Thermal Arc ArcMaster 200 ACDC Service Manual_(0

Thermal Arc ArcMaster 200 ACDC Service Manual_(0
200 AC/DC
ARCMASTER
®
INVERTER ARC WELDER
Art # A-07235
Service Manual
Revision No: AB
Issue Date: May 22, 2006
Manual No.: 0-4939B
Operating Features:
200
Amp
1
50Hz
60
INVERTER
230
V
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
ArcMaster 200 AC/DC Inverter Arc Welder
Service Manual Number 0-4939B for:
Part Number 10-3088
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2006, 2007, 2008 by
Thermadyne Industries 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:
Revision AB Date:
May 22, 2006
January 29, 2008
Record the following information for Warranty purposes:
Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
i
CONTENTS
1 SAFETY INSTRUCTION AND WARNINGS
1
2
3
4
5
6
7
Arc Welding Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
PRECAUTIONS DE SECURITE EN SOUNDAGE A L'ARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Dangers relatifs au soudage a l'arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
STATEMENT OF WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
2 INTRODUCTION
1
2
3
4
5
6
7
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receipt Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–1
2–1
2–1
2–2
2–3
2–4
2–4
3 INSTALLATION
1
2
3
4
5
6
7
8
9
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Input Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Frequency Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Frequency Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–1
3–1
3–1
3–1
3–2
3–2
3–3
3–3
3–4
4 OPERATOR CONTROLS
1
2
3
4
5
ARC MASTER 200ACDC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Process selection for ARC MASTER 200ACDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Parameter Descriptions for ARC MASTER 200ACDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Parameters for ARC MASTER 200ACDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1
4–2
4–3
4–5
4–6
5 SET-UP FOR SMAW (STICK) AND GTAW (TIG)
6 SEQUENCE OF OPERATION
1
2
3
4
5
Stick Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC or DC HF TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slope Mode Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slope Mode with repeat sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6–1
6–1
6–2
6–2
6–2
7 ROUTINE MAINTENANCE
8 BASIC TROUBLESHOOTING
1
2
3
TIG Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Stick Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Power Source Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
9 VOLTAGE REDUCTION DEVICE (VRD)
1
2
3
VRD Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
VRD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
Switching VRD On / Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
10 POWER SOURCE ERROR CODES
11 ADVANCED TROUBLE SHOOTING
1
2
3
4
5
System-Level Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
1. 1 Opening the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
Verification and Remedy to the Indicated Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
2. 1 E01 "Over-Temperature at the primary side" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
2. 2 E02 "Over-Temperature at the secondary side". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
2. 3 E03 "Primary Over-Current Failure" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
2. 4 E04 "Torch Cable Failure" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
2. 5 E11 "Main Supply Over Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
2. 6 E12 "Main Supply Under Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
2. 7 E81 "Abnormal Input Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
2. 8 E82 "Rated Voltage Selection Circuit abnormality" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
2. 9 E83 "Abnormalities in Mains Supply Voltage Detection" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6
2. 10 E85 "Pre-charge abnormality" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6
2. 11 E94 "Thermistor malfunction". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6
2. 12 E99 "Initial Power Receiving". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6
Verification and Remedy to Failures without Indication Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7
3. 1 "Cooling Fan (FAN1) Failure"(Fan is not rotating.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7
3. 2 "Gas Valve Failure" (No Gas flow through unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7
3. 3 "No Weld Output" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8
3. 4 "Operating Panel Failure" (LED's do not light properly or welding setting cannot be establish.) . . . . . . . . . . . . . . . 11–8
3. 5 "High Frequency Output Failure" (Unit does not generate High Frequency.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–9
Fault Isolation Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10
4. 1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10
Verification of the Power Input Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10
5. 1 Verification of the AC Input Voltage using an AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10
5. 2 Verfication of Power Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11
12 MAINTENANCE
1
2
Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5
2. 1 Tools and parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5
2. 2 Notes of disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5
3 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6
3. 1 PCB1 (WK-5477) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6
3. 2 PCB2 (WK-5596) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7
3. 3 PCB3 (WK-5548), PCB5 (WK-5551) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9
3. 4 PCB4 (WK-4819) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10
3. 5 PCB6 (WK-5549) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10
3. 6 PCB7 (WK-5550) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11
3. 7 PCB8 (WK-5479) (IGBT (Q1~Q6)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11
3. 8 PCB9 (WK-5479) (IGBT (Q7~Q12)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12
3. 9 PCB10 (WK-5527) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13
3. 10 PCB11 (WK-5528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13
3. 11 PCB12 (WK-5615), Transformer (T1), Current Trans (CT2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15
3. 12 PCB13 (WK-5569) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18
3. 13 PCB16 (WK-5499) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–19
3. 14 PCB14 (WK-5570) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–19
3. 15 PCB17 (WK-4917) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20
3. 16 PCB18 (WK-5861) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21
3. 17 Discharge Resistor (R3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–22
3. 18 Current Limiting Resistor (R4, R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–23
3. 19 Resistor on High Frequency Unit (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24
3. 20 Coupling Coil (CC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24
3. 21 Reactor (FCH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–25
CONTENTS
3. 22
3. 23
3. 24
3. 25
3. 26
3. 27
3. 28
3. 29
3. 30
3. 31
3. 32
3. 33
3. 34
Primary Thermistor (TH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Thermistor (TH2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Fan (FAN1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valve (SOL1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main ON/OFF Switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Connector (CON1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Freguency Unit (HF.UNIT1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hall C.T. (HCT1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Diode (D2, D4, D5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary IGBT (Q13) (PCB15 (WK-3367)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reactor (L101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Earth Inductance (L103). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12–26
12–26
12–27
12–28
12–29
12–29
12–31
12–31
12–32
12–33
12–34
12–35
12–35
APPENDIX 1 PARTS LIST
1
2
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1
How To Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1
APPENDIX 2 CONNECTION WIRING GUIDE
APPENDIX 3 INTERCONNECT DIAGRAM
APPENDIX 4 DIODE TESTING BASICS
ARCMASTER 200 ACDC
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
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.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
WARNING
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
ELECTRIC SHOCK can kill.
11. Do not touch electrode while in contact with the work (ground)
circuit.
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.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
1. Do not touch live electrical parts.
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.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
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.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
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.
May 22, 2006
1-1
ARCMASTER 200 ACDC
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
WARNING
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
WELDING can cause fire or explosion.
5. Use approved ear plugs or ear muffs if noise level is high.
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.
WARNING
FUMES AND GASES can be hazardous to your health.
1. Protect yourself and others from flying sparks and hot metal.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
2. Do not weld where flying sparks can strike flammable material.
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.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
3. If ventilation is poor, use an approved air-supplied respirator.
5. Watch for fire, and keep a fire extinguisher nearby.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
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 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 closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
Electrode Size
Filter
2
3 or 4
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
3 or 4
4 or 5
5 or 6
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in.,
Over 1/4 in., 6.4 mm
4 or 5
5 or 6
6 or 8
10
12
14
Welding or cutting
Electrode Size
Gas metal-arc
Non-ferrous base metal
All
Ferrous base metal
All
Gas tungsten arc welding
All
(TIG)
All
Atomic hydrogen welding
All
Carbon arc welding
All
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
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
May 22, 2006
ARCMASTER 200 ACDC
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
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
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.
CYLINDERS can explode if damaged.
4. Do not overfill tank — allow room for fuel to expand.
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.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
WARNING
MOVING PARTS can cause injury.
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.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
3. Keep cylinders away from any welding or other electrical circuits.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
4. Never allow a welding electrode to touch any cylinder.
2. Stop engine before installing or connecting unit.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
6. Turn face away from valve outlet when opening cylinder valve.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
!
WARNING
Engines can be dangerous.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
WARNING
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
ENGINE EXHAUST GASES can kill.
3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases.
4. Do not use welder to charge batteries or jump start vehicles.
1. Use equipment outside in open, well-ventilated areas.
5. Observe correct polarity (+ and –) on batteries.
May 22, 2006
1-3
ARCMASTER 200 ACDC
1.02
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.
2. Wear gloves and put a rag over cap area when removing cap.
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.
3. Allow pressure to escape before completely removing cap.
!
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.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, 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.
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-BP-E-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
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.
1-4
May 22, 2006
ARCMASTER 200 ACDC
1.03
Precautions de Securite en Soudage à l’Arc
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de
sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.04
Dangers Relatifs au Soudage à l’Arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension
dès la mise en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou
la bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à la terre
est dangereux.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
1. Ne touchez pas à des pièces sous tension.
15. Fermez solidement tous les panneaux et les capots.
2. Portez des gants et des vêtements isolants, secs et non troués.
3
Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
May 22, 2006
1-5
ARCMASTER 200 ACDC
AVERTISSEMENT
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements
et aux produits nettoyants.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
portez un respirateur à adduction d’air. Les gaz protecteurs de
soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
malaises ou la mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de
filtre oculaire
Brassage tendre
au chalumeau
toutes conditions
2
Brassage fort
au chalumeau
toutes conditions
3 ou 4
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dimensions
12
Oxycoupage
mince
moins de 1 po. (25 mm)
moyen de 1 á 6 po. (25 á 150 mm)
épais
plus de 6 po. (150 mm)
2 ou 3
4 ou 5
5 ou 6
Soudage aux gaz
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
Opération de coupage
ou soudage
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plasma (PAW)
mince
moins de 1/8 po. (3 mm)
moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais
Soudage á l'arc avec
électrode enrobees
(SMAW)
4 ou 5
Gougeage Air-Arc avec
électrode de carbone
5 ou 6
mince
12
plus de 1/2 po. (12 mm)
6 ou 8
épais
14
moins de 5/32 po. (4 mm)
10
5/32 á 1/4 po. (4 á 6.4 mm)
12
mince
moins de 300 amperès
9
plus de 1/4 po. (6.4 mm)
14
moyen
de 300 á 400 amperès
12
plus de 400 amperès
14
Coupage á l'arc Plasma (PAC)
épais
1-6
May 22, 2006
ARCMASTER 200 ACDC
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que si
l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du
soudage.
AVERTISSEMENT
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un échauffement ou un
incendie.
2. Portez des vêtements appropriés pour protéger la peau.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
May 22, 2006
1-7
ARCMASTER 200 ACDC
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de
faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
AVERTISSEMENT
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
1-8
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
1.05
Principales Normes de Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, 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, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
May 22, 2006
ARCMASTER 200 ACDC
1.06
Declaration Of Conformity
Manufacturer:
Address:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council
Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC Directive” (European Council Directive
89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of
manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
•
CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
•
UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
•
CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
•
ISO/IEC 60974-1 (BS 638-PT10)
equipment and associated accessories.
•
For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192 when used in
conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
•
Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process.
This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as
specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all
design specifications.
(EN
60
974-1)
(EN50192)
(EN50078)
applicable
to
plasma
cutting
Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative:
Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
May 22, 2006
1-9
ARCMASTER 200 ACDC
1-10
May 22, 2006
2 INTRODUCTION
2 Equipment Identification
1 How To Use This Manual
INTRODUCTION
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.
This Service 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:
WARNING
3 Receipt Of Equipment
A WARNING gives information regarding possible
personal injury.
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.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
Include all equipment identification numbers as described above along with a full description of the
parts in error.
A NOTE offers helpful information concerning certain operating procedures.
Move the equipment to the installation site before
uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to uncrate the unit.
Additional copies of this manual may be purchased
by contacting Thermal Arc at the address and
phone number in your area listed in the inside
back cover of this manual. Include the 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 Thermal Arc web site listed below and clicking
on the Literature Library link:
http://www.thermalarc.com
2–1
200ACDC
2
INTRODUCTION
4 Symbol Chart
Note that only some of these symbols will appear on your model.
Amperage
STICK
(Shielded Metal Arc SMAW)
Voltage
Pulse Current Function
Hertz (frequency)
Spot Time (GTAW)
t
SEC
Seconds
Remote Control
(Panel/Remote)
%
Percent
Remote Function
DC (Direct Current)
Arc Control (SMAW)
AC (Alternating Current)
t2
Standard Function
t1
VRD
Slope Function
Gas Post-Flow
Gas Pre-Flow
Voltage Reduction Device
Circuit
Slope W/Repeat Function
Negative
Spot Function
Positive
Impulse Starting
(High Frequency GTAW)
Gas Input
Touch Start
(Lift Start TIG circuit GTAW)
Gas Output
2–2
200ACDC
2
INTRODUCTION
5 Description
The Thermal Arc™ Model 200ACDC is a self contained three -phase AC/DC arc welding power
source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage
Meter, gas control valve, built in Sloper and Pulser, lift arc starter, and high-frequency arc starter for use with
Gas Tungsten Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed (GTAW-P) Gas Tungsten Arc Welding-Sloped (GTAW-S), and Shielded Metal Arc Welding (SMAW) processes. The power source is totally enclosed in an impact resistant, flame retardant and non-conductive plastic case.
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.
(V)
OCV
5A
160A
(A)
STICK Process
(V)
OCV
(V)
OCV
5A
200A
(A)
5A
LIFT TIG Process
200A
HF TIG Process
Figure 2-1: Model 200ACDC Volt-Ampere curve
2–3
(A)
200ACDC
2
INTRODUCTION
6 Functional Block Diagrams
Figure 2-2 illustrates the functional block diagram of the 200ACDC-power supply.
DC Power
To each control circuit
+/-12VDC +15VDC
Secandary
Voltage Sensor
Input
Power
Main
Circuit
Switch
Input
Diode
Filter
Capacitor
DC Power
Primary
Voltage
Sensor
IGBT
Inverter
Main
Transformer
(PCB14)
Thermal
Detector
Output
Diodes
Output
Inductor
Thermal
Detector
Hall Current
Secondary
IGBT
Inverter
Transformer
(HCT1)
Coupling
Coil
To each control circuit
+/-15VDC +18VDC
+24VDC +5VDC
Drive
Circuit
Thermal
Sensor
Circuit
HF-UNIT Stick Mode
Control
VRD
Circuit
Sensing
Circuit
Lift Tig Mode
Output Short
Sensing
Circuit
High
Frequency
Unit
Primary
Current
Sensor
Trouble
Sensing
Circuit
Sequence
Control
Torch Control
Connection
(CON1)
Fan Control
Circuit
Fan
Gas Control
Circuit
Solenoid
Current
Reference
Adjustment
Adjustment &
circuit
Mode select Switches
Panel Circuit Board
Figure 2-2: 200ACDC Model Functional Block Diagram
7 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 deenergized 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
Drive
Circuit
3 INSTALLATION
1 Environment
3 Electrical Input Connec-
INSTALLATION
tions
The ARC MASTER 185ACDC / 200ACDC is
designed for use in adverse environments.
WARNING
Examples of environments with increased adverse
conditions are:
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input power.
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;
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.
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, or
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.
4 Electrical Input Requirement
Environments with adverse conditions do not include places where electrically conductive parts
are in the near vicinity of the operator, which can
cause increased hazard, have been insulated.
Operate the welding power source from a 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 any
inspection required.
2 Location
Be sure to locate the welder according to the following guidelines:
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.
 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.
NOTE
These units are equipped with a three-conductor
with earth power cable that is connected at the
welding power source end for single and three
phase electrical input power.
 In areas, not subjected to abnormal vibration or
shock.
 In areas, not exposed to direct sunlight or rain.
 Place at a distance of 12" (304.79mm) or more
from walls or similar boundaries that could
restrict natural airflow for cooling.
Do not connect an input (BROWN or BLUE or
RED) conductor to the ground terminal.
Do not connect the ground (GREEN/YELLOW)
conductor to an input line terminal.
WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3–1
200ACDC
Refer to figure 3-1 and:
Minimum Current & Duty Cycle
Primary Supply
Primary
Lead Size
Current
Model
(Factory
TIG
STICK
Circuit Size
Fitted)
(Vin/Amps)
ARC
240/32 [email protected]%
2.5mm sq/3
MASTER
1φ
minimum
240/38
[email protected]%
200ACDC
2. Connect ends of line 1 (BROWN) and line 2
(BLUE) input conductors to a de-energized line
disconnect switch.
3. Use Table 3-2 and Table 3-4 as a guide to select line fuses for the disconnect switch.
Table 3-2: 240V Primary Current Circuit sizes to
achieve maximum current
Fuse Size
60 Amps
The ARC MASTER 200ACDC is designed for use
with a generator as an input power source. Contact an accredited Thermal Arc service agent for
the proper sizing and set-up recommendations of a
generator power source system. As a general rule,
depending on the type of generator used, the generator capacity should be twice the maximum rating of the welder.
Table 3-1: Electrical Input Connections 200ACDC
NOTE
Fuse size is based on not more than 200 percent of
the rated input amperage of the welding power
source (Based on Article 630, National Electrical
Code).
Welding Power Supply
Ground Terminal
INSTALLATION
The following 240V Primary Current recommendations are required to obtain the maximum welding
current and duty cycle from this welding equipment:
1. Connect end of ground (GREEN/YELLOW)
conductor to a suitable ground. Use a grounding method that complies with all applicable
electrical codes.
Input Voltage
240V
3
6 High Frequency Introduction
Ground Conductor
Line Disconnect
Switch
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.
Line Fuse
Primary Power Cable
Figure 3-1: Electrical Input Connections
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.
5 Input Power
Each unit incorporates an INRUSH circuit and input
voltage sensing circuit. When the MAIN CIRCUIT
SWITCH is turned on, the inrush circuit provides a
pre-charging of the input capacitors. At this point
the Bus Voltages are checked and the welder is
enabled after the input capacitors have charged to
full operating voltage (after approximately 5 seconds).
NOTE
Note the available input power. Damage to the
welder could occur if 460VAC or higher is applied.
3–2
WARNING: Computers
It is also possible that operation close to computer
installations may cause computer malfunction.
200ACDC
3
INSTALLATION
7 High Frequency Interfer-
8 Duty Cycle
ence
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.
Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the
following ways:
1. 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.
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.
2. 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.
CAUTION
Continually exceeding the duty cycle ratings can
cause damage to the welding power source and
will void the manufactures warranty.
3. 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.
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. 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.
3–3
200ACDC
3
INSTALLATION
9 Specifications
Rated Output
Duty Cycle
Parameter
Amperes
Volts
Duty Cycle
TIG
200ACDC
200
18
20%
200A/[email protected]%
160A/[email protected]%
130A/[email protected]%
100A/[email protected]%
160A/[email protected]%
130A/[email protected]%
100A/[email protected]%
STICK
Output Current
Range
TIG
STICK
Open Circuit Voltage
Width
Dimensions
Height
Length
Weight
[email protected] Load Rated Input Voltage
Output Amperes
Output Volts
Duty Cycle
KVA
KW
[email protected] Load
KVA
KW
Input Volts Single Phase
240V
5–200 (DC)
5–200 (AC)@60Hz, 50% Cleaning
5–160 (DC)
5–160 (AC)@60Hz, 50% Cleaning
65V
7.08” (180mm)
14.7” (360mm)
16.54” (420mm)
37.4 lb. 17 kg
Single-phase
160A
27V
40%
9.0
5.4
0.5
0.3
Amperage [email protected] Load
No Load Amps
40
2.2
Thermal Arc 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.
3–4
4 OPERATOR CONTROLS
1 ARC MASTER 200ACDC
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.
OPERATOR CONTROLS
Controls
2. Remote Control Socket: The 8 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.
1
2
360
GND
5
2
3
15
4
1
12 3456 78
5
4
3
8
7
6
180
Fr ont vi ew 8-Socket R eceptacl e
420
5k Ohms
Figure 4-2: 8-Socket Receptacle
Socket
Pin
1
Earth (Ground)
2
3
4
5
6
6
7
7
8
Function
Torch Switch Input (24V) to (connect pins 2 & 3
to turn on welding current)
Torch Switch Input (0V) to energize weld
current (connect pins 2 & 3 to turn on welding
current)
Connect pin 4 to pin 8 to instruct machine that a
remote current control device is connected (12V
DC supply)
5k ohm (maximum) connection to 5k ohm
remote control potentiometer
Zero ohm (minimum) connection to 5k ohm
remote control potentiometer
Wiper arm connection to 5k ohm remote control
potentiometer
Connect pin 4 to pin 8 to instruct machine that a
remote current control device is connected (0V)
Table 4-1: Socket Pin Functions
8
Figure 4-1: ARC MASTER 200ACDC Power Source
4–1
200ACDC
4 OPERATOR CONTROLS
2 Weld Process selection for
3. Positive Terminal: Welding current flows from
the Power Source via heavy duty Dinse type
terminal (50 mm). It is essential, however,
that the male plug is inserted and turned
securely to achieve a sound electrical connection.
ARC MASTER 200ACDC
4. Negative Terminal: Welding current flows
from the Power Source via heavy duty Dinse
type terminal (50 mm). It is essential, however, that the male plug is inserted and turned
securely to achieve a sound electrical connection.
Parameter
Weld Mode
HF LIFT
STICK
TIG TIG
STD
Yes
Yes
Yes
No
Yes
Yes
SLOPE
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being fused
in the bayonet terminal.
No
Yes
Yes
No
Yes
No
2T operation spot welding
in HF TIG using a remote
contactor device.
No
Yes
Yes
Pulse operation in TIG
Modes.
Yes
Yes
Yes
Selects AC or DC weld
current.
CONTACTOR
ON/OFF
Yes
No
Yes
Contactor operation in
Stick Mode.
Yes
Yes
Selects mode of operation:
Panel or Remote.
SPOT
6. ON/OFF Switch: This switch connects the Primary supply voltage to the inverter when in the
ON position. This enables the Power Supply.
PULSE
ON/OFF
WARNING
When the welder is connected to the Primary supply voltage, the internal electrical components
may be at 720V potential with respect to earth.
AC/DC
DC
AC
7. Input Cable: The input cable connects the Primary supply voltage to the equipment.
8. Gas Inlet: The Gas Inlet is a BSP-3/8 inch
female gas fitting.
2T operation in TIG
Modes using remote
devices to control
contactor & current.
4T operation in TIG
Modes with crater fill
using a remote contactor
device to control
sequence.
4T operation in TIG
Modes with repeat
operation and crater fill
using a remote contactor
device.
REPEAT
5. Gas Outlet: Torch/Gas Terminal is an all-inone design of the Gas Outlet and the Negative
Terminal. Gas Outlet is a BSP-3/8 inch female
gas fitting.
Description
Operation
PANEL/
REMOTE
Yes
Table 4-2: Weld Process selection verses Weld Mode
for ARC MASTER 200ACDC
4–2
200ACDC
4 OPERATOR CONTROLS
3 Weld Parameter Descriptions for ARC MASTER 200ACDC
Figure 4-3: ARC MASTER 200ACDC Front Panel with Parameter Description
Parameter
PRE-FLOW
t1
HOT START
INITIAL CUR.
UP SLOPE
PEAK CUR.
WELD
BASE
(Background Current)
SPOT TIME
PULSE WIDTH
PULSE FREQ.
AC FREQUENCY
Description
This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to
striking the arc, once the torch trigger switch has been pressed. This control is used to
dramatically reduce weld porosity at the start of a weld.
This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld
zone in TIG modes or improve the start characteristics for stick electrodes. e.g. low hydrogen
electrodes. It sets the peak start current on top of the BASE (WELD) current.
e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps & HOT START
= 30 amps
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the start
current for TIG. The Start Current remains on until the torch trigger switch is released after it has
been depressed.
This parameter operates in TIG modes only and is used to set the time for the weld current to
ramp up, after the torch trigger switch has been pressed then released, from INITIAL CUR to
PEAK or BASE current
This parameter sets the PEAK weld current when in PULSE mode
This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and SPOT modes when
PULSE is off. This parameter also sets the STICK weld current.
This parameter sets the Background current when in Pulse TIG mode.
This parameter sets the duration of the SPOT TIME in HF TIG mode only
This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current
when the PULSE is on.
This parameter sets the PULSE FREQUENCY when the PULSE is on.
This parameter operates in AC mode only and is used to set the frequency for the AC weld
current.
4–3
200ACDC
Parameter
Description
This parameter is used for aluminium AC TIG mode and is used to set the penetration to
cleaning action ratio for the AC weld current.
Generally WAVE BALANCE is set to 50% for AC STICK welding. The WAVE BALANCE control
changes the ratio of penetration to cleaning action of the AC TIG welding arc. Maximum weld
penetration is achieved when the WAVE BALANCE control is set to 10%. Maximum cleaning of
heavily oxidised aluminum or magnesium alloys is achieved when the WAVE BALANCE control
is set to 65%.
WAVE BALANCE=50%
WAVE BALANCE
4 OPERATOR CONTROLS
WAVE BALANCE=10%
10%
(+)
50%
(+)
(+)
65%
90%
(-)
50%
(-)
Balanced with 50% penetration
and 50% cleaning
WAVE BALANCE=65%
Maximum Penetration and
reduced cleaning
35%
(-)
Maximum Cleaning and
reduced penetration
DOWN SLOPE
This parameter operates in TIG modes only and is used to set the time for the weld current to
ramp down, after the torch trigger switch has been pressed, to CRATER CUR. This control is
used to eliminate the crater that can form at the completion of a weld.
CRATER CUR.
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the finish
current for TIG. The CRATER Current remains on until the torch trigger switch is released after it
has been depressed.
POST-FLOW
t2
SAVE
LOAD
This parameter operates in TIG modes only and is used to adjust the post gas flow time once the
arc has extinguished. This control is used to dramatically reduce oxidation of the tungsten
electrode.
The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into the
200ACDC memory.
SAUVEGARDER CHARGER
Table 4-3: (Continued) Weld Parameter Descriptions for ARC MASTER 200ACDC
4–4
200ACDC
4 OPERATOR CONTROLS
4 Weld Parameters for ARC MASTER 200ACDC
Weld Parameter
Parameter Range
Factory Setting
Incremental Unit
PRE-FLOW
0.0 to 1.0 sec
0 sec
0.1 sec
HOT START
0 to 70A
20 A
1A
INITIAL CUR.
5 to 200A
30 A
1A
0 to 15 sec
1 sec
5 to 200A
120 A
5 to 200A
80 A
UP SLOPE
PULSE PEAK CUR.
PULSE BASE CUR.
Weld Mode
STICK
HF TIG
LIFT TIG
No
Yes
Yes
Yes
Yes
No
No
Yes
Yes
0.1 sec
No
Yes
Yes
1A
No
Yes
Yes
1A
No
Yes
Yes
WELD CUR. (TIG)
5 to 200A
80 A
1A
No
Yes
Yes
WELD CUR. (STICK)
5 to 160 A
80 A
1A
Yes
No
No
SPOT TIME
0.5 to 5.0 sec
2 sec
0.1 sec
No
Yes
Yes
PULSE WIDTH
15 to 80 %
50%
1%
No
Yes
Yes
PULSE FREQ.
0.5 to 500 Hz
100.0Hz
See Table Table 4-5
No
Yes
Yes
AC FREQUENCY
15 to 150 Hz
60Hz
1Hz
Yes
Yes
Yes
WAVE BALANCE
10 to 65%
50%
1%
Yes
Yes
Yes
DOWN SLOPE
0 to 25 sec
3 sec
0.1 sec
No
Yes
Yes
CRATER CUR.
POST-FLOW
5 to 200A
30 A
1A
No
Yes
Yes
0.0 to 60 sec
10 sec
0.1 sec
No
Yes
Yes
Table 4-4: Weld Parameters for ARC MASTER 200ACDC
PULSE FREQ. Range
0.5 to 20Hz
Incremental Unit
0.1Hz
20 to 100Hz
100 to 500Hz
1Hz
5Hz
Table 4-5: PULSE FREQ. Range and Incremental Units
4–5
200ACDC
4 OPERATOR CONTROLS
5 Power Source Features
Feature
New Digital Control
Touch Panel Switches
Front Control Cover
Digital Meter
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.
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.
Intelligent Fan Control
The intelligent cooling system is designed to reduce dust and foreign material build-up,
whilst providing optimum cooling.
 Fan speed reduces approximately 30 seconds after machine is turned on.
 Fan speed increases when internal components reach operating temperature.
ON/OFF switch
 Primary voltage Supply ON/OFF switch located on rear panel.
Voltage Reduction Device
(VRD)
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 IEC 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.
Control Knob
Self Diagnosis Using Error
Codes





For the selected weld parameter, rotating the knob clockwise increases the parameter.
Rotating the knob counter-clockwise decreases the parameter.
A selected weld parameter value can be adjusted at any time even while welding.
Pushing the knob in displays actual arc voltage.
An error code is displayed on the Digital Meter when a problem occurs with Primary supply voltage or internal component problems. Refer to troubleshooting guide.
 A total number of 5 programs can be saved into the 200ACDC memory.
SAVE the Current Weld Parameters into Memory
 Press the SAVE button.
 Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter.
 After selecting the desired memory location (ie 1 to 5), press the right scroll button and
Save/Load function
the machine will give a beep to confirm the weld parameters from the control panel are
saved.
LOAD (retrieve) a Program to Control Panel
 Press the LOAD button.
 Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter.
After selecting the desired memory location (ie 1 to 5), press the right scroll button and the
machine will give a beep to confirm the weld parameters are loaded onto the control panel.
Table 4-6: Power Source Features
4–6
5. SET-UP FOR SMAW (STICK) AND GTAW (TIG)
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
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.
CAUTION
Figure 5-1: 200ACDC Set-up
DO NOT change the Weld Mode or Weld Process
Mode until after POST-FLOW time has finished.
5–1
200ACDC
5.
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
PAGE LEFT INTENTIONALLY BLANK
5–2
6 SEQUENCE OF OPERATION
NOTE
1 Stick Welding
SEQUENCE OF OPERATION
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 the
Symbols Table located in the front of the manual
for Symbol descriptions.
1




Connect work lead to negative terminal.
Connect electrode lead to positive terminal.
Switch machine on.
Set AC or DC weld current. If AC is selected
then set AC FREQ to 60Hz & WAVE BALANCE to 50%.
 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.
Commence welding.
9
10
2
8
5
3
7
4
2 AC or DC HF TIG Welding
6
Figure 6-1: 200ACDC Front Panel




Connect work lead to positive terminal.
Connect TIG torch to negative terminal.
Switch machine on.
Set AC or DC weld current. If AC is selected
then set AC FREQ & WAVE BALANCE .
 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 PRE-FLOW time.
 Set HOT START current.
 Set POST-FLOW time.
 Set (WELD) PEAK CUR current.
 Set POST-FLOW time.
Slope Mode Parameters if required.
 Set INTIAL CUR current.
 Set UP SLOPE time.
 Set (WELD) PEAK CUR current.
 Set BASE current.
 Set DOWN SLOPE time.
 Set CRATER CUR current.
Pulse Mode parameters if required.
 Set PULSE WIDTH % for PEAK CURRENT.
 Set PEAK CURRENT.
 Set PULSE FREQ.
Commence welding.
1) Pulse function: Pressing this button enables
the TIG current pulse functions.
2) Remote Current function: Pressing this buttons enables remote current functions.
3) TIG Mode Functions: Pressing this button
scrolls through the output TIG function modes
(Standard, Slope, Slope w/repeat, Spot).
4) 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.
5) Save/Load Buttons: by using the Save &
Load buttons the operator can easily save up
to 5 welding parameter programs.
6) Control knob: allows the operator to adjust
the output amperage within the entire range of
the power source and sets each parameter
value.
7) Process Button: This button selects between
STICK, HF TIG and Lift TIG mode.
8) Scroll Buttons: used to select the parameters
to be set. The LED's show which function is
being adjusted on the Sequence Graph.
9) AC/DC Button: Selects between AC or DC
welding output.
10) Contactor function: Pressing this button
enables Contactor functions.
6–1
200ACDC
3 Slope Mode Sequence
Switch
Closed
Switch
Open
Initial
Current
Up
Slope
Weld Current
Switch
Closed
Down
Slope
SEQUENCE OF OPERATION
4 Slope Mode with repeat
sequence
Switch
Open
The repeat function is operated during the down
slope cycle of the Slope Sequence and is active
through the down slope period only. During the down
slope period by opening the Remote Switch contacts
the current will increase back to weld current. Within
the Down Slope period the repeat function can operated as many times as desired. To continue slope cycle and end slope sequence close remote switch
contacts and allow weld current to reach final current
setting. Once final current setting is reached opening
the Remote Switch again will turn off the welding arc
and post flow begins.
Final
Current
Postflow
Preflow
6
Figure 6-2: Slope Mode Sequence
1) To start Slope sequence Close remote switch
contacts. Once the welding arc is established
the Power Source will maintain initial current
setting as long as the remote switch contacts
are closed.
a. In the HF TIG mode, after Preflow time, High
Frequency is present at the torch. When the
torch is positioned close to the work the
welding current will transfer to the work and
establish the arc at the initial current setting.
5 Pulse Controls
(Pulse Width)
(Pulse Frequency)
(Peak Current)
b. In the Lift TIG mode, after Preflow time, Lift
Start current is present at the torch. When
the electrode is touched to the work and
lifted off, the welding arc is established at the
initial current setting.
(Base)
Background
Current
The Pulse controls are used primarily to control
heat input. Pulse offers a number of advantages as
follows:
2) Open Remote Switch - current increases to
weld current. Once welding arc has reached
weld current the power source will maintain
weld current as long as the remote switch contacts are open.
1. Control puddle - size and fluidity
(especially out of position).
2. Increase penetration
3. Travel speed control
3) Close Remote Switch - Welding current
decreases to final current setting. Once final
welding current is reached the power source
will maintain final current setting as long as the
remote switch contacts are closed.
4. Better consistent quality
5. Decreased distortion on lighter or thinner
materials.
Pulse-current provides a system in which the welding current continuously changes between two levels. During the periods of Peak current, heating
and fusion takes place, and during the background
(base) current periods, cooling and solidification
take place. Pulse Width is the time in one cycle the
current remains at the peak current setting. Pulse
Frequency, measured in Hertz, is the number of cycles per second the current travels between peak
and background current settings. It is as if the foot
rheostat were moved up and down to increase and
decrease the welding current on a regular basis.
The faster you move the foot rheostat up and
down the faster the frequency.
4) Open Remote Switch - Welding arc stops and
post flow begins.
6–2
7 ROUTINE MAINTENANCE
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 (refer to
Section 10.02, Opening 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.
7–1
Warning!
Disconnect input power before maintaining.
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
Thermal Arc Service Center
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-07331
7-2
Maintain more often
if used under severe
conditions
8 BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to
open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power
measurements and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
1. TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.
Description
Possible Cause
Welding current is too low.
Remedy
Increase weld current and/or faulty joint
preparation.
1 Excessive bead buildup or poor penetration
or poor fusion at edges
of weld.
Welding current is too high.
Decrease weld current.
2 Weld bead too wide
and flat or undercut at
edges of weld or
excessive burn
through.
Travel speed too fast.
Reduce travel speed.
3 Weld bead too small or
insufficient penetration
or ripples in bead are
widely spaced apart.
Travel speed too slow.
Increase travel speed.
4 Weld bead too wide or
excessive bead build
up or excessive
penetration in butt joint.
Wrong placement of filler rod.
Re-position filler rod.
5 Uneven leg length in
fillet joint.
6 Electrode melts when
A Electrode is connected to the '+' terminal. A Connect the electrode to the '–' terminal.
arc is struck.
B WAVE BALANCE is greater than 50%.
B Reduced WAVE BALANCE to below 50%
or increase the electrode size.
7 Dirty weld pool.
A Electrode contaminated through contact A Clean the electrode by grinding off the
with work piece or filler rod material.
contaminates.
B Gas contaminated with air.
B Check gas lines for cuts and loose fitting
or change gas cylinder.
8 Electrode melts or
A No gas flowing to welding region.
A Check the gas lines for kinks or breaks
oxidizes when an arc is
and gas cylinder contents.
struck.
B Torch is clogged with dust.
B Clean torch.
C Gas hose is cut.
C Replace gas hose.
D Gas passage contains impurities.
E Gas regulator turned off.
D Disconnect gas hose from torch then
raise gas pressure and blow out
impurities.
E Turn on.
F Torch valve is turned off.
F Turn on.
8–1
200ACDC
Description
Possible Cause
8
BASIC TROUBLESHOOTING
Remedy
8 Electrode melts or
G The electrode is too small for the welding G Increase electrode diameter or reduce
oxidizes when an arc is
current.
the welding current.
struck.
H WAVE BALANCE is set above 50%.
H Reduced WAVE BALANCE to below 50%
or increase the electrode size.
Inadequate
shielding
gas.
Increase
gas flow or check gas line for
9 Poor weld finish.
gas flow problems.
10 Arc flutters during TIG A Tungsten electrode is too large for the
A Select the right size electrode. Refer to
welding.
welding current.
Basic TIG Welding guide.
B Absence of oxides in the weld pool.
B Refer Basic TIG Welding Guide for ways
to reduce arc flutter.
11 Welding arc can not be A Work clamp is not connected to the work A Connect the work clamp to the work piece
established.
piece or the work/torch leads are not
or connect the work/torch leads to the
connected to the right welding terminals.
right welding terminals.
B Torch lead is disconnected.
B Connect it to the '–' terminal.
C Gas flow incorrectly set, cylinder empty or
the torch valve is off.
12 Arc start is not smooth. A Tungsten electrode is too large for the
welding current.
B The wrong electrode is being used for the
welding job.
C Gas flow rate is too high.
D Incorrect shielding gas is being used.
E Poor work clamp connection to work
piece.
C Select the right flow rate, change
cylinders or turn torch valve on.
A Select the right size electrode. Refer to
Basic TIG Welding Guide.
B Select the right electrode type. Refer to
Basic TIG Welding Guide.
C Select the correct rate for the welding job.
Refer to Basic TIG Welding Guide.
D Select the right shielding gas. Refer to
Basic TIG Welding Guide.
E Improve connection to work piece.
Table 8-1: TIG Welding Problems
8–2
200ACDC
8
BASIC TROUBLESHOOTING
2. Stick Welding Problems
Description
Possible Cause
Remedy
1 Gas pockets or voids in A Electrodes are damp.
weld metal (Porosity).
B Welding current is too high.
A Dry electrodes before use.
B Reduce welding current.
C Surface impurities such as oil, grease,
paint, etc.
2 Crack occurring in weld A Rigidity of joint.
metal soon after
solidification
commences.
B Insufficient throat thickness.
C Clean joint before welding.
C Cooling rate is too high.
3 A gap is left by failure of A Welding current is too low.
the weld metal to fill the B Electrode too large for joint.
root of the weld.
C Insufficient gap.
D Incorrect sequence.
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.
Incorrect sequence
Insufficient gap
Figure 8-1: Example of insufficient gap or incorrect sequence
Description
Possible Cause
Remedy
4 Portions of the weld run A Small electrodes used on heavy cold
do not fuse to the
plate.
surface of the metal or B Welding current is too low.
edge of the joint.
C Wrong electrode angle.
D Travel speed of electrode is too high.
A Use larger electrodes and pre-heat the
plate.
B Increase welding current.
C Adjust angle so the welding arc is
directed more into the base metal.
D Reduce travel speed of electrode.
E Scale or dirt on joint surface.
E Clean surface before welding.
Lack of fusion caused by dirt,
electrode angle incorrect, rate
of travel too high
Lack of inter-run Fusion
Lack of side fusion, scale
dirt, small electrode,
amperage too low
Lack of Root Fusion
Figure 8-2: Example of lack of fusion
8–3
200ACDC
8
BASIC TROUBLESHOOTING
Description
Possible Cause
Remedy
5 Non-metallic particles
are trapped in the weld
metal (slag inclusion).
A Non-metallic particles may be trapped in
undercut from previous run.
A If bad undercut is present, clean slag out
and cover with a run from a smaller
diameter electrode.
B Allow for adequate penetration and room
for cleaning out the slag.
C If very bad, chip or grind out irregularities.
B Joint preparation too restricted.
C Irregular deposits allow slag to be
trapped.
D Lack of penetration with slag trapped
beneath weld bead.
D Use smaller electrode with sufficient
current to give adequate penetration. Use
suitable tools to remove all slag from
corners.
E Rust or mill scale is preventing full fusion. E Clean joint before welding.
F Wrong electrode for position in which
welding is done.
F Use electrodes designed for position in
which welding is done, otherwise proper
control of slag is difficult.
Table 8-2: (continued): STICK Welding Problems
Not cleaned, or
incorrect electrode
Slag trapped in
undercut
Slag trapped in root
Figure 8-3: Examples of slag inclusion
8–4
200ACDC
8
BASIC TROUBLESHOOTING
3. Power Source Problems
Description
Possible Cause
Remedy
1 The welding arc cannot A The Primary supply voltage has not been A Switch ON the Primary supply voltage.
be established.
switched ON.
B The Welding Power Source switch is
B Switch ON the Welding Power Source.
switched OFF.
C Loose connections internally.
C Have an Accredited Thermal Arc Service
Agent repair the connection.
Defective
control
circuit.
Have
an Accredited Thermal Arc Service
2 Maximum output
Agent repair the connection.
welding current can not
be achieved with
nominal Mains supply
voltage.
3 Welding current
A Loose welding cable connections.
A Tighten all welding cable connections.
reduces when welding. B Incorrect welding cable size.
B Use proper size and type of cable.
C Improper input connections.
D Poor electrode condition.
E Wrong welding polarity.
4 No gas flow when the
torch trigger switch is
depressed.
A Gas hose is cut.
B Gas passage contains impurities.
C
D
5 Gas flow won't shut off. A
B
C
D
6 The TIG electrode has
been contaminated due
to the gas flow shutting
off before the
programmed POSTFLOW time has
elapsed.
C Refer to Section 2.05 Electrical Input
Requirements.
D Replace electrode.
E Verify output torch connections.
A Replace gas hose.
B Disconnect gas hose from the rear of
Power Source then raise gas pressure
and blow out impurities.
Gas regulator turned off.
C Turn gas regulator on.
Torch trigger switch lead is disconnected D Reconnect lead or repair faulty switch/
or switch/cable is faulty.
cable.
Weld Mode (STD, SLOPE, REPEAT or
A Strike an arc to complete the weld cycle.
SPOT) was changed before POSTOR
FLOW gas time had finished.
Switch machine off then on to reset
solenoid valve sequence.
Gas valve is faulty.
B Have an Accredited Thermal Arc Service
Agent repair or replace the gas valve
Gas valve jammed open.
C Have an Accredited Thermal Arc Service
Agent repair or replace the gas valve
POST-FLOW control is set to 60 sec.
D Reduce POST-FLOW time.
The Weld Process Mode (STICK, HF TIG
Do not change Weld Process Mode
or LIFT TIG) was changed before POSTbefore the POST-FLOW gas time had finFLOW gas time had finished.
ished.
Table 8-3: Power Source Problems
8–5
200ACDC
8
BASIC TROUBLESHOOTING
PAGE LEFT INTENTIONALLY BLANK
8–6
9 VOLTAGE REDUCTION DEVICE (VRD)
1. VRD Specification
If this equipment is used in a location or an environment with a high risk of electrocution then the
above tests should be carried out prior to entering
this location.
VOLTAGE REDUCTION DEVICE (VRD)
ARC
MASTER
Notes
200ACDC
VRD Open
15.3 to
Open circuit voltage
Circuit Voltage
19.8V
between welding terminals.
The required resistance
VRD
148 to 193 between welding terminals
Resistance
ohms
to turn ON the welding
power.
The time taken to turn OFF
VRD Turn
0.2 to 0.3 the welding power once
OFF Time
seconds the welding current has
stopped.
Description
The test of VRD is shown below:
1) In STICK welding mode, mark and then turn
potentiometer VR1 on PCB6 (WK-5549) all the
way to the left and turn on the electric shock
protector function (Voltage-Reduction-Device,
VRD).
2) Contactor function is put into the state of on
pushing Function button. Refer to section 6.
3) Verify the no-load voltage (OCV) using a DC
voltmeter. (The capability of the voltmeter
should be more than 100VDC.)
Table 9-1: VRD Specification
4) The normal no-load voltage is approximately 18V.
2. VRD Maintenance
5) In STICK welding mode, mark and then turn
potentiometer VR1 on PCB6 (WK-5549) all the
way to the right and turn off the VRD.
Routine inspection and testing (power source):
An inspection of the power source should 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.
6) Contactor function is put into the state of "ON"
pushing Function button. Refer to section 6.
WARNING
Electric shock hazard. The unit will generate OCV
(Open Circuit Voltage) immediately when contactor
function is put into the state of on pushing Function
button at STICK mode.
NOTE
7) Verify the no-load voltage (OCV) using a DC
voltmeter. (The capability of the voltmeter
should be more than 100VDC.)
A transportable power source is any equipment
that is not permanently connected and fixed in the
position in which it is operated.
8) The normal no-load voltage is approximately
65V.
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 Thermal Arc service agent.
Description
VRD Open
Circuit Voltage
VRD Resistance
VRD
Turn OFF Time
IEC 60974-1 Requirements
Less than 20V; at Vin=230/460V
Less than 200 ohms
Less than 0.3 seconds
Table 9-2: Periodic Tests
If this equipment is used in a location or an environment with a high risk of electrocution then the
above tests should be carried out prior to entering
this location.
9–1
200ACDC
3. Switching VRD On / Off
9
VOLTAGE REDUCTION DEVICE (VRD)
c) Access the VRD control by gently prying back
the front panel controls to reveal the VRD on/
off potentiometer (see Figure 9-3).
Switch the machine Off.
CAUTION
a) Remove the clear plastic cover from the control
panel (see Figure 9-1).
Do not pull back the front panel with excessive
force as this will unplug control PCB. Plugging the
control PCB back into the front panel controls can
only be achieved by removing the Side Panel.
 Lift up the cover so it rests on the top of the
unit.
 Place a small flat bladed screw driver between
the cover hinge on the front panel.
 Gently lift the cover hinge out of the front cover
mounting hole.
 Remove the control's clear plastic cover.
VR1
2
2
3
1
Figure 9-3: VRD ON/OFF Step D
d) Turning the VRD ON/OFF (see Figure 9-3).
 To turn VRD ON: rotate the trim potentiometer
(VR1) on the display PCB fully clockwise.
When VRD is turned ON check that it operates
as per VRD Specifications on section 9.1.
Figure 9-1: VRD ON/OFF Step A
b) Remove four mounting screws from the control
panel (see Figure 9-2).
1
 To turn VRD OFF: rotate the trim potentiometer
(VR1) on the display PCB fully counter clockwise.
1
WARNING
The VRD ON/OFF trim potentiometer MUST ONLY
be positioned fully clockwise OR fully counter
clockwise as the VRD function will be unknown for
every other position.
2
1
1
Figure 9-2: VRD ON/OFF Step B, C
9–2
10 POWER SOURCE ERROR CODES
POWER SOURCE ERROR CODES
Description
Possible Cause
Remedy
Remarks
A The Welding Power
Source's duty cycle has
been exceeded.
B Fan ceases to operate.
C Air flow is restricted by
vents being blocked.
A Let Power Source cool
down then keep within its
duty cycle.
B Have an Accredited
Thermal Arc Service
Agent investigate.
C Unblock vents then let
Power Source cool down.
Weld current ceases.
Buzzer sounds constantly.
Fan operates at max speed.
E01 resets when TH1
decreases to 70°C for about
30 seconds.
2 E02 error code
A The Welding Power
Source's duty cycle has
displayed
been exceeded.
Temperature sensor
TH2 (protects secondary B Fan ceases to operate.
diodes) is greater than
C Air flow is restricted by
80°C for about 1 second.
vents being blocked.
A Let Power Source cool
down then keep within its
duty cycle.
B Have an Accredited
Thermal Arc Service
Agent investigate.
C Unblock vents then let
Power Source cool down.
Weld current ceases.
Buzzer sounds constantly.
Fan operates at max speed.
E02 resets when TH2
decreases to 70°C for about
30 seconds.
1 E01 error code
displayed
Temperature sensor
TH1 (protects IGBTs) is
greater than 80°C for
about 1 second.
3 E03 error code
displayed
Primary (input) current
too high.
A Primary current is too
A Reduce length of welding
high because welding arc
arc.
is too long.
B Have an Accredited
B Mains supply voltage is
Thermal Arc Service
more than 10% below
Agent or a qualified
nominal voltage.
electrician check for low
Mains voltage.
Weld current ceases.
Buzzer sounds constantly.
Switch machine off then on to
reset E03 error.
4 E04 error code
displayed
Output voltage exceeds
the secondary voltage
specification.
TIG torch cable and/or
work lead are too long or
leads are coiled.
Reduce the length of the
TIG torch cable and/or
work lead or un-coiled
leads.
Weld current ceases.Buzzer
sounds constantly.Switch
machine off then on to reset
E04 error.
5 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 10%.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Primary voltage.
Weld current ceases.Buzzer
sounds constantly.Error code
E11 automatically will reset
when the voltage reduces.
6 E14 error code
displayed
Under mains supply
(input) voltage warning
primary capacitors is
reduced for one second.
Mains supply voltage is
less than the nominal
operating voltage less
10%.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
Weld current available.
Buzzer sounds intermittently.
Error code E14 automatically
will reset when the voltage
increases.
7 E12 error code
displayed
Under mains supply
(input) voltage primary
capacitors is reduced for
one second
Mains supply voltage is
down to a dangerously
low level.
A Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
B Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
primary cable and fuses.
Weld current ceases.
Buzzer sounds constantly.
Error code E12 automatically
will reset when the voltage
increases.
10 – 1
200ACDC
Description
Possible Cause
10
POWER SOURCE ERROR CODES
Remedy
Remarks
8 E81 error code
displayed
Wrong Primary supply
(input) voltage
connected.
When 3 phase machine
is first turned on with the
wrong Primary supply
(input) voltage
connected.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
No weld current is available.
Buzzer sounds constantly.
Switch machine off.
9 E82 error code
displayed
Rated voltage selection
circuit abnormality.
The Primary supply
(input) voltage fluctuates
and is not stable.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
No weld current is
available.Buzzer sounds
constantly.Switch machine
off then on to reset E82 error.
10 E83 error code
displayed
CPU checks mains
supply (input) voltage
when the on/off switch
on rear panel of machine
is turned ON.
The Primary supply
(input) voltage fluctuates
and is not stable.
Have an Accredited
Thermal Arc Service
Agent check connector
plug on input PCB and
the Mains voltage.
No weld current is
available.Buzzer sounds
constantly.Switch machine
off then on to reset E83 error.
11 E85 error code
displayed
Pre-charge abnormality.
Due to malfunction inside
the Welding Power
Source, primary
capacitors are not
charging correctly.
Have an Accredited
Thermal Arc Service
Agent service the
machine.
No weld current is
available.Buzzer sounds
constantly.Switch machine
off then on to reset E85 error.
12 E93 error code
displayed
Memory chip (EEPROM)
on control PCB can not
read/write weld
parameters.
Memory chip (EEPROM)
error.
Have an Accredited
Thermal Arc Service
Agent check the control
PCB.
Weld current ceases.Buzzer
sounds constantly.Switch
machine off.
13 E94 error code
displayed
Temperature sensor
TH1 for IGBTs or sensor
TH2 for secondary
diodes are open circuit.
The Welding Power
Source's temperature
sensors have malfunctioned.
Have an Accredited Ther- Weld current ceases.Buzzer
mal Arc Service Agent
sounds constantly.Switch
check or replace the tem- machine off.
perature sensors.
14 E99 error code
A Main on/off switch on
A Turn on/off switch on.
machine has been turned B Have an Accredited
displayed
off
Mains supply (input)
Thermal Arc Service
voltage has been turned B Mains supply (input)
Agent or a qualified
off but control circuit has
voltage has been turned
electrician check the
power from the primary
off.
Mains voltage and fuses.
capacitors.
Table 10-1: Power Source Error Codes
10 – 2
Weld current ceases.Buzzer
sounds constantly.Must
switch machine off then on to
reset E99 error.
11 ADVANCED TROUBLE SHOOTING
ADVANCED TROUBLE SHOOTING
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.
1 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.
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
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
1) Confirm that the switch on the power supply and
the switch on switchboard (distribution panel)
are all OFF.
Figure 11-1: Switch OFF
200ACDC
CAUTION
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.
11 ADVANCED TROUBLE SHOOTING
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.
2) Remove all screws and nuts on the Side Panel.
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 Panel.
NOTE
DO NOT remove the screws completely.
Figure 11-5: Remove Side Panel
Figure 11-3: Loosen screws
11 – 2
11 ADVANCED TROUBLE SHOOTING
200ACDC
6) Remove protection cover sheet by removing
the plastic tabs.
2.1 E01 "Over-Temperature at
the primary side"
Cause
1
Occurs when an over-temperature condition of the
primary IGBT is detected.
2
1
Verification/Remedy
1
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.
1
b) Verify the ventilating condition.
Figure 11-6: Remove PCB cover
NOTE
When you re-assemble the parts, conduct the
above process backwards.
2 Verification and Remedy to
the Indicated Error Codes
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
[Chapter11-1.1].
NOTE
During the "Verification/Remedy" procedures
below, follow the alphabetical sequence (a, b, c...)
and proceed with your verification and confirmation.
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
 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.
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.
 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 12.3.24 for the replacement
of FAN1.
 Refer to section 11.5.3 for additional FAN1
tests.
d) Replace PCB6 (WK-5549).
 Refer to section 8.02.04.05 for the replacement of PCB6.
200ACDC
2.2 E02 "Over-Temperature at the
secondary side"
11 ADVANCED TROUBLE SHOOTING
2.3 E03 "Primary 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 2.06. Exceeding the duty cycle can
damage the unit and void the warranty. Refer
also to section 2.07 for additional information.
 Refer to the specification data sheet in Section 3.9.
b) Verify the secondary diode (D2, D4 and D5).
b) Verify the ventilating condition.
 Refer to section 11.5.2.4 for the test.
 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.
 Refer to section 12.3.32 for the replacement.
c) Verify the H.F. unit (HF. UNIT1).
 Refer to section 12.3.29 for the replacement
of HF.UNIT 1.
 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.
d) Verify the secondary IGBT (Q13).
 Refer to section 11.5.2.6 for the test.
 Refer to section 12.3.33 for the replacement.
e) Replace the Hall CT, HCT1.
NOTE
Pay special attention to the installed direction of HCT1.
The Hall CT will not function properly if installed in
the incorrect direction.
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.
 If broken or cracked FAN1 blades or abnormal sounds are emanating from FAN1,
replace FAN1.
 Refer to section 12.3.30 for the replacement
of HCT1.
2.4 E04 "Torch Cable Failure"
 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 12.3.24 for the replacement
of FAN1.
 Refer to section 11.5.2.1 for additional FAN1
tests.
d) Replace PCB6 (WK-5549).
 Refer to section 12.3.6 for the replacement of
PCB6.
Cause
The combined length of the torch cable and the
work cable is too long.
Verification/Remedy
a) Verify the rated duty cycles of the torch/work
cable and the power supply.
 Only use appropriate sized torch cables
(length and capacity). The recommended
total combined length of the torch and work
cable is 50 feet.
 Torch and work cable should not be "coiled"
during welding operations.
 Maintain the duty cycle of the power supply.
11 – 4
200ACDC
11 ADVANCED TROUBLE SHOOTING
Refer to 2.9 for the recommended duty cycle.
b) Replace PCB6 (WK-5549) and PCB13 (WK5569).
 Refer to section 12.3.6 for the replacement of
PCB6.
2.7 E81 "Abnormal Input Voltage"
Cause
The detection circuitry of main supply voltage is
abnormal.
 Refer to section 12.3.13 for the replacement
of PCB13.
Verification/Remedy
2.5 E11 "Main Supply Over Voltage"
a) Verify main supply voltage.
 Perform what is described in the section
“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 PCB17 (WK-4917).
 Re-install the harness with a secure connection.
 Contact the manufacturer if you find any broken connectors or a damaged wiring harness.

Cause
Main supply voltage occurs at about 275V or
more.
Verification/Remedy
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) Replace PCB4 (WK-4819).
 Verify PCB4 (WK-4819) and replace it if necessary. Refer to section 12.3.4.
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 12.3.5.
2.6 E12 "Main Supply Under Voltage"
Cause
Main supply voltage occurs in about 150V or less.
2.8 E82 "Rated Voltage Selection
Circuit abnormality"
Cause
Verification/Remedy
Rated voltage selection circuit inside the Welding
Power Source is not functioning properly.
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) Replace PCB4 (WK-4819).
Verification/Remedy
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.

Verify PCB4 (WK-4819) and replace it if
necessary.
Refer to section 12.3.4.
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 – 5
200ACDC
2.9 E83 "Abnormalities in Mains
Supply Voltage Detection"
11 ADVANCED TROUBLE SHOOTING
c) Verify the primary IGBT (Q1-Q12).
 Verify IGBT. Refer to section 11.5.2.5.
 Replace IGBT. Refer to section 12.3.8,
12.3.9.
Cause
d) Replace PCB2 (WK-5482) and PCB4 (WK-4819).
Abnormalities, such as an input voltage detection
circuit
 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.
Verification/Remedy
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 PCB17 (WK-4917).
2.11 E94 "Thermistor malfunction"
Cause
Thermistors for detecting temperature of internal
components have malfunctioned.
 Re-install the harness with a secure connection.
Verification/Remedy
 Contact the manufacturer if you find any broken connectors or damaged wiring harness.
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.
c) Verify PCB4 (WK-4819) and replace it if necessary.
 Contact the manufacturer if you find any broken connectors or a damaged wiring harness.
 Check whether there are any abnormalities
on the appearance of PCB4.
b) Replace thermistors (TH1, TH2).
 Refer to section 12.3.22, 12.3.23.
 Replace PCB4. Refer to section 12.3.5.
c) Replace PCB6 (WK-5549).
2.10 E85 "Pre-charge abnormality"
 Refer to section 12.3.6.
Cause
Due to malfunction inside the Welding Power Source,
primary capacitors are not charging correctly.
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
a) Verify the connection PCB2 (WK-5482) 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 R4 and R5.
 Perform what is described in a section of
“Verification of the Power Supply Voltage”.
Refer to section 11.5.2.
Verification/Remedy
a) Confirm a secure connection of the harness
wired between CN1 on PCB17 (WK-4917) and
CN2 on PCB3 (WK-5548).
 Re-install the harness with a secure connection.
 Contact the manufacturer if you find any broken connectors or a damaged wiring harness.
b) Verify the primary diode (D1).
 Verify D1. Refer to section 11.5.2.3.
 Replace D1. Refer to section 12.3.31.
11 – 6
200ACDC
11 ADVANCED TROUBLE SHOOTING
b) Verify PCB4 (WK-4819) and replace it if necessary.
c) Verify the drive circuitry of the cooling fan
(FAN1) on PCB3.
 Confirm a secure connection of all harnesses wired to PCB3 and PCB4.
 Verify the drive circuitry of the cooling fan
(FAN1) on PCB3.
 Replace PCB4. Refer to section 12.3.5.
 Refer to section 11.5.2.1.
 Replace PCB3 if necessary.
c) Replace PCB6 (WK-5549).
 Refer to section 12.3.6.
 Refer to section 12.3.4.
3.2 "Gas Valve Failure" (No Gas
flow through unit)
3 Verification and Remedy to
Failures without Indication
Codes
Cause
Occurs when the gas valve (SOL1) is defective,
damaged or the driving voltage is incorrect.
Refer to Note on Section 11.02.
Verification/Remedy
3.1 "Cooling Fan (FAN1) Failure"
(Fan is not rotating.)
a) Confirm that TIG welding is selected on the
welding mode.
Cause
Occurs when the cooling fan (FAN1) is defective,
damaged or the driving voltage is incorrect.
Verification/Remedy
a) Verify the cooling fan (FAN1).
 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.
 Replace the fan if there are any broken,
cracked or missing fan blades.
 Refer to section 12.3.24.
 Do not change welding modes while welding.
Only change welding modes when the unit is
idle (torch switch OFF).
 Verify the setting of Pre-flow and Post-flow on
the front panel. If the Pre-flow or Post-flow
time is set to 0 seconds, change them to
higher setting.
b) Verify the layout the of the gas hose.
 Confirm that the hose is securely connected
into the fitting at the inlet and the outlet.
Confirm that the layout of the gas hose so
that it is not bent or kinked. Confirm there are
no breaks, burns or holes in the hose.
 Confirm the layout of the TIG torch gas hose
and that the hose adapters are properly connected.
c) Verify the wiring harness and connection of gas
valve (SOL1) and CN11 on PCB3 (WK-5548).
d) Verify the drive circuitry of the gas valve
(SOL1).
 Verify the drive circuitry of the gas valve
(SOL1).
 Refer to section 11.5.2.2.
 Replace PCB3, when abnormal.
b) Verify the wiring harness between the cooling
fan (FAN1) and CN11 on PCB3 (WK-5548).
 Refer to section 12.3.4.
 Confirm a secure connection of the harness
to CN11 on PCB3.
11 – 7
e) Replace the PCB6 (WK-5549).
 Refer to section 12.3.6.
200ACDC
3.3 "No Weld Output"
11 ADVANCED TROUBLE SHOOTING
c) Verify the no-load voltage (OCV).
(Applies to STICK, High Frequency TIG (HF
TIG) mode.)
When in High Frequency TIG (HF TIG) mode, if the
High Frequency is not generated (present), refer to
"High Frequency Output Failure". Refer to the page
2-31.
 Refer to the section "Verification of No-load
voltage (OCV)" on page 11-16.
 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.
Cause
Occurs when the remote connector (CON1) or
associated circuitry is defective, damaged, or the
TIG torch cable is defective.
1. Secondary IGBT (Q13)
Verification/Remedy
 Verification. Refer to section 11.5.2.6.
 Replacement. Refer to section 12.3.33.
CAUTION
2. Secondary diode (D2, D4, D5)
Read and understand this entire section before
proceeding. Extreme personal harm and test
equipment damage will occur if the procedures are
not performed accurately.
 Verification. Refer to section 11.5.2.4.
 Replacement. Refer to section 12.3.32.
3. Coupling coil (CC1)
 Replacement. Refer to sectoion 12.3.20.
a) Verify the remote connector (CON1).
(Applies to LIFT TIG and High Frequency TIG
(HF TIG) mode.)
4. Reactor (FCH1)
 Replacement. Refer to section 12.3.21.
 Confirm a secure between the remote connector (CON1) and the TIG torch cable.
5. Transformer (T1)
 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.
6. Primary IGBT (Q1-Q12)
 Replacement. Refer to section 12.3.12.
 Verification. Refer to sectoion 11.5.2.5.
 Replacement. Refer to section 12.3.8,
12.3.9.
 Contact the manufacture if you find any broken connectors or damaged wiring harnesses.
 Confirm the proper pins-outs of the remote
connector at the TIG Torch side. (Refer to
section in 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
section Operating Manual.)
7. Hall C.T. (HCT1)
 Replacement. Refer to sectoion 12.3.30.
3.4 "Operating Panel Failure"
(LED's do not light properly
or welding setting cannot be
established.)
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
dinse connectors and there are no open circuits.
11 – 8
Cause
Occurs when there is a connection failure among
PCB6 (WK-5549), PCB10 (WK-5527) and PCB6 or
PCB10 are defective.
Verification/Remedy
a) Verify the harness connection between CN21
on PCB6 (WK-5549) and CN2 on PCB10 (WK5527).
200ACDC
11 ADVANCED TROUBLE SHOOTING
 Confirm a secure connection of the harness
and the connections between CN21 on PCB6
(WK-5549) and CN2 on PCB10 (WK-5527).
 Contact the manufacturer if you find any broken
connectors or damaged wiring harnesses.
b) Verify the connection between PCB5 (WK5551) and PCB6 (WK-5549).
c) Replace PCB5 (WK-5551) and PCB6 (WK5549).
 Refer to section 12.3.4, 12.3.6.
d) Replace PCB6 (WK-5549) and PCB10 (WK5527).
 Refer to section 12.3.6, 12.3.10.
3.5 "High Frequency Output Failure" (Unit does not generate
High Frequency.)
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.
 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.
 Confirm there are no short circuits, burnt or
broken wires between AC1 and AC2.
Cause
d) Verify and replace the Gap (GAP) of the High
Frequency Unit (HF UNIT1).
Occurs when the HF unit (HF UNIT1) is defective
or blown.
 Confirm that the GAP is connected to HF
UNIT1 correctly and completely.
Verification/Remedy
 Confirm there is no dust or foreign debris
between the space of the GAP.
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. 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
Unit (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 12.3.20.
11 – 9
 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.
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 12.3.19.
f) Replace the High Frequency Unit (HF UNIT1).
 Refer to section 12.3.29.
g) Replace PCB3 (WK-5548).
 Refer to section 12.3.4.
200ACDC
4 Fault Isolation Tests
11 ADVANCED TROUBLE SHOOTING
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
W1 on switch S1 are indicated in Figure 11-7.
When using a single-phase connection, the voltage can be verified only between U1 and V1.
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.)
NOTE
Operate at all input voltages as noted on the nameplate on the rear panel when testing the power supply.
U2
S1
U1
V2
W2
2) Remove the Side Panel. Refer to the section
11.1.1.
3) Close primary power source wall disconnect
switch or circuit breaker.
V1
W1
4) Place power supply MAIN CIRCUIT SWITCH
(S1) on rear of the unit in the ON position.
WARNING
Figure 11-7: Check points U1, U2, V1, V2, W1 and W2
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.
5 Verification of the Power
Input Circuitry
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 11.4.1.
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
11 – 10
2) If the input voltage is out of the operating range of
the unit, which is m 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.
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 V2 on the input switch, S1.
 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 S1 are 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 m 10% (187~253/414~ 506VAC) of
the rated voltage (208, 230 / 460V), replace S1
following the process in section 12.3.26.
200ACDC
11 ADVANCED TROUBLE SHOOTING
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
corresponding range (260 ~ 360 / 580 ~ 720
VDC) following the process in section
12.3.31.
PCB1
TB1
TB2
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-5477).
2
5.2 Verfication of Power Supply
Voltage
1
CAUTION
D1
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
11.4.1.
Figure 11-8: The check points 1 (P) and 2 (N)
6) Verify bus voltage (the voltage of the electrolytic capacitor after rectification) using a DC
voltmeter. (The capability of the voltmeter
should be more than 1000VDC.) Using a DC
voltmeter, measure between the points TB1
(P) [+] and TB2 (N) [-] on PCB1 (WK-5477)
Points TB1 (P) and TB2 (N) can be
found on the parts side of PCB1. See Figure
11-9. 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 corresponding range (260 ~ 360 / 580 ~ 720 VDC)
11 – 11
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.
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 top side of
PCB6 (WK-5549). The locations of points are
indicated in Figure 11-10, 11-11.
200ACDC
11 ADVANCED TROUBLE SHOOTING
5.2.1 Verification of the Cooling Fan,
FAN1, Drive Circuitry
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
11.4.1.
TP3
TP0
TP1
PCB6
TP2
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.
Figure 11-10: Checkpoints TP0-TP3 on PCB6
Check Point
PCB6
TP1
TP2
TP3
Reference
PCB6
TP0
TP0
TP0
ACCEPTABLE
VALUE
+5VDC
+15VDC
–15VDC
Table 11-1: Checkpoints TP0-TP3 on PCB6
1pin
2pin
PCB3
pin 1
pin 3
CN11
PCB3
Figure 11-12: Verification of the FAN1
CN18
2) Using the measurement taken above, follow
the chart below for possible failure modes.
FAN1
Status
Figure 11-11: Checkpoints CN18 on PCB3
Check Point
PCB3
Pin 1 on CN18
Reference
PCB3
Pin 3 on CN18
Table 11-2: Checkpoints CN18 on PCB3
3) If any of these voltages are not present or are
below a 10% tolerance, replace PCB3
(WK-5548). Refer to section 12.3.4.
Remedy
FAN1 drive circuit is
normal.
Replace PCB3.
Case
Rotating Below DC 18V
2
Refer to section 12.3.4.
Replace PCB3.
Refer to section 12.3.4.
4
Case
Inactive Below DC 18V
3
Perform “2. Verfication of
Power Supply Voltage”.
Refer to section 11.5.2.
Replace the FAN1.
Case
Inactive DC 18 ~ 25V
4
Refer to section 12.3.24.
Case
Rotating
1
ACCEPTABLE
VALUE
+24VDC
Voltage
measurement.
(1PIN-2PIN of
CN11 on
PCB3)
DC 18 ~ 25V
Table 11-3: Verification of the FAN1
11 – 12
200ACDC
11 ADVANCED TROUBLE SHOOTING
 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.
2) Using the measurement taken above, follow
the chart below for possible failure modes.
Voltage
measurement.
(1PIN-2PIN of
CN11 on 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).
Remedy
Case
1
Below DC 18V
Replace PCB1.
Refer to section 12.3.1.
Case
2
DC 18 ~ 25V
Replace SOL1.
Refer to section 12.3.25.
Table 11-4: Verification of the SOL1
5.2.2 Verification of the Gas Valve,
SOL1, Drive Circuitry
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).
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
11.4.1.
5.2.3 Verification of the primary Diode
(D1)
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
11.4.1.
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 mea1) Verify the characteristic of the primary diode,
sure the above voltage, do not remove the
D1, using a diode tester.
connector. Conduct the measurement while
2) Refer bellow Table 11-5 and Figure 11-14 for
the connector plug and receptacle are still connected.
the checkpoints on D1.
pin 3
pin 4
PCB3
CN11
TERMINALS
COMPONENT
Positive
Negative
TESTED
lead
lead
3, 4, 5
0
0
3, 4, 5
Diode of D1
3, 4, 5
2
2
3, 4, 5
0
1
Thyristor of D1
1
0
ACCEPTABLE
VALUE
0.3 to 0.5V
Open
Open
0.3 to 0.5V
Open
Open
Table 11-5: Tester checkpoints for D1
Figure 11-13: Verification of the SOL1
11 – 13
200ACDC
11 ADVANCED TROUBLE SHOOTING
5.2.4 Verification of the secondary
Diode (D2, D4, D5)
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
11.4.1.
3
4
5
2
1
6
0
1) Verify the characteristic of the secondary
diode, D2, D4 and D5, using a diode tester.
7
2) Refer to Table11-6 and Figure 11-15 for
the checkpoints on D2, D4 and D5.
0
6
7
1
5
TERMINALS
COMPONENT
Positive
Negative
TESTED
lead
lead
Anode
Cathode
Diode 1 of D2,
Cathode
Anode
D4 and D5
Anode
Cathode
Diode 2 of D2,
Cathode
Anode
D4 and D5
ACCEPTABLE
VALUE
0.2 to 0.3V
Open
0.2 to 0.3V
Open
Table 11-6: Tester checkpoints for D2, D4 and D5
4
3
Anode
2
Cathode
Anode
Cathode
Figure 11-14: Tester checkpoints for D1 and showing
the connection diagram
Figure 11-15: Tester checkpoints in the D2, D4 and D5
11 – 14
200ACDC
11 ADVANCED TROUBLE SHOOTING
5.2.5 Verification of the primary IGBT
(Q1-Q12)
5.2.6 Verification of the secondary
IGBT (Q13)
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
an above section "1. Preparation". Refer to section
11.4.1.
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
11.4.1.
1) Check whether there are any abnormalities in
the appearance of PCB8 and PCB9.
1) Check whether there are any abnormalities on
the appearance of PCB14.
2) Verify the characteristic of the primary IGBT
(Q1-Q12), using a diode tester.
2) Verify the characteristic of the secondary IGBT
(Q13), using a diode tester.
3) Refer to Table 11-7 and Figure 11-16 for
the checkpoints on PCB8 and PCB9.
3) Refer to Table 11-8 and Figure 11-17 for
the checkpoints on Q13.
TERMINALS
COMPONENT
TESTED
Positive
lead
C
CE
CE
E
Collector-Emitter
of Q1A'Q12 with
PCB8 and PCB9
Negative
lead
CE
C
E
CE
ACCEPTABL
EVALUE
COMPONENT
TESTED
Open
0.2 to 0.5V
Open
0.2 to 0.5V
Collector-Emitter
of Q13
(By PCB15
connection)
CE
ACCEPTAB
LEVALUE
Open
0.2 to 0.5V
Open
0.2 to 0.5V
Table 11-8: Tester checkpoints for Q13
Table 11-7: Tester checkpoints for Q1-Q12
C
TERMINALS
Positive
Negative
lead
lead
C1
C2E1
C2E1
C1
C2E1
E2
E2
C2E1
E
C1
PCB8
E2
PCB9
C2E1
Figure 11-17: Tester checkpoints in the Q13
Figure 11-16: Tester checkpoints in the Q1-Q12
11 – 15
200ACDC
5.2.7 Verification of No-load Voltage
(OCV)
11 ADVANCED TROUBLE SHOOTING
3) 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.
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
11.4.1.
a. Verify the no-load voltage in STICK mode.
1) In STICK welding mode, mark and then turn
potentiometer VR1 on PCB6 (WK-5549) all
the way to the right and turn off the electric
shock protector function (Voltage-Reduction-Device, VRD).
2) Contactor function is put into the state of "ON"
pushing Function button. Refer to section 6.
WARNING
Electric shock hazard. The unit will generate OCV
immediately when contactor function is put into the
state of "ON pushing Function button enabling
STICK mode.
Figure 11-18: Removal and installation from the HF UNIT1
(To disable the operation of the HF unit.)
3) Verify the no-load voltage using a DC voltmeter. (The capability of the voltmeter
should be more than 100VDC.)
4) The normal no-load voltage is approximately 65V.
b. Verify the no-load voltage (OCV) in High Frequency TIG mode.
4) Press the Welding mode selection button to
select HF TIG welding mode.
5) 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.
6) The normal no-load voltage is approximately
58-62V.
WARNING
This welding mode produces high frequency and
high voltage. Extra care shall be taken to prevent
electric shock.
7) Return the setting variable resister (VR1) to the
original position. (Return to the position
recorded by "a. 1)" clause.)
 Fully clockwise: VRD ON
 Fully counterclockwise: VRD OFF
8) Return connection with HF UNIT1 to the original position.
11 – 16
12 MAINTENANCE
1 Maintenance List
MAINTENANCE
8
9
1
2
3
4
5
6
7
No.
DWG No.
1 PCB3
Parts name
Print Circuit Board (WK-5548)
Reference page
12-9
2
PCB10
Print Circuit Board (WK-5527)
12-13
3
PCB11
Print Circuit Board (WK-5528)
12-13
4
PCB12
Print Circuit Board (WK-5615)
12-15
5
PCB13
Print Circuit Board (WK-5569)
12-18
6
PCB14
Print Circuit Board (WK-5570)
12-19
7
PCB16
Print Circuit Board (WK-5499)
12-19
8
PCB17
Print Circuit Board (WK-4917)
12-20
9
PCB18
Print Circuit Board (WK-5861)
12-21
12 – 1
Note
200ACDC
12 MAINTENANCE
3
6
5
2
4
8
7
1
No.
DWG No.
1 PCB1
Print Circuit Board (WK-5477)
Parts name
Reference page
12-6
Part No.
W7001402
2
PCB2
Print Circuit Board (WK-5596)
12-7
W7001601
3
PCB4
Print Circuit Board (WK-4819)
12-10
10-6635
4
PCB5
Print Circuit Board (WK-5551)
12-10
W7001417
5
PCB6
Print Circuit Board (WK-5549)
12-10
W7001727
6
PCB7
Print Circuit Board (WK-5550)
12-11
W7001423
7
PCB8 (Q1~Q6)
Print Circuit Board (WK-5479) (Primary IGBT)
12-11
W7001318
8
PCB9 (Q7~Q12)
Print Circuit Board (WK-5479) (Primary IGBT)
12-12
W7001318
12 – 2
200ACDC
12 MAINTENANCE
10
11
3
8
2
12
7
5
4
6
1
9
No.
DWG No.
1 CC1
Parts name
Coupling Coil
Reference page
12-24
Part No.
W7001384
2
CT2
Current Trans
12-15
W7001304
3
D1
Primary Diode
12-32
10-6628
4
D2
Secondary Diode
12-33
10-6629
5
D4
Secondary Diode
12-33
10-6629
6
D5
Secondary Diode
12-33
10-6629
7
FCH1
Reactor
12-31
W7001502
8
HCT1
Hall C. T.
12-25
10-5003
9
HF. UNIT
High Freguency Unit
12-31
W7001399
10
L101
Reactor
12-35
W7001400
11
L103
Earth Inductance
12-35
W7001605
12
T1
Main Trans
12-15
W7001456
12 – 3
200ACDC
12 MAINTENANCE
8
5
6
4
2
10
1
11
9
7
3
No.
DWG No.
1 CON1
Parts name
Remote Connector
Reference page
12-29
Part No.
W7001595
2
FAN1
Cooling Fan
12-27
W7001307
3
Q13 (PCB15)
Secondary IGBT (WK-3367)
12-34
10-6643
4
R3
Discharge Resistor
12-22
10-5137
5
R4
Current Limiting Resistor
12-23
W7001452
6
R5
Current Limiting Resistor
12-23
W7001452
7
R6
Resistor on High Frequency Unit
12-24
W7001451
8
S1
Main ON/OFF Switch
12-29
W7001453
9
SOL1
Solenoid Valve
12-28
W7001604
10
TH1
Primary Thermistor
12-26
10-5228
11
TH2
Secondary Thermistor
12-26
10-5228
12 – 4
200ACDC
12 MAINTENANCE
2 Service Tools
2.1 Tools and parts
The tools and parts to be used for maintenance are shown by icons.
Spanner
(5.5, 8, 10, 17mm)
Philips Head
Screwdriver
Long Nose
Pliers
C-Ring Pliers
Snap Band
Silicon
Compound
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
200ACDC
12 MAINTENANCE
3 Replacement Procedure
3.1 PCB1 (WK-5477) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB18 (WK-5861). [Reference page: 12-21]
3) Remove PCB2 (WK-5596). [Reference page: 12-7]
4) Remove the PCB8 (WK-5479). [Reference page: 12-11]
5) Remove the PCB9 (WK-5479). [Reference page: 12-12]
6) Remove the four screws. Pull out the Rear Control Cover and bring it down.
1
1
2
1
1
7) Remove the five screws and the PCB1 (WK-5477). Remove the two screws and two terminals.
1
1
1
2
3
8) Remove the four screws and remove the four terminals and 200V Input Bus Bar.
1
2
1
1
2
2
2
3
3
12 – 6
200ACDC
12 MAINTENANCE
3.2 PCB2 (WK-5596) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB18 (WK-5861). [Reference page: 12-11]
3) Disconnect the 13 connectors.
CN17
CN1
CN3
CN7 CN19
CN21
CN2
CN8
CN1
CN9
CN8
CN9
CN11
4) Remove the four screws and two ground terminals.
5) Remove the PCB3, PCB4, PCB5, PCB6, and PCB7 unit and then disconnect the two connectors.
12 – 7
200ACDC
Remove the Insulated Sheet.
1
CN15
2
CN14
2
3
6) Remove the three screws and seven terminals. Remove the PCB2 (WK-5596).
1
2
7) Disconnect the three connectors and two terminal from the PCB2 (WK-5596).
CN2
1
CN3
1
1
CN1
2
TB6
12 – 8
TB5
12 MAINTENANCE
200ACDC
12 MAINTENANCE
3.3 PCB3 (WK-5548), PCB5 (WK-5551) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove PCB4 (WK-4819). [Reference page: 12-10]
3) Remove PCB6 (WK-5549). [Reference page: 12-10]
4) Remove PCB7 (WK-5550). [Reference page: 12-11]
5) Disconnect the 11 connectors.
CN21
CN20
CN9
CN23
CN22
CN11
CN8
CN19
CN1
CN2
CN3
6) Remove the four screws and then the two ground terminals. Remove the PCB3 and PCB5 unit.
Disconnect the two connectors.
1
CN14
CN15
2
7) Disconnect the one connector and remove the two screws, and then remove the PCB5 (WK-5551) from
the PCB3 (WK-5548).
Remove the one screw and one ground terminal from the PCB5 (WK-5551).
CN20
1
2
12 – 9
200ACDC
8) Disconnect the two connectors from the PCB3 (WK-5548).
CN18
CN33
3.4 PCB4 (WK-4819) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the two screws and three connectors and remove the PCB4 (WK-4819).
Disconnect the one connector.
2
CN4
1
CN5
CN4
3.5 PCB6 (WK-5549) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Disconnect the six connectors.
CN21
CN17
CN1
CN9
CN8
CN20
12 – 10
CN6
12 MAINTENANCE
200ACDC
12 MAINTENANCE
3) Remove the three screws and five connectors. Remove the PCB6 (WK-5549).
CN27
CN18
CN32
CN30
CN31
3.6 PCB7 (WK-5550) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB6 (WK-5549). [Reference page: 12-10]
3) Remove the two screws and three connectors. Remove the PCB7 (WK-5550).
CN30
CN31
CN32
3.7 PCB8 (WK-5479) (IGBT (Q1~Q6)) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the four screws and two IGBT Chassis.
12 – 11
200ACDC
3) Remove the two connectors and three screws. Remove the PCB8 (WK-5479).
 Remember to install silicone rubber sheets when reinstalling the PCB8 (WK-5479).
CN1
CN2
3.8 PCB9 (WK-5479) (IGBT (Q7~Q12)) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the four screws and two IGBT Chassis.
3) Remove the two connectors and three screws. Remove the PCB9 (WK-5479).
 Remember to install silicone rubber sheets when reinstalling the PCB9 (WK-5479).
CN1
CN2
12 – 12
12 MAINTENANCE
200ACDC
12 MAINTENANCE
3.9 PCB10 (WK-5527) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB11 (WK-5528). [Reference page: 12-13]
3) Remove the three latches of Front Control Cover and then the PCB10 (WK-5527).
2
1
1
 When reinstalling the PCB10 (WK-5527), engage two latches of Front Control Cover first.
1
2
3.10 PCB11 (WK-5528) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Protection Cover.
2
2
3
1
12 – 13
200ACDC
12 MAINTENANCE
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 PCB10 (WK-5527). Remove the four screws. Pull out the Operation Panel and bring it down.
2
2
1
CN2
3
2
2
5) Remove the one connector and two screws. Remove the PCB11 (WK-5528).
Remove the Encoder Cover from the PCB11 (WK-5528).
2
4
1
3
CN1
12 – 14
200ACDC
12 MAINTENANCE
3.11 PCB12 (WK-5615), Transformer (T1), Current Trans (CT2) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove PCB13 (WK-5569). [Reference page: 12-18]
3) Disconnect the one connector and cut the one snap band.
CN7
4) Remove the one screw and one nut. Remove the two screws and remove the two terminals.
2
3
1
5) Open the Dust Cover Sheet. Remove the three screws and three terminals.
1
2
2
2
12 – 15
200ACDC
6) Remove the 16 screws.
7) Remove the PCB12 and T1 unit.
8) Cut the one snap band and remove the Current Trans (CT2).
2
1
12 – 16
12 MAINTENANCE
200ACDC
12 MAINTENANCE
9) Remove the Dust Cover Sheet. Extend the electrode and remove the T-D Bus Bar1, T-D Bus Bar2 and T
Center Bus Bar.
2
3
2
1
10) Remove the two PCB supporters and cushion.
Remove the four screws and remove the Main Trans (T1).
2
1
4
3
1
12 – 17
200ACDC
12 MAINTENANCE
3.12 PCB13 (WK-5569) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel.
3
1
4
1
2
2
3) Disconnect the six connectors and remove the two screws and two terminals.
CN2
CN1
CN4
CN6
CN3
CN5
4) Remove the two screws and two PCB supporters and remove the PCB13 (WK-5569).
12 – 18
200ACDC
12 MAINTENANCE
3.13 PCB16 (WK-5499) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Nylon Hose.
2
1
3) Disconnect the two connectors.
Remove the three PCB supporters and remove the PCB16 (WK-5499).
2
1
CN1
CN3
1
3.14 PCB14 (WK-5570) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB16 (WK-5499). [Reference page: 12-19]
3) Remove the five screws and three terminals and remove the PCB14 (WK-5570).
3
1
2
1
1
1
2
2
12 – 19
200ACDC
4) Remove the three PCB supporters from the PCB14 (WK-5570).
3.15 PCB17 (WK-4917) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the four screws and four terminals.
2
2
1
3) Remove the four screws and then open the Rear Board.
1
1
2
1
1
12 – 20
1
12 MAINTENANCE
200ACDC
12 MAINTENANCE
4) Disconnect the one connector.
Remove the two screws and one ground terminal and remove the PCB17 unit.
2
1
CN1
3
2
4
5) Remove the two screws and remove the S1 Bus Bar from the PCB17 (WK-4917).
2
1
3.16 PCB18 (WK-5861)
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the four screws and then remove the four cables.Remove the two screws. Remove the PCB18
(WK-5861).
1
1
2
2
12 – 21
200ACDC
12 MAINTENANCE
3.17 Discharge Resistor (R3)
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Nylon Hose. Remove the two bolts, two toothed washers, one washer, and one terminal.
2
2
1
1
3
2
3) Remove the four screws and open the Front Panel.
1
1
2
1
1
4) Cut the one snap band and disconnect the one connector.
1
2
12 – 22
CN5
200ACDC
12 MAINTENANCE
5) Remove the one screw and one nut and remove the one terminal.
6) Remove the two screws and remove the Discharge Resistor (R3).
1
2
1
3.18 Current Limiting Resistor (R4, R5)
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB18 (WK-5861). [Reference page: 12-21]
3) Remove the PCB2 (WK-5596). [Reference page: 12-7]
4) Remove the one screw and remove the Current Limiting Resistor (R4, R5).
12 – 23
200ACDC
12 MAINTENANCE
3.19 Resistor on High Frequency Unit (R6) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Cut the one snap band and remove the two terminals. Remove the one screw and remove the Resistor
on High Frequency Unit (R6).
3
4
2
1
3.20 Coupling Coil (CC1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Nylon Hose. Remove the two bolts, two toothed washers, one washer, and one terminal.
2
2
1
1
3
2
3) Remove the four screws and open the Front Panel.
1
1
2
1
1
12 – 24
200ACDC
12 MAINTENANCE
4) Remove the two terminals. Remove the one screw and two terminals.
1
1
2
5) Remove the one screw and one nut. Remove the one screw and Coupling Coil (CC1).
1
1
3
2
3.21 Reactor (FCH1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB16 (WK-5499). [Reference page: 12-19]
3) Remove the PCB14 (WK-5570). [Reference page: 12-19]
4) Remove the Coupling Coil (CC1). [Reference page: 12-24]
5) Remove the two posts, two screws and two nuts.
12 – 25
200ACDC
12 MAINTENANCE
6) Remove the four screws and remove the Reactor (FCH1). Remove the Insulating Sheet.
1
3
2
1
3.22 Primary Thermistor (TH1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Cut the three snap bands. Disconnect the one connector.
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.
CN8
3.23 Secondary Thermistor (TH2) 
1)
2)
3)
4)
Remove the Side Panel. [Reference page: 11-1]
Remove the PCB13 (WK-5569). [Reference page: 12-18]
Remove the PCB12 (WK-5615). [Reference page: 12-15]
Remove the one screw and one nut and remove the bus bar.
12 – 26
200ACDC
12 MAINTENANCE
5) Cut the four snap bands. Disconnect the one connector.
Remove the one screw and then detach the Secondary Thermistor (TH2).
 Before installing a new therminstor, apply a uniform coat of silicone compound
(Shinetsu Silicone G-747 or equivalent) on the base.
CN9
3.24 Cooling Fan (FAN1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel.
3
1
4
1
2
2
3) Cut the four snap bands and disconnect the one connector.
CN11
12 – 27
200ACDC
12 MAINTENANCE
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.
3.25 Solenoid Valve (SOL1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel.
3
1
4
1
2
2
3) Remove the C-ring and detach the Solenoid Valve (SOL1).
 When reinstalling, make sure that the C-ring seats in the solenoid valve groove.
2
1
12 – 28
200ACDC
12 MAINTENANCE
3.26 Main ON/OFF Switch (S1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the four screws and four terminals.
1
2
2
1
3) Remove the two screws and detach the Main ON/OFF Switch (S1). Remove the two posts.
3.27 Remote Connector (CON1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Protection Cover.
2
2
3
1
12 – 29
200ACDC
3) Remove the four screws. Pull out the Front Control Cover and bring it down.
1
1
2
1
1
4) Disconnect the two connectors. Remove the one screw and two ground terminals.
2
1
CN15
1
CN14
5) Remove the two screws and Remote Socket (CON1).
2
1
12 – 30
12 MAINTENANCE
200ACDC
12 MAINTENANCE
3.28 High Freguency Unit (HF.UNIT1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the High Freguency Gap. Remove the six terminals.
3) Remove the two screws, two washers and detach the High Freguency Unit (HF. UNIT1).
1
2
1
3.29 Hall C.T. (HCT1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Nylon Hose. Remove the four screws. Remove the two terminals and open the Rear Panel.
3
1
4
1
2
2
12 – 31
200ACDC
12 MAINTENANCE
3) Remove the one screw and one nut. Disconnect the one connector.
1
CN1
2
1
4) Remove the one screw. Remove the Hall C. T. (HCT1) while slighty pressing down the bus bar.
2
3
1
3.30 Primary Diode (D1) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB18 (WK-5861). [Reference page: 12-21]
3) Remove the PCB2 (WK-5596). [Reference page: 12-7]
4) Remove the two screws and four 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
12 – 32
200ACDC
12 MAINTENANCE
3.31 Secondary Diode (D2, D4, D5) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the PCB13 (WK-5569). [Reference page: 12-18]
3) Remove the PCB12 (WK-5615). [Reference page: 12-15]
4) Remove the two screws and two nuts and remove the bus bar.
5) Remove the six screws and then detach the Secondary Diode (D2, D4, D5).
 Do not have the wrong direction of the diodes when reinstalling.
Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747
or equivalent) on the base.
12 – 33
200ACDC
12 MAINTENANCE
3.32 Secondary IGBT (Q13) (PCB15 (WK-3367)) 
1) Remove the side cover. [Reference page: 11-1]
2) Remove the PCB16 (WK-5499). [Reference page: 12-19]
3) Remove the PCB14 (WK-5570). [Reference page: 12-19]
4) Remove the one bolt and remove the one toothed washer, one washer and one terminal.
5) Remove the three posts, bus bar and two terminals.
6) Remove the one connector and two screws and remove the Secondary IGBT (Q13).
 Before sinstalling a new IGBT, apply a uniform coat of silicone compound (Shinetsu Silicone G-747
or equivalent) on the base.
CN1
12 – 34
200ACDC
12 MAINTENANCE
3.33 Reactor (L101) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the Earth Inductance (L103). [Reference page: 12-35]
3) Remove the two screws and two cables.
2
1
4) Cut the snap band. Open the Reactor (L101) and Remove the Reactor (L101).
1
2
3.34 Earth Inductance (L103) 
1) Remove the Side Panel. [Reference page: 11-1]
2) Remove the nut and then remove the two ground cables from the Rear Control Cover.
2
1
12 – 35
200ACDC
3) Remove the two screws and the nut. Remove the Earth Inductance (L103).
1
2
1
1
12 – 36
12 MAINTENANCE
THIS PAGE LEFT INTENTIONALLY BLANK
APPENDIX 1 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 Specificazztion 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.
ARC MASTER 200ACDC 10-3088
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
DWG No.
CC1
CON1
CT2
D1
D2
D4
D5
FAN1
FCH1
HCT1
HF.UNIT1
L101
L103
PCB1
PCB2
PCB3
PCB4
PCB5
PCB6
PCB7
PCB8-9
PCB10
PCB11
PCB12
PCB13
PCB14
PCB16
PCB17
PCB18
Q13
R2
R3
Part No.
W7001384
W7001595
W7001304
10-6628
10-6629
10-6629
10-6629
W7001307
W7001502
10-5003
W7001399
10-6633
W7001400
W7001605
W7001402
W7001601
W7001314
10-6635
W7001417
W7001727
W7001423
W7001318
W7001812
W7001320
W7001594
W7001433
W7001434
W7001324
10-6740
W7001602
10-6643
W7001449
10-5137
Description
Coupling Coil, gen 3.1, IPS
Post, Output, gen 3.1, IPS
Transformer, gen 3.1, IPS
Diode, gen 3.1, IPS
Diode, gen 3.1, IPS
Diode, gen 3.1, IPS
Diode, gen 3.1, IPS
Fan, gen 3.1, IPS
Inductor, gen 3.1, IPS
Sensor, Current, gen 3.1, IPS
HF, Unit, gen 3.1, IPS
HF, Gap, gen 3.1, IPS
Reactor, gen 3.1, IPS
Inductor, earth, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB,WK5527 U13,GEN3.1,IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
Transistor, gen 3.1, IPS
Resistor, gen 3.1, IPS
Resistor, gen 3.1, IPS
1
Type & Rating
F3A040600 200A CC
206433-1 8P (with Wiring Assembly)
F2A503001 CT 1:40
DFA50BA160
DBA200UA60
DBA200UA60
DBA200UA60
109E5724H507 DC 24V 16.8W
F3A285101 AC/DC FCH
HC-TN200V4B15M 200A 4V
HF.UNIT (WK-4840 U04)
U0A601100
ZCAT-3035-1330
SNG-25B-600
WK-5477 U01 MAIN_PCB
WK-5596 U02 CVM CONTROL PCB
WK-5548 U01 DDC PCB
WK-4819 U01 DETECT PCB
WK-5551 U01 CONECT PCB
WK-5549 U07-1 200A CTRL PCB
WK-5550 U01 FILTER PCB
WK-5479 U01 GATE PCB (with
WK-5527 U13 PANEL PCB
WK-5528 U01 ENCODER PCB
WK-5615 U01 DIODE SNUBBER PCB
WK-5569 U01 GATE/INPOSE PCB
WK-5570 U01 IGBT SNUBBER PCB
WK-5499 U01 FILTER PCB
WK-4917 U04 INPUT FILTER PCB
WK-5861 CE FILTER PCB
GCA200CA60 (with WK-3367 U04)
ERG3SJ220H 3W 22Ω
JG23V101J 68W 100Ω
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
2
200ACDC PARTS LIST
No.
34
35
36
37
DWG No.
R4-5
R6
S1
SOL1
Part No.
W7001452
W7001451
W7001453
W7001604
Description
Resistor, gen 3.1, IPS
Resistor, gen 3.1, IPS
Switch, gen 3.1, IPS
Solenoid Valve, gen 3.1, IPS
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
T1
TH1, 2
W7001456
10-5228
W7001465
W7001466
W7001467
W7001331
W7001584
W7001598
10-6791
Transformer, gen 3.1, IPS
Thermistor, gen 3.1, IPS
Panel, Front, gen 3.1, IPS
Panel, Rear, gen 3.1, IPS
Label, Side, gen 3.1, IPS
Case, cover, gen 3.1, IPS
Cover, Rear, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Cover, Encoder, gen 3.1, IPS
Cover, PCB, gen 3.1, IPS
Label, Name, gen 3.1, IPS
Label, Side, gen 3.1, IPS
Label, 1 Warning, gen 3.1, IPS
Label, 2 Warning, gen 3.1, IPS
Label, output term gen 3.1, IPS
Label, Gas Input, gen 3.1, IPS
Label, VRD, gen 3.1, IPS
Outlet, Gas, gen 3.1, IPS
C-Ring, gen 3.1, IPS
Terminal, Output F, gen 3.1, IPS
Cable, Input, gen 3.1, IPS
Clamp, Input, gen 3.1, IPS
Heatsink, gen 3.1, IPS
Heatsink, gen 3.1, IPS
Spring Clip,IGBT, gen 3.1, IPS
Chassis, PCB1, gen 3.1, IPS
Chassis, gen 3.1, IPS
Knob, gen 3.1, IPS
Knob Cap, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Sheet, rubber, gen 3.1, IPS
Post, 1(M5), gen 3.1, IPS
Bus Bar, 1 D-L, gen 3.1, IPS
Bus Bar, 2 D-L, gen 3.1, IPS
Bus Bar, 1 T-D, gen 3.1, IPS
Bus Bar, 2 T-D, gen 3.1, IPS
Bus Bar, S1, gen 3.1, IPS
Bus Bar, gen 3.1, IPS
Bus Bar, T-CC, gen 3.1, IPS
Bus Bar, T, gen 3.1, IPS
Bus Bar, gen 3.1, IPS
Insulated Board, gen 3.1, IPS
Insulation Sheet, gen 3.1, IPS
Insulation Sheet, gen 3.1, IPS
W7001600
W7001338
W7001339
W7001340
W7001615
10-6733
W7001345
W7001603
10-5184
10-6660
N/A
10-6662
W7001574
W7001575
W7001351
W7001583
W7001582
10-6665
10-6666
W7001585
W7001357
W7001358
W7001576
W7001577
W7001578
10-6868
W7001610
W7001611
W7001612
W7001613
W7001369
W7001607
W7001614
2
Type & Rating
MHS20A221KI 20W 220Ω
MHS20A101KI 20W 100Ω
DCP-52SR50C-480V 2P-480V (185ACDC)
5505NBR1.5 DC24V 11VA/10W (with Gas
Inlet and PC4-02)
F3A063501 200A MAIN TR
ERTA53D203 20kΩ/25°CB=3950K
E0D005301
E0D005501
E0D005407
E0C346000
JDA173200 (200ACDC)
E0C303200
EBA514400
E1B537600 (with Dustcover Sheet)
N4A932900 (200ACDC)
N4A785200
N1B029700
N1B029800
N4A670600
N4A040700
N4A919100
EDA268800 (with PC4-02)
TRAK-BE35-70S
132"10/3SOWBLKW/R650 (185ACDC)
EBA045800
E1B869900
E1B870000
E1B850100
J5B017400
J3C356500
2621603
3021104
N1B016200
EDA227700
EBA643600 (M5-M5)
ECA879500
ECA879600
ECA887200
ECA887300
ECA321000
ECA901400
ECA904200
EDA022400
EDA069100
E1B872000
E1B859500
EDA174000
QTY.
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
2
1
1
2
1
4
1
1
1
1
1
4
3
1
1
1
1
2
1
1
1
2
2
1
1
200ACDC PARTS LIST
No.
82
83
84
85
86
87
DWG No.
Part No.
W7001616
W7001609
W7001374
W7001618
10-2020
300X4903
Description
Sheet, dust cover F, gen 3.1, IPS
Sheet, dust cover R, gen 3.1, IPS
Clip, gen 3.1, IPS
Hose, Nylon, gen 3.1, IPS
Plug, Output, gen 3.1, IPS
Operating Manual, gen 3.1, IPS
Type & Rating
E1B935200 E1B935600
#74 NATURAL 4
T0425B Nylon Hose L=0.5m
TRAK-SK50
Operating Manual
QTY.
1
1
4
1
1
1
50
44
49
29
69 74
36
42
74
69
58
47
59
41
84
13
56
23
37
43
67
46
24
48
66
8
54
53
65
42
45
85
40
51
52
57
2
56
57
55
49
3
200ACDC PARTS LIST
20
19
62
18
78
21
17
34
16
22
62
34
4
68
15
81
64
68
80
14
79
63
22 62
62
33
9
76
79
60
82
61
1
10
60 39
31
79
79
30
3
83
39
64
35
75
71
6
38
5 7
11
32
27
25
70
28
12
77
73
72
4
26
APPENDIX 2 CONNECTION WIRING GUIDE
CONNECTION WIRING GUIDE
APPENDIX 2 Connection Wiring Guide
Destination
A
PCB2
CN2
↔
PCB3
B
PCB2
CN3
↔
D1
C
PCB3
CN1
↔
D1
D
PCB3
CN2
↔
PCB17
E
PCB3
CN7
↔
CT2
F
G
PCB3
CN11
↔
FAN1
SOL1
H
PCB3
CN20
↔
PCB8
CN1
I
PCB3
CN21
↔
PCB8
CN2
J
PCB3
CN22
↔
PCB9
CN1
K
PCB3
CN23
↔
PCB9
CN2
L
PCB3
CN18
↔
PCB7
CN20
M
PCB3
CN33
↔
PCB6
CN20
N
PCB6
CN1
↔
HCT1
O
PCB6
CN8
↔
TH1
P
PCB6
CN9
↔
TH2
Q
PCB6
CN17
↔
PCB13
PCB16
CN4
CN3
R
PCB6
CN21
↔
PCB10
CN2
CN14
↔
CON1
↔
PCB11
CN1
↔
PCB15
CN1
S
T
U
V
PCB7
PCB10
CN15
CN1
PCB13
CN6
5
CN3
CN1
200ACDC CONNECTION WIRING GUIDE
CN3
CN21
R
PCB17
CN17
PCB6
CN1
D
CN20
N
CN8
U
CN2
CN9
O
CN1
M
TH1
CN1
P
CN2
F
CN1
E
CT2
CN33
FAN1
G
PCB4
PCB10
PCB11
T
SOL1
L
J
CN18
CN7
PCB7
CN11
CN1
CN15
CN20
K
CN14
S
I
CN22
CN2
CN20
CN23
CON1
A
C
CN1
Q
CN21
PCB9
H
CN2
PCB3
TH2
CN1
PCB8
PCB16
CN3
CN3
CN2
PCB15
PCB2
CN1
CN6
B
V
CN4
HCT1
D1
PCB13
6
APPENDIX 3 INTERCONNECT DIAGRAM
INTERCONNECT DIAGRAM
APPENDIX 3 INTERCONNECT DIAGRAM
INTERCONNECT DIAGRAM
G(6)
P
R(3)
N
(2)
EA
N
G2
E2
TB2
TB2
EA
E PCB17
Filter
Circuit Board
[WK-4917]
Ground
PCB2
Link
Circuit Board
[WK-5482]
SIDE CHASSIS 2
CN1
SIDE CHASSIS 1
1
2
3
4
5
1 2
REAR
PANEL
G3
E3
SOL1
CN31 CN32
CN31 CN32
CN1
CN4
1
2
3
4
CT1
CT2
CN30
CN30
CN131 CN132
CN131 CN132
1
2
8
1
5
4
7
6
3
CON1
1
2
CN27
3
4
CN27
5
CN15
2
CN17
CN17
Q10
G
E
C
Q11
G
E
C
Q12
1 2 3 4 5 6
1 2 3 4 5 6 7
CN21
CN22
CN23
PCB6
Control
Circuit Board
[WK-5549]
CN18
CN18
CN14
TB0
PCB7
Filter
Circuit
Board
[WK-5550]
CN20
EA
Q9
G
E
C
1 2 3 4 5 6 7
CN130
CN130
1 : Chassis Ground
2 : Contactor Control/+24VDC
3 : Contactor Control/GND
4 : Not Used
5 : Potentiometer Maximum
6 : Potentiometer Minimum(GND)
7 : Amperage Control Wiper 0-10VDC
8 : Not Used
EA
Q8
G
E
PCB3
Control Souce
PCB5
Circuit Board
Conect Circuit Board [WK-5548] 1 2 3 4 5 6
[WK-5551]
CN20
CN11
1
2
3
4
CN6
CN6
Q7
G
E
C
E2
G2
CN5
CN5
FAN1
+
C2E
PCB4
Detect
Circuit Board
[WK-4819]
1
2
3
4
E1
G1
CN4
1
2
3
4
-
1
2
3
G4
E4
CN7
R2
CN3
CN1
P
CN2
C
IGBT Gate
Circuit E
Board C
1 2 3 4 5
E1C
1
2
3
4
5
6
Q6
[WK-5479]
1 2 3
N
Q5
G
E
C
PCB9 G
TB4
CN1
1 2 3
Q4
G
E
C
G
E
TB3
CN2
+
L103
1
2
3
4
CN2
T(5)
CN1
+
1
2
3
CN20
CN9
CN8
1 2
1 2 3
1 2
CN18
1 2 3
CN19
1 2 3
1 2 3
CN33
1
2
3
TH2
7
E4
G4
R2
TB2 TB5 TB4
Ground
G1
E1
R2
G
E
C
TH1
CN17
(0)
S(4)
Q3
[WK-5479]
TB1
1
2
3
4
5
6
7
CN21
TB3
CN2
TB0
PCB18
CE Filter
Circuit
Board
[WK-5861]
C2E
TB1
E1C
S1
L101
Q2
P+21V
PGND
EA
Q1
G
E
C
PCB1
Main
PCB8
Circuit
IGBT GateG
Board
Circuit E
[WK-5477]
Board C
P
K(7)
C
1
2
3
4
CN1
+
(1)
R5
TB5 TB6
E3
G3
1
2
D1
CN1
CN3
R4
1
2
3
4
200ACDC INTERCONNECT DIAGRAM
TB22
TB12
CT2
Q13
G1 G1
PCB15
IGBT Gate E1 E1
Circuit Board
[WK-3367] G2 G2
D5
TB21
CN1
TO1
+Output
Terminal
E2 E2
1 2 3 4 5
AC4
CT2
CT1
PCB14
IGBT Snubber
Circuit Board
[WK-5570]
G7
E7
D2
TB1
E8
G8
T1
FCH1
D4
AC2
TB7
TB20
SH.DET+
AC1
PCB12
DIODE Snubber
Circuit Board
[WK-5615]
TB2
+
RY+15V
/RY_ON
1
2
3
HCT1
Ground
CN1
CN3
SH.DET-
1 2 3 4 5
PCB16
Filter Circuit
Board
SIDE CHASSIS 3
[WK-5499]
Torch/Gas
CC1
Terminal
34
12
TO2
+15
-15
IS
GND
R3
R1
1
2
CN2
S+15V
1
2
3
SH.DET+
SH.DET-
AC4
AC2
AC3
EB
S+15V
SG
SG
CN8
CN9
AC1
CN5
R2
R2
AC3
R6
PCB13
Super Inpose
Circuit Board
[WK-5569]
AC3
AC1
1
2
3
4
5
6
7
8
G7
E7
G8
E8
FRONT
PANEL
1 2 3 4 5 6 7
EA
+
Ground
RY+15V
1
2
3
4
5
6
+15
-15
IS
GND
PCB10
Panel
Circuit Board
[WK-5527]
SIDE CHASSIS 2
PCB11
Encoder
Board
[WK-5528]
CN2
1 2 3 4 5 6 7 8 9
TB2
CN4
/RY_ON
1 2 3 4 5
1 2
CN6
CN1
P+21V
PGND
CN3
TB1
N
-Output
Terminal
CC1
HF.UNIT1
1
2
3
4
P
CC2
CN1
CN1
1 2 3 4
8
1 2 3 4
APPENDIX 4 DIODE TESTING BASICS
DIODE TESTING BASIC
APPENDIX 4 DIODE TESTING BASIC
Testing of diode modules requires a digital Volt/
Ohmmeter that has a diode test scale.Locate the
diode module to be tested.Remove cables from
mounting studs on diodes to isolate them within the
module.Set the digital volt/ohm meter to the diode
test scale.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
1. 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.
COM
A
Forward Bias
Diode Conducting
Anode
2. 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".
Cathode
Figure 13-1: Forward bias diode test
3. If any diode in the module tests as faulty,
replace the diode module.
4. Reconnect all cables to the proper terminals.
VR
COM
Reverse Bias
Diode Not Conducting
Cathode
Anode
Figure 13-2: Reverse bias diode test
9
A
LIMITED WARRANTY AND SCHEDULE
This information applies to Thermadyne products that were purchased in the United Kingdom
April 2006
Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in
accordance with the written instructions as defined in the owner’s manual supplied with the machine. Thermadyne
welding products are manufactured for use by commercial and industrial users and trained personnel with experience
in the use and maintenance of electrical welding and cutting equipment.
Thermadyne warranty will not apply to:
1. Equipment that has been modified by any other party other than Thermadyne’s own service personnel or
with prior written consent obtained from Thermadyne service department (UK).
2. Equipment that has been used beyond the specifications established in the owners manual.
3. Installation not in accordance with the installation/service manual.
4. Failure to clean and maintain the machine as set forth in the owner, installation or service manual.
If warranty is being sought, please contact Thermadyne's UK warranty department for a warranty authorization returns
form.
Welding Equipment - Limited Warranty Period
Product
200S, 300S, 400S, 200TS, 300TS, 400TS, 400 MST, 200AC/DC, 300AC/DC,
PowerMaster 320SP, 400SP, 500SP,
Fabricator 200, Ultrafeed VA4000, Portafeed VS212
150SE, 155SE, 250SE, 400SE, 250TE, 400TE, 180AC/DC, 250AC/DC, 400AC/DC
Fabricator 250, Fabricator 330, Fabricator 400, Fabricator 450, 220GMS
Options and Accessories
Repair and Replacement Parts
Torch Consumables
Cutting Equipment -Limited Warranty Period
Product
CutMaster 38, 51, 81,101, 151
PakMaster 150XL, Drag-Gun Plus
CutSkill C-35A, C-70A, C-100A, Drag-Gun
1TorchTM, SureLokTM Torches and PCH 120
Other Torches
Repair Parts
Arc Accessories - Limited Warranty Period
Product
All Products
Consumables
Torch Consumables
Period
3 Years
2 Years
6 Months
3 Months
None
Period
3 Years
2 Years
1 Year
1 Year
6 Months
3 Months
Period
1 Month
None
None
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: [email protected]
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
Cigweld, Australia
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: [email protected]
www.thermalarc.com
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