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ARC
WELDER
MODEL 300TSW AC/DC CC
STICK
TIG - Lift Start
HF Start
OPERATING MANUAL
CONTENTS
SYMBOL LEGEND ............................................................................................................................................................ 5
STATEMENT OF WARRANTY ........................................................................................................................................ 6
1.0 GENERAL INFORMATION......................................................................................................................................... 7
1.01 Notes, Cautions and Warnings ................................................................................................................................ 7
1.02 Important Safety Precautions.................................................................................................................................... 7
1.03 Publications ............................................................................................................................................................. 8
1.04 Note, Attention et Avertissement............................................................................................................................. 9
1.05 Precautions De Securite Importantes....................................................................................................................... 9
1.06 Documents De Reference ...................................................................................................................................... 11
2.0 INTRODUCTION AND DESCRIPTION ................................................................................................................... 13
2.01 Description ............................................................................................................................................................. 13
2.02 Functional Block Diagrams .................................................................................................................................... 14
2.03 Transporting Methods............................................................................................................................................. 14
3.0 Installation Recommendations...................................................................................................................................... 15
3.01 Environment ........................................................................................................................................................... 15
3.02 Location.................................................................................................................................................................. 15
3.03 Electrical Input Connections................................................................................................................................... 16
3.03.01 Electrical Input Requirements ....................................................................................................................... 16
3.03.02 Input Power ................................................................................................................................................... 18
3.03.03 High Frequency Introduction......................................................................................................................... 19
3.03.04 High Frequency Interference ......................................................................................................................... 19
3.04 Specifications ......................................................................................................................................................... 20
3.05 Duty Cycle.............................................................................................................................................................. 21
4.0 OPERATOR CONTROLS ........................................................................................................................................... 23
4.01 Pro-Wave 300TSW Controls.................................................................................................................................. 23
4.02 Weld Process selection for Pro-Wave 300TSW ..................................................................................................... 25
4.03 Weld Parameter Descriptions for Pro-Wave 300TSW ........................................................................................... 26
4.04 Weld Parameters for Pro-Wave 300TSW............................................................................................................... 28
4.05 Power Source Features ........................................................................................................................................... 29
5.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................................................................. 31
6.0 SEQUENCE OF OPERATION.................................................................................................................................... 32
6.01 Stick Welding ......................................................................................................................................................... 33
6.02 AC or DC HF TIG Welding ................................................................................................................................... 33
6.02.01 Save-Load Operation..................................................................................................................................... 34
6.02.02 Slope Mode Sequence ................................................................................................................................... 35
6.02.03 Slope Mode with repeat sequence ................................................................................................................. 36
6.02.04 Pulse Controls................................................................................................................................................ 36
7.0 BASIC TIG WELDING GUIDE.................................................................................................................................. 38
7.01 Explanation of Fluttery Arc when AC TIG Welding on Aluminum ................................................................... 38
7.02 Electrode Polarity ................................................................................................................................................... 39
7.03 Tungsten Electrode Current Ranges ....................................................................................................................... 39
7.04 Tungsten Electrode Types ...................................................................................................................................... 39
7.05 Guide for Selecting Filler Wire Diameter............................................................................................................... 40
7.06 Shielding Gas Selection.......................................................................................................................................... 40
7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ...................................................................... 40
7.08 Welding Parameters for Aluminum........................................................................................................................ 41
7.09 Welding Parameters for Steel ................................................................................................................................. 41
8.0 Basic Arc Welding Guide............................................................................................................................................. 42
8.01 Electrode Polarity ................................................................................................................................................... 42
8.02 Effects of Stick Welding Various Materials ........................................................................................................... 42
9.0 ROUTINE MAINTENANCE ...................................................................................................................................... 43
10.0 BASIC TROUBLESHOOTING................................................................................................................................. 44
10.01 TIG Welding Problems......................................................................................................................................... 44
10.02 Stick Welding Problems ....................................................................................................................................... 46
10.03 Power Source Problems........................................................................................................................................ 48
11.0 Voltage Reduction Device (VRD).............................................................................................................................. 50
11.01 VRD Specification................................................................................................................................................ 50
11.02 VRD Maintenance ................................................................................................................................................ 50
SYMBOL LEGEND
Amperage
Voltage
Hertz (frequency)
SEC
Seconds
Percent
Remote Function
DC (Direct Current)
AC (Alternating Current
Gas Post-Flow
Standard Function
Gas Pre-Flow
Slope Function
VRD
Negative
Spot Function
Positive
Gas Input
Gas Output
STATEMENT OF WARRANTY
LIMITED WARRANTY: Thermal Arc, Inc., A Thermadyne Company, hereafter, Thermal Arc warrants to customers of its
authorized distributors hereafter Thermal; Arc that its products will be free of defects in workmanship or material. Should any
failure to conform to this warranty appear within the time period applicable to the 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 Arcs 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 Arcs 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 ARCS 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 NONAUTHORIZED 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
LABOR
3 YEAR
3 YEAR
3 YEAR
3 YEAR
3 YEAR
3 YEAR
1 YEAR
1 YEAR
1 YEAR
1 YEAR
180 DAYS
180 DAYS
REPAIR/REPLACEMENT PARTS
90 DAYS
90 DAYS
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 purchasers 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 Purchasers risk and expense. This warranty supersedes all previous Thermal Arc
warranties.
Thermal Arc is a Registered Trademark of Thermadyne Industries Inc.
An
operation,
procedure,
or
background
information
which
requires additional emphasis or is
helpful in efficient operation of the
system.
CAUTION
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
OPERATION
AND
MAINTENANCE
OF
ARC
WELDING EQUIPMENT CAN BE
DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.
ELECTRIC SHOCK
NOISE
Noise can cause permanent hearing loss. Arc
welding/cutting processes can cause noise levels
to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of
hearing.
To protect your hearing from loud noise,
wear protective ear plugs and/or ear muffs.
Protect others in the workplace.
Noise levels should be measured to be sure
the decibels (sound) do not exceed safe
levels.
For information on how to test for noise, see
item 1 in Subsection 1.03, Publications, in
this manual.
1.03 Publications
Refer to the following standards or their latest
revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR
1910,
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government Printing Office, Washington, D.C.
20402
2. ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING, obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126
3.
8.
NOTE
Toute opration, procdure ou
renseignement gnral sur lequel il
importe dinsister davantage ou qui
contribue
lefficacit
de
fonctionnement du systme.
ATTENTION
Toute procdure pouvant rsulter
lendommagement du matriel en cas
de non-respect de la procdure en
question.
AVERTISSEMENT
Toute procdure pouvant provoquer
des blessures de loprateur ou des
autres personnes se trouvant dans la
zone de travail en cas de non-respect
de la procdure en question.
FUME et GAZ
La fume et les gaz produits par le procd de jet
de plasma peuvent prsenter des risques et des
dangers de sant.
Eloignez toute fume et gaz de votre zone de
respiration. Gardez votre tte hors de la
plume de fume provenant du chalumeau.
cadmium
chrome
cobalt
cuivre
manganse
mercure
nickel
plomb
slnium
CHOC ELECTRIQUE
Les chocs lectriques peuvent blesser ou mme
tuer. Le procd au jet de plasma requiert et
produit de lnergie lectrique haute tension. Cette
nergie lectrique peut produire des chocs graves,
voire mortels, pour loprateur et les autres
personnes sur le lieu de travail.
Ne touchez jamais une pice sous tension
ou vive; portez des gants et des vtements
secs. Isolez-vous de la pice de travail ou des
autres parties du circuit de soudage.
Rparez ou remplacez toute pice use ou
endommage.
10
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent rsulter
des scories chaudes, des tincelles ou de larc de
plasma. Le procd larc de plasma produit du
mtal, des tincelles, des scories chaudes pouvant
mettre le feu aux matires combustibles ou
provoquer lexplosion de fumes inflammables.
Soyez certain quaucune matire combustible
ou inflammable ne se trouve sur le lieu de
travail. Protgez toute telle matire quil est
impossible de retirer de la zone de travail.
Procurez une bonne aration de toutes les
fumes inflammables ou explosives.
BRUIT
Le bruit peut provoquer une perte permanente de
loue. Les procds de soudage larc de plasma
peuvent provoquer des niveaux sonores
suprieurs aux limites normalement acceptables.
Vous d4ez vous protger les oreilles contre les
bruits forts afin dviter une perte permanente de
loue.
Pour protger votre oue contre les bruits
forts, portez des tampons protecteurs et/ou
des protections auriculaires. Protgez
galement les autres personnes se trouvant
sur le lieu de travail.
Il faut mesurer les niveaux sonores afin
dassurer que les dcibels (le bruit) ne
dpassent pas les niveaux srs.
Pour des renseignements sur la manire de
tester le bruit, consultez larticle 1, page 5.
11
Superintendent
of
Documents,
U.S.
Government Printing Office, Washington,
D.C. 20402
2. Norme ANSI Z49.1, LA SCURIT DES
OPRATIONS
DE
COUPE
ET
DE
SOUDAGE, disponible auprs de la Socit
Amricaine de Soudage (American Welding
Society), 550 N.W. LeJeune Rd., Miami, FL
33126
3. NIOSH, LA SCURIT ET LA SANT LORS
DES OPRATIONS DE COUPE ET DE
SOUDAGE LARC ET AU GAZ,
disponible auprs du Superintendent of
Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES
POUR LA PROTECTION DES YEUX ET DU
VISAGE AU TRAVAIL ET DANS LES
ECOLES, disponible de lInstitut Amricain
des Normes Nationales (American National
Standards Institute), 1430 Broadway, New
York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible
auprs de lAmerican National Standards
Institute, 1430 Broadway, New York, NY
10018
6. Norme ANSI Z49.2, PRVENTION DES
INCENDIES LORS DE LEMPLOI DE
PROCDS DE COUPE ET DE SOUDAGE,
disponible auprs de lAmerican National
Standards Institute, 1430 Broadway, New
York, NY 10018
7. Norme A6.0 de lAssociation Amricaine du
Soudage (AWS), LE SOUDAGE ET LA
COUPE
DE
CONTENEURS
AYANT
RENFERM
DES
PRODUITS
COMBUSTIBLES, disponible auprs de la
American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126
8. Norme 51 de lAssociation Amricaine pour
la Protection contre les Incendies (NFPA),
LES
SYSTEMES
GAZ
AVEC
ALIMENTATION EN OXYGENE POUR LE
SOUDAGE, LA COUPE ET LES PROCDS
ASSOCIS, disponible auprs de la National
Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE
NATIONAL, disponible auprs de la
National
Fire
Protection
Association,
Batterymarch Park, Quincy, MA 02269
Norme
AWSF4.1
de
lAssociation
Amricaine
de
Soudage,
RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRPARATION LA
COUPE
ET
AU
SOUDAGE
DE
CONTENEURS ET TUYAUX AYANT
RENFERM DES PRODUITS DANGEREUX
, disponible auprs de la American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL
33126
12
(V)
OCV
5A
300A
(A)
STICK Process
(V)
(V)
OCV
OCV
10V
25A
300A
(A)
5A
300A
(A)
HF TIG Process
Note 1
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.
13
WARNING 1
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input
power conductors from de-energized supply line before moving the welding power source.
WARNING 2
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
14
b.
c.
Environments with hazardous environments do not include places where electrically conductive
parts in the near vicinity of the operator, which can cause increased hazard, have been
insulated.
3.02 Location
Be sure to locate the welder according to the following guidelines:
WARNING 3
Thermal Arc advises that this equipment be electrically connected by a qualified
electrician.
15
WARNING 4
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of
input power.
16
Input Voltage
208 VAC
230 VAC
460 VAC
Fuse Size
100 Amps
90 Amps
25 Amps
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).
17
Note 3
Note the available input power. Damage to the PCA could occur if 575VAC or higher is
applied.
The following Primary Current recommendations are required to obtain the maximum
welding current and duty cycle from this welding equipment:
Model
Minimum Primary
Current Circuit Size
(Vin/Amps)
208/31
Primary Supply
Lead Size
230/28
8/4 AWG minimum
(Factory Fitted)
PRO-WAVE 300TSW
STICK
-
300A @ 25%
460/14
208/47
230/43
460/21
300A @ 25%
208/67
8/3 AWG minimum
230/60
300A @ 25%
208/96
230/87
300A @ 25%
18
19
3.04 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle
300TSW
TIG
STICK
Output Current
TIG
Range
STICK
300
32
25%
300A / 22V @ 25%
190A / 17V @ 60%
150A / 16V @ 100%
300A / 32V @ 25%
190A / 27V @ 60%
150A / 26V @ 100%
5 300 (DC)
5 300 (AC) @ 60Hz, 50% Cleaning
5 300 (DC)
5 300 (AC) @ 60Hz, 50% Cleaning
69V
8.27 (210mm)
16.89 (420mm)
17.72 (450mm)
63.8 lb. 29 kg
Three-phase
Single-phase
300A
300A
32V
32V
25%
25%
17
20
12.8
12
0.5
0.13
Amperage Draw @ Rated Load
96
87
47
43
21
No Load Amps
2.5
1.8
1.4
1.1
0.7
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment
previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
20
WARNING 5
Exceeding the duty cycle ratings will cause the thermal overload protection circuit to
become energized and shut down the output until the unit has cooled to normal operating
temperature.
CAUTION 1
Continually exceeding the duty cycle ratings can cause damage to the welding power
source and will void the manufactures warranty.
NOTE 4
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and weights quoted are approximate only. Achievable
capacities and ratings in use and operation will depend upon correct installation, use, applications,
maintenance and service.
21
22
E
A
A B C D E F G H I J K L MN
B
C
L
D
I
N
M
E
5k ohms
J
K
H
G
Front view of 14
Socket Receptacle
23
Socket Pin
A
B
C
D
E
G
F,H,I,J,K,L
M
N
Function
Torch Switch Input (24V) to energize weld current.
(connect pins A & B to turn on welding current)
Torch Switch Input (0V) to energize weld current
(connect pins A & B to turn on welding current)
5k ohm (maximum) connection to 5k ohm remote control potentiometer
Zero ohm (minimum) connection to 5k ohm remote control potentiometer
Wiper arm connection to 5k ohm remote control potentiometer
Mains Earth
Not Used F and L used to manually set current control to REMOTE
OK to move current detect signal for robotics applications
OK to move current detect signal for robotics applications
3 Positive Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.
4 Negative Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.
CAUTION 2
Loose welding terminal connections can cause overheating and result in the male plug
being fused in the bayonet terminal and/or melting of the housing (case).
5 Gas Outlet
The Gas Outlet is a 5/8 18 UNF female gas fitting.
6 ON/OFF Switch
This switch connects the Primary supply voltage to the inverter when in the ON position.
This enables the Power Supply.
WARNING 6
When the welder is connected to the Primary supply voltage, the internal electrical
components maybe at 500V potential with respect to earth.
7 Input Cable
The input cable connects the Primary supply voltage to the equipment.
8 Gas Inlet
The Gas Inlet is a 5/8 18 UNF female gas fitting.
24
STICK
HF
TIG
LIFT
TIG
Yes
Yes
Yes
No
Yes
Yes
No
Yes
Yes
No
Yes
No
No
Yes
Yes
Yes
Yes
Yes
STD
SLOPE
REPEAT
SPOT
Description
PULSE ON/OFF
Table 3 Weld Process selection verses Weld Mode for Pro-Wave 300TSW
25
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
PEAK CUR.
WELD
Description
This parameter operates in TIG modes only and is used to get gas to the
weld zone prior to striking the arc, once the torch trigger switch has been
pressed. This control is used to dramatically reduce weld porosity at the
start of a weld.
This parameter operates in all weld modes except Lift TIG mode and is
used to heat up the weld zone in TIG modes or improve the start
characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets
the peak start current on top of the BASE (WELD) current.
e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps &
HOT START = 30 amps
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and
is used to set the start current for TIG. The Start Current remains on until
the torch trigger switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to set the time for
the weld current to ramp up, after the torch trigger switch has been
pressed then released, from INITIAL CUR to PEAK or BASE current
This parameter sets the PEAK weld current when in PULSE mode
This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and
SPOT modes when PULSE is off. This parameter also sets the STICK
weld current.
26
Parameter
BASE
(Background
Current)
SPOT TIME
PULSE WIDTH
Description
This parameter sets the Background current when in Pulse TIG mode.
This parameter sets the duration of the SPOT TIME in HF TIG mode only
This parameter sets the percentage on time of the PULSE FREQUENCY
for PEAK weld current when the PULSE is on.
PULSE FREQ.
This parameter sets the PULSE FREQUENCY when the PULSE is on.
AC FREQUENCY This parameter operates in AC mode only and is used to set the frequency
for the AC weld current.
WAVE BALANCE This parameter is used for aluminum AC TIG mode and is used to set the
penetration to cleaning action for the AC weld current. Generally WAVE
BALANCE is set to 50% for AC STICK welding. The WAVE BALANCE
control changes the ratio of penetration to cleaning action of the AC TIG
welding arc. Maximum weld penetration is achieved when the WAVE
BALANCE control is set to 10%. Maximum cleaning of heavily oxidised
aluminium or magnesium alloys is achieved when the WAVE BALANCE
control is set to 65%.
WAVE BALANCE=50% WAVE BALANCE=10%
50%
10%
(+ )
(-)
50%
Balanced with 50% penetration
and 50% cleaning
DOWN SLOPE
CRATER CUR.
POST-FLOW
65%
(+ )
(-)
WAVE BALANCE=65%
90%
Maximum Penetration and
reduced cleaning
(+ )
(-)
35%
Maximum Cleaning and
reduced penetration
This parameter operates in TIG modes only and is used to set the time for
the weld current to ramp down, after the torch trigger switch has been
pressed, to CRATER CUR. This control is used to eliminate the crater that
can form at the completion of a weld.
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and
is used to set the finish current for TIG. The CRATER Current remains on
until the torch trigger switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to adjust the post
gas flow time once the arc has extinguished. This control is used to
dramatically reduce oxidation of the tungsten electrode.
The SAVE/LOAD buttons are used to save and retrieve a total number of 5
programs into the 300TSW memory.
Table 4 Weld Parameter Descriptions for Pro-Wave 300TSW
27
Weld
Parameter
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
PEAK CUR.
WELD CUR
(TIG)
WELD CUR
(STICK)
SPOT TIME
PULSE WIDTH
PULSE FREQ.
Parameter
Range
0.0 to 1.0 sec
0 to 70A
5 to 300A
0 to 15 sec
5 to 300A
Factory
Setting
0.1 sec
20A
30A
1 sec
120A
Incrementa
l Unit
0.1 sec
1A
1A
0.1 sec
1A
5 to 300A
80A
1A
No
Yes
Yes
5 to 300A
80A
1A
Yes
No
No
2 sec
50%
100.0Hz
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
AC FREQUENCY
WAVE BALANCE
DOWN SLOPE
CRATER CUR.
POST-FLOW
15 to 150Hz
10 to 65%
0 to 25 sec
5 to 300A
0.0 to 60 sec
50Hz
50%
3 sec
30A
10 sec
0.1 sec
1%
See
Table 6
1Hz
1%
0.1 sec
1A
0.1 sec
Yes
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Incremental Unit
0.1Hz
1Hz
5Hz
28
Description
Almost all welding parameters are adjustable.
Digital Meter
ON/OFF switch
Voltage Reduction Device (VRD)
Control Knob
Save/Load function
Feature
Description
knob, 1 to 5 is displayed on the meter.
After selecting the desired memory location (ie 1 to
5), press the right scroll button and the machine will
give a beep to confirm the weld parameters from the
control panel are saved.
LOAD (retrieve) a Program to Control Panel
Press the LOAD button.
Select a memory location by rotating the control
knob, 1 to 5 is displayed on the meter.
After selecting the desired memory location (ie 1 to
5), press the right scroll button and the machine will
give a beep to confirm the weld parameters are loaded
onto the control panel.
30
31
7
3
32
34
Switch
Closed
Initial
Current
Switch
Open
Up
Slope
Switch
Closed
Weld Current
Down
Slope
Switch
Open
Final
Current
Postflow
Preflow
Note 5
Slope function operates with a Remote ON/OFF device only.
1) To start Slope sequence Close remote switch contacts. Once the welding arc is established the
Power Source will maintain initial current setting as long as the remote switch contacts are
closed.
a) In the HF TIG mode, after Preflow time High Frequency is present at the torch. When the
torch is positioned close to the work the welding current will transfer to the work and
establish the arc at the initial current setting.
b) In the Lift TIG mode, after preflow time Lift Start current is present at the torch. When the
electrode is touched to the work and lifted off, the welding arc is established at the initial
current setting.
2) Open Remote Switch current increases to weld current. Once welding arc has reached weld
current the power source will maintain weld current as long as the remote switch contacts are
open.
3) Close Remote Switch Welding current decreases to final current setting. Once final welding
current is reached the power source will maintain final current setting as long as the remote
switch contacts are closed.
4) Open Remote Switch Welding arc stops and post flow begins.
35
(Pulse Frequency)
(Peak Current)
(Base)
Background
Current
The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as
follows:
1)
2)
3)
4)
5)
Pulse-current provides a system in which the welding current continuously changes between two
levels. During the periods of Peak current, heating and fusion takes place, and during the
background (base) current periods, cooling and solidification take place. Pulse Width is the time in
one cycle the current stays at the peak current setting. Pulse Frequency measured in Hertz is the
number of cycles per second the current travels between peak and background current settings. It is
as if the foot rheostat were moved up and down to increase and decrease the welding current on a
regular basis. The faster you moved the foot rheostat up and down the faster the frequency.
36
37
38
AC Current (Amps)
DC Current (Amps)
0.040 (1.0mm)
30 70
30 60
1/16 (1.6mm)
60 95
60 115
3/32 (2.4mm)
125 150
100 165
1/8 (3.2mm)
130 225
135 200
5/32 (4.0mm)
190 280
190 280
3/16 (4.8mm)
250 340
250 340
Thoriated 2%
Zirconated 1%
Ceriated 2%
Welding Application
Features
Color
Code
Red
White
39
Grey
AC Current Range
(Amps)
DC Current Range
(Amps)
30-95
20 - 90
125-160
65 - 115
180-240
100 - 165
220-320
200-350
Alloy
7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter
Current Range DC
Amperes
Thoriated 2%
3/32 (2.4 mm)
120 - 170
Yes
Thoriated 2%
3/32 (2.4 mm)
100 - 160
Yes
Thoriated 2%
3/32 (2.4 mm)
90 - 130
No
Joint Preparation
Table 12 TIG welding parameters for low carbon & low alloy steel pipe
40
AC Current for
Aluminum
Tungsten
Electrode
Diameter
0.040
30-45
35-50
0.040
1.0mm
1/16
1.6mm
5-7
Butt/Corner
Lap/ Fillet
40-60
45-70
0.040
1.0mm
1/16
1.6mm
5-7
Butt/Corner
Lap/ Fillet
60-85
70-95
1/16
1.6mm
1/16
1.6mm
Butt/Corner
Lap/ Fillet
125-150
130-160
3/32
2.4mm
10
Butt/Corner
Lap/ Fillet
180-225
190-240
3/32
2.4mm
1/8
3.2mm
1/8
3.2mm
1/8
3.2mm
10
Butt/Corner
Lap/ Fillet
240-280
250-320
3/16
4.8mm
3/16
4.8mm
13
Butt/Corner
Lap/ Fillet
1.0mm
0.045
1.2mm
1/16
1.6mm
1/8
3.2mm
3/16
4.8mm
6.4mm
Joint Type
Filler Rod
Diameter
(if required)
Argon Gas
Flow Rate
Liters/min
1/16
1.6mm
5-7
Butt/Corner
Lap/ Fillet
1/16
1.6mm
5-7
Butt/Corner
Lap/ Fillet
Joint Type
1/16
1.6mm
60-70
70-90
40-60
50-70
1/16
1.6mm
1/16
1.6mm
Butt/Corner
Lap/ Fillet
1/8
3.2mm
80-100
90-115
65-85
90-110
1/16
1.6mm
3/32
2.4mm
Butt/Corner
Lap/ Fillet
3/16
4.8mm
115-135
140-165
100-125
125-150
3/32
2.4mm
1/8
3.2mm
10
Butt/Corner
Lap/ Fillet
6.4mm
160-175
170-200
135-160
160-180
1/8
3.2mm
5/32
4.0mm
10
Butt/Corner
Lap/ Fillet
42
WARNING 8
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 the Opening the Enclosure section in the
300TSW Service Manual P/N 430429-517) and use a vacuum cleaner to remove any accumulated
dirt and dust. The unit should also be wiped clean, if necessary; with solvents that are
recommended for cleaning electrical apparatus.
CAUTION 5
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.
43
Possible Cause
1 Excessive beard
build-up or poor
penetration or poor
fusion at edges of
weld.
44
Remedy
Description
Possible Cause
Remedy
6 Electrode melts
A Electrode is connected to the A Connect the electrode to the
when arc is struck.
+ terminal.
terminal.
B WAVE BALANCE is greater B Reduced WAVE BALANCE to
than 50%.
below 50% or increase the
electrode size.
7 Dirty weld pool.
A Electrode contaminated
through contact with work
piece or filler rod material.
B Gas contaminated with air.
45
Description
Possible Cause
Remedy
C Select the right flow rate,
change cylinders or turn torch
valve on.
Possible Cause
1 Gas pockets or
A Electrodes are damp.
voids in weld metal B Welding current is too high.
(Porosity).
C Surface impurities such as
oil, grease, paint, etc.
2 Crack occurring in A Rigidity of joint.
weld metal soon
after solidification
commences
B Insufficient throat thickness.
3 A gap is left by
failure of the weld
metal to fill the
root of the weld.
Remedy
A Dry electrodes before use.
B Reduce welding current.
C Clean joint before welding.
A Redesign to relieve weld joint
of severe stresses or use crack
resistance electrodes.
B Travel slightly slower to allow
greater build up in throat.
C Preheat plate and cool slowly.
A Increase welding current
B Use smaller diameter
electrode.
C Allow wider gap.
D Use correct build-up sequence.
46
4 Portions of the
weld run do not
fuse to the surface
of the metal or
edge of the joint.
E
F
47
Possible Cause
Remedy
2 Maximum output
Defective control circuit
Have an Accredited Thermal
welding current can
Arc Service Agent inspect
not be achieved
then repair the welder.
with nominal
Mains supply
voltage.
3 Welding current
Poor work lead connection to
Ensure that the work lead has
reduces when
the work piece.
a positive electrical
welding
connection to the work piece.
4 No gas flow when A Gas hose is cut.
A Replace gas hose.
the torch trigger
B Gas passage contains
B Disconnect gas hose from the
switch is
impurities.
rear of Power Source then
depressed.
raise gas pressure and blow
out impurities.
C Gas regulator turned off.
C Turn gas regulator on.
D Torch trigger switch lead is
D Reconnect lead or repair faulty
disconnected or switch/cable
switch/cable.
is faulty.
48
Description
Possible Cause
Remedy
49
Description
VRD Open Circuit Voltage
VRD Resistance
VRD Turn OFF Time
Pro-Wave
300TSW
15.3 to 19.8V
Notes
Open circuit voltage between welding
terminals
148 to 193 ohms The required resistance between welding
terminals to turn ON the welding power
0.2 to 0.3 seconds The time taken to turn OFF the welding
power once the welding current has
stopped
50
Description
Possible Cause
51
Remarks
B Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check for low Mains
voltage.
Remedy
52
Possible Cause
Description
Have an Accredited
Thermal Arc Service Agent
check connector plug on
input PCB and the Mains
voltage
Have an Accredited
Thermal Arc Service Agent
check connector plug on
input PCB.
Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the Mains voltage.
Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the Mains voltage
Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the Mains voltage.
Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the Primary voltage.
Remedy
No weld current is
available.
Buzzer sounds constantly.
Switch machine off then on
to reset E83 error.
No weld current is
available.
Buzzer sounds constantly.
Switch machine off.
No weld current is
available.
Buzzer sounds constantly.
Switch machine off.
Remarks
53
Possible Cause
Description
Remarks
Have an Accredited
Weld current ceases.
Thermal Arc Service Agent Buzzer sounds constantly.
check or replace the
Switch machine off.
temperature sensors.
Have an Accredited
Weld current ceases.
Thermal Arc Service Agent Buzzer sounds constantly.
check the control PCB.
Switch machine off.
Remedy
Inductor
HF. Unit
HF. Gap
Inductor
FCH
HF.UNIT
L105
Description
Coupling Coil
Remote Socket
Current Sensor
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Fan
DWG. No.
CC
CON1
CT1
D1
D2
D3
D4
D5
D6
D6
FAN
54
QTY.
1
1
1
1
1
1
1
1
1
1
1
F2A677600
U0A632200
U0A601100
63200006500
Code No.
F2A677800
U0A727700
11251003000
454180160
4583A0060
4583A0060
4583A0060
4583A0060
4583A0060
4583a0060
U0A738200
10-6771
10-6632
10-6633
10-6538
Order No.
10-6767
10-6768
10-5003
10-6769
10-6629
10-6629
10-6629
10-6629
10-6629
10-6629
10-6770
Transistor
Transistor
Transistor
PCB2
PCB3
PCB4
PCB5
PCB6
PCB9
PCB10
PCB11
PCB14
PCB15
PCB16
PCB17
PCB18
PCB19
Q1
Q2
Q3
Q4
DWG. No.
Description
PCB1
Printed Circuit Board
55
10-6856
10-6780
10-6853
10-6853
10-6876
10-6856
10-6773
10-6635
10-6774
10-6846
10-6775
10-6740
10-6776
10-6777
10-6778
10-6852
Order No.
10-6772
Description
Resistor
Resistor
Switch
Switch
Solenoid Valve
Transformer
Transformer
Transformer
Thermistor
Front Panel
Rear Panel
Side Panel
Front Control Cover
Rear Control Cover
Protection Cover
Encoder Cover
PCB Cover
DWG. No.
R2
R3
S1
S2
SOL
T1
T2
T3
TH1,2
56
QTY.
1
2
1
1
1
F2A705700
F2A705700
F2A869300
U0A733300
E0D004800
E0D004900
E0D006200
J4B570500
U0A728000
E0C299200
EBA514400
E1B547900
Code No.
40310211500
40511000200
25850003700
24704531400
U0A705700
10-6782
10-6782
10-6877
10-6784
10-6785
10-6786
10-6787
10-6788
10-6789
10-6790
10-6791
10-6792
Order No.
10-5081
10-5137
10-6857
10-6781
10-6645
DWG. No.
Description
Name Label
Side Label
VRD Label
Warranty Label
Warning Label 1
Warning Label 2
Output Terminal Label
Gas Input Label
Gas Outlet
C-Ring
Output Terminal
(female)
Input Cable
Input Cable Clamp
Heatsink
Heatsink
Knob
Knob Cap
Control Cover Sheet
Flat Cable
57
1
1
1
1
1
1
1
1
TRAK-BE35-70S
QTY.
2
2
1
1
1
1
1
1
1
2
2
U0A722400
EBA156800
E1B548900
E1B549000
50990001650
50990003400
N0B882700
EAA547301
Code No.
N4A056400
N4A009200
N4A155900
N4A155800
N0B891300
N0B476400
N4A040600
N4A040700
U0A705800
53003000600
26999025900
Ref. Only
10-6795
10-6796
10-6797
10-6798
10-6799
10-6800
10-6668
Order No.
10-6793
10-6657
Ref. Only
Ref. Only
10-5497
10-5496
10-6794
10-6733
10-6659
10-5184
10-6660
DWG. No.
Description
Post11 (S1)
Post2 (Q4)
Post3 (D1,Q1,Q2)
Post421 (D2-6)
Post410
S1 Bus Bar
Transformer Bus Bar 1
Q2,3 Bus Bar 1
Q2,3 Bus Bar 2
Q-(+) Bus Bar
D Bus Bar 2
D Total Bus Bar 1
D Total Bus Bar 3
D Total Bus Bar 4
D Total Bus Bar 5
D Total Bus Bar 6
58
QTY.
3
3
9
8
4
3
1
2
1
1
1
1
1
1
1
1
Code No.
EBA643600
EBA425000
EBA425100
53602020600
53602011500
ECA321000
EBA365600
EBA429000
EBA429100
EBA501200
EBA364800
ECA129100
ECA129300
ECA129400
ECA129600
ECA129700
Order No.
10-6751
10-6801
10-6802
10-6803
10-6867
10-6868
10-6804
10-6806
10-6807
10-6808
10-6810
10-6870
10-6871
10-6872
10-6878
10-6879
DWG. NO.
59
Description
QTY.
4
1
1
1
1
1
1
2
1
1
2
1
1
10-6820
10-6821
10-6681
10-2020
430429-511
430429-517
Order No.
10-5259
10-6814
10-6815
10-6816
10-6817
10-6818
10-6819
APPENDIX A
CN2
INTERCONNECT DIAGRAM
PCB1
1 2
V1
(TB1)
Q1
C1
TB1
C2E1
G2
E2
E1
G1
G 6
S1
L1
PCB17
CN12
1
2
5
6
PCB7
+ 7
PCB9
1
4
CN2
P
1
CN1
Ti1
INPUT
VG1
VG2
CN1
PGND
CN1
1
2
AC_in
TB11
(TB2)
G1
E1
TB7
TB8
D1
L2
L3
R2
PCB16
G2
CN3
TB12
E2
E2
CN13
E
E2
TB2
N
N
(TB3)
V2
C1
TB3
TB4
1
3
5
CN3
PCB18 CN12
3
(TB4)
V3
C1
Q2
CN2
1 2 3
1 2
G4
E4
E3
G3
1
2
5
6
TB13
(TB5)
G1
E1
TB9
TB10
G2
CN3
TB14
E2
E2
(TB6)
CN13
V4
T3
250V
CN21
CN22
1 2 5
1 2 3 4 5
1 2
1 2 5
1 2 3 4 5
1 2
CN118
CN121
CN122
PCB2
+
1
2
3
4
1
2
N
M
H
G
1
2
3
4
5
1
3
CN123
CN7 CN8
CN3
CN223
CN5 CN6
CN1
PCB3
PCB4
CN5
CN4
CN7
CN10
CN4
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3
1 2
2 4 3
460V
L
D
CON1
CN19
CN15
60
P+12V B
/TAP200
P+12V A
/L IN K 2 0 0
/LINK400
E3
G3
G4
E4
E1
G1
G2
E2
A B C D E F G H I J K L M N CON1
230V
FAN
1
2
SOL
A
CN18
CN1
AC_in
PGND
CN12
CN23
0V
FRONT
PANEL
250V
1
4
P+12V B
/TAP200
P+12V A
/LINK200
/LINK400
460V
230V
VG3
VG4
PCB8
CN2
CN1
CN1
CN1
PCB14
CN1
C2E1
1
3
5
S2
1
5
CN2
PCB19
CN3
V G3
V G4
1
4
V G1
V G2
CN1
AC1
PCB10
1
3
5
V1
V2
V3
V4
1
2
CN2
RY +12 V
/RY _ON
PCB15
CN1
1 4 7 10
D5
TB9
S _ DET+
FCH
TB10
CT1
TB8
Q3
C1
G1
C2E1 C2E1
E1
E1
G7
E7
E8
G8
5
4
2
1
+12V
-12V
I_SENSE
GND
G1
CN1
5
4
2
1
CN1
G5
E5
E6
G6
PCB12
D6
123
4
C1
PCB13
T1
b
To
OUTPUT
D7
G2
G2
E2
E2
TB6
E2
Q4
TB7
S _ DET-
TB2
TB3
CN5
D2
CC
1
2
CN4
TB1
T2
E2
9
8
7
6
4
3
2
1
D3
d
e
G5
E5
G7
E7
E6
G6
E8
G8
CC2
CC1
R2
HF.UNIT
D4
CN3
S _ DETS _ DET+
1 2 3 4 5 6 7
1 3 5 7 9
5 2 1
CN10
CN9
RY +12 V
/RY _ON
TH1
1 2 3 4 5 6 7
1 2 3 4
CN3
CN8
PCB5
1
CN17
CN2
12
CN5
12
26
1
2
3
4
5
6
7
PCB6
26
1
2
3
4
5
6
7
TH2
+1 2V
-1 2 V
I_ S ENS E
GND
CN1
PCB2
CN13
L105
1
2
3
4
CN4
CN7
12
12
61
CN6
AC2
1
3
AC2
2 5 0V
0V
3
1
AC1
TB5
CN2
TB4
CN1
R1
CN16
R3
PCB11
R2