Thermal Arc ARCMASTER 200 TS Service Manual
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Thermal Arc ARCMASTER 200 TS Service Manual

Inverter arc welder
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200 TS
®
ARCMASTER
INVERTER ARC WELDER
Art # A-06912

Service Manual

Revision No: AB
Issue Date: May 7, 2008
Manual No.: 0-4941B
Operating Features:

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Summary of Contents for Thermal Arc ARCMASTER 200 TS

  • Page 1: Service Manual

    200 TS ® ARCMASTER INVERTER ARC WELDER Art # A-06912 Service Manual Revision No: AB Issue Date: May 7, 2008 Manual No.: 0-4941B Operating Features:...
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. ArcMaster 200 TS CE Inverter Arc Welder Service Manual Number 0-4941B for: Part Number 10-3085 Published by: Thermadyne Industries, Inc.

  • Page 4: Table Of Contents

    CONTENTS 1 SAFETY INSTRUCTIONS AND WARNINGS 1 Arc Welding Hazards................1–1 2 PRINCIPAL SAFETY STANDARDS .
  • Page 5 9 VOLTAGE REDUCTION DEVICE (VRD) 1 VRD Specification ................9–1 2 VRD Maintenance .
  • Page 6 CONTENTS APPENDIX 1 PARTS LIST 1 Equipment Identification ............... . . 13–1 2 How To Use This Parts List .

  • Page 7: Safety Instructions And Warnings

    ARCMASTER 200 TS 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.
  • Page 8 ARCMASTER 200 TS 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. WELDING can cause fire or explosion.
  • Page 9 ARCMASTER 200 TS 2. If used in a closed area, vent engine exhaust outside and away from any building air intakes. WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

  • Page 10: Principal Safety Standards

    ARCMASTER 200 TS 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S.

  • Page 11: Precautions De Securite En Soundage A L'arc

    ARCMASTER 200 TS 1.03 Precautions de Securite en Soudage à l’Arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS.
  • Page 12 ARCMASTER 200 TS AVERTISSEMENT AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX POUR LA SANTE. ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. Le soudage dégage des vapeurs et des fumées L’arc de soudage produit une chaleur et des rayons dangereuses à...
  • Page 13 ARCMASTER 200 TS 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.

  • Page 14: Principales Normes De Securite

    ARCMASTER 200 TS Les accumulateurs contiennent de l’électrolyte acide et 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. dégagent des vapeurs explosives. 2. Si vous utilisez ces équipements dans un endroit confiné, les 1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

  • Page 15: Declaration Of Conformity

    ARCMASTER 200 TS 1.06 Declaration Of Conformity Manufacturer: Thermadyne Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
  • Page 16 ARCMASTER 200 TS 1-10 May 22, 2006...

  • Page 17: Introduction

    Electronic copies of this manual can also be down- loaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link: http://www.thermalarc.com Equipment Identification The unit’s identification number (specification or...

  • Page 18: Symbol Chart

    200TS INTRODUCTION Symbol Chart Note that only some of these symbols will appear on your model. STICK Amperage (Shielded Metal Arc SMAW) Pulse Current Function Voltage Spot Time (GTAW) Hertz (frequency) Remote Control Seconds (Panel/Remote) Remote Function Percent Arc Control (SMAW) DC (Direct Current) Gas Post-Flow AC (Alternating Current)

  • Page 19: Description

    200TS INTRODUCTION Description The Thermal Arc Model 200TS is a self contained single-phase DC arc welding power sources with Con- stant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas con- trol valve, built in Sloper and Pulser, lift arc starter, and high-frequency arc starter for use with Gas Tungsten Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed (GTAW-P) Gas Tungsten Arc Welding-Sloped (GTAW-S), and Shielded Metal Arc Welding (SMAW) processes.

  • Page 20: Functional Block Diagrams

    200TS INTRODUCTION Functional Block Diagrams Figure 2-2 illustrates the functional block diagram of the 200TS-power supply. Input Hall Current Main Input IGBT Main Output Capacitor Circuit Diode Inverter Transformer Transformers Diodes Power Switch (HCT1) Filter DC Power (T1) Thermal Primary Detector Voltage Output...

  • Page 21: Installation

    WARNING Thermal Arc advises that this equipment be electri- Do not connect an input (BROWN or BLUE) con- cally connected by a qualified electrician. ductor to the ground terminal.

  • Page 22: Input Power

    (Based on Article 630, National Electrical a generator as an input power source. Contact an Code). accredited Thermal Arc service agent for the proper sizing and set-up recommendations of a generator power source system. As a general rule, Ground...

  • Page 23: High Frequency Interference

    200TS INSTALLATION High Frequency Interfer- Duty Cycle ence The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can Interference may be transmitted by a high fre- be operated at a given output without causing over- quency initiated or stabilized arc welding machine heating and damage to the unit.

  • Page 24: Specifications

    No Load Phase @Rated Load 230V Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifica- tions or design of this or any product without prior notice. Such updates or changes do not entitle the...

  • Page 25: Operator Control

    OPERATOR CONTROL 1. Control Knob: ARC MASTER 160TS This control sets the selected weld parameter, Controls rotating it clockwise increases the parameter that is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage. 2. Remote Control Socket: The 8 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source.

  • Page 26: Weld Process Selection For 200Ts

    200TS OPERATOR CONTROL Weld Process selection for 3. Positive Terminal: Welding current flows from the Power Source 200TS via heavy duty Dinse type terminal (25 mm) It is essential, however, that the male plug is inserted and turned securely to achieve a Weld Mode sound electrical connection.

  • Page 27: Weld Parameter Descriptions For Arc Master 200Ts

    200TS OPERATOR CONTROL Weld Parameter Descriptions for ARC MASTER 200TS Figure 4-3: ARC MASTER 200TS Front Panel with Parameter Description Parameter Description This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc, once the torch trigger switch has been pressed. This control is used to dramatically reduce weld porosity at the start of a weld.

  • Page 28: Weld Parameters For Arc Master 200Ts

    200TS OPERATOR CONTROL Parameter Description POST-FLOW This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished. This control is used to dramatically reduce oxidation of the tungsten electrode. The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into the 200TS memory.

  • Page 29: Power Source Features

    200TS OPERATOR CONTROL Power Source Features Feature Description  Almost all welding parameters are adjustable. New Digital Control  Touch switches eliminate mechanical damage. Touch Panel Switches  Protects front panel controls. Front Control Cover  Displays selected weld parameter value. ...

  • Page 30: Set-Up For Smaw (Stick) And Gtaw (Tig)

    SET-UP FOR SMAW (STICK) AND GTAW (TIG) SET-UP FOR SMAW (STICK) AND GTAW (TIG) 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 pro- vided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects.

  • Page 31: Sequence Of Operation

    SEQUENCE OF OPERATION Stick Welding NOTE SEQUENCE OF OPERATION Scroll Buttons are used to select the parameters to • Connect work lead to negative terminal. be set. The LED’s show which function is being adjusted on the weld sequence graph. Refer to the •...

  • Page 32: Slope Mode Sequence

    200TS SEQUENCE OF OPERATION Slope Mode Sequence Slope Mode with repeat sequence Switch Switch Switch Switch Closed Closed Open Open The repeat function is operated during the down Down Weld Current slope cycle of the Slope Sequence and is active Slope Slope Initial...

  • Page 33: Routine Maintenance

    ROUTINE MAINTENANCE The only routine maintenance required for the ROUTINE MAINTENANCE power supply is a thorough cleaning and inspec- tion, with the frequency depending on the usage and the operating environment. 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 34 200TS ROUTINE MAINTENANCE PAGE LEFT INTENTIONALLY BLANK 7 – 2...

  • Page 35: 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 Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques.

  • Page 36: Stick Welding Problems

    200TS BASIC TROUBLESHOOTING Description Possible Cause Remedy Inadequate shielding gas. Increase gas flow or check gas line for gas 9 Poor weld finish. flow problems. 10 Arc flutters during TIG A Tungsten electrode is too large for the A Select the right size electrode. Refer to welding.
  • Page 37 200TS BASIC TROUBLESHOOTING Description Possible Cause Remedy 4 Portions of the weld run A Small electrodes used on heavy cold A Use larger electrodes and pre-heat the do not fuse to the plate. plate. surface of the metal or B Welding current is too low. B Increase welding current.

  • Page 38: Power Source Problems

    A Switch ON the Primary supply voltage. be established. switched ON. B Switch ON the Welding Power Source. B The Welding Power Source switch is C Have an Accredited Thermal Arc Service switched OFF. Agent repair the connection. C Loose connections internally. Defective control circuit.

  • Page 39: Voltage Reduction Device (Vrd)

    In addition to the above tests and specifically in relation to the VRD fitted to this machine, the fol- lowing periodic tests should also be conducted by an accredited Thermal Arc service agent. Description IEC 60974-1 Requirements VRD Open Circuit Voltage Less than 20V; at Vin=230V...

  • Page 40: Switching Vrd On/Off

    200TS VOLTAGE REDUCTION DEVICE (VRD) Switching VRD On/Off C) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see Figure 9-3). Switch the machine Off. A) Remove the clear plastic cover from the control CAUTION panel (see Figure 9-1).

  • Page 41: Power Source Error Code

    Fan operates at max B Fan ceases to operate. B Have an Accredited about 1 second. speed.E01 resets when Thermal Arc Service Agent TH1 decreases to 70°C investigate. for about 30 seconds. C Air flow is restricted by C Unblock vents then let vents being blocked.
  • Page 42 200TS POWER SOURCE ERROR CODE PAGE LEFT INTENTIONALLY BLANK 10 – 2...

  • Page 43: Advanced Troubleshooting

    The faulty subassembly should then be returned to The capacitors inside the power supply will slowly Thermal Arc through established procedures. discharged after you turn off the switch of the power supply or the switch at the breaker box (dis- tribution panel).
  • Page 44 200TS ADVANCED TROUBLESHOOTING 3) Loosen the screws on the front panel and the 5) Remove the side panels. rear panel by turning them approximately two turns CCW. NOTE DO NOT remove the screws completely. Figure 11-5: Remove Side Panel 6) Remove protection cover sheet by removing the plastic tabs.

  • Page 45: Verification And Remedy To The Indicated Error Codes

    200TS ADVANCED TROUBLESHOOTING Verification and Remedy to c) Verify the operation of the cooling fan, FAN1, and replace it if necessary. the Indicated Error Codes  Verify the condition of FAN1. Verify that there are no broken or cracked fan blades and that NOTE FAN1 is not producing any abnormal sounds.

  • Page 46: E03 "Primary Over-Current Failure

    200TS ADVANCED TROUBLESHOOTING 2.4 E94 “Thermistor malfunction” c) Verify the operation of the cooling fan, FAN1, and replace it if necessary. Cause  Verify the condition of FAN1. Verify that there are no broken or cracked fan blades and that Thermistors for detecting temperature of internal FAN1 is not producing any abnormal sounds.

  • Page 47: Verification And Remedy To Failures Without Indication Codes

    200TS ADVANCED TROUBLESHOOTING Verification and Remedy to 3.2 “Gas Valve Failure” (No Gas flow through unit) Failures without Indication Codes Cause Occurs when the gas valve (SOL1) is defective, Refer to Note on Section 11.02. damaged or the driving voltage is incorrect. 3.1 “Cooling Fan (FAN1) Failure”...

  • Page 48: No Weld Output

    200TS ADVANCED TROUBLESHOOTING 3.3 “No weld output”  Refer to the section “Verification of No-load voltage (No OCV)” in the page 11-13. When in High Frequency TIG (HF TIG) mode, if the  If performing the “No-Load Voltage Failure” High Frequency is not generated (present), refer to procedure does not rectify the failure, per- “High Frequency Output Failure”.

  • Page 49: High Frequency Output Failure" (Unit Does Not Generate High Frequency.)

    200TS ADVANCED TROUBLESHOOTING b) Verify the connection between PCB5 (WK-  Verify there are no short circuits, burnt or bro- 5448) and PCB4 (WK-5460). ken wires between the HF UNIT1 and the R3 (R4).  Verify that there is no omission of a loosening screws and connected harness between the c) Verify the connection between the terminals PCB4 and PCB5.

  • Page 50: Fault Isolation Tests

    200TS ADVANCED TROUBLESHOOTING Fault Isolation Tests Verification of the Power Input Circuitry 4.1 Preparation The following initial conditions must be met prior to CAUTION starting any of the procedures in this section. Before performing any portion of the procedure below, make certain the unit is placed in the initial set up condition as described in section 11.4.1 1) Connect the appropriate input voltage.

  • Page 51: Verification Of The Power Supply Voltage

    200TS ADVANCED TROUBLESHOOTING points U2 and V2 on the input switch, S1. The location of points U2 and V2 on switch S1 are indicated in Figure 11-7. 4) If this voltage is out of the operating range, which is ±10% (207~253VAC) of the rated volt- age (230V), replace S1 following the process in section 12.3-4.

  • Page 52: Verification Of The Cooling Fan, Fan1, Drive Circuitry

    200TS ADVANCED TROUBLESHOOTING 5.3 Verification of the Cooling Test Point Reference ACCEPTABLE Fan, FAN1, Drive Circuitry PCB6 PCB6 VALUE +5VDC CAUTION +12VDC –12VDC Before performing any portion of the procedure below, make certain the unit is placed in the initial Table 11-1: Checkpoints TP0-TP3 on PCB6 set up condition as described in section 11.4.1 "Preparation".

  • Page 53: Verification Of The Gas Valve, Sol1, Drive Circuitry

    200TS ADVANCED TROUBLESHOOTING Voltage FAN1 measurement. Remedy Status (1PIN-2PIN of CN2 on PCB1) PCB1(WK-5713) Replace PCB1. Refer to the page 12-5. Perform Case 3 Inactive Below DC 18V “2. Verification of the Power Supply Voltage Test”. Refer to the page 11-9.

  • Page 54: Verification Of The Secondary Diode (D2, D3)

    200TS ADVANCED TROUBLESHOOTING 2) Refer to Table 11-5 and Figure 11-14 for TERMINALS the checkpoints on D1. COMPONENT ACCEPTABLE Positive Negative TESTED VALUE lead lead TERMINALS COMPONENT ACCEPTABLE Diode 1 of D2, Anode Cathode 0.2 to 0.3V Positive Negative TESTED VALUE and D3, Cathode...

  • Page 55: Verification Of No-Load Voltage (Ocv)

    200TS ADVANCED TROUBLESHOOTING a) Verify the no-load voltage in STICK mode. TERMINALS 1) In STICK welding mode, mark and then COMPONENT ACCEPTABLE Positive Negative TESTED VALUE turn potentiometer VR1 on PCB4 (WK- lead lead 5449) all the way to the right and turn off Collector-Emitter the electric shock protector function (Volt- Open...
  • Page 56 200TS ADVANCED TROUBLESHOOTING 2) Press the Welding mode selection button to select HF TIG welding mode. 3) While depressing the Torch switch, verify the OCV using a DC voltmeter. (The capability of the voltmeter should be more than 100VDC.) The check point with a tester is the voltage between output termi- nal + and -.

  • Page 57: Maintenance

    MAINTENANCE Subsystem Test and Replacement Procedures MAINTENANCE 1.1 Preparation This section provides specific procedures for verifying the operation and replacement of each subsystem within the power supply. Before undertaking any of these procedures, eliminate the obvious first-visually inspect the suspect sub- system for physical damage, overheating, and loose connections.
  • Page 58 200TS MAINTENANCE REFERENCE DWG NO. PARTS NAME PART NO. PAGE Capacitor 12-8 10-6510 C101-C102 Capacitor 12-21 W7001622 C103 Capacitor 12-24 W7001621 Capacitor 12-25 W7001620 C.C. Coupling Coil 12-15                   W7001384 FCH1 Reactor 12-15 W7001502 HF - UNIT High Freguency Unit 12-19 W7001399 L101 Ring Core 12-21...
  • Page 59 200TS MAINTENANCE REFERENCE DWG NO. PARTS NAME PART NO. PAGE 12-22 10-6627 CON1 Remote Receptacle 12-17 10-5003 Hall Current Trans 12-5 W7001481 Primary Diode 12-15 10-6629 Secondary Diode 12-15 10-6629 Secondary Diode 12-18 10-5227 FAN1 Cooling Fan 12-21 W7001453 Switch 12-20 W7001635 SOL1...

  • Page 60: Service Tools

    200TS MAINTENANCE Service Tools 2.1 Tools and parts The tools and parts to be used for maintenance are shown by icons. Philips Head Long Nose Soldering Copper Silicon Spanner C-Ring Pliers Snap Band Compound Screwdriver (solder) Pliers 2.2 Notes of disassembly and assembly NOTE When removing the locking type connectors and board supporters, disengage the locking mechanism first and then disconnect them.

  • Page 61: Replacement Procedure

    200TS MAINTENANCE Replacement Procedure 3.1 PCB1 (WK-5713) and Primary Diode D1  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the L102. [See section “12.3-18”] 3) Remove the screw and three cables. Cut the snap band. 4) Remove the terminal and Disconnect the three connectors CN1 (PCB4), CN101, 103 (PCB1). CN103 CN101 5) Remove the terminal.
  • Page 62 200TS MAINTENANCE 6) Remove the Gas Tube. Remove the two bolts, two toothed washers, and the terminal. 7) Remove the four screws and the Front Panel. 8) Remove the Gas Tube and the two cables. 12 – 6...
  • Page 63 200TS MAINTENANCE 9) Remove the four screws and the Rear Panel. 10) Remove the four screws and the two cables. Disconnect the eight connectors CN1-8 on the PCB1. CN4 CN5 CN6 CN8 CN7 11) Remove the four screws and Remove the PCB1 unit. 12 –...

  • Page 64: Pcb2 (Wk-5417), Capacitor C1 And Resistor R1

    200TS MAINTENANCE 12) Remove the Primary Diode D1 with the soldering iron from the PCB1.  Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base. 3.2 PCB2 (WK-5417), Capacitor C1 and Resistor R1  1) Remove the Side Panel.
  • Page 65 200TS MAINTENANCE 5) Remove the eight screws and the PCB2 unit. 6) Remove the screw and Remove the Capacitor C1 and Resistor R1 from the PCB2. Remove the two edge holders and the PCB2 Insulation Sheet from PCB2. 12 – 9...

  • Page 66: Pcb3 (Wk-5609) And T1 "Transformer

    200TS MAINTENANCE 3.3 PCB3 (WK-5609) and T1 “Transformer” 1) Remove the Side Panel. [See section "11.1-1"] 2) Remove the CT1. [See section “12.3-10”] 3) Cut the snap band and Remove the cables. Disconnect the three connectors CN1-3 on the PCB3. Remove the three screws and the three cables.

  • Page 67: Pcb4 (Wk-5449)

    200TS MAINTENANCE 3.4 PCB4 (WK-5449)  1) Remove the Side Panel. [See section "11.1-1"] 2) Remove the Protection Cover. 3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob. 4) Disconnect the two connectors CN1,3 on the PCB4. Remove the four screws. Pull out the operation panel and bring it down.

  • Page 68: Pcb5 (Wk-5448)

    200TS MAINTENANCE 5) Remove the four screws. Remove the PCB4. 3.5 PCB5 (WK-5448)  1) Remove the Side Panel. [See section "11.1-1"] 2) Remove the PCB4. [See section “12.3-4”] 3) Remove the three latches of Front Control Cover and then remove the PCB5. ...

  • Page 69: Pcb6 (Wk-5460) And Q1A-Q2C "Primary Igbt

    200TS MAINTENANCE 3.6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT”  1) Remove the Side Panel. [See section "11.1-1"] 2) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder. 3) Disconnect the connector CN1 on the PCB6. Cut the lead of the Q1A-Q2C. ...

  • Page 70: Pcb7 (Wk-5460) And Q3A-Q4C "Primary Igbt

    200TS MAINTENANCE 3.7 PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder. 3) Disconnect the connector CN1 on the PCB6. Cut the lead of the Q3-Q4C. ...

  • Page 71: D2 And D3 "Secondary Diode

    200TS MAINTENANCE 3.8 D2 and D3 “Secondary Diode”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove PCB3 (WK-5569) and T1. [See section “12.3-3”] 3) Remove six screws and then detach the D2 and D3.  Do not have the wrong direction of the diodes when reinstalling. ...
  • Page 72 200TS MAINTENANCE 3) Remove the four screws and the Front Panel. 4) Remove the screw and then remove the cable. Remove the two terminals from HF. UNIT. Remove the terminal from PCB3. 5) Remove the C.C. and FCH1. 12 – 16...

  • Page 73: Ct1 "Hole Current Trans

    200TS MAINTENANCE 3.10 CT1 “Hole Current Trans”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the bolts, the spring, and the washer. Remove the three screws and then remove the Output Bus Bar. 3) Remove the CT1. Disconnect the connector. 12 –...

  • Page 74: Fan1 "Cooling Fan

    200TS MAINTENANCE 3.11 FAN1 “Cooling Fan”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the Gas Tube. Remove the two terminals and Cut the three snap bands. 3) Disconnect the connector CN2 on the PCB1 and Cut the snap band. 4) Remove the four screws and then open the Rear Panel.

  • Page 75: Hf Unit1 "High Frequency Unit

    200TS MAINTENANCE 5) Remove the FAN1.  Do not have the wrong direction of the fan when reinstalling. 3.12 HF UNIT1 “High Frequency Unit” 1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the high frequency gap. Remove the four terminals. 3) Remove the two screws and the two washers.

  • Page 76: Sol1 "Solenoid Gas Valve

    200TS MAINTENANCE 3.13 SOL1 “Solenoid GAS Valve”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the Gas Tube and two terminals. 3) Remove the C-ring and then detach the SOL1.  When reinstalling, make sure that the C-ring seats in the solenoid valve groove. 12 –...

  • Page 77: C101-C102 "Capacitor", L101 "Ring Core" And S1 "Switch

    200TS MAINTENANCE 3.14 C101-C102 “Capacitor”, L101 “Ring Core” and S1 “Switch”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the four screws and the six cables. Remove the one nut and one terminal. Remove the C101- C102. 3) Cut off the snap band.

  • Page 78: Con1 "Remote Receptacle

    200TS MAINTENANCE 3.15 CON1 “Remote Receptacle”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the screw and then three ground cables. Cut the two snap bands. 3) Cut the snap band and disconnect connector CN1 on the PCB1. 4) Open the Panel Protects.

  • Page 79: Th1 "Primary Thermistor

    200TS MAINTENANCE 3.16 TH1 “Primary Thermistor”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the snap band. Disconnect the connector CN5 on the PCB1. Remove the screw and then detach the TH1. Before installing a new Thermistor, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.

  • Page 80: C103 "Capacitor" And L102 "Reactor

    200TS MAINTENANCE 3.18 C103 “Capacitor” and L102 “Reactor”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove four screws, six terminals. Remove the C103 and L102. Note : When C103 is installed again, it is a thing fixed to former place on PCB3 by RTV silicon rubber. 3.19 L103 “Reactor”...

  • Page 81: C2 "Capacitor" And R2 "Resistor

    200TS MAINTENANCE 4) Remove four screws and open the Rear Control Cover. 5) Remove one nut, one washer and two terminals. Remove the L103. 3.20 C2 “Capacitor” and R2 “Resistor”  1) Remove the Side Panel. [See section “11.1-1”] 2) Remove the Gas Tube and the two cables. 12 –...
  • Page 82 200TS MAINTENANCE 3) Remove the four screws and open the Rear Panel. 4) Remove the CT1. [See section “12.3-10”] 5) Cut the snap band and remove the cables. Disconnect the three connectors CN1-3 on the PCB3. Remove the three screws and the three cables. Remove the terminal. 6) Remove the 11 screws and PCB3 unit.
  • Page 83 200TS MAINTENANCE 7) Remove the screw and C2 unit. 8) Remove the C2 with the soldering iron from the R2. 12 – 27...

  • Page 84: Equipment Identification

    APPENDIX 1 PARTS LIST Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Part or Assembly numbers. How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a break- down of the equipment into assemblies, subassemblies, and detail parts.
  • Page 85 200TS PARTS LIST DWG No. Part No. Description Additional Information QTY. W7001453 Switch, gen 3.1, IPS DCP-52SR50C-480V 2P-480V SOL1 W7001635 Solenoid Valve, gen 3.1, IPS 5505NBR1.5 DC24V 11VA/10W (with Gas Inlet and PC4-02) W7001501 Transformer, gen 3.1, IPS F3A013701 200A MTR TH1, TH2 10-5228 Thermistor, gen 3.1, IPS...
  • Page 86 200TS PARTS LIST...
  • Page 87 200TS PARTS LIST...

  • Page 88: Appendix 2 Connection Wiring Guide

    APPENDIX 2 CONNECTION WIRING GUIDE CONNECTION WIRING GUIDE APPENDIX 2 Connection Wiring Guide Destination Destination ↔ PCB1 CON1 FAN1 ↔ PCB1 SOL1 ↔ PCB1 PCB3 ↔ PCB1 ↔ PCB1 ↔ PCB1 ↔ PCB1 PCB6 ↔ PCB1 PCB7 ↔ PCB1 CN101 PCB4 ↔...
  • Page 89 200TS CONNECTION WIRING GUIDE CN101 FAN1 PCB4 CN103 CON1 PCB1 PCB7 PCB6 PCB3 SOL1 ACT2 ACT1 HF-UNIT...

  • Page 90: Appendix 3 Interconnect Diagram

    APPENDIX 3 INTERCONNECT DIAGRAM APPENDIX 3 Interconnect Diagram PCB2 Main Circuit Board [WK-5714] L102 PCB6 PCB7 Line1 IGBT Gate IGBT Gate L101 TB10 Circuit Circuit C101 TB11 Board Board [WK-5460] [WK-5460] Line2 Ground TB12 L103 SIDE CHASSIS 1 REAR PANEL FAN1 FRONT PANEL...
  • Page 91 200TS INTERCONNECT DIAGRAM PCB3 2nd Diode Circuit Board [WK-5609] +Output Terminal Torch/GAS FCH1 C.C. -Output Terminal HF UNIT 2 3 4 5 PCB4 Control Circuit Board [WK-5449] PCB5 Panel Circuit Board [WK-5448]...

  • Page 92: Appendix 4 Diode Testing Basics

    APPENDIX 4 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. 2. Remove cables from mounting studs on diodes to isolate them within the module.
  • Page 94 LIMITED WARRANTY AND SCHEDULE This information applies to Thermadyne products that were purchased in the United Kingdom April 2006 Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in the owner’s manual supplied with the machine. Thermadyne welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment.

  • Page 95: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION 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 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Telephone: 603+ 6092 2988 Fax: 800-535-0557...
  • Page 96 World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 Fascimile: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.com...

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