300 MST
®
ARCMASTER
INVERTER ARC WELDER
Operating Manual
Art # A-07367
Version No: 1 Issue Date: March 22, 2006 Manual No.: 0-4865
Operating Features:
WE APPRECIA TE 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 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 marketleading, 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.
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.
ArcMaster 300 MST Inverter Arc Welder
Instruction Manual Number 0-4865 for:
Part Number W1000700
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2006 by
Thermadyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: March 22, 2006
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________
TABLE OF CONTENTS
1.0 SAFETY INSTRUCTIONS AND WARNINGS...................................................................................... 1
1.01 Arc Welding hazards ............................................................................................................................................ 1
1.02 Principal Safety Standards ................................................................................................................................... 4
1.03 Precautions de Securite en Soudage à l’Arc ......................................................................................................... 5
1.04 Dangers Relatif au Soudage à l’Arc ...................................................................................................................... 5
1.05 Principales Normes de Securite ........................................................................................................................... 8
SYMBOL LEGEND......................................................................................................................... 9
2.0 INTRODUCTION AND DESCRIPTION........................................................................................... 10
2.01 Description......................................................................................................................................................... 10
2.02 Functional Block Diagram................................................................................................................................... 11
2.03 Transporting Methods........................................................................................................................................ 11
2.04 Installation Recommendations........................................................................................................................... 12
2.04.01 Environment........................................................................................................................................... 12
2.04.02 Location................................................................................................................................................. 12
2.05 Electrical Input Connections............................................................................................................................... 13
2.05.01 Electrical Input Requirements ................................................................................................................13
2.05.02 Input Power ........................................................................................................................................... 15
2.05.03 High Frequency Introduction.................................................................................................................. 16
2.05.04 High Frequency Interference .................................................................................................................. 16
2.06 Specifications..................................................................................................................................................... 17
2.07 Duty Cycle.......................................................................................................................................................... 18
3.0 OPERATOR CONTROLS..........................................................................................................19
3.01 ARC MASTER 300 MST Controls ....................................................................................................................... 19
3.02 Weld Parameter Descriptions for ARC MASTER 300 MST.................................................................................. 22
3.03 Weld Process Selection for the ARC MASTER 300 MST .................................................................................... 23
3.04 Weld Parameter Descriptions............................................................................................................................. 23
3.04.01 WELD (V)............................................................................................................................................... 23
3.04.02 INDUCTANCE......................................................................................................................................... 23
3.04.03 HOT START............................................................................................................................................ 24
3.04.04 WELD (A)............................................................................................................................................... 24
3.04.05 ARC CONTROL....................................................................................................................................... 24
3.05 Weld Parameters................................................................................................................................................ 25
3.06 Power Source Features ...................................................................................................................................... 25
4.0 SEQUENCE OF OPERATION ..................................................................................................... 27
4.01 Stick Welding..................................................................................................................................................... 28
4.02 LIFT TIG Welding ............................................................................................................................................... 28
4.03 MIG Welding...................................................................................................................................................... 28
4.04 Save-Load Operation.......................................................................................................................................... 29
5.0 BASIC WELDING GUIDE ......................................................................................................... 30
5.01 Electrode Polarity............................................................................................................................................... 30
5.02 Tungsten Electrode Current Ranges................................................................................................................... 30
5.03 Tungsten Electrode Types.................................................................................................................................. 30
5.04 Guide for Selecting Filler Wire Diameter............................................................................................................. 31
5.05 Shielding Gas Selection...................................................................................................................................... 31
5.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe....................................................................... 31
5.07 Welding Parameters for Steel............................................................................................................................. 32
TABLE OF CONTENTS
6.0 BASIC STICK WELDING GUIDE ................................................................................................. 33
6.01 Electrode Polarity ...............................................................................................................................................33
6.02 Effects of Stick Welding Various Materials .........................................................................................................33
7.0 BASIC MIG WELDING GUIDE....................................................................................................35
7.01 Setting of the Power Source...............................................................................................................................35
7.02 Position of MIG Torch ........................................................................................................................................35
7.03 Distance from the MIG Torch Nozzle to the Work Piece...................................................................................... 35
7.04 Travel Speed....................................................................................................................................................... 36
7.05 Electrode Wire Size Selection ............................................................................................................................. 36
7.06 Deposition Rate Comparison..............................................................................................................................36
8.0 ROUTINE MAINTENANCE........................................................................................................37
9.0 BASIC TROUBLESHOOTING..................................................................................................... 38
9.01Solving MIG Problems Beyond the Welding Terminals........................................................................................38
9.01.01 Porosity.................................................................................................................................................. 38
9.01.02 Inconsistent Wire Feed...........................................................................................................................39
9.02 MIG Welding Problems ......................................................................................................................................40
9.03 TIG Welding Problems........................................................................................................................................41
9.04 Stick Welding Problems .....................................................................................................................................43
9.05 Power Source Problems..................................................................................................................................... 45
10.0 VOLTAGE REDUCTION DEVICE (VRD) ......................................................................................... 46
10.01 VRD Specification............................................................................................................................................. 46
10.02 VRD Maintenance.............................................................................................................................................46
10.03 Switching VRD ON/OFF ....................................................................................................................................47
11.0 POWER SOURCE ERROR CODES............................................................................................... 49
APPENDIX A - INTERCONNECT DIAGRAM ........................................................................................... 51
APPENDIX B - ARCMASTER 300MST ACCESSORIES............................................................................... 53
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION....................................................... Inside Rear Cover
ARCMASTER 300 MST
1.0 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:
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit
and machine internal circuits are also live when power
is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
SAFETY IN WELDING AND CUTTING. This publication and other
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.
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.
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.
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.
1
ARCMASTER 300 MST
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
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.
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.
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.
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.
Eye protection filter shade selector for welding or cutting
Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter
Torch soldering 2 Gas metal-arc
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen C utting Ferrous base metal All 12
Light 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 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light 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 gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
(goggles or helmet), from AWS A6.2-73.
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
2
WARNING
ARCMASTER 300 MST
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
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.
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
!
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
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.
3
ARCMASTER 300 MST
1.02 Principal Safety Standards
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.
WARNING
!
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some
cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
4
ARCMASTER 300 MST
1.03 Precautions de Securite en Soudage à l’Arc
MISE EN GARDE
!
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de
sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.04 Dangers Relatifs au Soudage à l’Arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension
dès la mise en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou
la bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à la terre
est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
5
ARCMASTER 300 MST
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements
et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
portez un respirateur à adduction d’air. Les gaz protecteurs de
soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
malaises ou la mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Opération de coupage
ou soudage
Brassage tendre
au chalumeau
Brassage fort
au chalumeau
Oxycoupage métaux ferreux toutes conditions 12
mince moins de 1 po. (25 mm) 2 ou 3
moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5
Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12
mince moins de 1/8 po. (3 mm) 4 ou 5
moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12
Soudage á l'arc avec
électrode enrobees
(SMAW)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
toutes conditions 2
toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11
épais plus de 6 po. (150 mm) 5 ou 6
épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14
moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)
5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9
plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12
Nuance de
filtre oculaire
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Gougeage Air-Arc avec
électrode de carbone
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
toutes conditions 12
toutes conditions 12
toutes conditions 12
épais plus de 400 amperès 14
Nuance de
filtre oculaire
6
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que si
l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du
soudage.
AVERTISSEMENT
ARCMASTER 300 MST
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un échauffement ou un
incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
7
ARCMASTER 300 MST
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau e
carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un
accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.
1.05 Principales Normes de Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
8
SYMBOL LEGEND
Amperage
Voltage
STICK (Shielded Metal Arc SMAW)
Pulse Current Function
SEC
%
Hertz (frequency)
Seconds
Percent
DC (Direct Current)
AC (Alternating Current
Standard Function
Slope Function
Spot Time (GTAW)
Remote Control (Panel/Remote)
Remote Function
Arc Control (SMAW)
Gas Post-Flow
Gas Pre-Flow
Voltage Reduction Device Circuit
VRD
Slope W/Repeat Function
Spot Function
Impulse Starting (High Frequency
GTAW)
Touch Start (Lift Start TIG circuit
GTAW)
Negative
Positive
Gas Input
Gas Output
9
2.0 INTRODUCTION AND DESCRIPTION
2.01 Description
The Thermal Arc™ ARC MASTER 300 MST is a single & three-phase DC arc welding power source with Constant
Current (CC) and Constant Voltage (CV) output characteristics. This unit is equipped with a Digital Volt/Amperage, lift
arc starter for use with Gas Tungsten Arc Welding (GTAW), Arc Control and Hot Start for Shielded Metal Arc Welding
(SMAW), Inductance Control for Gas Metal Arc Welding (GMAW) processes. The power source is totally enclosed in
an impact resistant, flame resistant and non-conductive plastic case.
(V)
OCV
18V
160A
300A5A
320A
STICK Process
(V)
OCV
(V)
OCV
29V
10V
10V
300A25A (A)
5A (A)
LIFT-TIG Process MIG Process
Figure 1. Model 300 MST Volt-Ampere Curve
Note 1
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding
power source. Curves of other settings will fall between the curves shown.
10
300A
320A
2.02 Functional Block Diagram
Figure 2 illustrates the Functional Block Diagram of the 300 MST-power supply.
Input
Power
Main
Circuit
Switch
Filter
Down
Tr ansformers
AC115V,AC24V
(T3)
Over
Current
Protect
14PIN
Receptacle
(CON1)
19PIN
Receptacle
(CON2)
Input
Diode
Capacitor
DC Power
Primary
Voltage
Sensor
To each c ontrol c irc uit
+/-15VDC +18VDC
+24VDC +5VDC
IGBT
Inverter
Thermal
Detector
Trouble
Sensing
Circuit
Drive
Circuit
Main
Transformers
(T1)
Thermal
Sensor
Circuit
Primary
Circuit
Sensor
Current
Adjustment
Circuit
Output
Diodes
Thermal
Detector
StickMode
VRD
Sensin g
Circuit
Sequence
Control
Reference
Adjustment &
Modeselect Switch
Panel Circuit Board
Output
Inductor
Figure 2. 300 MST Model Functional Block Diagram
Lift T ig Mode
Output Short
Sensing
Circuit
Fan Control
14PIN-19PIN
Select Switch
(S3)
Circuit
Hall Current
Transformer
(HCT1)
Fan
2.03 Transporting Methods
This unit is equipped with a handle for carrying purposes.
WARNING 1
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors
from de-energized supply line before moving the welding power source.
WARNING 2
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Lift unit with handle on top of case.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper skid before transporting.
11
2.04 Installation Recommendations
2.04.01 Environment
The ARC MASTER 300 MST is designed for use in hazardous environments.
Examples of environments with increased hazardous environments are:
a. In locations in which freedom of movement is restricted, so that the operator is forced to perform the
work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts.
b. In locations which are fully or partially limited by conductive elements, and in which there is a high
risk of unavoidable or accidental contact by the operator.
c. In wet or damp hot locations where humidity or perspiration considerably reduces the skin
resistance of the human body and the insulation properties of accessories.
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.
2.04.02 Location
Be sure to locate the welder according to the following guidelines:
In areas, free from moisture and dust.
•
•
Ambient temperature between 0 degrees C to
40 degrees C.
•
In areas, free from oil, steam and
corrosive gases.
•
In areas, not exposed to direct sunlight
or rain.
•
In areas, not subjected to abnormal vibration
or shock.
•
Place at a distance of 12” (304.79mm) or more
from walls or similar that could restrict natural
airflow for cooling.
WARNING 3
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
12
2.05 Electrical Input Connections
WARNING 4
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.
2.05.01 Electrical Input Requirements
Operate the welding power source from a single or three-phase 50/60 Hz, AC power supply. The input
voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate.
Contact the local electric utility for information about the type of electrical service available, how proper
connections should be made, and inspection required.
The line disconnect switch provides a safe and convenient means to completely remove all electrical power
from the welding power supply whenever necessary to inspect or service the unit.
Note 2
This unit is equipped with a three-conductor with earth power cable that is connected at the welding
power source end for single or three-phase electrical input power.
Do not connect an input (WHITE, BLACK or RED) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
Refer to Figure 3 and:
1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies
with all applicable electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors to a de-energized line
disconnect switch.
3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.
Note 3
For Single-Phase operation connect the GREEN, BLACK and WHITE input conductors. Insolate
the RED Conductor, it is not used for Single-phase operation.
13
Table 1 – Electrical Input Connections
Input Voltage Fuse Size
208 VAC 100 Amps
230 VAC 75 Amps
460 VAC 50 Amps
Note 4
Fuse size is based on not more than 200 percent of the rated input amperage of the welding power
source (Based on Article 630, National Electrical Code).
Figure 3. Electrical Input Connections
14
2.05.02 Input Power
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN SWITCH is
turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control
Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after
approximately 5 seconds).
Note 5
Note the available input power. Damage to the PCA could occur if 575VAC or higher is applied.
The following 208-230/460V Primary Current recommendations are required to obtain the maximum welding
current and duty cycle from this welding equipment:
Model
ARC
MASTER
300 MST
Primary Supply
Lead Size
8/4 AWG minimum
(Factory Fitted) 3 Phase
8/3 AWG minimum
Phase
Minimum Primary
Current Circuit Size
(Vin/Amps)
208/41
230/37
460/19
208/31
230/28
460/14
208/45
230/41
460/21
208/55
230/49
1
208/41
230/37 -
300A @
250A @
Current & Duty Cycle
MIG TIG STICK
- -
40%
- -
-
-
- -
- -
-
300A @
40%
-
- -
- -
300A @ 40%
- -
- -
40%
- -
-
250A @
40%
-
-
Table 2 – Primary Current Circuit Sizes to Achieve Maximum Current
208/61
230/55 - -
- 250A @ 40%
15
2.05.03 High Frequency Introduction
The importance of correct installation of high frequency welding equipment cannot be over-emphasized.
Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper
installation. The following information is intended as a guide for personnel installing high frequency
welding machines.
Warning
Explosives
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.
2.05.04 High Frequency Interference
Interference may be transmitted by a high frequency initiated or stabilized arc-welding machine in the
following ways:
Direct Radiation
Radiation from the machine can occur if the case is metal and is not properly grounded. It can occur
through apertures such as open access panels. The shielding of the high frequency unit in the Power
Source will prevent direct radiation if the equipment is properly grounded.
Transmission via the Supply Lead
Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the
installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction.
Adequate shielding and filtering is provided in the Power Source.
Radiation from Welding Leads
Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes
rapidly with distance. Keeping leads as short as possible will minimize this type of interference.
Looping and suspending of leads should be avoided where possible.
Re-radiation from Unearthed Metallic Objects
A major factor contributing to interference is re-radiation from unearthed metallic objects close to the
welding leads. Effective grounding of such objects will prevent re-radiation in most cases.
16
2.06 Specifications
Parameter 300 MST
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle TIG
STICK
MIG
300
32
40%
300A/ 22V@ 40%
250A/ 20V @ 60%
180A/ 18V @ 100%
300A / 32V @ 40%
250A / 30V @ 60%
180A / 28V @ 100%
300A / 29V @ 40%
250A / 27V @ 60%
180A / 23V @ 100%
Output Current
Range
Output Voltage
Range
TIG
STICK
MI
G 10 – 32V
5 – 300A
Open Circuit Voltage 65V
Dimensions
Width
Height
Length
8.27” (210mm)
16.89” (420mm)
17.72” (450mm)
Weight 55.1lb. 25kg
Output @ Rated Load
Rated Input Voltage
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Single Phase
208V
230V
Input Volts Three Phase
208V
230V
460V
Three-phase
208-230/460V
300A
32V
40%
16.0kVA
12.0kW
0.5
0.13
Amperage Draw @ Rated Load
Single-phase
208-230V
250A
30V
40%
15.7kVA
9.4kW
61
55
45
41
21
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment
previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
No Load
2.4
1.8
1.4
1.1
0.7
17
2.07 Duty Cycle
The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be
operated at a given output without causing overheating and damage to the unit. If the welding amperes
decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty
cycle will decrease.
WARNING 5
Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become
energized and shut down the output until the unit has cooled to normal operating temperature.
CAUTION 1
Continually exceeding the duty cycle ratings can cause damage to the welding power source and
will void the manufactures warranty.
NOTE 6
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.
18
3.0 OPERATOR CONTROLS
3.01 ARC MASTER 300 MST Controls
6
1
3
1.
Control Knob
This control sets the selected weld
parameter, rotating it clockwise increases
the parameter and is indicated on the
digital meter. Pushing the knob in
previews the actual welding voltage while
welding.
2
Remote Control Socket
The 14 pin Remote Control Socket is
used to connect remote current control
devices to the welding Power Source. To
make connections, align keyway, insert
plug, and rotate threaded collar fully
clockwise.
E
ＡＢＣＤＥＦＧＨＩＪＫＬＭＮ
5k ohms
Figure 5. 8-Socket Receptacle
2
4
5
Figure 4. ARC MASTER 300 MST Power Source
Socket Pin Function
A 24VAC auxiliary high side.
B
C
D
E
F Current feedback Ifb = 100Amps/Volt
G
AJ
BKI
CLNH
DMG
FE
Front view of 14
Socket Receptacle
H Voltage Feedback Vfb = 10 Arc Volts/Volt
I 115 VAC auxiliary high side
J
K Chassis ground
L Not used
M Current Detect
N Current Detect
9
8
7
10
11
Input to energize solid state contactor.
(Contact closure between pin A and pin B)
5k ohm (maximum) connection to 5k ohm
remote control potentiometer
Zero ohm (minimum) connection to 5k
ohm remote control potentiometer
Wiper arm connection to 5k ohm remote
control potentiometer
24/115 VAC circuit common, also
connected to chassis
115 VAC input to energize solid state
contactor (Contact closure between pin I
and pin J)
19
3.
Positive Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
4.
Negative Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION 2
Loose welding terminal connections can cause overheating and result in the male plug being
fused in the bayonet terminal and /or melting of the housing (case).
5.
Remote Control Socket
The 19 pin Remote Control Socket is used to connect remote current control devices to the welding
Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
Socket Pin Function
A
B Contactor circuit in, (closure between pin A and Pin B will energize output.)
C Scaled output voltage signal: Vfb = 10 Arc Volts/Volt
D
E 115 VAC auxiliary power high side
G Chassis ground
H Remote control maximum
J Remote control wiper (0 – 10 Volts)
K Remote Control minimum
J Remote control wiper (0 – 10 Volts)
L Control circuit common
M Arc Establish = +12 Volts
N Control Circuit common
P 24 VAC auxiliary power high side
R 24/115 VAC neutral
S N/C
T N/C
U Scaled output signal: Ifb = 100 Amps/Volt
V N/C
Contactor circuit (+15 Volts)
24 VAC auxiliary power high side
20
6.
ON/OFF Switch
This switch connects the Primary supply voltage to the inverter when in the ON position. This enables
the Power Supply.
WARNING 6
When the welder is connected to the Primary supply voltage, the internal electrical components
may be at 500V potential with respect to earth.
7.
Input Cable
The input cable connects the Primary supply voltage to the equipment.
Voltage Input Select Switch (Smart Logic Switch)
8.
User selectable switch.
A manual slide switch selects the proper input voltage range. If this slide switch is not set to the
position that matches the input line voltage, the Smart Logic will inhibit the welding power source from
turning on and a warning indication will be displayed
WARNING 7
Do not alter the position of the Voltage Input Select Switch when the ON/OFF Switch is in the ON
position and the unit is powered up.
14/19 Pin Remote Control Select Switch
9.
User selectable switch.
Position this switch for the remote control device socket to be utilized. The unselected Remote Control
Socket is disabled at this time and cannot be utilized. Do not alter the position of this switch while one
of the Remote Control Sockets is being utilized.
24VAC Remote Device C/B
10.
Push to reset. Controls the 24VAC power source for the wire feeders controlled through the Remote
Control Sockets.
11.
115VAC Remote Device C/B
Push to reset. Controls the 115VAC power source for the wire feeders controlled through the Remote
Control Sockets.
21
3.02 Weld Parameter Descriptions for ARC MASTER 300 MST
Figure 6. ARC MASTER 300 MST Front Panel with Parameter Description
Parameter Description
This parameter provides a suitable short circuit current in STICK welding to
improve electrode sticking and arc stability.
ARC CONTROL
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.
HOT START
DC (A)
Weld Current (Amperage)- when lit parameter knob sets the STICK and TIG WELD
current.
DC (V)
Weld Voltage (Volt) – when lit parameter knob sets the MIG voltage.
Contactor operation in Stick Mode.
Contactor ON/OFF
22
Parameter Description
Selects in operation Panel board or Remote.
Operation
PANEL/REMOTE
This parameter, similar to the ARC CONTROL in STICK mode, allows for the
INDUCTANCE
adjustment of the dynamic property of the arc. As the inductance is increased the
output voltage may need to be adjusted to achieve the desired weld characteristics.
The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs
into the 300 MST memory.
Table 3 – Weld Parameter Descriptions for ARC MASTER 300 MST
3.03
Weld Process Selection for the ARC MASTER 300 MST
Weld Mode
Weld Parameter
STICK
WELD (V)
INDUCTANCE
HOT START
WELD (A)
ARC CONTROL
Table 4 – Weld Process Selection verses Weld Mode
3.04 Weld Parameter Descriptions
3.04.01 WELD (V)
This parameter sets the MIG weld arc voltage in MIG mode.
3.04.02 INDUCTANCE
This parameter sets the INDUCTANCE when MIG welding. It controls the dynamic properties of the arc
in dip transfer welding mode. When this parameter is set to 0%, i.e. minimum inductance, the arc has
a fast response with a resulting crisp arc noise and coarse spatter. When this parameter is set to
100%, i.e. maximum inductance, the arc has a slow response with a resulting soft arc and fine spatter.
MIG
LIFT
TIG
Description
Weld voltage MIG Mode.
Inductance control in MIG Mode.
Start current in amps is added to the WELD (A).
WELD (A) current for STICK or LIFT TIG.
Adjusts percentage increase in welding current and is
proportional to arc length (arc voltage).
As the INDUCTANCE is increased, the WELD (V) may need to be adjusted to achieve the desired
weld characteristic.
NOTE 7
23
3.04.03 HOT START
This parameter operates in STICK mode and improves the start characteristics for stick electrodes. e.g.
low hydrogen electrodes. It sets the peak start current on top of the WELD current.
e.g. HOT START current = 150 amps when Weld Current = 100 amps & HOT START = 50A
3.04.04 WELD (A)
This parameter sets the STICK & Lift TIG weld current.
3.04.05 ARC CONTROL
This parameter operates in STICK mode only and is used to adjust percentage increase in welding
current and is proportional to arc length (arc voltage). This control provides an adjustable amount of
arc control (or dig). This feature can be particularly beneficial in providing the operator with the ability
to compensate for variability in joint fit up in certain situations with particular electrodes, e.g. cellulose
and hydrogen controlled electrodes. In all welding processes, the amount of penetration obtained is
dependent on the welding current; ie the greater the penetration, the greater the current.
Arc Force Position
Current Increase when Arc
Effect on Welding Performance
Voltage is less than 18V
Minimum (0) 0A Soft arc, Low spatter, Low
penetration
Medium (20%) 32A Normal arc, Improved fusion
characteristics,
Normal penetration
Maximum (100%) 160A Hard arc, Deep penetration
Table 5 – Weld Parameter Descriptions
In general, having the ARC CONTROL set at 100% (maximum) allows greater penetration control
to be achieved. With the ARC CONTROL set at 0% (minimum) the Power Source has a constant
current characteristic. In other words, varying the arc length does not significantly affect the
welding current. When the ARC CONTROL set to 100%, it is possible to control the welding
current by varying the arc length. This is very useful for controlling penetration on root runs and
side wall wash on vertical up fillet welds.
i) Root runs
During root runs the weld pool forms a “keyhole” shape. If too much weld current is
used, the hole blows out and the weld collapses. If too little weld current is used, the
hole closes up and penetration is lost. The size of the hole also determines the arc
length; i.e. as the hole gets bigger, the arc gets longer.
If arc force is used, the increase in the arc length causes the weld current to decrease
until the hole starts to close up but if the hole closes up to much then the arc length
decreases which causes the weld current to increase. Too little or too much arc force
makes this process unstable. The operator must adjust the arc force until a happy
medium is reached.
24
ii) Vertical up welding
When welding vertical up with arc force on, the operator can control the amount of
current by changing arc length, ie voltage. Weld metal is deposited by “digging” the
electrode into the side of the base metal joint and then increasing the arc length with a
flicking motion, to allow the weld pool to freeze, before digging the electrode into the
other side of the base metal joint.
Without arc force, increasing the arc length does not decrease the weld current
sufficiently and the operator has to manually decrease the current via a remote current
control to freeze the weld pool. This welding current reduction also reduces the
penetration.
The arc force allows the weld pool to freeze during the “flick” phase without decreasing the amount of
weld current available during the “dig” phase thus maximizing penetration.
3.05 Weld Parameters
Weld Mode
Weld
Parameter
WELD (V)
MIG
INDUCTANCE
HOT START
WELD (A)
TIG or STICK
ARC CONTROL
Parameter Range Factory
10.0 to 32.0V DC 17.0V 0.1V
5 to 300A DC 80A 1A
3.06 Power Source Features
Feature Description
New Digital Control
Touch Panel Switches
Front Control Cover
Digital Meter Volt & Ammeter
Incremental
Setting
0 to 100% 10% 1%
0 to 70A 20A 1A
0 to 100% 10% 1%
Table 6 – Weld Parameters
• All welding parameters are adjustable
• Touch switches eliminate mechanical damage
• Protects front panel controls
• Displays selected weld parameter value
• Displays average weld current when welding
• Displays average weld current for 20 seconds after weld
has been completed
• A selected weld parameter value can be adjusted at any
time even while welding
Unit
STICK
MIG
LIFT TIG
25
Feature Description
Intelligent Fan Control
ON/OFF Switch
Voltage Reduction Device (VRD)
(shipped de-activated, field capable)
See Section 10 for activation instructions.
Control Knob
Self Diagnosis Using Error Codes
• The intelligent cooling system is designed to reduce
dust and foreign material build-up, while providing
optimum cooling.
• Fan speed reduces approximately 30 seconds after
machine is turned on.
• Fan speed increases when internal components reaches
operating temperature.
• Mains ON/OFF switch located on rear panel.
Reduces the OCV when the power supply is not in use.
Eliminates the need for add on voltage reducers and has
no effect on arc starting.
• VRD fully complies to IEC 60974-1
• When Stick mode is selected the green VRD light is
ON when not welding and red when welding.
• When in TIG modes VRD is OFF.
• For the selected weld parameter, rotating the knob
clockwise increases the parameter.
• Rotating the knob counter-clockwise decreases
the parameter.
• A selected weld parameter value can be adjusted at
any time even while welding.
• Pushing the knob in sets the selected parameter then
displays the next parameter.
• An error code is displayed on the
Digital Meter
when a
problem occurs with Mains supply voltage or internal
component problems.
Save/Load Function
• A total number of 5 programs can be saved into the
300 MST memory.
SAVE
the Current Weld Parameters into Memory
Press and HOLD the
•
digital display will show a number 1.
SAVE
button. Beep will sound and
• Select a memory location by rotating the control knob,
1 to 5 is displayed on the meter.
• After selecting the desired memory location (i.e. 1 to 5),
press the parameter button and the machine give a beep
to confirm the weld parameters from the control panel
are saved.
LOAD
(retrieve) a Program to Control Panel
Press and HOLD the
•
and digital display will show a number 1.
LOAD
button. Beep will sound
• Select a memory location by rotating the control knob,
1 to 5 is displayed on the meter.
After selecting the desired memory location (i.e. 1 to 5), press
the parameter button and the machine give a beep to confirm
the weld parameters are loaded onto the control panel.
26
4.0 SEQUENCE OF OPERATION
7
NOTE: Parameter Buttons are used to select the parameters to be set. The LED’s
show which function is being adjusted on the weld sequence graph. Refer to
Symbols Table located in the front of the manual for Symbol descriptions.
1
2
4
3
Figure 7. 300 MST Front Panel
1. Contactor Function: Pressing this buttons enables Contactor functions.
2. Remote Functions: Pressing this buttons enables remote current functions.
3. Digital LED Displays: Welding amperage, Voltage and parameter values are displayed in this window.
Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator
by a warning sound and error message on the screen.
4. Save/Load Buttons: By using the Save & Load buttons the operator can easily save up to 5 welding
parameter programs.
5. Control Knob: Allows the operator to adjust the output amperage/voltage within the entire range of the
power source, also used to set each parameter value.
6. Process Button: This button selects between STICK, Lift TIG, and MIG modes. MIG modes include MS for
mild steel and SS for stainless steel.
7. Parameter Button: This button select between HOT START, WELD CURRENT, and ARC CONTROL while in
STICK and Lift TIG modes and selects between WELD VOLTAGE and INDUCTANCE CONTROL while in MIG
mode. This button is also used in conjunction with the Save/Load buttons to save and load welding programs.
5
6
27
4.01 Stick Welding
• Connect work lead to negative terminal
• Connect electrode lead to positive terminal
• Switch machine on
• Set weld current.
• Set Contactor.
• Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the control knob to adjust each parameter.
• Set
• Set
• Set
HOT START
ARC CONTROL
WELD
current
Commence welding
4.02 LIFT TIG Welding
• Connect work lead to positive terminal
• Connect TIG torch to negative terminal
• Switch machine on
• Set weld current.
• Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the control knob to adjust each parameter.
Commence welding
4.03 MIG Welding
• Connect work lead to negative terminal
• Connect electrode lead to positive terminal
• Switch machine on
• Set weld voltage.
• Set Inductance
• Connect Wire feeder
• Set wire feed speed (IPM)
Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the control knob to adjust each parameter.
Commence welding
28
4.04 Save-Load Operation
A total number of 5 programs can be saved into the 300 MST memory.
SAVE the Current Weld Parameters into Memory
• Press and HOLD the
SAVE
button. Beep will sound and digital display will show a number 1.
• Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter.
• After selecting the desired memory location (i.e. 1 to 5), press the parameter button and the machine.
will beep to confirm the weld parameters from the control panel are saved.
LOAD
(retrieve) a Program to Control Panel
LOAD
• Press and HOLD the
button. Beep will sound and digital display will show a number 1.
• Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter.
• After selecting the desired memory location (i.e. 1 to 5), press the parameter button and the machine
will beep to confirm the weld parameters are loaded onto the control panel.
29
5.0 BASIC WELDING GUIDE
5.01 Electrode Polarity
Connect the TIG torch to the - /
TORCH
terminal and the work lead to the
+ / WORK
terminal for direct
current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding.
It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece.
5.02 Tungsten Electrode Current Ranges
Electrode Diameter AC Current (Amps) DC Current (Amps)
0.040” (1.0mm) 30 – 70 30 – 60
1/16” (1.6mm) 60 – 95 60 – 115
3/32” (2.4mm) 125 – 150 100 – 165
1/8” (3.2mm) 130 – 225 135 – 200
5/32” (4.0mm) 190 – 280 190 – 280
3/16” (4.8mm) 250 – 340 250 – 340
Table 7 – Current Ranges for Various Tungsten Electrode Sizes
5.03 Tungsten Electrode Types
Electrode Type
Welding Application Features
(Ground Finish)
Thoriated 2%
Zirconated 1%
DC welding of mild steel,
stainless steel and copper.
High quality AC welding of
aluminium, magnesium and
their alloys.
Ceriated 2%
AC & DC welding of mild steel,
stainless steel, copper,
aluminium, magnesium and
their alloys.
Excellent arc starting, Long life,
High current carrying capacity.
Self cleaning, Long life,
Maintains balled end, High
current carrying capacity.
Longer life, More stable arc,
Easier starting, Wider current
range, Narrower more
concentrated arc.
Table 8 – Tungsten Electrode Types
Color
Code
Red
White
Grey
30
5.04 Guide for Selecting Filler Wire Diameter
Filler Wire Diameter
1/16” (1.6 mm) 30-95 20 - 90
3/32” (2.4 mm) 125-160 65 - 115
1/8” (3.2 mm) 180-240 100 - 165
3/16” (4.8 mm) 220-320 200-350
The filler wire diameter specified in the above table is a guide only, other diameter wires may be
used according to the welding application.
5.05 Shielding Gas Selection
Alloy
AC Current Range
(Amps)
Table 9 – Filler Wire Selection Guide
NOTE 8
Shielding Gas
Argoshield is a registered trademark of BOC Gases Limited.
DC Current Range
(Amps)
Aluminium & alloys Welding Argon, Argoshield 80T, 81T
Carbon Steel Welding Argon
Stainless Steel Welding Argon, Argoshield 71T, 80T, 81T
Nickel Alloy Welding Argon, Argoshield 71T
Copper Welding Argon, Argoshield 81T
Titanium Welding Argon, Argoshield 80T, 81T
Table 10 – Shielding Gas Selection
5.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Current Range DC
Amperes
120 - 170 Yes
100 - 160 Yes
90 - 130 No
Filler Rod for
Root Pass
Joint Preparation
Table 11 – TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
31
5.07 Welding Parameters for Steel
Base Metal
Thickness
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
3/16”
4.8mm
¼”
6.4mm
DC Current for
Mild Steel
35-45 20-30 Butt/Corner
40-50 25-35
45-55 30-45 Butt/Corner
50-60 35-50
60-70 40-60 Butt/Corner
70-90 50-70
80-100 65-85 Butt/Corner
90-115 90-110
115-135 100-125 Butt/Corner
140-165 125-150
160-175 135-160 Butt/Corner
170-200 160-180
DC Current for
Stainless
Steel
Tungsten
Electrode
Diameter
0.040”
1.0mm
0.040”
1.0mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
Filler Rod
Diameter
(if required)
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
5/32”
4.0mm
Argon Gas
Flow Rate
Liters/min
5-7
5-7
7
7
10
10
Joint Type
Lap/ Fillet
Lap/ Fillet
Lap/ Fillet
Lap/ Fillet
Lap/ Fillet
Lap/ Fillet
Table 12 – DC TIG Welding Parameters
32
6.0 BASIC STICK WELDING GUIDE
6.01 Electrode Polarity
Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘−’ terminal but if in doubt
consult the electrode manufacturers literature.
6.02 Effects of Stick Welding Various Materials
High tensile and alloy steels
The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area,
and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone
and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using
higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in
a furnace.
Manganese steels
The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is
absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip
welding to distribute the heat.
Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld it. Trouble may also be experienced when welding whiteheart malleable, due to the porosity caused by gas held in this type of iron.
Copper and alloys
The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections
necessary to give proper fusion of weld and base metal.
Types of Electrodes
Arc Welding electrodes are classified into a number of groups depending on their applications. There are a
great number of electrodes used for specialized industrial purposes which are not of particular interest for
everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for
welding large diameter pipes, etc. The range of electrodes dealt with in this publication will cover the vast
majority of applications likely to be encountered; are all easy to use and all will work on even the most basic
of welding machines.
Metals being joined Electrode Comments
Mild steel 6013 Ideal electrodes for all general purpose
Mild steel 7014 All positional electrode for use on mild and
Cast iron 99% Nickel Suitable for joining all cast irons except
Stainless steel 316L-16 High corrosion resistance. Ideal for dairy
work. Features include out standing
operator appeal, easy arc starting and low
spatter.
galvanized steel furniture, plates, fences,
gates, pipes and tanks etc. Especially
suitable for vertical-down welding.
white cast iron.
work, etc. on stainless steels.
33
Metals being joined Electrode Comments
Copper, Bronze, Brass, etc. Bronze
5.7 ERCUSI-A
High Alloy Steels,
Dissimilar Metals,
Crack Resistance.
All Hard-To-Weld Jobs.
312-16 It will weld most problematical jobs such
Easy to use electrode for marine fittings,
water taps and valves, water trough float
arms, etc. Also for joining copper to steel
and for bronze overlays on steel shafts.
as springs, shafts, broken joins mild steel
to stainless and alloy steels.
Not suitable for Aluminium.
Table 13 - Types of Electrodes
34
7.0 BASIC MIG WELDING GUIDE
7.01 Setting of the Power Source
The setting of the ARC MASTER 300 MST requires some practice by the operator, the welding Power
Source/Wirefeeder having two control settings that have to balance. These are the Wirespeed control
and the Voltage Control. The welding current is determined by the Wirespeed control, the current will
increase with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current
and lengthen the arc. Increasing the welding voltage hardly alters the welding current level, but
lengthens the arc. By decreasing the voltage, a shorter arc is obtained with little change in
welding current.
When changing to a different electrode wire diameter, different control settings are required. A thinner
electrode wire needs more Wirespeed to achieve the same current level.
A satisfactory weld cannot be obtained if the wirespeed and voltage switch settings are not adjusted to
suit the electrode wire diameter and dimensions of the workpiece.
If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the
molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack
of fusion. If, however, the welding voltage is too high, large drops will form on the end of the electrode
wire, causing spatter. The correct setting of voltage and Wirespeed can be seen in the shape of the weld
deposit and heard by a smooth regular arc sound.
7.02 Position of MIG Torch
The angle of MIG torch to the weld has an effect on the width of the weld run.
7.03 Distance from the MIG Torch Nozzle to the Work Piece
The electrode stick out from the MIG Torch nozzle should be between ¼” to 3/8”. This distance may
vary depending on the type of joint that is being welded.
Figure 8. MIG Torch Angle
35
p
7.04 Travel Speed
Speed at which a weld travels influences the width of the weld and penetration of the welding run.
7.05 Electrode Wire Size Selection
The choice of electrode wire size in conjunction with shielding gas used depends on:
The position of welding Thickness of the metal to be welded
The deposition rate required Capacity of the wire feed unit and power source
The bead profile desired The amount of penetration required
Type of joint Cost of the electrode wire
Weld metal deposition rate is proportional to current density. Current density is defined as the current
2
per cross sectional area of the electrode wire and is normally expressed as amps per mm
. An example
is tabled below.
Electrode Wire Size
0.035” (0.9mm) 200 380 6.3
0.034” (1.2mm) 200 177 6.0
Current (Amps)
Current Density
2
(Amps/mm
)
Deposition Rate
(lb/hour)
7.06 Deposition Rate Comparison
This demonstrates that where the upper limit of current is limited by machine capacity and duty cycle, higher
deposition rates and therefore greater
productivity will be achieved by using smaller
electrode wire. The ARC MASTER 300 MST is a
particularly efficient MIG welder with the 0.9mm
steel wire in spray transfer mode. The savings
from decreased welding time will more than
cover the small cost penalty of the smaller
electrode wire sizes. 0.035” wire cost
approximately 10% more than 0.045”, but is
deposited approximately 15% faster. Higher
current density (or smaller diameter wire) also
Wire Penetration Com
arison
gives deeper penetration as shown.
36
8.0 ROUTINE MAINTENANCE
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the
frequency depending on the usage and the operating environment.
The unit should be wiped clean as necessary with solvents that are recommended for cleaning electrical
apparatus. Turn Power Switch to OFF before proceeding. Internal cleaning of the unit should be done every 6
months by an authorized Thermal Arc Service Center to remove any accumulated dirt and dust. This may need
to be done more frequently under exceptionally dirty conditions.
CAUTION 3
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.
37
9.0 BASIC TROUBLESHOOTING
WARNING 8
There are extremely dangerous voltages and power levels present inside this product. Do not attempt
to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training
in power measurements and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited
Thermal Arc Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
9.01 Solving MIG Problems Beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work
through to the MIG torch. There are two main areas where problems occur with GMAW:
9.01.01 Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from
some contaminant within the molten weld pool which is in the process of escaping during solidification of the
molten metal.
Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be
reduced by checking the following points:
1. Gas cylinder contents and flow meter.
2. Gas leaks.
3. Internal gas hose in the Wire Feeder.
4. Welding in a windy environment.
5. Welding dirty, oily, painted, oxidized or
greasy plate.
6. Distance between the MIG torch nozzle and
the work piece.
7. Maintain the MIG torch in good working order.
Check that the MIG torch O-rings are not damaged.
Ensure that the gas cylinder is not empty and the flow meter
is correctly adjusted to 25 cubic feet per hour.
Check for gas leaks between the regulator/cylinder
connection and in the gas hose to the Wire Feeder.
Ensure the hose from the solenoid valve to the MIG torch
adapter has not fractured and that it is connected to the MIG
torch adapter.
Shield the weld area from the wind or increase the gas flow.
Clean contaminates off the plate.
Keep the distance between the MIG torch nozzle and the work
piece to a minimum.
Ensure that the gas holes are not blocked and gas is exiting
out of the torch nozzle.
Do not restrict gas flow by allowing spatter to build up inside
the MIG torch nozzle.
38
WARNING 9
Disengage the drive roll when testing for gas flow by ear.
9.01.02 Inconsistent Wire Feed
Checking the following points can reduce wire-feeding problems:
1. Wire spool brake is too tight.
2. Wire spool brake is too loose.
3. Worn or incorrect feed roller size.
4. Misalignment of inlet/outlet guides.
5. Liner blocked with wire debris.
6. Incorrect or worn contact tip.
Feed roller driven by motor in the cabinet will
slip.
Wire spool can unwind and tangle.
Use 'U' groove drive feed roller matched to the
aluminum wire size you are welding.
Use 'V' groove drive feed roller matched to the
steel wire size you are welding.
Use ‘knurled V’ groove drive feed roller matched
to the flux cored wire size you are welding.
Wire will rub against the misaligned guides and
reduces wire feedability.
Wire debris is produced by the wire passing
through the feed roller, if excessive pressure is
applied to the pressure roller adjuster.
Wire debris can also be produced by the wire
passing through an incorrect feed roller groove
shape or size.
Wire debris is fed into the liner where it
accumulates thus reducing wire feedability.
The contact tip transfers the weld current to the
electrode wire. If the hole in the contact tip is to
large then arcing may occur inside the contact tip
resulting in the electrode wire jamming in the
contact tip.
7. Poor work lead contact to work piece.
8. Bent liner.
When using soft electrode wire such as
aluminium it may become jammed in the contact
tip due to expansion of the wire when heated. A
contact tip designed for soft electrode wires
should be used.
If the work lead has a poor electrical contact to
the work piece then the connection point will
heat up and result in a reduction of power at the
arc.
This will cause friction between the wire and the
liner thus reducing wire feedability.
39
9.02 MIG Welding Problems
Description
1 Undercut. A Welding arc voltage too high. A
B Incorrect torch angle. B Adjust angle.
C Excessive heat input. C
2 Lack of penetration. A Welding current too low. A
B
C Shielding gas incorrect. C Change to a gas which gives higher penetration.
3 Lack of fusion. Voltage too low Increase
4 Excessive spatter. A Voltage too high A
B Voltage too low B
5
Irregular weld
shape.
B Wire is wandering. B Replace contact tip
C Incorrect shielding gas. C Check shielding gas
D
6 Weld cracking. A Weld beads too small A Decrease travel speed
B
C Excessive weld stresses C
D Excessive voltage D
E Cooling rate too fast E
7 Cold weld puddle. A Faulty rectifier unit A
B Loose welding cable connection B Check all welding cable connections.
C Low Primary Voltage C Contact supply authority
8
Arc does not have a
crisp sound, that
short arc exhibits,
when the wirefeed
speed and voltage
are adjusted
correctly.
A
Possible Cause
Joint preparation too narrow or
gap too tight.
Incorrect voltage and current
settings. Convex, voltage too
low. Concave, voltage too high.
Insufficient or excessive heat
input.
Weld penetration narrow
and deep
The MIG torch has been
connected to the wrong voltage
polarity on the front panel.
Remedy
Reduce
feed speed.
Increase the torch travel speed and/or reduce
welding current by reducing the
control or reducing the wire feed speed.
Increase welding current by increasing wire feed
speed and increasing
B Increase joint angle or gap.
WELD (V)
WELD (V)
Lower the voltage by reducing the
control or increase wirespeed control.
Raise the voltage by increasing the
control or reduce wirespeed control.
A
Adjust voltage and current by adjusting the
WELD (V)
D
Adjust the wirespeed control or the voltage
selection switches.
B
Reduce current and voltage and increase MIG
torch travel speed or select a lower penetration
shielding gas.
Increase weld metal strength or
revise design.
Decrease voltage by reducing the
WELD (V)
Slow the cooling rate by preheating part
to be welded or cool slowly.
Have an accredited Thermal Arc Service Agent
to test then replace the faulty component.
Connect the MIG torch to the positive (+)
welding terminal for solid wires and gas
shielded flux cored wires. Refer to the electrode
wire manufacturer for the correct polarity.
control and the wirespeed control.
control.
control or increase the wire
WELD (V)
WELD (V)
control.
control.
WELD (V)
WELD (V)
40
9.03 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and
proper welding technique.
Description Possible Cause Remedy
Excessive beard build-
1
up or poor penetration
or poor fusion at edges
of weld.
Weld bead too wide
2
and flat or undercut at
edges of weld
or excessive
burn through.
Weld bead too small or
3
insufficient penetration
or ripples in bead are
widely spaced apart.
Weld bead too wide or
4
excessive bead build up
or excessive penetration in
butt joint.
Uneven leg length in
5
fillet joint.
Electrode melts when
6
arc is struck.
Welding current is too low.
Welding current is too high. Decrease weld current.
Travel speed too fast. Reduce travel speed.
Travel speed too slow. Increase travel speed.
Wrong placement of filler rod. Re-position filler rod.
Electrode is connected to the
‘+’ terminal.
Increase weld current and/or faulty
joint preparation.
Connect the electrode to the
‘−’ terminal.
7 Dirty weld pool. A
B Gas contaminated with air. B
Electrode melts or
8
oxidizes when an arc is
struck.
B Torch is clogged with dust. B Clean torch
C Gas hose is cut. C Replace gas hose.
D Gas passage contains impurities. D
E Gas regulator turned OFF. E Turn ON.
F Torch valve is turned OFF. F Turn ON.
G
Electrode contaminated through
contact with work piece or filler
rod material.
No gas flowing to
A
welding region.
The electrode is too small for
the welding current.
Clean the electrode by grinding off
A
the contaminates.
Check gas lines for cuts
and loose fitting or change
gas cylinder.
Check the gas lines for kinks
A
or breaks and gas
cylinder contents.
Disconnect gas hose from torch
then raise gas pressure and blow
out impurities.
Increase electrode diameter or
G
reduce the welding current.
41
Description Possible Cause Remedy
9 Poor weld finish. Inadequate shielding gas.
Arc flutters during TIG
10
welding.
B
Welding arc cannot be
11
established.
B Torch lead is disconnected. B
C
12 Arc start is not smooth. A
B
C Gas flow rate is too high. C
D
E
Tungsten electrode is too
A
large for the welding current.
Absence of oxides in the
weld pool.
Work clamp is not connected to the
A
work piece or the work/torch leads
are not connected to the right
welding terminals.
Gas flow incorrectly set, cylinder
empty or the torch valve is OFF.
Tungsten electrode is too large for
the welding current.
The wrong electrode is being used
for the welding job.
Incorrect shielding gas is
being used.
Poor work clamp connection
to work piece.
Increase gas flow or check gas line
for gas flow problems.
Select the right size electrode. Refer
A
to Basic TIG
Welding guide.
Refer Basic TIG Welding Guide for
B
ways to reduce arc flutter.
Connect the work clamp to the work
A
piece or connect the work/torch
leads to the right welding terminals.
Connect it to the ‘−‘ terminal.
Select the right flow rate, change
C
cylinders or turn torch valve ON.
Select the right size electrode. Refer
A
to Basic TIG Welding Guide.
Select the right electrode type.
B
Refer to Basic TIG Welding Guide.
Select the correct rate for the
welding job.
Refer to Basic TIG Welding Guide.
Select the right shielding gas. Refer
D
to Basic TIG Welding Guide.
E Improve connection to work piece.
42
9.04 Stick Welding Problems
Description Possible Cause Remedy
1
Gas pockets or voids in
weld metal (Porosity).
2 Crack occurring in weld
metal soon after
solidification
commences.
3 A gap is left by failure of
the weld metal to fill the
root of the weld.
D Incorrect sequence. D Use correct build-up sequence.
Portions of the weld run
4
do not fuse to the
surface of the metal or
edge of the joint.
C Wrong electrode angle. C Adjust angle so the welding arc is
D Travel speed of electrode is too
E Scale or dirt on joint surface. E Clean surface before welding.
A
Electrodes are damp.
B
Welding current is too high.
C
Surface impurities such as oil,
grease, paint, etc.
Rigidity of joint.
A
Insufficient throat thickness.
B
Cooling rate is too high.
C
Welding current is too low.
A
Electrode too large for joint.
B
Insufficient gap.
C
Figure 9. Example of Insufficient Gap or Incorrect Sequence
Small electrodes used on heavy cold
A
plate.
Welding current is too low.
B
high.
A
Dry electrodes before use.
B
Reduce welding current.
C
Clean joint before welding.
Redesign to relieve weld joint of
A
severe stresses or use crack
resistance electrodes.
Travel slightly slower to allow greater
B
build up in throat.
Preheat plate and cool slowly.
C
Increase welding current
A
Use smaller diameter
B
electrode.
Allow wider gap.
C
Use larger electrodes and pre-heat
A
the plate.
Increase welding current
B
directed more into the base metal
D Reduce travel speed of electrode
Figure 10. Example of Lack of Fusion
43
Non-metallic
5
particles are trapped in
the weld metal
(slag inclusion).
B Joint preparation too restricted. B Allow for adequate penetration and
C Irregular deposits allow slag to be
D Lack of penetration with slag
E Rust or mill scale is preventing full
F Wrong electrode for position in
A Non-metallic particles may be
trapped in undercut from previous
run.
trapped.
trapped beneath weld bead.
fusion.
which welding is done.
A If bad undercut is present, clean slag
out and cover with a run from a
smaller diameter electrode.
room for cleaning out
the slag.
C If very bad, chip or grind out
irregularities.
D Use smaller electrode with sufficient
current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
E Clean joint before welding.
F Use electrodes designed for position
in which welding is done, otherwise
proper control of slag
is difficult.
Figure 11. Examples of Slag Inclusion
44
9.05 Power Source Problems
Description Possible Cause Remedy
A
The welding arc
1
cannot be established.
C Loose connections internally. C
A
The Primary supply voltage has
not been switched ON.
The Welding Power Source
B
switch is switched OFF.
Switch ON the Primary
supply voltage.
Switch ON the Welding
B
Power Source.
Have an accredited Thermal Arc
Service Agent repair the connection.
Maximum output welding
2
current
cannot be achieved with
nominal Mains
supply voltage.
Welding current reduces
3
when welding.
4 No gas flow when
the torch trigger switch is
depressed.
C Gas regulator turned OFF. C Turn gas regulator ON.
D Torch trigger switch lead is
5 Gas flow won’t
shut OFF.
B Gas valve is faulty. B Have an accredited Thermal Arc
C Gas valve jammed open. C Have an accredited Thermal Arc
D
6 The TIG electrode has
been contaminated due to
the gas flow shutting OFF
before the programmed
POST-FLOW
elapsed.
time has
Defective control circuit
Poor work lead connection to the
work piece.
A B Gas hose is cut.
Gas passage contains impurities.A B
disconnected or switch/cable is
faulty.
A Weld Mode (
REPEAT
before
finished.
POST-FLOW
to 60 sec.
The Weld Process Mode (STICK,
HF TIG or LIFT TIG) was changed
before
finished.
STD, SLOPE
or
SPOT
) was changed
POST-FLOW
control is set
POST-FLOW
,
gas time had
gas time had
Have an accredited Thermal Arc
Service Agent inspect then repair the
welder.
Ensure that the work lead has a
positive electrical connection to the
work piece.
Replace gas hose.
Disconnect gas hose from the rear of
Power Source then raise gas pressure
and blow out impurities.
D Reconnect lead or repair faulty
switch/cable.
A Strike an arc to complete the
weld cycle.
OR
Switch machine OFF then ON to reset
solenoid valve sequence.
Service Agent replace gas valve.
Service Agent repair or replace gas
valve.
D Reduce
Do not change Weld Process Mode
before the
gas time had finished.
POST-FLOW
POST-FLOW
time.
45
10.0 VOLTAGE REDUCTION DEVICE (VRD)
10.01 VRD Specification
Description
ARC MASTER
300 MST
Notes
VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between welding terminals.
VRD Resistance 148 to 193 ohms The required resistance between welding
terminals to turn ON the welding power.
VRD Turn OFF Time 0.2 to 0.3 seconds The time taken to turn OFF the welding power
once the welding current has stopped.
10.02 VRD Maintenance
Routine inspection and testing (power source)
An inspection of the power source, an insulation resistance test and an earth resistance test shall be
carried out.
a) For transportable equipment, at least once every 3 months.
b) For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests.
Note 9
A transportable power source is any equipment that is not permanently connected and fixed in
the position in which it is operated.
In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following
periodic tests should also be conducted by an accredited Thermal Arc service agent.
Description IEC 60974-1 Requirements
VRD Open Circuit Voltage Less than 20V; at Vin=230V or 460V
VRD Turn ON Resistance Less than 200 ohms
VRD Turn OFF Time Less than 0.3 seconds
If this equipment is used in a hazardous location or environments with a high risk of electrocution then
the above tests should be carried out prior to entering this location.
46
10.03 Switching VRD ON/OFF
Switch the machine OFF.
a) Remove the clear plastic cover from the control panel. (see Figure 12)
• Lift up the cover so it rests on the top of the unit.
• Place a small flat bladed screw driver between the cover hinge on the front panel.
• Gently lift the cover hinge out of the front cover mounting hole.
• Remove the control’s clear plastic cover.
Figure 12
. VRD ON/OFF Step A
b) Remove four mounting screws from the control panel. (see Figure 13)
c) Access the VRD control by gently prying back the front panel controls to reveal
the VRD ON/OFF potentiometer. (see Figure 13)
CAUTION 4
Do not pull back the front panel with excessive force as this will unplug control PCB. Plugging the
control PCB back into the front panel controls can only be achieved by removing the side covers.
Figure 13.
VRD ON/OFF Step B,C
47
d) Turning the VRD ON/OFF. (see Figure 14)
• To turn VRD ON: rotate the trim potentiometer (VR1) on the display PCB fully clockwise.
When VRD is turned ON check that it operates as per VRD Specifications on page 46.
• To turn VRD OFF: rotate the trim potentiometer (VR1) on the display PCB fully
counter-clockwise.
WARNING 10
The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter
clockwise as the VRD function will be unknown for every other position.
Figure 14.
VRD ON/OFF Step D
48
11.0 Power Source Error Codes
Description Possible Cause Remedy Remarks
A
1 E01 error code displayed
Temperature sensor TH1
(protects IGBTs) is greater
than 80ºC for about 1 second.
2 E02 error code displayed
Temperature sensor TH2
(protects secondary diodes)
is greater than 80ºC for about
1 second.
The Welding Power
Source’s duty cycle has
been exceeded.
B
Fan ceases to operate.
C
Air flow is restricted by
vents being blocked.
A
The Welding Power
Source’s duty cycle has
been exceeded.
Fan ceases to operate.
B
C
Air flow is restricted by
vents being blocked.
A
Let Power Source cool
down then keep within its
duty cycle.
B
Have an Accredited
Thermal Arc Service
Agent investigate
Unblock vents then let
C
Power Source cool down.
A
Let Power Source cool
down then keep within
its duty cycle.
Have an accredited
B
Thermal Arc Service
Agent investigate.
C
Unblock vents then let
Power Source cool down.
Weld current ceases.
Buzzer sounds constantly.
Fan operates at max
speed. E01 resets when
TH1 decreases to 70ºC for
about 30 seconds.
Weld current ceases.
Buzzer sounds constantly.
Fan operates at max
speed. E02 resets when
TH1 decreases to 70ºC for
about 30 seconds.
3 E03 error code displayed
Primary (input) current
too high.
4 E11 error code displayed
Over Primary supply (input)
voltage at primary capacitors
is exceeded for one second.
5 E14 error code displayed
Under mains supply (input)
voltage warning primary
capacitors is reduced for
one second.
A
Primary current is too
high because welding
arc is too long.
B
Mains supply voltage is
more than 10% below
nominal voltage .
Primary supply voltage
is greater than the
nominal voltage
plus 10%.
Mains supply voltage
is less than the nominal
operating voltage
less 10%.
A
Reduce length of
welding arc.
B
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check for low
Mains voltage.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Primary voltage.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
Weld current ceases.
Buzzer sounds constantly.
Switch machine OFF then
ON to reset E03 error.
Weld current ceases.
Buzzer sounds constantly.
Error code E11
automatically will reset
when the voltage reduces.
Weld current available.
Buzzer sounds
intermittently.
Error code E14
automatically will reset
when the voltage
increases.
6 E12 error code displayed
Mains supply voltage is
Under mains supply (input)
voltage primary capacitors is
reduced for one second.
down to a dangerously
low level.
49
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
Weld current ceases.
Buzzer sounds constantly.
Error code E12
automatically will reset
when the voltage
increases.
Description Possible Cause Remedy Remarks
7 E81 error code displayed
Wrong Primary supply (input)
voltage connected.
8 E82 error code displayed
Link switch plug
not connected.
9 E83 error code displayed
CPU checks mains supply
(input) voltage when the
ON/OFF switch on rear panel of
machine is turned ON.
10 E93 error code displayed
Memory chip (EEPROM) on
control PCB can not read/write
weld parameters .
11 E94 error code displayed
Temperature sensor TH1 for
IGBTs or sensor TH2 for
secondary diodes are
open circuit.
When 3 phase machine
is first turned ON with
the wrong Primary
supply (input) voltage
connected.
Link switch plug
not connected.
The Primary supply
(input) voltage
fluctuates and is
not stable.
Memory chip
(EEPROM) error.
The Welding Power
Source’s temperature
sensors have
malfunctioned.
Have an accredited
Thermal Arc Service
Agent or a qualified
electrician check
the Mains voltage.
Have an accredited
Thermal Arc Service
Agent check connector
plug on input PCB.
Have an accredited
Thermal Arc Service
Agent check connector
plug on input PCB and the
Mains voltage.
Have an accredited
Thermal
Arc Service Agent check
the control PCB.
Have an accredited
Thermal Arc Service
Agent check or replace the
temperature sensors.
No weld current is
available.
Buzzer sounds constantly.
Switch machine OFF.
No weld current is
available. Buzzer
sounds constantly.
Switch machine OFF.
No weld current is
available. Buzzer sounds
constantly.Switch machine
OFF then ON to reset
E83 error.
Weld current ceases.
Buzzer sounds constantly.
Switch machine OFF.
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.
Mains supply (input)
B
voltage has been
turned OFF.
A
Turn ON/OFF Switch ON.
Have an accredited
B
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage and fuses
Weld current ceases.
Buzzer sounds constantly.
Must switch machine OFF
then ON to reset E99 error.
50
APPENDIX A – INTERCONNECT DIAGRAM
Ground
+
SIDE CHASSIS 1
REAR
PANEL
N
P
R2
460V
S2
230V
FAN1
+-
1
2
3
4
5
6
1
2
3
4
1
2
CN33
3
1
2
CN18
3
S1
Line1
Line2
Line3
PCB21
E
Filter
Circuit Bord
[WK-4917]
CN1
2
1
1
2 3
CN2
CN1
1
2
3
4
CN11
1
2
3
4
1
2
3
D1
K(7)
G(6)
R(3)
S(4)
T(5)
0V
230V
460V
T1
0V
24V
115V
MCB1
MCB2
0V
24V
115V
1
2 3 4 5
CN3
PCB4
Detect
Circuit Bord
CN4
[WK-4819]
CN5 CN6 CN4
CN30CN31
CN32
CN31 CN30
CN32
PCB5
Conect Circuit Bord
[WK-5696]
CN131 CN130
CN20
CN20
CN130CN131
CN132
CN132
CN27
CN27
CN1
1
2 3 4 5 6 7 1 2 3
+
(1)
(0)
-
(2)
1
CN7
1
2
CN3
P
P
R2
R2
N
N
1
2
3
CN5
4
5
PCB2
Link
Circuit Bord
[WK-5597]
1
2
3
CN2
4
5
CN1
1
2 3
2 3
2
1
CN10
CN1CN6CN5
PCB3
Control Souce
Circuit Bord
[WK-5548]
CN18
CN18
Filter Circuit Bord
[WK-5689]
TB1
TB2
TB3
TB4
CN4
1
2
PCB7
1
2
3
CN7
4
TB13
UB3
TB14
TB15
PCB1
Main
Circuit
Bord
[WK-5493]
TB1
G1
E1
G2
E2
TB2
TB3
TB18
TB19
TB20
TB4
G3
E3
G4
E4
CT1
CT2
CT3
CT4
E1
G1
1
2 3 4 5 6
CN20
CN3
CN3
CN13
C
CE
E
PCB8
IGBT
Gate
Circuit
Bord
[WK-5479]
1
2
CN1
3
1
2
3
CN2
4
C
CE
E
PCB9
IGBT
Gate
Circuit
Bord
[WK-5479]
1
2
CN1
3
1
2
3
CN2
4
E5
G5
1
2 3 4 5 6 7
CN15
1 2 3 4 5
E2
C
G
E
G
E
G
E
C
G
E
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
G2
CN21
Q1
Q2C
Q3C
G4
E4
Q4
Q5C
G3
E3
Q6
Q7
UB1
Q8
Q9
G7
E7
Q10
Q11
G8
E8
Q12
E6
G6
Circuit Bord
[WK-5688]
CN16
1
2 3 4
TB10
TB11
TB12
TB5
TB6
TB7
E7
G7
1
2 3 4 5 6
CN22
PCB6
Control
1
C
CE
E
PCB10
IGBT
Gate
Circuit
Bord
[WK-5479]
1
2
CN1
3
1
2
3
CN2
4
C
CE
E
PCB11
IGBT
Gate
Circuit
Bord
[WK-5479]
1
2
CN1
3
1
2
3
CN2
4
E3
G3
CN2
2 3 4 5 6
C
Q13
G
E
C
Q14
G
E
C
Q15
G
E
C
Q16
G
E
C
Q17
G
E
C
Q18
G
E
C
Q19
G
E
C
Q20
G
E
C
Q21
G
E
C
Q22
G
E
C
Q23
G
E
C
Q24
G
E
E8
G8
1
2 3 4 5 6 7
CN23
CN19
1
2 3
E4
G4
0V
24V
115V
S3
1
2
3
4
CN1
5
6
19P
14P
CON2 CON1
CN7
2 3 4 5 6 7
1
C
U H J N KVAB MLRF D PG ETS
1
2 3 4 5 1 2 3 6 74 5
CN3
Socket Receptacle Circuit Bord
CN6
2 38
1
CN5
2 3 4 5 6
1
PCB17
[WK-5699]
EC
CN10
2 3 4 5 6 7
1
51
1
CN4 CN2
CN9
2 3 4
1
D E H F N JCKGBILANM
2 3 4 5 6
1
2 3 4 5 6
CN8
EC
1
CN15
2 3
TB1
UB2
UB4
TB7
TB21
TB8
TB16
[WK-5594]
CT2
CT1
CT2
L1
PCB14
TRANS
Bord
TB35
TB33
TB34
TB30
TB32
PCB15
DIODE Snubber
Circuit Bord
[WK-5606]
AC2 AC1
D7
D2
D5
IS
-15
+15
GND
SH.DET+
2
1
HCT1
4
3
1
2
3
1
2 3 4 5
CN1
PCB18
Filter Circuit
CN3
Bord
[WK-5499]
TO1
+Output
Terminal
Ground
+
SIDE CHASSIS 3
TB17
1
TB22
CT3
2 3 4 5
CN8
TB31
D4
AC4
CT4
CT3
TH2 TH1
2 3
EB
AC4
AC2
2 3 4 5 6 789
1
CN9
1
CN9
SH.DET-
SH.DET+
1
2 3 4
CN8
FCH1
1
2
3
4
CN17
5
6
7
1
2
3
CN21
4
1
2
3
CN1
4
R2
R3
+15
-15
IS
GND
TO2
-Output
Terminal
FRONT
PANEL
SH.DET-
UB2UB1
SIDE CHASSIS 2
UB4UB3
EB
Ground
+
PCB12
Panel
Circuit Board
[WK-5527]
PCB13
Encorder
Board
1
2
3
4
CN2
5
6
CN1
1 2 3 4
[WK-5528]
CN1
1 2 3 4
A
M
L
NU
B
CV
RSHD
GFE
JKTP
AJ
BK I
CLNH
DMG
FE
CON2 CON1
52
APPENDIX B - ARCMASTER 300 MST ACCESSORIES
ACCESSORIES PART NO. DESCRIPTION
Stick Kit 10-4082A Work clamp with 10’ cable, and stick electrode with 25’ #1 cable
TIG Kit 10-4080 Includes regulator/flowgauge, 12.5ft 200 Amp TIG torch with
valve, accessory kit includes 1 ea of 0.040”x7”, 1/16”x7”,
3/32”x7” 2% Tungsten with collet & collet bodies, 1 ea 1/4”,
5/16”, 3/8” alumina cup
Dinse Connector 10-2020 T50mm Dinse style male plug
Hand Held Pendant 10-2005 Includes contactor On/Off switch and current control
with 25ft cable and 14-pin male plug
Foot Control 10-2008 Contactor On/Off and current control with 15ft cable
and 14-pin male plug
10-2007 Contactor On/Off and current control with 25ft cable
and 14-pin male plug
Extension Cable 10-2030 3ft with 14-pin male plug and 14-pin female cable receptacle
10-2031 15ft with 14-pin male plug and 14-pin female cable receptacle
10-2032 25ft with 14-pin male plug and 14-pin female cable receptacle
10-2033 50ft with 14-pin male plug and 14-pin female cable receptacle
10-2034 75ft with 14-pin male plug and 14-pin female cable receptacle
Torch Switch On/Off 10-2001 25ft torch mounted with 14-pin male plug
Torch Switch On/Off
w/current control
10-2003 25ft torch mounted with 14-pin male plug
10-2004 25ft torch mounted with 14-pin male plug
Rack Systems 10-4029 4 pack w/electrical
10-4031 6 pack w/electrical
10-4033 8 pack w/electrical
10-2002 25ft torch mounted with 14-pin male plug
- adapts to 5/8”-7/8” torch
- adapts to 7/8”-1-1/8” torch handle
- adapts to 1-1/8”-1-3/8” torch handle
53
LIMITED WARRANTY
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This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
LIMITED WARRANTY: Thermal Arc
®
, Inc., A Thermadyne Company ("Thermal Arc"),
warrants to customers of a uthorized distributors ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warrant
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommenda tions and recognized stan dard industry practic e, and not subject to misu se,
repair, neglect, alteration, or damage, correct such defects by suitable repair o
replacement, at Thermal Arc's sole option, of any components or parts of the produc
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty o
merchantability, fitness for any particular purpose, or other warranty o
quality, whether express, implied, or statutory.
Limitation of liability: Therm al Arc shall not under an y circumstances be lia ble for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal A rc with respect to any co ntract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whethe
arising out of contract, tort, includ ing negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is base d.
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound b
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.
This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of an y Thermal Arc product. Purchaser’s rights under this warrant
are void if the product is sold to pur chaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Th ermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All return ed goods
st
shall be at the Purchaser's risk and expense. This warranty dated April 1
®
supersedes all previous Thermal Arc warranties. Thermal Arc
is a Registered
2006
Trademark of Thermal Arc, Inc .
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR
Scout, Raider, Explorer
Original Main Power Stators and Inductors.................................................................................. 3 years
Original Main Power Rectifiers, Control P.C. Boards................................................................... 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer............................................................. See the Engine’s Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.......... ....... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors...................................................................1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics....................................................................................................5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.......... ....... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors...................................................................1 year
PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years
Welding Console, Weld Controller, Weld Timer........................................................................... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator................................1 year
SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Dragster 85
Original Main Power Magnetics.....................................................................................................1 year 1 year
Original Main Power Rectifiers, Control P.C. Boards....................................................................1 year 1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year
160S, 300S, 400S
Original Main Power Magnetics....................................................................................................5 years 3 years
Original Main Po w e r Rect ifiers, Control P.C. Bo a rds ..................... ................... .................. .........3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year
GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR
Water Recirculators.......................................................................................................................1 year 1 year
Plasma Welding Torches.............................................................................................................180 days 180 days
Gas Regulators (Supplied with power sources)..........................................................................180 days Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil
Replacement repair parts.............................................................................................................90 days Nil
MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil
3 years
3 years
1 year
1 year
1 year
1 year
1 year
1 year
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: sales@thermalarc.com
www.thermalarc.com
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