Thermal Arc ARCMASTER 400TS, ARCMASTER 400S, ARCMASTER 300TS Service Manual

400TS

400S

300TS

300S

®

ARCMASTER

INVERTER ARC WELDERS

Service Manual

VV

ersion No:ersion No:

V

ersion No: AA.03

VV

ersion No:ersion No:

Operating FeaturesOperating Features

Operating Features:

Operating FeaturesOperating Features

Issue Date:Issue Date:

Issue Date: May 22, 2006

Issue Date:Issue Date:

Art # A-07263

Manual NoManual No

Manual No: 0-4895B

Manual NoManual No

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.

Service Manual Number 0-4895B for:
ArcMaster 400TS Inverter Arc Welder Part Number 10-3071
ArcMaster 400S Inverter Arc Welder Part Number 10-3070
ArcMaster 300TS Inverter Arc Welder Part Number 10-3096
ArcMaster 300S Inverter Arc Welder Part Number 10-3093

Published by:
Thermadyne Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermalarc.com

Copyright 2006 by
Thermadyne Inc.

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: May 22, 2006

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

i

CONTENTS

1 SAFETY INSTRUCTIONS AND WARNINGS

1 Arc Welding H a z a rd s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

2 PRINCIPAL SAFETY STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6

3 PRECAUTIONS DE SECURITE EN SOUNDAGE A L'ARC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6

4 Dangers relatifs au soudage à l’arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7

5 PRINCIPLE S

AFETY STANDARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11

2 INTRODUCTION

1 How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

2 Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

3 S

ymbol Cha rt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

4 Descriptio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

5 Functional Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2– 4

6 Transpor t i n g M e th o ds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

3 INSTALLATION

1 Environme n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

2 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

3 Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

4 Electrical Input Requirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

5 Input Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

6 High Frequency Introduction (300/400TS only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

7 High Frequency Interference (300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

8 Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

9 Specifica t io n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 –4

4 OPERATO R CONTROLS

1 ARC MASTER 300/400TS and 300/400S Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

2 Weld Process selection for ARC MASTER 300/400TS and 300/400S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

3 Weld Parameter Descriptions for ARC MASTER 300/400TS and 300/400S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

4 Weld Parameters for ARC MASTER 300/400TS and 300/400S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5

5 Power Sour ce Fe atures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6

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

6 SEQUENCE OF OPERATION

1 Stick Weldi n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

2 HF TIG Welding (300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

3 Lift TIG Wel d in g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

4 Slope Mode Sequence(300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6– 2

5 Slope Mode with repeat sequence (300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

6 Pulse Controls (300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

7 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 BASIC TROUBLESHOOTING

1 TIG Welding Pro b l e ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

2 Stick Weldi n g Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

3 Power Sourc e Pr o b l e ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5

9 VOLTAGE REDUCTION DEVICE (VRD)

1 VRD Specific a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

2 VRD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

3 Switching VR D On /Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –2

10 POWER SOURCE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11 ADVANCED TROUBLESHOOTING

1 System-Level Fault Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

1.1 Opening the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

2 Verification and Remedy to the Indicated Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3

2. 1 E01 "Over-Temperature at the primary side" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3

2.2 E02 "Over-Temperature at the secondary side" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4

2. 3 E03 "Transformer Over-Current Failure". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4

2. 4 E04 "Torch Cable Failure". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1–5

2.5 E11 "Main Supply Over Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1–5

2.6 E12 "Main Supply Under Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5

2.7 E81 "Wrong Main Supply Voltage". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 5

2.8 E82 "Rated Voltage Selection Circuit abnormality" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6

2.9 E83 "Abnormalities in Mains Supply Voltage Detection" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11– 6

2.10 E85 "Pre-charge abnormality" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 –6

2.11 E94 "Thermistor malfunction". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

2.12 E99 "Initial Power Receiving". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

3 Verification and Remedy to Failures without Indication Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

3.1 "Cooling Fan (FAN1) Failure" (Fan is not rotating.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7

3.2 "Gas Valve Failure" (No Gas flow through unit)(300/400TS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8

3.3 "No Weld Out p u t". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8

3.4 "Operating Panel Failure" (LED's do not light properly or welding setting cannot be established.) . . . . . . . . . . . . . .1

1–9

3.

5 "High Frequency Output Failure" (Unit does not generate High Frequency.) (300/400TS only) . . . . . . . . . . . . . . . . 11–9

4 Fault Isola t io n Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10

4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10

5 Verification of the Power Input Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1–11

5.1 Verification of the AC input voltage using an AC voltmeter.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11

5.2 Verification of the Power Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–12

5.3 Verification of the Cooling Fan, FAN1, Drive Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–13

5.4 Verification of the Gas Valve, SOL1, Drive Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–14

5.5 Verification of the primary Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–14

5.6 Verification of the secondary Diode (D2-D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15

5.7 Verificat io n o f the primary IGBT (Q1 - Q 2 4 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1–15

5.8 Verification of the secondary IGBT (Q25-Q26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16

5.9 Verification of No-load Voltage (OCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16

12 MAINTENANCE

1 Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1

2 Service Too l s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5

2.1 Tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5

2.2 Notes of disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–5

3 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6

3.1 PCB1 (WK-5493) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–6

3.2 PCB2 (WK-5597) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7

3.3 PCB3 (WK-5548), PCB7 (WK-5550) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–9

3.4 PCB4 (WK-4819) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10

3.5 PCB5 (WK-5551) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11

3.6 PCB6 (WK-5549) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11

CONTENTS

3.7 PCB8, PCB9 (WK-5479) and Q1-Q12 “Primary IGBT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12

3.8 PCB10, PCB11 (WK-5479) and Q13-Q24 “Primary IGBT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12

3.9 PCB12 (W K-5527) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12

3.10 PC B13 (W K-5528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13

3.11 PCB14 (WK-5594) <T1 “Main Transformer”>

.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1 4

3.

12 PCB15 (WK-5606) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16

3.13 PC B20 (W K-5499) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16

3.14 PC B21 (W K-4917) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17

3. 15 Current Limiting Resistor (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18

3.16 Resistor ( R 7 , R8 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12– 1 9

3.17 Coupling Coil (CC1) * 300/400TS only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12–20

3.18 Reactor (FCH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20

3. 19 Primary Thermistor (TH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21

3.20 Sec ondary Thermistor (TH2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –22

3.21 Cooling Fan ( F AN 1 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–22

3.22 Solenoid Valve (S OL1) * 300/400TS only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–23

3. 23 Main ON/OFF Switch (S1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24

3. 24 Input Voltage Switch (S2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–25

3. 25 Remote Socket (CON1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2–26

3.26 High Freguency Unit (HF.UNIT1) * 300/400TS only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–26

3.27 Hall Current Sensor (HCT1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –27

3.28 Pr imary Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–28

3.29 Secondary Diode (D2, D4, D5 and D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –28

3. 30 Current Trans (CT2, CT3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–29

3.31 Ring Core (L 1 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–30

3.32 Ring Core (L105) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –30

APPENDIX 1 PARTS LIST

1 Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1

2 How To Use This Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–1

APPENDIX 2 CONNECTION WIRING GUIDE
APPENDIX 3 INTERCONNECT DIAGRAM
APPENDIX 4 DIODE TESTING BASICS

ARCMASTER 400TS, 400S, 300TS, 300S

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS.
READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property,
if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Anyone not having extensive training in welding and
cutting practices should not attempt to weld. Certain of the practices apply to equipment connected to power lines;
other practices apply to engine driven equipment.

Safe practices are outlined in the American National Standard Z49.1 entitled:
This publication and other guides to what you should learn before operating this equipment are listed at the end of
these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED

ONLY BY QUALIFIED PEOPLE.

SAFETY IN WELDING AND CUTTING.

1.01 Arc Welding Hazards

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

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.

power disconnect switch open, or remove line fuses
so power cannot be turned on accidentally.

5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.

6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or out
of service.

7. Use fully insulated electrode holders. Never dip holder
in water to cool it or lay it down on the ground or the
work surface. Do not touch holders connected to two
welding machines at the same time or touch other
people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly
spliced cables.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body
protection.

May 22, 2006

9. Do not wrap cables around your body.

10.Ground the workpiece to a good electrical (earth)
ground.

1-1

ARCMASTER 400TS, 400S, 300TS, 300S

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.

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.

4. Wear protective clothing made from durable, flame­resistant material (wool and leather) and foot
protection.

5. Use approved ear plugs or ear muffs if noise level is
high.

WARNING

FUMES AND GASES can be hazardous to your
health.

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

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

2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied
respirator.

1. Wear a welding helmet fitted with a proper shade of
filter (see ANSI Z49.1 listed in Safety Standards) to
protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields
recommended.

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

Eye p rotecti on fi lter shade selector for wel ding or cu t t ing

(g oggles or h elmet), f rom AWS A6.2-73.

Weldi ng or cut ting Electrode Size Filter Welding or c utting Elec trode Size F ilter

Torch soldering 2

Tor c h br azing 3 or 4 Non-ferr ous base met a l A l l 11

Oxyg en Cutting

Light Under 1 in. , 25 mm 3 or 4 Gas tungsten arc welding All 12

Heavy 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Medium Over 6 in., 150 mm 5 or 6 Atomic hy d r oge n we lding All 12

G as welding

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

Heavy 1/ 8 to 1/2 in., 3-12 mm 5 or 6

Medium Over 1/2 in. , 12 mm 6 or 8 Light 12

Sh ielded metal-ar c

Under 5/ 3 2 in. , 4 mm 10 Heavy 14

5/32 to 1/4 in., 12

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

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.

Gas metal - ar c

Fer r ous base met al All 12

Carbon ar c welding All 12

C arbon a rc air gouging

Plasma arc cutting

Heavy 300 to 400 Amp 12

Medium Over 40 0 Amp 14

1-2

May 22, 2006

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.

WARNING

WELDING can cause fire or explosion.

ARCMASTER 400TS, 400S, 300TS, 300S

WARNING

FLYING SPARKS AND HOT METAL can cause
injury.

Chipping and grinding cause flying metal. As
welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side
shields recommended.

2. Wear proper body protection to protect skin.

WARNING

Sparks and spatter fly off from the welding
arc. The flying sparks and hot metal, weld
spatter, hot workpiece, and hot equipment can
cause fires and burns. Accidental contact of
electrode or welding wire to metal objects can
cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and
hot metal.

2. Do not weld where flying sparks can strike flammable
material.

3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover them
with approved covers.

4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.

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

6. Be aware that welding on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.

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

8. Connect work cable to the work as close to the welding
area as practical to prevent welding current from
traveling long, possibly unknown paths and causing
electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

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.

10.Remove stick electrode from holder or cut off welding
wire at contact tip when not in use.

May 22, 2006

1-3

ARCMASTER 400TS, 400S, 300TS, 300S

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

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 produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside
and away from any building air intakes.

WARNING

ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any
sparks or open flames.

3. Allow engine to cool before fueling. If possible, check
and add fuel to cold engine before beginning job.

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

5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.

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

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting
battery cables.

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

4. Do not use welder to charge batteries or jump start
vehicles.

5. Observe correct polarity (+ and –) on batteries.

WARNING

STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.

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.

1-4

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.

May 22, 2006

ARCMASTER 400TS, 400S, 300TS, 300S

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

The following is a quotation from the General Conclusions
Section of the U.S. Congress, Office of Technology
Assessment,
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 and
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.

Biological Effects of Power

1.02 Principal Safety Standards

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.

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.

May 22, 2006

1-5

ARCMASTER 400TS, 400S, 300TS, 300S

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. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et
non troués.

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.

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.

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 porte­électrodes 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.

1-6

May 22, 2006

ARCMASTER 400TS, 400S, 300TS, 300S

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.

AVERTISSEMENT

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

LE RAYONNEMENT DE L’ARC PEUT BRÛLER
LES YEUX ET LA PEAU; LE BRUIT PEUT
ENDOMMAGER L’OUIE.

DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées

dangereuses à respirer.

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.

SELECTION DES NUANCES DE FILTRES OCULAIRS PO UR LA PROTECTION

DES YEUX EN COUPA G E ET SOUDAGE (selon AWS á 6.

Opération de coupage

ou soudage

Brassage t endr e
au chalumeau
Brassage fort
au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

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

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)

May 22, 2006

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

tout es condit ions 3 ou 4 métaux non- ferreux tout es condit ions 11

mince moins de 1 po. (25 mm) 3 ou 4

épais plus de 6 po. (150 mm) 5 ou 6

mince moins de 1/8 po. (3 mm) 4 ou 5

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 P lasma (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

fi l tre oculai re

Opération de coupage

ou soudage

Soudage á l'arc sous gaz
avec f il plein (GMAW)

Soudage á l'arc sous gaz avec
élect r ode de t ungstène (GTAW)

Soudage á l'hydrogène
at omique (AHW )
Soudage á l'arc avec
élect r ode de carbone ( CAW)

Gougeage A i r - Arc avec
élect r ode de carbone

2-73)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

toutes conditions 12

toutes conditions 12

épais plus de 400 am pe rès 14

Nuance de

fi l tre oculai re

1-7

ARCMASTER 400TS, 400S, 300TS, 300S

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.

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.

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.

AVERTISSEMENT

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.

1-8

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.

1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont
recommandés.

2. Portez des vêtements appropriés pour protéger
la peau.

May 22, 2006

ARCMASTER 400TS, 400S, 300TS, 300S

1. Utilisez l’équipement à l’extérieur dans des aires
ouvertes et bien ventilées.

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.

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. 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.

5. Faites attention de ne pas renverser de carburant.
Nettoyez tout carburant renversé avant de faire
démarrer le moteur.

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.

Les moteurs produisent des gaz d’échappement nocifs.

May 22, 2006

1-9

ARCMASTER 400TS, 400S, 300TS, 300S

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.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER
UN ACCUMULATEUR; L’ELECTROLYTE D’UN
ACCUMU-LATEUR PEUT BRULER LA PEAU ET
LES YEUX.

Les accumulateurs contiennent de l’électrolyte
acide et dégagent des vapeurs explosives.

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.

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.

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.

1-10

May 22, 2006

2 INTRODUCTION

1

How To Use This Manual

2

Equipment Identification

This Service Manual applies to just specification or
part numbers listed on page i.

To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.

Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily
recognized as follows:

WARNING

A WARNING gives information regarding possible
personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning cer­tain operating procedures.

The unit's identification number (specification or
part number), model, and serial number usually
appear on a nameplate attached to the control
panel. In some cases, the nameplate may be
attached to the rear panel. Equipment which does
not have a control panel such as gun and cable
assemblies is identified only by the specification or
part number printed on the shipping container.
Record these numbers on the bottom of page i
future reference.

for

Additional copies of this manual may be purchased
by contacting Thermal Arc at the address and
phone number in your area listed in the inside back
cover of this manual. Include the Service Manual
number and equipment identification numbers.

Electronic copies of this manual can also be down­loaded at no charge in Acrobat PDF format by
going to the Thermal Arc web site listed below and
clicking on the Literature Library link:

http://www.thermalarc.com

2 – 1

3

Symbol Chart

Note that only some of these symbols will appear on your model.

300/400TS and 300/400S 2 INTRODUCTION

SEC

%

Amperage

Voltage

Hertz (frequency)

Seconds

Percent

DC (Direct Current)

AC (Alternating Current)

STICK
(Shielded Metal Arc SMAW)

Pulse Current Function

t

t2

Spot Time (GTAW)

Remote Control
(Panel/Remote)

Remote Function

Arc Control (SMAW)

Gas Post-Flow

Standard Function

Slope Function

Slope W/Repeat Function

Spot Function

Impulse Starting
(High Frequency GTAW)

Touch Start
(Lift Start TIG circuit GTAW)

2 – 2

t1

VRD

Gas Pre-Flow

Voltage Reduction Device
Circuit

Negative

Positive

Gas Input

Gas Output

300/400TS and 300 /400S 2 INTRODUCTION

2 – 3

4

Description

The Thermal ArcTM Model ARC MAST ER 300TS and 400T S is a si ngle/thr ee-phase DC arc weldin g power
source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage
Meter, gas control valve, built in Sloper and Pulser, lift arc starter, and high-frequency arc starter for use with
Gas Tungsten Ar c W el din g ( GTA W) , G as Tungsten Arc Welding-Pulse (G TAW - P) , G as T ung sten Arc Weld­ing-Sloped (GTSW-S ), and Shielded Metal Arc Weld ing (SMAW) processes. The power s ource is totally
enclosed in an impact resistant, flame resistant and non-conductive plastic case.

The Thermal Arc

TM

Model ARCMASTER 300S and 400S is a self contained single/three-phase DC arc weld­ing power source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/
Amperage Meter and li ft ar c starter for use with Gas Tungsten Arc We ldi ng ( GT AW ) and Shi el ded Meta l A rc
Welding (SMAW) process es. The power source is totally enclosed in an impa ct resistant, flame resistant
and non-conductive plastic case.

Figure2-1: 300/400TS and 300/400S Volt-Ampere Curves

300A5A (A)

(V)

OCV

STICK Process

300A25A (A)

(V)

OCV

10V

LIFT TIG Process

300A (A)

(V)

OCV

5A

HF TIG Process

[ 300TS ]

400A5A (A)

(V)

OCV

STICK Process

400A (A)

(V)

OCV

5A

HF TIG Process

400A25A (A)

(V)

OCV

10V

LIFT TIG Process

[ 400TS ]

[ 300S ]

300A25A (A)

(V)

OCV

10V

LIFT TIG Process

300A 320A

160A

18V

5A (A)

(V)

OCV

STICK Process

400A25A (A)

(V)

OCV

10V

LIFT TIG Process

400A 420A

160A

18V

5A (A)

(V)

OCV

STICK Process

[ 400S ]

300/400TS and 300/400S 2 INTRODUCTION

2 – 4

5

Functional Block Diagrams

Figure 2-2 illust rates the functi onal block diagram of the 300TS and 400TS power sup ply. Figure 2-3 il lus­trates the functional block diagram of the 300S and 400S power supply.

Figure 2-2: 300/400TS Model Functional Block Diagram

Figure 2-3: 300/400S Model Functional Block Diagram

Main

Circuit
Switch

Filter

Input

Diode

Primary

Capacitor
DC Power

Voltage
Sensor

IGBT

Inverter

Thermal
Detector

To each control circuit

+/-15VDC +18VDC

+24VDC +5VDC

Trouble
Sensing

Circuit

Drive

Circuit

Torch Control

Connection

(CON1)

circuit

Current

Adjustment

Reference

Adjust ment &

Mode select Switches

Panel Circuit Board

Sequence

Control

Thermal
Sensor

Circuit

Mai n

Transformer

(PCB14)

Output
Diodes

HF-UNIT

Control

Circuit

Stick Mode

VRD

Sensing

Circuit

Lift Tig Mode

Output Short

Sensing

Circuit

Coupling

High

Coil

Frequency

Unit

Fan Control

Circuit

Gas Co ntrol

Circuit

Fan

Solenoid

Hall Current
Transformer

(HCT1)

Output

Inductor

Thermal
Detector

+

-

+-

Input

Power

Primary
Current
Sensor

Main

Circuit
Switch

Filter

Input

Diode

Primary

Capacitor

DC Power
Voltage

Sensor

IGBT

Inverter

Thermal
Detector

To each control circuit

+/-15VDC +18VDC

+24VDC +5VDC

Trouble
Sensing

Circuit

Drive

Circuit

Torch Control

Connection

(CON1)

circuit

Current

Adjustment

Reference

Adjust ment &

Mode select Switches

Panel Circuit Board

Sequence

Control

Thermal
Sensor

Circuit

Mai n

Transformer

(PCB14)

Output

Diodes

Stick Mode

VRD

Sensing

Circuit

Lift Tig Mode

Output Short

Sensing

Circuit

Fan Control

Circuit

Fan

Hall Current
Transformer

(HCT1)

Output

Inductor

Thermal
Detector

+

-

+-

Input

Power

Primary
Current
Sensor

300/400TS and 300 /400S 2 INTRODUCTION

2 – 5

6

Transporting Methods

These units are equipped with a handle for carrying
purposes.

WARNING

ELECTRIC SHOCK can kill.

 DO NOT TOUCH live electrical parts.
 Disconnect input power conductors from de-

energized supply li ne befo re mo vi ng t he we ld ing
power source.

WARNING

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 usin g a fork lift veh icle, place and sec ure unit

on a proper skid before transporting.

300/400TS and 300/400S 2 INTRODUCTION

2 – 6

PAGE LEFT INTENTIONALLY BLANK

3 INSTALLATION

3 – 1

INSTALLATION

1

Environment

The ARC MASTER 300/400TS and 300/400S are
designed for use in adverse environments.

Examples of environme nts with increased adv erse
conditions 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, or

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 adverse conditions do not
include places where electrically conductive parts
are in the near vicinity of th e operator, which can
cause increased hazard, have been insulated.

2

Location

Be sure to locate th e 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 su bjected to abnormal vibration or

shock.

 In areas, not exposed to direct sunlight or rain.
 Place at a distance of 12

” (304.79mm) or more

from walls or similar boundaries that could
restrict natural airflow for cooling.

WARNING

Thermal Arc advises that thi s equip men t be el ec tri­cally connected by a qualified electrician.

3

Electrical Input Connec­tions

WARNING

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.

4

Electrical Input Require­ment

Operate the welding power source from a single­phase 50/60 Hz, AC power su pply. The input volt­age must match one of the elect rica l in put volt ages
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 connection s should be ma de, and any
inspection required.

The line disconnect switch provides a safe and
convenient mean s to co mpl ete ly r em ov e a ll e lec tri­cal power from the welding power supply whenever
necessary to inspect or service the unit.

NOTE

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

Do not connect an input (WHITE or BLACK or
RED) conductor to the ground terminal.

Do not connect the ground (GREEN) conductor to
an input line terminal.

300/400TS and 300/400S 3 INSTALLATION

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.

Input Voltage Fuse Size

208V 100 Amps
230V 90 Amps
460V 30 Amps

Table3-1: Electrical Input Connections

NOTE

Fuse size is based on not more than 200 percent of
the rated input amperage of the welding power
source (Based on Article 630, National Electrical
Code).

The following 208-230/460V Primary Current rec­ommendations are required to obtain the maximum
welding current and duty cycle from this welding
equipment:

Current & Duty

Cycle

TIG STICK

300A

@ 40%

300A

@ 40%

250A

@ 40%

250A

@ 40%

400A

@ 25%

400A

@ 25%

300A

@ 25%

300A

@ 25%

−

−

−

−

Model

ARC

MASTER

300TS

300S

ARC

MASTER

400TS

400S

Primary

Supply

Lead Size

(Factory

Fitted)

8/4 AWG
minimum

8/3 AWG
minimum

8/4 AWG
minimum

8/3 AWG
minimum

Minimum

Primary

Current
Circuit Size
(Vin/Amps)

208/31
230/28 −
460/14 −

3φ

208/45 −
230/41 −
460/21 −
208/51
230/46 −

1φ

208/76 −
230/68 −
208/49
230/44 −
460/22 −

3φ

208/67 −
230/61 −
460/31 −
208/67
230/60 −

1φ

208/97 −
230/87 −

Figure3-1: Electrical Input Connections

5

Input Power

Each unit incorporates an INRUSH circuit and input
voltage sensing circuit. When the MAIN CIRCUIT
SWITCH is turned on, the inrush circuit provides a
pre-charging of the input capacitors. At this point,
the Bus Voltages are checked and the welder is
enabled after the input capacitors have charged to
full operating voltage (after approximately 5 seconds).

NOTE

Note the available input power. Damage to the
welder could occur if 575VAC or higher is applied.

208-230/460V Primary Current Circuit sizes

Table3-2:

to achieve maximum current

The ARC MASTER 300/400TS and 300/400S are
designed for use with a generator as an input
power source. Contact an accredited Thermal Arc
service agent for the proper sizing and set-up rec­ommendations of a generator power source sys­tem. As a general rule, depending on the type of
generator used, the generator capacity should be
twice the maximum rating of the welder.

3 – 2

300/400TS and 300 /400S 3 INSTALLATION

3 – 3

6

High Frequency Introduc­tion (300/400TS only)

The importance of correct installation of high fre­quency welding equipmen t cannot be over-e mpha­sized. Interferenc e due to high fr equency initia ted
or stabilized arc is almost invariably traced to
improper installa tion. The following information is
intended as a guide for personnel installing high
frequency welding mach ine s.

WARNING: Explosives

The high frequency se ction of thi s machin e has an
output similar to a radio tran smitter. The machine
should NOT be used in the vicinity of blasting oper­ations due to the danger of premature firing.

WARNING: Computers

It is also possible t hat operation close to com puter
installations may cause com puter malfunction.

7

High Frequency Interfer­ence (300/400TS only)

Interference may be transmitted by a high fre­quency initiated or stabilized arc we lding machine
in the following ways:

1. 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.

2. 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.

3. 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.

4. 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.

8

Duty Cycle

The duty cycle of a welding power source is the
percentage of a ten (10) minut e period that it can
be operated at a given output without causing over­heating and damage to the unit. If the welding
amperes decreas e, the duty cycle in crease s. If the
welding amperes are increased beyond the rated
output, the duty cycle will decrease.

WARNING

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

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

NOTE

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

300/400TS and 300/400S 3 INSTALLATION

3 – 4

9

Specifications

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 an y product without prior
notice. Such updates or cha nge s do not entitl e the
buyer of equipment previously sold or sh ipped to
the corresponding changes, updates, improve­ments or replacement of such items.

The values specifi ed in the tabl e abo ve are optim al
values, your values may differ. Individual equip­ment may differ from th e above specifications due
to in part, but not exclusively, to any one or more of

the following; variations or changes in manufac­tured components, installation location and condi­tions and local power grid supply conditions .

Parameter 300TS / 300S 400TS / 400S

Rated Output 208-230/460VAC 208-230/460VAC

Amperes 300 400
Volts 32 36
Duty Cycle 40% 25%

Duty Cycle 300A / 32V @ 40% (3ph) 400A / 36V @ 25% (3ph)

200A / 28V @ 60% (3ph) 300A / 32V @ 60% (3ph)

250A / 30V @ 40% (1ph) 300A / 32V @ 25% (1ph)
Output Current Range 5 - 300 Amps 5 - 400 Amps
Open Circuit Voltage 65V

Dimensions

Width 8.3” (210mm)
Height 16.5” (420mm)
Length 17.7” (450mm)

Weight 52.9 lb. 24 kg (300/400TS)

44.1 lb. 20 kg (300/400S)

Output @ Rated Load Three-phase Single-phase Three-phase Single-phase

Output Amperes 300A 250A 400A 300A
Output Volts 32V 30V 36V 32V
Duty Cycle 40% 40% 25% 25%
KVA 18.0 15.7 24.0 20.0
KW 12.0 9.4 18.0 12.0

Output @ No Load

KVA 0.5
KW 0.13

Input Volts Three Phase

Amperage Draw @

Rated Load

No Load

Amperage Draw @

Rated Load

No Load

208V 45 1.4 67 1.4
230V 41 1.3 61 1.3
460V 21 0.7 31 0.7

Input Volts Single Phase

208V 76 2.5 97 2.5

230V 68 2.2 87 2.2

4 OPERATOR CONTROLS

4 – 1

OPERATOR CONTROLS

1

ARC MASTER 300/400TS and 300/400S Controls

Figure 4-1: ARC MASTER Power Source

1. Control Knob: This control sets the selected
weld parameter, rotating it clockwise increases
the parameter that is indicated on the digital
meter. Pushing the knob inward displays the
actual welding voltage.

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.

Figure 4-2: 14-Socket Receptacle

Table 4-1: Socket Pin Functions

450

210

435

1

3

5

9

2

7

8

6

4

Socket

Pin

Function

A

Torch Switch Input (24V) to connect pins A &
B to turn on the welding current.

B

Torch Switch Input (0V) to energize weld
current (connect pins A & B to tu rn o n wel din g
current).

C

5k ohm (maximum) connection to 5k ohm
remote control potentiometer.

D

Zero ohm (minimum) connection to 5k ohm
remote control potentiometer.

E

Wiper arm connection to 5k ohm remote
control potentiometer.

G Mains Earth.

F,H,I,J,

K,L

Not Used.

M

OK to move current detect signal for robotics
applications.

N

OK to move current detect signal for robotics
applications.

AJ

BKI

CLNH

DMG

FE

ABCDEFGHIJKLMN

E

Front view of 14
Socket Receptacle

5k ohms

300/400TS and 300/400S 4 OPERATOR CONTROLS

4 – 2

3. Positive Terminal: Welding current flows from
the Power Source via heavy duty Dinse type
terminal (50 mm). It is essential, however,
that the male plug is inserted and turned
securely to achieve a sound electrical connec­tion.

4. Negative Terminal: Wel di ng cu rren t flows
from the Power Source via heavy duty Dinse
type terminal (50 mm). It is essential, how­ever, that the male plug is inserted and turned
securely to achieve a sound electrical connec­tion.

CAUTION

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

5. Gas Outlet: The Gas Outlet is a 5/8 18 UNF
female gas fitting. (300/400TS only)

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

When the welder is conne cted to the Primary su p­ply voltage, the internal electrical components
maybe at 240V potential with respect to earth.

7. Input Cable: The input cable connects the Pri­mary supply voltage to the equipment.

8. SMART Logic Switch: Manual slide switch
mounted on the back panel selects the pr

oper

i

nput voltage. If this slide is not set to the posi­tion that matches the input voltage from the
electrical source the Smart Logic circuit will
inhibit welding power source output. The digi­tal meter will show primary input error code.

9. Gas Inlet: The Gas Inlet is a 5/8 18 UNF
female gas fitting. (300/400TS only)

2

Weld Process selection for
ARC MASTER 300/400TS
and 300/400S

Table4-2:

Weld Process selection verses Weld Mode for

ARC MASTER 300/400TS and 300/400S

Weld Mode

Weld Process

Selection

STICK

HF

TIG

LIFT

TIG

Description

Yes Yes Yes

2T operation in
TIG Modes using
remote device s to
control contactor
& current.

No Yes Yes

4T operation in
TIG Modes with
crater fill using a
remote contactor
device to control
sequence.

(300/400TS only)

No Yes Yes

4T operation in
TIG Modes with
repeat operation
and crater fill
using a remote
contactor device.

(300/400TS only)

No Yes No

2T operation spot
welding in HF TIG
using a remote
contactor device.

(300/400TS only)

No Yes Yes

Pulse operation
in TIG Modes.

(300/400TS only)

Yes No Yes

Contactor
operation in Stick
Mode

Yes Yes Yes

Selects mode of
operation: Panel
or Remote

STD

SLOPE

REPEAT

SPOT

PULSE
ON/OFF

Contactor ON/OFF

Operation

PANEL /REMOTE

300/400TS and 300 /400S 4 OPERATOR CONTROLS

4 – 3

3

Weld Parameter Descriptions for ARC MASTER 300/400TS
and 300/400S

Figure 4-3:

ARC MASTER 300/400TS

Front Panel with Param e ter Descriptio n

Parameter Description

PRE-FLOW

This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to
striking the arc, once th e torch trigg er swi tch has be en press ed. This control is used to dra matic ally
reduce weld porosity at the start of a weld.

HOT START

This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld
zone in TIG modes or improve the start characteristics for stick electrodes. e.g. low hydrogen
electrodes. It sets the peak start current on top of the BASE (WELD) current.
e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps & HOT START = 30 amps

INITIAL CUR.

This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the start
current for TIG. The Start Current remains on until the torch trigger switch is released after it has
been depressed.

UP SLOPE

This parameter operate s in TIG modes only and is used to set the time for the weld curre nt to ramp
up, after the torch trigger switch has been pressed then released, from INITIAL CUR to PEAK or
BASE current.

PEAK CUR. This parameter sets the PEAK weld current when in PULSE mode.

WELD

This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and SPOT modes when
PULSE is off. This parameter also sets the STICK weld current.

BASE

(Background

Current)

This parameter sets the Background current when in Pulse TIG mode.

SPOT TIME This parameter sets the duration of the SPOT TIME in HF TIG mode only.

PULSE WIDTH

This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current
when the PULSE is on.

PULSE FREQ. This parameter sets the PULSE FREQUENCY when the PULSE is on.

DOWN SLOPE

This parameter operate s in TIG modes only and is used to set the time for the weld curre nt to ramp
down, after the torch trigger switch has been pressed, to CRATER CUR. This control is used to
eliminate the crater that can form at the completion of a weld.

CRATER CUR.

This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is used to set the finish
current for TIG. The CRATER Current remains on until the torch trigger switch is released after it
has been depressed.

t1

300/400TS and 300/400S 4 OPERATOR CONTROLS

4 – 4

Table4-3: Weld Parameter Descriptions for ARC MASTER 300/400TS

Figure 4-4:

ARCMASTER 300/400S

Front Panel with Param e ter Descriptio n

Table4-4: Weld Parameter Descriptions 300/400S

POST-FLOW

This parameter operates in TIG modes only and is used to adjust the post gas flow time once the
arc has extinguished. This control is used to dramatically reduce oxidation of the tungsten
electrode.

The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into the 300/
400TS and 300/400S memory.

Parameter Description

t2

SAUVEGARDER CHARGER

SAVE LOAD

Parameter Description

HOT START This parameter operates in STICK weld mode and is used to improve the start characteristics for

stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the WELD
current.

Weld Current (Amperage)- sets the STICK and TIG WELD current.

ARC CONTROL - This parameter pr ovides a suitable short circuit current in STICK welding to
improve electrode sticking and arc stability.