Tweco 400MSTP User Manual

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400 MSTP

ARCMASTER

INVERTER ARC WELDER

Operating Manual

Version No: AB Issue Date: June 21, 2010 Manual No.: 0-4864

Operating Features:

GMAW FCAW

SMAW

CAG

GTAW

1/3

PHASE

50 60

INVERTER

CC CV

230

208

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-752-7621, or visit us on the web at www.thermalarc.com.

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

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is 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 400 MSTP Inverter Arc Welder Instruction Manual Number 0-4864 for: Part Number 10-3076

Published by: Thermadyne Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

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: August 31, 2006 Revision Date: June 21, 2010

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

1.0 SAFETY INSTRUCTIONS AND WARNINGS................................................................................1

SYMBOL LEGEND....................................................................................................................9

2.0 INTRODUCTION AND DESCRIPTION .................................................................................... 10

2.01 Description ................................................................................................................................................11

2.02 Functional Block Diagram ..........................................................................................................................12

2.03 Transporting Methods................................................................................................................................12

2.04 Installation Recommendations...................................................................................................................13

2.04.01 Environment ..................................................................................................................................13

2.04.02 Location................................................................................................................................................13

2.05 Electrical Input Connections.......................................................................................................................14

2.05.01 Electrical Input Requirements........................................................................................................14

2.05.02 Input Power...................................................................................................................................16

2.05.03 High Frequency Introduction..........................................................................................................17

2.05.04 High Frequency Interference..........................................................................................................17

2.07 Duty Cycle..................................................................................................................................................19

3.0 OPERATOR CONTROLS ................................................................................................... 20

3.01 ARC MASTER 400 MSTP Controls.............................................................................................................21

3.02 Weld Parameter Descriptions for ARC MASTER 400 MSTP.......................................................................24

3.03 Weld Process Selection for the ARC MASTER 400 MSTP..........................................................................26

3.04 Weld Parameter Descriptions.....................................................................................................................26

3.04.01 WELD (V).......................................................................................................................................26

3.04.02 INDUCTANCE.................................................................................................................................26

3.04.03 HOT START....................................................................................................................................26

3.04.04 WELD (A).......................................................................................................................................26

3.04.05 ARC CONTROL ..............................................................................................................................27

3.05 Weld Parameters........................................................................................................................................28

3.06 Power Source Features..............................................................................................................................28

4.0 SEQUENCE OF OPERATION............................................................................................... 30

4.01 Stick Welding.............................................................................................................................................32

4.02 LIFT TIG Welding .......................................................................................................................................32

4.03 MIG Welding..............................................................................................................................................33

4.04 Pulse-MIG Welding....................................................................................................................................33

4.05 Save-Load Operation..................................................................................................................................29

4.06 Pulsed GMAW............................................................................................................................................30

4.07 SAFE Mode ................................................................................................................................................33

5.0 BASIC WELDING GUIDE................................................................................................... 37

5.01 Electrode Polarity.......................................................................................................................................37

5.02 Tungsten Electrode Current Ranges...........................................................................................................37

5.03 Tungsten Electrode Types..........................................................................................................................37

5.04 Guide for Selecting Filler Wire Diameter.....................................................................................................38

5.05 Shielding Gas Selection .............................................................................................................................38

5.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ..............................................................38

5.07 Welding Parameters for Steel.....................................................................................................................39

6.0 BASIC STICK WELDING GUIDE........................................................................................... 40

6.01 Electrode Polarity.......................................................................................................................................40

6.02 Effects of Stick Welding Various Materials.................................................................................................40

TABLE OF CONTENTS

7.0 BASIC MIG WELDING GUIDE .............................................................................................42

7.01 Setting of the Power Source......................................................................................................................42

7.02 Position of MIG Torch................................................................................................................................42

7.03 Distance from the MIG Torch Nozzle to the Work Piece.............................................................................42

7.04 Travel Speed..............................................................................................................................................43

7.05 Electrode Wire Size Selection.....................................................................................................................43

7.06 Deposition Rate Comparison.....................................................................................................................43

8.0 ROUTINE MAINTENANCE ................................................................................................. 44

9.0 BASIC TROUBLESHOOTING...............................................................................................45

9.01 Solving MIG Problems Beyond the Welding Terminals..............................................................................45

9.01.01 Porosity.........................................................................................................................................45

9.01.01 Inconsistent Wire Feed..................................................................................................................46

9.02 MIG Welding Problems..............................................................................................................................47

9.03 TIG Welding Problems...............................................................................................................................48

9.04 Stick Welding Problems.............................................................................................................................50

9.05 Power Source Problems............................................................................................................................52

10.0 VOLTAGE REDUCTION DEVICE (VRD)...................................................................................53

10.01 VRD Specification....................................................................................................................................53

10.02 VRD Maintenance....................................................................................................................................53

10.03 Switching VRD ON/OFF............................................................................................................................54

11.0 POWER SOURCE ERROR CODES ........................................................................................ 56

APPENDIX A - INTERCONNECT DIAGRAM ......................................................................................58

APPENDIX B - ARCMASTER 400 MSTP ACCESSORIES .......................................................................60

LIMITED WARRANTY SCHEDULE

WARRANTY SCHEDULE

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

ARCMASTER 400 MSTP

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.

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.

15. Keep all panels and covers securely in place.

WARNING

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

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

2. Wear approved safety glasses. Side shields recommended.

ARCMASTER 400 MSTP

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

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

(goggles or helmet), from AWS A6.2-73.

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

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

WARNING

ARCMASTER 400 MSTP

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.

ARCMASTER 400 MSTP

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 P1, 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.

ARCMASTER 400 MSTP

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.

ARCMASTER 400 MSTP

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

épais plus de 400 amperès 14

Nuance de

filtre oculaire

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 400 MSTP

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.

ARCMASTER 400 MSTP

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.

AVERTISSEMENT

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.

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.

AVERTISSEMENT

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.

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

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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

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2.0 INTRODUCTION AND DESCRIPTION

2.01 Description

The Thermal Arc™ ARC MASTER 400 MSTP 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

400A5A (A)

420A

STICK Process

(V)

OCV

(V)

OCV

36V 10V

10V

400A25A (A)

5A (A)

LIFT-TIG Process MIG Process

Figure 1. Model 400 MSTP 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.

400A

480A

2.02 Functional Block Diagram

Figure 2 illustrates the Functional Block Diagram of the 400 MSTP-power supply.

Input

Power

Main Circuit Switch

Filter

Down

Transformers

AC115V,AC24V

(T3)

Over Current Protect

14PIN

Receptacle

(CON1)

19PIN

Receptacle

(CON2)

Input

Diode

Capacitor DC Power

Primary

Voltage

Sensor

To eac h control circuit

+/-15VDC +18VDC +24VDC +5VDC

IGBT

Inverter

Themal Detector

Trouble

Sensing

Circuit

Drive

Circuit

Main

Transformers

(T1)

Thermal

Sensor

Circuit

Primary

Circuit

Sensor

Current

Adjus tment

Circuit

Output Diodes

Themal

Detector

Stick Mode

VRD

Sensing

Circuit

Sequenc e

Control

Reference

Adjustment &

Mode select Sw itch

Panel Circuit Boad

Output

Inductor

Select Switch

Figure 2. 400 MSTP Model Functional Block Diagram

Lift Tig Mode

Out put Short

Sensing

Circuit

Fan Control

14PIN-19PIN

(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.

2.04 Installation Recommendations

2.04.01 Environment

The ARC MASTER 400 MSTP 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.

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.

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

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

400 MSTP

Primary Supply

Lead Size

8/4 AWG minimum

(Factory Fitted)

8/3 AWG minimum

Minimum Primary

Current Circuit Size

(Vin/Amps)

Phase

208/63 230/57

400A @

460/29 208/49 230/44 460/22 208/67 230/61 460/31 208/88

300A @

230/79 208/67 230/60 -

Current & Duty Cycle

MIG TIG STICK

- -

25%

- -

- 400A @

25%

- -

400A @ 25%

- -

25%

- -

300A @

25%

208/97 230/87 - -

- 300A @ 25%

Table 2 – Primary Current Circuit sizes to achieve maximum current

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.

2.06 Specifications

Parameter 400 MSTP Rated Output

Amperes Volts Duty Cycle Duty Cycle TIG

STICK

MIG

400 36 25% 400A/ 26V@ 25% 300A/ 22V @ 60% 200A/ 18V @ 100% 400A / 36V @ 25% 300A / 32V @ 60% 200A / 28V @ 100% 400A / 34V @ 25% 300A / 29V @ 60% 200A / 24V @ 100%

Output Current Range

Output Voltage Range

TIG STICK

5 – 400A

MIG 5 – 36V

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 Single-phase 208-230/460V 208-230V 400A 300A 36V 32V 25% 25%

24.0kVA 20.0kVA

18.0kW 12.0kW

0.5

0.13

Amperage Draw @ Rated Load

97 87

67 61 31

No Load

2.4

2.2

1.4

1.3

0.7

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.

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.

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3.0 OPERATOR CONTROLS

3.01 ARC MASTER 400MSTP Controls

Figure 4. ARC MASTER 400 MSTP Power Source

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.

Socket Pin Function

A B Input to energize solid state contactor

C 5k ohm (maximum) connection to 5k ohm remote control potentiometer D E Wiper arm connection to 5k ohm remote control potentiometer F Current feedback Ifb = 100Amps/Volt G 24/115 VAC circuit common, also connected to chassis H Voltage Feedback Vfb = 10 Arc Volts/Volt

I 115 VAC auxiliary high side

J 115 VAC input to energize solid state contactor (Contact closure between

K Chassis ground

L,M,N Not used

24VAC auxiliary high side.

(Contact closure between pin A and pin B)

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

pin 1 and pin J)

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.

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).

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

F G Chassis ground H Remote control maximum

J Remote control wiper (0 – 10 Volts) K Remote Control minimum 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

24/115 VAC neutral

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.

Input Cable

The input cable connects the Primary supply voltage to the equipment.

Voltage Input Select Switch (Smart Logic Switch)

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

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.

10.

24VAC Remote Device C/B

Push to reset. Controls the 24VAC power source for the wire feeders controlled through the Remote Control Sockets.

115VAC Remote Device C/B

11.

Push to reset. Controls the 115VAC power source for the wire feeders controlled through the Remote Control Sockets.

12. Remote Control Socket: The 10 pin Remote Control Socket is used to connect remote control

devices for Pulse MIG welding. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Socket Pin Function

1 5 VDC auxiliary high side 2 Communication signal

3 Communication signal 4

5 6 5 VDC neutral

7 Chassis ground 8 N/C 9 N/C

10 N/C

Communication signal Communication signal

3.02 Weld Parameter Descriptions for ARC MASTER 400 MSTP

Figure 5. ARC MASTER 400 MSTP Front Panel with Parameter Description

Parameter Description

ARC CONTROL

HOT START

DC (A)

DC (V)

Contactor ON/OFF

This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability.

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 (Amperage) - when lit parameter knob sets the STICK and TIG WELD current.

Weld Voltage (Volt) – when lit parameter knob sets the MIG voltage.

Contactor operation in Stick Mode.

Selects in operation Panel board or Remote.

(WELD)

current.

Operation

PANEL/REMOTE

INDUCTANCE

This parameter, similar to the ARC CONTROL in STICK mode, allows for the 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 400MSTP memory.

Table 3 – Weld Parameter Descriptions for ARC MASTER 400 MSTP

3.03 Weld Process Selection for the ARC MASTER 400 MSTP

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.

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.

NOTE 7

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; i.e. the greater the penetration, the greater the current.

Arc Force Position

Minimum (0) 0A Soft arc, Low spatter, Low

Medium (20%) 32A Normal arc, Improved fusion

Maximum (100%) 160A Hard arc, Deep penetration

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.

Current Increase when Arc

Voltage is less than 18V

Table 5 – Weld Parameter Descriptions

Effect on Welding Performance

penetration

characteristics,

Normal penetration

ii) Vertical up welding

When welding vertical up with arc force on, the operator can control the amount of current by changing arc length, i.e. 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 36.0V DC 17.0V 0.1V

1 to 400A DC 80A 1A

3.06 Power Source Features

Feature Description

New Digital Control Touch Panel Switches Front Control Cover Digital Meter Volt & Ammeter

Intelligent Fan Control

ON/OFF Switch

Incremental

Setting

0 to 100% 10% 1%

0 to 70A 20A 1A

0 to 100% 10% 1%

Unit

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

• 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

STICK

MIG

LIFT TIG

Feature Description

Voltage Reduction Device (VRD) (Shipped de-activated, field capable)

See Section 11 for activation instructions.

Control Knob

Self Diagnosis Using Error Codes

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

200AC/DC memory.

SAVE

the Current Weld Parameters into Memory

• Press and HOLD the

SAVE

button. Beep will sound

and Digital Meter 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 right scroll button and the machine will give a beep to confirm the weld parameters are loaded onto the control panel.

LOAD

(retrieve) a Program to Control Panel

LOAD

• Press and HOLD the

button. Beep will sound and

Digital Meter 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 right scroll button and the machine will give a beep to confirm the weld parameters are loaded onto the control panel.

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4.0 SEQUENCE OF OPERATION

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.

3 8

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.

Figure 6. 400 MSTP Front Panel

7. Scroll Buttons: 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.

8. SAFE MODE: SAFE (Special Application Function Environment) is a mode of operation that

the 400MSTP of welding power source can enter in order to customize the welder for a special application. See section 4.06.

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

Commence welding

HOT START ARC CONTROL WELD

current

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

4.04 Pulse-Mig Welding

• Connect work lead to negative terminal

• Connect electrode lead to positive terminal

• Switch machine on

• Set proces to Pulse-MIG mode

• Set Schedule to desired program for application

• Connect Wire feeder

• Set wire feed speed (IPM)

Set Arc Length. The meter will display a reference number between 0 and 440. The higher the reference number the higher the pulse rate and arc voltage. 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 adjust each parameter.

4.05 SAVE-LOAD OPERATION

A total number of 5 programs can be saved into the 400MSTP memory.

SAVE

the Current Weld Parameters into Memory

SAVE

• Press and HOLD the

• 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 right scroll button and the machine

will give a beep to confirm the weld parameters from the control panel are saved.

button. Beep will sound and Digital Meter display will show a number 1.

LOAD

(retrieve) a Program to Control Panel

LOAD

• Press and HOLD the

• 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 right scroll button and the machine

will give a beep to confirm the weld parameters are loaded onto the control panel.

button. Beep will sound and Digital Meter display will show a number 1.

4.06 Pulsed GMAW General

Pulse-GMAW (referred to as Pulse-MIG) is a welding process that involves the pulsing of the welding current from a high value (peak current) to a low value (background current) to produce a clean spatter-free weld. The intent of this manual is not to present a comprehensive coverage of this welding process, but to give an explanation of the terms used and how they apply to the 400MSTP power source.

Explanation of Terms: (See Figure A)

Ist: Ist is the amplitude of the initial pulse of current during the arc starting interval.

Ipk: Ipk is the amplitude of the high pulse of welding current (peak current).The current is forced to

this high value by the power source for a brief time (Tpeak). The peak current melts the wire and forms a droplet. This droplet is then propelled to the weld pool.

Vpk: Vpk is the amplitude of the arc voltage during the high pulse of weld current.

Tpk: Tpk is the amount of time that is spent at the peak current. This time must be sufficient to form a

droplet.

Ibak: Ibak (background current) is the low value of the weld current. The background current serves to preheat the wire and work piece. The background current must not be allowed to go too low or the arc will become unstable and difficult to maintain.

Vbak: Vbak is the amplitude of the arc voltage during the background time.

Tbak: Tbak (background time) is the amount of time that the weld current is at the low value.

Normally, this would be a larger amount of time than is spent at peak current.

Pulse Rate: The pulse rate is the number of pulses of current that produced per second. The 400MTSP allows a pulse rate of approximately 30-300 pulses per second.

Pulsing Frequency: Pulsing frequency is the same as pulse rate. A pulse rate of 60Hz means that the power source produces 60 pulses of current per second.

Ibak (min): Ibak (min) refers to a minimum background current level. If the current falls below this minimum level, it will become difficult to maintain a stable arc.

Arc Length: The distance between the end of the wire electrode (the wire being fed through the torch or gun) and the weld pool. This distance is usually set to give a smooth, spatter-free weld.

Ist Tpk

Ipk

Figure A: Pulse Waveforms

Tbak

Background Time

(Ibak,Vbak)

BAK

SCHEDULE

STD WIRE TYPE

1 Mild steel .035 350 300 2.5 20.0 92%Ar 8%CO2 2 Mild steel .045 450 350 2.5 20.0 92%Ar 8%CO2 3 Stainless Steel .035 350 276 2.6 18.0 81%Ar 1%CO2 18%He 4 Stainless Steel .045 400 326 2.8 19.0 81%Ar 1%CO2 18%He 5 Aluminum .035 400 224 1.4 17.0 100%Ar 6 Aluminum 3/64 450 274 1.4 17.0 100%Ar 7 Metal Core .045 450 400 1.5 16.0 92%Ar 8%CO2 8 Nickel .035 350 276 2.6 18.0 75%Ar 25%He

WIRE SIZE

(INCHES)

Ist

(Amps)

Ipk

(Amps)

Tpk

(Amps)

Vbak

(Volts) GAS MIXTURE

Pulse MIG Schedule for the 400MSTP

The 400MSTP pulse machine comes with 8 pre-programmed weld schedules for use in the Pulsed MIG mode. Each schedule was developed around the particular wire/gas combination given in table 1. These schedules should give good results for most applications. It is possible to use a number of other wire and gas combinations other then those. It will be necessary, however, for the user to determine the optimum weld schedule to use. For welding applications where none of the 8 schedules will give adequate results, any or all 8 schedules can be changed by the operator to fit the application. In order to change them, an optional Programming Pendant is required. The programming pendant plugs into the Programming Pendant connector located on the rear of the 400MSTP. Using the pendant, a schedule can easily be modified by characteristics.

1. Connect the wire feeder to the power source using the 14 or 19 pin socket receptacle on the front of

the power source.

2. Connect the welding leads to the power source and wire feeder.

3. Turn AC power switch to the ON position. The initial power up sequence will be complete in

approximately ten seconds.

4. Press the Process button to select the Pulsed MIG process. The light next to the button should be on

indicating that PULSED MIG is now active.

5. Keeps pushing the LOAD buttons and then use the Control knob to select one of the eight schedules.

See the chart in this manual or the sticker on the machine for schedule information.

6. For LOCAL control make sure the REMOTE light is off by pressing the REMOTE button if necessary.

The light should toggle on and off as the REMOTE button is pressed repeatedly.

7. To set the output, proceed as follows: First set the wire feed speed at the wire feeder. As in

conventional Pulse Mig Welding. The wire feeder will control the average amperage or heat input. Second set the correct arc length by adjusting the output of the power source. Press the forward button or buck button. Select voltage as the adjustable value. The meter will display a “Reference Number” between 0 and 440. The higher the “Reference Number” the higher the pulsing rate and arc voltage. (The actual number of pulses per second will vary between approximately 30 and 300 as the number varies between 0 and 440.) To increase arc length, increase the “reference number” setting. To decrease arc length, decrease the “reference number” setting. This is essentially the same as adjusting voltage for conventional MIG

welding. As with conventional MIG welding, the power source must be adjusted to correspond with the correct heat input for a given wire feed speed setting.

8. For REMOTE control make sure the REMOTE light on by pressing the REMOTE button if necessary.

Now the arc voltage can be controlled at the wire feeder (if the feeder is equipped with a voltage control). See Step 6 for an explanation of how to set the output of the power source. If the wire feeder is equipped with a digital meter, it will also display the preset “reference number”; however it will show a decimal point. For example, if the wire feeder displays 23.5 the power source will display 235.

9. The power source is now ready to weld. To initiate the weld, activate the torch switch on the MIG

torch.

10. To end the weld, release the torch switch. As with conventional MIG welding, a wire conditioning

sequence will leave the wire with a very small ball on the end, thus making the next arc strike easier.

Optional Programming Pendant

AN optional programming pendant allows any or all eight of the factory pulse schedules to be overridden. To use the pendant, turn the power source OFF, and plug the pendant into the pendant plug on the rear of the power source. Then turn the power source back ON. To work properly, the pendant must only be plugged into the power source with the power source turned off.

1. Select the PULSED MIG mode on the front panel.

2. Keeps pushing the LOAD buttons and then use the Control knob to select one of the eight schedules.

The schedule number will appear on the pendant.

3. Select the parameter to be adjusted on the pendant. The parameters are Ist, Ipk, Tpk and Vbak.

4. Use the increase and decrease buttons (or the control knob of the pendant) to adjust the value.

NOTE: It is not the intent of this manual to try to describe how to arrive at the correct values for a “good” schedule. This manual just provides the procedure.

5. Select the next parameter to be changed.

6. After all parameter have been changed, press the SAVE button on the pendant. This will

“permanently” save the new date into the memory on the power source. The new date can still be over-ridden with the programming pendant.

7. To restore the factory setting for the selected schedule, press the RESET button on the pendant.

4.07 SAFE MODE

SAFE (Special Application Function Environment) is a mode of operation that the 400MSTP of welding power source can enter in order to customize the welder for a special application. In most cases this power source feature can be ignored. The factory default settings are expected to be sufficient for most of our customers. In the few cases that the factory default settings are not adequate, the 400MSTP can be programmed to meet special specifications. There are two separate safes, one for single phase operation and one for three phase operation. These safes are independent of each other, and are accessed automatically when the machine is powered up in either the single or three phase mode. Any changes to one will not affect the other.

The following parameters are programming in the SAFE:

OPTION

NUMBER

OPTION

RESET THE SYSTEM. . This option resets all SAFE parameters to their factory default setting. "no" means do not reset the system to factory default while "rES" means reset the system to factory default settings. Only the single phase settings will be reset if the machine is hooked up to single phase power. Likewise, only the three phase setting will be reset when hooked to three phase power. NOTE: THE SAVE BUTTON MUST BE DEPRESSED WHEN EXITING THE SAFE MODE IN ORDER FOR THE RESET TO OCCUR.

FACTORY DEFAULT

1PHASE 3FHASE

no no XX0

DIPSLAY FORMAT

WIRE SHARP VOLTAGE SETING. . This is the voltage that will be present on the wire following a

GMAW or Pulsed GMAW weld. This feature "sharpens" the wire by burning off the ball of filler metal that often forms on the end of the wire following a GMAW weld. The voltage can be set to any value between 0 and 20 volts in increments of 1 volt.

WIRE SHARP TIME. . Wire sharp time is the length of time following a GMAW or Pulsed GMAW weld that the wire sharp voltage will remain on the filler wire. This variable time is adjustable between 0 and 1 second in increments of 0.01 seconds. Longer times will give more of a burn back effect.

MAXIMUM SELECTABLE AMPERAGE. . Maximum selectable amperage is the largest amperage value that the user is capable of setting in SMAW, Lift GTAW, or GTAW local mode. This feature is effective when the user would like to insure that the amperage is never set above a particular amperage level. The range of values permitted is 5-275 amps (single phase) and 5-400 amps (three phase). The maximum selectable amperage is never permitted to be set less than the minimum selectable amperage.

10 10 XX1

0.25 0.25 XX2

275 400 XX3

OPTION

NUMBER OPTION

MINIMUM SELECTABLE AMPERAGE. . Minimum selectable amperage is the lowest amperage value that the user is capable of setting in SMAW, Lift GTAW, and GTAW local mode. This feature is effective when the user would

like to insure that the amperage is never set below a particular amperage level. The range of values permitted is 5-275 amps (single phase) and 5-400 amps (three phase). The minimum selectable amperage is never permitted to be set greater than the maximum selectable amperage.

MAXIMUM SELECTABLE VOLTAGE. . This voltage is largest value that the user is capable of setting in GMAW local welding mode. Voltages above this value can not be entered by the user in local mode. This voltage value can be exceeded in remote by using a feeder with voltage setting capability. The range of values permitted is 10-31 volts (single phase) and 10-36 volts (three phase). The maximum selectable voltage is never permitted to be set less than the minimum selectable voltage.

FACTORY DEFAULT

1PHASE 3FHASE

5 5 XX4

31.0 36.0 XX5

DIPSLAY

FORMAT

MINIMUM SELECTABLE VOLTAGE. . This voltage is the lowest value that the user is capable of setting in GMAW local welding mode. Voltage below this value can not be entered by the user in local mode. This voltage value

can be overridden in remote by using a feeder with voltage setting capability. The range of value permitted is 10-31 volts (single phase) and 10-36 (three phase). The minimum selectable voltage is never permitted to be set greater than the maximum selectable voltage.

MAXIMUM SELECTABLE REFERENCE. . This reference is the largest value that the user is capable of setting in Pulsed GMAW local welding mode. Reference above this value can not be entered by the user in local mode. The reference value can be exceeded in remote by using a feeder with voltage setting capability. The ranges of value permitted are between 0 and 440 in increments of 1. The maximum selectable reference is never permitted to be set less than the minimum selectable reference.

10.0 10.0 XX6

440 440

XX7

OPTION

NUMBER

OPTION

MINIMUM SELECTABLE REFERENCE. . Minimum reference is the lowest value that user is capable of setting in Pulsed GMAW local welding mode. A reference value less than the minimum reference can not be entered by the user in local mode. This reference value can be overridden in remote by using a feeder with voltage setting capability. Minimum selectable reference can have a range of value between 0 and 440 in increments of 1. The minimum selectable reference is never permitted to be set greater than the maximum selectable reference.

LIFT START INITIAL APMS VALUE. . The purpose of Lift GTAW is to allow for striking the arc by momentarily touching the electrode to the work piece. The lift circuit functions to reduce the amperage during the arc start to a low level to give a good soft start. This initial start amperage is adjustable between 5 and 100 amps in increments of 1 amp.

FACTORY DEFAULT

1PHASE 3FHASE

0 0 XX8

20 20 XX9

DIPSLAY FORMAT

METER HOLD TIME. . The hold time is the time following a successful arc that the actual weld amps and volts are held in memory and displayed This parameter is adjustable between 0 and 60 seconds in increments of 1 second. A time of 0 seconds disables meter hold.

AVC ON/OFF. . AVC (Automatic Voltage Control) is available in the 400MSTP unit only. By turning on this function an additional 8 AVC schedules are made available in addition to the 8 standard schedules.

LIFT GTAW ON/OFF. . Lift GTAW ON/OFF changes Lift GTAW into standard GTAW. In the on mode, Lift GTAW is operational. Starts will have to be done with an external arc starter or by scratch methods.

CODE Code is the password code that the user must enter prior to entering the SAFE. The acceptable range of values is between 0 and 999. . NOTE: In the case that you change and forget the code, contact Thermal Arc for instructions on how to access the SAFE and retrieve/change the code.

5 5 XXA

oFF oFF XXb

on on XXC

350 350 XXd

OPTION

NUMBER

EXIT EXIT is the option that returns from the SAFE mode to the welding mode. It is possible to escape by turning on and pushing the SAVE button when escaping from the SAFE mode without changing the option of the SAFE mode.

OPTION

To enter the SAFE, press the SAFE MODE button of the panel. Continue to press the button until the meter displays the word “PAS”. The SAFE is waiting for the correct password code to be entered using the Control knob, and press the Forward button. It is possible to enter the SAFE mode if a correct code (350 by factory default) is input. This code insures that inadvertent access to the SAFE is not possible. A correct code will cause the 400MSTP display “1P0” (For 1phase) or “3P0” (For 3phase).

Access to the SAFE has now been established. The first two digits, reading left to right, is the 1phase or 3phase. It is displayed, 1phase it "1Px", and 3phase it "3Px". The rightmost digit is an option number of the parameter that is currently being set. An explanation and description of this option can be found in the preceding table. The following three digits correspond to the parameter values. These digits will flash.

FORWARD BUTTON

BACK BUTTON

INPUT PHASE

ENTER

SAFE

PARAMETER VALUE

OPTION NUMBER

FACTORY DEFAULT

1PHASE 3FHASE

on on XXF

DIPSLAY

FORMAT

Changed to the displayed parameter value can be made by turning the Control knob.

To gain access to the next option number, press the Forward and Back button. At each option proceed as described in the previous paragraph.

After all changes have been made to the SAFE, the SAVE button must be pressed in order to save the new parameters and restart the system. A successful saving of the information will be followed by the 400MSTP re-starting and entering into the “normal” weld mode. Failure to save will cause all changes to be lost. A power down prior to saving will also cause all changes made while in the SAFE to be lost.

SAVE BUTTON

LOAD BUTTON

CONTROL KNOB

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5.0 BASIC WELDING GUIDE

5.01 Electrode Polarity

Connect the TIG torch to the - / 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.

TORCH

terminal and the work lead to the

+ / WORK

terminal for direct current

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 Varies Tungsten Electrode Sizes

5.03 Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

Welding Application Features

DC welding of mild steel, stainless steel and copper.

High quality AC welding of aluminium, magnesium and their alloys.

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

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

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 3/32”

2.4mm

1/8”

3.2mm 5/32”

4.0mm

Argon Gas

Flow Rate

Liters/min

5-7

Joint Type

Lap/ Fillet

Table 12 – DC TIG Welding Parameters

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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

work. Features include out standing operator appeal, easy arc starting and low spatter.

Mild steel 7014 All positional electrode for use on mild and

galvanized steel furniture, plates, fences, gates, pipes and tanks etc. Especially suitable for vertical-down welding.

Cast iron 99% Nickel Suitable for joining all cast irons except

white cast iron.

Stainless steel 316L-16 High corrosion resistance. Ideal for dairy

work, etc. on stainless steels.

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

7.0 BASIC MIG WELDING GUIDE

7.01 Setting of the Power Source

The setting of the ARC MASTER 400 MSTP 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.

Figure 7. MIG Torch Angle

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.

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

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

(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 400MSTP 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.

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.

THIS PAGE INTENTIONALLY BLANK

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.

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.

7. Maintain the MIG torch in good

working order.

Check that the MIG torch O-rings are not damaged.

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.

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 aluminium 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.

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

C Shielding gas incorrect. C

3 Lack of fusion. Voltage too low. Increase 4 Excessive spatter. A Voltage too high. A

B Voltage too low. B

Irregular weld shape.

B Wire is wandering. B Replace contact tip. C Incorrect shielding gas. C Check shielding gas. D Insufficient or excessive heat input. D

6 Weld cracking. A Weld beads too small. A Decrease travel speed.

B Weld penetration narrow and deep. 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.

Arc does not have a crisp sound, that short arc exhibits, when the wirefeed speed and voltage are adjusted correctly.

Joint preparation too narrow or gap too tight.

Incorrect voltage and current settings. Convex, voltage too low. Concave, voltage too high.

The MIG torch has been connected to the wrong voltage polarity on the front panel.

Possible Cause

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.

Change to a gas which gives higher penetration.

WELD (V)

Lower the voltage by reducing the control or increase wirespeed control.

Raise the voltage by increasing the control or reduce wirespeed control.

Adjust voltage and current by adjusting the

WELD (V)

Adjust the wirespeed control or the voltage selection switches.

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

control.

WELD (V)

control.

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-up

or poor penetration or poor fusion at edges of weld.

Weld bead too wide and

flat or undercut at edges of weld or excessive burn through.

Weld bead too small or

insufficient penetration or ripples in bead are widely spaced apart.

Weld bead too wide or

excessive bead build up or excessive penetration in butt joint.

Uneven leg length in

fillet joint. Electrode melts when arc

is struck.

7 Dirty weld pool. A

B Gas contaminated with air. B

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.

Electrode contaminated through contact with work piece or filler rod material.

Increase weld current and/or faulty joint preparation.

Connect the electrode to the ‘−’ terminal.

Clean the electrode by grinding off

the contaminates.

Check gas lines for cuts and loose fitting or change gas cylinder.

Electrode melts or

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

No gas flowing to

welding region.

The electrode is too small for the welding current.

Check the gas lines for kinks

or breaks and gas cylinder contents.

Disconnect gas hose from torch then raise gas pressure and blow out impurities.

Increase electrode diameter or

reduce the welding current.

Description Possible Cause Remedy

9 Poor weld finish. Inadequate shielding gas.

Arc flutters during

TIG welding.

Welding arc cannot be

established.

B Torch lead is disconnected. B C

12 Arc start is not smooth. A

C Gas flow rate is too high. C

Tungsten electrode is too large for

the welding current. Absence of oxides in the

weld pool. Work clamp is not connected to the

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 to Basic TIG Welding guide. Refer Basic TIG Welding Guide for

ways to reduce arc flutter. Connect the work clamp to the work

piece or connect the work/torch leads to the right welding terminals.

Connect it to the ‘−‘ terminal. Select the right flow rate, change

cylinders or turn torch valve ON. Select the right size electrode.

Refer to Basic TIG Welding Guide. Select the right electrode type.

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 to Basic TIG Welding Guide. Improve connection to

work piece.

9.04 Stick Welding Problems

Description Possible Cause Remedy

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.

Electrodes are damp.

Welding current is too high.

Surface impurities such as oil, grease, paint, etc.

Rigidity of joint.

Insufficient throat thickness.

Cooling rate is too high.

Welding current is too low.

Electrode too large for joint.

Insufficient gap.

igure 8. Example of Insufficient Gap or Incorrect Sequence

Dry electrodes before use.

Reduce welding current.

Clean joint before welding.

Redesign to relieve weld joint of severe stresses or use crack resistance electrodes.

Travel slightly slower to allow greater

build up in throat. Preheat plate and cool slowly.

Increase welding current.

Use smaller diameter electrode.

Allow wider gap.

Use larger electrodes and

Small electrodes used on heavy

4 Portions of the weld

run 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

E Scale or dirt on joint surface. E Clean surface before welding.

cold plate. Welding current is too low.

too high.

Figure 9. Example of Lack of Fusion

pre-heat the plate. Increase welding current.

directed more into the base metal.

D Reduce travel speed of electrode.

5 Non-metallic 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

D Lack of penetration with slag

E Rust or mill scale is preventing

F Wrong electrode for position in

A Non-metallic particles may be

trapped in undercut from previous run.

be trapped.

trapped beneath weld bead.

full 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 10. Examples of Slag Inclusion

9.05 Power Source Problems

Description Possible Cause Remedy

The welding arc cannot

be established.

C Loose connections internally. C

The Primary supply voltage has not been switched ON.

The Welding Power Source switch

is switched OFF.

Switch ON the Primary supply voltage.

Switch ON the Welding

Power Source. Have an accredited Thermal Arc

Service Agent repair the connection.

Maximum output

welding current cannot be achieved with nominal Mains supply voltage.

Welding current reduces

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

6 The TIG electrode has

been contaminated due to the gas flow shutting OFF before the programmed time has elapsed.

POST-FLOW

Defective control circuit.

Poor work lead connection to the work piece.

A B Gas hose is cut.

Gas passage contains impurities.

disconnected or switch/cable is faulty.

A Weld Mode (

SPOT

POST-FLOW

to 60 sec.

The Weld Process Mode (STICK, HF

TIG or LIFT TIG) was changed before had finished.

STD, SLOPE, REPEAT

) was changed before

gas time had finished.

control is set

POST-FLOW

gas time

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.

A BReplace gas hose.

Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities.

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

time.

10.0 VOLTAGE REDUCTION DEVICE (VRD)

10.01 VRD Specification

Description

ARC MASTER

400 MSTP

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.

10.03 Switching VRD On/Off

Switch the machine OFF.

a) Remove the clear plastic cover from the control panel. (see Figure 11)

• 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 11.

VRD ON/OFF Step A

b) Remove four mounting screws from the control panel. (see Figure 12) c) Access the VRD control by gently prying back the front panel controls to reveal the

VRD ON/OFF potentiometer. (see Figure 12)

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 12.

VRD ON/OFF Step B,C

d) Turning the VRD ON/OFF (see Figure 13).

• 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 13.

VRD ON/OFF Step D

11.0 POWER SOURCE ERROR CODES

Description Possible Cause Remedy Remarks

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.

3 E03 error code displayed

Primary (input) current too high.

The Welding Power Source’s duty cycle has been exceeded.

Fan ceases to operate.

Air flow is restricted by vents being blocked.

The Welding Power Source’s duty cycle has been exceeded.

Fan ceases to operate.

Air flow is restricted by vents being blocked.

Primary current is too high because welding arc is too long.

Mains supply voltage is more than 10% below nominal voltage.

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

Have an accredited Thermal Arc Service

Agent investigate. Unblock vents then let

Power Source cool down.

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

Have an accredited

Thermal Arc Service Agent investigate.

Unblock vents then let

Power Source cool down.

Reduce length of welding arc.

Have an accredited Thermal Arc Service Agent or a qualified electrician check for low Mains voltage.

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.

Weld current ceases. Buzzer sounds constantly. Switch machine OFF then ON to reset E03 error.

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.

Primary supply voltage

is greater than the nominal voltage plus 10%.

Mains supply voltage is

less than the nominal operating voltage less 10%.

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. 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.

Description Possible Cause Remedy Remarks

6 E12 error code displayed

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

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.

Mains supply voltage is

down to a dangerously low level.

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.

Have an accredited

Thermal Arc Service Agent or a qualified electrician check the Mains voltage.

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.

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

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.

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.

12 E99 error code displayed

Mains supply (input) voltage has been turned OFF but control circuit has power from the primary capacitors.

Memory chip

(EEPROM) error.

The Welding Power

Source’s temperature sensors have malfunctioned.

Main ON/OFF switch on machine has been turned OFF.

Mains supply (input) voltage has been turned OFF.

Have an accredited

Thermal Arc Service Agent check the control PCB.

Have an accredited

Thermal Arc Service Agent check or replace the temperature sensors.

Turn ON/OFF Switch ON.

Have an accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage and fuses.

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

Weld current ceases. Buzzer sounds constantly. Must switch machine OFF then ON to reset E99 error.

APPENDIX A - INTERCONNECT DIAGRAM

APPENDIX B - ARCMASTER 400 MSTP ACCESSORIES

ACCESSORIES PART NO. DESCRIPTION

Stick Kit 10-4082A Work Lead with 25’ #1 cable and stick electrode holder with 25’

#1 cable.

TIG Kit 10-4080 Includes regulator/flowgauge, 12.5ft 150 Amp TIG torch with

valve, accessory kit includes 1 ea of 0040”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

LIMITED WARRANTY

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 authorized 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, recommendat ions 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: Therma l 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, in cluding negligence or strict liability, or under any warranty, or otherwise, shall not exceed the price of the goods upon which such liability is based.

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 any T hermal Arc product. Purchaser’s rights under this warrant are void if the product is sold to purcha ser 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 Thermal 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 returned goods 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, Ex p lorer

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-PR OCESS INVERT ER W ELDING 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 Con tr o lle r , Weld Timer............ ............... ................................................ 3 year s 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, Con tr o l 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 Power Rectifiers, Con tr o l P.C. Boards........... ........................ ........................ ........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

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 FAX:

(636) 728-3010

Email: sales@thermalarc.com

www.thermalarc.com

Tweco 400MSTP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual