Thermal Arc PRO-WAVE 300 TSW Service Manual
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Thermal Arc PRO-WAVE 300 TSW Service Manual

Ac/dc cc inverter arc welder
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300 TSW
Service Manual
PRO-WAVE
AC/DC CC INVERTER
ARC WELDER
Version: AA
Issue Date: August 10, 2005
Operating Features:
®
Manual No.: 0-4752

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  • Page 1 300 TSW ® PRO-WAVE AC/DC CC INVERTER ARC WELDER Service Manual Version: AA Issue Date: August 10, 2005 Manual No.: 0-4752 Operating Features:...
  • Page 2 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
  • Page 3 WARNINGS 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 judgement, the Manufacturer assumes no liability for its use. Pro-Wave Inverter Welding Power Supply Instruction Manual Number 430429-511 for: Pro-Wave 300TSW Spec Number 10-3074...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............1-1 1.01 Arc Welding Hazards ..................1-1 1.02 PRINCIPAL SAFETY STANDARDS ..............1-5 1.03 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC ........1-6 1.04 Dangers relatifs au soudage à l’arc ..............1-6 1.05 PRINCIPALES NORMES DE SECURITE ............
  • Page 5 TABLE OF CONTENTS (continued) TABLE OF CONTENTS F. Pulse Controls ..................4-13 4.08 Voltage Reduction Device (VRD) ..............4-14 A. VRD Lights Operation ................4-14 B. VRD Specification ................4-14 C. VRD Maintenance ................4-15 D. Switching VRD ON/OFF ................ 4-15 4.09 Welding Parameter Setting (Factory Setting) ..........
  • Page 6 9.01 Equipment Identification ................. 9-1 9.02 How To Use This Parts List ................9-1 9.03 300 TSW Parts List ..................9-2 APPENDIX 1: GENERAL INFORMATION ..............A-1 APPENDIX 2: PRO-WAVE 300 TSW PARTS ARRANGEMENT......... A-2 APPENDIX 3: PRO-WAVE 300 TSW INTERCONNECTION DIAGRAM ........ A-4...

  • Page 7: Safety Instructions And Warnings

    PRO-WAVE 300TSW 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. Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
  • Page 8 PRO-WAVE 300TSW 11. Do not touch electrode while in contact with the work 4. Wear protective clothing made from durable, flame- (ground) circuit. resistant material (wool and leather) and foot protection. 12. Use only well-maintained equipment. Repair or replace damaged parts at once. 5.
  • Page 9 PRO-WAVE 300TSW 6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can WARNING react with vapors to form highly toxic and irritating gases. FLYING SPARKS AND HOT METAL can cause 7.
  • Page 10 PRO-WAVE 300TSW 4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery. WARNING 5. Keep hands, hair, loose clothing, and tools away from moving parts. Engines can be dangerous. 6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

  • Page 11: Principal Safety Standards

    PRO-WAVE 300TSW 1.02 PRINCIPAL SAFETY STANDARDS WARNING Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, This product, when used for welding or FL 33126. cutting, produces fumes or gases which contain chemicals know to the State of Safety and Health Standards, OSHA 29 CFR 1910, from California to cause birth defects and, in some Superintendent of Documents, U.S.

  • Page 12: Precautions De Securite En Soudage A L'arc

    PRO-WAVE 300TSW 1.03 PRECAUTIONS DE SECURITE EN SOUDAGE A 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).
  • Page 13 PRO-WAVE 300TSW 10. N’utilisez qu’une bonne prise de masse pour la mise à 1. Portez une casque de soudeur avec filtre oculaire de la terre de la pièce à souder. nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les 11.
  • Page 14 PRO-WAVE 300TSW 1. Eloignez la tête des fumées pour éviter de les respirer. 1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud. 2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont 2.
  • Page 15 PRO-WAVE 300TSW 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. AVERTISSEMENT 2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment. LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs...

  • Page 16: Principales Normes De Securite

    PRO-WAVE 300TSW 4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative. AVERTISSEMENT 5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils. VAPEUR LIQUIDE REFROIDISSEMENT BRULANT SOUS...

  • Page 17: Limited Warranty

    Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

  • Page 19: Introduction

    Thermadyne, Inc. had training in high power electronics mea- surement and troubleshooting. Thermal Arc Technical Service Department 82 Benning Street 2.02 General Service Philosophy West Lebanon, New Hampshire, USA 03784 Several key points are essential to properly support the (603) 298-5711 application and operation of this equipment.

  • Page 20: Symbol Chart

    PRO-WAVE 300TSW 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...

  • Page 21: Description

    PRO-WAVE 300TSW Note 2.05 Description Volt-Ampere curves show the maximum The Thermal Arc™ Model 300TSW is a single/three-phase Voltage and Amperage output capabilities of AC/DC arc welding power sources with Constant Current the welding power source. Curves of other (CC) output characteristics. This unit is equipped with a settings will fall between the curves shown.

  • Page 22: Functional Block Diagrams

    PRO-WAVE 300TSW 2.06 Functional Block Diagrams Art # A-05525 Figure 2-2: Functional Block Diagram 2.07 Transporting Methods These units are equipped with a handle for carrying 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 23: Section

    PRO-WAVE 300TSW 2.08 High Frequency Introduction possible will minimize this type of interference. Looping and suspending of leads should be avoided The importance of correct installation of high frequency where possible. welding equipment cannot be overemphasized. 4. Re-radiation from Unearthed Metallic Objects Interference due to high frequency initiated or stabilized A major factor contributing to interference is re- arc is almost invariably traced to improper installation.

  • Page 24: Specifications

    PRO-WAVE 300TSW 2.10 Specifications Description (See NOTE) 300TSW Power Source Part Number 700723 Plant Part Number Cooling Fan Cooled with Intelligent Operation Welder Type & Welding process Heavy Duty Inverter; AC/DC GTAW (TIG) & MMAW (Stick) Welding Power Source mass 27kg Dimensions H420mm x W210mm x D450mm...

  • Page 25: Electrical Parameters For 300Tsw

    PRO-WAVE 300TSW 2.11 Electrical Parameters For 300TSW Check Open Circuit condition, at 415V and maximum output, to be within the following limits: Set Weld Mode to Stick Output Voltage 62 ± 2V Input Current 2 ± 1 A Enable VRD Set Weld Mode to Stick and, check VRD operation parameters VRD green ON light is illuminated Green VRD light is ON Output Voltage...

  • Page 26: Duty Cycle

    PRO-WAVE 300TSW 2.12 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.

  • Page 27: Installation

    WARNING ground. Use a grounding method that complies with all applicable electrical codes. Thermal Arc advises that this equipment be 2. Connect ends of line 1 (BLACK) and line 2 (WHITE) electrically connected by a qualified electrician. and line 3 (RED) input conductors to a deenergized ine disconnect switch.
  • Page 28 PRO-WAVE 300TSW NOTE: For Single-Phase operation, connect the GREEN, BLACK and WHITE input conductors. Insolate the RED Conductor, it is not used for Single-phase operation. Input Voltage Fuse Size 208 VAC 100 Amps 230 VAC 90 Amps 460 VAC 25 Amps Table 3-1: Electrical Input Connections NOTE: Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source...

  • Page 29: Input Power

    PRO-WAVE 300TSW 3.05 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).
  • Page 30 PRO-WAVE 300TSW August 10, 2005...

  • Page 31: Operator Controls

    PRO-WAVE 300TSW SECTION 4: OPERATOR CONTROLS 4.01 Pro-Wave 300TSW Controls Art # A-05527 Figure 4-1: Pro-Wave 300TSW Power Source 1. Control Knob : This control sets the selected weld parameter, rotating it clockwise increases the parameter and is indicated on the digital meter. Pushing the knob in previews the actual welding voltage while welding. 2.
  • Page 32 PRO-WAVE 300TSW Socket Pin Function Torch Switch Input (24V) to energize weld current. (connect pins A & B to turn on welding current) Torch Switch Input (0V) to energize weld current (connect pins A & B to turn on welding current) 5k ohm (maximum) connection to 5k ohm remote control Zero ohm (minimum) connection to 5k ohm remote control Wiper arm connection to 5k ohm remote control potentiometer...

  • Page 33: Weld Process Selection For Pro-Wave 300Tsw

    PRO-WAVE 300TSW 4.02 Weld Process selection for Pro-Wave 300TSW Weld Mode Weld Process LIFT Selection STICK 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 sequence.

  • Page 34: Weld Parameter Descriptions For Pro-Wave 300Tsw

    PRO-WAVE 300TSW 4.03 Weld Parameter Descriptions for Pro-Wave 300TSW Art # A-05529 Figure 4-3: Pro-Wave 300TSW 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.
  • Page 35 PRO-WAVE 300TSW Parameter Description BASE This parameter sets the Background current when in Pulse TIG mode. (Background Current) SPOT TIME SPOT TIME HF TIG This parameter sets the duration of the mode only PULSE WIDTH This parameter sets the percentage on time of the PULSE FREQUENCY PULSE PEAK weld current when the...

  • Page 36: Weld Parameters For Pro-Wave 300Tsw

    PRO-WAVE 300TSW 4.04 Weld Parameters for Pro-Wave 300TSW Weld Mode Weld LIFT Parameter Factory Incremental Parameter Range Setting Unit STICK PRE-FLOW 0.0 to 1.0 sec 0.1 sec 0.1 sec HOT START 0 to 70A INITIAL CUR. 5 to 300A UP SLOPE 0 to 15 sec 1 sec 0.1 sec...

  • Page 37: Power Source Features

    PRO-WAVE 300TSW 4.05 Power Source Features Feature Description New Digital Control · Almost all welding parameters are adjustable. Touch Panel Switches · Touch switches eliminate mechanical damage. Front Control Cover · Protects front panel controls. · Digital Meter Displays selected weld parameter value. ·...
  • Page 38 PRO-WAVE 300TSW Feature Description · A total number of 5 programs can be saved into the Save/Load function   300TSW memory. SAVE the Current Weld Parameters into Memory · SAVE Press the button · Select a memory location by rotating the control knob, 1  ...

  • Page 39: Set-Up For Smaw (Stick) And Gtaw (Tig)

    PRO-WAVE 300TSW 4.06 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 provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects.

  • Page 40: Sequence Of Operation

    PRO-WAVE 300TSW 4.07 Sequence of Operation Art # A-05531 NOTE Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions.

  • Page 41: Stick Welding

    PRO-WAVE 300TSW · Set PEAK CURRENT A. Stick Welding · Set PULSE FREQ · Connect work lead to negative terminal Commence welding · Connect electrode lead to positive terminal C. Save-Load Operation · Switch machine on A total number of 5 programs can be saved into the ·...

  • Page 42: Slope Mode Sequence

    PRO-WAVE 300TSW D. Slope Mode Sequence Switch Switch Switch Switch Closed Open Closed Open Weld Current Down Slope Slope I nitial Final Current Current Pr ef low Postflow Art # A-05533 Figure 4-6: Slope Mode Sequence NOTE Slope function operates with a Remote ON/OFF device only. 1) To start Slope sequence Close remote switch contacts.

  • Page 43: Pulse Controls

    PRO-WAVE 300TSW F. Pulse Controls (Pulse Frequency) (Pulse Width) (Peak Current) (Base) Background Current Art # A-05534 Figure 4-7: Pulse Controls The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows: 1) Control puddle – size and fluidity (especially out of position). 2) Increase penetration 3) Travel speed control 4) Better consistent quality...

  • Page 44: Voltage Reduction Device (Vrd)

    The time taken to turn VRD TURN ON PROCEDURE Time seconds OFF the welding power once the Thermal Arc recommends that an welding current has AccreditedThermal Arc Service Provider stopped TURNS ON the VOLTAGE REDUCTION DEVICE (VRD) as they have the knowledge and...

  • Page 45: Vrd Maintenance

    PRO-WAVE 300TSW C. VRD Maintenance Refer to section 9 Routine Inspection,Testing & Maintenance. D. Switching VRD ON/OFF 1. Remove the controls clear cover · Lift up the cover so it rests on the top of the unit. · Place a small flat bladed screw driver between the cover hinge and the front panel.

  • Page 46: Welding Parameter Setting (Factory Setting)

    PRO-WAVE 300TSW 4.09 Welding Parameter Setting (Factory Setting) CAUTION When replacing PCB5 (WK-4919) the Welding Parameter Factory Setting must be set. A C /DC V R D PUL SE PUL SE PE AK PUL SE CUR . W IDT H R efer to Manual for correct use DOW N...

  • Page 47: Maintenance

    · Flexible cord is of the multi-core tough rubber or an Accredited Thermal Arc Service Provider. plastic sheathed type of adequate rating, correctly Disconnect the Welding Power Source from connected and in good condition.

  • Page 48: 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 Provider and you have had training in power measurements and troubleshooting techniques.
  • Page 49 PRO-WAVE 300TSW Description Possible Cause Remedy Electrode melts A. Electrode is connected to A. Connect the electrode to the '-' when arc is struck. the '+' terminal. terminal. Wave Balance is greater B. Reduced Wave Balance to below than 50%. 50% or increase the electrode size.

  • Page 50: Stick Welding Problems

    PRO-WAVE 300TSW Description Possible Cause Remedy Welding arc can not C. Gas flow incorrectly set, C. Select the right flow rate, change be established. cylinder empty or the torch cylinders or turn torch valve on. (cont) valve is off. 12. Arc start is not A.
  • Page 51 PRO-WAVE 300TSW Description Possible Cause Remedy 4. Portions of the weld A. Small electrodes used on A. Use larger electrodes and bead do not fuse to heavy cold plate. preheat the plate. B. Welding current is too low. B. Increase the welding current. C.

  • Page 52: Power Source Problems

    B. The Welding Power Source B. Switch ON the Welding Power switch is switched OFF. Source C. Loose connections C. Have an Accredited Thermal Arc internally. Service Agent inspect then repair the welder. 2. Maximum output Defective control circuit.
  • Page 53 B. Gas valve is faulty. B. Have an Accredited Thermal Arc Service Agent inspect then repair the welder. C. Gas valve jammed open. C. Have an Accredited Thermal Arc Service Agent replace gas valve.

  • Page 54: Error Code Details

    PRO-WAVE 300TSW 6.04 Error Code Details Description Possible Cause Remedy Remarks A. The Welding A. Let Power Source cool E01 error code displayed Weld current ceases. Power Source’s down then keep within its Temperature sensor TH1 Buzzer sounds duty cycle has duty cycle.
  • Page 55 B. Mains supply B. Have an Accredited to reset E03 error. voltage is more Thermal Arc Service Agent than 10% below or a qualified electrician nominal voltage. check for low Mains voltage.
  • Page 56 E11 error code displayed Primary supply Have an Accredited Weld current ceases. Over Primary supply (input) voltage is greater Thermal Arc Service Agent Buzzer sounds voltage at primary than the nominal or a qualified electrician constantly. Error capacitors is exceeded for...
  • Page 57 PRO-WAVE 300TSW Description Possible Cause Remedy Remarks E14 error code displayed A. DC Voltage is A. Check that mains voltage Weld current Under mains supply (input) less than 423 is greater than 300 VAC. available. Buzzer voltage warning primary VDC between sounds intermittently.
  • Page 58 PRO-WAVE 300TSW Description Possible Cause Remedy Remarks E82 error code displayed A. Link switch plug A. Check link switch plug No weld current is Link switch plug not not connected. connection at connector available. Buzzer connected. CN4 on PCB3 (WK-4819). sounds constantly.
  • Page 59 PRO-WAVE 300TSW Description Possible Cause Remedy Remarks E85 error code displayed A. The Primary A. Measure between No weld current is Primary Capacitors are not capacitors pre- terminals TB1 and TB6 available. Buzzer charging correctly charge circuit is (-ve) at PCB1 (WK-4961). sounds constantly.
  • Page 60 PRO-WAVE 300TSW Description Possible Cause Remedy Remarks E94 error code displayed A. Poor electrical A. Check wiring and Weld current ceases. Temperature sensor TH1 connection connections from TH1 Buzzer sounds for IGBTs or sensor TH2 between TH1 and TH2 to connector constantly.
  • Page 61 PRO-WAVE 300TSW Description Possible Cause Remedy Remarks E99 error code displayed A. Mains supply A. check mains input supply Weld current ceases. Mains supply (input) (input) voltage is voltage. Buzzer sounds voltage has been turned off not present constantly. Must but control circuit has switch machine off power from the primary...

  • Page 63: Advanced Troubleshooting

    PRO-WAVE 300TSW SECTION 7: ADVANCED TROUBLESHOOTING If the problem cannot be solved by the basic (external) trouble shooting guide, the Power Source enclosure will have to be removed. The advanced level of troubleshooting allows the technician with a few common tools to remove the plastic enclosure and analyse some failures.
  • Page 64 PRO-WAVE 300TSW 4) Pull the front panel slightly forward and pull the rear 6) Remove protection cover sheet by removing the plastic panel slightly backward. tabs. The interlocking hooks of the side case covers can now be disengaged from the front and rear panels. Art # A-05572 Figure 7-3: Front panel removal.

  • Page 65: Visually Inspect

    PRO-WAVE 300TSW 7.03 Visually Inspect Visually inspect the inside the Power Source. The high levels of power present in the Power Source can cause burning or arcing of components and PCBs when a failure occurs. Carefully inspect all components including the Input Recti- fier, IGBT Modules, Secondary Diode Modules and the PCBs.

  • Page 66: Advanced Power Source Malfunctions

    PRO-WAVE 300TSW 7.04 Advanced Power Source Malfunctions Problem Possible Cause Remedy 1. Cooling Fan is not A. Airflow Obstructed A. Clear any obstructions or dust that may inhibit rotating, and cooling. B. Cooling Fan Wiring or B. Check wiring between cooling fan and Plug connector.
  • Page 67 PRO-WAVE 300TSW Problem Possible Cause Remedy G. Defective Cooling Fan G. After Power Source is turned on for approx 8 driver circuit seconds check CN12 between Pins 1 and 2(-ve) components on on PCB2 (WK-4983) for 24VDC supply to PCB2 (WK-4983). Cooling fan.
  • Page 68 PRO-WAVE 300TSW Problem Possible Cause Remedy F. Poor IGBT Q3, Q4 F. Check wiring and connections for Q3, Q4 Gate Gate Driver Driver signals between connector CN3 on Connections between PCB5 (WK-4919) and connector CN3 on PCB11 PCB5 (WK-4919) and (WK-4963) are connected firmly.
  • Page 69 PRO-WAVE 300TSW Problem Possible Cause Remedy F. Ribbon Cable F. Check Ribbon Cable connections at connector CN17 connection between on PCB2 (WK-4983) and connector PCB2 (WK-4983) and CN2 on PCB5 (WK-4919) are connected firmly. PCB5 (WK-4919). G. Defective Gas solenoid G.
  • Page 70 PRO-WAVE 300TSW Problem Possible Cause Remedy E. Connection between E. Check that the quick-disconnect terminals from R2 High Frequency H.F. are inserted onto the terminals of H.F. Unit and Current Unit correctly and completely. Confirm there are no Limiting Resistor R2. short circuits, burnt or broken wires between the H.F.
  • Page 71 PRO-WAVE 300TSW Problem Possible Cause Remedy B. Ribbon Cable B. Check ribbon cable connections at connector CN17 connection between on PCB2 (WK-4983) and connector CN2 on PCB5 PCB2 (WK-4983) and (WK-4919) are connected firmly. PCB5 (WK-4919). C. Connector plug C. Check wiring and plug connectors at connector connections from PCB2 CN16 on PCB2 (WK-4983) and connector CN1 on (WK-4983) to PCB5...
  • Page 72 PRO-WAVE 300TSW 7-10 August 10, 2005...

  • Page 73: Pcb Descriptions

    PRO-WAVE 300TSW SECTION 8: PCB DESCRIPTIONS 8.01 Main PCB (WK-4961) Main PCB circuit description. Input Rectifier reservoir Capacitor PCB. This PCB contains Input Rectifier Capacitors and Precharge circuit. Also RC dv/dt snubbers and primary current transformers. Circuit Function Parts Used In rush current protection R44, RY1, RY2 Input rectifier circuit...

  • Page 74: Control Source Pcb Pcb2 (Wk-4983)

    PRO-WAVE 300TSW Main PCB PCB1 WK-4961 U01 Connector Value Description CN21 +12V 0/12V pre-charge start 0/12V gate on approx. 5V approx. 5V CN22 3V pulse 3V pulse 8.02 Control Source PCB PCB2 (WK-4983) Control Source PCB circuit description. Auxiliary Power Supply and Interface PCB. Circuit Function Parts Used Auxiliary power supply circuit...
  • Page 75 PRO-WAVE 300TSW Control Source PCB PCB2 WK-4983 U01 Connector Value Description 300VDC Not used Not used 1-12 0/5V running enable 0/5V running enable 0/5V input voltage error 0/5V input voltage error 0/5V internal process 0/5V internal process 0/5V internal process 0/5V internal process 30V 100kHz...
  • Page 76 PRO-WAVE 300TSW Control Source PCB PCB2 WK-4983 U01 Connector Value Description CN15 short/open ok to move Not used Not used short/open ok to move CN16 +12VDC +5VDC -12VDC CN17 1-26 CN19 0/12 remote/panel signal 0-10V remote signal 0-10V remote signal 0-10V remote signal 0/12...

  • Page 77: Power Supply Voltage Reference Points On Control Pcb2 (Wk-4983)

    PRO-WAVE 300TSW 8.03 Power Supply Voltage Reference Points on Control PCB2 (WK-4983) Power Supply Voltage Reference Points on Control PCB PCB2 WK-4983 U01 Connector Value Reference Description CN16 +12VDC CN16 Pin 4 Secondary Circuit Power Supply. Voltage Regulator IC4 CN16 +5VDC CN16 Pin 4 Secondary Circuit Power Supply.
  • Page 78 PRO-WAVE 300TSW Detection PCB PCB3 WK-4819 U01 Connector Value Description +12V Vdd for primary circuit (input) Not used Not used Vcc for primary circuit (input) Not used Not used GND for primary circuit Not used Not used Reserved (output) 0V if pre-charge pre-charge signal (output) Not used Not used 0-5V as primary...

  • Page 79: Igbt Driver Pcb Pcb4(Wk-4984)

    PRO-WAVE 300TSW 8.05 IGBT Driver PCB PCB4(WK-4984) IGBT Driver circuit description. Isolated IGBT Gate Drive PCB. Circuit Function Parts Used Primary IGBT gate driver circuit Pulse transformer Art # A-05578 CN223 Figure 8-4: IGBT Driver PCB WK-4984 IGBT Driver PCB PCB4 WK-4984 U01 Connector Pin Value Description...

  • Page 80: Control Pcb Pcb5 (Wk-4919)

    PRO-WAVE 300TSW 8.06 Control PCB PCB5 (Wk-4919) Control PCB circuit description. Control Display and user interface drive PCB. Circuit Function Parts Used Control circuit IC20 Sequence circuit IC20 Protection circuit IC20 Model selection circuit DIP Switch DSW1, DSW2 CN8 CN5 VRD-ON/OFF CN10 Art # A-05579...

  • Page 81: Power Supply Reference Points On Pcb5 (Wk-4919)

    PRO-WAVE 300TSW Control PCB PCB5 WK-4919 UO6 Connector Value Description 2VDC as Io=100A output current detection 2VAC as Vo=10V output voltage detection 2VAC as Vo=10V output voltage detection 0/5V output short detection 0/12V torch on/off signal 0/12V ok to move signal 0/12V panel/remote select signal +10V...

  • Page 82: Front Controls Pcb Pcb6 (Wk-4971)

    PRO-WAVE 300TSW 8.08 Front Controls PCB PCB6 (WK-4971) Circuit Function Parts Used Operation circuit Encoder LED circuit Switch Encoder Art # A-05580 Figure 8-6: Front Controls PCB WK-4971 Front Controls PCB PCB6 WK-4971 U05 Connector Value Description 1-12 1-12 1-12 1-12 8-10 August 10, 2005...

  • Page 83: Filter 430V Pcb Pcb9 (Wk-4917)

    PRO-WAVE 300TSW 8.09 Filter 430V PCB PCB9 (WK-4917) Filter 430V PCB circuit description. Transient Suppression PCB. Circuit Function Parts Used Input filter circuit Y Capacitor Surge protection circuit Input voltage detection circuit Discharge GAP, SA5 Art # A-05581 Figure 8-7: Filter 430V PCB WK-4917 Filter 430V PCB PCB9 WK-4917 U02 Connector Value...

  • Page 84: Start Pcb Pcb10 (Wk-4970)

    PRO-WAVE 300TSW 8.10 Start PCB PCB10 (WK-4970) Start PCB circuit description. Starting Arc stability and filter circuit. Circuit Function Parts Used Output filter circuit Starting arc stability circuit Art # A-05582 Figure 8-8: Start PCB WK-4970 Start PCB PCB10 WK-4970 U01 Connector Value Description...

  • Page 85: Secondary Igbt Gate Driver Pcb Pcb11 (Wk-4963)

    PRO-WAVE 300TSW 8.11 Secondary IGBT Gate Driver PCB PCB11 (WK-4963) Secondary IGBT Gate Driver PCB circuit description. Secondary IGBT Gate Driver PCB. Circuit Function Parts Used Secondary IGBT gate driver Transformer Super Impose circuit PHC, IGBT PHC2 PHC3 Art # A-05583 Figure 8-9: Secondary IGBT Gate Driver PCB WK-4963 Secondary IGBT Gate Driver PCB PCB11 WK-4963 U01 Connector...

  • Page 86: Filter Pcb Pcb14 (Wk-5022)

    PRO-WAVE 300TSW Se co n d a ry IGBT Ga te Drive r PCB PCB1 1 WK-4 9 6 3 U0 1 Co n n e cto r Va lu e De scrip tio n 0 /1 5 V n eg ative p o le 0 /1 5 V n eg ative p o le 0 /1 5 V...

  • Page 87: 300Tsw Control Pcb 5 (Wk -4919) Switch Settings

    PRO-WAVE 300TSW 8.13 300TSW Control PCB 5 (WK -4919) Switch Settings CAUTION When fitting a new Control PCB5 (WK-4919) the Welding Parameter Setting must be set. Refer to section 4.09 . Art # A-05585 Figure 8-11: Control PCB5 (WK-4919) Art # A-05586 Figure 8-12: Control PCB5 Switch Settings August 10, 2005 8-15...

  • Page 88: Test Procedure For Input Rectifier D1

    PRO-WAVE 300TSW 8.14 Test Procedure for Input Rectifier D1 Part No: 454160160 Type: DFA50BA160 Input Rectifier Front of machine Art # A-005587 Figure 8-13: View with PCB1 (WK-4961) removed Test Procedure: a. In order to check Input Rectifier D1 remove PCB1 (WK-4961) from the Power Source Refer to Figure 8-13. b.

  • Page 89: Test Procedure For Igbt Q1, Q2

    PRO-WAVE 300TSW 8.15 Test Procedure for IGBT Q1, Q2. Part No: UOA705300 supplied complete with PCB WK-5012. Type: CM100DUS-12F IGBT s Q1, Q2 Front of machine Art # A-05590 Figure 8-16: View with PCB1 (WK-4961) removed. Test Procedure: a. To check IGBT Q1, Q2 remove PCB1 (WK-4961) from the Power Source Refer to Figure 8-16 b.
  • Page 90 PRO-WAVE 300TSW COMPONENT TESTED TERMINALS TESTER ACCEPTABLE Positive lead Negative lead MODE VALUE Collector-Emitter of Q1, C2E1 Open circuit Diode Test Q2 with PCB7, PCB8 C2E1 0.2 to 0.5V Collector-Emitter of Q1, C2E1 Open circuit Diode Test Q2 with PCB7, PCB8 C2E1 0.2 to 0.5V Gate-Emitter of Q1,Q2...

  • Page 91: Test Procedure For Igbt's Q3, Q4

    PRO-WAVE 300TSW 8.16 Test Procedure for IGBT’s Q3, Q4 Part No: UOA705400 supplied with PCB WK-3367 Type: GCA200CA60 IGBT's Q3, Q4 Front of machine Art # A-05593 Figure 8-19: View with PCB11 (WK-4963) and links removed Test Procedure: a. In order to check IGBT Q3, Q4 remove PCB11 (WK-4963) and links from the Power Source See Figure 8-19. b.
  • Page 92 PRO-WAVE 300TSW TERMINALS COMPONENT TESTED Tester Mode ACCEPTABLE VALUE Positive lead Negative lead Collector-Emitter of Q3, C1 (3) C2E1 (1) Open circuit Diode Test Q4 with PCB12, PCB13. C2E1 (1) C1 (3) 0.2 to 0.4V Collector-Emitter of Q3, C2E1 (1) E2 (2) Open circuit Diode Test...

  • Page 93: Test Procedure For Secondary Diode D2, D3, D4, D5, D6

    PRO-WAVE 300TSW 8.17 Test Procedure for Secondary Diode D2, D3, D4, D5, D6 Part No: 4583A0060 Type: DBA200UA60 Diode D2, D3, D4, D5 , D6 Front of machine Art # A-05596 figure 8-22: View with PCB15 (WK-4962) and links removed. Test Procedure: a.
  • Page 94 PRO-WAVE 300TSW Diode D2 D3 D4 D5 D6 Torque Values (Refer to CAUTION on previous page) Mounting Screws M4 1.0-1.4 N.m Terminal Screws M4 1.0-1.4 N.m Art # A-05597 Table 8-8: Diodes D2, D3, D4, D5, D6 Torque Values Figure 8-23: Diodes D2, D3, D3, D4, D5, D6 Test Points 8-22 August 10, 2005...

  • Page 95: High Frequency Points Gap Adjustment

    PRO-WAVE 300TSW 8.18 High Frequency Points Gap Adjustment. WARNING The unit will generate a High Voltage component that can cause extreme personal harm and test equipment damage. The H.F. unit is located underneath the heat sink assembly. Confirm that the points are connected to H.F. Unit correctly and completely.

  • Page 96: Replacing Pre Charge Circuit Components On Pcb1 (Wk-4961)

    PRO-WAVE 300TSW 8.19 Replacing Pre Charge circuit components on PCB1 (WK-4961) Pre Charge Kit Part Number : 710035 Contains the following: 1 x 12VDC 10A Relay (RY1) 1 x 12VDC 5A Relay (RY2) 1 x Resistor (R44) Remove faulty components by carefully removing all solder using a de-soldering tool. Solder in replacement components as supplied with kit.

  • Page 97: Replacing Cooling Fan/Gas Solenoid Driver Circuit Components On Pcb2 (Wk-4983)

    PRO-WAVE 300TSW 8.20 Replacing Cooling Fan/Gas Solenoid Driver circuit components on PCB2 (WK- 4983) Cooling Fan/Gas Solenoid Driver Kit Part Number : 710029 Contains the following: 1 x Transistor (Q20) Cooling Fan. 1 x Transistor (Q21) Cooling Fan 1 x Opto coupler (PHC4) Cooling Fan. 1 x Transistor (Q5) Gas Solenoid 1 x Opto coupler (PHC3) Gas Solenoid.

  • Page 98: Replacing Igbt Q3, Q4 Gate Driver Circuit Components On Pcb11 (Wk-4963)

    PRO-WAVE 300TSW 8.21 Replacing IGBT Q3, Q4 Gate Driver circuit components on PCB11 (WK-4963) IGBT Q3, Q4 Gate Driver Components Kit Part Number : 710032 Contains the following: 1 x Resistor (R29), 1 x Resistor (R30), 1 x Resistor (R32) 1 x Resistor (R33) 1 x Zener Diode (ZD4) 1 x Zener Diode (ZD5)

  • Page 99: Parts List

    PRO-WAVE 300TSW SECTION 9: PARTS LIST 9.01 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 Specification or Assembly numbers.

  • Page 100: Tsw Parts List

    PRO-WAVE 300TSW 9.03 300 TSW Parts List Ref. Des. . Des. . Des. . Des. Qty..Description Description Description Part Number Part Number Part Number . Des. Description Description Part Number Part Number Coupling Coil - F2A677800 CC 10-6767 CON1 Remote Socket - MS3102A20-27S...
  • Page 101 PRO-WAVE 300TSW Ref. Des. . Des. . Des. . Des. . Des. Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Front Panel - E0D004800 10-6785 Rear Panel - E0D004900 10-6786 Side Panel - E0D006200 10-6787...
  • Page 102 PRO-WAVE 300TSW . Des. . Des. Qty..Description Description Part Number Part Number Ref. Des. . Des. . Des. Description Description Description Part Number Part Number Part Number Right Chassis - J2C977100 10-6814 Left Chassis - J2C976800 10-6815 PCB10 Chassis - JDA013400 10-6816...

  • Page 103: Appendix 1: General Information

    PRO-WAVE 300TSW APPENDIX 1: GENERAL INFORMATION • Note the model and specification number shown on the equipment nameplate. August 10, 2005...

  • Page 104: Appendix 2: Pro-Wave 300 Tsw Parts Arrangement

    PRO-WAVE 300TSW APPENDIX 2: PRO-WAVE 300 TSW PARTS ARRANGEMENT PCB11 PCB13 PCB12 L105 CON1 PCB15 T01 (-) T01 (+) August 10, 2005...
  • Page 105 PRO-WAVE 300TSW L101 L104 L103 L102 PCB2 PCB4 PCB5 PCB3 PCB14 PCB9 PCB6 PCB1 PCB1 HF. UNIT PCB8 PCB7 Art # A-05602 August 10, 2005...

  • Page 106: Appendix 3: Pro-Wave 300 Tsw Interconnection Diagram

    PRO-WAVE 300TSW APPENDIX 3: PRO-WAVE 300 TSW INTERCONNECTION DIAGRAM P CB1 AC_in PGND (TB1) C 2E1 TB11 (TB2) P CB9 INPUT TB12 PCB16 (TB3) (TB4) C 2E1 TB13 (TB5) TB10 TB14 (TB6) CN18 CN21 CN22 FRONT 3 4 5 PANEL A--Conta ctor Control +24V DC B--Co ntactor Control.
  • Page 107 PRO-WAVE 300TSW PCB19 PCB10 RY+12V /RY_ON PCB15 S_DET+ TB10 1 2 3 C2E1 C2E1 OUTPUT S_DET- PCB11 CC 2 CC 1 HF.UNIT 250V S_DET- S_DET+ 3 4 5 6 7 RY+12V 5 7 9 /RY_ON CN10 L105 +12V -12V I_SENSE PCB2 3 4 5 6 7 PCB5...
  • Page 109 Global Customer Service Contact Information Thermadyne USA Thermadyne Asia Pacific Pte Ltd 82 Benning Street 5 Shenton Way West Lebanon, NH 03784 USA #37-02 / 38-02 UIC Building Telephone: (603) 298-5711 Singapore 068808 800-752-7621 Telephone: 65-6832-8066 Fax: 800-221-4401 Fax : 65+ 6763 5812 Email: sales@thermalarc.com Thermadyne, China Thermadyne Victor Brasil...
  • Page 110 Corporate Headquarters 82 Benning Street West Lebanon, NH 03784 USA Telephone: (603) 298-5711 800-752-7621 Fascimile: 800-221-4401 Email: sales@thermalarc.com www.thermalarc.com...

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