Thermal Arc ARCMASTER 400TS Service Manual
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Thermal Arc ARCMASTER 400TS Service Manual

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400TS
400S
300TS
300S
Service Manual
ARCMASTER
INVERTER ARC WELDERS
ersion No: AA.03
V V V V V ersion No:
ersion No:
ersion No:
ersion No:
Operating Features
Operating Features
Operating Features:
Operating Features
Operating Features
Art # A-07263
Issue Date:
Issue Date: May 22, 2006
Issue Date:
Manual No: 0-4895B
Manual No
Manual No
Issue Date:
Issue Date:
Manual No
Manual No
®

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  • Page 1 400TS 400S ® ARCMASTER INVERTER ARC WELDERS 300TS 300S Art # A-07263 Service Manual ersion No: AA.03 V V V V V ersion No: ersion No: ersion No: Issue Date: Issue Date: Issue Date: May 22, 2006 Manual No Manual No: 0-4895B Manual No ersion No: Issue Date:...
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Service Manual Number 0-4895B for: ArcMaster 400TS Inverter Arc Welder Part Number 10-3071 ArcMaster 400S Inverter Arc Welder Part Number 10-3070...

  • Page 4: Table Of Contents

    CONTENTS 1 SAFETY INSTRUCTIONS AND WARNINGS 1 Arc Welding Hazards................1–1 2 PRINCIPAL SAFETY STANDARDS .
  • Page 5 8 BASIC TROUBLESHOOTING 1 TIG Welding Problems ................8–1 2 Stick Welding Problems .
  • Page 6 CONTENTS 3. 7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” ..........12–12 3.

  • Page 7: Safety Instructions And Warnings

    ARCMASTER 400TS, 400S, 300TS, 300S 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 400TS, 400S, 300TS, 300S 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.
  • Page 9 ARCMASTER 400TS, 400S, 300TS, 300S 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 ARCMASTER 400TS, 400S, 300TS, 300S 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

    ARCMASTER 400TS, 400S, 300TS, 300S 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...

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

    ARCMASTER 400TS, 400S, 300TS, 300S 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).
  • Page 13 ARCMASTER 400TS, 400S, 300TS, 300S 9. N’enroulez pas de câbles électriques autour de votre 1. Portez une casque de soudeur avec filtre oculaire de corps. nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les 10.
  • Page 14 ARCMASTER 400TS, 400S, 300TS, 300S 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 ARCMASTER 400TS, 400S, 300TS, 300S 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.

  • Page 16: Principales Normes De Securite

    ARCMASTER 400TS, 400S, 300TS, 300S 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.

  • 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...

  • Page 18: Symbol Chart

    300/400TS and 300/400S 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...

  • Page 19: Description

    300/400TS and 300/400S INTRODUCTION Description The Thermal Arc Model ARC MASTER 300TS and 400TS is a single/three-phase DC arc welding power source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas control 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-Pulse (GTAW-P), Gas Tungsten Arc Weld- ing-Sloped (GTSW-S), and Shielded Metal Arc Welding (SMAW) processes.

  • Page 20: Functional Block Diagrams

    300/400TS and 300/400S INTRODUCTION Functional Block Diagrams Figure 2-2 illustrates the functional block diagram of the 300TS and 400TS power supply. Figure 2-3 illus- trates the functional block diagram of the 300S and 400S power supply. Hall Current Input Main Input IGBT Main...

  • Page 21: Transporting Methods

    300/400TS and 300/400S INTRODUCTION 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 22 300/400TS and 300/400S INTRODUCTION PAGE LEFT INTENTIONALLY BLANK 2 – 6...

  • Page 23: Installation

    RED) conductor to the ground terminal. restrict natural airflow for cooling. Do not connect the ground (GREEN) conductor to an input line terminal. WARNING Thermal Arc advises that this equipment be electri- cally connected by a qualified electrician. 3 – 1...

  • Page 24: Input Power

    Figure 3-1: Electrical Input Connections The ARC MASTER 300/400TS and 300/400S are designed for use with a generator as an input power source. Contact an accredited Thermal Arc Input Power service agent for the proper sizing and set-up rec- ommendations of a generator power source sys- Each unit incorporates an INRUSH circuit and input tem.

  • Page 25: High Frequency Introduction (300/400Ts Only)

    300/400TS and 300/400S INSTALLATION High Frequency Introduc- 3. Radiation from Welding Leads: Radiated interference from welding leads, although pro- tion (300/400TS only) nounced in the vicinity of the leads, diminishes rapidly with distance. Keeping leads as short The importance of correct installation of high fre- as possible will minimize this type of interfer- quency welding equipment cannot be over-empha- ence.

  • Page 26: Specifications

    460V Input Volts Single Phase 208V 230V Thermal Arc continuously strives to produce the the following; variations or changes in manufac- best product possible and therefore reserves the tured components, installation location and condi- right to change, improve or revise the specifica- tions and local power grid supply conditions.

  • Page 27: Operator Controls

    OPERATOR CONTROLS ARC MASTER 300/400TS and 300/400S Controls OPERATOR CONTROLS 1. Control Knob: This control sets the selected weld parameter, rotating it clockwise increases the parameter that is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage. 2.
  • Page 28 300/400TS and 300/400S OPERATOR CONTROLS 3. Positive Terminal: Welding current flows from Weld Process selection for the Power Source via heavy duty Dinse type ARC MASTER 300/400TS terminal (50 mm). It is essential, however, and 300/400S that the male plug is inserted and turned securely to achieve a sound electrical connec- tion.

  • Page 29: Weld Parameter Descriptions For Arc Master 300/400Ts And 300/400S

    300/400TS and 300/400S OPERATOR CONTROLS Weld Parameter Descriptions for ARC MASTER 300/400TS and 300/400S Figure 4-3: ARC MASTER 300/400TS 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.
  • Page 30 300/400TS and 300/400S OPERATOR CONTROLS 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.

  • Page 31: Weld Parameters For Arc Master 300/400Ts And 300/400S

    300/400TS and 300/400S OPERATOR CONTROLS Weld Parameters for ARC MASTER 300/400TS and 300/400S Weld Mode Parameter Weld Parameter Factory Setting Incremental Unit STICK HF TIG LIFT TIG Range PRE-FLOW 0.0 to 1.0 sec 0 sec 0.1 sec HOT START 0 to 70A 300TS 5 to 300A INITIAL CUR.

  • Page 32: Power Source Features

    300/400TS and 300/400S OPERATOR CONTROLS Power Source Features Feature Description Feature Description  An error code is displayed on the Self  Almost all welding parameters are New Digital Diagnosis Digital Meter when a problem adjustable. Control Using Error occurs with Primary supply volt- ...

  • Page 33: 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 34 300/400TS and 300/400S SET-UP FOR SMAW (STICK) AND GTAW (TIG) PAGE LEFT INTENTIONALLY BLANK 5 – 2...

  • Page 35: Sequence Of Operation

    SEQUENCE OF OPERATION 4. Digital LED display: SEQUENCE OF OPERATION NOTE Welding amperage and parameter values are Scroll Buttons are used to select the parameters to displayed in this window. Internal warnings be set. The LED's show which function is being such as over temperature, low or high input adjusted on the weld sequence graph.

  • Page 36: Hf Tig Welding (300/400Ts Only)

    300/400TS and 300/400S SEQUENCE OF OPERATION HF TIG Welding Slope Mode Sequence (300/400TS only) (300/400TS only)  Connect work lead to positive terminal. Switch Switch Switch Switch Closed Closed  Connect TIG torch to negative terminal. Open Open Down  Switch machine on. Weld Current Slope Slope...

  • Page 37: Slope Mode With Repeat Sequence (300/400Ts Only)

    300/400TS and 300/400S SEQUENCE OF OPERATION Slope Mode with repeat increase and decrease the welding current on a regular basis. The faster you move the foot rheo- sequence stat up and down, the faster the frequency. (300/400TS only) The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the down slope period only.
  • Page 38 300/400TS and 300/400S SEQUENCE OF OPERATION PAGE LEFT INTENTIONALLY BLANK 6 – 4...

  • Page 39: Routine Maintenance

    ROUTINE MAINTENANCE ROUTINE MAINTENANCE The only routine maintenance required for the 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 40 6 Months Bring the unit to an authorized Thermal Arc Service Center to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

  • Page 41: 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 42 300/400TS and 300/400S BASIC TROUBLESHOOTING 9. Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems. 10.Arc flutters during TIG welding. A. Tungsten electrode is too large A. Select the right size electrode. Refer for the welding current.

  • Page 43: Stick Welding Problems

    300/400TS and 300/400S BASIC TROUBLESHOOTING Stick Welding Problems Description Possible Cause Remedy 1. Gas pockets or voids in weld A. Electrodes are damp. A. Dry electrodes before use. metal (Porosity). B. Welding current is too high. B. Reduce welding current. C.
  • Page 44 300/400TS and 300/400S BASIC TROUBLESHOOTING Description Possible Cause Remedy 5. Non-metallic particles are trapped A. Non-metallic particles may be A. If bad undercut is present, clean in the weld metal (slag inclusion). trapped in undercut from previous slag out and cover with a run from a run.

  • Page 45: Power Source Problems

    B. The Welding Power Source switch B. Switch ON the Welding Power is switched OFF. Source. C. Loose connections internally. C. Have an Accredited Thermal Arc Service Agent repair the connection. 2. Maximum output welding current Defective control circuit. Have an Accredited Thermal Arc can not be achieved with nominal Service Agent repair the connection.
  • Page 46 300/400TS and 300/400S BASIC TROUBLESHOOTING PAGE LEFT INTENTIONALLY BLANK 8 – 6...

  • Page 47: 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 Less than 20V;...

  • Page 48: Switching Vrd On/Off

    300/400TS and 300/400S 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 49: Power Source Error Code

    E01 resets when TH1 B. Fan ceases to operate. B. Have an Accredited about 1 second. decreases to 70°C for about Thermal Arc Service 30 seconds. Agent investigate. C. Air flow is restricted by C. Unblock vents then let vents being blocked.
  • Page 50 E99 error. B. Mains supply (input) B. Have an Accredited power from the primary voltage has been turned Thermal Arc Service capacitors. off. Agent or a qualified electrician check the Mains voltage and fuses.

  • Page 51: Advanced Troubleshooting

    Service Manual, the subas- sembly should be replaced with a new one. The faulty subassembly should then be returned to Thermal Arc through established procedures. Figure 11-1: Switch OFF WARNING CAUTION...
  • Page 52 300/400TS and 300/400S 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 53: Verification And Remedy To The Indicated Error Codes

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 6) Remove protection cover sheet by removing 2.1 E01 "Over-Temperature at 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 54: E02 "Over-Temperature At The Secondary Side

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 2.2 E02 "Over-Temperature at 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. ing into the primary side of the main transformer. Verification/Remedy Verification/Remedy a) Unit may be in thermal shutdown mode.

  • Page 55: E04 "Torch Cable Failure

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 2.4 E04 "Torch Cable Failure" 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. Verification/Remedy Verification/Remedy a) Verify the rated duty cycle of the torch/work...

  • Page 56: E82 "Rated Voltage Selection Circuit Abnormality

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 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 in the appearance of PCB4. Cause  Replace PCB4. Refer to section 12.3.4. Rated voltage selection circuit inside the Welding Power Source is not functioning properly.

  • Page 57: E94 "Thermistor Malfunction

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 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 3.1 "Cooling Fan (FAN1) Failure" a) Confirm a secure connection of the harness (Fan is not rotating.) wired between CN8-9 on PCB6 (WK-5549) and Thermistors (TH1, TH2).

  • Page 58: Gas Valve Failure" (No Gas Flow Through Unit)(300/400Ts Only)

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 3.2 "Gas Valve Failure" (No Gas 3.3 "No Weld Output" flow through unit) When in High Frequency TIG (HF TIG) mode, if the (300/400TS only) High Frequency is not generated (present), refer to "High Frequency Output Failure" section 11.3.5. Cause Occurs when the gas valve (SOL1) is defective, Cause...

  • Page 59: Operating Panel Failure" (Led's Do Not Light Properly Or Welding Setting Cannot Be Established.)

    300/400TS and 300/400S 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 60: Fault Isolation Tests

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING b) Verify the connection between High Frequency Fault Isolation Tests Unit (HF UNIT1) and the current limiting resistor (R2). 4.1 Preparation  Verify the connection between HF UNIT1 and The following initial conditions must be met the current limiting resistor (R2).

  • Page 61: Verification Of The Power Input Circuitry

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING Verification of the Power 3) Verify input voltage after the input switch (S1) using an AC voltmeter. (The capability of the Input Circuitry voltmeter should be more than 600VAC.) • Using an AC voltmeter, measure between CAUTION the points U2 and V2 on the input switch, S1.

  • Page 62: Verification Of The Power Supply Voltage

    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. The check points and the refer- be more than 1000VDC.

  • Page 63: Verification Of The Cooling Fan, Fan1, Drive Circuitry

    300/400TS and 300/400S 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. Voltage FAN1 measurement.

  • Page 64: Verification Of The Gas Valve, Sol1, Drive Circuitry

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 5.4 Verification of the Gas Valve, 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 below, make certain the unit is placed in the initial set up condition as described in section 11.4.1 set up condition as described in section 11.4.1...

  • Page 65: Verification Of The Secondary Diode (D2-D7)

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 1) Check whether there are any abnormalities in 5.6 Verification of the secondary the appearance of PCB8-PCB11. Diode (D2-D7) 2) Verify the characteristic of the primary IGBT CAUTION (Q1-Q24), using a diode tester. Before performing any portion of the procedure 3) Refer to Table 11-7 and Figure 11-16 for below, make certain the unit is placed in the initial the checkpoints on PCB8-PCB11.

  • Page 66: Verification Of The Secondary Igbt (Q25-Q26)

    300/400TS and 300/400S ADVANCED TROUBLESHOOTING 5.8 Verification of the secondary 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 below, make certain the unit is placed in the initial set up condition as described in section 11.4.1 set up condition as described in section 11.4.1...
  • Page 67 300/400TS and 300/400S 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 should be taken to prevent electric shock. 1) When in HF TIG mode, the unit will gener- ate high voltage.

  • Page 68: Maintenance

    MAINTENANCE Maintenance List MAINTENANCE Part No. DWG No. Parts name Reference page W7001313 12- 7 PCB2 Printed Circuit Board (WK-5597) W7001314 12- 9 PCB3 Printed Circuit Board (WK-5548) 10-6635 12- 10 PCB4 Printed Circuit Board (WK-4819) W7001417 12- 11 PCB5 Printed Circuit Board (WK-5551) W7001423 12- 9...
  • Page 69 300/400TS and 300/400S MAINTENANCE DWG No. Parts name Reference page Part No. Printed Circuit Board (WK-5493) PCB1 12- 6 W7001312 Printed Circuit Board (WK-5549) 300S PCB6 12- 11 W7001730 Printed Circuit Board (WK-5549) 400S 12- 11 W7001731 PCB6 PCB6 Printed Circuit Board (WK-5549) 300TS 12- 11 W7001734 PCB6...
  • Page 70 300/400TS and 300/400S MAINTENANCE Part No. DWG No. Parts name Reference page W7001666 CON1 Remote Socket 12- 26 10-6769 Primary Diode 12- 28 10-6629 Secondary Diode 12- 28 10-6629 Secondary Diode 12- 28 10-6629 Secondary Diode 12- 28 10-6629 Secondary Diode 12- 28 7* HF.UNIT1 High Frequency Unit...
  • Page 71 300/400TS and 300/400S MAINTENANCE DWG No. Parts name Reference page Part No. Coupling Coil 12- 20 W7001382 Current Trans 12- 29 W7001304 Current Trans 12- 29 W7001304 FAN1 Cooling Fan 12- 22 W7001307 FCH1 Reactor 12- 20 W7001681 HCT1 Hall Current Sensor 12- 27 10-5003 Ring Core...

  • Page 72: Service Tools

    300/400TS and 300/400S MAINTENANCE Service Tools 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 Compound Screwdriver 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 73: Replacement Procedure

    300/400TS and 300/400S MAINTENANCE Replacement Procedure 3.1 PCB1 (WK-5493)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB2 (WK-5597). [Reference page : 12-7] 3) Remove the Primary Diode (D1). [Reference page : 12-28] 4) Remove the Current Trans (CT2/CT3). [Reference page : 12-29] 5) Remove the Nylon Hose.

  • Page 74: Pcb2 (Wk-5597)

    300/400TS and 300/400S MAINTENANCE 8) Remove the 18 screws and remove the PCB1 (WK-5493). 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. CN17 CN22 CN21...
  • Page 75 300/400TS and 300/400S MAINTENANCE 4) Remove the four screws. Remove the PCB3, PCB4, PCB5, PCB6, and PCB7 unit. Disconnect the three connectors. CN13 CN15 CN14 5) Remove the six screws, three terminals and three connectors. 6) Remove the two PCB supporters and then the PCB2 (WK-5597) and insulation sheet. 12 –...

  • Page 76: Pcb3 (Wk-5548), Pcb7 (Wk-5550)

    300/400TS and 300/400S MAINTENANCE 3.3 PCB3 (WK-5548), PCB7 (WK-5550)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB4 (WK-4819). [Reference page : 12-10] 3) Remove the PCB6 (WK-5549). [Reference page : 12-11] 4) Remove the PCB5 (WK-5551). [Reference page : 12-11] 5) Disconnect the 11 connectors from the PCB3 (WK-5548).

  • Page 77: Pcb4 (Wk-4819)

    300/400TS and 300/400S MAINTENANCE 8) Disconnect the one connector and remove the two screws, and then remove the PCB7 (WK-5550) from the PCB3 (WK-5548). Remove one screw and one ground terminal from the PCB7 (WK-5550). CN20 9) Disconnect the two connectors from the PCB3 (WK-5548). CN18 CN33 3.4 PCB4 (WK-4819) ...

  • Page 78: Pcb5 (Wk-5551)

    300/400TS and 300/400S MAINTENANCE 3.5 PCB5 (WK-5551)  1) Remove the side cover. [Reference page : 11-1] 2) Remove the PCB6 (WK-5549). [Reference page : 12-11] 3) Remove the two screws and three connectors. Remove the PCB5 (WK-5551) from the PCB3 (WK- 5548).

  • Page 79: Pcb8, Pcb9 (Wk-5479) And Q1-Q12 "Primary Igbt

    300/400TS and 300/400S MAINTENANCE 3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT”  1) Remove the side cover. [Reference page : 11-1] 2) Remove the eight screws and four device clips. Remove the four connectors and six screws. Remove the PCB8 (WK-5479) and PCB9 (WK-5479). ...

  • Page 80: Pcb13 (Wk-5528)

    300/400TS and 300/400S MAINTENANCE  When reinstalling the PCB12 (WK-5527), engage two latches of Front Control Cover first. 3.10 PCB13 (WK-5528)  1) Remove the side cover. [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. 12 –...

  • Page 81: Pcb14 (Wk-5594)

    300/400TS and 300/400S MAINTENANCE 4) Disconnect the one connector from the PCB12 (WK-5527). Remove the nut, washer and terminal. Remove the four screws. Pull out the Operation Panel and bring it down. 5) Remove the one connector and two screws. Remove the PCB13 (WK-5528) and Encoder Cover. 3.11 PCB14 (WK-5594) <T1 “Main Transformer”>...
  • Page 82 300/400TS and 300/400S MAINTENANCE 6) Remove the Nylon Hose and two terminals of SOL1. Remove the four screws and open the Rear Panel. 7) Remove the four screws from the PCB1 (WK-5477). Remove the seven terminals. The cables are drawn out. 8) Remove the four screws and then two cables from bottom.

  • Page 83: Pcb15 (Wk-5606)

    300/400TS and 300/400S MAINTENANCE 3.12 PCB15 (WK-5606)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the Nylon Hose and two terminals of SOL1. 3) Open the Dust sheet. Remove the eight screws. Remove the two PCB supporters and remove the PCB15 (WK-5606).

  • Page 84: Pcb21 (Wk-4917)

    300/400TS and 300/400S MAINTENANCE 3.14 PCB21 (WK-4917)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the six screws from the S1 and remove the six terminals. 3) Remove the four screws and then open the Rear Board. 4) Disconnect the one connector.

  • Page 85: Current Limiting Resistor (R6)

    300/400TS and 300/400S MAINTENANCE 5) Remove the three screws and the S1 Bus Bar from the PCB21 (WK-4917). 3.15 Current Limiting Resistor (R6)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the HF.UNIT1. [Reference page : 12-26] 3) Cut the cable.

  • Page 86: Resistor (R7, R8)

    300/400TS and 300/400S MAINTENANCE 3.16 Resistor (R7, R8)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the main ON/OFF switch (S1). [Reference page : 12-24] 3) Remove the four screws and four terminals. 4) Remove two screws and the Resistor (R7, R8) 12 –...

  • Page 87: Coupling Coil (Cc1) * 300/400Ts Only

    300/400TS and 300/400S MAINTENANCE 3.17 Coupling Coil (CC1)  *300/400TS only 1) Remove the side cover. [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 the two terminals.

  • Page 88: Primary Thermistor (Th1)

    300/400TS and 300/400S MAINTENANCE 3) Remove one screw, one nut and two terminals. Remove one screw, one nut and one terminal. 4) Remove four screws and remove the Reactor (FCH1). 3.19 Primary Thermistor (TH1)  1) Remove the Side Panel. [Reference page : 11-1] 2) Disconnect the one connector CN8 on PCB6.

  • Page 89: Secondary Thermistor (Th2)

    300/400TS and 300/400S MAINTENANCE 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 90: Solenoid Valve (Sol1) * 300/400Ts Only

    300/400TS and 300/400S 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). Be sure that the fan is in the correct direction when reinstalling. 3.22 Solenoid Valve (SOL1) *300/400TS only 1) Remove the Side Panel.

  • Page 91: Main On/Off Switch (S1)

    300/400TS and 300/400S MAINTENANCE 3) Remove the C-ring and detach the Solenoid Valve (SOL1).  When reinstalling, make sure that the C-ring seats in the Solenoid Valve groove. 3.23 Main ON/OFF Switch (S1)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the six screws and six terminals.

  • Page 92: Input Voltage Switch (S2)

    300/400TS and 300/400S MAINTENANCE 3.24 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. Remove the two screws and two nuts and then remove the Input Voltage Switch (S2).

  • Page 93: Remote Socket (Con1)

    300/400TS and 300/400S MAINTENANCE 3.25 Remote Socket (CON1)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the Ring Core (L105). [Reference page : 12-30] 3) Disconnect the three connectors CNB-15 on the PCB7. Remove the one screw and one ground terminals. CN13 CN15 CN14...

  • Page 94: Hall Current Sensor (Hct1)

    300/400TS and 300/400S MAINTENANCE 3) Remove the two screws and detach the High Frequency Unit (HF. UNIT1). 3.27 Hall Current Sensor (HCT1)  1) Remove the Side cover. [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.

  • Page 95: Primary Diode (D1)

    300/400TS and 300/400S MAINTENANCE 3.28 Primary Diode (D1)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the PCB3 (WK-5548). [Reference page : 12-9] 3) Remove the six screws and 13 terminals. Remove the two screws and then detach the Primary Diode (D1).

  • Page 96: Current Trans (Ct2, Ct3)

    300/400TS and 300/400S MAINTENANCE 4) Remove the eight screws and then detach the Secondary Diodes (D2, D4, D5, D7). Be sure that the diodes are placed in the correct direction when reinstalling.  Before installing a new diodes, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or equivalent) on the base.

  • Page 97: Ring Core (L1)

    300/400TS and 300/400S MAINTENANCE 3.31 Ring Core (L1)  1) Remove the Side Panel. [Reference page : 11-1] 2) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel. 3) Remove the two screws and two terminals. Cut the snap band and remove the Ring Core (L1). 3.32 Ring Core (L105) ...
  • Page 98 300/400TS and 300/400S MAINTENANCE 3) Remove the four screws. Pull out the Operation Panel and bring it down. 4) Cut the snap band remove the Ring Core (L105). 12 – 31...
  • Page 99 THIS PAGE LEFT INTENTIONALLY BLANK...

  • Page 100: Appendix 1 Parts List

    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 101 300/400TS and 300/400S PARTS LIST DWG No. Part No. Description Additional Information QTY. MHS20A101KI 20W 100Ω W7001451 Resistor, gen 3.1, IPS R7-8 MHS20A151JI 20W 150OHM W7001325 Resistor, gen 3.1, IPS DCP-103SR100C-480V 3P-480V 10-6857 Switch, gen 3.1, IPS SDKGA4-A-1-A 10-5222 Switch, gen 3.1, IPS SOL1 5505NBR1.5 DC24V 11VA/10W (with Gas Inlet and PC4-02) 10-6645...
  • Page 102 300/400TS and 300/400S PARTS LIST DWG No. Part No. Description Additional Information QTY. EDA047300 W7001367 Bus Bar, T-CC, gen 3.1, IPS ECA867900 W7001368 Post, Output, gen 3.1, IPS E1B872000 W7001369 Insulated Board, gen 3.1, IPS E1B859700 W7001370 Insulation Sheet, gen 3.1, IPS EDA079800 W7001371 Insulation Sheet, gen 3.1, IPS...
  • Page 103 300/400TS and 300/400S PARTS LIST 300/400TS 4 84...
  • Page 104 300/400TS and 300/400S PARTS LIST 300/400S No. DWG No. Part No. Description Additional Information QTY. CON1 MS3102A20-27S(NIC) 14P (with wiring assembly) W7001666 Socket, Remote, gen 3.1, IPS CT2-3 F2A503001 CT 1:40 W7001304 Transformer, gen 3.1, IPS DFA100BA160 10-6769 Diode, gen 3.1, IPS D2,4,5,7 10-6629 Diode, gen 3.1, IPS...
  • Page 105 300/400TS and 300/400S PARTS LIST No. DWG No. Part No. Description Additional Information QTY. N4A146500 W7001342 Label, Switch, gen 3.1, IPS N4A598700 W7001511 Label, VRD, gen 3.1, IPS TRAK-BE35-70S 10-6660 Terminal, Output, gen 3.1, IPS Cable, Input, gen 3.1, IPS SOOW AWG8X4C L=3.4m EBA156800 10-6795...
  • Page 106 300/400TS and 300/400S PARTS LIST...
  • Page 107 300/400TS and 300/400S PARTS LIST 3 74...

  • Page 108: Appendix 2 Connection Wiring Guide

    APPENDIX 2 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 ↔...
  • Page 109 300/400TS and 300/400S 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 3 Interconnect Diagram

    APPENDIX 3 INTERCONNECT DIAGRAM INTERCONNECT DIAGRAM APPENDIX 3 INTERCONNECT DIAGRAM 300/400TS TB13 TB10 TB14 TB11 PCB8 PCB10 TB15 TB12 PCB1 IGBT IGBT K(7) Main Gate Gate Circuit G(6) Circuit Circuit Board Board Board [WK-5493] R(3) Line1 [WK-5479] [WK-5479] S(4) Line2 T(5) Line3 Ground...
  • Page 111 300/400TS and 300/400S INTERCONNECT DIAGRAM PCB15 DIODE Snubber Circuit Board [WK-5606] PCB14 TRANS Board 1 2 3 [WK-5594] TB35 +Output Terminal TB33 HCT1 TB21 TB34 TB30 TB16 1 2 3 4 5 Ground TB32 RY+15V PCB20 Filter Circuit /RY_ON Board SIDE CHASSIS 3 TB22 [WK-5499]...
  • Page 112 300/400TS and 300/400S INTERCONNECT DIAGRAM 300/400S TB13 TB10 TB14 TB11 PCB8 PCB10 TB15 TB12 PCB1 IGBT IGBT K(7) Main Gate Gate Circuit G(6) Circuit Circuit Board Board Board [WK-5493] R(3) Line1 [WK-5479] [WK-5479] S(4) Line2 T(5) Line3 Ground PCB21 PCB2 Filter Link TB18...
  • Page 113 300/400TS and 300/400S INTERCONNECT DIAGRAM PCB15 DIODE Snubber Circuit Board [WK-5606] PCB14 TRANS Board 1 2 3 [WK-5594] TB35 +Output Terminal TB33 HCT1 TB21 TB34 TB30 TB16 1 2 3 4 5 Ground TB32 RY+15V PCB20 /RY_ON Filter Circuit Board SIDE CHASSIS 3 TB22 [WK-5499]...

  • Page 114: 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 116: Limited Warranty

    No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt.
  • Page 117 WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. April 2006 ENGINE DRIVEN WELDERS ARRANTY ERIOD ABOR Scout, Raider, Explorer Original Main Power Stators and Inductors .................. 3 years 3 years Original Main Power Rectifiers, Control P.C. Boards ..............3 years...
  • Page 119 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 120 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...

This manual is also suitable for:

Arcmaster 400sArcmaster 300tsArcmaster 300s

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