Tweco 401MST User Manual

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ARCMASTER 401MST

Operating Manual

3163339

Art # A-12449_AB

Revision: AB Issue Date: June 17, 2014 Manual No.: 0-5287

Tweco.com

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WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Tweco product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.

For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time.

We strive to enhance your productivity, efﬁciency and welding performance enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions.

If you have any questions or concerns regarding your new Tweco product, please contact our friendly and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.Tweco.com

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WARNINGS

Read and understand this entire Manual and your employer’s safety practices if applicable before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use.

Operating Manual Number 0-5287 for: Tweco ArcMaster 401MST Power Source Part Number W1009500

Published by: Victor Technologies, Inc. 16052 Swingley Ridge Road, Suite 300 St. Louis, MO 63017 USA

www.victortechnologies.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: May 15, 2014 Revision Date: June 17, 2014

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

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TABLE OF CONTENTS

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 General Safety Information for Victor Regulator ............................................... 1-5

1.03 Principal Safety Standards .............................................................................. 1-7

1.04 Symbol Chart .................................................................................................. 1-8

1.05 Precautions De Securite En Soudage A L’arc .................................................. 1-9

1.06 Dangers relatifs au soudage à l’arc ................................................................. 1-9

1.07 Informations Générales de Sécurité .............................................................. 1-14

1.08 Principales Normes De Securite ................................................................... 1-16

1.09 Graphique de Symbole .................................................................................. 1-17

SECTION 2: INTRODUCTION ............................................................................. 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identiﬁcation ................................................................................. 2-1

2.03 Receipt of Equipment ...................................................................................... 2-1

2.04 Description ..................................................................................................... 2-2

2.05 User Responsibility ......................................................................................... 2-2

2.06 Transporting Methods ..................................................................................... 2-2

2.07 Packaged Items .............................................................................................. 2-2

2.08 Duty Cycle ....................................................................................................... 2-3

2.09 Speciﬁcations ................................................................................................. 2-4

SECTION 3: INSTALLATION, OPERATION AND SETUP ................................................ 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Ventilation ....................................................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-1

3.05 High Frequency Introduction .......................................................................... 3-3

3.06 High Frequency Interference ........................................................................... 3-4

3.07 Electromagnetic Compatibility ........................................................................ 3-4

3.08 ArcMaster 401MST Power Source Controls, Indicators and Features ............. 3-6

3.09 Welding Parameters ...................................................................................... 3-11

3.10 Setup for LIFT TIG (GTAW) Welding ............................................................. 3-14

3.11 Setup for STICK (SMAW) Welding ................................................................ 3-16

3.12 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 3-18

3.13 Setup for FCAW Flux Core Arc Welding ......................................................... 3-20

3.14 Special Function ........................................................................................... 3-22

3.15 Shielding Gas Flowmeter/ Regulator Operating Instructions ......................... 3-23

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TABLE OF CONTENTS

SECTION 4: BASIC WELDING GUIDE .................................................................... 4-1

4.01 Stick (SMAW) Basic Welding Technique ......................................................... 4-1

4.02 Stick (SMAW) Welding Troubleshooting ....................................................... 4-10

4.03 TIG (GTAW) Basic Welding Technique .......................................................... 4-12

4.04 TIG (GTAW) Welding Problems ..................................................................... 4-14

SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS ............ 5-1

5.01 Maintenance and Repair ................................................................................. 5-1

5.02 Power Source Status Messages ...................................................................... 5-2

5.03 Error Messages ............................................................................................... 5-2

5.04 Routine Inspection, Testing & Maintenance .................................................... 5-4

5.05 Cleaning the Welding Power Source ............................................................... 5-4

SECTION 6: KEY SPARE PARTS .......................................................................... 6-1

6.01 401MST Power Source Spare Parts ................................................................ 6-1

APPENDIX A: CIRCUIT DIAGRAM ........................................................................ A-1

Tweco - LIMITED WARRANTY TERMS

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ARCMASTER 401MST POWER SOURCE

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS

WARNING

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

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

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. 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: SAFETY IN WELDING AND CUTTING. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK

PERFORMED ONLY BY QUALIFIED PEOPLE.

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 semi-automatic 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.

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.

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

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

9. Do not wrap cables around your body.

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

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. In conﬁned spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above ﬂoor level.

15. Keep all panels and covers securely in place.

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ARCMASTER 401MST POWER SOURCE

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.

AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida

Guide for Shade Numbers

Process

Shielded Metal Arc Welding (SMAW)

Electrode Size in.

(mm)

Less than 3/32 (2.4)

3/32-5/32 (2.4-4.0)

5/32-1/4 (4.0-6.4)

More than 1/4 (6.4)

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

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.

Arc Current

(Amperes)

Less than 60

60-160 160-250 250-550

Minimum

Protective

Shade

8 10 11

Suggested*

Shade No.

(Comfort)

10 12 14

Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW)

Gas Tungsten arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Plasma Arc Welding (PAW)

Plasma Arc Cutting (PAC)

* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufﬁcient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the ﬂux produces a high yellow light, it is desirable to use a ﬁlter lens that absorbs the yellow or sodium line of the visible light spectrum.

(Light)

(Heavy)

Less than 60

60-160 160-250 250-550

Less than 50

50-150 150-500

Less than

500

500-1000

Less than 20

20-100 100-400 400-800

Less than 20

20-40 40-60 60-80

80-300 300-400 400-800

7 10 10 10

8 10

10 11

8 10 11

9 10

11 12 14

10 12 14

12 14

6 to 8

10 12 14

4 5 6 8

9 12 14

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ARCMASTER 401MST POWER SOURCE

1. Keep your head out of the fumes. Do not breathe 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 airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

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

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

2. Wear proper body protection to protect skin.

WARNING

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.

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.

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.

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ARCMASTER 401MST POWER SOURCE

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

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

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

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

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

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.

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.

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

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

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

WARNING

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

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.

2. Stop engine before installing or connecting unit.

SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5287

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ARCMASTER 401MST POWER SOURCE

1.02 General Safety Information for

WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm.

after handling.

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

WARNING

Wash hands

A Fire Prevention

Welding and cutting operations use ﬁre or combustion as a basic tool. The process is very useful when properly controlled. However, it can be extremely destructive if not performed cor rectly in the proper environment.

Victor Regulator

1. The work area must have a ﬁreproof ﬂoor.

2. Work benches or tables used during welding or cutting operations must have ﬁreproof tops.

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, OTABP-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.

3. Use heat resistant shields or other approved material to protect nearby walls or unprotected ﬂooring from sparks and hot metal.

4. Keep an approved ﬁre extinguisher of the proper size and type in the work area. Inspect it regularly to ensure that it is in proper working order. Know how to use the ﬁre extin guisher.

5. Move combustible materials away from the work site. If you can not move them, protect them with ﬁreproof covers.

WARNING

NEVER perform welding, heating, or cutting operations on a container that has held toxic, combustible or ﬂammable liq uids, or vapors. NEVER perform welding, heating, or cutting operations in an area containing combustible vapors, ﬂam mable liquids, or explosive dust.

B Housekeeping

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.

Manual 0-5287 1-5 SAFETY INSTRUCTIONS AND WARNINGS

NEVER allow oxygen to contact grease, oil, or

other ﬂam mable substances. Although oxygen by itself will not burn, these substances become highly explosive. They can ignite and burn violently in the presence of oxygen.

Keep ALL apparatus clean and free of grease, oil and other ﬂammable substances.

WARNING

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ARCMASTER 401MST POWER SOURCE

C Ventilation

WARNING

Ade quately ventilate welding, heating, and cutting work areas to prevent accumulation of explosive or toxic concen trations of gases. Certain combinations of metals, coatings, and gases generate toxic fumes. Use respiratory protection equipment in these circumstances. When welding/brazing, read and understand the Material Safety Data Sheet for the welding/brazing alloy.

D Personal Protection

Gas ﬂames produce infrared radiation which may have a harm ful effect on the skin and especially on the eyes. Select goggles or a mask with tempered lenses, shaded 4 or darker, to protect your eyes from injury and provide good visibility of the work.

Always wear protective gloves and ﬂame-resistant clothing to protect skin and clothing from sparks and slag. Keep collars, sleeves, and pockets buttoned. DO NOT roll up sleeves or cuff pants.

When working in a non-welding or cutting environment, always wear suitable eye protection or face shield.

WARNING

Practice the following safety and operation precautions EVERY TIME you use pressure regulation equipment. Deviation from the following safety and operation instructions can result in fire, explosion, damage to equipment, or injury to the operator.

E Compressed Gas Cylinders

The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases used for welding or cutting operations.

1. Place the cylinder (Figure 1-1) where you will use it. Keep the cylinder in a vertical position. Secure it to a cart, wall, work bench, post, etc.

Figure 1-1: Gas Cylinders

WARNING

Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or mis use of compressed gas cylinders DO NOT drop the cylinder, knock it over, or expose it to excessive heat, ﬂames or sparks. DO NOT strike it against other cylinders. Contact your gas supplier or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.

NOTE

CGA P-1 publication is available by writing the Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly,VA 201512923

2. Place the valve protection cap on the cylinder whenever mov ing it, placing it in storage, or not using it. Never drag or roll cylinders in any way. Use a suitable hand truck to move cylin ders.

3. Store empty cylinders away from full cylinders. Mark them “EMPTY” and close the cylinder valve.

SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5287

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ARCMASTER 401MST POWER SOURCE

4. NEVER use compressed gas cylinders without a pressure reducing regulator attached to the cylinder valve.

5. Inspect the cylinder valve for oil, grease, and damaged parts.

WARNING

DO NOT use the cylinder if you ﬁnd oil, grease or damaged parts. Inform your gas supplier of this condition immediately.

6. Momentarily open and close (called “cracking”) the cylinder valve to dislodge any dust or dirt that may be present in the valve.

CAUTION

Open the cylinder valve slightly. If you open the valve too much, the cylinder could tip over. When cracking the cylinder valve, DO NOT stand directly in front of the cylinder valve. Always perform cracking in a well ventilated area. If an acetylene cylinder sprays a mist when cracked, let it stand for 15 minutes. Then, try to crack the cylinder valve again. If this problem persists, contact your gas supplier.

1.03 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

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

Manual 0-5287 1-7 SAFETY INSTRUCTIONS AND WARNINGS

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ARCMASTER 401MST POWER SOURCE

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Dangerous Voltage

Off

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle RatingAuxiliary Power

Art # A-04130_AB

115V 15A

IPM

MPM

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld Mode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

4 Step Trigger Operation

2 Step Trigger Operation

See Note

Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides. Cannot be disposed with household garbage.

1.04 Symbol Chart

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

SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5287

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ARCMASTER 401MST POWER SOURCE

1.05 Precautions De Securite En Soudage A 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.

1.06 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.

3 Isolez-vous de la pièce à souder et de la mise à la

terre au moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation aﬁn d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

Manual 0-5287 1-9 SAFETY INSTRUCTIONS AND WARNINGS

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ARCMASTER 401MST POWER SOURCE

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.

AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida

Guide for Shade Numbers

Process

Shielded Metal Arc Welding (SMAW)

Electrode Size in.

(mm)

Less than 3/32 (2.4)

3/32-5/32 (2.4-4.0)

5/32-1/4 (4.0-6.4)

More than 1/4 (6.4)

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.

Arc Current

(Amperes)

Less than 60

60-160 160-250 250-550

Minimum

Protective

Shade

8 10 11

Suggested*

Shade No.

(Comfort)

10 12 14

Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW)

Gas Tungsten arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Plasma Arc Welding (PAW)

Plasma Arc Cutting (PAC)

(Light)

(Heavy)

Less than 60

60-160 160-250 250-550

Less than 50

50-150 150-500

Less than

500

500-1000

Less than 20

20-100 100-400 400-800

Less than 20

20-40 40-60 60-80

80-300 300-400 400-800

7 10 10 10

8 10

10 11

8 10 11

9 10

11 12 14

10 12 14

12 14

6 to 8

10 12 14

4 5 6 8

9 12 14

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ARCMASTER 401MST POWER SOURCE

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.

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.

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.

AVERTISSEMENT

Manual 0-5287 1-11 SAFETY INSTRUCTIONS AND WARNINGS

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ARCMASTER 401MST POWER SOURCE

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

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.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

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

2. Portez des vêtements appropriés pour protéger la peau.

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.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

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

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.

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.

SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5287

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ARCMASTER 401MST POWER SOURCE

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualiﬁées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

AVERTISSEMENT: Ce produitcontient des produits chimiques, notamment du plomb, reconnu par l’Étatde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système reproductif.

Se laver les mains après manipulation.

AVERTISSEMENT

REMARQUE

Facteurs relatifs au soudage et aux effets des champs magnétiques et électriques de basse fréquence

AVERTISSEMENT

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

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

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

Manual 0-5287 1-13 SAFETY INSTRUCTIONS AND WARNINGS

Voici une citation tirée du chapitre des conclusions générales du document de base de l’Ofﬁce of Technology Assessment (bureau des évaluations technologiques) del’U.S. Congress, « Biological Effects of Power Frequency Electric & Magnetic Fields », OTA-BP-E-63 (Washington, DC : U.S. Government Printing Ofﬁce, mai 1989) : « ... il existe de nos jours, un nombre très élevé de travaux scientiﬁques qui rapportent les résultats d’expériences menées au niveau cellulaire et d’études auprès d’homme et d’animaux qui établissent nettement le rapport entre les champs magnétiques de basse fréquence et les systèmes biologiques, soit par des interactions ou des modiﬁcations. Quoique la plupart de ces travaux soient de très bonne qualité, les résultats sont complexes. Àla lumière des connaissances scientiﬁques actuelles, il nous est encore impossible d’interpréter les évidences en un seul cadre de référence cohérent. La situation est toutefois très contrariante. En effet, il nous est aussi impossible de tirer des conclusions déﬁnitives quant aux risques éventuels ou de proposer des stratégies fondées sur

Page 20

ARCMASTER 401MST POWER SOURCE

des faits scientiﬁques visant à atténuer ou éviter des risques potentiels ».

Pour atténuer les champs magnétiques sur les lieux detravail, respectez les procédures qui suivent :

1. Maintenez les câbles l’un près de l’autre en les entrelaçant ou les reliant ensemble au ruban.

2. Acheminez les câbles à un côté du soudeur, le plus loin possible.

3. N’enroulez pas de câble autour du corps.

4. Maintenez le bloc d’alimentation du poste desoudage et les câbles aussi loin que possible du corps.

AVERTISSEMENT

N’effectuez JAMAIS d’opérations de soudage sur un récipient qui a contenu des liquides ou vapeurs toxiques, combustibles ou inﬂammables. N’effectuez JAMAIS d’opérations de soudage dans une zone contenant des vapeurs combustibles, des liquides inﬂammables ou des poussières explosives.

B Entretien des Locaux

AVERTISSEMENT

STIMULATEURS CARDIAQUES :

Les procédures décrites ci-dessus sont habituellement celles recommandées pour les porteurs de stimulateurs cardiaques. Pour de plus amples renseignements, consulter unmédecin.

1.07 Informations Générales de Sécurité

A Prévention D’incendie Les opérations de soudage utilisent le feu ou la combustion

comme outil de base. Ce processus est très utile quand il est cor rectement contrôlé.

1. La zone doit comporter un sol ignifugé.

2. Les établis ou tables utilisés pendant les opérations de soudage doivent avoir un revêtement ignifuge.

3. Utilisez des écrans résistants à la chaleur ou en matériau approuvé pour protéger les cloisons proches ou le sol vul nérable des étincelles et du métal chaud.

4. Gardez un extincteur approuvé du bon type et de la bonne taille dans la zone de travail. Inspectez-le régulièrement pour vous assurer qu’il est en état de fonctionner. Apprenez à vous en servir.

5. Enlevez tous les matériaux combustibles de la zone de travail. Si vous ne pouvez pas les enlever, protégez-les avec une cou vre ignifuge.

Ne laissez jamais l’oxygène en contact avec la graisse, l’huile ou d’autres substances inﬂammables. Bien que l’oxygène elle même ne brûle pas, ces substances peuvent devenir extrême ment explosives. Elles peuvent prendre feu et brûler violem ment en présence d’oxygène.

Gardez TOUS les appareils propres et exempts de graisse, huile ou autres substances inﬂammables.

C Aération

AVERTISSEMENT

Ventilez les zones de soudage, chauffage et découpage de façon adéquate pour éviter l’accumulation de gaz explosifs ou toxiques. Certaines combinaisons de métaux, revêtements et gaz génèrent des fumées toxiques: Utilisez un équipement de protection respiratoire dans ces circonstances. Si vous soudez ou brasez, lisez et assimilez la ﬁche technique de sécurité de matériau relative à l’alliage de soudage/brasage.

D Protection Personnelle Les ﬂammes de gaz produisent une radiation infrarouge

qui peut avoir un effet néfaste sur la peau, et particulièrement sur les yeux. Choisissez des lunettes ou un masque avec des verres trempés assombris au niveau 4 ou plus sombre, pour protéger vos yeux des dommages et garder une bonne visibilité sur le travail.

Portez en permanence des gants de protection et des vête ments ignifuges pour la protection de la peau et des vêtements contre les étincelles et le laitier. Gardez col,

SAFETY INSTRUCTIONS AND WARNINGS 1-14 Manual 0-5287

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manches et poches boutonnés. Il ne faut pas remonter vos manches ou les pantalons à revers.

Quand vous travaillez dans un environnement non dédié au soudage ou découpage, portez toujours une protection des yeux appropriées ou un masque facial.

AVERTISSEMENT

Mettez en pratique les procédures de sécurité et de mode opératoire suivantes à chaque fois que vous utilisez cet appareil de régulation de pression. Si vous déviez de ces procédures, cela peut entraîner incendie, explosion, dégâts matériels et/ou blessures corporelles pour l’opérateur.

E Bouteilles de Gaz Comprimé Le Département des Transports américain (DOT) ap-

prouve la conception et la fabrication des bouteilles qui contiennent les gaz utilisés pour les opérations de soudage ou de découpage.

AVIS

Ce document CGA p. t peut être obtenu en écrivant à “Compressed Gas Association”, 4221 Walney Roed, 5th Floor. Chantilly, VA

20151.2923, USA.

2. Placez le bouchon de protection de vanne sur la bouteille à chaque fois que vous la déplacez ou ne l’utilisez pas. Ne faites jamais glisser ou rouler d’aucune manière les bouteilles. Utilisez un diable approprié pour les déplacer.

3. Entreposez les bouteilles vides à l’écart des bouteilles pleines. Marquez-les “VIDE” et refermez leur vanne.

4. N’utilisez JAMAIS des bouteilles de gaz comprimé sans un régulateur de pression en série sur la vanne de bouteille.

5. Inspectez la vanne de bouteille pour y détecter de l’huile ou de la graisse, ou dès pièces endommagées.

1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la en position verticale. Fixez-la sur un chariot une cloison, un établi, etc.

Le schéma 1-1: Cylindres de gaz

AVERTISSEMENT

Les bouteilles sont sous haute pression. Manipulez-les avec précautions. Des accidents sérieux peuvent résulter d’une mauvaise manutention ou d’un mauvais emploi des bouteilles de gaz comprimé. NE faites PAS tomber la bouteille, ne la cognez pas, ne l’exposez pas à une chaleur excessive, aux ﬂammes ou étincelles. NE la cognez PAS contre d’autres bouteilles. Contactez votre fournisseur de gaz ou reportez vous à la publication CGA P-1 “Manipulation sécurisée des gaz comprimés en conteneur” pour plus d’informations sur l’utilisation et la manutention des bouteilles.

AVERTISSEMENT

N’UTILISEZ PAS la bouteille si vous trouvez de l’huile, de la graisse ou des pièces endommagées. Informez immédiate ment votre fournisseur de’ gaz de cet état.

6. Ouvrez et fermez momentanément la vanne de la bouteille, délogeant ainsi d’éventu lIes poussières ou saletés. qui pour raient être présentes dans la vanne.

Mise en Garde

Ouvrez la vanne de bouteille légèrement. Si vous l’ouvrez trop en grand, la bouteille pourrait se renverser. Quand vous ouvrez/ fermez rapidement la vanne de bouteille, ne vous tenez pas directement devant. Opérez toujours cette opération dans une zone bien ventilée. Si une bouteille d’acétylène crache un brouillard, laissez reposer pendant 15 minutes. Essayez de nouveau la vanne. Si le problème persiste, con tactez votre fournisseur de gaz.

Manual 0-5287 1-15 SAFETY INSTRUCTIONS AND WARNINGS

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1.08 Principales Normes De Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33128. Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Ofﬁce,

Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous

Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128. National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA

02269. Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson

Davis Highway, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards

Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National

Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy,

MA 02269.

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Soudage á L’arc Avec Electrode Non Fusible (GTAW)

Decoupe Arc Carbone (CAC-A)

Courant Constant

Tension Constante Ou Potentiel Constant

Haute Température

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Tension dangereuse

Hors Tension

SousTension

Panneau/Local

Soudage Arc Electrique Avec Electrode Enrobé (SMAW)

Soudage á L’arc Avec Fil Electrodes Fusible (GMAW)

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Distant

Facteur de Marche

Pourcentage

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de PriseSource Auxiliaire

Art # A-07639_AB

115V 15A

IPM

MPM

Fusible

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Durée de Pré-Dèbit

Durée de Post-Dèbit

Duréc du Pulse

Soudure Par Point

Appuyez pour dèruarer l’alimentation du fils et la soudure, le relâcher pour arrêter.

Purge Du Gaz

Mode Continu de Soudure

Pouces Par Minute

Mètres Par Minute

Torch de

Soudage

Probléme de Terre

Maintenez appuyez pour pré-dèbit, relailez pour initier l'arc. Appuyez pour arrêter l'arc, et mainteuir pour pré-dèbit.

Détente à 4-Temps

Détente à 2-Temps

Voir Note

Note: Pour les environnements avec des risques de choc électrique, le fournisseur d'énergie portant la marque conforme

à EN50192 lorsqu'utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à l'hauteur de buse correctement installé. Ne pas déposer avec les déchets ménagers.

1.09 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Manual 0-5287 1-17 SAFETY INSTRUCTIONS AND WARNINGS

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SAFETY INSTRUCTIONS AND WARNINGS 1-18 Manual 0-5287

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ARCMASTER 401MST POWER SOURCE

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

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

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

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

You will also notice icons from the safety section appearing throughout the manual. These are to advise you of speciﬁc types of hazards or cautions related to the portion of information that follows. Some may have multiple hazards that apply and would look something like this:

2.02 Equipment Identiﬁcation

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

2.03 Receipt of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to ﬁle a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identiﬁcation numbers as described above along with a full description of the parts in error.

Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

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ARCMASTER 401MST POWER SOURCE

2.04 Description

The Tweco ArcMaster 401MST is a welding power source incorporating to provide Lift TIG, MIG & FCAW, Stick, and Gouging welding process.

The units are also fully compliant to CSA E 60974-1 and UL 60974-1.

The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efﬁciency and quality from the Power Source. Please read these instructions thoroughly before using the unit.

2.05 User Responsibility

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualiﬁed persons approved by Tweco. Advice in this regard can be obtained by contacting an Accredited Tweco Distributor.

2.06 Transporting Methods

Disconnect input power conductors from de-energized supply line before moving the welding Power Source.

Lift Power Source with handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, secure the Power Source on a proper skid before transporting.

2.07 Packaged Items

ArcMaster 401MST Inverter Power Source (Part No. W1009500)

• ArcMaster401MSTInverterPowerSourcew/10

ft input power cable

• 50mm male Dinse connector × 2

• OperatingManual,English

• CD-OperatingManual(Eng/Fr/Sp)

This equipment or any of its parts should not be altered from standard speciﬁcation without prior written approval of Tweco. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modiﬁcation from standard speciﬁcation, faulty maintenance, damage or improper repair by anyone other than appropriately qualiﬁed persons approved by Tweco.

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100

2.08 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 40% duty cycle, 170 amperes at 26.8 volts. This means that it has been designed and built to provide the rated amperage (170A) for 4 minutes, i.e. arc welding time, out of every 10 minute period (40% of 10 minutes is 4 minutes). During the other 6 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.

SAFE OPERATING REGION

Duty Cycle (PERCENTAGE)

3 phase

1 phase

0255075 100 125150 175 200 225 250 275 300 325350 375400 425 450 475 500

Art # A-12450

Welding Current (AMPS)

Figure 2-1: Duty Cycle

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ARCMASTER 401MST POWER SOURCE

2.09 Speciﬁcations

Description ArcMaster 401MST

Power Source Part Number W1009500 Power Source Mass 55lb (25kg) Power Source Dimensions 16.5"(H) x 8.3"(W) x 17.7(D)

H420mm x W210mm x D450mm Cooling Fan Cooled Welder Type Inverter Power Source Output Terminal Type DinseTM 50 Standards CSA E 60974-1

UL 60974-1 Number of Phases 1/3 phase Nominal Supply Voltage 208-230/460VAC (1 phase)

+/-15% Nominal Supply Frequency 50/60Hz Welding Current Range 10 - 300A (1 phase) 10 - 400A, (3 phase) Effective Input Current (I1eff) (note2) 40A (208V, 1 phase)

38.1A (230V, 1 phase) 20A (460V, 1 phase)

Maximum Input Current (I1max) 84.7A (208V, 1 phase)

76.2A (230V, 1 phase)

40.1A (460V, 1 phase)

Generator Requirement (note4) 14.40kW STICK (SMAW) Welding Output, 40ºC, 10 min.

Lift TIG (GTAW) Welding Output, 40ºC, 10 min.

MIG & FCAW (GMAW FCAW) Welding Output, 40ºC, 10 min.

Open Circuit Voltage 80V DC Protection Class IP23S

300A @ 22%, 32V (1 phase)

230A @ 60%, 29.2V (1 phase)

180A @ 100%, 27.2V (1 phase)

300A @ 25%, 22V (1 phase)

230A @ 60%, 19.2V (1 phase)

180A @ 100%, 17.2V (1 phase)

300A @ 25%, 29V (1 phase)

230A @ 60%, 25.5V (1 phase)

180A @ 100%, 23V (1 phase)

208-230/460VAC (3 phase)

+/-15%

26.6A (208V, 3 phase)

24.6A (230V, 3 phase)

14.3A (460V, 3 phase)

53.2A (208V, 3 phase)

49.1A (230V, 3 phase)

28.6A (460V, 3 phase)

400A @ 25%, 36V (3 phase) 300A @ 60%, 32V (3 phase)

220A @ 100%, 28.8V (3 phase)

400A @ 25%, 26V (3 phase) 300A @ 60%, 22V (3 phase)

220A @ 100%, 18.8V (3 phase)

400A @ 25%, 34V (3 phase) 300A @ 60%, 29V (3 phase)

220A @ 100%, 25V (3 phase)

Table 2-1: Speciﬁcation

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ARCMASTER 401MST POWER SOURCE

NOTE

Note 1: 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.

Note 2: The Effective Input Current should be used for the determination of cable size & supply requirements.

Note 3: Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation in this regard.

Note 4: Generator Requirements at the Maximum Output Duty Cycle. Due to large variations in performance and speciﬁcations of different brands and types of generators,

Tweco cannot guarantee full welding output power or duty cycle on every brand or type of generator. Tweco recommends that when selecting a generator, that the particular power source / generator com-

bination be adequately tested to ensure the combination performs to the users expectations. Note 5: Tweco reserves the right to change product performance and speciﬁcations without notice.

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INTRODUCTION 2-6 Manual 0-5287

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ARCMASTER 401MST POWER SOURCE

SECTION 3:

INSTALLATION, OPERATION AND SETUP

3.01 Environment

These units are designed for use in environments with increased hazard of electric shock as outlined in EN 60974-1.

A. Examples of environments with increased hazard of

electric shock are:

1. 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.

2. 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.

3. In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories.

exceed the stated conditions. For further information please refer to EN 60529.

H. Precautions must be taken against the power source

toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

WARNING

This equipment should be electrically connected by a qualiﬁed electrician.

3.03 Ventilation

WARNING

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

B. Environments with increased hazard of electric shock

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:

A. In areas, free from moisture and dust. B. Ambient temperature between 32 to 104°F. C. In areas, free from oil, steam and corrosive gases. D. In areas, not subjected to abnormal vibration or

shock. E. In areas, not exposed to direct sunlight or rain. F. Place at a distance of 300mm or more from walls or

similar that could restrict natural air flow for cooling. G. The enclosure design of this power source meets

the requirements of IP23S as outlined in EN 60529. This provides adequate protection against solid objects (greater than 12mm), and direct protection from vertical drops. Under no circumstances should the unit be operated or connected in a micro environment that will

3.04 Mains Supply Voltage Requirements

The Mains supply voltage should be within ± 15% of the rated mains supply voltage. Too low a voltage may cause poor welding performance. Too high a supply voltage will cause components to overheat and possibly fail.

The Welding Power Source must be:

• Correctly installed,if necessary,bya qualied

electrician.

• Correctlyearthed(electrically)inaccordancewith

local regulations.

• Connectedtothecorrectsizepowerpointandfuse

as per the Speciﬁcations on page 2-4 (2-6).

WARNING

Any electrical work must be carried out by a qualiﬁed Electrical Tradesperson.

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ARCMASTER 401MST POWER SOURCE

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/

tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Electrical Input Requirements

Operate the welding power source from a single or three-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.

NOTE

This unit is equipped with a three-conductor with earth power cable that is connected at the welding power source end for single or three-phase electrical input power.

Do not connect an input (WHITE, BLACK or RED) conductor to the ground terminal. Do not connect the ground (GREEN) conductor to an input line terminal. Refer to Figure 3-1 and:

1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes.

2. For 3- phase operation, connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors to a de-energized line disconnect switch.

For 1- phase operation, connect BLACK and WHITE input conductors. Insulate the RED Conductor.

3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.

Fuse Size

Input Voltage 1 Phase 3 Phase

208 VAC 100 Amps 60 Amps 230 VAC 80 Amps 50 Amps 460 VAC 50 Amps 30 Amps

Table 3-1 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).

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ARCMASTER 401MST POWER SOURCE

Welding Power Source

Ground Terminal

Figure 3-1 Electrical Input Connections

Input Power

Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN SWITCH is turned ON, the inrush circuit provides a pre-charging of the input capacitors. A relay in the Main Power PCB2 will turn on after the input capacitors have charged to operating voltage (after approximately 5 seconds).

NOTE

Ground Conductor

Line Disconnect Switch

Line Fuse

Primary Power Cable

Art # A-12451

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

3.05 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilised 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

WARNING COMPUTER

It is also possible that operation close to computer installations may cause computer malfunction.

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3.06 High Frequency Interference

Interference may be transmitted by a high frequency initiated or stabilised arc welding machine in the following ways.

1. Direct Radiation: Radiation from the machine can occur if the case is metal and is not properly grounded. It can occur through apertures such as open access panels. The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded.

2. Transmission via the Supply Lead: Without adequate shielding and ﬁltering, high frequency energy may be fed to the wiring within the installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction. Adequate shielding and ﬁltering is provided in the Power Source.

3. Radiation from Welding Leads: Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with distance. Keeping leads as short as possible will minimise this type of interference. Looping and suspending of leads should be avoided wherever possible.

below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer troublesome.

NOTE

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC 60974-13 Arc Welding Equipment - Installation and use (under preparation).

B. Assessment of Area

Before installing welding equipment, the user shall

make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account

4. Re-Radiation from Unearthed Metallic Objects: A major factor contributing to interference is re-radiation from unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent re-radiation in most cases.

3.07 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the

welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE

1. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the welding equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pacemakers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The insulation of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

The size of the surrounding area to be considered

will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

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C. Methods of Reducing Electromagnetic Emissions

1. Main Power Supply Welding equipment should be connected to the

mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as ﬁltering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment The welding equipment should be routinely

maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modiﬁed in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilising devices should be adjusted and maintained according to the manufacturer’s recommendations.

emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

6. Screening and Shielding Selective screening and shielding of other cables

and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications.

3. Welding Cables The welding cables should be kept as short

as possible and should be positioned close together, running at or close to the ﬂoor level.

4. Equipotential Bonding Bonding of all metallic components in the

welding installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Grounding of the Workpiece Where the workpiece is not bonded to earth

for electrical safety, nor connected to earth grounding because of it’s size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce

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3.08 ArcMaster 401MST Power Source Controls, Indicators and Features

Art # A-12452_AC

Figure 3-2

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ARCMASTER 401MST POWER SOURCE

Control PCB5

Output Voltage

1 VRD (Voltage Reduction Device) Indicator Lights

A VRD (voltage reduction device) is a hazard reducing device designed to reduce electric shock hazards present on the output of welding power source when operating in SMAW (STICK) mode. Note that the presence of VRD should not be used as a substitute for the use of appropriate safety practices as indicated in section one

of this manual. Please Note: VRD is factory set to OFF on the 401MST. Both LED's will be off. To enable, turn VRD switch on

Control PCB5 (refer to Figure 3-3) to the "ON" position. If VRD is active, green LED will be on. When arc is established green LED will turn off and red LED will turn on.

Adjustment

Potentiometer

VRD Switch

Art # A-12454

Figure 3-3

2 Amphenol Selector (14 PIN / 19 PIN Remote Button)

This button is used to select 14 PIN or 19 PIN mode of operation. Refer to 3.14 Special Function for more info.

When in 14 PIN Remote mode, the 14 PIN control socket is active and remote voltage controls will be active. When in 19 PIN Remote mode, the 19 PIN control socket is active and remote voltage controls will be active. Both 14 pin and 19 pin connectors work in all modes.

3 Parameter Selection Button

This button is used to select between HOT START, WELDING CURRENT, and ARC FORCE while in SMAW (STICK) mode and select between WELDING VOLTAGE and INDUCTANCE CONTROL while in GMAW (MIG) mode. This button is also used in conjunction with the Save/Load buttons to save and load welding programs.

Refer to 3.14 Special Function for more info.

4 Digital Meter Volt & Ammeter

Welding amperage, Voltage and parameter values are displayed in this window. Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by error message on the screen. When welding, it displays average welding current. After weld has been completed, it displays average welding

current for 10 seconds.

5 Encoder Control

It allows the operator to adjust the weld parameters within the entire range of the power source, also used to set each parameter value. This control sets the selected weld parameter, rotating it clockwise increases the parameter value and counterclockwise to decrease. A selected weld parameter can be adjusted at any time

even while welding. Refer to 3.14 Special Function for more info.

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Local Control

6 Save/Load Buttons

By using the Save & Load buttons the operator can easily save up to 10 welding parameter programs (including welding process, current/ voltage and other parameters such as arc force, inductance and hot start).

To Save a program

• PressandHOLDtheSAVEbuttonfor2seconds.

• SelectajobnumberbyrotatingtheEncoderControl,withjobnumberdisplayedonthelowermeter.

• Afterselectingthedesiredjobnumber(i.e.1to10),pressParameterSelectionButton(Item3)tosave

the job.

To Load a program

• PressandHOLDtheLOADbuttonfor2seconds.

• SelectajobnumberbyrotatingtheEncoderControl,withjobnumberdisplayedonthemeter.

• Afterselectingthedesiredjobnumber(i.e.1to10),pressParameterSelectionButton(Item3)toload

the job.

7 Process Selection Button

The process selection control is used to select the desired welding mode. Six modes are available for the 401MST:

The MIG function has two modes: MIG (GMAW/FCAW)-The Process light is illuminated; CO2 (GMAW/FCAW)The Process light is blinking.

Lift TIG (GTAW)- The Process light is illuminated. The Stick function has two modes: Stick (SMAW)- The Process light is illuminated; Arc Gouging (CAC-A)- The

Process light is blinking. 6010 Stick (SMAW)- The Process light is illuminated.

The standard mode will be MIG with argon or argon mixes. The LED for MIG will be on. The other mode will be dedicated for straight CO2 gas operation. The same LED will be on, but will blink instead.

8 Remote Control

Remote Control

The remote control A/V is for both Current or Voltage depending on the process selected. This control toggles between Local and Remote. Refer to 3.14 Special Function for more info.

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9 Contactor Control

Local Control

ARCMASTER 401MST POWER SOURCE

Remote Control

Contactor Control either enables the weld output or assigns this function to a remote device. Refer to 3.14 Special Function for more info.

10 Positive Welding 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.

11 Negative Welding 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

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

12 Intelligent Fan Control

The intelligent cooling system is designed to reduce dust and foreign material build-up, while providing optimum cooling. Fan speed reduces approximately 30 seconds after machine is turned on and increases when internal components reaches operating temperature.

13 14 Pin Remote Control Socket

The 14 pin Remote Control Socket is used to connect Remote Control devices or wire feeders that use a 14 pin connection to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Pin Function Description

A 24VAC

B Contactor Connect A&B -> contactor enable

C +10VDC Remote Ctrl (Max) 10 VDC for remote potentiometer supply D Remote Ctrl return/common (Min) Common E Remote Demand/Wiper Remote control demand signal. Voltage: 0<=Vin<=10V F Amperage output signal Output current signal. 1Vout/100Aout G 24/115VAC Common 24/115VAC common and chassis ground H Output voltage signal Voltage feedback. 1Vout/10Varc

I 115VAC

J Contactor Enable Connect I&J --> contactor enable

K Chassis ground

M Arc established Relay contact between M & N will close while welding is active

N Arc established

Table 3-2 14 Pin Interconnection Control Plug Conﬁguration, 401MST

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14 19 Pin Remote Control Socket

The 19 pin Remote Control Socket is used to connect Remote Control devices or wire feeders that use a 19 pin connection to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Pin Function Description

A +16VDC contactor 16 VDC supply voltage for contactor. Connect A & B for contactor enable B Contactor in Contactor input. Connect A & B for contactor enable C Volt Meter Voltage feedback. 1Vout/10Varc D 24VAC

E 115VAC F 24/115VAC neutral VAC neutral

G Ground

H +10VDC remote ctrl 10 VDC for remote potentiometer supply

J Remote Input 0<=Vin<=10V K Remote ctrl ground/common Also control circuit common L BF04 ground / common

M 12VDC arc established +12 VDC while welding active, otherwise off

N Ground / common

P 24VAC R N VAC 24/115VAC neutral and chassis ground

S CAN_high CAN bus; positive signal T CAN_low CAN bus; negative signal U Amp Meter Current feedback. 1Vout/100AAout V +24VDC + 24VDC CAN supply

Table 3-3 19 Pin Interconnection Control Plug Conﬁguration, 401MST

15 ON/OFF Switch

This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Supply.

WARNING

When the welder is connected to the Primary supply voltage, the internal electrical components may be at 500V potential with respect to earth.

16 Input Cable

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

17. 2.5A Circuit Breaker

2.5A Circuit Breaker is for the 115 VAC auxiliary power connected to 14 pin or 19 pin remote control socket.

18. 10A Circuit Breaker

10A Circuit Breaker is for the 24 VAC auxiliary power connected to 14 pin or 19 pin remote control socket.

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3.09 Welding Parameters

Local Control

Parameter Description

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

Arc Force

This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes. e.g. low hydrogen electrodes. This parameter also works in TIG mode allowing a softer or harder arc start. It sets

Hot Start

the peak start current on top of the (WELD) current. Weld Current (Amperage) - when lit Encoder Control sets the STICK and TIG

WELD current.

Weld Voltage (Volt) – when lit Encoder Control sets the MIG voltage.

Contactor operates in MIG, TIG , and Stick modes. When the local Control LED is illuminated the output is enabled, and when the

Remote Control is illuminated the output is enabled by a remote control.

ARCMASTER 401MST POWER SOURCE

Remote Control

Contactor Control

Remote Control

Inductance

Selects either local or remote amperage or voltage control depending on the selected process. Local Control allows the voltage or current to be adjusted on the front panel, while Remote Control is used if you have a remote control connected to the welder.

This parameter, similar to the Arc Force in Stick mode. In MIG mode, inductance allows for the adjustment of the dynamic property of the arc. As the inductance is increased the output voltage may need to be adjusted to achieve the desired weld characteristics.

The SAVE/LOAD buttons are used to save and retrieve a total number of 10 jobs into the 400MST memory.

Table 3-4 Welding Parameters Description

Manual 0-5287 3-11 INSTALLATION, OPERATION AND SETUP

Page 42

ARCMASTER 401MST POWER SOURCE

Weld Process Selection

Weld Mode

Weld Parameter STICK MIG

WELD (V)

INDUCTANCE

× √ × × √ ×

HOT START

√ × √

WELD (A)

√ × √

ARC FORCE

√ × ×

Table 3-5 Weld Process Selection verses Weld Mode

Weld Parameter Descriptions

WELD (V)

This parameter operates the MIG weld arc voltage in MIG mode.

LIFT

TIG

Description

Weld voltage MIG Mode. Inductance control in MIG Mode.

Start current in amps is added or subtracted. In STICK mode the Hot Start is 100% to 200%, factory default 125%; while in TIG mode the range is 50% to 200%, factory default 50%. WELD (A) current for STICK or LIFT TIG. Adjusts percentage increase in welding current and is proportional to arc length (arc voltage).

INDUCTANCE

This parameter operates the INDUCTANCE when MIG welding. It controls the dynamic properties of the arc in dip transfer welding mode. When this parameter is set to 0%, i.e. minimum inductance, the arc has a fast response with a resulting crisp arc noise and coarse spatter. When this parameter is set to 200%, i.e. maximum inductance, the arc has a slow response with a resulting soft arc and ﬁne spatter.

NOTE

As the INDUCTANCE is increased, the WELD (V) may need to be adjusted to achieve the desired weld characteristic.

HOT START

This parameter operates in Stick and TIG modes. Hot start can subtract 50% of the weld current during arc starts some times desirable in TIG welding, or add up to 200% of weld current during arc starts, helping with low hydrogen electrode ignition.

WELD (A)

This parameter operates the Stick, Gouging, and TIG weld current.

ARC FORCE CONTROL

This parameter operates in STICK mode only and is used to adjust percentage increase in welding current and is proportional to arc length (arc voltage). This control provides an adjustable amount of arc control (or dig). This feature can be particularly beneﬁcial in providing the operator with the ability to compensate for variability in joint ﬁt up in certain situations with particular electrodes, e.g. cellulose and hydrogen controlled electrodes. In all welding processes, the amount of penetration obtained is dependent on the welding current; i.e. the greater the penetration, the greater the current.

Arc Force Position Effect on Welding Performance

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

Medium (100%)

Maximum (200%) Hard arc, Deep penetration

Table 3-6 Weld Parameter Descriptions

INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5287

Normal arc, Improved fusion

characteristics, Normal penetration

Page 43

ARCMASTER 401MST POWER SOURCE

In general, having the Arc Force set at 200% (maximum) allows greater penetration to be achieved. With the

ARC set at 0% (minimum) the Power Source has a constant current characteristic. In other words, varying the

arc length does not signiﬁcantly affect the welding current. When the Arc Force is set to 100%, it is possible

to control the welding current by varying the arc length. This is very useful for controlling penetration and

side wall wash on vertical up ﬁllet welds.

i) Root runs

During root runs the weld pool forms a “keyhole” shape. If too much weld current is used, the hole blows

out and the weld collapses. If too little weld current is used, the hole closes up and penetration is lost. The size of the hole also determines the arc length; i.e. as the hole gets bigger, the arc gets longer.

If arc force is used, the increase in the arc length causes the weld current to decrease until the hole starts

to close up but if the hole closes up to much then the arc length decreases which causes the weld current to increase. Too little or too much arc force makes this process unstable. The operator must adjust the

arc force until a happy medium is reached. ii) Vertical up welding When welding vertical up with arc force on, the operator can control the amount of current by changing arc

length, i.e. voltage. Weld metal is deposited by “digging” the electrode into the side of the base metal joint

and then increasing the arc length with a ﬂicking motion, to allow the weld pool to freeze, before digging

the electrode into the other side of the base metal joint. Without arc force, increasing the arc length does not decrease the weld current sufﬁciently and the operator

has to manually decrease the current via a Remote Control to freeze the weld pool. This welding current

reduction also reduces the penetration. The arc force allows the weld pool to freeze during the “ﬂick” phase without decreasing the amount of weld

current available during the “dig” phase thus maximizing penetration.

Weld

Parameter

WELD (V)

MIG

INDUCTANCE

HOT START (TIG)

HOT START (STICK)

WELD (A) (1 phase)

TIG or STICK

WELD (A) (3 phase)

TIG or STICK

ARC FORCE

Parameter Range Factory

Setting

10.0 to 38V 20V 0.1V

0 to 200% 100% 1%

50 to 200% 50% 1%

100 to 200% 125% 1%

10 to 300A 100A 1A

10 to 400A 100A 1A

0 to 200% 100% 1%

Table 3-7 Weld Parameter Setting

Incremental

Unit

Manual 0-5287 3-13 INSTALLATION, OPERATION AND SETUP

Page 44

ARCMASTER 401MST POWER SOURCE

3.10 Setup for LIFT TIG (GTAW) Welding

For TIG welding a TIG torch with valve is required for this power source. A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via

dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the optional TIG Torch to the negative welding terminal (-). Welding current flows from the Power

Source via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

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

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off. Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable

stationary support to prevent falling or tipping.

D. Ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright

position. E. Select TIG mode by pressing Process Selection Button until TIG indicator lights up. F. Connect the TIG Torch trigger switch / remote control to the 14 pin or 19 pin socket on the Power Source as

applicable. It will operate in lift TIG mode with either a remote connected to the 14 or 19 pin connector, or the

contactor enabled on the panel. The TIG Torch will operate in LIFT TIG mode. G. Fit the Flowmeter/ Regulator to the gas cylinder then connect the gas hose from the TIG Torch to the Flowmeter

outlet. The Power Source is not fitted with a shielding gas solenoid to control the gas flow in LIFT TIG mode,

therefore the TIG Torch will require a gas valve.

TIG Welding Current Range Factory setting

Welding current I1 10 to 300 A (1 phase)

10 to 400 A (3 phase)

Table 3-8 TIG Welding Current

H. Arc Ignition. Open the valve 19 on the TIG welding torch. Briefly touch the workpiece with the tip of the electrode

at the point to be welded. Lift the electrode a little. The arc burns between the workpiece and the electrode

100

Figure 3-4 Arc Ignition

INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5287

Art # A-12455

Page 45

Graphic for TIG

I Current I1 Welding current ISt Hot start current Iz Short circuit t Time tSt Hot start

ARCMASTER 401MST POWER SOURCE

Art # A-12456

Figure 3-5 TIG Current Routing Diagram

Positive Welding Terminal (+)

Work Lead

19 Pin Control Socket

ARCMASTER 401MST

Negative Welding Terminal (-)

Art # A-12550

Tig Torch

Figure 3-6 Setup for TIG (GTAW) Welding

Manual 0-5287 3-15 INSTALLATION, OPERATION AND SETUP

Page 46

ARCMASTER 401MST POWER SOURCE

3.11 Setup for STICK (SMAW) Welding

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the Electrode Holder to the positive welding terminal (+) (or negative welding terminal (-)). If in doubt,

consult the electrode manufacturer. Welding current flows from the Power Source via dinse type connectors. It

is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C. Connect the work lead to the negative welding terminal (-) (or positive welding terminal (+)). If in doubt, consult

the electrode manufacturer. Welding current flows from the Power Source via dinse type connectors. It is

essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

WARNING

The polarity of the electrode depends on the type of electrode and the welding process. Please follow the manufacturer's instructions on the electrode packaging for this purpose.

CAUTION

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

WARNING

Before connecting the work clamp to the workpiece make sure the mains power supply is switched off.

D. Select STICK mode by pressing Process Selection Button until the STICK/Gouging and 6010 Process LEDs are

lit (Please refer to Page 3-8 for detailed info).

STICK Welding Current Range Factory setting

Welding current l1

Table 3-9 STICK Welding Current

E. Arc ignition. Brieﬂy touch the workpiece at the point to be welded using the electrode and lift the electrode a

little. The arc burns between the workpiece and the electrode.

10 to 300 A (1 phase)

100

10 to 400 A (3 phase)

INSTALLATION, OPERATION AND SETUP 3-16 Manual 0-5287

Page 47

Graphic for SMAW (STICK)

I Current I1 Welding current ISt Hot start current t Time tSt Hot start time

ARCMASTER 401MST POWER SOURCE

Art # A-12457

Figure 3-7 STICK Current Routing Diagram

Positive Welding Terminal (+)

Electrode Holder

ARCMASTER 401MST

Negative Welding Terminal (-)

Work Lead

Figure 3-8 Setup for STICK (SMAW) Welding

Art # A-12551

Manual 0-5287 3-17 INSTALLATION, OPERATION AND SETUP

Page 48

ARCMASTER 401MST POWER SOURCE

3.12 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire

A wire feeder (optional) is required for MIG welding.

NOTE

NOTE 1: The operations required may differ depending on the version and the conﬁguration of the wirefeeder!

NOTE 2: Please read the wirefeeder operating manual!

Power Source Connections

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the work lead to the negative welding terminal (-) [positive welding terminal(+) for flux cored electrode

wire]. If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via

dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a

sound electrical connection.

CAUTION

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

WARNING

stationary support to prevent falling or tipping.

C. Ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright

position. D. Select MIG mode by pressing Process Selection Button until MIG/ CO2 symbol lights up (Please refer to Page

3-8 for detailed info).

Wirefeeder Connections

A. Connect the welding power cable to the positive welding terminal (+) [negative welding terminal (-) for flux

cored wire]. If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source

via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve

a sound electrical connection. B. Connect the control cable from the Wirefeeder to the 14 PIN or 19 PIN socket on the Power Source as applicable.

Select appropriate connector by pressing the button on front panel.

INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5287

Page 49

Tweco No. 4 MIG Torch

ARCMASTER 401MST POWER SOURCE

Positive Welding Terminal (+)

ARCMASTER 401MST

Negative Welding Terminal (-)

Work Lead

19 Pin Control Socket

Art # A-12552

Wirefeeder

Figure 3-9 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire

Manual 0-5287 3-19 INSTALLATION, OPERATION AND SETUP

Page 50

ARCMASTER 401MST POWER SOURCE

3.13 Setup for FCAW Flux Core Arc Welding

A wire feeder (optional) is required for MIG welding.

NOTE

NOTE 1: The operations required may differ depending on the version and the conﬁguration of the wirefeeder!

NOTE 2: Please read the wire feed operating manual!

Power Source Connections

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.

Welding current flows from the Power Source via dinse type connectors. It is essential, however, that the male

plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

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

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off.

C. Select MIG mode by pressing Process Selection Button until MIG/ CO2 symbol lights up (Please refer to Page

3-8 for detailed info).

INSTALLATION, OPERATION AND SETUP 3-20 Manual 0-5287

Page 51

ARCMASTER 401MST POWER SOURCE

WIREFEEDER CONNECTIONS

A. Connect the welding power cable to the negative welding terminal (-). If in doubt, consult the electrode wire

manufacturer. Welding current flows from the Power Source via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

B. Connect the control cable from the Wirefeeder to the 14 PIN or 19 PIN socket on the Power Source as applicable.

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off.

NOTE

Welding Setup Program Storage (10 programs) applies to MIG, Stick and Lift Tig modes.

Positive Welding Terminal (+)

Work Lead

Tweco No. 4 MIG Torch

ARCMASTER 401MST

Negative Welding Terminal (-)

19 Pin Control Socket

Art # A-12553

Wirefeeder

Figure 3-10 Setup for FCAW Flux Core Arc Welding

Manual 0-5287 3-21 INSTALLATION, OPERATION AND SETUP

Page 52

ARCMASTER 401MST POWER SOURCE

3.14 Special Function

Amphenol Selector

Parameter Selection

Button

Contactor Control

Remote Control

Art # A-12458_AB

Gouging

In Stick mode hold the Process Selection Button for 2 seconds and the LED will blink indicating Gouging mode is enabled.

Lock/ Unlock User Interface (UI)

UI Lock Function can be enabled or disabled by pressing Encoder Control for 5 seconds.

Encoder Control

Figure 3-11

Process Selection Button

NOTE

The function lock setting is saved! If the machine is switched off with the function lock activated, the control panel is still locked when the machine is switched back on.

LED Test

Press Amphenol Selector or Parameter Selection Button for 2 seconds to start LED test. The test will last for about 5 seconds. During the test all LEDs are lit.

Enable Calibration in MIG Mode

In MIG mode, the adjustment to output voltage can be enabled or disabled as below:

1. Press Contactor Control and Process Selection Button at the same time for 2 seconds.

2. Rotate Encoder Control to select CAL ON/OFF. 2a. Adjust the output voltage with the potentiometer on Control PCB 5 by +/- 5% (refer to Figure 3-3).

3. Press Encoder Button Encoder Control to save the setting.

Display Software Version

Press Remote Control and Contactor Control buttons at the same time for 2 seconds and it will display the software version of User Interface (UI), master and process.

Master Reset

WARNING

All personal settings will be lost!

The 401MST can have master reset. All the jobs saved will be deleted and all parameters will be set back to factory setting. This function is accessed by pressing Parameter Selection Button and Remote Control Button

at the same time for 2 seconds.

INSTALLATION, OPERATION AND SETUP 3-22 Manual 0-5287

Page 53

ARCMASTER 401MST POWER SOURCE

3.15 Shielding Gas Flowmeter/ Regulator Operating Instructions

WARNING

This equipment is designed for use with welding grade (Inert) shielding gases only.

Shielding Gas Flowmeter/ Regulator Safety

Designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.

If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the users responsibility to prevent such conditions. Before handing or using the equipment, understand and comply at all times with the safe practices prescribed in this instruction.

SPECIFIC PROCEDURES for the use of ﬂowmeter/ regulators are listed below.

1. NEVER subject the ﬂowmeter/ regulator to inlet pressure greater than its rated inlet pressure.

2. NEVER pressurize a ﬂowmeter/ regulator that has loose or damaged parts or is in a questionable condition. NEVER loosen a connection or attempt to remove any part of a ﬂowmeter/ regulator until the gas pressure has been relieved. Under pressure, gas can dangerously propel a loose part.

3. DO NOT remove the ﬂowmeter/ regulator from a cylinder without ﬁrst closing the cylinder valve and releasing gas in the ﬂowmeter/ regulator high and low pressure chambers.

4. DO NOT use the ﬂowmeter/ regulator as a control valve. When downstream equipment is not in use for extended periods of time, shut off the gas at the cylinder valve and release the gas from the equipment.

5. OPEN the cylinder valve SLOWLY. Close after use.

User Responsibilities

This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary for continued safe and reliable performance. Defective equipment should not be used. Parts that are broken, missing, obviously worn, distorted, or contaminated should be replaced immediately.

The user of this equipment will generally have the sole responsibility for any malfunction, which results from improper use, faulty maintenance, or by repair by anyone other than an accredited repairer.

CAUTION

Match ﬂowmeter/ regulator to cylinder. NEVER CONNECT a ﬂowmeter/ regulator designed for a particular gas or gases to a cylinder containing any other gas.

INLET

CONNECTION

OUTLET

CONNECTION

HIGH PRESSURE GAUGE (SUPPLY)

FLOW GAUGE (DELIVERY)

PRESSURE

ADJUSTING

SCREW

Art # A-12126

Figure 3-12 Adjusting Flow Rate

Manual 0-5287 3-23 INSTALLATION, OPERATION AND SETUP

Page 54

ARCMASTER 401MST POWER SOURCE

NOTE

The ﬂowmeter/ regulator used with argon based and carbon dioxide shielding gases are different. The ﬂowmeter/ regulator supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide ﬂowmeter/ regulator will need to be ﬁtted.

NOTE

All valves downstream of the ﬂowmeter/ regulator must be opened to obtain a true ﬂow rate reading on the outlet gauge. (Welding power source must be triggered) Close the valves after the pressure has been set.

Installation

1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog oriﬁces and damage seats before connecting the ﬂowmeter/ regulator.

Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.

Wipe with a clean lint free cloth.

2. Match ﬂowmeter/ regulator to cylinder. Before connecting, check that the ﬂowmeter/ regulator label and cylinder marking agree and that the ﬂowmeter/ regulator inlet and cylinder outlet match. NEVER CONNECT a ﬂowmeter/ regulator designed for a particular gas or gases to a cylinder containing any other gas.

3. Connect the ﬂowmeter/ regulator inlet connection to cylinder or pipeline and tighten it ﬁrmly but not excessively, with a suitable spanner.

4. Connect and tighten the outlet hose ﬁrmly and attach down-stream equipment.

5. To protect sensitive down-stream equipment a separate safety device may be necessary if the ﬂowmeter/ regulator is not ﬁtted with a pressure relief device.

Operation

With the ﬂowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows:

1. Stand to one side of ﬂowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal ﬂowmeter/ regulator parts.

2. With valves on downstream equipment closed, adjust ﬂowmeter/ regulator to approximate working pressure. It is recommended that testing for leaks at the ﬂowmeter/ regulator connection points be carried out using a suitable leak detection solution or soapy water.

3. Purge air or other unwanted welding grade shielding gas from equipment connected to the ﬂowmeter/ regulator by individually opening then closing the equipment control valves. Complete purging may take up to ten seconds or more, depending upon the length and size of the hose being purged.

Adjusting Flow Rate

Figure 3-13 Adjust Flow Rate

INSTALLATION, OPERATION AND SETUP 3-24 Manual 0-5287

Page 55

ARCMASTER 401MST POWER SOURCE

With the ﬂowmeter/ regulator ready for operation, adjust working ﬂow rate as follows:

1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required ﬂow rate.

NOTE

It may be necessary to re-check the shielding gas

ﬂowmeter/ regulator

ﬂow rate following the ﬁrst weld

sequence due to back pressure present within shielding gas hose assembly.

2. To reduce ﬂow rate, allow the welding grade shielding gas to discharge from ﬂowmeter/ regulator by opening the downstream valve. Bleed welding grade shielding gas into a well ventilated area and away from any ignition source. Turn adjusting screw counter clockwise, until the required ﬂow rate is indicated on the gauge. Close downstream valve.

Shutdown

Close cylinder valve whenever the ﬂowmeter/ regulator is not in use. To shut down for extended periods (more than 30 minutes).

1. Close cylinder or upstream valve tightly.

2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any ignition source.

3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.

4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove Flowmeter/ Regulators.

Manual 0-5287 3-25 INSTALLATION, OPERATION AND SETUP

Page 56

ARCMASTER 401MST POWER SOURCE

This Page Intentionally Blank

INSTALLATION, OPERATION AND SETUP 3-26 Manual 0-5287

Page 57

ARCMASTER 401MST POWER SOURCE

SECTION 4:

BASIC WELDING GUIDE

4.01 Stick (SMAW) Basic Welding Technique

Size of Electrode

The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufﬁcient current (amperage) to run the smaller size electrodes.

For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode for a given application.

Storage of Electrodes

Always store electrodes in a dry place and in their original containers.

Electrode Polarity

Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited Tweco Distributor.

Effects of Arc Welding Various Materials

A. 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 may result. 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.

Low Hydrogen Electrodes must be used for this application.

B. Austenitic 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.

C. 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 white-heart malleable, due to the porosity caused by gas held in this type of iron.

D. 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.

Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section.

Manual 0-5287 4-1 BASIC WELDING GUIDE

Page 58

ARCMASTER 401MST POWER SOURCE

Art # A-07688

Art # A-07689

Art # A-07690

Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in ﬂat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-5 through 4-12.

Art # A-07687

Figure 4-1: Flat Position, Down Hand Butt Weld

Art A-07691

Figure 4-5: Vertical Position, Butt Weld

Figure 4-2: Flat Position, Gravity Fillet Weld

Figure 4-3: Horizontal Position, Butt Weld

Figure 4-4: Horizontal-Vertical (HV) Position

Art # A-07692

Figure 4-6: Vertical Position, Fillet Weld

Art# A-07693

Figure 4-7: Overhead Position, Butt Weld

Art # A-07694

Figure 4-8: Overhead Position, Fillet Weld

BASIC WELDING GUIDE 4-2 Manual 0-5287

Page 59

ARCMASTER 401MST POWER SOURCE

Open Square Butt

Single Vee Butt Joint

Not less than

Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-9.

Joint

Gap varies from

1.6mm (1/16”) to 4.8mm (3/16”) depending on plate thickness

Single Vee Butt Joint

Lap Joint

Fillet Joint

Corner Weld

Not less than

45°

(Fillet both sides of the

1.6mm (1/16”)

Double Vee Butt Joint

1.6mm (1/16”)

Tee Joints

joint)

Edge Joint

70°

Not less than

70°

1.6mm (1/16” ) max

1.6mm (1/16”) max

Plug Weld Plug Weld

Art # A-07695_AE

Figure 4-9: Typical Joint Designs for Arc Welding

Arc Welding Technique - A Word to Beginners

For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about thick and a electrode. Clean any paint, loose scale or grease off the plate and set it ﬁrmly on the work bench so that welding can be carried out in the downhand position. Make sure that the work

Manual 0-5287 4-3 BASIC WELDING GUIDE

Page 60

ARCMASTER 401MST POWER SOURCE

20°

clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

The Weldor

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax and you will ﬁnd that the job becomes much easier. You can add much to your peace of mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting alight to your clothes.

Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock.

Striking the Arc

Practice this on a piece of scrap plate before going on to more exacting work. You may at ﬁrst experience difﬁculty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck. As soon as the arc is established, maintain an imperial dimensions 1/16" to 1/8" gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difﬁculty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

Art # A-07696_AB

1.6 mm (1/16”)

Figure 4-10: Striking an Arc

Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will ﬁnd that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is ﬂattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidiﬁed in. If this should happen, give the electrode a quick twist back over the weld to detach it.

Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

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20°-30°

Making Welded Joints

Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in Figure 4-11, allowing 1/16" to 3/32" gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment. Plates thicker than 1/4" should have their mating edges bevelled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Deposit a run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufﬁcient to produce a wellformed bead. At ﬁrst you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

Electrode

Tack Weld

Art # A-07697_AB

Figure 4-11: Butt Weld

Art # A-07698

Figure 4-12: Weld Build up Sequence

Heavy plate will require several runs to complete the joint. After completing the ﬁrst run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-12. The width of weave should not be more than three times the core wire diameter of the electrode. When the joint is completely ﬁlled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-4.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) ﬁllet. Strike the arc and immediately bring the electrode to a position perpendicular to the line of the ﬁllet and about 45º from the vertical. Some electrodes require to be sloped about 20º away

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Art # A-07699_AB

from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 4-13. Do not attempt to build up much larger than width with a electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-14. Weaving in HV ﬁllet welds is undesirable.

45° from vertical

60° - 70° from line of weld

accumulate in the centre of the weld. Figure 4-16 illustrates multi-run technique and Figure 4-17 shows the effects of pausing at the edge of weave and of weaving too rapidly.

Art # A-07701

Figure 4-15: Single Run Vertical Fillet Weld

Figure 4-13: Electrode Position for HV Fillet Weld

Art # A-07700_AB

Figure 4-`14: Multi-runs in HV Fillet Weld

C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron

to your work bench in an upright position. Use a electrode and set the current. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the ﬁllet. The electrode needs to be about 10º from the horizontal to enable a good bead to be deposited. Refer Figure 4-15. Use a short arc, and do not attempt to weave on the ﬁrst run. When the ﬁrst run has been completed de-slag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necessary to cover the ﬁrst run and obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will

Art # A-07702

Figure 4-16: Multi Run Vertical Fillet Weld

Art # A-07703

Figure 4-17: Examples of Vertical Fillet Welds

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2. Vertical Down

The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated

so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about 45º.

3. Overhead Welds

Apart from the rather awkward position necessary, overhead welding is not much more difﬁcult that

downhand welding. Set up a specimen for overhead welding by ﬁrst tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-18). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead ﬁllet welds. Deposit the ﬁrst run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.

Art # A-07704

Figure 4-18: Overhead Fillet Weld

Distortion

Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.

The Cause of Distortion

Distortion is caused by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to ﬂow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint in imperial dimensions sheet, the contracting weld metal may cause the sheet to become distorted.

B. Expansion and Contraction of Parent Metal in the Fusion Zone:

While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or "along the weld", it meets considerable resistance, and to fulﬁl the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset". When the weld area begins to cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does

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Upsetting

Art # A-07706_AC

Weld

Permanent Upset

Contraction with tension

not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal. Several things can then happen.

The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain "locked-up" stresses in the job. Figures 4-19 and 4- 20 illustrate how distortion is created.

Hot

Weld

Hot

Expansion with compression

Cool

Art # A-07705_AB

Figure 4-19: Parent Metal Expansion

Figure 4-20: Parent Metal Contraction

Overcoming Distortion Effects

There are several methods of minimizing distortion effects.

A. Peening

This is done by hammering the weld while it is still hot. The weld metal is ﬂattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.

B. Distribution of Stresses

Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-20 through 4-23 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack welds are methods employed with this in view.

D. Presetting

It is possible in some cases to tell from past experience or to ﬁnd by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment. A simple example is shown in Figure 4-21.

BASIC WELDING GUIDE 4-8 Manual 0-5287

E. Preheating

Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-22 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

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Art # A-07707

ARCMASTER 401MST POWER SOURCE

Figure 4-21: Principle of Presetting

Art # A-07708

Dotted lines show effect if no preheat is used

Weld

PreheatPreheat

Figure 4-22: Reduction of Distortion by Preheating

Art # A-07709

Art # A-07428_AB

Figure 4-26: Chain Intermittent Welding

Art # A-07713_AB

Figure 4-27: Staggered Intermittent Welding

Figure 4-23: Examples of Distortion

Art # A-07710_AB

Block Sequence. The spaces between the welds are ﬁlled in when the welds are cool.

Figure 4-24: Welding Sequence

Figure 4-25: Step back Sequence

Manual 0-5287 4-9 BASIC WELDING GUIDE

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Art: A-04971

4.02 Stick (SMAW) Welding Troubleshooting

FAULT CAUSE REMEDY

1 Welding current

ﬂuctuations

2 A gap is left by

failure of the weld metal to ﬁll the root of the weld.

3 Non-metallic par-

ticles are trapped in the weld metal.

ARC FORCE parameter is set at a value that causes the welding current to vary excessively with the arc

Reduce the ARC FORCE parameter until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig” the electrode into the workpiece.

length.

A Welding current too low A Increase welding current. B Electrode too large for

B Use smaller diameter electrode.

joint.

C Insufﬁcient gap. C Allow wider gap.

A Non-metallic particles may

be trapped in undercut

A If a bad undercut is present clean slag bout and

cover with a run from a smaller gauge electrode.

from previous bead.

Joint preparation too restricted.

C Irregular deposits allow

B Allow for adequate penetration and room for

cleaning out the slag.

C If very bad, chip or grind out irregularities.

slag to be trapped.

D Lack of penetration with

slag trapped beneath weld bead.

D Use smaller electrode with sufﬁcient current to

give adequate penetration. Use suitable tools to remove all slag from comers.

E Rust or mill scale is pre-

E Clean joint before welding.

venting full fusion.

F Wrong electrode for posi-

tion in which welding is done.

F Use electrodes designed for position in which

welding is done, otherwise proper control of slag is difﬁcult.

Figure 1-Example of insufﬁcient gap or incorrect sequence

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4 A groove has been

formed in the base metal adjacent to the toe of a weld and has not been ﬁlled by the weld metal (undercut).

5 Portions of the

weld bead do not fuse to the surface of the metal or edge of the joint.

A Welding current is too

A Reduce welding current.

high.

B Welding arc is too long. B Reduce the length of the welding arc.

C Angle of the electrode is

incorrect.

D Joint preparation does not

allow correct electrode

C Electrode should not be inclined less than 45° to

the vertical face.

D Allow more room in joint for manipulation of the

electrode.

angle.

E Electrode too large for

E Use smaller gauge electrode.

joint.

F Insufﬁcient deposit time at

edge of weave.

A Small electrodes used on

F Pause for a moment at edge of weave to allow

weld metal buildup.

A Use larger electrodes and preheat the plate.

heavy cold plate.

B Welding current is too low. B Increase welding current. C Wrong electrode angle. C Adjust angle so the welding arc is directed more

into the base metal.

D Travel speed of electrode

D Reduce travel speed of electrode.

is too high.

6 Gas pockets or

voids in weld metal (porosity)

E Scale or dirt on joint

E Clean surface before welding.

surface.

Art: A-04972

Figure 2: Example of Lack of Fusion

A High levels of sulphur in

steel.

A Use an electrode that is designed for high sul-

phur steels. B Electrodes are damp. B Dry electrodes before use. C Welding current is too

C Reduce welding current.

high.

D Surface impurities such as

D Clean joint before welding.

oil, grease, paint, etc.

E Welding in a windy envi-

E Shield the weld area from the wind.

ronment.

F Electrode damaged ie ﬂux

coating incomplete.

F Discard damaged electrodes and only use elec-

trodes with a complete ﬂux coating.

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Welds Made With or Without

Addition of Filler Metal

Work Piece

Can Be Any Commercial

Metal

Gas Cup Either Ceramic, High-lmpact or

Water Cooled

Metal

Inert Gas

Shields Electrode

and Weld Puddle

Tungsten Electrode

Non-Consumable

Art # A-09658_AC

7 Crack occurring in

weld metal soon after solidiﬁcation commences

A Rigidity of joint. A Redesign to relieve weld joint of severe stresses

or use crack resistance electrodes.

B Insufﬁcient throat thick-

ness.

B Travel slightly slower to allow greater build up in

throat.

C Weld current is too high. C Decrease welding current.

Art: A-04973

Figure 3: Example of Slag Inclusion

Table 4-1: Welding Problems SMAW (Stick)

4.03 TIG (GTAW) Basic Welding Technique

Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas which is generally Argon. A ﬁller metal may also be added manually in some circumstances depending on the welding application.

BASIC WELDING GUIDE 4-12 Manual 0-5287

Figure 4-28: TIG Welding Application Shot

Page 69

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 4-2: Current Ranges for Various Tungsten Electrode Sizes

Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)

1/16” (1.6mm) 20-90 3/32” (2.4mm) 65-115

1/8” (3.2mm) 100-165 3/16” (4.8mm) 200-350

Table 4-3: Filler Wire Selection Guide

ARCMASTER 401MST POWER SOURCE

Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

TIG Welding Filler Rods

Welding Application Features Colour Code

DC welding of mild steel, stainless steel and copper

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

AC & DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys

Table 4-4: Tungsten Electrode Types

AWS Std Type/Application

ER70S-4 ER70S-6 ER70S-2

For mild-medium strength steels. Pipes, tubing, roll cages, etc.

Excellent arc starting, Long life, High current carrying capacity

Self cleaning, Long life, Maintains balled end, High current carrying capacity.

Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc.

Red

White

Grey

ER80S-B2 ER90S-B3

ER308L ER309L ER316L

Manual 0-5287 4-13 BASIC WELDING GUIDE

For welding of high strength Cr-Mo steels used at elevated temperatures.

For stainless steels. Stainless pipes, tubing, architectural uses, etc.

Table 4-5: TIG Welding Filler Rods

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Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm 1/16”

1.6mm

1/8”

3.2mm 3/16”

4.8mm

1/4”

6.4mm

TIG Welding is generally regarded as a specialized process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www.tweco.com or contact Tweco.

DC Current

for Mild

Steel

35-45 40-50

45-55 50-60

60-70 70-90

80-100 90-115

115-135 140-165

160-175 170-200

DC Current

for Stainless

Steel

20-30 25-35

30-45 35-50

40-60 50-70

65-85

90-110

100-125 125-150

135-160 160-180

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

Table 4-6: Welding Rate

Diameter (if

Filler Rod

required)

1/16”

1.6mm 1/16”

1.6mm 3/32”

2.4mm

1/8”

3.2mm 5/32”

4.0mm

Argon Gas Flow Rate

CFH

11-15 Butt/Corner

15 Butt/Corner

21 Butt/Corner

Joint Type

Lap/Fillet

4.04 TIG (GTAW) Welding Problems

FAULT 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

Welding current is too low

Welding current is too high

Travel speed too fast Reduce travel speed.

Travel speed too slow Increase travel speed.

Wrong placement of ﬁller rod

Increase weld current and/or faulty joint preparation.

Decrease weld current.

Re-position ﬁller rod.

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6 Electrode melts or oxidizes

when an arc is struck.

7 Dirty weld pool A Electrode contami-

8 Poor weld ﬁnish Inadequate shielding

9 Arc start is not smooth. A Tungsten electrode is

A Torch lead connected

to positive welding terminal.

B No gas ﬂowing to

welding region.

C Torch is clogged with

dust or dirt.

D Gas hose is cut. D Replace gas hose.

E Gas passage contains

impurities.

F Gas regulator turned

off.

G The electrode is too

small for the welding current.

H Power source is set for

STICK welding.

nated by contact with work piece or ﬁller rod material.

B Work piece surface has

foreign material on it.

C Gas contaminated with

air.

gas.

too large for the welding current.

B The wrong electrode

is being used for the welding job.

C Gas ﬂow rate is too

high.

A Connect torch lead to negative welding

terminal.

B Check the gas lines for kinks or breaks

and gas cylinder contents.

C Clean torch.

E Disconnect gas hose from the rear of

Power Source then raise gas pressure and blow out impurities.

F Turn on.

G Increase electrode diameter or reduce

the welding current.

H Set Power Source to a GTAW operating

mode.

A Clean the electrode by grinding off the

contaminates.

B Clean surface.

C Check gas lines for cuts and loose ﬁtting

or change gas cylinder. Increase gas ﬂow or check gas line for gas ﬂow problems.

A Select the right size tungsten electrode.

Refer to Table 4-3 Tweco Tungsten Electrode Selection Chart.

B Select the right tungsten electrode type.

C Select the right rate for the welding job.

Refer to Table 4-6.

D Incorrect shielding gas

is being used.

E Poor work clamp con-

nection to work piece.

10 Arc ﬂutters during TIG

welding.

Manual 0-5287 4-15 BASIC WELDING GUIDE

Tungsten electrode is too large for the welding current.

Table 4-7

D Select the right shielding gas.

E Improve connection to work piece.

Select the right size tungsten electrode.

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This Page Intentionally Blank

BASIC WELDING GUIDE 4-16 Manual 0-5287

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SECTION 5:

POWER SOURCE PROBLEMS AND ROUTINE SERVICE

REQUIREMENTS

5.01 Maintenance and Repair

WARNING

There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualiﬁed electrical tradesperson 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 Tweco Service Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge. Refer also to section 4 for solving welding problems.

The machine requires a minimum of care and maintenance. Only a few items need to be checked to ensure troublefree long-term operation.

Check the following points for damage before starting up the welding machine, –– Mains plug and cable –– Welding torch and connections –– Keyboard membrane and control panel Check the dust ﬁlter every two months. –– Switch the machine off –– Disconnect the mains plug –– Unscrew the ventilation grid on the rear side ––Check the dust ﬁlter for pollution ––Replace the dust ﬁlter if it is polluted (dust ﬁlter) Use only original TWECO spare parts for maintenance and repair. If you experience problems or need repairs, contact a dealer authorised by Victor. Never make repairs or technical

changes yourself. In this case the manufacturer's warranty is no longer valid.

Manual 0-5287 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

Page 74

ARCMASTER 401MST POWER SOURCE

5.02 Power Source Status Messages

An error code is displayed in the digital displays in the event of a malfunction. You can switch over between error code and sub-error (sub code) in the digital displays by pressing Process Selection Button.

After the message has been displayed, the machine will only function to a limited extent; the error must be corrected as quickly as possible.

The status message can be deleted by pressing Encoder Control.

Code Note Cause Possible Remedy

H08 Short-circuit Short-circuit in the output circuit Eliminate the short-circuit (pick up

electrode holder, ...)

H30 Conﬁguration Component group recognition faulty Take to an accredited Tweco Service

Center for repair.

H31 Communication CAN bus communication faulty Check connected devices and CAN

connections

Table 5-1 Power Source Status Messages

5.03 Error Messages

WARNING

There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited Tweco Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

Code Error Cause Possible Remedy

E01 Excessive Temperature Duty cycle exceeded Allow switched-on machine to cool

down for a few minutes

Dust ﬁlter contaminated Replace dust ﬁlter

E02 Overvoltage Mains voltage too high Check mains voltage E06 Overvoltage Secondary Initial voltage too high Take to an accredited Tweco Service

Center for repair.

E07 EEPROM Communication with EEPROM

defec tive

E08-1 Excess Wirefeeder Voltage Wirefeeder voltage too high Take to an accredited Tweco Service

E08-2 Wirefeeder Motor Error in Wirefeeder Motor Take to an accredited Tweco Service

E08-3 Overcurrent on Wirefeeder Wirefeeder current continu-

ously too high

E08-10 Torch Connection Torch/torch connection error Check torch and torch connection.

Switch machine off and on and execute Master reset. If error code returns take to and accredited Tweco Service Center for repair.

Center for repair.

Center for repair. Reduce motor load

Switch the equipment off and on again

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-2 Manual 0-5287

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ARCMASTER 401MST POWER SOURCE

Code Error Cause Possible Remedy

E08-11 V/I Acquisition Voltage/current measuring

systems faulty

E08-13 CAN Identiﬁcation Unknown device connected Check connected devices and CAN

E09 Output Voltage Voltage measuring system

faulty. Torch is touching work piece

E12 Power Section Power section start-up faulty.

Torch is touching work piece

E13 Temperature Sensor Temperature sensor not ready

for operation

E14 Supply Voltage Internal supply voltage too low Check mains voltages E15 Current Detection Error during current measure-

ment

E18 Overload Protection Safety switch device to protect

elec trical components

E22 Mains Undervoltage Mains voltage on power unit is

too low

E25 Idle Generator Idle generator faulty Take to an accredited Tweco Service

E30 Error Conﬁguration Faulty or wrong pc-board,

wrong software system installed

E31 Communications Fault CAN bus communication

faulty

E32 FPGA FPGA faulty Take to an accredited Tweco Service

E33 Power Section Power module not symmetri-

cal

E34 Fans Fan current faulty Take to an accredited Tweco Service

E39 Protective Earth Conductor

Monitoring

E40 Voltage detection Voltage measurement faulty at

E47 Undeﬁned Mains Mains voltage between per-

Fault current to protective earth con ductor

the socket

mitted ranges

Table 5-2 Power Source Error Messages

Take to an accredited Tweco Service Center for repair.

connections Take to an accredited Tweco Service

Center for repair. Raise Torch from contact with work piece.

Take to an accredited Tweco Service Center for repair. Raise Torch from contact with work piece.

Take to an accredited Tweco Service Center for repair.

Check mains voltages

Center for repair. Take to an accredited Tweco Service

Center for repair.

Switch the equipment off and on again

Center for repair. Take to an accredited Tweco Service

Center for repair.

Center for repair. Connect the welding earth lead

Take to an accredited Tweco Service Center for repair.

Check mains

Manual 0-5287 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

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ARCMASTER 401MST POWER SOURCE

5.04 Routine Inspection, Testing & Maintenance

The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician. Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Tweco original speciﬁcations.

A. Testing Schedule

1. For transportable equipment, at least once every 3 months; and

2. For ﬁxed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.

A transportable power source is deemed to be any equipment that is not permanently connected and ﬁxed in the position in which it is operated.

B. General Maintenance Checks

Welding equipment should be regularly checked by an accredited Tweco Service Provider to ensure that:

1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition.

2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit.

3. The Welding System is clean internally, especially from metal ﬁling, slag, and loose material.

C. Accessories

Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall not be used.

D. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited Tweco Service Provider.

5.05 Cleaning the Welding Power Source

WARNING

There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualiﬁed electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal ﬁlings, slag and loose material. Keep the surfaces clean.

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-4 Manual 0-5287

Page 77

SECTION 6:

KEY SPARE PARTS

6.01 401MST Power Source Spare Parts

ARCMASTER 401MST POWER SOURCE

Art # A-12459

38 39

37 39

Figure 6-1 ArcMaster 401MST Spare Parts

ArcMaster 401MST Spare Parts

Item Description

Des. Ref. Quantity Part Number

1 Side Panel Left 1 W7006700 2 Side Panel Right 1 W7006701 3 Top Panel with Display Sheet 1 W7006702 4 Front Panel 1 W7006703 5 Rear Panel 1 W7006704 6 Front Grill 1 W7006705 7 Rear Grill 1 W7006706 8 Handle Tube 1 W7006707 9 Mains Label 1 W7006708

Manual 0-5287 6-1 KEY SPARE PARTS

Page 78

ARCMASTER 401MST POWER SOURCE

10 Display Panel Overlay 1 W7006709 11 Strain relief 1 W7006710 12 Foam Spacer 1 W7006711 13 Foam inlay 1 W7006712 14 Foam inlay 1 W7006713 15 Foam Plate Self-adhesive 1 W7006714 16 Rear Filter 1 W7006715 17 Wire Gauze 1 W7006716 18 Knob Body 1 W7006717 19 Knob Cap 1 W7006718 20 Control PCB PCB 5 1 W7006719 21 Capacitor PCB PCB 3 1 W7006720 22 Output PCB PCB 7 1 W7006721 23 ADP10 PCB PCB 6 1 W7006722 24 Front Panel PCB PCB 4 1 W7006723 25 Main Power PCB PCB 2 1 W7006724 26 Input PCB PCB 1 1 W7006725 27 Aux. Transformer T2 1 W7006726 28 Main Transformer T1 1 W7006727 29 ON/OFF Switch SW1 1 W7006728 30 Bridge Rectiﬁer BR1 1 W7006729 31 Input Mains Cable 1 W7006730 32 14 pin Remote Socket with Harness 1 W7006731 33 Insulating Bush 1 W7006732 34 Insulation Foil 3 W7006733 35 Insulation Foil 1 W7006734 36 Shunt 1 W7006735 37 Circuit breaker 2.5A 240V (115VAC) CB1 1 W7006736 38 Circuit breaker 10A 240V (24VAC) CB2 1 W7006737 39 Protection cover IP64 1 W7006738 40 50 mm Dinse Output Terminal 1 W7006739 41 Output Diode D1, D2, D3 3 W7006740 42 Unit Thermal Sensor TS1 1 W7006741 43 Cooling Fan M1 1 W7006742 44 Display Protection Cover 1 W7006743 45 Label +/- Tweco 1 W7006744 46 Label 401MST 1 W7006745 47 Warning Sticker 1 W7006746 48 Cover Plate (not shown) 1 W7006747 49 Sticker Tweco 261 x 93 (not shown) 1 W7006748

Table 6-1 ArcMaster 401MST Spart Parts

KEY SPARE PARTS 6-2 Manual 0-5287

Page 79

ARCMASTER 401MST POWER SOURCE

APPENDIX A: CIRCUIT DIAGRAM

X9/2

X9/1

PE L1 L3

LP5

SF02

LP6

LP7

LP4

LP8

LP15

TR1

NEFI

L11L25L3

LP1

LP13

LP14 LP2

X5/3

X5/4

DRV02

X2/1

1 2 3 4 5 6 7X5/1

A13

DMR05

LP11

LP3

LP12

X7/1

X7/2

red

blue

X7/2 X5/2 X5/3 X5/4 X5/5 X7/1

X1/4 X1/3 X1/2

red

X1/1

X2/2

X10/1

X6/5

X6/6

X6/7

X6/8

X10/2

X6/1

X6/2

X6/3

X6/4

MF-07

S00.0069.7

1 2 3 4 5 6 7

A10 A11

DC01

X2/1

X2/2

X2/3

X2/4 X5/7

X2/6 X2/5

X5/8 X5/6

X5/2

X5/1

X7/1

X7/2

X7/3

X7/6

X7/4

X7/5

X7/7

Mapro01

X7/8

X7/9

X1 X1

X8/1 X8/2

X7/10

X8/3 X8/4

X6-1 9

X6-2 10

X6-3 3

X6-4 4

X6-5 5

X6-6 6

X6-7 7

X6-8 8

X6/9

X6/10

X6/11

X6/12

BF03

X2X2

A12

BF-Folie

HR 33

extern

Art # A-12461

Manual 0-5287 A-1 APPENDIX

Page 80

ARCMASTER 401MST POWER SOURCE

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APPENDIX A-2 Manual 0-5287

Page 81

TWECO - LIMITED WARRANTY TERMS

LIMITED WARRANTY: Tweco ®, Inc, A Victor Technologies Company, warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Tweco products as stated below, Tweco shall, upon notiﬁcation thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Tweco’s speciﬁcations, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Tweco’s sole option, of any components or parts of the product determined by Tweco to be defective.

TWECO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: TWECO SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of Tweco 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 Tweco whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Tweco is authorized to change this warranty in any way or grant any other warranty.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN TWECO’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY TWECO PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED 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 Tweco delivered the product to the authorized distributor.

Page 82

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Page 83

WARRANTY SCHEDULE

5 Years Parts* / 3 Years Labor

ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster

Portafeed, Ultrafeed, Ultima 150, WC 100B

* 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards.

* 3 years on Power Supply Components

2 Years Parts and Labor Unless specified

Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy

Victor Regulator for Fabricator 141i (No labor)

1 Years Parts and Labor Unless specified

95S, Water recirculators

All Plasma Welding consols (i.e WC-1 Controller, WT Timer,

WF-100 Capstain Feeder, etc)

180 days parts and Labor Unless specified

Plasma Welding Torch and leads packages

Gas Regulators "Supplied with power sources" (No Labor)

90 days parts / No Labor

Remote Controls

MIG and TIG Torches (Supplied with power sources)

Replacement repair parts

30 days parts / No Labor

MIG Torch for Fabricator 141i

5-2-1 years Parts / No Labor

FirePower® Welders

5 Years Parts / No Labor

Victor® Professional

Victor Technologies limited warranty shall not apply to:

Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that fail due normal wear

* Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized VICTOR TECHNOLOGIES® repair facility within thirty (30) days of the repair.

* No employee, agent, or representative of VICTOR TECHNOLOGIES® is authorized to change this warranty in any way or grant any other warranty, and VICTOR TECHNOLOGIES® shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of VICTOR TECHNOLOGIES®’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 VICTOR TECHNOLOGIES®'s sole judgment, impaired the safety or performance of any VICTOR TECHNOLOGIES® product. Purchaser’s rights under this warranty are void if the product is sold to purchaser by unauthorized persons.

Page 84

THE AMERICAS

Denton, TX USA U.S. Customer Care

Ph 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph 1-940-381-1212 Fax: 1-940-483-8178

Miami, FL USA Sales Office, Latin America

Ph 1-954-727-8371 Fax: 1-954-727-8376

Oakville, Ontario, Canada Canada Customer Care

Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree)

EUROPE

Chorley, United Kingdom Customer Care

Ph +44 1257-261755 Fax: +44 1257-224800

Milan, Italy Customer Care

Ph +39 0236546801 Fax: +39 0236546840

ASIA/PACIFIC

Cikarang, Indonesia Customer Care

Ph 6221-8990-6095 Fax: 6221-8990-6096

Rawang, Malaysia Customer Care

Ph +603 6092-2988 Fax: +603 6092-1085

Melbourne, Australia Australia Customer Care

Ph 1300-654-674 (tollfree) Ph 61-3-9474-7400 Fax: 61-3-9474-7391

International

Ph 61-3-9474-7508 Fax: 61-3-9474-7488

Shanghai, China Sales Office

Ph +86 21-64072626 Fax: +86 21-64483032

Singapore Sales Office

Ph +65 6832-8066 Fax: +65 6763-5812

INNOVATION TO SHAPE THE WORLD™

U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178