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Summary of Contents for Thermal Arc ARCMASTER 300 MST
- Page 1 300 MST ® ARCMASTER INVERTER ARC WELDER Art # A-07367 Operating Manual Version No: 1 Issue Date: March 22, 2006 Manual No.: 0-4865 Operating Features:...
- Page 2 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.
- Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. ArcMaster 300 MST Inverter Arc Welder Instruction Manual Number 0-4865 for: Part Number W1000700 Published by:...
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Page 4: Table Of Contents
TABLE OF CONTENTS 1.0 SAFETY INSTRUCTIONS AND WARNINGS ..................1 1.01 Arc Welding hazards ............................1 1.02 Principal Safety Standards ........................... 4 1.03 Precautions de Securite en Soudage à l’Arc ......................5 1.04 Dangers Relatif au Soudage à l’Arc ........................5 1.05 Principales Normes de Securite ........................... - Page 5 TABLE OF CONTENTS 6.0 BASIC STICK WELDING GUIDE ....................33 6.01 Electrode Polarity ............................... 33 6.02 Effects of Stick Welding Various Materials ......................33 7.0 BASIC MIG WELDING GUIDE....................35 7.01 Setting of the Power Source ..........................35 7.02 Position of MIG Torch ............................35 7.03 Distance from the MIG Torch Nozzle to the Work Piece..................
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Page 7: Safety Instructions And Warnings
ARCMASTER 300 MST 1.0 SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. - Page 8 ARCMASTER 300 MST 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. WELDING can cause fire or explosion.
- Page 9 ARCMASTER 300 MST 2. If used in a closed area, vent engine exhaust outside and away from any building air intakes. WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
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Page 10: Principal Safety Standards
ARCMASTER 300 MST 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S. -
Page 11: Precautions De Securite En Soudage À L'arc
ARCMASTER 300 MST 1.03 Precautions de Securite en Soudage à l’Arc 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. - Page 12 ARCMASTER 300 MST AVERTISSEMENT AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX POUR LA SANTE. ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. Le soudage dégage des vapeurs et des fumées L’arc de soudage produit une chaleur et des rayons dangereuses à...
- Page 13 ARCMASTER 300 MST 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.
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Page 14: Principales Normes De Securite
ARCMASTER 300 MST Les accumulateurs contiennent de l’électrolyte acide et 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. dégagent des vapeurs explosives. 2. Si vous utilisez ces équipements dans un endroit confiné, les 1. Portez toujours un écran facial en travaillant sur un accumu-lateur. -
Page 15: Symbol Legend
SYMBOL LEGEND Amperage STICK (Shielded Metal Arc SMAW) Voltage Pulse Current Function Hertz (frequency) Spot Time (GTAW) Seconds Remote Control (Panel/Remote) Percent Remote Function DC (Direct Current) Arc Control (SMAW) AC (Alternating Current Gas Post-Flow Standard Function Gas Pre-Flow Slope Function Voltage Reduction Device Circuit Slope W/Repeat Function Negative... -
Page 16: Introduction And Description
2.0 INTRODUCTION AND DESCRIPTION 2.01 Description The Thermal Arc™ ARC MASTER 300 MST is a single & three-phase DC arc welding power source with Constant Current (CC) and Constant Voltage (CV) output characteristics. This unit is equipped with a Digital Volt/Amperage, lift arc starter for use with Gas Tungsten Arc Welding (GTAW), Arc Control and Hot Start for Shielded Metal Arc Welding (SMAW), Inductance Control for Gas Metal Arc Welding (GMAW) processes. -
Page 17: Functional Block Diagram
2.02 Functional Block Diagram Figure 2 illustrates the Functional Block Diagram of the 300 MST-power supply. Input Hall Current Main Input Output IGBT Main Capacitor Circuit Diode Inverter Diodes Transformers Transformer Power Switch DC Power Thermal (T1) (HCT1) Thermal Filter Detector Detector Primary... -
Page 18: Installation Recommendations
In areas, not exposed to direct sunlight Place at a distance of 12” (304.79mm) or more or rain. from walls or similar that could restrict natural airflow for cooling. WARNING 3 Thermal Arc advises that this equipment be electrically connected by a qualified electrician. -
Page 19: Electrical Input Connections
2.05 Electrical Input Connections WARNING 4 ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. - Page 20 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 based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code).
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Page 21: Input Power
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 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). -
Page 22: High Frequency Introduction
2.05.03 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. -
Page 23: Specifications
460V 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... -
Page 24: Duty Cycle
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 without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases. -
Page 25: Operator Controls
3.0 OPERATOR CONTROLS 3.01 ARC MASTER 300 MST Controls Figure 4. ARC MASTER 300 MST Power Source Control Knob This control sets the selected weld parameter, rotating it clockwise increases Socket Pin Function the parameter and is indicated on the 24VAC auxiliary high side. - Page 26 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. 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.
- Page 27 ON/OFF Switch This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Supply. WARNING 6 When the welder is connected to the Primary supply voltage, the internal electrical components may be at 500V potential with respect to earth. Input Cable The input cable connects the Primary supply voltage to the equipment.
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Page 28: Weld Parameter Descriptions For Arc Master 300 Mst
3.02 Weld Parameter Descriptions for ARC MASTER 300 MST Figure 6. ARC MASTER 300 MST Front Panel with Parameter Description Parameter Description This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability. ARC CONTROL This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes. -
Page 29: Weld Process Selection For The Arc Master 300 Mst
Parameter Description Selects in operation Panel board or Remote. Operation PANEL/REMOTE This parameter, similar to the ARC CONTROL in STICK mode, allows for the adjustment of the dynamic property of the arc. As the inductance is increased the INDUCTANCE output voltage may need to be adjusted to achieve the desired weld characteristics. The SAVE/LOAD buttons are used to save and retrieve a total number of 5 programs into the 300 MST memory. -
Page 30: Hot Start
3.04.03 HOT START This parameter operates in STICK mode and improves the start characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of the WELD current. e.g. HOT START current = 150 amps when Weld Current = 100 amps & HOT START = 50A 3.04.04 WELD (A) This parameter sets the STICK &... -
Page 31: Weld Parameters
ii) Vertical up welding When welding vertical up with arc force on, the operator can control the amount of current by changing arc length, ie voltage. Weld metal is deposited by “digging” the electrode into the side of the base metal joint and then increasing the arc length with a flicking motion, to allow the weld pool to freeze, before digging the electrode into the other side of the base metal joint. - Page 32 Feature Description • Intelligent Fan Control The intelligent cooling system is designed to reduce dust and foreign material build-up, while providing optimum cooling. • Fan speed reduces approximately 30 seconds after machine is turned on. • Fan speed increases when internal components reaches operating temperature.
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Page 33: Sequence Of Operation
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 on the weld sequence graph. Refer to Symbols Table located in the front of the manual for Symbol descriptions. Figure 7. -
Page 34: Stick Welding
4.01 Stick Welding • Connect work lead to negative terminal • Connect electrode lead to positive terminal • Switch machine on • Set weld current. • Set Contactor. • Connect remote control device if required Use the Scroll Buttons to move to the parameter to be set. The LED will show which function is being adjusted on the weld sequence graph. -
Page 35: Save-Load Operation
4.04 Save-Load Operation A total number of 5 programs can be saved into the 300 MST memory. SAVE the Current Weld Parameters into Memory • SAVE Press and HOLD the button. Beep will sound and digital display will show a number 1. •... -
Page 36: Basic Welding Guide
5.0 BASIC WELDING GUIDE 5.01 Electrode Polarity TORCH + / WORK Connect the TIG torch to the - / terminal and the work lead to the 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. -
Page 37: Guide For Selecting Filler Wire Diameter
5.04 Guide for Selecting Filler Wire Diameter Filler Wire Diameter AC Current Range DC Current Range (Amps) (Amps) 1/16” (1.6 mm) 30-95 20 - 90 3/32” (2.4 mm) 125-160 65 - 115 1/8” (3.2 mm) 180-240 100 - 165 3/16” (4.8 mm) 220-320 200-350 Table 9 –... -
Page 38: Welding Parameters For Steel
5.07 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 (if required) Liters/min 35-45 20-30 Butt/Corner 0.040” 0.040” 1/16” 40-50 25-35 Lap/ Fillet 1.0mm... -
Page 39: Basic Stick Welding Guide
6.0 BASIC STICK WELDING GUIDE 6.01 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. 6.02 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. - Page 40 Metals being joined Electrode Comments Copper, Bronze, Brass, etc. Bronze Easy to use electrode for marine fittings, water taps and valves, water trough float 5.7 ERCUSI-A arms, etc. Also for joining copper to steel and for bronze overlays on steel shafts. High Alloy Steels, 312-16 It will weld most problematical jobs such...
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Page 41: Basic Mig Welding Guide
7.0 BASIC MIG WELDING GUIDE 7.01 Setting of the Power Source The setting of the ARC MASTER 300 MST requires some practice by the operator, the welding Power Source/Wirefeeder having two control settings that have to balance. These are the Wirespeed control and the Voltage Control. -
Page 42: Travel Speed
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 Selection The choice of electrode wire size in conjunction with shielding gas used depends on: The position of welding Thickness of the metal to be welded The deposition rate required... -
Page 43: Routine Maintenance
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. -
Page 44: Basic Troubleshooting
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. -
Page 45: Inconsistent Wire Feed
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 wire-feeding problems: 1. Wire spool brake is too tight. Feed roller driven by motor in the cabinet will slip. -
Page 46: Mig Welding Problems
7 Cold weld puddle. A Faulty rectifier unit A Have an accredited Thermal Arc Service Agent to test then replace the faulty component. B Loose welding cable connection B Check all welding cable connections. -
Page 47: Tig Welding Problems
9.03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique. Description Possible Cause Remedy 1 Excessive beard build- Welding current is too low. Increase weld current and/or faulty up or poor penetration joint preparation. - Page 48 Description Possible Cause Remedy 9 Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems. 10 Arc flutters during TIG A Tungsten electrode is too A Select the right size electrode. Refer welding. large for the welding current.
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Page 49: Stick Welding Problems
9.04 Stick Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in Electrodes are damp. Dry electrodes before use. weld metal (Porosity). Welding current is too high. Reduce welding current. Surface impurities such as oil, Clean joint before welding. grease, paint, etc. - Page 50 5 Non-metallic A Non-metallic particles may be A If bad undercut is present, clean slag particles are trapped in trapped in undercut from previous out and cover with a run from a the weld metal run. smaller diameter electrode. (slag inclusion). B Joint preparation too restricted.
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Page 51: Power Source Problems
The Welding Power Source Switch ON the Welding switch is switched OFF. Power Source. C Loose connections internally. C Have an accredited Thermal Arc Service Agent repair the connection. 2 Maximum output welding Defective control circuit Have an accredited Thermal Arc... -
Page 52: Voltage Reduction Device (Vrd)
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... -
Page 53: Switching Vrd On/Off
10.03 Switching VRD ON/OFF Switch the machine OFF. a) Remove the clear plastic cover from the control panel. (see Figure 12) • 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. •... - Page 54 d) Turning the VRD ON/OFF. (see Figure 14) • 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 46. •...
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Page 55: Power Source Error Codes
80ºC for about 1 second. speed. E01 resets when Fan ceases to operate. Have an Accredited TH1 decreases to 70ºC for Thermal Arc Service about 30 seconds. Agent investigate Air flow is restricted by Unblock vents then let vents being blocked. - Page 56 7 E81 error code displayed When 3 phase machine Have an accredited No weld current is Wrong Primary supply (input) is first turned ON with Thermal Arc Service available. voltage connected. the wrong Primary Agent or a qualified Buzzer sounds constantly.
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Page 58: Appendix A - Interconnect Diagram
APPENDIX A – INTERCONNECT DIAGRAM TB13 TB10 TB14 TB11 TB15 TB12 PCB8 PCB10 PCB1 K(7) IGBT IGBT Main Gate Gate Circuit G(6) Circuit Circuit Bord Bord Bord [WK-5493] R(3) Line1 [WK-5479] [WK-5479] S(4) Line2 T(5) Line3 Ground PCB21 PCB2 Filter Link TB18 Circuit Bord... - Page 59 PCB15 DIODE Snubber Circuit Bord [WK-5606] PCB14 TRANS Bord 1 2 3 [WK-5594] TB35 +Output Terminal TB33 HCT1 TB21 TB34 1 2 3 4 5 Ground PCB18 TB30 Filter Circuit TB16 Bord SIDE CHASSIS 3 [WK-5499] TB32 TB22 TB31 FCH1 -Output Terminal TB17...
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Page 60: Appendix B - Arcmaster 300Mst Accessories
APPENDIX B - ARCMASTER 300 MST ACCESSORIES ACCESSORIES PART NO. DESCRIPTION Stick Kit 10-4082A Work clamp with 10’ cable, and stick electrode with 25’ #1 cable TIG Kit 10-4080 Includes regulator/flowgauge, 12.5ft 200 Amp TIG torch with valve, accessory kit includes 1 ea of 0.040”x7”, 1/16”x7”, 3/32”x7”... -
Page 62: Limited Warranty
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. - Page 63 WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. April 2006 ENGINE DRIVEN WELDERS ARRANTY ERIOD ABOR Scout, Raider, Explorer Original Main Power Stators and Inductors .................. 3 years 3 years Original Main Power Rectifiers, Control P.C. Boards ..............3 years...
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Page 65: Global Customer Service Contact Information
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988... - Page 66 World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 Fascimile: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.com...
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