Tweco 401MST Operating Manual

Tweco 401MST Operating Manual
ARCMASTER
401MST
Operating
Manual
Art # A-12449_AB
Revision: AB
Issue Date: June 17, 2014
Manual No.: 0-5287
3163339
Tweco.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on receiving your new Tweco product. We are proud to have you as our customer and
will strive to provide you with the best service and support in the industry. This product is backed by
our extensive warranty and world-wide service network.
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.
YOU ARE IN GOOD COMPANY!
Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish
ourselves from our competition through market-leading innovation and truly dependable products that
will stand the test of time.
We strive to enhance your productivity, efficiency and welding performance enabling you to excel in
your craft. We design products with the welder in mind delivering- advanced features, durability, ease
of use and ergonomic comfort.
Above all, we are committed to a safer working environment within the welding industry. Your
satisfaction with this product and its safe operation is our ultimate concern. Please take the time to
read the entire manual, especially the Safety Precautions.
If you have any questions or concerns regarding your new Tweco product, please contact our friendly
and knowledgeable Customer Service Team at:
1-800-462-2782 (USA) and 1-905-827-4515 (Canada),
or visit us on the web at www.Tweco.com
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices if applicable
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.
Operating Manual Number 0-5287 for:
Tweco ArcMaster 401MST Power Source
Part Number W1009500
Published by:
Victor Technologies, Inc.
16052 Swingley Ridge Road,
Suite 300 St. Louis, MO 63017
USA
www.victortechnologies.com
Copyright © 2014 by
Victor Technologies, Inc.
® All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this Manual, whether such error results
from negligence, accident, or any other cause.
Publication Date: May 15, 2014
Revision Date: June 17, 2014
Record the following information for Warranty purposes:
Where Purchased:
_____________________________________
Purchase Date:
_____________________________________
Equipment Serial #:
_____________________________________
TABLE OF CONTENTS
SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS................................................ 1-1
1.01
1.02
1.03
1.04
1.05
1.06
1.07
1.08
1.09
Arc Welding Hazards........................................................................................ 1-1
General Safety Information for Victor Regulator................................................ 1-5
Principal Safety Standards............................................................................... 1-7
Symbol Chart................................................................................................... 1-8
Precautions De Securite En Soudage A L’arc................................................... 1-9
Dangers relatifs au soudage à l’arc.................................................................. 1-9
Informations Générales de Sécurité............................................................... 1-14
Principales Normes De Securite.................................................................... 1-16
Graphique de Symbole................................................................................... 1-17
SECTION 2: INTRODUCTION .............................................................................. 2-1
2.01
How To Use This Manual................................................................................. 2-1
2.02
Equipment Identification.................................................................................. 2-1
2.03
Receipt of Equipment....................................................................................... 2-1
2.04Description...................................................................................................... 2-2
2.05
User Responsibility.......................................................................................... 2-2
2.06
Transporting Methods...................................................................................... 2-2
2.07
Packaged Items............................................................................................... 2-2
2.08
Duty Cycle........................................................................................................ 2-3
2.09Specifications.................................................................................................. 2-4
SECTION 3: INSTALLATION, OPERATION AND SETUP................................................. 3-1
3.01Environment.................................................................................................... 3-1
3.02Location........................................................................................................... 3-1
3.03Ventilation........................................................................................................ 3-1
3.04
Mains Supply Voltage Requirements............................................................... 3-1
3.05
High Frequency Introduction........................................................................... 3-3
3.06
High Frequency Interference............................................................................ 3-4
3.07 Electromagnetic Compatibility......................................................................... 3-4
3.08
ArcMaster 401MST Power Source Controls, Indicators and Features.............. 3-6
3.09
Welding Parameters....................................................................................... 3-11
3.10
Setup for LIFT TIG (GTAW) Welding.............................................................. 3-14
3.11
Setup for STICK (SMAW) Welding................................................................. 3-16
3.12
Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire...................... 3-18
3.13
Setup for FCAW Flux Core Arc Welding.......................................................... 3-20
3.14
Special Function............................................................................................ 3-22
3.15
Shielding Gas Flowmeter/ Regulator Operating Instructions.......................... 3-23
TABLE OF CONTENTS
SECTION 4: BASIC WELDING GUIDE ..................................................................... 4-1
4.01
4.02
4.03
4.04
Stick (SMAW) Basic Welding Technique.......................................................... 4-1
Stick (SMAW) Welding Troubleshooting........................................................ 4-10
TIG (GTAW) Basic Welding Technique........................................................... 4-12
TIG (GTAW) Welding Problems...................................................................... 4-14
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS............. 5-1
5.01
5.02
5.03
5.04
5.05
Maintenance and Repair.................................................................................. 5-1
Power Source Status Messages....................................................................... 5-2
Error Messages................................................................................................ 5-2
Routine Inspection, Testing & Maintenance..................................................... 5-4
Cleaning the Welding Power Source................................................................ 5-4
SECTION 6: KEY SPARE PARTS........................................................................... 6-1
6.01
401MST Power Source Spare Parts................................................................. 6-1
APPENDIX A: CIRCUIT DIAGRAM......................................................................... A-1
Tweco - LIMITED WARRANTY TERMS
ARCMASTER 401MST 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.
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.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training
in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.
This publication and other guides to what you should learn before operating this equipment are listed at the
end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK
PERFORMED ONLY BY QUALIFIED PEOPLE.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
1.01 Arc Welding Hazards
6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
out of service.
WARNING
ELECTRIC SHOCK can kill.
7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the ground
or the work surface. Do not touch holders connected
to two welding machines at the same time or touch
other people with the holder or electrode.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever the
output is on. The input power circuit and
machine internal circuits are also live when
power is on. In semi-automatic or automatic
wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the
welding wire are electrically live. Incorrectly
installed or improperly grounded equipment
is a hazard.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10.Ground the workpiece to a good electrical (earth)
ground.
1. Do not touch live electrical parts.
11.Do not touch electrode while in contact with the work
(ground) circuit.
2. Wear dry, hole-free insulating gloves and body
protection.
12.Use only well-maintained equipment. Repair or
replace damaged parts at once.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
13.In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line fuses
so power cannot be turned on accidentally.
14.Wear a safety harness to prevent falling if working
above floor level.
15.Keep all panels and covers securely in place.
Manual 0-5287
1-1
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
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.
ARC RAYS can burn eyes and skin; NOISE
can damage hearing. Arc rays from the
welding process produce intense heat and
strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can
damage hearing.
5. Use approved ear plugs or ear muffs if noise level
is high.
1. Wear a welding helmet fitted with a proper shade
of filter (see ANSI Z49.1 listed in Safety Standards)
to protect your face and eyes when welding or
watching.
WARNING
FUMES AND GASES can be hazardous to
your health.
Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.
2. Wear approved safety glasses. Side shields
recommended.
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
Electrode Size in.
(mm)
Arc Current
(Amperes)
Minimum
Protective
Shade
Suggested*
Shade No.
(Comfort)
Less than 3/32 (2.4)
3/32-5/32 (2.4-4.0)
5/32-1/4 (4.0-6.4)
More than 1/4 (6.4)
Less than 60
60-160
160-250
250-550
7
8
10
11
10
12
14
Gas Metal Arc Welding (GMAW)
and Flux Cored Arc Welding
(FCAW)
Less than 60
60-160
160-250
250-550
7
10
10
10
11
12
14
Gas Tungsten arc Welding
(GTAW)
Less than 50
50-150
150-500
Less than
500
500-1000
Less than 20
20-100
100-400
400-800
8
8
10
10
12
14
10
11
12
14
6
8
10
11
6 to 8
10
12
14
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
4
5
6
8
8
9
10
4
5
6
8
9
12
14
Process
Shielded Metal Arc Welding
(SMAW)
Air Carbon Arc Cutting (CAC-A)
Plasma Arc Welding (PAW)
Plasma Arc Cutting (PAC)
(Light)
(Heavy)
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter
shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas
welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable
to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.
SAFETY INSTRUCTIONS AND WARNINGS
1-2
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
1. Keep your head out of the fumes. Do not breathe
the fumes.
6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.
2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
7. Do not weld on closed containers such as tanks or
drums.
3. If ventilation is poor, use an approved air-supplied
respirator.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding current
from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
9. Do not use welder to thaw frozen pipes.
10.Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
5. Work in a confined space only if it is well ventilated,
or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing
injury or death. Be sure the breathing air is safe.
WARNING
6. Do not weld in locations near degreasing, cleaning,
or spraying operations. The heat and rays of the
arc can react with vapors to form highly toxic and
irritating gases.
FLYING SPARKS AND HOT METAL can cause
injury.
Chipping and grinding cause flying metal. As
welds cool, they can throw off slag.
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
WARNING
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to treat
them carefully.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding
arc. The flying sparks and hot metal, weld
spatter, hot workpiece, and hot equipment
can cause fires and burns. Accidental contact
of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
1. Protect yourself and others from flying sparks and
hot metal.
2. Do not weld where flying sparks can strike flammable
material.
3. Keep cylinders away from any welding or other
electrical circuits.
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.
4. Never allow a welding electrode to touch any
cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific
application; maintain them and associated parts in
good condition.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
Manual 0-5287
6. Turn face away from valve outlet when opening
cylinder valve.
1-3
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
!
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from
battery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
WARNING
Engines can be dangerous.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
WARNING
ENGINE EXHAUST GASES can kill.
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated
areas.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working
on a battery.
WARNING
ENGINE FUEL can cause fire or explosion.
4. Do not use welder to charge batteries or jump start
vehicles.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
5. Observe correct polarity (+ and –) on batteries.
2. Do not add fuel while smoking or if unit is near any
sparks or open flames.
3. Allow engine to cool before fueling. If possible, check
and add fuel to cold engine before beginning job.
WARNING
4. Do not overfill tank — allow room for fuel to expand.
STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
The coolant in the radiator can be very hot
and under pressure.
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
WARNING
2. Wear gloves and put a rag over cap area when
removing cap.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
3. Allow pressure to escape before completely
removing cap.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Stop engine before installing or connecting unit.
SAFETY INSTRUCTIONS AND WARNINGS
1-4
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
!
1.02 General Safety Information for
Victor Regulator
WARNING
A Fire Prevention
Welding and cutting operations use fire or combustion
as a basic tool. The process is very useful when properly
controlled. ­However, it can be extremely destructive
if not performed cor­rectly in the proper environment.
WARNING: This product contains chemicals, including
lead, known to the State of California to cause birth
defects and other reproductive harm. Wash hands
after handling.
NOTE
1. The work area must have a fireproof floor.
Considerations About Welding And The
Effects of Low Frequency Electric and Magnetic Fields
2. Work benches or tables used during welding or
cutting operations must have fireproof tops.
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology
Assessment, Biological Effects of Power Frequency
Electric & Magnetic Fields - Background Paper, OTABP-E-63 (Washington, DC: U.S. Government Printing
Office, May 1989): “...there is now a very large volume
of scientific findings based on experiments at the cellular level and from studies with animals and people
which clearly establish that low frequency magnetic
fields interact with, and produce changes in, biological systems. While most of this work is of very high
quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the
evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite
conclusions about questions of possible risk or to offer
clear science-based advice on strategies to minimize or
avoid potential risks.”
3. Use heat resistant shields or other approved material to protect nearby walls or unprotected flooring
from sparks and hot metal.
4. Keep an approved fire extinguisher of the proper
size and type in the work area. Inspect it regularly to ensure that it is in proper working order.
Know how to use the fire extin­guisher.
5. Move combustible materials away from the work
site. If you c­ an not move them, protect them
with fireproof covers. ­
!
NEVER perform welding, heating, or cutting operations on a container that has held
toxic, combustible or flammable liq­uids, or
vapors. NEVER perform welding, heating,
or cutting operations in an area containing
combustible vapors, flam­mable liquids, or
explosive dust.
To reduce magnetic fields in the workplace, use the
following procedures.
1. Keep cables close together by twisting or taping
them.
BHousekeeping
2. Arrange cables to one side and away from the
operator.
!
3. Do not coil or drape cable around the body.
WARNING
NEVER allow oxygen to contact grease, oil, or
other flam­mable substances. Although oxygen by itself will not burn, these substances
become highly explosive. They can ignite
and burn violently in the presence of oxygen.
4. Keep welding Power Source and cables as far
away from body as practical.
ABOUT PACEMAKERS:
Keep ALL apparatus clean and free of grease, oil and
other flammable substances.
The above procedures are among those
also normally recommended for pacemaker
wearers. Consult your doctor for complete
information.
Manual 0-5287
WARNING
1-5
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
E Compressed Gas Cylinders
The Department of Transportation (DOT) approves the
design and manufacture of cylinders that contain gases
used for welding or cutting operations.
CVentilation
!
WARNING
Ade­quately ventilate welding, heating, and
cutting work areas to prevent accumulation of explosive or toxic concen­trations
of gases. Certain combinations of metals,
coatings, and gases generate toxic fumes.
Use respiratory protection equipment in
these circumstances. When welding/brazing,
read and understand the Material Safety Data
Sheet for the welding/brazing alloy.
1. Place the cylinder (Figure 1-1) where you will
use it. Keep the cylinder in a vertical position.
Secure it to a cart, wall, work bench, post, etc.
D Personal Protection
Gas flames produce infrared radiation which may have
a harm­ful effect on the skin and especially on the eyes.
Select goggles or a mask with tempered lenses, shaded
4 or darker, to protect your eyes from injury and provide
good visibility of the work.
Figure 1-1: Gas Cylinders
!
Always wear protective gloves and flame-resistant clothing
to protect skin and clothing from sparks and slag. Keep
collars, sleeves, and pockets buttoned. DO NOT roll up
sleeves or cuff pants.
Cylinders are highly pressurized. Handle
with care. Serious accidents can result from
improper handling or mis­use of compressed
gas cylinders DO NOT drop the cylinder,
knock it over, or expose it to excessive heat,
flames or sparks. DO NOT strike it against
other cylinders. Contact your gas supplier
or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.
When working in a non-welding or cutting environment,
always wear suitable eye protection or face shield.
!
WARNING
WARNING
Practice the following safety and operation
precautions EVERY TIME you use pressure
regulation equipment. Deviation from the
following safety and operation instructions
can result in fire, explosion, damage to
equipment, or injury to the operator.
NOTE
CGA P-1 publication is available by writing
the Compressed Gas Association, 4221
Walney Road, 5th Floor, Chantilly,VA 201512923
2. Place the valve protection cap on the cylinder
whenever mov­ing it, placing it in storage, or not
using it. Never drag or roll cylinders in any way.
Use a suitable hand truck to move cylin­ders.
3. Store empty cylinders away from full cylinders.
Mark them “EMPTY” and close the cylinder
valve.
SAFETY INSTRUCTIONS AND WARNINGS
1-6
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
1.03 Principal Safety Standards
4. NEVER use compressed gas cylinders without
a pressure reducing regulator attached to the
cylinder valve. ­
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
5. Inspect the cylinder valve for oil, grease, and
damaged parts.
!
Safety and Health Standards, OSHA 29 CFR 1910,
from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.
WARNING
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
DO NOT use the cylinder if you find oil,
grease or damaged parts. Inform your gas
supplier of this condition immediately.
6. Momentarily open and close (called “cracking”)
the cylinder valve to dislodge any dust or dirt that
may be present in the valve.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
CAUTION
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington,
VA 22202.
Open the cylinder valve slightly. If you open
the valve too much, the cylinder could tip
over. When cracking the cylinder valve, DO
NOT stand directly in front of the cylinder
valve. Always perform cracking in a well
ventilated area. If an acetylene cylinder
sprays a mist when cracked, let it stand for
15 minutes. Then, try to crack the cylinder
valve again. If this problem persists, contact
your gas supplier.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.
Cutting and Welding Processes, NFPA Standard 51B,
from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Manual 0-5287
1-7
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
115V 15A
X
%
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Spot Time
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
S
See Note
See Note
Voltage Input
Art # A-04130_AB
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the S mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.
SAFETY INSTRUCTIONS AND WARNINGS
1-8
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
1.05 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.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité
et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques
doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi
un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent
les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les
pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser
cet équipement sont présentés à la fin de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION,
D’ENTRETIEN ET D’ESSAI.
1.06 Dangers relatifs au soudage à
l’arc
3 Isolez-vous de la pièce à souder et de la mise à la
terre au moyen de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement
ou arrêtez le moteur avant de l’installer ou d’en faire
l’entretien. Bloquez le commutateur en circuit ouvert
ou enlevez les fusibles de l’alimentation afin d’éviter
une mise en marche accidentelle.
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
5. Veuillez à installer cet équipement et à le mettre à
la terre selon le manuel d’utilisation et les codes
nationaux, provinciaux et locaux applicables.
Une décharge électrique peut tuer ou
brûler gravement. L’électrode et le circuit
de soudage sont sous tension dès la mise
en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi
sous tension dès la mise en marche. En
soudage automatique ou semi-automatique
avec fil, ce dernier, le rouleau ou la bobine
de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact
avec le fil de soudage sont sous tension.
Un équipement inadéquatement installé ou
inadéquatement mis à la terre est dangereux.
6. Arrêtez tout équipement après usage. Coupez
l’alimentation de l’équipement s’il est hors d’usage
ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne
jamais plonger les porte-électrodes dans l’eau pour
les refroidir. Ne jamais les laisser traîner par terre ou
sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre
avec l’électrode ou le porte-électrode.
1. Ne touchez pas à des pièces sous tension.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.
2. Portez des gants et des vêtements isolants, secs et
non troués.
Manual 0-5287
1-9
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
9. N’enroulez pas de câbles électriques autour de votre
corps.
AVERTISSEMENT
10.N’utilisez qu’une bonne prise de masse pour la mise
à la terre de la pièce à souder.
LE RAYONNEMENT DE L’ARC PEUT BRÛLER
LES YEUX ET LA PEAU; LE BRUIT PEUT
ENDOMMAGER L’OUIE.
11.Ne touchez pas à l’électrode lorsqu’en contact avec
le circuit de soudage (terre).
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.
12.N’utilisez que des équipements en bon état. Réparez
ou remplacez aussitôt les pièces endommagées.
13.Dans des espaces confinés ou mouillés, n’utilisez
pas de source de courant alternatif, à moins qu’il
soit muni d’un réducteur de tension. Utilisez plutôt
une source de courant continu.
14.Portez un harnais de sécurité si vous travaillez en
hauteur.
1. Portez une casque de soudeur avec filtre oculaire
de nuance appropriée (consultez la norme ANSI Z49
indiquée ci-après) pour vous protéger le visage et
les yeux lorsque vous soudez ou que vous observez
l’exécution d’une soudure.
15.Fermez solidement tous les panneaux et les capots.
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
Electrode Size in.
(mm)
Arc Current
(Amperes)
Minimum
Protective
Shade
Suggested*
Shade No.
(Comfort)
Less than 3/32 (2.4)
3/32-5/32 (2.4-4.0)
5/32-1/4 (4.0-6.4)
More than 1/4 (6.4)
Less than 60
60-160
160-250
250-550
7
8
10
11
10
12
14
Gas Metal Arc Welding (GMAW)
and Flux Cored Arc Welding
(FCAW)
Less than 60
60-160
160-250
250-550
7
10
10
10
11
12
14
Gas Tungsten arc Welding
(GTAW)
Less than 50
50-150
150-500
Less than
500
500-1000
Less than 20
20-100
100-400
400-800
8
8
10
10
12
14
10
11
12
14
6
8
10
11
6 to 8
10
12
14
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
4
5
6
8
8
9
10
4
5
6
8
9
12
14
Process
Shielded Metal Arc Welding
(SMAW)
Air Carbon Arc Cutting (CAC-A)
Plasma Arc Welding (PAW)
Plasma Arc Cutting (PAC)
(Light)
(Heavy)
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter
shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas
welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable
to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.
SAFETY INSTRUCTIONS AND WARNINGS
1-10
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
2. Portez des lunettes de sécurité approuvées. Des
écrans latéraux sont recommandés.
AVERTISSEMENT
3. Entourez l’aire de soudage de rideaux ou de cloisons
pour protéger les autres des coups d’arc ou de
l’éblouissement; avertissez les observateurs de ne
pas regarder l’arc.
LE SOUDAGE PEUT CAUSER UN INCENDIE
OU UNE EXPLOSION
L’arc produit des étincellies et des projections. Les particules volantes, le métal
chaud, les projections de soudure et
l’équipement surchauffé peuvent causer
un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode
avec un objet métallique peut provoquer des
étincelles, un échauffement ou un incendie.
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille
approuvés lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des
fumées dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est
bien ventilée ou que les fumées et les vapeurs sont
aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur
à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes
du fabricant relatives aux métaux, aux produits
consummables, aux revêtements et aux produits
nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien
ventilé; sinon, portez un respirateur à adduction d’air.
Les gaz protecteurs de soudage peuvent déplacer
l’oxygène de l’air et ainsi causer des malaises ou la
mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir avec des vapeurs
et former des gaz hautement toxiques et irritants.
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 l’espace est bien ventilé;
si nécessaire portez un respirateur à adduction d’air.
Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au
moment du soudage.
Manual 0-5287
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.
2. Ne soudez pas dans un endroit où des particules
volantes ou des projections peuvent atteindre des
matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon
de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage
susceptibles de pénétrer dans des aires adjacentes
par de petites ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur
à portée de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut
enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir
ou un baril.
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.
10.Otez l’électrode du porte-électrode ou coupez le fil
au tube-contact lorsqu’inutilisé après le soudage.
11.Portez des vêtements protecteurs non huileux, tels
des gants en cuir, une chemise épaisse, un pantalon
revers, des bottines de sécurité et un casque.
1-11
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS
BRULANTES PEUVENT CAUSER DES BLESSURES.
8. Lisez et respectez les consignes relatives aux
bouteilles de gaz comprimé et aux équipements
connexes, ainsi que la publication P-1 de la CGA,
identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
Le piquage et le meulage produisent des
particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats
de laitier.
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS
PEUVENT ETRE MORTELS.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont
recommandés.
Les moteurs produisent des gaz d’échappement nocifs.
2. Portez des vêtements appropriés pour protéger
la peau.
1. Utilisez l’équipement à l’extérieur dans des aires
ouvertes et bien ventilées.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
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 contiennent des gaz protecteurs sous haute pression. Des bouteilles
endommagées peuvent exploser. Comme
les bouteilles font normalement partie du
procédé de soudage, traitez-les avec soin.
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.
1. Protégez les bouteilles de gaz comprimé contre les
sources de chaleur intense, les chocs et les arcs de
soudage.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.
2. Enchainez verticalement les bouteilles à un support
ou à un cadre fixe pour les empêcher de tomber ou
d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou
de tout soudage.
4. Empêchez tout contact entre une bouteille et une
électrode de soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des
détendeurs, des boyauxs et des raccords conçus
pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus
en bon état.
AVERTISSEMENT
Le carburant est hautement inflammable.
2. Ne faites pas le plein en fumant ou proche d’une
source d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de
faire le plein de carburant ou d’en vérifier le niveau
au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant.
Nettoyez tout carburant renversé avant de faire
démarrer le moteur.
6. Ne placez pas le visage face à l’ouverture du robinet
de la bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en
utilisation ou lorsque raccordé pour utilisation.
SAFETY INSTRUCTIONS AND WARNINGS
1-12
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT
CAUSER DES BLESSURES.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION
PEUVENT BRULER LA PEAU ET LES YEUX.
Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent
couper doigts et mains, ou accrocher des
vêtements amples.
1. Assurez-vous que les portes, les panneaux, les
capots et les protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez
le moteur.
3. Seules des personnes qualifiées doivent démonter
des protecteurs ou des capots pour faire l’entretien
ou le dépannage nécessaire.
Le liquide de refroidissement d’un radiateur
peut être brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur
n’est pas refroidi.
2. Mettez des gants et posez un torchon sur le bouchon
pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.
4. Pour empêcher un démarrage accidentel pendant
l’entretien, débranchez le câble d’accumulateur à la
borne négative.
!
5. N’approchez pas les mains ou les cheveux de pièces
en mouvement; elles peuvent aussi accrocher des
vêtements amples et des outils.
AVERTISSEMENT: Ce produitcontient des produits
chimiques, notamment du plomb, reconnu par l’Étatde
la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système
reproductif. Se laver les mains après manipulation.
6. Réinstallez les capots ou les protecteurs et fermez
les portes après des travaux d’entretien et avant de
faire démarrer le moteur.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE
D’UN ACCUMU-LATEUR PEUT BRULER LA
PEAU ET LES YEUX.
Les accumulateurs contiennent de
l’électrolyte acide et dégagent des vapeurs
explosives.
1. Portez toujours un écran facial en travaillant sur un
accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler
sur un accumulateur.
4. N’utilisez pas une source de courant de soudage
pour charger un accumulateur ou survolter momentanément un véhicule.
Manual 0-5287
AVERTISSEMENT
REMARQUE
Facteurs relatifs au soudage et aux effets
des champs magnétiques et électriques de
basse fréquence
Voici une citation tirée du chapitre des conclusions
générales du document de base de l’Office of Technology
Assessment (bureau des évaluations technologiques)
de l’U.S. Congress, « Biological Effects of Power
Frequency Electric & Magnetic Fields », OTA-BP-E-63
(Washington, DC : U.S. Government Printing Office,
mai 1989) : « ... il existe de nos jours, un nombre
très élevé de travaux scientifiques qui rapportent les
résultats d’expériences menées au niveau cellulaire et
d’études auprès d’homme et d’animaux qui établissent
nettement le rapport entre les champs magnétiques
de basse fréquence et les systèmes biologiques, soit
par des interactions ou des modifications. Quoique
la plupart de ces travaux soient de très bonne
qualité, les résultats sont complexes. À la lumière
des connaissances scientifiques actuelles, il nous est
encore impossible d’interpréter les évidences en un seul
cadre de référence cohérent. La situation est toutefois
très contrariante. En effet, il nous est aussi impossible
de tirer des conclusions définitives quant aux risques
éventuels ou de proposer des stratégies fondées sur
1-13
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
des faits scientifiques visant à atténuer ou éviter des
risques potentiels ».
!
Pour atténuer les champs magnétiques sur les lieux
de travail, respectez les procédures qui suivent :
N’effectuez JAMAIS d’opérations de soudage
sur un récipient qui a contenu des liquides
ou vapeurs toxiques, combustibles ou inflammables. N’effectuez JAMAIS d’opérations
de soudage dans une zone contenant des
vapeurs combustibles, des liquides inflammables ou des poussières explosives.
1. Maintenez les câbles l’un près de l’autre en les
entrelaçant ou les reliant ensemble au ruban.
2. Acheminez les câbles à un côté du soudeur, le
plus loin possible.
3. N’enroulez pas de câble autour du corps.
4. Maintenez le bloc d’alimentation du poste
de soudage et les câbles aussi loin que possible
du corps.
B Entretien des Locaux
!
Les procédures décrites ci-dessus sont
habituellement celles recommandées pour
les porteurs de stimulateurs cardiaques.
Pour de plus amples renseignements,
consulter un médecin.
Gardez TOUS les appareils propres et exempts de graisse,
huile ou autres substances inflammables.
CAération
A Prévention D’incendie
Les opérations de soudage utilisent le feu ou la combustion
comme outil de base. Ce processus est très utile quand il
est cor­rectement contrôlé.
!
2. Les établis ou tables utilisés pendant les opérations de soudage doivent avoir un revêtement
ignifuge.
4. Gardez un extincteur approuvé du bon type et de
la bonne taille dans la zone de travail. Inspectez-le
régulièrement pour vous assurer qu’il est en état de
fonctionner. Apprenez à vous en servir.
5. Enlevez tous les matériaux combustibles de la
zone de travail. Si vous ne pouvez pas les enlever,
protégez-les avec une cou­vre ignifuge.
SAFETY INSTRUCTIONS AND WARNINGS
AVERTISSEMENT
Ventilez les zones de soudage, chauffage et
découpage de façon adéquate pour éviter
l’accumulation de gaz explosifs ou toxiques.
Certaines combinaisons de métaux, revêtements et gaz génèrent des fumées toxiques:
Utilisez un équipement de protection respiratoire dans ces circonstances. Si vous
soudez ou brasez, lisez et assimilez la fiche
technique de sécurité de matériau relative à
l’alliage de soudage/brasage.
1. La zone doit comporter un sol ignifugé.
3. Utilisez des écrans résistants à la chaleur ou en
matériau approuvé pour protéger les cloisons
proches ou le sol vul­nérable des étincelles et du
métal chaud.
AVERTISSEMENT
Ne laissez jamais l’oxygène en contact avec
la graisse, l’huile ou d’autres substances inflammables. Bien que l’oxygène elle­même ne
brûle pas, ces substances peuvent devenir
extrême­ment explosives. Elles peuvent prendre feu et brûler violem­ment en présence
d’oxygène.
STIMULATEURS CARDIAQUES :
1.07 Informations Générales de
Sécurité
AVERTISSEMENT
D Protection Personnelle
Les flammes de gaz produisent une radiation infrarouge
qui peut avoir un effet néfaste sur la peau, et particulièrement sur les yeux. Choisissez des lunettes ou un
masque avec des verres trempés assombris au niveau 4
ou plus sombre, pour protéger vos yeux des dommages
et garder une bonne visibilité sur le travail.
Portez en permanence des gants de protection et des
vête­ments ignifuges pour la protection de la peau et des
vêtements contre les étincelles et le laitier. Gardez col,
1-14
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
AVIS
Ce document CGA p. t peut être obtenu en
écrivant à “Compressed Gas Association”,
4221 Walney Roed, 5th Floor. Chantilly, VA
20151.2923, USA.
manches et poches boutonnés. Il ne faut pas remonter
vos manches ou les pantalons à revers.
Quand vous travaillez dans un environnement non
dédié au soudage ou découpage, portez toujours une
protection des yeux appropriées ou un masque facial.
!
2. Placez le bouchon de protection de vanne sur
la bouteille à chaque fois que vous la déplacez
ou ne l’utilisez pas. Ne faites jamais glisser ou
rouler d’aucune manière les bouteilles. Utilisez
un diable approprié pour les déplacer.
AVERTISSEMENT
Mettez en pratique les procédures de sécurité et de mode opératoire suivantes à
chaque fois que vous utilisez cet appareil
de régulation de pression. Si vous déviez de
ces procédures, cela peut entraîner incendie,
explosion, dégâts matériels et/ou blessures
corporelles pour l’opérateur.
3. Entreposez les bouteilles vides à l’écart des
bouteilles pleines. Marquez-les “VIDE” et refermez leur vanne.
4. N’utilisez JAMAIS des bouteilles de gaz comprimé
sans un régulateur de pression en série sur la
vanne de bouteille.
5. Inspectez la vanne de bouteille pour y détecter
de l’huile ou de la graisse, ou dès pièces
endommagées.
E Bouteilles de Gaz Comprimé
Le Département des Transports américain (DOT) approuve la conception et la fabrication des bouteilles
qui contiennent les gaz utilisés pour les opérations de
soudage ou de découpage.
!
1. Placez la bouteille (Le schéma 1) là où elle sera
utilisée. Gardez-la en position verticale. Fixez-la sur
un chariot une cloison, un établi, etc.
AVERTISSEMENT
N’UTILISEZ PAS la bouteille si vous trouvez
de l’huile, de la graisse ou des pièces endommagées. Informez immédiate­ment votre
fournisseur de’ gaz de cet état.
6. Ouvrez et fermez momentanément la vanne de
la bouteille, délogeant ainsi d’éventu lIes poussières ou saletés. qui pour­raient être présentes
dans la vanne.
Le schéma 1-1: Cylindres de gaz
!
Mise en Garde
Ouvrez la vanne de bouteille légèrement.
Si vous l’ouvrez trop en grand, la bouteille
pourrait se renverser. Quand vous ouvrez/
fermez rapidement la vanne de bouteille, ne
vous tenez pas directement devant. Opérez
toujours cette opération dans une zone bien
ventilée. Si une bouteille d’acétylène crache
un brouillard, laissez reposer pendant 15
minutes. Essayez de nouveau la vanne. Si le
problème persiste, con­tactez votre fournisseur de gaz.
AVERTISSEMENT
Les bouteilles sont sous haute pression. Manipulez-les avec précautions. Des accidents sérieux
peuvent résulter d’une mauvaise manutention
ou d’un mauvais emploi des bouteilles de gaz
comprimé. NE faites PAS tomber la bouteille,
ne la cognez pas, ne l’exposez pas à une chaleur
excessive, aux flammes ou étincelles. NE la cognez
PAS contre d’autres bouteilles. Contactez votre
fournisseur de gaz ou reportez­vous à la publication
CGA P-1 “Manipulation sécurisée des gaz comprimés en conteneur” pour plus d’informations sur
l’utilisation et la manutention des bouteilles.
Manual 0-5287
1-15
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
1.08 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous
Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA
02269.
Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards
Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National
Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
SAFETY INSTRUCTIONS AND WARNINGS
1-16
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
1.09 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension
Mono Phasé
Déroulement du Fil
Hors Tension
Trois Phasé
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Tri-Phase Statique
Torch de Soudage
Tension dangereuse
Fréquence Convertisseur
Transformateur-Redresseur
Augmentez/Diminuer
Distant
Purge Du Gaz
Facteur de Marche
Mode Continu de
Soudure
Pourcentage
Soudure Par Point
Disjoncteur
Source AC Auxiliaire
X
%
Fusible
Panneau/Local
Intensité de Courant
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Tension
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Hertz (cycles/sec)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Fréquence
Decoupe Arc Carbone
(CAC-A)
t
Duréc du Pulse
Durée de Pré-Dèbit
t1
t2
Durée de Post-Dèbit
Détente à 2-Temps
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Détente à 4-Temps
Courant Constant
Négatif
Positif
Tension Constante
Ou Potentiel Constant
Courant Continue (DC)
Haute Température
Terre de Protection
Force d'Arc
Ligne
Amorçage de L’arc au
Contact (GTAW)
Connexion de la Ligne
Inductance Variable
Source Auxiliaire
115V 15A
V
Tension
Classement de PriseSource Auxiliaire
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
t
Probléme de Terre
IPM
Pouces Par Minute
MPM
Mètres Par Minute
S
Voir Note
Voir Note
Art # A-07639_AB
Note: Pour les environnements avec des risques de choc électrique, le fournisseur d'énergie portant la marque S conforme
à EN50192 lorsqu'utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à
l'hauteur de buse correctement installé.
Ne pas déposer avec les déchets ménagers.
Manual 0-5287
1-17
SAFETY INSTRUCTIONS AND WARNINGS
ARCMASTER 401MST POWER SOURCE
This Page Intentionally Blank
SAFETY INSTRUCTIONS AND WARNINGS
1-18
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
2.02 Equipment Identification
To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.
The unit’s identification number (specification or part
number), model, and serial number usually appear on
a nameplate attached to the control panel. In some
cases, the nameplate may be attached to the rear panel.
Equipment which does not have a control panel such
as gun and cable assemblies is identified only by the
specification or part number printed on the shipping
container. Record these numbers on the bottom of page
ii for future reference.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
These special annotations are easily recognized as
follows:
!
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning certain operating procedures.
You will also notice icons from the safety section appearing throughout the manual. These are to advise
you of specific types of hazards or cautions related to
the portion of information that follows. Some may have
multiple hazards that apply and would look something
like this:
Manual 0-5287 2.03 Receipt of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If
there is any damage, notify the carrier immediately to
file a claim. Furnish complete information concerning
damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
Include all equipment identification numbers as described above along with a full description of the parts
in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
2-1INTRODUCTION
ARCMASTER 401MST POWER SOURCE
2.04Description
2.06 Transporting Methods
The Tweco ArcMaster 401MST is a welding power
source incorporating to provide Lift TIG, MIG & FCAW,
Stick, and Gouging welding process.
!
Disconnect input power conductors from de-energized supply line before moving
the welding Power Source.
The units are also fully compliant to CSA E 60974-1
and UL 60974-1.
Lift Power Source with handle on top of case. Use
handcart or similar device of adequate capacity. If using
a fork lift vehicle, secure the Power Source on a proper
skid before transporting.
The following instructions detail how to correctly and
safely set up the machine and give guidelines on gaining
the best efficiency and quality from the Power Source.
Please read these instructions thoroughly before using
the unit.
2.07 Packaged Items
2.05 User Responsibility
ArcMaster 401MST Inverter Power Source (Part
No. W1009500)
This equipment will perform as per the information contained herein when installed, operated, maintained and
repaired in accordance with the instructions provided.
This equipment must be checked periodically. Defective
equipment (including welding leads) should not be used.
Parts that are broken, missing, plainly worn, distorted or
contaminated, should be replaced immediately. Should
such repairs or replacements become necessary, it
is recommended that such repairs be carried out by
appropriately qualified persons approved by Tweco.
Advice in this regard can be obtained by contacting an
Accredited Tweco Distributor.
• ArcMaster 401MST Inverter Power Source w/10
ft input power cable
• 50mm male Dinse connector × 2
• Operating Manual, English
• CD - Operating Manual (Eng/Fr/Sp)
This equipment or any of its parts should not be altered
from standard specification without prior written approval of Tweco. The user of this equipment shall have
the sole responsibility for any malfunction which results
from improper use or unauthorized modification from
standard specification, faulty maintenance, damage or
improper repair by anyone other than appropriately
qualified persons approved by Tweco.
INTRODUCTION
2-2
Manual 0-5287
ARCMASTER 401MST 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 welding 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. Suppose a Welding Power Source is designed to
operate at a 40% duty cycle, 170 amperes at 26.8 volts. This means that it has been designed and built to provide
the rated amperage (170A) for 4 minutes, i.e. arc welding time, out of every 10 minute period (40% of 10 minutes
is 4 minutes). During the other 6 minutes of the 10 minute period the Welding Power Source must idle and be
allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.
100
Duty Cycle (PERCENTAGE)
90
80
3 phase
70
60
50
1 phase
40
30
SAFE OPERATING REGION
20
10
0
0
25
50
75
100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500
Welding Current (AMPS)
Art # A-12450
Figure 2-1: Duty Cycle
Manual 0-5287 2-3INTRODUCTION
ARCMASTER 401MST POWER SOURCE
2.09Specifications
Description
Power Source Part Number
Power Source Mass
Power Source Dimensions
Cooling
Welder Type
Output Terminal Type
Standards
Number of Phases
Nominal Supply Voltage
Nominal Supply Frequency
Welding Current Range
Effective Input Current (I1eff) (note2)
Maximum Input Current (I1max)
Generator Requirement (note4)
STICK (SMAW)
Welding Output, 40ºC, 10 min.
Lift TIG (GTAW)
Welding Output, 40ºC, 10 min.
MIG & FCAW (GMAW FCAW)
Welding Output, 40ºC, 10 min.
Open Circuit Voltage
Protection Class
ArcMaster 401MST
W1009500
55lb (25kg)
16.5"(H) x 8.3"(W) x 17.7(D)
H420mm x W210mm x D450mm
Fan Cooled
Inverter Power Source
DinseTM 50
CSA E 60974-1
UL 60974-1
1/3 phase
208-230/460VAC (1 phase)
208-230/460VAC (3 phase)
+/-15%
+/-15%
50/60Hz
10 - 300A (1 phase)
10 - 400A, (3 phase)
40A (208V, 1 phase)
26.6A (208V, 3 phase)
38.1A (230V, 1 phase)
24.6A (230V, 3 phase)
20A (460V, 1 phase)
14.3A (460V, 3 phase)
84.7A (208V, 1 phase)
53.2A (208V, 3 phase)
76.2A (230V, 1 phase)
49.1A (230V, 3 phase)
40.1A (460V, 1 phase)
28.6A (460V, 3 phase)
14.40kW
300A @ 22%, 32V (1 phase)
400A @ 25%, 36V (3 phase)
230A @ 60%, 29.2V (1 phase)
300A @ 60%, 32V (3 phase)
180A @ 100%, 27.2V (1 phase)
220A @ 100%, 28.8V (3 phase)
300A @ 25%, 22V (1 phase)
400A @ 25%, 26V (3 phase)
230A @ 60%, 19.2V (1 phase)
300A @ 60%, 22V (3 phase)
180A @ 100%, 17.2V (1 phase)
220A @ 100%, 18.8V (3 phase)
300A @ 25%, 29V (1 phase)
400A @ 25%, 34V (3 phase)
230A @ 60%, 25.5V (1 phase)
300A @ 60%, 29V (3 phase)
180A @ 100%, 23V (1 phase)
220A @ 100%, 25V (3 phase)
80V DC
IP23S
Table 2-1: Specification
INTRODUCTION
2-4
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
NOTE
Note 1: Due to variations that can occur in manufactured products, claimed performance, voltages,
ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications,
maintenance and service.
Note 2: The Effective Input Current should be used for the determination of cable size & supply requirements.
Note 3: Motor start fuses or thermal circuit breakers are recommended for this application. Check local
requirements for your situation in this regard.
Note 4: Generator Requirements at the Maximum Output Duty Cycle.
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 combination be adequately tested to ensure the combination performs to the users expectations.
Note 5: Tweco reserves the right to change product performance and specifications without notice.
Manual 0-5287 2-5INTRODUCTION
ARCMASTER 401MST POWER SOURCE
This Page Intentionally Blank
INTRODUCTION
2-6
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
SECTION 3:
INSTALLATION, OPERATION AND SETUP
3.01Environment
exceed the stated conditions. For further information
please refer to EN 60529.
These units are designed for use in environments with
increased hazard of electric shock as outlined in EN
60974-1.
H. Precautions must be taken against the power source
toppling over. The power source must be located on
a suitable horizontal surface in the upright position
when in use.
A. Examples of environments with increased hazard of
electric shock are:
1. In locations in which freedom of movement
is restricted, so that the operator is forced to
perform the work in a cramped (kneeling, sitting
or lying) position with physical contact with
conductive parts.
WARNING
This equipment should be electrically
connected by a qualified electrician.
3.03Ventilation
2. In locations which are fully or partially limited
by conductive elements, and in which there is
a high risk of unavoidable or accidental contact
by the operator.
!
3. In wet or damp hot locations where humidity
or perspiration considerable reduces the skin
resistance of the human body and the insulation
properties of accessories.
WARNING
Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.
3.04 Mains Supply Voltage
Requirements
B. Environments with increased hazard of electric shock
do not include places where electrically conductive
parts in the near vicinity of the operator, which can
cause increased hazard, have been insulated.
The Mains supply voltage should be within ± 15% of the
rated mains supply voltage. Too low a voltage may cause
poor welding performance. Too high a supply voltage
will cause components to overheat and possibly fail.
3.02Location
Be sure to locate the welder according to the following
guidelines:
The Welding Power Source must be:
• Correctly installed, if necessary, by a qualified
electrician.
A. In areas, free from moisture and dust.
B. Ambient temperature between 32 to 104°F.
C. In areas, free from oil, steam and corrosive gases.
• Correctly earthed (electrically) in accordance with
local regulations.
D. In areas, not subjected to abnormal vibration or
shock.
• Connected to the correct size power point and fuse
as per the Specifications on page 2-4 (2-6).
!
E. In areas, not exposed to direct sunlight or rain.
F. Place at a distance of 300mm or more from walls or
similar that could restrict natural air flow for cooling.
Any electrical work must be carried out by a
qualified Electrical Tradesperson.
G. The enclosure design of this power source meets
the requirements of IP23S as outlined in EN 60529.
This provides adequate protection against solid objects
(greater than 12mm), and direct protection from vertical
drops. Under no circumstances should the unit be
operated or connected in a micro environment that will
Manual 0-5287 WARNING
3-1
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST 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.
Electrical Input Requirements
Operate the welding power source from a single or three-phase 50/60 Hz, AC power supply. The input voltage
must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the
local electric utility for information about the type of electrical service available, how proper connections should
be made, and inspection required. The line disconnect switch provides a safe and convenient means to completely
remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.
NOTE
This unit is equipped with a three-conductor with earth power cable that is connected at the welding
power source end for single or three-phase electrical input power.
Do not connect an input (WHITE, BLACK or RED) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
Refer to Figure 3-1 and:
1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies
with all applicable electrical codes.
2. For 3- phase operation, connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors
to a de-energized line disconnect switch.
For 1- phase operation, connect BLACK and WHITE input conductors. Insulate the RED Conductor.
3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.
Fuse Size
Input Voltage
1 Phase
3 Phase
208 VAC
100 Amps
60 Amps
230 VAC
80 Amps
50 Amps
460 VAC
50 Amps
30 Amps
Table 3-1 Electrical Input Connections
NOTE
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).
INSTALLATION, OPERATION AND SETUP
3-2
Manual 0-5287
ARCMASTER 401MST 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. A relay in the Main Power PCB2 will turn on
after the input capacitors have charged to operating voltage (after approximately 5 seconds).
NOTE
Note the available input power. Damage to the PCB could occur if 575VAC or higher is applied.
3.05 High Frequency Introduction
The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference
due to high frequency initiated or stabilised arc is almost invariably traced to improper installation. The following
information is intended as a guide for personnel installing high frequency welding machines.
!
WARNING EXPLOSIVES
The high frequency section of this machine has an output similar to a radio transmitter. The machine
should NOT be used in the vicinity of blasting operations due to the danger of premature firing
!
WARNING COMPUTER
It is also possible that operation close to computer installations may cause computer malfunction.
Manual 0-5287 3-3
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
below. In other cases it could involve constructing
an electromagnetic screen enclosing the Welding
Power Source and the work, complete with
associated input filters. In all cases, electromagnetic
disturbances shall be reduced to the point where
they are no longer troublesome.
3.06 High Frequency Interference
Interference may be transmitted by a high frequency
initiated or stabilised arc welding machine in the
following ways.
1. Direct Radiation: Radiation from the machine can
occur if the case is metal and is not properly grounded.
It can occur through apertures such as open access
panels. The shielding of the high frequency unit in
the Power Source will prevent direct radiation if the
equipment is properly grounded.
NOTE
The welding circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be
authorised by a person who is competent to
assess whether the changes will increase the
risk of injury, e.g. by allowing parallel welding
current return paths which may damage the
earth circuits of other equipment. Further
guidance is given in IEC 60974-13 Arc
Welding Equipment - Installation and use
(under preparation).
2. Transmission via the Supply Lead: Without
adequate shielding and filtering, high frequency energy
may be fed to the wiring within the installation (mains)
by direct coupling. The energy is then transmitted by
both radiation and conduction. Adequate shielding and
filtering is provided in the Power Source.
3. Radiation from Welding Leads: Radiated interference
from welding leads, although pronounced in the vicinity
of the leads, diminishes rapidly with distance. Keeping
leads as short as possible will minimise this type of
interference. Looping and suspending of leads should
be avoided wherever possible.
B. Assessment of Area
4. Re-Radiation from Unearthed Metallic Objects: A
major factor contributing to interference is re-radiation
from unearthed metallic objects close to the welding
leads. Effective grounding of such objects will prevent
re-radiation in most cases.
1. Other supply cables, control cables, signalling
and telephone cables; above, below and adjacent
to the welding equipment.
2. Radio and television transmitters and receivers.
3. Computer and other control equipment.
3.07 Electromagnetic Compatibility
4. Safety critical equipment, e.g. guarding of
industrial equipment.
5. The health of people around, e.g. the use of
pacemakers and hearing aids.
WARNING
Extra precautions for Electromagnetic
Compatibility may be required when this
Welding Power Source is used in a domestic
situation.
6. E q u i p m e n t u s e d f o r c a l i b r a t i o n a n d
measurement.
7. The time of day that welding or other activities
are to be carried out.
A. Installation and Use - Users Responsibility
8. The insulation of other equipment in the
environment: the user shall ensure that other
equipment being used in the environment
is compatible: this may require additional
protection measures.
The user is responsible for installing and using the
welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are
detected then it shall be the responsibility of the user
of the welding equipment to resolve the situation
with the technical assistance of the manufacturer.
In some cases this remedial action may be as
simple as earthing the welding circuit, see NOTE
INSTALLATION, OPERATION AND SETUP
Before installing welding equipment, the user shall
make an assessment of potential electromagnetic
problems in the surrounding area. The following
shall be taken into account
3-4
The size of the surrounding area to be considered
will depend on the structure of the building and other
activities that are taking place. The surrounding area
may extend beyond the boundaries of the premises.
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
C. Methods of Reducing Electromagnetic Emissions
emissions in some, but not all instances. Care
should be taken to prevent the earthing of the
workpiece increasing the risk of injury to users,
or damage to other electrical equipment. Where
necessary, the connection of the workpiece to
earth should be made by direct connection to the
workpiece, but in some countries where direct
connection is not permitted, the bonding should
be achieved by suitable capacitance, selected
according to national regulations.
1. Main Power Supply
Welding equipment should be connected to the
mains supply according to the manufacturer’s
recommendations. If interference occurs, it may
be necessary to take additional precautions such
as filtering of the mains supply. Consideration
should be given to shielding the supply cable
of permanently installed welding equipment
in metallic conduit or equivalent. Shielding
should be electrically continuous throughout its
length. The shielding should be connected to the
Welding Power Source so that good electrical
contact is maintained between the conduit and
the Welding Power Source enclosure.
6. Screening and Shielding
2. Maintenance of Welding Equipment
Selective screening and shielding of other cables
and equipment in the surrounding area may
alleviate problems of interference. Screening the
entire welding installation may be considered for
special applications.
The welding equipment should be routinely
maintained according to the manufacturer’s
recommendations. All access and service doors
and covers should be closed and properly
fastened when the welding equipment is in
operation. The welding equipment should not
be modified in any way except for those changes
and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of
arc striking and stabilising devices should
be adjusted and maintained according to the
manufacturer’s recommendations.
3. Welding Cables
The welding cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor level.
4. Equipotential Bonding
Bonding of all metallic components in the
welding installation and adjacent to it should
be considered. However. Metallic components
bonded to the work piece will increase the
risk that the operator could receive a shock
by touching the metallic components and the
electrode at the same time. The operator should
be insulated from all such bonded metallic
components.
5. Grounding of the Workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
grounding because of it’s size and position, e.g.
ship’s hull or building steelwork, a connection
bonding the workpiece to earth may reduce
Manual 0-5287 3-5
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
3.08 ArcMaster 401MST Power Source Controls, Indicators and Features
9
1
2
8
3
4
7
5
6
17
18
13
10
16
15
11
14
Art # A-12452_AC
Figure 3-2
INSTALLATION, OPERATION AND SETUP
3-6
Manual 0-5287
ARCMASTER 401MST 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.
Please Note: VRD is factory set to OFF on the 401MST. Both LED's will be off. To enable, turn VRD switch on
Control PCB5 (refer to Figure 3-3) to the "ON" position. If VRD is active, green LED will be on. When arc is
established green LED will turn off and red LED will turn on.
Output Voltage
Adjustment
Potentiometer
VRD Switch
Art # A-12454
Control PCB5
Figure 3-3
2 Amphenol Selector (14 PIN / 19 PIN Remote Button)
This button is used to select 14 PIN or 19 PIN mode of operation. Refer to 3.14 Special Function for more info.
When in 14 PIN Remote mode, the 14 PIN control socket is active and remote voltage controls will be active.
When in 19 PIN Remote mode, the 19 PIN control socket is active and remote voltage controls will be active.
Both 14 pin and 19 pin connectors work in all modes.
3 Parameter Selection Button
This button is used to select between HOT START, WELDING CURRENT, and ARC FORCE while in SMAW
(STICK) mode and select between WELDING VOLTAGE and INDUCTANCE CONTROL while in GMAW (MIG)
mode. This button is also used in conjunction with the Save/Load buttons to save and load welding programs.
Refer to 3.14 Special Function for more info.
4 Digital Meter Volt & Ammeter
Welding amperage, Voltage and parameter values are displayed in this window. Internal warnings such as over
temperature, low or high input voltage applied are signaled to the operator by error message on the screen.
When welding, it displays average welding current. After weld has been completed, it displays average welding
current for 10 seconds.
5 Encoder Control
It allows the operator to adjust the weld parameters within the entire range of the power source, also used to
set each parameter value. This control sets the selected weld parameter, rotating it clockwise increases the
parameter value and counterclockwise to decrease. A selected weld parameter can be adjusted at any time
even while welding. Refer to 3.14 Special Function for more info.
Manual 0-5287 3-7
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
6 Save/Load Buttons
By using the Save & Load buttons the operator can easily save up to 10 welding parameter programs (including
welding process, current/ voltage and other parameters such as arc force, inductance and hot start).
To Save a program
• Press and HOLD the SAVE button for 2 seconds.
• Select a job number by rotating the Encoder Control, with job number displayed on the lower meter.
• After selecting the desired job number (i.e. 1 to 10), press Parameter Selection Button (Item 3) to save
the job.
To Load a program
• Press and HOLD the LOAD button for 2 seconds.
• Select a job number by rotating the Encoder Control, with job number displayed on the meter.
• After selecting the desired job number(i.e. 1 to 10), press Parameter Selection Button (Item 3) to load
the job.
7 Process Selection Button
The process selection control is used to select the desired welding mode. Six modes are available for the 401MST:
The MIG function has two modes: MIG (GMAW/FCAW)-The Process light is illuminated; CO2 (GMAW/FCAW)The Process light is blinking.
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 Stick (SMAW)- The Process light is illuminated.
The standard mode will be MIG with argon or argon mixes. The LED for MIG will be on. The other mode will be
dedicated for straight CO2 gas operation. The same LED will be on, but will blink instead.
8 Remote Control
Local Control
Remote Control
The remote control A/V is for both Current or Voltage depending on the process selected. This control toggles
between Local and Remote. Refer to 3.14 Special Function for more info.
INSTALLATION, OPERATION AND SETUP
3-8
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
9 Contactor Control
Local Control
Remote Control
Contactor Control either enables the weld output or assigns this function to a remote device. Refer to 3.14
Special Function for more info.
10 Positive Welding 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.
11 Negative Welding 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.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
12 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 and increases when internal
components reaches operating temperature.
13 14 Pin Remote Control Socket
The 14 pin Remote Control Socket is used to connect Remote Control devices or wire feeders that use a
14 pin connection to the welding Power Source. To make connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
Pin
A
B
C
D
E
F
G
H
I
J
K
M
N
Function
Description
24VAC
Contactor
Connect A&B -> contactor enable
+10VDC Remote Ctrl (Max)
10 VDC for remote potentiometer supply
Remote Ctrl return/common (Min) Common
Remote Demand/Wiper
Remote control demand signal. Voltage: 0<=Vin<=10V
Amperage output signal
Output current signal. 1Vout/100Aout
24/115VAC Common
24/115VAC common and chassis ground
Output voltage signal
Voltage feedback. 1Vout/10Varc
115VAC
Contactor Enable
Connect I&J --> contactor enable
Chassis ground
Arc established
Relay contact between M & N will close while welding is active
Arc established
Table 3-2 14 Pin Interconnection Control Plug Configuration, 401MST
Manual 0-5287 3-9
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
14 19 Pin Remote Control Socket
The 19 pin Remote Control Socket is used to connect Remote Control devices or wire feeders that use a
19 pin connection to the welding Power Source. To make connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
Pin
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
Function
Description
+16VDC contactor
16 VDC supply voltage for contactor. Connect A & B for contactor enable
Contactor in
Contactor input. Connect A & B for contactor enable
Volt Meter
Voltage feedback. 1Vout/10Varc
24VAC
115VAC
24/115VAC neutral
VAC neutral
Ground
+10VDC remote ctrl
10 VDC for remote potentiometer supply
Remote Input
0<=Vin<=10V
Remote ctrl ground/common Also control circuit common
BF04 ground / common
12VDC arc established
+12 VDC while welding active, otherwise off
Ground / common
24VAC
N VAC
24/115VAC neutral and chassis ground
CAN_high
CAN bus; positive signal
CAN_low
CAN bus; negative signal
Amp Meter
Current feedback. 1Vout/100AAout
+24VDC
+ 24VDC CAN supply
Table 3-3 19 Pin Interconnection Control Plug Configuration, 401MST
15 ON/OFF Switch
This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the
Power Supply.
!
WARNING
When the welder is connected to the Primary supply voltage, the internal electrical components may
be at 500V potential with respect to earth.
16 Input Cable
The input cable connects the Primary supply voltage to the equipment.
17.2.5A Circuit Breaker
2.5A Circuit Breaker is for the 115 VAC auxiliary power connected to 14 pin or 19 pin remote control socket.
18.10A Circuit Breaker
10A Circuit Breaker is for the 24 VAC auxiliary power connected to 14 pin or 19 pin remote control socket.
INSTALLATION, OPERATION AND SETUP
3-10
Manual 0-5287
ARCMASTER 401MST 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
Hot Start
This parameter operates in STICK weld mode and is used to improve the
start characteristics for stick electrodes. e.g. low hydrogen electrodes. This
parameter also works in TIG mode allowing a softer or harder arc start. It sets
the peak start current on top of the (WELD) current.
Weld Current (Amperage) - when lit Encoder Control sets the STICK and TIG
WELD current.
Weld Voltage (Volt) – when lit Encoder Control sets the MIG voltage.
Local Control
Contactor operates in MIG, TIG , and Stick modes.
When the local Control LED is illuminated the output is enabled, and when the
Remote Control is illuminated the output is enabled by a remote control.
Remote Control
Contactor Control
Local Control
Selects either local or remote amperage or voltage control depending on the
selected process. Local Control allows the voltage or current to be adjusted
on the front panel, while Remote Control is used if you have a remote control
connected to the welder.
Remote Control
Remote Control
Inductance
This parameter, similar to the Arc Force in Stick mode. In MIG mode,
inductance allows for the adjustment of the dynamic property of the arc. As
the inductance is increased the 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 10
jobs into the 400MST memory.
Table 3-4 Welding Parameters Description
Manual 0-5287 3-11
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
Weld Process Selection
Weld Mode
Weld Parameter
STICK
MIG
LIFT
TIG
WELD (V)
INDUCTANCE
HOT START
×
×
√
√
×
×
√
×
√
√
×
√
√
×
×
WELD (A)
ARC FORCE
Description
Weld voltage MIG Mode.
Inductance control in MIG Mode.
Start current in amps is added or subtracted.
In STICK mode the Hot Start is 100% to 200%,
factory default 125%; while in TIG mode the range
is 50% to 200%, factory default 50%.
WELD (A) current for STICK or LIFT TIG.
Adjusts percentage increase in welding current
and is proportional to arc length (arc voltage).
Table 3-5 Weld Process Selection verses Weld Mode
Weld Parameter Descriptions
WELD (V)
This parameter operates the MIG weld arc voltage in MIG mode.
INDUCTANCE
This parameter operates the INDUCTANCE when MIG welding. It controls the dynamic properties of the arc
in dip transfer welding mode. When this parameter is set to 0%, i.e. minimum inductance, the arc has a fast
response with a resulting crisp arc noise and coarse spatter. When this parameter is set to 200%, i.e. maximum
inductance, the arc has a slow response with a resulting soft arc and fine spatter.
NOTE
As the INDUCTANCE is increased, the WELD (V) may need to be adjusted to achieve the desired weld
characteristic.
HOT START
This parameter operates in Stick and TIG modes. Hot start can subtract 50% of the weld current during arc
starts some times desirable in TIG welding, or add up to 200% of weld current during arc starts, helping with
low hydrogen electrode ignition.
WELD (A)
This parameter operates the Stick, Gouging, and TIG weld current.
ARC FORCE CONTROL
This parameter operates 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). This feature can be particularly beneficial in providing the operator with the ability to compensate for
variability in joint fit up in certain situations with particular electrodes, e.g. cellulose and hydrogen controlled
electrodes. In all welding processes, the amount of penetration obtained is dependent on the welding current;
i.e. the greater the penetration, the greater the current.
Arc Force Position
Minimum (0)
Effect on Welding Performance
Soft arc, Low spatter, Low penetration
Normal arc, Improved fusion
Medium (100%)
characteristics, Normal penetration
Maximum (200%)
Hard arc, Deep penetration
Table 3-6 Weld Parameter Descriptions
INSTALLATION, OPERATION AND SETUP
3-12
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
In general, having the Arc Force set at 200% (maximum) allows greater penetration to be achieved. With the
ARC set at 0% (minimum) the Power Source has a constant current characteristic. In other words, varying the
arc length does not significantly affect the welding current. When the Arc Force is set to 100%, it is possible
to control the welding current by varying the arc length. This is very useful for controlling penetration and
side wall wash on vertical up fillet welds.
i) Root runs
During root runs the weld pool forms a “keyhole” shape. If too much weld current is used, the hole blows
out and the weld collapses. If too little weld current is used, the hole closes up and penetration is lost. The
size of the hole also determines the arc length; i.e. as the hole gets bigger, the arc gets longer.
If arc force is used, the increase in the arc length causes the weld current to decrease until the hole starts
to close up but if the hole closes up to much then the arc length decreases which causes the weld current
to increase. Too little or too much arc force makes this process unstable. The operator must adjust the
arc force until a happy medium is reached.
ii) Vertical up welding
When welding vertical up with arc force on, the operator can control the amount of current by changing arc
length, i.e. 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.
Without arc force, increasing the arc length does not decrease the weld current sufficiently and the operator
has to manually decrease the current via a Remote Control to freeze the weld pool. This welding current
reduction also reduces the penetration.
The arc force allows the weld pool to freeze during the “flick” phase without decreasing the amount of weld
current available during the “dig” phase thus maximizing penetration.
Weld
Parameter
WELD (V)
MIG
Parameter Range
Factory
Setting
Incremental
Unit
10.0 to 38V
20V
0.1V
INDUCTANCE
0 to 200%
100%
HOT START (TIG)
50 to 200%
50%
HOT START (STICK)
100 to 200%
125%
WELD (A) (1 phase)
10 to 300A
100A
TIG or STICK
WELD (A) (3 phase)
10 to 400A
100A
TIG or STICK
ARC FORCE
0 to 200%
100%
Table 3-7 Weld Parameter Setting
Manual 0-5287 3-13
1%
1%
1%
1A
1A
1%
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
3.10 Setup for LIFT 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.
B. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via
dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a
sound electrical connection.
C. Connect the optional TIG Torch to the negative welding terminal (-). Welding current flows from the Power
Source via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely
to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
!
WARNING
Before connecting the work clamp to the work piece make sure the mains power supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable
stationary support to prevent falling or tipping.
D. Ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright
position.
E. Select TIG mode by pressing Process Selection Button until TIG indicator lights up.
F. Connect the TIG Torch trigger switch / remote control to the 14 pin or 19 pin socket on the Power Source as
applicable. It will operate in lift TIG mode with either a remote connected to the 14 or 19 pin connector, or the
contactor enabled on the panel. The TIG Torch will operate in LIFT TIG mode.
G. Fit the Flowmeter/ Regulator to the gas cylinder then connect the gas hose from the TIG Torch to the Flowmeter
outlet. The Power Source is not fitted with a shielding gas solenoid to control the gas flow in LIFT TIG mode,
therefore the TIG Torch will require a gas valve.
TIG Welding Current
Welding current I1
Range
Factory setting
10 to 300 A (1 phase)
10 to 400 A (3 phase)
100
Table 3-8 TIG Welding Current
H. Arc Ignition. Open the valve 19 on the TIG welding torch. Briefly touch the workpiece with the tip of the electrode
at the point to be welded. Lift the electrode a little. The arc burns between the workpiece and the electrode
1
2
Art # A-12455
Figure 3-4 Arc Ignition
INSTALLATION, OPERATION AND SETUP
3-14
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
Graphic for TIG
ICurrent
I1
Welding current
ISt Hot start current
Iz
Short circuit
tTime
tSt Hot start
Art # A-12456
Figure 3-5 TIG Current Routing Diagram
Positive Welding
Terminal (+)
ARCMASTER
401MST
Work Lead
Negative Welding
Terminal (-)
19 Pin Control Socket
Tig Torch
Art # A-12550
Figure 3-6 Setup for TIG (GTAW) Welding
Manual 0-5287 3-15
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
3.11 Setup for STICK (SMAW) Welding
A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.
B. Connect the Electrode Holder to the positive welding terminal (+) (or negative welding terminal (-)). If in doubt,
consult the electrode manufacturer. Welding current flows from the Power Source via dinse type connectors. It
is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
C. Connect the work lead to the negative welding terminal (-) (or positive welding terminal (+)). If in doubt, consult
the electrode manufacturer. Welding current flows from the Power Source via dinse type connectors. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
!
WARNING
The polarity of the electrode depends on the type of electrode and the welding process. Please follow
the manufacturer's instructions on the electrode packaging for this purpose.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
!
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/Gouging and 6010 Process LEDs are
lit (Please refer to Page 3-8 for detailed info).
STICK Welding Current
Welding current l1
Range
10 to 300 A (1 phase)
10 to 400 A (3 phase)
Factory setting
100
Table 3-9 STICK Welding Current
E. Arc ignition. Briefly touch the workpiece at the point to be welded using the electrode and lift the electrode a
little. The arc burns between the workpiece and the electrode.
INSTALLATION, OPERATION AND SETUP
3-16
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
Graphic for SMAW (STICK)
I
Current
I1
Welding current
ISt Hot start current
tTime
tSt Hot start time
Art # A-12457
Figure 3-7 STICK Current Routing Diagram
Positive Welding
Terminal (+)
Electrode Holder
ARCMASTER
401MST
Negative Welding
Terminal (-)
Work Lead
Art # A-12551
Figure 3-8 Setup for STICK (SMAW) Welding
Manual 0-5287 3-17
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
3.12 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire
A wire feeder (optional) is required for MIG welding.
NOTE
NOTE 1: The operations required may differ depending on the version and the configuration of the
wirefeeder!
NOTE 2: Please read the wirefeeder operating manual!
Power Source Connections
A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.
B. Connect the work lead to the negative welding terminal (-) [positive welding terminal(+) for flux cored electrode
wire]. If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via
dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a
sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
!
WARNING
Before connecting the work clamp to the work piece make sure the mains power supply is switched off.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable
stationary support to prevent falling or tipping.
C. Ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright
position.
D. Select MIG mode by pressing Process Selection Button until MIG/ CO2 symbol lights up (Please refer to Page
3-8 for detailed info).
Wirefeeder Connections
A. Connect the welding power cable to the positive welding terminal (+) [negative welding terminal (-) for flux
cored wire]. If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source
via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve
a sound electrical connection.
B. Connect the control cable from the Wirefeeder to the 14 PIN or 19 PIN socket on the Power Source as applicable.
Select appropriate connector by pressing the button on front panel.
INSTALLATION, OPERATION AND SETUP
3-18
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
Positive Welding
Terminal (+)
ARCMASTER 401MST
Negative Welding Terminal (-)
Work Lead
19 Pin Control Socket
Art # A-12552
Wirefeeder
Tweco No. 4 MIG Torch
Figure 3-9 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire
Manual 0-5287 3-19
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
3.13 Setup for FCAW Flux Core Arc Welding
A wire feeder (optional) is required for MIG welding.
NOTE
NOTE 1: The operations required may differ depending on the version and the configuration of the
wirefeeder!
NOTE 2: Please read the wire feed operating manual!
Power Source Connections
A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.
B. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.
Welding current flows from the Power Source via dinse type connectors. It is essential, however, that the male
plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
!
WARNING
Before connecting the work clamp to the work piece make sure the mains power supply is switched off.
C. Select MIG mode by pressing Process Selection Button until MIG/ CO2 symbol lights up (Please refer to Page
3-8 for detailed info).
INSTALLATION, OPERATION AND SETUP
3-20
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
WIREFEEDER CONNECTIONS
A. Connect the welding power cable to the negative welding terminal (-). If in doubt, consult the electrode wire
manufacturer. Welding current flows from the Power Source via dinse type connectors. It is essential, however,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
B. Connect the control cable from the Wirefeeder to the 14 PIN or 19 PIN socket on the Power Source as applicable.
!
WARNING
Before connecting the work clamp to the work piece make sure the mains power supply is switched off.
NOTE
Welding Setup Program Storage (10 programs) applies to MIG, Stick and Lift Tig modes.
Positive Welding
Terminal (+)
Work Lead
ARCMASTER
401MST
Negative Welding Terminal (-)
19 Pin Control Socket
Art # A-12553
Wirefeeder
Tweco No. 4 MIG Torch
Figure 3-10 Setup for FCAW Flux Core Arc Welding
Manual 0-5287 3-21
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
3.14 Special Function
Amphenol Selector
Contactor Control
Parameter Selection
Button
Remote Control
Encoder Control Process Selection Button
Art # A-12458_AB
Figure 3-11
Gouging
In Stick mode hold the Process Selection Button for 2 seconds and the LED will blink indicating Gouging
mode is enabled.
Lock/ Unlock User Interface (UI)
UI Lock Function can be enabled or disabled by pressing Encoder Control for 5 seconds.
NOTE
The function lock setting is saved! If the machine is switched off with the function lock activated, the
control panel is still locked when the machine is switched back on.
LED Test
Press Amphenol Selector or Parameter Selection Button for 2 seconds to start LED test. The test will last for
about 5 seconds. During the test all LEDs are lit.
Enable Calibration in MIG Mode
In MIG mode, the adjustment to output voltage can be enabled or disabled as below:
1. Press Contactor Control and Process Selection Button at the same time for 2 seconds.
2. Rotate Encoder Control to select CAL ON/OFF.
2a.Adjust the output voltage with the potentiometer on Control PCB 5 by +/- 5% (refer to Figure 3-3).
3. Press Encoder Button Encoder Control to save the setting.
Display Software Version
Press Remote Control and Contactor Control buttons at the same time for 2 seconds and it will display the
software version of User Interface (UI), master and process.
Master Reset
!
WARNING
All personal settings will be lost!
The 401MST can have master reset. All the jobs saved will be deleted and all parameters will be set back to
factory setting. This function is accessed by pressing Parameter Selection Button and Remote Control Button
at the same time for 2 seconds.
INSTALLATION, OPERATION AND SETUP
3-22
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
3.15 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.
If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the users
responsibility to prevent such conditions. Before handing or using the equipment, understand and comply at all
times with the safe practices prescribed in this instruction.
SPECIFIC PROCEDURES for the use of flowmeter/ regulators are listed below.
1. NEVER subject the flowmeter/ regulator to inlet pressure greater than its rated inlet pressure.
2. NEVER pressurize a flowmeter/ regulator that has loose or damaged parts or is in a questionable condition.
NEVER loosen a connection or attempt to remove any part of a flowmeter/ regulator until the gas pressure
has been relieved. Under pressure, gas can dangerously propel a loose part.
3. DO NOT remove the flowmeter/ regulator from a cylinder without first closing the cylinder valve and
releasing gas in the flowmeter/ regulator high and low pressure chambers.
4. DO NOT use the flowmeter/ regulator as a control valve. When downstream equipment is not in use for
extended periods of time, shut off the gas at the cylinder valve and release the gas from the equipment.
5. OPEN the cylinder valve SLOWLY. Close after use.
User Responsibilities
This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in
accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced, or
reset as necessary for continued safe and reliable performance. Defective equipment should not be used. Parts
that are broken, missing, obviously worn, distorted, or contaminated should be replaced immediately.
The user of this equipment will generally have the sole responsibility for any malfunction, which results from
improper use, faulty maintenance, or by repair by anyone other than an accredited repairer.
CAUTION
Match flowmeter/ regulator to cylinder. NEVER CONNECT a flowmeter/ regulator designed for a particular
gas or gases to a cylinder containing any other gas.
INLET
CONNECTION
OUTLET
CONNECTION
HIGH PRESSURE
GAUGE (SUPPLY)
FLOW GAUGE (DELIVERY)
PRESSURE
ADJUSTING
SCREW
Art # A-12126
Figure 3-12 Adjusting Flow Rate
Manual 0-5287 3-23
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST 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.
NOTE
All valves downstream of the flowmeter/ regulator must be opened to obtain a true flow rate reading
on the outlet gauge. (Welding power source must be triggered) Close the valves after the pressure
has been set.
Installation
1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices
and damage seats before connecting the flowmeter/ regulator.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.
Wipe with a clean lint free cloth.
2. Match flowmeter/ regulator to cylinder. Before connecting, check that the flowmeter/ regulator label and
cylinder marking agree and that the flowmeter/ regulator inlet and cylinder outlet match. NEVER CONNECT
a flowmeter/ regulator designed for a particular gas or gases to a cylinder containing any other gas.
3. Connect the flowmeter/ regulator inlet connection to cylinder or pipeline and tighten it firmly but not
excessively, with a suitable spanner.
4. Connect and tighten the outlet hose firmly and attach down-stream equipment.
5. To protect sensitive down-stream equipment a separate safety device may be necessary if the flowmeter/
regulator is not fitted with a pressure relief device.
Operation
With the flowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged,
pressurize as follows:
1. Stand to one side of flowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden
pressure surge may damage internal flowmeter/ regulator parts.
2. With valves on downstream equipment closed, adjust flowmeter/ regulator to approximate working pressure.
It is recommended that testing for leaks at the flowmeter/ regulator connection points be carried out using
a suitable leak detection solution or soapy water.
3. Purge air or other unwanted welding grade shielding gas from equipment connected to the flowmeter/
regulator by individually opening then closing the equipment control valves. Complete purging may take
up to ten seconds or more, depending upon the length and size of the hose being purged.
Adjusting Flow Rate
Figure 3-13 Adjust Flow Rate
INSTALLATION, OPERATION AND SETUP
3-24
Manual 0-5287
ARCMASTER 401MST 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.
2. To reduce flow rate, allow the welding grade shielding gas to discharge from flowmeter/ regulator by
opening the downstream valve. Bleed welding grade shielding gas into a well ventilated area and away
from any ignition source. Turn adjusting screw counter clockwise, until the required flow rate is indicated
on the gauge. Close downstream valve.
Shutdown
Close cylinder valve whenever the flowmeter/ regulator is not in use. To shut down for extended periods (more
than 30 minutes).
1. Close cylinder or upstream valve tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from
any ignition source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove Flowmeter/
Regulators.
Manual 0-5287 3-25
INSTALLATION, OPERATION AND SETUP
ARCMASTER 401MST POWER SOURCE
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INSTALLATION, OPERATION AND SETUP
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SECTION 4:
BASIC WELDING GUIDE
4.01 Stick (SMAW) Basic Welding Technique
Size of Electrode
The electrode size is determined by the thickness of metals being joined and can also be governed by the type
of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the
smaller size electrodes.
For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A
little practice will soon establish the most suitable electrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their original containers.
Electrode Polarity
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. 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 may result.
Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes,
preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits
or tempering in a furnace.
Low Hydrogen Electrodes must be used for this application.
B. Austenitic manganese steels
The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it
is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip
welding to distribute the heat.
C. Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally
cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable,
due to the porosity caused by gas held in this type of iron.
D. Copper and alloys
The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections
necessary to give proper fusion of weld and base metal.
Arc Welding Practice
The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally
enough, different types of electrodes would be used for different metals as described in the preceding section.
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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. Some of the common types of welds are shown in Figures 4-5 through 4-12.
Art # A-07687
Figure 4-1: Flat Position, Down Hand Butt Weld
Art A-07691
Figure 4-5: Vertical Position, Butt Weld
Art # A-07688
Figure 4-2: Flat Position, Gravity Fillet Weld
Art # A-07692
Figure 4-6: Vertical Position, Fillet Weld
Art # A-07689
Figure 4-3: Horizontal Position, Butt Weld
Art# A-07693
Figure 4-7: Overhead Position, Butt Weld
Art # A-07690
Figure 4-4: Horizontal-Vertical (HV) Position
Art # A-07694
Figure 4-8: Overhead Position, Fillet Weld
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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.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed
from oxy-cut surfaces. Typical joint designs are shown in Figure 4-9.
Single Vee Butt Joint
Open Square Butt
Joint
Not less than
70°
1.6mm (1/16” ) max
Gap varies from
1.6mm (1/16”) to 4.8mm (3/16”)
depending on plate thickness
1.6mm (1/16”)
Single Vee Butt Joint
Not less than
45°
Double Vee Butt Joint
Lap Joint
Not less than
70°
1.6mm (1/16”) max
1.6mm (1/16”)
Tee Joints
(Fillet both sides of the
joint)
Fillet Joint
Corner Weld
Edge Joint
Plug Weld
Plug Weld
Art # A-07695_AE
Figure 4-9: Typical Joint Designs for Arc Welding
Arc Welding Technique - A Word to Beginners
For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap
plate. Use mild steel plate about thick and a electrode. Clean any paint, loose scale or grease off the plate and set
it firmly on the work bench so that welding can be carried out in the downhand position. Make sure that the work
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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.
The Weldor
Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much
work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon
make you feel tired. Relax and you will find that the job becomes much easier. You can add much to your peace of
mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting
alight to your clothes.
Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder
lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If
the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand.
Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock.
Striking the Arc
Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience difficulty
due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the
work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of
the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck.
As soon as the arc is established, maintain an imperial dimensions 1/16" to 1/8" gap between the burning electrode
end and the parent metal. Draw the electrode slowly along as it melts down.
Another difficulty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the
arc is broken again. A little practice will soon remedy both of these faults.
20°
Art # A-07696_AB
1.6 mm (1/16”)
Figure 4-10: Striking an Arc
Arc Length
The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will find
that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal
comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short arc is essential
if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag
and the electrode tip being solidified in. If this should happen, give the electrode a quick twist back over the weld
to detach it.
Rate of Travel
After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the
molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to
form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be
adjusted so that a well-formed bead is produced.
If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules.
If the travel is too slow, the weld metal piles up and the bead will be too large.
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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. This is to prevent contraction stresses from the cooling weld metal pulling
the plates out of alignment. Plates thicker than 1/4" should have their mating edges bevelled to form a 70º to
90º included angle. This allows full penetration of the weld metal to the root. Deposit a run of weld metal on
the bottom of the joint.
Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a wellformed bead. At first you may notice a tendency for undercut to form, but keeping the arc length short, the
angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this.
The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc.
To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.
20°-30°
Electrode
Tack Weld
Tack Weld
Art # A-07697_AB
Figure 4-11: Butt Weld
Art # A-07698
Figure 4-12: Weld Build up Sequence
Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and
clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run.
Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence
shown in Figure 4-12. The width of weave should not be more than three times the core wire diameter of the
electrode. When the joint is completely filled, the back is either machined, ground or gouged out to remove slag
which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing
bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in
securing proper fusion at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces
meeting at right angles. Refer to Figure 4-4.
A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked
together at right angles. Position angle iron with one leg horizontal and the other vertical. This is known as a
horizontal-vertical (HV) fillet. Strike the arc and immediately bring the electrode to a position perpendicular
to the line of the fillet and about 45º from the vertical. Some electrodes require to be sloped about 20º away
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from the perpendicular position to prevent slag
from running ahead of the weld. Refer to Figure
4-13. Do not attempt to build up much larger than
width with a electrode, otherwise the weld metal
tends to sag towards the base, and undercut forms
on the vertical leg. Multi-runs can be made as
shown in Figure 4-14. Weaving in HV fillet welds
is undesirable.
accumulate in the centre of the weld. Figure
4-16 illustrates multi-run technique and Figure
4-17 shows the effects of pausing at the edge
of weave and of weaving too rapidly.
Art # A-07701
45° from
vertical
60° - 70° from line
of weld
Figure 4-15: Single Run Vertical Fillet Weld
Art # A-07699_AB
Art # A-07702
Figure 4-13: Electrode Position for HV Fillet Weld
Art # A-07700_AB
6
3
5
1
2
4
Figure 4-16: Multi Run Vertical Fillet Weld
Figure 4-`14: Multi-runs in HV Fillet Weld
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron
to your work bench in an upright position.
Use a electrode and set the current. Make
yourself comfortable on a seat in front of the
job and strike the arc in the corner of the fillet.
The electrode needs to be about 10º from
the horizontal to enable a good bead to be
deposited. Refer Figure 4-15. Use a short arc,
and do not attempt to weave on the first run.
When the first run has been completed de-slag
the weld deposit and begin the second run at
the bottom. This time a slight weaving motion
is necessary to cover the first run and obtain
good fusion at the edges. At the completion of
each side motion, pause for a moment to allow
weld metal to build up at the edges, otherwise
undercut will form and too much metal will
BASIC WELDING GUIDE
Art # A-07703
Figure 4-17: Examples of Vertical Fillet Welds
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2. Vertical Down
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. The electrode should point upwards at an angle
of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary, overhead welding is not much more difficult that
downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right
angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in
a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode
is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-18). The tip of the electrode may
be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for
overhead fillet welds. Deposit the first run by simply drawing the electrode along at a steady rate. You will
notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.
Art # A-07704
Figure 4-18: Overhead Fillet Weld
Distortion
Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible,
but in other cases allowance has to be made before welding commences for the distortion that will subsequently
occur. The study of distortion is so complex that only a brief outline can be attempted hear.
The Cause of Distortion
Distortion is caused by:
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a
cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded
joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes
the weld metal to flow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking
volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy
section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still
remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint
in imperial dimensions sheet, the contracting weld metal may cause the sheet to become distorted.
B. Expansion and Contraction of Parent Metal in the Fusion Zone:
While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high
temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface
of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or "along the weld", it
meets considerable resistance, and to fulfil the desire for continued expansion, it has to deform plastically, that
is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes
against the cooler, harder metal further away, and tends to bulge (or is "upset". When the weld area begins to
cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does
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not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal.
Several things can then happen.
The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful
contraction stresses (distortion), or the weld may crack, in any case, there will remain "locked-up" stresses
in the job. Figures 4-19 and 4- 20 illustrate how distortion is created.
Upsetting
Weld
Art # A-07705_AB
Expansion with
compression
Hot
Hot
Cool
Figure 4-19: Parent Metal Expansion
Art # A-07706_AC
Weld
Permanent Upset
Contraction
with tension
Figure 4-20: Parent Metal Contraction
Overcoming Distortion Effects
There are several methods of minimizing distortion effects.
A.Peening
This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of
this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable
on the last layer.
B. Distribution of Stresses
Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that
they tend to cancel each other out. See Figures 4-20 through 4-23 for various weld sequences. Choice of a
suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable
sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful
in eliminating distortion.
C. Restraint of Parts
Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack
welds are methods employed with this in view.
D.Presetting
It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to
calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the
components to be welded, constructional stresses can be made to pull the parts into correct alignment. A
simple example is shown in Figure 4-21.
E.Preheating
Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce
distortion. Figure 4-22 shows a simple application. By removing the heating source from b and c as soon as
welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.
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Art # A-07707
Figure 4-21: Principle of Presetting
Art # A-07428_AB
Figure 4-26: Chain Intermittent Welding
Art # A-07708
B
C
Preheat
Art # A-07713_AB
Preheat
Weld
Dotted lines show effect if no preheat is used
Figure 4-22: Reduction of Distortion by Preheating
Art # A-07709
Figure 4-27: Staggered Intermittent Welding
Figure 4-23: Examples of Distortion
3
2
1
Art # A-07710_AB
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
Figure 4-24: Welding Sequence
4
3
2
1
Art # A-07711_AB
Figure 4-25: Step back Sequence
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4.02 Stick (SMAW) Welding Troubleshooting
FAULT
CAUSE
1 Welding current
fluctuations
REMEDY
ARC FORCE parameter is
set at a value that causes
the welding current to vary
excessively with the arc
length.
2 A gap is left by
A Welding current too low
failure of the weld B Electrode too large for
metal to fill the
joint.
root of the weld.
C Insufficient gap.
Reduce the ARC FORCE parameter until welding
current is reasonably constant while prohibiting the electrode from sticking to the work piece
when you “dig” the electrode into the workpiece.
A Increase welding current.
B Use smaller diameter electrode.
C Allow wider gap.
3 Non-metallic par- A Non-metallic particles may A If a bad undercut is present clean slag bout and
ticles are trapped
be trapped in undercut
cover with a run from a smaller gauge electrode.
in the weld metal.
from previous bead.
B Joint preparation too
restricted.
B Allow for adequate penetration and room for
cleaning out the slag.
C Irregular deposits allow
slag to be trapped.
C If very bad, chip or grind out irregularities.
D Lack of penetration with D Use smaller electrode with sufficient current to
slag trapped beneath weld
give adequate penetration. Use suitable tools to
bead.
remove all slag from comers.
E Rust or mill scale is preventing full fusion.
E Clean joint before welding.
F Wrong electrode for posi- F Use electrodes designed for position in which
tion in which welding is
welding is done, otherwise proper control of slag
done.
is difficult.
Art: A-04971
Figure 1-Example of insufficient gap or incorrect sequence
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4 A groove has been A Welding current is too
formed in the base
high.
metal adjacent to B Welding arc is too long.
the toe of a weld
and has not been
filled by the weld C Angle of the electrode is
incorrect.
metal (undercut).
D Joint preparation does not
allow correct electrode
angle.
E Electrode too large for
joint.
A Reduce welding current.
B Reduce the length of the welding arc.
C Electrode should not be inclined less than 45° to
the vertical face.
D Allow more room in joint for manipulation of the
electrode.
E Use smaller gauge electrode.
F Insufficient deposit time at F Pause for a moment at edge of weave to allow
edge of weave.
weld metal buildup.
5 Portions of the
A Small electrodes used on A Use larger electrodes and preheat the plate.
weld bead do not
heavy cold plate.
fuse to the surface
B Welding current is too low. B Increase welding current.
of the metal or
C Adjust angle so the welding arc is directed more
edge of the joint. C Wrong electrode angle.
into the base metal.
D Travel speed of electrode
is too high.
D Reduce travel speed of electrode.
E Scale or dirt on joint
surface.
E Clean surface before welding.
Art: A-04972
Figure 2: Example of Lack of Fusion
6 Gas pockets or
voids in weld
metal (porosity)
A High levels of sulphur in
steel.
A Use an electrode that is designed for high sulphur steels.
B Electrodes are damp.
B Dry electrodes before use.
C Welding current is too
high.
C Reduce welding current.
D Surface impurities such as D Clean joint before welding.
oil, grease, paint, etc.
E Welding in a windy environment.
E Shield the weld area from the wind.
F Electrode damaged ie flux F Discard damaged electrodes and only use eleccoating incomplete.
trodes with a complete flux coating.
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7 Crack occurring in A Rigidity of joint.
weld metal soon
after solidification B Insufficient throat thickcommences
ness.
C Weld current is too high.
A Redesign to relieve weld joint of severe stresses
or use crack resistance electrodes.
B Travel slightly slower to allow greater build up in
throat.
C Decrease welding current.
Art: A-04973
Figure 3: Example of Slag Inclusion
Table 4-1: Welding Problems SMAW (Stick)
4.03 TIG (GTAW) Basic Welding Technique
Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process
in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable)
electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding
gas which is generally Argon. A filler metal may also be added manually in some circumstances depending on
the welding application.
Art # A-09658_AC
Work Piece
Can Be Any Commercial
Metal
Gas Cup
Either Ceramic,
High-lmpact or
Water Cooled
Metal
Tungsten Electrode
Non-Consumable
Welds Made With or Without
Addition of Filler Metal
Inert Gas
Shields Electrode
and Weld Puddle
Figure 4-28: TIG Welding Application Shot
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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
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter DC Current Range (Amps)
1/16” (1.6mm)
20-90
3/32” (2.4mm)
65-115
1/8” (3.2mm)
100-165
3/16” (4.8mm)
200-350
Table 4-3: Filler Wire Selection Guide
Tungsten Electrode Types
Electrode Type
(Ground Finish)
Welding Application
Features
Colour Code
Thoriated 2%
DC welding of mild steel,
stainless steel and copper
Excellent arc starting, Long
life, High current carrying
capacity
Zirconated 1%
High quality AC welding of
aluminium, magnesium and
their alloys.
Self cleaning, Long life, Maintains balled end, High current
carrying capacity.
White
Ceriated 2%
AC & DC welding of mild
steel, stainless steel, copper,
aluminium, magnesium and
their alloys
Longer life, More stable arc,
Easier starting, Wider current range, Narrower more
concentrated arc.
Grey
Red
Table 4-4: Tungsten Electrode Types
TIG Welding Filler Rods
AWS Std
ER70S-4
ER70S-6
ER70S-2
Type/Application
For mild-medium strength steels.
Pipes, tubing, roll cages, etc.
ER80S-B2
ER90S-B3
For welding of high strength Cr-Mo
steels used at elevated temperatures.
For stainless steels. Stainless pipes,
tubing, architectural uses, etc.
ER308L
ER309L
ER316L
Table 4-5: TIG Welding Filler Rods
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Base Metal
Thickness
DC Current DC Current
for Mild for Stainless
Steel
Steel
Tungsten
Electrode
Diameter
Filler Rod
Diameter (if
required)
Argon Gas
Flow Rate
CFH
Joint Type
0.040”
1.0mm
35-45
40-50
20-30
25-35
0.040”
1.0mm
1/16”
1.6mm
11-15
Butt/Corner
Lap/Fillet
0.045”
1.2mm
45-55
50-60
30-45
35-50
0.040”
1.0mm
1/16”
1.6mm
11-15
Butt/Corner
Lap/Fillet
1/16”
1.6mm
60-70
70-90
40-60
50-70
1/16”
1.6mm
1/16”
1.6mm
15
Butt/Corner
Lap/Fillet
1/8”
3.2mm
80-100
90-115
65-85
90-110
1/16”
1.6mm
3/32”
2.4mm
15
Butt/Corner
Lap/Fillet
3/16”
4.8mm
115-135
140-165
100-125
125-150
3/32”
2.4mm
1/8”
3.2mm
21
Butt/Corner
Lap/Fillet
1/4”
6.4mm
160-175
170-200
135-160
160-180
1/8”
5/32”
3.2mm
4.0mm
Table 4-6: Welding Rate
21
Butt/Corner
Lap/Fillet
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.
4.04 TIG (GTAW) Welding Problems
1
2
3
4
5
FAULT
Excessive bead build up or
poor penetration or poor
fusion at edges of weld.
Weld bead too wide and
flat or undercut at edges
of weld or excessive burn
through.
Weld bead too small or
insufficient penetration or
ripples in bead are widely
spaced apart.
Weld bead too wide or
excessive bead build up or
excessive penetration in
butt joint.
Uneven leg length in fillet
joint
BASIC WELDING GUIDE
CAUSE
Welding current is too
low
REMEDY
Increase weld current and/or faulty joint
preparation.
Welding current is too
high
Decrease weld current.
Travel speed too fast
Reduce travel speed.
Travel speed too slow
Increase travel speed.
Wrong placement of
filler rod
Re-position filler rod.
4-14
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
6
Electrode melts or oxidizes A Torch lead connected
when an arc is struck.
to positive welding
terminal.
B No gas flowing to
welding region.
C Torch is clogged with
dust or dirt.
D Gas hose is cut.
E Gas passage contains
impurities.
7
Dirty weld pool
8
Poor weld finish
9
Arc start is not smooth.
F Gas regulator turned
off.
G The electrode is too
small for the welding
current.
H Power source is set for
STICK welding.
A Electrode contaminated by contact with
work piece or filler rod
material.
B Work piece surface has
foreign material on it.
C Gas contaminated with
air.
Inadequate shielding
gas.
A Tungsten electrode is
too large for the welding current.
B The wrong electrode
is being used for the
welding job.
C Gas flow rate is too
high.
A Connect torch lead to negative welding
terminal.
B Check the gas lines for kinks or breaks
and gas cylinder contents.
C Clean torch.
D Replace gas hose.
E Disconnect gas hose from the rear of
Power Source then raise gas pressure
and blow out impurities.
F Turn on.
G Increase electrode diameter or reduce
the welding current.
H Set Power Source to a GTAW operating
mode.
A Clean the electrode by grinding off the
contaminates.
B Clean surface.
C Check gas lines for cuts and loose fitting
or change gas cylinder.
Increase gas flow or check gas line for
gas flow problems.
A Select the right size tungsten electrode.
Refer to Table 4-3 Tweco Tungsten Electrode Selection Chart.
B Select the right tungsten electrode type.
C Select the right rate for the welding job.
Refer to Table 4-6.
D Incorrect shielding gas D Select the right shielding gas.
is being used.
E Poor work clamp con- E Improve connection to work piece.
nection to work piece.
10 Arc flutters during TIG
welding.
Tungsten electrode is
too large for the welding current.
Select the right size tungsten electrode.
Table 4-7
Manual 0-5287 4-15
BASIC WELDING GUIDE
ARCMASTER 401MST POWER SOURCE
This Page Intentionally Blank
BASIC WELDING GUIDE
4-16
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
SECTION 5:
POWER SOURCE PROBLEMS AND ROUTINE SERVICE
REQUIREMENTS
5.01 Maintenance and Repair
!
WARNING
There are extremely dangerous voltage and power levels present inside this product. Do not attempt
to open or repair unless you are a qualified electrical tradesperson 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
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.
The machine requires a minimum of care and maintenance. Only a few items need to be checked to ensure troublefree long-term operation.
Check the following points for damage before starting up the welding machine,
–– Mains plug and cable
–– Welding torch and connections
–– Keyboard membrane and control panel
Check the dust filter every two months.
–– Switch the machine off
–– Disconnect the mains plug
–– Unscrew the ventilation grid on the rear side
––Check the dust filter for pollution
––Replace the dust filter if it is polluted (dust filter)
Use only original TWECO spare parts for maintenance and repair.
If you experience problems or need repairs, contact a dealer authorised by Victor. Never make repairs or technical
changes yourself. In this case the manufacturer's warranty is no longer valid.
Manual 0-5287 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
ARCMASTER 401MST POWER SOURCE
5.02 Power Source Status Messages
An error code is displayed in the digital displays in the event of a malfunction. You can switch over between error
code and sub-error (sub code) in the digital displays by pressing Process Selection Button.
After the message has been displayed, the machine will only function to a limited extent; the error must be corrected as quickly as possible.
The status message can be deleted by pressing Encoder Control.
Code
H08
Note
Short-circuit
Cause
Short-circuit in the output circuit
H30
Configuration
Component group recognition faulty
H31
Communication
CAN bus communication faulty
Possible Remedy
Eliminate the short-circuit (pick up
electrode holder, ...)
Take to an accredited Tweco Service
Center for repair.
Check connected devices and CAN
connections
Table 5-1 Power Source Status Messages
5.03 Error Messages
!
WARNING
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.
An error code is displayed in the digital displays in the event of a malfunction. You can switch over between error
code and sub-error (sub code) in the digital displays by pressing any button. As long as there is an error code
on display welding is not possible.
Code
Error
E01
Excessive Temperature
E02
E06
Overvoltage
Overvoltage Secondary
E07
EEPROM
E08-1
Excess Wirefeeder Voltage
E08-2
Wirefeeder Motor
E08-3
Overcurrent on Wirefeeder
E08-10
Torch Connection
Cause
Possible Remedy
Duty cycle exceeded
Allow switched-on machine to cool
down for a few minutes
Dust filter contaminated
Replace dust filter
Mains voltage too high
Check mains voltage
Initial voltage too high
Take to an accredited Tweco Service
Center for repair.
Communication with EEPROM Switch machine off and on and
defec­tive
execute Master reset. If error code
returns take to and accredited Tweco
Service Center for repair.
Wirefeeder voltage too high
Take to an accredited Tweco Service
Center for repair.
Error in Wirefeeder Motor
Take to an accredited Tweco Service
Center for repair.
Wirefeeder current continuReduce motor load
ously too high
Torch/torch connection error Check torch and torch connection.
Switch the equipment off and on
again
POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
5-2
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
Code
Error
E08-11
V/I Acquisition
E08-13
CAN Identification
E09
Output Voltage
Voltage measuring system
faulty.
Torch is touching work piece
E12
Power Section
Power section start-up faulty.
Torch is touching work piece
E13
Temperature Sensor
E14
E15
E18
E22
E25
E30
E31
E32
E33
E34
E39
E40
E47
Cause
Voltage/current measuring
systems faulty
Unknown device connected
Possible Remedy
Take to an accredited Tweco Service
Center for repair.
Check connected devices and CAN
connections
Take to an accredited Tweco Service
Center for repair.
Raise Torch from contact with work
piece.
Take to an accredited Tweco Service
Center for repair.
Raise Torch from contact with work
piece.
Take to an accredited Tweco Service
Center for repair.
Check mains voltages
Take to an accredited Tweco Service
Center for repair.
Take to an accredited Tweco Service
Center for repair.
Check mains voltages
Temperature sensor not ready
for operation
Supply Voltage
Internal supply voltage too low
Current Detection
Error during current measurement
Overload Protection
Safety switch device to protect
elec­trical components
Mains Undervoltage
Mains voltage on power unit is
too low
Idle Generator
Idle generator faulty
Take to an accredited Tweco Service
Center for repair.
Error Configuration
Faulty or wrong pc-board,
Take to an accredited Tweco Service
wrong software system
Center for repair.
installed
Communications Fault
CAN bus communication
Switch the equipment off and on
faulty
again
FPGA
FPGA faulty
Take to an accredited Tweco Service
Center for repair.
Power Section
Power module not symmetri- Take to an accredited Tweco Service
cal
Center for repair.
Fans
Fan current faulty
Take to an accredited Tweco Service
Center for repair.
Protective Earth Conductor
Fault current to protective
Connect the welding earth lead
Monitoring
earth con­ductor
Voltage detection
Voltage measurement faulty at Take to an accredited Tweco Service
the socket
Center for repair.
Undefined Mains
Mains voltage between perCheck mains
mitted ranges
Table 5-2 Power Source Error Messages
Manual 0-5287 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
ARCMASTER 401MST POWER SOURCE
5.04 Routine Inspection, Testing & Maintenance
The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician. 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. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.
A transportable power source is deemed to be any equipment that is not permanently connected and fixed in
the position in which it is operated.
B. General Maintenance Checks
Welding equipment should be regularly checked by an accredited Tweco Service Provider to ensure that:
1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly
connected and in good condition.
2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short
circuit.
3. The Welding System is clean internally, especially from metal filing, slag, and loose material.
C.Accessories
Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be
inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable
condition. All unsafe accessories shall not be used.
D.Repairs
If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited
Tweco Service Provider.
5.05 Cleaning the Welding Power Source
!
WARNING
There are dangerous voltage and power levels present inside this product. Do not attempt to open or
repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from
the Mains Supply Voltage before disassembling.
To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated
dirt, metal filings, slag and loose material. Keep the surfaces clean.
POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
5-4
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
SECTION 6:
KEY SPARE PARTS
6.01 401MST Power Source Spare Parts
47
8
3
15
26
23
20
1
36
12
10
33 24
16
13
14
5
32
19
27
4
18
46
45
44
37 29 11 38
39
39
17
6
30
35
28
40
7
9
2
25
32
31
21
22
34
43
42
41
Art # A-12459
Figure 6-1 ArcMaster 401MST Spare Parts
ArcMaster 401MST Spare Parts
Item
Description
Des. Ref.
1
Side Panel Left
2
Side Panel Right
3
Top Panel with Display Sheet
4
Front Panel
5
Rear Panel
6
Front Grill
7
Rear Grill
8
Handle Tube
9
Mains Label
Manual 0-5287 6-1
Quantity
Part Number
1
1
1
1
1
1
1
1
1
W7006700
W7006701
W7006702
W7006703
W7006704
W7006705
W7006706
W7006707
W7006708
KEY SPARE PARTS
ARCMASTER 401MST POWER SOURCE
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
KEY SPARE PARTS
Display Panel Overlay
Strain relief
Foam Spacer
Foam inlay
Foam inlay
Foam Plate Self-adhesive
Rear Filter
Wire Gauze
Knob Body
Knob Cap
Control PCB
PCB 5
Capacitor PCB
PCB 3
Output PCB
PCB 7
ADP10 PCB
PCB 6
Front Panel PCB
PCB 4
Main Power PCB
PCB 2
Input PCB
PCB 1
Aux. Transformer
T2
Main Transformer
T1
ON/OFF Switch
SW1
Bridge Rectifier
BR1
Input Mains Cable
14 pin Remote Socket with Harness
Insulating Bush
Insulation Foil
Insulation Foil
Shunt
Circuit breaker 2.5A 240V (115VAC)
CB1
Circuit breaker 10A 240V (24VAC)
CB2
Protection cover IP64
50 mm Dinse Output Terminal
Output Diode
D1, D2, D3
Unit Thermal Sensor
TS1
Cooling Fan
M1
Display Protection Cover
Label +/- Tweco
Label 401MST
Warning Sticker
Cover Plate (not shown)
Sticker Tweco 261 x 93 (not shown)
Table 6-1 ArcMaster 401MST Spart Parts
6-2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
W7006709
W7006710
W7006711
W7006712
W7006713
W7006714
W7006715
W7006716
W7006717
W7006718
W7006719
W7006720
W7006721
W7006722
W7006723
W7006724
W7006725
W7006726
W7006727
W7006728
W7006729
W7006730
W7006731
W7006732
W7006733
W7006734
W7006735
W7006736
W7006737
W7006738
W7006739
W7006740
W7006741
W7006742
W7006743
W7006744
W7006745
W7006746
W7006747
W7006748
Manual 0-5287
ARCMASTER 401MST POWER SOURCE
APPENDIX A: CIRCUIT DIAGRAM
X1
*
PE
L1
F1
Q1
L2
L3
L1
L2
L3
1
5
7
X5
A13
X7/2
X5/2
X5/3
X5/4
X5/5
X7/1
X5/1
LP4
blue
F2
TR1
KL
A3
X7/1
-
S00.0069.7
1
2
3
4
5
6
7
X1/4
X1/3
X1/2
X1/1
X2/1
M1 M
X2/2
A4
DRV02
X10/1
M2 M
X1
X6/8
X6/7
X6/6
X6/1
X6/2
X6/3
X6/4
X6/5
3
1
4
SF02
2
X5/3
X5/4
B
A
X9/1
X9/2
LP8
red
NEFI
red
LP12
blue
A1
LP7
LP11
+
AC
LP6
~
X7/2
+
LP5
~
LP3
AC
~
LP1
AC
3
LP2
A2
LP13
LP14
-
LP15
DMR05
MF-07
1
2
3
4
5
6
7
X10/2
16
X2/1
X2/2
X2/3
X2/4
X2/6
X2/5
DC01
A9
A10
A11
X1
X7/9
X7/8
X7/5
X5/8
X5/6
X5/7
X7/10
A6
X7/7
X7/1
X7/2
X7/3
X7/6
X7/4
T1
X8/1
X8/2
X8/3
X8/4
X2
10
A8
BF03
X2
A12
BF-Folie
16
X4
16
X6
X6-1
+
A7
X4
9
X6-2
10
X6-3
3
X6-4
4
X6-5
5
X6-6
6
X6-7
7
HR 33
Mapro01
R1
X2
X5/2
X5/1
X6-8
8
X6/9
11
X6/10
12
X6/11
13
X6/12
14
extern
X3
+
-
Art # A-12461
Manual 0-5287 A-1APPENDIX
ARCMASTER 401MST POWER SOURCE
This Page Intentionally Blank
APPENDIX
A-2 Manual 0-5287
TWECO - LIMITED WARRANTY TERMS
LIMITED WARRANTY: Tweco ®, Inc, A Victor Technologies Company, warrants to customers of its authorized
distributors hereafter “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, operated, and maintained in accordance with Tweco’s specifications, instructions, recommendations and recognized
standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects
by suitable repair or replacement, at Tweco’s sole option, of any components or parts of the product determined
by Tweco to be defective.
TWECO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU
OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: TWECO SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of Tweco 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 Tweco 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. No employee, agent, or representative of
Tweco is authorized to change this warranty in any way or grant any other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE
USED WHICH IN TWECO’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY TWECO
PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers
the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more
than the time stated plus one year from the date Tweco delivered the product to the authorized distributor.
This Page Intentionally Blank
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)
1 Years Parts and Labor Unless specified
95S, Water recirculators
All Plasma Welding consols (i.e WC-1 Controller, WT Timer,
WF-100 Capstain Feeder, etc)
180 days parts and Labor Unless specified
Plasma Welding Torch and leads packages
Gas Regulators "Supplied with power sources" (No Labor)
90 days parts / No Labor
Remote Controls
MIG and TIG Torches (Supplied with power sources)
Replacement repair parts
30 days parts / No Labor
MIG Torch for Fabricator 141i
5-2-1 years Parts / No Labor
FirePower® Welders
5 Years Parts / No Labor
Victor® Professional
Victor Technologies limited warranty shall not apply to:
Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that fail due
normal wear
* Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized VICTOR TECHNOLOGIES® repair
facility within thirty (30) days of the repair.
* No employee, agent, or representative of VICTOR TECHNOLOGIES® is authorized to change this warranty in any way or grant any other
warranty, and VICTOR TECHNOLOGIES® shall not be bound by any such attempt. Correction of non-conformities, in the manner and time
provided herein, constitutes fulfillment of VICTOR TECHNOLOGIES®’s obligations to purchaser with respect to the product.
* This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in VICTOR
TECHNOLOGIES®'s sole judgment, impaired the safety or performance of any VICTOR TECHNOLOGIES® product. Purchaser’s rights
under this warranty are void if the product is sold to purchaser by unauthorized persons.
THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph1-940-381-1212
Fax: 1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph1-954-727-8371
Fax: 1-954-727-8376
Oakville, Ontario, Canada
Canada Customer Care
Ph1-905-827-4515
Fax: 1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph+44 1257-261755
Fax: +44 1257-224800
Milan, Italy
Customer Care
Ph+39 0236546801
Fax: +39 0236546840
ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph6221-8990-6095
Fax: 6221-8990-6096
Rawang, Malaysia
Customer Care
Ph+603 6092-2988
Fax: +603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph1300-654-674 (tollfree)
Ph61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph61-3-9474-7508
Fax: 61-3-9474-7488
Shanghai, China
Sales Office
Ph+86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph+65 6832-8066
Fax: +65 6763-5812
INNOVATION TO SHAPE THE WORLD™
U.S. Customer Care: 800-426-1888 / FAX 800-535-0557
Canada Customer Care: 905-827-4515 / FAX 800-588-1714
International Customer Care: 940-381-1212 / FAX 940-483-8178
© 2012 Victor Technologies International, Inc.
www.victortechnologies.com
Printed in China
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