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Thermadyne THERMAL ARC ARC-MASTER 351 Owner's Manual

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ARC-MASTER 351
For the Following Specs:
• 500123A-1
OWNER'S MANUAL Number 430429-290
Revised December 1, 1997
IMPORTANT: Read these instructions before installing, operating, or servicing this system.
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.

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Summary of Contents for Thermadyne THERMAL ARC ARC-MASTER 351

  • Page 1 ARC-MASTER 351 For the Following Specs: • 500123A-1 OWNER’S MANUAL Number 430429-290 Revised December 1, 1997 IMPORTANT: Read these instructions before installing, operating, or servicing this system. THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.

  • Page 3: Table Of Contents

    430429-290 Table of Contents INTRODUCTION How To Use This Manual ........1-1 Equipment Identification .

  • Page 4: Introduction

    430429-290 INTRODUCTION INTRODUCTION How To Use This Manual Receipt Of Equipment This Owner’s Manual usually applies to just the When you receive the equipment, check it against underlined specification or part numbers listed on the invoice to make sure it is complete and inspect the cover.
  • Page 5 430429-290 INTRODUCTION This page intentionally left blank. December 1, 1997 Revised...

  • Page 6: Arc Welding Safety Instructions And Warnings

    ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ARC WELDING can be hazardous. 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/INSTRUC- TION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 7 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 FUMES AND GASES can be hazardous 4. Read the Material Safety Data Sheets (MSDSs) and the manu- to your health. facturer’s instruction for metals, consumables, coatings, and cleaners. 5. Work in a confined space only if it is well ventilated, or while Welding produces fumes and gases.
  • Page 8 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ENGINE FUEL can cause fire or 2. Do not add fuel while smoking or if unit is near any sparks or open explosion. flames. 3. Allow engine to cool before fueling. If possible, check and add Engine fuel is highly flammable.
  • Page 9 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 This page intentionally left blank. May 8, 1996...
  • Page 10 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 ′ PRECAUTIONS DE SECURITE EN SOUDAGE A L 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).
  • Page 11 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE ( selon AWS A 8.2-73 ) Opération Dimension d’électrode ou Nuance de Epaisseur de métal ou de filtre Coupage ou soudage Intensité...
  • Page 12 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN IN- 4. Méfiez-vous des projections brulantes de soudage susceptibles CENDIE OU UNE EXPLOSION de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures. L’arc produit des étincellies et des projections. Les 5.
  • Page 13 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 DES PIECES EN MOUVEMENT PEU- 3. Seules des personnes qualifiées doivent démonter des protec- VENT CAUSER DES BLESSURES. teurs ou des capots pour faire l’entretien ou le dépannage nécessaire. Des pièces en mouvement, tels des ventilateurs, des 4.

  • Page 14: Description Of Equipment

    430429-290 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT General contains pre-programmed weld schedules for 24 wire/gas combinations. All 24 schedules may also The ARC-MASTER 351 is a primary inverter DC be programmed by the operator. An optional Pro- power source that can be used for constant voltage, gramming Pendant (204180-1) is required to do constant current, and pulse welding processes.
  • Page 15 430429-290 DESCRIPTION OF EQUIPMENT Figure 3-1 June 13, 1996 Revised...

  • Page 16: Protection Features

    430429-290 DESCRIPTION OF EQUIPMENT Protection Features tinue to operate to cool the machine. The power source will remain off with the RED light on until it The machine has several built-in protection fea- is reset by momentarily turning the AC power tures designed to assure reliability.

  • Page 17: Description Of Controls And Features

    430429-290 DESCRIPTION OF EQUIPMENT Description of Controls and 4 — Ready Indicator (GREEN): This green light will be on whenever the power source is Ready-to- Features Weld. If the green light is not on, the power source (See Figure 3-3) will not produce any output power.
  • Page 18 430429-290 DESCRIPTION OF EQUIPMENT 6 — AC Power ON/OFF Switch: This switch is 14 — Programming Pendant plug: Optional Pro- used to control the three-phase input power applied gramming Pendant (204180-1) plugs in here. This to the power source. When this switch is in the ON option allows the user to customize any or all of the position, the digital meter display should light up, 24 pulsed-MIG schedules to their particular applica-...
  • Page 19 430429-290 DESCRIPTION OF EQUIPMENT 19 — Duplex Receptacle: This receptacle can 20 — Circuit Breaker: This 10-amp pushbutton provide up to 10 amps of 120-V AC auxiliary power breaker provides protection for the 24 V AC circuit. for powering wire feeders, water circulators, etc. June 13, 1996 Revised...

  • Page 20: Installation

    430429-290 INSTALLATION INSTALLATION Location is provided in the rear panel of the machine for the entry of the input conductors. For best operating characteristics and longest unit life, take care in selecting an installation site. Avoid locations exposed to high humidity, dust, high am- DANGER: ELECTRIC SHOCK bient temperature, or corrosive fumes.

  • Page 21: Connection Instructions

    430429-290 INSTALLATION Connect the three-phase line leads to terminals L1, L2, and L3 on the line switch inside the welding machine cabinet. See Figure 4-1. Figure 4-1 Figure 4-2 200 Volt Link Arrangement Connection Instructions 1. Check nameplate of welder to be certain that it is designed for the line voltage to which it is to be connected.

  • Page 22: Grounding

    430429-290 INSTALLATION Figure 4-5 460 Volt Link Arrangement Figure 4-4 400 Volt Link Arrangement the metal sheathing or conduit must be effectively grounded per local and national codes. WARNING: Never connect the safety ground screw to one of Rubber-tire mounted equipment shall be grounded to conform to local and national codes.

  • Page 23: Welding Leads

    430429-290 INSTALLATION ground wire size is adequate before the machine is correct voltage at the arc. When considering voltage operated. drop, the entire loop (electrode plus work lead) must be considered. CAUTION: Be sure to replace the cabinet side to assure adequate internal ventila- Refer to Table 4-2 as a basic guideline to the tion and prevent component failure.

  • Page 24: Pulsed-Gmaw Schedule Selection

    430429-290 INSTALLATION Pulsed-GMAW Schedule To change to the Metric schedules, follow these directions. Selection 1) Turn off power to the Arc-Master and discon- The Arc-Master has two different sets of Pulsed- nect the input power line. GMAW weld schedules: 2) Remove the pulsed-mig panel assembly 1) Standard Factory Schedules from the front of the machine by removing the 2) Metric Schedules...
  • Page 25 430429-290 INSTALLATION This page intentionally left blank. June 13, 1996 Revised...

  • Page 26: Operation

    430429-290 OPERATION OPERATION General The Operation chapter of this manual is intended as a guideline to the operation of the ARC-MASTER Read and understand the safety instructions at the 351 power source, and not as a tutorial on welding beginning of this manual prior to operating this processes and techniques.

  • Page 27: Gtaw Operation

    430429-290 OPERATION 5. Set the ARC FORCE control to the desired arc 2. Provide suitable shielding gas connections and force setting. Full clockwise is maximum arc force. controls to the torch. The power source does not The higher the arc force setting the more drive or provide connections for the shielding gas.

  • Page 28: Gmaw/Fcaw Operation

    430429-290 OPERATION ductance. Lower values of inductance give a faster 7. Set the REMOTE/LOCAL control to LOCAL. Adjust the AMPS/VOLTS control to the desired cooling puddle with a “harsher” type of arc. Higher welding amperage. This will be the maximum am- inductance settings give a very soft arc and a slower perage available with the remote current control.
  • Page 29 430429-290 OPERATION Figure 5-3 Pulse Waveforms preheat the wire and maintain the arc between the pulse frequency is preset by the user and weld wire and the workpiece. The background current schedules 1–12 are active. The pulse frequency must not be allowed to go too low, or the arc can be varied by adjusting the AMPS/VOLTS con- becomes unstable and difficult to maintain.
  • Page 30 430429-290 OPERATION For welding applications where none of the 24 GRAMMING PENDANT connector located on the schedules will give adequate results, any or all 24 front of the ARC-MASTER (Item 18, Figure 3-2). schedules can be changed by the operator to fit the Using the Pendant, a schedule can easily be modi- application.

  • Page 31: Operation, Standard Mode (Std)

    430429-290 OPERATION SCHEDULE WIRE SIZE WIRE TYPE (mm) (Amps) (msec) (Amps) (Volts) GAS MIXTURE 19.0 Mild Steel 80% Ar 20% CO 20.0 Mild Steel 80% Ar 20% CO 20.0 Mild Steel 80% Ar 20% CO 18.0 Stainless Steel 97.5% Ar 2.5% CO 18.0 Stainless Steel 97.5% Ar 2.5% CO...

  • Page 32: Operation, Automatic Voltage Control Mode (Avc)

    430429-290 OPERATION heat input. As with conventional MIG welding, the 4. Set the STD/AVC switch to the AVC position. power source must be adjusted to correspond with This puts the machine into the automatic voltage the correct heat input for a given wire feed speed control (AVC) mode.
  • Page 33 430429-290 OPERATION This page intentionally left blank. June 13, 1996 Revised...

  • Page 34: Maintenance

    430429-290 MAINTENANCE MAINTENANCE If this equipment does not operate properly, stop For uninterrupted, satisfactory service from this work immediately and investigate the cause of the welding machine, it is necessary to keep the ma- malfunction. Maintenance work must be performed chine clean, dry, and well ventilated.
  • Page 35 430429-290 MAINTENANCE This page intentionally left blank. June 13, 1996 Revised...

  • Page 36: Troubleshooting

    430429-290 TROUBLESHOOTING TROUBLESHOOTING WARNING: Disconnect the power source from the input power source before carrying out any service or repair work. Hazardous voltages can be present in the machine whenever input power is connected. FRONT PANEL STATUS Indicator Green Digital Ready Overload Meter...
  • Page 37 430429-290 TROUBLESHOOTING Is some type of contactor control or gun switch connected? The power source requires an A-B closure on one of the amphenol connectors, except in “SMAW” mode, before it will produce output voltage. To check power source: disconnect welding leads, turn process select switch to “SMAW” and measure output voltage with a V-O-M.

  • Page 38: Parts List

    430429-290 PARTS LIST PARTS LIST to another part. The part descriptions may be Equipment Identification indented to show part relationships. All identification numbers as described in the In- troduction chapter must be furnished when ordering To determine the part number, description, quan- parts or making inquiries.
  • Page 39 430429-290 PARTS LIST Figure 8-1 Arc-Master 351 Welder Assembly June 13, 1996 Revised...
  • Page 40 430429-290 PARTS LIST Parts List for Figure 8-1 Item Part Description Number Assy 500123A-1 Welder - Arc-Master 351 204121-3 . Panel - Top 12CW-2170 . Boot - Lifting Eye 204036 . Label - Precautionary, Static 204122-3 . Panel -Side, Right 204230 .
  • Page 41 430429-290 PARTS LIST This page intentionally left blank. June 13, 1996 Revised...
  • Page 42 430429-290 PARTS LIST Parts List for Figure 8-1 Item Part Description Number Assy 204080-1 . Bracket - Fan Motor 404044-3 . Thermostat - Overload 404044-6 . Thermostat - Overload 404915-2 . Spacer - P.C. Board 204711 . Board - P.C., IGBT Control 204017-1 .
  • Page 43 430429-290 PARTS LIST Figure 8-2 PC Boards Parts List for Figure 8-2 Item Part Description Number Assy Ref. Board - PC Regulator, Control 203203-1 . Display - Digital 409997-1 . Switch - DPDT, PC Mount, Toggle 203980-1 . Potentiometer - 3-3/4 Turn 406355-1 .
  • Page 44 430429-290 DIAGRAMS DIAGRAMS • Note the model and specification number shown on the equipment nameplate. • Locate these numbers in the model and specification number columns below. • Use only those diagrams and instructions that are applicable. SCHEMATIC VOLTAGE SPECIFICATION CONNECTION CHANGEOVER NUMBER...
  • Page 48 LIMITED WARRANTY: Thermal Arc , Inc., A Thermadyne Company, warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice,...

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