CIGWELD transarc 300 Si Service Manual
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CIGWELD transarc 300 Si Service Manual

Inverter welding power supply
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300 Si

Service Manual

tranSarc
InVErtEr arc WELDEr
Revision: AA
Operating Features:
3
PHASE
SMAW
GTAW
®
Issue Date: January 15, 2008
50
415
INVERTER
DC
Hz
60
V
Manual No: 0-5000
300
CC
AMP

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Summary of Contents for CIGWELD transarc 300 Si

  • Page 1: Service Manual

    300 Si tranSarc ® InVErtEr arc WELDEr Service Manual Revision: AA Issue Date: January 15, 2008 Manual No: 0-5000 Operating Features: INVERTER PHASE SMAW GTAW...
  • Page 2 800-752-7621, or visit us on the web at www.cigweld.au.com. This Operating Manual has been designed to instruct you on the correct use and operation of your Cigweld product. Your satisfaction ® with this product and its safe operation is our ultimate concern.
  • Page 3 WARNING Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Servce Manual Number 0-5000 for: Transarc 300 S Inverter Weldng Power Supply Part No.

  • Page 4: Table Of Contents

    OPERATOR CONTROLS ................4-1 4.01 Transarc 300 Si Controls ................. 4-1 4.02 Weld Parameter Description ................4-2 4.03 Weld Parameters for Transarc 300 Si .............. 4-3 4.04 Power Source Features ................... 4-4 SECTION 5: SET-UP FOR SMAW (STICK) AND GTAW (TIG) ..........5-1 SECTION 6: SEQUENCE OF OPERATION .................
  • Page 5 Table of Contents SECTION 7: BASIC TIG WELDING GUIDE ................ 7-1 7.01 Electrode Polarity .................... 7-1 7.02 Tungsten Electrode Current Ranges ..............7-1 7.03 Tungsten Electrode Types ................7-1 7.04 Guide for Selecting Filler Wire Diameter ............7-1 7.05 Shielding Gas Selection .................. 7-2 7.06 TIG Welding Parameters for Low Carbon &...
  • Page 6 Table of Contents 11.05 Verification of the Power Input Circuitry ........... 11-11 11.5.1 Verification of the AC Input Voltage using an AC voltmeter....11-11 11.5.2 Verification of the Power Supply Voltage ......... 11-12 11.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry ...... 11-13 11.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry ......
  • Page 7 Table of Contents 12.3.29 Ring Core (L1) ................12-32 12.3.30 Ring Core (L105) ................12-34 12.3.31 Reactor (L101) ................12-35 12.3.32 Reactor (L102) ................12-36 12.3.33 Reactor (L103) ................12-37 APPENDIX 1: OPTIONS AND ACCESSORIES ............A-1 APPENDIX 2: INTERCONNECT DIAGRAM .............. A-2 APPENDIX 3: PARTS LIST .................
  • Page 8 TRANSARC 300 Si SERVICE MANUAL THIS PAGE LEFT INTENTIONALLY BLANK. January 15, 2008...

  • Page 9: Safety Instructions And Warnings

    SERVICE MANUAL TRANSARC 300 Si SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. Weldng products and weldng processes can cause serous njury or death, or damage to other equpment or property, f the operator does not strctly observe all safety rules and take precautonary actons.
  • Page 10 TRANSARC 300 Si SERVICE MANUAL 1. Protect yourself and others from flyng sparks and hot metal. 2. Do not weld where flyng sparks can strke flammable materal. 3. Remove all flammables wthn 35 ft (10.7 m) of the weldng arc. If WARNING ths s not possble, tghtly cover them wth approved covers.
  • Page 11 SERVICE MANUAL TRANSARC 300 Si WARNING WARNING CYLINDERS can explode if damaged. MOVING PARTS can cause injury. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders Movng parts, such as fans, rotors, and belts can cut fingers and hands are normally part of the welding process, be sure to treat and catch loose clothng.

  • Page 12: Principal Safety Standards

    TRANSARC 300 Si SERVICE MANUAL NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The followng s a quotaton from the General Conclusons Secton of the U.S. Congress, Office of Technology Assessment, Bologcal Effects of Power Frequency Electrc &...

  • Page 13: Declaration Of Conformity

    Vctora 3072 Australa Descrpton of equpment: Weldng Equpment (GMAW, MMAW, GTAW). Includng, but not lmted to CIGWELD Transtg 200 P, Transtg 200 AC/DC, Transarc 300 S, Transtg 300 P, Transtg 300 AC/DC, Transmg 400  and assocated accessores. Seral numbers are unque wth each ndvdual pece of equpment and detals descrpton, parts used to manufacture a unt and date of manufacture.
  • Page 14 TRANSARC 300 Si SERVICE MANUAL NOTES January 15, 2008...

  • Page 15: Introduction And Description

    SERVICE MANUAL TRANSARC 300 Si SECTION 2: INTRODUCTION AND DESCRIPTION 2.01 How To Use This Manual 2.02 Equipment Identification The unt’s dentfcaton number (specfcaton or part Ths Owner’s Manual apples to just specficaton or part numbers lsted on page . number), model, and seral number usually appear on a nameplate attached to the control panel.

  • Page 16: Symbol Chart

    TRANSARC 300 Si SERVICE MANUAL 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas Increase/Decrease Remote Continuous Weld...

  • Page 17: Description

    SERVICE MANUAL TRANSARC 300 Si 2.05 Description The Cgweld Model Transarc 300 S s a self contaned three-phase DC arc weldng power source wth Constant Current (CC) output characterstcs. Ths unt s equpped wth a Dgtal Volt/Amperage Meter and lft arc starter for use wth Gas Tungsten Arc Weldng (GTAW) and Shelded Metal Arc Weldng (SMAW) processes.

  • Page 18: Transporting Methods

    TRANSARC 300 Si SERVICE MANUAL 2.07 Transporting Methods These unts are equpped wth a handle for carryng purposes. WARNING ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

  • Page 19: Installation Recommendations

    • Place at a dstance of 12” (305mm) or more from Do not connect the ground (YELLOW/GREEN) conductor to walls or smlar that could restrct natural arflow for an nput lne termnal. coolng. WARNING Cigweld advises that this equipment be electrically connected by a qualified electrician. January 15, 2008...

  • Page 20: Mains Supply Voltage Requirements

    • Connected to the correct sze 415V Mans Current Crcut as per the Specficatons WARNING CIGWELD advises that this equipment be electrically connected by a qualified electrical trades-person. The followng 415V Mans Current Crcut recommendatons are requred to obtan the maxmum weldng current and duty cycle from ths weldng equpment:.

  • Page 21: Specifications

    IP23S Cigweld 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.

  • Page 22: Duty Cycle

    TRANSARC 300 Si SERVICE MANUAL 3.06 Duty Cycle The duty cycle of a weldng power source s the percentage of a ten (10) mnute perod that t can be operated at a gven output wthout causng overheatng and damage to the unt. If the weldng amperes decrease, the duty cycle ncreases.

  • Page 23: Operator Controls

    SERVICE MANUAL TRANSARC 300 Si SECTION 4: OPERATOR CONTROLS 4.01 Transarc 300 Si Controls Art # A-08345 Fgure 4 – Transarc 300 S Power Source 1. Control Knob Ths control sets the selected weld parameter, rotatng t clockwse ncreases the parameter that s ndcated on the dgtal meter.
  • Page 24 TRANSARC 300 Si SERVICE MANUAL 3. Postve Termnal Weldng current flows from the Power Source va heavy duty Dnse type termnal. It s essental, however, that the male plug s nserted and turned securely to acheve a sound electrcal connecton.

  • Page 25: Weld Parameter Description

    SERVICE MANUAL TRANSARC 300 Si 4.02 Weld Parameter Description PRESS AND HOLD Fgure 5 - Transarc 300 S Front Panel wth Parameter Descrpton This parameter operates in STICK weld mode and is used to improve HOT START the start characteristics for stick electrodes. e.g. low hydrogen electrodes.

  • Page 26: Weld Parameters For Transarc 300 Si

    TRANSARC 300 Si SERVICE MANUAL 4.03 Weld Parameters for Transarc 300 Si Weld Mode Weld Factory Incremental Parameter Parameter Range Setting Unit STICK LIFT TIG HOT START 0 to 70A WELD CUR 5 to 300A DC ARC CONTROL 0 to 100% 4.04 Power Source Features Feature Description New Digital Control • Almost all weldng parameters are adjustable Touch Panel Switches •...

  • Page 27: Set-Up For Smaw (Stick) And Gtaw (Tig)

    SERVICE MANUAL TRANSARC 300 Si SECTION 5: SET-UP FOR SMAW (STICK) AND GTAW (TIG) Conventonal operatng procedures apply when usng the Weldng Power Source, .e. connect work lead drectly to work pece and electrode lead s used to hold electrode. Wde safety margns provded by the col desgn ensure that the Weldng Power Source wll wthstand short-term overload wthout adverse effects.
  • Page 28 TRANSARC 300 Si SERVICE MANUAL NOTES January 15, 2008...

  • Page 29: Sequence Of Operation

    SERVICE MANUAL TRANSARC 300 Si SECTION 6: SEQUENCE OF OPERATION NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show whch functon s beng adjusted on the weld sequence graph. Refer to Symbols Table located n the front of the manual for Symbol descrptons.

  • Page 30: Stick Welding

    TRANSARC 300 Si SERVICE MANUAL 6.01 Stick Welding • Connect work lead to negatve termnal • Connect electrode lead to postve termnal • Swtch machne on • Set Contactor • Connect remote control devce f requred Use the Scroll Buttons to move to the parameter to be set. The LED wll show whch functon s beng adjusted on the weld sequence graph.

  • Page 31: Basic Tig Welding Guide

    SERVICE MANUAL TRANSARC 300 Si SECTION 7: BASIC TIG WELDING GUIDE 7.01 Electrode Polarity Connect the TIG torch to the - / TORCH termnal and the work lead to the + / WORK termnal for drect current straght polarty. Drect current straght polarty s the most wdely used polarty for DC TIG weldng. It allows lmted wear of the electrode snce 70% of the heat s concentrated at the work pece.

  • Page 32: Shielding Gas Selection

    TRANSARC 300 Si SERVICE MANUAL 7.05 Shielding Gas Selection Alloy Shielding Gas Aluminium & alloys Argon Carbon Steel Argon Stainless Steel Argon Copper Argon Table 7 – Sheldng gas selecton 7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe Electrode Type & Current Range DC Filler Rod for Root...

  • Page 33: Basic Arc Welding Guide

    SERVICE MANUAL TRANSARC 300 Si SECTION 8: Cast Iron Most types of cast ron, except whte ron, are weldable. BASIC ARC WELDING GUIDE Whte ron, because of ts extreme brttleness, generally cracks when attempts are made to weld t. Trouble 8.01 Electrode Polarity may also be experenced when weldng whte-heart malleable, due to the porosty caused by gas held n Stck electrodes are generally connected to the ‘+’...
  • Page 34 TRANSARC 300 Si SERVICE MANUAL NOTES January 15, 2008...

  • Page 35: Routine Maintenance

    SERVICE MANUAL TRANSARC 300 Si SECTION 9: ROUTINE MAINTENANCE The only routne mantenance requred for the power supply s a thorough cleanng and nspecton, wth the frequency dependng on the usage and the operatng envronment. WARNING Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.
  • Page 36 TRANSARC 300 Si SERVICE MANUAL Warning! Disconnect input power before maintaining. Maintain more often if used under severe conditions Each Use Visual check of torch Visual check of Consumable parts regulator and pressure Weekly Visually inspect the torch Visually inspect the body and consumables cables and leads.

  • Page 37: Vrd Specification

    SERVICE MANUAL TRANSARC 300 Si 9.01 VRD Specification Description Transarc 300 Si Notes VRD Open Crcut Voltage 15.3 to 19.8V Open crcut voltage between weldng termnals The requred resstance between weldng VRD Resstance 148 to 193 ohms termnals to turn ON the weldng power...
  • Page 38 TRANSARC 300 Si SERVICE MANUAL THIS PAGE LEFT INTENTIONALLY BLANK. January 15, 2008...

  • Page 39: Basic Troubleshooting

    WARNING There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an Accredited Cigweld™ Service Provider and you have had training in power measurements and troubleshooting techniques. If major complex subassembles are faulty, then the Weldng Power Source must be returned to an Accredted Cgweld Servce Provder for repar.
  • Page 40 TRANSARC 300 Si SERVICE MANUAL Description Possible Cause Remedy Electrode melts when arc s Electrode s connected to the ‘+’ Connect the electrode to the ‘−’ struck. termnal. termnal. 7. Drty weld pool. A. Electrode contamnated through A. Clean the electrode by grndng off contact wth work pece or filler rod the contamnates.

  • Page 41: Stick Welding Problems

    SERVICE MANUAL TRANSARC 300 Si 10.02 Stick Welding Problems Description Possible Cause Remedy 1. Gas pockets or vods n weld metal Electrodes are damp. Dry electrodes before use. (Porosty). Weldng current s too hgh. Reduce weldng current. Surface mpurtes such as ol, Clean jont before weldng.

  • Page 42: Power Source Problems

    TRANSARC 300 Si SERVICE MANUAL 5. Non-metallc partcles are A. Non-metallc partcles may be trapped A. If bad undercut s present, clean trapped n the weld metal n undercut from prevous run. slag out and cover wth a run from a (slag ncluson).

  • Page 43: Power Source Error Codes

    SERVICE MANUAL TRANSARC 300 Si 10.04 Power Source Error Codes Description Possible Cause Remedy Remarks 1 E01 error code A The Welding Power A Let Power Source cool Weld current displayed. Source’s duty cycle has down then keep within ceases. Buzzer Temperature been exceeded.
  • Page 44 TRANSARC 300 Si SERVICE MANUAL Description Possible Cause Remedy Remarks 6 E14 error code Mains supply voltage is less Have an Accredited Cigweld Weld current displayed. than the nominal operating Service Provider or a available. Buzzer Under mains supply voltage plus 15%.

  • Page 45: Advanced Troubleshooting

    TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING 11.01 System-Level Fault Isola- ADVANCED TROUBLESHOOTING If you are here, all of the troubleshooting sugges- tions in Section 8-Basic Troubleshooting have tion either failed to resolve the faulty operation or have indicated that one or more of the subsystems If none of the suggestions provided in Section 8 within the power supply are defective.
  • Page 46 SERVICE MANUAL TRANSARC 300 Si ADVANCED TROUBLESHOOTING 2) Remove all screws and nuts on the side cov- 4) Pull the front panel slightly forward and pull the ers. rear panel slightly backward. The interlocking hooks of the side case covers can now be dis- engaged from the front and rear panels.

  • Page 47: E01 "Over-Temperature At The Primary Side

    TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING 11.2.1 E01 "Over-Temperature at 6) Remove protection cover sheet by removing the plastic tabs. the primary side" Cause Occurs when an over-temperature condition of the primary IGBT is detected. Verification/Remedy a) Unit may be in thermal shutdown mode.

  • Page 48: E02 "Over-Temperature At The Secondary Side

    SERVICE MANUAL TRANSARC 300 Si ADVANCED TROUBLESHOOTING 11.2.2 E02 "Over-Temperature at 11.2.3 E03 "Transformer the secondary side" Over-Current Failure" Cause Cause Occurs when an over-temperature condition of the Occurs when excessive current is detected flow- secondary IGBT and diode are detected.

  • Page 49: E04 "Torch Cable Failure

    TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING 11.2.4 E04 "Torch Cable Failure" 11.2.6 E12 "Main Supply Under Volt- age" Cause Cause The combined length of the torch cable and the work cable is too long. Main supply voltage occurs at about 150V or less.

  • Page 50: E82 "Rated Voltage Selection Circuit Abnormality

    SERVICE MANUAL TRANSARC 300 Si ADVANCED TROUBLESHOOTING 11.2.8 E82 "Rated Voltage Selection c) Verify PCB4 (WK-4819) and replace it if neces- sary. Circuit abnormality" Check whether there are any abnormalities on the appearance of PCB4. Cause Replace PCB4. Refer to section 12.3.4.

  • Page 51: E94 "Thermistor Malfunction

    TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING 11.03 11.2.11 E94 "Thermistor malfunction" Verification and Remedy to Failures without Indication Cause Codes Thermistors for detecting temperature of internal components have malfunctioned. Verification/Remedy 11.3.1 "Cooling Fan (FAN1) Failure" a) Confirm a secure connection of the harness (Fan is not rotating.)

  • Page 52: No Weld Output

    SERVICE MANUAL TRANSARC 300 Si ADVANCED TROUBLESHOOTING 11.3.3 "No Weld Output" When in High Frequency TIG (HF TIG) mode, if the High Frequency is not generated (present), refer to "High Frequency Output Failure". Refer to page 11-9. Cause Occurs when the remote connector (CON1) or associated circuitry is defective, damaged, or the TIG torch cable is defective.

  • Page 53: Operating Panel Failure

    TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING c) Verify the no-load voltage (OCV). b) Verify the connection between PCB6 (Applies to STICK, High Frequency TIG (HF (WK-5549) and PCB12 (WK-5527). TIG) mode.) c) Replace PCB6 (WK-5549) and PCB12 Refer to the section "Verification of No-load (WK-5527).

  • Page 54: Fault Isolation Tests

    SERVICE MANUAL TRANSARC 300 Si ADVANCED TROUBLESHOOTING 11.04 Fault Isolation Tests b) Verify the connection between High Frequency (HF UNIT1) and the current limiting resistor (R2). 11.4.1 Preparation Verify the connection between HF UNIT1 and The following initial conditions must be met...

  • Page 55: Verification Of The Power Input Circuitry

    TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING 11.05 3) Verify input voltage after the input switch (S1) Verification of the Power using an AC voltmeter. (The capability of the Input Circuitry voltmeter should be more than 600VAC.) ? Using an AC voltmeter, measure between the points U2 and V2 on the input switch, S1.

  • Page 56: Verification Of The Power Supply Voltage

    SERVICE MANUAL TRANSARC 300 Si ADVANCED TROUBLESHOOTING 2) On the PCB3 (WK-5548) and PCB6 (WK- 6) Verify bus voltage (the voltage of the electrolytic capacitor after rectification) using a 5549), measure the voltages according to the DC Voltmeter. The capacity of the DVM should following table.

  • Page 57: Verification Of The Cooling Fan, Fan1, Drive Circuitry

    TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING 3) If any of these voltages are not present or 2) Using the measurement taken above, follow are below a 10% tolerance, replace the the chart below for possible failure modes. PCB3 (WK-5548). Refer to section 12.3.3.

  • Page 58: Verification Of The Gas Valve, Sol1, Drive Circuitry

    SERVICE MANUAL TRANSARC 300 Si ADVANCED TROUBLESHOOTING 11.5.4 Verification of the Gas Valve, 11.5.5 Verification of the primary SOL1, Drive Circuitry Diode (D1) CAUTION CAUTION Before performing any portion of the procedure Before performing any portion of the procedure below, make certain the unit is placed in the initial...

  • Page 59: Verification Of The Secondary Diode (D2-D7)

    TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING 11.5.6 Verification of the secondary 1) Check whether there are any abnormalities on the appearance of PCB8-PCB11. Diode (D2-D7) 2) Verify the characteristic of the primary IGBT CAUTION (Q1-Q24), using a diode tester.
  • Page 60 MAINTENANCE 12.01 Maintenance List DWG No. Parts name Reference page Part No. 12- 8 W7001678 PCB2 Print Circuit Board (WK-5597) 12- 9 PCB3 Print Circuit Board (WK-5548) W7001314 12- 11 10-6635 PCB4 Print Circuit Board (WK-4819) 12- 11 PCB5 Print Circuit Board (WK-5551) W7001417 12- 9 PCB7...
  • Page 61 TRANSARC 300 Si SERVICE MANUAL MAINTENANCE DWG No. Parts name Reference page Part No. Print Circuit Board (WK-5493) PCB1 12-6 W7001312 Print Circuit Board (WK-5549) W7001733 PCB6 12-11 Print Circuit Board (WK-5479) PCB8 (Q1-Q6) 12-12 W7001318 (Primary IGBT) Print Circuit Board (WK-5479)
  • Page 62 SERVICE MANUAL TRANSARC 300 Si MAINTENANCE DWG No. Parts name Reference page Part No. CON1 Remote Socket 12- 29 W7001666 Primary Diode 12- 31 10-6628 Secondary Diode 12- 32 10-6629 10-6629 Secondary Diode 12- 32 Secondary Diode 12- 32 10-6629...
  • Page 63 TRANSARC 300 Si SERVICE MANUAL MAINTENANCE DWG No. Parts name Reference page Part No. Coupling Coil 12- 23 300 Pi/ 300 ACDC only Current Trans 12- 33 W7001304 Current Trans 12- 33 W7001304 FAN1 Cooling Fan 12- 25 W7001307 FCH1...

  • Page 64: Verification Of The Secondary Igbt (Q25-Q26)

    SERVICE MANUAL TRANSARC 300 Si ADVANCED TROUBLESHOOTING 11.5.8 Verification of the secondary 11.5.9 Verification of No-load Volt- IGBT (Q25-Q26) age (OCV) CAUTION CAUTION Before performing any portion of the procedure Before performing any portion of the procedure below, make certain the unit is placed in the initial...
  • Page 65 TRANSARC 300 Si SERVICE MANUAL ADVANCED TROUBLESHOOTING b. Verify the no-load voltage (OCV) in High Fre- quency TIG mode. WARNING This welding mode produces high frequency and high voltage. Extra care shall be taken to prevent electric shock. 1) When in HF TIG mode, the unit will gener- ate high voltage.

  • Page 66: Maintenance

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.02 Service Tools 12.2.1 Tools and parts The tools and parts to be used for maintenance are shown by icons. Long Nose Philips Head Silicon Spanner C-Ring Pliers Snap Band Pliers Screwdriver Compound 12.2.2 Notes of disassembly and assembly...

  • Page 67: Replacement Procedure

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 12.03 Replacement Procedure 12.3.1 PCB1 (WK-5493) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB2 (WK-5597). [Reference page : 12-8] 3) Remove the Primary Diode (D1). [Reference page : 12-31] 4) Remove the Current Trans (CT2/CT3).

  • Page 68: Pcb2 (Wk-5597)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 8) Remove the 18 screws and remove the PCB1 (WK-5493). 12.3.2 PCB2 (WK-5597) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the screw and then disconnect the four ground terminals. Disconnect the 19 connectors.

  • Page 69: Pcb3 (Wk-5548), Pcb7 (Wk-5550)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 4) Remove the six screws, three terminals and three connectors. 5) Remove the two PCB supporters and then the PCB2 (WK-5597) and insulation sheet. 12.3.3 PCB3 (WK-5548), PCB7 (WK-5550) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB4 (WK-4819).
  • Page 70 SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 6) Remove the screw and then the four ground terminals. Remove the four screws and then remove the PCB3 and PCB7 unit. Disconnect the three connectors from the PCB7 (WK-5550). CN14 CN15 CN13 7) Disconnect the one connector and remove the two screws, and then remove the PCB7 (WK-5550) from the PCB3 (WK-5548).

  • Page 71: Pcb4 (Wk-4819)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 12.3.4 PCB4 (WK-4819) 1) Remove the Side Panel. [Reference page : 11-1] 2) Disconnect the two connectors. Remove the two screws and three connectors and remove the PCB4 (WK-4819) from the PCB3 (WK-5548). 12.3.5 PCB5 (WK-5551) 1) Remove the Side Panel.

  • Page 72: Pcb8, Pcb9 (Wk-5479) And Q1-Q12 "Primary Igbt

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549) from the PCB5 (WK-5551) and PCB7 (WK-5550). CN27 CN18 CN32 CN30 CN31 12.3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the eight screws and four device clips.

  • Page 73: Pcb10, Pcb11 (Wk-5479) And Q13-Q24 "Primary Igbt

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 12.3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the eight screws and four device clips. Remove the four connectors and six screws. Remove the PCB10 (WK-5479) and PCB11 (WK-5479).

  • Page 74: Pcb13 (Wk-5528)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.3.10 PCB13 (WK-5528) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the Protection Cover. 3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob. 4) Disconnect the one connector from the PCB12 (WK-5527).

  • Page 75: Pcb14 (Wk-5594)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 5) Remove the one connector and two screws. Remove the PCB13 (WK-5528) and Encoder Cover. 12.3.11 PCB14 (WK-5594) <T1 “Main Transformer”> 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the Coupling Coil (CC1). [Reference page : 12-23] 3) Remove the PCB20 (WK-5499).

  • Page 76: Pcb15 (Wk-5606)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 7) Remove the four screws from the PCB1 (WK-5477). Remove the seven terminals. The cables is drawn out. 8) Remove the four screws and then two cables from bottom. Remove the two screws and then drags out the PCB14 (WK-5594) and D Bus Bar1, D Bus Bar2, D Bus Bar3, D Bus Bar4 and Dust Cover Sheet (Rear).

  • Page 77: Pcb20 (Wk-5499)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 12.3.13 PCB20 (WK-5499) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove one screw and one terminal. Remove one bolt, toothed washer, washer and terminal. Remove one screw, nut and the Output Bus Bar. Disconnect one connector from HCT1.
  • Page 78 SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 3) Remove the four screws and then open the Rear Board. 4) Disconnect the one connector. Remove the two screws and one ground terminal. Remove the PCB21 (WK-4917). 5) Remove the three screws and the S1 Bus Bar from the PCB21 (WK-4917).

  • Page 79: Pcb22 (Wk-5022)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 12.3.15 PCB22 (WK-5022) 1) Remove the Side Panel. [Reference page : 11-1] 2) Disconnect one connector. Remove the four screws and one terminal. Remove the PCB22 (WK-5022). 3) Remove three board supports. 12.3.16 Current Limiting Resistor (R6) 1) Remove the Side Panel.

  • Page 80: Resistor (R7, R8)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.3.17 Resistor (R7, R8) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove four screws and three terminals. 3) Cut off one snap band and disconnect one connector. Remove the one screw.
  • Page 81 TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 5) Remove four screws and open the Rear Panel. 6) Remove four screws and six terminals. Remove the Resistors (R7 and R8). 12 – 20...

  • Page 82: Reactor (Fch1)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.3.18 Reactor (FCH1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the Nylon Hose. Remove the two bolts, and one terminal. Remove the four screws and open the Front Panel. 3) Remove one screw, one nut and two terminals. Remove one screw, one nut and one terminal.

  • Page 83: Primary Thermistor (Th1)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 12.3.19 Primary Thermistor (TH1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Disconnect the one connector CN8 on the PCB6. Remove the one screw and then detach the Primary Thermistor (TH1). Before installing a new therminstor, apply a uniform coat of silicone compound (Shinetsu Silicone G- 747 or equivalent) on the base.

  • Page 84: Secondary Thermistor (Th2)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.3.20 Secondary Thermistor (TH2) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB16 (WK-5569). [Reference page : 12-16] 3) Cut the three snap bands and disconnect the one connector CN9 on the PCB6. Remove the one screw and Secondary Thermister (TH2).
  • Page 85 TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 3) Cut the one snap band and disconnect the one connector CN11 on the PCB3. CN11 4) Remove the two screws and detach the Cooling Fan (FAN1). Do not have the wrong direction of the fan when reinstalling.

  • Page 86: Main On/Off Switch (S1)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.3.22 Main ON/OFF Switch (S1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the six screws and six terminals. 3) Remove the two screws and detach the Main ON/OFF Switch (S1). Remove the three posts.

  • Page 87: Input Voltage Switch (S2)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 12.3.23 Input Voltage Switch (S2) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the six screws and six terminals. 3) Remove the four screws, and open the Rear Board. 4) Disconnect the one connector CN4 on the PCB4.

  • Page 88: Remote Socket (Con1)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.3.24 Remote Socket (CON1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the Ring Core (L105). [Reference page : 12-36] 3) Disconnect the three connectors CNB-15 on the PCB7. Remove the one screw and one ground terminals.

  • Page 89: Hall Current Sensor (Hct1)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 12.3.25 Hall Current Sensor (HCT1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove one screw and one terminal. Remove one bolt. toothed washer, washer and terminal. Remove one screw. nut and the Output Bus Bar. Disconnect one connector from HCT1.

  • Page 90: Primary Diode (D1)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.3.26 Primary Diode (D1) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB3 (WK-5548). [Reference page : 12-9] 3) Remove four screws and three terminals. 4) Cut off one snap band and disconnect one connector. Remove the one screw.

  • Page 91: Secondary Diode (D2, D4, D5 And D7)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 6) Remove the six screws and 14 terminals. Remove the two screws and then detach the Primary Diode (D1). Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.

  • Page 92: Current Trans (Ct2, Ct3)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 12.3.28 Current Trans (CT2, CT3) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove four screws and three terminals. 3) Cut off one snap band and disconnect one connector. Remove the one screw.

  • Page 93: Ring Core (L1)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 5) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel. 6) Cut the three snap bands and remove the connector from the PCB3 (WK-5548). Remove two screws and three terminals from the PCB1 (WK-5493).
  • Page 94 SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 3) Cut off one snap band and disconnect one connector. Remove the one screw. 4) Remove two screws and remove the PCB22 unit. 5) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.

  • Page 95: Ring Core (L105)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 6) Remove the two screws and three terminals. Cut the snap band and remove the Ring Core (L1). 12.3.30 Ring Core (L105) 1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the Protection Cover.

  • Page 96: Reactor (L101)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 4) Cut the snap band remove the Ring Core (L105). 12.3.31 Reactor (L101) 1) Remove the Side Panel. [Reference page: 9-1] 2) Remove four screws and three terminals. 3) Remove four screws and open the rear panel. Remove one nut, one washer and one terminal. Remove the Reactor (L101).

  • Page 97: Reactor (L102)

    TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 4) Remove harness from the Reactor (L101). The harness is rolled three times at the installation. 12.3.32 Reactor (L102) 1) Remove the Side Panel. [Reference page: 9-1] 2) Remove four screws and three terminals.

  • Page 98: Reactor (L103)

    SERVICE MANUAL TRANSARC 300 Si MAINTENANCE 4) Remove two screws and remove the PCB22 unit. 5) Remove six screws, nine terminals and remove the Reactor (L102). 12.3.33 Reactor (L103) 1) Remove the Side Panel. [Reference page: 9-1] 2) Remove one screw and two terminals.
  • Page 99 TRANSARC 300 Si SERVICE MANUAL MAINTENANCE 3) Remove four screws and open the rear panel. Remove one nut, one washer and one terminal. 4) Cut off one snap band. Remove the Reactor (L103). 12 – 38...
  • Page 100 SERVICE MANUAL TRANSARC 300 Si THIS PAGE LEFT INTENTIONALLY BLANK...
  • Page 101 SERVICE MANUAL TRANSARC 300 Si APPENDIX 1: TRANSARC 300 Si ACCESSORIES Description Part No. Details 17 Series air cooled TIG torch 518710402 TIG torch with 4 metre cable & remote (suitable for TransTig 200Pi) current control 26 Series air cooled TIG torch 538720401 TIG torch with 4 metre cable & remote...
  • Page 102 TRANSARC 300 Si SERVICE MANUAL APPENDIX B: TRANSARC 300 Si INTERCONNECT DIAGRAM TB13 TB10 TB14 TB11 TB15 TB12 PCB1 K(7) Main PCB8 PCB10 Circuit Board G(6) IGBT Gate IGBT Gate [WK-5493] Circuit Board Circuit Board R(3) [WK-5479] [WK-5479] Line1 S(4) Line2 Line3 T(5) Ground PCB21 PCB2...
  • Page 103 SERVICE MANUAL TRANSARC 300 Si PCB15 DIODE Snubber Circuit Board [WK-5606] PCB14 TRANS Board 1 2 3 [WK-5594] TB35 +Output Terminal HCT1 TB33 TB21 TB34 TB30 TB16 TB16 1 2 3 4 5 Ground TB32 RY+15V PCB20 /RY_ON Filter Circuit Board...

  • Page 104: Appendix 3 Parts List

    To determine the part number, description, quantity, or application of an item, simply locate the item in question from the illustration and refer to that item num- ber in the corresponding Parts List. PART NUMBERS: Transarc 300 Si 625781 DWG No.

  • Page 105: Parts List

    SERVICE MANUAL TRANSARC 300 Si PARTS LIST DWG No. Part No. Description Type & Rating QTY. W7001472 Panel, Front, gen 3.1, IPS E0D004801 W7001329 Panel, Rear, gen 3.1, IPS E0D004901 E0D005207 W7001330 Label, Side, gen 3.1, IPS E0C346000 W7001331 Case, Front, gen 3.1, IPS...
  • Page 106 TRANSARC 300 Si SERVICE MANUAL PARTS LIST A-339...
  • Page 107 SERVICE MANUAL TRANSARC 300 Si PARTS LIST 3 77...

  • Page 108: Appendix 4 Connection Wiring Guide

    TRANSARC 300 Si SERVICE MANUAL APPENDIX 4 CONNECTION WIRING GUIDE CONNECTION WIRING GUIDE APPENDIX 2 Connection Wiring Guide Destination PCB2 PCB4 PCB2 PCB3 PCB2 PCB3 PCB3 PCB21 PCB3 FAN1 PCB3 CN11 SOL1 PCB3 CN20 PCB8 PCB3 CN21 PCB8 PCB3 CN22...
  • Page 109 SERVICE MANUAL TRANSARC 300 Si CONNECTION WIRING GUIDE CN17 CN21 PCB6 CN20 PCB21 PCB13 PCB12 PCB4 CN22 CN23 PCB10 CN33 CN11 PCB11 FAN1 PCB3 PCB7 CN13 CN18 CN15 CN20 CN14 SOL1 PCB2 CN21 CON1 CN20 HCT1 PCB9 PCB20 PCB8...

  • Page 110: Appendix 5 Diode Testing Basics

    TRANSARC 300 Si SERVICE MANUAL APPENDIX 5 DIODE TESTING BASICS DIODE TESTING BASIC APPENDIX 4 DIODE Testing Basic Testing of diode modules requires a digital Volt/ Ohmmeter that has a diode test scale. 1. Locate the diode module to be tested.
  • Page 111 CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedes of the Purchaser set forth heren are exclusve and the lablty of CIGWELD wth respect to any contract, or anythng done n connecton therewth such as the performance or breach thereof, or from the manufacture, sale, delvery, resale, or use...
  • Page 112 CIGWELD. 4. CIGWELD declares that, to the extent permtted by law, t hereby lmts ts lablty n respect of the supply of goods whch are not of a knd ordnarly acqured for personal, domestc or household use or consumpton to any one or more of the followng (the choce of whch shall be at the opton of CIGWELD).
  • Page 113 Accredted Dstrbutor of the equpment. Notwthstandng the foregong, n no event shall the warranty perod extend more than the tme stated plus one year from the date CIGWELD delvered the product to the Accredted Dstrbutor. Unless otherwse stated the warranty perod ncludes parts and labour. CIGWELD reserves the rght to request documented evdence of date of purchase.
  • Page 115 Chang Ning District Australia, 3072 Shanghai, PR, 200052 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510 Telephone: 86-21-69171135 Fax: 86-21-69171139 Email: cigweldsales@cigweld.com.au Thermadyne Asia Sdn Bhd Thermadyne USA Lot 151, Jalan Industri 3/5A 2800 Airport Road Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA...
  • Page 116 Corporate Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7488 Email: cigweldsales@cigweld.com.au www.cigweld.com.au...

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