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Service Manual ARCMASTER® 400 MST

1. E TB10 c C bug G k 12 PCB10 IGBT Gate G Circuit Circuit Board C Q3 1 Board 015 WK 5479 WK 5479 D GET 5 a4 E7218 CL ate IK EX EX 05 FI Cx 017 y T E3 2 2 8 DK 4 CT ais O k 1 E om dinis i dom ci E A 4 PCB2 ae ju T1 i i Filter u Link l Q7 TB5DC C 019 Circuit Board 5 Circuit Board TB1 CE G UB1 86 G WK 4917 WK 5597 HA HK ORB M 7 11 E a 4 IGBT oS 99 gt Gate G a lt TBA 1 Gate 1 ate v Circuit OAK Circuit OF 55 Board 09 1 Board 021 547 547 WK 5479 WK 5479 PCB4 Detect Circuit Board WK 4819 CN5 CN6
2. 21 9 1CN11 Lt 400MST 9 ADVANCED TROUBLESHOOTING 6 Remove five screws three terminals and five connectors from PCB2 WK 5597 7 Cut off one snap band Remove two board supports and then remove PCB2 WK 5597 and the insulat ing sheet 2 4 3 PCB3 WK 5548 PCB7 WK 5689 1 Remove the side cover Reference page 9 1 Remove PCB4 WK 4819 Reference page 9 26 Remove PCB6 WK 5688 Reference page 9 27 Remove PCB5 WK 5696 Reference page 9 26 Disconnect 11 connectors from PCB3 WK 5548 oa OQ Inm 400MST 9 ADVANCED TROUBLESHOOTING 6 Loosen two screws Rotate the resistors R2 and R3 to expose two screws WK 5548 7 Remove one screw and three ground terminals Remove four screws and remove PCB3 PCB Dis connect five connectors from PCB7 WK 5689 8 Disconnect one connector and remove two screws and then remove PCB7 WK 5689 from WK 5548 Remove one screw and one ground terminal from PCB7 WK 5689 400MST 9 ADVANCED TROUBLESHOOTING 9 Disconnect two connectors from PCB3 WK 5548 2 4 4 4 WK 4819 1 Remove the side cover Reference page 9 1 2 Disconnect three connectors Remove two screws and disconnect three connectors and then remove PCB4 WK 48
3. 5 1 6 BASIC TROUBLE SHOOTING 1 Solving MIG Problems Beyond the Welding 6 1 u et 6 1 1 2 Inconsistent Wire Feed 2 2 2 2 66 eee dae ede eee 6 1 2 MIG Welding Problems x aa eoe Rer aer he eae We ee dt ats Wee ae ek ee 6 2 3 TIG Welding RrODle MS el atin e alicia sp e na fk 6 3 4 Stick Welding Problems aries fees et e ad e eee ne mie oe eee eee ede 6 4 5 Power Source Problemis 5 to ce te e e o eee dre PN Poenum aem da 6 6 7 VOLTAGE REDUCTION DEVICE VRD 1 VRD Specifications b 7 1 S VBD Maititenalicern m PQ te tse tap ar educ tnt a RC a T er 7 1 Ss owitching VRD uu u Diyuspa cuc aie lee Suk Lie akg ee cp ie eee Sete Sec ay ees 7 1 8 POWER SOURCE ERROR CODES 8 1 9 ADVANCED TROUBLESHOOTING 1 System Level Fault Isolation ccc cewek ee RR DERE LOO RR Ree EEE ES 9 1 1 1 Opening the EnclosUte xc oer ede tttm Io RD e cede os ee ie p eee ea e nae dece 9 1 1 2 Verification and Remedy to the Indicated Error Codes 2 9 4
4. 4 Negative Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal It is essen Figure 3 1 400MST Power Source tial however that the male plug is inserted and turned securely to achieve a sound electrical connection 400MST 3 OPERATOR CONTROLS CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal and or melting of the hous ing case 5 Remote Control Socket The 19 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source To make connections align keyway insert plug and rotate threaded collar fully clockwise Function Contactor circuit 15 Volts Contactor circuit in closure between pin A and Pin B will energize output Scaled output voltage signal Vfb 10 Arc Volts Volt 24 VAC auxiliary power high side 115 VAC auxiliary power high side Chassis ground Remote control maximum Remote control wiper 0 10 Volts Remote Control minimum Remote control wiper 0 10 Volts Control circuit common Arc Establish 12 Volts Control Circuit common 24 VAC auxiliary power high side 24 115 VAC neutral N C N C Scaled output signal 100 Amps Volt lt 4 MO D Z r A e T Omo oO 6 ON OFF Switch This switch conn
5. EN time or touch other people with the holder or electrode 8 Do not use worn damaged undersized or poorly spliced cables WARNING 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground ELECTRIC SHOCK can kill 11 Do not touch electrode while in contact with the work ground circuit Touching live electrical parts can cause fatal shocks or 12 Use only well maintained equipment Repair or replace damaged severe burns The electrode and work circuit is electrically parts at once live whenever the output is on The input power circuit and machine internal circuits are also live when power 13 In confined spaces or damp locations do not use a welder with is on In semiautomatic or automatic wire welding the AC output unless it is equipped with a voltage reducer Use wire wire reel drive roll housing and all metal parts equipment with DC output touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard 14 Wear a safety harness to prevent falling if working above floor level Rp 1 Do not touch live electrical parts 15 Keep all panels and covers securely in place 2 Wear dry hole free insulating gloves and body protection 4h 3 Insulate yourself from work and ground using dry insulating mats or covers WARNING 4 Disconnect input power or stop engine
6. 2 9 28 2 4 9 PCB12 WK 5527 a En ntt son ae Rr dm 9 28 2 4 10 PCB13 WK 5528 Rr ERRARE ER ERR pat RE RE ER 9 29 2 4 11 PCBT4 WK B594 o eae er a etc eene ont pen od dor P dec ene ele Que ee te RT ee 9 30 2 412 els E ESSI 9 31 2 4 13 PCB16 WK 4917 dus be nat paies E d ts RE Rr RETE Ros 9 32 2 4 14 PCB17 WK 5699 rhe E a e capa ete tH RA 9 33 94 45 PCB18 WK 5499 sieri Bonde EB RYE 9 33 2 4 6 Inductor sites reme ete ee y em quedes ERR som Se ae aa 9 34 2 4 17 Thermistor THI oir eC Fx een de eiae ee 9 35 2 421 cs tte ne retour alte Bleed 9 36 2 4 19 Fan de Ree heh x Lae eae ew el ee nea Hane Re 9 36 2 4 20 Switch ST i i eine ates ata CTI Rt RA a gee 9 37 2 4 21 Switchi S2 arid S3 ten ie eo a A US P GOR A Q AR ra an D AN Ce nr ee 9 38
7. Nuance de Op ration de coupage Dimension eode Nuance de Epiasseur de m tal ou Epiasseur de m talou ou soudage No filtre oculaire ou soudage filtre oculaire Intensit de courant Intensit de courant Brassage tendre toutes conditions 2 Soudage a l arc sous gaz au chalumeau avec fil plein GMAW Brassage fort toutes conditions 4 m taux non ferreux toutes conditions 11 au chalumeau Soudage l arc sous gaz avec moins de 1 po 25 mm 3 ou 4 lectrode de tungst ne GTAW toutes conditions 4 Soudage l hydrog ne de 1 46 po 2541 4 e146 po 25 4 150 mm ou 5 atomique AHW toutes conditions 12 z Soudage 4 l arc avec ER pais lus de 6 po 150 mm 50u6 tout t 12 po lectrode de carbone CAW outes E Soudage aux gaz 227771 Soudage 4 l arc Plasma PAW toutes dimensions mince moins de 1 8 po 3 mm 4045 Gougeage Alr Aro aveg lectrode de carbone ________ 1084102 8812 5 ou 6 pais plus de 1 2 po 12 mm 60u8 pais Soudage l arc avec lectrode enrobees moins de 5 32 po 4 mm SMAW o 5 32 amp 1A po 4 46 4 mm 12 plus de 1 4 po 6 4 mm 14 Coupage l arc Plasma PAC moins de 300 amperis de 300 4 400 amperes pais plus de 400 amper s Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si
8. 5 2 4 22 Current Sensor HCT ater a n son e RO nera 9 39 2 4 23 Diode D1 soute EL laya eee ee RUNE Eo or Rm a dos Rod ek bate eee 9 39 2 4 24 Diode D2 D4 D5 and DZ i Lie AR entree er Eh dre aa Ur T 9 40 2 4 25 Current Transformer CT2 9 41 2 4 26 Reactor LI ise wen dut eee va Dee eet iene anne de UE ut 9 41 2 4 27 Molded Case Circuit Breaker MCB1 and 2 9 42 2 4 28 esistor H2 and RIJ u edd nere Run cid ae OL Rua Ret ce TRUE a leech a Eee 9 43 2 4 29 Transformer T1 4244228 Re mer ue IE REP dede FR Rp Re dnos 9 44 2 4 30 14 Pin Heceptacle CONT m rte rn ae Oe UR e peek Poe ate erteilen m o aac Rente 9 47 2 4 31 19 Pin Receptacle 2 9 48 APPENDIX 1 SPARE PARTS LIST 1 Equipment Identification x itcr nce eats le Ste abe TER ae wad ee ee RUE e oerte 10 1 2 How Use This Parts 10 1 APPENDIX 2 CONNECTION WIRING GUIDE APPENDIX 3 INTERCONNECT DIAGRAM APPENDIX 4 DIODE TESTING BASIC ARCMASTER 400 MST 1 0 SAFET
9. Inductance control in MIG Mode Start current in amps is added to the WELD A WELD A current for STICK or LIFT TIG Adjusts percentage increase in welding current and is proportional to arc length arc voltage Table 3 2 Weld Process selection verses Weld Mode 4 Weld Parameter Descrip tions 4 1 WELD V This parameter sets the MIG weld arc voltage in MIG mode 4 2 INDUCTANCE This parameter sets the INDUCTANCE when MIG welding It controls the dynamic properties of the arc in dip transfer welding mode When this param eter is set to 0 ie minimum inductance the arc has a fast response with a resulting crisp arc noise and coarse spatter When this parameter is set to 100 maximum inductance the arc has a slow response with a resulting soft arc and fine spatter NOTE As the INDUCTANCE is increased the WELD V may need to be adjusted to achieve the desired weld characteristic 400MST 3 OPERATOR CONTROLS 4 3 HOT START This parameter operates in STICK mode and improves the start characteristics for stick elec trodes e g low hydrogen electrodes It sets the peak start current on top of the WELD current e g HOT START current 150 amps when Weld Current 100 amps amp HOT START 50A 4 4 WELD A This parameter sets the STICK amp Lift TIG weld cur rent 4 5 ARC CONTROL This parameter operates in STICK mode only and is used to adjust pe
10. 400MST 9 ADVANCED TROUBLESHOOTING 4 Remove one screw one terminal and one nut 2 4 17 Thermistor TH1 MBOR 1 Remove the side cover Reference page 9 1 2 Cut off one snap band and disconnect one connector Remove one screw and remove the thermistor TH1 When replacing the thermistor with a new one apply an oil compound SHINETSU SILICONE G 747 or equivalent evenly to the base 9 35 400MST 9 ADVANCED TROUBLESHOOTING 2 4 18 Thermistor TH2 MBOR 1 Remove the side cover Reference page 9 11 2 Remove PCB17 WK 5699 3 Cutoff three snap bands and disconnect one connector Remove one screw and remove the thermistor TH2 When replacing the thermistor with a new one apply an oil compound SHINETSU SILICONE G 747 or equivalent evenly to the base 2 eo ZE Say ral o 1 oo 9 9 2 4 19 Fan 1 1 Remove the side cover Reference page 9 1 2 Remove four screws and open the rear cabinet 400MST 9 ADVANCED TROUBLESHOOTING 4 Remove two screws and remove the fan FAN1 Pay attention to the installation direction of the fan A ROTATION 2 4 20 Switch S1 1 Remove the side cover Referen
11. 9 48 400MST 9 ADVANCED TROUBLESHOOTING 4 Cut off one snap band Cut off one snap band that ties together the harness of CN7 on PCB17 WK 5699 and the harness wired to the rear side Cut off one snap band that ties together the harness on the secondary side of the transformer T1 and the harness of CN7 CN1 on PCB17 WK 5699 E 5 Remove five snap bands When reinstalling the receptacle bend both the harnesses of CN6 CN7 CN9 CN10 on PCB17 WK 5699 and the ones of N pin L pin of the 19 pin receptacle CON2 and then use snap bands to tie together the bent harnesses and the ones of CN1 CN5 CN8 on PCB17 WK 5699 400MST 9 ADVANCED TROUBLESHOOTING 6 Disconnect three connectors Remove one screw and three ground terminals Cut off two snap bands ME pr EJ Dk c 7 Cut the harnesses of N pin L pin of the 19 pin receptacle CON2 which are connected with the insu lated terminals x KZ APPENDIX 1 PARTS LIST 1 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate atta
12. Confirm the wiring and connections on the 14 pin receptacle or 19 pin receptacle located on the wire feeder equipment c Verify the circuit breaker used for the wire feeder equipment power supply MCB1 and MCB2 Confirm whether MCB1 or MCB2 has tripped or not When the MCB trips the yellow knob will be exposed NOTE If the circuit breaker of the wire feeder power sup ply has tripped there are other possible failures that must be considered For example the capacity of the wire feeder equipment motor is large or there are some other problems in the wire feeder equipment Before continuing onto the next sec lion verify and eliminate the above possible failure conditions Refer the operating manual supplied by the wire feeder manufacture e Press the yellow knob down AFTER the faults in the wire feeder equipment are resolved If the wire feeder equipment still does not operate verify MCB1 and MCB2 Replace them if necessary Refer to section 9 2 4 27 for the replacement of MCB1 and MCB2 d Verify the transformer T1 and replace it if nec essary Refer to section 9 2 4 29 for the replacement of T1 e Verify the wire feeder equipment and replace it if necessary Refer to the operating manual supplied by the wire feeder manufacture before any work is performed on the wire feeder 1 3 3 No weld output Cause Occurs when the 14 pin receptacle 19 pin recep tacle or associated circu
13. Verify the condition of FAN1 Verify that there are no broken or cracked fan blades and that FAN1 is not producing any abnormal sounds If broken or cracked 1 blades or abnor mal sounds are emanating from FAN1 replace FAN1 Refer to section 9 2 4 19 for the replacement of FAN1 Refer to section 9 1 4 4 for additional FAN1 tests Verify the operation of the cooling fan and replace it if the condition of FAN1 is inactive Follow the instruction in section 9 1 4 4 d Replace WK 5548 Refer to section 9 2 4 3 for the replacement of PCB3 400MST 9 ADVANCED TROUBLESHOOTING 1 2 2 E02 Over Temperature at the secondary side Cause Occurs when an over temperature condition of the secondary IGBT and diode are detected Verification Remedy a Unit may be in thermal shutdown mode e Review the rated duty cycle of the unit per section 2 6 Exceeding the duty cycle can damage the unit and void the warranty Refer also to section 2 7 for addi tional information b Verify the ventilating condition Maintain a clear and unobstructed distance of more than 12 in in the front and more that 20 in in the rear of the unit for ventilation pur poses Verify and maintain clean dust free front and rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working envi ronment is recommended Extremely dusty environments will r
14. wei 5 2 enso 3 PCB5 Control Souce 4 Conect Circuit Board Circuit Board WK 5696 WK 5548 ee ee EE 5 EN131 1 2 CN130 Em PCB6 8 Control o 5 Circuit Board WK 5688 mnl gt gt nn sr E CN27 CN18 PCB7 CN3 z 2 i ircui 6 6 CN CN16 CN2 CN19 cups 21446 ARP SE S S 18445 1 3 4 H 35 5 Le 121311 5 E a s Ji 2 5 2845 213 OV PCB17 Socket Receptacle Circuit Board m NIS z 6 5 WK 5699 CN5 CN10 CN9 CN8 15V TB1 112131415 6 11213141516 71H11121314 11213141516 400MST INTERCONNECT DIAGRAM PCB15 DIODE Snubber Circuit Board WK 5606 Ground 1 1 18 HB e 7 Board SIDE CHASSIS 3 WK 5499 0 lt UB4 eae Output erminal FRONT PANEL al ee G Ground R2 TH2 TH1 1 4 R8 SIDE CHASSIS 2 8 2
15. 9 26 10 6635 Print Circuit Board WK 5696 9 26 W7001315 9 24 W7001317 9 28 W7001319 Print Circuit Board WK 5528 9 29 W7001320 Print Circuit Board WK 5594 9 30 W7001321 Print Circuit Board WK 5689 Print Circuit Board WK 5527 Print Circuit Board WK 4917 9 17 9 32 10 6740 400MST 9 ADVANCED TROUBLESHOOTING 2 o DWG Parts name Reference page Part No PCB1 Print Circuit Board WK 5493 9 22 W7001312 PCB6 Print Circuit Board WK 5688 9 27 W7001742 PCB8 Q1 Q6 Print Circuit Board WK 5479 9 27 W7001318 PCB9 Q7 Q12 Print Circuit Board WK 5479 9 27 W7001318 PCB10 Q13 Q18 9 28 W7001318 PCB11 Q19 Q24 9 28 W7001318 PCB15 Print Circuit Board WK 5606 9 31 W7001322 PCB17 Print Circuit Board WK 5699 9 33 W7001323 NI O 0 PCB18 Print Circuit Board WK 5479 Print Circuit Board WK 5479 Print Circuit Board WK 5499 9 18 9 33 W7001324 400MST 9 ADVANCED TROUBLESHOOTING Parts name Reference page Part No 14 PIN Receptacle 9 47 W7001302 19 PIN Receptacle 9 48 W7001303 Diode
16. 1 2 1 E01 Over Temperature at the primary 5 9 4 1 2 2 E02 Over Temperature at the secondary side 9 5 1 2 3 E03 Primary Over Current Failure 9 5 1 2 4 E11 High Input Voltage Fail re 4 44 etta re m hae u acr a P Rte dn 9 5 1 2 5 E12 Low Input Voltage 9 6 1 2 6 E14 Low Input Voltage 0 9 6 1 2 7 E81 Abnormal Input Voltage se plene aee reed eg rac a 9 6 1 2 8 E82 Rated voltage selection circuit 9 6 1 2 9 E83 Abnormal mains supply 1 4 9 6 1 2 10 E85 Pre Charge Error sur eer ed Rot RE o RU aie fa OR aal n Ren oh 9 7 1 2 11 E94 ThermistorFailute 2 RR m hr ERR Rez Cr Ra ee UR Re Roa de 9 7 1 2 12 E99 Initial Power Receiving lt lt ater e ae Pace ep eos a e ear tre ege ee 9 7 1 3 Verification and Remedy to Failures without Indication Codes 9 8 1 3 1 Cooling Fan Failure Fan is not rotating er eer eret o Y Ua uir te P ei ee ce na
17. 9 39 10 6769 Diode 9 40 10 6629 Diode 9 40 10 6629 Diode 9 40 10 6629 Circuit Breaker 9 42 W7001310 Circuit Breaker 9 42 10 2235 Switch 9 37 10 6857 Switch 9 38 10 5222 Switch 9 38 10 5222 Transformer 9 44 W7001326 9 19 400MST 9 ADVANCED TROUBLESHOOTING Z o Parts name Reference page Part No Current Trans 9 41 W7001304 Current Trans 9 41 W7001304 Cooling Fan 9 36 W7001307 Inductor 9 34 W7001308 Current Sensor 9 39 10 5003 Reactor 9 41 W7001309 Resistor 9 43 W7001325 Resistor 9 43 W7001325 Thermistor 9 35 10 5228 Thermistor 9 36 10 5228 jo N o oO 5 O 400MST 9 ADVANCED TROUBLESHOOTING 2 3 Service Tools 2 3 1 Tools and parts The tools and parts to be used for maintenance are shown by icons Philips Head S Long Nose Bi Silicon spanner Screwdriver Pliers Snap Band Compound 2 3 2 Notes of disassembly and assembly NOTE When removing the locking type connectors and board supporters disengage the locking mechanism first and then disconnect them Locking type connectors and board supporters are indicated in this manual using the following symbols black star marks for locking connectors and white star marks for locking board supports
18. Primary Primary Supply Current Lead Size Circuit Size Vin Amps Current amp Duty Cycle MIG STICK 208 63 230 57 460 29 208 49 230 44 Fitted 460 22 208 67 230 61 460 31 208 88 230 79 208 67 230 60 208 97 230 87 Table 2 2 Primary Current Circuit sizes to achieve max imum current 8 4 AWG minimum Factory 8 3 AWG minimum 400MST 2 INTRODUCTION AND DESCRIPTION 6 Specifications 400MST Parameter Rated Output Amperes Volts Duty Cycle 400 36 25 400A 26V 25 300A 22V 96095 200A 18V 100 400A 36V 25 STICK 300A 32V 60 200A 28V 100 400A 34V 25 MIG 300A 29V 96096 200A 24V 9 100 TIG STICK Output Current 5 400 Output Voltage Range MIG 5 36 V Open Circuit Voltage 65V Dimensions Width Height Length Weight 8 27 210mm 16 89 420mm 17 72 450mm 55 1 Ib 25 0 kg Output Rated Load Rated Input Voltage Output Amperes Output Volts Duty Cycle KVA KW Three phase Single phase 208 230 460V 208 230V 400A 300A 36V 32V 25 25 24 0 20 0 18 0 12 0 Output No Load KVA KW 0 5 0 13 Input Volts Single Phase 208V 230V Amperage Draw Rated Load 97 87 Input Volts Three Phase 208V 230V 460V Thermal Arc continuously strives to produce th
19. Skipping portions of procedures or performing steps out of sequence can result in damage to the unit and possible injury or worse to the operator 1 1 Opening the Enclosure 1 Confirm that the switch on the power supply and the switch on the switchboard distribution panel are all OFF 400MST 9 ADVANCED TROUBLESHOOTING CAUTION The capacitors inside the power supply will slowly discharged after you turn off the switch of the power sup ply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete 2 Remove all screws and nuts on the side covers 3 Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW NOTE DO NOT remove the screws completely 400MST 9 ADVANCED TROUBLESHOOTING 4 Pull the front panel slightly forward and pull the rear panel slightly backward The interlocking hooks of the side case covers can now be disengaged from the front and rear panels NOTE When you re assemble the parts conduct the above process backwards 9 3 400MST 9 ADVANCED TROUBLESHOOTING 1 2 Verification and Remedy to the Indicated Error Codes NOTE The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box dis tribution panel Wait at least 5 minutes for the dis char
20. The MIG torch has been connected to the wrong voltage polarity on the front panel 8 Arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly 3 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables maintenance of equipment and proper welding technique Description Possible Cause Remedy Excessive beard build up or poor penetration or poor fusion at edges of weld Welding current is too low Increase weld current and or faulty joint preparation Weld bead too wide and flat or undercut at edges of weld or excessive burn through Welding current is too high Decrease weld current Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart Travel speed too fast Reduce travel speed Weld bead too wide or excessive bead build up or excessive penetration in butt joint Travel speed too slow Increase travel speed Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod Electrode melts when arc is struck A Electrode is connected to the terminal A Connect the electrode to the terminal Dirty weld pool A Electrode contaminated through contact with work piece or filler rod material Gas contaminated with air A Clean the electrode by grinding off the contaminates
21. Trouble Sensing Circuit Drive Circuit Circuit Thermal Sensor Primary Circuit Sensor 19PIN Receptacle CON2 Circuit Current Adjustment Sequence Control Stick Mo VRD Circuit Sensing de Lift Tig Mode Output Short Sensing Circuit Fan Control Circuit Fan Reference Adjustment amp Mode select Switch Panel Circuit Board Figure 2 2 400MST Model functional block diagram 2 1 14PIN 19PIN Select Switch 400MST 2 INTRODUCTION AND DESCRIPTION 3 Transporting Methods These units are equipped with a handle for carrying purposes A WARNING ELECTRIC SHOCK can DO NOT TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving the welding power source A FALLING EQUIPMENT can cause serious per sonal injury and equipment damage Lift unit with handle on top of case Use handcart or similar device of adequate capac ity If using a fork lift vehicle place and secure unit on a proper skid before transporting 4 Installation Recommenda tions 4 1 Environment The 400MST is designed for use in hazardous environments Examples of environments with increased hazard ous environments are In locations in which freedom of movement is restricted so that the operator is forced to per form
22. dig phase thus maximizing penetration 400MST 3 OPERATOR CONTROLS 4 6 Weld Parameters Weld Mode Weld Parameter Units of Increment STICK Parameter Range Factory Setting LIFT TIG 10 0 to 36 0v pc 170V 0 1V x Oto 100 10 1 70 20A 1 1 to 400A DC 80A 1A 0 to 100 CONTROL Table 3 4 Weld Parameters 4 7 Power Source Features Feature Description Feature Description Control Knob For the selected weld parameter rotating the knob clockwise increases the parameter Rotating the knob counter clock wise decreases the parameter A selected weld parameter value can be adjusted at any time even while welding Pushing the knob in sets the selected parameter then displays the next parameter Self Diagnosis Using Error Codes An error code is displayed on the Digital Meter when a problem occurs with Mains supply voltage or internal component problems Save Load function New Digital Control All welding parameters are adjust able Touch switches eliminate mechani cal damage Touch Panel Switches Front Control Cover Protects front panel controls Digital Meter Volt amp Ammeter Displays selected weld parameter value Displays average weld current when welding Displays average weld current for 20 seconds after weld has been completed A selected weld parameter value
23. gen 3 1 IPS 58 W7001352 1 gen 3 14 IPS 1J5B017500 59 W7001353 gen 31 436356600 60 10 6665 gen 3 1 1PS 7 2624609 C 6 110 6666 gen 3 1 1PS 3024104 C 6 wz001356 Protector gen 3 1 IPS N1B039200 63 1 1 wzo001357 Sheet Rubber gen 3 1 IPS EDA227700 4 64 7001358 1 5 gen 3 1 IPS 643600 5 5 3 6 ______ 1359 BusBar D gen3 1 IPS EDA761400 1 66 1 wzr001360 Bus Bar T D gen 3 1 IPS 00800 4 67 ______ 7001361 Bar 1 D gen 3 1 5 _____ EDAO46900 41 eas _______ 7001362 BusBar 2D gen 3 1 IPS EDAO4700 69 wzro01363 3 D gen 3 1 IPS 47100 1 1 wz001364 Bar 4D gen3 1 IPS ____ 47200 1 71 10 6868 Bar 51 gen 3 1 X ECA32100 72 1 wz001366 Bus Bar Output gen 3 5 IPS EDA761300 73 6 Bus Bar T CC gen 3 1 IPS EDAO4730 74 7 wz001368 Post Output gen 3 1 IPS ECA867900 7 75 7 7001369 Insulated Board gen 3 1 E1B87200 C C 76 7 7001370 Insulation Sheet gen 3 1 IPS E18859700 177 7001371 Insulation Sheet gen 3 1 IPS EDAO79800 141 78 C 7001372 Protector gen 3 1 IPS E189339
24. 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 Protec tion ANSI Standard 287 1 from American National Standards Insti tute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 ARCMASTER 400 MST 1 03 Precautions de Securite en Soudage l Arc A MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION QU LES INSTRUCTIONS AVANT D INSTALLER UTILISER QU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pa
25. AC input voltage using a voltmeter Follow the instruction in section 9 1 4 2 b Verify the wiring harness and connection of CN1 on PCB16 WK 4917 and CN2 on PCB3 WK 5548 e Confirm a secure connection of the harness 400MST 9 ADVANCED TROUBLESHOOTING between CN1 on PCB16 and CN2 on PCB3 Contact the manufacturer if you find any bro ken connectors or damaged wiring har nesses Verify PCB4 WK 4819 for burned or discol ored components or printed circuit board Confirm that the PCB is securely fastened in place No loose screws e Refer to section 9 2 4 4 for the replacement of PCB4 1 2 10 E85 Pre Charge Error Cause Occurs after you apply power when a failure is detected during the preliminary charging of the capacitors Verification Remedy a Verify the AC input voltage and the Capacitor Bus Voltage on PCB2 WK 5597 Follow the instruction in section 9 1 4 2 b Verify the input diode D1 Refer to section 9 1 4 5 for the test and replacement of D1 c Verify the IGBT Q1 Q24 Refer to section 9 1 4 7 for the test and sections 9 2 4 7 and 9 2 4 8 for replacement of Q1 Q2 Q23 and Q24 d Replace PCB2 WK 5597 and PCB4 WK 4819 If the tests the above sections b c within expected results and the unit is still defective replace PCB2 and PCB4 Refer to section 9 2 4 2 9 2 4 4 for the replacement of PCB2 and PCB4 1 2 11 E94
26. NOTE During your maintenance or repair please cut any tie wraps necessary However after your maintenance or repair please reassemble and tie wrap all components and wiring in the same manner as before the mainte nance or repair CAUTION Please note that you remove each connector grasp and pull out by the connector part only Do not pull the harness cable part A WARNING The capacitors inside the power supply will slowly discharged after you turn off the switch of the power sup ply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete 9 21 400MST 9 ADVANCED TROUBLESHOOTING 2 4 Replacement Procedure 2 4 1 PCB1 WK 5493 SONDE 2 4 5 1 Remove the side cover Reference page 9 11 Remove PCB2 WK 5597 Reference page 9 23 3 Remove the diode D1 Reference page 9 39 Remove the current transformers CT2 and CT3 Reference page 9 41 Remove two screws and three terminals from PCB1 WK 5493 6 Remove the reactor L1 Reference page 9 41 7 Disconnect one connector and remove four terminals SS Vj d 400MST 9 ADVANCED TROUBLESHOOTING 2 4 2 PCB2 WK 5597 1 Remove the side cover Reference page 9 11 2 Remove PCB6 WK 5688 Reference page 9 27 3 Remove one screw and three ground terminals Disconnect 13 connectors
27. PCB3 Remedy NOTE When verifying the voltage confirm that the AC input voltage remain within the operating range of the unit The AC input does not drop below 180VAC 1 4 5 Verification of the primary Diode D1 CAUTION Before performing any portion of the procedure below make certain unit is placed in the initial set up condition as described in section 9 1 4 1 Preparation 1 Verify the characteristic of the primary diode D1 using a diode tester 2 Refer to Table 9 1 and Figure 9 7 9 8 for the checkpoints on D1 Rotating DC 18 25V Fan drive circuit is normal Rotating Below DC 18V Replace PCB3 WK 5548 Refer to section 9 2 4 3 Inactive Below DC 18V Replace PCB3 WK 5548 Refer to section 9 2 4 3 Conduct the Verification of the power input circuitry in section 9 1 4 2 Inactive NOTE DC 18 25V Replace FAN1 Refer to section 9 2 4 19 TERMINALS COMPONENT ACCEPTABLE TESTED Positive Negative VALUE lead lead 3 4 5 0 0 3 to 0 5V Diode of D1 0 3 4 5 3 4 5 2 Open Diego Up 2 3 4 5 O3to0 5V 0 1 Thyristor of 01 1 0 Open Table 9 1 Tester checkpoints in the primary diode D1 This welding unit has a feature that will slow the rotational speed of the cooling fan during low out put current and while in standby Under these con ditions the voltages in the
28. Remove the side cover Reference page 9 11 2 Remove six screws from the switch S1 and disconnect six terminals 4 Disconnect the one connector Remove the two screws and one ground terminal Remove the PCB16 WK 4917 400MST 9 ADVANCED TROUBLESHOOTING 5 Remove the three screws and the bus bar from the PCB16 WK 4917 2 4 14 PCB17 WK 5699 1 Remove the side cover Reference page 9 11 2 Disconnect 11 connectors and remove one terminal Remove four screws and remove PCB17 WK 5699 CND 1 FE ______ 15 once 2 4 15 PCB18 WK 5499 6 1 Remove the side cover Reference page 9 11 2 Remove PCB17 WK 5699 Reference page 9 33 3 Remove one screw and one terminal Remove one bolt one toothed washer one washer and one ter minal Disconnect one connector Remove one screw and one nut and detach the bus bar 400MST 9 ADVANCED TROUBLESHOOTING 4 Disconnect two connectors Remove four board supports and remove PCB18 WK 5499 H MD 2 4 16 Inductor FCH1 O 1 Remove the side cover Reference page 9 11 2 Disconnect one connector Remove one screw and three ground terminals
29. Thermistor Failure Cause Occurs when the thermistor for the temperature detection circuitry is open Verification Remedy a Verify the wiring harness and connection between CN8 and CN9 on PCB6 WK 5688 and thermistors TH1 and TH2 e Confirm a secure connection of the harness wired between CN8 and CN9 on PCB6 and TH1 and TH2 and re install the harnesses with a secure connection Contact the manufacturer if you find any bro ken connectors or damaged wiring har nesses b Replace thermistors TH1 and TH2 e Refer to section 9 2 4 17 and 9 2 4 18 for the replacement of TH1 and TH2 c Replace PCB6 WK 5688 Refer to section 9 2 4 6 for the replacement of PCB6 1 2 12 E99 Initial Power Receiving Cause Occurs when the initial power received signal has not reached the CPU NOTE This error occurs normally during the power OFF sequence of the unit Verification Remedy a Verify the wiring harness and connection of CN1 on PCB16 WK 4917 and CN2 on PCB3 WK 5548 Confirm a secure connection of the harness wired between CN1 on PCB21 and CN2 on PCB3 and re install the harness with a Secure connection Contact the manufacturer if you find any bro ken connectors or a damaged wiring harness b Verify and replace 4 WK 4819 During the installation of PCB4 and confirm that the PCB s are securely fastened in place No loose screws Refer
30. Weld current ceases Buzzer sounds constantly Error code E12 automatically will reset when the voltage increases E81 error code displayed Wrong Primary supply input voltage connected When 3 phase machine is first turned on with the wrong Primary supply input voltage connected Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage No weld current is available Buzzer sounds constantly Switch machine off E82 error code displayed Link switch plug not connected Link switch plug not connected Have an Accredited Thermal Arc Service Agent check connector plug on input PCB No weld current is available Buzzer sounds constantly Switch machine off E83 error code displayed CPU checks mains supply input voltage when the on off switch on rear panel of machine is turned ON The Primary supply input voltage fluctuates and is not stable Have an Accredited Thermal Arc Service Agent check connector plug on input PCB and the Mains voltage No weld current is available Buzzer sounds constantly Switch machine off then on to reset E83 error 400MST 8 Power Source Error Codes Description Possible Cause Remedy Remarks 10 E93 error code displayed Memory chip EEPROM on control PCB can not read write weld parameter Memory chip EEPROM error Have an Accredited Thermal Arc Service Agent check the control P
31. above table will be inaccurate therefore when verifying the voltage do so during the failure condition 9 13 400MST 9 ADVANCED TROUBLESHOOTING 1 Verify the characteristic of the secondary diode D2 03 D4 and D5 using a diode tester 2 Refer to Table 9 2 and Figure 11 for the checkpoints on D2 D3 D4 and D5 TERMINALS Positive Negative lead lead Anode Cathode Cathode Anode Anode Cathode Cathode Anode COMPONENT TESTED ACCEPTABLE VALUE 0 2 to 0 3V Open 0 2 to 0 3V Open Diode 1 of D2 D3 D4 D5 Diode 2 of D2 D3 D4 D5 Table 9 2 Tester checkpoints in the secondary diode D2 D3 D4 D5 Figure 9 7 Tester checkpoints in the primary diode D1 0 6 7 1 5 4 3 2 Figure 9 8 The primary diode D1 interconnection diagrams Figure 9 9 Tester checkpoints in the secondary diode D2 7 1 4 7 Verification of the primary IGBT Q1 24 CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described in section 9 1 4 1 Preparation 1 Check whether there are any abnormalities on the appearance of PCB8 and PCB9 2 Verify the characteristic of the primary IGBT 1 4 6 Verification of the secondary Diode D2 5 CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial
32. by increasing the WELD V control or reduce wirespeed control Irregular weld shape Incorrect voltage and current settings Adjust voltage and current by adjusting voltage too high Wire is wandering Incorrect shielding gas Convex voltage too low Concave the WELD V control and the wirespeed control Replace contact tip Check shielding gas Insufficient or excessive heat input Adjust the wirespeed control or the voltage selection switches Weld cracking Weld beads too small Excessive weld stresses Excessive voltage Cooling rate too fast Decrease travel speed Weld penetration narrow and deep Reduce current and voltage and increase MIG torch travel speed or select a lower penetration shielding gas Increase weld metal strength or revise design Decrease voltage by reducing the WELD V control Slow the cooling rate by preheating part to be welded or cool slowly 400MST 6 BASIC TROUBLE SHOOTING Possible Cause A Faulty rectifier unit A Loose welding cable connection C Low Primary Voltage Description 7 Cold weld puddle Remedy Have an Accredited Thermal Arc Service Agent to test then replace the faulty component B Check all welding cable connections C Contact supply authority Connect the MIG torch to the positive welding terminal for solid wires and gas shielded flux cored wires Refer to the electrode wire manufacturer for the correct polarity
33. by the input voltage detection cir cuit etc Verification Remedy a Verify the AC input voltage using a voltmeter Follow the instruction in section 9 1 4 2 b Verify the wiring harness and connection of CN1 on PCB16 WK 4917 and CN2 on PCB3 WK 5548 e Confirm a secure connection of the harness between CN1 on PCB16 and CN2 on PCB3 9 6 Contact the manufacturer if you find any bro ken connectors or damaged wiring har nesses Verify PCB4 WK 4819 for burned or discol ored components or printed circuit board Confirm that the PCB is securely fastened in place No loose screws Refer to section 9 2 4 4 for the replacement of PCB4 1 2 8 E82 Rated voltage selection cir cuit abnormality Cause Failure detected by the input voltage detection cir cuit etc Verification Remedy a Verify the wiring harness and connection of CN4 on PCB4 WK 4819 Confirm a secure connection of CN4 on Contact manufacturer if you find any bro ken connectors or damaged wiring har nesses b Verify PCB4 WK 4819 for burned or discol ored components or printed circuit board Confirm that the PCB is securely fastened in place No loose screws Refer to section 9 2 4 4 for the replacement of PCB4 1 2 9 E83 Abnormal mains supply voltage Cause Failure detected by the input voltage detection cir cuit etc Verification Remedy J a Verify the
34. can be adjusted at any time even while welding Intelligent Fan Control The intelligent cooling system is designed to reduce dust and for eign material build up while provid ing optimum cooling Fan speed reduces approximately 30 seconds after machine is turned on Fan speed increases when internal components reach operating temperature ON OFF switch Mains ON OFF switch located on rear panel Voltage Reduction Device VRD fully complies to IEC 60974 1 VRD light is ON and operational when in STICK mode A total number of 5 programs be saved into the 400MST memory SAVE the Current Weld Parameters into Memory Press the SAVE button Select a memory location by rotat ing the control knob 1 to 5 is dis played on the meter After selecting the desired memory location ie 1 to 5 press the parameter button and the machine give a beep to confirm the weld parameters from the control panel are saved LOAD retrieve a Program to Control Panel Press the LOAD button Select a memory location by rotat ing the control knob 1 to 5 is dis played on the meter After selecting the desired memory location ie 1 to 5 press the parameter button and the machine give a beep to confirm the weld parameters are loaded onto the control panel 400MST 3 OPERATOR CONTROLS PAGE LEFT INTENTIONALLY BLANK 4 NOT
35. do not light properly or weld set tings cannot be established Cause Occurs when there is a connection failure among PCB3 WK 5548 PCB6 WK 5688 and PCB12 WK 5527 or PCB3 PCB6 and PCB12 are defec tive Verification Remedy Verify the PCB connection between 21 on PCB6 WK 5688 and CN2 on PCB12 WK 5527 Confirm a secure connection of the harness and the connections between CN21 on PCB6 and CN2 on PCB12 Contact the manufacturer if you find any broken connectors or damaged wiring harnesses b Verify the connection between PCB5 WK 5696 and PCB6 WK 5688 Confirm that all three connectors between PCB5 and PCB6 are tightly connected Confirm the condition of the pins on the con nectors and the connectors themselves bent pins or damaged connectors are found replace the suspected PCB Refer to section 9 2 4 5 and 9 2 4 6 for the replacement and installation of PCB5 and PCB6 c Replacement of PCB6 WK 5688 and PCB12 WK 5527 Refer to section 9 2 4 6 for the replacement and installation of PCB6 and section 9 2 4 9 for PCB12 1 4 Fault Isolation Tests 1 4 1 Preparation The following initial conditions must be met prior to starting any of the procedures in this section 9 1 4 1 Connect the appropriate input voltage Check the name plate on the rear of the power supply for the proper input voltage NOTE Operate at ALL input voltages as noted on th
36. kaa at rm end 2 4 7 Duty Cycl icy sasa ays RR RR RERO et 2 4 3 OPERATOR CONTROLS 1 400 u TL ds os anand 3 1 2 Weld Parameter Descriptions for 400 5 3 2 3 Weld Process selection for the 400MST 3 3 4 Weld Parameter Descriptions ce eee dee bee ced re Re n eed Rede pera 3 3 44 E 3 3 4 2 INDUCTANCE i Ren b Cen ER Me 3 3 AS HOT STARTE vase Ea et aura 3 4 UA EIE DA LS um e n OR MEER PER REACHES RS 3 4 4 5 CONTROL rcr m ain Rex ei Rem dri 3 4 4 6 Weld Parameters ico eh edic rne Werle igang entries RD e DR tue E RT ceca ice 3 5 4 7 Power Source 3 5 4 SEQUENCE OF OPERATION fu SticleWelding 4 5 Mr tees ea DE eens a edes terere oe ee RR Gate e e OO 4 1 2 LIFT TIG Welding 2 44 cee us RR ERR Ra eS ER erem Rr Rede ram a d erae a 4 1 3 MIG Weldihg ku thc ele eee d PLC UR 4 1 5 ROUTINE
37. l espace est bien ventil si n cessaire portez un respirateur ad duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie TE Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de
38. main areas where problems occur with GMAW 1 1 Porosity When there is a gas problem the result is usually porosity within the weld metal Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping dur ing solidification of the molten metal Contaminants range from no gas around the weld ing arc to dirt on the work piece surface Porosity can be reduced by checking the following points 1 Gas cylinder contents and flow meter Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 25 cubic feet per hour 2 Gas leaks Check for gas leaks between the regulator cylinder connection and in the gas hose to the Wire Feeder Internal gas hose in the Wire Feeder 3 Internal gas hose in the Wire Feeder Ensure the hose from the solenoid valve to the MIG torch adapter has not fractured and that it is connected to the MIG torch adapter 4 Welding in a windy environment Shield the weld area from the wind or increase the gas flow 6 1 5 Welding dirty oily painted oxidized greasy plate Clean contaminates off the plate 6 Distance between the MIG torch nozzle and the work piece Keep the distance between the MIG torch nozzle and the work piece to a minimum 7 Maintain the MIG torch in good working order Ensure that the gas holes are not blocked and gas is exiting out of the torch nozzle Do not restrict gas flow by allowing
39. 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 ie 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 ie 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 cur rent via a remote current control to freeze the weld pool This welding current reduction also reduces the penetration The arc force allows the weld pool to freeze during the flick phase without decreasing the amount of weld current available during the
40. sets the selected weld parameter rotating it clockwise increases the parameter and is indicated on the digital meter Pushing the knob in previews the actual welding volt age while welding 2 Remote Control Socket The 14 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source To make connections align keyway insert plug and rotate threaded collar fully clockwise Socket Pin Function 24VAC auxiliary high side Input to energize solid state contactor Contact closure between pin A and pin B 5k ohm maximum connection to 5k ohm remote control potentiometer Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control potentiometer Current feedback 100Amps Volt 24 115 VAC circuit common also connected to chassis Voltage Feedback Vfb 10 Arc Volts Volt 115 VAC auxiliary high side 115 VAC input to energize solid state contactor Contact closure between pin and pin J Chassis ground Not used Current Detect Current Detect ix 3 Positive Terminal e Welding current flows from the Power Source EE via heavy duty Dinse type terminal It is essen tial however that the male plug is inserted and turned securely to achieve a sound electrical connection
41. spatter to build up inside the MIG torch nozzle Check that the MIG torch O rings are not damaged A WARNING Disengage the drive roll when testing for gas flow by ear 1 2 Inconsistent Wire Feed Checking the following points can reduce wire feeding problems 1 Wire spool brake is too tight Feed roller driven by motor in the cabinet will slip 2 Wire spool brake is too loose Wire spool can unwind and tangle 3 Worn or incorrect feed roller size Use U groove drive feed roller matched to the aluminium wire size you are welding Use V groove drive feed roller matched to the steel wire size you are welding Use knurled V groove drive feed roller matched to the flux cored wire size you are welding 4 Misalignment of inlet outlet guides Wire will rub against the misaligned guides and reduce wire feedability 5 Liner blocked with wire debris Wire debris is produced by the wire passing through the feed roller if excessive pressure is applied to the pressure roller adjuster Wire debris can also be produced by the wire passing through an incorrect feed roller groove shape or size 400MST 6 BASIC TROUBLE SHOOTING Wire debris is fed into the liner where it accumulates thus reducing wire feedability 6 Incorrect or worn contact tip The contact tip transfers the weld current to the electrode wire If the hole in the contact tip is to large then arcing may occur inside the contact tip resulting
42. tenon the NS nn 9 17 2 2 Test and Replacement Parts 1 9 17 2 3 Service Tools uso en hera eren e RH NU E te a Ic o e ane Cic rene de a ahi ca cem I ice 9 21 2 3 1 Tools and parts eor ea Ib ea Ye dw RR RR hr da ye 9 21 2 3 2 Notes of disassembly and 9 21 2 4 Replacement Procedure as ira tih sa ee AUR en gob aE aa w m fs ala 9 22 2 4 1 PCB1 WK 5493 eae ro e rr he ene de dev nae ae cee RESET REESE 9 22 2 4 2 PCB2 WK 5597 erre nth prete dh na Ig Ea E e qu Ceca d eh BUE PR de a P 9 23 2 4 3 WK 5548 PCB7 WK 5689 4 9 24 2 4 4 PCB4 WK 4819 iile e remm ERR E Qasa e e m DIR 9 26 2 4 5 PCB5 WK 5696 o oe erre ae ee ech dace te PX er ute one e ce Tn 9 26 2 4 6 PCBO6 WK 5b688 dre ee euin a S tala Moth ot Aa ee noe a 9 27 2 4 7 PCB8 WK 5479 9 WK 5479 1 9 27 2 4 8 10 WK 5479 11 WK 5479 1 43
43. 0 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor Original Main Power Rectifiers Control P C Boards power switch semi conductors All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors GTAW TIG amp MULTI PROCESS INVERTER WELDING EQUIPMENT LABOR 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year PLASMA WELDING EQUIPMENT LABOR Ultima 150 Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years Welding Console Weld Controller Weld Timer 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year 1 year SMAW Stick WELDING EQUIPMENT Dragster 85 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans powe
44. 00 114 79 W7001373 Protector gen 3 1 IPS E18933100 14 so wzr001374 Clip gen 3 1 5 _________ 74 ___ 4 81 7001375 3 1 IPS 1070500 20 with String 1 82 10 6874 Cover CON2 3 1 IPS 97121 422R with String 1 83 wz001377 Edge Protect gen 3 1 IPS EH18U 2 84 102020 Plug Output gen 3 1 1PS TRAK SK50 41 85 6 Operating Manual gen 3 1 IPS JOperetingManual 400MST PARTS LIST SN i ON 400MST PARTS LIST APPENDIX 2 CONNECTION WIRING GUIDE Destination 4 PCB3 PCBS CN23 CN2 Di PCB3 CNi8 o PCB7 CN20 PCB4 PCB3 CN33 e PCB6 0 Di o S2 Ti 230V PCB6 CNT Ti 460V PCB6 21 o PCB12 16 PCB7 o PCB17 PCB8 PCB7 o PCB17 CN2 PCB9 CN PCB7 CNi3 PCBI7 PCB8 CN PCB7 15 PCB9 PCB7 CN16 PCB10 CN2 PCB12 CNT o PCB13 CNI PCB11 O TOZETX lt 400MST CONNECTION WIRING GUIDE CN2 J 2 APPENDIX 3 INTERCONNECT DIAGRAM
45. 19 2 4 5 5 WK 5696 1 Remove the side cover Reference page 9 1 2 Remove PCB6 WK 5688 Reference page 9 27 3 Remove two screws and disconnect three connectors Remove PCB5 WK 5696 400MST 9 ADVANCED TROUBLESHOOTING 2 4 6 PCB6 WK 5688 1 Remove the side cover Reference page 9 1 2 Disconnect five connectors 2 4 7 PCB8 WK 5479 and PCB9 WK 5479 1 Remove the side cover Reference page 9 11 2 Remove eight screws and four component clips Disconnect four connectors and remove six screws and then remove PCB8 WK 5479 and PCB9 WK 5479 When reinstalling remember to install new silicon rubber sheets CN CN2 e 991 cad DE 11 A Rubber Sheet Las l hr 400MST 9 ADVANCED TROUBLESHOOTING 2 4 8 PCB10 WK 5479 PCB11 WK 5479 1 Remove the side cover Reference page 9 1 2 Remove eight screws and four component clips Disconnect four connectors and remove six screws and then remove PCB10 WK 5479 and PCB11 WK 5479 When reinstalling remember to install new silicon rubber sheets SC CN1 Prat 19 2 4 9 12 WK 5527 1 Remove the side cover Reference page 9 1 2 Remove PCB13 WK 5528 Reference page 9 29 3 Release three hooks and remove PCB12 WK 5527 400MST 9 ADVANCED TROUBLESHOOTING 2 4 10
46. 3 1 CN9 CN8 E 5 zm i 1 ea 2 PCB12 A A 3 2 4 Circuit Board WK 5527 EZ 1 7 EERE 7 174 5 6789 1 Breede oar CN IwK 5528 5 s FE SL 3 i i 212 6 L4 APPENDIX 4 DIODE TESTING BASICS Testing of diode modules requires a digital Volt Ohmmeter that has a diode test scale 1 2 Locate the diode module to be tested Remove cables from mounting studs on diodes to isolate them within the module Set the digital volt ohm meter to the diode test scale Using figure 1 and 2 check each diode in the module Each diode must be checked in both the forward bias positive to negative and reverse bias negative to positive direction To check the diode in the forward bias direc tion connect the volt ohm meter positive lead to the anode positive of the diode and the negative lead to the cathode negative of the diode refer to Figure 10 1 A properly functioning diode will conduct in the forward bias direction and will indicate between 0 3 and 0 9 volts To check the diode in the reverse bias direc tion reverse the meter leads refer to Figure 10 1 A properly functioning diode will block current flow in the reverse bias direction and depending on the meter function will indicate an open or OL If any diode in
47. B Check gas lines for cuts and loose fitting or change gas cylinder Electrode melts or oxidizes when an arc is struck No gas flowing to welding region Torch is clogged with dust Gas hose is cut Gas passage contains impurities Gas regulator turned off Torch valve is turned off The electrode is too small for the welding current oQmmoou A Check the gas lines for kinks or breaks and gas cylinder contents B Clean torch Replace gas hose D Disconnect gas hose from torch then raise gas pressure and blow out impurities E Turn on F Turn on G Increase electrode diameter or reduce the welding current 400MST 6 BASIC TROUBLE SHOOTING Description Possible Cause Remedy 9 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for gas flow problems 10 Arc flutters during TIG welding Tungsten electrode is too large for the welding current B Absence of oxides in the weld pool A B Select the right size electrode Refer to Basic TIG Welding guide Refer Basic TIG Welding Guide for ways to reduce arc flutter 11 Welding arc can not be established A Work clamp is not connected to the work piece or the work torch leads are not connected to the right welding terminals Torch lead is disconnected Gas flow incorrectly set cylinder empty or the torch valve is off A Connect the work clamp to the work piece or connect th
48. CB Weld current ceases Buzzer sounds constantly Switch machine off 11 E94 error code displayed Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit The Welding Power Source s temperature sensors have malfunctioned Have an Accredited Thermal Arc Service Agent check or replace the temperature sensors Weld current ceases Buzzer sounds constantly Switch machine off 12 E99 error code displayed Mains supply input voltage has been turned off but control circuit has power from the primary capacitors A Main on off switch on machine has been turned off Mains supply input voltage has been turned off A Turn on off switch on B Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage and fuses Weld current ceases Buzzer sounds constantly Must switch machine off then on to reset E99 error 9 ADVANCED TROUBLESHOOTING If you are here all of the troubleshooting sugges tions in Section 7 Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective This section provides the information needed to take live mea surements on the various subsystems within the power supply and replace those subsystems that prove faulty CAUTION Troubleshooting and repairing this unit is a pro cess which shoul
49. CTION AND DESCRIPTION 1 Description The Thermal Arc 400MST is a single amp three phase DC arc welding power source with Constant Current CC and Constant Voltage CV output characteristics This unit is equipped with a Digital Volt Amperage lift arc starter for use with Gas Tungsten Arc Welding GTAW Arc Control and Hot Start for Shielded Metal Arc Welding SMAW Inductance Control for Gas Metal Arc Welding GMAW processes The power source is totally enclosed in an impact resistant flame resistant and non conductive plastic case V V 34V 10V 18V poe TT 10V 160A 5A 400A 420A A 25A 400A A 5A 400A 480A A STICK Process LIFT TIG Process MIG Process Figure 2 1 Model 400MST volt ampere curve NOTE Volt Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source Curves of other settings will fall between the curves shown 2 Functional Block Diagrams Figure 2 2 illustrates the functional block diagram of the 400MST power supply Input IGBT Main Output Capacitor Inverter Transformers Diodes Power T1 Down Transformers AC115V AC24V T3 Over Current Protect 14PIN Receptacle CON1 Output Inductor Toeach control circuit 15VDC 18VDC 24VDC 5 0
50. DC fol lowing the process in section 9 2 4 23 Figure 9 2 The check points 1 P and 2 N Verify bus voltage the voltage of the electro lytic capacitor after rectification using a DC voltmeter The capability of the DVM should be more than 1000VDC Using a DC voltmeter measure between the output studs C and E on PCB8 WK 5479 PCB9 WK5479 PCB10 WK 5479 and PCB11 WK5479 See Figure 9 2 The measured voltage should be approxi mately 1 4 times larger than the input voltage measured in 1 above except when running at 460V where the bus voltage will be shared across all boards ie each board receiving 0 7 times the input voltage measured in step 1 above Replace if the 400MST 9 ADVANCED TROUBLESHOOTING calculated measurement is not within the cor responding range 260 360 580 720VDC fol 7 After the replacement of D1 if the above volt age is still abnormal replace PCB1 WK 5493 1 4 3 Power Supply Voltage Test Connect the power supply to a source of rated input voltage Check the name plate on the rear of the power supply for the proper input voltage Apply power to the unit and place the switch of the power supply to the ON position Figure 9 5 The check points PIN1 PIN3 of CN18 on Reference CN18 WK 5548 Test Point CN18 on ACCEPTABLE VALUE WK 5548 On the PCB6 WK 5549 a
51. E Parameter Buttons are used to select the parameters to be set The LED s show which func tion is being adjusted on the weld sequence graph Refer to Symbols Table located in the front of the manual for Symbol descriptions Figure 4 1 400MST Front Panel Contactor function Pressing this button enables Contactor functions Remote functions Pressing this button enables remote current functions Digital LED displays Welding amperage Volt age and parameter values are displayed in this window Internal warnings such as over tem perature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen Save Load Buttons By using the Save amp Load buttons the operator can easily save up to 5 welding parameter programs Control knob Allows the operator to adjust the output amperage voltage within the entire range of the power source also used to set each parameter value Process Button This button selects between STICK Lift TIG and MIG modes MIG modes include MS for mild steel and SS for stainless steel Parameter Button This button selects between HOT START WELD CURRENT and ARC CONTROL while in STICK and Lift TIG modes and selects between WELD VOLTAGE and INDUCTANCE CONTROL while in MIG mode This button is also used in conjunction with the Save Load buttons to save and load welding programs 1 Stick Welding Connect work lead to negative termin
52. IHERMAL ARC 400 MST ARCMASTER INVERTER ARG WELDER Art A 07368 Service Manual Version No AA 03 Issue Date May 22 2006 Manual No 0 49448 Operating Features IHERMAL WARNINGS Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use ArcMaster 400 MST Inverter Arc Welder Service Manual Number 0 4944B for Part Number 10 3072 Published by Thermadyne Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 by Thermadyne Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date May 22 2006 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial 5 1 GENERAL INFORMATION 1 Notes Cautions and 06 4 1 1 2 Important Safety Preca
53. NING WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use eee Light Under 300 Amp 9 WARNING FLYING SPARKS AND HOT METAL can cause injury w Chipping and grinding cause flying metal As welds cool the
54. PCB13 WK 5528 1 Remove the side cover Reference page 9 1 2 Remove the operation cover 4 Disconnect one connector from PCB12 WK 5527 Remove four screws and pull out the operation panel and tilt it 400MST 9 ADVANCED TROUBLESHOOTING 5 Disconnect one connector and remove two screws and then remove PCB13 WK 5528 2 4 11 14 WK 5594 9 1 Remove the side cover Reference page 9 1 2 Remove PCB17 WK 5699 Reference page 9 33 3 Remove the inductor FCH1 Reference page 9 34 4 Remove two screws from the front side and detach the bus bar 400MST 9 ADVANCED TROUBLESHOOTING 6 Remove two screws from PCB1 WK 5477 and disconnect three terminals Cut off two snap bands and slide the insulating tube Remove two screws two nuts and four terminals S I e j EN 7 Remove four screws from the bottom and disconnect one terminal Remove two screws from the rear side and remove PCB14 WK 5594 by pulling it out Remove four screws and detach the bus bar 2 4 12 PCB15 WK 5606 1 Remove the side cover Reference page 9 11 2 Remove PCB17 WK 5699 Reference page 9 33 3 Remove the sheet and remove eight screws Remove two board supports and remove PCB15 WK 5606 400MST 9 ADVANCED TROUBLESHOOTING 2 4 13 PCB16 WK 4917 1
55. Reference page 9 1 2 Remove PCB17 WK 5699 Reference page 9 33 3 Remove PCB15 WK 5606 Reference page 9 31 4 Remove one screw and one nut Remove 20 screws and one terminal and detach the bus bar 1 ee merae 4 D we Tam e o e 5 Remove eight screws and remove the diodes D2 D3 D4 and D5 When replacing the diode with a new one apply an oil compound SHINETSU SILICONE G 747 or equivalent evenly to the base Pay attention to the installation direction of the diode B Jet ans le er 400MST 9 ADVANCED TROUBLESHOOTING 2 4 25 Current Transformer CT2 and 1 Remove the side cover Reference page 9 1 2 Remove PCB6 WK 5688 Reference page 9 27 3 Remove four screws and open the rear cabinet 4 Cut off one snap band and disconnect one connector from PCB3 WK 5548 Remove two screws and two terminals from PCB1 WK 5493 Cut off two snap bands and remove the current transformers CT2 and CT3 2 4 26 Reactor L1 1 Remove the side cover Reference page 9 11 2 Remove four screws and open the rear cabinet 400MST 9 ADVANCED TROUBLESHOOTING 3 Remove two screws and two terminals Cut off one snap band and remove the reactor L1 2 4 27 Molded Case Circuit Breaker MCB1 and MCB2 1 Remove the side cover Reference page 9 1 2 Rem
56. Side gen 3 1 IPS EODO05207 2 36 w7001331 Front gen3 14 IPS Eoca4600 1 7001332 Board Front gen 3 1 IPS JEA496001 114 38 wzr001333 Cover Rear gen 3 1 IPS JDAz88900 4 39 7 7001334 Protector gen 3 1 IPS E0c29920 1 10 6791 Cover Encoder gen 3 1 IPS EBA514400 1 42 7001718 Label Name gen 3 1 IPS N4A831400 400M98D 1 43 7001338 Label Side gen 3 1 IPS 785200 2 44 7001339 1 Warning gen 3 1 IPS 318029700 114 45 7 7001340 Label 2 Warning den 3 1 IPS N1B029800 1 46 wz7001341 Label Output Terminal gen 3 1 N4A178600 4 47 W7001342 Switch gen 3 1 IPS 4 41400 Y 4 48 W7001343 Label 14 19 Switch gen 3 1 IPS N4A311800 1 1 1 49 7001344 Label MCB gen 3 1 IPS N4A144200 11 50 7001345 Label VRD gen 3 1 IPS N4A919100 4 51 _______ 1511 Label gen 3 1 IPS N4A598700 1414 52 10 6660 Terminal Output F gen 3 1 IPS 5 705 2 53 Cable Input gen3 1 IPS_ SOOWAWG8X4CL 34m 41 54 10 6795 Input gen 3 1 IPS 156800 C 1 55 7001349 Heatsink gen 3 1 IPS 895000 2 56 wz001350 Heatsink gen 3 1 IPS E1B870100 5 7 7001351 Spring Clip IGBT
57. Sockets 2 Weld Parameter Descrip tions for 400MST Figure 3 2 400MST Front Panel with Parameter Description 400MST 3 OPERATOR CONTROLS Parameter Description ARC CONTROL This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability HOT START This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes e g low hydrogen electrodes It sets the peak start current on top of the WELD current Weld Current Amperage when lit parameter knob sets the STICK and TIG WELD current Weld Voltage Volt when lit parameter knob sets the MIG voltage Contactor ON OFF Contactor operation in Stick Mode Operation PANEL REMOTE Selects mode of operation Panel or Remote INDUCTANCE This parameter similar to the ARC CONTROL in STICK mode allows for the adjustment of the dynamic property of the arc As the inductance is increased the output voltage may need to be adjusted to achieve the desired weld characteristics SAUVEGARDER CHARGER Table 3 1 Weld Parameter Descriptions for 400MST The SAVE LOAD buttons are used to save and retrieve a total number of 5 programs into the 400MST memory 3 Weld Process selection for the 400MST Weld Mode Weld Parameter LIFT STICK TIG MIG Description Weld voltage MIG
58. VOLTAGE REDUCTION DEVICE 1 VRD Specification ArcMaster 400MST Notes Description Open circuit voltage between welding terminals The required resistance 148 to 193 between welding ohms terminals to turn ON the welding power The time taken to turn OFF the welding power once the welding current has stopped VRD Open Circuit Voltage 15 3 to 19 8V VRD Resistanc VRD Turn OFF 0 2 to 0 3 Time seconds 2 VRD Maintenance Routine inspection and testing power source An inspection of the power source an insulation resistance test and an earth resistance test shall be carried out a Fortransportable equipment at least once every 3 months b For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests NOTE A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated In addition to the above tests and specifically in relation to the VRD fitted to this machine the fol lowing periodic tests should also be conducted by an accredited Thermal Arc service agent Description IEC 60974 1 Requirements VRD Open Less than 20V at Vin 230V 460V Circuit Voltage VRD Turn ON Less than 200 ohms Resistance VRD Turn OFF Less than 0 3 seconds Time If this equipment is used in a hazardous location or environments wi
59. Y INSTRUCTIONS AND WARNINGS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUCTION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Some of these practices apply to equipment connected to power lines other practices apply to engine driven equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Safe practices are outlined in the American National Standard 749 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 01 Welding Hazards 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
60. YTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur Wa P AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression lia p s 1 N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant d ter compl tement le bouchon 1 05 Principales Normes De Securite Safety in Welding and Cutting norme ANSI 749 1 American Weld ing Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substanc
61. al Connect electrode lead to positive terminal Switch machine on Set weld current Set Contactor Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set HOT START Set ARC CONTROL Set WELD current Commence welding 2 LIFT TIG Welding Connect work lead to positive terminal Connect TIG torch to negative terminal Switch machine on Set weld current Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Commence welding 3 MIG Welding Connect work lead to negative terminal Connect electrode lead to positive terminal Switch machine on Set weld voltage Set Inductance Connect Wire feeder Set wire feed speed IPM Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Commence welding 5 ROUTINE MAINTENANCE The only routine maintenance required for the power supply is a thorough cleaning and inspec tion with the frequency depending on the usage and the operat
62. alia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 5 Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters THERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE DK i St Louis M0 63017 Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com
63. be liable for special indirect incidental or consequential damages including but not limited to lost profits and business interruption The remedies of the purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty and Thermal Arc shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or accessories which in Thermal Arc s sole judgment impaired the safety or performance of any Thermal Arc product Purchaser s rights under this warranty are void if the product is sold to purchaser by unauthorized persons The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser No
64. before installing or servicing this equipment Lock input power disconnect switch ARC RAYS can burn eyes and skin NOISE can damage open or remove line fuses so power cannot be turned on hearing Arc rays from the welding process produce accidentally intense heat and strong ultraviolet rays that can burn 5 Properly install and ground this equipment according to its Owner s skin Noise from some processes damage Manual and national state and local codes 6 Turn off all equipment when not in use Disconnect power to Wear a welding helmet fitted with a proper shade of filter see equipment if it will be left unattended or out of service ANSI 749 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended ARCMASTER 400 MST 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high 19 WARNING EI e 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 Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and ga
65. ce page 9 11 2 Remove six screws and six terminals 400MST 9 ADVANCED TROUBLESHOOTING 2 4 21 Switch 52 and 53 1 Remove the side cover Reference page 9 1 2 Remove six screws and six terminals 4 Cut off one snap band and disconnect one connector from PCB4 WK 4819 Remove two screws and two nuts and remove the switch S2 Disconnect one connector from the switch S3 Remove two nuts and remove the switch S3 400MST 9 ADVANCED TROUBLESHOOTING 2 4 22 Current Sensor HCT1 1 Remove the side cover Reference page 9 11 2 Remove PCB17 WK 5699 Reference page 9 33 3 Remove one screw and one terminal Remove one bolt and one terminal Disconnect one connector Remove one screw and one nut and detach the bus bar 2 4 23 Diode 01 1 Remove the side cover Reference page 9 11 2 Remove WK 5548 Reference page 9 24 3 Remove six screws and 13 terminals Remove two screws and remove the diode D1 When replacing the diode with a new one apply an oil compound SHINETSU SILICONE G 747 or equivalent evenly to the base 400MST 9 ADVANCED TROUBLESHOOTING 2 4 24 Diode D2 D3 D4 05 OQ F 1 Remove the side cover
66. ched to the equipment Be sure to include any dash numbers following the Part or Assembly numbers 2 HowTo Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a break down of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and per manently attached items which are soldered riveted or welded to other parts The part descriptions may be indented to show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the correspond ing Parts List PART NUMBERS ARC MASTER 400MST 10 3072 DWGNo PartNo Description Additional Information CON1 W7001302 Socket Remote gen 3 1 IPS 53102 20 275 14 with Wiring 1 Assembl W7001303 Socket Remote gen 3 1 IPS 53102 22 145 19 with Wiring Assembl D1 I1 110 5003 Sensor Current aen 3 1 IPS HC IN200V4B15M 200M4V 1 Q o z N 2 1 SDKGA4 A 1 A 1 6 8 9 DWG No PartNo Description Additional Information OQTY 33 7001328 Panel Front gen 3 1 1 6 EODO06301 41 34 7001329 Panel Rear gen 3 1 5 ______00004907 141 35 1 wz001330 Label
67. d be undertaken only by those familiar with high voltage high power electronic equipment A wARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have training in power electronics measurement and troubleshoot ing techniques 1 System Level Fault Isolation Under no circumstances are field repairs to be attempted on printed circuit boards or other subas semblies of this unit Evidence of unauthorized repairs will void the factory warranty If a subas sembly is found to be defective by executing any of the procedures in this Service Manual the subas sembly should be replaced with a new one The faulty subassembly should then be returned to Thermal Arc through established procedures WARNING Disconnect primary power at the source before dis assembling the power supply Frequently review the Principal Safety Standards in section 1 02 Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operator s body comes into con tact with the work piece or any internal components while the unit is activated If none of the suggestions provided in Section 7 have solved the problem or corrected the faulty operation the next step is to isolate one or more of the internal subassemblies that may be defective CAUTION Perform all steps in each procedure in sequence
68. d fully clockwise OR fully counter clockwise as the VRD function will be unknown for every other position gt 85 Figure 7 3 ON OFF Step D 8 POWER SOURCE ERROR CODES Description Possible Cause Remedy Remarks E01 error code displayed Temperature sensor TH1 protects IGBTs is greater than 80 C for about 1 second The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Weld current ceases Buzzer sounds constantly Fan operates at max speed E01 resets when TH1 decreases to 70 C for about 30 seconds E02 error code displayed Temperature sensor TH2 protects secondary diodes is greater than 80 C for about 1 second The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Weld current ceases Buzzer sounds constantly Fan operates at max speed E02 resets when TH1 decreases to 70 C for about 30 seconds E03 error code displayed Primary input current too high Primary cur
69. d re t eie da ow pte ar defe 9 8 1 3 2 Wire feeding failure or inconsistent wire delivery Wire feeder does not work 9 8 1 3 3 weld 2 eee ERE ETE Mabel Masta bare edu et Roe 9 9 1 3 4 Operating Panel Failure LED s do not light properly or weld settings cannot be establish 9 10 1 4 Fault Isolation Tests cir n mr RR mere RE OR eee T RU RR RU EUR 9 10 1 41 Preparatign zc sere Toe E WE P eR ens PaL ERR ede RA TON Qu E a ne RR edid 9 10 1 4 2 Verification of the Power Input Circuitry 9 11 1 4 3 Power Supply Voltage 1 9 12 1 4 4 Verification of the Cooling Fan FAN1 Drive Circuitry 9 12 1 4 5 Verification of the primary Diode 1 2 9 13 1 4 6 Verification of the secondary Diode 2 7 9 14 1 4 7 Verification of the primary IGBT Q1 24 1 1 2 1 9 14 1 4 8 Verification of No load Voltage 9 15 2 Subsystem Test and Replacement Procedures 9 17 2 Pr paration a dp NER lense
70. dercut from previous run Joint preparation too restricted Irregular deposits allow slag to be trapped Lack of penetration with slag trapped beneath weld bead Rust or mill scale is preventing full fusion Wrong electrode for position in which welding is done Slag trapped in undercut Slag trapped in root A If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode Allow for adequate penetration and room for cleaning out the slag If very bad chip or grind out irregularities Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from corners Clean joint before welding Use electrodes designed for position in which welding is done otherwise proper control of slag is difficult Figure 6 3 Examples of slag inclusion 400MST 6 BASIC TROUBLE SHOOTING Description 5 Power Source Problems Possible Cause Remedy The welding arc cannot be established The Primary supply voltage has not been switched ON The Welding Power Source switch is switched OFF C Loose connections internally A Switch ON the Primary supply voltage B Switch ON the Welding Power Source C Have an Accredited Thermal Arc Service Agent repair the connection Maximum output welding current can not be achieved with nominal Mains supply voltage Defective control circuit Have an Accredited Th
71. e best product possible and therefore reserves the right to change improve or revise the specifica tions or design of this or any product without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes updates improve ments or replacement of such items 7 Duty Cycle The duty cycle of a welding power source is the percentage of a ten 10 minute period that it can be operated at a given output without causing over heating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease A WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become ener gized and shut down the output until the unit has cooled to normal operating temperature CAUTION Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty NOTE Due to variations that can occur in manufactured products claimed performance voltages ratings 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 3 OPERATOR CONTROLS 1 400MST Controls 1 Control Knob This control
72. e nameplate on the rear panel when testing the power supply 2 Close primary power source wall disconnect Switch or circuit breaker 3 Place power supply MAIN CIRCUIT SWITCH S1 on rear of unit in the ON position A WARNING Dangerous voltage and power levels are present inside this unit Be sure the operator is equipped with proper gloves clothing and eye and ear pro tection Make sure no part of the operator s body comes into contact with the workpiece or any inter nal components while the unit is activated 9 10 400MST 9 ADVANCED TROUBLESHOOTING 1 4 2 Verification of the Power Input 1 Circuitry Verify the AC input voltage using an AC volt meter Verify input voltage Phase to Phase using an AC voltmeter The capability of the voltmeter should be more than 600VAC Measure the point between lines U1 and V1 on the input switch S1 Measure the point between lines U1 and W1 on the input switch S1 Measure the point between lines V1 and W1 on the input switch 51 The location of points U1 V1 and W1 on switch 1 are indicated in Figure 9 1 When using a single phase connection the voltage can be verified only between U1 and Figure 9 1 Check points U1 U2 V1 V2 W1 and W2 2 If the input voltage is out of the operating range of the unit which is 10 187 253 414 506 VAC of the rated voltage 208 230 460V verify the available power capacity at the installed site I
73. e 3 RED input conductors to a de energized line disconnect switch 3 Use Table 1 and Table 2 as guide to select line fuses for the disconnect switch NOTE For Single Phase operation connect the GREEN BLACK and WHITE input conductors Insulate the RED Conductor it is not used for Single phase operation Fuse Size 100 Amps Input Voltage 208 VAC 230 VAC 460 VAC 75 Amps 50 Amps Table 2 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 Weiding Power Supply NY Ground Conductor NN Line Disconnect Switch Ground Terminal Line Fuse Primary Power Cable Figure 2 3 Electrical input connections 5 2 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 charg ing of the input capacitors At this point the Bus Voltages are checked and the welder is enabled after the input capacitors have charged to full operating voltage after approximately 5 seconds NOTE Note the available input power Damage to the welder could occur if 575VAC or higher is applied The following 208 230 460V Primary Current rec ommendations are required to obtain the maximum welding current and duty cycle from this welding equipment Minimum
74. e cables connected to the wire feeder equipment including welding and base metal cables Applies to MIG mode only 400MST 9 ADVANCED TROUBLESHOOTING Confirm the connections of the required cables control cable for the wire feeder equipment cable for welding and a cable for the base metal are all secured Confirm that there are no connection errors or broken wires of the required cables con trol cable for the wire feeder equipment cable for welding and a cable for the base metal d Verify the no load voltage OCV Applies to STICK and MIG mode Refer to section Verification of No Load volt age OCV in the section 9 1 4 8 first before continuing this section If performing the No Load Voltage Failure procedure does not rectify the failure per form the following tests in the sequence below Replace any defective components found 1 Diode D2 D3 D4 and D5 Refer to the Section 9 1 4 6 2 Reactor FCH Confirm the connection of FCH and PCB14 WK 5594 Refer to the Section Appendix 3 3 8 PCB9 PCB10 PCB11 WK 5479 Refer to the Section 9 2 4 7 and 9 2 48 4 Hall CT HCT1 Confirm the connection of FCT1 and PCB6 WK 5688 Refer to the Section 9 2 4 22 e Verify the wire feeder equipment and replace it if necessary Refer to the operating manual supplied by the wire feeder manufacture before any work is performed on the wire feeder 1 3 4 Operating Panel Failure LED s
75. e plein en fumant ou proche d une source d tincelles ou d une flamme nue 3 Sic est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage 4 Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur w AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROL
76. e soudure d air approuv 2 l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc 2 Portez des lunettes de s curit approuv es Des crans lat raux Lisez les fiches signal tiques et les consignes du fabricant rela sont recommand s tives aux m taux aux produits consummables aux rev tements 3 Entourez l aire de soudage de rideaux ou de cloisons pour prot ger et aux produits nettoyants les autres des coups d arc ou de l blouissement avertissez les 5 Ne travaillez dans un espace confin que s il est bien ventil sinon observateurs de ne pas regarder l arc portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respi ration 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev 6 Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 6 2 73 Op ration de coupage Diners
77. e tests and replacement of the cooling fan 1 Follow the instruction in section 9 1 4 4 1 3 2 Wire feeding failure or inconsis tent wire delivery Wire feeder does not work Cause Power Source Faulty or damaged 14 pin recepta cle and 19 pin receptacle tripped or damaged the circuit breaker MCB1 MCB2 blown down transformer associated wiring Wire Feeder Feeder gear failure Refer to the wire feeder operator manual supplied by the wire feeder manufacturer for additional informa tion Verification Remedy a Confirm wire setting b Verify CON1 of 14 pin receptacle CON2 of 19 pin receptacle Applies to MIG mode Confirm the wiring harness and connections between CON1 of 14 pin receptacle CON2 of 19 pin receptacle and the wire feeder device are secure Confirm the wiring harness and connections between CON1 of 14 pin receptacle or CON2 of 19 pin receptacle and PCB17 WK 5699 Contact the manufacturer if you find any bro ken connectors or damaged wiring harn esses e Confirm that the voltage between pin I and pin G of the 14 pin CON1 receptacle is AC115V AC100 125V Confirm that the voltage between pin E and pin F of the 19 pin receptacle is AC115V AC100 125V 400MST 9 ADVANCED TROUBLESHOOTING e Confirm the pin out numbers of the 14 pin receptacle or 19 pin receptacle located on the wire feeder equipment Refer to section 3 1
78. e work torch leads to the right welding terminals Connect it to the terminal Select the right flow rate change cylinders or turn torch valve on 12 Arc start is not smooth Tungsten electrode is too large for the welding current The wrong electrode is being used for the welding job Gas flow rate is too high Incorrect shielding gas is being used Poor work clamp connection to work piece 4 Stick Welding Problems Select the right size electrode Refer to Basic TIG Welding Guide Select the right electrode type Refer to Basic TIG Welding Guide Select the correct rate for the welding job Refer to Basic TIG Welding Guide Select the right shielding gas Refer to Basic TIG Welding Guide Improve connection to work piece Description Possible Cause Remedy 1 Gas pockets or voids in A Electrodes are damp A Dry electrodes before use weld metal Porosity Welding current is too high B Reduce welding current C Surface impurities such as oil grease C Clean joint before welding paint etc 2 Crack occurring in weld A Rigidity of joint A Redesign to relieve weld joint of severe metal soon after B Insufficient throat thickness Stresses or use crack resistance solidification C Cooling rate is too high electrodes commences B Travel slightly slower to allow greater build up in throat C Preheat plate and cool slowly 3 is left by failure Welding current is to
79. ects the Primary supply volt age to the inverter when in the ON position This enables the Power Supply A war When the welder is connected to the Primary sup ply voltage the internal electrical components may be at 720V potential with respect to earth 7 Input Cable The input cable connects the Primary supply voltage to the equipment 8 Voltage Input Select Switch Smart Logic Switch User selectable switch A manual slide switch selects the proper input voltage range If this slide switch is not set to the position that matches the input line voltage the Smart Logic will inhibit the welding power source from turning on and a warning indica tion will be displayed WARNING Do not alter the position of the Voltage Input Select Switch when the ON OFF Switch is in the ON posi tion and the unit is powered up 9 14 19 Pin Remote Control Select Switch User selectable switch Position this switch for the remote control device socket to be utilized The unselected Remote Control Socket is disabled at this time and cannot be utilized Do not alter the posi tion of this switch while one of the Remote Control Sockets is being utilized 10 24VAC Remote Device C B Push to reset Controls the 24VAC power source for the wire feeders controlled through the Remote Control Sockets 11 115VAC Remote Device C B Push to reset Controls the 115VAC power source for the wire feeders controlled through the Remote Control
80. equire more frequent cleanings C Verify the operation of the cooling fan FAN1 and replace it if necessary Verify the condition of FAN1 Verify that there are no broken or cracked fan blades and that FAN1 is not producing any abnormal sounds If broken or cracked FAN1 blades or abnor mal sounds are emanating from FAN1 replace FAN1 Refer to section 9 2 4 19 for the replacement of FAN1 Refer to section 9 1 4 4 for additional FAN1 tests Verify the operation of the cooling fan and replace it if the condition of FAN1 is inactive Follow the instruction in section 9 1 4 4 d Replace PCB3 WK 5548 Refer to section 9 2 4 3 for the replacement of PCB3 1 2 3 E03 Primary Over Current Failure Cause Occurs when excessive current is detected flow ing into the primary side of the main transformer Verification Remedy a Confirm the operation of the machine within the rated specification Refer to the specification data sheet in Sec tion 2 6 b Verify the secondary diode D2 D3 D4 D5 Refer to section 9 1 4 6 for the test and replacement of D2 and to section 9 2 4 24 for D3 D4 D5 c Replace the Hall CT HCT1 NOTE Pay special attention to installed direction of HCT1 The Hall CT will not function properly if installed in the incorrect direction Refer to section 9 2 4 22 for the replacement of HCT1 1 2 4 E11 High Input Voltage Failure Cause Occ
81. ermal Arc Service Agent inspect then repair the welder Welding current reduces when welding Poor work lead connection to the work piece Ensure that the work lead has a positive electrical connection to the work piece No gas flow when the torch trigger switch is depressed A Gas hose is cut B Gas passage contains impurities C Gas regulator turned off D Torch trigger switch lead is disconnected or switch cable is faulty A Replace gas hose B Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities C Turn gas regulator on Reconnect lead or repair faulty switch cable Gas flow won t shut off Weld Mode STD SLOPE REPEAT or SPOT was changed before POST FLOW gas time had finished Gas valve is faulty Gas valve jammed open POST FLOW control is set to 60 sec Strike an arc to complete the weld cycle OR Switch machine off then on to reset solenoid valve sequence Have an Accredited Thermal Arc Service Agent replace gas valve C Have an Accredited Thermal Arc Service Agent repair or replace gas valve D Reduce POST FLOW time The TIG electrode has been contaminated due to the gas flow shutting off before the programmed POST FLOW time has elapse The Weld Process Mode STICK HF TIG or LIFT TIG was changed before POST FLOW gas time had finished Do not change Weld Process Mode before the POST FLOW gas time had finished 7
82. ers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci dessous f AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs ARCMASTER 400 MST 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es 2 Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent amp tre envoy es l ext rieur loin des prises d air du b timent AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein 2 Nefaites pas l
83. es norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Pro tection Association Batterymarch Park Quincy MA 02269 SYMBOL LEGEND Amperage STICK Shielded Metal Arc SMAW Voltage Pulse Current Function Hertz frequency Spot Time GTAW Seconds Remote Control Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current Gas Post Flow Standard Function Gas Pre Flow Slope Function Voltage Reduction Device Circuit Slope W Repeat Function Negative Spot Function Positive Impulse Starting High Frequency GTAW Gas Input Touch Start Lift Start TIG circuit GTAW Gas Output 2 INTRODU
84. f the input voltage is within the operating range recheck the input voltage while welding as welding may cause the input voltage to decrease to a value below the operating range of the unit Verify input voltage after the input switch S1 using an AC voltmeter The capability of the voltmeter should be more than 600VAC Using an AC voltmeter measure between the points U2 and V2 on the input switch 51 Using an AC voltmeter measure between the points U2 and W2 on the input switch 51 Using an AC voltmeter measure between the points V2 and W2 on the input switch 51 The location of points U2 V2 and W2 on switch S1 are indicated in Figure 9 1 When 9 11 6 diode D1 using a single phase connection the voltage can be verified only between U2 and V2 If this voltage is out of the operating range which is 10 187 253 414 506 VAC of the rated voltage 208 230 460V replace 51 fol lowing the process in section 9 2 4 20 Verify the rectified output voltage of the input diode D1 using a DC voltmeter The capabil ity of the voltmeter should be more than 1000VDC Using a DC voltmeter measure between the points 1 P and 2 N on D1 Points 1 P and 2 N are on D1 See Figure 9 2 The measured voltage should be approxi mately 1 4 times larger than input voltage mea sured in 1 above Replace diode D1 if the calculated measurement is not within the cor responding range 260 360 580 720V
85. ge to complete and then remove the cases to continue your inspection and repair or mainte nance inside the power supply As for the removal and installation of the case refer to section 9 1 1 NOTE During the Verification Remedy procedures below follow the alphabetical sequence a b c and proceed with your verification and confirma tion NOTE After you confirm and replace all spare parts and components confirm that there are no damaged harnesses or connectors uninstalled or loose screws 1 2 1 E01 Over Temperature at the primary side Cause Occurs when an over temperature condition of the primary IGBT is detected Verification Remedy a Unit may be in thermal shutdown mode Review the rated duty cycle of the unit per page 2 4 Exceeding the duty cycle can damage the unit and void the warranty Refer also to section 2 7 for addi tional information b Verify the ventilating condition Maintain a clear and unobstructed distance of more than 12 in in the front and more that 20 in in the rear of the unit for ventilation pur poses Verify and maintain clean dust free front and rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working envi ronment is recommended Extremely dusty environments will require more frequent cleanings c Verify the operation of the cooling fan FAN1 and replace it if necessary
86. gether the harness of CN7 on PCB17 WK 5699 and the harness wired to the rear side Cut off one snap band that ties together the harness on the secondary side of the transformer T1 and the harnesses of CN7 CN1 on PCB17 WK 5699 5 400MST 9 ADVANCED TROUBLESHOOTING 7 Remove four terminals 400MST 9 ADVANCED TROUBLESHOOTING 2 4 30 14 Pin Receptacle CON1 1 Remove the side cover Reference page 9 1 2 Disconnect three connectors Remove one screw and three ground terminals Cut off two snap bands 4 Cut off five snap bands When reinstalling the receptacle bend both the harnesses of CN6 CN7 CN9 CN10 on PCB17 WK 5699 and the ones of N pin L pin of 19 pin receptacle CON2 and then use snap bands to tie together the bent harnesses and the ones of CN1 CN5 CN8 on PCB17 WK 5699 400MST 9 ADVANCED TROUBLESHOOTING 5 Remove two screws Remove the and remove the 14 pin receptacle 1 2 4 31 19 Pin Receptacle CON2 1 Remove the side cover Reference page 9 11 2 Remove four screws and open the rear cabinet 0 3 Cut off three snap bands When reinstalling the receptacle secure the harnesses to the holders using snap bands 10
87. in the electrode wire jamming in the contact tip When using soft electrode wire such as alu minium it may become jammed in the con tact tip due to expansion of the wire when 2 MIG Welding Problems Description Possible Cause heated A contact tip designed for soft elec trode wires should be used 7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the arc 8 Bent liner This will cause friction between the wire and the liner thus reducing wire feedability Remedy Undercut Welding arc voltage too high Incorrect torch angle Excessive heat input Reduce WELD V control or increase the wire feed speed Adjust angle Increase the torch travel speed and or reduce welding current by reducing the WELD V control or reducing the wire feed speed Lack of penetration Welding current too low tight Shielding gas incorrect Joint preparation too narrow or gap too Increase welding current by increasing wire feed speed and increasing WELD V control Increase joint angle or C Change to a gas which gives higher penetration Lack of fusion Voltage too low Increase WELD V control Excessive spatter Voltage too high Voltage too low A Lower the voltage by reducing the WELD V control or increase wirespeed control B Raise the voltage
88. ine exhaust outside and away from any building air intakes y 7 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine w 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 5 WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 19 Always wear face shield when working a battery Stop engine before discon
89. ing environment A WARNING Disconnect primary power at the source before opening the enclosure Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure refer to Opening the Enclosure section 9 1 1 and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean if necessary with solvents that are recommended for cleaning electrical apparatus CAUTION Do not blow air into the power supply during clean ing Blowing air into the unit can cause metal parti cles to interfere with sensitive electrical components and cause damage to the unit 6 BASIC TROUBLE SHOOTING A WARNING There are extremely dangerous voltages and power levels present inside this product Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques If major complex subassemblies are faulty then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair The basic level of troubleshooting is that which can be performed without special equipment or knowl edge 1 Solving MIG Problems Beyond the Welding Termi nals The general approach to fix Gas Metal Arc Welding GMAW problems is to start at the wire spool then work through to the MIG torch There are two
90. itry is defective dam aged or the TIG torch cable is defective and Wire feeder Abnormality Verification Remedy CAUTION Head and understand this entire section before proceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately a Verify the 14 pin receptacle Applies to LIFT TIG and MIG mode e Confirm a secure connection between CON1 of the 14 pin receptacle and the wire feeder e Confirm a secure connection between CON1 of the 14 pin receptacle and the remote device e Confirm a secure connection of the harness and the connections between CON1 and PCB17 WK 5699 are all correct and there are no open circuit Contact the manufacturer if you find any bro ken connectors or damaged wiring har nesses e Confirm the proper pin outs of the 14 pin receptacle on the wire feeder side Refer to section 3 1 e Confirm the proper pins outs of the 14 pin receptacle on the remote device side Refer to section 3 1 Confirm that the wire feeder has no open circuit on the 14 pin receptacle at the remote device side b Verify the condition and connect the connec tions of the welding cable the stick rod holders and the base metal cables Applies to STICK and LIFT TIG mode Confirm a secure connection of the welding cable stick rod holders base metal cables and dinse connectors and there are no open circuits Verify th
91. la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque ARCMASTER 400 MST 4h 4 AVERTISSEMENT gt LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau 2 LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin a s Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renv
92. n receptacle CON2 of the 19 pin receptacle and the remote device 2 Confirm a secure connection of the har ness and the connections between CON1 or CON2 and PCB17 WK 5699 are all correct and there are no open circuits Contact the manufacturer if you find any broken connectors or damaged wiring har nesses 4 Contactor function is put into the state of on pushing Function button CAUTION Electric shock hazard The unit will generate OCV immediately when contactor function is put into the state of ON pushing Function button enabling MIG mode 5 The normal no load voltage is approxi mately 65V 6 Return potentiometer VR1 to the original position THIS PAGE LEFT INTENTIONALLY BLANK 400MST 9 ADVANCED TROUBLESHOOTING 2 Subsystem Test and Replacement Procedures 2 1 Preparation This section provides specific procedures for verifying the operation and replacement of each subsystem within the power supply Before undertaking any of these procedures eliminate the obvious first visually inspect the suspect sub system for physical damage overheating and loose connections 2 2 Test and Replacement Parts List lt res Parts name e UAR BS Reference page Part No Print Circuit Board WK 5597 9 23 W7001313 Print Circuit Board WK 5548 9 24 W7001314 Print Circuit Board WK 4819
93. nd PCB3 WK 5548 measure the voltages according to the following table The test point and the reference are obtain able on the parts side of PCB6 WK 5549 and WK 5548 The location of points TPO 3 are indicated in Figure 9 4 The location of points PIN1 PIN3 of 18 on are indicated in Figure 9 5 Figure 9 4 The check points 3 ACCEPTABLE VALUE Reference PCB6 WK 5688 Test Point PCB6 WK 5688 TP1 TPO 15VDC TP2 TPO 5VDC TP3 TPO 15VDC 9 12 24VDC If any of these voltages are not present or are below 10 tolerance replace PCB3 WK 5548 1 4 4 Verification of the Cooling Fan FAN1 Drive Circuitry Verify the condition of the cooling fan FAN1 using a DC voltmeter The capability of the voltmeter should be more than 50VDC Using a DC voltmeter measure between PIN 1 and PIN 2 of CN11 on PCB3 WK 5548 The location of connector CN11 of PCB3 WK 5548 is indicated in Figure 9 6 NOTE When you measure the above voltage do not remove the connector Conduct the measurement while the connector plug and receptacle are still connected 400MST 9 ADVANCED TROUBLESHOOTING Figure 9 6 The location of connector CN11 of PCB3 WK 5548 Using the measurement taken above follow the chart below for possible failure modes Fan Status Voltage measurement PIN1 PIN2 of CN11 on
94. necting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries ARCMASTER 400 MST AT P WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure 1 Do not remove radiator cap when engine is hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with and produce changes in biological sys
95. o low A Increase welding current of the weld metal to fill B Electrode too large for joint B Use smaller diameter electrode the root of the weld Insufficient Allow wider D Incorrect sequence D Use correct build up sequence X Insufficient gap Incorrect sequence Figure 6 1 Example of insufficient gap or incorrect sequence 6 4 400MST 6 BASIC TROUBLE SHOOTING Description Possible Cause Remedy 4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint Small electrodes used heavy cold plate Welding current is too low Wrong electrode angle Travel speed of electrode is too high Scale or dirt on joint surface Use larger electrodes and pre heat the plate Increase welding current Adjust angle so the welding arc is directed more into the base metal Reduce travel speed of electrode Clean surface before welding Description Lack of fusion caused by dirt E electrode angle incorrect rate of travel too high gt lt Lack of side fusion scale dirt small electrode amperage too low lt Lack of inter run Fusion N Lack of Root Fusion Figure 6 2 Example of lack of fusion Possible Cause Remedy 5 Non metallic particles are trapped in the weld metal slag inclusion Not cleaned or incorrect electrode Non metallic particles may be trapped in un
96. ove six screws and six terminals 400MST 9 ADVANCED TROUBLESHOOTING 4 Remove four terminals Remove two nuts and remove the molded case circuit breakers MCB1 and MCB2 purple orange Blue brown 2 4 28 Resistor R2 and R3 1 Remove the side cover Reference page 9 1 2 Remove the switch S1 Reference page 9 37 3 Remove four screws and four terminals 400MST 9 ADVANCED TROUBLESHOOTING 2 4 29 Transformer T1 1 Remove the side cover Reference page 9 1 2 Cut off one snap band and disconnect one connector Remove one screw and three ground terminals Cut off two snap bands 3 Cut the tap wires on the primary side of the transformer T1 which are connected with the insulated ter minal Incorrect wiring of each tap wire when reinstalling the transformer may damage the welding machine Check the electrical schematic diagram before connecting the tap wires 5s 400MST 9 ADVANCED TROUBLESHOOTING 4 Remove four screws and open the rear cabinet 5 Cut off three snap bands e When reinstalling the transformer secure the harnesses to the holders using snap bands 6 Cut off one snap band Cut off one snap band that ties to
97. put 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 5 1 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 volt ages shown on the input data label on the unit nameplate Contact the local electric utility for infor mation about the type of electrical service avail able how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electri cal power from the welding power supply whenever necessary to inspect or service the unit 400MST 2 INTRODUCTION AND DESCRIPTION NOTE These units are 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 2 3 and 1 Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 BLACK and line 2 WHITE and lin
98. r switch semi conductors 160S 300S 400S Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors GENERAL ARC EQUIPMENT LABOR Water Recirculators 1 year Plasma Welding Torches 180 days 180 days Gas Regulators Supplied with power sources 180 days Nil MIG and TIG Torches Supplied with power sources Nil Replacement repair parts Nil MIG TIG and Plasma welding torch consumable items i Nil IHERMAL ARC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park JIn Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia T1 Gower Street Preston Victoria Austr
99. rcentage increase in welding current and is proportional to arc length arc volt age 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 eg cellulose and hydrogen controlled electrodes In all welding processes the amount of penetration obtained is dependent on the welding current ie the greater the penetration the greater the current Current Increase when Arc Voltage is less than 18V Arc Force Position Effect on Welding Performance Minimum 0 Soft arc Low spatter Low penetration Normal arc Improved fusion characteristics Normal penetration Hard arc Deep penetration 0A Medium 2096 Maximum 100 Table 3 3 Weld Parameter Descriptions In general having the ARC CONTROL set at 100 maximum allows greater penetration control to be achieved With the ARC CONTROL set at 0 minimum the Power Source has a constant cur rent characteristic In other words varying the arc length does not significantly effect the welding cur rent When the ARC CONTROL set to 100 it is possible to control the welding current by varying the arc length This is very useful for controlling penetration on root runs and side wall wash on ver tical up fillet welds i Root runs During root runs the weld
100. rent is too high because welding arc is too long Mains supply voltage is more than 10 below nominal voltag Reduce length of welding arc Have an Accredited Thermal Arc Service Agent or a qualified electrician check for low Mains voltage Weld current ceases Buzzer sounds constantly Switch machine off then on to reset E03 error E11 error code displayed Over Primary supply input voltage at primary capacitors is exceeded for one second Primary supply voltage is greater than the nominal voltage plus 10 Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Primary voltage Weld current ceases Buzzer sounds constantly Error code E11 automatically will reset when the voltage reduces E14 error code displayed Under mains supply input voltage warning primary capacitors is reduced for one second Mains supply voltage is less than the nominal operating voltage less 1096 Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Weld current available Buzzer sounds intermittently Error code E14 automatically will reset when the voltage increases E12 error code displayed Under mains supply input voltage primary capacitors is reduced for one second Mains supply voltage is down to a dangerously low level Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage
101. s les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 749 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 04 Dangers Relatifs au Soudage Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilise
102. ses If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners 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 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded Torch soldering Torch brazing C Under lin 25mm Oxygen Cutting Under 1 in 25 mm Gas welding 1 8 to 1 2 in 3 12 mm EN 5 82 to 1 4in 12 Plasma arc cutting eee 14 goggles or helmet from AWS A6 2 73 Filter 2 Ferrous base metal 12 Atomic hydrogen welding Plasma arc welding fo Carbon arc air gouging or 1 to 6 in 25 150 mm TIG Over 6 in 150 mm 300 to 400 Amp Over 400 Amp WAR
103. set up condition as described in section 9 1 4 1 Preparation Q1 24 using a diode tester 3 Refer to Table 9 3 and Figure 9 10 for the checkpoints on PCB8 and 9 9 14 400MST 9 ADVANCED TROUBLESHOOTING TERMINALS COMPONENT TESTED Positive lead Negative lead ACCEPTABLE VALUE Collector Emitter of Q1 24 with PCB8 and PCB9 C CE CE Open 0 2 to 0 5V Collector Emitter of Q1 24 with 8 and PCB9 CE Open 0 2 to 0 5V AVR Figure 9 10 Tester checkpoints in the primary IGBT Q1 24 1 4 8 Verification of No load Voltage OCV a Verify the no load voltage in STICK mode 1 STICK welding mode mark and then turn potentiometer VR1 on PCB6 WK 5688 fully counter clockwise to turn off the electric shock protector function Voltage Reduction Device VRD 2 Contactor function is put into the state of ON by pushing the Function button CAUTION Electric shock hazard The unit will generate OCV immediately when contactor function is put into the state of ON pushing Function button enabling STICK mode 3 Verify the no load voltage using a DC volt meter The capability of the voltmeter should be more than 100VDC 4 The normal no load voltage is approxi mately 65V b Verify the no load voltage in MIG mode 1 Confirm a secure connection between of the 14 pi
104. t des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables ARCMASTER 400 MST a AVERTISSEMENT AR AVERTISSEMENT LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX LES VAPEURS ET LES FUMEES SONT DANGEREUSES ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE POUR LA SANTE L arc de soudage produit une chaleur et des rayons Le soudage d gage des vapeurs et des fum es ultraviolets intenses susceptibles de br ler les yeux et dangereuses respirer la peau Le bruit caus par certains proc d s peut endommager louie 1 Eloignez la t te des fum es pour viter de les respirer E P si 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI 249 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que 3 Sila ventilation est inadequate portez un respirateur adduction vous observez l ex cution d un
105. tems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cable around the body Es Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS EE The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 1 02 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 749 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 Ameri can Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard
106. th a high risk of electrocution then the above tests should be carried out prior to enter ing this location 7 1 3 Switching VRD On Off Switch the machine Off a Remove the clear plastic cover from the control panel see Figure 7 1 Lift up the cover so it rests on the top of the unit Place a small flat bladed screw driver between the cover hinge on the front panel Gently lift the cover hinge out of the front cover mounting hole Remove the control s clear plastic cover Figure 7 1 VRD ON OFF Step b Remove four mounting screws from the control panel see Figure 7 2 Access the VRD control by gently prying back the front panel controls to reveal the VRD on off potentiometer see Figure 7 2 CAUTION Do not pull back the front panel with excessive force as this will unplug control PCB Plugging the control PCB back into the front panel controls can only be achieved by removing the side covers Figure 7 2 VRD ON OFF Step B C 400MST 7 Voltage Reduction Device d Turning the VRD ON OFF see Figure 7 3 To turn ON rotate the trim potentiometer VR1 on the display PCB fully clockwise When VRD is turned ON check that it operates as per VRD Specifications on page 7 1 To turn VRD OFF rotate the trim potentiometer VR1 on the display PCB fully counter clock wise warnine The VRD ON OFF trim potentiometer MUST ONLY be positione
107. the module tests as faulty replace the diode module Reconnect all cables to the proper terminals Forward Bias Diode Conducting Cathode Figure 10 1 Forward bias diode test Anode Reverse Bias Diode Not Conducting Cathode Anode Figure 10 2 Reverse bias diode test LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 LIMITED WARRANTY Thermal Arc Inc A Thermadyne Company Thermal Arc warrants to customers of authorized distributors Purchaser that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the warranty period stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained accordance with Thermal specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or damage correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective This warranty is exclusive and in lieu of any warranty of merchantability fitness for any particular purpose or other warranty of quality whether express implied or statutory Limitation of liability Thermal Arc shall not under any circumstances
108. the work in a cramped kneeling sitting or lying position with physical contact with con ductive parts In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator or In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insula tion properties of accessories Environments with hazardous environments do not include places where electrically conductive parts in the near vicinity of the operator which can cause increased hazard have been insulated 4 2 Location Be sure to locate the welder according to the fol lowing guidelines In areas free from moisture and dust Ambient temperature between 0 degrees to 40 degrees C n areas free from oil steam and corrosive gases n areas not subjected to abnormal vibration or shock n areas not exposed to direct sunlight or rain Place at a distance of 12 304 79mm or more from walls or similar that could restrict natural airflow for cooling A WARNING Thermal Arc advises that this equipment be electri cally connected by a qualified electrician 5 Electrical Input Connec tions A 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 in
109. to section 9 2 4 4 for the replacement of PCB4 c Replace PCB6 WK 5688 Refer to section 9 2 4 6 for the replacement of PCB6 400MST 9 ADVANCED TROUBLESHOOTING 1 3 Verification and Remedy to Failures without Indication Codes Refer to Notes on Page 9 4 1 3 1 Cooling Fan Failure Fan is not rotating Cause Occurs when the cooling fan is defective dam aged or the driving voltage is incorrect Verification Remedy a Verify the cooling fan FAN1 Inspect the condition of the fan blades and all peripheral parts Clean the fan blades and all peripheral parts if covered with dust Clean ing and removing dust from the fan blades once every 6 months in a normal environ ment is recommended Extremely dusty envi ronments will require more frequent cleanings e Verify that there are no wiring harnesses entangled inside the fan confirm that the har nesses do not have any brakes in the wire or damaged connectors Contact the manufacturer if you find any broken connectors or damaged wiring harn esses Replace the fan if there are any broken cracked or missing fan blades Refer to section 9 2 4 19 for replacement of FAN1 b Verify the wiring harness between the cooling fan FAN1 and CN11 on WK 5548 Confirm a secure connection of the harness to CN11 on PCB3 Contact the manufacturer if you find any broken connectors or damaged wiring harn esses C Cooling fan voltag
110. twithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shall pay no transportation costs of any kind under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty dated April 1 2006 supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermal Arc Inc WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout Raider Explorer Original Main Power Stators and Inductors 3 years Original Main Power Rectifiers Control P C Boards 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year Engines and associated components are NOT warranted by Thermal Arc although most are warranted by the engine manufacturer GMAW FCAW MIG WELDING EQUIPMENT Fabricator 131 181 190 21
111. urs when the input voltage is more than approximately 275VAC at input voltage 230V or 520VAC at input voltage 460V 1 1 41 of the maximum value of the sinusoidal wave Verification Remedy a Verify input voltage Follow the instruction in section 9 1 4 2 b Replace 4 WK 4819 If the voltage and current available is deter mined to be sufficient replace Refer to section 9 2 4 4 for the replacement of PCB4 400MST 9 ADVANCED TROUBLESHOOTING 1 2 5 E12 Low Input Voltage Failure Cause Occurs when the input voltage is less than approximately 150VAC 1 1 41 of the maximum value of the sinusoidal wave Verification Remedy a Verify input voltage Follow the instruction in section 9 1 4 2 b Replace 4 WK 4819 If the voltage and current available is deter mined to be sufficient replace PCBA Refer to section 9 2 4 4 for the replacement of PCB4 1 2 6 E14 Low Input Voltage Warning Cause Occurs when the input voltage is less than approximately 173VAC 1 1 41 of the maximum value of the sinusoidal wave Verification Remedy a Verify input voltage Follow the instruction in section 9 1 4 2 b Replace 4 WK 4819 If the voltage and current available is deter mined to be sufficient replace PCBA Refer to section 9 2 4 4 for the replacement of PCB4 1 2 7 E81 Abnormal Input Voltage Cause Failure detected
112. utions sis sine EY ve ea EA Pe egere a A Re nee e 1 1 SxPUbliCatioOns ce eee e es hed ernie Ma mS ed aan 1 2 4 Note Attention et Avertissement uu au en a Rod S DM ELE a PN DISCI LET Ran 1 3 5 Precautions De Securite 1 3 6 Documents De osos eom e hne itr Oe eee he y ee ee PORE EC a 1 5 2 INTRODUCTION AND DESCRIPTION 1 PONE TEE APP ETT 2 1 2 F nctiorial Block Diagrams es Eee cop RC MER e TR RH e E 2 1 3 Transporting ele Glace calle pea metre tent saan cnm tem aa e e c xe de n Pn seat nea o 2 2 4 Installation Recommendations 4 2 2 4 T Environment ers eh heb e buc cae haath pA e E ed 2 2 42 Locatloti qe NR LE alt E UE RR 2 2 5Electrical Input Connections 4 WR RUE Y QUIT TRUE Wr ence dane ew Rol ke 2 2 5 1 Electrical Input Requirements 2 2 5 2 INPUT s uy MR PP etn vr Nar ee M e e MER hu UE e RUE e eR RIDE 2 3 Specifications tirent eo ve aree e ehe akiwa
113. y can throw off slag Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin N WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards Engines can be dangerous 9 f WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases Use equipment outside in open well ventilated areas 2 ARCMASTER 400 MST If used in a closed area vent eng
114. z pas de cables lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT ETRE MORTELLE 9 N enroulez pas de c bles lectriques autour de votre corps 10 N utilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique peut tuer ou br ler gravement la pi ce souder L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de circuits internes de l quipement sont aussi sous ten soudage terre sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou 12 N utilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux pum uu 14 Portez un harnais de s curit si vous travaillez en hauteur 1 Ne touchez pas des pi ces sous tension 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants e

Service Manual ARCMASTER® 400 MST

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Service Manual ARCMASTER&reg; 400 MST

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Service Manual ARCMASTER® 400 MST