Tweco 400 MSTP Arcmaster Manuel d'utilisateur

5060Hz1/3PHASEGTAWCAGSMAWGMAWFCAW460VCCCVDC230V208VINVERTEROperating ManualARCMASTER®Version No: AB Issue Date: June 21, 2010

4ARCMASTER 400 MSTP WARNINGSTEAM AND PRESSURIZED HOT COOLANT can burnface, eyes, and skin.The coolant in the radiator can be very hot and underpre

ARCMASTER 400 MSTP51.03 Precautions de Securite en Soudage à l’Arc! MISE EN GARDELE SOUDAGE A L’ARC EST DANGEREUXPROTEGEZ-VOUS, AINSI QUE LES AUTRES,

6ARCMASTER 400 MSTP AVERTISSEMENTLE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUXET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.L’arc de soudage produit une

ARCMASTER 400 MSTP77. Ne soudez des tôles galvanisées ou plaquées au plomb ou aucadmium que si les zones à souder ont été grattées à fond, que sil’esp

8ARCMASTER 400 MSTP1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bienventilées.2. Si vous utilisez ces équipements dans un endroit

9 SYMBOL LEGEND Amperage STICK (Shielded Metal Arc SMAW) Voltage Pulse Current Function Hertz (frequency) Spot Time (GTAW) SEC Second

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11 2.0 INTRODUCTION AND DESCRIPTION 2.01 Description The Thermal Arc™ ARC MASTER 400 MSTP is a single & three-phase DC arc welding power source w

12 2.02 Functional Block Diagram Figure 2 illustrates the Functional Block Diagram of the 400 MSTP-power supply. T o eac h control circ uitMa i nCir

13 2.04 Installation Recommendations 2.04.01 Environment The ARC MASTER 400 MSTP is designed for use in hazardous environments. Examples of environm

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Thermal Arc product. We are proudto have you as our customer and will strive to provide you wi

14 2.05 Electrical Input Connections WARNING 4 ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOU

15 Input Voltage Fuse Size 208 VAC 100 Amps 230 VAC 75 Amps 460 VAC 50 Amps Table 1 – Electrical Input Connections Note 4 Fuse size is bas

16 2.05.02 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN SWITCH is turned ON, the inrush cir

17 2.05.03 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be over-emphasized. Interfe

18 2.06 Specifications Parameter 400 MSTP Rated Output Amperes Volts Duty Cycle 400 36 25% 400A/ 26V@ 25% 300A/ 22V @ 60% Duty Cycle TIG 200A/ 18V

19 2.07 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 w

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21 3.0 OPERATOR CONTROLS 3.01 ARC MASTER 400MSTP Controls Figure 4. ARC MASTER 400 MSTP Power Source 1. Control Knob This control sets the selecte

22 3. Positive Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plu

23 WARNING 6 When the welder is connected to the Primary supply voltage, the internal electrical components may be at 500V potential with respect to

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

24 12. Remote Control Socket: The 10 pin Remote Control Socket is used to connect remote control devices for Pulse MIG welding. To make connections,

25 Parameter Description ARC CONTROL This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and

26 3.03 Weld Process Selection for the ARC MASTER 400 MSTP Weld Mode Weld Parameter STICK MIG LIFT TIG Description WELD (V)    Weld v

27 3.04.05 ARC CONTROL This parameter operates in STICK mode only and is used to adjust percentage increase in welding current and is proporti

28 ii) Vertical up welding When welding vertical up with arc force on, the operator can control the amount of current by changing arc length, i.e. v

29 Feature Description Voltage Reduction Device (VRD) (Shipped de-activated, field capable) See Section 11 for activation instructions.Reduces the O

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31 4.0 SEQUENCE OF OPERATION NOTE: Parameter Buttons are used to select the parameters to be set. The LED’s show which function is being adjusted o

32 4.01 Stick Welding • Connect work lead to negative terminal • Connect electrode lead to positive terminal • Switch machine on • Set weld c

33 4.03 MIG Welding • Connect work lead to negative terminal • Connect electrode lead to positive terminal • Switch machine on • Set weld vol

34 LOAD (retrieve) a Program to Control Panel • Press and HOLD the LOAD button. Beep will sound and Digital Meter display will show a number 1. •

35 Figure A: Pulse Waveforms Ist TpkIpkBAKTbakBackground Time(Ib

36 SCHEDULE STD WIRE TYPE WIRE SIZE (INCHES) Ist (Amps)Ipk (Amps)Tpk (Amps)Vbak (Volts) GAS MIXTURE 1 Mild steel .035 350 300 2.5 20.0

37 welding. As with conventional MIG welding, the power source must be adjusted to correspond with the correct heat input for a given wire feed speed

38 4.07 SAFE MODE SAFE (Special Application Function Environment) is a mode of operation that the 400MSTP of welding power source can enter in o

39 FACTORY DEFAULT OPTION NUMBER OPTION 1PHASE 3FHASE DIPSLAY FORMAT 4 MINIMUM SELECTABLE AMPERAGE. .

40 FACTORY DEFAULT OPTION NUMBER OPTION 1PHASE 3FHASE DIPSLAY FORMAT 8 MINIMUM SELECTABLE REFERENCE. . Minimum ref

41 FACTORY DEFAULT OPTION NUMBER OPTION 1PHASE 3FHASE DIPSLAY FORMAT F EXIT

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43 5.0 BASIC WELDING GUIDE 5.01 Electrode Polarity Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for di

TABLE OF CONTENTS 1.0 SAFETY INSTRUCTIONS AND WARNINGS...1 SYMBOL LEGEND

44 5.04 Guide for Selecting Filler Wire Diameter Filler Wire Diameter AC Current Range (Amps) DC Current Range (Amps) 1/16” (1.6 mm) 30-95 20 -

45 5.07 Welding Parameters for Steel Base Metal Thickness DC Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Fille

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47 6.0 BASIC STICK WELDING GUIDE 6.01 Electrode Polarity Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘−’

48 Metals being joined Electrode Comments Copper, Bronze, Brass, etc. Bronze 5.7 ERCUSI-A Easy to use electrode for marine fittings, water taps

49 7.0 BASIC MIG WELDING GUIDE 7.01 Setting of the Power Source The setting of the ARC MASTER 400 MSTP requires some practice by the operator, the

50 7.04 Travel Speed Speed at which a weld travels influences the width of the weld and penetration of the welding run. 7.05 Electrode Wire Size Sel

51 8.0 ROUTINE MAINTENANCE The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency dep

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53 9.0 BASIC TROUBLESHOOTING WARNING 8 There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open

TABLE OF CONTENTS 7.0 BASIC MIG WELDING GUIDE ... 42 7.01

54 WARNING 9 Disengage the drive roll when testing for gas flow by ear. 9.01.02 Inconsistent Wire Feed Checking the following points can reduce wir

55 9.02 MIG Welding Problems Description Possible Cause Remedy 1 Undercut. A Welding arc voltage too high. AReduce WELD (V) control or increa

56 9.03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding tech

57 Description Possible Cause Remedy 9 Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems

58 9.04 Stick Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in weld metal (Porosity). A B C Electrodes are damp.

59 5 Non-metallic particles are trapped in the weld metal (slag inclusion). A Non-metallic particles may be trapped in undercut from previous run.

60 9.05 Power Source Problems Description Possible Cause Remedy 1 The welding arc cannot be established. A B The Primary supply voltage has

61 10.0 VOLTAGE REDUCTION DEVICE (VRD) 10.01 VRD Specification Description ARC MASTER 400 MSTP Notes VRD Open Circuit Voltage 15.3 to 19.8V O

62 10.03 Switching VRD On/Off Switch the machine OFF. a) Remove the clear plastic cover from the control panel. (see Figure 11) • Lift up the co

63 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

ARCMASTER 400 MSTP17. Use fully insulated electrode holders. Never dip holder in water tocool it or lay it down on the ground or the work surface. Do

64 11.0 POWER SOURCE ERROR CODES Description Possible Cause Remedy Remarks 1 E01 error code displayed Temperature sensor TH1 (protects IGBTs) i

65 Description Possible Cause Remedy Remarks 6 E12 error code displayed Under mains supply (input) voltage primary capacitors is reduced for on

67 APPENDIX A - INTERCONNECT DIAGRAM

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69 APPENDIX B - ARCMASTER 400 MSTP ACCESSORIES ACCESSORIES PART NO. DESCRIPTION Stick Kit 10-4082A Work Lead with 25’ #1 cable and stic

LIMITED WARRANTYThis information applies to Thermal Arc products that were purchased in the USA and Canada.April 2006 LIMITED WARRANTY: Thermal Arc®,

WARRANTY SCHEDULEThis information applies to Thermal Arc products that were purchased in the USA and Canada.April 2006 ENGINE DRIVEN WELDERS WARRANT

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World HeadquartersThermadyne Holdings CorporationSuite 300, 16052 Swingley Ridge RoadSt. Louis, MO 63017Telephone: (636) 728-3000FAX: (636) 728

2ARCMASTER 400 MSTP3. Use protective screens or barriers to protect others from flashand glare; warn others not to watch the arc.4. Wear protective cl

ARCMASTER 400 MSTP3 WARNINGFLYING SPARKS AND HOT METAL can cause injury.Chipping and grinding cause flying metal. As welds cool,they can throw of