Tweco ARCMASTER 401S Operating Manual
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Tweco ARCMASTER 401S Operating Manual

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ARCMASTER
401S
Operating
Manual
Art # A-12546_AB
Revision: AC
Issue Date: November 11, 2014 Manual No.: 0-5345
3163339
Tweco.com

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Summary of Contents for Tweco ARCMASTER 401S

  • Page 1 ARCMASTER 401S Operating Manual Art # A-12546_AB Revision: AC Issue Date: November 11, 2014 Manual No.: 0-5345 3163339 Tweco.com...
  • Page 2 We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done. For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5345 for: Tweco ArcMaster 401S Power Source Part Number W1009100 Published by: Victor Technologies, Inc.

  • Page 4: Table Of Contents

    High Frequency Introduction ................3-3 3.06 High Frequency Interference ................3-4 3.07 Electromagnetic Compatibility ................ 3-4 3.08 ArcMaster 401S Power Source Controls, Indicators and Features ....3-6 3.09 Welding Parameters ..................3-10 3.10 Setup for TIG (GTAW) Welding ..............3-12 3.11 Setup for STICK (SMAW) Welding ..............
  • Page 5 TABLE OF CONTENTS SECTION 6: KEY SPARE PARTS ................... 6-1 6.01 401S Power Source Spare Parts ..............6-1 APPENDIX A: CIRCUIT DIAGRAM ................ A-1 TWECO - LIMITED WARRANTY TERMS ..........iNSIDE REAR COVER...
  • Page 6 This Page Intentionally Blank...

  • Page 7: Safety Instructions And Warnings

    ARCMASTER 401S POWER SOURCE 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 401S POWER SOURCE 2. Wear approved safety glasses. Side shields recommended. 3. Use protective screens or barriers to protect others WARNING from flash and glare; warn others not to watch the ARC RAYS can burn eyes and skin; NOISE arc.
  • Page 9 ARCMASTER 401S POWER SOURCE 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from FUMES AND GASES can be hazardous to welding can easily go through small cracks and your health.
  • Page 10 ARCMASTER 401S POWER SOURCE 4. Never allow a welding electrode to touch any cylinder. WARNING 5. Use only correct shielding gas cylinders, flowmeters/ regulators, hoses, and fittings designed for the MOVING PARTS can cause injury. specific application; maintain them and associated Moving parts, such as fans, rotors, and belts can cut parts in good condition.
  • Page 11 ARCMASTER 401S POWER SOURCE 1. Do not remove radiator cap when engine is hot. Allow engine to cool. 2. Wear gloves and put a rag over cap area when ABOUT PACEMAKERS: removing cap. The above procedures are among those 3. Allow pressure to escape before completely also normally recommended for pacemaker removing cap.

  • Page 12: Principal Safety Standards

    ARCMASTER 401S POWER SOURCE 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 13: Symbol Chart

    ARCMASTER 401S POWER SOURCE 1.03 Symbol Chart Note that only some of these symbols will appear on your model. Single Phase Wire Feed Function Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun...
  • Page 14 ARCMASTER 401S POWER SOURCE This Page Intentionally Blank SAFETY INSTRUCTIONS AND WARNINGS Manual 0-5345...

  • Page 15: Introduction

    ARCMASTER 401S POWER SOURCE SECTION 2: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification To ensure safe operation, read the entire manual, includ- The unit’s identification number (specification or part ing the chapter on safety instructions and warnings.

  • Page 16: Description

    ARCMASTER 401S POWER SOURCE 2.04 Description 2.06 Transporting Methods The Tweco ArcMaster 401S is a welding power source incorporating to provide TIG, Stick and Gouging weld- Disconnect input power con- ing process. ductors from de-energized supply line before moving The units are also fully compliant to CSA E 60974-1 the welding Power Source.

  • Page 17: Duty Cycle

    ARCMASTER 401S POWER SOURCE 2.08 Duty Cycle The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated weld- ing current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used.

  • Page 18: Specifications

    ARCMASTER 401S POWER SOURCE 2.10 Specifications Description ArcMaster 401S Power Source Part Number W1009100 Power Source Mass 51lb (23kg) Power Source Dimensions 16.5"(H) x 8.3"(W) x 17.7(D) H420mm x W210mm x D450mm Cooling Fan Cooled Welder Type Inverter Power Source...
  • Page 19 Due to large variations in performance and specifications of different brands and types of generators, Tweco cannot guarantee full welding output power or duty cycle on every brand or type of generator. Tweco recommends that when selecting a generator, that the particular power source / generator com- bination be adequately tested to ensure the combination performs to the users expectations.
  • Page 20 ARCMASTER 401S POWER SOURCE This Page Intentionally Blank INTRODUCTION Manual 0-5345...

  • Page 21: Installation, Operation And Setup

    ARCMASTER 401S POWER SOURCE SECTION 3: INSTALLATION, OPERATION AND SETUP exceed the stated conditions. For further information 3.01 Environment please refer to EN 60529. These units are designed for use in environments with H. Precautions must be taken against the power source increased hazard of electric shock as outlined in EN toppling over.
  • Page 22 ARCMASTER 401S POWER SOURCE WARNING 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 23: High Frequency Introduction

    ARCMASTER 401S POWER SOURCE Welding Power Source Ground Conductor Ground Terminal Line Disconnect Switch Line Fuse Primary Power Cable Art # A-12451 Figure 3-1 Electrical Input Connections 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.

  • Page 24: High Frequency Interference

    ARCMASTER 401S POWER SOURCE below. In other cases it could involve constructing 3.06 High Frequency Interference an electromagnetic screen enclosing the Welding Power Source and the work, complete with Interference may be transmitted by a high frequency associated input filters. In all cases, electromagnetic...
  • Page 25 ARCMASTER 401S POWER SOURCE C. Methods of Reducing Electromagnetic Emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece 1. Main Power Supply increasing the risk of injury to users, or damage to other electrical equipment.

  • Page 26: Arcmaster 401S Power Source Controls, Indicators And Features

    ARCMASTER 401S POWER SOURCE 3.08 ArcMaster 401S Power Source Controls, Indicators and Features Art # A-12453_AB Figure 3-2 INSTALLATION, OPERATION AND SETUP Manual 0-5345...
  • Page 27 ARCMASTER 401S POWER SOURCE 1 VRD (Voltage Reduction Device) Indicator Lights A VRD (voltage reduction device) is a hazard reducing device designed to reduce electric shock hazards present on the output of welding power source when operating in SMAW (STICK) mode. Note that the presence of VRD should not be used as a substitute for the use of appropriate safety practices as indicated in section one of this manual.
  • Page 28 ARCMASTER 401S POWER SOURCE Lift TIG (GTAW)- The Process light is illuminated. The Stick function has two modes: Stick (SMAW)- The Process light is illuminated; Arc Gouging (CAC-A)- The Process light is blinking. 6010 vertical up (SMAW)- The Process light is illuminated; 6010 Vertical down (SMAW)- the light is blinking.
  • Page 29 ARCMASTER 401S POWER SOURCE 11 14 Pin Remote Control Socket The 14 pin Remote Control Socket is used to connect Remote Control devices to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

  • Page 30: Welding Parameters

    ARCMASTER 401S POWER SOURCE 3.09 Welding Parameters Parameter Description This parameter provides an adjustable short circuit current in STICK welding to improve electrode sticking and arc stability Arc Force This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes.
  • Page 31 ARCMASTER 401S POWER SOURCE ARC FORCE CONTROL This parameter encoder controls in STICK mode only and is used to adjust percentage increase in welding current and is proportional to arc length (arc voltage). This control provides an adjustable amount of arc control (or dig).

  • Page 32: Setup For Tig (Gtaw) Welding

    ARCMASTER 401S POWER SOURCE 3.10 Setup for TIG (GTAW) Welding For TIG welding a TIG torch with valve is required for this power source. A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.

  • Page 33: Setup For Stick (Smaw) Welding

    ARCMASTER 401S POWER SOURCE Graphic for TIG Current Welding current Hot start current Short circuit Time Hot start Art # A-12456 Figure 3-5 TIG Current Routing Diagram Positive Welding Terminal (+) Work Lead Negative Welding Terminal (-) Art # A-12554...
  • Page 34 ARCMASTER 401S POWER SOURCE WARNING Before connecting the work clamp to the workpiece make sure the mains power supply is switched off. D. Select STICK mode by pressing Process Selection Button until the STICK or 6010 Process LEDs are lit.

  • Page 35: Special Function

    ARCMASTER 401S POWER SOURCE 3.12 Special Function Contactor Control Parameter Selection Button Remote Control Art # A-12547_AB Encoder Control Process Selection Button Figure 3-9 Gouging and 6010 Vertical Down There are two special functions that can be accessed by pressing the selection button for 2 seconds: Gouging and 6010 Vertical Down.

  • Page 36: Shielding Gas Flowmeter/ Regulator Operating Instructions

    ARCMASTER 401S POWER SOURCE 3.13 Shielding Gas Flowmeter/ Regulator Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Flowmeter/ Regulator Safety Designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 37 ARCMASTER 401S POWER SOURCE NOTE The flowmeter/ regulator used with argon based and carbon dioxide shielding gases are different. The flowmeter/ regulator supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide flowmeter/ regulator will need to be fitted.
  • Page 38 ARCMASTER 401S POWER SOURCE With the flowmeter/ regulator ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate. NOTE It may be necessary to re-check the shielding gas flowmeter/ regulator flow rate following the first weld sequence due to back pressure present within shielding gas hose assembly.

  • Page 39: Basic Welding Guide

    Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited Tweco Distributor. Effects of Arc Welding Various Materials A.
  • Page 40 ARCMASTER 401S POWER SOURCE Welding Position The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these.
  • Page 41 ARCMASTER 401S POWER SOURCE Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
  • Page 42 ARCMASTER 401S POWER SOURCE clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.
  • Page 43 ARCMASTER 401S POWER SOURCE Making Welded Joints Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints. A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 4-11, allowing 1/16" to 3/32" gap between them and tack weld at both ends.
  • Page 44 ARCMASTER 401S POWER SOURCE from the perpendicular position to prevent slag accumulate in the centre of the weld. Figure from running ahead of the weld. Refer to Figure 4-16 illustrates multi-run technique and Figure 4-13. Do not attempt to build up much larger than...
  • Page 45 ARCMASTER 401S POWER SOURCE 2. Vertical Down The electrode makes welding in this position particularly easy. Use a electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag.
  • Page 46 ARCMASTER 401S POWER SOURCE cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal.
  • Page 47 ARCMASTER 401S POWER SOURCE Art # A-07707 Figure 4-21: Principle of Presetting Art # A-07428_AB Figure 4-26: Chain Intermittent Welding Art # A-07708 Art # A-07713_AB Preheat Preheat Weld Dotted lines show effect if no preheat is used Figure 4-22: Reduction of Distortion by Preheating...

  • Page 48: Stick (Smaw) Welding Troubleshooting

    ARCMASTER 401S POWER SOURCE 4.02 Stick (SMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE parameter is Reduce the ARC FORCE parameter until welding fluctuations set at a value that causes current is reasonably constant while prohibit- the welding current to vary...
  • Page 49 ARCMASTER 401S POWER SOURCE FAULT CAUSE REMEDY 4 A groove has been A Welding current is too A Reduce welding current. formed in the base high. metal adjacent to B Welding arc is too long. B Reduce the length of the welding arc.

  • Page 50: Tig (Gtaw) Basic Welding Technique

    ARCMASTER 401S POWER SOURCE FAULT CAUSE REMEDY 7 Crack occurring in A Rigidity of joint. A Redesign to relieve weld joint of severe stresses weld metal soon or use crack resistance electrodes. after solidification B Insufficient throat thick- B Travel slightly slower to allow greater build up in commences ness.
  • Page 51 ARCMASTER 401S POWER SOURCE Tungsten Electrode Current Ranges Electrode Diameter DC Current (Amps) 0.040” (1.0mm) 30-60 1/16” (1.6mm) 60-115 3/32” (2.4mm) 100-165 1/8” (3.2mm) 135-200 5/32” (4.0mm) 190-280 3/16” (4.8mm) 250-340 Table 4-2: Current Ranges for Various Tungsten Electrode Sizes...

  • Page 52: Tig (Gtaw) Welding Problems

    TIG Welding is generally regarded as a specialized process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www.tweco.com or contact Tweco.
  • Page 53 9 Arc start is not smooth. A Tungsten electrode is A Select the right size tungsten electrode. too large for the weld- Refer to Table 4-3 Tweco Tungsten Elec- ing current. trode Selection Chart. B The wrong electrode B Select the right tungsten electrode type.
  • Page 54 ARCMASTER 401S POWER SOURCE This Page Intentionally Blank BASIC WELDING GUIDE 4-16 Manual 0-5345...

  • Page 55: Power Source Problems And Routine Service Requirements

    If major complex subassemblies are faulty, then the Welding Power Source must be returned to an accredited Tweco Service Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge. Refer also to section 4 for solving welding problems.

  • Page 56: Power Source Status Messages

    There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited Tweco Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
  • Page 57 ARCMASTER 401S POWER SOURCE Code Error Cause Possible Remedy Output Voltage Voltage measuring system Take to an accredited Tweco Service faulty Center for repair Power Section Power section start-up faulty Take to an accredited Tweco Service Center for repair Temperature Sensor...

  • Page 58: Routine Inspection, Testing & Maintenance

    The inspection and testing of the power source and associated accessories shall be carried out by a licensed elec- trician. Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Tweco original specifications. A. Testing Schedule 1.

  • Page 59: Key Spare Parts

    ARCMASTER 401S POWER SOURCE SECTION 6: KEY SPARE PARTS 6.01 401S Power Source Spare Parts Art # A-12460_AB Figure 6-1 ArcMaster 401S Spare Parts ArcMaster 401S Spare Parts Item Description Des. Ref. Quantity Part Number Side Panel Left W7006700 Side Panel Right...
  • Page 60 D1, D2, D3 W7006740 Unit Thermal Sensor W7006741 Cooling Fan W7006742 Label +/- Tweco W7006744 Label 401S W7006750 Warning Sticker W7006746 Sticker Tweco 261 x 93 (not shown) W7006748 Table 6-1 ArcMaster 401S Spart Parts KEY SPARE PARTS Manual 0-5345...
  • Page 61 ARCMASTER 401S POWER SOURCE APPENDIX A: CIRCUIT DIAGRAM Manual 0-5345 APPENDIX...
  • Page 62 “Purchaser” 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 Tweco products as stated below, Tweco shall, upon notification thereof and substantiation that the product has been stored, installed, oper- ated, and maintained in accordance with Tweco’s specifications, instructions, recommendations and recognized...

  • Page 63: Warranty Schedule

    WARRANTY SCHEDULE 5 Years Parts* / 3 Years Labor ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster Portafeed, Ultrafeed, Ultima 150, WC 100B * 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards. * 3 years on Power Supply Components 2 Years Parts and Labor Unless specified Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy Victor Regulator for Fabricator 141i (No labor)
  • Page 64 THE AMERICAS Denton, TX USA U.S. Customer Care Ph 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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