Thermal Arc 400MSTW CC Operating Manual
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Thermal Arc 400MSTW CC Operating Manual

Thermal Arc 400MSTW CC Operating Manual

Inverter arc welder
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A THERMADYNE
Company
®
INVERTER
ARC
WELDER
MODEL 400MSTW CC/CV
• STICK
•TIG - Lift Start
•MIG - Short Circuit
- Globular
- Spray
OPERATING MANUAL
July 1, 2001
Manual No. 430429-490

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  • Page 1 A THERMADYNE Company ® INVERTER WELDER MODEL 400MSTW CC/CV • STICK •TIG - Lift Start •MIG - Short Circuit - Globular - Spray OPERATING MANUAL July 1, 2001 Manual No. 430429-490...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1.0 GENERAL INFORMATION ...........2 1.01 Notes, Cautions and Warnings ..........2 1.02 Important Safety Precautions ..........3 1.03 Publications ................6 1.04 Note, Attention et Avertissemen ..........7 1.05 Precautions De Securite Importantes ........8 1.06 Documents De Reference .............11 1.07 Statement of Warranty .............12 2.0 INTRODUCTION AND DESCRIPTION ......14 2.01 Description ................14 2.02 Functional Block Diagrams ..........15...
  • Page 4 5.0 BASIC TROUBLESHOOTING ..........51 5.01 Common Welding Operation Faults ........51 5.02 Specific Problems ..............51 5.03 Error Code List ..............54 6.0 PARTS LIST ................55 APPENDIX A – REMOTE 14-Pin CONNECTIONS ....59 APPENDIX B - ACCESORIES ............60 APPENDIX C - INTERCONNECTION DIAGRAMS ....61...
  • Page 5 WARNING While the information contained in this Operating Manual represents our best judgement, Thermal Arc INC. assumes no liability for its use. Thermal Arc Models 400MSTW CC/CV Welder Operating Manual Number 430429-490 Published by: Thermal Arc INC.

  • Page 6: General Information

    1.0 GENERAL INFORMATION 1.01 NOTES, CAUTIONS AND WARNINGS Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment.

  • Page 7: Important Safety Precautions

    WARNING 1.02 IMPORTANT SAFETY PRECAUTIONS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-937-440-0100 or your local distributor if you have any questions.
  • Page 8 IMPORTANT SAFETY PRECAUTIONS (CONTINUED) ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. •...
  • Page 9 IMPORTANT SAFETY PRECAUTIONS (CONTINUED) PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and bum your skin if you are not properly protected •...

  • Page 10: Publications

    1.03 PUBLICATIONS Refer to the following standards or their latest revisions for more information: 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W.

  • Page 11: Note, Attention Et Avertissemen

    1.04 NOTE, ATTENTION ET AVERTISSEMENT Dans ce manuel, les mots "note," "attention," et "avertissement" sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit: NOTET oute opération, procédure ou renseignement général sur lequel il importe d'insister davantage ou qui contribue à...

  • Page 12: Precautions De Securite Importantes

    AVERTISSEMENT 1.05 PRECAUTIONS DE SECURITE IMPORTANTES L'OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L'ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ. Il aut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d'éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité...
  • Page 13 PRECAUTIONS DE SECURITE IMPORTANTES CHOC ELECTRIQUE Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l'énergie electrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l'opérateur et les autres persormes sur le lieu de travail. •...
  • Page 14 PRECAUTIONS DE SECURITE IMPORTANTES RAYONS D'ARC DE PLASMA Les rayons provenant de l'arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l'rarc de plasma produit une lumière in&a-rouge et des rayons ultra-violets très forts. Ces rayons d'arc nuiront à...

  • Page 15: Documents De Reference

    1.06 DOCUMENTS DE REFERENCE Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus ampies renseignements: 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 16: Statement Of Warranty

    “Thermal; Arc” 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...
  • Page 17 PAGE LEFT INTENTIONALY BLANK MANUAL 430429-490 INTRODUCTION...

  • Page 18: Introduction And Description

    2.0 INTRODUCTION AND DESCRIPTION 2.01 Description The Thermal Arc™ Model 400MSTW is a single or three-phase DC arc welding power sources with Constant Current (CC) and Constant Voltage (CV) output characteristics. This unit is designed for use with Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), and Gas Tungsten Arc Welding (GTAW) processes.

  • Page 19: Functional Block Diagrams

    2.02 Functional Block Diagrams Figure 2 illustrates the functional block diagram of the 400MSTW power supply. Input Main Current Input Inrush Current IGBT Inv erter Output Output Coupling Circuit Capacitor Diode Suppressor Module Transformers Diode Coil Breaker Power Transformer (CT-1) Thermal Sensor Control...

  • Page 20: Transporting Methods

    2.03 Transporting Methods These units are equipped with a handle for carrying purposes. WARNING ELECTRIC SHOCK can kill. • DO NOT TOUCH live electrical parts. • Disconnect input power conductors from de-energized supply line before moving welding power source. WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage.
  • Page 21 • To operate signal-phase, do not connect the RED input conductor. • Do not connect an input (WHITE or BLACK) conductor to the ground terminal. • Do not connect the ground (GREEN) conductor to an input line terminal. Refer to figure 3 and: 1.
  • Page 22 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT BREAKER 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 23: Specifications

    2.05 Specifications Parameter 400MSTW Rated Output Amperes Volts Duty Cycle Output Range (Min.- MAX.) 5-400A(STICK/LIFT TIG/SCRACH/CARBON ARC CUTTING) Amperes 10-36V(MIG) Volts Open Circuit Voltage Maximum OCV Input Data 50/60Hz Dimensions/Weight Width 8.3 in (210 mm) Height: 16.9 in (430 mm) Length: 16.5 in (420 mm)kg) Weight:...

  • Page 24: Duty Cycle

    2.06 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 400MSTW Front & Rear Panels Amperage/Voltage Control – The amperage / voltage control selects the desired amperage or open circuit voltage within the entire range of the welding power source. Rotating this control in a clockwise direction increases the amperage or voltage output.
  • Page 26 24V Circuit Breaker – Push to reset. Controls 24V power source for wire feeders controlled through 14-Pin receptacle. 115V Circuit Breaker – Push to reset. Controls 115V power source for wire feeders controlled through 14-Pin receptacle. Primary Power Switch - Placing the Primary Power Switch (circuit breaker) located on the rear panel to the ON position energizes the welding power source.

  • Page 27: Setup For Operation

    3.02 Setup for Operation 3.02.1 Selection of Welding Mode WARNING Read and follow all safety precautions on pages 1-5 of this manual before preceding with operation Determination of Welding PROCESS 1. Install and connect unit according to the installation instructions in section 2.04 of this manual.
  • Page 28 6. When you sequence through the welding modes and reach the last mode, the list will wrap back to the top of the list. STICK MODE(DEFAULT) LIFT TIG MODE SCRATCH TIG MODE CARBON ARC CUTTING MIG WELDING Figure 5. Welding Process Flow Chart NOTE Once you turn off the power supply, it records the welding mode at that...

  • Page 29: Shielded Metal Arc Welding (Smaw)

    3.02.2 Shielded Metal Arc Welding (SMAW) WARNING Read and follow all safety precautions on pages 1-5 of this manual before preceding with operation 1. Install and connect unit according to the installation instructions in section 2.04 of this manual. 2. Wear dry insulating gloves and clothing. 3.
  • Page 30 3) Hot Start Sets the hot current time when the arc is initiated. Selectable from10ms to 1000ms (Default 600ms) 4) Hot Cur. Sets the hot current amperage when the arc is initiated. Selectable from 0A to 100A (Default 30A) 5) Arc Control Sets the amount of arc control.
  • Page 31 DOWN SELECT DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT Figure 6. STICK Mode Operation Diagram MANUAL 430429-490 SAVE/LOAD OPERATION...

  • Page 32: Gas Tungsten Arc Welding (Gtaw) Lift Start

    3.02.3 Gas Tungsten Arc Welding (GTAW) Lift Start WARNING Read and follow all safety precautions on pages 1-5 of this manual before preceding with operation 1. Install and connect unit according to the installation instructions in section 2.04 of this manual. 2.
  • Page 33 9. Turn on shielding gas. 10. Wear welding helmet with proper filter lens according to ANSI Z49.1. 11. Place the PRIMARY POWER switch (18) to ON. 12. After power on, push “PROCESS” button and set to “STK” mode. 13. Following the “LIFT TIG Mode Operation Diagram”, set each kind of welding parameter.
  • Page 34 4) Pulse Freq. Sets the desired pulse frequency. This parameter is only displayed and available for modification when the ‘Pulser’ parameter in the previous step is set to ON. Selectable from 0.5Hz to 500Hz (Default 100Hz) 5) Pulse Width Sets the desired pulse width of the peak current. This parameter is only displayed and available for modification when the ‘Pulser’...
  • Page 35 10) Up Slope Sets the desired up slope (rise time) time. This parameter is only displayed and available for modification when the ‘Sloper’ parameter listed previously is set to ON. Selectable from 0 sec. to 60 sec. (Default 3 sec.) 11) Down Slope Sets the desired down slope (fall time) time.
  • Page 36 DOWN SELECT DOWN SELECT SELECT DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT SELECT DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT Figure 7. LIFT TIG Mode Operation Diagram SETUP FOR OPERATION MANUAL 430429-490...

  • Page 37: Gas Tungsten Arc Welding (Gtaw) Scratch Start

    3.02.4 Gas Tungsten Arc Welding (GTAW) Scratch Start WARNING Read and follow all safety precautions on pages 1-5 of this manual before preceding with operation 1. Install and connect unit according to the installation instructions in section 2.04 of this manual. 2.
  • Page 38 9. Turn on shielding gas. 10. Wear welding helmet with proper filter lens according to ANSI Z49.1. 11. Place the PRIMARY POWER switch (18) to ON. 12. After power on, press the “PROCESS” button and set to “SCR” mode. 13. Following “LIFT TIG Mode Operation Diagram”, set each kind of welding parameter.
  • Page 39 4) Pulse Freq. Sets the desired pulse frequency. This parameter is only displayed and available for modification when the ‘Pulser’ parameter listed previously is set to ON. Selectable from 0.5Hz to 500Hz (Default 100Hz) 5) Pulse Width Sets the desired pulse width of the peak current. This parameter is only displayed and available for modification when the ‘Pulser’...
  • Page 40 10) Up Slope Sets the desired up slope (rise time) time. This parameter is only displayed and available for modification when the ‘Sloper’ parameter listed previously is set to ON. Selectable from 0 sec. to 60 sec. (Default 3 sec.) 11) Down Slope Sets the desired down slope (fall time) time.
  • Page 41 DOWN SELECT DOWN SELECT SELECT DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT SELECT DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT DOWN DOWN SELECT Figure SCRATCH Mode Operation Diagram MANUAL 430429-490 SAVE/LOAD OPERATION...

  • Page 42: Carbon Arc Cutting (Cac)

    3.02.5 Carbon Arc Cutting (CAC) WARNING Read and follow all safety precautions on pages 1-5 of this manual before preceding with operation 1. Install and connect unit according to the installation instructions in section 2.04 of this manual. 2. Wear dry insulating gloves and clothing. 3.
  • Page 43 Modifiable Parameters 1) Contactor Selects whether the welding current is ON/OFF. Remote (Default) Current controlled by a remote switch Current available 2) A/V Set the desired welding current with the ‘Amperage/Voltage control’ (1) or with a remote device. PANEL (Default) A/V set with ‘Amperage/voltage control’...

  • Page 44: Gas Metal Arc Welding (Gtaw)

    3.02.6 Gas Metal Arc Welding (GTAW) WARNING Read and follow all safety precautions on pages 1-5 of this manual before preceding with operation 1. Install and connect unit according to the installation instructions in section 2.04 of this manual. 2. Install and connect wire feed system according to its Owners Manual. Connect the wire feeder to the POSITIVE output terminals.
  • Page 45 Modifiable Parameters 1) Contactor Selects whether the welding current is ON/OFF. Remote (Default) Current controlled by a remote switch Current available 2) A/V Set the desired welding current with the ‘Amperage/Voltage control’ (1) or with a remote device. PANEL (Default) A/V set with ‘Amperage/voltage control’...
  • Page 46 DOWN SELECT DOWN SELECT DOWN DOWN SELECT DOWN Figure 10. MIG Mode Operation Diagram SETUP FOR OPERATION MANUAL 430429-490...

  • Page 47: Shutdown Operation

    3.02.7 Shutdown Operation 1. Stop welding. 2. Move the PRIMARY POWER switch (18) to the OFF position. 3. Turn off the shielding gas and water supplies if applicable. MANUAL 430429-490 SAVE/LOAD OPERATION...

  • Page 48: Electrode Selection Guide

    3.02.8 Electrode Selection Guide Table 2. Electrode Selection Table Electrode/Diameter Amperage Range DC-Argon Electrode DC-Argon Electrode Negative/Straight Polarity Positive/Reverse Polarity Pure Tungsten ( Green Band ) 0.010 in. (0.25mm) 1-15 0.020in. (0.51mm) 5-20 0.040in. (1.02mm) 15-80 1/16 in. (1.59mm) 70-150 10-20 3/32 in.

  • Page 49: Save/Load Operation

    4.0 SAVE/LOAD OPERATION 4.01 Outline This welding machine can record the welding parameter into the memory inside the machine. As the occasion demands, it can recall those welding prameters. Characteristics Although you turn off the power, the recorded data will not be deleted. Because of the EEPROM, it does not require batteries, etc.

  • Page 50: Save Operation

    4.02 SAVE Operation The SAVE operation must be performed only when the machine is idling. The machine can be in any mode of operation to SAVE but no welding should be performed during a SAVE operation. To SAVE perform the following steps. 1.

  • Page 51: Load Operation

    4.03 LOAD Operation The LOAD operation can be performed only when the machine is idling. The machine can be in any mode of operation to LOAD but no welding should be performed during a LOAD operation. To LOAD a previously saved program, perform the following steps.

  • Page 52: Save/Load Data

    4.04 SAVE/LOAD Data Parameters accessed during a SAVE/LOAD operation During a SAVE/LOAD operation, all welding parameters are stored/retrieved. For example, if the welder chooses to save a MIG program, all other parameters for other modes of operation such as STK/LFT/SCR/CAC are saved as well. When a SAVEd program is LOADed, all parameters for other modes of operation are loaded as well.
  • Page 53 Parameters that are not accessed during a SAVE/LOAD operation. 1) Weld mode. The weld mode is not saved. The operator, after a LOAD, must press the ‘PROCESS KEY’ (5) until the desired weld mode is displayed in the ‘MODE LED’ (4). 2) Voltage or Current value.

  • Page 54: Initial Parameter Settings

    4.05 Initial Parameter Settings The chart below shows the initial turn on parameters of the machine. Upon subsequent power ups, the machine will automatically load the prior power off conditions. Table 5. Initial Parameter PANEL Hot Start 600ms STICK MODE Hot Cur.

  • Page 55: Basic Troubleshooting

    5.0 BASIC TROUBLESHOOTING General Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage, high power electronic equipment. WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.
  • Page 56 A. No Weld Output; Unit is Completely Inoperative 1. Line disconnect switch is in OFF position. a. Place line disconnect switch in ON position. 2. Linefuse(s) open a. Check and replace line fuse(s). 3. Improper electrical input connections a. See Section 2.04, Electrical Input Requirements, for proper input connections.
  • Page 57 D. Rear Panel 24V or 115V Circuit Breaker(s) Trips 1. Faulty feeder/remote device a.Verify operation of external feeder device and replace if necessary. 2. The wiring of 14pin receptacle is in error. APPENDIX A a. Install and connect 14pin receptacle according to of this manual.

  • Page 58: Error Code List

    5.0 BASIC TROUBLESHOOTING 5.03 Error Code List When you need a service and the following steps do not solve the problem, please call 1- (937)-440-0100 for assistance. Table 6. Error Code Allow the unit to cool for E01 Temp NG Thermal shutdown five minutes...

  • Page 59: Parts List

    Address all inquiries to our authorized Thermal Arc distributor. If a Thermal Arc product must be returned for service, contact your Thermal Arc distributor. Materials returned to Thermal Arc without proper...

  • Page 60: Parts List

    PARTS LISTS Table 7. 400MSTW – 208/230/380/415/460/575V Parts List No.1 DV. No. Description Type & Rating Code No. Order No. Capacitor ECQE12104MZ 42422137100 10-2270 DC1250V 0.1µF C2,3 Capacitor ECW-H10H103JR 42421138400 10-5014 C6,7 Capacitor ECKATS103MF 0.01µF 42442007100 10-2219 Capacitor ECW-H10H683JR 42421138500 10-5013 DC1KV 0.068µF CON1...
  • Page 61 Table 7. 400MSTW – 208/230/380/415/460/575V Parts List No.1 DV. No. Description Type & Rating Code No. Order No. PCB9,10 Printed WK-3367 S02 P0A336702 10-6585 Circuit Board OR WK-3367 P0A336700 IGBT GATE PCB11, Printed WK-3366 S05 P0A336605 10-6586 Circuit Board OR WK-3366 S03 SNUBBER PCB13 Printed...
  • Page 62 Table 8. 400MSTW – 208/230/380/415/460/575V Parts List No.2 Description Type & Rating Code No. Order No. Case Half E0C181200 E0C181200 10-5461 Code Connector SS S-1 31mm 606014302 10-6591 Chassis J2B747600 J2B747600 10-5482 Clip #74 NATURAL 606024220 10-5259 Diode Bus Bar E6A695500, Cu E6A695500 10-5441...

  • Page 63: Appendix A - Remote 14-Pin Connections

    PARTS LISTS ( 400MST 230/460V ) Table 3. 400MST - 230/460V Parts List No.1 DV. No. Description Type & Rating Code No. Order No. Capacitor ECQE12104MZ 42422137100 10-2270 DC1250V 0.1µF C2,3 Capacitor ECW-H10H103JR 42421138400 10-5014 C6,7 Capacitor ECKATS103MF 0.01µF 42442007100 10-2219 Capacitor ECW-H10H683JR...
  • Page 64 Table 3. 400MST - 230/460V Parts List No.1 DV. No. Description Type & Rating Code No. Order No. PCB9,10 Printed WK-3367 S02 P0A336702 10-6585 Circuit Board OR WK-3367 P0A336700 IGBT GATE PCB11,12 Printed WK-3366 S04 P0A336604 10-6617 Circuit Board OR WK-3366 P0A336600 SNUBBER Q1,2 KIT...
  • Page 65 Table 4. 400MST - 230/460V Parts List No.2 Description Type & Rating Code No. Order No. Case Half E0C181200 E0C181200 10-5461 Code Connector SS S-1 31mm 606014302 10-6591 Chassis J2B747600 J2B747600 10-5482 Clip #74 NATURAL 606024220 10-5259 Diode Bus Bar E6A695500, Cu E6A695500 10-5441...
  • Page 66 PARTS LISTS ( 400MST 380/415V ) Table 5. 400MST - 380/415V Parts List No.1 DV. No. Description Type & Rating Code No. Order No. Capacitor ECQE12104MZ 42422137100 10-2270 DC1250V 0.1µF C2,3 Capacitor ECW-H10H103JR 42421138400 10-5014 C6,7 Capacitor ECKATS103MF 0.01µF 42442007100 10-2219 Capacitor ECW-H10H683JR...
  • Page 67 Table 5. 400MST - 380/415V Parts List No.1 DV. No. Description Type & Rating Code No. Order No. PCB11,12 Printed WK-3366 S04 P0A336604 10-6617 Circuit Board OR WK-3366 SNUBBER Q1,2 KIT Transistor CM100DUS12F 600V 100A 43401008500 10-6623 R2,3 Resistor ERG-3ANJ 220 3W 22Ω 40305122000 10-2213 Resistor...
  • Page 68 Table 6. 400MST - 380/415V Parts List No.2 Description Type & Rating Code No. Order No. Case Half E0C181200 E0C181200 10-5461 Code Connector SS S-1 31mm 606014302 10-6591 Chassis J2B747600 J2B747600 10-5482 Clip #74 NATURAL 606024220 10-5259 Diode Bus Bar E6A695500, Cu E6A695500 10-5441...
  • Page 69 PARTS LISTS Table 7. 400MST - 460/575V Parts List No.1 DV. No. Description Type & Rating Code No. Order No. Capacitor ECQE12104MZ 42422137100 10-2270 DC1250V 0.1µF C2,3 Capacitor ECW-H10H103JR 42421138400 10-5014 C6,7 Capacitor ECKATS103MF 0.01µF 42442007100 10-2219 Capacitor ECW-H10H683JR 42421138500 10-5013 DC1KV 0.068µF CON1...
  • Page 70 Table 3. 400MST - 460/575V Parts List No.1 DV. No. Description Type & Rating Code No. Order No. PCB9,10 Printed WK-3367 S02 P0A336702 10-6585 Circuit Board OR WK-3367 P0A336700 IGBT GATE PCB11, Printed WK-3366 S05 P0A336605 10-6586 Circuit Board OR WK-3366 S03 SNUBBER Q1,2 KIT Transistor...
  • Page 71 Table 8. 400MST - 460/575V Parts List No.2 Description Type & Rating Code No. Order No. Case Half E0C181200 E0C181200 10-5461 Code Connector SS S-1 31mm 606014302 10-6591 Chassis J2B747600 J2B747600 10-5482 Clip #74 NATURAL 606024220 10-5259 Diode Bus Bar E6A695500, Cu E6A695500 10-5441...
  • Page 72 REMOTE 14-Pin Connections The REMOTE 14-Pin receptacle is used to connect any of the following equipment to the welding power source circuitry: - Remote Contactor Control - Remote Amperage Control - Wire Feeder (one which provides contactor to welding power source) - Combination of the above To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

  • Page 73: Appendix B - Accesories

    APPENDIX B – ACCESSORIES MANUAL 430429-490 APPENDIX B ACCESORIES...

  • Page 74: Appendix C - Interconnection Diagrams

    400MSTW Interconnection Diagram PCB11 PCB12 C2E1 C2E1 I G B T I n v e r te r (Q 2 ) M C B I G B T I n v e r te r (Q 1 ) C2E1 C2E1 I n p u t D i o d e B r i d g e (D 1 ) PCB9...
  • Page 75 PCB13 OUTPUT FILTER NETWORK Output Voltage Detect Output Voltage Detect Input Voltage Detect Input Voltage Detect +12VDC -12VDC Output Current Detect 0V to -4V Ground Terminal Output Detect Terminal Output Detect OK To Move OK To Move PCB5 Remote Potentiometer Min Output Current Monitor Output Voltage Monitor Remote Potentiometer Max...
  • Page 76 400MST ( 230/460V ) Interconnection Diagram PCB11 PCB12 C2E1 C2E1 I G B T I n v e r te r (Q 2 ) M C B I G B T I n v e r te r (Q 1 ) C2E1 C2E1 I n p u t D i o d e...
  • Page 77 OUTPUT FILTER NETWORK Output Voltage Detect Output Voltage Detect Input Voltage Detect Input Voltage Detect +12VDC -12VDC Output Current Detect 0V to -4V Ground Terminal Output Detect Terminal Output Detect OK To Move OK To Move PCB5 Remote Potentiometer Min Output Current Monitor Output Voltage Monitor Remote Potentiometer Max...
  • Page 78 400MST ( 380/415V ) Interconnection Diagram PCB11 PCB12 C2E1 C2E1 I G B T I n v e r te r (Q 2 ) M C B I G B T I n v e r te r (Q 1 ) C2E1 C2E1 I n p u t D i o d e...
  • Page 79 OUTPUT FILTER NETWORK Output Voltage Detect Output Voltage Detect Input Voltage Detect Input Voltage Detect +12VDC -12VDC Output Current Detect 0V to -4V Ground Terminal Output Detect Terminal Output Detect OK To Move OK To Move PCB5 Remote Potentiometer Min Output Current Monitor Output Voltage Monitor Remote Potentiometer Max...
  • Page 80 400MST ( 460/575V ) Interconnection Diagram PCB11 PCB12 C2E1 C2E1 I G B T I n v e r te r (Q 2 ) M C B I G B T I n v e r te r (Q 1 ) C2E1 C2E1 I n p u t D i o d e...
  • Page 81 OUTPUT FILTER NETWORK Output Voltage Detect Output Voltage Detect Input Voltage Detect Input Voltage Detect +12VDC -12VDC Output Current Detect 0V to -4V Ground Terminal Output Detect Terminal Output Detect OK To Move OK To Move PCB5 Remote Potentiometer Min Output Current Monitor Output Voltage Monitor Remote Potentiometer Max...

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