Thermal Arc ArcMaster 300 S Operating Manual_(0

Thermal Arc ArcMaster 300 S Operating Manual_(0
300 S
®
ARCMASTER
INVERTER ARC WELDER
Operating Manual
Version No: 1
Issue Date: March 31, 2006
Manual No: 0-4856
DC CC
Operating Features:
1/3
SMAW
GTAW
PHASE
50Hz
60
INVERTER
208
V
230 460
V
V
300
AMP
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc® product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 800-752-7621, or visit us
on the web at www.thermalarc.com.
This Operating Manual has been designed to instruct you on the correct
use and operation of your Thermal Arc® product. Your satisfaction with
this product and its safe operation is our ultimate concern. Therefore,
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may
exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc® is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer
assumes no liability for its use.
Instruction Manual Number 0-4856 for:
ArcMaster 300 S Inverter Weldiing Power Supply Part No. 10-3093
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright © 2006 by
Thermadyne Industires, 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: March 31, 2006
Record the following information for Warranty purposes:
Where Purchased:
_______________________________
Purchase Date:
_______________________________
Equipment Serial #:
_______________________________
i
ARCMASTER® 300 S
Table of Contents
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS .................................................. 1-1
1.01 Arc Welding Hazards.................................................................................1-1
1.02 Principal Safety Standards ........................................................................1-4
1.03 Precautions De Securite En Soudage A L’arc ............................................1-5
1.04 Dangers relatifs au soudage à l’arc ...........................................................1-5
1.05 Principales Normes De Securite ...............................................................1-8
SECTION 2:
INTRODUCTION AND DESCRIPTION ......................................................... 2-1
2.01 How To Use This Manual ..........................................................................2-1
2.02 Equipment Identification ...........................................................................2-1
2.03 Receipt Of Equipment ...............................................................................2-1
2.04 Symbol Chart ............................................................................................2-2
2.05 Description................................................................................................2-3
2.06 Functional Block Diagrams........................................................................2-3
2.07 Transporting Methods ...............................................................................2-4
SECTION 3:
INSTALLATION RECOMMENDATIONS ........................................................ 3-1
3.01 Environment..............................................................................................3-1
3.02 Location ....................................................................................................3-1
3.03 Electrical Input Connections......................................................................3-1
3.04 Specifications............................................................................................3-4
3.05 Duty Cycle .................................................................................................3-5
SECTION 4:
OPERATOR CONTROLS ........................................................................ 4-1
4.01 ARCMASTER 300 S Controls ....................................................................4-1
4.02 Weld Parameter Description .....................................................................4-2
4.03 Weld Parameters for ARCMASTER 300 S .................................................4-3
4.04 Power Source Features .............................................................................4-4
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG) ............................................. 5-1
SECTION 6:
SEQUENCE OF OPERATION .................................................................... 6-1
6.01 Stick Welding ............................................................................................6-1
6.02 DC LIFT TIG Welding.................................................................................6-1
ii
March 31, 2006
ARCMASTER® 300 S
SECTION 7:
BASIC TIG WELDING GUIDE ................................................................... 7-1
7.01 Electrode Polarity ......................................................................................7-1
7.02 Tungsten Electrode Current Ranges ..........................................................7-1
7.03 Tungsten Electrode Types .........................................................................7-1
7.04 Guide for Selecting Filler Wire Diameter ...................................................7-1
7.05 Shielding Gas Selection ............................................................................7-2
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe .............7-2
SECTION 8:
BASIC ARC WELDING GUIDE .................................................................. 8-1
8.01 Electrode Polarity ......................................................................................8-1
8.02 Effects of Stick Welding Various Materials ................................................8-1
SECTION 9:
ROUTINE MAINTENANCE ..................................................................... 9-1
SECTION 10:
BASIC TROUBLESHOOTING .................................................................. 10-1
10.01 TIG Welding Problems ..........................................................................10-1
10.02 Stick Welding Problems ........................................................................10-3
10.03 Power Source Problems .......................................................................10-4
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD) ....................................................... 11-1
11.01 VRD Specification .................................................................................11-1
11.02 VRD Maintenance .................................................................................11-1
11.03 Switching VRD On/Off...........................................................................11-2
SECTION 12:
POWER SOURCE ERROR CODES ............................................................ 12-1
APPENDIX A:
INTERCONNECT DIAGRAM ................................................................... A-2
APPENDIX B:
OPTIONS AND ACCESSORIES ................................................................. B-1
March 31, 2006
iii
ARCMASTER® 300 S
iv
March 31, 2006
ARCMASTER® 300 S
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL
CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING
OR SERVICING THIS EQUIPMENT.
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.
1.01 Arc Welding Hazards
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts
at once.
WARNING
ELECTRIC SHOCK can kill.
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
semiautomatic 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.
1. Do not touch live electrical parts.
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.
14. Wear a safety harness to prevent falling if working above floor level.
15. Keep all panels and covers securely in place.
WARNING
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.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or
covers.
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.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to equipment
if it will be left unattended or out of service.
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.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material
(wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
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.
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.
March 31, 2006
1-1
ARCMASTER® 300 S
2. Do not weld where flying sparks can strike flammable material.
WARNING
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.
FUMES AND GASES can be hazardous to your health.
4. Be alert that welding sparks and hot materials from welding can easily
go through small cracks and openings to adjacent areas.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instruction for metals, consumables, coatings, and cleaners.
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.
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.
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 air-supplied
respirator. The coatings and any metals containing these elements can
give off toxic fumes if welded.
7. Do not weld on closed containers such as tanks or drums.
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.
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.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
WARNING
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 yourself and others from flying sparks and hot metal.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Electrode Size
Filter
Welding or cutting
Electrode Size
2
Gas metal-arc
3 or 4
Non-ferrous base metal
All
Ferrous base metal
All
Under 1 in., 25 mm
3 or 4
Gas tungsten arc welding
All
1 to 6 in., 25-150 mm
4 or 5
(TIG)
All
Over 6 in., 150 mm
5 or 6
Atomic hydrogen welding
All
Carbon arc welding
All
Under 1/8 in., 3 mm
4 or 5
Plasma arc welding
1/8 to 1/2 in., 3-12 mm 5 or 6
Carbon arc air gouging
Over 1/2 in., 12 mm
6 or 8
Light
Under 5/32 in., 4 mm
10
Heavy
5/32 to 1/4 in.,
12
Plasma arc cutting
Over 1/4 in., 6.4 mm
14
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp
Filter
11
12
12
12
12
12
12
14
9
12
14
March 31, 2006
ARCMASTER® 300 S
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
WARNING
CYLINDERS can explode if damaged.
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.
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.
3. Keep cylinders away from any welding or other electrical circuits.
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.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
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.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use
or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
!
WARNING
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY
ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
Engines can be dangerous.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
WARNING
5. Observe correct polarity (+ and –) on batteries.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away from
any building air intakes.
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn face,
eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
WARNING
ENGINE FUEL can cause fire or explosion.
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
Engine fuel is highly flammable.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
1. Stop engine before checking or adding fuel.
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.
4. Do not overfill tank — allow room for fuel to expand.
March 31, 2006
1-3
ARCMASTER® 300 S
!
1.02 Principal Safety Standards
WARNING
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the State of
California to cause birth defects and, in some cases, cancer.
(California Health & Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
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, OTA-BP-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 and 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.”
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.
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.
National Electrical Code, NFPA Standard 70, from National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
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.
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from body
as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor
for complete information.
1-4
March 31, 2006
ARCMASTER® 300 S
1.03 Precautions De Securite En Soudage A L’arc
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER,
NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE
MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
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.
1.04 Dangers relatifs au soudage à l’arc
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés
ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la
pièce à souder.
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
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.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
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.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
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.
15. Fermez solidement tous les panneaux et les capots.
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA
PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
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.
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.
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.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont
recommandés.
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 porteélectrode.
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.
March 31, 2006
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir)
et des chaussures de sécurité.
1-5
ARCMASTER® 300 S
5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque
le niveau de bruit est élevé.
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
AVERTISSEMENT
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.
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.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal
chaud.
3. Si la ventilation est inadequate, portez un respirateur à adduction d’air
approuvé.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux
métaux, aux produits consummables, aux revêtements et aux produits
nettoyants.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres
autour de l’arc, ou couvrez-les soigneusement avec des bâches
approuvées.
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.
4. Méfiez-vous des projections brulantes de soudage susceptibles de
pénétrer dans des aires adjacentes par de petites ouvertures ou
fissures.
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.
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.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Opération de coupage
ou soudage
Brassage tendre
au chalumeau
Brassage fort
au chalumeau
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
toutes conditions
2
toutes conditions
3 ou 4
Oxycoupage
mince
moins de 1 po. (25 mm)
moyen de 1 á 6 po. (25 á 150 mm)
épais
plus de 6 po. (150 mm)
2 ou 3
4 ou 5
5 ou 6
Soudage aux gaz
mince
moins de 1/8 po. (3 mm)
4 ou 5
5 ou 6
6 ou 8
10
12
14
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
Soudage á l'arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dimensions
12
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plasma (PAW)
moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais plus de 1/2 po. (12 mm)
Soudage á l'arc avec
électrode enrobees
moins de 5/32 po. (4 mm)
(SMAW)
5/32 á 1/4 po. (4 á 6.4 mm)
plus de 1/4 po. (6.4 mm)
1-6
Opération de coupage
ou soudage
Gougeage Air-Arc avec
électrode de carbone
mince
épais
12
14
Coupage á l'arc Plasma (PAC)
mince
moyen
moins de 300 amperès
de 300 á 400 amperès
9
12
épais
plus de 400 amperès
14
March 31, 2006
ARCMASTER® 300 S
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. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
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.
AVERTISSEMENT
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des
écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
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.
1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur
intense, les chocs et les arcs de soudage.
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.
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.
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.
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
1. A r r ê t e z l e m o t e u r a v a n t d e v é r i f i e r l e n i v e a u e
carburant ou de faire le plein.
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.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
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.
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.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE
MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
March 31, 2006
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.
1-7
ARCMASTER® 300 S
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.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1.05 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.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT
SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.
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.
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.
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.
1-8
March 31, 2006
ARCMASTER® 300 S
SECTION 2:
INTRODUCTION AND DESCRIPTION
2.01 How To Use This Manual
2.02 Equipment Identification
This Owner’s Manual applies to just specification or part
numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
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:
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 i for future reference.
!
WARNING
A WARNING gives information regarding possible
personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
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.
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number in
your area listed in the inside back cover of this manual. Include
the Owner’s Manual number and equipment identification
numbers.
Electronic copies of this manual can also be downloaded at
no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
March 31, 2006
2-1
ARCMASTER® 300 S
2.04 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
2-2
Spot Time
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
IPM
Inches Per Minute
Line Connection
Touch Start (GTAW)
MPM
Meters Per Minute
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
Voltage Input
t
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
Disturbance In
Ground System
Art # A-04130
115V 15A
X
%
March 31, 2006
ARCMASTER® 300 S
2.05 Description
The Thermal Arc™ Model ARCMASTER 300 S is a self contained single/three-phase DC arc welding power source with Constant
Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter and lift arc starter for use with
Gas Tungsten Arc Welding (GTAW) and Shielded Metal Arc Welding (SMAW) processes. The power source is totally enclosed
in an impact resistant, flame resistant and non-conductive plastic case.
(V)
(V)
OCV
OCV
18V
10V
160A
5A
25A
300A 320A (A)
300A
S T I C K P r o cess
(A)
L I F T -T I G P r o cess
Figure 1 - Model 300 S volt-ampere curve
NOTE
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source.
Curves of other settings will fall between the curves shown.
2.06 Functional Block Diagrams
Figure 2 illustrates the functional block diagram of the 300 S-power supply.
Input
Power
Main
Circuit
Switch
Filter
Input
Diode
Capacitor
DC Power
Primary
Voltage
Sensor
Main
Transformer
(PCB14)
IGBT
Inverter
Thermal
Detector
Hall Current
Output
Diodes
Thermal
Detector
Transformer
(HCT1)
Output
Inductor
To each control circuit
+/-15VDC +18VDC
+24VDC +5VDC
Trouble
Sensing
Circuit
Drive
Circuit
Stick Mode
VRD
Sensing
Circuit
Themal
Sensor
Circuit
+
-
Lift T ig Mode
Output Short
Sensing
Circuit
Primary
Current
Sensor
+
Sequence
Control
Torch Control
Connection
(CON1)
Current
Adjustment
circuit
-
Fan Control
Circuit
Fan
Reference
Adjustment &
Mode select Switches
Panel Circuit Board
Figure 2 - 300 S Model functional block diagram
March 31, 2006
2-3
ARCMASTER® 300 S
2.07 Transporting Methods
These units are equipped with a handle for carrying
purposes.
!
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH
live electrical parts. Disconnect input power
conductors from de-energized supply line before
moving the welding power source.
!
WARNING
FALLING EQUIPMENT can cause serious personal
injury and equipment damage.
• Lift unit with handle on top of case.
• Use handcart or similar device of adequate capacity.
• If using a fork-lift vehicle, place and secure unit on a
proper skid before transporting.
2-4
March 31, 2006
ARCMASTER® 300 S
SECTION 3:
INSTALLATION RECOMMENDATIONS
3.01 Environment
3.03 Electrical Input Connections
The ARCMASTER 300 S is designed for use in hazardous
environments.
Examples of environments with increased hazardous
environments are a. 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,
b. 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,
c. In wet or damp hot locations where humidity or
perspiration considerably reduces the skin resistance
of the human body and the insulation properties of
accessories.
Environments with hazardous environments do not include
places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard,
have been insulated.
3.02 Location
Be sure to locate the welder according to the following
guidelines:
• In areas free from moisture and dust.
• Ambient temperature between 0 degrees C to 40
degrees C.
• In areas free from oil, steam and corrosive gases.
• In areas not subjected to abnormal vibration or shock.
• In areas not exposed to direct sunlight or rain.
• Place at a distance of 12” (304.79mm) or more from
walls or similar that could restrict natural airflow for
cooling.
!
WARNING
!
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/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
These units are equipped with a three-conductor
with earth power cable that is connected at the
welding power source end for single and three
phase electrical input power.
Do not connect an input (BROWN or BLUE or RED) conductor
to the ground terminal.
Do not connect the ground (YELLOW/GREEN) conductor to an
input line terminal.
Refer to figure 3 and:
Thermal Arc advises that this equipment be
electrically connected by a qualified electrician.
March 31, 2006
3-1
ARCMASTER® 300 S
1. Connect end of ground (YELLOW/GREEN) conductor to a suitable ground. Use a grounding method that complies with
all applicable electrical codes.
2. Connect ends of line 1 (BROWN) and line 2 (BLUE) and line 3 (RED) input conductors to a de-energized line disconnect
switch.
3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.
NOTE
For Single-Phase operation connect the GREEN, BLACK and WHITE input conductors. Insolate the RED Conductor,
it is not used for Single-phase operation.
Input Voltage
208
230
460
Fuse Size
100
90
30
Table 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).
Figure 3 - Electrical Input Connections
3-2
March 31, 2006
ARCMASTER® 300 S
• Input Power
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT BREAKER is turned on,
the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after
the input capacitors have charged to full operating voltage (after approximately 5 seconds).
NOTE
Note the available input power. Damage to the PCA could occur if 575VAC or higher is applied.
The following 208-230/460V Primary Current recommendations are required to obtain the maximum welding current and duty
cycle from this welding equipment:
Primary Supply
Lead Size
(Factory Fitted)
Model
ARCMASTER 300S
8/4 AWG minimum
Minimum Primary
Current Circuit Size
(Vin/Amps)
208/31
230/28
460/14
3
208/45
phase
230/41
460/21
208/51
230/46
1
phase
208/76
230/68
Current & Duty Cycle
TIG
300A @ 40%
STICK
-
-
300A @ 40%
250A @ 40%
-
-
250A @ 40%
Table 2 – 208-230/460V Primary Current Circuit sizes to achieve maximum current
• High Frequency Introduction
The importance of correct installation of high frequency
welding equipment cannot be over-emphasized. Interference
due to high frequency initiated or stabilized 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.
Computers
It is also possible that operation close to computer
installations may cause computer malfunction.
• High Frequency Interference
Interference may be transmitted by a high frequency initiated
or stabilized arc-welding machine in the following ways:
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.
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.
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 minimize this type of interference. Looping and
suspending of leads should be avoided where possible.
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.
March 31, 2006
3-3
ARCMASTER® 300 S
3.04 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle
Stick
TIG
Output Current Range
Open Circuit Voltage
Dimensions
Width
Height
Length
Weight
Output @ Rated Load
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Three Phase
208V
230V
460V
Input Volts Single Phase
208V
230V
300 S
208-230/460VAC
300
32
40%
300A / 32V @ 40% (3ph)
200A / 28V @ 60% (3ph)
250A / 30V @ 40% (1ph)
300A / 22V @ 40% (3ph)
200A / 18V @ 60% (3ph)
200A / 20V @ 40% (1ph)
5 – 300 Amps
65V
8.3” (210mm)
16.5” (420mm)
17.7” (450mm)
44.1 lb. 20 kg
Three-phase
300A
32V
40%
18.0
12.0
Single-phase
250A
30V
40%
15.6
9.4
0.5
0.13
Amperage Draw No Load
@ Rated Load
45
41
21
1.4
1.1
0.7
97
87
2.5
1.8
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change,
improve or revise the specifi cations or design of this or any product without prior notice. Such updates or
changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates,
improvements or replacement of such items.
The values specifi ed in the table above are optimal values, your values may differ. Individual equipment may
differ from the above specifi cations due to in part, but not exclusively, to any one or more of the following;
variations or changes in manufactured components, installation location and conditions and local power grid
supply conditions.
3-4
March 31, 2006
ARCMASTER® 300 S
3.05 Duty Cycle
The duty cycle of a welding power source is the percentage
of a ten (10) minute period that it can be operated at a given
output without causing overheating and damage to the unit.
If the welding amperes decrease, the duty cycle increases. If
the welding amperes are increased beyond the rated output,
the duty cycle will decrease.
!
WARNING
Exceeding the duty cycle ratings will cause the
thermal overload protection circuit to become
energized and shut down the output until the unit
has cooled to normal operating temperature.
CAUTION
Continually exceeding the duty cycle ratings can
cause damage to the welding power source and
will void the manufactures warranty.
NOTE
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.
March 31, 2006
3-5
ARCMASTER® 300 S
3-6
March 31, 2006
ARCMASTER® 300 S
SECTION 4:
OPERATOR CONTROLS
4.01 ARCMASTER 300 S Controls
5
7
6
1
2
3
4
Figure 4 – ARCMASTER 300 S Power Source
1. Control Knob
2. Remote Control Socket
This control sets the selected weld parameter, rotating it
clockwise increases the parameter that is indicated on
the digital meter. Pushing the knob inward displays the
actual welding voltage.
The 14 pin Remote Control Socket is used to connect
remote current control devices to the welding Power
Source. To make connections, align keyway, insert plug,
and rotate threaded collar fully clockwise.
E
A
B
ABCDEFGHIJKLMN
C
J
K
L
D
I
N
M
E
H
G
F
5k ohms
Front view of 14
Socket Receptacle
Socket Pin
Function
A
Torch Switch Input (24V) to energize weld current.
(connect pins A & B to turn on welding current)
B
Torch Switch Input (0V) to energize weld current
(connect pins A & B to turn on welding current)
C
5k ohm (maximum) connection to 5k ohm remote control potentiometer
D
Zero ohm (minimum) connection to 5k ohm remote control potentiometer
E
Wiper arm connection to 5k ohm remote control potentiometer
G
Mains Earth
F,H,I,J,K,L Not Used
M
OK to move current detect signal for robotics applications
N
OK to move current detect signal for robotics applications
March 31, 2006
4-1
ARCMASTER® 300 S
3. Positive Terminal
6. Input Cable
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.
The input cable connects the Primary supply voltage to
the equipment.
7. SMART Logic Switch
4. Negative 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 bayonet terminal.
5. ON/OFF Switch
This switch connects the Primary supply voltage to the
inverter when in the ON position. This enables the Power
Supply.
!
Manual slide switch mounted on the back panel selects
for proper input voltage. If this slide is not set to the
position that matches the input voltage from the electrical
source the Smart Logic circuit will inhibit welding power
source output. The digital meter will show primary input
error code.
NOTE
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.
WARNING
When the welder is connected to the Primary
supply voltage, the internal electrical components
maybe at primary potential with respect to
earth.
4.02 Weld Parameter Description
Figure 5 - ARCMASTER 300 S Front Panel with Parameter Description
4-2
March 31, 2006
ARCMASTER® 300 S
P ar am et er
HOT START
A
D escr i p t i on
This parameter operates in STICK weld mode and is used to improve
the start characteristics for stick electrodes. e.g. low hydrogen
electrodes. It sets the peak start current on top of the (WELD) current.
Weld Current (Amperage)- sets the STICK and TIG WELD current.
ARC CONTROL - This parameter provides a suitable short circuit
current in STICK welding to improve electrode sticking and arc
stability.
LIFT TIG mode of operation. A remote control device may be used for
use during LIFT TIG operation. See section 4.01, section 2 “Remote
Control Socket ”, for complete details of the remote device.
STICK Mode of operation
Contactor operation in STICK Mode
CONTACTOR
Selects in operation Panel board or Remote
REMOTE
Table 3 – Weld Parameter Descriptions
4.03 Weld Parameters for ARCMASTER 300 S
Weld Mode
Weld
Parameter
HOT START
WELD CUR
ARC CONTROL
March 31, 2006
Parameter Range
0 to 70A
5 to 300A DC
0 to 100%
Factory
Setting
20A
80A
10%
Incremental
Unit
1A
1A
1%
STICK
Yes
Yes
Yes
LIFT TIG
No
Yes
No
4-3
ARCMASTER® 300 S
4.04 Power Source Features
Feature
New Digital Control
Touch Panel Switches
Front Control Cover
•
•
•
•
Description
Almost all welding parameters are adjustable
Touch switches eliminate mechanical damage
Protects front panel controls
Displays selected weld parameter value
• Displays weld current when welding
Digital Meter
• Displays weld current for 20 seconds after weld has been
completed
• A selected weld parameter value can be adjusted at any time
even while welding
• The intelligent cooling system is designed to reduce dust and
foreign material build-up, whilst providing optimum cooling.
Intelligent Fan Control
ON/OFF switch
Voltage Reduction Device (VRD)
• Fan speed reduces approximately 30 seconds after machine
is turned on
• Fan speed increases when internal components reaches
operating temperature
• Primary voltage Supply ON/OFF switch located on rear panel
Reduces the OCV when the power supply is not in use. Eliminates
the need for add on voltage reducers and has no effect on arc
starting.
• VRD fully complies to IEC 60974-1
• When Stick mode is selected the green VRD light is ON when
not welding and red when welding.
• When in TIG modes VRD is off.
4-4
March 31, 2006
ARCMASTER® 300 S
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the
Welding Power Source, i.e. connect work lead directly to
work piece and electrode lead is used to hold electrode. Wide
safety margins provided by the coil design ensure that the
Welding Power Source will withstand short-term overload
without adverse effects. The welding current range values
should be used as a guide only. Current delivered to the arc
is dependent on the welding arc voltage, and as welding arc
voltage varies between different classes of electrodes, welding
current at any one setting would vary according to the type of
electrode in use. The operator should use the welding current
range values as a guide, then finally adjust the current setting
to suit the application.
!
WARNING
Before connecting the work clamp to the work
and inserting the electrode in the electrode
holder make sure the Primary power supply is
switched off.
CAUTION
Remove any packaging material prior to use.
Do not block the air vents at the front or rear
or sides of the Welding Power Source.
Figure 6 – 300 S Set-up
March 31, 2006
5-1
ARCMASTER® 300 S
5-2
March 31, 2006
ARCMASTER® 300 S
SECTION 6:
SEQUENCE OF OPERATION
NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show which function
is being adjusted on the weld sequence graph. Refer to Symbols Table located in the front of the
manual for Symbol descriptions.
5
6
1
2
4
3
Figure 7 – 300 S Front Panel
1. Scroll Buttons – used to select the parameter to be set.
The LED’s show which function is being adjusted on the
Sequence Graph.
2. Digital LED display – Welding amperage 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 a warning sound
and error message on the screen.
3. Control knob – allows the operator to adjust the output
amperage within the entire range of the power source,
also used to set each parameter value.
Use the Scroll Buttons to move to the parameter to be set.
The LED will show which function is being adjusted on the
weld sequence graph. Use the control knob to adjust each
parameter.
• Set HOT START
• Set WELD current
• Set Arc Control
Commence welding
6.02 DC LIFT TIG Welding
4. Process Button – This button selects between STICK or
Lift TIG mode.
• Connect work lead to positive terminal
5. Contactor function – Pressing this buttons enables
Contactor functions.
• Switch machine on
6. Remote Current function – Pressing this buttons enables
remote current functions.
6.01 Stick Welding
• Connect work lead to negative terminal
• Connect electrode lead to positive terminal
• Switch machine on
• Connect TIG torch to negative terminal
• Set weld current.
• Connect remote control device if desired
Use the Scroll Buttons to move to the parameter to be set.
The LED will show which function is being adjusted on the
weld sequence graph. Use the control knob to adjust each
parameter.
• Set WELD current
Commence welding
• Set Contactor
• Connect remote control device if required
March 31, 2006
6-1
ARCMASTER® 300 S
6-2
March 31, 2006
ARCMASTER® 300 S
SECTION 7:
BASIC TIG WELDING GUIDE
7.01 Electrode Polarity
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity.
Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since
70% of the heat is concentrated at the work piece.
7.02 Tungsten Electrode Current Ranges
Electrode Diameter
DC Current (Amps)
0.040” (1.0mm)
1/16” (1.6mm)
3/32” (2.4mm)
1/8” (3.2mm)
5/32” (4.0mm)
3/16” (4.8mm)
30 – 60
60 – 115
100 – 165
135 – 200
190 – 280
250 – 340
Table 4 – Current ranges for varies tungsten electrode sizes
7.03 Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Ceriated 2%
Welding Application
DC welding of mild steel,
stainless steel and copper.
Features
Color
Code
Excellent arc starting, Long life,
High current carrying capacity.
Longer life, More stable arc,
DC welding of mild steel,
Easier starting, Wider current
stainless steel, copper,
l i i
i
d
N
Table 5 – Tungsten electrode types
Red
Grey
7.04 Guide for Selecting Filler Wire
Diameter
Filler Wire Diameter
1/16” (1.6 mm)
3/32” (2.4 mm)
1/8” (3.2 mm)
3/16” (4.8 mm)
DC Current Range (Amps)
20 - 90
65 - 115
100 - 165
200-350
NOTE
The filler wire diameter specified in Table 6 is a
guide only, other diameter wires may be used
according to the welding application.
Table 6 – Filler wire selection guide
March 31, 2006
7-1
ARCMASTER® 300 S
7.05 Shielding Gas Selection
Alloy
Aluminium & alloys
Carbon Steel
Stainless Steel
Nickel Alloy
Copper
Titanium
Shielding Gas
Argon
Argon
Argon
Argon
Argon
Argon
Table 7 – Shielding gas selection
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Thoriated 2%
3/32” (2.4 mm)
Current Range DC
Amperes
Filler Rod for Root
Pass
120 - 170
Yes
100 - 160
Yes
90 - 130
No
Joint Preparation
Table 8 – TIG welding parameters for low carbon & low alloy steel pipe
7.07 Welding Parameters for Steel
Base Metal
Thickness
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
3/16”
4.8mm
¼”
6.4mm
DC Current DC Current for Tungsten
for Mild
Stainless
Electrode
Steel
Steel
Diameter
35-45
20-30
0.040”
40-50
25-35
1.0mm
45-55
30-45
0.040”
50-60
35-50
1.0mm
60-70
40-60
1/16”
70-90
50-70
1.6mm
80-100
65-85
1/16”
90-115
90-110
1.6mm
115-135
100-125
3/32”
140-165
125-150
2.4mm
160-175
135-160
1/8”
170-200
160-180
3.2mm
Filler Rod
Diameter
(if required)
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
5/32”
4.0mm
Argon Gas
Flow Rate
Liters/min Joint Type
5-7
Butt/Corner
Lap/ Fillet
5-7
Butt/Corner
Lap/ Fillet
7
Butt/Corner
Lap/ Fillet
7
Butt/Corner
Lap/ Fillet
10
Butt/Corner
Lap/ Fillet
Butt/Corner
10
Lap/ Fillet
Table 9 – DC TIG welding parameters
7-2
March 31, 2006
ARCMASTER® 300 S
SECTION 8:
BASIC ARC WELDING GUIDE
Cast Iron
8.01 Electrode Polarity
Stick electrodes are generally connected to the ‘+’ terminal
and the work lead to the ‘-’ terminal but if in doubt consult
the electrode manufacturers literature.
8.02 Effects of Stick Welding Various
Materials
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. 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.
Manganese steels
The effect on manganese steel of slow cooling from
high temperatures is to em brittle 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.
Metals being joined
Mild steel
Mild steel
Cast iron
Stainless steel
Copper, Bronze, Brass, etc.
High Alloy Steels,
Dissimilar Metals,
Crack Resistance.
All Hard-To-Weld Jobs.
March 31, 2006
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.
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.
Types of Electrodes
Arc Welding electrodes are classified into a number of
groups depending on their applications. There are a
great number of electrodes used for specialized industrial
purposes which are not of particular interest for everyday
general work. These include some low hydrogen types
for high tensile steel, cellulose types for welding large
diameter pipes, etc. The range of electrodes dealt with in
this publication will cover the vast majority of applications
likely to be encountered; are all easy to use and all will
work on even the most basic of welding machines.
Electrode
Comments
Ideal electrodes for all general purpose work.
6013
Features include out standing operator appeal,
easy arc starting and low spatter.
All positional electrode for use on mild and
galvanized steel furniture, plates, fences,
7014
gates, pipes and tanks etc. Especially suitable
for vertical-down welding.
Suitable for joining all cast irons except white
99% Nickel
cast iron.
High corrosion resistance. Ideal for dairy work,
318L-16
etc. On stainless steels.
Easy to use electrode for marine fittings, water
Bronze
taps and valves, water trough float arms, etc.
Also for joining copper to steel and for bronze
5.7
ERCUSI-A
overlays on steel shafts.
It will weld most problematical jobs such as
springs, shafts, broken joins mild steel to
312-16
stainless and alloy steels.
Not suitable for Aluminum.
Table 10 - Types of Electrodes
8-1
ARCMASTER® 300 S
8-2
March 31, 2006
ARCMASTER® 300 S
SECTION 9:
ROUTINE MAINTENANCE
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending
on the usage and the operating environment.
!
WARNING
Disconnect primary power at the source before
opening the enclosure. Wait at least two minutes
before opening the enclosure to allow the primary
capacitors to discharge.
To clean the unit, open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also
be wiped clean, if necessary; with solvents that are recommended for cleaning electrical apparatus.
CAUTION
Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause
metal particles to interfere with sensitive electrical
components and cause damage to the unit.
March 31, 2006
9-1
ARCMASTER® 300 S
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions
Each Use
Visual check of torch
Consumable parts
Visual check of
regulator and pressure
Weekly
Visually inspect the torch
body and consumables
Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all
broken parts
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
Thermal Arc Service Center
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-07331
9-2
March 31, 2006
ARCMASTER® 300 S
SECTION 10:
BASIC TROUBLESHOOTING
!
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or
repair unless you are an Accredited Thermal Arc™ Service Agent and you have had training in power measurements
and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc
Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
10.01 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding
technique.
1.
2.
3.
4.
5.
6.
7.
Description
Excessive beard 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
Electrode melts when arc is
struck.
Dirty weld pool.
A.
March 31, 2006
Possible 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
Electrode is connected to the ‘+’
Connect the electrode to the ‘−’
terminal.
terminal.
Electrode contaminated through A. Clean the electrode by grinding off
contact with work piece or filler rod
the contaminates.
material.
B. Gas contaminated with air.
B. Check gas lines for cuts and loose
fitting or change gas cylinder.
10-1
ARCMASTER® 300 S
8.
9.
Description
Electrode melts or oxidizes when
an arc is struck.
Poor weld finish.
Possible Cause
A. No gas flowing to welding region.
A.
B. Torch is clogged with dust.
C. Gas hose is cut.
D. Gas passage contains impurities.
B.
C.
D.
E. Gas regulator turned off.
E.
F. Torch valve is turned off.
F.
G. The electrode is too small for the G.
welding current.
Inadequate shielding gas.
10. Arc flutters during TIG welding.
A. Tungsten electrode is too large for A.
the welding current.
B. Absence of oxides in the weld pool. B.
11. Welding arc can not be
established.
A. Work clamp is not connected to
the work piece or the work/torch
leads are not connected to the right
welding terminals.
B. Torch lead is disconnected.
C. Gas flow incorrectly set, cylinder
empty or the torch valve is off.
A. Tungsten electrode is too large for
the welding current.
12. Arc start is not smooth.
B.
C.
D.
E.
10-2
A.
Remedy
Check the gas lines for kinks or
breaks and gas cylinder contents.
Clean torch
Replace gas hose.
Disconnect gas hose from torch
then raise gas pressure and blow
out impurities.
Turn on.
Turn on.
Increase electrode diameter or
reduce the welding current.
Increase gas flow or check gas line
for gas flow problems.
Select the right size electrode. Refer
to Basic TIG Welding guide.
Refer Basic TIG Welding Guide for
ways to reduce arc flutter.
Connect the work clamp to the work
piece or connect the work/torch leads
to the right welding terminals.
B. Connect it to the ‘−‘ terminal.
C. Select the right flow rate, change
cylinders or turn torch valve on.
A. Select the right size electrode.
Refer to Section 7, Basic TIG
Welding Guide.
The wrong electrode is being used B. Select the right electrode type.
for the welding job
Refer to Section 7, Basic TIG
Welding Guide.
Gas flow rate is too high.
C. Select the correct rate for the
welding job.
Refer to Section 7, Basic TIG
Welding Guide.
Incorrect shielding gas is being D. Select the right shielding gas.
used.
Refer to Section 7, Basic TIG
Welding Guide.
Poor work clamp connection to work E. Improve connection to work piece.
piece.
March 31, 2006
ARCMASTER® 300 S
10.02 Stick Welding Problems
Description
1. Gas pockets or voids in weld metal
(Porosity).
2. Crack occurring in weld metal soon
after solidification commences
3. A gap is left by failure of the weld
metal to fill the root of the weld.
Possible Cause
A. Electrodes are damp.
B. Welding current is too high.
C. Surface impurities such as oil,
grease, paint, etc.
A. Rigidity of joint.
A.
B. Insufficient throat thickness.
B.
C. Cooling rate is too high.
A. Welding current is too low.
B. Electrode too large for joint.
C.
A.
B.
C. Insufficient gap.
D. Incorrect sequence.
C.
D.
A.
B.
C.
Remedy
Dry electrodes before use.
Reduce welding current.
Clean joint before welding.
Redesign to relieve weld joint
of severe stresses or use crack
resistance electrodes.
Travel slightly slower to allow
greater build up in throat.
Preheat plate and cool slowly.
Increase welding current
Use smaller diameter
electrode.
Allow wider gap.
Use correct build-up sequence.
Figure 8 – Example of insufficient gap or incorrect sequence
4. Portions of the weld run do not fuse A . Small electrodes used on heavy A. Use larger electrodes and pre-heat
to the surface of the metal or edge of
cold plate.
B. the plate.
the joint.
B. Welding current is too low.
Increase welding current
C. Wrong electrode angle.
C. Adjust angle so the welding arc is
directed more into the base metal
D. Travel speed of electrode is too D. Reduce travel speed of electrode
high.
E. Scale or dirt on joint surface.
E. Clean surface before welding.
Figure 9 – Example of lack of fusion
March 31, 2006
10-3
ARCMASTER® 300 S
5. Non-metallic particles are A. Non-metallic particles may be trapped A. If bad undercut is present, clean slag
trapped in the weld metal
in undercut from previous run.
out and cover with a run from a smaller
(slag inclusion).
diameter electrode.
B. Joint preparation too restricted.
B. Allow for adequate penetration and room
for cleaning out the slag.
C. Irregular deposits allow slag to be C. I f v e r y b a d , c h i p o r g r i n d o u t
trapped.
irregularities.
D. Lack of penetration with slag trapped D. Use smaller electrode with sufficient
beneath weld bead.
current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
E. Rust or mill scale is preventing full E. Clean joint before welding.
fusion.
F. Wrong electrode for position in which F. Use electrodes designed for position in
welding is done.
which welding is done, otherwise proper
control of slag is difficult.
Figure 10 – Examples of slag inclusion
10.03 Power Source Problems
Description
Possible Cause
1. The welding arc cannot be A . The Primary supply voltage has not A .
established
been switched ON.
B. The Welding Power Source switch B.
is switched OFF.
C. Loose connections internally.
C.
2. Maximum output welding
current can not be achieved
with nominal Mains supply
voltage.
3. Welding current reduces when
welding
Defective control circuit
Poor work lead connection to the
work piece.
4. No gas flow when the torch A.. Gas hose is cut.
trigger switch is depressed.
B. Gas passage contains impurities.
A..
B.
C. Gas regulator turned off.
C.
D. Torch trigger switch lead is D.
disconnected or switch/cable is
faulty.
10-4
Remedy
Switch ON the Primar y supply
voltage.
Switch ON the Welding Power Source.
Have an Accredited Thermal Arc Service
Agent repair the connection.
Have an Accredited Thermal Arc Service
Agent inspect then repair the welder.
Ensure that the work lead has a
positive electrical connection to the
work piece.
Replace gas hose.
Disconnect gas hose from the rear of
Power Source then raise gas pressure
and blow out impurities.
Turn gas regulator on.
Reconnect lead or repair faulty switch/
cable.
March 31, 2006
ARCMASTER® 300 S
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD)
11.01 VRD Specification
Description
VRD Open Circuit Voltage
ArcMaster 400 S
15.3 to 19.8V
VRD Resistance
148 to 193 ohms
VRD Turn OFF Time
0.2 to 0.3 seconds
11.02 VRD Maintenance
Routine inspection and testing (power source)
An inspection of the power source, an insulation resistance
test and an earth resistance test shall be carried out.
a) For transportable equipment, at least once every 3
months; and
b) For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of
the periodic tests.
Description
VRD Open Circuit Voltage
VRD Turn ON Resistance
VRD Turn OFF Time
Notes
Open circuit voltage between welding terminals
The required resistance between welding
terminals to turn ON the welding power
The time taken to turn OFF the welding power
once the welding current has stopped
NOTE
A transportable power source is any equipment
that is not permanently connected and fixed in
the position in which it is operated.
In addition to the above tests and specifically in relation to
the VRD fitted to this machine, the following periodic tests
should also be conducted by an accredited Thermal Arc
service agent.
IEC 60974-1 Requirements
Less than 20V; at Vin=208-230V or 460V
Less than 200 ohms
Less than 0.3 seconds
If this equipment is used in a hazardous location or environments with a high risk of electrocution then the above tests should
be carried out prior to entering this location.
March 31, 2006
11-1
ARCMASTER® 300 S
11.03 Switching VRD On/Off
Switch the machine Off.
a) Remove the clear plastic cover from the control panel (see Figure 11).
• Lift up the cover so it rests on the top of the unit.
• Place a small flat bladed screw driver between the cover hinge on the front panel.
• Gently lift the cover hinge out of the front cover mounting hole.
• Remove the control’s clear plastic cover.
b) Remove four mounting screws from the control panel (see Figure 12).
c) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see Figure 12).
d) Turning the VRD ON/OFF (see Figure 13).
• To turn VRD ON: rote the trim potentiometer (VR1) on the display PCB fully clockwise. When VRD is turned ON check that
it operates as per VRD Specifications on page 5-13.
• To turn VRD OFF: rote the trim potentiometer (VR1) on the display PCB fully counter clockwise.
Figure 11 - VRD ON/OFF Step A
CAUTION
Do not pull back the front panel with excessive force as this will unplug control PCB. Plugging the control PCB back
into the front panel controls can only be achieved by removing the side covers.
11-2
March 31, 2006
ARCMASTER® 300 S
Figure 12 - VRD ON/OFF Step B,C
!
WARNING
The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the
VRD function will be unknown for every other position.
Figure 13 - VRD ON/OFF Step D
March 31, 2006
11-3
ARCMASTER® 300 S
11-4
March 31, 2006
March 31, 2006
B Have an Accredited Thermal Arc
Service Agent investigate
C Unblock vents then let Power Source
cool down.
A Reduce length of welding arc.
B Fan ceases to operate.
C Air flow is restricted by vents being
blocked
A Primary current is too high because
welding arc is too long.
Weld current ceases.
E02 resets when TH1 decreases to
70ºC for about 30 seconds.
Fan operates at max speed.
Buzzer sounds constantly.
Possible Cause
Remedy
Remarks
A The Welding Power Source’s duty cycle A Let Power Source cool down then keep Weld current ceases.
has been exceeded.
within its duty cycle.
B Fan ceases to operate.
B Have an Accredited Thermal Arc
Buzzer sounds constantly.
Service Agent investigate
C Air flow is restricted by vents being
C Unblock vents then let Power Source Fan operates at max speed.
blocked
cool down.
E01 resets when TH1 decreases to
70ºC for about 30 seconds.
A The Welding Power Source’s duty cycle A Let Power Source cool down then keep Weld current ceases.
has been exceeded.
within its duty cycle.
B Mains supply voltage is more than 10% B Have an Accredited Thermal Arc
Buzzer sounds constantly.
below nominal voltage
Service Agent or a qualified electrician
check for low Mains voltage.
Switch machine off then on to reset
E03 error.
Weld current ceases.
4 E11 error code displayed
Primary supply voltage is greater than
Have an Accredited Thermal Arc
the nominal voltage plus 10%
Service Agent or a qualified electrician
check the Primary voltage.
Over Primary supply (input) voltage
Buzzer sounds constantly.
at primary capacitors is exceeded
for one second
Error code E11 automatically will
reset when the voltage reduces.
Primary (input) current too high
3 E03 error code displayed
Temperature sensor TH2 (protects
secondary diodes) is greater than
80ºC for about 1 second
2 E02 error code displayed
Temperature sensor TH1 (protects
IGBTs) is greater than 80ºC for
Description
1 E01 error code displayed
ARCMASTER® 300 S
SECTION 12:
POWER SOURCE ERROR CODES
12-1
12-2
Link switch plug not connected
8 E82 error code displayed
Wrong Primary supply (input)
voltage connected
7 E81 error code displayed
Under mains supply (input) voltage
primary capacitors is reduced for
one second
6 E12 error code displayed
Under mains supply (input) voltage
warning primary capacitors is
reduced for one second
5 E14 error code displayed
Link switch plug not connected
When 3 phase machine is first turned on
with the wrong Primary supply (input)
voltage connected
Mains supply voltage is down to a
dangerously low level.
Mains supply voltage is less than the
nominal operating voltage less 10%.
Buzzer sounds constantly.
Switch machine off.
Switch machine off.
No weld current is available.
Have an Accredited Thermal Arc
Service Agent check connector plug on
input PCB
Buzzer sounds constantly.
Have an Accredited Thermal Arc
No weld current is available.
Service Agent or a qualified electrician
check the Mains voltage
Error code E12 automatically will
reset when the voltage increases.
Buzzer sounds constantly.
Have an Accredited Thermal Arc
Service Agent or a qualified electrician
check the primary cable & fuses.
A Have an Accredited Thermal Arc
Weld current ceases.
Service Agent or a qualified electrician
check the Mains voltage
Error code E14 automatically will
reset when the voltage increases.
Buzzer sounds intermittently.
Weld current available.
Have an Accredited Thermal Arc
Service Agent or a qualified electrician
check the Mains voltage.
ARCMASTER® 300 S
March 31, 2006
March 31, 2006
Mains supply (input) voltage has
been turned off but control circuit
has power from the primary
capacitors
Switch machine off.
Weld current ceases.
Buzzer sounds constantly.
Must switch machine off then on to
reset E99 error.
Switch machine off.
A Main on/off switch on machine has been A Turn on/off switch on.
Weld current ceases.
turned off
B Mains supply (input) voltage has been
B Have an Accredited Thermal Arc
Buzzer sounds constantly.
turned off
Service Agent or a qualified electrician
check the Mains voltage and fuses
Have an Accredited Thermal Arc
Service Agent check or replace the
temperature sensors.
The Welding Power Source’s
temperature sensors have
malfunctioned.
11 E94 error code displayed
Temperature sensor TH1 for IGBTs
or sensor TH2 for secondary diodes
are open circuit
12 E99 error code displayed
Have an Accredited Thermal Arc
Service Agent check the control PCB
Memory chip (EEPROM) error
10 E93 error code displayed
Memory chip (EEPROM) on control
PCB can not read/write weld
parameters
Switch machine off then on to reset
E83 error.
Weld current ceases.
Buzzer sounds constantly.
Have an Accredited Thermal Arc
No weld current is available.
Service Agent check connector plug on Buzzer sounds constantly.
input PCB and the Mains voltage
The Primary supply (input) voltage
fluctuates and is not stable.
9 E83 error code displayed
CPU checks mains supply (input)
voltage when the on/off switch on
rear panel of machine is turned ON.
ARCMASTER® 300 S
12-3
ARCMASTER® 300 S
12-4
March 31, 2006
ARCMASTER® 300 S
March 31, 2006
13-1
ARCMASTER® 300 S
UB3
+
(1)
P
S1
Line1
P
R(3)
TB1
(0)
C
CE
TB15
E
G
E
C
G1
E1
R2
S(4)
Line2
C
TB14
1
2
3
R2
G2
E2
N
TB2
+
Ground
1
2
3
4
Q4
C
Q13
CE
TB12
E
G
E
C
Q14
PCB10 G
IGBTGate E
CircuitBord
C
[WK-5479]
G4
E4
1
2
3
Q5 G3
1
2
3
4
E3
G
E
C
TB2
C
TB11
Q3
G
E
C
CN2
(2)
TB10
Q2
G
E
C
N
T(5)
Line3
Q1
PCB1
Main
PCB8
CircuitBord IGBTGate G
[WK-5493] CircuitBord E
C
[WK-5479]
TB1
K(7)
G(6)
TB13
CN1
D1
CN1
1
2
Q6
CN2
CN3
APPENDIX A:
INTERCONNECT DIAGRAM
G
E
TB3
Q15
G
E
C
Q16
G
E
C
Q17
G
E
C
Q18
G
E
TB3
D
M
E
H
G
F
1
2
3
G
E
C
Q11
G
E
C
G8
E8
Q12
1
2
3
CN1
Q21
G
E
C
Q22
G
E
C
Q23
G
E
C
Q24
E4
G4
E8
G8
G
E
1 2 3 4 5 6
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
CN20
CN21
CN22
CN23
CN20
CN9
CN8
1 2
1 2 3
1 2
CN18
1 2 3
1
2
3
4
G
E
CN18
CN18
PCB7
Filter
CircuitBord
[WK-5550]
1
2
3
G7
Q10 E7
PCB6
Control
CircuitBord
[WK-5549]
CN14
1
2
CN27
3
CN27
4
5
I
N
1
2
CN17
CN17
Q20
PCB11 G
IGBTGate E
CircuitBord C
[WK-5479]
Q9
G
E
C
CT1
CT2
CT3
CT4
CN130
CN130
CN20
L
TB0
CN15
C
K
EB
PCB3
ControlSouce
CircuitBord
[WK-5548]
G
E
C
CN19
1 2 3
1 2 3
CN17
CN131 CN132
CN131 CN132
CN13
B
CON1
J
CN30
CN30
PCB5
ConectCircuitBord
[WK-5551]
A : Contactor Control /+24VDC
B : Contactor Control /Contactor Clouser To"A"
C : 0 To +10Vdc Output To Remote Control
D : Remote Control Circuit Common
E : 0 To +10Vdc Intput From Remote Control
F : Not Used
G : Chassis Ground
H : Not Used
I : Not Used
J : Not Used
K : Not Used
L : Not Used
M : OK to Move(Current Detect Signal)
N : OK to Move(Current Detect Signal)
L105
CN32
CN32
1
2
3
4
E
1
2
3
4
5
6
7
CN21
CN31
CN31
CN11
1
2
3
4
CN1
CN4
TB7
1
2
3
4
CN1
FAN1
+
CN6
CN6
E1
G1
CN5
CN5
CN7
CN7
230V
PCB4
Detect
CircuitBord
[WK-4819]
Q19
CN2
1 2 3
1
2
3
4
S2
A
1
2
3
4
C
CE
E3
G3
G4
E4
460V
-
1
2
3
C
TB6
E7
G7
CN3
Q8
E6
G6
CN2
G
E
C
TB5
1
2
3
4
CN33
TH2
TH1
P+21V
PGND
1 2 3 4 5
UB1
PCB9 G
IGBTGate E
CircuitBord C
[WK-5479]
G3
E3
CN1
1 2 3
CN4
R2
E
CN1
1
2
3
4
5
6
P
TB20
TB4
1 2 3
N
CE
CN1
REAR
PANEL
TB4
C
TB19
CN2
1
2
3
4
5
1 2
Q7
C
TB18
E2
G2
CN1
SIDECHASSIS 1
CN2
PCB2
Link
CircuitBord
[WK-5597]
E5
G5
PCB21
Filter
CircuitBord
[WK-4917]
E
EC
A-2
March 31, 2006
D5
AC1
PCB14
TRANSBord
[WK-5594]
SH.DET+
PCB15
DIODESnubber
Circuit Bord
[WK-5606]
+15
-15
IS
GND
ARCMASTER® 300 S
4
123
TO1
TB35
+Output
Terminal
AC2
TB33
CT2
CT1
TB7
HCT1
TB21
TB34
CT2
D7
TB8
UB2
L1
D2
TB30
TB16
1 2 3 4 5
UB4
PCB20
Filter Circuit Bord
[WK-5499]
TO2
-Output
Terminal
SH.DET-
AC4
D4
SH.DET+
SH.DET-
AC2
AC4
1 2 3 4 5
1 2 3 4 5 6 7 8 9
CN8
CN9
FRONT
PANEL
EB
+
/RY_ON
PCB12
Panel
Circuit Board
[WK-5527]
1
2
3
4
5
6
+15
-15
IS
GND
Ground
SIDE CHASSIS 2
PCB13
Encorder Board
[WK-5528]
R2
UB1
UB2
R3
CN2
RY+15V
March 31, 2006
SIDE CHASSIS 3
FCH1
CT4
CT3
EB
1
2
3
RY+15V
/RY_ON
TB31
TB17 CT3
Ground
CN3
TB32
TB22
+
CN1
CN1
CN1
UB3
UB4
1 2 3 4
1 2 3 4
A-3
ARCMASTER® 300 S
A-4
March 31, 2006
ARCMASTER® 300 S
APPENDIX B:
OPTIONS AND ACCESSORIES
PRODUCT
PART NO.
Stick Kit
10-4082A
TIG Kit
10-4080
Dinse Connector
Hand Held Pendant
10-2020
10-2005
Foot Control
10-2008
10-2007
Extension Cable
10-2030
10-2031
10-2032
10-2033
10-2034
Torch Switch On/Off
10-2001
Torch Switch On/Off w/current 10-2002
control
10-2003
10-2004
Rack Systems
March 31, 2006
10-4029
10-4031
10-4033
DESCRIPTION
Work clamp with 25’ #1 cable, and stick electrode with 25’ #1
cable
Includes regulator/flowgauge, 12.5ft 200 Amp TIG torch with valve,
accessory kit includes 1 ea of 0040”x7”, 1/16”x7”, 3/32”x7”
2% Tungsten with collet & collet bodies, 1 ea 1/4”, 5/16”, 3/8”
alumina cup
T50mm Dinse style male plug
Includes contactor On/Off switch and current control with 25ft
cable and 14-pin male plug
Contactor On/Off and current control with 15ft cable and 14-pin
male plug
Contactor On/Off and current control with 25ft cable and 14-pin
male plug
3ft with 14-pin male plug and 14-pin female cable receptacle
15ft with 14-pin male plug and 14-pin female cable receptacle
25ft with 14-pin male plug and 14-pin female cable receptacle
50ft with 14-pin male plug and 14-pin female cable receptacle
75ft with 14-pin male plug and 14-pin female cable receptacle
25ft torch mounted with 14-pin male plug
25ft torch mounted with 14-pin male plug - adapts to 5/8”-7/8”
torch
25ft torch mounted with 14-pin male plug - adapts to 7/8”-11/8” torch handle
25ft torch mounted with 14-pin male plug - adapts to 1-1/8”-13/8” torch handle
4 pack w/electrical
6 pack w/electrical
8 pack w/electrical
B-1
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company ("Thermal Arc"),
warrants to customers of authorized distributors ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warranty
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair or
replacement, at Thermal Arc's sole option, of any components or parts of the product
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of
merchantability, fitness for any particular purpose, or other warranty of
quality, whether express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc with respect to any contract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whether
arising out of contract, tort, including negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’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 Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchaser’s rights under this warranty
are void if the product is sold to purchaser by unauthorized 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 Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned goods
shall be at the Purchaser's risk and expense. This warranty dated April 1st 2006
supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered
Trademark of Thermal Arc, Inc.
WARRANTY SCHEDULE
April 2006
ENGINE DRIVEN WELDERS
W ARRANTY P ERIOD
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years
LABOR
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer ............................................................. See the Engine Manufactures Warranty for
Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................ 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
PLASMA WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year
1 year
SMAW (Stick) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
GENERAL ARC EQUIPMENT
W ARRANTY P ERIOD
LABOR
Water Recirculators ....................................................................................................................... 1 year
1 year
Plasma Welding Torches.............................................................................................................180 days
180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days
Replacement repair parts .............................................................................................................90 days
Nil
Nil
MIG, TIG and Plasma welding torch consumable items................................................................... Nil
Nil
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: [email protected]
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
Cigweld, Australia
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: [email protected]
www.thermalarc.com
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