ARCMASTER
401S
Operating
Manual
3163339
Art # A-12546_AB
Revision: AC Issue Date: November 11, 2014 Manual No.: 0-5345
Tweco.com
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:
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or visit us on the web at www.Tweco.com
!
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 0-5345 for:
Tweco ArcMaster 401S Power Source Part Number W1009100
Published by:
Victor Technologies, Inc.
16052 Swingley Ridge Road,
Suite 300 St. Louis, MO 63017
USA
www.victortechnologies.com
Copyright © 2014 by
Victor Technologies, Inc.
® All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this Manual, whether such error results
from negligence, accident, or any other cause.
Publication Date: April 25, 2014
Revision Date: November 11, 2014
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 Principal Safety Standards .............................................................................. 1-6
1.03 Symbol Chart .................................................................................................. 1-7
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
2.10 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 401S Power Source Controls, Indicators and Features .................. 3-6
3.09 Welding Parameters ...................................................................................... 3-10
3.10 Setup for TIG (GTAW) Welding ..................................................................... 3-12
3.11 Setup for STICK (SMAW) Welding .............................................................. 3-13
3.12 Special Function ........................................................................................... 3-15
3.13 Shielding Gas Flowmeter/ Regulator Operating Instructions ......................... 3-16
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
TABLE OF CONTENTS
SECTION 6:
KEY SPARE PARTS ................................................................................... 6-1
6.01 401S Power Source Spare Parts ..................................................................... 6-1
APPENDIX A: CIRCUIT DIAGRAM ........................................................................ A-1
TWECO - LIMITED WARRANTY TERMS ............................................iNSIDE REAR COVER
This Page Intentionally Blank
ARCMASTER 401S 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 European Standard EN60974-1 entitled: Safety in welding and allied processes
Part 2: Electrical. 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
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
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.
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.
Manual 0-5345 1-1 SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401S POWER SOURCE
2. Wear approved safety glasses. Side shields
recommended.
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.
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.
6. Never wear contact lenses while welding.
Arc Current
(Amperes)
Less than 60
60-160
160-250
250-550
Minimum
Protective
Shade
7
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
8
10
10
11
6
8
10
11
4
5
6
8
8
9
10
11
12
14
10
12
14
12
14
6 to 8
10
12
14
4
5
6
8
9
12
14
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5345
ARCMASTER 401S POWER SOURCE
3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover them
WARNING
FUMES AND GASES can be hazardous to
your health.
Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.
1. Keep your head out of the fumes. Do not 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 vapours 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.
with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or
drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding current
from travelling 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
CYLINDERS can explode if damaged.
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
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.
can cause sparks, overheating, or fire.
2. Install and secure cylinders in an upright position by
1. Protect yourself and others from flying sparks and
hot metal.
2. Do not weld where flying sparks can strike flammable
material.
Manual 0-5345 1-3 SAFETY INSTRUCTIONS AND WARNINGS
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.
ARCMASTER 401S POWER SOURCE
!
4. Never allow a welding electrode to touch any
cylinder.
5. Use only correct shielding gas cylinders, flowmeters/
regulators, hoses, and fittings designed for the
specific application; maintain them and associated
parts in good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
WARNING
Engines can be dangerous.
WARNING
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from
battery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
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.
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 fuelling. If possible,
check and add fuel to cold engine before beginning
job.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working
on a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuelling is spilled, clean up before
starting engine.
STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
The coolant in the radiator can be very hot
and under pressure.
SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5345
ARCMASTER 401S POWER SOURCE
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.
ABOUT PACEMAKERS:
3. Allow pressure to escape before completely
removing cap.
!
WARNING: This product contains chemicals, including
lead, known to the State of California to cause birth
defects and other reproductive harm.
after handling.
WARNING
Wash hands
NOTE
Considerations About Welding And The
Effects of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology
Assessment, 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.”
The above procedures are among those
also normally recommended for pacemaker
wearers. Consult your doctor for complete
information.
To reduce magnetic fields in the workplace, use the
following procedures.
1. Keep cables close together by twisting or taping
them.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cable around the body.
4. Keep welding Power Source and cables as far
away from body as practical.
Manual 0-5345 1-5 SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401S POWER SOURCE
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous
Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235
Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5345
ARCMASTER 401S POWER SOURCE
1.03 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
Hertz (cycles/sec)
Frequency
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
t2
Preflow Time
Postflow Time
2 Step Trigger
Operation
t1
Press to initiate wirefeed and
welding, release to stop.
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
115V 15A
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.
Receptacle RatingAuxiliary Power
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
V
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
IPM
MPM
S
S
4 Step Trigger
Operation
Burnback Time
Inches Per Minute
Meters Per Minute
See Note
See Note
Art # A-04130_AB
Manual 0-5345 1-7 SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401S POWER SOURCE
This Page Intentionally Blank
SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5345
ARCMASTER 401S 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.
Manual 0-5345 2-1 INTRODUCTION
ARCMASTER 401S POWER SOURCE
2.04 Description
The Tweco ArcMaster 401S is a welding power source
incorporating to provide TIG, 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 401S Inverter Power Source (Part
No. W1009100)
• ArcMaster 401SInverterPower Sourcew/10ft
input power cable
• 50mm male Dinse connector × 2
• OperatingManual,English
• CD-OperatingManual(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.
INTRODUCTION 2-2 Manual 0-5345
ARCMASTER 401S POWER SOURCE
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.
90
80
70
60
50
40
30
SAFE OPERATING REGION
20
Duty Cycle (PERCENTAGE)
10
3 phase
1 phase
0
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
Manual 0-5345 2-3 INTRODUCTION
ARCMASTER 401S POWER SOURCE
2.10 Specifications
Description ArcMaster 401S
Power Source Part Number W1009100
Power Source Mass 51lb (23kg)
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) 14.4kW
STICK (SMAW)
Welding Output, 40ºC, 10 min.
TIG (GTAW)
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)
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)
Table 2-2: Specification
INTRODUCTION 2-4 Manual 0-5345
ARCMASTER 401S 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 combination 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.
Manual 0-5345 2-5 INTRODUCTION
ARCMASTER 401S POWER SOURCE
This Page Intentionally Blank
INTRODUCTION 2-6 Manual 0-5345
ARCMASTER 401S 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, bya qualied
electrician.
• Correctlyearthed(electrically)inaccordancewith
local regulations.
• Connectedtothecorrectsizepowerpointandfuse
as per the Specifications on page 2-4 (2-6).
!
WARNING
Any electrical work must be carried out by a
qualified Electrical Tradesperson.
Manual 0-5345 3-1 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S 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).
INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5345
ARCMASTER 401S 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 529VAC 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.
Manual 0-5345 3-3 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S POWER SOURCE
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.
INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5345
ARCMASTER 401S POWER SOURCE
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.
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. Earthing of the Workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
because of it’s size and position, e.g. ship’s hull
or building steelwork, a connection bonding
the workpiece to earth may reduce emissions
Manual 0-5345 3-5 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S POWER SOURCE
3.08 ArcMaster 401S Power Source Controls, Indicators and Features
1
2
3
4
Art # A-12453_AB
7
6
5
11
8
9
13
12
Figure 3-2
INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5345
ARCMASTER 401S 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 401S. The red LED will be on when unit is powered up. 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 (standby below 12V). When arc is established, red LED will blink (above 12V).
Adjustment
Potentiometer
VRD Switch
Art # A-12454
Figure 3-3
2 Parameter Selection Button
This button is used to select between HOT START, WELDING CURRENT, and ARC FORCE while in SMAW (STICK)
mode and HOT START and WELDING CURRENT in TIG mode. Refer to 3.12 Special Function for more info.
3 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.
4 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 3.12 Special Function for more info.
5 Process Selection Button
The process selection control is used to select the desired welding mode. Five modes available for 401S. These
modes are selected by pressing the selection button. For modes where there are two variations available press
and hold the button until it blinks to select the second function.
Manual 0-5345 3-7 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S POWER SOURCE
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 vertical up (SMAW)- The Process light is illuminated; 6010 Vertical down (SMAW)- the light is blinking.
6 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 3.12 Special Function for more info.
7 Contactor Control
Contactor Control either enables the weld output or assigns this function to a remote device. Refer to 3.12
Special Function for more info.
8 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.
9 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.
10 Intelligent Fan Control
The intelligent cooling system is designed to reduce dust and foreign material build-up, while providing optimum
cooling. Machine does a fan test at startup. Fan speed is controlled by various parameters and follows no
fixed sequence. Parameters are: - temperatures measured by temperature sensors - output current - output
active - welding time. If machine is switched on in a cold state, fans will be off (except fan test). If machine
is switched off, while it’s hot and running with high fan speed, and then switched back on, fans will turn on
with high speed again. After machine has cooled down, fans will stop.
INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5345
ARCMASTER 401S POWER SOURCE
11 14 Pin Remote Control Socket
The 14 pin Remote Control Socket is used to connect Remote Control devices to the welding Power Source.
To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
Pin Function Description
16 VDC supply voltage for contactor. Connect A & B for
A +16VDC contactor
B Contactor in Contactor input. Connect A & B for contactor enable.
C +10VDC Remote Ctrl (Max) 10 VDC for remote potentiometer supply
D Remote ctrl ground/common (min) Also control circuit common
E Remote Input 0<=Vin<=10V
F n.c.
G Chassis ground
H n.c.
I n.c.
J n.c.
K CAN_high CAN bus; positive signal
L CAN_low CAN bus; negative signal
M Current detect relay 1 Relay contact between M & N will close while welding is active
N Current detect relay 2
Table 3-2 14 Pin Interconnection Control Plug Configuration
contactor enable.
12 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.
13 Input Cable
The input cable connects the Primary supply voltage to the equipment.
Manual 0-5345 3-9 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S POWER SOURCE
3.09 Welding Parameters
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
Contactor Control
the peak start current on top of the (WELD) current.
Weld Current (Amperage) - when lit Encoder Control sets the STICK and TIG
WELD current.
Contactor operation in 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.
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.
Remote Control
Table 3-3 Welding Parameters Description
Weld Process Selection
Weld Mode
Weld
Parameter
STICK/
GOUGING
HOT START
√ √ √
WELD (A)
√ √ √
ARC FORCE
√ √ ×
Weld Parameter Descriptions
HOT START
This parameter encoder controls 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.
6010 VERTICAL UP/
6010 VERTICAL DOWN
Table 3-4 Weld Process Selection verses Weld Mode
LIFT
TIG
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).
Description
WELD (A)
This parameter encoder controls the Stick, Gouging, and TIG weld current.
INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5345
ARCMASTER 401S POWER SOURCE
ARC FORCE CONTROL
This parameter encoder controls 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 3-5 Weld Parameter Descriptions
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.
Normal arc, Improved fusion
characteristics, Normal penetration
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
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
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 3-6 Weld Parameter Setting
Incremental
Unit
Manual 0-5345 3-11 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S POWER SOURCE
!
3.10 Setup for 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. Fit the gas 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 3-7 TIG Welding Current
G. 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
1
2
100
Art # A-12455
Figure 3-4 Arc Ignition
INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5345
Graphic for TIG
I Current
I1 Welding current
ISt Hot start current
Iz Short circuit
t Time
tSt Hot start
ARCMASTER 401S POWER SOURCE
Art # A-12456
Figure 3-5 TIG Current Routing Diagram
Positive Welding
Terminal (+)
Work Lead
ARCMASTER 401S
Negative Welding
Terminal (-)
Tig Torch
Art # A-12554
Figure 3-6 Setup for TIG (GTAW) Welding
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.
Manual 0-5345 3-13 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S POWER SOURCE
!
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 or 6010 Process LEDs are lit.
STICK Welding Current Range Factory setting
Welding current l1
10 to 300 A (1 phase)
100
10 to 400 A (3 phase)
Table 3-8 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.
Graphic for SMAW (STICK)
I Current
I1 Welding current
ISt Hot start current
t Time
tSt Hot start time
Art # A-12457
Figure 3-7 STICK Current Routing Diagram
Positive Welding
Terminal (+)
Electrode Holder
ARCMASTER 401S
Negative Welding
Terminal (-)
Work Lead
Art # A-12555
Figure 3-8 Setup for STICK (SMAW) Welding
INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5345
3.12 Special Function
Parameter Selection
Button
ARCMASTER 401S POWER SOURCE
Contactor Control
Remote Control
Art # A-12547_AB
Gouging and 6010 Vertical Down
There are two special functions that can be accessed by pressing the selection button for 2 seconds: Gouging
and 6010 Vertical Down.
Gouging - In Stick mode hold the process Selection Button for 2 seconds and the LED will blink indicating
Gouging mode is enabled.
6010 Down - In 6010 mode hold the process Selection Button for 2 seconds and the LED will blink indicating
6010 Vertical Down 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 Process Selection Button
Figure 3-9
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 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.
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 401S 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.
Manual 0-5345 3-15 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S POWER SOURCE
3.13 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 user's
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 3-10 Adjusting Flow Rate
INSTALLATION, OPERATION AND SETUP 3-16 Manual 0-5345
ARCMASTER 401S 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 3-11 Adjust Flow Rate
Manual 0-5345 3-17 INSTALLATION, OPERATION AND SETUP
ARCMASTER 401S 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.
INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5345
ARCMASTER 401S 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 0-5345 4-1 BASIC WELDING GUIDE
ARCMASTER 401S 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 0-5345
ARCMASTER 401S 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 0-5345 4-3 BASIC WELDING GUIDE
ARCMASTER 401S 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.
BASIC WELDING GUIDE 4-4 Manual 0-5345
ARCMASTER 401S POWER SOURCE
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 6.0mm 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
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
Manual 0-5345 4-5 BASIC WELDING GUIDE
ARCMASTER 401S POWER SOURCE
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
6
3
1
5
2
4
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 at 100 amps.
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
BASIC WELDING GUIDE 4-6 Manual 0-5345
ARCMASTER 401S POWER SOURCE
2. Vertical Down
The electrode makes welding in this position particularly easy. Use a electrode at 100 amps. 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
Manual 0-5345 4-7 BASIC WELDING GUIDE
ARCMASTER 401S POWER SOURCE
Upsetting
Art # A-07706_AC
Weld
Permanent Upset
Contraction
with tension
cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does
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 0-5345
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.
Art # A-07707
ARCMASTER 401S POWER SOURCE
Figure 4-21: Principle of Presetting
Art # A-07708
B
Dotted lines show effect if no preheat is used
Weld
C
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
3
Art # A-07710_AB
1
2
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
Figure 4-24: Welding Sequence
2
3
4
Figure 4-25: Step back Sequence
1
Manual 0-5345 4-9 BASIC WELDING GUIDE
ARCMASTER 401S POWER SOURCE
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 run.
B
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
BASIC WELDING GUIDE 4-10 Manual 0-5345
ARCMASTER 401S POWER SOURCE
FAULT CAUSE REMEDY
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 run 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.
Manual 0-5345 4-11 BASIC WELDING GUIDE
ARCMASTER 401S POWER SOURCE
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
FAULT CAUSE REMEDY
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 0-5345
Figure 4-28: TIG Welding Application Shot
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 401S 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 0-5345 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
ARCMASTER 401S POWER SOURCE
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
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
11-15 Butt/Corner
15 Butt/Corner
15 Butt/Corner
21 Butt/Corner
21 Butt/Corner
Joint Type
Lap/Fillet
Lap/Fillet
Lap/Fillet
Lap/Fillet
Lap/Fillet
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.
BASIC WELDING GUIDE 4-14 Manual 0-5345
FAULT CAUSE REMEDY
6 Electrode melts or oxidizes
when an arc is struck.
A Torch lead connected
to positive welding
terminal.
B No gas flowing to
welding region.
ARCMASTER 401S POWER SOURCE
A Connect torch lead to negative welding
terminal.
B Check the gas lines for kinks or breaks
and gas cylinder contents.
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.
7 Dirty weld pool A Electrode contami-
nated by contact with
work piece or filler rod
material.
B Work piece surface has
foreign material on it.
C Gas contaminated with
air.
8 Poor weld finish Inadequate shielding
gas.
9 Arc start is not smooth. A Tungsten electrode is
too large for the welding current.
B The wrong electrode
is being used for the
welding job.
C Gas flow rate is too
high.
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 0-5345 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.
ARCMASTER 401S POWER SOURCE
This Page Intentionally Blank
BASIC WELDING GUIDE 4-16 Manual 0-5345
ARCMASTER 401S POWER SOURCE
!
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 0-5345 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
ARCMASTER 401S 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
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.
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 any button. As long as there is an error code
on display welding is not possible.
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.
E08-11 V/I Acquisition Voltage/current measuring
systems faulty
E08-13 CAN Identification Unknown device connected Check connected devices and CAN
Switch machine off and on again,
ex ecute master reset
Center for repair
Center for repair
Reduce motor load
Switch the equipment off and on
again
Take to an accredited Tweco Service
Center for repair
connections
POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-2 Manual 0-5345
ARCMASTER 401S POWER SOURCE
Code Error Cause Possible Remedy
E09 Output Voltage Voltage measuring system
faulty
E12 Power Section Power section start-up faulty Take to an accredited Tweco Service
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
E41 Phase Loss The primary DSP detected a
E47 Undefined Mains Mains voltage between per-
Fault current to protective
earth con ductor
the socket
loss of at least one phase of
the mains.
mitted ranges
Table 5-2 Power Source Error Messages
Take to an accredited Tweco Service
Center for repair
Center for repair
Take to an accredited Tweco Service
Center for repair
Take to an accredited Tweco Service
Center for repair
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
Take to an accredited Tweco Service
Center for repair
Check mains
Manual 0-5345 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
ARCMASTER 401S 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 0-5345
SECTION 6:
KEY SPARE PARTS
6.01 401S Power Source Spare Parts
ARCMASTER 401S POWER SOURCE
43
8
3
16
20
13
19
10
33
25
28
22
27
23
34
38
35
30
14
39
15
2
Art # A-12460_AB
7
17
5
9
24
29
40
36
12
21
37
26
11
1
4
42
41
11
18
6
32
31
Figure 6-1 ArcMaster 401S Spare Parts
ArcMaster 401S 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 0-5345 6-1 KEY SPARE PARTS
ARCMASTER 401S POWER SOURCE
Item Description
10 Display Panel Overlay 1 W7006749
11 Cover black AD 10,3 LD 9,5 1 W7006751
12 Strain relief 1 W7006710
13 Foam Spacer 1 W7006711
14 Foam inlay 1 W7006712
15 Foam inlay 1 W7006713
16 Foam Plate Self-adhesive 1 W7006714
17 Rear Filter 1 W7006715
18 Wire Gauze 1 W7006716
19 Knob Body 1 W7006717
20 Knob Cap 1 W7006718
21 Control PCB PCB 5 1 W7006719
22 Capacitor PCB PCB 3 1 W7006720
23 Output PCB PCB 7 1 W7006721
24 ADP10 PCB PCB 6 1 W7006722
25 Front Panel PCB PCB 4 1 W7006752
26 Main Power PCB PCB 2 1 W7006724
27 Input PCB PCB 1 1 W7006725
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 W7006753
33 Insulating Bush 1 W7006732
34 Insulation Foil 3 W7006733
35 Insulation Foil 1 W7006734
36 Shunt 1 W7006735
37 50 mm Dinse Output Terminal 2 W7006739
38 Output Diode D1, D2, D3 3 W7006740
39 Unit Thermal Sensor TS1 1 W7006741
40 Cooling Fan M1 1 W7006742
41 Label +/- Tweco 1 W7006744
42 Label 401S 1 W7006750
43 Warning Sticker 1 W7006746
44 Sticker Tweco 261 x 93 (not shown) 2 W7006748
Table 6-1 ArcMaster 401S Spart Parts
Des. Ref. Quantity Part Number
KEY SPARE PARTS 6-2 Manual 0-5345
ARCMASTER 401S POWER SOURCE
APPENDIX A: CIRCUIT DIAGRAM
X4
14pin.
Brennertaster
AGB
C
D
E
Current detect
M
N
CAN
K
L
Art # A-12671
X3/1
M
M1
X2/1
X2/2
LP4
LP3
LP2
LP1
A1
Rel01
-
+
LP9
LP7
LP8
LP6
~
~
~
X5/4
X5/3
X5/2
X5/1
-
B
A
+
A4
TR1
X3/5
X3/6
BF 04
A8
M
M2
X10/1
X10/2
X6/8
X6/7
X6/6
X6/5
X6/4
X6/3
X6/2
X6/1
DRV04
X7/2
X3/4
X3/2
X6/1
X6/2
X3/14
X3/13X2/3
X3/12X2/2
X3/11
16
X1 X1
X7/10
X7/9
X7/8
X7/7
X7/5
X7/4
X7/6
X7/3
X7/2
X7/1
X5/6
X5/8
X5/7
A9
X2/4
CAN-TV
A10
X2/1
X1-1X8/1
X1-2
X1/3
X1/4
X8/2
X8/3
X8/4
Mapro
X5/1
X5/2
~
-
AC
~~
3
AC
+
AC
+
A2
PEL1
L3
L3
L2
X1
7
L2
5
L1
1
Q1
KL
A3
SF02
X7/1
3
4
1
2
F1
T1
A5
X2/1
DC01
X2/2
X2/3
X2/4
A7 A8
A8
X2/6
X2/5
R1
X3
+
+
X2
Manual 0-5345 A-1 APPENDIX
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.
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.
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
© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in Germany
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