Thermal Arc 300 ACDC Inverter Arc Welder (O)_(0

Thermal Arc 300 ACDC Inverter Arc Welder (O)_(0
300 AC/DC
ARCMASTER
®
INVERTER ARC WELDER
Art # A-07238
Operating Manual
Version No: AB.01
Operating Features:
Issue Date: February 22, 2006
Manual No.: 0-4863
230
460
1/3
208
V
50Hz
60
INVERTER
V
V
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
1-800-752-7621, 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 judgement,
the Manufacturer assumes no liability for its use.
ArcMaster 300 AC/DC Inverter Arc Welder
Instruction Manual Number 0-4863 for:
Part Number 10-3074
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2006 by
Thermadyne Corporation
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: February 22, 2006
Record the following information for Warranty purposes:
Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01
1.02
1.03
1.04
1.05
Arc Welding Hazards ...................................................................................... 1-1
Principal Safety Standards ............................................................................. 1-5
Precautions de Securite en Soudage à L’Arc .................................................. 1-6
Dangers Relatifs au Soudage à L’Arc .............................................................. 1-6
Principales Normes de Securite ................................................................... 1-10
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Symbol Chart ................................................................................................. 2-2
2.05 Description ..................................................................................................... 2-3
2.06 Functional Block Diagrams ............................................................................. 2-4
2.07 Transporting Methods .................................................................................... 2-4
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
Environment ................................................................................................... 3-1
Location ......................................................................................................... 3-1
Electrical Input Connections ........................................................................... 3-1
Electrical Input Requirements ........................................................................ 3-2
Input Power .................................................................................................... 3-3
High Frequency Introduction .......................................................................... 3-3
High Frequency Interference .......................................................................... 3-4
Duty Cycle ...................................................................................................... 3-4
Specifications ................................................................................................. 3-5
SECTION 4:
OPERATOR CONTROLS ............................................................................. 4-1
4.01
4.02
4.03
4.04
4.05
ArcMaster 300 ACDC Controls ....................................................................... 4-1
Weld Process Selection for ArcMaster 300 ACDC .......................................... 4-3
Weld Parameter Descriptions for ArcMaster 300 ACDC ................................. 4-4
Weld Parameters for ArcMaster 300 ACDC .................................................... 4-6
Power Source Features................................................................................... 4-7
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................. 5-1
TABLETABLE
OF CONTENTS
OF CONTENTS
(continued)
SECTION 6:
SEQUENCE OF OPERATION ........................................................................ 6-1
6.01 Stick Welding ................................................................................................. 6-3
6.02 AC or DC HF TIG Welding ............................................................................... 6-3
6.03 Slope Mode Sequence .................................................................................... 6-4
6.04 Slope Mode with Repeat Sequence ................................................................ 6-4
6.05 Pulse Controls ................................................................................................ 6-5
SECTION 7:
BASIC TIG WELDING GUIDE ....................................................................... 7-1
7.01 Explanation of “Fluttery Arc” when AC TIG Welding on Aluminum ................. 7-1
7.02 Electrode Polarity ........................................................................................... 7-2
7.03 Tungsten Electrode Current Ranges ............................................................... 7-2
7.04 Tungsten Electrode Types ............................................................................... 7-2
7.05 Guide for Selecting Filler Wire Diameter ......................................................... 7-3
7.06 Shielding Gas Selection .................................................................................. 7-3
7.07 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe .................. 7-3
7.08 Welding Parameters for Aluminum ................................................................ 7-4
7.09 Welding Parameters for Steel ......................................................................... 7-4
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 ............................................................................. 10-4
10.03 Power Source Problems ............................................................................. 10-7
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
TABLE OF CONTENTS
APPENDIX 1: ARCMASTER 300 AC/DC ACCESSORIES ............................................... A-1
APPENDIX 2: ARCMASTER 300 AC/DC INTERCONNECT DIAGRAM................................. A-2
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
ARCMASTER 300 ACDC
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS.
READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property,
if the operator does not strictly observe all safety rules and take precautionary actions.
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
3. Insulate yourself from work and ground using dry
insulating mats or covers.
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.
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.
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.
1. Do not touch live electrical parts.
9. Do not wrap cables around your body.
2. Wear dry, hole-free insulating gloves and body
protection.
10. Ground the workpiece to a good electrical (earth)
ground.
February 22, 2006
1-1
ARCMASTER 300 ACDC
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.
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.
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.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
4. Wear protective clothing made from durable, flameresistant material (wool and leather) and foot
protection.
5. Use approved ear plugs or ear muffs if noise level is
high.
WARNING
FUMES AND GASES can be hazardous to your
health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
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.
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 Filter
2
Gas metal-arc
3 or 4
Non-ferrous base metal
All
11
Ferrous base metal
All
12
Under 1 in., 25 mm
3 or 4 Gas tungsten arc welding
All
12
1 to 6 in., 25-150 mm 4 or 5
(TIG)
All
12
Over 6 in., 150 mm
5 or 6 Atomic hydrogen welding
All
12
Carbon arc welding
All
12
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
12
Under 5/32 in., 4 mm
10
Heavy
14
5/32 to 1/4 in.,
12
Plasma arc cutting
Over 1/4 in., 6.4 mm
14
Light Under 300 Amp
9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp
14
February 22, 2006
ARCMASTER 300 ACDC
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.
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
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.
2. Do not weld where flying sparks can strike flammable
material.
3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover them
with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
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.
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.
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.
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.
February 22, 2006
1-3
ARCMASTER 300 ACDC
WARNING
Engines can be dangerous.
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.
WARNING
WARNING
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.
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.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
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.
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.
5. Observe correct polarity (+ and –) on batteries.
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.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
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.
WARNING
STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
The coolant in the radiator can be very hot
and under pressure.
1. Do not remove radiator cap when engine is hot. Allow
engine to cool.
2. Wear gloves and put a rag over cap area when
removing cap.
3. Allow pressure to escape before completely removing
cap.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
1-4
February 22, 2006
ARCMASTER 300 ACDC
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.”
To reduce magnetic fields in the workplace, use the
following procedures.
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from
American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 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.
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.
February 22, 2006
1-5
ARCMASTER 300 ACDC
1.03 Precautions de Securite en Soudage à L’Arc
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ
PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT
CONSULTE UN MEDECIN). 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.
1. Ne touchez pas à des pièces sous tension.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE
DES TRAVAUX D’INSTALLATION, DE REPARATION,
2. Portez des gants et des vêtements isolants, secs et
D’ENTRETIEN ET D’ESSAI.
non troués.
1.04 Dangers Relatifs au Soudage à L’Arc
3 Isolez-vous de la pièce à souder et de la mise à la
terre au moyen de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement
ou arrêtez le moteur avant de l’installer ou d’en faire
l’entretien. Bloquez le commutateur en circuit ouvert
ou enlevez les fusibles de l’alimentation afin d’éviter
une mise en marche accidentelle.
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
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.
1-6
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.
6. Arrêtez tout équipement après usage. Coupez
l’alimentation de l’équipement s’il est hors d’usage
ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne
jamais plonger les porte-électrodes dans l’eau pour
les refroidir. Ne jamais les laisser traîner par terre ou
sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre
avec l’électrode ou le porte-électrode.
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.
February 22, 2006
ARCMASTER 300 ACDC
10. N’utilisez qu’une bonne prise de masse pour la mise à
la terre de la pièce à souder.
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.
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.
2. Portez des lunettes de sécurité approuvées. Des écrans
latéraux sont recommandés.
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.
4. Portez des vêtements en matériaux ignifuges et
durables (laine et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille
approuvés lorsque le niveau de bruit est élevé.
AVERTISSEMENT
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.
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (s elon AWS á 8.2-73)
Opération de coupage
ou soudage
Bras sage tendre
au chalum eau
Bras sage fort
au chalum eau
Dim ens ion d'électrode ou
Nuance de
Epiasseur de m étal ou
filtre oculaire
Intensité de courant
toutes conditions
3 ou 4
m étaux non-ferreux
toutes conditions
11
m étaux ferreux
toutes conditions
12
2 ou 3
Soudage á l'arc sous gaz avec
électrode de tungs tène (GTAW)
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dim ens ions
12
m oins de 1 po. (25 m m )
plus de 6 po. (150 m m )
4 ou 5
5 ou 6
Soudage aux gaz
m ince
Soudage á l'hydrogène
atom ique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plas m a (PAW)
m oins de 1/8 po. (3 m m )
m oyen de 1/8 á 1/2 po. (3 á 12 m m )
épais plus de 1/2 po. (12 m m )
Soudage á l'arc avec
électrode enrobees
m oins de 5/32 po. (4 m m )
(SMAW)
5/32 á 1/4 po. (4 á 6.4 m m )
plus de 1/4 po. (6.4 m m )
February 22, 2006
Soudage á l'arc sous gaz
avec fil plein (GMAW)
2
m oyen de 1 á 6 po. (25 á 150 m m )
épais
Dim ens ion d'électrode ou
Nuance de
Epias seur de m étal ou
filtre oculaire
Intensité de courant
toutes conditions
Oxycoupage
m ince
Opération de coupage
ou s oudage
4 ou 5
5 ou 6
6 ou 8
10
12
14
Gougeage Air-Arc avec
électrode de carbone
m ince
épais
12
14
Coupage á l'arc Plasm a (PAC)
m ince
m oyen
m oins de 300 am perès
de 300 á 400 am perès
9
12
épais
plus de 400 amperès
14
1-7
ARCMASTER 300 ACDC
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est
bien ventilée ou que les fumées et les vapeurs sont
aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur
à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du
fabricant relatives aux métaux, aux produits
consummables, aux revêtements et aux produits
nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien
ventilé; sinon, portez un respirateur à adduction d’air.
Les gaz protecteurs de soudage peuvent déplacer
l’oxygène de l’air et ainsi causer des malaises ou la
mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La
chaleur et les rayons de l’arc peuvent réagir avec des
vapeurs et former des gaz hautement toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb
ou au cadmium que si les zones à souder ont été
grattées à fond, que si l’espace est bien ventilé; si
nécessaire portez un respirateur à adduction d’air. Car
ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au
moment du soudage.
1. Protégez-vous, ainsi que les autres, contre les
étincelles et du métal chaud.
2. Ne soudez pas dans un endroit où des particules
volantes ou des projections peuvent atteindre des
matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon
de 10, 7 mètres autour de l’arc, ou couvrez-les
soigneusement avec des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage
susceptibles de pénétrer dans des aires adjacentes
par de petites ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à
portée de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond,
un plancher, une cloison ou une paroi peut enflammer
l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou
un baril.
8. Connectez le câble de soudage le plus près possible
de la zone de soudage pour empêcher le courant de
suivre un long parcours inconnu, et prévenir ainsi les
risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au
tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels
des gants en cuir, une chemise épaisse, un pantalon
revers, des bottines de sécurité et un casque.
AVERTISSEMENT
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE OU
UNE EXPLOSION
L’arc produit des étincellies et des projections.
Les particules volantes, le métal chaud, les
projections de soudure et l’équipement
surchauffé peuvent causer un incendie et des
brûlures. Le contact accidentel de l’électrode
ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un
échauffement ou un incendie.
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.
1-8
February 22, 2006
ARCMASTER 300 ACDC
1. Utilisez l’équipement à l’extérieur dans des aires
ouvertes et bien ventilées.
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.
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
LE CARBURANT PEUR CAUSER UN INCENDIE
OU UNE EXPLOSION.
Le carburant est hautement inflammable.
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.
1. Arrêtez le moteur avant de vérifier le niveau 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. Eloignez les bouteilles de tout circuit électrique ou de
tout soudage.
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. Empêchez tout contact entre une bouteille et une
électrode de soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez
de l’espace pour son expansion.
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.
5. Faites attention de ne pas renverser de carburant.
Nettoyez tout carburant renversé avant de faire
démarrer le moteur.
6. Ne placez pas le visage face à l’ouverture du robinet
de la bouteille lors de son ouverture.
AVERTISSEMENT
7. Laissez en place le chapeau de bouteille sauf si en
utilisation ou lorsque raccordé pour utilisation.
DES PIECES EN MOUVEMENT PEUVENT
CAUSER DES BLESSURES.
8. Lisez et respectez les consignes relatives aux bouteilles
de gaz comprimé et aux équipements connexes, ainsi
que la publication P-1 de la CGA, identifiée dans la
liste de documents ci-dessous.
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.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS
PEUVENT ETRE MORTELS.
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.
Les moteurs produisent des gaz d’échappement nocifs.
February 22, 2006
1-9
ARCMASTER 300 ACDC
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
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.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER
UN ACCUMULATEUR; L’ELECTROLYTE D’UN
ACCUMU-LATEUR PEUT BRULER LA PEAU ET
LES YEUX.
Les accumulateurs contiennent de l’électrolyte
acide et dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un
accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de
déconnecter des câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler
sur un accumulateur.
4. N’utilisez pas une source de courant de soudage pour
charger un accumulateur ou survolter
momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur
n’est pas refroidi.
2. Mettez des gants et posez un torchon sur le bouchon
pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter
complètement le bouchon.
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.
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.
1-10
February 22, 2006
ARCMASTER 300 ACDC
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
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:
!
WARNING
A WARNING gives information regarding
possible personal injury.
2.02 Equipment Identification
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.
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.
CAUTION
A CAUTION refers to possible equipment
damage.
Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
NOTE
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 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
February 22, 2006
2-1
ARCMASTER 300 ACDC
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
115V 15A
2-2
X
%
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Spot Time
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
Voltage Input
Art # A-04130
February 22, 2006
ARCMASTER 300 ACDC
2.05 Description
The Thermal ArcTM Model 300ACDC is a self contained
single/three-phase AC/DC arc welding power source with
Constant Current (CC) output characteristics. This unit is
equipped with a Digital Volt/Amperage Meter, gas control
valve, built in Sloper and Pulser, lift arc starter, and highfrequency arc starter for use with Gas Tungsten Arc
Welding (GTAW), Gas Tungsten Arc Welding-Pulsed
(GTAW-P) Gas Tungsten Arc Welding- Sloped (GTAW-S),
and Shielded Metal Arc Welding (SMAW) processes. The
power source is totally enclosed in an impact resistant,
flame retardant and non-conductive plastic case.
(V)
OCV
Art # A-04980
5A
300A
(A )
300A
(A )
STICK Process
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.
(V)
OCV
10V
25A
LIFT TIG Process
(V)
OCV
5A
300A
(A)
HF TIG Process
Figure 2-1: Model 300 ACDC Volt-Ampere curve
February 22, 2006
2-3
ARCMASTER 300 ACDC
2.06 Functional Block Diagrams
Figure 2-2 illustrates the functional block diagram of the 300 ACDC-power supply.
To each control circuit
+/-12VDC +15VDC
DC Power
Drive
Circuit
Input
Power
Main
Circuit
Switch
Filter
Input
Diode
Capacitor
DC Power
Primary
Voltage
Sensor
Main
Transformer
(PCB14)
IGBT
Inverter
Thermal
Detector
Output
Diodes
Thermal
Detector
Hall Current
Secondary
IGBT
Inverter
Output
Inductor
Transformer
(HCT1)
Coupling
Coil
To each control circuit
+/-15VDC +18VDC
+24VDC +5VDC
Drive
Circuit
Th ermal
Sensor
Circuit
HF-UNIT
Control
Circuit
Stick Mode
VRD
Sensing
Circuit
Lift Tig Mode
Output Short
Sensing
Circuit
High
Frequency
Unit
Primary
Current
Sensor
Trouble
Sensing
Circuit
Sequence
Control
Torch Control
Connection
(CON1)
Current
Adjustment
circuit
Fan Control
Circuit
Fan
Gas Control
Circuit
Solenoid
Reference
Adjustment &
Mode select Switches
Panel Circuit Board
Art # A-04981
Figure 2-2: 300 ACDC Model Functional Block Diagram
2.07 Transporting Methods
These units are equipped with a handle for carrying
purposes.
WARNING
• 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.
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.
2-4
February 22, 2006
ARCMASTER 300 ACDC
SECTION 3:
INSTALLATION
3.01 Environment
The ArcMaster 300 ACDC is designed for use in adverse
environments.
Examples of environments with increased adverse
conditions 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;
3.03 Electrical Input Connections
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.
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 adverse conditions 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 boundaries that could restrict natural
airflow for cooling.
WARNING
Thermal Arc advises that this equipment be
electrically connected by a qualified electrician.
Februrary 22, 2006
3-1
ARCMASTER 300 ACDC
Do not connect an input (WHITE or BLACK or RED)
conductor to the ground terminal.
3.04 Electrical Input Requirements
Operate the welding power source from a single or threephase 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 any inspection required.
Do not connect the ground (GREEN) conductor to an input
line terminal.
Refer to Figure 3-1 and:
1. Connect end of ground (GREEN) conductor to a
suitable ground. Use a grounding method that complies
with all applicable electrical codes.
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.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE)
and line 3 (RED) input conductors to a de-energized line
disconnect switch.
NOTE
3. Use Table 3-1 and Table 3-2 as a guide to select line
fuses for the disconnect switch.
These units are equipped with a threeconductor with earth power cable that is
connected at the welding power source end
for single and three phase electrical input
power.
Input Voltage
208V
230V
480V
Fuse Size
100 Amps
100 Amps
50 Amps
Table 3-1: Electrical Input Connections
NOTE
Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source
(Based on Article 630, National Electrical Code).
Welding Power Supply
Art # A-04982
Ground Conductor
Ground Terminal
Line Disconnect Switch
Line Fuse
Primary Power Cable
3-2
Figure 3-1: Electrical Input Connections
February 22, 2006
ARCMASTER 300 ACDC
3.05 Input Power
3.06 High Frequency Introduction
Each unit incorporates an INRUSH circuit and input voltage
sensing circuit. When the MAIN CIRCUIT SWITCH is
turned on, the inrush circuit provides a pre-charging of
the input capacitors. At this point, the Bus Voltages are
checked and the welder is enabled after the input
capacitors have charged to full operating voltage (after
approximately 5 seconds).
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
NOTE
Note the available input power. Damage to the
welder 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:
The high frequency section of this machine
has an output similar to a radio transmitter.
The machine should NOT be used in the
vicinity of blasting operations due to the
danger of premature firing.
WARNING: COMPUTERS
Primary
Supply
Model
Minimum
Primary
Lead Size
Current
(Factory
Fitted)
Circuit Size
(Vin/Amps)
Current & Duty
Cycle
TIG
STICK
300 @
25%
----
----
300 @
25%
300 @
25%
---
---
300 @
25%
208/31
230/28
3φ
ARC
MASTER
300ACDC
460/14
208/45
230/41
8/4 AWG
minimum
460/21
208/67
1φ
230/60
208/97
230/87
It is also possible that operation close to
computer installations may cause computer
malfunction.
Table 3-2 208/230V Primary Current Circuit sizes to
achieve maximum current
Februrary 22, 2006
3-3
ARCMASTER 300 ACDC
3.07 High Frequency Interference
3.08 Duty Cycle
Interference may be transmitted by a high frequency
initiated or stabilized arc welding machine in the following
ways:
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.
1. Direct Radiation: Radiation from the machine can
occur if the case is metal and is not properly grounded.
It can occur through apertures such as open access
panels. The shielding of the high frequency unit in
the Power Source will prevent direct radiation if the
equipment is properly grounded.
2. Transmission via the Supply Lead: Without adequate
shielding and filtering, high frequency energy may be
fed to the wiring within the installation (mains) by
direct coupling. The energy is then transmitted by
both radiation and conduction. Adequate shielding
and filtering is provided in the Power Source.
3. Radiation from Welding Leads: Radiated interference
from welding leads, although pronounced in the
vicinity of the leads, diminishes rapidly with distance.
Keeping leads as short as possible will minimize this
type of interference. Looping and suspending of leads
should be avoided where possible.
4. Re-radiation from Unearthed Metallic Objects:
A major factor contributing to interference is reradiation from unearthed metallic objects close to the
welding leads. Effective grounding of such objects
will prevent re-radiation in most cases.
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.
3-4
February 22, 2006
ARCMASTER 300 ACDC
3.09 Specifications
Parameter
Rated Output
300ACDC
Amperes
Volts
Duty Cycle
Duty Cycle
300
22
25%
300A / 22V @ 25% 190A / 17V @
60% 150A / 16V @ 100%
TIG
STICK
300A / 32V @ 25%
190A / 27V @ 60%
150A / 26V @ 100%
Output
Current
Range
TIG
5 - 300 (DC) 5 - 300 (AC) @
60Hz, 50% Cleaning
STICK
5 - 300 (DC)
Thermal Arc continuously strives to produce the best
product possible and therefore reserves the right to
change, improve or revise the specifications 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 specified in this table are optimal values, your
values may differ. Individual equipment may differ from
the above specifications 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.
5 - 300 (AC) @ 60Hz,
50% Cleaning
Open Circuit Voltage
65V
Dimensions
Width
8.3” (210mm)
Height
Length
16.5” (420mm)
17.7” (450mm)
Weight
Output @ Rated Load
52.8 lb. 24 kg
Rated Input Voltage
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
Three-phase
300A
32V
25%
18.0
12.0
Single-phase
300A
32V
25%
20.0
12.0
Rated Input Voltage
KVA
KW
Input Volts Three Phase
208V 230V 460V
Three-phase
0.5
0.13
Amperage
Draw @ Rated
Load 45 41 21
Single-phase
0.5
0.13
No Load Amps
1.4 1.3 0.7
Input Volts Single
Phase 208V 230V
Amperage
Draw @ Rated
Load 97 87
No Load Amps
2.5 2.2
Table 3-3: Parameter Specifications
Februrary 22, 2006
3-5
ARCMASTER 300 ACDC
3-6
February 22, 2006
ARCMASTER 300 ACDC
SECTION 4:
OPERATOR CONTROLS
4.01 ArcMaster 300 ACDC Controls
1. Control Knob: 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.
1
435
2
5
4
3
2 . Remote Control Socket: 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.
Art # A-07653
210
E
A
B
Art # A-04983
C
A B C D E F GH I J K L MN
J
K
L
D
I
N
M
E
H
G
F
5k ohms
Front view of 14
Socket Receptacle
Figure 4-2: 14-Socket Receptacle
Socket
Pin
A
450
B
6
8
C
7
D
E
9
Figure 4-1: ArcMaster 300 ACDC Power Source
G
Function
Torch Switch Input (24V) to (connect
pins A & B to turn on welding current).
Torch Switch Input (0V) to energize weld
current (connect pins A & B to turn on
welding current).
5k ohm (maximum) connection to 5k
ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k
ohm remote control potentiometer.
Wiper arm connection to 5k ohm remote
control potentiometer.
Mains Earth.
F,H,I,J,
Not Used.
K,L
OK to move current detect signal for
M
robotics applications.
OK to move current detect signal for
N
robotics applications.
Table 4-1: Socket Pin Functions
February 22, 2006
4-1
ARCMASTER 300 ACDC
3. Positive 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.
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. Gas Outlet: The Gas Outlet is a 5/8 18 UNF female gas
fitting.
6. ON/OFF Switch: This switch connects the Primary
supply voltage to the inverter when in the ON position.
This enables the Power Supply.
WARNING
When the welder is connected to the Primary
supply voltage, the internal electrical
components maybe at 720V potential with
respect to earth.
7. Input Cable: The input cable connects the Primary
supply voltage to the equipment.
8. SMART Logic Switch: 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.
8 . Gas Inlet: The Gas Inlet is a 5/8 18 UNF female gas
fitting.
4-2
February 22, 2006
ARCMASTER 300 ACDC
4.02 Weld Process Selection for ArcMaster 300 ACDC
Weld Mode
Weld Process
Selection
STICK
HF
TIG
LIFT
TIG
Yes
Yes
Yes
STD
2T operation in TIG Modes using remote
devices to control contactor & current
SLOPE
No
Yes
Yes
4T operation in TIG Modes with crater fill
using a remote contactor device to control
sequence.
No
Yes
Yes
4T operation in TIG Modes with repeat
operation and crater fill using a remote
contactor device.
No
Yes
No
2T operation spot welding in HF TIG using
a remote contactor device.
No
Yes
Yes
Pulse operation in TIG Modes
Yes
Yes
Yes
Selects AC or DC weld current
Yes
No
Yes
Contactor operation in Stick Mode
Yes
Yes
Yes
Selects mode of operation Panel or
Remote
REPEAT
SPOT
PULSE ON/OFF
Description
Contactor ON/OFF
Operation
PANEL/REMOTE
Table 4-2: Weld Process selection versus Weld Mode for ArcMaster 300 ACDC
February 22, 2006
4-3
ARCMASTER 300 ACDC
4.03 Weld Parameter Descriptions for ArcMaster 300 ACDC
Art # A-07654
Figure 4-3: ArcMaster 300 ACDC Front Panel
Parameter
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
Description
This parameter operates in TIG modes only and is used to provide gas
to the weld zone prior to striking the arc, once the torch trigger switch
has been pressed. This control is used to dramatically reduce weld
porosity at the start of a weld.
This parameter operates in all weld modes except Lift TIG mode and is
used to heat up the weld zone in TIG modes or improve the start
characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets
the peak start current on top of the BASE (WELD) current.
e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps &
HOT START = 30 amps
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and
is used to set the start current for TIG. The Start Current remains on until
the torch trigger switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to set the time
for the weld current to ramp up, after the torch trigger switch has been
pressed then released, from INITIAL CUR to PEAK or BASE current
Table 4-3: ArcMaster 300 ACDC Front Panel Parameter Description
4-4
February 22, 2006
ARCMASTER 300 ACDC
PEAK CUR.
WELD
This parameter sets the PEAK weld current when in PULSE mode
This parameter sets the TIG WELD current in STD , SLOPE , REPEAT and
SPOT modes when PULSE is off. This parameter also sets the STICK
weld current.
BASE (BackgroundCurrent) This parameter sets the Background current when in Pulse TIG mode.
SPOT TIME
This parameter sets the duration of the SPOT TIME in HF TIG mode only
PULSE WIDTH
This parameter sets the percentage on time of the PULSE FREQUENCY
for PEAK weld current when the PULSE is on.
PULSE FREQ.
This parameter sets the PULSE FREQUENCY when the PULSE is on.
AC FREQUENCY
This parameter operates in AC mode only and is used to set the
frequency for the AC weld current.
WAVE BALANCE
This parameter is used for aluminum AC TIG mode and is used to set the
penetration to cleaning action ratio for the AC weld current. Generally
WAVE BALANCE is set to 50% for AC STICK welding. The WAVE
BALANCE control changes the ratio of penetration to cleaning action of
the AC TIG welding arc. Maximum weld penetration is achieved when
the WAVE BALANCE control is set to 10%. Maximum cleaning of heavily
oxidised aluminium or magnesium alloys is achieved when the WAVE
BALANCE control is set to 65%.
WAVE BALANCE=50%
50%
10%
(+ )
CRATER CUR.
POST-FLOW
WAVE BALANCE=65%
65%
(+ )
(+ )
(-)
(-)
(-)
50%
90%
35%
Balanced with 50% pen etration
an d 50% cle an in g
DOWN SLOPE
WAVE BALANCE=10%
M aximu m Pen etratio n and
redu ced cleaning
Maximum Cle an in g and
red uced pen etration
This parameter operates in TIG modes only and is used to set the time
for the weld current to ramp down, after the torch trigger switch has
been pressed, to CRATER CUR. This control is used to eliminate the
crater that can form at the completion of a weld.
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and
is used to set the finish current for TIG. The CRATER Current remains on
until the torch trigger switch is released after it has been depressed.
This parameter operates in TIG modes only and is used to adjust the
post gas flow time once the arc has extinguished. This control is used to
dramatically reduce oxidation of the tungsten electrode.
The SAVE/LOAD buttons are used to save and retrieve a total number of
5 programs into the 300ACDC memory.
SAUVEGARDER CHARGER
Table 4-3 (continued): ArcMaster 300 ACDC Front Panel Parameter Description
February 22, 2006
4-5
ARCMASTER 300 ACDC
4.04 Weld Parameters for ArcMaster 300 ACDC
PRE-FLOW
HOT START
INITIAL CUR.
UP SLOPE
PULSE PEAK CUR.
PULSE BASE CUR.
WELD CUR.
SPOT TIME
PULSE WIDTH
Parameter
Range
0.0 to 1.0 sec
0 to 70A
5 to 300A
0 to 15 sec
5 to 300A
5 to 300A
5 to 300A
0.5 to 5.0 sec
15 to 80%
Factory
Setting
0 sec
20A
30A
1 sec
120A
80A
80A
2 sec
50%
PULSE FREQ.
0.5 to 500Hz
100.0Hz
AC FREQUENCY
WAVE BALANCE
DOWN SLOPE
CRATER CUR.
POST-FLOW
15 to 150Hz
10 to 65%
0 to 25 sec
5 to 300A
0.0 to 60 sec
60Hz
50%
3 sec
30A
10 sec
Weld Parameter
Incremental
Unit
0.1 sec
1A
1A
0.1 sec
1A
1A
1A
0.1 sec
1%
See Table
Table 4-5
1Hz
1%
0.1 sec
1A
0.1 sec
Weld Mode
HF
STICK
TIG
No
Yes
Yes
Yes
No
Yes
No
Yes
No
Yes
No
Yes
Yes
Yes
No
Yes
No
Yes
LIFT
TIG
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Table 4-4: Weld Parameters for ArcMaster 300 ACDC
PULSE FREQ. Range
0.5 to 20Hz
20 to 100Hz
100 to 500Hz
Incremental Unit
0.1Hz
1Hz
5Hz
Table 4-5: PULSE FREQ. Range and Incremental Units
4-6
February 22, 2006
ARCMASTER 300 ACDC
4.05 Power Source Features
Feature
New Digital Control
Touch Panel Switches
Front Control Cover
Digital Meter
Intelligent Fan Control
ON/OFF Switch
Voltage Reduction
Device (VRD)
Control Knob
Self Diagnosis Using
Error Codes
Save/Load Function
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
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, while providing optimum cooling.
Fan speed reduces approximately 30 seconds after machine is turned on
Fan speed increases when internal components reach 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.
For the selected weld parameter, rotating the knob clockwise increases the
parameter
Rotating the knob counter-clockwise decreases the parameter
A selected weld parameter value can be adjusted at any time even while welding
Pushing the knob in displays actual arc voltage.
An error code is displayed on the Digital Meter when a problem occurs with
Primary supply voltage or internal component problems. Refer to
troubleshooting guide.
A total number of 5 programs can be saved into the 300ACDC memory.
SAVE the Current Weld Parameters into Memory.
Press the SAVE button.
Select a memory location by rotating the control knob, 1 to 5 is displayed on
the meter.
After selecting the desired mem-ory location (ie 1 to 5), press the right scroll
button and the machine will give a beep to confirm the weld parameters from
the control panel are saved.
LOAD (retrieve) a Program to Control Panel.
Press the LOAD button.
Select a memory location by rotating the control knob, 1 to 5 is displayed on
the meter.
After selecting the desired memory location (ie 1 to 5), press the right scroll
button and the machine will give a beep to confirm the weld parameters are
loaded onto the control panel.
Table 4-6:Power Source Features
February 22, 2006
4-7
ARCMASTER 300 ACDC
4-8
February 22, 2006
ARCMASTER 300 ACDC
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the
Welding Power Source, i.e. connect work lead directly to
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.
Art #A-07655
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 5-1: 300 ACDC AC/DC Set-up
CAUTION
DO NOT change the Weld Mode or Weld
Process Mode until after POST-FLOW time has
finished.
February 22, 2006
5-1
ARCMASTER 300 ACDC
5-2
February 22, 2006
ARCMASTER 300 ACDC
SECTION 6:
SEQUENCE OF OPERATION
NOTE:
Scroll Buttons are used to select the parameters to be set. The LED’s show which function is being
adjusted on the weld sequence graph. Refer to the Symbols Table located in the front of the manual for
Symbol descriptions.
Art # A-07654
Figure 6-1a: 300 ACDC Front Panel
February 22, 2006
6-1
ARCMASTER 300 ACDC
9
1
Art # A-07656
10
2
8
5
3
7
4
6
Figure 6-1b: 300 ACDC Front Panel
1. Pulse Function:
Pressing this button enables the TIG current pulse
functions.
6. Control Knob: Allows the operator to adjust the output amperage within the entire range of the power
source and sets each parameter value.
2. Remote Current function:
Pressing this button enables remote current functions.
7. Process Button:
This button selects between STICK, HF TIG and Lift
TIG mode.
3. TIG Mode Functions:
Pressing this button scrolls through the output TIG
function modes (Standard, Slope, Slope w/repeat,
Spot).
8. Scroll Buttons:
Used to select the parameters to be set. The LED's
show which function is being adjusted on the
Sequence Graph.
4. 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.
9. AC/DC Button:
Selects between AC or DC welding output.
10.Contactor Function:
Pressing this button enables Contactor functions.
5. Save/Load Buttons:
By using the Save & Load buttons the operator can
easily save up to 5 welding parameter programs.
6-2
February 22, 2006
ARCMASTER 300 ACDC
6.01 Stick Welding
6.02 AC or DC HF TIG Welding
· Connect work lead to negative terminal
· Connect work lead to positive terminal
· Connect electrode lead to positive terminal
· Connect TIG torch to negative terminal
· Switch machine on
· Switch machine on
· Set AC or DC weld current. If AC is selected then set
AC FREQ to 60Hz & WAVE BALANCE to 50%.
· Set AC or DC weld current. If AC is selected then set
AC FREQ & WAVE BALANCE
· Connect remote control device if required.
· Connect remote control device. . See section 4.01,
2. Remote Control Socket, for complete details of
the remote device.
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
Commence welding
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 PRE-FLOW time
· Set HOT START current
· Set POST-FLOW time
· Set WELD current
· Set POST-FLOW time
Slope Mode Parameters if required
· Set INITIAL CUR current
· Set UP SLOPE time
· Set (WELD) PEAK CUR current
· Set BASE current
· Set DOWN SLOPE time
· Set CRATER CUR current
Pulse Mode parameters if required
· Set PULSE WIDTH % for PEAK CURRENT
· Set PEAK CURRENT
· Set PULSE FREQ
Commence welding
February 22, 2006
6-3
ARCMASTER 300 ACDC
6.03 Slope Mode Sequence
Art # A-04989
Switch
Closed
Initial
Current
Switch
Open
Up
Slope
Switch
Closed
Weld Current
Down
Slope
Switch
Open
Final
Current
Postflow
Preflow
Figure 6-2: Slope Mode Sequence
1. To start the Slope Sequence, close remote switch
contacts. Once the welding arc is established the
Power Source will maintain the initial current setting
as long as the remote switch contacts are closed.
2. Open Remote Switch – current increases to weld
current. Once welding arc has reached weld current
the power source will maintain weld current as long
as the remote switch contacts are open.
a. In the HF TIG mode, after Preflow time, High
Frequency is present at the torch. When the torch
is positioned close to the work the welding current
will transfer to the work and establish the arc at
the initial current setting.
3. Close Remote Switch – Welding current decreases to
final current setting. Once final welding current is
reached the power source will maintain final current
setting as long as the remote switch contacts are
closed.
b. In the Lift TIG mode, after Preflow time, Lift Start
current is present at the torch. When the electrode
is touched to the work and lifted off, the welding
arc is established at the initial current setting.
4. Open Remote Switch – Welding arc stops and post
flow begins.
6.04 Slope Mode with Repeat Sequence
The repeat function is operated during the down slope
cycle of the Slope Sequence and is active through the
down slope period only. During the down slope period,
by opening the Remote Switch contacts, the current will
increase back to weld current. Within the Down Slope
period the repeat function can be operated as many times
as desired. To continue slope cycle and end slope
sequence close remote switch contacts and allow weld
current to reach final current setting. Once final current
setting is reached, opening the Remote Switch again will
turn off the welding arc and post flow begins.
6-4
February 22, 2006
ARCMASTER 300 ACDC
6.05 Pulse Controls
(Pulse Width)
(Pulse Frequency)
Art # A-04990
(Peak Current)
(Base)
Background
Current
Figure 6-3: Pulse Controls
The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows:
1) Control puddle – size and fluidity (especially out of position).
2) Increase penetration
3) Travel speed control
4) Better consistent quality
5) Decreased distortion on lighter or thinner materials.
Pulse-current provides a system in which the welding current continuously changes between two levels. During the
periods of Peak current, heating and fusion takes place, and during the background (base) current periods, cooling
and solidification take place. Pulse Width is the time in one cycle the current remains at the peak current setting.
Pulse Frequency, measured in Hertz, is the number of cycles per second the current travels between peak and background
current settings. It is as if the foot rheostat were moved up and down to increase and decrease the welding current on
a regular basis. The faster you move the foot rheostat up and down the faster the frequency.
February 22, 2006
6-5
ARCMASTER 300 ACDC
6-6
February 22, 2006
ARCMASTER 300 ACDC
SECTION 7:
BASIC TIG WELDING GUIDE
7.01 Explanation of “Fluttery Arc” when
AC TIG Welding on Aluminum
The following will assist in understanding the
phenomenon of Arc Flutter, also referred to as Arc
Rectification.
The basic thesis is that the fluttering is caused by lack of
oxide in the weld pool.
The oxide layer on the plate reduced the energy for
electron emission. Electron emission from the weld pool
(DC+) causes the oxide layers to be disrupted, the socalled “cleaning action”. However once the cleaning action
has produced a mirror like surface on the weld pool, the
effect of the oxide layer is limited because the oxide layer
has dissipated. This makes electron emission from the
weld pool more difficult and increases the chance of arc
instability.
This idea is supported by the observation that once
fluttering starts it can be made to stop by working the arc
away from the mirror like weld pool to an area of oxide
coated material. As soon as this is done the arc settles
back to a stable condition. So while the arc is “consuming”
oxide coated plate the instability does not occur. But once
the arc is stationary, the pool becomes thoroughly
“cleaned” by election emission, the fluttering begins.
Tests conducted on various types of AC TIG power
sources, Fluttery Arc is not confined to one type of power
source or it’s design, both conventional and inverter types
suffer from the same problem.
AC TIG on aluminum
1. The Problem: Arc appears unstable and pulses or flutters. ie. appears to rapidly change welding current.
Conditions that accentuate arc flutter:
· Cold work piece,
· Very short arc length,
Conditions that minimizes arc flutter:
· Preheat the work piece,
· Increase the arc length,
· Weld pool crater about 0.39” to
0.47” (10 to 12mm) diameter,
· Introduce filler rod material to the
weld pool, which introduces oxides.
· Arc field in one spot to produce
“mirror” clean weld pool,
· Move the weld pool around to
introduce oxides to the weld pool.
· Increased cleaning action.
· Decrease the cleaning action by
turning the WAVE BALANCE to below
50% or move the weld pool around.
ie. Prolonged oxide emission from a
stationary weld pool increases the
likelihood of arc flutter,
· Accentuated when tungsten running
near its current capacity, ie. Molten ball
on end.
· Use a larger diameter tungsten
electrode.
Table 7-1: Reduction of Arc Flutter
2. Conclusion: Fluttery arc in AC TIG is a physical phenomenon independent of machine design.
February 22, 2006
7-1
ARCMASTER 300 ACDC
7.02 Electrode Polarity
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight
polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of
the electrode since 70% of the heat is concentrated at the work piece.
7.03 Tungsten Electrode Current Ranges
Electrode Diameter
0.040” (1.0mm)
1/16” (1.6mm)
3/32” (2.4mm)
1/8” (3.2mm)
5/32” (4.0mm)
3/16” (4.8mm)
AC Current (Amps)
30 – 70
60 – 95
125 – 150
130 – 225
190 – 280
250 – 340
DC Current (Amps)
30 – 60
60 – 115
100 – 165
135 – 200
190 – 280
250 – 340
Table 7-2: Current ranges for various tungsten electrode sizes
7.04 Tungsten Electrode Types
Electrode Type
(Ground Finish)
Welding Application
Features
Color
Code
DC welding of mild steel,
Thoriated 2% stainless steel and copper.
Excellent arc starting, Long life,
High current carrying capacity.
High quality AC welding of
Zirconated 1% aluminium, magnesium and
their alloys.
Self cleaning, Long life,
Maintains balled end, High
current carrying capacity.
White
Longer life, More stable arc,
Easier starting, Wider current
range, Narrower more
concentrated arc.
Grey
Ceriated 2%
AC & DC welding of mild steel,
stainless steel, copper,
aluminium, magnesium and
their alloys
Red
Table 7-3: Tungsten electrode types
7-2
Februrary 22, 2006
ARCMASTER 300 ACDC
7.05 Guide for Selecting Filler Wire Diameter
NOTE
The filler wire diameter specified in Table 7-4 is a guide only, other diameter wires may be used according
to the welding application
Filler Wire Diameter
1/16” (1.6 mm)
3/32” (2.4 mm)
1/8” (3.2 mm)
3/16” (4.8 mm)
AC Current Range
(Amps)
30-95
125-160
180-240
220-320
DC Current Range
(Amps)
20 - 90
65 - 115
100 - 165
200-350
Table 7-4: Filler wire selection guide
7.06 Shielding Gas Selection
Alloy
Aluminium & alloys
Carbon Steel
Stainless Steel
Nickel Alloy
Copper
Titanium
Shielding Gas
Argoshield is a registered trademark of BOC Gases
Limited.
Welding Argon, Argoshield 80T, 81T
Welding Argon
Welding Argon, Argoshield 71T, 80T, 81T
Welding Argon, Argoshield 71T
Welding Argon, Argoshield 81T
Welding Argon, Argoshield 80T, 81T
Table 7-5: Shielding gas slection
7.07 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
120 - 170
Filler Rod for
Root Pass
Yes
100 - 160
Yes
90 - 130
No
Joint Preparation
Table 7-6: TIG welding parameters for low carbon & low alloy steel pipe
February 22, 2006
7-3
ARCMASTER 300 ACDC
7.08 Welding Parameters for Aluminum
Base Metal
Thickness
AC Current for
Aluminum
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
30-45
35-50
40-60
45-70
60-85
70-95
125-150
130-160
3/16”
4.8mm
¼”
6.4mm
180-225
190-240
240-280
250-320
Tungsten
Electrode
Diameter
0.040”
1.0mm
0.040”
1.0mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
1/8”
3.2mm
3/16”
4.8mm
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
3/16”
4.8mm
Argon Gas
Flow Rate
Liters/min
5-7
5-7
7
10
10
13
Joint Type
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Table 7-7: AC TIG welding parameters
7.09 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 Filler Rod Argon Gas
for Mild
Stainless
Electrode Diameter Flow Rate
Steel
Steel
Diameter (if required) Liters/min
35-45
20-30
0.040”
1/16”
5-7
40-50
25-35
1.0mm
1.6mm
45-55
30-45
0.040”
1/16”
5-7
50-60
35-50
1.0mm
1.6mm
60-70
40-60
1/16”
1/16”
7
70-90
50-70
1.6mm
1.6mm
80-100
65-85
1/16”
3/32”
7
90-115
90-110
1.6mm
2.4mm
115-135
100-125
3/32”
1/8”
10
140-165
125-150
2.4mm
3.2mm
160-175
135-160
1/8”
5/32”
10
170-200
160-180
3.2mm
4.0mm
Joint Type
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Table 7-8: DC TIG welding parameters
7-4
Februrary 22, 2006
ARCMASTER 300 ACDC
SECTION 8:
BASIC ARC WELDING GUIDE
8.01 Electrode Polarity
Stick electrodes are generally connected to the ‘+’ terminal
and the work lead to the ‘-’ terminal but if in doubt consult
the electrode manufacturers literature.
8.02 Effects of Stick Welding Various
Materials
1. 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.
2. Manganese steels: The effect on manganese steel of
slow cooling from high temperatures is to embrittle
it. For this reason it is absolutely essential to keep
manganese steel cool during welding by quenching
after each weld or skip welding to distribute the heat.
3. Cast Iron: Most types of cast iron, except white iron,
are weldable. White iron, because of its extreme
brittleness, generally cracks when attempts are made
to weld it. Trouble may also be experienced when
welding white-heart malleable, due to the porosity
caused by gas held in this type of iron.
February 22, 2006
4. 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.
5. 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.
8-1
ARCMASTER 300 ACDC
Metals being
joined
Mild steel
Electrode
Comments
6013
Ideal electrodes for all general purpose work.
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, gates,
pipes and tanks etc. Especially suitable for
vertical-down welding.
Suitable for joining all cast irons except white cast
iron.
High corrosion resistance. Ideal for dairy work,
etc. On stainless steels.
Easy to use electrode for marine fittings, water
taps and valves, water trough float arms, etc.
Also for joining copper to steel and for bronze
It will weld most problematical jobs such as
springs, shafts, broken joins mild steel to
stainless and alloy steels.
Not suitable for Aluminum.
Mild steel
7014
Cast iron
99% Nickel
Stainless steel
Copper, Bronze,
Brass, etc.
High Alloy Steels,
Dissimilar Metals,
Crack Resistance.
All Hard-To-Weld
318L-16
Bronze
5.7 ERCUSI-A
312-16
Table 8-1: Types of Electrodes
8-2
February 22, 2006
ARCMASTER 300 ACDC
SECTION 9:
ROUTINE MAINTENANCE
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency
depending on the usage and the operating environment.
WARNING
Disconnect primary power at the source before opening the enclosure. Wait at least two minutes before
opening the enclosure to allow the primary capacitors to discharge.
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.
February 22, 2006
9-1
ARCMASTER 300 ACDC
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
Visually inspect the Wire
feed mechanisms
3 Months
Replace all
broken parts
Gas and
air lines
Clean
exterior
of power supply
6 Months
Visually check and
use a vacuum to carefully
clean the interior
Art # A-06950
9-2
February 22, 2006
ARCMASTER 300 ACDC
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
Description
Excessive bead buildup 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.
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.
Table 10-1: TIG Welding Problems
February 22, 2006
10-1
ARCMASTER 300 ACDC
Description
6 Electrode melts when
arc is struck.
7 Dirty weld pool.
8 Electrode melts or
oxidizes when an arc
is struck.
9 Poor weld finish.
Possible Cause
A Electrode is connected to
the ‘+’ terminal.
B WAVE BALANCE is greater
than 50%.
A
B
A Electrode contaminated
through contact with work
piece or filler rod material.
B Gas contaminated with air.
A
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.
F Torch valve is turned off.
G The electrode is too small
for the welding current.
E
F
G
H WAVE BALANCE is set
above 50%.
H
B
Inadequate shielding gas.
10 Arc flutters during TIG A Tungsten electrode is too
welding.
large for the welding
current.
B Absence of oxides in the
weld pool.
A
B
Remedy
Connect the electrode to the
‘-’ terminal.
Reduced WAVE BALANCE to
below 50% or increase the
electrode size.
Clean the electrode by
grinding off the
contaminates.
Check gas lines for cuts and
loose fitting or change gas
cylinder.
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.
Reduced WAVE BALANCE to
below 50% or increase the
electrode size.
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.
Table 10-1 (continued): TIG Welding Problems
10-2
February 22, 2006
ARCMASTER 300 ACDC
Description
11 Welding arc can not
be established.
12 Arc start is not
smooth.
Possible Cause
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.
B The wrong electrode is
being used for the welding
job.
C Gas flow rate is too high.
D Incorrect shielding gas is
being used.
E Poor work clamp
connection to work piece.
Remedy
A 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 Basic
TIG Welding Guide.
B Select the right electrode
type. Refer to Basic TIG
Welding Guide.
C Select the correct rate for
the welding job.
Refer to Basic TIG Welding
Guide.
D Select the right shielding
gas. Refer to Basic TIG
Welding Guide.
E Improve connection to work
piece.
Table 10-1 (continued): TIG Welding Problems
February 22, 2006
10-3
ARCMASTER 300 ACDC
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.
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.
B
C
3 A gap is left by failure A
of the weld metal to fill B
the root of the weld.
C
D
Remedy
A Dry electrodes before use.
B Reduce welding current.
C Clean joint before welding.
A Redesign to relieve weld
joint of severe stresses or
use crack resistance
electrodes.
Insufficient throat thickness. B Travel slightly slower to
allow greater build up in
throat.
Cooling rate is too high.
C Preheat plate and cool
slowly.
Welding current is too low. A Increase welding current
Electrode too large for joint. B Use smaller diameter
electrode.
Insufficient gap.
C Allow wider gap.
Incorrect sequence.
D Use correct build-up
sequence.
Table 10-2: Stick Welding Problems
Art # A-04991
Incorrect sequence
Insufficient
gap
Figure 10-1: Example of insufficient gap or incorrect sequence
10-4
February 22, 2006
ARCMASTER 300 ACDC
Description
Possible Cause
A Small electrodes used on
4 Portions of the weld
heavy cold plate.
run do not fuse to the
surface of the metal or B Welding current is too low.
edge of the joint.
C Wrong electrode angle.
D Travel speed of electrode is
too high.
E Scale or dirt on joint
surface.
Remedy
A Use larger electrodes and
pre-heat the plate.
B Increase welding current.
C Adjust angle so the welding
arc is directed more into the
base metal.
D Reduce travel speed of
electrode.
E Clean surface before
welding.
Table 10-2 (continued): Stick Welding Problems
Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Art # A-04992
Lack of inter-run
fusion
Lack of side fusion, scale
dirt, small electrode,
amperage too low
Lack of root fusion
Figure 10-2: Example of lack of fusion
February 22, 2006
10-5
ARCMASTER 300 ACDC
Possible Cause
Remedy
Description
A If bad undercut is present,
5 Non-metallic parti­cles A Non-metallic particles may
clean slag out and cover
are trapped in the
be trapped in undercut from
with a run from a smaller
weld metal (slag
previous run.
diameter electrode.
inclusion).
B Joint preparation too
B Allow for adequate
restricted.
penetration and room for
cleaning out the slag.
C Irregular deposits allow slag C If very bad, chip or grind
to be trapped.
out irregularities.
D Use smaller electrode with
D Lack of penetration with
sufficient current to give
slag trapped beneath weld
adequate penetration. Use
bead.
suitable tools to remove all
slag from corners.
E Rust or mill scale is
E Clean joint before welding.
preventing full fusion.
F Wrong electrode for position F Use electrodes designed for
in which welding is done.
position in which welding is
done, otherwise proper
control of slag is difficult.
Table 10-2 (continued): Stick Welding Problems
Art # A-04993
Not cleaned, or
incorrect
electrode
Slag trapped in
undercut
Slag trapped in root
Figure 10-3: Examples of slag inclusion
10-6
February 22, 2006
ARCMASTER 300 ACDC
10.03 Power Source Problems
Description
Possible Cause
A The Primary supply voltage
1 The welding arc
has not been switched ON.
cannot be established.
B The Welding Power Source
switch is switched OFF.
C Loose connections
internally.
2 Maximum output
welding current can
not be achieved with
nominal Mains supply
voltage.
3 Welding current
reduces when
welding.
4 No gas flow when the
torch trigger switch is
depressed.
Defective control circuit.
Remedy
A Switch ON the Primary
supply voltage.
B Switch ON the Welding
Power Source.
C Have an Accredited Thermal
Arc Service Agent repair the
connection
Have an Accredited Thermal
Arc Service Agent repair the
connection
A Loose welding cable
A Tighten all welding cable
connections.
connections.
B Incorrect welding cable size. B Use proper size and type of
cable.
C Improper input connections. C Refer to Section 2.05
Electrical Input
Requirements.
D Poor electrode condition.
D Replace electrode.
E Wrong welding polarity.
E Verify output torch
connections.
A Gas hose is cut.
A Replace gas hose.
B Gas passage contains
B Disconnect gas hose from
impurities.
the rear of Power Source
then raise gas pressure and
blow out impurities.
C Gas regulator turned off.
C Turn gas regulator on.
D Torch trigger switch lead is D Reconnect lead or repair
faulty switch/cable.
disconnected or
switch/cable is faulty.
Table 10-3: Power Source Problems
February 22, 2006
10-7
ARCMASTER 300 ACDC
Description
5 Gas flow won’t shut
off.
Possible Cause
A Weld Mode (STD , SLOPE ,
REPEAT or SPOT ) was
changed before POSTFLOW gas time had
finished.
A
B Gas valve is faulty.
B
C Gas valve jammed open.
C
D POST-FLOW control is set
to 60 sec.
6 The TIG electrode has
The Weld Process Mode
been contaminated
(STICK, HF TIG or LIFT TIG)
due to the gas flow
was changed before POSTshutting off before the
FLOW gas time had
pro­grammed POSTfinished.
FLOW time has
elapsed.
D
Remedy
Strike an arc to complete the
weld cycle.
OR
Switch machine off then on
to reset solenoid valve
sequence.
Have an Accredited Thermal
Arc Service Agent repair or
replace the gas valve
Have an Accredited Thermal
Arc Service Agent repair or
replace the gas valve
Reduce POST-FLOW time.
Do not change Weld
Process Mode before the
POST-FLOW gas time had
finished.
Table 10-3 (continued): Power Source Problems
10-8
February 22, 2006
ARCMASTER 300 ACDC
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD)
11.01 VRD Specification
Description
VRD Open Circuit Voltage
VRD Resistance
VRD Turn OFF Time
ArcMaster
300ACDC
15.3 to 19.8V
Notes
Open circuit voltage between welding
terminals.
148 to 193 ohms The required resistance between
welding terminals to turn ON the
welding power.
0.2 to 0.3
The time taken to turn OFF the welding
seconds
power once the welding current has
stopped.
Table 11-1: VRD Specification
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 should be carried out
a. For transportable equipment, at least once every 3 months;
b. For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests.
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.
Description
VRD Open Circuit Voltage
VRD Turn ON Resistance
VRD Turn OFF Time
IEC 60974-1 Requirements
Less than 20V; at Vin=230V
Less than 200 ohms
Less than 0.3 seconds
Table 11-2: Periodic Tests
If this equipment is used in a location or an environment with a high risk of electrocution then the above tests should
be carried out prior to entering this location.
February 22, 2006
11-1
ARCMASTER 300 ACDC
11.03 Switching VRD On/Off
Switch the machine Off.
A) Remove the clear plastic cover from the control panel (see Figure 11-1).
• Lift up the cover so it rests on the top of the unit
• Place a small flat bladed screw driver between the cover hinge on the front panel
• Gently lift the cover hinge out of the front cover mounting hole
• Remove the control's clear plastic cover
2
2
3
1
Art # A-07079
Figure 11-1: VRD ON/OFF Step A
B) Remove the four mounting screws from the the control panel (see Figure 11-2).
Art # A-07080
1
1
2
1
1
Figure 11-2: VRD ON/OFF Step B
11-2
February 22, 2006
ARCMASTER 300 ACDC
C) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see
Figure 11-3).
!
CAUTION
DO NOT pull back the front panel with excessive force as this will unplug control PCB. Plugging the control
PCB back into the front panel controls can only be achieved by removing the side covers.
VR1
Art # A-07081
Figure 11-3: VRD ON/OFF Step C and D
D) Turning the VRD ON/OFF (see Figure 11-3)
• To turn VRD ON: rotate the trim potentiometer on the display PCB fully clockwise. When VRD is turned ON check
that it operates as per VRD Specifications on page 11-1.
• To turn VRD OFF: rotate the trim potentiometer on the display PCB fully counter clockwise.
!
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.
February 22, 2006
11-3
ARCMASTER 300 ACDC
11-4
February 22, 2006
ARCMASTER 300 ACDCR
SECTION 12:
POWER SOURCE ERROR CODES
Description
Possible Cause
A The Welding Power
1 E01 error code
Source’s duty cycle
displayed
has been exceeded.
Temperature sensor
TH1 (protects
B Fan ceases to
IGBTs) is greater
operate.
than 80ºC for about
1 second.
C Air flow is restricted
by vents being
blocked.
A The Welding Power
2 E02 error code
Source’s duty cycle
displayed
has been exceeded.
Temperature sensor
TH2 (protects
B Fan ceases to
secondary diodes)
operate.
is greater than 80ºC
for about 1 second.
C Air flow is restricted
by vents being
blocked.
A Primary current is
3 E03 error code
too high because
displayed
welding arc is too
Primary (input)
long.
current too high.
B Mains supply
voltage is more than
10% below nominal
voltage .
4 E04 error code
displayed
Output voltage
exceeds the
secondary voltage
specification.
A
B
C
A
B
C
A
Remedy
Let Power Source
cool down then
keep within its duty
cycle.
Have an Accredited
Thermal Arc Service
Agent investigate.
Unblock vents then
let Power Source
cool down.
Let Power Source
cool down then
keep within its duty
cycle.
Have an Accredited
Thermal Arc Service
Agent investigate
Unblock vents then
let Power Source
cool down.
Reduce length of
welding arc.
B Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check for
low Mains voltage.
Reduce the length
TIG torch cable
of the TIG torch
and/or work lead are
cable and/or work
too long or leads
lead or un-coiled
are coiled.
leads.
Remarks
Weld current
ceases. Buzzer
sounds constantly.
Fan operates at max
speed.
E01 resets when
TH1 decreases to
70ºC for about 30
seconds.
Weld current
ceases. Buzzer
sounds constantly.
Fan operates at max
speed.
E02 resets when
TH2 decreases to
70ºC for about 30
seconds.
Weld current
ceases. Buzzer
sounds constantly.
Fan operates at max
speed.
Switch machine off
then on to reset E03
error.
Weld current
ceases. Buzzer
sounds constantly.
Switch machine off
then on to reset E04
error.
Table 12-1 Power Source Error Codes
February 22, 2006
12-1
ARCMASTER 300 ACDC
5 E11 error code
displayed
Over Primary supply
(input) voltage at
primary capacitors
is exceeded for one
second.
6 E14 error code
displayed
Under mains supply
(input) voltage
warning primary
capacitors is
reduced for one
second.
7 E12 error code
displayed
Under mains supply
(input) voltage
primary capacitors
is reduced for one
second.
8 E81 error code
displayed
Wrong Primary
supply (input)
voltage connected.
Primary supply
voltage is greater
than the nominal
voltage plus 10%.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Primary voltage.
Mains supply
voltage is less than
the nominal
operating voltage
less 10%.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
A Have an Accredited
Mains supply
Thermal Arc Service
voltage is down to a
Agent or a qualified
dangerously low
electrician check the
level.
Mains voltage.
B Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
primary cable and
fuses.
When 3 phase
Have an Accredited
machine is first
Thermal Arc Service
turned on with the
Agent or a qualified
wrong Primary
electrician check the
supply (input)
Mains voltage.
voltage connected.
Weld current
ceases. Buzzer
sounds contstantly.
Error code E11
automatically will
reset when the
voltage reduces.
Weld current
available. Buzzer
sounds
intermittently.
Error code E14
automatically will
reset when the
voltage increases.
Weld current
ceases. Buzzer
sounds contstantly.
Error code E12
automatically will
reset when the
voltage increases.
No weld current is
available. Buzzer
sounds constantly.
Switch machine off.
Table 12-1 (continued): Power Source Error Codes
12-2
February 22, 2006
ARCMASTER 300 ACDCR
9 E82 error code
displayed
Rated voltage
selection circuit
abnormality.
10 E83 error code
displayed
CPU checks mains
supply (input)
voltage when the
on/off switch on
rear panel of
machine is turned
ON.
11 E85 error code
displayed
Pre-charge
abnormality.
12 E93 error code
displayed
Memory chip
(EEPROM) on
control PCB can not
read/write weld
parameters.
The Primary supply
(input) voltage
fluctuates and is not
stable.
The Primary supply
(input) voltage
fluctuates and is not
stable.
Due to malfunction
inside the Welding
Power Source,
primary capacitors
are not charging
Memory chip
(EEPROM) error.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage.
Have an Accredited
Thermal Arc Service
Agent check
connector plug on
input PCB and the
Mains voltage
No weld current is
available. Buzzer
sounds constantly.
Switch machine off
then on to reset E82
No weld current is
available. Buzzer
sounds constantly.
Switch machine off
then on to reset E83
error.
Have an Accredited
Thermal Arc Service
Agent service the
machine
No weld current is
available. Buzzer
sounds constantly.
Switch machine off
then on to reset E85
Have an Accredited Weld current
Thermal Arc Service ceases. Buzzer
Agent check the
sounds constantly.
control PCB.
Switch machine off.
Table 12-1 (continued): Power Source Error Codes
February 22, 2006
12-3
ARCMASTER 300 ACDC
13 E94 error code
The Welding Power
displayed
Source’s
Temperature sensor
temperature
TH1 for IGBTs or
sensors have
sensor TH2 for
malfunctioned.
secondary diodes
are open circuit.
A Main on/off switch
14 E99 error code
displayed
on machine has
been turned off
Mains supply
Mains supply
(input) voltage has
(input) voltage has
been turned off but
been turned off.
control circuit has
power from the
primary capacitors.
Have an Accredited
Thermal Arc Service
Agent check or
replace the
temperature
sensors
Weld current
ceases. Buzzer
sounds constantly.
Switch machine off.
A Turn on/off switch
on.
Weld current
ceases. Buzzer
sounds constantly.
B Have an Accredited Must switch
Thermal Arc Service machine off then on
Agent or a qualified to reset E99 error.
electrician check the
Mains voltage and
fuses.
Table 12-1 (continued): Power Source Error Codes
12-4
February 22, 2006
ARCMASTER 300 AC/DC
APPENDIX 1: ARCMASTER 300 AC/DC ACCESSORIES
ACCESSORIES
Stick Kit
TIG Kit
TWECO® TC900 Water Cooler*
Dinse Connector
PART NO.
10-4082
10-4081
4010-1010
4010-1011
10-2020
Hand Held Pendant
10-2005
Foot Control
10-2008
10-2007
Extension Cable
10-2030
10-2031
10-2032
10-2033
10-2034
Torch Switch On/Off
Torch Switch On/Off
w/current control
10-2001
10-2002
10-2003
10-2004
Running Gear/Cylinder Cart
600298
600299
205199
DESCRIPTION
Work clamp with 25’ #1 cable, and stick electrode
with 25’ #1cable
Includes regulator/flowmeter with 12’ gas hose, 12.5’
200 Amp TIG torch, 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, 15’ cable with clamp & T50 dinse plug
TC900-G cooler w/gear pump
TC900-V cooler w/vane pump
T50mm Dinse style male plug
AVAILABLE 2nd QUARTER
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”-1-1/8” torch handle
25ft torch mounted with 14-pin male plug - adapts to
1-1/8”-1-3/8” torch handle
Rotary amperage control 5k 15’ velcro for TD14
Rotary amperage control 5k 25’ velcro for TD14
For welding power source and/or gas cylinders
*Note: For detailed information see Tweco MIG Water cooler product information
February 22, 2006
A-1
ARCMASTER 300 AC/DC
TB13
UB3
TB14
P
P
TB1
G1
E1
R2
1
2
3
R2
N
C
TB19
CE
TB4
TB4
A
B
C
K
L
D
N
H
G
F
1
2
1
2
3
EC
C
CE
TB7
E PCB11E
IGBT C
1
2
3
G7
Q10 E7
1
2
3
Q21
E
C
Q22
1
2
3
4
Q12
CN2
E
C
E
C
G8
E8
E
C
G
E
E
E7
G7
Q23
G
G
E3
G3
CN2
Q11
Q24
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
CN21
CN22
CN23
CN20
CN9
CN8
1 2
1 2 3
1 2
CN18
1 2 3
Q20
G
PCB6
Control
Circuit Board
[WK-5549]
PCB7
Filter
Circuit Board
[WK-5550]
G
G
G
CN20
CN17 CN18
CN17 CN18
Q19
C
Gate G
Circuit E
BoardC
[WK-5479]
Q9
E2
G2
E5
G5
E1
G1
CN30
CN30
CN14
TB0
1
2
CN27
3
4
CN27
5
I
M
E
CON1
J
EB
TB5
UB1
TB6
Q8
E
C
CT1
CT2
CT3
CT4
1
2
3
4
CN131 CN132 CN130
CN131 CN132 CN130
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
CN1
CN4
PCB3
Control
Souce
PCB5
Circuit Board
Connect Circuit Board
1 2 3 4 5 6
[WK-5548]
[WK-5551]
CN31 CN32
CN31 CN32
CN15
SOL1
CN6
CN6
CN13
1
2
3
4
CN11
-
Q7
E6
G6
CN5
CN5
FAN1
+
E
Q18
CN19
1 2 3
1 2 3
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
CN33
TH2
TH1
P+21V
PGND
230V
PCB4
CN7
Detect
Circuit Board
[WK-4819]
CN7
S2
E
E
C
1
2
3
4
1 2 3
1
2
3
4
G
PCB9 E
IGBT C
Gate G
Circuit E
BoardC
[WK-5479]
1
2
3
G4
E4
460V
E
C
G
CN20
R2
CN3
CN4
P
CN2
Q17
G
G
E
CN1
G3
E3
CN1
1
2
3
4
5
6
Q6
G
1 2 3
N
E3
G
CN1
1 2 3 4 5
E
C
1
2
3
4
E4
G4
REAR
PANEL
CN2
1 2
Q5 G3
C
TB18
TB20
1
2
3
4
5
CN1
Q16
TB3
PCB2
Link
Circuit Board
[WK-5597]
PCB21
Filter
Circuit Board
[WK-4917]
E
C
G
E
C
TB3
E
1
2
3
E8
G8
Ground
G4
Q4 E4
G
TB2
Q15
G
E
C
1
2
3
4
G2
E2
CN2
(2)
Q14
Gate
Circuit G
E
BoardC
[WK-5479]
G
TB2
1 2 3
E PCB10E
IGBT C
Q3
E
C
N
SIDE CHASSIS 1
TB12
G
CN17
Line2
+
CE
CN21
(0)
T(5)
C
TB11
G
S(4)
Line3
Q2
Q13
C
TB10
CN1
R(3)
CN1
S1
Line1
G
CE
TB15 E PCB8 E
PCB1
IGBT C
Main
Gate G
Circuit
Circuit
Board
E
[WK-5493] BoardC
[WK-5479]
TB1
K(7)
G(6)
Q1
C
C
CN2
+
(1)
CN1
1
2
D1
CN1
CN3
APPENDIX 2: ARCMASTER 300 INTERCONNECT DIAGRAM
Art # A-07657
A-2
February 22, 2006
TB33
AC1
FCH1
TB34
4
123
Q25
G1 G1
G1 G1
PCB18
E1 E1
IGBT Gate
Circuit Board
[WK-3367] G2 G2
D7
CN1
TB8
PCB19
IGBT Gate
Circuit Board
G2 G2 [WK-3367]
E1 E1
E2 E2
TB1
G12
E12
E9
G9
G10
E10
D2
1 2 3 4 5
TB2
TB30
TB16
1
2
3
TB31
TB1
P+21V
PGND
1
2
CN2
S+15V
1
2
3
CN3
SH.DET+
SH.DET-
AC4
AC2
AC3
EB
N
SG
1 2 3 4 5 6 7 8 9
CN8
CN9
R2
R2
AC3
R6
AC3
PCB16
Super Inpose
Circuit Board
[WK-5569]
CN4
/RY_ON
1 2 3 4 5
R1
AC1
CN5
CC1
HF.UNIT1
1 2
TB2
AC1
CN6
1
2
3
4
CC2
CN1
P
PCB20
Filter Circuit
Board
[WK-5499] SIDE CHASSIS 3
TO2
CC1
-Output
Terminal
SH.DET-
AC4
R3
CT4
CT3
D4
CN3
RY+15V
/RY_ON
TB22
CT3
Ground
CN1
D3
TB32
S+15V
SG
+
1 2 3 4 5
UB4
TB17
CN1
E2 E2
1 2 3 4 5
UB2
L1
TO1
+Output
Terminal
Q26
HCT1
D6
TB21
CT2
+15
-15
IS
GND
PCB17
IGBT Snubber
Circuit Board
[WK-5570]
E11
G11
CT2
CT1
TB7
AC2
PCB14
TRANS
Board
[WK-5594]TB35
PCB15
DIODE Snubber
Circuit Board
[WK-5606]
D5
SH.DET+
ARCMASTER 300 AC/DC
1
2
3
4
5
6
7
8
G9
E9
G11
E11
G10
E10
G12
E12
FRONT
PANEL
1 2 3 4 5 6 7
EB
+
Ground
RY+15V
1
2
3
4
5
6
+15
-15
IS
GND
SIDE CHASSIS 2
PCB13
Encoder
Board
[WK-5528]
CN2
PCB12
Panel
Circuit Board
[WK-5527]
R2
UB1
UB2
R3
CN1
CN1
UB3
UB4
1 2 3 4
1 2 3 4
Art # A-07657
February 22, 2006
A-3
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
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
ENGINE DRIVEN WELDERS
WARRANTY PERIOD
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,
1 year
switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer .............................................................
See the Engine’s Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
WARRANTY PERIOD
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
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
WARRANTY PERIOD
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
PLASMA WELDING EQUIPMENT
WARRANTY PERIOD
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year
SMAW (Stick) WELDING EQUIPMENT
WARRANTY PERIOD
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
GENERAL ARC EQUIPMENT
WARRANTY PERIOD
Water Recirculators ....................................................................................................................... 1 year
Plasma Welding Torches.............................................................................................................180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
LABOR
1 year
LABOR
1 year
180 days
Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days
Replacement repair parts .............................................................................................................90 days
MIG, TIG and Plasma welding torch consumable items...................................................................Nil
Nil
Nil
Nil
3 years
3 years
1 year
LABOR
3 years
3 years
1 year
LABOR
3 years
3 years
3 years
1 year
LABOR
1 year
1 year
1 year
3 years
3 years
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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