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Hi thermal arc pro wave 300 tsw question. I wired wrong. trying to walk it back.

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  • Hi thermal arc pro wave 300 tsw question. I wired wrong. trying to walk it back.

    Hi first of all i am brand new to the site. My friend sold me a thermal arc pro wave 300 tsw a few months ago finally got around to trying to wire it up and idk why or what i was thinking but wired it 3 wire as it will be single phase, however iwent hot ground hot on the main power in switch should be hot hot and case ground. welder turned on fan came on then charging sound then leds on front then everything off and not on again since. since i just about threw up realizing what i had done and cursed myself for trying to rush on a Sunday afternoon i have gotten the manual and all info the best i can online. i wired main switch s1 black and white hot and case ground and according to there manual . now based on there trouble shooting it goes main power 2 hot in directly to a dc rectifier which should have power out and does not. however i diode tested the rectifier and its checked out nominal they said between .3 and .5 i believe. it was like .45 . for the life of me i cannot find the pcb with 6 large ac relays on it in there manuals and i believe this might be the culprit. https://www.manualslib.com/manual/10...page=61#manual



    also


    https://www.manualslib.com/manual/84...sw.html#manual




    any who has done something this stupid please help or just a kind soul with a minute to spare to save a guy some grief would be appreciated . any and all criticism or advice welcome.


    pretty much all voltage stops at the rectifier and then the board that has all the relays on it there are some small wires with ac going to that board as well as heavy gauge wires going from the dc side of the rectifier to that board in 3 locations .

  • #2
    I'll come back when that's been edited with punctuation, capitalization, and some clarity of what happened. I spent too much time already trying to understand it.

    Comment


    • #3
      Hi. Yes sorry i wrote that late last night after messing around with the machine and a volt meter most of the day, and in between getting the kids to bed. Not sure how to edit so here is the simple version. I originally wired my ground to a hot terminal on this machine with no case ground. if you look at the manual my ground was connected to connection V1 on S1 which is the main power switch to this machine. The machine powered up (fan came on) . I heard a capacitor charging sound, and finally the LED's in front came on. Then the machine promptly shut off. I have not had any sign of life from this machine since. It is now wired correctly . I have power to U1 and V1 of S1. As well as through power to U2 and V2 of S1 when switch is thrown. these large gauge wires then go to a rectifier. The manual states i should have DC volts coming off the other side of this rectifier and i do not. I did a diode test and it tested ok. The 2 links in my previous post are to the page showing the S1 switch and then the Rectifier D1 i believe and then to a general manual. thanks. wondering if my rectifier needs to be switched on with power or is supposed to be always on, and also the only other power to anything is a board with 6 relays that have 240 ac printed on them. There is power to that board and it doesn't leave that board.




      ps i cannot find that board in any manuals for this machine but it has wk-5040 and the relays are potter and brumfied 240vac with 12 vdc also printed on them. This board has small ac wires and some heavy gauge dc wires coming from the rectifier it has ac power but the rectifier is not producing dc voltage.

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      • #4
        First, verify you didn't trip the circuit breaker to the outlet you were using and that you do, indeed, now have the proper voltage entering the machine.

        I now see your last sentence seems to say you've confirmed AC voltage (what method? what voltage?) to the rectifier, but no DC coming out (what method?).

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        • #5
          I have power up until the rectifier

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          • #6
            240 ac volts into the rectifier,and into the relay circuit board connection . no fan. No LEDs. No movement or noise what so ever. When main switch with power is thrown.

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            • #7
              With a volt meter reading ac voltage 120 per leg or 240 as a pair. Also checked for DC voltage after rectifier and had none. Did a diode test as described in manual and got nominal readings of .42 I believe when I removed rectified from machine and tested independently.

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              • #8
                This unit uses an SCR that will gate once the precharge is done. If you are not getting any DC voltage to the large cap bank then the precharge circuit may be bad.

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                • #9
                  Thank you. Keith . I am getting nothing. no fan. no precharge. what does scr stand for. i will look at thermal arcs manual and see what i cant find.As of right now 2 hot legs with power reach the rectifier and no dc power there are 5 smaller wires in total leaving ac side of rectifier as well. i have no auxilary power at all for fan or front panel. does not seem to be coming off the board that has ac power going into it with all the relays however i cant find this board on any manual.

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                  • #10
                    You may want to try and contact Thermal Arc since they will be the experts on this. www.thermalarc.com or 1-800-462-2782.

                    Comment


                    • #11
                      Originally posted by carl800 View Post
                      Thank you. Keith . I am getting nothing. no fan. no precharge. what does scr stand for. i will look at thermal arcs manual and see what i cant find.As of right now 2 hot legs with power reach the rectifier and no dc power there are 5 smaller wires in total leaving ac side of rectifier as well. i have no auxilary power at all for fan or front panel. does not seem to be coming off the board that has ac power going into it with all the relays however i cant find this board on any manual.
                      SCR is Silicon Control Rectifier.... Sort of a diode with "gating" capabilities (voltage or current) ... May look like diode with extra terminal... Could be like any of the items in image below depending on circuit design...



                      Dale

                      Last edited by Dale M.; 10-01-2019, 12:31 PM.
                      "Fear The Government That Wants To Take Your Guns" - Thomas Jefferson..

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                      • #12
                        so Just an update. I have spoken with thermal arc and at least 2 boards are bad according to them. The customer support was awesome i might add. I was skeptical because id heard since being bought by esab things where bad. all in all minum 1000 bucks for the main board though. so if anyone on here has details on where i might find used machines or parts i need some partts for a 2003-2004 ish thermal dynamics thermal arc pro wave 300tsw.

                        Comment


                        • #13
                          Sorry for being late to this thread, but I just picked up a broken Thermal Arc 300TSW, will figure out the year from the serial number. I plan to fix this, but can walk you through board testing/repair if you're interested. It may take me a little while to get to it because I have a Thermal Arc 400GMS (front panel PCB oxidation, chasing down gremlins), a Lincoln Power Wave 355 (blew the bus capacitors), and a couple POWCONs before I can get to the Pro Wave 300. Mine blew a bus capacitor, so I am replacing all 6 plus repairing the board. Here is where it is in the process right now, ready to put a copper patch over the damaged section.

                          Jon

                          Click image for larger version

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                          • #14
                            Reading your problem a bit, that rectifier is a Sanrex DFA100BA1600 (or should be, that's the one I replaced in mine). It has both a three phase rectifier (you checked the three phase rectifier diodes) and a SCR (electronic one-way switch) It's worth downloading the data sheet. There is a pre-charge resistor between the rectifier part and the capacitors. Once they charge to ~325VDC, the circuit board monitoring their voltage sends a signal through a relay to turn on the SCR in the Sanrsx module. This gives a direct connection from the rectifier to the DC bus capacitors. It sounds like the way you had it wired that you really only had ~120V going through your system (and your machine chassis/panel/common hot). Luckily you weren't electrocuted touching the machine/panel/etc with one hand and something conducting to ground (metal table or something), but I don't believe that would have fried your board (unless your neutral was floating very high). I need to think about it a bit more though. Anyways, you should be able to check the SCR on the Sanrex module separately (in the tech manual) to ensure that the entire module is good. You should also be able to check the pre-charge resistor. I would start with the pre-charge resistor first.

                            In my picture above, look in the lower right corner. That is your pre-charge circuit, R44 is the pre-charge resistor. Check to see if the pre-charge resistor is damaged. It's probably worth looking at the underside of the relay to see if the lead or board traces overheated.

                            Hope this helps,
                            Jon
                            Last edited by jjohn76; 01-07-2020, 12:22 AM.

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