. (Japan) 50 Seaview Blvd. 301056, Nishi-Awaji, Higashiyodogawa Port Washington NY 11050 Osaka Japan 533-0031...
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