CIGWELD transarc 300 Si Service manual

300 Si
transarc
®
INVERTER ARC WELDER
Service Manual
Revision: AA
Operating Features:
Issue Date: January 15, 2008
3
SMAW
GTAW
PHASE
50Hz
60
INVERTER
415
V
Manual No: 0-5000
DC CC
300
AMP
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new CIGWELD® product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 800-752-7621, or visit us
on the web at www.cigweld.au.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Cigweld® product. Your satisfaction
with this product and its safe operation is our ultimate concern.
Therefore, please take the time to read the entire manual, especially
the Safety Precautions. They will help you to avoid potential hazards
that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Cigweld® 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.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
!
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer
assumes no liability for its use.
Service Manual Number 0-5000 for:
Transarc 300 Si Inverter Welding Power Supply Part No. 625781
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermadyne.com
Copyright © 2008 by
Thermadyne Industires, Inc.
® All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or
damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Publication Date: January 15, 2008
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
_______________________________
Equipment Serial #:
_______________________________
_______________________________
Table of Contents
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS........................................................ 1-1
1.01Arc Welding Hazards........................................................................................ 1-1
1.02Principal Safety Standards............................................................................... 1-4
1.03Precautions De Securite En Soudage A L’arc................................................... 1-5
1.04Dangers relatifs au soudage à l’arc.................................................................. 1-5
1.05Principales Normes De Securite...................................................................... 1-8
1.06Declaration Of Conformity............................................................................... 1-9
SECTION 2:
INTRODUCTION AND DESCRIPTION............................................................... 2-1
2.01How To Use This Manual................................................................................. 2-1
2.02Equipment Identification.................................................................................. 2-1
2.03Receipt Of Equipment...................................................................................... 2-1
2.04 Symbol Chart................................................................................................... 2-2
2.05 Description....................................................................................................... 2-3
2.06 Functional Block Diagrams............................................................................... 2-3
2.07 Transporting Methods...................................................................................... 2-4
SECTION 3:
INSTALLATION RECOMMENDATIONS.............................................................. 3-1
3.01 Environment..................................................................................................... 3-1
3.02 Location........................................................................................................... 3-1
3.03 Electrical Input Connections............................................................................. 3-1
3.04Mains Supply Voltage Requirements............................................................... 3-2
3.05 Specifications................................................................................................... 3-3
3.05 Duty Cycle........................................................................................................ 3-4
SECTION 4:
OPERATOR CONTROLS.............................................................................. 4-1
4.01 Transarc 300 Si Controls.................................................................................. 4-1
4.02 Weld Parameter Description............................................................................ 4-2
4.03 Weld Parameters for Transarc 300 Si............................................................... 4-3
4.04 Power Source Features.................................................................................... 4-4
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG)................................................... 5-1
SECTION 6:
SEQUENCE OF OPERATION.......................................................................... 6-1
6.01 Stick Welding................................................................................................... 6-1
6.02 DC LIFT TIG Welding........................................................................................ 6-1
Table of Contents
SECTION 7:
BASIC TIG WELDING GUIDE......................................................................... 7-1
7.01 Electrode Polarity............................................................................................. 7-1
7.02 Tungsten Electrode Current Ranges................................................................. 7-1
7.03 Tungsten Electrode Types................................................................................ 7-1
7.04 Guide for Selecting Filler Wire Diameter.......................................................... 7-1
7.05 Shielding Gas Selection................................................................................... 7-2
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe.................... 7-2
SECTION 8:
BASIC ARC WELDING GUIDE........................................................................ 8-1
8.01 Electrode Polarity............................................................................................. 8-1
8.02 Effects of Stick Welding Various Materials....................................................... 8-1
SECTION 9:
ROUTINE MAINTENANCE ........................................................................... 9-1
9.01 VRD Specification............................................................................................ 9-3
9.01 VRD Maintenance............................................................................................ 9-3
SECTION 10:
BASIC TROUBLESHOOTING........................................................................10-1
10.01 TIG Welding Problems................................................................................. 10-1
10.02 Stick Welding Problems............................................................................... 10-3
10.03 Power Source Problems.............................................................................. 10-4
10.04 Power Source Error Codes........................................................................... 10-5
SECTION 11:
ADVANCED TROUBLESHOOTING..................................................................11-1
11.01 System-Level Fault Isolation........................................................................ 11-1
11.1.1 Opening the Enclosure........................................................................ 11-1
11.02 Verification and Remedy to the Indicated Error Codes................................. 11-3
11.2.1 E01 “Over-Temperature at the primary side”...................................... 11-3
11.2.2 E02 “Over-Temperature at the secondary side”.................................. 11-4
11.2.3 E03 “Transformer Over-Current Failure”............................................ 11-4
11.2.4 E04 “Torch Cable Failure”.................................................................. 11-5
11.2.5 E11 “Main Supply Over Volt-age”....................................................... 11-5
11.2.6 E12 “Main Supply Under Volt-age”..................................................... 11-5
11.2.7 E81 “Wrong Main Supply Voltage”..................................................... 11-5
11.2.8 E82 “Rated Voltage Selection Circuit abnormality”............................. 11-6
11.2.9 E83 “Abnormalities in Mains Supply Voltage Detection”..................... 11-6
11.2.10 E85 “Pre-charge abnormality”.......................................................... 11-6
11.2.11 E94 “Thermistor malfunction”.......................................................... 11-7
11.2.12 E99 “Initial Power Receiving”........................................................... 11-7
11.03 Verification and Remedy to Failures without Indication Codes..................... 11-7
11.3.1 “Cooling Fan (FAN1) Failure” (Fan is not rotating.)............................. 11-7
11.3.2 ”No Weld Output”............................................................................... 11-8
11.3.3 ”Operating Panel Failure”.................................................................... 11-9
11.04 Fault Isolation Tests................................................................................... 11-10
11.4.1 Preparation....................................................................................... 11-10
Table of Contents
11.05 Verification of the Power Input Circuitry.................................................... 11-11
11.5.1 Verification of the AC Input Voltage using an AC voltmeter.............. 11-11
11.5.2 Verification of the Power Supply Voltage.......................................... 11-12
11.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry....................... 11-13
11.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry.......................... 11-14
11.5.5 Verification of the Primary Diode (D1).............................................. 11-14
11.5.6 Verification of the Secondary Diode (D2-D7).................................... 11-15
11.5.7 Verification of the Primary IGBT (Q1-Q24)....................................... 11-15
11.5.8 Verification of the Secondary IGBT (Q25-Q26)................................. 11-16
11.5.9 Verification of No-load Volt-age (OCV)............................................. 11-16
SECTION 12:
MAINTENANCE.......................................................................................12-1
12.01 Maintenance List.......................................................................................... 12-1
12.02 Service Tools................................................................................................ 12-5
12.2.1 Tools and parts................................................................................... 12-5
12.2.2 Notes of disassembly and assembly................................................... 12-5
12.03Replacement Procedure................................................................................ 12-6
12.3.1 PCB1(WK-5493)................................................................................. 12-6
12.3.2 PCB2 (WK-5597)................................................................................ 12-7
12.3.3 PCB3 (WK-5548), PCB7 (WK-5550)................................................... 12-8
12.3.4 PCB4 (WK-4819).............................................................................. 12-10
12.3.5 PCB5 (WK-5551).............................................................................. 12-10
12.3.6 PCB6 (WK-5549).............................................................................. 12-10
12.3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT”...................... 12-11
12.3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT”................ 12-12
12.3.9 PCB12 (WK-5527)............................................................................ 12-12
12.3.10 PCB13 (WK-5528).......................................................................... 12-13
12.3.11 PCB14 (WK-5594) <T1 “Main Transformer”>................................. 12-14
12.3.12 PCB15 (WK-5606).......................................................................... 12-15
12.3.13 PCB20 (WK-5499).......................................................................... 12-16
12.3.14 PCB21 (WK-4917).......................................................................... 12-16
12.3.15 PCB22 (WK-5022).......................................................................... 12-18
12.3.16 Current Limiting Resistor (R6)....................................................... 12-18
12.3.17 Resistor (R7, R8)............................................................................ 12-19
12.3.18 Reactor (FCH1)................................................................................12.21
12.3.19 Primary Thermistor (TH1).............................................................. 12-22
12.3.20 Secondary Thermistor (TH2).......................................................... 12-23
12.3.21 Cooling Fan (FAN1)......................................................................... 12-23
12.3.22 Main ON/OFF Switch (S1)............................................................... 12-25
12.3.23 Input Voltage Switch (S2)............................................................... 12-26
12.3.24 Remote Socket (CON1)................................................................... 12-27
12.3.25 Hall Current Sensor (HCT1)............................................................ 12-28
12.3.26 Primary Diode (D1)......................................................................... 12-29
12.3.27 Secondary Diode (D2, D4, D5 and D7)........................................... 12-30
12.3.28 Current Trans (CT2, CT3)................................................................ 12-31
Table of Contents
12.3.29 Ring Core (L1)................................................................................ 12-32
12.3.30 Ring Core (L105)............................................................................ 12-34
12.3.31 Reactor (L101)............................................................................... 12-35
12.3.32 Reactor (L102)............................................................................... 12-36
12.3.33 Reactor (L103)............................................................................... 12-37
APPENDIX 1: OPTIONS AND ACCESSORIES ............................................................ A-1
APPENDIX 2: INTERCONNECT DIAGRAM ............................................................... A-2
APPENDIX 3: PARTS LIST.................................................................................. A-3
APPENDIX 4: CONNECTION WIRING GUIDE............................................................. A-8
APPENDIX 5: DIODE TESTING BASICS..................................................................A-10
CIQWELD LIMITED WARRANTY
Terms of Warranty – January 2008
Warranty Schedule – January 2008
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION............................ Inside Rear Cover
TRANSARC 300 Si
SERVICE MANUAL
THIS PAGE LEFT INTENTIONALLY BLANK.
vi
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY
UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
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.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training
before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides
to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION,
MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
WARNING
13. In confined spaces or damp locations, do not use a welder with AC
output unless it is equipped with a voltage reducer. Use equipment
with DC output.
ELECTRIC SHOCK can kill.
14. Wear a safety harness to prevent falling if working above floor
level.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In
semiautomatic or automatic wire welding, the wire, wire
reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or
covers.
4. Disconnect input power or stop engine before installing or servicing
this equipment. Lock input power disconnect switch open, or remove
line fuses so power cannot be turned on accidentally.
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see ANSI
Z49.1 listed in Safety Standards) to protect your face and eyes when
welding or watching.
2. Wear approved safety glasses. Side shields recommended.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
3. Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not touch
holders connected to two welding machines at the same time or
touch other people with the holder or electrode.
5. Use approved ear plugs or ear muffs if noise level is high.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
January 15, 2008
1-1
TRANSARC 300 Si
SERVICE MANUAL
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
WARNING
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
7. Do not weld on closed containers such as tanks or drums.
welding fumes and gases.
8. Connect work cable to the work as close to the welding area as
3. If ventilation is poor, use an approved air-supplied respirator.
practical to prevent welding current from traveling long, possibly
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
unknown paths and causing electric shock and fire hazards.
instruction for metals, consumables, coatings, and cleaners.
9. Do not use welder to thaw frozen pipes.
5. Work in a confined space only if it is well ventilated, or while wearing an
air-supplied respirator. Shielding gases used for welding can displace 10. Remove stick electrode from holder or cut off welding wire at contact
tip when not in use.
air causing injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area, the
area is well ventilated, and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing these elements can
give off toxic fumes if welded.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and hot
equipment can cause fires and burns. Accidental contact of
electrode or welding wire to metal objects can cause sparks,
overheating, or fire.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Electrode Size
Filter
Welding or cutting
Electrode Size
2
Gas metal-arc
3 or 4
Non-ferrous base metal
All
Ferrous base metal
All
Under 1 in., 25 mm
3 or 4
Gas tungsten arc welding
All
1 to 6 in., 25-150 mm
4 or 5
(TIG)
All
Over 6 in., 150 mm
5 or 6
Atomic hydrogen welding
All
Carbon arc welding
All
Under 1/8 in., 3 mm
4 or 5
Plasma arc welding
1/8 to 1/2 in., 3-12 mm 5 or 6
Carbon arc air gouging
Over 1/2 in., 12 mm
6 or 8
Light
Under 5/32 in., 4 mm
10
Heavy
5/32 to 1/4 in.,
12
Plasma arc cutting
Over 1/4 in., 6.4 mm
14
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp
Filter
11
12
12
12
12
12
12
14
9
12
14
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
WARNING
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to treat
them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
!
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
WARNING
Engines can be dangerous.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
ENGINE EXHAUST GASES can kill.
WARNING
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away from
any building air intakes.
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn face,
eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
ENGINE FUEL can cause fire or explosion.
2. Wear gloves and put a rag over cap area when removing cap.
Engine fuel is highly flammable.
3. Allow pressure to escape before completely removing cap.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open
flames.
3. Allow engine to cool before fueling. If possible, check and add fuel
to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
January 15, 2008
!
WARNING
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some
cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
1-3
TRANSARC 300 Si
SERVICE MANUAL
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S.
Congress, Office of Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background Paper, OTA-BPE-63 (Washington, DC: U.S. Government Printing Office, May 1989):
“...there is now a very large volume of scientific findings based on
experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields and
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from body
as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers That Have Held Hazardous Substances, American Welding
Society Standard AWS F4.1, from American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
1-4
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
1.03 DECLARATION OF CONFORMITY
Manufacturer:
Address:
CIGWELD
71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (GMAW, MMAW, GTAW). Including, but not limited to CIGWELD Transtig 200 Pi,
Transtig 200 AC/DC, Transarc 300 Si, Transtig 300 Pi, Transtig 300 AC/DC, Transmig 400 i and associated accessories.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive 73/23/EU, as
recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the Directive.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
• AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and
regulations.
• EN60974-1 applicable to welding equipment and associated accessories.
• AS60974.1 applicable to welding equipment and associated accessories.
Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated into the
manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra
safe operation and world class quality for more than 30 years and will continue to achieve excellence.
January 15, 2008
1-5
TRANSARC 300 Si
SERVICE MANUAL
NOTES
1-6
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 2:
INTRODUCTION AND DESCRIPTION
2.01 How To Use This Manual
2.02 Equipment Identification
This Owner’s Manual applies to just specification or part
numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION,
and NOTE may appear. Pay particular attention to the
information provided under these headings. These special
annotations are easily recognized as follows:
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
nameplate attached to the control panel. In some cases, the
nameplate may be attached to the rear panel. Equipment
which does not have a control panel such as gun and cable
assemblies is identified only by the specification or part
number printed on the shipping container. Record these
numbers on the bottom of page i for future reference.
!
2.03 Receipt Of Equipment
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Cigweld at the address and phone number in your
area listed in the inside back cover of this manual. Include
the Owner’s Manual number and equipment identification
numbers.
Electronic copies of this manual can also be downloaded at
no charge in Acrobat PDF format by going to the
Cigweld web site listed below and clicking on the Literature
Library link:
http://www.cigweld.au.com
January 15, 2008
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there is
any damage, notify the carrier immediately to file a claim.
Furnish complete information concerning damage claims
or shipping errors to the location in your area listed in the
inside back cover of this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when
using bars, hammers, etc., to un-crate the unit.
CAUTION
The products applicable to this Service Manual
are manufactured in various configurations
for differing global requirements. Some
specifications and and electrical data quoted
within this Service Manual may not be applicable
to all products and regions. For this reason due
caution and care must be exercised when using
this Service Manual.
2-1
TRANSARC 300 Si
SERVICE MANUAL
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
2-2
Spot Time
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
IPM
Inches Per Minute
Line Connection
Touch Start (GTAW)
MPM
Meters Per Minute
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
Disturbance In
Ground System
Art # A-04130
115V 15A
X
%
Voltage Input
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
2.05 Description
The Cigweld Model Transarc 300 Si is a self contained three-phase DC arc welding power source with Constant Current
(CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter and lift arc starter for use with Gas
Tungsten Arc Welding (GTAW) and Shielded Metal Arc Welding (SMAW) processes. The power source is totally enclosed
in an impact resistant, flame resistant and non-conductive plastic case.
(V)
(V)
OCV
OCV
18V
10V
160A
5A
25A
300A 320A (A)
300A
S T I C K P r o cess
(A)
L I F T -T I G P r o cess
Figure 1 - Transarc 300 Si volt-ampere curve
NOTE
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power
source. Curves of other settings will fall between the curves shown.
2.06 Functional Block Diagrams
Figure 2 illustrates the functional block diagram of the Transarc 300 Si power source.
Input
Power
Main
Circuit
Switch
Filter
Input
Diode
Capacitor
DC Power
Primary
Voltage
Sensor
IGBT
Inverter
Thermal
Detector
Main
Transformer
(PCB14)
Hall Current
Output
Diodes
Thermal
Detector
Transformer
(HCT1)
-
Output
Inductor
To each control circuit
+/-15VDC +18VDC
+24VDC +5VDC
Trouble
Sensing
Circuit
Drive
Circuit
Themal
Sensor
Circuit
Stick Mode
VRD
Sensing
Circuit
+
Lift T ig Mode
Output Short
Sensing
Circuit
Primary
Current
Sensor
+
Sequence
Control
Torch Control
Connection
(CON1)
Current
Adjustment
circuit
-
Fan Control
Circuit
Fan
Reference
Adjustment &
Mode select Switches
Panel Circuit Board
Figure 2 - Transarc 300 Si functional block diagram
January 15, 2008
2-3
TRANSARC 300 Si
SERVICE MANUAL
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.
!
WARNING
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
• Lift unit with handle on top of case.
• Use handcart or similar device of adequate
capacity.
• If using a fork-lift vehicle, place and secure unit on a
proper skid before transporting.
2-4
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 3:
INSTALLATION RECOMMENDATIONS
3.01 Environment
3.03 Electrical Input Connections
The Transarc 300 Si is designed for use in hazardous
environments.
Examples of environments with increased hazardous
environments are a. In locations in which freedom of movement is
restricted, so that the operator is forced to perform the
work in a cramped (kneeling, sitting or lying) position
with physical contact with conductive parts,
b. In locations which are fully or partially limited by
conductive elements, and in which there is a high
risk of unavoidable or accidental contact by the
operator,
c. In wet or damp hot locations where humidity or
perspiration considerably reduces the skin resistance
of the human body and the insulation properties of
accessories.
Environments with hazardous environments do not
include places where electrically conductive parts in the
near vicinity of the operator, which can cause increased
hazard, have been insulated.
3.02 Location
Be sure to locate the welder according to the following
guidelines:
• In areas free from moisture and dust.
• Ambient temperature between 0 degrees C to 40
degrees C.
• In areas free from oil, steam and corrosive gases.
• In areas not subjected to abnormal vibration or
shock.
• In areas not exposed to direct sunlight or rain.
• Place at a distance of 12” (305mm) or more from
walls or similar that could restrict natural airflow for
cooling.
!
!
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input
power employing lockout/tagging procedures. Lockout/
tagging procedures consist of padlocking line disconnect
switch in open position, removing fuses from fuse box,
or shutting off and red-tagging circuit breaker or other
disconnecting device.
• Electrical Input Requirements
Operate the welding power source from a single/threephase 50/60 Hz, AC power supply. The input voltage must
match one of the electrical input voltages shown on the
input data label on the unit nameplate. Contact the local
electric utility for information about the type of electrical
service available, how proper connections should be made,
and inspection required.
The line disconnect switch provides a safe and convenient
means to completely remove all electrical power from the
welding power supply whenever necessary to inspect or
service the unit.
NOTE
These units are equipped with a threeconductor with earth power cable that is
connected at the welding power source end for
single and three phase electrical input power.
Do not connect an input (BROWN or BLUE or RED) conductor
to the ground terminal.
Do not connect the ground (YELLOW/GREEN) conductor to
an input line terminal.
WARNING
Cigweld advises that this equipment be
electrically connected by a qualified
electrician.
January 15, 2008
3-1
TRANSARC 300 Si
SERVICE MANUAL
3.04 Mains Supply Voltage Requirements
The Mains supply voltage should be within ± 15% of the rated Mains supply voltage. Too low a voltage may cause the
fuse or circuit breaker to rupture due to the increased primary current. Too high a supply voltage will cause the Power
Source to fail.
415V Mains Current Circuit Requirements for the Transarc 300 Si
The Welding Power Source must be:
• Correctly installed, if necessary, by a qualified electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size 415V Mains Current Circuit as per the Specifications
!
WARNING
CIGWELD advises that this equipment be electrically connected by a qualified electrical trades-person.
The following 415V Mains Current Circuit recommendations are required to obtain the maximum welding current and
duty cycle from this welding equipment:.
Model
Minimum 415V Mains
Current Circuit Size
Transarc 300 Si
22.3 Amps
Table 1: 415V Mains Current Circuit Sizes to achieve maximum current
NOTE
Motor Start Fuses or Circuit Breakers are recommended for this application.
• High Frequency Introduction
The importance of correct installation of high frequency welding equipment cannot be over-emphasized. Interference due
to high frequency initiated or stabilized arc is almost invariably traced to improper installation. The following information
is intended as a guide for personnel installing high frequency welding machines.
!
WARNING
Explosives
The high frequency section of this machine has an output similar to a radio transmitter. The machine should
NOT be used in the vicinity of blasting operations due to the danger of premature firing.
Computers
It is also possible that operation close to computer installations may cause computer malfunction.
3-2
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
• High Frequency Interference
Interference may be transmitted by a high frequency initiated or stabilized arc-welding machine in the following ways:
Direct Radiation
Radiation from the machine can occur if the case is metal and is not properly grounded. It can occur through apertures
such as open access panels. The shielding of the high frequency unit in the Power Source will prevent direct radiation
if the equipment is properly grounded.
Transmission via the Supply Lead
Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the installation (mains)
by direct coupling. The energy is then transmitted by both radiation and conduction. Adequate shielding and filtering
is provided in the Power Source.
Radiation from Welding Leads
Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with
distance. Keeping leads as short as possible will minimize this type of interference. Looping and suspending of
leads should be avoided where possible.
Re-radiation from Unearthed Metallic Objects
A major factor contributing to interference is re-radiation from unearthed metallic objects close to the welding leads.
Effective grounding of such objects will prevent re-radiation in most cases.
3.05 Specifications
Parameter
Power Source Part Number
Cooling
Welder Type
Welding Power Source Mass
Dimensions
Manufactured to Australian Standard
Number of Phases
Nominal Supply Voltage
Nominal Supply Frequency
Open Circuit Voltage
Welding Current Range
Effective Input Current (I1eff)
Maximum Input Current (I1max)
Three Phase Generator Requirement
Welding Output, 400C, 10 min.
(quoted figures refer to MMAW output)
Transarc 300 Si
625781
Fan Cooled
Inverter Power Source
20kg
H 420mm x W 210mm x D 450mm
AS 60974.1-2006
3
415V ±15%
50Hz
65V
5 - 300 Amps
14.1 Amps
22.3 Amps
16 KVA
Welding Output 400C, 10 min.
(Quoted figures refer to GTAW output)
300A @ 40%, 22.0V
250A @ 60%, 20.0V
180A @ 100%, 17.2V
Protection Class
300A @ 40%, 32.0V
250A @ 60%, 30.0V
180A @ 100%, 27.2V
IP23S
Cigweld continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment
previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above
specifications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components,
installation location and conditions and local power grid supply conditions.
January 15, 2008
3-3
TRANSARC 300 Si
SERVICE MANUAL
3.06 Duty Cycle
The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given
output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases.
If the welding amperes are increased beyond the rated output, the duty cycle will decrease.
!
WARNING
Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and
shut down the output until the unit has cooled to normal operating temperature.
CAUTION
Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void
the manufactures warranty.
NOTE
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities,
measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in
use and operation will depend upon correct installation, use, applications, maintenance and service.
3-4
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 4:
OPERATOR CONTROLS
4.01 Transarc 300 Si Controls
5
7
6
1
2
3
4
Art # A-08345
Figure 4 – Transarc 300 Si Power Source
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. Remote Control Socket
The 14 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source.
To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
E
A
ABCDEFGHIJKLMN
B
C
J
K
L
D
I
N
M
E
H
G
F
5k ohms
Front view of 14
Socket Receptacle
22
Socket Pin
Function
A
Torch Switch Input (24V) to energize weld current.
(connect pins A & B to turn on welding current)
B
Torch Switch Input (0V) to energize weld current
(connect pins A & B to turn on welding current)
C
5k ohm (maximum) connection to 5k ohm remote control potentiometer
D
Zero ohm (minimum) connection to 5k ohm remote control potentiometer
E
Wiper arm connection to 5k ohm remote control potentiometer
G
Mains Earth
F,H,I,J,K,L Not Used
M
OK to move current detect signal for robotics applications
N
OK to move current detect signal for robotics applications
January 15, 2008
4-1
TRANSARC 300 Si
SERVICE MANUAL
3. Positive Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the
male plug is inserted and turned securely to achieve a sound electrical connection.
4. Negative Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the
male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
bayonet terminal.
5. ON/OFF Switch
This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power
Supply.
!
WARNING
When the welder is connected to the Primary supply voltage, the internal electrical components maybe at
primary potential with respect to earth.
6. Input Cable
The input cable connects the Primary supply voltage to the equipment.
7. SMART Logic Switch
Manual slide switch mounted on the back panel selects for proper input voltage. If this slide is not set to the position
that matches the input voltage from the electrical source the Smart Logic circuit will inhibit welding power source
output. The digital meter will show primary input error code.
NOTE
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities,
measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in
use and operation will depend upon correct installation, use, applications, maintenance and service.
4-2
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
4.02 Weld Parameter Description
PRESS AND HOLD
Figure 5 - Transarc 300 Si Front Panel with Parameter Description
P ar am et er
HOT START
A
D escr i p t i on
This parameter operates in STICK weld mode and is used to improve
the start characteristics for stick electrodes. e.g. low hydrogen
electrodes. It sets the peak start current on top of the (WELD) current.
Weld Current (Amperage)- sets the STICK and TIG WELD current.
ARC CONTROL - This parameter provides a suitable short circuit
current in STICK welding to improve electrode sticking and arc
stability.
LIFT TIG mode of operation. A remote control device may be used for
use during LIFT TIG operation. See section 4.01, section 2 “Remote
Control Socket ”, for complete details of the remote device.
STICK Mode of operation
Selects Mode of Operation: Panel or Remote
REMOTE
By using the Save & Load buttons, the operator can easily save up to 5 welding
parameter programs.
NOTE
The Save/Load button must remain depressed for 3 seconds in order to store the settings.
Table 3 – Weld Parameter Descriptions
January 15, 2008
4-3
TRANSARC 300 Si
SERVICE MANUAL
4.03 Weld Parameters for Transarc 300 Si
Weld Parameter
HOT START
WELD CUR
ARC CONTROL
Parameter Range
0 to 70A
5 to 300A DC
0 to 100%
Factory
Setting
20A
80A
10%
Incremental
Unit
1A
1A
1%
Weld Mode
STICK
LIFT TIG
Yes
No
Yes
Yes
Yes
No
4.04 Power Source Features
Feature
New Digital Control
Touch Panel Switches
Front Control Cover
•
•
•
•
Description
Almost all welding parameters are adjustable
Touch switches eliminate mechanical damage
Protects front panel controls
Displays selected weld parameter value
• Displays weld current when welding
Digital Meter
• Displays weld current for 20 seconds after weld has been
completed
• A selected weld parameter value can be adjusted at any time
even while welding
• The intelligent cooling system is designed to reduce dust and
foreign material build-up, whilst providing optimum cooling.
Intelligent Fan Control
ON/OFF switch
Voltage Reduction Device (VRD)
• Fan speed reduces approximately 30 seconds after machine
is turned on
• Fan speed increases when internal components reaches
operating temperature
• Primary voltage Supply ON/OFF switch located on rear panel
Reduces the OCV when the power supply is not in use. Eliminates
the need for add on voltage reducers and has no effect on arc
starting.
• VRD fully complies to AS 60974.1
• When Stick mode is selected the green VRD light is ON when
not welding and red when welding.
• When in TIG modes VRD is off.
4-4
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 5:
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. The welding current range
values should be used as a guide only. Current delivered
to the arc is dependent on the welding arc voltage, and as
welding arc voltage varies between different classes of
electrodes, welding current at any one setting would vary
according to the type of electrode in use. The operator
should use the welding current range values as a guide, then
finally adjust the current setting to suit the application.
!
WARNING
Before connecting the work clamp to the work
and inserting the electrode in the electrode
holder make sure the Primary power supply is
switched off.
CAUTION
Remove any packaging material prior to use.
Do not block the air vents at the front or rear
or sides of the Welding Power Source.
January 15, 2008
Figure 6 – Transarc 300 Si Set-up
5-1
TRANSARC 300 Si
SERVICE MANUAL
NOTES
5-2
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 6:
SEQUENCE OF OPERATION
NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted on the
weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions.
1
5
6
2
PRESS AND HOLD
4
3
Figure 7 – Transarc 300 Si Front Panel
1. Scroll Buttons – used to select the parameter to be set. The LED’s show which function is being adjusted on the
Sequence Graph.
2. Digital LED display – Welding amperage and parameter values are displayed in this window. Internal warnings such
as over temperature, low or high input voltage applied are signaled to the operator by a warning sound and error
message on the screen.
3. Control Knob – allows the operator to adjust the output amperage within the entire range of the power source, also
used to set each parameter value.
4. Process Button – This button selects between STICK or Lift TIG mode.
5. Remote Current Function – Pressing this buttons enables remote current functions.
6. Save & Load Buttons – Press and hold these buttons for 3 seconds to save or load up to 5 welding parameter
programs.
January 15, 2008
6-1
TRANSARC 300 Si
SERVICE MANUAL
6.01 Stick Welding
• Connect work lead to negative terminal
• Connect electrode lead to positive terminal
• Switch machine on
• Set Contactor
• Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the
weld sequence graph. Use the control knob to adjust each parameter.
• Set HOT START
• Set WELD current
• Set Arc Control
Commence welding
6.02 DC LIFT TIG Welding
• Connect work lead to positive terminal
• Connect TIG torch to negative terminal
• Switch machine on
• Set weld current.
• Connect remote control device if desired
Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the
weld sequence graph. Use the control knob to adjust each parameter.
• Set WELD current
Commence welding
6-2
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 7:
BASIC TIG WELDING GUIDE
7.01 Electrode Polarity
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight
polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the
electrode since 70% of the heat is concentrated at the work piece.
7.02 Tungsten Electrode Current Ranges
Electrode Diameter
DC Current (Amps)
0.040” (1.0mm)
1/16” (1.6mm)
3/32” (2.4mm)
1/8” (3.2mm)
5/32” (4.0mm)
3/16” (4.8mm)
30 – 60
60 – 115
100 – 165
135 – 200
190 – 280
250 – 340
Table 4 – Current ranges for varies tungsten electrode sizes
7.03 Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Ceriated 2%
Welding Application
DC welding of mild steel,
stainless steel and copper.
Features
Excellent arc starting, Long life,
High current carrying capacity.
Longer life, More stable arc,
DC welding of mild steel,
Easier starting, Wider current
stainless steel, copper,
l i i
i
d
N
Table 5 – Tungsten electrode types
Color
Code
Red
Grey
7.04 Guide for Selecting Filler Wire Diameter
Filler Wire Diameter
1/16” (1.6 mm)
3/32” (2.4 mm)
1/8” (3.2 mm)
3/16” (4.8 mm)
DC Current Range (Amps)
20 - 90
65 - 115
100 - 165
200-350
Table 6 – Filler wire selection guide
NOTE
The filler wire diameter specified in Table 6 is a guide only, other diameter wires may be used according to
the welding application.
January 15, 2008
7-1
TRANSARC 300 Si
SERVICE MANUAL
7.05 Shielding Gas Selection
Alloy
Aluminium & alloys
Carbon Steel
Stainless Steel
Copper
Shielding Gas
Argon
Argon
Argon
Argon
Table 7 – Shielding gas selection
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Current Range DC
Amperes
Filler Rod for Root
Pass
120 - 170
Yes
100 - 160
Yes
90 - 130
No
Joint Preparation
Table 8 – TIG welding parameters for low carbon & low alloy steel pipe
7.07 Welding Parameters for Steel
Base Metal
Thickness
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
3/16”
4.8mm
¼”
6.4mm
DC Current DC Current for Tungsten
for Mild
Stainless
Electrode
Steel
Steel
Diameter
35-45
20-30
0.040”
40-50
25-35
1.0mm
45-55
30-45
0.040”
50-60
35-50
1.0mm
60-70
40-60
1/16”
70-90
50-70
1.6mm
80-100
65-85
1/16”
90-115
90-110
1.6mm
115-135
100-125
3/32”
140-165
125-150
2.4mm
160-175
135-160
1/8”
170-200
160-180
3.2mm
Filler Rod
Diameter
(if required)
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
5/32”
4.0mm
Argon Gas
Flow Rate
Liters/min Joint Type
5-7
Butt/Corner
Lap/ Fillet
5-7
Butt/Corner
Lap/ Fillet
7
Butt/Corner
Lap/ Fillet
7
Butt/Corner
Lap/ Fillet
10
Butt/Corner
Lap/ Fillet
10
Butt/Corner
Lap/ Fillet
Table 9 – DC TIG welding parameters
7-2
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 8:
BASIC ARC WELDING GUIDE
8.01 Electrode Polarity
Stick electrodes are generally connected to the ‘+’ terminal
and the work lead to the ‘-’ terminal but if in doubt consult
the electrode manufacturers literature.
8.02 Effects of Stick Welding Various
Materials
High tensile and alloy steels
The two most prominent effects of welding these
steels are the formation of a hardened zone in the
weld area, and, if suitable precautions are not taken,
the occurrence in this zone of under-bead cracks.
Hardened zone and under-bead cracks in the weld
area may be reduced by using the correct electrodes,
preheating, using higher current settings, using larger
electrodes sizes, short runs for larger electrode deposits
or tempering in a furnace.
Manganese steels
The effect on manganese steel of slow cooling from
high temperatures is to em brittle it. For this reason it
is absolutely essential to keep manganese steel cool
during welding by quenching after each weld or skip
welding to distribute the heat.
Metals being joined
Electrode
Mild steel
6013
Mild steel
7014
Cast iron
99% Nickel
Stainless steel
Copper, Bronze, Brass, etc.
High Alloy Steels,
Dissimilar Metals,
Crack Resistance.
All Hard-To-Weld Jobs.
318L-16
Bronze
5.7
ERCUSI-A
312-16
Cast Iron
Most types of cast iron, except white iron, are weldable.
White iron, because of its extreme brittleness, generally
cracks when attempts are made to weld it. Trouble
may also be experienced when welding white-heart
malleable, due to the porosity caused by gas held in
this type of iron.
Copper and alloys
The most important factor is the high rate of heat
conductivity of copper, making preheating of heavy
sections necessary to give proper fusion of weld and
base metal.
Types of Electrodes
Arc Welding electrodes are classified into a number
of groups depending on their applications. There are
a great number of electrodes used for specialized
industrial purposes which are not of particular interest
for everyday general work. These include some low
hydrogen types for high tensile steel, cellulose types
for welding large diameter pipes, etc. The range of
electrodes dealt with in this publication will cover the
vast majority of applications likely to be encountered;
are all easy to use and all will work on even the most
basic of welding machines.
Comments
Ideal electrodes for all general purpose work.
Features include out standing operator appeal,
easy arc starting and low spatter.
All positional electrode for use on mild and
galvanized steel furniture, plates, fences,
gates, pipes and tanks etc. Especially suitable
for vertical-down welding.
Suitable for joining all cast irons except white
cast iron.
High corrosion resistance. Ideal for dairy work,
etc. On stainless steels.
Easy to use electrode for marine fittings, water
taps and valves, water trough float arms, etc.
Also for joining copper to steel and for bronze
overlays on steel shafts.
It will weld most problematical jobs such as
springs, shafts, broken joins mild steel to
stainless and alloy steels.
Not suitable for Aluminum.
Table 10 - Types of Electrodes
January 15, 2008
8-1
TRANSARC 300 Si
SERVICE MANUAL
NOTES
8-2
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 9:
ROUTINE MAINTENANCE
The only routine maintenance required for the power supply is a thorough cleaning and inspection, 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.
To clean the unit, open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should
also be wiped clean, if necessary; with solvents that are recommended for cleaning electrical apparatus.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.
January 15, 2008
9-1
TRANSARC 300 Si
SERVICE MANUAL
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Visual check of torch
Consumable parts
Visual check of
regulator and pressure
Weekly
Visually inspect the torch
body and consumables
Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all
broken parts
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
CIGWELD Service Provider
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-07681_AC
9-2
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
9.01 VRD Specification
Description
VRD Open Circuit Voltage
Transarc 300 Si
15.3 to 19.8V
VRD Resistance
148 to 193 ohms
VRD Turn OFF Time
0.2 to 0.3 seconds
Notes
Open circuit voltage between welding terminals
The required resistance between welding
terminals to turn ON the welding power
The time taken to turn OFF the welding power
once the welding current has stopped
9.02 VRD Maintenance
Routine inspection and testing (power source)
An inspection of the power source, an insulation resistance test and an earth resistance test shall be carried out.
a) For transportable equipment, at least once every 3 months; and
b) For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests.
NOTE
A transportable power source is any equipment that is not permanently connected and fixed in the position
in which it is operated.
In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests
should also be conducted by an accredited Cigweld Service Provider.
Description
VRD Open Circuit Voltage
VRD Turn ON Resistance
VRD Turn OFF Time
Required Parameters
Less than 20V; at Vin=415V
Less than 200 ohms
Less than 0.3 seconds
If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests
should be carried out prior to entering this location.
January 15, 2008
9-3
TRANSARC 300 Si
SERVICE MANUAL
THIS PAGE LEFT INTENTIONALLY BLANK.
9-4
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
SECTION 10:
BASIC TROUBLESHOOTING
!
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to
open or repair unless you are an Accredited Cigweld™ Service Provider and you have had training in power
measurements and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Cigweld
Service Provider for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
10.01 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding
technique.
1.
2.
3.
4.
5.
Description
Excessive beard build-up or poor
penetration or poor fusion at
edges of weld.
Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through
Weld bead too small or insufficient
penetration or ripples in bead are
widely spaced apart
Weld bead too wide or excessive
bead build up or excessive penetra­
tion in butt joint
Uneven leg length in fillet joint
January 15, 2008
Possible Cause
Welding current is too low
Remedy
Increase weld current and/or faulty
joint preparation
Welding current is too high
Decrease weld current
Travel speed too fast
Reduce travel speed
Travel speed too slow
Increase travel speed
Wrong placement of filler rod
Re-position filler rod
10-1
TRANSARC 300 Si
Description
Electrode melts when arc is
struck.
7. Dirty weld pool.
6.
8.
Electrode melts or oxidizes when
an arc is struck.
9.
Poor weld finish.
10. Arc flutters during TIG welding.
11. Welding arc can not be
established.
12. Arc start is not smooth.
10-2
SERVICE MANUAL
Possible Cause
Remedy
Electrode is connected to the ‘+’
Connect the electrode to the ‘−’
terminal.
terminal.
A. Electrode contaminated through A. Clean the electrode by grinding off
contact with work piece or filler rod
the contaminates.
material.
B. Gas contaminated with air.
B. Check gas lines for cuts and loose
fitting or change gas cylinder.
A. No gas flowing to welding region. A. Check the gas lines for kinks or
breaks and gas cylinder contents.
B. Torch is clogged with dust.
B. Clean torch
C. Gas hose is cut.
C. Replace gas hose.
D. Gas passage contains impurities. D. Disconnect gas hose from torch
then raise gas pressure and blow
out impurities.
E. Gas regulator turned off.
E. Turn on.
F. Torch valve is turned off.
F. Turn on.
G. The electrode is too small for the G. Increase electrode diameter or
welding current.
reduce the welding current.
Inadequate shielding gas.
Increase gas flow or check gas line
for gas flow problems.
A. Tungsten electrode is too large for A. Select the right size electrode.
the welding current.
Refer to Basic TIG Welding guide.
B. Absence of oxides in the weld pool. B. Refer Basic TIG Welding Guide for
ways to reduce arc flutter.
A. Work clamp is not connected to A. Connect the work clamp to the
the work piece or the work/torch
work piece or connect the work/
leads are not connected to the right
torch leads to the right welding
welding terminals.
terminals.
B. Torch lead is disconnected.
B. Connect it to the ‘−‘ terminal.
C. Gas flow incorrectly set, cylinder C. Select the right flow rate, change
empty or the torch valve is off.
cylinders or turn torch valve on.
A. Tungsten electrode is too large for A. Select the right size electrode.
the welding current.
Refer to Section 7, Basic TIG
Welding Guide.
B. The wrong electrode is being used B. Select the right electrode type.
for the welding job
Refer to Section 7, Basic TIG
Welding Guide.
C. Gas flow rate is too high.
C. Select the correct rate for the
welding job.
Refer to Section 7, Basic TIG
Welding Guide.
D. Incorrect shielding gas is being D. Select the right shielding gas.
used.
Refer to Section 7, Basic TIG
Welding Guide.
E. Poor work clamp connection to work E. Improve connection to work piece.
piece.
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
10.02 Stick Welding Problems
Description
1. Gas pockets or voids in weld metal
(Porosity).
2. Crack occurring in weld metal soon
after solidification commences
Possible Cause
A. Electrodes are damp.
B. Welding current is too high.
C. Surface impurities such as oil,
grease, paint, etc.
A. Rigidity of joint.
B. Insufficient throat thickness.
3. A gap is left by failure of the weld
metal to fill the root of the weld.
C. Cooling rate is too high.
A. Welding current is too low.
B. Electrode too large for joint.
C. Insufficient gap.
D. Incorrect sequence.
Remedy
A. Dry electrodes before use.
B. Reduce welding current.
C. Clean joint before welding.
A. Redesign to relieve weld joint
of severe stresses or use
crack resistance electrodes.
B. Travel slightly slower to allow
greater build up in throat.
C. Preheat plate and cool slowly.
A. Increase welding current
B. Use smaller diameter
electrode.
C. Allow wider gap.
D. Use correct build-up
sequence.
Figure 8 – Example of insufficient gap or incorrect sequence
4. Portions of the weld run do not fuse A. Small electrodes used on heavy A .
to the surface of the metal or edge
cold plate.
of the joint.
B. Welding current is too low.
B.
C. Wrong electrode angle.
C.
Use larger electrodes and pre-heat
the plate.
Increase welding current
Adjust angle so the welding arc is
directed more into the base metal
D. Travel speed of electrode is too D. Reduce travel speed of electrode
high.
E. Scale or dirt on joint surface.
E. Clean surface before welding.
Figure 9 – Example of lack of fusion
January 15, 2008
10-3
TRANSARC 300 Si
SERVICE MANUAL
5. Non-metallic parti­cles are A. Non-metallic particles may be trapped A. If bad undercut is present, clean
trapped in the weld metal
in undercut from previous run.
slag out and cover with a run from a
(slag inclusion).
smaller diameter electrode.
B. Joint preparation too restricted.
B. Allow for adequate penetration and
room for cleaning out the slag.
C. Irregular deposits allow slag to be C. If very bad, chip or grind out
trapped.
irregularities.
D. Lack of penetration with slag trapped D. Use smaller electrode with sufficient
beneath weld bead.
current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
E. Rust or mill scale is preventing full E. Clean joint before welding.
fusion.
F. Wrong electrode for position in which F. Use electrodes designed for position
welding is done.
in which welding is done, otherwise
proper control of slag is difficult.
Figure 10 – Examples of slag inclusion
10.03 Power Source Problems
Description
Possible Cause
1. The welding arc cannot be A . The Primary supply voltage has not A .
established
been switched ON.
B. The Welding Power Source switch B.
is switched OFF.
C. Loose connections internally.
C.
2. Maximum output welding
current can not be achieved
with nominal Mains supply
voltage.
3. Welding current reduces when
welding
Defective control circuit
Poor work lead connection to the
work piece.
4. No gas flow when the torch A. Gas hose is cut.
trigger switch is depressed.
B. Gas passage contains impurities.
A.
B.
C. Gas regulator turned off.
C.
D. Torch trigger switch lead is D.
disconnected or switch/cable is
faulty.
10-4
Remedy
Switch ON the Primary supply
voltage.
Switch ON the Welding Power
Source.
Have an Accredited Cigweld
Service Provider repair the
connection.
Have an Accredited Cigweld
Service Provider inspect then
repair the welder.
Ensure that the work lead has a
positive electrical connection to
the work piece.
Replace gas hose.
Disconnect gas hose from the
rear of Power Source then raise
gas pressure and blow out
impurities.
Turn gas regulator on.
Reconnect lead or repair faulty
switch/cable.
January 15, 2008
SERVICE MANUAL TRANSARC 300 Si
10.04 Power Source Error Codes
Description
1
Possible Cause
Remedy
Remarks
E01 error code
displayed.
Temperature
sensor TH1
(protects IGBTs)
is greater than
80°C for about 1
second.
A The Welding Power
Source’s duty cycle has
been exceeded.
A Let Power Source cool
down then keep within
its duty cycle.
B Fan ceases to operate.
B Have an Accredited
Cigweld Service Provider
investigate.
C Air flow is restricted by
vents being blocked.
C Unblock vents then
let Power Source cool
down.
E02 error code
displayed.
Temperature
sensor TH2
(protects IGBTs)
is greater than
90°C for about 1
second.
A The Welding Power
Source’s duty cycle has
been exceeded.
A Let Power Source cool
down then keep within
its duty cycle.
B Fan ceases to operate.
B Have an Accredited
Cigweld Service Provider
investigate.
C Air flow is restricted by
vents being blocked.
C Unblock vents then
let Power Source cool
down.
E03 error code
displayed.
Primary (input)
current too high.
A Primary current too
high because welding
arc is too long
A Reduce length of
welding arc
4
E11 error code
displayed.
Over Primary
supply (input)
voltage at
primary
capacitors is
exceeded for one
second.
Primary supply voltage
is greater than the
nominal voltage plus
15%.
Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the Primary
voltage.
Weld current
ceases. Buzzer
sounds constantly.
Error code E11
automatically will
reset when the
voltage reduces.
5
E12 error code
displayed.
Under mains
supply (input)
voltage warning
primary
capacitors is
reduced for one
second.
Mains supply voltage is down to a dangerously
low level.
Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the Mains voltage.
Have an Accredited
Cigweld Service Provider
or a qualified electrician
check the primary cable
& fuses.
Weld current
ceases. Buzzer
sounds constantly.
Error code E12 will
automatically reset
when the voltage
increases.
2
3
January 15, 2008
B Mains supply voltage is B Have an Accredited
more than 15% below
Cigweld Service Provider
nominal voltage
or a qualified electrician
check for low Mains
voltage.
Weld current
ceases. Buzzer
sounds constantly.
E01 resets when
TH1 decreases to
70°C for about 30
seconds.
Weld current
ceases. Buzzer
sounds constantly.
E02 resets when
TH2 decreases to
70°C for about 30
seconds.
Weld current
ceases. Buzzer
sounds constantly.
Switch machine
off then on to reset
E03 error.
10-5
TRANSARC 300 Si
Description
SERVICE MANUAL
Possible Cause
6 E14 error code
Mains supply voltage is less
displayed.
than the nominal operating
Under mains supply voltage plus 15%.
(input) voltage
warning primary
capacitors is reduced
for one second.
Remedy
Remarks
Have an Accredited Cigweld
Service Provider or a
qualified electrician check the
Mains voltage.
Weld current
available. Buzzer
sounds intermittently.
Error code E14 will
automatically reset
when the voltage
increases.
7 E81 error code
displayed.
Wrong Primary
supply (input) voltage
connected.
When 3 phase machine is
Have an Accredited Cigweld
first turned on with the wrong Service Provider check the
Primary supply (input) voltage Mains voltage.
connected.
No weld current is
available. Buzzer
sounds constantly.
Switch machine off.
8 E82 error code
displayed.
Link switch plug not
connected.
Link switch plug not
connected.
Have an Accredited Cigweld
Service Provider or a
qualified electrician check the
connector plug on input PCB.
No weld current is
available. Buzzer
sounds constantly.
Switch machine off.
9 E83 error code
The Primary supply (input)
displayed.
voltage fluctuates and is not
CPU checks mains
stable.
supply (input) voltage
when the on/off
switch on rear panel
of machine is turned
ON.
Have an Accredited Cigweld
Service Provider or a
qualified electrician check the
connector plug on the input
PCB and the Mains voltage.
No weld current is
available. Buzzer
sounds constantly.
Switch machine off
then on to reset E83
error.
10 E93 error code
displayed.
Memory chip
(EEPROM) on
control PCB can
not read/write weld
parameters.
Memory chip (EEPROM)
error.
Have an Accredited Cigweld
Service Provider or a
qualified electrician check the
control PCB.
Weld current is
ceases. Buzzer
sounds constantly.
Switch machine off.
11 E94 error code
displayed.
Temperature sensor
TH1 for IGBTs is an
open circuit.
The Welding Power Source’s
temperature sensors have
malfunctioned.
Have an Accredited Cigweld
Service Provider check or
replace the temperature
sensors.
Weld current ceases.
Buzzer sounds
constantly. Switch
machine off.
12 E99 error code
A Main on/off switch on
displayed.
machine has been turned
Mains supply (input)
off.
voltage has been
B Mains supply (input)
turned off, but control
voltage has been turned
circuit has power
off.
from the primary
capacitors.
10-6
A Turn on/off switch on.
Weld current ceases.
Buzzer sounds
B Have an Accredited
constantly. Must
Cigweld Service Provider switch machine off
or a qualified electrician then on to reset E99
check the Main voltage
error.
and fuses.
January 15, 2008
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
ADVANCED TROUBLESHOOTING
If you are here, all of the troubleshooting suggestions in Section 8-Basic Troubleshooting have
either failed to resolve the faulty operation or have
indicated that one or more of the subsystems
within the power supply are defective. This section
provides the information needed to take live measurements on the various subsystems within the
power supply, and replace those subsystems that
prove faulty.
11.01 System-Level Fault Isolation
If none of the suggestions provided in Section 8
have solved the problem or corrected the faulty
operation, the next step is to isolate one or more of
the internal subassemblies that may be defective.
CAUTION
Perform all steps in each procedure, in sequence.
Skipping portions of procedures, or performing
steps out of sequence can result in damage to the
unit, and possible injury, or worse, to the operator.
CAUTION
Troubleshooting and repairing this unit is a process, which should be undertaken only by those
familiar with high voltage/high power electronic
equipment.
11.1.1 Opening the Enclosure
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have training in
power electronics, measurement and troubleshooting techniques.
Under no circumstances are field repairs to be
attempted on printed circuit boards or other subassemblies of this unit. Evidence of unauthorized
repairs will void the factory warranty. If a subassembly is found to be defective by executing any of
the procedures in this Service Manual, the subassembly should be replaced with a new one. The
faulty subassembly should then be returned to
Thermal Arc through established procedures.
WARNING
1) Confirm that the switch of power supply and
the switch on switchboard (distribution panel)
are all OFF.
Figure 11-1: Switch OFF
CAUTION
Disconnect primary power at the source before disassembling the power supply. Frequently review
the "Important Safety Precautions" in section 1.02.
Be sure the operator is equipped with proper
gloves, clothing and eye and ear protection. Make
sure no part of the operator's body comes into contact with the work piece or any internal components
while the unit is activated.
11 – 1
The capacitors inside the power supply will slowly
discharged after you turn off the switch of the
power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete.
SERVICE MANUAL
TRANSARC 300 Si
11 ADVANCED TROUBLESHOOTING
2) Remove all screws and nuts on the side covers.
4) Pull the front panel slightly forward and pull the
rear panel slightly backward. The interlocking
hooks of the side case covers can now be disengaged from the front and rear panels.
Figure 11-2: Remove screws
3) Loosen the screws on the front panel and the
rear panel by turning them approximately two
turns CCW.
Figure 11-4: Loosen front and rear panels
5) Remove the side covers.
Figure 11-3: Loosen screws
NOTE
DO NOT remove the screws completely.
Figure 11-5: Remove Side covers
11 – 2
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
6) Remove protection cover sheet by removing
the plastic tabs.
11.2.1 E01 "Over-Temperature at
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.
Review the rated duty cycle of the unit per
section 3.8. Exceeding the duty cycle can
damage the unit and void the warranty. Refer
also to section 1.6 for additional information.
b) Verify the ventilating condition.
Maintain a clear and unobstructed distance
of more than 30cm in the front and more that
50cm in the rear of the unit for ventilation purposes.
Figure 11-6: Remove PCB cover
NOTE
When you re-assemble the parts, conduct the
above process backwards.
11.02 Verification and Remedy
to the Indicated Error Codes
Verify and maintain clean, dust free, front and
rear airflow paths. Cleaning and removing
dust from the front and rear panels once
every six months in a normal working environment is recommended. Extremely dusty
environments will require more frequent
cleanings.
c) Verify the operation of the cooling fan, FAN1,
and replace it if necessary.
NOTE
The capacitors inside the power supply will slowly
discharged after you turn off the switch of the
power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete and then remove the cases to
continue your inspection and repair (or maintenance) inside the power supply. As for the removal
and installation of the case, refer to section 11.1.1.
NOTE
During the "Verification/Remedy" procedures
below, follow the alphabetical sequence (a, b, c...)
and proceed with your verification and confirmation.
Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing any abnormal sounds.
If broken or cracked FAN1 blades, or abnormal sounds are emanating from FAN1,
replace FAN1.
Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section.
Refer to section 12.3.21 for the replacement
of FAN1.
Refer to section 11.5.3 for additional FAN1
tests.
d) Replace PCB6 (WK-5549).
NOTE
After you confirm and replace all spare parts and
components, confirm that there are no damaged
harnesses or connectors, uninstalled or loose
screws.
11 – 3
Refer to section 12.3.6 for the replacement of
PCB6.
SERVICE MANUAL
TRANSARC 300 Si
11 ADVANCED TROUBLESHOOTING
11.2.2 E02 "Over-Temperature at
the secondary side"
11.2.3 E03 "Transformer
Over-Current Failure"
Cause
Cause
Occurs when an over-temperature condition of the
secondary IGBT and diode are detected.
Occurs when excessive current is detected flowing into the primary side of the main transformer.
Verification/Remedy
Verification/Remedy
a) Unit may be in thermal shutdown mode.
a) Confirm the operation of the machine within
the rated specification.
Review the rated duty cycle of the unit per
section 3.8. Exceeding the duty cycle can
damage the unit and void the warranty.
Refer to the specification data sheet in Section 3.9.
b) Verify the secondary diode (D2, D4, D5 and
D7).
b) Verify the ventilating condition.
Maintain a clear and unobstructed distance
of more than 30cm in the front and more that
50cm in the rear of the unit for ventilation purposes.
Verify and maintain clean, dust free, front and
rear airflow paths. Cleaning and removing
dust from the front and rear panels once
every six months in a normal working environment is recommended. Extremely dusty
environments will require more frequent
cleanings.
Refer to section 11.5.6 for the test and
replacement of D2, D4, D5 and D7.
c) Replace the Hall CT, HCT1.
Refer to section 12.3.29 for the replacement
of HF.UNIT 1.
NOTE
Pay special attention to installed direction of HCT1.
The Hall CT will not function properly if installed in
the incorrect direction.
Refer to section 12.3.27 for the replacement
of HCT1.
c) Verify the operation of the cooling fan, FAN1,
and replace it if necessary.
Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing any abnormal sounds.
d) Verify the H.F. unit (HF. UNIT1).
If broken or cracked FAN1 blades, or abnormal sounds are emanating from FAN1,
replace FAN1.
(300 Pi & 300 AC/DC only)
Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section.
Refer to section 12.3.21 for the replacement
of FAN1.
Refer to section 11.5.3 for addition FAN1
tests.
d) Replace PCB6 (WK-5549).
Refer to section 12.3.6 for the replacement of
PCB6.
11 – 4
Refer to section 12.3.26 for the replacement
of HF.UNIT 1.
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
11.2.4 E04 "Torch Cable Failure"
11.2.6 E12 "Main Supply Under Voltage"
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
cable and the power supply.
a) Verify main supply voltage.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer to section 11.5.2
Only use appropriate sized torch cables
(length and capacity). The recommended
total combined length of the torch and work
cable is 50 feet.
b) Replace PCB4 (WK-4819)
Replace PCB4, when abnormalities occur,
even if carries out the above-mentioned verifications. Refer to section 12.3.4.
Torch and work cable should not be "coiled"
during welding operations.
Maintain the duty cycle of the power supply.
Refer to section 3.8 for the recommended
duty cycle.
b) Replace PCB6 (WK-5549)
11.2.7 E81 "Wrong Main Supply
Voltage"
Refer to section 12.3.6 for the replacement of
PCB6.
11.2.5 E11 "Main Supply Over Voltage"
Cause
The detection circuitry of main supply voltage is
abnormality.
Verification/Remedy
a) Verify main supply voltage.
Cause
Main supply voltage occurs in about 275V or
more.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer to section 11.5.2.
b) Confirm a secure connection of the harness
wired between CN2 on PCB3 (WK-5548) and
CN1 on PCB21 (WK-4917)
Verification/Remedy
a) Verify main supply voltage.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer section 11.5.2.
b) Replace PCB4 (WK-4819)
Verify PCB4 (WK-4819) and replace it if necessary. Refer to section 12.3.4.
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
When the PCB fixed screw is loosening, it
fastens certainly.
c) Verify PCB4 (WK-4819) and replace it if necessary
Check whether there are any abnormalities
on the appearance of PCB4.
Replace PCB4. Refer to section 12.3.4.
11 – 5
SERVICE MANUAL
TRANSARC 300 Si
11 ADVANCED TROUBLESHOOTING
11.2.8 E82 "Rated Voltage Selection
Circuit abnormality"
c) Verify PCB4 (WK-4819) and replace it if necessary.
Check whether there are any abnormalities
on the appearance of PCB4.
Cause
Rated voltage selection circuit inside the Welding
Power Source is not functioning properly.
Replace PCB4. Refer to section 12.3.4.
11.2.10 E85 "Pre-charge abnormality"
Verification/Remedy
Cause
a) Verify the wiring harness and connection of
CN4 on PCB4 (WK-4819).
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
When the PCB fixed screw is loosening, it
fastens certainly.
b) Verify PCB4 (WK-4819) and replace it if necessary.
Check whether there are any abnormalities
on the appearance of PCB4.
Replace PCB4. Refer to section 12.3.4.
11.2.9 E83 "Abnormalities in Mains
Supply Voltage Detection"
Due to a malfunction inside the Welding Power
Source, primary capacitors are not charging correctly.
Verification/Remedy
a) Verify the connection PCB2 (WK-5597) and
the rectified output voltage of the rectifier.
Verify the connection between CN2 on PCB2
and CN3 on PCB3.
Confirm whether there is any breakage
(blown, burnt, cracked, etc.) of R18 on PCB2.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer to section 11.5.2.
b) Verify the primary diode (D1).
Verify D1. Refer to section 11.5.5.
Replace D1. Refer to section 12.3.28.
Cause
Abnormalities, such as an input voltage detection
circuit.
c) Verify the primary IGBT (Q1-Q24).
Verify IGBT. Refer to section 11.5.7.
Replace IGBT. Refer to section 12.3.7, 12.3.8.
Verification/Remedy
d) Replace PCB2 (WK-5597) and PCB4
(WK-4819).
a) Verify main supply voltage.
Perform what is described in a section of
"Verification of the Power Supply Voltage".
Refer to section 11.5.2.
b) Confirm a secure connection of the harness
wired between CN2 on PCB3 (WK-5548) and
CN1 on PCB21 (WK-4917).
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
11 – 6
Replace PCB2 and PCB4, when abnormalities
occur, even if you carry out the above-mentioned
verifications. Refer to section 12.3.2, 12.3.4.
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
11.2.11 E94 "Thermistor malfunction" 11.03
Verification and Remedy to
Failures without Indication
Codes
Cause
Thermistors for detecting temperature of internal
components have malfunctioned.
Verification/Remedy
11.3.1 "Cooling Fan (FAN1) Failure"
(Fan is not rotating.)
a) Confirm a secure connection of the harness
wired between CN8-9 on PCB6 (WK-5549)
and Thermistors (TH1, TH2).
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
b) Replace thermistors (TH1, TH2).
Cause
Occurs when the cooling fan (FAN1) is defective,
damaged or the driving voltage is incorrect.
Verification/Remedy
a) Verify the cooling fan (FAN1).
Refer to section 12.3.19, 12.3.20.
c) Replace PCB6 (WK-5549).
Refer to section 12.3.6.
11.2.12 E99 "Initial Power Receiving"
Cause
Occurs when the initial AC power received signal
has not reached the CPU. This error occurs normally during the power "OFF" sequence of the
unit.
Verification/Remedy
Inspect the condition of the fan blades and all
peripheral parts. Clean the fan blades and all
peripheral parts if covered with dust. Cleaning and removing dust from the fan blades
once every 6 months in a normal environment is recommended. Extremely dusty
environments will require more frequent
cleanings.
Verify that there are no wiring harnesses
entangled inside the fan, confirm that the harnesses do not have any brakes in the wire or
damaged connectors.
Replace wiring harnesses if you find any broken connectors or damaged wiring harnesses.
a) Confirm a secure connection of the harness
wired between CN1 on PCB21 (WK-4917) and
CN2 on PCB3 (WK-5548).
Replace the fan if there are any broken,
cracked or missing fan blades.
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken connectors or damaged wiring harness.
b) Verify PCB4 (WK-4819) and replace it if necessary.
Confirm a secure connection of all the harnesses wired to PCB3 and PCB4.
Replace PCB4. Refer to section 12.3.4.
Refer to section 12.3.21.
b) Verify the wiring harness between the cooling
fan (FAN1) and CN11 on PCB3 (WK-5548).
Confirm a secure connection of the harness
to CN11 on PCB3.
c) Verify the drive circuitry of the cooling fan
(FAN1) on PCB3.
Verify the drive circuitry of the cooling fan
(FAN1) on PCB3.
Refer to section 11.5.3.
c) Replace PCB6 (WK-5549).
Refer to section 12.3.6.
Replace PCB3 if necessary.
Refer to section 12.3.3.
11 – 7
SERVICE MANUAL
TRANSARC 300 Si
11 ADVANCED TROUBLESHOOTING
11.3.3 "No Weld Output"
When in High Frequency TIG (HF TIG) mode, if the
High Frequency is not generated (present), refer to
"High Frequency Output Failure". Refer to page
11-9.
Cause
Occurs when the remote connector (CON1) or
associated circuitry is defective, damaged, or the
TIG torch cable is defective.
Verification/Remedy
Caution
Read and understand this entire section before
proceeding. Extreme personal harm and test
equipment damage will occur if the procedures are
not performed accurately.
a) Verify the remote connector (CON1).
(Applies to LIFT TIG and High Frequency TIG
(HF TIG) mode.)
Confirm a secure between the remote connector (CON1) and the TIG torch cable.
Confirm a secure connection of the harness
and the connections between the remote
connector (CON1) and PCB7 (WK-5550) are
all correct and there are no open circuits.
Contact the manufacture if you find any broken connectors or damaged wiring harnesses.
Confirm the proper pin-outs of the remote
connector at the TIG Torch side. (Refer to
the Operating Manual.)
Confirm that there is no open circuit on the
remote connector at TIG Torch side.
In equipment for remote control use, confirm
the pin specification of a connector. (Refer to
the Operating Manual.)
b) Verify the condition and connections of the
welding cable, the stick rod holders and the
ground clamp. (Applies to all welding modes.)
Confirm a secure connection of the welding
cable, stick rod holders, ground clamp and
dense connectors and there are no open circuits.
11 – 8
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
c) Verify the no-load voltage (OCV).
(Applies to STICK, High Frequency TIG (HF
TIG) mode.)
Refer to the section "Verification of No-load
voltage (OCV)" in section 11.5.9.
If performing the "No-Load Voltage Failure"
procedure does not rectify the failure, perform the following tests in the sequence
below. Replace any defective components
found.
1. Secondary diode (D2, D4, D5 and D7).
Verification. Refer to section 11.5.6.
Replacement. Refer to section 12.3.29.
2. Reactor (FCH1)
Replacement. Refer to section 12.3.18.
3. PCB14 (T1)
Replacement. Refer to section 12.3.11.
4. PCB8-PCB11 (Q1~Q24)
Verification. Refer to section 11.5.7.
Replacement. Refer to section 12.3.7,
12.3.8.
5. Hall C.T. (HCT1)
Replacement. Refer to section 12.3.27.
d) Replacement. Refer to section 12.3.
b) Verify the connection between PCB6
(WK-5549) and PCB12 (WK-5527).
c) Replace PCB6 (WK-5549) and PCB12
(WK-5527).
Refer to section 12.3.6, 12.3.9.
d) Verify the connection between PCB5
(WK-5551) and PCB6 (WK-5549).
e) Replace PCB5 (WK-5551) and PCB6
(WK-5549).
Refer to section 12.3.5, 12.3.6.1
11.3.5 "High Frequency Output Failure" (Unit does not generate
High Frequency.)
(300 Pi & 300 AC/DC only)
Cause
Occurs when the HF. unit (HF UNIT1) is defective
or blown.
Verification/Remedy
Caution
11.3.4 "Operating Panel Failure"
(LED's do not light properly
or welding setting cannot be
established.)
Cause
Occurs when there is a connection failure among
PCB6 (WK-5549), PCB12 (WK-5527) and PCB6
or PCB12 are defective.
Verification/Remedy
a) Verify the harness connection between CN21
on PCB6 (WK-5549) and CN2 on PCB12
(WK-5527).
Confirm a secure connection of the harness
and the connections between CN21 on PCB6
(WK-5549) and CN2 on PCB12 (WK-5527).
Contact the manufacture if you find any broken connectors or damaged wiring harnesses.
11 – 9
Read and understand this entire section before
proceeding. Extreme personal harm and test
equipment damage will occur if the procedures are
not performed accurately. The unit will generate a
High Voltage component that can cause extreme
personal harm and test equipment damage.Capacitors installed inside the Welding Power Source are
electrically charged for a while after the Mains ON/
OFF switch or distribution panel switch has been
turned off. Before inspecting the inside of the Welding Power Source, leave it for about 5 min. after
switching off power for discharging the capacitors,
and then remove the top and side panels.
a) Verify the connection between High Frequency
(HF UNIT1) and Coupling Coil (CC1).
Verify the connection between the HF UNIT1
and CC1; confirm that the quick-disconnect
terminals are inserted onto the terminals of
HF UNIT1 (TB5-TB6) correctly and completely.
Confirm there are no short circuits, burnt or
broken wires at CC1.
Replace CC1.
Refer to section 12.3.17.
SERVICE MANUAL
TRANSARC 300 Si
11 ADVANCED TROUBLESHOOTING
b) Verify the connection between High Frequency
(HF UNIT1) and the current limiting resistor
(R2).
Verify the connection between HF UNIT1 and
the current limiting resistor (R2), confirm that
the quick-disconnect terminals are inserted
onto the terminals of HF UNIT1 (TB3-TB4)
correctly and completely.
11.04 Fault Isolation Tests
11.4.1 Preparation
The following initial conditions must be met
prior to starting any of the procedures in this
section.
1) Connect the appropriate input voltage.
(Check the name plate on the rear of the
power supply for the proper input voltage.)
Confirm there are no short circuits, burnt or
broken wires between the HF UNIT1 and the
current limiting resistor (R2).
c) Verify the connection between the terminals
between AC1-AC2 (TB1-TB2).
Verify the connection between AC1-AC2,
confirm that the quick-disconnect terminals
are inserted onto the terminals of HF UNIT1
correctly and completely.
NOTE
Operate at all input voltages as noted on the nameplate on the rear panel when testing the power supply.
2) Remove the side covers. Refer to the section 11-01.
Confirm there are no short circuits, burnt or
broken wires between AC1 and AC2.
3) Close primary power source wall disconnect switch or circuit breaker.
d) Verify and replace the Gap (GAP) of the High
Frequency (HF UNIT1).
4) Place power supply MAIN CIRCUIT
SWITCH (S1) on rear of the unit in the ON
position.
Confirm that the GAP is connected to HF
UNIT1 correctly and completely.
Confirm there is no dust or foreign debris
between the space of the GAP.
If there are any abnormalities observed with
the GAP, replace the GAP.
A setup of a gap is 1.0mm.
In the case of a gap 1.0mm or more, high frequency voltage and a period increase.
In the case of a gap 1.0mm or less, high frequency voltage and a period decrease.
WARNING
Dangerous voltage and power levels are present
inside this unit. Be sure the operator is equipped
with proper gloves, clothing and eye and ear protection. Make sure no part of the operator's body
comes into contact with the work piece or any internal components while the unit is activated.
e) Verify and replace the Current limiting Resistor
(R6) on HF UNIT1.
If R6 is defective (blown, burnt, cracked,
etc.), replace R6.
Refer to section 12.3.15.
f) Replace the High Frequency (HF UNIT1).
Refer to section 12.3.26.
g) Replace PCB3 (WK-5548).
Refer to section 12.3.3.
11 – 10
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
11.05 Verification of the Power
Input Circuitry
? Using an AC voltmeter, measure between
the points U2 and V2 on the input switch, S1.
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
section 11.4.1 " Preparation" on page 11-10.
11.5.1 Verification of the AC Input
Voltage using an AC voltmeter.
1) Verify input voltage (Phase-to Phase) using an
AC voltmeter. (The capability of the voltmeter
should be more than 600VAC). Measure the
point between lines U1 and V1 on the input
switch, S1.Measure the point between lines U1
and W1 on the input switch, S1. Measure the
point between lines V1 and W1 on the input
switch, S1. The location of points U1, V1 and
W1on switch S1 are indicated in Figure 11-7.
When using a single-phase connection, the
voltage can be verified only between U1 and
V1.
U2
S1
U1
3) Verify input voltage after the input switch (S1)
using an AC voltmeter. (The capability of the
voltmeter should be more than 600VAC.)
? Using an AC voltmeter, measure between
the points U2 and W2 on the input switch, S1.
? Using an AC voltmeter, measure between
the points V2 and W2 on the input switch, S1.
The location of points U2, V2 and W2 on
switch S1are indicated in Figure 11-7. When
using a single-phase connection, the voltage
can be verified only between U2 and V2.
4) If this voltage is out of the operating range,
which is ±10% (187 ? 253/414 ? 506 VAC) of
the rated voltage (208, 230/460V), replace S1
following the process in section 12.3.23.
5) Verify the rectified output voltage of the input
diode, D1 using a DC voltmeter. (The capability
of the voltmeter should be more than
1000VDC.) Using a DC voltmeter, measure
between the points 1 (P) [+] and 2 (N) [-] on D1.
Points 1 (P) and 2 (N) are on D1. See Figure
11-8. The measured voltage should be approximately 1.4 times larger than input voltage measured in #1 above. Replace diode D1 if the
calculated measurement is not within the coresponding range (260 ? 360/580 ? 720 VDC)
following the process in section 12.3.28.
V2
W2
1
2
V1
0
D1
W1
Figure 11-7: Check points U1, U2, V1, V2, W1 and W2
2) If the input voltage is out of the operating range
of the unit, which is ±10% (187 ? 253/414 ? 506
VAC) of the rated voltage (208, 230/460V),
verify the available power capacity at the
installed site. If the input voltage is within the
operating range, recheck the input voltage
while welding, as welding may cause the input
voltage to decrease to a value below the operating range of the unit.
11 – 11
Figure 11-8: The check points 1 (P) and 2 (N)
SERVICE MANUAL
TRANSARC 300 Si
11 ADVANCED TROUBLESHOOTING
6) Verify bus voltage (the voltage of the
electrolytic capacitor after rectification) using a
DC Voltmeter. The capacity of the DVM should
be more than 1000VDC.
Measure between the output studs C and E on
PCB8 (WK5479), PCB9 (WK5479), PCB10
(WK5479) and PCB11 (WK5479).
The measured voltage should be approximately
1.4 times larger than the input voltage measured
in step 1 (above), except when running at 460V
where the bus voltage will be shared across all
boards, i.e., each board receiving 0.7 times the
input voltage measured in step 1 (above).
Replace diode D1 if the calculated measurement
is not within the corresponding range (260 ~
360/580 ~ 720VDC). Follow the process in
12.3.28.
TB4(N)
2) On the PCB3 (WK-5548) and PCB6 (WK5549), measure the voltages according to the
following table. The check points and the reference are obtainable on the solder side of
PCB4 (WK-4819). The locations of points are
indicated in Figure 11-10, 11-11.
TP3 TP1
TP0
TP2
PCB6
TB1(P)
Figure 11-10: Checkpoints TP0-TP3 on PCB6
PCB2
Check Point
PCB6
Reference
PCB6
ACCEPTABLE
VALUE
TP1
TP0
+5VDC
TP2
TP0
+15VDC
TP3
TP0
-15VDC
Table 11-1: Checkpoints TP0-TP3 on PCB6
Figure 11-9: The check points TB1(P) and TB2(N)
7) After the replacement of D1, if the above voltage is still abnormal, replace PCB1
(WK-5493).
1pin
3pin
PCB3
11.5.2 Verification of the Power Supply Voltage
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
an above section "1.Preparation".
1) Verify Power Supply voltage using an DC voltmeter. (The capability of the voltmeter should
be more than 50VDC.) Operate at all input voltages as noted on the nameplate on the rear
panel when testing the power supply.
11 – 12
CN18
Figure 11-11: Checkpoints CN18 on PCB3
Check Point
PCB3
Pin 1 on CN18
Reference
PCB3
Pin 3 on CN18
ACCEPTABLE
VALUE
+24VDC
Table 11-2: Checkpoints CN18 on PCB3
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
3) If any of these voltages are not present or
are below a 10% tolerance, replace the
PCB3 (WK-5548). Refer to section 12.3.3.
2) Using the measurement taken above, follow
the chart below for possible failure modes.
FAN1
Status
11.5.3 Verification of the Cooling
Fan, FAN1, Drive Circuitry
Case 1 Rotating
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
section 11.4.1 " Preparation" on page 11-10.
1) Verify the condition of the cooling fan, FAN1,
using a DC voltmeter. (The capability of the
voltmeter should be more than 50VDC.) Using
a DC voltmeter, measure between PIN 1 (Positive [+]) and PIN 2 (Negative [-]) of CN11 on
PCB3 (WK-5548). The location of connector
CN11 of PCB3 is indicated in Figure 11-12.
When you measure the above voltage, do not
remove the connector. Conduct the measurement while the connector plug and receptacle
are still connected.
Case 2 Rotating
Case 3 Inactive
Case 4 Inactive
Voltage
measurement.
(1PIN-2PIN of
CN11 on PCB3)
Remedy
FAN1 drive circuit
is normal.
Replace PCB3.
Below DC 18V Refer to section
12.3.3.
Replace PCB3.
Refer to section
12.3.3.
DC 18 a 25V
4
Perform
Below DC 18V
"Verification of the
Power Supply
Voltage".
Refer to section
11.5.2.
Replace the FAN1.
DC 18 a 25V Refer to section
12.3.21.
Table 11-3: Verification of the FAN1
At the time of a low output and standby, as
for this equipment, rotation of a fan becomes
slow. Therefore, exact voltage measuring
becomes impossible. Perform the check of
voltage in the state of abnormalities.
1pin
2pin
PCB3
When verifying the voltage, confirm that the
AC input voltage remain within the operating
range of the unit. (The AC input does not
drop below 180VAC).
CN11
Figure 11-12: Verification of the FAN1
11 – 13
SERVICE MANUAL
TRANSARC 300 Si
11 ADVANCED TROUBLESHOOTING
11.5.4 Verification of the Gas Valve, 11.5.5 Verification of the primary
SOL1, Drive Circuitry
Diode (D1)
CAUTION
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
section 11.4.1 " Preparation" on page 11-10.
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
section 11.4.1 " Preparation" on page 11-10.
1) Verify the voltage between the PIN 3 (Positive
[+]) and PIN 4 (Negative [-]) of connector CN11
on PCB3 (WK-5548) while you press the torch
switch while in TIG Mode. (The capacity of the
voltmeter should be more than 50VDC.) The
location of connector CN11 of PCB3 (WK5548) is indicated in Figure 11-13. When you
measure the above voltage, do not remove the
connector. Conduct the measurement while
the connector plug and receptacle are still connected.
1) Verify the characteristic of the primary diode,
D1, using a diode tester.
2) Refer to Table 11-5 and Figure 11-14 for
the checkpoints on D1.
COMPONENT
TESTED
Diode of D1
Diode of D1
Thyristor of D1
3pin
4pin
PCB3
Gate of D1
TERMINALS
Positive Negative
lead
lead
3, 4, 5
0
0
3, 4, 5
3, 4, 5
2
2
3, 4, 5
0
1
1
0
6
7
ACCEPTABLE
VALUE
0.3 to 0.5V
Open
Open
0.3 to 0.5V
Open
Open
52 +3, ±3ohms
Table 11-5: Tester checkpoints in D1
CN11
Figure 11-13: Verification of the SOL1
3
Case 1
Case 2
Remedy
Below DC 18V
Replace PCB1.
Refer to the page 12-23.
DC 18 a 25V
Replace SOL1.
Refer to the page 12-23.
4
67
D1
2) Using the measurement taken above, follow
the chart below for possible failure modes.
Voltage
measurement.
(PIN 1-PIN 2 of
CN11 on PCB3)
5
0
1
2
0
6 7
1
5
Table 11-4: Verification of the SOL1
4
3) When verifying the voltage, confirm that the AC
input voltage remain within the operating range
of the unit.
(The AC input does not drop below 180VAC).
11 – 14
3
2
Figure 11-14: Tester checkpoints for D1 showing the
interconnection diagrams
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
11.5.6 Verification of the secondary
Diode (D2-D7)
1) Check whether there are any abnormalities on
the appearance of PCB8-PCB11.
2) Verify the characteristic of the primary IGBT
(Q1-Q24), using a diode tester.
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
section 11.4.1 " Preparation" on page 11-10.
1) Verify the characteristic of the secondary
diode, D2-D7, using a diode tester.
2) Refer to Table 11-6 and Figure 11-15 for
the checkpoints on D2-D7.
COMPONENT
TESTED
Diode 1 of
D2-D7
Diode 2 of
D2-D7
TERMINALS
Positive Negative
lead
lead
Anode
Cathode
Cathode
Anode
Anode
Cathode
Cathode
Anode
3) Refer to Table 11-7 and Figure 11-16 for
the checkpoints on PCB8-PCB11.
TERMINALS
COMPONENT
TESTED
Positive Negative
lead
lead
ACCEPTABLE
VALUE
Collector-Emitter
of Q1aQ12 with
PCB8 and PCB9
C
CE
CE
C
Open
0.2 to 0.5V
Collector-Emitter
of Q13aQ24 with
PCB10 and PCB11
CE
E
E
CE
Open
0.2 to 0.5V
ACCEPTABLE
VALUE
Table 11-7: Tester checkpoints in the Q1-Q24
0.2 to 0.3V
Open
0.2 to 0.3V
Open
Table 11-6: Tester checkpoints for D2-D7
PCB10
D4
C
Diode 1
Anode
CE
PCB11
E
Diode 2
Anode
D2
D7
Cathode
TRO_0031
Cathode
D5
PCB8
Figure 11-15: Tester checkpoints for D2-D7
PCB9
C
CE
E
11.5.7 Verification of the primary
IGBT (Q1-Q24)
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
an above section "1.Preparation". Refer to section
11.04.
11 – 15
Figure 11-16: Tester checkpoints for Q1-Q24
12 MAINTENANCE
12.01 Maintenance List
9
3
2
4
5
6
1
7
8
No.
DWG No.
Parts name
Reference page
Part No.
1
PCB2
Print Circuit Board (WK-5597)
12- 8
W7001678
2
PCB3
Print Circuit Board (WK-5548)
12- 9
W7001314
3
PCB4
Print Circuit Board (WK-4819)
12- 11
10-6635
4
PCB5
Print Circuit Board (WK-5551)
12- 11
W7001417
5
PCB7
Print Circuit Board (WK-5550)
12- 9
W7001423
6
PCB12
Print Circuit Board (WK-5527)
12- 14
W7001319
7
PCB13
Print Circuit Board (WK-5528)
12- 15
W7001320
8
PCB14
Print Circuit Board (WK-5594)
12- 16
W7001321
9
PCB21
Print Circuit Board (WK-4917)
12- 18
10-6740
12 – 1
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
5
9
2
6
4
1
3
7
8
No.
1
2
DWG No.
Parts name
Reference page
Part No.
PCB1
Print Circuit Board (WK-5493)
12-6
W7001312
PCB6
Print Circuit Board (WK-5549)
12-11
W7001733
12-12
W7001318
12-12
W7001318
12-14
W7001318
12-14
W7001318
12-17
W7001322
3
PCB8 (Q1-Q6)
4
PCB9 (Q7-Q12)
5
PCB10 (Q13Q18)
6
PCB11 (Q19-Q24)
7
PCB15
Print Circuit Board (WK-5479)
(Primary IGBT)
Print Circuit Board (WK-5479)
(Primary IGBT)
Print Circuit Board (WK-5479)
(Primary IGBT)
Print Circuit Board (WK-5479)
(Primary IGBT)
Print Circuit Board (WK-5606)
8
PCB20
Print Circuit Board (WK-5499)
12-18
W7001324
9
PCB22
Print Circuit Board (WK-5022)
12-20
W7001677
12 – 2
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
10
11
8
9
2
5
1
6
3
4
7
No.
DWG No.
Parts name
Reference page
Part No.
1
CON1
Remote Socket
12- 29
W7001666
2
D1
Primary Diode
12- 31
10-6628
3
D2
Secondary Diode
12- 32
10-6629
4
D4
Secondary Diode
12- 32
10-6629
5
D5
Secondary Diode
12- 32
10-6629
6
D7
Secondary Diode
12- 32
10-6629
7
HF.UNIT1
High Frequency Unit
8
L101
Reactor
12- 37
W7001670
9
L102
Reactor
12- 38
W7001672
10
S1
Main ON/OFF Switch
12- 27
10-6857
11
S2
Input Voltage Switch
12- 28
300 Pi/ 300 ACDC only
12- 29
12 – 3
300 Pi/ 300 ACDC only
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
8
2
7
3
11
12
4
9
5
13
14
15
10
6
1
No.
DWG No.
1 CC1
Parts name
Coupling Coil
Reference page
12- 23
Part No.
300 Pi/ 300 ACDC only
2
CT2
Current Trans
12- 33
W7001304
3
CT3
Current Trans
12- 33
4
FAN1
Cooling Fan
12- 25
W7001304
W7001307
5
FCH1
Reactor
12- 23
W7001653
6
HCT1
Hall Current Sensor
12- 30
10-5003
7
L1
Ring Core
12- 34
W7001309
8
L103
Reactor
12- 39
W7001605
9
L105
Ring Core
12- 36
W7001400
10
R6
Current Limiting Resistor
12- 20
11
R7
Resistor
12- 21
W7001325
12
R8
Resistor
12- 21
W7001325
13
SOL1
Solenoid Valve
12- 26
300 Pi/ 300 ACDC only
14
TH1
Primary Thermistor
12- 24
15
TH2
Secondary Thermistor
12- 25
10-5228
10-5228
12 – 4
300 Pi/ 300 ACDC only
SERVICE MANUAL
TRANSARC 300 Si
11 ADVANCED TROUBLESHOOTING
11.5.8 Verification of the secondary 11.5.9 Verification of No-load VoltIGBT (Q25-Q26)
age (OCV)
CAUTION
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
section 11.4.1 " Preparation" on page 11-10.
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described at the beginning of
an above section "1.Preparation". Refer to tsection
11.04.
1) Check whether there are any abnormalities on
the appearance of PCB17.
a. Verify the no-load voltage in STICK mode.
1) In STICK welding mode, mark and then
turn potentiometer VR1 on PCB6 (WK5549) all the way to the right and turn off
the electric shock protector function (Voltage-Reduction-Device, VRD).
2) Verify the characteristic of the secondary IGBT
(Q25-Q26), using a diode tester.
3) Refer bellow Table 11-8 and Figure 11-17 for
the checkpoints on Q25-Q26.
2) Contactor function is put into the state of
on pushing Function button.
TERMINALS
COMPONENT
TESTED
Positive
lead
Negative
lead
ACCEPTABLE
VALUE
WARNING
Collector-Emitter
of Q25
(By PCB18
connection)
C1
C2E1
C2E1
C1
Open
0.2 to 0.5V
Collector-Emitter
of Q26
(By PCB19
connection)
C2E1
E2
E2
C2E1
Open
0.2 to 0.5V
Electric shock hazard. The unit will generate OCV
immediately when contactor function is put into the
state of on pushing Function button at STICK
mode.
3) Verify the no-load voltage using a DC voltmeter.
(The capability of the voltmeter should be
more than 100VDC.)
Table 11-8: Tester checkpoints for Q25-Q26
4) The normal no-load voltage is approximately 65V.
C2E1
Q25
Q26
E2
C1
Figure 11-17: Tester checkpoints in the Q25-Q26
11 – 16
TRANSARC 300 Si
SERVICE MANUAL
11 ADVANCED TROUBLESHOOTING
b. Verify the no-load voltage (OCV) in High Frequency TIG mode.
WARNING
This welding mode produces high frequency and
high voltage. Extra care shall be taken to prevent
electric shock.
1) When in HF TIG mode, the unit will generate high voltage. To prevent personal harm
and test equipment damage, mark and
then remove the indicated wire from the HF
UNIT1 shown in Figure 11-18. To prevent
electric shock, always wrap the removed
wire with electrical tape or other suitable
insulation.
HF. UNIT1
Figure 11-18: Removal and installation
from the HF UNIT1
(To disable the operation of the HF unit.)
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 terminal + and
-. In TIG mode, the OCV ceases 3 seconds
after you depress the torch switch.
4) The normal no-load voltage is approximately 65V.
5) Return the setting variable resister (VR1)
to the original position. (Return to the position recorded by "a. 1)" clause.)
• fully clockwise:
VRD ON
• fully counter-clockwise: VRD OFF
6) Return connection with HF UNIT1 to the
original position.
11 – 17
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.02 Service Tools
12.2.1 Tools and parts
The tools and parts to be used for maintenance are shown by icons.
Spanner
Philips Head
Screwdriver
Long Nose
Pliers
C-Ring Pliers
Snap Band
Silicon
Compound
12.2.2 Notes of disassembly and assembly
NOTE
When removing the locking type connectors and board supporters, disengage the locking mechanism first
and then disconnect them.
Locking type connectors and board supporters are indicated in this manual using the following symbols;
black star marks for locking connectors and white star marks for locking board supports.
NOTE
During your maintenance or repair, please cut any tie-wraps necessary. However, after your maintenance or
repair, please reassemble and tie-wrap all components and wiring in the same manner as before the maintenance or repair.
CAUTION
Please note that you remove each connector, grasp and pull out by the connector part only. Do not pull the
harness (cable) part.
WARNING
The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete.
12 – 5
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
12.03 Replacement Procedure
12.3.1 PCB1 (WK-5493) UVX[\
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the PCB2 (WK-5597). [Reference page : 12-8]
3) Remove the Primary Diode (D1). [Reference page : 12-31]
4) Remove the Current Trans (CT2/CT3). [Reference page : 12-33]
5) Remove the Nylon Hose. Remove the two bolts, and one terminal.
Remove the four screws and open the front cabinet.
2
3
1
3
4
2
3
3
1
2
6) Remove the two screws and three terminals from the PCB1 (WK-5493).
7) Remove the Reactor (L1). [Reference page : 12-34]
12 – 6
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
8) Remove the 18 screws and remove the PCB1 (WK-5493).
2
1
1
12.3.2 PCB2 (WK-5597) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the screw and then disconnect the four ground terminals. Disconnect the 19 connectors.
CN7
CN17
CN4
CN1
CN7
1
CN3
CN2
2
CN22
CN23
CN8
CN21
CN19
CN1
2
CN9
CN21
CN20 CN9
CN8
CN11
3) Remove the four screws. Remove the PCB3, PCB4, PCB5, PCB6, and PCB7 unit.
Disconnect the three connectors.
CN1
2
CN15
CN16
CN2
CN13
12 – 7
1
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
4) Remove the six screws, three terminals and three connectors.
CN1
CN2
CN3
5) Remove the two PCB supporters and then the PCB2 (WK-5597) and insulation sheet.
12.3.3 PCB3 (WK-5548), PCB7 (WK-5550) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the PCB4 (WK-4819). [Reference page : 12-11]
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).
CN21
CN20
CN9
CN23
CN22
CN11
CN8
CN19
CN1
CN2
CN3
12 – 8
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
6) Remove the screw and then the four ground terminals. Remove the four screws and then remove the
PCB3 and PCB7 unit. Disconnect the three connectors from the PCB7 (WK-5550).
1
2
CN14
CN15
CN13
3
7) 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
1
2
8) Disconnect the two connectors from the PCB3 (WK-5548).
CN18
CN33
12 – 9
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
12.3.4 PCB4 (WK-4819) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Disconnect the two connectors. Remove the two screws and three connectors and remove the PCB4
(WK-4819) from the PCB3 (WK-5548).
1
2
CN7
CN4
CN5
CN4
CN6
12.3.5 PCB5 (WK-5551) V
1) Remove the Side Panel. [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 (WK5548).
CN30
CN31
CN32
12.3.6 PCB6 (WK-5549) V
1) Remove the Side Panel. [Reference page :11-1]
2) Disconnect the six connectors.
CN21
CN17
CN1
CN9
CN8
CN20
12 – 10
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549) from the PCB5 (WK-5551)
and PCB7 (WK-5550).
CN27
CN18
CN32
CN30
CN31
12.3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the eight screws and four device clips. Remove the four connectors and six screws.
Remove the PCB8 (WK-5479) and PCB9 (WK-5479).
Remember to install Silicone Rubber Sheets where silicone compound (Shinetsu silicone G-747 or
equivalent) was spread when reinstalling the PCB8 and PCB9. Spread the silicone compound on
IGBT.
CN1
CN2
2
2 CN1
CN2
1
Silicone rubber sheets
3
12 – 11
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
12.3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the eight screws and four device clips.
Remove the four connectors and six screws. Remove the PCB10 (WK-5479) and PCB11 (WK-5479).
Remember to install Silicone Rubber Sheets where silicone compound (Shinetsu silicone G-747 or equivalent) was spread when reinstalling the PCB10 and PCB11. Spread the silicone compound on IGBT.
CN2
CN1
CN1
2 CN2
1
Silicone rubber sheets
3
12.3.9 PCB12 (WK-5527) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the PCB13 (WK-5528). [Reference page :12-15]
3) Remove the three latches of Front Control Cover and then the PCB12 (WK-5527).
2
1
1
When reinstalling the PCB12 (WK-5527), engage two latches of Front Control Cover first.
1
2
12 – 12
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.3.10 PCB13 (WK-5528) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the Protection Cover.
2
2
3
1
3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob.
2
1mm
1
3
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.
1
3
2
3
CN2
4
3
3
12 – 13
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
5) Remove the one connector and two screws. Remove the PCB13 (WK-5528) and Encoder Cover.
2
4
1
CN1
3
12.3.11 PCB14 (WK-5594) <T1 “Main Transformer”> UVX[
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the Coupling Coil (CC1). [Reference page : 12-23]
3) Remove the PCB20 (WK-5499). [Reference page : 12-18]
4) Remove the Reactor (FCH1). [Reference page : 12-23]
5) Remove the two screws and the T-CC Bus Bar from the front side.
6) Remove the Nylon Hose and two terminals of SOL1. Remove the four screws and open the Rear Panel.
3
2
3
4
1
3
1
2
3
12 – 14
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
7) Remove the four screws from the PCB1 (WK-5477). Remove the seven terminals.
The cables is drawn out.
2
2
1
8) Remove the four screws and then two cables from bottom. Remove the two screws and then drags out
the PCB14 (WK-5594) and D Bus Bar1, D Bus Bar2, D Bus Bar3, D Bus Bar4 and Dust Cover Sheet
(Rear). Remove the four screws and then remove the D Bus Bar1, D Bus Bar2, D Bus Bar3, D Bus Bar4
and Dust Cover Sheet (Rear) form PCB14.
1
2
3
12.3.12 PCB15 (WK-5606) V
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).
3
1
2
3
12 – 15
2
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
12.3.13 PCB20 (WK-5499) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove one screw and one terminal. Remove one bolt, toothed washer, washer and terminal. Remove
one screw, nut and the Output Bus Bar. Disconnect one connector from HCT1.
4
3
1
CN1
5
2
3) Disconnect the two connectors.
Remove the four PCB board supporters and then remove the PCB20 (WK-5499).
1
CN1
1
CN3
2
2
3
12.3.14 PCB21 (WK-4917) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the six screws from the S1 and remove the six terminals.
2
2
1
12 – 16
1
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
3) Remove the four screws and then open the Rear Board.
1
1
2
1
1
4) Disconnect the one connector. Remove the two screws and one ground terminal.
Remove the PCB21 (WK-4917).
3
2
1
CN1
2
5) Remove the three screws and the S1 Bus Bar from the PCB21 (WK-4917).
12 – 17
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
12.3.15 PCB22 (WK-5022) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Disconnect one connector.
Remove the four screws and one terminal. Remove the PCB22 (WK-5022).
1
2
CN1
2
3
3) Remove three board supports.
12.3.16 Current Limiting Resistor (R6) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the HF.UNIT1 [Reference page : 11-15]
3) Cut the cable. Remove one screw and then remove the Current Limiting Resistor (R6).
2
1
12 – 18
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.3.17 Resistor (R7, R8) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove four screws and three terminals.
3) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
4) Remove two screws and remove the PCB22 unit.
1
2
1
12 – 19
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
5) Remove four screws and open the Rear Panel.
1
1
2
1
1
6) Remove four screws and six terminals. Remove the Resistors (R7 and R8).
1
1
2
2
1
1
12 – 20
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.3.18 Reactor (FCH1)
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the Nylon Hose. Remove the two bolts, and one terminal.
Remove the four screws and open the Front Panel.
2
3
1
3
4
2
3
3
1
2
3) Remove one screw, one nut and two terminals. Remove one screw, one nut and one terminal.
1
3
2
1
2
3
4) Remove four screws and remove the Reactor (FCH1).
1
2
1
12 – 21
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
12.3.19 Primary Thermistor (TH1)
1) Remove the Side Panel. [Reference page : 11-1]
2) Disconnect the one connector CN8 on the PCB6. Remove the one screw and then detach the Primary
Thermistor (TH1).
Before installing a new therminstor, apply a uniform coat of silicone compound (Shinetsu Silicone G747 or equivalent) on the base.
1
CN8
2
12 – 22
3
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.3.20 Secondary Thermistor (TH2) VX[\
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).
Before installing a new therminstor, apply a uniform coat of silicone compound (Shinetsu Silicone G747 or equivalent) on the base.
1
1
2
1
CN9
4
3
12.3.21 Cooling Fan (FAN1) VX[
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
2
3
4
1
3
1
2
3
12 – 23
TRANSARC 300 Si
SERVICE MANUAL
12 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).
AIR FLOW
ROTATION
Do not have the wrong direction of the fan when reinstalling.
12 – 24
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.3.22 Main ON/OFF Switch (S1)
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the six screws and six terminals.
2
1
2
1
3) Remove the two screws and detach the Main ON/OFF Switch (S1). Remove the three posts.
12 – 25
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
12.3.23 Input Voltage Switch (S2) UV
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the six screws and six terminals.
2
1
2
1
3) Remove the four screws, and open the Rear Board.
1
1
2
1
1
4) Disconnect the one connector CN4 on the PCB4.
Remove the two screws and two nuts and then remove the Input Voltage Switch (S2).
CN4
12 – 26
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.3.24 Remote Socket (CON1)
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the Ring Core (L105). [Reference page : 12-36]
3) Disconnect the three connectors CNB-15 on the PCB7. Remove the one screw and one ground terminals.
2
CN13
1
CN15
1
CN14
1
4) Remove the two screws and remove the Remote Socket (CON1).
2
1
12 – 27
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
12.3.25 Hall Current Sensor (HCT1)
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove one screw and one terminal. Remove one bolt. toothed washer, washer and terminal. Remove
one screw. nut and the Output Bus Bar. Disconnect one connector from HCT1.
4
3
1
CN1
5
2
3) Remove the one screw and detach the Hall Current Sensor (HCT1) from the Output Bus Bar.
1
2
12 – 28
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.3.26 Primary Diode (D1) V\
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the PCB3 (WK-5548). [Reference page : 12-9]
3) Remove four screws and three terminals.
4) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
5) Remove two screws and remove the PCB22 unit.
1
2
1
12 – 29
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
6) Remove the six screws and 14 terminals. Remove the two screws and then detach the Primary Diode
(D1).
Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or
equivalent) on the base.
1
2
1
12.3.27 Secondary Diode (D2, D4, D5 and D7) V\
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the PCB15 (WK-5606). [Reference page : 12-17]
3) Remove one screw and one nut. Remove 20 screws and two terminals. Remove the D Bus Bar, D Bus
Bar1, D Bus Bar2, D Bus Bar3 and D Bus Bar4.
4
2
1
3
2
2
1
2
4) Remove the eight screws and then detach the Secondary Diodes (D2, D4, D5, D7).
Do not have the wrong direction of the diodes when reinstalling.
Before installing a new diodes, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or
equivalent) on the base.
D4
D2
D7
D5
12 – 30
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
12.3.28 Current Trans (CT2, CT3) VX[
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove four screws and three terminals.
3) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
4) Remove two screws and remove the PCB22 unit.
1
2
1
12 – 31
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
5) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.
3
2
3
4
1
3
1
2
3
6) Cut the three snap bands and remove the connector from the PCB3 (WK-5548). Remove two screws
and three terminals from the PCB1 (WK-5493). Cut two snap bands and remove the Current Trans (CT2,
CT3).
5
5
3
3
1
1
4
1
2
CN7
12.3.29 Ring Core (L1) VX[
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove four screws and three terminals.
12 – 32
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
3) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
4) Remove two screws and remove the PCB22 unit.
1
2
1
5) Remove the Nylon Hose and two terminals. Remove the four screws and open the Rear Panel.
3
2
3
4
1
3
1
2
3
12 – 33
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
6) Remove the two screws and three terminals. Cut the snap band and remove the Ring Core (L1).
1
1
3
2
12.3.30 Ring Core (L105) V
1) Remove the Side Panel. [Reference page : 11-1]
2) Remove the Protection Cover.
2
2
3
1
3) Remove the four screws. Pull out the Operation Panel and bring it down.
1
1
2
1
1
12 – 34
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
4) Cut the snap band remove the Ring Core (L105).
12.3.31 Reactor (L101)VU
1) Remove the Side Panel. [Reference page: 9-1]
2) Remove four screws and three terminals.
1
2
3) Remove four screws and open the rear panel. Remove one nut, one washer and one terminal. Remove
the Reactor (L101).
1
1
3
2
1
1
12 – 35
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
4) Remove harness from the Reactor (L101).
The harness is rolled three times at the installation.
12.3.32 Reactor (L102) VX[
1) Remove the Side Panel. [Reference page: 9-1]
2) Remove four screws and three terminals.
3) Cut off one snap band and disconnect one connector. Remove the one screw.
2
3
1
CN1
12 – 36
SERVICE MANUAL
TRANSARC 300 Si
12 MAINTENANCE
4) Remove two screws and remove the PCB22 unit.
1
2
1
5) Remove six screws, nine terminals and remove the Reactor (L102).
2
1
3
12.3.33 Reactor (L103) VX[
1) Remove the Side Panel. [Reference page: 9-1]
2) Remove one screw and two terminals.
12 – 37
TRANSARC 300 Si
SERVICE MANUAL
12 MAINTENANCE
3) Remove four screws and open the rear panel. Remove one nut, one washer and one terminal.
1
1
3
2
1
1
4) Cut off one snap band. Remove the Reactor (L103).
1
2
12 – 38
SERVICE MANUAL
TRANSARC 300 Si
THIS PAGE LEFT INTENTIONALLY BLANK
SERVICE MANUAL TRANSARC 300 Si
APPENDIX 1: TRANSARC 300 Si ACCESSORIES
Description
Part No.
Details
17 Series air cooled TIG torch
(suitable for TransTig 200Pi)
518710402
TIG torch with 4 metre cable & remote
current control
26 Series air cooled TIG torch
538720401
TIG torch with 4 metre cable & remote
current control
200 Amp lead set, 5 metre
646323
1 x 5m work lead; 1 x 5m electrode holder
400 Amp lead set, 8 metre
646325
1 x 8m work lead; 1 x 8m electrode holder
OTD 10/4013
200Pi, 200AC/DC slider only
OTD 10/2004
300Pi, 300AC/DC, 400i slider only
OTD 10/4014
200Pi, 200AC/DC hand pendant only
OTD 10/2005
300Pi, 300AC/DC, 400i hand pendant only
OTD 10/4016
200Pi, 200AC/DC
OTD 10/2007
300Pi, 300AC/DC, 400i
CIGWELD COMET argon regulator
301527
Regulator only
CIGWELD COMET argon flowmeter
0-15 lpm
301710
Flowmeter only
CIGWELD COMET argon flowmeter
10-40 lpm
301711
Flowmeter only
CIGWELD COMET argon regulator/
flowmeter
301526
Regulator/flowmeter only
VAF-4 Wirefeeder (for 400i ONLY)
705700
VAF-4 wirefeeder, 8m interconnection,
operating manual
VS212 Voltage sensing wirefeeder
W3512006
VS212 wirefeeder, operating manual
Tweco® 4 MIG Torch
717201
MIG torch with 3.6m cable, T4 connection
ArcMaster Pro Auto-darkening
Helmet, 9-13 – blue
454294
Welding helmet, 2 x spare cover lenses,
product bag, operating manual
ArcMaster Pro Auto-darkening
Helmet, 9-13 – blue with graphic
454295
Welding helmet, 2 x spare cover lenses,
product bag, operating manual
ArcMaster Pro Auto-darkening
Helmet, 9-13 – black with graphic
454296
Welding helmet, 2 x spare cover lenses,
product bag, operating manual
Slide controller
Hand pendant
Foot controller
January 15, 2008
A-1
TRANSARC 300 Si
SERVICE MANUAL
APPENDIX B: TRANSARC 300 Si INTERCONNECT DIAGRAM
P
TB1
G1
E1
R2
1
2
3
R2
TB2
TB3
C
J
K
L
D
I
N
M
E
CN131 CN132
CN131 CN132
EB
CN17
CN17
TB0
1
2
1
2
CN27
3
CN27
4
5
H
G
F
EC
Q7
Q8
PCB9 G
IGBT Gate E
Circuit BoardC
[WK-5479]
1
2
3
4
TB5
C
C
Q19
TB6
CE
TB7
E
G
E
C
Q20
PCB11 G
IGBT Gate E
Circuit BoardC
[WK-5479]
Q9
G
E
C
G7
E7
Q10
G
E
C
Q11
G
E
C
G8
E8
Q12
Q22
G
E
C
Q23
G
E
C
Q24
1 2 3 4 5 6
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
CN20
CN21
CN22
CN23
CN18
CN18
CN20
CN9
CN8
1 2
1 2 3
1 2
CN18
1
2
3
G
E
C
G
E
PCB6
Control
Circuit Board
[WK-5549]
1 2 3
1
2
3
4
G
E
CT1
CT2
CT3
CT4
CN130
CN130
PCB7
Filter
Circuit Board
[WK-5550]
1
2
3
Q21
E4
G4
1
2
3
UB1
E8
G8
CN30
CN30
1
2
3
4
PCB3
Control Souce
PCB5
Circuit Board
Connect Circuit Board [WK-5548]
[WK-5551]
1
2
3
A-2
CN32
CN32
CN1
CN4
Q18
G
E
CN19
1 2 3
CN33
1 2 3
TH2
TH1
CN17
B
CON1
CN6
CN6
CN15
A
E
E5
G5
CN31
CN31
A : Contactor Control /+24VDC
B : Contactor Control /Contactor Clouser To"A"
C : 0 To +10Vdc Output To Remote Control
D : Remote Control Circuit Common
E : 0 To +10Vdc Intput From Remote Control
F : Not Used
G : Chassis Ground
H : Not Used
I : Not Used
J : Not Used
K : Not Used
L : Not Used
M : OK to Move(Current Detect Signal)
N : OK to Move(Current Detect Signal)
L105
CN5
CN5
CN20
1
2
3
4
CN11
-
230V
PCB4
CN7
Detect
Circuit Board
[WK-4819]
CN7
S2
FAN1
+
TB20
G
E
C
G4
E4
1 2 3
1
2
3
4
460V
CN4
R2
CN3
CN14
P
CN2
CN13
1
2
3
4
5
6
C
CE
G3
E3
CN1
N
C
TB19
TB4
1 2 3
1 2 3 4 5
Q6
Q17
G
E
C
1
2
3
4
5
6
7
CN21
TB4
TB18
CN1
1 2 3
1
2
3
4
E3
Q16
G
E
C
1
2
3
4
CN1
REAR
PANEL
Q5 G3
G
E
C
CN1
1 2
CN2
SIDE CHASSIS 1
1
2
3
4
5
1
2
3
Q15
G
E
C
TB3
PCB2
Link
Circuit Board
[WK-5597]
CN1
Q14
PCB10 G
IGBT Gate E
Circuit Board
C
[WK-5479]
CN2
PCB21
Filter
Circuit Board
[WK-4917]
E
E
G
E
CN1
Ground
TB2
E1
G1
+
1
2
3
4
CN2
G2
E2
N
TB12
G4
G
E
C
CN2
(2)
Q13
G
E
C
Q4 E4
E2
G2
T(5)
C
CE
Q3
G
E
C
N
Line3
C
TB11
E3
G3
(0)
S(4)
Line2
Q2
TB10
E7
G7
R(3)
E
Q1
1
2
3
4
P+21V
PGND
Line1
TB15
G
E
C
E6
G6
G(6)
C
CE
PCB1
Main
PCB8 G
Circuit Board
IGBT Gate E
[WK-5493]Circuit Board
C
[WK-5479]
TB1
K(7)
S1
C
TB14
CN1
P
TB13
CN2
UB3
CN1
+
(1)
CN3
1
2
D1
January 15, 2008
SERVICE MANUAL CT2
CT1
TB33
TB21
SH.DET+
AC1
TB34
CT2
+15
-15
IS
GND
PCB15
DIODE Snubber
Circuit Board
[WK-5606]
D5
4
123
TO1
+Output
Terminal
AC2
PCB14
TRANS
Board
[WK-5594] TB35
TB7
HCT1
D7
TB8
L1
D2
TB30
TB16
UB4
TB32
TB22
1
2
3
FCH1
CN1
PCB20
Filter Circuit Board
SIDE CHASSIS 3
[WK-5499]
TO2
-Output
Terminal
SH.DET+
SH.DET-
AC2
AC4
1 2 3 4 5
1 2 3 4 5 6 7 8 9
CN8
CN9
FRONT
PANEL
EB
+
/RY_ON
PCB12
Panel
Circuit Board
[WK-5527]
1
2
3
4
5
6
+15
-15
IS
GND
Ground
SIDE CHASSIS 2
PCB13
Encoder Board
[WK-5528]
R2
UB1
UB2
R3
CN2
RY+15V
January 15, 2008
Ground
SH.DET-
AC4
D4
CT4
CT3
EB
RY+15V
/RY_ON
TB31
TB17CT3
+
1 2 3 4 5
CN3
UB2
TRANSARC 300 Si
CN1
CN1
UB3
UB4
1 2 3 4
1 2 3 4
A-3
TRANSARC 300 Si
SERVICE MANUAL
APPENDIX 3 PARTS LIST
1 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.
2 How To Use This Parts List
The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are
listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc.,
and permanently attached items which are soldered, riveted, or welded to other parts. The part descriptions may be indented to show part relationships. To determine the part number, description, quantity, or
application of an item, simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List.
PART NUMBERS: Transarc 300 Si
No.
DWG No.
Part No.
625781
Description
Type & Rating
QTY.
1
CON1
W7001666
Post, Output, gen 3.1, IPS
MS3102A20-27S(NIC) 14P (with Wiring Assembly)
1
2
CT2-3
W7001304
Transformer, gen 3.1, IPS
F2A503001 CT 1:40
2
3
D1
10-6628
Diode, gen 3.1, IPS
DFA50BA160
1
4
D2,4,5,7
10-6629
Diode, gen 3.1, IPS
DBA200UA60
4
5
FAN1
W7001307
Fan, gen 3.1, IPS
109E5724H507 DC 24V 16.8W
1
6
FCH1
W7001653
Inductor, gen 3.1, IPS
F3A285201 DC FCH
1
7
HCT1
10-5003
Sensor, Current, gen 3.1, IPS
HC-TN200V4B15M 200A 4V
1
8
L1
W7001309
Reactor, gen 3.1, IPS
GP-7
1
9
L101
W7001670
Reactor, gen 3.1, IPS
DFR47ZMD
1
10
L102
W7001672
Reactor, gen 3.1, IPS
F2A734000
1
11
L103
W7001605
Reactor, gen 3.1, IPS
SNG-25B-600
1
12
L105
W7001400
Reactor, gen 3.1, IPS
ZCAT-3035-1330
1
13
PCB1
W7001312
PCB, gen 3.1, IPS
WK-5493 U01 MAIN PCB
1
14
PCB2
W7001678
PCB, gen 3.1, IPS
WK-5597 U02 LINK PCB
1
15
PCB3
W7001314
PCB, gen 3.1, IPS
WK-5548 U01 DDC PCB
1
16
PCB4
10-6635
PCB, gen 3.1, IPS
WK-4819 U01 DETECT PCB
1
17
PCB5
W7001417
PCB, gen 3.1, IPS
WK-5551 U01 CONECT PCB
1
18
PCB6
W7001733
PCB, 400S, gen 3.1, IPS
WK-5549 U05-2 DC CTRL PCB
1
18
PCB6
W7001732
PCB, 300S, gen 3.1, IPS
WK-5549 U05-1 DC CTRL PCB
1
19
PCB7
W7001423
PCB, gen 3.1, IPS
WK-5550 U01 FILTER PCB
1
20
PCB8-11
W7001318
PCB, gen 3.1, IPS
WK-5479 U01 GATE PCB (with IRGP20B60PD)
4
21
PCB12
W7001319
PCB, gen 3.1, IPS
WK-5527 U05 PANEL PCB
1
22
PCB13
W7001320
PCB, gen 3.1, IPS
WK-5528 U01 ENCODER PCB
1
23
PCB14
W7001321
PCB, gen 3.1, IPS
WK-5594 U01 TRANS PCB
1
24
PCB15
W7001322
PCB, gen 3.1, IPS
WK-5606 U01 DIODE SNUBBER PCB
1
25
PCB20
W7001324
PCB, gen 3.1, IPS
WK-5499 U01 FILTER PCB
1
26
PCB21
10-6740
PCB, gen 3.1, IPS
WK-4917 U04 INPUT FILTER PCB
1
27
PCB22
W7001677
PCB, gen 3.1, IPS
WK-5022 U01 INPUT FILTER PCB
1
28
R7-8
W7001325
Resistor, gen 3.1, IPS
MHS20A151JI 20W 150OHM
2
29
S1
10-6857
Switch, gen 3.1, IPS
DCP-103SR100C-480V 3P-480V
1
30
TH1,2
10-5228
Thermistor, gen 3.1, IPS
ERTA53D203 20kΩ/25°CB=3950K
2
A-4
SERVICE MANUAL
TRANSARC 300 Si
PARTS LIST
Part No.
Description
31
No.
DWG No.
W7001472
Panel, Front, gen 3.1, IPS
E0D004801
Type & Rating
QTY.
1
32
W7001329
Panel, Rear, gen 3.1, IPS
E0D004901
1
33
W7001330
Label, Side, gen 3.1, IPS
E0D005207
2
1
34
W7001331
Case, Front, gen 3.1, IPS
E0C346000
35
W7001332
Board, Front, gen 3.1, IPS
JEA496001
1
36
W7001656
Cover, Rear, gen 3.1, IPS
JDA173300
1
37
W7001334
Cover, Protector, gen 3.1, IPS
E0C299200
1
38
10-6791
Cover, Encoder, gen 3.1, IPS
EBA514400
1
39
W7001336
Cover, PCB, gen 3.1, IPS
E1B547900 (with Dustcover Sheet)
1
40
W7001676
Label, Name, gen 3.1, IPS
N4A933000 (300S)
1
41
W7001663
Label, Name, gen 3.1, IPS
N4A933100 (400S)
1
42
W7001338
Label, Side, gen 3.1, IPS
N4A785200
2
1
43
W7001339
Label, 1 Warning, gen 3.1, IPS
N1B029700
44
W7001340
Label, 2 Warning, gen 3.1, IPS
N1B029800
1
45
10-6888
Post, Output, gen 3.1, IPS
N4A040400
1
46
W7001342
Label, Switch, gen 3.1, IPS
N4A146500
1
47
10-6660
Post, Output, gen 3.1, IPS
TRAK-BE35-70S
2
48
N/A
Cable, Input, gen 3.1, IPS
H07RN-F#1600106 L=3.9m
1
49
10-6795
Clamp, Input, gen 3.1, IPS
EBA156800
1
50
W7001349
Heatsink, gen 3.1, IPS
E1B895000
2
51
W7001350
Heatsink, gen 3.1, IPS
E1B870100
1
8
52
W7001351
Spring Clip,IGBT, gen 3.1, IPS
E1B850100
53
W7001352
Chassis, PCB1, gen 3.1, IPS
J5B017500
1
54
W7001353
Chassis, gen 3.1, IPS
J3C356600
1
55
10-6665
Knob, gen 3.1, IPS
2621603
1
56
10-6666
Knob Cap, gen 3.1, IPS
3021104
1
57
W7001356
Cover, Protector, gen 3.1, IPS
N1B039200
1
58
W7001357
Post, Output, gen 3.1, IPS
EDA227700
4
59
W7001358
Post, 1(M5), gen 3.1, IPS
EBA643600 (M5-M5)
3
1
60
W7001645
Bus Bar, D, gen 3.1, IPS
ECA903300
61
W7001360
Bus Bar, T-D, gen 3.1, IPS
EDA003800
4
62
W7001361
Bus Bar, 1 D, gen 3.1, IPS
EDA046900
1
63
W7001362
Bus Bar, 2 D, gen 3.1, IPS
EDA047000
1
64
W7001363
Bus Bar, 3 D, gen 3.1, IPS
EDA047100
1
65
W7001364
Bus Bar, 4 D, gen 3.1, IPS
EDA047200
1
66
10-6868
Bus Bar, S1, gen 3.1, IPS
ECA321000
3
67
W7001646
Bus Bar, Output, gen 3.1, IPS
ECA904000
1
68
W7001671
Bus Bar, input, gen 3.1, IPS
EDA069200
1
1
69
W7001673
Chassis, PCB22, gen 3.1, IPS
J5B348000
70
W7001369
Insulated Board, gen 3.1, IPS
E1B872000
2
71
W7001370
Insulation Sheet, gen 3.1, IPS
E1B859700
1
72
W7001371
Insulation Sheet, gen 3.1, IPS
EDA079800
1
73
W7001643
Cover, Protector, gen 3.1, IPS
E1B933000
1
74
W7001373
Cover, Protector, gen 3.1, IPS
E1B933100
1
75
W7001374
Clip, gen 3.1, IPS
#74 NATURAL
4
76
W7001375
Cover, CON1, gen 3.1, IPS
1070500-20 (with String)
1
77
W7001377
Post, Output, gen 3.1, IPS
EH18U
2
Plug, Output, gen 3.1, IPS
TRAK-SK50
1
300x4899
Operating Manual, gen 3.1, IPS
Operating Manual (300S)
1
300x4900
Operating Manual, gen 3.1, IPS
Operating Manual (400S)
1
Label, VRD, gen 3.1, IPS
N4A919100
1
78
10-2020
W7001345
A-5
TRANSARC 300 Si
SERVICE MANUAL
PARTS LIST
45
36
42
41
A-339
29
26
59
33
75
66
59
66
49
48
32
11
22
38
21
35
34
57
56
5
55
46
40
37
33
40
31
12
1
43
76
41
47
47
44
A-6
SERVICE MANUAL
TRANSARC 300 Si
PARTS LIST
2
8
3 77
10
9
77
27
18
17
16
2
28
15
13
69
28
68
71
19
52
14
53
52
20
50
20
50
58
72
58
20
30
54
70
52
20
23
52
51
6
70
4
4
25
61
4
61
54
62
73
63
64
30
65
60
74
24
67
7
A-7
TRANSARC 300 Si
SERVICE MANUAL
APPENDIX 4 CONNECTION WIRING GUIDE
CONNECTION WIRING GUIDE
APPENDIX 2 Connection Wiring Guide
Destination
l
l
l
l
l
A
B
C
D
E
PCB2
PCB2
PCB2
PCB3
PCB3
CN1
CN2
CN3
CN1
CN2
F
PCB3
CN7
l
PCB3
CN11
l
PCB3
PCB3
PCB3
PCB3
PCB3
PCB3
PCB4
PCB6
PCB6
PCB6
CN20
CN21
CN22
CN23
CN18
CN33
CN4
CN1
CN8
CN9
l
l
l
l
l
l
S
PCB6
CN17
l
T
U
V
W
X
PCB6
CN21
CN13
CN14
CN15
CN1
l
PCB4
PCB3
D1
D1
PCB21
CT2
CT3
FAN1
SOL1
PCB8
PCB8
PCB10
PCB9
PCB7
PCB6
S2
HCT1
TH1
TH2
PCB16
PCB20
PCB12
l
CON1
l
PCB13
G
*
I
J
K
L
M
N
O
P
Q
R
PCB7
PCB12
l
l
l
CN4
CN3
CN1
CN1
CN2
CN1
CN2
CN20
CN20
CN4
CN3
CN2
CN1
*
A-8
SERVICE MANUAL
TRANSARC 300 Si
CONNECTION WIRING GUIDE
CT2
CT3
CN17
CN21
X
T
CN1
PCB6
F
CN1
CN2
O
P
CN1
CN20
CN8
PCB21
CN9
PCB13
S2
N
K
CN1
CN4
E
PCB12
CN1
PCB4
L
CN2
CN1
CN2
CN22
CN7
CN23
PCB10
A
C
CN2
CN3
D
CN1
CN33
CN11
PCB11
PCB7
CN13
U
CN15
W
V
D1
B
CN18
CN20
CN3
CN14
FAN1
PCB3
G
M
CN2
SOL1
H
PCB2
CN1
S
I
CN21
CON1
HCT1
CN1
CN20
J
PCB20
CN2
CN1
PCB9
PCB8
CN3
TH2
A-9
TH1
R
Q
CN2
TRANSARC 300 Si
SERVICE MANUAL
APPENDIX 5 DIODE TESTING BASICS
DIODE TESTING BASIC
APPENDIX 4 DIODE Testing Basic
Testing of diode modules requires a digital Volt/
Ohmmeter that has a diode test scale.
1. Locate the diode module to be tested.
2. Remove cables from mounting studs on diodes
to isolate them within the module.
3. Set the digital volt/ohm meter to the diode test
scale.
4. Using figure 1 and 2, check each diode in the
module. Each diode must be checked in both
the forward bias (positive to negative) and
reverse bias (negative to positive) direction.
VR
COM
A
Forward Bias
Diode Conducting
5. To check the diode in the forward bias direction, connect the volt/ohm meter positive lead
to the anode (positive, +) of the diode and the
negative lead to the cathode (negative, –) of
the diode (refer to Figure 13-1. A properly
functioning diode will conduct in the forward
bias direction, and will indicate between 0.3
and 0.9 volts.
Anode
Cathode
Figure 13-1: Forward bias diode test
6. To check the diode in the reverse bias direction, reverse the meter leads (refer to Figure
13-1). A properly functioning diode will block
current flow in the reverse bias direction, and
depending on the meter function, will indicate
an open or "OL".
7. If any diode in the module tests as faulty,
replace the diode module.
8. Reconnect all cables to the proper terminals.
VR
COM
Reverse Bias
Diode Not Conducting
Cathode
Anode
Figure 13-2: Reverse bias diode test
A-10
A
CIGWELD LIMITED WARRANTY
LIMITED WARRANTY: CIGWELD, A Thermadyne Company, hereafter, “CIGWELD” warrants to customers of its authorized
distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure
to conform to this warranty appear within the time period applicable to the CIGWELD products as stated below, CIGWELD
shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained
in accordance with CIGWELD’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement,
at CIGWELD’s sole option, of any components or parts of the product determined by CIGWELD to be defective.
CIGWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS,
INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: CIGWELD SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR
CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies
of the Purchaser set forth herein are exclusive and the liability of CIGWELD 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 CIGWELD 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. No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or
grant any other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN
CIGWELD’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY CIGWELD PRODUCT. PURCHASER’S
RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products
to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated
plus one year from the date CIGWELD delivered the product to the authorized distributor.
Terms of Warranty – January 2008
1. The Trade Practices Act 1974 (Commonwealth) and similar State Territory legislation relating to the supply of
goods and services, protects consumers’ interests by ensuring that consumers are entitled in certain situations
to the benefit of various conditions, warranties, guarantees, rights and remedies (including warranties as to
merchantability and fitness for purpose) associated with the supply of goods and services. A consumer should
seek legal advice as to the nature and extent of these protected interests. In some circumstances, the supplier of
goods and services may legally stipulate that the said conditions, warranties, guarantees, rights and remedies are
limited or entirely excluded. The warranties set out in Clause 2 shall be additional to any nonexcludable warranties
to which the Customer may be entitled pursuant to any statute.
2. Subject to Clause 3. CIGWELD gives the following warranties to the Customer:
Insofar as they are manufactured or imported by CIGWELD, goods will upon delivery be of merchantable quality
and reasonably fit for the purpose for which they are supplied by CIGWELD.
CIGWELD will repair or, at its option, replace those of the goods which, upon examination, are found by CIGWELD
to be defective in workmanship and/or materials.
CIGWELD reserves the right to request documented evidence of date of purchase.
3. The Warranty in Clause 2;
Is conditional upon:
The Customer notifying CIGWELD or our Accredited Distributor in writing of its claim within seven (7) days of
becoming aware of the basis thereof, and at its own expense returning the goods which are the subject of the
claim to CIGWELD or nominated Accredited Distributor/Accredited Service Provider. The goods being used in
accordance with the Manufacturer’s Operating Manuals, and under competent supervision.
Does not apply to:
Obsolete goods sold at auction, second-hand goods and prototype goods.
Breakdown or malfunction caused by accident, misuse or normal wear and tear.
Repairs or replacement made other than by CIGWELD or Accredited Service Providers, unless by prior arrangement
with CIGWELD.
Replacement parts or accessories which may affect product safety or performance and which are not manufactured,
distributed or approved by CIGWELD.
4. CIGWELD declares that, to the extent permitted by law, it hereby limits its liability in respect of the supply of goods
which are not of a kind ordinarily acquired for personal, domestic or household use or consumption to any one
or more of the following (the choice of which shall be at the option of CIGWELD).
The replacement of the goods or the supply of equivalent goods.
The repair of goods.
The payment of cost of replacing the goods or acquiring equivalent goods.
The payment of the cost of having goods repaired.
5. Except as provided in Clauses 2 to 4 above, to the extent permitted by statute, CIGWELD hereby excludes all
liability for any loss, damage, death or injury of any kind whatsoever occasioned to the Customer in respect of
the supply of goods including direct, indirect, consequential or incidental loss, damage or injury of any kind.
Warranty Schedule – January 2008
These warranty periods relate to the warranty conditions in clause 2. All warranty periods are from date of sale from
the Accredited Distributor of the equipment. Notwithstanding the foregoing, in no event shall the warranty period
extend more than the time stated plus one year from the date CIGWELD delivered the product to the Accredited
Distributor. Unless otherwise stated the warranty period includes parts and labour. CIGWELD reserves the right to
request documented evidence of date of purchase.
MULTI PROCESS EQUIPMENT WARRANTY PERIOD
WARRANTY
PERIOD
LABOR
Original Main Power Magnetics.........................................................................................
3 years
2 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semiconductors........
2 years
2 years
All other circuits and components including, but not limited to, relays, switches,
contactors, solenoids, fans, electric motors......................................................................
1 year
1 year
CIGWELD PROFESSIONAL INVERTER WELDING EQUIPMENT
Transtig 200 Pi, Transtig 200 AC/DC, Transarc 300 Si, Transtig 300 Pi,
Transtig 300 AC/DC, Transmig 400 i
Please note that the information detailed in this statement supersedes any prior published data produced by
CIGWELD.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Email: cigweldsales@cigweld.com.au
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Thermadyne,Utama Indonesia
Kawasan Industri Jababeka
JI Jababeka VI Blok P No. 3
Cikarang - Bekasi, 17550
Indonesia
Tel: +62 21 893 6071
Fax: +62 21 893 6067 / 6068
http://www.thermadyne.com
Corporate Headquarters
71 Gower Street
Preston, Victoria, Australia, 3072
Telephone: +61 3 9474 7400
FAX:
+61 3 9474 7488
Email: cigweldsales@cigweld.com.au
www.cigweld.com.au