DocLib_2855_Transarc 300 Si Service Manual_AA - 0-5000

5060

Hz3PHASEGTAWSMAW CC 300AMP415V

INVERTER DC

300 SitranSarcInVErtEr arc WELDEr

Service ManualRevision: AA IssueDate:January 15, 2008 ManualNo:0-5000OperatingFeatures:

WE APPRECIATE YOUR BUSINESS!Congratulations on your new CIGWELD product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 800-752-7621, or visit us on the web at www.cigweld.au.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Cigweld product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore, please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!The Brand of Choice for Contractors and Fabricators Worldwide. Cigweld is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

! WARNINGRead and understand this entire Manual and your employers safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturers best judgment, the Manufacturer assumes no liability for its use.

Servce Manual Number 0-5000 for:Transarc 300 S Inverter Weldng Power Supply Part No. 625781

Publshed by:Thermadyne Industres, Inc.82 Bennng StreetWest Lebanon, New Hampshre, USA 03784(603) 298-5711

www.thermadyne.com

Copyrght 2008 byThermadyne Industres, Inc.

All rghts reserved.

Reproducton of ths work, n whole or n part, wthout wrtten permsson of the publsher s prohbted.

The publsher does not assume and hereby dsclams any lablty to any party for any loss or damage caused by any error or omsson n ths Manual, whether such error results from neg-lgence, accdent, or any other cause.

Publcaton Date: January 15, 2008

RecordthefollowinginformationforWarrantypurposes:

Where Purchased: _______________________________ Purchase Date: _______________________________

Equpment Seral #: _______________________________

Table of Contents

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-11.02 Principal Safety Standards .............................................................................. 1-41.03 Precautions De Securite En Soudage A Larc .................................................. 1-51.04 Dangers relatifs au soudage larc ................................................................. 1-51.05 Principales Normes De Securite ..................................................................... 1-81.06 Declaration Of Conformity .............................................................................. 1-9

SECTION 2: INTRODUCTION AND DESCRIPTION .............................................................. 2-1

2.01 How To Use This Manual ................................................................................ 2-12.02 Equipment Identification ................................................................................. 2-12.03 Receipt Of Equipment ..................................................................................... 2-12.04 Symbol Chart .................................................................................................. 2-22.05 Description ...................................................................................................... 2-32.06 Functional Block Diagrams .............................................................................. 2-32.07 Transporting Methods ..................................................................................... 2-4

SECTION 3: INSTALLATION RECOMMENDATIONS ............................................................. 3-1

3.01 Environment .................................................................................................... 3-13.02 Location .......................................................................................................... 3-13.03 Electrical Input Connections ............................................................................ 3-13.04 Mains Supply Voltage Requirements .............................................................. 3-23.05 Specifications .................................................................................................. 3-33.05 Duty Cycle ....................................................................................................... 3-4

SECTION 4: OPERATOR CONTROLS ............................................................................. 4-1

4.01 Transarc 300 Si Controls ................................................................................. 4-14.02 Weld Parameter Description ........................................................................... 4-24.03 Weld Parameters for Transarc 300 Si .............................................................. 4-34.04 Power Source Features ................................................................................... 4-4

SECTION 5: SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................. 5-1

SECTION 6: SEQUENCE OF OPERATION ......................................................................... 6-1

6.01 Stick Welding .................................................................................................. 6-16.02 DC LIFT TIG Welding ....................................................................................... 6-1

Table of Contents

SECTION 7: BASIC TIG WELDING GUIDE ........................................................................ 7-1

7.01 Electrode Polarity ............................................................................................ 7-17.02 Tungsten Electrode Current Ranges ................................................................ 7-17.03 Tungsten Electrode Types ............................................................................... 7-17.04 Guide for Selecting Filler Wire Diameter ......................................................... 7-17.05 Shielding Gas Selection .................................................................................. 7-27.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ................... 7-2

SECTION 8: BASIC ARC WELDING GUIDE ....................................................................... 8-1

8.01 Electrode Polarity ............................................................................................ 8-18.02 Effects of Stick Welding Various Materials ...................................................... 8-1

SECTION 9: ROUTINE MAINTENANCE .......................................................................... 9-1

9.01 VRD Specification ........................................................................................... 9-39.01 VRD Maintenance ........................................................................................... 9-3

SECTION 10: BASIC TROUBLESHOOTING .......................................................................10-1

10.01 TIG Welding Problems ................................................................................ 10-110.02 Stick Welding Problems .............................................................................. 10-310.03 Power Source Problems ............................................................................. 10-410.04 Power Source Error Codes .......................................................................... 10-5

SECTION 11: ADVANCED TROUBLESHOOTING .................................................................11-1

11.01 System-Level Fault Isolation ....................................................................... 11-111.1.1 Opening the Enclosure ....................................................................... 11-1

11.02 Verification and Remedy to the Indicated Error Codes ................................ 11-311.2.1 E01 Over-Temperature at the primary side ..................................... 11-311.2.2 E02 Over-Temperature at the secondary side ................................. 11-411.2.3 E03 Transformer Over-Current Failure ........................................... 11-411.2.4 E04 Torch Cable Failure ................................................................. 11-511.2.5 E11 Main Supply Over Volt-age ...................................................... 11-511.2.6 E12 Main Supply Under Volt-age .................................................... 11-511.2.7 E81 Wrong Main Supply Voltage .................................................... 11-511.2.8 E82 Rated Voltage Selection Circuit abnormality ............................ 11-611.2.9 E83 Abnormalities in Mains Supply Voltage Detection .................... 11-611.2.10 E85 Pre-charge abnormality ......................................................... 11-611.2.11 E94 Thermistor malfunction ......................................................... 11-711.2.12 E99 Initial Power Receiving .......................................................... 11-7

11.03 Verification and Remedy to Failures without Indication Codes .................... 11-711.3.1 Cooling Fan (FAN1) Failure (Fan is not rotating.) ............................ 11-711.3.2 No Weld Output .............................................................................. 11-811.3.3 Operating Panel Failure ................................................................... 11-9

11.04 Fault Isolation Tests .................................................................................. 11-1011.4.1 Preparation ...................................................................................... 11-10

Table of Contents

11.05 Verification of the Power Input Circuitry ................................................... 11-1111.5.1 Verification of the AC Input Voltage using an AC voltmeter.............. 11-1111.5.2 Verification of the Power Supply Voltage ......................................... 11-1211.5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry ...................... 11-1311.5.4 Verification of the Gas Valve, SOL1, Drive Circuitry ......................... 11-1411.5.5 Verification of the Primary Diode (D1) ............................................. 11-1411.5.6 Verification of the Secondary Diode (D2-D7) ................................... 11-1511.5.7 Verification of the Primary IGBT (Q1-Q24) ...................................... 11-1511.5.8 Verification of the Secondary IGBT (Q25-Q26) ................................ 11-1611.5.9 Verification of No-load Volt-age (OCV)............................................. 11-16

SECTION 12: MAINTENANCE ......................................................................................12-1

12.01 Maintenance List ......................................................................................... 12-112.02 Service Tools ............................................................................................... 12-5

12.2.1 Tools and parts .................................................................................. 12-512.2.2 Notes of disassembly and assembly .................................................. 12-5

12.03Replacement Procedure ............................................................................... 12-612.3.1 PCB1(WK-5493) ................................................................................ 12-612.3.2 PCB2 (WK-5597) ............................................................................... 12-712.3.3 PCB3 (WK-5548), PCB7 (WK-5550) .................................................. 12-812.3.4 PCB4 (WK-4819) ............................................................................. 12-1012.3.5 PCB5 (WK-5551) ............................................................................. 12-1012.3.6 PCB6 (WK-5549) ............................................................................. 12-1012.3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 Primary IGBT ..................... 12-1112.3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 Primary IGBT ............... 12-1212.3.9 PCB12 (WK-5527) ........................................................................... 12-1212.3.10 PCB13 (WK-5528) ......................................................................... 12-1312.3.11 PCB14 (WK-5594) ................................ 12-1412.3.12 PCB15 (WK-5606) ......................................................................... 12-1512.3.13 PCB20 (WK-5499) ......................................................................... 12-1612.3.14 PCB21 (WK-4917) ......................................................................... 12-1612.3.15 PCB22 (WK-5022) ......................................................................... 12-1812.3.16 Current Limiting Resistor (R6) ...................................................... 12-1812.3.17 Resistor (R7, R8) ........................................................................... 12-1912.3.18 Reactor (FCH1) ...............................................................................12.2112.3.19 Primary Thermistor (TH1) ............................................................. 12-2212.3.20 Secondary Thermistor (TH2) ......................................................... 12-2312.3.21 Cooling Fan (FAN1) ........................................................................ 12-2312.3.22 Main ON/OFF Switch (S1) .............................................................. 12-2512.3.23 Input Voltage Switch (S2) .............................................................. 12-2612.3.24 Remote Socket (CON1) .................................................................. 12-2712.3.25 Hall Current Sensor (HCT1) ........................................................... 12-2812.3.26 Primary Diode (D1) ........................................................................ 12-2912.3.27 Secondary Diode (D2, D4, D5 and D7) .......................................... 12-3012.3.28 Current Trans (CT2, CT3) ............................................................... 12-31

Table of Contents

12.3.29 Ring Core (L1) ............................................................................... 12-3212.3.30 Ring Core (L105) ........................................................................... 12-3412.3.31 Reactor (L101) .............................................................................. 12-3512.3.32 Reactor (L102) .............................................................................. 12-3612.3.33 Reactor (L103) .............................................................................. 12-37

APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1

APPENDIX 2: INTERCONNECT DIAGRAM .............................................................. A-2

APPENDIX 3: PARTS LIST ................................................................................. A-3

APPENDIX 4: CONNECTION WIRING GUIDE ............................................................ A-8

APPENDIX 5: DIODE TESTING BASICS .................................................................A-10

CIQWELD LIMITED WARRANTY

Terms of Warranty January 2008

Warranty Schedule January 2008

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ........................... Inside Rear Cover

TRANSARC 300 Si SERVICE MANUAL

January 15, 2008v

THISPAGELEFTINTENTIONALLYBLANK.

SERVICE MANUAL TRANSARC 300 Si

January 15, 2008 1-1

SECTION1:SAFETYINSTRUCTIONSANDWARNINGS

!

WARNING

PROTECTYOURSELFANDOTHERSFROMPOSSIBLESERIOUSINJURYORDEATH.KEEPCHILDRENAWAY.PACEMAKERWEARERSKEEPAWAYUNTILCONSULTINGYOURDOCTOR.DONOTLOSETHESEINSTRUCTIONS.READOPERATING/INSTRUCTIONMANUALBEFOREINSTALLING,OPERATINGORSERVICINGTHISEQUIPMENT.

Weldng products and weldng processes can cause serous njury or death, or damage to other equpment or property, f the operator does not strctly observe all safety rules and take precautonary actons.

Safe practces have developed from past experence n the use of weldng and cuttng. These practces must be learned through study and tranng before usng ths equpment. Some of these practces apply to equpment connected to power lnes; other practces apply to engne drven equpment. Anyone not havng extensve tranng n weldng and cuttng practces should not attempt to weld.

Safe practces are outlned n the Amercan Natonal Standard Z49.1 enttled: SAFETY IN WELDING AND CUTTING. Ths publcaton and other gudes to what you should learn before operatng ths equpment are lsted at the end of these safety precautons. HAVEALLINSTALLATION,OPERATION,MAINTENANCE,ANDREPAIRWORKPERFORMEDONLYBYQUALIFIEDPEOPLE.

1.01 ArcWeldingHazards

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 lve electrcal parts.

2. Wear dry, hole-free nsulatng gloves and body protecton.

3. Insulate yourself from work and ground usng dry nsulatng mats or covers.

4. Dsconnect nput power or stop engne before nstallng or servcng ths equpment. Lock nput power dsconnect swtch open, or remove lne fuses so power cannot be turned on accdentally.

5. Properly nstall and ground ths equpment accordng to ts Owners Manual and natonal, state, and local codes.

6. Turn off all equpment when not n use. Dsconnect power to equpment f t wll be left unattended or out of servce.

7. Use fully nsulated electrode holders. Never dp holder n water to cool t or lay t down on the ground or the work surface. Do not touch holders connected to two weldng machnes at the same tme or touch other people wth the holder or electrode.

8. Do not use worn, damaged, underszed, or poorly splced cables.

9. Do not wrap cables around your body.

10. Ground the workpece to a good electrcal (earth) ground.

11. Do not touch electrode whle n contact wth the work (ground) crcut.

12. Use only well-mantaned equpment. Repar or replace damaged parts at once.

13. In confined spaces or damp locatons, do not use a welder wth AC output unless t s equpped wth a voltage reducer. Use equpment wth DC output.

14. Wear a safety harness to prevent fallng f workng above floor level.

15. Keep all panels and covers securely n place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

1. Wear a weldng helmet fitted wth a proper shade of filter (see ANSI Z49.1 lsted n Safety Standards) to protect your face and eyes when weldng or watchng.

2. Wear approved safety glasses. Sde shelds recommended.

3. Use protectve screens or barrers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protectve clothng made from durable, flame-resstant materal (wool and leather) and foot protecton.

5. Use approved ear plugs or ear muffs f nose level s hgh.


January 15, 20081-2

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If nsde, ventlate the area and/or use exhaust at the arc to remove weldng fumes and gases.

3. If ventlaton s poor, use an approved ar-suppled resprator.

4. Read the Materal Safety Data Sheets (MSDSs) and the manufacturers nstructon for metals, consumables, coatngs, and cleaners.

5. Work n a confined space only f t s well ventlated, or whle wearng an ar-suppled resprator. Sheldng gases used for weldng can dsplace ar causng njury or death. Be sure the breathng ar s safe.

6. Do not weld n locatons near degreasng, cleanng, or sprayng operatons. The heat and rays of the arc can react wth vapors to form hghly toxc and rrtatng gases.

7. Do not weld on coated metals, such as galvanzed, lead, or cadmum plated steel, unless the coatng s removed from the weld area, the area s well ventlated, and f necessary, whle wearng an ar-suppled resprator. The coatngs and any metals contanng these elements can gve off toxc fumes f 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 flyng sparks and hot metal.

2. Do not weld where flyng sparks can strke flammable materal.

3. Remove all flammables wthn 35 ft (10.7 m) of the weldng arc. If ths s not possble, tghtly cover them wth approved covers.

4. Be alert that weldng sparks and hot materals from weldng can easly go through small cracks and openngs to adjacent areas.

5. Watch for fire, and keep a fire extngusher nearby.

6. Be aware that weldng on a celng, floor, bulkhead, or partton can cause fire on the hdden sde.

7. Do not weld on closed contaners such as tanks or drums.

8. Connect work cable to the work as close to the weldng area as practcal to prevent weldng current from travelng long, possbly unknown paths and causng electrc shock and fire hazards.

9. Do not use welder to thaw frozen ppes.

10. Remove stck electrode from holder or cut off weldng wre at contact tp when not n use.

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 sheld or safety goggles. Sde shelds recommended.

2. Wear proper body protecton to protect skn.

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size FilterTorch soldering 2 Gas metal-arc Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting Ferrous base metal All 12Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gougingHeavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 145/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

Eye protection filter shade selector for welding or cutting(goggles or helmet), from AWS A6.2-73.


January 15, 2008 1-3

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 cylnders from excessve heat, mechancal shocks, and arcs.

2. Install and secure cylnders n an uprght poston by channg them to a statonary support or equpment cylnder rack to prevent fallng or tppng.

3. Keep cylnders away from any weldng or other electrcal crcuts.

4. Never allow a weldng electrode to touch any cylnder.

5. Use only correct sheldng gas cylnders, regulators, hoses, and fittngs desgned for the specfic applcaton; mantan them and assocated parts n good condton.

6. Turn face away from valve outlet when openng cylnder valve.

7. Keep protectve cap n place over valve except when cylnder s n use or connected for use.

8. Read and follow nstructons on compressed gas cylnders, assocated equpment, and CGA publcaton P-1 lsted n Safety Standards.

! WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engnes produce harmful exhaust gases.

1. Use equpment outsde n open, well-ventlated areas.

2. If used n a closed area, vent engne exhaust outsde and away from any buldng ar ntakes.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engne before checkng or addng fuel.

2. Do not add fuel whle smokng or f unt s near any sparks or open flames.

3. Allow engne to cool before fuelng. If possble, check and add fuel to cold engne before begnnng job.

4. Do not overfill tank allow room for fuel to expand.

5. Do not spll fuel. If fuel s splled, clean up before startng engne.

WARNING

MOVING PARTS can cause injury.

Movng parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothng.

1. Keep all doors, panels, covers, and guards closed and securely n place.

2. Stop engne before nstallng or connectng unt.

3. Have only qualfied people remove guards or covers for mantenance and troubleshootng as necessary.

4. To prevent accdental startng durng servcng, dsconnect negatve (-) battery cable from battery.

5. Keep hands, har, loose clothng, and tools away from movng parts.

6. Renstall panels or guards and close doors when servcng s finshed and before startng engne.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteres contan acd and generate explosve gases.

1. Always wear a face sheld when workng on a battery.

2. Stop engne before dsconnectng or connectng battery cables.

3. Do not allow tools to cause sparks when workng on a battery.

4. Do not use welder to charge batteres or jump start vehcles.

5. Observe correct polarty (+ and ) on batteres.

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 radator cap when engne s hot. Allow engne to cool.

2. Wear gloves and put a rag over cap area when removng cap.

3. Allow pressure to escape before completely removng cap.

!

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals know to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety code Sec. 25249.5 et seq.)


January 15, 20081-4

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

The followng s a quotaton from the General Conclusons Secton of the U.S. Congress, Office of Technology Assessment, Bologcal Effects of Power Frequency Electrc & Magnetc Felds - Background Paper, OTA-BP-E-63 (Washngton, DC: U.S. Government Prntng Office, May 1989): ...there s now a very large volume of scentfic findngs based on experments at the cellular level and from studes wth anmals and people whch clearly establsh that low frequency magnetc fields and nteract wth, and produce changes n, bologcal systems. Whle most of ths work s of very hgh qualty, the results are complex. Current scentfic understandng does not yet allow us to nterpret the evdence n a sngle coherent framework. Even more frustratng, t does not yet allow us to draw definte conclusons about questons of possble rsk or to offer clear scence-based advce on strateges to mnmze or avod potental rsks.

To reduce magnetc felds n the workplace, use the followng procedures.

1. Keep cables close together by twstng or tapng them.

2. Arrange cables to one sde and away from the operator.

3. Do not col or drape cable around the body.

4. Keep weldng power source and cables as far away from body as practcal.

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

1.02 PrincipalSafetyStandardsSafety n Weldng and Cuttng, ANSI Standard Z49.1, from Amercan Weldng Socety, 550 N.W. LeJeune Rd., Mam, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superntendent of Documents, U.S. Government Prntng Office, Washngton, D.C. 20402.

Recommended Safe Practces for the Preparaton for Weldng and Cuttng of Contaners That Have Held Hazardous Substances, Amercan Weldng Socety Standard AWS F4.1, from Amercan Weldng Socety, 550 N.W. LeJeune Rd., Mam, FL 33126.

Natonal Electrcal Code, NFPA Standard 70, from Natonal Fre Protecton Assocaton, Batterymarch Park, Quncy, MA 02269.

Safe Handlng of Compressed Gases n Cylnders, CGA Pamphlet P-1, from Compressed Gas Assocaton, 1235 Jefferson Davs Hghway, Sute 501, Arlngton, VA 22202.

Code for Safety n Weldng and Cuttng, CSA Standard W117.2, from Canadan Standards Assocaton, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontaro, Canada M9W 1R3.

Safe Practces for Occupaton and Educatonal Eye and Face Protecton, ANSI Standard Z87.1, from Amercan Natonal Standards Insttute, 1430 Broadway, New York, NY 10018.Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.


January 15, 2008 1-5

1.03 DECLARATIONOFCONFORMITYManufacturer: CIGWELD

Address: 71 Gower St, Preston Vctora 3072

Australa

Descrpton of equpment: Weldng Equpment (GMAW, MMAW, GTAW). Includng, but not lmted to CIGWELD Transtg 200 P, Transtg 200 AC/DC, Transarc 300 S, Transtg 300 P, Transtg 300 AC/DC, Transmg 400 and assocated accessores.

Seral numbers are unque wth each ndvdual pece of equpment and detals descrpton, parts used to manufacture a unt and date of manufacture.

The equpment conforms to all applcable aspects and regulatons of the Low Voltage Drectve (Drectve 73/23/EU, as recently changed n Drectve 93/68/EU and to the Natonal legslaton for the enforcement of the Drectve.

Natonal Standard and Techncal Specficatons

The product s desgned and manufactured to a number of standards and techncal requrements among them are:

AS/NZS 3652-(EMC Drectve EN50199) applcable to arc weldng equpment - generc emssons and

regulatons.

EN60974-1 applcable to weldng equpment and assocated accessores.

AS60974.1 applcable to weldng equpment and assocated accessores.

Extensve product desgn verficaton s conducted at the manufacturng faclty as part of the routne desgn and manufacturng process, to ensure the product s safe and performs as specfied. Rgorous testng s ncorporated nto the manufacturng process to ensure the manufactured product meets or exceeds all desgn specficatons.

CIGWELD has been manufacturng and merchandsng an extensve equpment range wth superor performance, ultra safe operaton and world class qualty for more than 30 years and wll contnue to acheve excellence.


January 15, 20081-6

NOTES


January 15, 2008 2-1

SECTION2:INTRODUCTIONANDDESCRIPTION

2.01 HowToUseThisManualThs Owners Manual apples to just specficaton or part numbers lsted on page .

To ensure safe operaton, read the entre manual, ncludng the chapter on safety nstructons and warnngs.

Throughout ths manual, the words WARNING, CAUTION, and NOTE may appear. Pay partcular attenton to the nformaton provded under these headngs. These specal annotatons are easly recognzed as follows:

! WARNINGA WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

Addtonal copes of ths manual may be purchased by contactng Cgweld at the address and phone number n your area lsted n the nsde back cover of ths manual. Include the Owners Manual number and equpment dentficaton numbers.

Electronc copes of ths manual can also be downloaded at no charge n Acrobat PDF format by gong to the

Cgweld web ste lsted below and clckng on the Lterature Lbrary lnk:

http://www.cgweld.au.com

2.02 EquipmentIdentificationThe unts dentfcaton number (specfcaton or part number), model, and seral number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equpment whch does not have a control panel such as gun and cable assembles s dentfied only by the specficaton or part number prnted on the shppng contaner. Record these numbers on the bottom of page for future reference.

2.03 ReceiptOfEquipmentWhen you receve the equpment, check t aganst the nvoce to make sure t s complete and nspect the equpment for possble damage due to shppng. If there s any damage, notfy the carrer mmedately to file a clam. Furnsh complete nformaton concernng damage clams or shppng errors to the locaton n your area lsted n the nsde back cover of ths manual.

Include all equpment dentficaton numbers as descrbed above along wth a full descrpton of the parts n error.

Move the equpment to the nstallaton ste before un-cratng the unt. Use care to avod damagng the equpment when usng bars, hammers, etc., to un-crate the unt.

CAUTION

The products applicable to this Service Manual are manufactured in various configurations for differing global requirements. Some specifications and and electrical data quoted within this Service Manual may not be applicable to all products and regions. For this reason due caution and care must be exercised when using this Service Manual.


January 15, 20082-2

2.04 SymbolChartNotethatonlysomeofthesesymbolswillappearonyourmodel.

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency Converter-Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating-Auxiliary Power

Art

# A

-041

30

115V 15A

t

t1

t2

%X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous WeldMode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Disturbance InGround System

Welding Gun

Burnback Time

Press and hold for preflow, releaseto start arc. Press to stop arc, andhold for preflow.

4 Step TriggerOperation

2 Step TriggerOperation


January 15, 2008 2-3

2.05 DescriptionThe Cgweld Model Transarc 300 S s a self contaned three-phase DC arc weldng power source wth Constant Current (CC) output characterstcs. Ths unt s equpped wth a Dgtal Volt/Amperage Meter and lft arc starter for use wth Gas Tungsten Arc Weldng (GTAW) and Shelded Metal Arc Weldng (SMAW) processes. The power source s totally enclosed n an mpact resstant, flame resstant and non-conductve plastc case.

300A5A (A)

(V)

OCV

18V

320A

160A

300A25A (A)

(V)

OCV

10V

ssecorP GIT-TFIL ssecorP KCITS

Fgure 1 - Transarc 300 S volt-ampere curve

NOTE

Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source. Curves of other settings will fall between the curves shown.

2.06 FunctionalBlockDiagramsFgure 2 llustrates the functonal block dagram of the Transarc 300 S power source.

MainCircuitSwitchFilter

InputDiode

Primary

Capacitor

DC Power

VoltageSensor

IGBTInverter

ThermalDetector

To each control c ircuit+/-15VDC +18VDC

+24VDC +5VDC

TroubleSensingCircuit

DriveCircuit

Torch ControlConnection

(CON1)

circuit

CurrentAdjustment

ReferenceAdjustment &

Mode select Switches

Panel Circuit Board

SequenceControl

ThemalSensorCircuit

MainTransformer

(PCB14)

OutputDiodes

Stick ModeVRD

SensingCircuit

Lift T ig ModeOutput Short

SensingCircuit

Fan ControlCircuit

Fan

Hall Current

Transformer(HCT1)

OutputInductor

ThermalDetector

+

-

+ -

Input

Power

PrimaryCurrentSensor

Fgure 2 - Transarc 300 S functonal block dagram


January 15, 20082-4

2.07 TransportingMethodsThese unts are equpped wth a handle for carryng purposes.

! WARNING ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

! WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lft unt wth handle on top of case.

Use handcart or smlar devce of adequate capacty.

If usng a fork-lft vehcle, place and secure unt on a proper skd before transportng.


January 15, 2008 3-1

SECTION3:INSTALLATIONRECOMMENDATIONS

3.01 EnvironmentThe Transarc 300 S s desgned for use n hazardous envronments.

Examples of envronments wth ncreased hazardous envronments are -

a. In locatons n whch freedom of movement s restrcted, so that the operator s forced to perform the work n a cramped (kneelng, sttng or lyng) poston wth physcal contact wth conductve parts,

b. In locatons whch are fully or partally lmted by conductve elements, and n whch there s a hgh rsk of unavodable or accdental contact by the operator,

c. In wet or damp hot locatons where humdty or perspraton consderably reduces the skn resstance of the human body and the nsulaton propertes of accessores.

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 LocationBe sure to locate the welder accordng to the followng gudelnes:

In areas free from mosture and dust.

Ambent temperature between 0 degrees C to 40 degrees C.

In areas free from ol, steam and corrosve gases.

In areas not subjected to abnormal vbraton or shock.

In areas not exposed to drect sunlght or ran.

Place at a dstance of 12 (305mm) or more from walls or smlar that could restrct natural arflow for coolng.

! WARNING Cigweld advises that this equipment be electr ical ly connected by a qual i f ied electrician.

3.03 ElectricalInputConnections

! WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DONOTTOUCHliveelectricalparts.SHUTDOWN weldng power source, dsconnect nput power employng lockout/taggng procedures. Lockout/taggng procedures consst of padlockng lne dsconnect swtch n open poston, removng fuses from fuse box, or shuttng off and red-taggng crcut breaker or other dsconnectng devce.

ElectricalInputRequirementsOperate the weldng power source from a sngle/three-phase 50/60 Hz, AC power supply. The nput voltage must match one of the electrcal nput voltages shown on the nput data label on the unt nameplate. Contact the local electrc utlty for nformaton about the type of electrcal servce avalable, how proper connectons should be made, and nspecton requred.

The lne dsconnect swtch provdes a safe and convenent means to completely remove all electrcal power from the weldng power supply whenever necessary to nspect or servce the unt.

NOTE

These units are equipped with a three-conductor with earth power cable that is connected at the welding power source end for single and three phase electrical input power.

Do not connect an nput (BROWN or BLUE or RED) conductor to the ground termnal.

Do not connect the ground (YELLOW/GREEN) conductor to an nput lne termnal.


January 15, 20083-2

3.04 MainsSupplyVoltageRequirementsThe Mans supply voltage should be wthn 15% of the rated Mans supply voltage. Too low a voltage may cause the fuse or crcut breaker to rupture due to the ncreased prmary current. Too hgh a supply voltage wll cause the Power Source to fal.

415VMainsCurrentCircuitRequirementsfortheTransarc300SiThe Weldng Power Source must be:

Correctly nstalled, f necessary, by a qualfied electrcan.

Correctly earthed (electrcally) n accordance wth local regulatons.

Connected to the correct sze 415V Mans Current Crcut as per the Specficatons

! WARNINGCIGWELD advises that this equipment be electrically connected by a qualified electrical trades-person.

The followng 415V Mans Current Crcut recommendatons are requred to obtan the maxmum weldng current and duty cycle from ths weldng equpment:.

Model Minimum 415V Mains Current Circuit Size

Transarc 300 Si 22.3 Amps

Table 1: 415V Mans Current Crcut Szes to acheve maxmum current

NOTE

Motor Start Fuses or Circuit Breakers are recommended for this application.

HighFrequencyIntroductionThe mportance of correct nstallaton of hgh frequency weldng equpment cannot be over-emphaszed. Interference due to hgh frequency ntated or stablzed arc s almost nvarably traced to mproper nstallaton. The followng nformaton s ntended as a gude for personnel nstallng hgh frequency weldng machnes.

! WARNINGExplosives

The high frequency section of this machine has an output similar to a radio transmitter. The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing.

Computers

It is also possible that operation close to computer installations may cause computer malfunction.


January 15, 2008 3-3

HighFrequencyInterferenceInterference may be transmtted by a hgh frequency ntated or stablzed arc-weldng machne n the followng ways:

Direct Radiation

Radaton from the machne can occur f the case s metal and s not properly grounded. It can occur through apertures such as open access panels. The sheldng of the hgh frequency unt n the Power Source wll prevent drect radaton f the equpment s properly grounded.

Transmission via the Supply Lead

Wthout adequate sheldng and filterng, hgh frequency energy may be fed to the wrng wthn the nstallaton (mans) by drect couplng. The energy s then transmtted by both radaton and conducton. Adequate sheldng and filterng s provded n the Power Source.

Radiation from Welding Leads

Radated nterference from weldng leads, although pronounced n the vcnty of the leads, dmnshes rapdly wth dstance. Keepng leads as short as possble wll mnmze ths type of nterference. Loopng and suspendng of leads should be avoded where possble.

Re-radiation from Unearthed Metallic Objects

A major factor contrbutng to nterference s re-radaton from unearthed metallc objects close to the weldng leads. Effectve groundng of such objects wll prevent re-radaton n most cases.

3.05 Specifications

Parameter Transarc 300 SiPower Source Part Number 625781Cooling Fan CooledWelder Type Inverter Power SourceWelding Power Source Mass 20kgDimensions H 420mm x W 210mm x D 450mmManufactured to Australian Standard AS 60974.1-2006Number of Phases 3Nominal Supply Voltage 415V 15%Nominal Supply Frequency 50HzOpen Circuit Voltage 65VWelding Current Range 5 - 300 AmpsEffective Input Current (I1eff) 14.1 AmpsMaximum Input Current (I1max) 22.3 AmpsThree Phase Generator Requirement 16 KVAWelding Output, 400C, 10 min. (quoted figures refer to MMAW output)

300A @ 40%, 32.0V 250A @ 60%, 30.0V 180A @ 100%, 27.2V

Welding Output 400C, 10 min. (Quoted figures refer to GTAW output)

300A @ 40%, 22.0V 250A @ 60%, 20.0V 180A @ 100%, 17.2V

Protection Class IP23S

Cigweld continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location and conditions and local power grid supply conditions.


January 15, 20083-4

3.06 DutyCycleThe duty cycle of a weldng power source s the percentage of a ten (10) mnute perod that t can be operated at a gven output wthout causng overheatng and damage to the unt. If the weldng amperes decrease, the duty cycle ncreases. If the weldng amperes are ncreased beyond the rated output, the duty cycle wll decrease.

! WARNINGExceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature.

CAUTION

Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty.

NOTE

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.


January 15, 2008 4-1

SECTION4:OPERATORCONTROLS

4.01 Transarc300SiControls

22

5

7

6

2

43

1

Art # A-08345

Fgure 4 Transarc 300 S Power Source

1. Control Knob

Ths control sets the selected weld parameter, rotatng t clockwse ncreases the parameter that s ndcated on the dgtal meter. Pushng the knob nward dsplays the actual weldng voltage.

2. Remote Control Socket

The 14 pn Remote Control Socket s used to connect remote current control devces to the weldng Power Source. To make connectons, algn keyway, nsert plug, and rotate threaded collar fully clockwse.

A J

B K I

C L N H

D M G

FE

E

Front view of 14Socket Receptacle

5k ohms

noitcnuFniP tekcoSTorch 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)

C 5k ohm (maximum) connection to 5k ohm remote control potentiometerD Zero ohm (minimum) connection to 5k ohm remote control potentiometerE Wiper arm connection to 5k ohm remote control potentiometerG Mains Earth

F,H,I,J,K,L Not UsedM OK to move current detect signal for robotics applicationsN OK to move current detect signal for robotics applications

A

B


January 15, 20084-2

3. Postve Termnal

Weldng current flows from the Power Source va heavy duty Dnse type termnal. It s essental, however, that the male plug s nserted and turned securely to acheve a sound electrcal connecton.

4. Negatve Termnal

Weldng current flows from the Power Source va heavy duty Dnse type termnal. It s essental, however, that the male plug s nserted and turned securely to acheve a sound electrcal connecton.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

5. ON/OFF Swtch

Ths swtch connects the Prmary supply voltage to the nverter when n the ON poston. Ths enables the Power Supply.

! WARNING When the welder is connected to the Primary supply voltage, the internal electrical components maybe at primary potential with respect to earth.

6. Input Cable

The nput cable connects the Prmary supply voltage to the equpment.

7. SMART Logc Swtch

Manual slde swtch mounted on the back panel selects for proper nput voltage. If ths slde s not set to the poston that matches the nput voltage from the electrcal source the Smart Logc crcut wll nhbt weldng power source output. The dgtal meter wll show prmary nput error code.

NOTE

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.


January 15, 2008 4-3

4.02 WeldParameterDescription

PRESS AND HOLD

Fgure 5 - Transarc 300 S Front Panel wth Parameter Descrpton

noitpircseD retemaraP

HOT START This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the (WELD) current.

A Weld Current (Amperage)- sets the STICK and TIG WELD current. ARC CONTROL - This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability.

LIFT TIG mode of operation. A remote control device may be used for use during LIFT TIG operation. See section 4.01, section 2 RemoteControl Socket , for complete details of the remote device. STICK Mode of operation

REMOTE

Selects Mode of Operation: Panel or Remote

By using the Save & Load buttons, the operator can easily save up to 5 weldingparameter programs.

NOTE

The Save/Load button must remain depressed for 3 seconds in order to store the settings.

Table 3 Weld Parameter Descrptons


January 15, 20084-4

4.03 WeldParametersforTransarc300Si

WeldModeWeld

Parameter ParameterRangeFactorySetting

IncrementalUnit

STICK LIFTTIG

HOT START 0 to 70A 20A 1A Yes NoWELD CUR 5 to 300A DC 80A 1A Yes Yes

ARC CONTROL 0 to 100% 10% 1% Yes No

4.04 PowerSourceFeatures

Feature DescriptionNewDigitalControl Almost all weldng parameters are adjustableTouchPanelSwitches Touch swtches elmnate mechancal damageFrontControlCover Protects front panel controls

DigitalMeter

Dsplays selected weld parameter value

Dsplays weld current when weldng

Dsplays weld current for 20 seconds after weld has been completed

A selected weld parameter value can be adjusted at any tme even whle weldng

IntelligentFanControl

The ntellgent coolng system s desgned to reduce dust and foregn materal buld-up, whlst provdng optmum coolng.

Fan speed reduces approxmately 30 seconds after machne s turned on

Fan speed ncreases when nternal components reaches operatng temperature

ON/OFFswitch Prmary voltage Supply ON/OFF swtch located on rear panel

VoltageReductionDevice(VRD)

Reduces the OCV when the power supply s not n use. Elmnates the need for add on voltage reducers and has no effect on arc startng.

VRD fully comples to AS 60974.1

When Stck mode s selected the green VRD lght s ON when not weldng and red when weldng.

When n TIG modes VRD s off.


January 15, 2008 5-1

SECTION5:SET-UPFORSMAW(STICK)AND

GTAW(TIG)

Conventonal operatng procedures apply when usng the Weldng Power Source, .e. connect work lead drectly to work pece and electrode lead s used to hold electrode. Wde safety margns provded by the col desgn ensure that the Weldng Power Source wll wthstand short-term overload wthout adverse effects. The weldng current range values should be used as a gude only. Current delvered to the arc s dependent on the weldng arc voltage, and as weldng arc voltage vares between dfferent classes of electrodes, weldng current at any one settng would vary accordng to the type of electrode n use. The operator should use the weldng current range values as a gude, then finally adjust the current settng to sut the applcaton.

! WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear or sides of the Welding Power Source.

Fgure 6 Transarc 300 S Set-up


January 15, 20085-2

NOTES


January 15, 2008 6-1

SECTION6:SEQUENCEOFOPERATION

NOTE:Scroll Buttons are used to select the parameters to be set. The LEDs show whch functon s beng adjusted on the weld sequence graph. Refer to Symbols Table located n the front of the manual for Symbol descrptons.

1

2

3

4

5

6PRESS AND HOLD

Fgure 7 Transarc 300 S Front Panel

1. Scroll Buttons used to select the parameter to be set. The LEDs show whch functon s beng adjusted on the Sequence Graph.

2. Dgtal LED dsplay Weldng amperage and parameter values are dsplayed n ths wndow. Internal warnngs such as over temperature, low or hgh nput voltage appled are sgnaled to the operator by a warnng sound and error message on the screen.

3. Control Knob allows the operator to adjust the output amperage wthn the entre range of the power source, also used to set each parameter value.

4. Process Button Ths button selects between STICK or Lft TIG mode.

5. Remote Current Functon Pressng ths buttons enables remote current functons.

6. Save & Load Buttons Press and hold these buttons for 3 seconds to save or load up to 5 weldng parameter programs.


January 15, 20086-2

6.01 StickWelding

Connect work lead to negatve termnal

Connect electrode lead to postve termnal

Swtch machne on

Set Contactor

Connect remote control devce f requredUse the Scroll Buttons to move to the parameter to be set. The LED wll show whch functon s beng adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

Set HOT START

Set WELD current

Set Arc Control

Commence weldng

6.02 DCLIFTTIGWelding

Connect work lead to postve termnal

Connect TIG torch to negatve termnal

Swtch machne on

Set weld current.

Connect remote control devce f desredUse the Scroll Buttons to move to the parameter to be set. The LED wll show whch functon s beng adjusted on the weld sequence graph. Use the control knob to adjust each parameter.

Set WELD currentCommence weldng


January 15, 2008 7-1

SECTION7:BASICTIGWELDINGGUIDE

7.01 ElectrodePolarityConnect the TIG torch to the - / TORCH termnal and the work lead to the + / WORK termnal for drect current straght polarty. Drect current straght polarty s the most wdely used polarty for DC TIG weldng. It allows lmted wear of the electrode snce 70% of the heat s concentrated at the work pece.

7.02 TungstenElectrodeCurrentRanges

Electrode Diameter DC Current (Amps)

0.040 (1.0mm) 30 601/16 (1.6mm) 60 1153/32 (2.4mm) 100 1651/8 (3.2mm) 135 200

5/32 (4.0mm) 190 2803/16 (4.8mm) 250 340

Table 4 Current ranges for vares tungsten electrode szes

7.03 TungstenElectrodeTypes

Electrode Type (Ground Finish)

Welding Application Features Color Code

Thoriated 2%

Ceriated 2%

Red

Grey

DC welding of mild steel, stainless steel and copper.

Excellent arc starting, Long life, High current carrying capacity.

DC welding of mild steel, stainless steel, copper, l i i i d

Longer life, More stable arc, Easier starting, Wider current

NTable 5 Tungsten electrode types

7.04 GuideforSelectingFillerWireDiameter

Fller Wre Dameter DC Current Range (Amps)1/16 (1.6 mm) 20 - 903/32 (2.4 mm) 65 - 1151/8 (3.2 mm) 100 - 165

3/16 (4.8 mm) 200-350

Table 6 Fller wre selecton gudeNOTE

The filler wire diameter specified in Table 6 is a guide only, other diameter wires may be used according to the welding application.


January 15, 20087-2

7.05 ShieldingGasSelection

Alloy Shielding Gas Aluminium & alloys Argon

Carbon Steel ArgonStainless Steel Argon

Copper Argon

Table 7 Sheldng gas selecton

7.06 TIGWeldingParametersforLowCarbon&LowAlloySteelPipe

Current Range DCAmperes

Thoriated 2%3/32 (2.4 mm)Thoriated 2%

3/32 (2.4 mm)Thoriated 2%

3/32 (2.4 mm)

Electrode Type & Diameter

Filler Rod for Root Pass

Joint Preparation

120 - 170 Yes

100 - 160 Yes

90 - 130 No

Table 8 TIG weldng parameters for low carbon & low alloy steel ppe

7.07 WeldingParametersforSteel

Filler Rod Diameter

(if required) Joint Type

0.040 35-45 20-30 0.040 1/16 Butt/Corner1.0mm 40-50 25-35 1.0mm 1.6mm Lap/ Fillet0.045 45-55 30-45 0.040 1/16 Butt/Corner1.2mm 50-60 35-50 1.0mm 1.6mm Lap/ Fillet1/16 60-70 40-60 1/16 1/16 Butt/Corner

1.6mm 70-90 50-70 1.6mm 1.6mm Lap/ Fillet1/8 80-100 65-85 1/16 3/32 Butt/Corner

3.2mm 90-115 90-110 1.6mm 2.4mm Lap/ Fillet3/16 115-135 100-125 3/32 1/8 Butt/Corner

4.8mm 140-165 125-150 2.4mm 3.2mm Lap/ Fillet 160-175 135-160 1/8 5/32 Butt/Corner

6.4mm 170-200 160-180 3.2mm 4.0mm Lap/ Fillet

7

10

10

Argon Gas Flow Rate Liters/min

5-7

5-7

7

DC Current for Mild

Steel

DC Current for Stainless

Steel

Tungsten Electrode Diameter

Base Metal Thickness

Table 9 DC TIG weldng parameters


January 15, 2008 8-1

Metalsbeingjoined Electrode Comments

Mld steel 6013Ideal electrodes for all general purpose work. Features nclude out standng operator appeal, easy arc startng and low spatter.

Mld steel 7014

All postonal electrode for use on mld and galvanzed steel furnture, plates, fences, gates, ppes and tanks etc. Especally sutable for vertcal-down weldng.

Cast ron 99% NckelSutable for jonng all cast rons except whte cast ron.

Stanless steel 318L-16Hgh corroson resstance. Ideal for dary work, etc. On stanless steels.

Copper, Bronze, Brass, etc.Bronze

5.7 ERCUSI-A

Easy to use electrode for marne fittngs, water taps and valves, water trough float arms, etc. Also for jonng copper to steel and for bronze overlays on steel shafts.

Hgh Alloy Steels, Dssmlar Metals, Crack Resstance. All Hard-To-Weld Jobs.

312-16

It wll weld most problematcal jobs such as sprngs, shafts, broken jons mld steel to stanless and alloy steels. Not sutable for Alumnum.

Table 10 - Types of Electrodes

SECTION8:BASICARCWELDINGGUIDE

8.01 ElectrodePolarityStck electrodes are generally connected to the + termnal and the work lead to the - termnal but f n doubt consult the electrode manufacturers lterature.

8.02 EffectsofStickWeldingVariousMaterials

High tensile and alloy steels

The two most promnent effects of weldng these steels are the formaton of a hardened zone n the weld area, and, f sutable precautons are not taken, the occurrence n ths zone of under-bead cracks. Hardened zone and under-bead cracks n the weld area may be reduced by usng the correct electrodes, preheatng, usng hgher current settngs, usng larger electrodes szes, short runs for larger electrode deposts or temperng n a furnace.

Manganese steels

The effect on manganese steel of slow coolng from hgh temperatures s to em brttle t. For ths reason t s absolutely essental to keep manganese steel cool durng weldng by quenchng after each weld or skp weldng to dstrbute the heat.

Cast Iron

Most types of cast ron, except whte ron, are weldable. Whte ron, because of ts extreme brttleness, generally cracks when attempts are made to weld t. Trouble may also be experenced when weldng whte-heart malleable, due to the porosty caused by gas held n ths type of ron.

Copper and alloys

The most mportant factor s the hgh rate of heat conductvty of copper, makng preheatng of heavy sectons necessary to gve proper fuson of weld and base metal.

Types of Electrodes

Arc Weldng electrodes are classfied nto a number of groups dependng on ther applcatons. There are a great number of electrodes used for specalzed ndustral purposes whch are not of partcular nterest for everyday general work. These nclude some low hydrogen types for hgh tensle steel, cellulose types for weldng large dameter ppes, etc. The range of electrodes dealt wth n ths publcaton wll cover the vast majorty of applcatons lkely to be encountered; are all easy to use and all wll work on even the most basc of weldng machnes.


January 15, 20088-2

NOTES


January 15, 2008 9-1

SECTION9:ROUTINEMAINTENANCE

The only routne mantenance requred for the power supply s a thorough cleanng and nspecton, wth the frequency dependng on the usage and the operatng envronment.

! WARNINGDisconnect 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 unt, open the enclosure and use a vacuum cleaner to remove any accumulated drt and dust. The unt should also be wped clean, f necessary; wth solvents that are recommended for cleanng electrcal apparatus.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.


January 15, 20089-2

Warning! Disconnect input power before maintaining.

Each Use

Visual check of regulator and pressure

Visual check of torchConsumable parts

Weekly

Visually inspect the torch body and consumables Visually inspect the

cables and leads.Replace as needed

3 Months

Cleanexteriorof power supply

6 Months

Replace all broken parts

Bring the unit to an authorizedCIGWELD Service Providerto remove any accumulated dirt and dust from the interior.This may need to be done morefrequently under exceptionallydirty conditions.

Maintain more often if used under severe conditions

Art # A-07681_AC


January 15, 2008 9-3

9.01 VRDSpecification

Description Transarc300Si

Notes

VRD Open Crcut Voltage 15.3 to 19.8V Open crcut voltage between weldng termnals

VRD Resstance 148 to 193 ohmsThe requred resstance between weldng termnals to turn ON the weldng power

VRD Turn OFF Tme 0.2 to 0.3 secondsThe tme taken to turn OFF the weldng power once the weldng current has stopped

9.02 VRDMaintenanceRoutne nspecton and testng (power source)

An nspecton of the power source, an nsulaton resstance test and an earth resstance test shall be carred out.

a) For transportable equpment, at least once every 3 months; and

b) For fixed equpment, at least once every 12 months.The owners of the equpment shall keep a sutable record of the perodc tests.

NOTE

A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated.

In addton to the above tests and specfically n relaton to the VRD fitted to ths machne, the followng perodc tests should also be conducted by an accredted Cgweld Servce Provder.

Description RequiredParametersVRD Open Crcut Voltage Less than 20V; at Vn=415V

VRD Turn ON Resstance Less than 200 ohms

VRD Turn OFF Tme Less than 0.3 seconds

If ths equpment s used n a hazardous locaton or envronments wth a hgh rsk of electrocuton then the above tests should be carred out pror to enterng ths locaton.


January 15, 20089-4

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January 15, 2008 10-1

SECTION10:BASICTROUBLESHOOTING

! WARNINGThere are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or repair unless you are an Accredited Cigweld Service Provider and you have had training in power measurements and troubleshooting techniques.

If major complex subassembles are faulty, then the Weldng Power Source must be returned to an Accredted Cgweld Servce Provder for repar.

The basc level of troubleshootng s that whch can be performed wthout specal equpment or knowledge.

10.01 TIGWeldingProblemsWeld qualty s dependent on the selecton of the correct consumables, mantenance of equpment and proper weldng technque.

Description PossibleCause Remedy1. Excessve beard buld-up or poor

penetraton or poor fuson at edges of weld.

Weldng current s too low Increase weld current and/or faulty jont preparaton

2. Weld bead too wde and flat or undercut at edges of weld or excessve burn through

Weldng current s too hgh Decrease weld current

3. Weld bead too small or nsufficent penetraton or rpples n bead are wdely spaced apart

Travel speed too fast Reduce travel speed

4. Weld bead too wde or excessve bead buld up or excessve penetra-ton n butt jont

Travel speed too slow Increase travel speed

5. Uneven leg length n fillet jont Wrong placement of filler rod Re-poston filler rod


January 15, 200810-2

Description PossibleCause Remedy6. Electrode melts when arc s

struck.Electrode s connected to the + termnal.

Connect the electrode to the termnal.

7. Drty weld pool. A. Electrode contamnated through contact wth work pece or filler rod materal.

A. Clean the electrode by grndng off the contamnates.

B. Gas contamnated wth ar. B. Check gas lnes for cuts and loose fittng or change gas cylnder.

8. Electrode melts or oxdzes when an arc s struck.

A. No gas flowng to weldng regon. A. Check the gas lnes for knks or breaks and gas cylnder contents.

B. Torch s clogged wth dust. B. Clean torch

C. Gas hose s cut. C. Replace gas hose.

D. Gas passage contans mpurtes. D. Dsconnect gas hose from torch then rase gas pressure and blow out mpurtes.

E. Gas regulator turned off. E. Turn on.

F. Torch valve s turned off. F. Turn on.

G. The electrode s too small for the weldng current.

G. Increase electrode dameter or reduce the weldng current.

9. Poor weld finsh. Inadequate sheldng gas. Increase gas flow or check gas lne for gas flow problems.

10. Arc flutters durng TIG weldng. A. Tungsten electrode s too large for the weldng current.

A. Select the rght sze electrode. Refer to Basc TIG Weldng gude.

B. Absence of oxdes n the weld pool. B. Refer Basc TIG Weldng Gude for ways to reduce arc flutter.

11. Weldng arc can not be establshed.

A. Work clamp s not connected to the work pece or the work/torch leads are not connected to the rght weldng termnals.

A. Connect the work clamp to the work pece or connect the work/torch leads to the rght weldng termnals.

B. Torch lead s dsconnected. B. Connect t to the termnal.

C. Gas flow ncorrectly set, cylnder empty or the torch valve s off.

C. Select the rght flow rate, change cylnders or turn torch valve on.

12. Arc start s not smooth. A. Tungsten electrode s too large for the weldng current.

A. Select the rght sze electrode. Refer to Secton 7, Basic TIG Welding Guide.

B. The wrong electrode s beng used for the weldng job

B. Select the rght electrode type. Refer to Secton 7, Basic TIG Welding Guide.

C. Gas flow rate s too hgh. C. Select the correct rate for the weldng job. Refer to Secton 7, Basic TIG Welding Guide.

D. Incorrect sheldng gas s beng used.

D. Select the rght sheldng gas. Refer to Secton 7, Basic TIG Welding Guide.

E. Poor work clamp connecton to work pece.

E. Improve connecton to work pece.


January 15, 2008 10-3

10.02 StickWeldingProblems

Description PossibleCause Remedy1. Gas pockets or vods n weld metal

(Porosty).A.

B.

C.

Electrodes are damp.

Weldng current s too hgh.

Surface mpurtes such as ol, grease, pant, etc.

A.

B.

C.

Dry electrodes before use.

Reduce weldng current.

Clean jont before weldng.

2. Crack occurrng n weld metal soon after soldficaton commences

A.

B.

C.

Rgdty of jont.

Insufficent throat thckness.

Coolng rate s too hgh.

A.

B.

C.

Redesgn to releve weld jont of severe stresses or use crack resstance electrodes.

Travel slghtly slower to allow greater buld up n throat.

Preheat plate and cool slowly.

3. A gap s left by falure of the weld metal to fill the root of the weld.

A.

B.

C.

Weldng current s too low.

Electrode too large for jont.

Insufficent gap.

A.

B.

C.

Increase weldng current

Use smaller dameter electrode.

Allow wder gap.

D. Incorrect sequence. D. Use correct buld-up sequence.

Fgure 8 Example of nsufficent gap or ncorrect sequence

4. Portons of the weld run do not fuse to the surface of the metal or edge of the jont.

A.

B.

Small electrodes used on heavy cold plate.

Weldng current s too low.

A .

B.

Use larger electrodes and pre-heat the plate.

Increase weldng current

C. Wrong electrode angle. C. Adjust angle so the weldng arc s drected more nto the base metal

D. Travel speed of electrode s too hgh.

D. Reduce travel speed of electrode

E. Scale or drt on jont surface. E. Clean surface before weldng.

Fgure 9 Example of lack of fuson


January 15, 200810-4

5. Non-metallc partcles are trapped n the weld metal (slag ncluson).

A. Non-metallc partcles may be trapped n undercut from prevous run.

A. If bad undercut s present, clean slag out and cover wth a run from a smaller dameter electrode.

B. Jont preparaton too restrcted. B. Allow for adequate penetraton and room for cleanng out the slag.

C. Irregular deposts allow slag to be trapped.

C. If very bad, chp or grnd out rregulartes.

D. Lack of penetraton wth slag trapped beneath weld bead.

D. Use smaller electrode wth sufficent current to gve adequate penetraton. Use sutable tools to remove all slag from corners.

E. Rust or mll scale s preventng full fuson.

E. Clean jont before weldng.

F. Wrong electrode for poston n whch weldng s done.

F. Use electrodes desgned for poston n whch weldng s done, otherwse proper control of slag s dfficult.

Fgure 10 Examples of slag ncluson

10.03 PowerSourceProblems

Description PossibleCause Remedy1. The weldng arc cannot be

establshedA .

B.

The Prmary supply voltage has not been swtched ON.

The Weldng Power Source swtch s swtched OFF.

A .

B.

Swtch ON the Prmary supply voltage.

Swtch ON the Weldng Power Source.

C. Loose connectons nternally. C. Have an Accredted Cgweld Servce Provder repar the connecton.

2. Maxmum output weldng current can not be acheved wth nomnal Mans supply voltage.

Defectve control crcut Have an Accredted Cgweld Servce Provder nspect then repar the welder.

3. Weldng current reduces when weldng

Poor work lead connecton to the work pece.

Ensure that the work lead has a postve electrcal connecton to the work pece.

4. No gas flow when the torch trgger swtch s depressed.

A.

B.

Gas hose s cut.

Gas passage contans mpurtes.

A.

B.

Replace gas hose.

Dsconnect gas hose from the rear of Power Source then rase gas pressure and blow out mpurtes.

C. Gas regulator turned off. C. Turn gas regulator on.

D. Torch tr gger swtch lead s dsconnected or swtch/cable s faulty.

D. Reconnect lead or repar faulty swtch/cable.


January 15, 2008 10-5

10.04 PowerSourceErrorCodes

Description Possible Cause Remedy Remarks1 E01 error code

displayed. Temperature sensor TH1 (protects IGBTs) is greater than 80C for about 1 second.

A The Welding Power Sources duty cycle has been exceeded.

A Let Power Source cool down then keep within its duty cycle.

Weld current ceases. Buzzer sounds constantly. E01 resets when TH1 decreases to 70C for about 30 seconds.

B Fan ceases to operate. B Have an Accredited Cigweld Service Provider investigate.

C Air flow is restricted by vents being blocked.

C Unblock vents then let Power Source cool down.

2 E02 error code displayed. Temperature sensor TH2 (protects IGBTs) is greater than 90C for about 1 second.

A The Welding Power Sources duty cycle has been exceeded.

A Let Power Source cool down then keep within its duty cycle.

Weld current ceases. Buzzer sounds constantly. E02 resets when TH2 decreases to 70C for about 30 seconds.

B Fan ceases to operate. B Have an Accredited Cigweld Service Provider investigate.

C Air flow is restricted by vents being blocked.

C Unblock vents then let Power Source cool down.

3 E03 error code displayed. Primary (input) current too high.

A Primary current too high because welding arc is too long

A Reduce length of welding arc

Weld current ceases. Buzzer sounds constantly. Switch machine off then on to reset E03 error.

B Mains supply voltage is more than 15% below nominal voltage

B Have an Accredited Cigweld Service Provider or a qualified electrician check for low Mains voltage.

4 E11 error code displayed. Over Primary supply (input) voltage at primary capacitors is exceeded for one second.

Primary supply voltage is greater than the nominal voltage plus 15%.

Have an Accredited Cigweld Service Provider or a qualified electrician check the Primary voltage.

Weld current ceases. Buzzer sounds constantly. Error code E11 automatically will reset when the voltage reduces.

5 E12 error code displayed. Under mains supply (input) voltage warning primary capacitors is reduced for one second.

Mains supply voltage is down to a dangerously low level.

Have an Accredited Cigweld Service Provider or a qualified electrician check the Mains voltage. Have an Accredited Cigweld Service Provider or a qualified electrician check the primary cable & fuses.

Weld current ceases. Buzzer sounds constantly. Error code E12 will automatically reset when the voltage increases.


January 15, 200810-6

Description Possible Cause Remedy Remarks6 E14 error code

displayed. Under mains supply (input) voltage warning primary capacitors is reduced for one second.

Mains supply voltage is less than the nominal operating voltage plus 15%.

Have an Accredited Cigweld Service Provider or a qualified electrician check the Mains voltage.

Weld current available. Buzzer sounds intermittently. Error code E14 will automatically reset when the voltage increases.

7 E81 error code displayed. Wrong Primary supply (input) voltage connected.

When 3 phase machine is first turned on with the wrong Primary supply (input) voltage connected.

Have an Accredited Cigweld Service Provider check the Mains voltage.

No weld current is available. Buzzer sounds constantly. Switch machine off.

8 E82 error code displayed. Link switch plug not connected.

Link switch plug not connected.

Have an Accredited Cigweld Service Provider or a qualified electrician check the connector plug on input PCB.

No weld current is available. Buzzer sounds constantly. Switch machine off.

9 E83 error code displayed. CPU checks mains supply (input) voltage when the on/off switch on rear panel of machine is turned ON.

The Primary supply (input) voltage fluctuates and is not stable.

Have an Accredited Cigweld Service Provider or a qualified electrician check the connector plug on the input PCB and the Mains voltage.

No weld current is available. Buzzer sounds constantly. Switch machine off then on to reset E83 error.

10 E93 error code displayed. Memory chip (EEPROM) on control PCB can not read/write weld parameters.

Memory chip (EEPROM) error.

Have an Accredited Cigweld Service Provider or a qualified electrician check the control PCB.

Weld current is ceases. Buzzer sounds constantly. Switch machine off.

11 E94 error code displayed. Temperature sensor TH1 for IGBTs is an open circuit.

The Welding Power Sources temperature sensors have malfunctioned.

Have an Accredited Cigweld Service Provider check or replace the temperature sensors.

Weld current ceases. Buzzer sounds constantly. Switch machine off.

12 E99 error code displayed. Mains supply (input) voltage has been turned off, but control circuit has power from the primary capacitors.

A Main on/off switch on machine has been turned off.

B Mains supply (input) voltage has been turned off.

A Turn on/off switch on.

B Have an Accredited Cigweld Service Provider or a qualified electrician check the Main voltage and fuses.

Weld current ceases. Buzzer sounds constantly. Must switch machine off then on to reset E99 error.

11 ADVANCED TROUBLESHOOTING

11 1

ADVANCED TROUBLESHOOTINGIf you are here, all of the troubleshooting sugges-tions in Section 8-Basic Troubleshooting haveeither failed to resolve the faulty operation or haveindicated that one or more of the subsystemswithin the power supply are defective. This sectionprovides the information needed to take live mea-surements on the various subsystems within thepower supply, and replace those subsystems thatprove faulty.

CAUTIONTroubleshooting and repairing this unit is a pro-cess, which should be undertaken only by thosefamiliar with high voltage/high power electronicequipment.

WARNINGThere are extremely dangerous voltage and powerlevels present inside this unit. Do not attempt todiagnose or repair unless you have training inpower electronics, measurement and troubleshoot-ing techniques.

Under no circumstances are field repairs to beattempted on printed circuit boards or other subas-semblies of this unit. Evidence of unauthorizedrepairs will void the factory warranty. If a subas-sembly is found to be defective by executing any ofthe procedures in this Service Manual, the subas-sembly should be replaced with a new one. Thefaulty subassembly should then be returned toThermal Arc through established procedures.

WARNINGDisconnect primary power at the source before dis-assembling the power supply. Frequently reviewthe "Important Safety Precautions" in section 1.02.Be sure the operator is equipped with propergloves, clothing and eye and ear protection. Makesure no part of the operator's body comes into con-tact with the work piece or any internal componentswhile the unit is activated.

11.01 System-Level Fault Isola-tion

If none of the suggestions provided in Section 8have solved the problem or corrected the faultyoperation, the next step is to isolate one or more ofthe internal subassemblies that may be defective.

CAUTIONPerform all steps in each procedure, in sequence.Skipping portions of procedures, or performingsteps out of sequence can result in damage to theunit, and possible injury, or worse, to the operator.

11.1.1 Opening the Enclosure1) Confirm that the switch of power supply and

the switch on switchboard (distribution panel)are all OFF.

Figure 11-1: Switch OFF

CAUTIONThe capacitors inside the power supply will slowlydischarged after you turn off the switch of thepower supply or the switch at the breaker box (dis-tribution panel). Wait at least 5 minutes for the dis-charge to complete.



11 2

2) Remove all screws and nuts on the side cov-ers.

Figure 11-2: Remove screws

3) Loosen the screws on the front panel and therear panel by turning them approximately twoturns CCW.

Figure 11-3: Loosen screws

NOTEDO NOT remove the screws completely.

4) Pull the front panel slightly forward and pull therear panel slightly backward. The interlockinghooks of the side case covers can now be dis-engaged from the front and rear panels.

Figure 11-4: Loosen front and rear panels

5) Remove the side covers.

Figure 11-5: Remove Side covers



11 3

6) Remove protection cover sheet by removingthe plastic tabs.

Figure 11-6: Remove PCB cover

NOTEWhen you re-assemble the parts, conduct the above process backwards.

11.02 Verification and Remedy to the Indicated Error Codes

NOTEThe capacitors inside the power supply will slowlydischarged after you turn off the switch of thepower supply or the switch at the breaker box (dis-tribution panel). Wait at least 5 minutes for the dis-charge to complete and then remove the cases tocontinue your inspection and repair (or mainte-nance) inside the power supply. As for the removaland installation of the case, refer to section 11.1.1.

NOTEDuring the "Verification/Remedy" proceduresbelow, follow the alphabetical sequence (a, b, c...)and proceed with your verification and confirma-tion.

NOTEAfter you confirm and replace all spare parts andcomponents, confirm that there are no damagedharnesses or connectors, uninstalled or loosescrews.

11.2.1 E01 "Over-Temperature at the primary side"

CauseOccurs when an over-temperature condition of theprimary IGBT is detected.

Verification/Remedya) Unit may be in thermal shutdown mode.

Review the rated duty cycle of the unit per

section 3.8. Exceeding the duty cycle candamage the unit and void the warranty. Referalso to section 1.6 for additional information.

b) Verify the ventilating condition.

Maintain a clear and unobstructed distance

of more than 30cm in the front and more that50cm in the rear of the unit for ventilation pur-poses.

Verify and maintain clean, dust free, front and

rear airflow paths. Cleaning and removingdust from the front and rear panels onceevery six months in a normal working envi-ronment is recommended. Extremely dustyenvironments will require more frequentcleanings.

c) Verify the operation of the cooling fan, FAN1, and replace it if necessary.

Verify the condition of FAN1. Verify that there

are no broken or cracked fan blades and thatFAN1 is not producing any abnormal sounds.

If broken or cracked FAN1 blades, or abnor-

mal sounds are emanating from FAN1,replace FAN1.

Verify the operation of the cooling fan and

replace it if the condition of FAN1 is inactive.Follow the instruction in section.

Refer to section 12.3.21 for the replacement

of FAN1.

Refer to section 11.5.3 for additional FAN1

tests.d) Replace PCB6 (WK-5549).

Refer to section 12.3.6 for the replacement of

PCB6.



11 4

11.2.2 E02 "Over-Temperature at the secondary side"

CauseOccurs when an over-temperature condition of thesecondary IGBT and diode are detected.

Verification/Remedya) Unit may be in thermal shutdown mode.

Review the rated duty cycle of the unit per

section 3.8. Exceeding the duty cycle can damage the unit and void the warranty.

b) Verify the ventilating condition.

Maintain a clear and unobstructed distance

of more than 30cm in the front and more that50cm in the rear of the unit for ventilation pur-poses.

Verify and maintain clean, dust free, front and

rear airflow paths. Cleaning and removingdust from the front and rear panels onceevery six months in a normal working envi-ronment is recommended. Extremely dustyenvironments will require more frequentcleanings.

c) Verify the operation of the cooling fan, FAN1, and replace it if necessary.

Verify the condition of FAN1. Verify that there

are no broken or cracked fan blades and thatFAN1 is not producing any abnormal sounds.

If broken or cracked FAN1 blades, or abnor-

mal sounds are emanating from FAN1,replace FAN1.

Verify the operation of the cooling fan and

replace it if the condition of FAN1 is inactive.Follow the instruction in section.


of FAN1.

Refer to section 11.5.3 for addition FAN1

tests.d) Replace PCB6 (WK-5549).

Refer to section 12.3.6 for the replacement of

PCB6.

11.2.3 E03 "Transformer Over-Current Failure"

CauseOccurs when excessive current is detected flow-ing into the primary side of the main transformer.

Verification/Remedya) Confirm the operation of the machine within

the rated specification.

Refer to the specification data sheet in Sec-

tion 3.9.b) Verify the secondary diode (D2, D4, D5 and

D7).

Refer to section 11.5.6 for the test and

replacement of D2, D4, D5 and D7.c) Replace the Hall CT, HCT1.


of HF.UNIT 1.

NOTEPay special attention to installed direction of HCT1.The Hall CT will n

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