Summary of Contents for Thermal Arc ARCMASTER 300 AC/DC
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300 AC/DC ® ARCMASTER INVERTER ARC WELDER Art # A-07238 Operating Manual Version No: 1 Issue Date: February 22, 2006 Manual No.: 0-4863 Operating Features: INVERTER...
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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.
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While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. ArcMaster 300 AC/DC Inverter Arc Welder Instruction Manual Number 0-4863 for: Part Number 10-3074 Published by:...
TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............1-1 1.01 Arc Welding Hazards ..................1-1 1.02 Principal Safety Standards ................1-5 1.03 Precautions de Securite en Soudage à L’Arc ..........1-6 1.04 Dangers Relatifs au Soudage à L’Arc .............. 1-6 1.05 Principales Normes de Securite ..............
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TABLE OF CONTENTS (continued) TABLE OF CONTENTS SECTION 6: SEQUENCE OF OPERATION ................ 6-1 6.01 Stick Welding ....................6-3 6.02 AC or DC HF TIG Welding ................6-3 6.03 Slope Mode Sequence ..................6-4 6.04 Slope Mode with repeat sequence ..............6-4 6.05 Pulse Controls ....................
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TABLE OF CONTENTS SECTION 13: PARTS LIST ..................13-1 13.01 ..................Equipment Identification 13.02 ................. How To Use This Parts List LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......Inside Rear Cover...
ARCMASTER 300 ACDC 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. Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
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ARCMASTER 300 ACDC 11. Do not touch electrode while in contact with the work 4. Wear protective clothing made from durable, flame- (ground) circuit. resistant material (wool and leather) and foot protection. 12. Use only well-maintained equipment. Repair or replace damaged parts at once.
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ARCMASTER 300 ACDC 6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can WARNING react with vapors to form highly toxic and irritating gases. FLYING SPARKS AND HOT METAL can cause 7.
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ARCMASTER 300 ACDC 4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery. WARNING 5. Keep hands, hair, loose clothing, and tools away from moving parts. Engines can be dangerous. 6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.
ARCMASTER 300 ACDC 1.02 Principal Safety Standards WARNING Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, This product, when used for welding or FL 33126. cutting, produces fumes or gases which contain chemicals know to the State of Safety and Health Standards, OSHA 29 CFR 1910, from California to cause birth defects and, in some...
ARCMASTER 300 ACDC 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).
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ARCMASTER 300 ACDC 10. N’utilisez qu’une bonne prise de masse pour la mise à 1. Portez une casque de soudeur avec filtre oculaire de la terre de la pièce à souder. nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les 11.
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ARCMASTER 300 ACDC 1. Eloignez la tête des fumées pour éviter de les respirer. 1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud. 2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont 2.
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ARCMASTER 300 ACDC 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. AVERTISSEMENT 2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment. LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT...
ARCMASTER 300 ACDC 4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative. AVERTISSEMENT 5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils. VAPEUR LIQUIDE REFROIDISSEMENT BRULANT SOUS...
Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
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ARCMASTER 300 ACDC 1-12 February 22, 2006...
Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link: http://www.thermalarc.com February 22, 2006...
ARCMASTER 300 ACDC 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...
ARCMASTER 300 ACDC 2.05 Description The Thermal Arc™ Model 300 ACDC is a self contained Art # A-04980 single-phase AC/DC arc welding power source with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter, gas...
ARCMASTER 300 ACDC 2.06 Functional Block Diagrams Figure 2-2 illustrates the functional block diagram of the 300 ACDC-power supply. Art # A-04981 Figure 2-2: 300 ACDC Model Functional Block Diagram 2.07 Transporting Methods These units are equipped with a handle for carrying •...
· In areas, not exposed to direct sunlight or rain. · Place at a distance of 12" (304.79mm) or more from walls or similar boundaries that could restrict natural airflow for cooling. WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician. Februrary 22, 2006...
ARCMASTER 300 ACDC 3.04 Electrical Input Requirements Do not connect an input (WHITE or BLACK) conductor to the ground terminal. Operate the welding power source from a single-phase Do not connect the ground (GREEN) conductor to an input 50/60 Hz, AC power supply. The input voltage must match line terminal.
ARCMASTER 300 ACDC 3.05 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT 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).
ARCMASTER 300 ACDC 3.07 High Frequency Interference 3.08 Duty Cycle Interference may be transmitted by a high frequency The duty cycle of a welding power source is the percentage initiated or stabilized arc welding machine in the following of a ten (10) minute period that it can be operated at a ways: given output without causing overheating and damage to the unit.
ARCMASTER 300 ACDC SECTION 4: OPERATOR CONTROLS 4.01 ArcMaster 300 ACDC Controls Art # A-04983 Figure 4-1: ArcMaster 300 ACDC Power Source 1. Control Knob: This control sets the selected weld Socket Pin Function parameter, rotating it clockwise increases the parameter Earth (Ground) that is indicated on the digital meter.
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ARCMASTER 300 ACDC 3. Positive Terminal: Welding current flows from the 6. ON/OFF Switch: This switch connects the Primary Power Source via heavy duty Dinse type terminal. It supply voltage to the inverter when in the ON position. is essential, however, that the male plug is inserted This enables the Power Supply.
ARCMASTER 300 ACDC 4.02 Weld Process Selection for ArcMaster 300 ACDC Weld Mode Weld STICK HF TIG LIFT TIG Process Selection Description 2T operation in TIG Modes using remote devices to control contactor & current 4T operation in TIG Modes with crater fill using a remote contactor device to control sequence.
ARCMASTER 300 ACDC 4.03 Weld Parameter Descriptions for ArcMaster 300 ACDC Art # A-04985 Figure 4-3: ArcMaster 300 ACDC Front Panel Parameter Description This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc, once the torch trigger switch has been pressed.
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ARCMASTER 300 ACDC PEAK CUR. PULSE This parameter sets the PEAK weld current when in mode WELD SLOPE REPEAT This parameter sets the TIG WELD current in SPOT PULSE modes when is off. This parameter also sets the STICK weld current. This parameter sets the Background current when in Pulse TIG mode.
ARCMASTER 300 ACDC 4.05 Power Source Features Feature Description New Digital Control · Almost all welding parameters are adjustable Touch Panel Switches · Touch switches eliminate mechanical damage Front Control Cover · Protects front panel controls · Displays selected weld parameter value Digital Meter · ...
ARCMASTER 300 ACDC 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 Art # A-04986 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.
ARCMASTER 300 ACDC 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 the Symbols Table located in the front of the manual for Symbol descriptions.
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ARCMASTER 300 ACDC Art # A-04988 Figure 6-1b: 300 ACDC Front Panel 1. Pulse function: Pressing this button enables the TIG 5. Control knob: allows the operator to adjust the output current pulse functions. amperage within the entire range of the power source, also used to set each parameter value.
ARCMASTER 300 ACDC 6.01 Stick Welding 6.02 AC or DC HF TIG Welding · Connect work lead to negative terminal · Connect work lead to positive terminal · Connect electrode lead to positive terminal · Connect TIG torch to negative terminal ·...
ARCMASTER 300 ACDC 6.03 Slope Mode Sequence Art # A-04989 Switch Switch Switch Switch Closed Closed Open Open Weld Current Down Slope Slope Initial Final Current Current Postflow Preflow Figure 6-2: Slope Mode Sequence 1. To start Slope sequence Close remote switch contacts. 2.
ARCMASTER 300 ACDC 6.05 Pulse Controls (Pulse Width) (Pulse Frequency) Art # A-04990 (Peak Current) (Base) Background Current Figure 6-3: Pulse Controls The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows: 1) Control puddle –...
ARCMASTER 300 ACDC SECTION 7: BASIC TIG WELDING GUIDE 7.01 Explanation of “Fluttery Arc” when This idea is supported by the observation that once fluttering starts it can be made to stop by working the arc AC TIG Welding on Aluminum away from the mirror like weld pool to an area of oxide coated material.
ARCMASTER 300 ACDC 7.02 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.
ARCMASTER 300 ACDC 7.05 Guide for Selecting Filler Wire Diameter NOTE The filler wire diameter specified in Table 7-4 is a guide only, other diameter wires may be used according to the welding application AC Current Range DC Current Range Filler Wire Diameter (Amps) (Amps)
ARCMASTER 300 ACDC 7.08 Welding Parameters for Aluminum Filler Rod Base Metal AC Current for Tungsten Argon Gas Joint Type Diameter Thickness Aluminum Electrode Flow Rate Diameter (if required) Liters/min 0.040” 30-45 0.040” 1/16” Butt/Corner 1.0mm 35-50 1.0mm 1.6mm Lap/ Fillet 0.045”...
ARCMASTER 300 ACDC SECTION 8: BASIC ARC WELDING GUIDE 8.01 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. 8.02 Effects of Stick Welding Various Materials 1.
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ARCMASTER 300 ACDC Metals being Electrode Comments joined Mild steel 6013 Ideal electrodes for all general purpose work. Features include out standing operator appeal, easy arc starting and low spatter. Mild steel 7014 All positional electrode for use on mild and galvanized steel furniture, plates, fences, gates, pipes and tanks etc.
ARCMASTER 300 ACDC 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. Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge.
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ARCMASTER 300 ACDC Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch Visual check of Consumable parts regulator and pressure Weekly Visually inspect the torch Visually inspect the Wire Visually inspect the body and consumables feed mechanisms...
WARNING 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.
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ARCMASTER 300 ACDC Description Possible Cause Remedy 6 Electrode melts when A Electrode is connected to A Connect the electrode to the arc is struck. the ‘+’ terminal. ‘-’ terminal. WAVE BALANCE WAVE BALANCE is greater B Reduced than 50%. below 50% or increase the electrode size.
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ARCMASTER 300 ACDC Description Possible Cause Remedy 11 Welding arc can not A Work clamp is not A Connect the work clamp to be established. connected to the work piece the work piece or connect or the work/torch leads are the work/torch leads to the not connected to the right right welding terminals.
ARCMASTER 300 ACDC 10.02 Stick Welding Problems Description Possible Cause Remedy A Electrodes are damp. A Dry electrodes before use. 1 Gas pockets or voids in weld metal B Welding current is too high. B Reduce welding current. (Porosity). C Surface impurities such as C Clean joint before welding.
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ARCMASTER 300 ACDC Description Possible Cause Remedy A Small electrodes used on A Use larger electrodes and 4 Portions of the weld heavy cold plate. pre-heat the plate. run do not fuse to the surface of the metal or B Welding current is too low. B Increase welding current.
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ARCMASTER 300 ACDC Description Possible Cause Remedy 5 Non-metallic particles A Non-metallic particles may A If bad undercut is present, are trapped in the be trapped in undercut from clean slag out and cover weld metal (slag previous run. with a run from a smaller inclusion).
ARCMASTER 300 ACDC 10.03 Power Source Problems Description Possible Cause Remedy A The Primary supply voltage A Switch ON the Primary 1 The welding arc has not been switched ON. supply voltage. cannot be established. B The Welding Power Source B Switch ON the Welding switch is switched OFF.
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ARCMASTER 300 ACDC Description Possible Cause Remedy Strike an arc to complete the SLOPE 5 Gas flow won’t shut A Weld Mode ( weld cycle. off. REPEAT SPOT ) was POST- changed before FLOW gas time had Switch machine off then on finished.
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 IEC 60974-1 Requirements VRD Open Circuit Voltage Less than 20V;...
ARCMASTER 300 ACDC 11.03 Switching VRD On/Off Switch the machine Off. A) Remove the clear plastic cover from the control panel (see Figure 11-1). • 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 •...
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ARCMASTER 300 ACDC C) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see Figure 11-3). CAUTION DO NOT pull back the front panel with excessive force as this will unplug control PCB. Plugging the control PCB back into the front panel controls can only be achieved by removing the side covers.
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ARCMASTER 300 ACDC 11-4 February 22, 2006...
Fan operates at max IGBTs) is greater B Fan ceases to B Have an Accredited speed. than 80ºC for about operate. Thermal Arc Service E01 resets when 1 second. Agent investigate. TH1 decreases to C Air flow is restricted C Unblock vents then 70ºC for about 30...
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ARCMASTER 300 ACDC E11 error code Primary supply Have an Accredited Weld current displayed voltage is greater Thermal Arc Service ceases. Buzzer Over Primary supply than the nominal Agent or a qualified sounds contstantly. (input) voltage at voltage plus 10%.
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ARCMASTER 300 ACDCR E82 error code The Primary supply Have an Accredited No weld current is displayed (input) voltage Thermal Arc Service available. Buzzer Rated voltage fluctuates and is not Agent or a qualified sounds constantly. selection circuit stable. electrician check the Switch machine off abnormality.
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ARCMASTER 300 ACDC E94 error code The Welding Power Have an Accredited Weld current displayed Source’s Thermal Arc Service ceases. Buzzer Temperature sensor temperature Agent check or sounds constantly. TH1 for IGBTs or sensors have replace the Switch machine off.
ARCMASTER 300 ACDC SECTION 13: PARTS LIST 13.01 Equipment Identification 13.02 How To Use This Parts List All identification numbers as described in the Introduc- The Parts List is a combination of an illustration and a tion chapter must be furnished when ordering parts or corresponding list of parts which contains a breakdown making inquiries.
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ARCMASTER 300 ACDC DWG. No. Description Type & Rating QTY. Code No. Order No. Post4(M4- EBA431100 EBA431100 10-6670 Post5(M4- EBA431200 EBA431200 10-6671 Post6(M5- EBA431300 EBA431300 10-6672 Post7(M5- EBA435900 EBA435900 10-6673 Post8(M5- EBA436000 EBA436000 10-6674 D2-4 Bus Bar EBA305600 EBA305600 10-6675 CC Bus Bar EBA306200 EBA306200...
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ARCMASTER 300 ACDC 13-6 February 22, 2006...
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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.
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...
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
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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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