pro-wave 300GtSw Service Manual

pro-wave 300GtSw Service Manual
300GTSW
pro-wave
Inverter arc welder
Art # A-06102
Service Manual
Version No: AB
Operating Features:
Issue Date: June 21, 2012
Manual No.: 0-2515
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 1-800-752-7621, or visit
us on the web at www.Thermalarc.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is the Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major
welding industry sectors worldwide including: Manufacturing,
Construction, Mining, Automotive, Engineering, Rural and DIY/
Hobbysit.
We distinguish ourselves from our competition through market
leading dependable brands that have stood the test of time, technical
innovation, competitive prices, excellent delivery, superior customer
service and technical support, together with excellence in sales and
marketing expertise.
We are committed to develop technologically advanced products to
achieve a safer working environment within the welding industry .
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Pro-Wavel 300GTSW Inverter Arc Welder
Service Manual Number 0-2515 for:
208/230VAC Single-Voltage, Single-/Three-Phase
208/230/460VAC Single-/Three-Phase
380/415VAC Single-Voltage, Three-Phase
Spec Number: 10-3024
Spec Number: 10-3025
Spec Number: 10-3038
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2001 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: January 20, 1997
Revision AB Date: June 21, 2012
Record the following information for Warranty purposes:
Where Purchased:
_____________________________________
Purchase Date:
_____________________________________
Equipment Serial #:
_____________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS........................................................ 1-1
1.01Arc Welding Hazards........................................................................................ 1-1
1.02PRINCIPAL SAFETY STANDARDS.................................................................... 1-5
1.03PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC..................................... 1-6
1.04Dangers relatifs au soudage à l’arc.................................................................. 1-6
1.05PRINCIPALES NORMES DE SECURITE.......................................................... 1-10
1.06DECLARATION OF CONFORMITY................................................................... 1-11
1.07LIMITED WARRANTY.................................................................................... 1-12
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01How To Use This Manual................................................................................. 2-1
2.02Equipment Identification.................................................................................. 2-1
2.03Receipt Of Equipment...................................................................................... 2-1
2.04Symbol Chart................................................................................................... 2-2
2.05General Description......................................................................................... 2-3
2.06Functional Block Diagram................................................................................ 2-4
2.07Transporting Methods...................................................................................... 2-5
2.08Specifications.................................................................................................. 2-6
2.09Duty Cycle........................................................................................................ 2-7
SECTION 3:
INSTALLATION........................................................................................ 3-1
3.01Electrical Input Connections............................................................................ 3-1
SECTION 4:
OPERATION............................................................................................ 4-1
4.01Operator Controls............................................................................................ 4-1
SECTION 5:
SERVICE................................................................................................ 5-1
5.01Routine Maintenance....................................................................................... 5-1
5.02Basic Troubleshooting .................................................................................... 5-1
5.03Common Welding Operation Faults................................................................. 5-1
5.04Specific Problems............................................................................................ 5-2
SECTION 6:
ADVANCED TROUBLESHOOTING................................................................... 6-1
6.01System-Level Fault Isolation............................................................................ 6-1
6.02Opening the Enclosure..................................................................................... 6-2
6.03Initial Setup Conditions.................................................................................... 6-2
6.04Easy Link Fault Isolation Test (208-230/460VAC Model only).......................... 6-3
6.05Power Supply Voltage Test.............................................................................. 6-4
6.06Output Load Test.............................................................................................. 6-6
6.07LIFT START Circuit Test................................................................................... 6-6
TABLETABLE
OF CONTENTS
OF CONTENTS
(continued)
6.08High Frequency (HF) START Circuit Test ......................................................... 6-7
6.09Subsystem Test Preparation............................................................................ 6-8
6.10Main Circuit Breaker (MCB) Replacement Procedure....................................... 6-8
6.11Main PCB1 Gate Drive Enable Signal Test...................................................... 6-10
6.12Lift Start Test................................................................................................. 6-12
6.13Gas Control Test ........................................................................................... 6-12
6.14High Frequency Test ..................................................................................... 6-12
6.15Main Circuit Board (PCB1) Replacement Procedure...................................... 6-13
6.16Gaining Access to Front Panel Circuit Board (PCB6) WK-3988...................... 6-18
6.17Front Panel PCB6 (WK-3988) Test Point Voltages......................................... 6-19
6.18Input Power Selector Switch Test.................................................................. 6-20
6.19Front Panel Circuit Board (PCB6) Replacement Procedure............................ 6-20
6.20Current Transformer Test Procedure.............................................................. 6-22
6.21Current Transformer Replacement Procedure................................................ 6-22
6.22Power Control Assembly............................................................................... 6-23
6.23Power Control Assembly (PCA) Test Procedures........................................... 6-23
6.24PCA Input Diode Bridge (D1) Test Procedure................................................ 6-24
6.25PCA Input Diode Bridge (D1) Replacement Procedure.................................. 6-24
6.26PCA IGBT Inverter Test Procedure................................................................. 6-26
6.27PCA IGBT Inverters Q1 and Q2 Replacement Procedure................................ 6-28
6.28PCA IGBT Inverter Q3/Q4 Replacement Procedure........................................ 6-30
6.29PCA Output Diodes (D2-D5) Test Procedure.................................................. 6-32
6.30PCA Output Diodes (D2 - D5) Replacement Procedure.................................. 6-33
6.31PCA Thermal Sensor (TH1) Test Procedure................................................... 6-36
6.32Thermal Sensor (TH1) Replacement.............................................................. 6-37
6.33Auxiliary Transformer (T3) Test Procedure ................................................... 6-38
6.34Auxiliary Transformer (T3) Replacement....................................................... 6-39
6.35Main Transformer Assembly (T1 and T2) Test Procedure.............................. 6-40
6.36Main Transformer (T1 and T2) Assembly Replacement Procedure................ 6-41
6.37Output Inductor Assembly Test and Replacement Procedures...................... 6-42
6.38Fan Assembly Replacement Procedure.......................................................... 6-44
6.39HF Unit Test and Replacement Procedures.................................................... 6-46
6.40HF Coupling Coil Test and Replacement Procedures...................................... 6-48
6.41Gas Solenoid Valve Replacement Procedure.................................................. 6-50
6.42IGBT Inverter Q3/Q4 Driver Circuit Board (PCB8) Test Procedure................. 6-51
6.43IGBT Inverter Q3/Q4 Driver Circuit Board (PCB8) Replacement Procedure... 6-52
6.44Sequence Timing Diagrams........................................................................... 6-53
SECTION 7:
PARTS LIST............................................................................................ 7-1
7.01Equipment Identification.................................................................................. 7-1
7.02How To Use This Parts List.............................................................................. 7-1
7.03Parts List......................................................................................................... 7-2
7.04Parts Pictures.................................................................................................. 7-6
TABLE OF CONTENTS
APPENDIX 1: GENERAL INFORMATION.................................................................. A-1
APPENDIX 2: 208/230VAC SINGLE-VOLTAGE SINGLE-/THREE-PHASE.............................. A-2
APPENDIX 3: 208/230/460VAC SINGLE-/THREE-PHASE............................................... A-4
APPENDIX 4: 380/415VAC SINGLE-VOLTAGE THREE-PHASE......................................... A-6
APPENDIX 5: WIRE CHART MAIN BOARD PCB1........................................................ A-8
APPENDIX 6: WIRE CHART FRONT PANEL PCB6 .....................................................A-12
APPENDIX 7: WIRE CHART AC IGBT GATE DRIVE PCB8..............................................A-14
APPENDIX 8: BOTTOM WIRING PLACEMENT DIAGRAM..............................................A-15
APPENDIX 9: DIODE TESTING BASICS..................................................................A-16
APPENDIX 10: METER CALIBRATION PROCEDURE...................................................A-18
pro-wave 300gtsw
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
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever the
output is on. The input power circuit and
machine internal circuits are also live when
power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the
welding wire are electrically live. Incorrectly
installed or improperly grounded equipment
is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
June 21, 2012
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.
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.
9. Do not wrap cables around your body.
10.Ground the workpiece to a good electrical (earth)
ground.
11.Do not touch electrode while in contact with the work
(ground) circuit.
12.Use only well-maintained equipment. Repair or replace
damaged parts at once.
1-1
Pro-wave 300gtsw
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.
WARNING
14.Wear a safety harness to prevent falling if working
above floor level.
FUMES AND GASES can be hazardous to
your health.
15.Keep all panels and covers securely in place.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
WARNING
1. Keep your head out of the fumes. Do not breath the
fumes.
ARC RAYS can burn eyes and skin; NOISE can
damage hearing.
2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
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.
3. If ventilation is poor, use an approved air-supplied
respirator.
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.
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and foot
protection.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
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.
5. Use approved ear plugs or ear muffs if noise level is
high.
Welding or cutting
Torch soldering
Torch b razin g
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
He a vy
Shielded metal-arc
1-2
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Electrode Size
Filter
Welding or cutting
Electrode Size Filter
2
Gas metal-arc
3 or 4
No n -fe rro us ba s e m eta l
Al l
11
Ferrous base metal
All
12
Under 1 in., 25 mm
3 or 4 Gas tungsten arc welding
All
12
1 to 6 in., 25-150 mm 4 or 5
(TIG)
All
12
Over 6 in., 150 mm
5 or 6 Atomic hydrogen welding
All
12
Carbon arc welding
All
12
Under 1/8 in., 3 mm
4 or 5
Plasma arc welding
1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Ove r 1 /2 i n., 1 2 m m
6 or 8
L ig h t
12
Un d er 5 /32 in ., 4 m m
10
Hea vy
14
5/32 to 1/4 in.,
12
Plasma arc cutting
Ove r 1/4 i n ., 6 .4 m m
14
L ig h t Und e r 3 0 0 Am p
9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp
14
June 21, 2012
pro-wave 300gtsw
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated,
and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc.
The flying sparks and hot metal, weld spatter,
hot workpiece, and hot equipment can cause
fires and burns. Accidental contact of electrode
or welding wire to metal objects can cause
sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot
metal.
2. Do not weld where flying sparks can strike flammable
material.
3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover them
with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
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.
June 21, 2012
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
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to treat
them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific application;
maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder
valve.
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA publication
P-1 listed in Safety Standards.
1-3
Pro-wave 300gtsw
WARNING
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
Engines can be dangerous.
WARNING
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes and
skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working on
a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any
sparks or open flames.
3. Allow engine to cool before fueling. If possible, check
and add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
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.
3. Allow pressure to escape before completely removing
cap.
1. Keep all doors, panels, covers, and guards closed
and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
1-4
June 21, 2012
pro-wave 300gtsw
1.02 PRINCIPAL SAFETY STANDARDS
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
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 and
interact with, and produce changes in, biological systems.
While most of this work is of very high quality, the results
are complex. Current scientific understanding does not
yet allow us to interpret the evidence in a single coherent
framework. Even more frustrating, it does not yet allow us
to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies
to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the
following procedures.
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society, 550
N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National
Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association, 1235
Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, from Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
1. 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.
June 21, 2012
1-5
Pro-wave 300gtsw
1.03 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE
LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS
N’AIENT CONSULTE UN MEDECIN). 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. Ne touchez pas à des pièces sous tension.
1.04 Dangers relatifs au soudage à l’arc
3 Isolez-vous de la pièce à souder et de la mise à la terre
au moyen de tapis isolants ou autres.
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
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.
1-6
2. Portez des gants et des vêtements isolants, secs et
non troués.
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.
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 porteélectrodes 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.
June 21, 2012
pro-wave 300gtsw
9. N’enroulez pas de câbles électriques autour de votre
corps.
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.
15.Fermez solidement tous les panneaux et les capots.
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER
LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
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.
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. Portez des lunettes de sécurité approuvées. Des écrans
latéraux sont recommandés.
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.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (s elon AWS á 8.2-73)
Opération de coupage
ou soudage
Bras sage tendre
au chalum eau
Bras sage fort
au chalum eau
Dim ens ion d'électrode ou
Nuance de
Epiasseur de m étal ou
filtre oculaire
Intensité de courant
toutes conditions
3 ou 4
m étaux non-ferreux
toutes conditions
11
m étaux ferreux
toutes conditions
12
2 ou 3
Soudage á l'arc sous gaz avec
électrode de tungs tène (GTAW)
toutes conditions
12
toutes conditions
12
toutes conditions
12
to u te s d im e n s io n s
12
m oins de 1 po. (25 m m )
plus de 6 po. (150 m m )
4 ou 5
5 ou 6
So u d a g e a u x g a z
m ince
Soudage á l'hydrogène
atom ique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
So u d a g e á l 'a rc Pla s m a (PAW)
m oins de 1/8 po. (3 m m )
m o ye n d e 1 /8 á 1 /2 p o . (3 á 1 2 m m )
é p a i s p l u s d e 1 /2 p o . (1 2 m m )
Soudage á l'arc avec
électrode enrobees
m oins de 5/32 po. (4 m m )
(SMAW)
5 /3 2 á 1 /4 p o . (4 á 6 .4 m m )
p l u s d e 1 /4 p o . (6 .4 m m )
June 21, 2012
Soudage á l'arc sous gaz
avec fil plein (GMAW)
2
m oyen de 1 á 6 po. (25 á 150 m m )
épais
Dim ens ion d'électrode ou
Nuance de
Epias seur de m étal ou
filtre oculaire
Intensité de courant
toutes conditions
Oxycoupage
m ince
Opération de coupage
ou s oudage
4 ou 5
5 ou 6
6 ou 8
10
12
14
Gougeage Air-Arc avec
électrode de carbone
m i n ce
é p a is
12
14
Coupage á l'arc Plasm a (PAC)
m i n ce
m o ye n
m o i n s d e 3 0 0 a m p e rè s
d e 3 0 0 á 4 0 0 a m p e rè s
9
12
épais
plus de 400 amperès
14
1-7
Pro-wave 300gtsw
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
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.
3. Si la ventilation est inadequate, portez un respirateur
à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du
fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.
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.
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
LE SOUDAGE PEUT CAUSER UN INCENDIE
OU UNE EXPLOSION
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.
1-8
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.
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.
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.
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger
la peau.
June 21, 2012
pro-wave 300gtsw
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. 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.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE
OU UNE EXPLOSION.
Le carburant est hautement inflammable.
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.
2. Enchainez verticalement les bouteilles à un support
ou à un cadre fixe pour les empêcher de tomber ou
d’être renversées.
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.
3. Eloignez les bouteilles de tout circuit électrique ou de
tout soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez
de l’espace pour son expansion.
4. Empêchez tout contact entre une bouteille et une
électrode de soudage.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer
le moteur.
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.
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
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.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS
PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.
June 21, 2012
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.
1-9
Pro-wave 300gtsw
6. Réinstallez les capots ou les protecteurs et fermez les
portes après des travaux d’entretien et avant de faire
démarrer le moteur.
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.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER
UN ACCUMULATEUR; L’ELECTROLYTE D’UN
ACCUMU-LATEUR PEUT BRULER LA PEAU
ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte
acide et dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un
accumu-lateur.
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.
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.
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.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT
BRULER LA PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur
peut être brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur
n’est pas refroidi.
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.
1-10
June 21, 2012
pro-wave 300gtsw
1.06 DECLARATION OF CONFORMITY
Manufacturer:
Victor Technologies
Address:
16052 Swingley Ridge Road, Suite 300
Chersterfiedl, MO 63017
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) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting
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.
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
June 21, 2012
1-11
Pro-wave 300gtsw
1.07 LIMITED WARRANTY
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of itsauthorized distributors hereafter
“Purchaser” that its products will be free of defects in workmanship or material. Should anyfailure to conform to this warranty appear within the time
period applicable to the Thermal Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been
stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard
industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal
Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.
THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING,
BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: THERMAL ARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL
DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are
exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach
thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract,
negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE
JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE
VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser.
Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered
the product to the authorized distributor.
POWER SUPPLIES
MAIN POWER MAGNETICS (STATIC & ROTATING)
ORIGINAL MAIN POWER RECTIFIER
CONTROL PC BOARD
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING BUT
NOT LIMITED TO: CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS.
ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC,
ALTHOUGH MOST ARE WARRANTED BY THE ENGINE
MANUFACTURER. SEE THE ENGINE MANUFACTURE'S
WARRANTY FOR DETAILS.
CONSOLES, CONTROL EQUIPMENT, HEAT EXCHANGES
ACCESSORY EQUIPMENT
ALL OTHER
POWER SUPPLIES
3 YEARS
3 YEARS
3 YEARS
LABOR
3 YEAR
3 YEAR
3 YEAR
1 YEAR
1 YEAR
1 YEAR
1 YEAR
NOTE: Dragster 85® excluded from this policy. Refer to Dragster 85 warranty in Dragster 85 Owner’s Manual.
Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within
thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk
and expense. This warranty supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered Trademark of Thermadyne Industries Inc.
September 27, 2004
1-12
June 21, 2012
pro-wave 300gtsw
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
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
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
2.02 Equipment Identification
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
1 for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there is
any damage, notify the carrier immediately to file a claim.
Furnish complete information concerning damage claims
or shipping errors to the location in your area listed in
the inside back cover of this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number
for your area given in the back cover. Include the Service
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
June 21, 2012
2-1
pro-wave 300gtsw
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
115V 15A
X
%
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Spot Time
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
S
See Note
See Note
Voltage Input
Art # A-04130_AB
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the S mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.
2-2
June 21, 2012
pro-wave 300gtsw
2.05 General Description
The Thermal Arc™ Model 300GTSW is a three-phase or
single-phase (if derated) AC/DC arc welding power source
with Constant Current (CC) output characteristics. The
unit is equipped with a 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.
OCV Less than 70V
C.C.
Art # A-06103
Arc Characteristics
"CURRENT" Control
VOLTS
19V
5
145
AMPS
300 310
Figure 2-1: 300GTSW volt-ampere curve
NOTE
Volt-Ampere curves show the maximum
Voltage and Amperage output capabilities of
the welding power source. Curves of other
settings will fall between the curves shown.
June 21, 2012
2-3
pro-wave 300gtsw
2.06 Functional Block Diagram
Figure 2-2 illustrates the functional block diagram of the 300GTSW power supply.
Input
Power
Main
Circuit
Breaker
Input
Diode
Inrush Current
Suppresor
Capacitor
IGBT Inverter
Module
Output
Transformers
Output
Diodes
Output
Inductor
Thermal
Sensor
DC Power
Supply for
Control Circuit
Coupling
Coil
To each control circuit
+12VDC +20VDC
+24VDC +5VDC
–
Art # A-06104
Trouble
Sensing
Circuit
Torch Control
Connection
(CON1)
+
Lift Tig Mode
Output Short
Sensing Circuit
Thermal
Sensor
Circuit
Voltage Sensor
Current
Transformer
(CT-1)
Drive Circuit
Primary
Current
Sensor
Drive Circuit
IGBT Inverter
Module
Sequence
Control
+
–
+
High
Frequency
Unit
Reference
Adjustments &
Control Switches
Gas
Control
Circuit
Current
Adjustment
Circuit
Figure 2-2: Block Diagram
!
WARNING
Disconnect primary power at the source before disassembling the power supply. Frequently review the
Important Safety Precautions (page ii). Be sure the operator is equipped with proper gloves, clothing, eye
and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece or
any internal components while the unit is activated. Wait at least two minutes for the input capacitors to
discharge before opening the enclosure.
2-4
June 21, 2012
pro-wave 300gtsw
2.07 Transporting Methods
These units are equipped with a handle for carrying
purposes.
!
WARNING
ELECTRIC SHOCK can kill.
• DO NOT TOUCH live electrical parts.
• Disconnect input power conductors from deenergized supply line before moving welding power
source.
!
WARNING
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
• Lift unit with handle on top of case.
• Use hand cart or similar device of adequate capacity.
• If using a fork lift vehicle, place and secure unit on
a proper skid before transporting.
June 21, 2012
2-5
pro-wave 300gtsw
2.08Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Output Range (Min. - Max.)
Amperes
Volts
Open Circuit Voltage
Maximum OCV
Input Data
Dimensions/Weight
Width
Height
Length
Weight
Output at Rated Output
Amperes
Volts
Duty Cycle
KVA
KW
Output at No Load
Input data 50/60 Hz/Duty Cycle
KVA
KW
Input Volts
208
230
460
208
230
380
400
415
460
208V/230V/460V
Three Phase
Single Phase
300
250
300
250
32
30
32
30
25%
40%
25%
40%
TIG/STICK
5-300 DC or 10-300 AC
10-32 Volts
64 V
50/60 Hz
8.3 in (210 mm)
16.9 in (430 mm)
16.5 in (420 mm)
46.2 lb (21 kg.)
Three-Phase
Single-Phase
300
250
300
32
30
32
25%
40%
25%
15.7
12.3
19.8
12.2
9.5
12.5
Three-Phase
44
40
24
23
22
20
No Load
250
30
40%
15.5
9.8
0.5
0.3
Amperage Draw
Single-Phase
95
74
86
67
43
34
34
31
19
18
17
15
-
0.5
0.3
No Load
2.2
2.2
1.1
1.4
1.3
0.8
0.7
0.7
0.6
Table 2-2: Specifications
2-6
June 21, 2012
pro-wave 300gtsw
2.09 Duty Cycle
The duty cycle of a welding power source is the percentage
of a ten (10) minute period that it can be operated at a
given output without causing overheating and damage to
the unit. If the welding amperes decrease, the duty cycle
increases. If the welding amperage are increased beyond
the rated output, the duty cycle will decrease.
!
Warning
Exceeding the Duty Cycle Ratings will cause
the Thermal Overload Protection Circuit to
become energized and shut down the output
until the unit has cooled to normal operating
temperature.
Continually exceeding the Duty Cycle Ratings can cause
damage to the welding power source.
To calculate duty cycle:
2
current = (rated current) x (rated duty cycle)
(desired duty cycle)
Art # A-06105
i.e. At the 300A rated output current, and 25% rated duty
cycle, the operator wants to work on a 50% duty cycle.
The maximum allowable current draw is:
current =
(300A)2 x (.25)
(.50)
current =
90,000 x (0.5)
current =
45,000
Art # A-06106
current = 212.1A
June 21, 2012
2-7
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2-8
June 21, 2012
pro-wave 300gtsw
SECTION 3:
INSTALLATION
3.01 Electrical Input Connections
!
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input
power.
• DO NOT TOUCH live electrical parts.
• SHUT DOWN welding power source, disconnect
input power employing lockout/tag out procedures.
Lockout/tag out procedures consist of padlocking
line disconnect switch in open position, removing
fuses from fuse box, or shutting off and red-tagging
circuit breaker or other disconnecting device.
Electrical Input Requirements Operate the welding power source from a single or threephase 50/60 Hz, AC power supply. The input voltage must
match one of the electrical input voltages shown on the
input data label on the unit nameplate. Contact the local
electric utility for information about the type of electrical
service available, how proper connections should be
made, and inspection required.
The line disconnect switch provides a safe and convenient
means to completely remove all electrical power from the
welding power supply whenever necessary to inspect or
service the unit.
NOTE
These units are equipped with a fourconductor with earth power cable that is
connected at the welding power source end for
single or three-phase electrical input power.
• To operate single-phase, do not connect the RED
input conductor.
• Do not connect an input (WHITE, BLACK or RED)
conductor to the ground terminal.
• Do not connect the ground (GREEN) conductor to
an input line terminal.
Refer to figure 3-1 and:
June 21, 2012
3-1
pro-wave 300gtsw
1. Connect end of ground (green) conductor to a suitable ground. Use a grounding method that complies with
all applicable electrical codes.
2. Connect ends of line 1 (black), line 2 (white) and line 3 (RED) input conductors to a de-energized line
disconnect switch.
3. Use Table 3-1 below as a guide to select line fuses for the disconnect switch.
Fuse Size (Amperes)
Three-Phase Single-Phase
208-230 VAC
208/230 VAC
60
125
208-230 VAC
60
125
208-230/460 VAC
460 VAC
23
75
380-415 VAC
380-415 VAC
30
N/A
Model
Input Voltage
Table 3-1: Fuse Size Selection
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).
Input Power
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the Main Circuit Breaker is
turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly
(PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds).
Ground
Conductor
Ground
Terminal
PRIMARY POWER
Line Fuse
INPUT SELECT
SWITCH
460V
208-230V
PRIMARY CABLE
OFF
3/1
ON
f1
f2
IEC974
X
U0
V
64
3/1
I2
U2
U1
V
208V
230V
460V
60/80 Hz
S1
5A/10V - 400A/36V
60%
25%
400/
300/
280A
210A
36/
32/
31V
28V
61/78A
66/70A
27/36A
21.9/
16.2kVA
40/63A
37/48A
18/24A
14.6/
10.9kVA
100%
230/
160A
28/
26V
28/37A
26/34A
13/17A
10/
8.0kVA
THERMADYNE
Thermal Dynamics
WEST LEBANON, NEW HAMPSHIRE USA 03784
MADE IN JAPAN
400S
TURN OFF YOUR MAIN POWER SOURCE AND
CIRCUIT BREAKER OF THIS WELDER BEFORE
MAINTENANCE OR INSPECTION
IP 23S
Line
Disconnect
Switch
Line Fuse
Art # A-06107
Welding Power Supply
Primary Power Cable
Figure 3-1: Electrical input connections
3-2
June 21, 2012
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SECTION 4:
OPERATION
4.01 Operator Controls
1.Amperage Control:
The Amperage Control selects the desired amperage
within the entire range of the welding power
source. Rotating this control in a clockwise
direction increases the amperage output. The
scale surrounding the amperage control represents
approximate actual amperage values.
2. Hot Start Control:
The Hot Start Control provides a variable selection of
start circuit current that operates in the STICK and
HF TIG modes. The Hot Start time is approximately
0.01 seconds in TIG and 0.06 seconds in STICK. The
current value is adjusted from 0 to 100 Amps over
the determined weld current set by the Amperage
Control. Rotating the control clockwise increases
Hot Start current.
3.ARC Control:
8.Sloper Switch:
When in the OFF position the Sloper is inactive.
Selecting the ON position activates the Sloper.
Selecting the SPOT position activates the spot
welding timer. The Slope sequence and spot modes
are activated by a remote ON/OFF switch connected
to the 8-pin receptacle. See the section on Slope
sequence on next page.
9.Pulser Switch:
When in the OFF position the Pulser is inactive.
Selecting H (HIGH) or L (LOW) will activate the TIG
pulser. The Pulse Frequency can be adjusted by
the Pulse Frequency control. Pulse width is fixed
at 35%. Background current is fixed at 1/5th of the
peak current.
10.AC Frequency Control:
When Output Selector Switch is in AC position,
controls frequency of AC waveform on output.
14
9
8
4
10
11
12
13
1
The Arc Control is in use in the SMAW mode only.
Rotate the control clockwise to increase the short
circuit current available to control the welding arc.
4.Process Selector Switch:
2
17
The Process Selector Switch allows the operator to
select the STICK welding (SMAW) process, LIFT TIG
(GTAW) or HF TIG (GTAW) process.
5.Warning Indicator:
3
5
The Warning Indicator located on the front panel will
become activated under the following conditions:
6
• Input voltage is too low
7
• Input voltage too high
15
• Thermal overload
6.AC Power Indicator:
The AC Power Indicator located on the front panel
lights when the Primary Power Switch is in the ON
position, indicating the unit is energized.
7.Output Selector Switch:
Selects between AC or DC output
June 21, 2012
18
16
Art # A-06108
Figure 4-1: Front panel operator controls
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pro-wave 300gtsw
11.Wave Balance:
This controls the portion of each AC output cycle
that has its polarity reversed. The reverse polarity
portion of the waveform is used to clean the oxides
of aluminum as it is welded. The control is variable
from 5% to 50%.
12.Spot Time Up/Down Slope Control:
This control provides Spot, Up and Down slope time
control. Rotating the control clockwise increases the
time. The scale surrounding the control represents
approximate actual values. The Spot and Up slope
time is adjustable from 0.5 to 5 seconds. The Down
slope time is twice the Up slope time at 0.5 to 10
seconds.
13.Pulse Frequency Control:
The Pulse Frequency control provides a means of
selecting the pulse frequency when the Pulse switch
is in the H (HIGH) or L (LOW) position. Rotating the
control clockwise increases the pulse frequency.
The two scales surrounding the control represent
approximate actual values. The pulse frequency is
adjustable from 0.5 to 25 Hz in LOW and 10 to 500
Hz in HIGH.
14.LED Voltage/Amperage Display (optional)
Sloper Sequence:
A. Remote ON/OFF switch closed:
Pre-flow starts to flow. In HF TIG mode HF and
initial current is present after pre-flow. (In LIFT
TIG mode HF is not present.) Initial current is 1/5th
of the welding current.
B. Remote ON/OFF switch opened:
Current increases to welding current at the rate set
by the UP/DOWN Slope control. Welding current
is set by the Amperage Control.
C. Remote ON/OFF switch closed:
Current decreases to final current at twice the rate
set for UP Slope. Final current is 1/5th of welding
current.
D. Remote ON/OFF switch opened:
Arc shuts off and post-flow time initiated.
14
9
8
4
10
11
12
13
1
2
15.Positive Terminal:
17
50mm DIN-style female receptacle.
16. Negative Terminal:
3
50mm DIN-style female receptacle.
17.8-Pin Receptacle:
5
Used for remote contactor and amperage controls.
18.Output Gas Fitting:
6
7
Gas output; fitting size 5/8"-18 unf female
18.Output Gas Fitting (European model):
15
European model gas output. Accommodates 3/8"
BSP monocable TIG torch.
NOTE
"F" and "G" revisions refer to the letter at the end
of the serial number for this product.
Gas Solenoid:
18
16
Art # A-06108
Figure 4-1: Front panel operator controls
The pre-flow is fixed at 150ms. On “F” revision and
earlier units the post-flow is automatically adjusted
from 1 to 30 seconds by the position of the welding
Amperage Control. On “G” revision and later the
unit has a separate post-flow adjustment from 0-60
seconds independent of current setting.
4-2
June 21, 2012
pro-wave 300gtsw
1.Primary Power Switch:
Placing the Primary Power Switch (circuit breaker)
located on the rear panel to the ON position
energizes the welding power source.
2.Voltage Selector:
Manual slide switch selects the proper input voltage
range. (208-230/460VAC Model only)
3. Input Cable:
10 feet
4. Input Gas Fitting:
The input gas connection is located on the bottom
center of the rear panel. Size 5/8"-18 unf female,
European Fitting - 3/8" BSP male. GTS Model only.
* If this slide switch is not set to the position that
matches the input voltage from the electrical source,
the warning indicator will be illuminated, and the unit
will not operate. (Not installed in single voltage unit
shown)
1
2
Art # A-06109
3
4
Figure 4-2: Rear panel operator controls (208/230
model shown)
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4-4
June 21, 2012
pro-wave 300gtsw
SECTION 5:
SERVICE
5.01 Routine Maintenance
The only routine maintenance required for the power
supply is a thorough cleaning and inspection, with the
frequency determined by the usage and the operating
environment.
!
5.02 Basic Troubleshooting
You should always attempt to isolate and fix a problem using
this section first. This section on basic troubleshooting
will help you isolate faults and problems that are easily
remedied without requiring that the power supply be
opened, or requiring specialized test equipment and
procedures. If the problem or fault cannot be corrected
by following the recommendations in this section, then
proceed to Section 6.0 on Advanced Troubleshooting.
5.03 Common Welding Operation Faults
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 (please refer to
Section 6.3, 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.
The following are some of the more common operating
faults that occur during welding operations:
A. Power
Main power not connected
Main power not turned on
MAIN CIRCUIT BREAKER set of OFF position
INPUT SELECTOR (Easy Link) Switch in wrong
position
B. Poor Weld
Wrong polarity
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.
Wrong electrode used
Electrode not properly prepared
Incorrect welding amperage setting
Speed too slow or too fast
Incorrect switch settings for intended operation
Poor weld output connection(s)
C. Remote Operation
Incorrect contactor switch settings
Remote not connected
If the problem is not resolved after checking the above,
the following guide may suggest more specific items to
check given the faulty operating symptom(s) you are
experiencing.
June 21, 2012
5-1
pro-wave 300gtsw
5.04 Specific Problems
How to Use This Guide
The following information is a guide to help you determine
the most likely causes for various symptoms.
This guide is set up in the following manner:
A. Symptom (Bold Type)
Any special instructions (Text Type)
1. Cause (Italic Type)
a. Check/Remedy (Text Type)
Locate your symptom, check the cause(s) (the simplest
or most likely is listed first), then perform the remedy
given. Repair as needed being sure to verify that the unit
is fully operational after any repairs.
A. No Weld Output; Unit is Completely Inoperative
1. Line disconnect switch is in OFF position
a. Place line disconnect switch in ON position.
2. Line fuse(s) open
a. Check and replace line fuse(s).
3. Improper electrical input connections
a. See Section 3.01 Electrical Input Requirements,
page 3-1, for proper input connections.
4. MAIN CIRCUIT BREAKER in OFF position
a. Check and reset MAIN CIRCUIT BREAKER if
necessary.
5. INPUT SELECTOR (Easy Link) switch is set
to incorrect position for applied input voltage,
208/230/460 model only
a. Verify primary source voltage and set INPUT
SELECT switch to correct setting.
B. WARNING Indicator is ON
1. Unit is in thermal shutdown mode
a. Allow cooling period of approximately five (5)
minutes with the power ON. Duty cycle should
be reviewed. To reset the WARNING indicator,
the power supply must be turned OFF, then ON
again.
2. Input voltage is low
a. Measure input voltage and verify that it
matches the INPUT SELECTOR (Easy Link)
switch setting. The length of the input power
cable must be considered, as there will be a
considerable voltage drop along its length.
3. Erratic input voltage – spikes over tolerance will
cause the warning light to come on for protection
a. Turn MCB off then on to reset the warning light.
C. Erratic or Improper Weld Output
1. Loose welding cable connections
a. Tighten all welding cable connections.
2. Incorrect welding cable size
a. U s e p r o p e r s i z e a n d t y p e o f c a b l e .
(see Operating Manual 0-2514)
3. Improper input connections
a. Refer to Section 3.1 Electrical Input
Requirements, page 3-1.
4. Poor electrode condition
a. Replace electrode.
5. If in GTAW mode, check the condition of the
tungsten electrode
a. Use the recommended 2% Thoriated tungsten.
6. In GTAW mode, incorrect argon gas flow
a. Verify that argon gas flow is correct;
approximately 12 SCFH.
7. Incorrectly set PROCESS SELECTOR switch
a. Verify the PROCESS SELECTOR switch is set
to match the type of welding process being
conducted.
8. Wrong welding polarity
a. Verify output torch connections.
5-2
June 21, 2012
pro-wave 300gtsw
D. Wandering Arc, Poor Control of Arc Direction
1. Wrong size tungsten electrode, typically larger than
recommended
a. Use proper size electrode for amperage
selected (see Operating Manual 0-2514).
2. Improperly prepared tungsten electrode
a. Prepare tungsten properly.
3. Gas Flow rate too high
a. Reduce flow rate to approximately 12 SCFH.
4. Drafts blowing shielding gas away from tungsten
electrode
a. Shield weld zone from drafts and check
condition of tungsten electrode.
5. Loose gas fitting on regulator or gas line drawing
air into weld zone, causing green/blue discoloration
of workpiece
a. Check and tighten all gas fittings.
6. Water in torch
a. Refer to torch parts list for part(s) requiring
replacement and repair torch as necessary.
E. No High Frequency at Torch When PROCESS
SELECTOR Switch is in HF TIG Position
1. PROCESS SELECTOR switch is not in the HF TIG
position
a. Place switch in HF TIG position.
2. Drafts blowing shielding gas away from tungsten
electrode
a. Shield weld zone from drafts and check
condition of tungsten electrode.
3. Loose gas fitting on regulator or gas line drawing
air into weld zone
a. Check and tighten all gas fittings.
4. Water in torch
a. Refer to torch parts list for part(s) requiring
replacement and repair torch as necessary.
5. Tungsten condition is poor
a. Replace electrode.
a. Reduce stand-off.
7. Faulty Main Circuit Board (PCB1)
a. Refer to the Main Circuit Board section 6.11,
page 6-10.
8. Faulty Current Transformer CT1
a. With no welding arc established, measure for
0VDC between CN1 pins 3 and 4 on PCB1.
Replace CT1 if voltage is greater than 0.1VDC.
9. Faulty High Frequency Unit
a. Refer to section 6.39, page 6-46.
10. Faulty TIG Torch
a. Replace TIG torch.
11. Work lead not connected
a. Verify all connections to torch and workpiece.
F. Lack of High Frequency; Difficulty in Establishing
an Arc
1. Dissipation of high frequency from torch cable or
conductive gas hose
a. Be sure that the torch cable is not near any
grounded metal. Do not use conductive gas
hose.
2. Weld cable leakage
a. Check cables and torch for cracked or
deteriorated insulation or bad connections.
Repair or replace necessary parts.
3. Poor ground connection to power supply
a. Verify ground by trying to strike arc within one
inch (2.54cm) of ground clamp.
G. Wall Fuse/Circuit Breaker Trips When Turned ON
1. Input voltage over rated limit
a. Connect to proper line voltage.
2. Shorted primary inverter components
a. Perform the PCA Input Diode Bridge Test,
section 6.24, page 6-24.
3. Faulty PCB1
a. Replace PCB1. Refer to page 6-13.
6. Electrode too high off metal
June 21, 2012
5-3
pro-wave 300gtsw
H. Green AC POWER Indicator OFF; Fan Not
Operating
1. Input line disconnect switch in OFF position
a. Place input line disconnect switch to ON
position.
2. Power supply MAIN CIRCUIT BREAKER (MCB) in
OFF position
a. Place MCB to ON position.
3. Input line breaker tripped/fuses blown
a. Reset MCB; check primary supply breaker or
fuses and replace if necessary. Refer to letter
G.
4. Power supply MCB faulty
a. Check external connections to the circuit
breaker and continuity. Replace if necessary.
NOTE
Verify that for single-phase operation, the RED
input line is not connected.
5. Open conductor in input power line
a. Check continuity and replace if necessary.
6. Faulty Main Circuit Board (PCB1)
a. Check the Main Circuit Board (PCB1) supply
voltages. Refer to section 6.05, page 6-4.
Replace the Main Circuit Board (PCB1) if any
of the voltages are not present, page 6-13.
7. Faulty auxiliary transformer (T3)
a. Check auxiliary transformer (T3) primary and
secondary windings for shorts or open circuits
and replace if necessary. Refer to section 6.33,
page 6-38.
I. Red WARNING Indicator ON; No Weld Output
1. Input voltage fluctuation causing protection circuits
to activate
a. Monitor input power for spikes and high voltage
conditions. Most power utilities will monitor
and verify line voltage.
2. Easy Link not operating correctly
a. Perform the Easy Link test, section 6.04, page
6-3.
5-4
3. Thermal sensor TH1 open (thermal shutdown)
a. Allow the unit to cool for five minutes before
turning the power supply ON. If the problem
still occurs, perform the PCA Thermal Sensor
(TH1) test, section 6.31, page 6-36.
4. Warning Indicator ON when output energized.
a. Check Q1, Q2 and Q3, Q4 Section 6.26
J. Power Supply Works When in DC output mode,
But Not in AC Output Mode
1. Faulty IGBT modules (Q3/Q4)
a. Check IGBT modules Q3/Q4 for shorted gate
circuit or defective diodes per section 6.26,
page 6-26 and replace if necessary.
K. No Weld or Output; Fan Operating; WARNING
Indicator OFF
1. Faulty Remote Control Device
a. Connect a jumper between pins 2 and 3 of the
REMOTE 8 receptacle for contactor closure.
If amperage and voltage can be adjusted with
front panel controls, repair or replace remote
control device.
2. Faulty Front Panel PCB
a. Refer to section 6.16, page 6-18, Front Panel
Test Point Voltages.
3. Faulty Main Circuit Board (PCB1)
a. Check all connections on the Main Circuit Board
(PCB1). Perform Power Supply Voltage tests,
section 6.05, page 6-4.
b. Check PWM waveforms from front panel PCB
to Main PCB and from Main PCB to the IGBT’s.
L. Low or Maximum Weld Output With No Control
1. Faulty remote control device
a. Connect a jumper between pins 2 and 3 of the
REMOTE 8 receptacle for contactor closure.
If amperage and voltage can be adjusted with
front panel controls, repair or replace remote
control device.
2. Faulty Front Panel Circuit Board (PCB6)
a. Replace PCB6. Refer to section 6.16, page
6-18.
June 21, 2012
pro-wave 300gtsw
M. Limited Weld Output
1. Poor primary input voltage
a. Check primary input voltageis within ±10% of
nominal voltage, i.e. 230VAC ±10%.
2. Faulty Current Transformer (CT1)
a. Check continuity and signals to current
transformer CT. Refer to tests in section 6.05,
page 6-4, and section 6.20, page 6-22
N. Erratic or Improper Weld Output
1. Loose welding cable connections
a. Tighten all welding cable connections.
2. Improper setup
a. Check for proper connection of input power.
b. Perform Front Panel Test Point Voltage
procedure, section 6.17, page 6-19.
3. Faulty Remote Device
a. Check all remote devices and repair or replace
if necessary.
4. Faulty Current Transformer (CT1)
a. Check continuity and signals to current
transformer CT. Refer to section 6.05, page 6-4,
measuring between pins 3 and 4, and section
6.20, page 6-22.
5. Tungsten condition is poor, causing discoloration
of workpiece
a. Replace electrode.
June 21, 2012
O. No Weld Output; Fan Not Operating; WARNING
Indicator OFF
1. Line voltage too low
a. Verify that input voltage matches setting on
rear panel INPUT SELECTOR switch.
b. Verify the INPUT SELECTOR (Easy Link) switch
is functioning properly by performing test in
section 6.05, page 6-3.
2. Loose connection on Main Circuit Board (PCB1)
a. Verify all connections.
3. Faulty Main Circuit Board (PCB1)
a. Verify gate drive signals from Main Circuit
Board by performing Gate Drive Enable Signal
test in section 6.11, page 6-10.
4. Faulty output diodes
a. Perform PCA Output Diode test in section 6.29,
page 6-32.
5. Faulty IGBT Inverter Module(s)
a. If there is weld output in AC output mode but
not DC, perform PCA IGBT Inverter test on Q3,
section 6.26, page 6-26.
P. Unit will not change polarity from AC to DC or DC
to AC.
a. Turn the post-flow control to minimum and
try again. The post-flow circuit must be timed
out before the unit will recognize a change in
status.
5-5
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5-6
June 21, 2012
pro-wave 300gtsw
SECTION 6:
ADVANCED TROUBLESHOOTING
If you are here, all of the troubleshooting suggestions in
Section 5 - 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.
CAUTION
Troubleshooting and repairing this unit is a
process which should be undertaken only by
those familiar with high voltage/high power
electronic equipment.
!
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.
6.01 System-Level Fault Isolation
If none of the suggestions provided in Section 5 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.
!
WARNING
There are extremely dangerous voltage and
power levels present inside this unit. Do not
attempt to diagnose or repair unless you have
had training in power electronics measurement
and troubleshooting techniques.
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.
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 Manual, the
subassembly should be replaced with a new one. The
faulty subassembly should then be returned to Thermal
Dynamics through established procedures.
!
WARNING
Disconnect primary power at the source
before disassembling the power supply.
Frequently review the Important Safety
Precautions (page ii). Be sure the operator
is equipped with proper gloves, clothing, eye
and ear protection. Make sure no part of the
operator’s body comes into contact with the
workpiece or any internal components while
the unit is activated.
June 21, 2012
6-1
pro-wave 300gtsw
6.02 Opening the Enclosure
To open the enclosure:
1. Turn off the MAIN CIRCUIT BREAKER (MCB) on
the rear of the power supply.
2. Wait at least two minutes to allow the input
capacitors to discharge.
3. Remove the two screws on the top and three
screws from bottom of the unit.
4. Remove the two screws from the middle of the
case on both sides of the unit.
5. Pull the plastic enclosure halves open and away
from the internal frame.
6. Remove the inner plastic shield by locating three
(3) white plastic retaining plugs on the sides of
the heatsink by pulling the plastic plug straight out
of the hole in the heatsink. For reassembly, make
a note of the relationship of the grounding screw
and the fourth hole in the plastic shield that did
not have a plastic plug.
Art # A-06110
To reassemble the enclosure:
1. Place the inner plastic shroud over the power
supply so the three holes that will accept the
plastic retaining plugs are in the correct position.
2. Insert the white plastic retaining plugs into the
holes in the heatsink through the matching holes
in the plastic shield.
3. Place the power supply into an enclosure half,
taking care that the front and rear panel edges are
seated properly into the matching grooves inside
the enclosure. Repeat for the second enclosure
half.
4. When the two enclosure halves are fully together,
secure the two halves together with the five screws
and matching nuts.
5. Install the two screws in the middle of each
enclosure half.
Figure 6-1: Screw locations on case.
6.03 Initial Setup Conditions
Before starting any of the system-level troubleshooting
procedures that follow, set the front panel controls of the
unit to the following. If necessary, refer to the Operator’s
Controls section 4, page 4-1, for the location of the various
controls for the unit.
1. Set the PROCESS SELECTOR switch to STICK
mode.
2. Set the OUTPUT MODE to DC OUTPUT position.
3. Set the AMPERAGE control to its minimum (fully
counterclockwise) position.
4. No connection should be made to the remote
receptacle(s).
6-2
June 21, 2012
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6.04 Easy Link Fault Isolation Test (208230/460VAC Model only)
The Easy Link circuit configures the internal power
circuits to accept the input power. This test verifies that
the INPUT SELECT switch is functioning properly, and
the Easy Link circuit can detect both the maximum 460
and the minimum 208-230V input power, and correctly
configure the internal power circuits for proper operation
under both input power conditions.
1. Disconnect primary power at the source. Make
sure the MAIN CIRCUIT BREAKER (MCB) is in
the OFF position.
2. Set the INPUT SELECTOR switch on the rear panel
to the low voltage (208-230VAC) range position.
3. Using an Ohmmeter, at CN13 on the Main Circuit
Board between pins 1 (BLUE) and 3 (GREEN)
should measure a short, and an open between
CN13 pins 2 (GRAY) and 3 (GREEN).
4. Set the INPUT SELECTOR switch to the high
voltage 460VAC range.
5. Using an Ohmmeter, at CN13 on the Main Circuit
Board between pins 1 (BLUE) and 3 (GREEN)
should measure an open, and a short between
CN13 pins 2 (GRAY) and 3 (GREEN).
June 21, 2012
6-3
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6.05 Power Supply Voltage Test
Refer to figure 6-2. For location of ribbon cables.
1. Connect the power supply to a source of either
208-230VAC or 460VAC.
2. Set the Input Select switch to match the input
voltage.
3. Apply power to the unit and place the Main
Circuit Breaker on the power supply to the
ON position.
4. The voltage at CN-7 as listed in Step 9. If any
voltages are incorrect then proceed to Step 6. If
all readings are correct the proceed to Step 12.
5. Turn the unit OFF.
6. At the Front Panel Circuit Board, disconnect the
ribbon cable at connector CN7. Pull up on the
retaining bar to release the ribbon cable from the
connector body.
7. Reapply power to the unit.
8. On the ribbon cable, measure for the following
voltages between pins:
Pins 2 (-) and 1 (+)
+12VDC
Pins 2 (-) and 5 (+)
-12VDC
Pins 2 (-) and 3 (+)
+5VDC
12.On the Main Circuit Board (PCB1), measure the
voltages between the following points:
CN1: Hall Effect
Pin 1 and pin 4
+12VDC
Pin 2 and pin 4
-12VDC
Pin 3 and pin 4
0V to +12VDC; varies
with AMPERAGE output under load. 50A/V
CN2:
Pin 1 and pin 2
+24VDC
CN21:
Pin 1 and pin 2
+12VDC
Pin 3 and pin 2
+5VDC
Pin 4 and pin 2
+5VDC
Pin 5 and pin 2
-12VDC
CN22:
Pin 13 and pin 4
+12VDC
CN23:
Pin 3 and pin 2
+12VDC
If any of these voltages are not present or are below a
10% tolerance, replace the Main Circuit Board (PCB1).
Pins 2 (-) and 4 (+)
+5VDC
If voltages are correct with CN-7 disconnected but not
with it connected, then the front panel PCB is defective.
9. Turn the unit OFF.
10.Reconnect the ribbon cable to connector CN7 on
the Front Panel Circuit Board.
11.Reapply power to the unit.
6-4
June 21, 2012
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Art # A-06111
CN7
CN13
CN9 (PCB6)
CN8 (PCB6)
CN7 (PCB6)
CN10
CN2
CN1
CN5
CN4
Figure 6-2: Power supply voltage connector locations.
June 21, 2012
6-5
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6.06 Output Load Test
6.07 LIFT START Circuit Test
This test verifies that the output controls are functioning
properly. A clamp-type amperage meter or equivalent
meter capable of reading approximately 300A full-scale
will be needed for this test if a digital meter is not present
in the unit.
This test verifies proper operation of the LIFT START
circuit. A clamp-type amperage meter or equivalent meter
capable of reading approximately 20A full-scale, and a
digital voltmeter capable of indicating 20VDC full-scale
will be needed for this test.
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the
initial setup condition as described at the
beginning of this section, (page 6-2).
1. Place the AMPERAGE control in its minimum (fully
counterclockwise) position.
2. Connect the POSITIVE (+) and NEGATIVE (-)
OUTPUT TERMINALS to a piece of metal,
separated by approximately three feet (one meter).
3. Connect the clamp-on amperage meter or
equivalent to the output loop between the
POSITIVE (+) and NEGATIVE (-) OUTPUT
TERMINALS.
4. Place the power supply Main Circuit Breaker
on the rear of the unit to the ON position. After
five (5) seconds, the amperage meter will indicate
approximately 5 Amps.
5. Slowly turn the AMPERAGE control clockwise
to the maximum of the power supply, then
counterclockwise, back to 5 Amps as the control
returns to its minimum position. The amperage
meter should indicate a continuous range of
Amperes between the 5 Amps minimum and the
300 Amps maximum of the power supply.
6. Place the power supply MAIN CIRCUIT BREAKER
on the rear of the unit to the OFF position.
7. Remove the dead short between the OUTPUT
TERMINALS.
This completes the output load test. If the results of any
step differ from those above, then refer to the various test
procedures in this section to isolate the problem. If the
results are as expected, then the power supply is giving
the proper output.
6-6
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the
initial setup condition previously described,
(page 6-2).
1. Make sure the MAIN CIRCUIT BREAKER (MCB)
is turned OFF.
2. Set the PROCESS SELECTOR switch to LIFT
START TIG mode.
3. Connect a digital voltmeter between the POSITIVE
(+) and NEGATIVE (-) OUTPUT TERMINALS of the
unit. Set the meter to indicate Volts DC.
4. Connect a jumper between pins 2 and 3 of the
REMOTE 8 connector, or if a remote contactor is
connected, close it. (Ensure that the remote device
is not faulty.)
5. Place the power supply MCB on the rear of the
unit to the ON position. After five (5) seconds, the
voltmeter will indicate approximately 6 volts open
circuit.
6. Turn off the power supply MCB.
7. Connect the POSITIVE (+) and NEGATIVE (-)
OUTPUT TERMINALS to a piece of metal,
separated by approximately three feet (one meter).
8. Connect a jumper between pins 2 and 3 of the
REMOTE 8 connector, or if a remote contactor is
connected, close it.
9. Place the power supply MCB on the rear of the
unit to the ON position. After five (5) seconds, the
voltmeter will indicate approximately 1 volt.
10. Turn off the power supply MCB.
11. Connect the clamp on the amperage meter
or equivalent to the output loop between the
POSITIVE (+) and NEGATIVE (-) OUTPUT
TERMINALS.
June 21, 2012
pro-wave 300gtsw
12. Place the power supply MCB on the rear of the
unit to the ON position. After five (5) seconds,
the amperage meter will indicate approximately
17Amps.
13. Turn off the power supply MCB.
14.Remove the loop connected between the POSITIVE
(+) and NEGATIVE (-) OUTPUT terminals.
This completes the LIFT START circuit test. If the results
of any step differ from those above, the Main Circuit Board
should be replaced.
6.08 High Frequency (HF) START Circuit
Test
This test verifies the operation of the HF START circuit.
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the
initial setup condition previously described
(page 6-2).
1. Make sure the MAIN CIRCUIT BREAKER (MCB)
is turned OFF.
2. Set the PROCESS SELECTOR switch to HF START
mode.
3. Connect TIG torch and shielding gas.
4. Connect a remote control or jumper between pins
2 and 3 of the REMOTE 8 receptacle for contactor
closure. If a remote switch is installed, close it.
5. Place the power supply MCB on the rear of the
unit to the ON position. After PRE-FLOW of 150
ms, the HF START circuit will turn ON. If the torch
is brought to within 3/8" to 1/2" of the work, lead
arc transfer will occur. After arc transfer, the HF
START circuit will turn OFF.
6. Remove the jumper, or open the remote control
switch if installed. The arc turns OFF.
7. Turn off the power supply MCB.
This completes the HF START circuit test. If the results
of any step differ from those above, perform the HF Unit
test, further in Advanced Troubleshooting. If the HF Unit
is good, replace the Main Circuit Board.
June 21, 2012
6-7
pro-wave 300gtsw
6.09 Subsystem Test Preparation
The following initial conditions must be met prior to
starting any of the procedures in the subsystem tests.
1. Set the PROCESS SELECTOR switch to STICK
mode.
2. Set the OUTPUT MODE to DC OUTPUT position.
3. Set the AMPERAGE control to its minimum (fully
counterclockwise) position.
4. No connection should be made to the remote
receptacle(s).
5. Connect the appropriate input voltage. (Check the
data tag 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.
6. Close primary power source wall disconnect
switch or circuit breaker.
7. Place power supply MAIN CIRCUIT BREAKER
(MCB) on rear of unit in the ON position.
!
6.10 Main Circuit Breaker (MCB)
Replacement Procedure
!
WARNING
Disconnect primary power at the source before
performing this procedure.
Refer to figure 6-3 on opposite page.
To remove the Main Circuit Breaker:
1. Remove the four screws from the rear panel that
secure the Main Circuit Breaker assembly to
the rear panel.
2. Remove the input power leads and output power
leads marked R and S in figures 6-4 and 6-5 from
the MCB terminals. Remove the MCB from the
metal shield. If the metal shield must be removed,
note that it is connected to a GREEN ground lead.
To replace the MCB, reverse the above steps, replacing the
input and output leads in the same matching positions.
Refer to figure 6-4 or 6-5.
WARNING
Dangerous voltage and power levels
are present inside this unit. Be sure
the operator is equipped with proper gloves,
clothing, eye and ear protection. Make sure no
part of the operator’s body comes into contact
with the workpiece or any internal components
while the unit is activated.
This section provides specific procedures for verifying
the operation and replacement of each subsystem within
the power supply. Before undertaking any of these
procedures, eliminate the obvious first ‑ visually inspect
the suspect subsystem for physical damage, overheating,
and loose connections.
6-8
June 21, 2012
pro-wave 300gtsw
Retaining Screws
Art # A-06112
Figure 6-3: Main Circuit Breaker
White
S
Black
R
Art # A-06113
Figure 6-4: Main Circuit Breaker connections - single phase
Art # A-06114
R
Black
S
White
T
Red
Figure 6-5: Main Circuit Breaker connection - three phase
June 21, 2012
6-9
pro-wave 300gtsw
6.11 Main PCB1 Gate Drive Enable
Signal Test
The gate drive signals are 21.3kHz square wave signals,
with an OFF level of -4VDC for 26µs, and the ON level of
+11VDC for 21µs. There is a 2.5µs dead time before and
after the ON time of each channel before the other goes
through its OFF/ON transition. Refer to figure 6-7.
1. Apply power to the unit and turn the Main
Circuit Breaker (MCB) ON.
2. Using an oscilloscope at the CN8 connector on the
Main Circuit Board (PCB1), measure the voltage
between Q1 signal pairs:
Pin 1 and 2
Pin 4 and 5
3. Using an oscilloscope at the CN9 connector on the
Main Circuit Board (PCB1), measure the voltage
between Q2 signal pairs:
Pin 1 and 2
Pin 4 and 5
4. Using a voltmeter, measure the voltage between
signal pins 1 and 2 and pins 4 and 5 at connector
CN8. The voltage between each pair of pins should
be +5VDC. Switch the PROCESS SELECTOR
switch to the TIG LIFT START position. The voltage
between both pair of pins should drop to -4VDC.
5. Return the PROCESS SELECTOR switch to the
STICK position.
6. Using a voltmeter, measure the voltage between
signal pins 1 and 2 and pins 4 and 5 at connector
CN9. The voltage between each pair of pins should
be +5VDC. Switch the PROCESS SELECTOR
switch to the TIG LIFT START position. The voltage
between both pair of pins should drop to -4VDC.
If the results of any of these tests are incorrect, replace
the Main Circuit Board (PCB1).
6-10
June 21, 2012
pro-wave 300gtsw
CN16
Art # A-06115
CN8
CN9
CN24
Figure 6-6: Main Circuit Board
Art # A-06116
CH1
+11.0V
10.0µs/div.
-4.0V
CH2
+11.0V
-4.0V
Figure 6-7: Gate drive enable waveform
June 21, 2012
6-11
pro-wave 300gtsw
6.12 Lift Start Test
1. Disconnect primary power at the source. Make
sure the MAIN CIRCUIT BREAKER is in the OFF
position.
2. Measure the continuity between the front panel
NEGATIVE (-) OUTPUT TERMINAL to CN5-3 on
the Main Circuit Board (PCB1), and from the front
panel POSITIVE (+) OUTPUT TERMINAL to CN5-1
on the Main Circuit Board (PCB1). Both should be
zero Ohms. Replace wire if continuity is broken.
6.14 High Frequency Test
1. Place the Process Selector switch in the
stick position.
2. Jumper pins 1 and 5 on the CN7 plug. Apply power
to the unit.
3. If the high frequency buzz is heard coming from
the HF Unit, the Main Circuit Board (PCB1) should
be replaced. If no sound is heard coming from the
HF Unit, the HF Unit should be replaced.
3. Reapply power to the unit by turning the MAIN
CIRCUIT BREAKER to the ON position.
4. Disconnect connectors CN8 and CN9 on the
Main Circuit Board (PCB1). Measure the voltage
between CN22-5 and CN22-4 for 0VDC. Install a
jumper between the POSITIVE (+) and NEGATIVE
(-) output terminals on the front panel. The
voltage between CN22-5 and CN22-4 should
increase to +5VDC.
If the voltage does not increase in step 4 above, replace
the Main Circuit Board (PCB1).
6.13 Gas Control Test
Disconnect the remote control device from the REMOTE
8 receptacle.
1. Measure for +24VDC between pins 3 and 4 on
CN2 on the Main Circuit Board (PCB1). Replace
the Main Circuit Board (PCB1) if the voltage is low
or not present.
2. Measure for +24VDC between CN7-1 and CN7-2.
If no voltage is present, check and replace wires
between CN7-1 (PCB4) and CN4-1 (PCB2) or
between CN7-2 (PCB4) and CN4-2 (PCB2).
With a remote control device connected to the REMOTE
8 receptacle and contact closure between pins 2 and
3, measure the voltage between the gas solenoid valve
terminals. If the voltage is 24VDC and the solenoid does
not operate, replace the solenoid valve. If the voltage is
low or not present, replace the Main Circuit Board (PCB1).
There is a 150ms delay built into the circuit before the
voltage will be there.
6-12
June 21, 2012
pro-wave 300gtsw
6.15 Main Circuit Board (PCB1)
Replacement Procedure
To remove the Main Circuit Board:
1. Locate connectors CN7, CN8 and CN9 at the top
edge of the Front Panel Circuit Board.
2. Gently pull up on the retainer bar on each side of
each connector to release the ribbon cable in the
connectors.
3. Remove the ribbon cable by gently pulling straight
up on the ribbon cable.
Art # A-06111
CN7
CN13
CN9 (PCB6)
CN8 (PCB6)
CN7 (PCB6)
CN10
CN2
CN1
CN5
CN4
Figure 6-8: Power supply voltage connector locations.
June 21, 2012
6-13
pro-wave 300gtsw
4. On the Main Circuit Board, remove the screw from TB12 and remove the GREEN ground wire lug from the
terminal (figure 6-9).
Art # A-06117
TB12
Figure 6-9: Location of TB12 on main circuit board
5. Remove all connectors from the left side and front of the Main Circuit Board — CN1 , CN2 , CN4, CN5 , CN7,
CN10, CN13 and CN26 (not shown).
Art # A-06111
CN7
CN13
CN9 (PCB6)
CN8 (PCB6)
CN7 (PCB6)
CN10
CN2
CN1
CN5
CN4
Figure 6-10: Connectors to be removed from left side and front of main circuit board
6. Cut any cable ties securing wire harnesses to TB1 or TB2 leads.
7. Move the wiring harness aside, clear of the Main Circuit Board.
6-14
June 21, 2012
pro-wave 300gtsw
TB3
TB1
TB4
Art # A-06118
TB5
TB2
TB6
Figure 6-11: Location of TB1 through TB6 on main circuit board
8. Remove the screws securing the Main Circuit Breaker to the rear panel.
9. Remove connectors CN6, CN8, CN9, and CN14 from the rear of the Main Circuit Board.
10. Remove screws, associated hardware and wire lugs from TB1 through TB6. Straighten the lugged wires that
were removed from TB1 and TB2 so they stand vertically. This will allow the wires to pass through the current
sensors when the Main Circuit Board is lifted away from the chassis in a later step.
CN16
Art # A-06115
CN8
CN9
CN24
Figure 6-12: Connectors to be removed from rear end of main circuit board
June 21, 2012
6-15
pro-wave 300gtsw
11.Cut the cable tie securing the CN18-to-CN24 ORANGE/GRAY wire pair to the BLACK lead attached to TB1.
12.Remove the four (4) mounting screws from the corners of the Main Circuit Board.
Art # A-06119
Figure 6-13: Main circuit board retaining screws
13.Lift the Main Circuit Board straight up, passing the lugged wires removed from TB1 and TB2 through the current sensors.
14.As you remove the Main Circuit Board, pass connectors CN8 and CN9 through the hole in the board.
15.Continue to pull the Main Circuit Board straight up and away from the chassis.
To replace the Main Circuit Board:
1. Hold the Main Circuit Board over the chassis, oriented so the three ribbon cables are toward the front panel
of the power supply.
2. As you lower the Main Circuit Board onto the chassis, pass the lugged wires that will attach to TB1 and TB2
through the current sensors, and connectors CN8 and CN9 through the hole in the board.
3. As you lower the Main Circuit Board onto the chassis, replace the connectors on the rear end of the board at
locations CN5, CN8, CN9, and CN14.
4. Continue lowering the board so the vertical bus bars pass through the slots in the boards, and line up with
TB3/4 and TB5/6. The board is properly seated when the holes in the vertical bus bar and the terminals TB1-6
line up, the board is seated on the black plastic spacers in the corners of the board, and there is no interference
with wire harnesses.
5. Carefully pull up through the current sensors the excess lead length of the two lugged wires that will connect
to TB1 and TB2.
6. Replace the hardware to secure the lugged wires to TB1 through TB6. The lugged wires that connect to TB1
and TB2 must be bent over in a loop.
7. Insert the screws and washers into the four corners of the Main Circuit Board. Do not tighten until all four
screws are started in their holes.
8. Replace all connectors on the Main Circuit Board and the Main Circuit Breaker on the rear panel.
6-16
June 21, 2012
pro-wave 300gtsw
TB3
TB1
TB4
Art # A-06118
TB5
TB2
TB6
Figure 6-14: TB1 through TB6 reconnections
June 21, 2012
6-17
pro-wave 300gtsw
6.16 Gaining Access to Front Panel Circuit Board (PCB6) WK-3988
To gain access to the test points on the Front Panel Circuit Board, it is necessary to remove the front panel of the
power supply unit. To accomplish this, do the following:
1. Locate and remove the six screws securing the Front Panel to the front of the power supply. Allow the front
panel to drop down to allow free access to the test points on the Front Panel Circuit Board (PCB6).
Art # A-06120
Figure 6-15: Front panel retaining screws
6-18
June 21, 2012
pro-wave 300gtsw
6.17 Front Panel PCB6 (WK-3988) Test Point Voltages
The test point voltages on the Front Panel Circuit Board should be verified as follows.
1. Set up the contactor closure circuit by installing a jumper between pins 2 and 3 of the REMOTE 8 receptacle;
2. Measure the voltage between test points TP8 and TP0 to be 12VDC.
3. Measure the voltage between test points TP4 and TP0 to be 5VDC.
4. Measure the voltage between test points TP5 and TP0 to be 5VDC.
5. Set up the contactor closure circuit by removing the jumper from the REMOTE 8 receptacle;
6. Measure the voltage between test points TP8 and TP0 to be 3.5VDC.
7. Measure the voltage between test points TP4 and TP0 to be 0VDC.
8. Measure the voltage between test points TP5 and TP0 to be 0VDC.
9. Measure between TP0 and the test points below to verify the voltages given:
TP0 0V Circuit Common
TP1
+5VDC
Regulated voltage of control circuit
TP2
+12VDC
Regulated voltage of control circuit
TP3
-12VDC
Regulated voltage of control circuit
TP6
+4VDC
TP0
Regulated voltage of control circuit
TP1
TP2
TP3
TP6
TP7
TP8
TP9
TP4
TP5
Art # A-06121
Figure 6-16: Front panel voltage test points
June 21, 2012
6-19
pro-wave 300gtsw
6.18 Input Power Selector Switch Test
1. Using an ohmmeter check continuity from CN13 Pin1 and Pin 3 with the input voltage selector switch in the
208/230 volt position.
2. Using an ohmmeter check continuity from CN13 Pin 2 and Pin 3 with the input voltage selector switch in the
460 volt position.
3. If any of the tests fail replace easylink switch on rear panel.
6.19 Front Panel Circuit Board (PCB6) Replacement Procedure
Refer to Figures 6-17 and 6-18.
To remove the Front Panel Circuit Board:
1. Remove the Main Circuit Board, referring to page 6-13.
2. Locate and remove five (5) screws from the Front Panel Circuit Board/Shield securing them to the inside of
the front panel of the unit.
Art # A-06122
Figure 6-17: Front panel circuit board retaining screws
3. Pull the Front Panel Circuit Board back toward the rear of the power supply and then up to free the controls
from their respective holes in the front panel. Fold the Front Panel Circuit Board down to expose the component
side of the board.
4. Remove all connectors from the Front Panel Circuit Board.
6-20
June 21, 2012
pro-wave 300gtsw
CN6
Art # A-06123
CN4
CN8
CN3
CN7
CN5
CN9
Figure 6-18: Component side of front panel circuit board
5. Remove the Front Panel Circuit Board from the power supply.
To replace the Front Panel Circuit Board, reverse the removal steps.
June 21, 2012
6-21
pro-wave 300gtsw
6.20 Current Transformer Test Procedure
1. Disconnect connector CN1 from the Main Circuit
Board (PCB1).
2. With an Ohmmeter set the Rx10 scale, measure
between the pins on the CN1 plug as follows:
Pin 4 (Yellow) and Pin 1 (Brown) > 120KOhms
Pin 4 (Yellow) and Pin 2 (Red) @ 20KOhms
6.21 Current Transformer Replacement
Procedure
Refer to figure 6-19.
To remove the Current Transformer (CT):
1. Remove the Output Inductor Assembly per section
6.37on page 6-42.
2. Remove hardware from Output Bus Bar/IGBT
Inverter (Q3/Q4) Bus Bar junction.
3. Remove the bolt and associated hardware from the
inside of the POSITIVE (+) OUTPUT TERMINAL.
4. Remove the connector with the RED/YELLOW/
ORANGE/BROWN twisted wiring harness from
the CT.
5. Remove the Output Bus Bar/CT.
6. At the end removed from the POSITIVE (+)
OUTPUT TERMINAL, bend the Output Bus Bar
sufficiently to allow the CT to slide off the end of
the bus bar.
To replace the Current Transformer:
1. Slide the new CT onto the Output Bus Bar, in the
same orientation as the one removed.
2. Return the end of the Output Bus Bar to a right
angle (90° bend).
The next step makes it much easier to complete the
replacement due to interference with the Coupling Coil.
3. On IGBT Inverter Q3/Q4, remove the two screws
securing the bus bar that was attached to the
Output Bus Bar/CT Assembly.
4. Replace the hardware to joint the bus bar removed
from Q3/Q4 and the Output Bus Bar/CT Assembly.
Finger tighten.
5. Replace the bus bar onto Q3/Q4. Securing the
two screws through the bus bar into Q3/Q4 may
require using a screwdriver at an angle, or a rightangle screwdriver if available.
6. Reverse the remaining removal steps.
Bolt, Positive (+) Output
Current Transformer
Output Bus Bar
Art # A-06124
Junction Hardware
IGBT Inverter Q3
Figure 6-19: Current transformer and output bus bar
6-22
June 21, 2012
pro-wave 300gtsw
6.22 Power Control Assembly
The Power Control Assembly (PCA) consists of input diode (D1), IGBT Inverters (Q1-Q4), output diodes (D2-D5), heat
sinks, main and auxiliary transformers, output inductors and high frequency coupling coil. Perform a careful inspection
of all components of the PCA first. Failure may be identified by burned insulation or other physical symptoms. If there
are no signs of physical damage, conduct the procedure that follows.
Auxiliary Transformer (T3)
IGBT Inverter Q2
TB2 Primary Lead
Input Diode Bridge (D1)
IGBT Inverter Q3
Driver Board (PCB8)
TB1 Primary Lead
Art # A-06125
IGBT Inverter Q1
Figure 6-20: Top of power control assembly (main circuit board removed)
6.23 Power Control Assembly (PCA) Test Procedures
!
WARNING
Disconnect primary power at the source before performing these procedures.
This procedure requires a digital Volt/Ohm meter that has a diode test scale. This procedure will give a general indication
of the condition of the PCA components; a more conclusive test requires specialized equipment. Therefore, even if
the results of these procedures check out as good, one or more components may still be faulty. If there is any doubt,
replace the faulty PCA component. It is assumed that you are familiar with diode testing basics. If not, please refer
to the Appendix.
June 21, 2012
6-23
pro-wave 300gtsw
6.24 PCA Input Diode Bridge (D1) Test
Procedure
6.25 PCA Input Diode Bridge (D1)
Replacement Procedure
Refer to figure 6-21
Refer to figure 6-21.
1. Select the Ohms scale on the digital meter.
2. Check CN14 on Main Circuit Board between pins
1 and 2. The resistance should read 44 Ohms.
3. Select the diode test setting on the digital meter.
4. Check the diodes between the following:
Main Circuit Breaker (MCB) wire R, and TB6
on the Main Circuit Board;
MCB wire S, and TB6 on the Main Circuit Board;
MCB wire T, and TB6 on the Main Circuit Board;
MCB wire R, and CN14 pin 4 on the Main Circuit
Board;
MCB wire S, and CN14 pin 4 on the Main Circuit
Board;
MCB wire T, and CN14 pin 4 on the Main Circuit
Board
To remove the Input Diode Bridge (D1), do the
following:
1. Remove the Main Circuit Board (PCB1) per page
6-13.
2. Remove the input power and sensing lugged wires
from the input terminals R and two RED, S and
two White, RED input line and BLACK.
3. Remove screws from all terminals with lugged
wires, and the corner bus bar.
4. Remove the two screws that secure the Input
Diode Bridge to the main chassis frame.
5. Slide the Bridge out from under the bus bar.
To replace the Input Diode Bridge (D1), do the
following:
1. Spread a light coating of thermal compound on
the bottom surface of the Bridge.
2. Slide the Bridge under the bus bar.
3. Reverse the remaining removal steps above. When
replacing the screws that secure the Bridge to the
chassis, make sure both screws are started before
tightening them.
6-24
June 21, 2012
pro-wave 300gtsw
Red Input Line
Art # A-06126
T
S
C1
R
R2 (Junction)
Thyristor Gate
Thyristor Cathode (+)
Diode Anode (–)
Figure 6-21: Power control assembly - input diode bridge (D1)
June 21, 2012
6-25
pro-wave 300gtsw
6.26 PCA IGBT Inverter Test Procedure
Refer to figures 6-22 and 6-23.
The IGBT Inverter sections contain four IGBT transistor/diode assemblies, Q1, Q2, Q3 and Q4. These can be tested
with the power OFF to verify their proper function.
Auxiliary Transformer (T3)
IGBT Inverter Q3
Driver Board (PCB8)
IGBT Inverter Q2
TB2 Primary Lead
Input Diode Bridge (D1)
TB1 Primary Lead
Art # A-06125
IGBT Inverter Q1
Figure 6-22: Top of power control assembly
Art # A-06127
HF Unit
Coupling Coil Leads
IGBT's
Inverter Q3/Q4
Figure 6-23: Power control assembly - IGBT inverters
6-26
June 21, 2012
pro-wave 300gtsw
Power OFF Test Procedure
1. Set the diode test scale on the digital meter.
Pin 1
Pin 2
Pin 4
Pin 5
Art # A-06128
2. For Q1, check the diodes between:
TB3 and TB1
TB4 and TB1
3. For Q2, check the diodes between:
TB5 and TB2
TB6 and TB2
White
Red (CN8, PCB1)
Orange (CN9, PCB1)
Blue (CN1, PCB8)
Black
White
A.To check the gate drive resistances for Q1 and
Q2 unplug CN8 and CN9 from the MAIN PCB.
Should measure 2.18kW.
CN8/CN9 plug PIN 1 to PIN 2
CN8/CN9 plug PIN 4 to PIN 5
4. For Q3/Q4, check the diodes between:
A quick check can be made across the POSITIVE
and NEGATIVE output terminals.
Set the meter to ohms and check the resistance
across the weld terminals and the reading should
be 2.5kW.
5. For Q3/Q4 check the diodes between;
Brown wire on the filter choke to the POSITIVE (+)
OUTPUT TERMINAL.
Gray wire on the filter choke to the POSITIVE (+)
OUTPUT TERMINAL.
6. If a component on the Q3,Q4 gate board (PCB9)
is damaged thenthe Driver PCB (PCB8) should
be checked.
Figure 6-24: Plug orientation for IGBT inverter power
OFF test
For Q3/Q4, refer to figure 6-25, then:
7. With the digital meter on the diode test scale,
measure between bus bars A-B and B-C.
8. On PCB1 mounted to Q3/Q4 there are 4 sets of
points E1G1, E2G2, E3G3, E4G4. Check each of
these with a meter on diode scale. A short is a bad
indication. If a short is detected remove the bus
bars and test individually to determine which is
bad Q3 or Q4.
C
A.Disconnect CN2 from PCB8.
B.Check the gate resistance on PCB9 between E1
to G1 and E2 to G2. Reading should be 1.1kW.
C.Check gate drive on PCB8 at CN2 between
CN2-1 to CN2-2 and CN2-4 to CN2-5. Reading
should be 1kW.
A
B
Art # A-06129
Figure 6-25: Q3/Q4 IGBT inverter measurement points
June 21, 2012
6-27
pro-wave 300gtsw
6.27 PCA IGBT Inverters Q1 and Q2
Replacement Procedure
Refer to figure 6-26.
4. Remove the two (2) screws securing the Inverter
to the main chassis frame.
To replace either Inverter (Q1 or Q2), do the
following:
To remove either of the IGBT Inverters Q1 or Q2, do
the following:
1. Spread a light coating of thermal compound on
the bottom surface of the Inverter.
Q1 is located on the right side of the unit Q2 on the left
as you face the front panel of the power supply.
2. Slide the Inverter in place under the bus bar
coming from the Input Diode Bridge.
1. Remove the Main Circuit Board per page 29.
3. Reverse the remaining removal steps above. When
replacing the screws that secure the Inverter to
the chassis, make sure both screws are started
before tightening them.
2. Remove the T1A or T2A heavy lugged lead,
depending on which Inverter you are removing.
Replace this screw if the printed circuit board is
to remain with the IGBT Inverter being removed
(PCB4 on Q1 or PCB5 on Q2).
3. Remove the screw from the terminal with the
double bus bar. Again, replace this screw if the
printed circuit board is to remain with the Inverter
being removed (PCB4 on Q1 or PCB5 on Q2). Be
sure the screw goes through only the hole in the
bus bar connected to the printed circuit board
(PCB4 or PCB5).
Auxiliary Transformer (T3)
IGBT Inverter Q3
Driver Board (PCB8)
IGBT Inverter Q2
TB2 Primary Lead
Input Diode Bridge (D1)
TB1 Primary Lead
IGBT Inverter Q1
Art # A-06125
Figure 6-26: IGBT Inverters Q1 and Q2
6-28
June 21, 2012
pro-wave 300gtsw
THIS PAGE INTENTIONALLY LEFT BLANK
June 21, 2012
6-29
pro-wave 300gtsw
6.28 PCA IGBT Inverter Q3/Q4
Replacement Procedure
To replace either Inverter Q3/Q4, do the following:
1. Spread a light coating of thermal compound on
the bottom surface of the Inverters.
Refer to figure 6-27.
To remove IGBT Inverters Q3/Q4, do the following.
1. Remove the Output Inductor Assembly refer to
the section further in Advanced Troubleshooting.
2. Remove the Output Bus Bar/CT Assembly by
removing the bolt inside the POSITIVE (+)
OUTPUT TERMINAL and the two screws on the
terminals of Q3/Q4 holding the Output Bus Bar/
IGBT Inverter bus bar to IGBT Inverter.
2. Reverse the remaining removal steps above. When
replacing the screws that secure the Inverter to the
chassis, make sure all screws are started before
tightening them. It may be helpful to connect CN2
and CN5 before seating the board fully onto the
chassis.
3. Disconnect the lugged wires at terminals AC1 and
AC2 on the HF Unit.
4. Disconnect connector CN1 on IGBT Inverter Q3/
Q4.
5. Remove the four (4) screws securing Q3/Q4 to
the chassis.
Bolt, Positive (+) Output
Current Transformer
Output Bus Bar
Art # A-06124
Junction Hardware
IGBT Inverter Q3
Figure 6-27: IGBT Inverter Q3
6-30
June 21, 2012
pro-wave 300gtsw
Art # A-06127
HF Unit
Coupling Coil Leads
IGBT's
Inverter Q3/Q4
Figure 6-28: IGBT Inverter Q3/Q4
June 21, 2012
6-31
pro-wave 300gtsw
6.29 PCA Output Diodes (D2-D5) Test Procedure
!
WARNING
Disconnect primary power at the source before performing this procedure.
Refer to figure 6-29 below.
The output section contains four diodes, D2 through D5. Check each diode between its positive (A) and negative
(K) terminals. Refer to figure 6-29. Note that these measurements can be accomplished without removing the main
transformers. (The transformers were removed in figure 6-29 to aid in identifying the diodes.)
To check for shorted diodes without dismantling the power supply, take a voltmeter set on the diode scale from the
GRAY wire and the BROWN on the FCH to the NEGATIVE weld terminal. A good reading will be .2V.
D4-A
D4
Art # A-06130
D2
D2-A/D4-K
D5-A/D3-A
D3-K
D2-K
D5 D5-K
D3
Figure 6-29: Power control assembly - output diodes (D2-D5) (Main transformers removed for clarity)
6-32
June 21, 2012
pro-wave 300gtsw
6.30 PCA Output Diodes (D2 - D5) Replacement Procedure
To gain access to the Output Diodes:
The Main Transformers T1 and T2 and their metal mounting brackets must be removed from the chassis.
1. Remove the Output Inductor Assembly refer to section 6.37 page 6-42.
2. Remove hardware at T1/T2 secondary lead junctions “C”, “D”, and “E”. (Figure 6-30)
White Wire
(to CN7-3)
Blue Wire
(to HF Unit AC1)
T1/T2 Secondary Lead
Junction "E"
T1/T2 Secondary Lead
Junction "C"
Art # A-06131
T1/T2 Secondary Lead
Junction "D" (center tap leads
bent upward; two black lugged
leads to CN7-1 and CN5-3)
Figure 6-30: Output inductor - T1/T2 lead junctions
June 21, 2012
6-33
pro-wave 300gtsw
8. Remove the two (2) screws securing the output
diode to the chassis.
3. Remove hardware at Coupling Coil/Bus Bar
junction. Remove bus bar. (Figure 6-31)
4. Remove the compression nut from the gas inlet
fitting on rear panel and move gas line away from
Main Transformers. (Figure 6-31)
To replace the Output Diodes (D2 -D5), do the
following:
5. Remove the two (2) screws that secure Main
Transformer T1 and T2 to their metal mounting
brackets. Allow the transformers to rest on the
work surface. (Figure 6-32)
6. Remove the two metal mounting brackets to
expose the output diodes.
1. Spread a light coating of thermal compound on
the bottom surface of the Diode Assembly.
2. Reverse the remaining removal steps above. When
replacing the screws that secure the Diode(s) to
the chassis, make sure both screws are started
before tightening them.
7. Remove the bus bar(s) and filter network(s)
attached to the terminals of the output diode(s) to
be replaced. Output Diodes shown in Figure 6-33.
Art # A-06132
Inductor /Coupling Coil Junction
Brown Wire
X
Gray Wire
Y
Cut cable tie
Gas Inlet
Z
W
Black Lugged Wires
Figure 6-31: Preparation - Main transformer lead junctions
6-34
June 21, 2012
pro-wave 300gtsw
T1/T2 Mounting Brackets
IGBT Inverter Q3
D2
Art # A-06133
D5
D3
D4
Figure 6-32: Output diodes and T1/T2 mounting brackets
D4
Art # A-06134
D2
D5
D3
Figure 6-33: Output diodes D2-D5
June 21, 2012
6-35
pro-wave 300gtsw
6.31 PCA Thermal Sensor (TH1) Test Procedure
!
WARNING
Disconnect primary power at the source before performing this procedure.
Refer to figure 6-34.
1. Select the Ohms scale on the digital meter.
2. Disconnect the connector at CN10 on the Main Circuit Board (PCB1).
3. The resistance of a good sensor measured between pins 1 and 2 on the connector should be in the 10KOhm
to 21.6KOhm range, with the reading decreasing as the temperature of the power supply increases. A shorted
reading indicates a bad sensor, and it should be replaced.
Art # A-06111
CN7
CN13
CN9 (PCB6)
CN8 (PCB6)
CN7 (PCB6)
CN10
CN2
CN1
CN5
CN4
Figure 6-34: Thermal sensor connector on main circuit board (PCB1)
6-36
June 21, 2012
pro-wave 300gtsw
6.32 Thermal Sensor (TH1) Replacement
Refer to figure 6-35.
To remove the Thermal Sensor (TH1), do the
following:
4. Cut cable ties as appropriate to free the BLACK/
BLACK wire harness that connects the Thermal
Sensor to connector CN10 plug.
To replace the Thermal Sensor (TH1), do the
following:
1. Remove the Main Circuit Board per section 6.15
page 6-13.
1. Spread a light coating of thermal compound on
the bottom surface of the Thermal Sensor.
2. Locate the sensor mounted on the main chassis,
between the circuit boards (PCB4 and PCB5) that
connect to IGBT Inverters Q1 and Q2.
2. Reverse the removal steps above.
3. Using a magnetic or split screwdriver, remove
the screw that secures the sensor to the chassis
frame.
PCB4
IGBT Inverter Q2
Input Diode
Bridge (D1)
Retaining Screw
PCB5
Art # A-06135
Thermal Sensor (TH1)
Figure 6-35: Thermal sensor TH1
June 21, 2012
6-37
pro-wave 300gtsw
6.33 Auxiliary Transformer (T3) Test
Procedure
The auxiliary transformer can be checked with either a
power OFF or power ON test. Do the power OFF test first.
Locate the auxiliary transformer in the bottom front of
the power supply.
Power OFF Test
!
WARNING
Disconnect primary power at the source before
performing this procedure.
1. Select the Ohms scale on the digital meter.
2. With the Main Circuit Breaker ON, verify
continuity between LINE1 on the MCB and CN19
pin 3 on PCB1-1.
3. Measure the primary winding resistance between
LINE 2 on the MCB and CN19 pin 1 to be 74 Ohms
(208-230V) or pin 5 (460V) to be 14.8 Ohms.
If there is no continuity, or the resistance measurement
yields an open circuit, replace the auxiliary transformer T3.
Retaining Screw
Auxiliary Transformer
CN2
Red and White
Leads to Input
Diode Bridge (D1)
Retaining Screw
Art # A-06136
Figure 6-36: Auxiliary transformer
6-38
June 21, 2012
pro-wave 300gtsw
6.34 Auxiliary Transformer (T3)
Replacement
Refer to figure 6-36.
To remove the Auxiliary Transformer (T3), do the
following:
1. Remove Main Circuit Board, per page 6-13.
2. Remove connector CN1 from PCB8.
3. Remove the RED and WHITE lugged wires from
the R and S terminals of the Input Diode Bridge
(D1).
4. Remove the two (2) screws securing the Auxiliary
Transformer to the chassis.
To replace the Auxiliary Transformer, reverse the removal
steps above.
June 21, 2012
6-39
pro-wave 300gtsw
6.35 Main Transformer Assembly (T1
and T2) Test Procedure
!
WARNING
Disconnect primary power at the source before
performing this procedure.
Inspect the primary winding wires on both Main
Transformers for breaks in the insulation, signs of
overheating or loose connections.
Check for continuity across the primary windings of both
transformers.
To do this, do the following:
1. Remove the lugged leads from TB1 and TB2. See
Figure 6-37.
Q2-C2E2/T2
Primary Lead
(Green Mark)
2. To test the primary of T1, measure the continuity
between Main Circuit Board connector CN8 pin 2
and the lugged transformer lead removed from
TB1.
3. To test the primary of T2, measure the continuity
between Main Circuit Board connector CN9 pin 2
and the lugged transformer lead removed from
TB2.
The secondaries of T1 and T2 cannot be isolated. To test
the parallel combination of secondaries:
4. Measure the continuity between the connector
CN7 pin 3 and CN5 pin 3.
Replace the Main Transformer/Inductor Assembly if no
continuity is found in any of the windings or if there is
evidence of overheating.
TB2-T2 Primary Lead
Art # A-06137
Q1-C2E2/T1
Primary Lead
(Green Mark)
TB1-T1 Primary Lead
Figure 6-37: Preparation for removal of main transformers T1/T2 (right side of unit from front)
Art # A-06138
Figure 6-38: T1/T2 primary lead routing through ferrite ring
6-40
June 21, 2012
pro-wave 300gtsw
6.36 Main Transformer (T1 and T2)
Assembly Replacement Procedure
To remove Main Transformer T1 or T2:
1. Remove the Main Circuit Board per page 6-13.
2. Remove Main Circuit Breaker and shield, per
page 24.
3. Cut cable ties securing T1 or T2 primary leads
(WHITE) to ferrite ring (L1). See Figure 6-37
4. Cut cable ties securing insulating sheath on
TB1 (T1) or TB2 (T2) at the BLACK/WHITE lead
junction.
5. Remove the hardware from the BLACK/WHITE
primary lead junction, and remove the lead from
the ferrite ring.
6. Remove the WHITE primary lead from the terminal
on Q1 (T1) or Q2 (T2).
7. Turn the unit on its side and feed the two WHITE
primary leads down through the hole in the chassis
in preparation for removing the transformer(s).
White Wire
(to CN7-3)
Blue Wire
(to HF Unit AC1)
T1/T2 Secondary Lead
Junction "E"
8. Remove the Output Inductor Assembly section
6.37 page 6-42.
9. Bend the secondary center tap leads of both
transformers T1 and T2 (“D)” up to expose the
“C” and “E” secondary lead junctions. See Figure
6-39
10. Remove the hardware from the “C” and “E”
secondary leads.
11. Remove the two (2) screws securing the
transformer plastic frame to the metal mounting
bracket.
To replace Main Transformers T1 or T2, reverse the
removal steps.
Note
For proper phase connections to T1 and T2,
the primary leads marked with GREEN paint
connect to the IGBT Inverter terminals. Also
note the lead routing through the ferrite ring
(L1). Refer to figure 6-38.
T1/T2 Secondary Lead
Junction "C"
Art # A-06131
T1/T2 Secondary Lead
Junction "D" (center tap leads
bent upward; two black lugged
leads to CN7-1 and CN5-3)
Figure 6-39: Preparation for removal of main transformers T1/T2
June 21, 2012
6-41
pro-wave 300gtsw
6.37 Output Inductor Assembly Test and
Replacement Procedures
Replacement Procedure
Test Procedure
To remove the Output Inductor Assembly:
Refer to Figures 6-40 and 6-41
1. Remove the four (4) bolts and hardware from the
Output Diode/Inductor Assembly junctions at W,
X, Y and Z.
1. Inspect the Output Inductor Assembly for signs
of overheating or loose connections.
2. Check for continuity through the Inductors by
measuring between pairs of test points “W” and
“X”, and “Y” and “Z”. Refer to figure 6-40.
2. Cut the middle cable tie securing the BLACK
gas hose/wire harness to the Output Inductor
Assembly lead Y.
Replace the Output Inductor Assembly if there is no
continuity or if there is evidence of overheating.
3. Remove the compression nut on the gas inlet on
the rear panel. Move the gas hose/wire harness
to clear the Output Inductor Assembly.
4. Cut two (2) cable ties that form an “X” which
secure the Coupling Coil to the frame of the Output
Inductor Assembly. Figure 6-41
5. Remove the four (4) screws that secure the frame
of the Output Inductor Assembly to the main
chassis frame.
6. Pull the Output Inductor Assembly out of power
supply.
To replace the Output Inductor Assembly, reverse the
removal steps above.
Art # A-06132
Inductor /Coupling Coil Junction
Brown Wire
X
Gray Wire
Y
Cut cable tie
Gas Inlet
Z
W
Black Lugged Wires
Figure 6-40: Output inductor assembly test points
6-42
June 21, 2012
pro-wave 300gtsw
Cable ties to cut
Art # A-06139
Figure 6-41: Coupling coil cable ties
June 21, 2012
6-43
pro-wave 300gtsw
6.38 Fan Assembly Replacement
Procedure
Refer to figures 6-42 and 6-43.
To remove fan:
1. Remove the Output Inductor Assembly per section
6.37 page 6-42.
2. Remove the bolt inside the POSITIVE (+) OUTPUT
TERMINAL and the hardware from the Output Bus
Bar/IGBT Inverter Q3/Q4 junction.
3. Disconnect the connector from the Current
Transformer and remove the Output Bus Bar/CT
Assembly.
4. Cut the cable ties securing wiring harnesses to
both screws that secure the fan assembly to the
front panel.
The next steps free the wiring harness/gas hose to allow
access to the fan retaining screws. Figure 6-43.
5. Loosen the top screw securing R6 to the front
panel to allow R6 to rotate downward.
6. Remove the compression nut on both ends of the
black gas hose.
7. Remove the YELLOW and VIOLET lugged wires
from the gas solenoid.
8. Disconnect CN1 from IGBT Inverter Q3/Q4.
9. Disconnect the lugged BLUE and GRAY wires from
the HF Unit.
10.Follow the RED/BLACK twisted wire pair from the
fan through the hole in the chassis. Cut cable ties
as needed to locate a section of the wire pair where
it can be cut and spliced together easily when the
fan assembly is replaced. Cut the RED/BLACK
wire pair (it connects to CN2 with the YELLOW
and VIOLET pair from the gas solenoid).
11.Remove the two (2) screws securing the fan
assembly to the front panel. Slide the fan assembly
back slightly and out toward the left side of the
unit, away from the R6 assembly.
To replace the fan reverse the removal steps above.
6-44
June 21, 2012
pro-wave 300gtsw
Bolt, Positive (+) Output
Current Transformer
Output Bus Bar
Art # A-06124
Art # A-06140
Junction Hardware
IGBT Inverter Q3
Figure 6-42: Output bus bar/CT assembly
IGBT Inverter Q3/Q4 Driver Board CN1
R6 Topscrew
R6
Fan Retaining Screw
Fan Assembly
Figure 6-43: Cable ties and R6 on right side of unit
June 21, 2012
6-45
pro-wave 300gtsw
6.39 HF Unit Test and Replacement
Procedures
HF Unit Test Procedure
1. Place the Process Selector switch in the
stick position.
2. Jumper pins 1 and 5 on the CN7 plug. Apply power
to the unit.
3. If the high frequency buzz is heard coming from
the HF Unit, the Main Circuit Board (PCB1) should
be replaced. If no sound is heard coming from the
HF Unit, the HF Unit should be replaced.
HF Unit Replacement Procedure
To remove the HF Unit:
1. Remove the Output Inductor Assembly per section
6.37 page 6-42.
2. Remove the Output Bus Bar/CT Assembly by
removing the bolt inside the POSITIVE (+)
OUTPUT TERMINAL and the two screws holding
the bus bar to Q3/Q4. Remove the connector from
CT1.
3. Remove the Coupling Coil by removing the bolt
inside the NEGATIVE (-) OUTPUT TERMINAL
and hardware from the bus bar/T1/T2 center tap
junction.
4. Disconnect BLACK wires to the HF Unit.
5. Remove the lugged wires from the AC1 and AC2
terminals.
6. Remove the two (2) screws that secure the HF
Unit to the chassis.
To replace the HF Unit:
1. Apply a liberal amount of thermally-conductive
grease to the bottom of the new HF Unit.
2. Hold the new HF Unit against the chassis while
you replace the two screws that hold the HF Unit
onto the chassis. Be sure to orient the new HF Unit
in a similar manner to the one just removed, with
the AC1/AC2 terminals and resistor R1 toward the
front of the unit.
3. Reverse the remaining removal steps.
6-46
June 21, 2012
pro-wave 300gtsw
Art # A-06141
HF Unit
AC1/AC2
Coupling Coil Connections
Figure 6-44: HF Unit replacement
June 21, 2012
6-47
pro-wave 300gtsw
6.40 HF Coupling Coil Test and
Replacement Procedures
HF Coupling Coil Test Procedure
1. Visually inspect coil primary and secondary for
overheating or other damage.
2. Check connections of coil wires on HF Unit
terminals CC1 and CC2.
3. Verify continuity through the coils.
Replace the HF Coupling Coil if damaged or continuity
is broken.
HF Coupling Coil Replacement Procedure
Refer to figure 6-45.
To remove the HF Coupling Coil:
1. Remove the Output Inductor Assembly per section
6.37 page 6-42.
2. Remove the bolt from the inside of the NEGATIVE
(-) OUTPUT TERMINAL.
3. Remove the bolt from the inside of the POSITIVE
(+) OUTPUT TERMINAL.
4. Disconnect the connector on CT1.
5. Remove the hardware securing the Output Bus
Bar to IGBT Inverter Q3. Remove the Output Bus
Bar/CT Assembly.
6. Remove the Coupling Coil from the unit,
disconnecting the BLACK lugged wires from the
HF Unit as the Coupling Coil is removed.
To replace the HF Coupling Coil, reverse the removal steps.
6-48
June 21, 2012
pro-wave 300gtsw
Bolt, Positive (+) Output
Current Transformer
Output Bus Bar
Art # A-06124
Junction Hardware
IGBT Inverter Q3
Figure 6-45: Output bus bar/CT assembly
Art # A-06127
HF Unit
Coupling Coil Leads
IGBT's
Inverter Q3/Q4
Figure 6-46: Coupling coil replacement
June 21, 2012
6-49
pro-wave 300gtsw
6.41 Gas Solenoid Valve Replacement Procedure
Refer to figure 6-47.
To remove the gas solenoid valve:
1. Remove the YELLOW/VIOLET wires from the lugs on the solenoid valve.
2. Remove the compression nut securing the black gas line to the solenoid valve.
3. Remove the “C” retaining ring from the gas input fitting on the exterior of the Front Panel.
4. Remove the gas solenoid valve from the unit.
To replace the gas solenoid valve, reverse the above steps.
"C" Ring
Solenoid
Yellow (Top)
Violet (Bottom)
Art # A-06142
Figure 6-47: Gas solenoid valve
6-50
June 21, 2012
pro-wave 300gtsw
6.42 IGBT Inverter Q3/Q4 Driver Circuit Board (PCB8) Test Procedure
Refer to figure 6-48.
1. Locate and remove connector CN1 on the IGBT Inverter Q3/Q4.
2. Using a digital meter on the diode scale, test for diodes on the CN1 connector plug between pin pairs 1-2 and
4-5. Shorted readings indicate that the IGBT inverter Q3/Q4 Driver Circuit Board (PCB8) should be replaced.
CN1
Art # A-06143
Figure 6-48: Location of CN1 on IGBT inverter Q3/Q4 driver board
June 21, 2012
6-51
pro-wave 300gtsw
6.43 IGBT Inverter Q3/Q4 Driver Circuit Board (PCB8) Replacement Procedure
Refer to figure 6-49.
To remove PCB8, do the following:
1. Remove the Main Circuit Board, per page 6.13.
2. Remove connector CN1, CN2 and CN4 from PCB8.
3. Cut cable ties securing ribbon cable at CN3 to GREEN ground wires.
4. Remove the four (4) screws securing PCB8 to the chassis. As the board is lifted off the chassis, disconnect
connector CN5.
To replace PCB8, reverse the removal steps above. It may be helpful to connect CN2 and CN5 before seating the board
fully back onto the chassis.
Retaining
Screw
Retaining Screw
CN1
CN3
CN2
Art # A-06144
CN4
Retaining Screw
CN5
Retaining
Screw
Figure 6-49: AC waveform circuit board (PCB8)
6-52
June 21, 2012
pro-wave 300gtsw
6.44 Sequence Timing Diagrams
HF TIG Mode
Figure 6-50 shows the HF TIG timing waveforms with the SLOPE control ON and OFF.
(SLOPE OFF) mode
On
Off
On
Off
(SLOPE ON) mode
On
Off
On
Off
Output Contactor
Shielding Gas
Output Current
Art # A-06145
Figure 6-50: HF TIG mode timing
Lift TIG Mode
Figure 6-51 shows the LIFT TIG timing waveforms with the SLOPE control ON and OFF.
(SLOPE OFF) mode
On
Off
On
Off
(SLOPE ON) mode
On
Off
On
Off
Output Contactor
Short Release
Electrode
Shielding Gas
Output Current
Art # A-06146
Figure 6-51: LIFT TIG mode timing
Current Waveform on PULSE ON mode
Art # A-06147
Figure 6-52: LIFT TIG mode pulse on current waveform
June 21, 2012
6-53
pro-wave 300gtsw
SPOT Mode
Figure 6-53 shows the SPOT timing waveforms with the SLOPE control OFF and ON.
Works only in HF TIG mode
(SLOPE OFF) mode
On
Off
On
Off
(SLOPE ON) mode
On
Off
On
Off
Output Contactor
Shielding Gas
Output Current
Art # A-06148
Figure 6-53: SPOT/HF TIG mode timing
6-54
June 21, 2012
pro-wave 300gtsw
SECTION 7:
PARTS LIST
7.01 Equipment Identification
All identification numbers as described in the Introduction
chapter must be furnished when ordering parts or making
inquiries. This information is usually found on the
nameplate attached to the equipment. Be sure to include
any dash numbers following the Specification or Assembly
numbers.
7.02 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.
SPEC NUMBERS:
208/230VAC Single-Voltage, Single-/Three-Phase
103024
208/230/460VAC Single-/Three-Phase103025
380/415VAC Single-Voltage, Three-Phase
June 21, 2012
103038
7-1
pro-wave 300gtsw
7.03 Parts List
ITEM #
1
1
2
2.1
3
not shown
not shown
not shown
5
6
6
7
8
not shown
not shown
not shown
not shown
10
not shown
11
12
13
14
15
16
17
not shown
not shown
20
20
not shown
not shown
not shown
not shown
not shown
23
24
24
24
7-2
DESCRIPTION
208/230
380/415
230/460
LOCATION QTY. MODEL CAT. # MODEL CAT. # MODEL CAT. #
Front Upper Metal Panel
Front Upper Metal Panel*
K nob, l arge
P oteni ometer
K nob, smal l
P oteni ometer
Remote Receptacle w/ harness
CON1
Remote Receptacle w/ harness
CON1
Front Plastic Frame
Gas Outlet Fitting
Gas Outlet Fitting (CE)
C -Ri ng, Gas V avl e
Female Output Terminal
Switch, toggle, 3 pos. (WK- pulse, slope,
3369)
process
Switch, toggle, 3 pos. (WK- pulse, slope,
3988)
process
Switch, toggle, 2 pos. (WK3369)
AC/DC
Switch, toggle, 2 pos. (WK3988)
AC/DC
Label, Warning, Explanation
Label, Warning, Illustration
Label , S i de
C ase Hal f
S crews
Rubber Foot
S crews
Main Circuit Breaker
MCB
Easylink Switch
S2
Input Cable Clamp
Input Power Cable
Gas Inlet Fitting
Gas Inlet Fitting (CE)
Rear Plastic Frame
Rear Upper Metal Panel
Rear Upper Metal Panel
Rear Upper Metal Panel (CE)
Rear Upper Metal Panel
Heatsi nk
Main PCB
PCB1
Main PCB
PCB1
Main PCB
PCB1
1
1
1
1
4
6
1
1
1
1
1
VENDOR #
2
10-5341
10-6346
10-5233
10-6363
10-5232
10-5056
10-6324
N/A
10-5462
10-5073
N/A
10-5184
10-5131
10-5341
10-6346
10-5233
10-6363
10-5232
10-5056
10-6324
10-6336
10-5462
10-5073
10-5449
10-5184
10-5131
10-5341
10-6346
10-5233
10-6363
10-5232
10-5056
10-6324
N/A
10-5462
10-5073
N/A
10-5184
10-5131
A3A439400
600019
50551002900
41114001000
50551002100
41114001100
U0A397400
U0A397800
A3A441900
E6A475200
E6A967700
53003000600
26999010100
3
10-5570
10-5570
10-5570
24703128400
3
10-6365
10-6365
10-6365
24655000100
1
10-5057
10-5057
10-5057
24703128000
1
1
1
2
2
4
4
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10-6364
10-5496
10-5497
10-5499
10-5461
10-6364
10-5496
10-5497
10-5499
10-5461
10-6364
10-5496
10-5497
10-5499
10-5461
24655000200
N0B476400
N0B476500
N0B 477000
E0C 181200
10-5411
10-5411
10-5411
E6A 181600
10-6321
N/A
10-5409
10-5239
10-5075
N/A
10-5525
10-5390
N/A
N/A
N/A
10-5455
10-6317
N/A
N/A
10-5224
N/A
10-5409
10-5239
10-5075
10-5201
10-5525
N/A
10-5391
10-5392
N/A
10-5455
N/A
10-6350
N/A
10-5224
10-5222
10-5409
10-5239
10-5075
N/A
10-5525
N/A
N/A
N/A
10-5393
10-5455
N/A
N/A
10-6318
25850001800
24704531400
A4A449800
52026000500
E5A925600
E6A586600
A3A446900
A3A444400
A3A444600
A3A444700
A3A444400
E0B 869600
P0A344816
P0A344815
P0A344817
June 21, 2012
pro-wave 300gtsw
ITEM #
DESCRIPTION
LOCATION
25
Fan Assembly
FAN1
25
Fan Assembly
before 9/29/95
26
Current Transformer
CT1
27
Coupling Coil
CC
28
HF Unit
28
HF Unit w/ resistor
29
Ouput Inductor
FCH
30
Transformer, Main
T1,T2
30
Transformer, Main
T1,T2
31
Front Panel PCB
PCB6
31
Front Panel PCB*
PCB6
32
Resistor
R6
not shown
11 Pin Ribbon Cable
not shown
15 Pin Ribbon Cable
not shown
12 Pin Ribbon Cable
36
Gas Valve
SOL1
3 6. 1
Elbow Union
37
Auxilary Transformer
T3
37
Auxilary Transformer
T3
37
Auxilary Transformer (CE)
T3
38
IGBT Kit
Q1,Q2
38
IGBT Kit
Q1,Q2
39
Input Rectifier
D1
39
Input Rectifier
D1
40
Capacitor
C1
41
Thermal Sensor
TH1
42
AC Driver PCB
PCB8
43
Secondary IGBT
Q3,Q4
44
Snubber Circuit
PCB10
45
Output Diodes
D2,D3,D4.D5
46
AC Gate PCB
PCB9
not shown
C over, P C B
not shown
C lip, P C B C over
not shown
Panel PCB Shield
Main Circuit Breaker
not shown
S heil d
Main Circuit Breaker
50
S hield (C E)
not shown
Male Output Terminal
not shown
6 Pin Ribbon Cable
53
Resistor
R2-R5
not shown
Capacitor
C2-C5
not shown
PLUG, 8 PIN REMOTE
-----BODY
-----CLAMP
-----PINS
not shown
HF resistor
R1
June 21, 2012
208/230
380/415
230/460
QTY. MODEL CAT. # MODEL CAT. # MODEL CAT. #
VENDOR #
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
2
1
1
1
2
2
1
1
1
1
1
2
1
4
1
1
4
1
10-5092
10-5142
10-5003
10-5146
1 0- 5 02 4
10-6325
10-5145
10-5474
N/A
10-5148
10-6347
10-5137
10-5236
10-5234
10-5235
10-5007
10-5316
10-5143
N/A
N/A
10-6320
N/A
10-2653
N/A
10-2270
10-5228
10-5149
10-5140
10-5151
10-2630
10-5150
1 0- 5 41 9
1 0- 5 25 9
10-5443
10-5092
10-5142
10-5003
10-5146
10 - 50 2 4
10-6325
10-5145
N/A
10-5475
10-5148
10-6347
10-5137
10-5236
10-5234
10-5235
10-5007
10 - 53 1 6
N/A
10-5469
10-5469
10-6320
N/A
N/A
10-5088
10-2270
10-5228
10-5149
10-5140
10-5151
10-2630
10-5150
10 - 54 1 9
10 - 52 5 9
10-5443
10-5092
10-5142
10-5003
10-5146
10 - 50 24
10-6325
10-5145
10-5474
N/A
10-5148
10-6347
10-5137
10-5236
10-5234
10-5235
10-5007
10-5316
10-5143
N/A
N/A
N/A
10-6320
10-2653
N/A
10-2270
10-5228
10-5149
10-5140
10-5151
10-2630
10-5150
10 - 54 19
10 - 52 59
10-5443
33311123600
33311119700
11251003000
F1A570400
U0A 329100
U0A418000
F1A541300
F1A611600
F1A611600
P0A336900
P0A398800
40511000200
52003000700
52003000500
52003000600
34910000400
67842112900
F1A540800
F1A540900
F1A540900
Z000348300
Z000348300
45707016000
45704016000
42422137100
46965000900
P0A339100
43460002101
P0A339300
458660050
P0A339200
E 6 A 49 01 0 0
6 06 0 24 22 0 00
E7A150000
1
1 0- 5 48 4
10 - 54 8 4
10 - 54 84
J2B 748200
1
2
1
12
4
N/A
10-2020
10-5237
10-2213
10-5014
10 - 54 8 8
10-2020
10-5237
10-2213
10-5014
N/A
10-2020
10-5237
10-2213
10-5014
J2B 858600
WDC50P
52003000800
40305122000
42421138400
1
1
7
1
10-5000
10-5001
10-5002
10-5080
10-5000
10-5001
10-5002
10-5080
10-5000
10-5001
10-5002
10-5080
206434-1
206062
745229-7
40511000600
7-3
pro-wave 300gtsw
ITEM #
DESCRIPTION
LOCATION
not shown Digital Meter Kit (opt.)
PCB7
not shown
Meter Lens
not shown
Meter PCB
PCB7
not shown
Capacitor
C6, C7
not shown
Capacitor
C8
not shown
Resistor
R7
not shown
Screws
R6
not shown
Screws
Fan
65
Snubber Circuit
PCB4, 5
66
Bus Bar
D1 to Q1
67
Bus Bar
D1 to Q2
68
Bus Bar
Q1,Q2 to PCB
69
Bus Bar
Q1,Q2 to PCB
Q3, Q4 to FCH
70
Bus Bar
71
Bus Bar
Output Diodes
72
Bus Bar
Output Diodes
73
Bus Bar
Output Diodes
74
Bus Bar
Output Diodes
75
Bus Bar
Q3, Q4 to FCH
76
Bus Bar
Transformer to choke
77
Bus Bar
Q3,Q4 to output stud
78
PCB 11
PCB11
not shown
Chassi s
not shown
Acrylic board
under main pcb
not shown
R1
on main pcb
not shown
PCB(CE)
PCB101
not shown
Filter
L1
not shown
Filter (CE)
L106, L107
not shown
Filter (CE)
L104
not shown
Filter (CE)
L102, L103
not shown
Filter (CE)
L104, L105
not shown Femal e Uni on (C E)
not shown
Hol der
not shown
CN1 Plug 4pos.
PCB1
not shown
CN2 Plug 6pos.
PCB1
not shown
CN4 Plug 2pos.
PCB1
not shown
CN5 Plug 5pos.
PCB1
not shown
CN6 Plug 7pos.
PCB1
not shown
CN7 Plug 5pos.
PCB1
not shown
CN8 Plug 5pos.
PCB1
not shown
CN9 Plug 5pos.
PCB1
not shown
CN10 Plug 2pos.
PCB1
not shown
CN13 Plug 3pos.
PCB1
not shown
CN14 Plug 4pos.
PCB1
not shown
CN18 Plug 3pos.
PCB1
not shown
CN19 Plug 5pos.
PCB1
not shown
CN24 Plug 3pos.
PCB1
not shown
CN26 Plug 3pos.
PCB1
7-4
208/230
380/415
230/460
QTY. MODEL CAT. # MODEL CAT. # MODEL CAT. #
1
1
1
2
1
1
2
2
2
1
1
4
5
1
2
2
1
1
1
1
1
1
1
1
1
1
2
1
2
2
1
4
10-4000
10-6340
10-5126
10-2219
10-5013
10-5010
10-5241
10-5240
10-5121
10-5412
10-5413
10-5414
10-5415
10-5447
10-5433
10-5434
10-5432
10-5420
10-5421
10-5429
10-5435
10-6345
10-5482
10-5431
10-6684
N/A
10-2290
N/A
N/A
N/A
N/A
N/A
10-5249
10-2663
10-2665
10-2662
10-2664
10-2666
10-2664
10-2664
10-2664
10-2662
10-2613
10-2663
10-2613
N/A
10-2613
10-2613
10-4000
10-6340
10-5126
10-2219
10-5013
10-5010
10-5241
10-5240
10-5121
10-5412
10-5413
10-5414
10-5415
10-5447
10-5433
10-5434
10-5432
10-5420
10-5421
10-5429
10-5435
10-6345
10-5482
10-5431
10-6684
10-5517
10-2290
10-5176
10-5229
10-5230
10-5231
10-5245
10-5249
10-2663
10-2665
10-2662
10-2664
10-2666
10-2664
10-2664
10-2664
10-2662
10-2613
10-2663
N/A
N/A
10-2613
10-2613
10-4000
10-6340
10-5126
10-2219
10-5013
10-5010
10-5241
10-5240
10-5121
10-5412
10-5413
10-5414
10-5415
10-5447
10-5433
10-5434
10-5432
10-5420
10-5421
10-5429
10-5435
10-6345
10-5482
10-5431
10-6684
N/A
10-2290
N/A
N/A
N/A
N/A
N/A
10-5249
10-2663
10-2665
10-2662
10-2664
10-2666
10-2664
10-2664
10-2664
10-2662
10-2613
10-2663
N/A
10-2664
10-2613
10-2613
VENDOR #
N/A
D6A 604700
P0A337500
42442007100
42421138500
40305147200
53001028200
53001026300
P0A336600
E6A419300
E6A419400
E6A419500
E6A419600
E6A930600
E6A653100
E6A653300
E6A52900A
E6A558900
E6A559000A
E6A652500
E6A653400A
P0A353600
J2B 747600
E6A652800
P0A347500
47953134100
47953005500
47953005500
47953014500
47953014600
53550011600
53692118900
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
June 21, 2012
pro-wave 300gtsw
ITEM #
DESCRIPTION
not shown
not shown
not shown
not shown
not shown
not shown
not shown
not shown
CN3 Plug 7pos.
CN4 Plug 3pos.
CN6 Plug 2pos.
CN1 Plug 3pos.
CN2 Plug 5pos.
CN4 Plug 5pos.
CN5 Plug 2pos.
P ins for P l ugs
* Last letter in S/N is
"G".
June 21, 2012
LOCATION QTY.
PCB6
PCB6
PCB6
PCB8
PCB8
PCB8
PCB8
208/230 MODEL 380/415 MODEL 230/460 MODEL
CAT. #
CAT. #
CAT. #
VENDOR #
10-2666
10-2613
10-2662
10-2613
10-2663
10-2663
10-2662
10-2671
10-2666
10-2613
10-2662
10-2613
10-2663
10-2663
10-2662
10-2671
10-2666
10-2613
10-2662
10-2613
10-2663
10-2663
10-2662
10-2671
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
7-5
pro-wave 300gtsw
7.04 Parts Pictures
1
2
3
5
6
7
Art # A-06149
8
Figure 7-1: Front Panel
7-6
June 21, 2012
pro-wave 300gtsw
10
11
12
13
(4 places)
Art # A-06150
15
(5 Places)
14
(4 Places)
Figure 7-2: Enclosure
June 21, 2012
7-7
pro-wave 300gtsw
16
Art # A-06151
17
6
Figure 7-3: Rear Panel
7-8
June 21, 2012
pro-wave 300gtsw
Main Circuit
Breaker
Heat
Sink
Main Circuit
Board
Art # A-06152
Figure 7-5
Fan
Main
Transformer
Output
Inductor
HF
Unit
Coupling
Coil
Current
Transformer
Figure 7-4: Left Side Parts
78
Art # A-06153
Figure 7-5: PCB 11
June 21, 2012
7-9
pro-wave 300gtsw
31
16
24
Art # A-06154
25
32
27
29
23
30
Figure 7-6: Right Side Parts
24
31
Art # A-06155
Figure 7-7: Top View Parts
7-10
June 21, 2012
pro-wave 300gtsw
36
29
27
20
Art # A-06156
26
30
Figure 7-8: Bottom View Parts
37
42
38
39
38
40
Art # A-06157
41
Figure 7-9: Internal Parts
June 21, 2012
7-11
pro-wave 300gtsw
66
65
69
68
67
Art # A-06158
Figure 7-10: Primary IGBT assembly
7-12
June 21, 2012
pro-wave 300gtsw
77
26
36
Art # A-06159
36.1
Figure 7-11: Output diode bus bar
June 21, 2012
7-13
pro-wave 300gtsw
76
Art # A-06160
Figure 7-12: Main Transformer
7-14
June 21, 2012
pro-wave 300gtsw
45 (D2)
38
44
45 (D4)
Art # A-06161
45 (D5)
45 (D3)
Figure 7-13: Internal Parts continued
June 21, 2012
7-15
pro-wave 300gtsw
71
71
72
45
73
74
53
Art # A-06162
Figure 7-14: Output diode assembly
7-16
June 21, 2012
pro-wave 300gtsw
28
43
46
27
25
Art # A-06163
32
Figure 7-15: Internal Parts continued
69
46
70
43
76
75
Art # A-06164
Figure 7-16: Q3, Q4 assembly
June 21, 2012
7-17
pro-wave 300gtsw
This page left blank intentially
7-18
June 21, 2012
pro-wave 300gtsw
APPENDIX 1: GENERAL INFORMATION
• Note the model and specification number shown on the equipment nameplate.
• Locate these numbers in the model and specification number columns below.
• Use only those diagrams and instructions that are applicable.
Specification Number
Model
103024
208/230VAC Single-Voltage, Single-/Three-Phase
103025
208/230/460VAC Single-/Three-Phase
103038
380/415VAC Single-Voltgae, Three-Phase
June 21, 2012
Appendix Location
2
3
4
A-1
pro-wave 300gtsw
APPENDIX 2: 208/230VAC SINGLE-VOLTAGE SINGLE-/THREE-PHASE
208/230/460VAC
Single-/Three-Phase
Ground
C1
IGBT
Inverter
(Q1)
E
PCB4
IGBT
Inverter
(Q2)
C2E1
E2
C1
G1
E1
G2
PCB5
C1
E2
C21E1
E2
C21E1
C2E1
E2
C1
E2
G1
E1
G2
E2
PCB2
PCB3
1
2
4
5
1
2
4
5
Single - Phase
R
S
S
S
T
T
T
R2 Orange
–
(Black)
CN1
CN5
CN23
CN22
15
14
13
12
11
10
9
8
5
4
3
2
1
CN21
1
2
3
4
5
6
7
8
9
10
11
CN4
CN27
CN27
CN28
CN28
5
4
2
1
CN16
CN15
CN15
TB12
CN16
TH1
1
2
CN17
CN17
CN10
PCB1-1
2
1
CN19
1
3
2
CN13
3
1
Thermal Detect (Black)
Thermal Detect (Black)
CN1
E
15V Pulse (Red)
PCB Common 0V (Blue)
P
S
N
1
4
1
1
3
3
CN18
CN5
1
4
80VPK From FCH (Brown)
300VPK Pulse (Yellow)
300VDC Supply Common –0V
CN26
1
3
5
CN24
CN4
CN3
IGBT Inverter
Q3/Q4 Driver
(PCB8)
1
2
3
4
5
6
CN2
+12VDC
F
Secondary IGBT Gate Drive
G
Secondary IGBT Gate Drive
H
Secondary IGBT Gate Drive
I
Secondary Overvoltage Signal
J
PCB Common – 0V
K
1
2
4
5
1
2
3
4
5
6
7
8
9
10
11
12
PCB1-3
0V
(Black)
IGBT Gate Drive - G6 (White)
IGBT Gate Drive - E6 (Black)
IGBT Gate Drive - G5 (Blue)
IGBT Gate Drive - E5 (White)
(Black)
(Bus Bar)
5
4
2
1
1
3
5
230V
INPUT SELECT (S2)
460V
1
3
5
CN20
3
4
125V
250VAC (Brown)
250VAC (Orange)
To
PCB6
CN5
7
4
1
1
2
Gas ON/OFF Control (Yellow)
Gas ON/OFF Control (Violet)
1
2
3
4
Main Circuit Board
(PCB1)
SOL1
TB2
CN20
CN8
0V
2
1
4
115V
0V
(Black)
E2
(B)
CN9
125V
+24VDC (Red)
PCB Common – 0V(Black)
FAN1
TB1
C1
(A)
CN2
0V
0V
(Gray)
TB6
E2
(B)
CN6
115V
115V
TB5
C1
(A)
CN14
0V
T3
TB4
CN7
(Red)
(White)
115V
TB3
PCB1-2
5
3
1
Line 3 (Black)
Line 2 (White)
Line 1 (Red)
(Bus Bar)
T
HF Unit ON/OFF (Gray)
S
Red
Output Voltage Detect (White)
Output Voltage Detect (Black)
IGBT Gate Drive - G3 (White)
IGBT Gate Drive - E3 (Orange)
IGBT Gate Drive - E4 (Black)
IGBT Gate Drive - G4 (White)
IGBT Gate Drive - G2 (White)
IGBT Gate Drive - E2 (Red)
IGBT Gate Drive - E1 (Black)
IGBT Gate Drive - G1(White)
Thyristor Cathode (Black)
Thyristor Gate (White)
Thyristor Anode (Orange)
R
Line 3 White
(Bus Bar)
(Bus Bar)
MCB
Line 1 Black
Line 2
C1
(Bus Bar)
Three - Phase
L1
White
(White)
Red
R
Black
G
(White)
Line 3 White
Line 2
Input Diode
Bridge (D1)
+
R
MCB
Line 1 Black
Art # A-06165
A-2
June 21, 2012
pro-wave 300gtsw
PCB10
C1
A
G1 E1
E
K
C
C6
2
3
C8
4
Output
Filter
Network
R7
C7
CC
–
IGBT
Q3
IGBT
Q4
C1
T2
C1
D3
A
1
C2E1
FCH1
E2
E2
X
E1 G1
B
W
G2
D
K
D2
R3 C3
G2
C
E2
T1
+
E2
A
A
P
C2
C2E1
R2
(Brown)
CT1
E2
C2E1
D
B
PCB9
E
1
2
4
5
R4
C4
(White)
(Blue)
(Black)
(White)
K
A
D4
R5 C5
FCH2
K
A
D5
Z
(Blue)
(Gray)
(Black)
(Yellow)
R6
S
(Gray)
Y
N
+12VDC (Brown)
–12VDC (Red)
Output Current Detect - 0V to –4V (Orange)
Ground (Yellow)
(Blue)
CC2
Output Short Detect (White)
Output Short Detect (Black)
Case Ground (Green)
R1
R1
CN3
CN6
CN1
CN1
7
6
5
4
2
3
1
8
2
1
2
Contactor Control 2 / +24VDC (Orange)
1
5
Contactor Control 1 / GND (Red)
Case Ground (Green)
Amperage Control Wiper 0-4VDC (Gray)
4
3
8
7
Amperage Maximum (Violet)
GND (Blue)
Amperage Control +12VDC (Yellow)
Case Ground (Brown)
6
Case Ground (Brown)
E
1 2 3 4 5 6 7 8
CON1
(Front View)
CN5
2
1
R2
CN2
CN2
Digital Panel Meter
(PCB7)
(Optional)
Front Panel
(PCB6)
June 21, 2012
11
10
9
8
7
6
5
4
3
2
1
(Gray)
CN4
Torch Control (Pink)
Torch Control (Yellow)
15
14
13
12
11
10
9
8
5
4
3
2
1
AC2
CN7
Thermal Control
Thermal Control
Output Voltage Detect
Output Voltage Detect
Output Current Detect
PCB Common - 0V
–12VDC
+5VDC
+5VDC
PCB Common - 0V
+12VDC
HF Unit
12
11
10
9
8
7
6
5
4
3
2
1
CN8
Input 1/3 Phase Detect
Input Changeover Control
+12VDC
PWM Gate Drive
PWM Gate Drive
Input Changeover Control
Input Changeover Control
Torch Switch Control
Output Short Circuit Detect
PCB Common - 0V
Primary Current Detect
Primary Current Detect
Primary Current Detect
AC1
CN9
Tripping Relay Control
Input Changeover Switch
Input Changeover Switch
Thyristor Gate Drive
Pre-charge Control
PCB Common - 0V
Undervoltage
Overvoltage
Reset Signal
+12VDC
PCB Common - 0V
Input Voltage Detect
CC1
1
2
3
4
5
6
F
G
H
I
J
K
To
PCB8
CN3
Art # A-06165
A-3
pro-wave 300gtsw
APPENDIX 3: 208/230/460VAC SINGLE-/THREE-PHASE
208/230VAC Single-Voltage
Single-/Three-Phase
Ground
C1
IGBT
Inverter
(Q1)
E
PCB4
IGBT
Inverter
(Q2)
C2E1
E2
C1
G1
E1
G2
PCB5
C1
E2
C21E1
E2
C21E1
C2E1
E2
C1
E2
G1
E1
G2
E2
PCB2
PCB3
1
2
4
5
1
2
4
5
Single - Phase
Red
R
R
S
S
S
T
T
T
Black
G
R2 Orange
–
1
2
3
4
5
6
7
8
9
10
11
12
CN22
15
14
13
12
11
10
9
8
5
4
3
2
1
CN21
1
2
3
4
5
6
7
8
9
10
11
CN4
CN2
Gas ON/OFF Control (Yellow)
Gas ON/OFF Control (Violet)
1
3
5
CN23
CN6
1
2
1
2
3
4
CN5
7
4
1
CN1
2
1
4
(Black)
5
4
2
1
TB2
1
2
Main Circuit Board
(PCB1)
5
4
2
1
(Black)
(Bus Bar)
5
3
1
TB1
3
4
0V
(Black)
E
CN15
CN15
TB12
CN16
PCB1-1
TH1
E
15V Pulse (Red)
PCB Common 0V (Blue)
P
S
N
1
4
1
1
3
3
CN26
CN5
1
4
80VPK From FCH (Brown)
300VPK Pulse (Yellow)
300VDC Supply Common –0V
CN18
1
3
5
CN24
CN4
CN3
1
2
3
4
5
6
2
1
CN16
3
1
Thermal Detect (Black)
Thermal Detect (Black)
CN1
IGBT Inverter
Q3/Q4 Driver
(PCB8)
+12VDC
F
Secondary IGBT Gate Drive
G
Secondary IGBT Gate Drive
H
Secondary IGBT Gate Drive
I
Secondary Overvoltage Signal
J
PCB Common – 0V
K
1
2
4
5
CN2
IGBT Gate Drive - G6 (White)
IGBT Gate Drive - E6 (Black)
IGBT Gate Drive - G5 (Blue)
IGBT Gate Drive - E5 (White)
2
3
1
CN10
250VAC (Brown)
250VAC (Orange)
CN13
0V
(Black)
CN17
125V
CN17
125V
To
PCB6
CN5
TB6
CN14
SOL1
115V
TB5
CN8
0V
+24VDC (Red)
PCB Common – 0V(Black)
FAN1
0V
(Gray)
115V
0V
115V
TB4
CN9
0V
T3
TB3
CN7
(White)
(Red)
115V
Line 3 (Black)
Line 2 (White)
Line 1 (Red)
(Bus Bar)
T
(Bus Bar)
S
Red
HF Unit ON/OFF (Gray)
R
Output Voltage Detect (White)
Output Voltage Detect (Black)
IGBT Gate Drive - G3 (White)
IGBT Gate Drive - E3 (Orange)
IGBT Gate Drive - E4 (Black)
IGBT Gate Drive - G4 (White)
IGBT Gate Drive - G2 (White)
IGBT Gate Drive - E2 (Red)
IGBT Gate Drive - E1 (Black)
IGBT Gate Drive - G1(White)
MCB
Line 3 White
Line 2
(Bus Bar)
Thyristor Cathode (Black)
Thyristor Gate (White)
Thyristor Anode (Orange)
Line 1 Black
C1
(Bus Bar)
Three - Phase
L1
White
(White)
Line 3 White
Line 2
Input Diode
Bridge (D1)
+
R
MCB
(White)
Line 1 Black
Art # A-06166
A-4
June 21, 2012
pro-wave 300gtsw
PCB10
C1
A
G1 E1
E
K
C
C6
2
3
C8
4
Output
Filter
Network
R7
C7
CC
–
IGBT
Q3
IGBT
Q4
C1
T2
C1
D3
A
1
C2E1
FCH1
E2
E2
X
E1 G1
B
W
G2
D
K
D2
R3 C3
G2
C
E2
T1
+
E2
A
A
P
C2
C2E1
R2
(Brown)
CT1
E2
C2E1
D
B
PCB9
E
1
2
4
5
R4
C4
(White)
(Blue)
(Black)
(White)
K
A
D4
R5 C5
FCH2
K
A
D5
Z
(Blue)
(Gray)
(Black)
(Yellow)
R6
S
(Gray)
Y
N
+12VDC (Brown)
–12VDC (Red)
Output Current Detect - 0V to –4V (Orange)
Ground (Yellow)
(Blue)
CC2
Output Short Detect (White)
Output Short Detect (Black)
Case Ground (Green)
R1
R1
CN3
CN6
CN1
CN1
7
6
5
4
2
3
1
8
2
1
2
Contactor Control 2 / +24VDC (Orange)
1
5
Contactor Control 1 / GND (Red)
Case Ground (Green)
Amperage Control Wiper 0-4VDC (Gray)
4
3
8
7
Amperage Maximum (Violet)
GND (Blue)
Amperage Control +12VDC (Yellow)
Case Ground (Brown)
6
Case Ground (Brown)
E
1 2 3 4 5 6 7 8
CON1
(Front View)
CN5
2
1
R2
CN2
CN2
Digital Panel Meter
(PCB7)
(Optional)
Front Panel
(PCB6)
June 21, 2012
11
10
9
8
7
6
5
4
3
2
1
(Gray)
CN4
Torch Control (Pink)
Torch Control (Yellow)
15
14
13
12
11
10
9
8
5
4
3
2
1
AC2
CN7
Thermal Control
Thermal Control
Output Voltage Detect
Output Voltage Detect
Output Current Detect
PCB Common - 0V
–12VDC
+5VDC
+5VDC
PCB Common - 0V
+12VDC
HF Unit
12
11
10
9
8
7
6
5
4
3
2
1
CN8
Input 1/3 Phase Detect
Input Changeover Control
+12VDC
PWM Gate Drive
PWM Gate Drive
Input Changeover Control
Input Changeover Control
Torch Switch Control
Output Short Circuit Detect
PCB Common - 0V
Primary Current Detect
Primary Current Detect
Primary Current Detect
AC1
CN9
Tripping Relay Control
Input Changeover Switch
Input Changeover Switch
Thyristor Gate Drive
Pre-charge Control
PCB Common - 0V
Undervoltage
Overvoltage
Reset Signal
+12VDC
PCB Common - 0V
Input Voltage Detect
CC1
1
2
3
4
5
6
F
G
H
I
J
K
To
PCB8
CN3
Art # A-06166
A-5
pro-wave 300gtsw
APPENDIX 4: 380/415VAC SINGLE-VOLTAGE THREE-PHASE
380/415VAC Single-Voltage
Three-Phase
Ground
C1
IGBT
Inverter
(Q1)
E
PCB4
E2
G1
G1
G2
E2
PCB3
L1
White
R2 Orange
T
–
C1
1
3
5
CN23
1
2
3
4
5
6
7
8
9
10
11
12
CN22
15
14
13
12
11
10
9
8
5
4
3
2
1
CN21
1
2
3
4
5
6
7
8
9
10
11
CN4
CN2
Gas ON/OFF Control (Yellow)
Gas ON/OFF Control (Violet)
1
2
3
4
CN5
CN6
1
2
TB2
1
2
Main Circuit Board
(PCB1)
7
4
1
TB1
CN1
(Bus Bar)
2
1
4
(Black)
(Bus Bar)
5
4
2
1
(Black)
(Bus Bar)
5
4
2
1
CN14
SOL1
TB6
5
3
1
115V
0V
(Black)
TB5
CN8
+24VDC (Red)
PCB Common – 0V(Black)
FAN1
TB4
CN9
3
4
125V
CN15
CN15
TB12
CN16
PCB1-1
TH1
E
15V Pulse (Red)
PCB Common 0V (Blue)
P
S
N
1
4
1
1
3
3
CN26
CN5
1
4
80VPK From FCH (Brown)
300VPK Pulse (Yellow)
300VDC Supply Common –0V
CN18
1
3
5
CN24
CN4
CN3
1
2
3
4
5
6
2
1
CN16
3
1
Thermal Detect (Black)
Thermal Detect (Black)
CN1
IGBT Inverter
Q3/Q4 Driver
(PCB8)
+12VDC
F
Secondary IGBT Gate Drive
G
Secondary IGBT Gate Drive
H
Secondary IGBT Gate Drive
I
Secondary Overvoltage Signal
J
PCB Common – 0V
K
1
2
4
5
CN2
IGBT Gate Drive - G6 (White)
IGBT Gate Drive - E6 (Black)
IGBT Gate Drive - G5 (Blue)
IGBT Gate Drive - E5 (White)
2
3
1
CN10
E
CN13
250VAC (Brown)
250VAC (Orange)
CN17
0V
(Black)
CN17
0V
0V
(Gray)
TB3
CN7
125V
HF Unit ON/OFF (Gray)
0V
Output Voltage Detect (White)
Output Voltage Detect (Black)
IGBT Gate Drive - G3 (White)
IGBT Gate Drive - E3 (Orange)
IGBT Gate Drive - E4 (Black)
IGBT Gate Drive - G4 (White)
IGBT Gate Drive - G2 (White)
IGBT Gate Drive - E2 (Red)
IGBT Gate Drive - E1 (Black)
IGBT Gate Drive - G1(White)
Thyristor Cathode (Black)
Thyristor Gate (White)
Thyristor Anode (Orange)
115V
115V
(Red)
0V
T3
(White)
115V
Line 3 (Black)
Line 2 (White)
Line 1 (Red)
(Bus Bar)
(Bus Bar)
To
PCB6
CN5
E1
Black
G
S
Red
E2
PCB2
(White)
Line 2
E2
(White)
Line 3 White
G2
C2E1
C1
1
2
4
5
Line 1 Black
E1
E2
C21E1
1
2
4
5
Input Diode
Bridge (D1)
+
R
MCB
IGBT
Inverter
(Q2)
C2E1
C1
PCB5
C1
E2
C21E1
Art # A-06167
A-6
June 21, 2012
pro-wave 300gtsw
PCB10
C1
A
G1 E1
E
K
C
2
3
C8
4
Output
Filter
Network
R7
C7
CC
–
IGBT
Q3
IGBT
Q4
C1
T2
C1
D3
A
1
C2E1
FCH1
E2
E2
X
C6
E1 G1
B
W
G2
D
K
D2
R3 C3
G2
C
E2
T1
+
E2
A
A
C2E1
P
C2
C2E1
R2
(Brown)
CT1
E2
D
B
PCB9
E
1
2
4
5
R4
C4
(White)
(Blue)
(Black)
(White)
K
A
D4
R5 C5
FCH2
K
A
D5
Z
(Blue)
(Gray)
(Black)
(Yellow)
R6
S
(Gray)
Y
N
+12VDC (Brown)
–12VDC (Red)
Output Current Detect - 0V to –4V (Orange)
Ground (Yellow)
(Blue)
CC2
Output Short Detect (White)
Output Short Detect (Black)
Case Ground (Green)
R1
R1
CN3
CN6
CN1
CN1
7
6
5
4
2
3
1
8
2
1
2
Contactor Control 2 / +24VDC (Orange)
1
5
Contactor Control 1 / GND (Red)
Case Ground (Green)
Amperage Control Wiper 0-4VDC (Gray)
4
3
8
7
Amperage Maximum (Violet)
GND (Blue)
Amperage Control +12VDC (Yellow)
Case Ground (Brown)
6
Case Ground (Brown)
E
1 2 3 4 5 6 7 8
CON1
(Front View)
CN5
2
1
R2
CN2
CN2
Digital Panel Meter
(PCB7)
(Optional)
11
10
9
8
7
6
5
4
3
2
1
Front Panel
(PCB6)
June 21, 2012
15
14
13
12
11
10
9
8
5
4
3
2
1
(Gray)
CN4
Torch Control (Pink)
Torch Control (Yellow)
12
11
10
9
8
7
6
5
4
3
2
1
AC2
CN7
Thermal Control
Thermal Control
Output Voltage Detect
Output Voltage Detect
Output Current Detect
PCB Common - 0V
–12VDC
+5VDC
+5VDC
PCB Common - 0V
+12VDC
HF Unit
CN8
Input 1/3 Phase Detect
Input Changeover Control
+12VDC
PWM Gate Drive
PWM Gate Drive
Input Changeover Control
Input Changeover Control
Torch Switch Control
Output Short Circuit Detect
PCB Common - 0V
Primary Current Detect
Primary Current Detect
Primary Current Detect
AC1
CN9
Tripping Relay Control
Input Changeover Switch
Input Changeover Switch
Thyristor Gate Drive
Pre-charge Control
PCB Common - 0V
Undervoltage
Overvoltage
Reset Signal
+12VDC
PCB Common - 0V
Input Voltage Detect
CC1
1
2
3
4
5
6
F
G
H
I
J
K
To
PCB8
CN3
Art # A-06167
A-7
pro-wave 300gtsw
APPENDIX 5: WIRE CHART MAIN BOARD PCB1
Connector
Wire color
Meter Reading
Comments
Number
CN1 -1
+ 1 2 Vd c
Po wer to CT 1
Bro wn
CN1 -2
-1 2Vd c
Po wer to CT 1
Red
CN1 -3
0 -4Vd c
1V= 5 0 Amp s
Orang e
CN1 -4
GND
commo n
Yello w
Red
CN2-1
+24Vdc
Fan supply voltage
CN2 -2
GND
Black
CN2-3
+24Vdc
Gas Valve supply voltage
Black
CN2-4
0Vdc
When gas valve on
White
CN2 -5
n o t u se d
CN2 -6
n o t u se d
CN4 -1
+ 2 4 Vd c
to rch switch
Yello w
CN4 -2
c o mm o n
to rch switch
Pin k
CN5-1
+9Vdc
Output short detect
CN5-3
common
Output short detect
CN5-5
chassis
CN6 -1
In p u t lin e vo ltag e
Red
CN6 -4
In p u t lin e vo ltag e
White
CN6 -7
In p u t lin e vo ltag e
Black
CN7 -1
Ou tp u t vo ltag e d etect
Black
CN7 -3
Ou tp u t vo ltag e d etect
White
CN7 -5
HF o n sig n al/ relay N/O
Gray
CN8-1
+5Vdc on / -4Vdc off
G1 Gate drive ref. To E1
Black
CN8 -2
c o mm o n
E1
White
CN8-4
+5Vdc on / -4Vdc off
G2 Gate drive ref. To E2
White
CN8 -5
c o mm o n
E2
Red
+5Vdc on / -4Vdc off
G3 Gate drive ref. To E3
Black
CN9-1
CN9 -2
c o mm o n
E3
White
CN9-4
+5Vdc on / -4Vdc off
G4 Gate drive ref. To E4
White
CN9 -5
c o mm o n
E4
Orang e
CN10-1
+5Vdc
Thermal sensor power supply
Black
CN10-2
variable
Thermal sensor input
Black
CN13-1 0V = 230V input / 5V = 460V input
Easylink switch
Blue
CN13-2
5V = 230V input 0V = 460V input
Easylink switch
Gray
CN1 3 -3
c o mm o n
commo n
Green
CN1 4 -1
T h yristo r g ate
Black
CN1 4 -2
T h yristo r cath o de
White
CN1 4 -3
n o t u se d
CN1 4 -4
T h yristo r ano d e
Orang e
CN1 8 -1
Th yristor gate d rive relay co n tact Orang e
CN1 8 -2
n o t u se d
CN1 8 -3
Th yristor gate d rive relay co n tact
Gray
A-8
June 21, 2012
pro-wave 300gtsw
Connector
Number
CN2 1 -1
CN2 1 -2
CN2 1 -3
CN2 1 -4
CN2 1 -5
CN2 1 -6
CN21-7
CN21-8
CN21-9
CN21-10
CN2 1 -1 1
CN22-1
CN22-2
CN22-3
CN2 2 -4
CN22-5
CN2 2 -6
CN2 2 -7
CN22-8
CN22-9
CN22-10
CN22-11
CN22-12
CN2 2 -1 3
CN22-14
CN2 2 -1 5
CN23-1
CN2 3 -2
CN2 3 -3
CN2 3 -4
CN23-5
CN23-6
CN2 3 -7
CN2 3 -8
CN2 3 -9
CN23-10
CN23-11
CN2 3 -1 2
CN2 4 -1
CN2 4 -2
CN2 4 -3
June 21, 2012
Meter Reading
Comments
Wire color
+ 1 2 Vd c
co mmon
+ 5 Vd c
+ 5 Vd c
-1 2 Vdc
co mmon
1V=50A
squarewave
squarewave
+5Vdc
variab le
squarewave
squarewave
squarewave
co mmon
+5V on / 0V off
Po wer su p p ly
Rib b o n
Rib b o n
Rib b o n
Rib b o n
Rib b o n
Rib b o n
Ribbon
Ribbon
Ribbon
Ribbon
Rib b o n
Ribbon
Ribbon
Ribbon
Rib b o n
Ribbon
Rib b o n
Rib b o n
Ribbon
Ribbon
Ribbon
Ribbon
Ribbon
Rib b o n
Ribbon
Rib b o n
Ribbon
Rib b o n
Rib b o n
Rib b o n
Ribbon
Ribbon
Rib b o n
Rib b o n
Rib b o n
Ribbon
Ribbon
Rib b o n
Gray
+12 on / 0V off
0V = 230V input 5V = 460V input
5V = 230V input 0V = 460V input
+12 off / +11 on
+12 off / +11 on
+ 1 2 Vd c
12V=230V input 0V=460V input
0V = 230V input 5V = 460V input
co mmon
+ 1 2 Vd c
0V= OVR detected / 5V no OVR
0V= UVR detected / 5V no UVR
co mmon
0V = 230V input 5V = 460V input
5V = 230V input 0V = 460V input
Po wer su p p ly
Po wer su p p ly
Po wer su p p ly
Output current detect
Output voltage detect
Output voltage detect
power supply for thermal
th ermal in p u t
Primary current detect
Primary current detect center tap
Primary current detect
Output short detect
HF o n /o ff
Gas valve o n /o ff
torch switch
Easylink switch
Easylink switch
PWM Gate drive( squarewave)
PWM Gate drive( squarewave)
Input changeover circuit
Sin gle/T h ree p h ase d etect
Input voltage detect
Po wer su p p ly
Reset sign al
Overvoltage detect
Undervoltage detect
Pre-ch arg e co n tro l
T h yristo r g ate d rive
Easylink switch
Easylink switch
T rip p in g relay co n tro l
T h yristo r g ate d rive relay co n tact
n o t u s ed
T h yristo r g ate d rive relay co n tact
Oran g e
A-9
pro-wave 300gtsw
Connector
Number
CN26-1
CN26-2
CN2 6 -3
CN30-1
CN3 0 -2
CN3 0 -3
A-10
Meter Reading
Comments
15V squarewave
common
Super-impose gate drive
+12Vdc
Wire color
n ot u sed
PCB11
n ot u sed
Trip p in g relay co n tro l
June 21, 2012
pro-wave 300gtsw
THIS PAGE INTENTIONALLY LEFT BLANK
June 21, 2012
A-11
pro-wave 300gtsw
APPENDIX 6: WIRE CHART FRONT PANEL PCB6
A-12
Connector
Number
CN1
CN2
CN3 -1
CN3-2
CN3-3
+ 1 2 Vd c
common
0V to 4V "F" or 0V to 10V"G"
CN3-4
0V to 4V "F" or 0V to 10V"G"
CN3-5
CN3 -6
CN3 -7
CN4 -1
CN4 -2
CN5 -1
CN5-2
CN5-3
CN5-4
CN5 -5
CN5 -6
CN6 -1
CN6 -2
CN7 -1
CN7 -2
CN7 -3
CN7 -4
CN7 -5
CN7 -6
CN7-7
CN7-8
CN7-9
CN7-10
CN7 -11
CN8-1
CN8-2
CN8-3
CN8 -4
CN8-5
CN8 -6
CN8 -7
CN8-8
CN8-9
CN8-10
+12Vdc
Meter Reading
+ 2 4 Vd c
co m m o n
+ 1 2 Vd c
squarewave
squarewave
squarewave
Comments
Meter circiu t
Meter circiu t
Pin 4
Remote Reference Common Pin 6
Remote Ref. Out Pin 5
Remote reference in from remote
control Pin 7
When remote plugged in Pin 8
T o rch switch Pin 2
T o rch switch Pin 3
to rch switch
to rch switch
Po wer su p p ly
Straight polarity gate drive
Reverse polarity gate drive
Super-impose gate drive
Seco n d ary o vervo ltag e sig n al
co m m o n
ch assis
Pin 1
ch assis
Pin 1
+ 1 2 Vd c
Po wer su p p ly
co m m o n
+ 5 Vd c
Po wer su p p ly
+ 5 Vd c
Po wer su p p ly
-1 2 Vd c
Po wer su p p ly
co m m o n
1V=50A
Output current detect
squarewave
Output voltage detect
squarewave
Output voltage detect
+5Vdc
power supply for thermal
variab le
th ermal in p u t
squarewave
Primary current detect
squarewave
Primary current detect center tap
squarewave
Primary current detect
co m m o n
+5V on / 0V off
Output short detect
0 /1 2
HF o n /o ff
0 /1 2
Gas valve o n /o ff
+12 on / 0V off
torch switch
0V = 230V input 12V = 460V input
Easylink switch
12V = 230V input 0V = 460V input
Easylink switch
Wire color
Yello w
Violet
Blue
Gray
Green
Red
Oran g e
Yello w
Pin k
Rib b o n
Ribbon
Ribbon
Ribbon
Rib b o n
Rib b o n
Brown
Brown
Rib b o n
Rib b o n
Rib b o n
Rib b o n
Rib b o n
Rib b o n
Ribbon
Ribbon
Ribbon
Ribbon
Rib b o n
Ribbon
Ribbon
Ribbon
Rib b o n
Ribbon
Rib b o n
Rib b o n
Ribbon
Ribbon
Ribbon
June 21, 2012
pro-wave 300gtsw
Connector
Number
CN8-11
CN8-12
CN8 -13
CN8-14
CN8-15
CN9-1
CN9 -2
CN9 -3
CN9 -4
CN9-5
CN9-6
CN9 -7
CN9 -8
CN9 -9
CN9-10
CN9-11
CN9 -12
June 21, 2012
Meter Reading
Comments
Wire color
+12 off / +11 on
+12 off / +11 on
+ 1 2 Vd c
0V = 230V input 12V = 460V input
not used
0V = 230V input 5V = 460V input
co m m o n
+ 1 2 Vd c
PWM Gate drive( squarewave)
PWM Gate drive( squarewave)
Ribbon
Ribbon
Rib b o n
Ribbon
Ribbon
Ribbon
Rib b o n
Rib b o n
Rib b o n
Ribbon
Ribbon
Rib b o n
Rib b o n
Rib b o n
Ribbon
Ribbon
Rib b o n
0V= OVR detected / 5V no OVR
0V= UVR detected / 5V no UVR
co m m o n
0V = 230V input 5V = 460V input
5V = 230V input 0V = 460V input
Input changeover circuit
Single/Three phase detect
Input voltage detect
Po wer su p p ly
Reset sig n al
Overvoltage detect
Undervoltage detect
Pre-ch arg e co n tro l
T h yristo r g ate d rive
Easylink switch
Easylink switch
Trip p in g relay co n tro l
A-13
pro-wave 300gtsw
APPENDIX 7: WIRE CHART AC IGBT GATE DRIVE PCB8
A-14
Connector
Number
CN 1 - 1
CN 1 - 2
CN 1 - 3
CN2-1
CN2-2
CN 2 - 3
CN2-4
CN2-5
CN 3 - 1
CN3-2
CN3-3
CN3-4
CN 3 - 5
CN 3 - 6
CN4-1
CN 4 - 2
CN4-3
CN 4 - 4
CN4-5
300Vpk common
CN5-1
squarewave
CN 5 - 2
co m m o n
Meter Reading
Comments
2 5 0 Va c
Wire color
Br o w n
not used
2 5 0 Va c
squarewave
squarewave
squarewave
squarewave
+ 1 2 Vd c
squarewave
squarewave
squarewave
co m m o n
80Vpk
300Vpk pulse
Q3 G5 gate drive
Q3 E5 gate drive
not used
Q3 G6 gate drive
Q3 E6 gate drive
Po we r s u p p ly
Straight polarity gate drive
Reverse polarity gate drive
Super-impose gate drive
Se c o n d a ry o v e rv o lta g e s ig n a l
Weld volts from FCH
not used
Super-impose output voltage
not used
Super-impose output voltage
15V pulse to fire super-impose
voltage
Ora n g e
White
Black
Blue
White
Rib b o n
Ribbon
Ribbon
Ribbon
Rib b o n
Rib b o n
Brown
Yellow
Gray
Red
Blu e
June 21, 2012
pro-wave 300gtsw
APPENDIX 8: BOTTOM WIRING PLACEMENT DIAGRAM
White on lower
diode bus
bar rear of unit
Black, Black, and Blue Wires
Gray to bus
bar in center
(2) black
to top
center
bus bar
Blue on
front lower
diode bus
bar
Art # A-06168
Brown to outside
FCH connection
June 21, 2012
White to outside
FCH connection
A-15
pro-wave 300gtsw
APPENDIX 9: DIODE TESTING BASICS
Testing of diode modules requires a digital Volt/Ohmmeter that has a diode test scale.
1. Locate the diode module to be tested.
2. Remove cables from mounting studs on diodes to isolate them within the module.
3. Set the digital volt/ohm meter to the diode test scale.
4. Using figure A-6 and A-7, 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.
5. To check the diode in the forward bias direction, connect the volt/ ohm meter positive lead to the anode (positive,
+) of the diode and the negative lead to the cathode (negative, -) of the diode (refer to figure A-6). A properly
functioning diode will conduct in the forward bias direction, and will indicate between 0.3 and 0.9 volts.
6. To check the diode in the reverse bias direction, reverse the meter leads (refer to figure A-6). A properly functioning diode will block current flow in the reverse bias direction, and depending on the meter function, will
indicate an open or “OL”.
7. If any diode in the module tests as faulty, replace the diode module.
8. Reconnect all cables to the proper terminals.
VR
COM
A
Forward Bias
Diode Conducting
Art # A-06015
Anode
Cathode
Forward Bias Diode Test
A-16
June 21, 2012
pro-wave 300gtsw
VR
COM
A
Reverse Bias
Diode Not Conducting
Art # A-06016
Anode
Cathode
Reverse Bias Diode Test
June 21, 2012
A-17
pro-wave 300gtsw
APPENDIX 10: METER CALIBRATION PROCEDURE
The digital meter (Cat. # 10-4000) calibration is controlled by a microprocessor inside the machine and adjusts for
variations in calibration. If you suspect a problem with the meter due to damage, etc. you can check the calibration
of the meter by the following test procedure below:
Make sure the remote voltage and amperage meters are calibrated and can measure frequencies above 42K Hz.
AMPERAGE MEASUREMENT (Stick mode)
Under load the preset voltage setting is arbitrary and is not adjustable. Under load the Panel meter voltage reading
versus the actual voltage reading maybe +5% dependent on the arc length and the combines length of the negative
and positive welding leads. Preset voltage is used for MIG operation and is valid on the LM300 and 400GMS.
AMPERAGE TEST
1. Set the controls for STICK mode, ARC CONTROL minimum, HOT START minimum.
2. Connect the negative and positive output terminals to a load capable of the maximum current of the power
supply.
3. Turn on the power supply.
4. To verify perform the following tests.
a)Set the preset to minimum amps. Load voltage under this test should be approximately 1 to 2 volt.
b)Set the preset to 150 amps. Load voltage under this test should be approximately 20 to 25 volts.
c)Set the preset to 300 amps. Load voltage under this test should be approximately 25 to 30 volts.
Panel Meter amperage versus measured amperage reading maybe + 5% depending on the load and length of cables.
A-18
June 21, 2012
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© 2012 Victor Technologies International, Inc.
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