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400 TS ARCMASTER® - Victor Technologies

1. I PSPS HEUNITI ACI AC3 T R6 eu seins FRONT PANEL I m l G Ground DE SIDE CHASSIS 2 PCBI2 gt mD Panel ween Circuit Board EncorderBoard R2 Fr Dr wa UBI W 787 i gt r 2 ggg e SANI l CS teen I i gt 52 APPENDIX B ARCMASTER 400 TS ACCESSORIES ACCESSORIES PART NO DESCRIPTION Stick Kit 10 4082A Work clamp with 25 cable and stick electrode with 25 1 cable TIG Kit 10 4081 Includes regulator flowgauge 12 5ft 200 Amp TIG torch accessory kit includes 1 ea of 0040 x7 1 16 x7 3 32 7 2 Tungsten with collet amp collet bodies 1 ea 1 4 5 16 3 8 alumina cup Dinse Connector 10 2020 150mm Dinse style male plug Hand Held Pendant 10 2005 Includes contactor On Off switch and current control with 25ft cable and 14 pin male plug Foot Control 10 2008 Contactor On Off and current control with 15ft cable and 14 pin male plug 10 2007 Contactor On Off and current control with 25ft cable and 14 pin male plug Extension Cable 10 2030 3ft with 14 pin male plug and 14 pin female cable receptacle 10 2031 15ft with 14 pin male plug and 14 pin female cable receptacle 10 2032 2oft wi
2. IIS Figure 13 VRD ON OFF Step D 47 12 0 POWER SOURCE ERROR CODES E01 error code displayed Temperature sensor TH1 protects IGBTs is greater than 80 C for about 1 second E02 error code displayed Temperature sensor TH2 protects secondary diodes is greater than 80 C for about 1 second E03 error code displayed Primary input current too high A The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked Primary current is too high because welding arc is too long Mains supply voltage is more than 1096 below nominal voltage Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Reduce length of welding arc Have an Accredited Thermal Arc Service Agent or a qualified electrician check for low Mains voltage Weld current ceases Buzzer sounds constantly Fan operates at max speed E01 resets when TH1 decreases to 70 C for about 30 seconds Weld current ceases Buzzer sound
3. t e RB Ee 29 6 02 HF TIG S Lift TIG Welding c tet eee t h n eek der tt ree 29 6 02 01 Slope Mode Sequence c ccccccsesesesscscscscesesesecscscsessesesececscsessesesececscsesaeseseeecsesesseseees 30 6 02 02 Slope Mode with Repeat Sequence nnn 30 6 02 03 ECH ll 31 6 03 Save Load Operation iii 32 7 0 BASIC TIG WELDING GUIDE 33 TOA Electrode FOIN s ot tenete ER e o oneri o onere 33 7 02 Tungsten Electrode Current Ranges nn nnne nnns 33 7 03 Tungsten Electrode Types 33 7 04 Guide for Selecting Filler Wire Diameter 34 17 05 Shielding Gas Selection sev tectae a eode 34 7 06 TIG Welding Parameters for Low Carbon A Low Alloy Steel 34 7 07 Welding Parameters for Steel 36 8 0 BASIC ARC WELDING GUIDE 37 8 01 Electrode Polafity o e e rt D aie eee 37 8 02 Effects of Stick Welding Various Materials 37 TABLE OF CONTENTS 9 0 ROUTINE MAINTENANGE AN 39 10 0 BASIC TROUBLESHOOTING 40 10 01 TIG Welding Proble MS itte Aa 40 10 02 Stick Welding Problems ss 42 10 03 Power Source Problems 44 11 0 VOLTAGE REDUCTION DEVICE VRD 46
4. welding terminals Torch lead is disconnected Connect it to the terminal Gas flow incorrectly set Select the right flow rate cylinder empty or the torch change cylinders or turn valve is off torch valve on 12 Arc start is not smooth Tungsten electrode is too large Select the right size electrode for the welding current Refer to Basic TIG Welding Guide The wrong electrode is being Select the right electrode type used for the welding job Refer to Basic TIG Welding Guide Gas flow rate is too high Select the correct rate for the welding job Refer to Basic TIG Welding Guide Incorrect shielding gas is Select the right shielding gas being used Refer to Basic TIG Welding Guide Poor work clamp connection Improve connection to to work piece Work piece 40 10 02 Stick Welding Problems 1 Gas pockets or voids in weld metal Porosity A Electrodes are damp Welding current is too high Surface impurities such as oil grease paint etc Crack occurring in Rigidity of joint weld metal soon after solidification commences Insufficient throat thickness Cooling rate is too high Welding current is too low Electrode too large for joint Insufficient gap Incorrect sequence Incorrect sequence Insufficient gap Small electrodes used on heavy cold plate Welding current is too low Portions of the weld run do not fuse to the surface of the metal or edge of the joint Wrong electro
5. terminal terminal 7 Dirty weld pool A Electrode contaminated through A Clean the electrode by grinding contact with work piece or filler off the contaminates rod material B Gas contaminated with air B Check gas lines for cuts and loose fitting or change gas cylinder 39 8 Electrode melts or A No gas flowing to welding A Check the gas lines for oxidizes when an region kinks or breaks and gas arc is struck cylinder contents B Torch is clogged with dust B Clean torch C Gas hose is cut C Replace gas hose D Gas passage contains D Disconnect gas hose from impurities torch then raise gas pressure and blow out impurities E Gas regulator turned off E Turn on F Torch valve is turned off F Turn on G The electrode is too small for G Increase electrode diameter or the welding current reduce the welding current 9 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for gas flow problems 10 Arc flutters during TIG Tungsten electrode is too large Select the right size electrode for the welding current Refer to Basic TIG Welding Guide B Absence of oxides in the B Refer Basic TIG Welding Guide weld pool for ways to reduce arc flutter 11 Welding arc can not be A Work clamp is not connected A Connect the work clamp to the established to the work piece or the Work piece or connect the work torch leads are not work torch leads to the right connected to the right welding terminals
6. to CRATER CUR This control is used to eliminate the crater that can form at the completion of a weld This parameter operates in SLOPE or REPEAT 4T TIG modes only and is used to set the finish current for TIG The CRATER Current remains ON until the torch trigger switch is released after it has been depressed This parameter operates in TIG modes only and is used to adjust the post gas flow time once the arc has extinguished This control is used to dramatically reduce oxidation of the tungsten electrode The SAVE LOAD buttons are used to save and retrieve a total number of 5 programs into the 400 TS memory Table 4 Weld Parameter Descriptions for ArcMaster 400 TS 23 4 04 Weld Parameters for ArcMaster 400 TS Weld Mode Weld Parameter Range Factory Incremental LIFT TIG Parameter Setting Unit PRE FLOW 0 0 to 1 0 sec 0 sec 0 1 sec Yes HOT START 0 to 70A 20A 1A No INITIAL CUR 5 to 400A 30A 1A Yes UP SLOPE to 15 sec 1 sec 0 1 sec Yes PEAK CUR 5 to 400A 120A 1A Yes WELD CUR 5 to 400A 80A 1A Yes TIG WELD CUR 5 to 400A 80A 1A STICK SPOT TIME 0 5 to 5 0 sec 2 Sec PULSE WIDTH 15 to 80 50 PULSE FREQ 0 5 to 500Hz 100 0Hz No DOWN SLOPE 0 to 25 sec 3 sec CRATER CUR 5 to 40A 30A POST FLOW 0 0 to 60 sec 10 sec Table 5 Weld Parameters for ArcMaster 400 TS PULSE FREQ Range Incremental Unit 0 5 to 20Hz 0 1Hz 20 to 100Hz 1Hz 100 t
7. 0 045 45 55 30 45 0 040 1 16 5 7 Butt Corner 1 2mm 50 60 35 50 1 0mm 1 6mm Lap Fillet 1 16 60 70 40 60 1 16 1 16 7 Butt Corner 1 6mm 70 90 50 70 1 6mm 1 6mm Lap Fillet 1 8 80 100 65 85 1 16 3 32 7 Butt Corner 3 2mm 90 115 90 110 1 6mm 2 4mm Lap Fillet 48mm 140 165 125 150 24mm 3 2mm ibus 160 175 135 160 1 8 5 32 10 Butt Corner 170 200 160 180 3 2mm 4 0mm Lap Fillet Table 12 DC TIG Welding Parameters 35 8 0 BASIC ARC WELDING GUIDE 8 07 Electrode Polarity Stick electrodes are generally connected to the terminal and the work lead to the terminal but if in doubt consult the electrode manufacturers literature 8 02 Effects of Stick Welding Various Materials High tensile and alloy steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area and if suitable precautions are not taken the occurrence in this zone of under bead cracks Hardened zone and under bead cracks in the weld area may be reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace Manganese steels The effect on manganese steel of slow cooling from high temperatures is to embrittle it For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distrib
8. Conventional operating procedures apply when using the Welding Power Source i e connect work lead directly to work piece and electrode lead is used to hold electrode Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short term overload without adverse effects The welding current range values should be used as a guide only Current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application A WARNING 7 Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off CAUTION 3 Remove any packaging material prior to use Do not block the air vents at the front or rear or sides of the Welding Power Source CAUTION 4 DO NOT change the Weld Mode or Weld Process Mode Until after POST FLOW time has finished Figure 6 400 TS Set up 27 6 0 SEQUENCE OF OPERATION NOTE Scroll Buttons used select the parameters be set The LED s show which function is being adjusted on the weld sequence graph Refer to Symbols Table located in
9. Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin i st eT 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 renvers 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 Ne 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 TS 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es 2 Si vous util
10. It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded Transmission via the Supply Lead Without adequate shielding and filtering high frequency energy may be fed to the wiring within the installation mains by direct coupling The energy is then transmitted by both radiation and conduction Adequate shielding and filtering is provided in the Power Source Radiation from Welding Leads Radiated interference from welding leads although pronounced in the vicinity of the leads diminishes rapidly with distance Keeping leads as short as possible will minimize this type of interference Looping and suspending of leads should be avoided where possible Re radiation trom Unearthed Metallic Objects A major factor contributing to interference is re radiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent re radiation in most cases 16 3 04 Specifications Parameter 400 TS Rated Output 208 230 460VAC Amperes 400 Volts 36 Duty Cycle 25 Duty Cycle 400A 36V 25 3ph 300A 32V Q 60 3ph 300A 32V 25 1ph Output Current Range 5 400 Amps Open Circuit Voltage 65V Dimensions Width 8 3 210mm Height 16 5 420mm Length 17 7 450mm Weight 52 9 Ib 24 kg Output Rated Load Three phase Sing
11. No weld current is available Buzzer sounds constantly Switch machine OFF then ON to reset E83 error Weld current ceases Buzzer sounds constantly Switch machine OFF 12 E94 error code displayed Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit E99 error code displayed Mains supply input voltage has been turned OFF but control circuit has power from the primary capacitors The Welding Power Source s temperature sensors have malfunctioned Main ON OFF switch on machine has been turned OFF Mains supply input voltage has been turned OFF 50 Have an Accredited Thermal Arc Weld current ceases Service Agent check or replace Buzzer sounds constantly the temperature sensors Switch machine OFF Turn ON OFF switch on Weld current ceases Buzzer sounds constantly Have an Accredited Thermal Must switch machine OFF Arc Service Agent or a qualified then ON to reset E99 error electrician check the Mains voltage and fuses APPENDIX A INTERCONNECT DIAGRAM Contactor Control 24VDC Contactor Control Contactor Clouser To A 0 To 10Vde Output To Remote Control D Remote Control Circuit Common 0 To 10Vde Intput From Remote Control F Not Used Chassis Ground H Not Used I Not Used J Not Used Not Used L Not Used M OK to Move Current Detect Signal OK to Move Current Detec
12. Spot Time GTAW SEC Seconds Remote Control Panel Remote Percent DC Direct Current AC Alternating Current lt N Remote Function Arc Control SMAW Gas Post Flow Standard Function Slope Function lt eC Gas Pre Flow Voltage Reduction Device Circuit GTAW Slope W Repeat Function Negative Spot Function Positive Impulse Starting High Frequency Gas Input GTAW EI Touch Start Lift Start TIG circuit Gas Output 2 0 INTRODUCTION AND DESCRIPTION 2 01 Description The Thermal Arc ArcMaster 400 TS is a single three phase DC arc welding power source with Constant Current CC output characteristics This unit is equipped with a Digital Volt Amperage Meter gas control valve built in Sloper and Pulser lift arc starter and high frequency arc starter for use with Gas Tungsten Arc Welding GTAW Gas Tungsten Arc Welding Pulse GTAW P Gas Tungsten Arc Welding Sloped GTAW S and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resistant flame resistant and non conductive plastic case V 10 5 400A A 25A 400A A STICK Process LIFT TIG Process V 5 400 HF TIG Process Figure 1 Model 400 TS Volt Ampere Curve Note 1 Volt Ampere curves show the maximum Voltage and Amperage out
13. Switching VRD ON OFF Switch the machine OFF a Remove the clear plastic cover from the control panel see Figure 11 Lift up the cover so it rests on the top of the unit Place a small flat bladed screw driver between the cover hinge on the front panel Gently lift the cover hinge out of the front cover mounting hole Remove the control s clear plastic cover Figure 11 VRD ON OFF Step A b Remove four mounting screws from the control panel see Figure 12 c Access the VRD control by gently prying back the front panel controls to reveal the VRD ON OFF potentiometer see Figure 12 CAUTION 6 Do not pull back the front panel with excessive force as this will unplug control PCB Plugging the control PCB back into the front panel controls can only be achieved by removing the side covers Figure 12 VRD ON OFF Step B C 46 d Turning the VRD ON OFF see Figure 13 To turn VRD ON rotate the trim potentiometer VR1 on the display PCB fully clockwise When VRD is turned ON check that it operates as per VRD Specifications on page 45 To turn VRD OFF rotate the trim potentiometer VR1 on the display PCB fully counter clockwise WARNING 9 The VRD ON OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the VRD function will be unknown for every other position
14. 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 l Arc 6 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 utilisez 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 ae la pi ce a 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 mar
15. approuv Lisez les fiches signal tiques et les consignes du fabricant rela tives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ve travaillez dans un espace confin que s il est bien ventil sinon 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 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 8 2 73 Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Brassage tendre toutes conditions 2 au chalumeau Brassage fort toutes conditions au chalumeau moins de 1 po 25 mm 2003 Nuance de filtre oculaire Op ration de coupage ou soudage moyen d61 46 po 254150mm 4005 plus de 6 po 150 mm 5 ou 6 de 1 8 1 2 po 3 12 mm pais plus de 1 2 po 12 mm Soudage l arc avec lectrode enrobees SMAW cy 5 22 41A po 4 6 4 mm plus de 1 4 po 6 4 mm Op ration de coupage Soudage l arc sous gaz avec fil plein GMAW Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydr
16. as far away from body as practical ABOUT PACEMAKERS M M 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 249 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 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 Z87 1 from American National Standards Insti tute 1430 Broadway New York NY 10018 Cutting and Welding Proce
17. 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 9 t2 WARNING E Se 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 gases 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 of
18. for robotics applications 3 Positive Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 4 Negative Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION 2 Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 5 Gas The Gas Outlet is a 5 8 UNF female gas fitting 6 ON OFF Switch This switch connects the Primary supply voltage to the inverter when in the ON position This enables the Power Supply A WARNING 6 When the welder is connected to the Primary supply voltage the internal electrical components may be at primary potential with respect to earth 20 7 Input Cable The input cable connects the Primary supply voltage to the equipment 8 SMART Logic Switch Manual slide switch mounted on the back panel selects for proper input voltage If this slide is not set to the position that matches the input voltage from the electrical source the Smart Logic circuit will inhibit welding power source output The digital meter will show primary input error code 9 Gas Inlet The Gas Inlet is a 5 8 UNF female gas fitting 4 02 Weld Process Se
19. is in 5 Keep hands hair loose clothing and tools away from moving use or connected for use parts 8 Read and follow instructions on compressed gas cylinders 6 Reinstall panels or guards and close doors when servicin associated equipment and CGA publication P 1 listed in Safety is starting engine 9 Standards i WARNING WARNING Engines can be dangerous SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin M Batteries contain acid and generate explosive gases d WARNING 1 ENGINE EXHAUST GASES can kill Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Engines produce harmful exhaust gases Do not use welder to charge batteries or jump start vehicles om 19 1 Use equipment outside in open well ventilated areas Observe correct polarity and on batteries ARCMASTER 400 TS 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
20. s chapper avant d ter compl tement le bouchon 1 05 Principales Normes de Securite Safety in Welding and Cutting norme ANSI 249 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 Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 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 V Amperage STICK Shielded Metal Arc A SMAW a a Voltage Pulse Current Function Hz Hertz frequency
21. 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 systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cable around the body Ee PS Keep welding power source and cables
22. 1101 VRD Specification u aan a apas ees e tre et e 46 11 02 VRD MainterialiCe re nt re rere Pe rr ren uu eret 46 11 03 Switching On Off iii 47 12 0 POWER SOURCE ERROR C0DES 49 APPENDIX A INTERCONNECT DIAGRAM nenne nennen 52 APPENDIX B ARCMASTER 400 TS ACCESS0RIES 54 LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT Inside Rear Cover ARCMASTER 400 TS 1 0 SAFETY 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 extens
23. IHERMAL A RC 400 TS ARCMASTER INVERTER ARC WELDER Art A 07263 Operating Manual Version No 1 Issue Date February 27 2006 Manual No 0 4860 Operating Features E SMAW GTAW PHASE M V V V IHERMAL ARC WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Arc product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 752 7621 or visit us on the web at www thermalarc com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction Mining Automotive Aerospace Engineering Rural and DIY Hobbyist We distinguish ourselves from our competition through market leading d
24. NEMENT DE L ARC PEUT BR LER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE L arc de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager l ouie E sl 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI 749 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 3 Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc 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 MAP AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer EH Eloignez la t te des fum es pour viter de les respirer A 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 Si la ventilation est inadequate portez un respirateur adduction d air
25. OTING A WARNING 8 There are extremely dangerous voltages and power levels present inside this product Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques If major complex subassemblies are faulty then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair The basic level of troubleshooting is that which can be performed without special equipment or knowledge 10 01 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables maintenance of equipment and proper welding technique 1 Excessive bead Welding current is too low Increase weld current and or build up or poor faulty joint preparation penetration or poor fusion at edges of weld 2 Weld bead too wide Welding current is too high Decrease weld current and flat or undercut at edges of weld or excessive burn through 3 Weld bead too small or Travel speed too fast Reduce travel speed insufficient penetration or ripples in bead are widely spaced apart 4 Weld bead too wide or Travel speed too slow Increase travel speed excessive bead build up or excessive penetration in butt joint 5 Uneven leg length in Wrong placement of filler rod Re position filler rod fillet joint 6 Electrode melts when Electrode is connected to the Connect the electrode to the arc is struck
26. TS SAFETY INSTRUCTIONS AND WARNINGS 1 SYMBOL LEGEND 21 122 3 In e en i utu a ds Ae ete aes 9 2 0 INTRODUCTION AND DESCRIPTION 10 egen u rte rete he rette Pe PO DR un edd e 10 2 02 Functional Block Diagram m u l m au ku an DEBE nnns 11 2 03 Transporting Methiods U uu u u e u uu u uu plut x 11 3 0 INSTALLATION RECOMMENDATI0NS 12 SO ENVIRONMENT sss e d a d eee a ee A Se eee 12 3 02 EOCationi ist o dee E e ce e e erat 12 3 03 Electrical Input Connechons 13 3 03 01 Electrical Input Requirements nnne 13 3 03 03 High Frequency Introduction 16 3 03 04 High Frequency Interference ss 16 E Re le 17 3 05 DUTY CY ClO ee a nn ette e ettet Monon 18 4 0 OPERATOR CONTROLS Lu eee EE EE 19 4 01 ARGMASTER 400 TS Controls t Et e ede duya hi 19 4 02 Weld Process selection for ArcMaster 400 TS 21 4 03 Weld Parameter Description l near rere p nl sentiers 22 4 04 Weld Parameters for ArcMaster 400 TS 24 4 05 Power Source Features 25 5 0 SET UP FOR SMAW STICK AND GTAW TIG 21 6 0 SEQUENCE OF OPERATION die de eA eA AAA Dees na rave ve vene 28 6 01 STICK Wel IN Gis
27. WARNING 3 Thermal Arc advises that this equipment be electrically connected by a qualified electrician 12 3 03 Electrical Input Connections WARNING 4 ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lockout tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device 3 03 07 Electrical Input Requirements Operate the welding power source from a single three phase 50 60 Hz AC power supply The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit Note 2 This unit is equipped with a three conductor with earth power cable that is connected at the welding power source end for single and three phase electrical input power Do not connect an input WHITE or BLACK or RED conductor to the ground terminal Do not connect the ground GREEN conductor to an input line termina
28. ashire 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 Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne 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
29. ce and secure unit on a proper skid before transporting 11 3 0 INSTALLATION RECOMMENDATIONS 3 01 Environment The ArcMaster 400 TS is designed for use in hazardous environments Examples of environments with increased hazardous environments are a In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts b In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator In wet damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories Environments with hazardous environments do not include places where electrically conductive parts the near vicinity of the operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines e nareas free from moisture and dust e Ambient temperature between 0 degrees C to 40 degrees C e n areas free from steam and e n areas not subjected to abnormal vibration corrosive gases or shock e n areas not exposed to direct sunlight e Place ata distance of 12 304 79mm or or rain more from walls or similar that could restrict natural airflow for cooling A
30. che 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 ue 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 et des v tements isolants secs et non trou s 3 lsolez 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 TS g AVERTISSEMENT ole d nn LE RAYON
31. contacts Once the welding arc is established the Power Source will maintain initial current setting as long as the remote switch contacts are closed a Inthe HF TIG mode after Preflow time High Frequency is present at the torch When the torch is positioned close to the work the welding current will transfer to the work and establish the arc at the initial current setting b Inthe Lift TIG mode after preflow time Lift Start current is present at the torch When the electrode is touched to the work and lifted off the welding arc is established at the initial current setting 2 Open Remote Switch current increases to weld current Once welding arc has reached weld current the power source will maintain weld current as long as the remote switch contacts are open 3 Close Remote Switch Welding current decreases to final current setting Once final welding current is reached the power source will maintain final current setting as long as the remote switch contacts are closed 4 Open Remote Switch Welding arc stops and post flow begins 6 02 02 Slope Mode with Repeat Sequence The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the down slope period only During the down slope period by opening the Remote Switch contacts the current will increase back to weld current Within the Down Slope period the repeat function can be operated as many times as desired To continue slope cycle an
32. d 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 131 181 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor 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 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 3 years Welding Console Weld Controller Weld Timer 3
33. d end slope sequence close remote switch contacts and allow weld current to reach final current setting Once final current setting is reached opening the Remote Switch again will turn off the welding arc and post flow begins 30 6 02 03 Pulse Controls Pulse Width lt EEN Peak Current Base Background Current The Pulse controls are used primarily to control heat input Pulse offers a number of advantages as follows Control puddle size and fluidity especially out of position Increase penetration Travel speed control Better consistent quality Distortion on lighter or thinner materials D Pulse current provides a system in which the welding current continuously changes between two levels During the periods of Peak current heating and fusion takes place and during the background base current periods cooling and solidification take place Pulse Width is the time in one cycle the current stays at the peak current setting Pulse Frequency measured in Hertz is the number of cycles per second the current travels between peak and background current settings It is as if the foot rheostat were moved up and down to increase and decrease the welding current on a regular basis The faster you moved the foot rheostat up and down the faster the frequency 31 6 03 Save Load Operation A total number of 5 programs can be saved into the 400 TS memory SAVE the Current Weld Parameters in
34. de angle Travel speed of electrode is too high Scale or dirt on joint surface Lack of fusion caused by dirt electrode angle incorrect rate of travel too high Lack of inter run fusion Lack of side fusion scale dirt small electrode amperage too low Lack of Root Fusion 41 Dry electrodes before use Reduce welding current Clean joint before welding Redesign to relieve weld joint of severe stresses or use crack resistance electrodes Travel slightly slower to allow greater build up in throat Preheat plate and cool slowly Increase welding current Use smaller diameter electrode Allow wider gap Use correct build up sequence Figure 8 Example of Insufficient Gap or Incorrect Sequence 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 Figure 9 Example of Lack of Fusion 5 Non metallic particles Non metallic particles may be If bad undercut is present clean are trapped in the trapped in undercut from slag out and cover with a run weld metal slag previous run from a smaller diameter electrode inclusion Joint preparation too restricted Allow for adequate penetration and room for cleaning out the slag Irregular deposits allow slag to If very bad chip or grind out be trapped irregularities Lack of penetration
35. e control panel are saved LOAD retrieve a Program to Control Panel e Press and HOLD the 4040 button Beep will sound and Digital Meter display will show a number 1 e Select a memory location by rotating the control knob 1 to 5 is displayed on the meter After selecting the desired memory location i e 1 to 5 press the right scroll button and the machine will give a beep to confirm the weld parameters are loaded 25 Feature Voltage Reduction Device VRD shipped de activated field capable See Section 11 for activation instructions Control Knob Self Diagnosis Using Error Codes Description Reduces the OCV when the power supply is not in use Eliminates the need for add on voltage reducers and has no effect on arc starting VRD fully complies to IEC 60974 1 e When Stick mode is selected the green VRD light is ON when not welding and red when welding When in TIG modes VRD is off e For the selected weld parameter rotating the knob clockwise increases the parameter e Rotating the knob counterclockwise decreases the parameter e selected weld parameter value can be adjusted at any time even while welding e Pushing the knob in displays actual arc voltage e An error code is displayed on the Digita Meter when a problem occurs with Primary supply voltage or internal component problems Refer to Troubleshooting Guide 26 5 0 SET UP FOR SMAW STICK AND GTAW TIG
36. ependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry WARNINGS Read and understand this entire Manual and your employers safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use ArcMaster 400 TS Inverter Arc Welder Instruction Manual Number 0 4860 for Part Number 10 3071 Published by Thermadyne Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 by Thermadyne Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date February 27 2006 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTEN
37. ereunder 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 Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shall pay no transportation costs of any kind under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty dated April 1 2006 supersedes all previous Thermal Arc warranties Thermal 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 an
38. f toxic fumes if welded Torch soldering Torch brazing 2 Under 1 25 Oxygen Cutting Under 1 in 25 mm Gas welding 1 8 to 1 2 in 3 12 mm 0 0 0 0 0 0 Under 1 8 in 3 mm 8 Over 1 2 in 12 mm Over 1 4 in 6 4 mm goggles or helmet from AWS A6 2 73 2 Gasmeakat Ferrous base metal A 12 Atomic hydrogen welding 1 to 6 in 25 150 mm TIG Carbon arc welding i r Over 6 in 150 mm i r Plasma arc welding Carbon arc air gouging Shielded metakarc Under 5 32 in 4 mm 10 14 l 5 32 10 1 41 Plasma arc cutting Eas 300 to 400 Over 400 WARNING WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying Sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire EN 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 nea
39. g Long life Thoriated 2 stainless steel and copper High current carrying capacity DC welding of mild steel Longer life More stable arc Ceriated 2 stainless steel copper Easier starting Wider current Grey aluminium magnesium and range Narrower more their alloys concentrated arc Table 8 Tungsten Electrode Types 33 7 04 Guide for Selecting Filler Wire Diameter Filler Wire Diameter DC Current Range Amps 1 16 1 6 mm 20 90 3 32 2 4 mm 65 115 1 8 3 2 mm 100 165 3 16 4 8 mm 200 350 Table 9 Filler Wire Selection Guide NOTE 7 The tiller wire diameter specified in Table 9 is a guide only Other diameter wires may be used according to the welding application 7 05 Shielding Gas Selection Table 10 Shielding Gas Selection 7 06 TIG Welding Parameters for Low Carbon amp Low Alloy Steel Pipe Electrode Type amp Current Range DC Filler Rod for Joint Preparation Diameter Amperes Root Pass Thoriated 2 3 32 2 4 mm VE MD 1 Thoriated 2 Thoriated 2 Table 11 TIG Welding Parameters for Low Carbon amp Low Alloy Steel Pipe 34 7 07 Welding Parameters for Steel Base Metal DC Current for DC Current for Tungsten Filler Rod Argon Gas Thickness Mild Steel Stainless Electrode Diameter Flow Rate Joint Type Steel Diameter ifrequired Liters min 0 040 35 45 20 30 0 040 1 16 5 7 Butt Corner 1 0mm 40 50 25 35 1 0mm 1 6mm Lap Fillet 0
40. ice Agent repair the connection Tighten all welding cable connections Use proper size and type of cable Refer to Section 3 03 01 Electrical Input Requirements Replace electrode E Verify output torch connections Replace gas hose Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities C Turn gas regulator on D Reconnect lead or repair faulty switch cable 5 Gasflow won t A Weld Mode S7D SLOPE A Strike an arc to complete shut off 6 The TIG electrode has been contaminated due to the gas flow shutting off before the programmed POST FLOWtime has elapsed 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 The Weld Process Mode STICK HF TIG or LIFT TIG was changed before POST FLOW gas time had finished 44 the weld cycle OR Switch machine off then on to reset solenoid valve sequence Have an accredited Thermal Arc Service Agent repair or replace the gas valve Have an accredited Thermal Arc Service Agent repair or replace the gas valve Reduce POS7 FLOWtime Do not change Weld Process Mode before the POST FLOW gas time had finished 11 0 VOLTAGE REDUCTION DEVICE VRD 11 01 VRD Specification ARC MASTER Description 400 TS Notes VRD Open Circuit Voltage 15 3 to 19 8V Open circuit vol
41. igher is applied The following Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment Primary Supply Minimum Primary Lead Size Current Circuit Size Factory Fitted Vin Amps 208 49 ER 230 44 4009255 46022 r Current amp Duty Cycle Phase 20867 AREMASTER EEES F E 400A 25 208 67 wasapa 300A 25 Table 2 208 230 460V Primary Current Circuit sizes to achieve maximum current 3 03 03 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be over emphasized Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation The following information is intended as a guide for personnel installing high frequency welding machines Warning Explosives The high frequency section of this machine has an output similar to a radio transmitter The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing Computers It is also possible that operation close to computer installations may cause computer malfunction 3 03 04 High Frequency Interference Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways Direct Radiation Radiation from the machine can occur if the case is metal and is not properly grounded
42. is turned ON E93 error code displayed Memory chip EEPROM on control PCB can not read write weld parameters Mains supply voltage is less than the nominal operating voltage less 10 Mains supply voltage is down to a dangerously low level When 3 phase machine is first turned ON with the wrong Primary supply input voltage connected Link switch plug not connected The Primary supply input voltage fluctuates and is not stable Memory chip EEPROM error 49 Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Mains voltage Have an Accredited Thermal Arc Service Agent check connector plug on input PCB Have an Accredited Thermal Arc Service Agent check connector plug on input PCB and the Mains voltage Have an Accredited Thermal Arc Service Agent check the control PCB Weld current available Buzzer sounds intermittently Error code E14 automatically will reset when the voltage increases Weld current ceases Buzzer sounds constantly Error code E12 automatically will reset when the voltage reduces No weld current is available Buzzer sounds constantly Switch machine OFF No weld current is available Buzzer sounds constantly Switch machine OFF
43. isez 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 Ne faites pas le 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 penda
44. ive training in welding and cutting practices should not attempt to weld Safe practices are outlined in the American National Standard Z49 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 01 Arc Welding Hazards 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 kee 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
45. l Refer to Figure 3 and 1 Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes Connect ends of line 1 BLACK and line 2 WHITE and line 3 RED input conductors to a de energized line disconnect switch Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch Note 3 For Single Phase operation connect the GREEN BLACK and WHITE input conductors Insolate the RED Conductor it is not used for Single phase operation Input Voltage Fuse Size 208 VAC 100 Amps 230 VAC 75 Amps 460 VAC 50 Amps Table 1 Electrical Input Connections NOTE Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code Weiding Power Supply R Ground Conductor Ground Terminal Line Disconnect Switch Line Fuse Primary Power Cable Figure 3 Electrical Input Connections 14 3 03 02 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit When the MAIN INPUT SWITCH is turned on the inrush circuit provides a pre charging of the input capacitors SCR s in the Power Control Assembly PCA will turn on after the input capacitors have charged to full operating voltage after approximately 5 seconds Note 4 Note the available input power Damage to the PCA could occur if 575VAC or h
46. le phase Rated Input Voltage 208 230 460V 208 230V Output Amperes 400A 300A Output Volts 36V 32V Duty Cycle 2596 2596 KVA 24 0 20 0 KW 18 0 12 0 Output No Load KVA 0 5 KW 0 13 Amperage Draw No Load Input Volts Three Phase Rated Load 208V 67 1 4 230V 61 1 3 460V 31 0 7 Input Volts Single Phase 208V 97 2 5 230V 87 2 2 Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change improve or revise the specifications or design of this or any product without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes updates improvements or replacement of such items 3 05 Duty Cycle The duty cycle of a welding power source is the percentage of a ten 10 minute period that it can be Operated at a given output without causing overheating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease A WARNING 5 Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature CAUTION 7 Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty NOTE 5 Due to variations that can occ
47. lection for ArcMaster 400 TS Weld Mode Weld Process Selection Description 2T operation in TIG Modes using remote devices to control contactor amp current AT operation in TIG Modes with crater fill using a remote contactor device to control sequence 4T operation in TIG Modes with repeat No Yes Yes Operation and crater fill using a remote contactor device 2T operation spot welding in HF TIG using a remote contactor device Pulse operation in TIG Modes gt Pn e Yes Contactor OWOFF en o Yes in Stick and Lift Contactor TIG Mode No Wee operation Selects in operation Panel board or Remote Operation PANEL REMOTE Table 3 Weld Process Selection verses Weld Mode for Arc Master 400 TS 21 4 03 Weld Parameter Description SAUVEGARDER CHARGER N18036500D Figure 5 ArcMaster 400 TS Front Panel with Parameter Description Parameter PRE FLOW HOT START INITIAL CUR UP SLOPE PEAK CUR WELD BASE Description This parameter operates in TIG modes only and is used to get gas to the weld zone prior to striking the arc once the torch trigger switch has been pressed This control is used to dramatically reduce weld porosity at the start of a weld This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick elect
48. n 99 Nickel Suitable for joining all cast irons except white cast iron Stainless steel 318L 16 High corrosion resistance Ideal for dairy work etc on stainless steels Copper Bronze Brass etc Bronze Easy to use electrode for marine fittings 5 7 ERCUSI A water taps and valves water trough float arms etc Also for joining copper to steel and for bronze overlays on steel shafts High Alloy Steels It will weld most problematical jobs such Dissimilar Metals as springs shafts broken joins mild steel Crack Resistance to stainless and alloy steels All Hard To Weld Jobs Not suitable for Aluminium Table 13 Types of Electrodes 37 9 0 ROUTINE MAINTENANCE The only routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment The unit should be wiped clean as necessary with solvents that are recommended for cleaning electrical apparatus Turn Power Switch to OFF before proceeding Internal cleaning of the unit should be done every 6 months by an authorized Thermal Arc Service Center to remove any accumulated dirt and dust This may need to be done more frequently under exceptionally dirty conditions CAUTION 5 Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles 10 interfere with sensitive electrical components and cause damage to the unit 38 10 0 BASIC TROUBLESHO
49. nt 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 ELECTROLYTE 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 L 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 j 1 W 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
50. o 500Hz 5Hz Table 6 PULSE FREQ Range and Incremental Units 24 4 05 Power Source Features Feature New Digital Control Touch Panel Switches Front Control Cover Digital Meter Intelligent Fan Control ON OFF Switch Save Load Function Description e Almostall welding parameters are adjustable e Touch switches eliminate mechanical damage e Protects front panel controls e Displays selected weld parameter value e Displays weld current when welding e Displays weld current for 20 seconds after weld has been completed e A selected weld parameter value can be adjusted at any time even while welding e The intelligent cooling system is designed to reduce dust and foreign material build up whilst providing optimum cooling e Fan speed reduces approximately 30 seconds after machine is turned on e Fan speed increases when internal components reaches Operating temperature e Primary voltage Supply ON OFF switch located on rear panel e A total number of 5 programs can be saved into the 400 TS memory SAVE the Current Weld Parameters into Memory e Press and HOLD the SAVE button Beep will sound and Digital Meter display will show a number 1 e Select a memory location by rotating the control knob 1 to 5 is displayed on the meter e After selecting the desired memory location i e 1 to 5 press the right scroll button and the machine will give a beep to confirm the weld parameters from th
51. og ne atomique AHW Soudage l arc avec toutes conditions 12 Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Nuance de ou soudage filtre oculaire toutes conditions toutes conditions 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 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 W 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 Hua M MH 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
52. ow which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter e Set HOT START e Set WELD current Commence welding 6 02 HF TIG amp Lift TIG Welding e Connect work lead to positive terminal e Connect TIG torch to negative terminal e Switch machine on e Set weld current e Connect remote control device A remote control device is required for use during LIFT TIG and HF TIG operation See section 4 01 section 2 Remote Control Socket for complete details of the remote device Use the Scroll Buttons to move to the parameter to be set The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter e Set PRE FLOW time e Set HOT START current e Set POST FLOWtime e Set WELD current e Set POST FLOWtime Slope Mode Parameters if required e Set T AL CUR current e Set UP SLOPE time e Set WELD PEAK CUR current e Set ASF current e Set DOWN SLOPEtime e Set CRATER CUR current Pulse Mode parameters if required e Set PULSE WIDTH for PEAK CURRENT e Set PEAK CURRENT e Set PULSE FREQ Commence welding 29 6 02 01 Slope Mode Sequence Switch Switch Switch Switch Closed Open Closed Open Up Weld Current Down Slope Slope Final Current Initial Current Preflow Postflow Note 6 Slope function operates with a Remote ON OFF device only 1 To start Slope sequence Close remote switch
53. pand Shielding gas cylinders contain gas under high pressure 5 Do not spill fuel If fuel is spilled clean up before starting engine If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully WARNING nl 1 Protect compressed gas cylinders from excessive heat mechanical shocks and arcs MOVING PARTS can cause injury 2 Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing ee 1 Keep all doors panels covers and guards closed and 3 Keep cylinders away from any welding or other electrical circuits 2 in 9 4 Never allow a welding electrode to touch any cylinder 2 Stop engine before installing or connecting unit 5 Use only correct shielding gas cylinders regulators hoses and 3 fittings designed for the specific application maintain them and associated parts in good condition Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect 6 Turn face away from valve outlet when opening cylinder valve negative battery cable from battery 7 Keep protective cap in place over valve except when cylinder
54. put capabilities of the welding power source Curves of other settings will fall between the curves shown 10 2 02 Functional Block Diagram Figure 2 illustrates the functional block diagram of the 400 TS power supply Input Main Capacitor IGBT Main Output Hall Current Se Inverter Transformer Diodes E m kd hermal PCB14 Thermal HCT1 ilter Primary Detecto Detecto u Output sensor Inductor Coupling o each control circuit Drive HF UNIT SE Lift Tig Mode 15VDC 18VDC Sensor Control Output Short 424VDC 5VDC 10424 Circuit Circuit Seni Sensing Circuit Circuit High Frequenc Troublel Sensing Circuit ES Fan Fan Control Torch Control E E Circuit Connection E CON1 Gas Control Circuit Current Reference djustmen Adjustment amp circuit Mode select Switches Panel Circuit Board Figure 2 400 TS Model Functional Block Diagram 2 03 Transporting Methods This unit is equipped with a handle for carrying purposes WARNING 7 Solenoid ELECTRIC SHOCK can kill DO NOT TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving the welding power source FALLING EQUIPMENT can cause serious personal injury and equipment damage WARNING 2 Lift unit with handle top of case Use handcart or similar device of adequate capacity If using a fork lift vehicle pla
55. rby 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 NIN N 1 Light 12 Light Under 300 Amp 9 ARCMASTER 400 TS 2 If used in a closed area vent engine exhaust outside and away WARNING from any building air intakes f FLYING SPARKS AND HOT METAL can cause injury WARNING Chipping and grinding cause flying metal As welds cool they can throw off slag ENGINE FUEL can cause fire or explosion V i Engine fuel is highly flammable 1 Wear approved face shield or safety goggles Side shields recommended 1 Stop engine before checking or adding fuel 2 Wear proper body protection to protect skin 2 Do not add fuel while smoking or if unit is near any sparks or N open flames D SJ WARNING 3 Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job CYLINDERS can explode if damaged 4 Do not overfill tank allow room for fuel to ex
56. 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 Kee 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 A 3 Insulate yourself from work and ground using dry insulating mats or covers WARNING 4 Disconnect input power or stop engine 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 inl skin Noise from some processes can 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 249 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 TS 3 Use protective screens or
57. rodes e g low hydrogen electrodes It sets the peak start current on top of the PEAK WELD current e g HOT START current 130 amps when PEAK WELD 100 amps amp HOT START 30 amps This parameter operates in SLOPE or REPEAT AT TIG modes only and is used to set the start current for TIG The Start Current remains on until the torch trigger switch is released after it has been depressed This parameter operates in TIG modes only and is used to set the time for the weld Current to ramp up after the torch trigger switch has been pressed then released from INITIAL CUR to PEAK or BASE current This parameter sets the PEAK weld current when in PULSE mode This parameter sets the TIG WELD current in 72 SLOPE REPEATand SPOT modes when PULSF is off This parameter also sets the STICK weld current This parameter sets the Background current when in Pulse TIG mode 22 Parameter Background Current SPOT TIME PULSE WIDTH PULSE FREQ DOWN SLOPE CRATER CUR POST FLOW M t2 SAUVEGARDER CHARGER Description This parameter sets the duration of the SPOT TIME in HF TIG mode only This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PULSEis ON This parameter sets the PULSE FREQUENCY when the PULSEis ON This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down after the torch trigger switch has been pressed
58. s constantly Fan operates at max speed E02 resets when TH1 decreases to 70 C for about 30 seconds Weld current ceases Buzzer sounds constantly Switch machine OFF then ON to reset E03 error E04 error code displayed Output voltage exceeds the secondary voltage specification E11 error code displayed Over Primary supply input voltage at primary capacitors is exceeded for one second TIG torch cable and or work lead are too long or leads are coiled Primary supply voltage is greater than the nominal voltage plus 1096 Reduce the length of the TIG torch cable and or work lead or un coiled leads Have an Accredited Thermal Arc Service Agent or a qualified electrician check the Primary voltage Weld current ceases Buzzer sounds constantly Switch machine OFF then ON to reset E04 error Weld current ceases Buzzer sounds constantly Error code E11 automatically will reset when the voltage reduces 48 E14 error code displayed Under mains supply input voltage warning primary capacitors is reduced for one second E12 error code displayed Under mains supply input voltage primary capacitors is reduced for one second E81 error code displayed Wrong Primary supply input voltage connected E82 error code displayed Link switch plug not connected E83 error code displayed CPU checks mains supply input voltage when the ON OFF switch on rear panel of machine
59. sses NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 ARCMASTER 400 TS 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 pas 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 entra nement avant d utiliser l equipement Toute personne n ayant pas suivi un entra nement intensif en soudage 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 249 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document
60. 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 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 h
61. t Signal Link Circuit Bord K 5597 Circuit Bord WK 4819 CN31 l L CN132 CN130 N131 CN132 CN130 Main Circuit Bord WK 5493 CN32 CN30 2 3 PCB3 SONS Control Souc gor Circuit Bor Conect Circuit Bord WK 5548 WK 5551 PCB7 Filter Circuit Bord WK 5550 51 PCB8 GBT Gate K IGBT Gate OK Circuit Bord 03 Circuit Bord Con WK 5479 SQ WK 5479 o G G K Se cS ate D cA 04 39 ch ue G eK 05 ra i 017 2 T K EI Q6 C 018 O i QE 1 Eb Q7 ch 019 Q UBI Q TBO CE G eb ma 50 o gt OS 9 Od PCBII GBT Gate E IGBT Gate Circuit Bord c Q9 1 Circuit Bord I 02 WK 5479 WK 5479 O G G E G7 1 ET 2 i 022 i 0 PCB10 lt 010 PCB6 Control Circuit Bord WK 5549 DIODE Snubber Circuit Bord WK 5606 D5 TRANS Bord WK 5594 4 Output Terminal CNI ISS 20 Z Filter Circuit Bord 3 WK 5499 SIDE CHASSIS 3 TO2 P Output d Terminal
62. tage between welding terminals VRD Resistance 148 to 193 ohms required resistance between welding terminals to turn ON the welding power VRD Turn OFF Time 0 2 to 0 3 seconds The time taken to turn OFF the welding power once the welding current has stopped 11 02 VRD Maintenance Routine inspection and testing power source An inspection of the power source an insulation resistance test and an earth resistance test shall be carried out in accordance with clause 4 1 of AS 1647 2 a For transportable equipment at least once every months b For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests Note 8 A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated In addition to the above tests and specifically in relation to the VRD fitted to this machine the following periodic tests should also be conducted by an accredited Thermal Arc service agent Description AS3195 amp IEC 60974 1 Requirements VRD Open Circuit Voltage Less than 20V at Vin 230V or 460V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0 3 seconds If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests should be carried out prior to entering this location 45 11 03
63. th 14 pin male plug and 14 pin female cable receptacle 10 2033 with 14 pin male plug and 14 pin female cable receptacle 10 2034 with 14 pin male plug and 14 pin female cable receptacle t Torch Switch On Off 10 2001 25ft torch mounted with 14 pin male plug Torch Switch On Off 10 2002 25ft torch mounted with 14 pin male plug w current control adapts to 5 0 7 8 torch 10 2003 2oft torch mounted with 14 pin male plug adapts to 7 8 1 1 8 torch handle 10 2004 2oft torch mounted with 14 pin male plug adapts to 1 1 8 1 3 8 torch handle Rack Systems 10 4029 4 pack w electrical 10 4031 6 pack w electrical 10 4033 8 pack w electrical 53 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 Arcs specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or damage correct
64. the front of the manual for Symbol descriptions N180365000 Figure 7 400 TS Front Panel 1 Pulse Function Pressing this button enables the TIG current pulse functions 2 Remote Current Function Pressing this buttons enables remote current functions 3 TIG Mode Functions Pressing this button scrolls through the output TIG function modes Standard Slope Slope w repeat Spot 4 Digital LED Display Welding amperage and parameter values are displayed in this window Internal warnings such as over temperature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen 5 Save Load Buttons By using the Save amp Load buttons the operator can easily save up to 5 welding parameter programs 6 Control Knob Allows the operator to adjust the output amperage within the entire range of the power source and sets each parameter value 7 Process Button This button selects between STICK HF TIG and Lift TIG mode 8 Scroll Buttons Used to select the parameters to be set The LED s show which function is being adjusted on the Sequence Graph 9 Contactor Function Pressing this buttons enables Contactor functions 28 6 01 Stick Welding e Connect work lead to negative terminal e Connect electrode lead to positive terminal e Switch machine on e Set Contactor e Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set The LED will sh
65. to Memory e Press the SAVE button until the buzzer rings e Select a memory location by rotating the control knob 1 to 5 is displayed on the meter e After selecting the desired memory location ie 1 to 5 press the right scroll button and the machine will give a beep to confirm the weld parameters from the control panel are saved LOAD retrieve a Program to Control Panel e Press the LOAD button until the buzzer rings e Select a memory location by rotating the control knob 1 to 5 is displayed on the meter After selecting the desired memory location i e 1 to 5 press the right scroll button and the machine give a beep to confirm the weld parameters are loaded onto the control panel 32 7 0 BASIC TIG WELDING GUIDE 7 01 Electrode Polarity Connect the TIG torch to the 7OACH terminal and the work lead to the WORK terminal for direct current straight polarity Direct current straight polarity is the most widely used polarity for DC TIG welding It allows limited wear of the electrode since 70 of the heat is concentrated at the work piece 7 02 Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0mm 30 60 1 16 1 6mm 3 32 2 4mm 1 8 3 2mm 5 32 4 0mm 3 16 4 8mm Table 7 Current Ranges for Varies Fungsten Electrode Sizes 7 03 Tungsten Electrode Types Electrode Type Welding Application Color Ground Finish Code DC welding of mild steel Excellent arc startin
66. 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 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 TS 4h B AVERTISSEMENT LES ETINCELLES ET LES PR0JECTIONS 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 e LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression
67. ur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are approximate only Achievable Capacities and ratings in use and operation will depend upon correct installation use applications maintenance and service 18 4 0 OPERATOR CONTROLS 4 01 ARCMASTER 400 TS Controls Figure 4 ARCMASTER 400 TS Power Source 1 Control Knob This control sets the selected weld parameter rotating it clockwise increases the parameter that is indicated on the digital meter Pushing the knob inward displays the actual welding voltage 2 Remote Control Socket The 14 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source To make connections align keyway insert plug and rotate threaded collar fully clockwise Pod Front view of 14 Y Y Socket Receptacle 19 x 1 Function Switch Input 24 energize weld current connect pins A amp B to turn on welding current Torch Switch Input OV to energize weld current connect pins A amp B to turn on welding current Wr 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 Mains Earth e Not Used OK to move current detect signal for robotics applications 0K to move current detect signal
68. ute the heat Cast Iron Most types of cast iron except white iron are weldable White iron because of its extreme brittleness generally cracks when attempts are made to weld it Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron Copper and alloys The most important factor is the high rate of heat conductivity of copper making preheating of heavy sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile steel cellulose types for welding large diameter pipes etc The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered are all easy to use and all will work on even the most basic of welding machines 36 Metals being joined Electrode Comments Mild steel 6013 Ideal electrodes for all general purpose work Features include out standing operator appeal easy arc starting and low spatter Mild steel 7014 All positional electrode for use on mild and galvanized steel furniture plates fences gates pipes and tanks etc Especially suitable for vertical down welding Cast iro
69. with slag Use smaller electrode with trapped beneath weld bead sufficient current to give adequate penetration Use suitable tools to remove all slag from corners Rust or mill scale is preventing Clean joint before welding full fusion Wrong electrode for position in Use electrodes designed for which welding is done position in which welding is done otherwise proper control of slag is difficult Not cleaned or incorrect eiectrode Slag trapped in undercut Figure 10 Examples of Slag Inclusion 42 70 03 Power Source Problems 1 The welding arc cannot be established Maximum output welding current cannot be achieved with nominal Mains supply voltage Welding current reduces when welding No gas flow when the torch trigger switch is depressed The Primary supply voltage has not been switched on The Welding Power Source switch is switched off Loose connections internally Defective control circuit Loose welding cable connections Incorrect welding cable size Improper input connections Poor electrode condition Wrong welding polarity Gas hose is cut Gas passage contains impurities C Gas regulator turned off Torch trigger switch lead is disconnected or switch cable is faulty 43 Switch on the Primary supply voltage Switch on the Welding Power Source Have an accredited Thermal Arc Service Agent repair the connection Have an accredited Thermal Arc Serv
70. years 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year 1 year SMAW Stick WELDING EQUIPMENT WARRANTY PERIOD 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 power 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 Anc 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 Lanc

400 TS ARCMASTER® - Victor Technologies

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400 TS ARCMASTER&reg; - Victor Technologies

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400 TS ARCMASTER® - Victor Technologies