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400 TS
®
ARCMASTER
INVERTER ARC WELDER
Operating Manual
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Operating FeaturesOperating Features
Operating Features:
Operating FeaturesOperating Features
Issue Date:Issue Date:
Issue Date: February 27, 2006
Issue Date:Issue Date:
Art # A-07263
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Manual No: 0-4860
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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.
Page 3
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 TS Inverter Arc Welder
Instruction Manual Number 0-4860 for:
Part Number 10-3071
Published by:
Thermadyne Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2006 by
Thermadyne Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: February 27, 2006
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________
Page 4
TABLE OF CONTENTS
SAFETY INSTRUCTIONS AND WARNINGS........................................................................... 1
SYMBOL LEGEND ....................................................................................................... 9
2.0 INTRODUCTION AND DESCRIPTION......................................................................... 10
2.01 Description ................................................................................................................................10
2.02 Functional Block Diagram ..........................................................................................................11
2.03 Transporting Methods................................................................................................................11
3.0 INSTALLATION RECOMMENDATIONS....................................................................... 12
3.01 Environment ..............................................................................................................................12
3.02 Location.....................................................................................................................................12
3.03 Electrical Input Connections.......................................................................................................13
3.03.01 Electrical Input Requirements........................................................................................13
3.03.03 High Frequency Introduction..........................................................................................16
3.03.04 High Frequency Interference ..........................................................................................16
3.04 Specifications ............................................................................................................................17
3.05 Duty Cycle..................................................................................................................................18
4.0 OPERATOR CONTROLS ....................................................................................... 19
4.01 ARCMASTER 400 TS Controls....................................................................................................19
4.02 Weld Process selection for ArcMaster 400 TS ............................................................................21
4.03 Weld Parameter Description ......................................................................................................22
4.04 Weld Parameters for ArcMaster 400 TS......................................................................................24
4.05 Power Source Features..............................................................................................................25
5.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG)............................................................ 27
6.0 SEQUENCE OF OPERATION................................................................................... 28
6.01 Stick Welding.............................................................................................................................29
6.02 HF TIG & Lift TIG Welding..........................................................................................................29
6.02.01 Slope Mode Sequence ...................................................................................................30
6.02.02 Slope Mode with Repeat Sequence................................................................................30
6.02.03 Pulse Controls ...............................................................................................................31
6.03 Save-Load Operation.................................................................................................................32
7.0 BASIC TIG WELDING GUIDE .................................................................................. 33
7.01 Electrode Polarity.......................................................................................................................33
7.02 Tungsten Electrode Current Ranges...........................................................................................33
7.03 Tungsten Electrode Types..........................................................................................................33
7.04 Guide for Selecting Filler Wire Diameter.....................................................................................34
7.05 Shielding Gas Selection .............................................................................................................34
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ..............................................34
7.07 Welding Parameters for Steel.....................................................................................................36
8.0 BASIC ARC WELDING GUIDE ................................................................................. 37
8.01 Electrode Polarity.......................................................................................................................37
8.02 Effects of Stick Welding Various Materials.................................................................................37
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TABLE OF CONTENTS
9.0 ROUTINE MAINTENANCE......................................................................................39
10.0 BASIC TROUBLESHOOTING...................................................................................40
10.01 TIG Welding Problems............................................................................................................. 40
10.02 Stick Welding Problems...........................................................................................................42
10.03 Power Source Problems.......................................................................................................... 44
11.0 VOLTAGE REDUCTION DEVICE (VRD) .......................................................................46
11.01 VRD Specification....................................................................................................................46
11.02 VRD Maintenance.................................................................................................................... 46
11.03 Switching VRD On/Off .............................................................................................................47
12.0 POWER SOURCE ERROR CODES.............................................................................49
APPENDIX A - INTERCONNECT DIAGRAM ..........................................................................52
APPENDIX B – ARCMASTER 400
TS ACCESSORIES................................................................54
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION...................................... Inside Rear Cover
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ARCMASTER 400 TS
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.
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ARCMASTER 400 TS
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
WARNING
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Eye protection filter shade selector for welding or cutting
(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
2
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WARNING
ARCMASTER 400 TS
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.
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ARCMASTER 400 TS
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.
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ARCMASTER 400 TS
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.
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ARCMASTER 400 TS
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements
et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
portez un respirateur à adduction d’air. Les gaz protecteurs de
soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
malaises ou la mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Opération de coupage
ou soudage
Brassage tendre
au chalumeau
Brassage fort
au chalumeau
Oxycoupage métaux ferreux toutes conditions 12
mince moins de 1 po. (25 mm) 2 ou 3
moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5
Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12
mince moins de 1/8 po. (3 mm) 4 ou 5
moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12
Soudage á l'arc avec
électrode enrobees
(SMAW)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
toutes conditions 2
toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11
épais plus de 6 po. (150 mm) 5 ou 6
épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14
moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)
5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9
plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12
Nuance de
filtre oculaire
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Gougeage Air-Arc avec
électrode de carbone
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
toutes conditions 12
toutes conditions 12
toutes conditions 12
épais plus de 400 amperès 14
Nuance de
filtre oculaire
6
Page 13
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 TS
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un échauffement ou un
incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
7
Page 14
ARCMASTER 400 TS
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.
8
Page 15
Page 16
SYMBOL LEGEND
Amperage
STICK (Shielded Metal Arc
SMAW)
SEC
%
Voltage
Hertz (frequency)
Seconds
Percent
DC (Direct Current)
AC (Alternating Current
Standard Function
Pulse Current Function
Spot Time (GTAW)
Remote Control (Panel/Remote)
Remote Function
Arc Control (SMAW)
Gas Post-Flow
Gas Pre-Flow
Slope Function
Voltage Reduction Device Circuit
VRD
Slope W/Repeat Function
Spot Function
Impulse Starting (High Frequency
GTAW)
Touch Start (Lift Start TIG circuit
GTAW)
Negative
Positive
Gas Input
Gas Output
9
Page 17
2.0 INTRODUCTION AND DESCRIPTION
2.01 Description
The Thermal Arc™ ArcMaster 400 TS is a single/three-phase DC arc welding power source with Constant Current (CC)
output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas control valve, built-in Sloper and
Pulser, lift arc starter, and high-frequency arc starter for use with Gas Tungsten Arc Welding (GTAW), Gas Tungsten Arc
Welding-Pulse (GTAW-P), Gas Tungsten Arc Welding-Sloped (GTAW-S), and Shielded Metal Arc Welding (SMAW)
processes. The power source is totally enclosed in an impact resistant, flame resistant and non-conductive plastic case.
(V)
OCV
(V)
OCV
10V
(V)
OCV
400A5A (A)
STICK Process LIFT TIG Process
5A
400A (A)
HF TIG Process
Figure 1. Model 400 TS Volt-Ampere Curve
Note 1
400A25A (A)
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding
power source. Curves of other settings will fall between the curves shown.
10
Page 18
2.02 Functional Block Diagram
Figure 2 illustrates the functional block diagram of the 400 TS power supply.
Main
Input
Power
Circuit
Switch
Filter
Input
Diode
Capacitor
DC Power
Primary
Voltage
Sensor
To each control circuit
+/-15VDC +18VDC
Thermal
Detector
+24VDC +5VDC
Torch Control
Connection
(CON1)
IGBT
Inverter
Troublel
Sensing
Circuit
Drive
Circuit
Transformer
Themal
Sensor
Circuit
Current
Adjus tment
circuit
Panel Circuit Board
Main
(PCB14)
Primary
Current
Sensor
Sequence
Control
Mode select Switches
Figure 2. 400 TS Model Functional Block Diagram
2.03 Transporting Methods
This unit is equipped with a handle for carrying purposes.
Thermal
Detector
Reference
Adjustment &
Output
Diodes
HF-UNIT
Stick Mode
Control
Circuit
VRD
Sensing
Circuit
+-
Output
Inductor
Fan Control
Circuit
Gas Control
Circuit
Lift Tig Mode
Out put Short
Sensing
Circuit
Coupling
Frequency
Fan
Solenoid
Hall Current
Transformer
Coil
High
Unit
(HCT1)
+
-
WARNING 1
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors
from de-energized supply line before moving the welding power source.
WARNING 2
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Lift unit with handle on top of case.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper skid before transporting.
11
Page 19
3.0 INSTALLATION RECOMMENDATIONS
3.01 Environment
The ArcMaster 400 TS 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.
3.02 Location
Be sure to locate the welder according to the following guidelines:
In areas, free from moisture and dust.
•
•
Ambient temperature between 0 degrees C to
40 degrees C.
•
In areas, free from oil, steam and
corrosive gases.
•
In areas, not exposed to direct sunlight
or rain.
•
In areas, not subjected to abnormal vibration
or shock.
•
Place at a distance of 12” (304.79mm) or
more from walls or similar that could restrict
natural airflow for cooling.
WARNING 3
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
12
Page 20
3.03 Electrical Input Connections
WARNING 4
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.
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.
3.03.01 Electrical Input Requirements
Operate the welding power source from a single/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 and three phase electrical input power.
Do not connect an input (WHITE or BLACK or RED) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
Refer to Figure 3 and:
1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies
with all applicable electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors to a de-energized line
disconnect switch.
3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.
Note 3
For Single-Phase operation connect the GREEN, BLACK and WHITE input conductors. Insolate the
RED Conductor, it is not used for Single-phase operation.
13
Page 21
Input Voltage Fuse Size
208 VAC 100 Amps
230 VAC 75 Amps
460 VAC 50 Amps
Table 1. Electrical Input Connections
NOTE: Fuse size is based on not more than 200 percent of the rated input amperage of the welding
power source (Based on Article 630, National Electrical Code).
Figure 3. Electrical Input Connections
14
Page 22
3.03.02 Input Powe
r
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN INPUT 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 4
Note the available input power. Damage to the PCA could occur if 575VAC or higher is applied.
The following Primary Current recommendations are required to obtain the maximum welding current and duty
cycle from this welding equipment:
ARCMASTER
Model
400 TS
Primary Supply
Lead Size
(Factory Fitted)
Minimum Primary
Current Circuit Size
(Vin/Amps)
Current & Duty Cycle
TIG STICK
-
208/49
400A @ 25%
400A @ 25%
300A @ 25%
300A @ 25%
8/4 AWG minimum
3
Phase
1
Phase
230/44 460/22
208/67 230/61 460/31 -
208/67 230/60
208/97 230/87 -
Table 2 – 208-230/460V Primary Current Circuit sizes to achieve maximum current
-
-
15
Page 23
3.03.03 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.
3.03.04 High Frequency Interference
Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the
following ways:
Direct Radiation
Radiation from the machine can occur if the case is metal and is not properly grounded. It can occur
through apertures such as open access panels. The shielding of the high frequency unit in the Power
Source will prevent direct radiation if the equipment is properly grounded.
Transmission via the Supply Lead
Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the
installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction.
Adequate shielding and filtering is provided in the Power Source.
Radiation from Welding Leads
Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes
rapidly with distance. Keeping leads as short as possible will minimize this type of interference.
Looping and suspending of leads should be avoided where possible.
Re-radiation from Unearthed Metallic Objects
A major factor contributing to interference is re-radiation from unearthed metallic objects close to the
welding leads. Effective grounding of such objects will prevent re-radiation in most cases.
16
Page 24
3.04 Specifications
Parameter 400 TS
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle 400A / 36V @ 25% (3ph)
Output Current Range 5 – 400 Amps
Open Circuit Voltage 65V
Dimensions
Width
Height
Length
Weight 52.9 lb. 24 kg
Output @ Rated Load
Rated Input Voltage
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Three Phase
Input Volts Single Phase
208V
230V
460V
208V
230V
208-230/460VAC
400
36
25%
300A / 32V @ 60% (3ph)
300A / 32V @ 25% (1ph)
8.3” (210mm)
16.5” (420mm)
17.7” (450mm)
Three-phase
208-230/460V
400A
36V
25%
24.0
18.0
Single-phase
208-230V
300A
32V
25%
20.0
12.0
0.5
0.13
Amperage Draw
@ Rated Load
67
61
31
97
87
No Load
1.4
1.3
0.7
2.5
2.2
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.
17
Page 25
3.05 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 5
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and weights quoted are approximate only. Achievable
capacities and ratings in use and operation will depend upon correct installation, use, applications,
maintenance and service.
18
Page 26
4.0 OPERATOR CONTROLS
4.01 ARCMASTER 400 TS Controls
Figure 4. ARCMASTER 400 TS Power Source
1
Control Knob
This control sets the selected weld parameter, rotating it clockwise increases the parameter
that is indicated on the digital meter. Pushing the knob inward displays the actual
welding voltage.
2
Remote Control Socket
The 14 pin Remote Control Socket is used to connect remote current control devices to the
welding Power Source. To make connections, align keyway, insert plug, and rotate threaded
collar fully clockwise.
E
AJ
ＡＢＣＤＥＦＧＨＩＪＫＬＭＮ
5k ohms
BKI
CLNH
DMG
FE
Front view of 14
Socket Receptacle
19
Page 27
Socket Pin Function
A
B Torch Switch Input (0V) to energize weld current
C 5k ohm (maximum) connection to 5k ohm remote control potentiometer
D
E Wiper arm connection to 5k ohm remote control potentiometer
G Mains Earth
F,H,I,J,K,L Not Used
M OK to move current detect signal for robotics applications
N OK to move current detect signal for robotics applications
3
Positive Terminal
Torch Switch Input (24V) to energize weld current
(connect pins A & B to turn on welding current)
(connect pins A & B to turn on welding current)
Zero ohm (minimum) connection to 5k ohm remote control potentiometer
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
4
Negative Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential,
however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION 2
Loose welding terminal connections can cause overheating and result in the male plug being
fused in the bayonet terminal.
5
Gas
The Gas Outlet is a 5/8 – UNF female gas fitting.
ON/OFF Switch
6
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 primary potential with respect to earth.
20
Page 28
7
Input Cable
The input cable connects the Primary supply voltage to the equipment.
SMART Logic Switch
8
Manual slide switch mounted on the back panel selects for proper input voltage. If this slide is not set
to the position that matches the input voltage from the electrical source the Smart Logic circuit will
inhibit welding power source output. The digital meter will show primary input error code.
9
Gas Inlet
The Gas Inlet is a 5/8 – UNF female gas fitting.
4.02 Weld Process Selection for ArcMaster 400 TS
Weld Mode
Weld Process
Selection
SLOPE
REPEAT
PULSE
STD
SPOT
ON/OFF
STICK
Yes Yes Yes
HF
TIG
LIFT
TIG
Description
2T operation in TIG Modes using remote
devices to control contactor & current.
4T operation in TIG Modes with crater fill
No Yes Yes
using a remote contactor device to
control sequence.
4T operation in TIG Modes with repeat
No Yes Yes
No Yes No
operation and crater fill using a remote
contactor device.
2T operation spot welding in HF TIG using a
remote contactor device.
No Yes Yes Pulse operation in TIG Modes.
Contactor ON/OFF
Operation
PANEL/REMOTE
Yes No Yes
Yes Yes Yes Selects in operation Panel board or Remote.
Contactor operation in Stick and Lift
TIG Mode.
Table 3 – Weld Process Selection verses Weld Mode for ArcMaster 400 TS
21
Page 29
4.03 Weld Parameter Description
Figure 5. ArcMaster 400 TS Front Panel with Parameter Description
Parameter Description
This parameter operates in TIG modes only and is used to get gas to the weld zone
prior to striking the arc, once the torch trigger switch has been pressed. This
control is used to dramatically reduce weld porosity at the start of a weld.
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
PEAK CUR.
WELD
BASE
This parameter operates in all weld modes except Lift TIG mode and is used to
heat up the weld zone in TIG modes or improve the start characteristics for stick
electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of
the
PEAK (WELD)
e.g.
HOT START
HOT START
This parameter operates in
set the start current for TIG. The Start Current remains on until the torch trigger
switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to set the time for the weld
current to ramp up, after the torch trigger switch has been pressed then released,
from INITIAL CUR to PEAK or BASE current.
This parameter sets the PEAK weld current when in
This parameter sets the TIG WELD current in
modes when
This parameter sets the Background current when in Pulse TIG mode.
current.
current = 130 amps when
= 30 amps
SLOPE
or
PEAK (WELD)
REPEAT
= 100 amps &
(4T) TIG modes only and is used to
PULSE
mode.
STD, SLOPE, REPEAT
PULSE
is off. This parameter also sets the STICK weld current.
and
SPOT
22
Page 30
Parameter Description
(Background
Current)
SPOT TIME
PULSE WIDTH
PULSE FREQ.
DOWN SLOPE
CRATER CUR.
POST-FLOW
This parameter sets the duration of the
This parameter sets the percentage on time of the
weld current when the
This parameter sets the
This parameter operates in TIG modes only and is used to set the time for the weld
current to ramp down, after the torch trigger switch has been pressed, to
CUR.
This control is used to eliminate the crater that can form at the completion of
a weld.
This parameter operates in
set the finish current for TIG. The CRATER Current remains ON until the torch
trigger switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to adjust the post gas flow
time once the arc has extinguished. This control is used to dramatically reduce
oxidation of the tungsten electrode.
PULSE
is ON.
PULSE FREQUENCY
SLOPE
SPOT TIME
or
REPEAT
in
HF TIG
mode only.
PULSE FREQUENCY
when the
PULSE
is ON.
for PEAK
CRATER
(4T) TIG modes only and is used to
The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs
into the 400 TS memory.
Table 4 – Weld Parameter Descriptions for ArcMaster 400 TS
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4.04 Weld Parameters for ArcMaster 400 TS
Weld Mode
INITIAL CUR.
PULSE WIDTH
PULSE FREQ.
DOWN SLOPE
CRATER CUR.
POST-FLOW
Weld
Parameter
PRE-FLOW
HOT START
UP SLOPE
PEAK CUR.
WELD CUR
(TIG)
WELD CUR
(STICK)
SPOT TIME
Parameter Range
0.0 to 1.0 sec 0 sec 0.1 sec No Yes Yes
0 to 70A 20A 1A Yes Yes No
5 to 400A 30A 1A No Yes Yes
0 to 15 sec 1 sec 0.1 sec No Yes Yes
5 to 400A 120A 1A No Yes Yes
5 to 400A 80A
5 to 400A 80A
0.5 to 5.0 sec 2 sec 0.1 sec No Yes Yes
15 to 80% 50% 1% No Yes Yes
0.5 to 500Hz 100.0Hz
0 to 25 sec 3 sec 0.1 sec No Yes Yes
5 to 40A 30A 1A No Yes Yes
0.0 to 60 sec 10 sec 0.1 sec No Yes Yes
Table 5 – Weld Parameters for ArcMaster 400 TS
Factory
Setting
Incremental
Unit
1A
1A
See
Table 6
STICK
No
Yes
No Yes Yes
HF
TIG
Yes
No
LIFT TIG
Yes
No
PULSE FREQ.
0.5 to 20Hz 0.1Hz
20 to 100Hz 1Hz
100 to 500Hz 5Hz
Table 6 –
Range Incremental Unit
PULSE FREQ.
Range and Incremental Units
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4.05 Power Source Features
Feature Description
New Digital Control
Touch Panel Switches
Front Control Cover
Digital Meter
Intelligent Fan Control
ON/OFF Switch
Save/Load Function
• Almost all welding parameters are adjustable.
• Touch switches eliminate mechanical damage.
• Protects front panel controls.
• Displays selected weld parameter value.
• Displays weld current when welding.
• Displays 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, whilst providing optimum
cooling.
• Fan speed reduces approximately 30 seconds after
machine is turned on.
• Fan speed increases when internal components reaches
operating temperature.
• Primary voltage Supply ON/OFF switch located on
rear panel.
• A total number of 5 programs can be saved into the
400 TS memory.
SAVE
the Current Weld Parameters into Memory
• Press and HOLD the
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 from the control
panel are saved.
LOAD
(retrieve) a Program to Control Panel
• Press and HOLD the
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.
SAVE
button. Beep will sound and
LOAD
button. Beep will sound and
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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 counterclockwise decreases the
parameter.
• A selected weld parameter value can be adjusted at any
time even while welding.
• Pushing the knob in displays actual arc voltage.
• An error code is displayed on the
problem occurs with Primary supply voltage or internal
component problems. Refer to Troubleshooting Guide.
Digital Meter
when a
26
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5.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead
directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil
design ensure that the Welding Power Source will withstand short-term overload without adverse effects.
The welding current range values should be used as a guide only. Current delivered to the arc is dependent
on the welding arc voltage, and as welding arc voltage varies between different classes of electrodes,
welding current at any one setting would vary according to the type of electrode in use. The operator should
use the welding current range values as a guide, then finally adjust the current setting to suit the application.
WARNING 7
Before connecting the work clamp to the work and
inserting the electrode in the electrode holder make
sure the Primary power supply is switched off.
CAUTION 3
Remove any packaging material prior to use. Do not
block the air vents at the front or rear or sides of the
Welding Power Source.
CAUTION 4
DO NOT change the Weld Mode or Weld Process Mode
Until after POST-FLOW time has finished.
Figure 6. 400 TS Set-up
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6.0 SEQUENCE OF OPERATION
NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show
which function is being adjusted on the weld sequence graph. Refer to Symbols
Table located in the front of the manual for Symbol descriptions.
1
9
2
8
3
1. Pulse Function: Pressing this button enables the TIG current pulse functions.
2. Remote Current Function: Pressing this buttons enables remote current functions.
3. TIG Mode Functions: Pressing this button scrolls through the output TIG function modes (Standard,
Slope, Slope w/repeat, Spot).
4. Digital LED Display: Welding amperage 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.
5. Save/Load Buttons: By using the Save & Load buttons the operator can easily save up to 5 welding
parameter programs.
6. Control Knob: Allows the operator to adjust the output amperage within the entire range of the power
source and sets each parameter value.
7. Process Button: This button selects between STICK, HF TIG and Lift TIG mode.
8. Scroll Buttons: Used to select the parameters to be set. The LED’s show which function is being
adjusted on the Sequence Graph.
9. Contactor Function: Pressing this buttons enables Contactor functions.
4 6
Figure 7. 400 TS Front Panel
8
7
28
Page 36
6.01 Stick Welding
• Connect work lead to negative terminal
• Connect electrode lead to positive terminal
• Switch machine on
• Set Contactor
• Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the control knob to adjust each parameter.
• Set
• Set
Commence welding
HOT START
WELD
current
6.02 HF TIG & 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. A remote control device is required for use during LIFT TIG and
HF TIG operation. See section 4.01, section 2 “
the remote device.
Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the control knob to adjust each parameter.
• Set
• Set
• Set
• Set
• Set
Slope Mode Parameters if required
• Set
• Set
• Set (WELD)
• Set
• Set
• Set
Pulse Mode parameters if required
• Set
• Set
• Set
Commence welding
PRE-FLOW
HOT START
POST-FLOW
WELD
POST-FLOW
INTIAL CUR
UP SLOPE
time
current
time
current
time
current
time
PEAK CUR
BASE
current
DOWN SLOPE
CRATER CUR
time
current
PULSE WIDTH
PEAK CURRENT
PULSE FREQ
current
% for
PEAK CURRENT
Remote Control Socket
”, for complete details of
29
Page 37
d
6.02.01 Slope Mode Sequence
Switch
Closed
Preflow
Initial
Current
Up
Slope
Switch
Open
Weld Current
Down
Slope
Switch
Close
Current
Switch
Open
Final
Postflow
Note 6
Slope function operates with a Remote ON/OFF device only.
1) To start Slope sequence Close remote switch contacts. Once the welding arc is established the Power
Source will maintain initial current setting as long as the remote switch contacts are closed.
a) In the HF TIG mode, after Preflow time High Frequency is present at the torch. When the torch is
positioned close to the work the welding current will transfer to the work and establish the arc at the
initial current setting.
b) In the Lift TIG mode, after preflow time Lift Start current is present at the torch. When the electrode
is touched to the work and lifted off, the welding arc is established at the initial
current setting.
2) Open Remote Switch – current increases to weld current. Once welding arc has reached weld
current the power source will maintain weld current as long as the remote switch contacts are open.
3) Close Remote Switch – Welding current decreases to final current setting. Once final welding current
is reached the power source will maintain final current setting as long as the remote switch contacts
are closed.
4) Open Remote Switch – Welding arc stops and post flow begins.
6.02.02 Slope Mode with Repeat Sequence
The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the
down slope period only. During the down slope period by opening the Remote Switch contacts the current
will increase back to weld current. Within the Down Slope period the repeat function can be operated as
many times as desired. To continue slope cycle and end slope sequence close remote switch contacts and
allow weld current to reach final current setting. Once final current setting is reached opening the Remote
Switch again will turn off the welding arc and post flow begins.
30
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6.02.03 Pulse Controls
The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages
as follows:
1) Control puddle – size and fluidity (especially out of position).
2) Increase penetration
3) Travel speed control
4) Better consistent quality
5) Distortion on lighter or thinner materials.
Pulse-current provides a system in which the welding current continuously changes between two levels.
During the periods of Peak current, heating and fusion takes place, and during the background (base) current
periods, cooling and solidification take place. Pulse Width is the time in one cycle the current stays at the
peak current setting. Pulse Frequency measured in Hertz is the number of cycles per second the current
travels between peak and background current settings. It is as if the foot rheostat were moved up and down
to increase and decrease the welding current on a regular basis. The faster you moved the foot rheostat up
and down the faster the frequency.
(Pulse Width) (Pulse Frequency)
(Peak Current)
(Base)
Background
Current
31
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6.03 Save-Load Operation
A total number of 5 programs can be saved into the 400 TS memory.
SAVE
the Current Weld Parameters into Memory
• Press the
• Select a memory location by rotating the control knob, 1 to 5 is displayed on the meter
• After selecting the desired memory location (ie 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.
LOAD
(retrieve) a Program to Control Panel
• Press 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 give a beep to confirm the
weld parameters are loaded onto the control panel
SAVE
button until the buzzer rings.
LOAD
button until the buzzer rings.
32
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7.0 BASIC TIG WELDING GUIDE
7.01 Electrode Polarity
Connect the TIG torch to the - /
current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding.
It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece.
TORCH
terminal and the work lead to the
+ / WORK
terminal for direct
7.02 Tungsten Electrode Current Ranges
Electrode Diameter DC Current (Amps)
0.040” (1.0mm) 30 – 60
1/16” (1.6mm) 60 – 115
3/32” (2.4mm) 100 – 165
1/8” (3.2mm) 135 – 200
5/32” (4.0mm) 190 – 280
3/16” (4.8mm) 250 – 340
Table 7 – Current Ranges for Varies Fungsten Electrode Sizes
7.03 Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Ceriated 2%
DC welding of mild steel,
stainless steel and copper.
DC welding of mild steel,
stainless steel, copper,
aluminium, magnesium and
their alloys
Welding Application Features
Excellent arc starting, Long life,
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
Grey
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7.04 Guide for Selecting Filler Wire Diameter
Filler Wire Diameter
1/16” (1.6 mm) 20 - 90
3/32” (2.4 mm) 65 - 115
1/8” (3.2 mm) 100 - 165
3/16” (4.8 mm) 200-350
Table 9 – Filler Wire Selection Guide
DC Current Range
(Amps)
NOTE 7
The filler wire diameter specified in Table 9 is a guide only. Other diameter wires may be used
according to the welding application.
7.05 Shielding Gas Selection
Alloy
Shielding Gas
Aluminium & alloys Argon
Carbon Steel Argon
Stainless Steel Argon
Nickel Alloy Argon
Copper Argon
Titanium Argon
Table 10 – Shielding Gas Selection
7.06 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
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7.07 Welding Parameters for Steel
Base Metal
Thickness
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
3/16”
4.8mm
¼”
6.4mm
DC Current for
Mild Steel
35-45 20-30 Butt/Corner
40-50 25-35
45-55 30-45 Butt/Corner
50-60 35-50
60-70 40-60 Butt/Corner
70-90 50-70
80-100 65-85 Butt/Corner
90-115 90-110
115-135 100-125 Butt/Corner
140-165 125-150
160-175 135-160 Butt/Corner
170-200 160-180
DC Current for
Stainless
Steel
Tungsten
Electrode
Diameter
0.040”
1.0mm
0.040”
1.0mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
Filler Rod
Diameter
(if required)
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
5/32”
4.0mm
Argon Gas
Flow Rate
Liters/min
5-7
5-7
7
7
10
10
Joint Type
Lap/ Fillet
Lap/ Fillet
Lap/ Fillet
Lap/ Fillet
Lap/ Fillet
Lap/ Fillet
Table 12 – DC TIG Welding Parameters
35
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8.0 BASIC ARC WELDING GUIDE
8.01 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.
8.02 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.
36
Page 44
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 318L-16 High corrosion resistance. Ideal for dairy
work, etc. on stainless steels.
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
37
Page 45
9.0 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 5
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.
38
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10.0 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.
10.01 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
1 Excessive bead
build-up or poor
penetration or poor
fusion at edges of weld.
2 Weld bead too wide
and flat or undercut at
edges of weld or
excessive burn through.
3 Weld bead too small or
insufficient penetration
or ripples in bead are
widely spaced apart.
4 Weld bead too wide or
excessive bead build up
or excessive penetration
in butt joint.
5 Uneven leg length in
fillet joint.
6 Electrode melts when
arc is struck.
Welding current is too low. Increase weld current and/or
faulty joint preparation.
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.
Connect the electrode to the ‘−’
terminal.
7 Dirty weld pool. A Electrode contaminated through
contact with work piece or filler
rod material.
B Gas contaminated with air. B Check gas lines for cuts
39
A Clean the electrode by grinding
off the contaminates.
and loose fitting or change
gas cylinder.
Page 47
Description Possible Cause Remedy
8 Electrode melts or
oxidizes when an
arc is struck.
A No gas flowing to welding
region.
A Check the gas lines for
kinks or breaks and gas
cylinder contents.
B Torch is clogged with dust. B Clean torch.
C Gas hose is cut. C Replace gas hose.
D Gas passage contains
impurities.
D Disconnect gas hose from
torch then raise gas pressure
and blow out impurities.
E Gas regulator turned off. E Turn on.
F Torch valve is turned off. F Turn on.
G The electrode is too small for
the welding current.
G Increase electrode diameter or
reduce the welding current.
9 Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas
line for gas flow problems.
10 Arc flutters during TIG
welding.
A Tungsten electrode is too large
for the welding current.
A Select the right size electrode.
Refer to Basic TIG Welding
Guide.
B Absence of oxides in the
weld pool.
B Refer Basic TIG Welding Guide
for ways to reduce arc flutter.
11 Welding arc can not be
established.
A Work clamp is not connected
to the work piece or the
work/torch leads are not
connected to the right
A Connect the work clamp to the
work piece or connect the
work/torch leads to the right
welding terminals.
welding terminals.
B Torch lead is disconnected. B
C Gas flow incorrectly set,
cylinder empty or the torch
valve is off.
12 Arc start is not smooth. A Tungsten electrode is too large
for the welding current.
B The wrong electrode is being
used for the welding job.
Connect it to the ‘−‘ terminal.
C Select the right flow rate,
change cylinders or turn
torch valve on.
A Select the right size electrode.
Refer to Basic TIG Welding Guide.
B Select the right electrode type.
Refer to Basic TIG Welding Guide.
C Gas flow rate is too high. C Select the correct rate for the
welding job.
Refer to Basic TIG Welding Guide.
D Incorrect shielding gas is
being used.
D Select the right shielding gas.
Refer to Basic TIG Welding
Guide.
E Poor work clamp connection
to work piece.
E Improve connection to
work piece.
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Page 48
10.02 Stick Welding Problems
Description Possible Cause Remedy
1 Gas pockets or
voids in weld metal
(Porosity).
2
Crack occurring in
weld metal soon
after solidification
commences.
3
A gap is left by failure
of the weld metal to fill
the root of the weld.
D Incorrect sequence. D Use correct build-up sequence.
Portions of the weld
4
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.
A
Electrodes are damp.
B
Welding current is too high.
C
Surface impurities such as oil,
grease, paint, etc.
Rigidity of joint.
A
Insufficient throat thickness.
B
Cooling rate is too high.
C
A
Welding current is too low.
B
Electrode too large for joint.
C
Insufficient gap.
Figure 8. Example of Insufficient Gap or Incorrect Sequence
Small electrodes used on heavy
A
cold plate.
Welding current is too low.
B
too high.
A
Dry electrodes before use.
B
Reduce welding current.
C
Clean joint before welding.
Redesign to relieve weld joint of
A
severe stresses or use crack
resistance electrodes.
Travel slightly slower to allow
B
greater build up in throat.
Preheat plate and cool slowly.
C
A
Increase welding current
Use smaller diameter electrode.
B
C
Allow wider gap.
Use larger electrodes and
A
pre-heat the plate.
Increase welding current.
B
directed more into the base metal.
D Reduce travel speed of electrode.
Figure 9. Example of Lack of Fusion
41
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Non-metallic particles
5
are trapped in the
weld metal (slag
A Non-metallic particles may be
trapped in undercut from
previous run.
A If bad undercut is present, clean
slag out and cover with a run
from a smaller diameter electrode.
inclusion).
B Joint preparation too restricted. B Allow for adequate penetration
and room for cleaning out
the slag.
C Irregular deposits allow slag to
be trapped.
D Lack of penetration with slag
trapped beneath weld bead.
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 Rust or mill scale is preventing
E Clean joint before welding.
full fusion.
F Wrong electrode for position in
which welding is done.
F Use electrodes designed for
position in which welding is done,
otherwise proper control of slag
is difficult.
Figure 10. Examples of Slag Inclusion
42
Page 50
10.03 Power Source Problems
Description Possible Cause Remedy
1 The welding arc
cannot be
established.
A
The Primary supply voltage has
not been switched on.
B
The Welding Power Source
switch is switched off.
A
Switch on the Primary
supply voltage.
B
Switch on the Welding
Power Source.
C Loose connections internally. C Have an accredited Thermal Arc
Service Agent repair
the connection.
2 Maximum output
welding current
cannot be achieved
Defective control circuit. Have an accredited Thermal Arc
Service Agent repair the
connection.
with nominal Mains
supply voltage.
3 Welding current
reduces when
welding.
Loose welding cable
A
connections.
Incorrect welding cable size.
B
C
Improper input connections.
D
Poor electrode condition.
Wrong welding polarity.
E
A
Tighten all welding cable
connections.
B
Use proper size and type
of cable.
Refer to Section 3.03.01 -
C
Electrical Input Requirements.
D
Replace electrode.
E
Verify output torch connections.
A
4 No gas flow when
the torch trigger
Gas hose is cut.
B
Gas passage contains impurities.
switch is depressed.
C Gas regulator turned off.
D Torch trigger switch lead is
disconnected or switch/cable
is faulty.
ABReplace gas hose.
Disconnect gas hose from the rear
of Power Source then raise gas
pressure and blow out impurities.
C Turn gas regulator on.
D Reconnect lead or repair faulty
switch/cable.
43
Page 51
Description Possible Cause Remedy
5 Gas flow won’t
shut off.
B Gas valve is faulty. B Have an accredited Thermal Arc
C Gas valve jammed open. C Have an accredited Thermal Arc
D
6 The TIG electrode has
been contaminated
due to the gas flow
shutting off before
the programmed
POST-FLOW
has elapsed.
time
A Weld Mode (
REPEAT
before
had finished.
POST-FLOW
to 60 sec.
The Weld Process Mode
(STICK, HF TIG or LIFT TIG)
was changed before
POST-FLOW
had finished.
STD, SLOPE
or
SPOT
) was changed
POST-FLOW
control is set
gas time
gas time
,
A Strike an arc to complete
the weld cycle.
OR
Switch machine off then
on to reset solenoid
valve sequence.
Service Agent repair or replace
the gas valve.
Service Agent repair or replace
the gas valve.
D Reduce
Do not change Weld Process
Mode before the
gas time had finished.
POST-FLOW
POST-FLOW
time.
44
Page 52
11.0 VOLTAGE REDUCTION DEVICE (VRD)
11.01 VRD Specification
Description
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
VRD Turn OFF Time 0.2 to 0.3 seconds The time taken to turn OFF the welding power
ARC MASTER
400 TS
Notes
terminals to turn ON the welding power.
once the welding current has stopped.
11.02 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 in accordance with clause 4.1 of AS 1647.2
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 8
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 AS3195 & 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.
45
Page 53
11.03 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 6
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
46
Page 54
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 45.
To turn VRD OFF: rotate the trim potentiometer (VR1) on the display PCB fully counter-clockwise.
WARNING 9
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
47
Page 55
12.0 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.
4 E04 error code displayed
Output voltage exceeds the
secondary voltage specification.
A
The Welding Power Source’s
duty cycle has been exceeded.
B
Fan ceases to operate.
C
Air flow is restricted by vents
being blocked.
A
The Welding Power Source’s
duty cycle has been exceeded.
B
Fan ceases to operate.
C
Air flow is restricted by vents
being blocked.
A
Primary current is too high
because welding arc is too long.
B
Mains supply voltage is
more than 10% below
nominal voltage.
TIG torch cable and/or work
lead are too long or leads
are coiled.
A
Let Power Source cool down
then keep within its duty cycle.
B
Have an Accredited Thermal
Arc Service Agent investigate.
C
Unblock vents then let Power
Source cool down.
A
Let Power Source cool down
then keep within its duty cycle.
B
Have an Accredited Thermal
Arc Service Agent investigate.
C
Unblock vents then let Power
Source cool down.
A
Reduce length of welding arc.
B
Have an Accredited Thermal
Arc Service Agent or a
qualified electrician check for
low Mains voltage.
Reduce the length of the TIG
torch cable and/or work lead
or un-coiled leads.
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.
Weld current ceases.
Buzzer sounds constantly.
Switch machine OFF then ON
to reset E04 error.
5 E11 error code displayed
Over Primary supply (input) voltage
at primary capacitors is exceeded for
one second.
Primary supply voltage is
greater than the nominal
voltage plus 10%
Have an Accredited Thermal
Arc Service Agent or a
qualified electrician check
the Primary voltage.
48
Weld current ceases.
Buzzer sounds constantly.
Error code E11 automatically
will reset when the
voltage reduces.
Page 56
Description Possible Cause Remedy Remarks
6 E14 error code displayed
Under mains supply (input) voltage
warning primary capacitors is reduced
for one second.
7 E12 error code displayed
Under mains supply (input) voltage
primary capacitors is reduced for
one second.
8 E81 error code displayed
Wrong Primary supply (input)
voltage connected.
9 E82 error code displayed
Link switch plug not connected.
10 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 less
than the nominal operating
voltage less 10%.
Have an Accredited Thermal
Arc Service Agent or a
qualified electrician check
the Mains voltage.
Mains supply voltage is down
to a dangerously low level.
Have an Accredited Thermal
Arc Service Agent or a
qualified electrician check
the Mains voltage.
When 3 phase machine is
first turned ON with the
wrong Primary supply (input)
voltage connected.
Have an Accredited Thermal
Arc Service Agent or a
qualified electrician check
the Mains voltage.
Link switch plug not connected. Have an Accredited Thermal
Arc Service Agent check
connector plug on input PCB.
The Primary supply (input)
voltage fluctuates and is
not stable.
Have an Accredited Thermal
Arc Service Agent check
connector plug on input PCB
and the Mains voltage.
Weld current available.
Buzzer sounds intermittently.
Error code E14 automatically
will reset when the
voltage increases.
Weld current ceases.
Buzzer sounds constantly.
Error code E12 automatically
will reset when the
voltage reduces.
No weld current is available.
Buzzer sounds constantly.
Switch machine OFF.
No weld current is available.
Buzzer sounds constantly.
Switch machine OFF.
No weld current is available.
Buzzer sounds constantly.
Switch machine OFF then ON
to reset E83 error.
11 E93 error code displayed
Memory chip (EEPROM) on control PCB
can not read/write weld parameters.
Memory chip (EEPROM) error. Have an Accredited Thermal
Arc Service Agent check the
control PCB.
49
Weld current ceases.
Buzzer sounds constantly.
Switch machine OFF.
Page 57
Description Possible Cause Remedy Remarks
12 E94 error code displayed
Temperature sensor TH1 for IGBTs or
sensor TH2 for secondary diodes are
open circuit.
13 E99 error code displayed
Mains supply (input) voltage has been
turned OFF but control circuit has
power from the primary capacitors.
The Welding Power Source’s
temperature sensors have
malfunctioned.
A
Main ON/OFF switch on
machine has been turned OFF.
B
Mains supply (input) voltage
has been turned OFF.
Have an Accredited Thermal Arc
Service Agent check or replace
the temperature sensors.
A
Turn ON/OFF switch on.
B
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.
50
Page 58
APPENDIX A - INTERCONNECT DIAGRAM
1
2
CN3
P
P
R2
R2
N
N
Circuit Bord
[WK-5597 ]
1
2
3
CN2
4
5
CN1
2 3
1
1
2 3
CN7
CN1CN6CN5
CN30CN31
CN130CN131
1
2
CN20
3
Line1
Line2
Line3
Ground
+
E
Circuit Bord
[WK-4917 ]
SIDE CHASSIS 1
REAR
PANEL
N
P
R2
460V
1
2
3
4
CN1
5
6
S2
230V
FAN1
+-
1
SOL1
A : Contactor Control /+24VDC
B : Contactor Control /Contactor Clouser To"A"
C : 0 To +10Vdc Output To Remote Control
D : Remote Control Circ uit Comm on
E : 0 T o +10Vdc I nt put From Re mot e C o nt r ol
F : Not Used
G : Chassis Ground
H : Not Used
I : Not Used
J : Not Used
K : Not Used
L : Not Used
M : OK to Move (C ur re n t De t ec t Signal )
N : OK to Move ( C urr e nt Dete ct Sign a l )
2
3
CN11
4
L105
CON1
AJ
BKI
CLNH
DMG
FE
EC
PCB21
Filter
CN1
1
1
CN2
2
2 3
EB
S1
1
2 3 4 5
CN3
1
2
3
4
CN31 CN30
CN131 CN130
1
2
1
2
CN27
3
4
CN27
5
1
2
3
D1
K(7)
G(6)
R(3)
S(4)
T(5)
PCB4
Detect
Circuit Bord
CN4
[WK-4819 ]
CN5 CN6 CN4
CN32
CN32
PCB5
Conect Circuit Bord
[WK-5551 ]
CN132
CN132
CN17
CN17
TB0
CN14CN13
PCB7
Filter
Circuit Bord
CN15
[WK- 5550 ]
+
(1)
(0)
-
(2)
CN18
CN18
TB1
TB2
TB3
PCB2
Link
TB4
PCB3
Control Souce
Circuit Bord
[WK- 5548 ]
CN18
1 2 3
CN7
1
2
3
4
CN20
1 2
1 2 3
CN33
TB1 3
UB3
TB1 4
TB1 5
PCB1
Main
Circuit Bord
[WK-5493 ]
TB1
G1
E1
G2
E2
TB2
TB3
TB1 8
TB1 9
TB2 0
TB4
G3
E3
G4
E4
CT1
CT2
CT3
CT4
E1
G1
2 3 4 5 6
1
CN20
C
CE
E
PCB8
IGBT Gate
Circuit Bord
[WK-5479 ]
1
2
CN1
3
1
2
3
CN2
4
C
CE
E
PCB9
IGBT Gate
Circuit Bord
[WK-5479 ]
1
2
CN1
3
1
2
3
CN2
4
E5
G5
CN9
1 2 3
TH2 TH1
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
E2
G2
2 3 4 5 6 7
1
CN21
PCB6
Control
Circuit Bord
[WK-5549]
CN8
1 2
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q9
Q10
Q11
Q12
Q13
C
C
TB1 0
CE
TB1 1
TB1 2
Circuit Bord
1
G4
2
E4
3
1
G3
2
E3
3
4
TB5
UB1
TB6
TB7
Circuit Bord
1
G7
2
E7
3
1
G8
2
E8
3
4
E6
E7
G6
G7
2 3 4 5 6
1
CN22
CN19
1 2 3
PGND
P+21V
E
PCB10
IGBT Gate
[WK- 5479 ]
CN1
CN2
C
CE
E
PCB11
IGBT Gate
[WK- 5479 ]
CN1
CN2
E3
G3
G
E
Q14
C
G
E
Q15
C
G
E
Q16
C
G
E
Q17
C
G
E
Q18
C
G
E
Q19
C
G
E
Q20
C
G
E
Q21
C
G
E
Q22
C
G
E
Q23
C
G
E
Q24
C
G
E
E8
G8
2 3 4 5 6 7
1
CN23
CN17
CN17
CN21
CN21
CN1
CN1
E4
G4
1
1
2
2
3
3
4
4
5
5
6
6
7
7
1
1
2
2
3
3
4
4
1
1
2
2
3
3
4
4
51
Page 59
PCB15
DIODE S n ubber
Circuit Bord
UB2
TB7
TB2 1
TB8
CT1
PCB14
TRANS Bord
[WK-5594]
CT2
CT2
TB3 5
TB3 3
TB3 4
AC2 AC1
[WK- 5606 ]
D5
D7
1
+15
2
HCT1
-15
IS
GND
SH.DET+
4
3
TO1
+Output
Terminal
UB4
TB1 7
1
2 3 4 5
CN8
TB1 6
TB1 6
TB2 2
TB2 2
CT3
CT4
CT3
EB
L1
AC4
AC3
1
2 3 4 5 6 789
CN9
TB3 0
TB3 2
TB3 1
AC2
/RY_ON
D2
1
2 3 4 5
CN1
PCB20
Filter Circuit Bord
CN3
[WK- 5499 ]
CC1
FCH1
RY+15V
/RY_ON
1
2
3
D4
AC4
CC2
CC1
SH.DET-
R1
HF.UNIT1
R2
AC1 AC3
Gro und
+
SIDE CHASSIS 3
TO2
R2
-Output
Terminal
R6
AC3
AC1
SH.DET-
SH.DET+
FRONT
PANEL
EB
Ground
+
RY+15V
+15
-15
GND
PCB12
Panel
Circuit Board
[WK-5 527 ]
1
2
3
4
CN2
5
6
CN1
IS
1 2 3 4
PCB13
Encorder Board
[WK- 5528 ]
CN1
1 2 3 4
SIDE CHASSIS 2
R2
UB2UB1
R3
UB4UB3
52
Page 60
APPENDIX B – ARCMASTER 400 TS ACCESSORIES
ACCESSORIES PART NO. DESCRIPTION
Stick Kit 10-4082A Work clamp with 25’ cable, and stick electrode with 25’ #1 cable
TIG Kit 10-4081 Includes regulator/flowgauge, 12.5ft 200 Amp TIG torch, 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
53
Page 61
Page 62
LIMITED WARRANTY
y
r
t
f
f
r
y
y
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 contract, 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 o f any Thermal Arc product. Purchaser’s rights under this warrant
are void if the product is sold to p urchaser 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
st
2006
Trademark of Thermal Arc, Inc.
Page 63
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer............................................................. See the Engine’s Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors...................................................................1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300A C/ DC, 400GT S W, 400MST,
300MST, 400MSTP
Original Main Power Magnetics....................................................................................................5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors...................................................................1 year
PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years
Welding Console, Weld Controller, Weld Timer........................................................................... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator................................1 year
SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Dragster 85
Original Main Power Magnetics.....................................................................................................1 year 1 year
Original Main Power Rectifiers, Control P.C. Boards ....................................................................1 year 1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year
160S, 300S, 400S
Original Main Power Magnetics....................................................................................................5 years 3 years
Original Main Po w e r Rect ifiers, Control P.C . 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
1 year
1 year
1 year
1 year
1 year
Page 64
Page 65
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
Page 66
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: sales@thermalarc.com
www.thermalarc.com
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