Thermal Arc 300GTSW Pro-Wave User manual

PRO-WAVE
INVERTER ARC WELDER
300GTSW
Service Manual
Version No: AB Issue Date: June 21, 2012 Manual No.: 0-2515
Operating Features:
Art # A-06102

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 1-800-752-7621, or visit
us on the web at www.Thermalarc.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is the Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major
welding industry sectors worldwide including: Manufacturing,
Construction, Mining, Automotive, Engineering, Rural and DIY/
Hobbysit.
We distinguish ourselves from our competition through market
leading dependable brands that have stood the test of time, technical
innovation, competitive prices, excellent delivery, superior customer
service and technical support, together with excellence in sales and
marketing expertise.
We are committed to develop technologically advanced products to
achieve a safer working environment within the welding industry .

WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Pro-Wavel 300GTSW Inverter Arc Welder
Service Manual Number 0-2515 for:
208/230VAC Single-Voltage, Single-/Three-Phase Spec Number: 10-3024
208/230/460VAC Single-/Three-Phase Spec Number: 10-3025
380/415VAC Single-Voltage, Three-Phase Spec Number: 10-3038
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermalarc.com
Copyright 2001 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the pub-
lisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: January 20, 1997
Revision AB Date: June 21, 2012
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
i

TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards....................................................................................... 1-1
1.02 PRINCIPAL SAFETY STANDARDS................................................................... 1-5
1.03 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC .................................... 1-6
1.04 Dangers relatifs au soudage à l’arc................................................................. 1-6
1.05 PRINCIPALES NORMES DE SECURITE......................................................... 1-10
1.06 DECLARATION OF CONFORMITY.................................................................. 1-11
1.07 LIMITED WARRANTY ................................................................................... 1-12
SECTION 2:
INTRODUCTION ..................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Symbol Chart.................................................................................................. 2-2
2.05 General Description ........................................................................................ 2-3
2.06 Functional Block Diagram ............................................................................... 2-4
2.07 Transporting Methods..................................................................................... 2-5
2.08 Specifications ................................................................................................. 2-6
2.09 Duty Cycle....................................................................................................... 2-7
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Electrical Input Connections ........................................................................... 3-1
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 Operator Controls ........................................................................................... 4-1
SECTION 5:
SERVICE............................................................................................... 5-1
5.01 Routine Maintenance ...................................................................................... 5-1
5.02 Basic Troubleshooting ................................................................................... 5-1
5.03 Common Welding Operation Faults ................................................................ 5-1
5.04 Specific Problems........................................................................................... 5-2
SECTION 6:
ADVANCED TROUBLESHOOTING .................................................................. 6-1
6.01 System-Level Fault Isolation........................................................................... 6-1
6.02 Opening the Enclosure.................................................................................... 6-2
6.03 Initial Setup Conditions................................................................................... 6-2
6.04 Easy Link Fault Isolation Test (208-230/460VAC Model only)......................... 6-3
6.05 Power Supply Voltage Test ............................................................................. 6-4
6.06 Output Load Test............................................................................................. 6-6
6.07 LIFT START Circuit Test .................................................................................. 6-6

TABLE OF CONTENTS (continued)TABLE OF CONTENTS
6.08 High Frequency (HF) START Circuit Test ........................................................ 6-7
6.09 Subsystem Test Preparation ........................................................................... 6-8
6.10 Main Circuit Breaker (MCB) Replacement Procedure...................................... 6-8
6.11 Main PCB1 Gate Drive Enable Signal Test..................................................... 6-10
6.12 Lift Start Test ................................................................................................ 6-12
6.13 Gas Control Test .......................................................................................... 6-12
6.14 High Frequency Test .................................................................................... 6-12
6.15 Main Circuit Board (PCB1) Replacement Procedure..................................... 6-13
6.16 Gaining Access to Front Panel Circuit Board (PCB6) WK-3988..................... 6-18
6.17 Front Panel PCB6 (WK-3988) Test Point Voltages ........................................ 6-19
6.18 Input Power Selector Switch Test ................................................................. 6-20
6.19 Front Panel Circuit Board (PCB6) Replacement Procedure........................... 6-20
6.20 Current Transformer Test Procedure............................................................. 6-22
6.21 Current Transformer Replacement Procedure............................................... 6-22
6.22 Power Control Assembly .............................................................................. 6-23
6.23 Power Control Assembly (PCA) Test Procedures.......................................... 6-23
6.24 PCA Input Diode Bridge (D1) Test Procedure ............................................... 6-24
6.25 PCA Input Diode Bridge (D1) Replacement Procedure ................................. 6-24
6.26 PCA IGBT Inverter Test Procedure ................................................................ 6-26
6.27 PCA IGBT Inverters Q1 and Q2 Replacement Procedure............................... 6-28
6.28 PCA IGBT Inverter Q3/Q4 Replacement Procedure....................................... 6-30
6.29 PCA Output Diodes (D2-D5) Test Procedure................................................. 6-32
6.30 PCA Output Diodes (D2 - D5) Replacement Procedure................................. 6-33
6.31 PCA Thermal Sensor (TH1) Test Procedure.................................................. 6-36
6.32 Thermal Sensor (TH1) Replacement............................................................. 6-37
6.33 Auxiliary Transformer (T3) Test Procedure .................................................. 6-38
6.34 Auxiliary Transformer (T3) Replacement ...................................................... 6-39
6.35 Main Transformer Assembly (T1 and T2) Test Procedure............................. 6-40
6.36 Main Transformer (T1 and T2) Assembly Replacement Procedure............... 6-41
6.37 Output Inductor Assembly Test and Replacement Procedures ..................... 6-42
6.38 Fan Assembly Replacement Procedure......................................................... 6-44
6.39 HF Unit Test and Replacement Procedures ................................................... 6-46
6.40 HF Coupling Coil Test and Replacement Procedures..................................... 6-48
6.41 Gas Solenoid Valve Replacement Procedure................................................. 6-50
6.42 IGBT Inverter Q3/Q4 Driver Circuit Board (PCB8) Test Procedure ................ 6-51
6.43 IGBT Inverter Q3/Q4 Driver Circuit Board (PCB8) Replacement Procedure .. 6-52
6.44 Sequence Timing Diagrams.......................................................................... 6-53
SECTION 7:
PARTS LIST........................................................................................... 7-1
7.01 Equipment Identification................................................................................. 7-1
7.02 How To Use This Parts List............................................................................. 7-1
7.03 Parts List ........................................................................................................ 7-2
7.04 Parts Pictures ................................................................................................. 7-6

TABLE OF CONTENTS
APPENDIX 1: GENERAL INFORMATION ................................................................. A-1
APPENDIX 2: 208/230VAC SINGLE-VOLTAGE SINGLE-/THREE-PHASE ............................. A-2
APPENDIX 3: 208/230/460VAC SINGLE-/THREE-PHASE .............................................. A-4
APPENDIX 4: 380/415VAC SINGLE-VOLTAGE THREE-PHASE ........................................ A-6
APPENDIX 5: WIRE CHART MAIN BOARD PCB1 ....................................................... A-8
APPENDIX 6: WIRE CHART FRONT PANEL PCB6 ....................................................A-12
APPENDIX 7: WIRE CHART AC IGBT GATE DRIVE PCB8 .............................................A-14
APPENDIX 8: BOTTOM WIRING PLACEMENT DIAGRAM.............................................A-15
APPENDIX 9: DIODE TESTING BASICS .................................................................A-16
APPENDIX 10: METER CALIBRATION PROCEDURE ..................................................A-18

PRO-WAVE 300GTSW
1-1
June 21, 2012
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever the
output is on. The input power circuit and
machine internal circuits are also live when
power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the
welding wire are electrically live. Incorrectly
installed or improperly grounded equipment
is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line fuses
so power cannot be turned on accidentally.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or out
of service.
7. Use fully insulated electrode holders. Never dip holder
in water to cool it or lay it down on the ground or the
work surface. Do not touch holders connected to two
welding machines at the same time or touch other
people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10.Ground the workpiece to a good electrical (earth)
ground.
11.Do not touch electrode while in contact with the work
(ground) circuit.
12.Use only well-maintained equipment. Repair or replace
damaged parts at once.
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS.
READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property,
if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned
through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.
This publication and other guides to what you should learn before operating this equipment are listed at the end of
these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED
ONLY BY QUALIFIED PEOPLE.

PRO-WAVE 300GTSW
1-2 June 21, 2012
13.In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
14.Wear a safety harness to prevent falling if working
above floor level.
15.Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can
damage hearing.
Arc rays from the welding process produce
intense heat and strong ultraviolet rays that
can burn eyes and skin. Noise from some
processes can damage hearing.
1. Wear a welding helmet fitted with a proper shade of
filter (see ANSI Z49.1 listed in Safety Standards) to
protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields
recommended.
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and foot
protection.
5. Use approved ear plugs or ear muffs if noise level is
high.
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 inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
5. Work in a confined space only if it is well ventilated,
or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing injury
or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can
react with vapors to form highly toxic and irritating
gases.
Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter
Torch soldering 2Ga s metal-arc
11llAlatemesabsuorref-noN4ro3gnizarbhcroT
Oxygen CuttingFerrous base metalAll 12
LightUnder 1 in., 25 mm 3 or 4Gas tungsten arc weldingAll 12
Medium1to 6 in., 25-150 mm 4 or 5 (TIG)All 12
HeavyOve r 6 in., 150 mm 5 or 6Atomic hydrogen weldingAll 12
Ga s weldingCarbon arc weldingAll 12
LightUnder 1/8 in., 3 mm 4 or 5Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
21thgiL8ro6mm21,.ni2/1revOyvaeH
Shielded metal-arc 41yvaeH01mm4,.ni23/5rednU
5/32 to 1/4 in., 12 Plasma arc cutting
9pmA003rednUthgiL41mm4.6,.ni4/
1revO
Medium 300 to 400 Am p12
HeavyOver 400 Am p14
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AW S A6.2-73.

PRO-WAVE 300GTSW
1-3
June 21, 2012
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated,
and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc.
The flying sparks and hot metal, weld spatter,
hot workpiece, and hot equipment can cause
fires and burns. Accidental contact of electrode
or welding wire to metal objects can cause
sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot
metal.
2. Do not weld where flying sparks can strike flammable
material.
3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover them
with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or
drums.
8. Connect work cable to the work as close to the welding
area as practical to prevent welding current from
traveling long, possibly unknown paths and causing
electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10.Remove stick electrode from holder or cut off welding
wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause
injury.
Chipping and grinding cause flying metal. As
welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to treat
them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific application;
maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder
valve.
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA publication
P-1 listed in Safety Standards.
Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter
Torch soldering 2Ga s metal-arc
11llAlatemesabsuorref-noN4ro3gnizarbhcroT
Oxygen CuttingFerrous base metalAll 12
LightUnder 1 in., 25 mm 3 or 4Gas tungsten arc weldingAll 12
Medium1to 6 in., 25-150 mm 4 or 5 (TIG)All 12
HeavyOve r 6 in., 150 mm 5 or 6Atomic hydrogen weldingAll 12
Ga s weldingCarbon arc weldingAll 12
LightUnder 1/8 in., 3 mm 4 or 5Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
21thgiL8ro6mm21,.ni2/1revOyvaeH
Shielded metal-arc 41yvaeH01mm4,.ni23/5rednU
5/32 to 1/4 in., 12 Plasma arc cutting
9pmA003rednUthgiL41mm4.6,.ni4/
1revO
Medium 300 to 400 Am p12
HeavyOver 400 Am p14
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AW S A6.2-73.

PRO-WAVE 300GTSW
1-4 June 21, 2012
WARNING
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any
sparks or open flames.
3. Allow engine to cool before fueling. If possible, check
and add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed
and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes and
skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working on
a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
The coolant in the radiator can be very hot and
under pressure.
1. Do not remove radiator cap when engine is hot. Allow
engine to cool.
2. Wear gloves and put a rag over cap area when
removing cap.
3. Allow pressure to escape before completely removing
cap.