Thermal Arc ARCMASTER 400S Operating Manual
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Thermal Arc ARCMASTER 400S Operating Manual

Inverter arc welder
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400 S
Operating Manual
ARCMASTER
INVERTER ARC WELDER
Version No: 1
Operating Features:
SMAW
GTAW
CAG
®
Issue Date: March 31, 2006
CC DC
50
INVERTER
1/3
Hz
60
PHASE
Manual No: 0-4857
460
V
208
230
V
V

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Summary of Contents for Thermal Arc ARCMASTER 400S

  • Page 1 400 S ® ARCMASTER INVERTER ARC WELDER Operating Manual Version No: 1 Issue Date: March 31, 2006 Manual No: 0-4857 Operating Features: CC DC INVERTER PHASE SMAW GTAW...
  • Page 2 800-752-7621, 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.
  • Page 3 WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Instruction Manual Number 0-4857 for: ArcMaster 400 S Inverter Welding Power Supply Part No.

  • Page 4: Table Of Contents

    ARCMASTER 400 S Table of Contents SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ..........1-1 1.01 Arc Welding Hazards .................1-1 1.02 Principal Safety Standards ................1-4 1.03 Precautions De Securite En Soudage A L’arc ..........1-5 1.04 Dangers relatifs au soudage à l’arc ............1-5 1.05 Principales Normes De Securite ...............1-8 SECTION 2: INTRODUCTION AND DESCRIPTION ............
  • Page 5 ARCMASTER 400 S SECTION 7: BASIC TIG WELDING GUIDE ..............7-1 7.01 Electrode Polarity ..................7-1 7.02 Tungsten Electrode Current Ranges ............7-1 7.03 Tungsten Electrode Types .................7-1 7.04 Guide for Selecting Filler Wire Diameter ...........7-1 7.05 Shielding Gas Selection ................7-2 7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe .....7-2 SECTION 8: BASIC ARC WELDING GUIDE ..............
  • Page 6 ARCMASTER 400 S March 31, 2006...

  • Page 7: Safety Instructions And Warnings

    ARCMASTER 400 S SECTION 1: 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 400 S 1. Protect yourself and others from fl ying sparks and hot metal. 2. Do not weld where fl ying sparks can strike fl ammable material. 3. Remove all fl ammables within 35 ft (10.7 m) of the welding arc. If this WARNING is not possible, tightly cover them with approved covers.
  • Page 9 ARCMASTER 400 S 3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job. WARNING 4. Do not overfi ll tank — allow room for fuel to expand. 5. Do not spill fuel. If fuel is spilled, clean up before starting engine. CYLINDERS can explode if damaged.

  • Page 10: Principal Safety Standards

    ARCMASTER 400 S 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding WARNING Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of This product, when used for welding or cutting, produces Documents, U.S.

  • Page 11: Precautions De Securite En Soudage A L'arc

    ARCMASTER 400 S 1.03 Precautions De Securite En Soudage A 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. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
  • Page 12 ARCMASTER 400 S 4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) bien ventilé; si nécessaire portez un respirateur à adduction d’air. et des chaussures de sécurité. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.
  • Page 13 ARCMASTER 400 S 8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie. 9. Ne dégelez pas les tuyaux avec un source de courant. AVERTISSEMENT 10.

  • Page 14: Principales Normes De Securite

    ARCMASTER 400 S 6. Réinstallez les capots ou les protecteurs et fermez les portes après 1.05 Principales Normes De Securite des travaux d’entretien et avant de faire démarrer le moteur. Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W.

  • Page 15: Introduction And Description

    Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identifi cation numbers.

  • Page 16: Symbol Chart

    ARCMASTER 400 S 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas...

  • Page 17: Description

    2.05 Description The Thermal Arc™ Model ARCMASTER 400 S is a self contained single/three-phase DC arc welding power source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter and lift arc starter for use with Gas Tungsten Arc Welding (GTAW) and Shielded Metal Arc Welding (SMAW) processes.

  • Page 18: Transporting Methods

    ARCMASTER 400 S 2.07 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 the welding power source. WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage.

  • Page 19: Installation Recommendations

    Do not connect the ground (GREEN) conductor to an input cooling. line terminal. WARNING Thermal Arc advises that this equipment be electrically connected by a qualifi ed electrician. March 31, 2006...
  • Page 20 ARCMASTER 400 S Refer to fi gure 3 and: 1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes. 2. Connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors to a de-energized line disconnect switch.
  • Page 21 230/57 460/29 208/49 8/4 AWG minimum 400A @ 230/44 (Factory Fitted) Phase 460/22 208/67 230/61 400A @ 25% MASTER 400S 460/31 208/88 300A @ 230/79 208/67 300A @ 8/3 AWG minimum Phase 230/60 208/97 300A @ 25% 230/87 Table 2 – 208-230/460V Primary Current Circuit sizes to achieve maximum current •...

  • Page 22: Specifi Cations

    208V 230V Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifi cations or design of this or any product without prior notice. Such updates or changes do...

  • Page 23: Duty Cycle

    ARCMASTER 400 S not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items. The values specifi ed in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifi...
  • Page 24 ARCMASTER 400 S March 31, 2006...

  • Page 25: Operator Controls

    ARCMASTER 400 S SECTION 4: OPERATOR CONTROLS 4.01 ARCMASTER 400 S Controls Figure 4 – ARCMASTER 400 S Power Source 2. Remote Control Socket 1. Control Knob The 14 pin Remote Control Socket is used to connect This control sets the selected weld parameter, rotating it remote current control devices to the welding Power clockwise increases the parameter that is indicated on Source.
  • Page 26 ARCMASTER 400 S Socket Pin Function Torch Switch Input (24V) to energize weld current. (connect pins A & B to turn on welding current) Torch Switch Input (0V) to energize weld current (connect pins A & B to turn on welding current) 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...

  • Page 27: Weld Parameter Description

    ARCMASTER 400 S 4.02 Weld Parameter Description Figure 5 - ARCMASTER 400 S Front Panel with Parameter Description This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes. e.g. low hydrogen HOT START electrodes.

  • Page 28: Weld Parameters For Arcmaster 400 S

    ARCMASTER 400 S 4.03 Weld Parameters for ARCMASTER 400 S Weld Mode Weld Factory Incremental Parameter Parameter Range Setting Unit STICK LIFT TIG HOT START 0 to 70A WELD CUR 5 to 400A DC ARC CONTROL 0 to 100% 4.04 Power Source Features Feature Description New Digital Control...

  • Page 29: Set-Up For Smaw (Stick) And Gtaw (Tig)

    ARCMASTER 400 S SECTION 5: SET-UP FOR SMAW (STICK) AND GTAW (TIG) 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.
  • Page 30 ARCMASTER 400 S March 31, 2006...

  • Page 31: Sequence Of Operation

    ARCMASTER 400 S SECTION 6: SEQUENCE OF OPERATION NOTE: Scroll 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.
  • Page 32 ARCMASTER 400 S March 31, 2006...

  • Page 33: Basic Tig Welding Guide

    ARCMASTER 400 S SECTION 7: BASIC TIG WELDING GUIDE 7.01 Electrode Polarity Connect the TIG torch to the - / TORCH 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.

  • Page 34: Shielding Gas Selection

    ARCMASTER 400 S 7.05 Shielding Gas Selection Alloy Shielding Gas Aluminium & alloys Argon Carbon Steel Argon Stainless Steel Argon Nickel Alloy Argon Copper Argon Titanium Argon Table 7 – Shielding gas selection 7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe Electrode Type &...

  • Page 35: Basic Arc Welding Guide

    ARCMASTER 400 S SECTION 8: BASIC ARC WELDING GUIDE 8.01 Electrode Polarity Cast Iron Most types of cast iron, except white iron, are weldable. Stick electrodes are generally connected to the ‘+’ terminal White iron, because of its extreme brittleness, generally and the work lead to the ‘-’...
  • Page 36 ARCMASTER 400 S March 31, 2006...

  • Page 37: Routine Maintenance

    ARCMASTER 400 S SECTION 9: 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. WARNING Disconnect primary power at the source before opening the enclosure.
  • Page 38 6 Months Bring the unit to an authorized Thermal Arc Service Center to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions.

  • Page 39: Basic Troubleshooting

    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.
  • Page 40 ARCMASTER 400 S Description Possible Cause Remedy Electrode melts or oxidizes when A. No gas fl owing to welding region. A. Check the gas lines for kinks or an arc is struck. breaks and gas cylinder contents. B. Torch is clogged with dust. B.

  • Page 41: Stick Welding Problems

    ARCMASTER 400 S 10.02 Stick Welding Problems Description Possible Cause Remedy 1. Gas pockets or voids in weld metal Electrodes are damp. Dry electrodes before use. (Porosity). Welding current is too high. Reduce welding current. Surface impurities such as oil, Clean joint before welding.

  • Page 42: Power Source Problems

    The Welding Power Source switch Switch ON the Welding Power Source. is switched OFF. C. Loose connections internally. Have an Accredited Thermal Arc Service Agent repair the connection. 2. Maximum output welding Defective control circuit Have an Accredited Thermal Arc Service current can not be achieved Agent inspect then repair the welder.

  • Page 43: Voltage Reduction Device (Vrd)

    For transportable equipment, at least once every 3 the VRD fi tted to this machine, the following periodic tests months; and should also be conducted by an accredited Thermal Arc b) For fi xed equipment, at least once every 12 months. service agent.

  • Page 44: Switching Vrd On/Off

    ARCMASTER 400 S 11.03 Switching VRD On/Off Switch the machine Off. a) Remove the clear plastic cover from the control panel (see Figure 11). • Lift up the cover so it rests on the top of the unit. • Place a small fl at bladed screw driver between the cover hinge on the front panel. •...
  • Page 45 ARCMASTER 400 S Figure 12 VRD ON/OFF Step B,C WARNING 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. Figure 13 VRD ON/OFF Step D March 31, 2006 11-3...
  • Page 46 ARCMASTER 400 S 11-4 March 31, 2006...

  • Page 47: Power Source Error Codes

    ARCMASTER 400 S SECTION 12: POWER SOURCE ERROR CODES March 31, 2006 12-1...
  • Page 48 ARCMASTER 400 S 12-2 March 31, 2006...
  • Page 49 ARCMASTER 400 S March 31, 2006 12-3...

  • Page 50: Interconnect Diagram

    ARCMASTER 400 S APPENDIX A: INTERCONNECT DIAGRAM TB13 TB10 TB14 TB11 TB15 TB12 PC B 1 K(7) M ain PC B 8 PC B 10 C ircuitB ord G(6) IGB TGate IGB TGate [W K-5493] C ircuitB ord C ircuitB ord R(3) [W K-5479] [W K-5479]...
  • Page 51 ARCMASTER 400 S PC B 15 DIODE Snubber C ircuit B ord [W K-5606] PC B 14 TR ANS B ord [W K-5594] 1 2 3 TB35 +Output Terminal HC T1 TB33 TB21 TB34 C T2 TB30 TB16 TB16 1 2 3 4 5 Ground TB32 RY+15V...
  • Page 52 ARCMASTER 400 S March 31, 2006...

  • Page 53: Options And Accessories

    ARCMASTER 400 S Appendix B: OPTIONS AND ACCESSORIES PRODUCT PART NO. DESCRIPTION Stick Kit 10-4082A Work lead with 25’ #1 cable, and stick electrode holder with 25’ #1 cable TIG Kit 10-4080 Includes regulator/fl owgauge, 12.5ft 200 Amp TIG torch with valve, accessory kit includes 1 ea of 0040”x7”, 1/16”x7”, 3/32”x7”...

  • Page 54: 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 55 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...
  • Page 57 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne Asia Sdn Bhd Thermadyne USA Lot 151, Jalan Industri 3/5A 2800 Airport Road Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA Telephone: (940) 566-2000 48000 Rawang Selangor Darul Ehsan 800-426-1888 West Malaysia Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 58 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...

This manual is also suitable for:

Arcmaster 300 s

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