Tweco 401S Operating Manual

Tweco 401S Operating Manual

ARCMASTER

Operating

Manual

Art # A-12546_AB

3163339

Revision:

AC

Issue Date:

November 11, 2014

Manual No.:

0-5345

Tweco.com

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Tweco product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.

For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time.

We strive to enhance your productivity, efficiency and welding performance enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions.

If you have any questions or concerns regarding your new Tweco product, please contact our friendly and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.Tweco.com

!

WARNINGS

Read and understand this entire Manual and your employer’s safety practices if applicable before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use.

Operating Manual Number 0-5345 for:

Tweco ArcMaster 401S Power Source

Published by:

Victor Technologies, Inc.

16052 Swingley Ridge Road,

Suite 300 St. Louis, MO 63017

USA

Part Number W1009100 www.victortechnologies.com

Copyright © 2014 by

Victor Technologies, Inc.

® All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: April 25, 2014

Revision Date: November 11, 2014

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

____________________________________

____________________________________

____________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 Principal Safety Standards .............................................................................. 1-6

1.03 Symbol Chart .................................................................................................. 1-7

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 Description ..................................................................................................... 2-2

2.05 User Responsibility ......................................................................................... 2-2

2.06 Transporting Methods ..................................................................................... 2-2

2.07 Packaged Items .............................................................................................. 2-2

2.08 Duty Cycle ....................................................................................................... 2-3

2.10 Specifications ................................................................................................. 2-4

SECTION 3:

INSTALLATION, OPERATION AND SETUP ........................................................ 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Ventilation ....................................................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-1

3.05 High Frequency Introduction .......................................................................... 3-3

3.06 High Frequency Interference ........................................................................... 3-4

3.07 Electromagnetic Compatibility ........................................................................ 3-4

3.08 ArcMaster 401S Power Source Controls, Indicators and Features .................. 3-6

3.09 Welding Parameters ...................................................................................... 3-10

3.10 Setup for TIG (GTAW) Welding ..................................................................... 3-12

3.11 Setup for STICK (SMAW) Welding .............................................................. 3-13

3.12 Special Function ........................................................................................... 3-15

3.13 Shielding Gas Flowmeter/ Regulator Operating Instructions ......................... 3-16

SECTION 4:

BASIC WELDING GUIDE ............................................................................ 4-1

4.01 Stick (SMAW) Basic Welding Technique ......................................................... 4-1

4.02 Stick (SMAW) Welding Troubleshooting ....................................................... 4-10

4.03 TIG (GTAW) Basic Welding Technique .......................................................... 4-12

4.04 TIG (GTAW) Welding Problems ..................................................................... 4-14

SECTION 5:

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS .................... 5-1

5.01 Maintenance and Repair ................................................................................. 5-1

5.02 Power Source Status Messages ...................................................................... 5-2

5.03 Error Messages ............................................................................................... 5-2

5.04 Routine Inspection, Testing & Maintenance .................................................... 5-4

5.05 Cleaning the Welding Power Source ............................................................... 5-4

TABLE OF CONTENTS

SECTION 6:

KEY SPARE PARTS ................................................................................... 6-1

6.01 401S Power Source Spare Parts ..................................................................... 6-1

APPENDIX A: CIRCUIT DIAGRAM ........................................................................ A-1

TWECO - LIMITED WARRANTY TERMS ............................................ iNSIDE REAR COVER

This Page Intentionally Blank

ARCMASTER 401S POWER SOURCE

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

!

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.

PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS.

READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

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 European Standard EN60974-1 entitled: Safety in welding and allied processes

Part 2: Electrical. 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

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

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 semi-automatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

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.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

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.

Manual 0-5345 1-1 SAFETY INSTRUCTIONS AND WARNINGS

ARCMASTER 401S POWER SOURCE

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.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

6. Never wear contact lenses while welding.

AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida

Guide for Shade Numbers

Process

Electrode Size in.

(mm)

Arc Current

(Amperes)

Minimum

Protective

Shade

Suggested*

Shade No.

(Comfort)

Shielded Metal Arc Welding

(SMAW)

Less than 3/32 (2.4)

3/32-5/32 (2.4-4.0)

5/32-1/4 (4.0-6.4)

More than 1/4 (6.4)

Less than 60

60-160

160-250

250-550

7

8

10

11

-

10

12

14

Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding

(FCAW)

Gas Tungsten arc Welding

(GTAW)

Air Carbon Arc Cutting (CAC-A)

Plasma Arc Welding (PAW)

 

 

(Light)

(Heavy)

 

Less than 60

60-160

160-250

250-550

Less than 50

50-150

150-500

Less than

500

500-1000

Less than 20

20-100

100-400

400-800

8

8

10

7

10

10

10

10

11

6

8

10

11

-

11

12

14

10

12

14

12

14

6 to 8

10

12

14

Plasma Arc Cutting (PAC)

 

Less than 20

20-40

40-60

60-80

80-300

300-400

400-800

8

9

10

6

8

4

5

9

12

14

6

8

4

5

* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5345

ARCMASTER 401S POWER SOURCE

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

WARNING

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.

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.

1. Keep your head out of the fumes. Do not breathe 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.

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 travelling long, possibly unknown paths and causing electric shock and fire hazards.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

WARNING

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapours 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 airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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

CYLINDERS can explode if damaged.

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.

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.

1. Protect yourself and others from flying sparks and hot metal.

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.

2. Do not weld where flying sparks can strike flammable material.

3. Keep cylinders away from any welding or other electrical circuits.

Manual 0-5345 1-3 SAFETY INSTRUCTIONS AND WARNINGS

ARCMASTER 401S POWER SOURCE

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, flowmeters/ 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.

!

WARNING

Engines can be dangerous.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

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.

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.

3. Allow engine to cool before fuelling. 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 fuelling is spilled, clean up before starting engine.

WARNING

SPARKS can cause BATTERY GASES TO

EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

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.

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5345

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.

!

WARNING

WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm.

Wash hands after handling.

NOTE

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 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. 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.

ARCMASTER 401S POWER SOURCE

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

Manual 0-5345 1-5 SAFETY INSTRUCTIONS AND WARNINGS

ARCMASTER 401S POWER SOURCE

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd.,

Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing

Office, Washington, D.C. 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.

SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5345

ARCMASTER 401S POWER SOURCE

1.03 Symbol Chart

Note that only some of these symbols will appear on your model.

On

Off

Dangerous Voltage

Single Phase

Wire Feed Function

Wire Feed Towards

Workpiece With

Output Voltage Off.

Welding Gun

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Three Phase

Three Phase Static

Frequency Converter-

Transformer-Rectifier

Remote

X

%

Duty Cycle

Percentage

Panel/Local

Shielded Metal

Arc Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Gas Tungsten Arc

Welding (GTAW)

Air Carbon Arc

Cutting (CAC-A)

Constant Current

Purging Of Gas

Continuous Weld

Mode

Spot Weld Mode

t1 t

Spot Time

Preflow Time

t2

Postflow Time

2 Step Trigger

Operation

Press to initiate wirefeed and welding, release to stop.

Positive

Direct Current (DC)

Protective Earth

(Ground)

Line

Line Connection

Auxiliary Power

115V 15A

Receptacle Rating-

Auxiliary Power

Constant Voltage

Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

V

Voltage Input

4 Step Trigger

Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

t

Burnback Time

IPM

Inches Per Minute

MPM

Meters Per Minute

S

See Note

See Note

Art # A-04130_AB when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.

Cannot be disposed with household garbage.

Manual 0-5345 1-7 SAFETY INSTRUCTIONS AND WARNINGS

ARCMASTER 401S POWER SOURCE

This Page Intentionally Blank

SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5345

ARCMASTER 401S POWER SOURCE

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

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.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

You will also notice icons from the safety section appearing throughout the manual. These are to advise you of specific types of hazards or cautions related to the portion of information that follows. Some may have multiple hazards that apply and would look something like this:

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 ii 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.

Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

Manual 0-5345 2-1 INTRODUCTION

ARCMASTER 401S POWER SOURCE

2.04 Description

The Tweco ArcMaster 401S is a welding power source incorporating to provide TIG, Stick and Gouging welding process.

The units are also fully compliant to CSA E 60974-1 and UL 60974-1.

The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source.

Please read these instructions thoroughly before using the unit.

2.05 User Responsibility

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided.

This equipment must be checked periodically. Defective equipment (including welding leads) should not be used.

Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Tweco.

Advice in this regard can be obtained by contacting an

Accredited Tweco Distributor.

This equipment or any of its parts should not be altered from standard specification without prior written approval of Tweco. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Tweco.

2.06 Transporting Methods

!

Disconnect input power conductors from de-energized supply line before moving the welding Power Source.

Lift Power Source with handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, secure the Power Source on a proper skid before transporting.

2.07 Packaged Items

ArcMaster 401S Inverter Power Source (Part

No. W1009100)

• ArcMaster 401S Inverter Power Source w/10 ft input power cable

• 50mm male Dinse connector × 2

• Operating Manual, English

• CD - Operating Manual (Eng/Fr/Sp)

INTRODUCTION 2-2 Manual 0-5345

ARCMASTER 401S POWER SOURCE

2.08 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 40% duty cycle, 170 amperes at 26.8 volts. This means that it has been designed and built to provide the rated amperage (170A) for 4 minutes, i.e. arc welding time, out of every 10 minute period (40% of 10 minutes is 4 minutes). During the other 6 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.

100

90

80

70

3 phase

60

50

40

30

1 phase

SAFE OPERATING REGION

20

10

0

0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500

Art # A-12450

Welding Current (AMPS)

Figure 2-1: Duty Cycle

Manual 0-5345 2-3 INTRODUCTION

ARCMASTER 401S POWER SOURCE

2.10 Specifications

Description

Power Source Part Number

Power Source Mass

Power Source Dimensions

Cooling

Welder Type

Output Terminal Type

Standards

Number of Phases

Nominal Supply Voltage

Nominal Supply Frequency

Welding Current Range

Effective Input Current (I

1eff

) (note2)

Maximum Input Current (I

1max

)

Generator Requirement (note4)

STICK (SMAW)

Welding Output, 40ºC, 10 min.

TIG (GTAW)

Welding Output, 40ºC, 10 min.

Open Circuit Voltage

Protection Class

ArcMaster 401S

W1009100

51lb (23kg)

16.5"(H) x 8.3"(W) x 17.7(D)

H420mm x W210mm x D450mm

Fan Cooled

Inverter Power Source

Dinse

TM

50

CSA E 60974-1

UL 60974-1

1/3 phase

208-230/460VAC (1 phase) 208-230/460VAC (3 phase)

+/-15% +/-15%

50/60Hz

10 - 300A (1 phase)

40A (208V, 1 phase)

38.1A (230V, 1 phase)

10 - 400A, (3 phase)

26.6A (208V, 3 phase)

24.6A (230V, 3 phase)

20A (460V, 1 phase)

84.7A (208V, 1 phase)

76.2A (230V, 1 phase)

14.3A (460V, 3 phase)

53.2A (208V, 3 phase)

49.1A (230V, 3 phase)

40.1A (460V, 1 phase) 28.6A (460V, 3 phase)

14.4kW

300A @ 22%, 32V (1 phase) 400A @ 25%, 36V (3 phase)

230A @ 60%, 29.2V (1 phase)

180A @ 100%, 27.2V (1 phase)

300A @ 25%, 22V (1 phase)

230A @ 60%, 19.2V (1 phase)

300A @ 60%, 32V (3 phase)

220A @ 100%, 28.8V (3 phase)

400A @ 25%, 26V (3 phase)

300A @ 60%, 22V (3 phase)

180A @ 100%, 17.2V (1 phase) 220A @ 100%, 18.8V (3 phase)

80V DC

IP23S

Table 2-2: Specification

INTRODUCTION 2-4 Manual 0-5345

ARCMASTER 401S POWER SOURCE

NOTE

Note 1: Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

Note 2: The Effective Input Current should be used for the determination of cable size & supply requirements.

Note 3: Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation in this regard.

Note 4: Generator Requirements at the Maximum Output Duty Cycle.

Due to large variations in performance and specifications of different brands and types of generators,

Tweco cannot guarantee full welding output power or duty cycle on every brand or type of generator.

Tweco recommends that when selecting a generator, that the particular power source / generator combination be adequately tested to ensure the combination performs to the users expectations.

Note 5: Tweco reserves the right to change product performance and specifications without notice.

Manual 0-5345 2-5 INTRODUCTION

ARCMASTER 401S POWER SOURCE

This Page Intentionally Blank

INTRODUCTION 2-6 Manual 0-5345

ARCMASTER 401S POWER SOURCE

SECTION 3:

INSTALLATION, OPERATION AND SETUP

3.01 Environment

exceed the stated conditions. For further information please refer to EN 60529.

These units are designed for use in environments with increased hazard of electric shock as outlined in EN

60974-1.

A. Examples of environments with increased hazard of electric shock are:

H. Precautions must be taken against the power source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts.

2. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator.

3. In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories.

B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

3.02 Location

Be sure to locate the welder according to the following guidelines:

A. In areas, free from moisture and dust.

B. Ambient temperature between 32 to 104°F.

C. In areas, free from oil, steam and corrosive gases.

D. In areas, not subjected to abnormal vibration or shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 300mm or more from walls or similar that could restrict natural air flow for cooling.

G. The enclosure design of this power source meets the requirements of IP23S as outlined in EN 60529.

This provides adequate protection against solid objects

(greater than 12mm), and direct protection from vertical drops. Under no circumstances should the unit be operated or connected in a micro environment that will

WARNING

This equipment should be electrically connected by a qualified electrician.

3.03 Ventilation

!

WARNING

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

3.04 Mains Supply Voltage

Requirements

The Mains supply voltage should be within ± 15% of the rated mains supply voltage. Too low a voltage may cause poor welding performance. Too high a supply voltage will cause components to overheat and possibly fail.

The Welding Power Source must be:

• Correctly installed, if necessary, by a qualified electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point and fuse as per the Specifications on page 2-4 (2-6).

!

WARNING

Any electrical work must be carried out by a qualified Electrical Tradesperson.

Manual 0-5345 3-1 INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/ tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Electrical Input Requirements

Operate the welding power source from a single or three-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.

NOTE

This unit is equipped with a three-conductor with earth power cable that is connected at the welding power source end for single or three-phase electrical input power.

Do not connect an input (WHITE, BLACK or RED) conductor to the ground terminal.

Do not connect the ground (GREEN) conductor to an input line terminal.

Refer to Figure 3-1 and:

1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes.

2. For 3- phase operation, connect ends of line 1 (BLACK) and line 2 (WHITE) and line 3 (RED) input conductors to a de-energized line disconnect switch.

For 1- phase operation, connect BLACK and WHITE input conductors. Insulate the RED Conductor.

3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.

Input Voltage

208 VAC

230 VAC

1 Phase

100 Amps

80 Amps

Fuse Size

3 Phase

60 Amps

50 Amps

460 VAC 50 Amps 30 Amps

Table 3-1 Electrical Input Connections

NOTE

Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based on Article 630, National Electrical Code).

INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5345

Welding Power Source

Ground Terminal

ARCMASTER 401S POWER SOURCE

Ground Conductor

Line Disconnect Switch

Line Fuse

Figure 3-1 Electrical Input Connections

Primary Power Cable

Art # A-12451

Input Power

Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN SWITCH is turned

ON, the inrush circuit provides a pre-charging of the input capacitors. A relay in the Main Power PCB2 will turn on after the input capacitors have charged to operating voltage (after approximately 5 seconds).

NOTE

Note the available input power. Damage to the PCB could occur if 529VAC or higher is applied.

3.05 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilised arc is almost invariably traced to improper installation. The following information is intended as a guide for personnel installing high frequency welding machines.

!

WARNING EXPLOSIVES

The high frequency section of this machine has an output similar to a radio transmitter. The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing

!

WARNING COMPUTER

It is also possible that operation close to computer installations may cause computer malfunction.

Manual 0-5345 3-3 INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

3.06 High Frequency Interference

Interference may be transmitted by a high frequency initiated or stabilised arc welding machine in the following ways.

1. Direct Radiation: Radiation from the machine can occur if the case is metal and is not properly grounded.

It can occur through apertures such as open access panels. The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded.

2. Transmission via the Supply Lead: Without adequate shielding and filtering, high frequency energy may be fed to the wiring within the installation (mains) by direct coupling. The energy is then transmitted by both radiation and conduction. Adequate shielding and filtering is provided in the Power Source.

3. Radiation from Welding Leads: Radiated interference from welding leads, although pronounced in the vicinity of the leads, diminishes rapidly with distance. Keeping leads as short as possible will minimise this type of interference. Looping and suspending of leads should be avoided wherever possible.

4. Re-Radiation from Unearthed Metallic Objects: A major factor contributing to interference is re-radiation from unearthed metallic objects close to the welding leads. Effective grounding of such objects will prevent re-radiation in most cases.

3.07 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic

Compatibility may be required when this

Welding Power Source is used in a domestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer.

In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding

Power Source and the work, complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer troublesome.

NOTE

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment. Further guidance is given in IEC 60974-13 Arc

Welding Equipment - Installation and use

(under preparation).

B. Assessment of Area

Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account

1. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the welding equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pacemakers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The insulation of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5345

C. Methods of Reducing Electromagnetic Emissions

1. Main Power Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the

Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilising devices should be adjusted and maintained according to the manufacturer’s recommendations.

3. Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

4. Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of it’s size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions

Manual 0-5345 3-5

ARCMASTER 401S POWER SOURCE

in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

6. Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications.

INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

3.08 ArcMaster 401S Power Source Controls, Indicators and Features

1

7

6

2

3

4

Art # A-12453_AB

5

8

9

11

INSTALLATION, OPERATION AND SETUP

Figure 3-2

3-6

13

12

Manual 0-5345

ARCMASTER 401S POWER SOURCE

1 VRD (Voltage Reduction Device) Indicator Lights

A VRD (voltage reduction device) is a hazard reducing device designed to reduce electric shock hazards present on the output of welding power source when operating in SMAW (STICK) mode. Note that the presence of

VRD should not be used as a substitute for the use of appropriate safety practices as indicated in section one of this manual.

Please Note: VRD is factory set to OFF on the 401S. The red LED will be on when unit is powered up. To enable, turn VRD switch on Control PCB5 (refer to Figure 3-3) to the "ON" position. If VRD is active, green LED will be on (standby below 12V). When arc is established, red LED will blink (above 12V).

Output Voltage

Adjustment

Potentiometer

VRD Switch

Control PCB5

Art # A-12454

Figure 3-3

2 Parameter Selection Button

This button is used to select between HOT START, WELDING CURRENT, and ARC FORCE while in SMAW (STICK) mode and HOT START and WELDING CURRENT in TIG mode. Refer to 3.12 Special Function for more info.

3 Digital Meter Volt & Ammeter

Welding amperage, Voltage and parameter values are displayed in this window. Internal warnings such as over temperature, low or high input voltage applied are signaled to the operator by error message on the screen.

When welding, it displays average welding current. After weld has been completed, it displays average welding current for 10 seconds.

4 Encoder Control

It allows the operator to adjust the weld parameters within the entire range of the power source, also used to set each parameter value. This control sets the selected weld parameter, rotating it clockwise increases the parameter value and counterclockwise to decrease. A selected weld parameter can be adjusted at any time even while welding. Refer to 3.12 Special Function for more info.

5 Process Selection Button

The process selection control is used to select the desired welding mode. Five modes available for 401S. These modes are selected by pressing the selection button. For modes where there are two variations available press and hold the button until it blinks to select the second function.

Manual 0-5345 3-7 INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

Lift TIG (GTAW)- The Process light is illuminated.

The Stick function has two modes: Stick (SMAW)- The Process light is illuminated; Arc Gouging (CAC-A)- The

Process light is blinking.

6010 vertical up (SMAW)- The Process light is illuminated; 6010 Vertical down (SMAW)- the light is blinking.

6 Remote Control

The remote control A/V is for both Current or Voltage depending on the process selected. This control toggles between Local and Remote. Refer to 3.12 Special Function for more info.

7 Contactor Control

Contactor Control either enables the weld output or assigns this function to a remote device. Refer to 3.12

Special Function for more info.

8 Positive Welding Terminal

Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

9 Negative Welding Terminal

Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

10 Intelligent Fan Control

The intelligent cooling system is designed to reduce dust and foreign material build-up, while providing optimum cooling. Machine does a fan test at startup. Fan speed is controlled by various parameters and follows no fixed sequence. Parameters are: - temperatures measured by temperature sensors - output current - output active - welding time. If machine is switched on in a cold state, fans will be off (except fan test). If machine is switched off, while it’s hot and running with high fan speed, and then switched back on, fans will turn on with high speed again. After machine has cooled down, fans will stop.

INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5345

ARCMASTER 401S POWER SOURCE

11 14 Pin Remote Control Socket

The 14 pin Remote Control Socket is used to connect Remote Control devices to the welding Power Source.

To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Pin Function Description

A +16VDC contactor

B Contactor in

16 VDC supply voltage for contactor. Connect A & B for contactor enable.

Contactor input. Connect A & B for contactor enable.

C +10VDC Remote Ctrl (Max) 10 VDC for remote potentiometer supply

D Remote ctrl ground/common (min) Also control circuit common

E Remote Input

F n.c.

0<=Vin<=10V

G Chassis ground

H n.c.

I n.c.

J n.c.

K CAN_high CAN bus; positive signal

L CAN_low CAN bus; negative signal

M Current detect relay 1

N Current detect relay 2

Relay contact between M & N will close while welding is active

Table 3-2 14 Pin Interconnection Control Plug Configuration

12 ON/OFF Switch

This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the

Power Supply.

!

WARNING

When the welder is connected to the Primary supply voltage, the internal electrical components may be at 500V potential with respect to earth.

13 Input Cable

The input cable connects the Primary supply voltage to the equipment.

Manual 0-5345 3-9 INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

3.09 Welding Parameters

Parameter Description

This parameter provides an adjustable short circuit current in STICK welding to improve electrode sticking and arc stability

Arc Force

Hot Start

This parameter operates in STICK weld mode and is used to improve the start characteristics for stick electrodes. e.g. low hydrogen electrodes. This parameter also works in TIG mode allowing a softer or harder arc start. It sets the peak start current on top of the (WELD) current.

Weld Current (Amperage) - when lit Encoder Control sets the STICK and TIG

WELD current.

Contactor operation in TIG and Stick modes.

When the local Control LED is illuminated the output is enabled, and when the

Remote Control is illuminated the output is enabled by a remote control.

Contactor Control

Selects either local or remote amperage or voltage control depending on the selected process. Local Control allows the voltage or current to be adjusted on the front panel, while Remote Control is used if you have a remote control connected to the welder.

Remote Control

Table 3-3 Welding Parameters Description

Weld Process Selection

Weld

Parameter

HOT START

STICK/

GOUGING

WELD (A)

ARC FORCE

Weld Mode

6010 VERTICAL UP/

6010 VERTICAL DOWN

LIFT

TIG

Description

×

Start current in amps is added or subtracted.

In STICK mode the Hot Start is 100% to 200%, factory default 125%; while in TIG mode the range is 50% to 200%, factory default 50%.

WELD (A) current for STICK or LIFT TIG.

Adjusts percentage increase in welding current and is proportional to arc length (arc voltage).

Table 3-4 Weld Process Selection verses Weld Mode

Weld Parameter Descriptions

HOT START

This parameter encoder controls in Stick and TIG modes. Hot start can subtract 50% of the weld current during arc starts some times desirable in TIG welding, or add up to 200% of weld current during arc starts, helping with low hydrogen electrode ignition.

WELD (A)

This parameter encoder controls the Stick, Gouging, and TIG weld current.

INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5345

ARCMASTER 401S POWER SOURCE

ARC FORCE CONTROL

This parameter encoder controls in STICK mode only and is used to adjust percentage increase in welding current and is proportional to arc length (arc voltage). This control provides an adjustable amount of arc control

(or dig). This feature can be particularly beneficial in providing the operator with the ability to compensate for variability in joint fit up in certain situations with particular electrodes, e.g. cellulose and hydrogen controlled electrodes. In all welding processes, the amount of penetration obtained is dependent on the welding current; i.e. the greater the penetration, the greater the current.

Arc Force Position Effect on Welding Performance

Minimum (0)

Medium (100%)

Maximum (200%)

Soft arc, Low spatter, Low penetration

Normal arc, Improved fusion characteristics, Normal penetration

Hard arc, Deep penetration

Table 3-5 Weld Parameter Descriptions

In general, having the Arc Force set at 200% (maximum) allows greater penetration to be achieved. With the

ARC set at 0% (minimum) the Power Source has a constant current characteristic. In other words, varying the arc length does not significantly affect the welding current. When the Arc Force is set to 100%, it is possible to control the welding current by varying the arc length. This is very useful for controlling penetration and side wall wash on vertical up fillet welds.

i) Root runs

During root runs the weld pool forms a “keyhole” shape. If too much weld current is used, the hole blows out and the weld collapses. If too little weld current is used, the hole closes up and penetration is lost. The size of the hole also determines the arc length; i.e. as the hole gets bigger, the arc gets longer.

If arc force is used, the increase in the arc length causes the weld current to decrease until the hole starts to close up but if the hole closes up to much then the arc length decreases which causes the weld current to increase. Too little or too much arc force makes this process unstable. The operator must adjust the arc force until a happy medium is reached.

ii) Vertical up welding

When welding vertical up with arc force on, the operator can control the amount of current by changing arc length, i.e. voltage. Weld metal is deposited by “digging” the electrode into the side of the base metal joint and then increasing the arc length with a flicking motion, to allow the weld pool to freeze, before digging the electrode into the other side of the base metal joint.

Without arc force, increasing the arc length does not decrease the weld current sufficiently and the operator has to manually decrease the current via a Remote Control to freeze the weld pool. This welding current reduction also reduces the penetration.

The arc force allows the weld pool to freeze during the “flick” phase without decreasing the amount of weld current available during the “dig” phase thus maximizing penetration.

Weld

Parameter

Parameter Range Factory

Setting

HOT START (TIG)

HOT START (STICK)

WELD (A) (1 phase)

TIG or STICK

50 to 200%

100 to 200%

10 to 300A

50%

125%

100A

WELD (A) (3 phase)

TIG or STICK

ARC FORCE

10 to 400A 100A

0 to 200% 100%

Table 3-6 Weld Parameter Setting

Incremental

Unit

1%

1%

1A

1A

1%

Manual 0-5345 3-11 INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

3.10 Setup for TIG (GTAW) Welding

For TIG welding a TIG torch with valve is required for this power source.

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.

B. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the optional TIG Torch to the negative welding terminal (-). Welding current flows from the Power

Source via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

!

WARNING

Before connecting the work clamp to the work piece make sure the mains power supply is switched off.

Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

D. Ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position.

E. Select TIG mode by pressing Process Selection Button until TIG indicator lights up.

F. Fit the gas flowmeter/ regulator to the gas cylinder then connect the gas hose from the TIG Torch to the

Flowmeter outlet. The Power Source is not fitted with a shielding gas solenoid to control the gas flow in LIFT

TIG mode, therefore the TIG Torch will require a gas valve.

Factory setting TIG Welding Current

Welding current I1

Range

10 to 300 A (1 phase)

10 to 400 A (3 phase)

Table 3-7 TIG Welding Current

100

G. Arc Ignition. Open the valve 19 on the TIG welding torch. Briefly touch the workpiece with the tip of the electrode at the point to be welded. Lift the electrode a little. The arc burns between the workpiece and the electrode

1 2

Art # A-12455

Figure 3-4 Arc Ignition

INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5345

ARCMASTER 401S POWER SOURCE

Graphic for TIG

I Current

I1 Welding current

ISt

Hot start current

Iz Short circuit t Time tSt

Hot start

Art # A-12456

Figure 3-5 TIG Current Routing Diagram

ARCMASTER 401S

Work Lead

Tig Torch

Art # A-12554

Figure 3-6 Setup for TIG (GTAW) Welding

3.11 Setup for STICK (SMAW) Welding

A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source.

B. Connect the Electrode Holder to the positive welding terminal (+) (or negative welding terminal (-)). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the negative welding terminal (-) (or positive welding terminal (+)). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via dinse type connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

!

WARNING

The polarity of the electrode depends on the type of electrode and the welding process. Please follow the manufacturer's instructions on the electrode packaging for this purpose.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

Manual 0-5345 3-13 INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

!

WARNING

Before connecting the work clamp to the workpiece make sure the mains power supply is switched off.

D. Select STICK mode by pressing Process Selection Button until the STICK or 6010 Process LEDs are lit.

STICK Welding Current

Welding current l1

Range

10 to 300 A (1 phase)

10 to 400 A (3 phase)

Table 3-8 STICK Welding Current

Factory setting

100

E. Arc ignition. Briefly touch the workpiece at the point to be welded using the electrode and lift the electrode a little. The arc burns between the workpiece and the electrode.

Graphic for SMAW (STICK)

I Current

I1 Welding current

ISt Hot start current t

Time tSt Hot start time

Art # A-12457

Figure 3-7 STICK Current Routing Diagram

Positive Welding

Terminal (+)

Electrode Holder

ARCMASTER 401S

Negative Welding

Terminal (-)

Work Lead

Art # A-12555

Figure 3-8 Setup for STICK (SMAW) Welding

INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5345

ARCMASTER 401S POWER SOURCE

3.12 Special Function

Parameter Selection

Button

Contactor Control

Remote Control

Art # A-12547_AB

Encoder Control

Figure 3-9

Process Selection Button

Gouging and 6010 Vertical Down

There are two special functions that can be accessed by pressing the selection button for 2 seconds: Gouging and 6010 Vertical Down.

Gouging - In Stick mode hold the process Selection Button for 2 seconds and the LED will blink indicating

Gouging mode is enabled.

6010 Down - In 6010 mode hold the process Selection Button for 2 seconds and the LED will blink indicating

6010 Vertical Down mode is enabled.

Lock/ Unlock User Interface (UI)

UI Lock Function can be enabled or disabled by pressing Encoder Control for 5 seconds.

NOTE

The function lock setting is saved! If the machine is switched off with the function lock activated, the control panel is still locked when the machine is switched back on.

LED Test

Press Parameter Selection Button for 2 seconds to start LED test. The test will last for about 5 seconds. During the test all LEDs are lit.

Display Software Version

Press Remote Control and Contactor Control buttons at the same time for 2 seconds and it will display the software version of User Interface (UI), master and process.

Master Reset

!

WARNING

All personal settings will be lost!

The 401S can have master reset. All the jobs saved will be deleted and all parameters will be set back to factory setting. This function is accessed by pressing Parameter Selection Button and Remote Control Button at the same time for 2 seconds.

Manual 0-5345 3-15 INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

3.13 Shielding Gas Flowmeter/ Regulator Operating Instructions

!

WARNING

This equipment is designed for use with welding grade (Inert) shielding gases only.

Shielding Gas Flowmeter/ Regulator Safety

Designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.

If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the user's responsibility to prevent such conditions. Before handing or using the equipment, understand and comply at all times with the safe practices prescribed in this instruction.

SPECIFIC PROCEDURES for the use of flowmeter/ regulators are listed below.

1. NEVER subject the flowmeter/ regulator to inlet pressure greater than its rated inlet pressure.

2. NEVER pressurize a flowmeter/ regulator that has loose or damaged parts or is in a questionable condition.

NEVER loosen a connection or attempt to remove any part of a flowmeter/ regulator until the gas pressure has been relieved. Under pressure, gas can dangerously propel a loose part.

3. DO NOT remove the flowmeter/ regulator from a cylinder without first closing the cylinder valve and releasing gas in the flowmeter/ regulator high and low pressure chambers.

4. DO NOT use the flowmeter/ regulator as a control valve. When downstream equipment is not in use for extended periods of time, shut off the gas at the cylinder valve and release the gas from the equipment.

5. OPEN the cylinder valve SLOWLY. Close after use.

User Responsibilities

This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary for continued safe and reliable performance. Defective equipment should not be used. Parts that are broken, missing, obviously worn, distorted, or contaminated should be replaced immediately.

The user of this equipment will generally have the sole responsibility for any malfunction, which results from improper use, faulty maintenance, or by repair by anyone other than an accredited repairer.

CAUTION

Match flowmeter/ regulator to cylinder. NEVER CONNECT a flowmeter/ regulator designed for a particular gas or gases to a cylinder containing any other gas.

INLET

CONNECTION

OUTLET

CONNECTION

HIGH PRESSURE

GAUGE (SUPPLY)

INSTALLATION, OPERATION AND SETUP

FLOW GAUGE (DELIVERY)

PRESSURE

ADJUSTING

SCREW

Art # A-12126

Figure 3-10 Adjusting Flow Rate

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ARCMASTER 401S POWER SOURCE

NOTE

The flowmeter/ regulator used with argon based and carbon dioxide shielding gases are different. The flowmeter/ regulator supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide flowmeter/ regulator will need to be fitted.

NOTE

All valves downstream of the flowmeter/ regulator must be opened to obtain a true flow rate reading on the outlet gauge. (Welding power source must be triggered) Close the valves after the pressure has been set.

Installation

1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the flowmeter/ regulator.

Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.

Wipe with a clean lint free cloth.

2. Match flowmeter/ regulator to cylinder. Before connecting, check that the flowmeter/ regulator label and cylinder marking agree and that the flowmeter/ regulator inlet and cylinder outlet match. NEVER CONNECT a flowmeter/ regulator designed for a particular gas or gases to a cylinder containing any other gas.

3. Connect the flowmeter/ regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively, with a suitable spanner.

4. Connect and tighten the outlet hose firmly and attach down-stream equipment.

5. To protect sensitive down-stream equipment a separate safety device may be necessary if the flowmeter/ regulator is not fitted with a pressure relief device.

Operation

With the flowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows:

1. Stand to one side of flowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal flowmeter/ regulator parts.

2. With valves on downstream equipment closed, adjust flowmeter/ regulator to approximate working pressure.

It is recommended that testing for leaks at the flowmeter/ regulator connection points be carried out using a suitable leak detection solution or soapy water.

3. Purge air or other unwanted welding grade shielding gas from equipment connected to the flowmeter/ regulator by individually opening then closing the equipment control valves. Complete purging may take up to ten seconds or more, depending upon the length and size of the hose being purged.

Adjusting Flow Rate

Manual 0-5345

Figure 3-11 Adjust Flow Rate

3-17 INSTALLATION, OPERATION AND SETUP

ARCMASTER 401S POWER SOURCE

With the flowmeter/ regulator ready for operation, adjust working flow rate as follows:

1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.

NOTE

It may be necessary to re-check the shielding gas flowmeter/ regulator

flow rate following the first weld sequence due to back pressure present within shielding gas hose assembly.

2. To reduce flow rate, allow the welding grade shielding gas to discharge from flowmeter/ regulator by opening the downstream valve. Bleed welding grade shielding gas into a well ventilated area and away from any ignition source. Turn adjusting screw counter clockwise, until the required flow rate is indicated on the gauge. Close downstream valve.

Shutdown

Close cylinder valve whenever the flowmeter/ regulator is not in use. To shut down for extended periods (more than 30 minutes).

1. Close cylinder or upstream valve tightly.

2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any ignition source.

3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.

4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove Flowmeter/

Regulators.

INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5345

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SECTION 4:

BASIC WELDING GUIDE

4.01 Stick (SMAW) Basic Welding Technique

Size of Electrode

The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes.

For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode for a given application.

Storage of Electrodes

Always store electrodes in a dry place and in their original containers.

Electrode Polarity

Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited Tweco Distributor.

Effects of Arc Welding Various Materials

A. High tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks may result.

Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.

Low Hydrogen Electrodes must be used for this application.

B. Austenitic manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

C. Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

D. Copper and alloys

The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to give proper fusion of weld and base metal.

Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section.

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Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-5 through 4-12.

Art # A-07687

Figure 4-1: Flat Position, Down Hand Butt Weld

Art A-07691

Figure 4-5: Vertical Position, Butt Weld

Art # A-07688

Figure 4-2: Flat Position, Gravity Fillet Weld

Art # A-07692

Figure 4-6: Vertical Position, Fillet Weld

Art # A-07689

Figure 4-3: Horizontal Position, Butt Weld

Art # A-07690

Figure 4-4: Horizontal-Vertical (HV) Position

Art# A-07693

Figure 4-7: Overhead Position, Butt Weld

Art # A-07694

Figure 4-8: Overhead Position, Fillet Weld

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Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-9.

Open Square Butt

Joint

Gap varies from

1.6mm (1/16”) to 4.8mm (3/16”)

depending on plate thickness

Single Vee Butt Joint

Not less than

70°

1.6mm (1/16” ) max

Single Vee Butt Joint

Not less than

45°

1.6mm (1/16”)

Double Vee Butt Joint

Not less than

70°

1.6mm (1/16”) max

Lap Joint

Fillet Joint

Corner Weld

Tee Joints

(Fillet both sides of the joint)

1.6mm (1/16”)

Edge Joint

Plug Weld Plug Weld

Art # A-07695_AE

Figure 4-9: Typical Joint Designs for Arc Welding

Arc Welding Technique - A Word to Beginners

For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about thick and a electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position. Make sure that the work

Manual 0-5345 4-3 BASIC WELDING GUIDE

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clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

The Weldor

Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax and you will find that the job becomes much easier. You can add much to your peace of mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting alight to your clothes.

Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand.

Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock.

Striking the Arc

Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience difficulty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck.

As soon as the arc is established, maintain an imperial dimensions 1/16" to 1/8" gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difficulty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

20°

Art # A-07696_AB

1.6 mm (1/16”)

Figure 4-10: Striking an Arc

Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will find that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in. If this should happen, give the electrode a quick twist back over the weld to detach it.

Rate of Travel

After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.

If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules.

If the travel is too slow, the weld metal piles up and the bead will be too large.

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Making Welded Joints

Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in Figure 4-11, allowing 1/16" to 3/32" gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment. Plates thicker than 6.0mm should have their mating edges bevelled to form a 70º to

90º included angle. This allows full penetration of the weld metal to the root. Deposit a run of weld metal on the bottom of the joint.

Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a wellformed bead. At first you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this.

The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc.

To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

20°-30°

Electrode

Tack Weld

Tack Weld

Figure 4-11: Butt Weld

Art # A-07697_AB

Art # A-07698

Figure 4-12: Weld Build up Sequence

Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run.

Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-12. The width of weave should not be more than three times the core wire diameter of the electrode. When the joint is completely filled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-4.

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet. Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45º from the vertical. Some electrodes require to be sloped about 20º away

Manual 0-5345 4-5 BASIC WELDING GUIDE

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from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure

4-13. Do not attempt to build up much larger than width with a electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-14. Weaving in HV fillet welds is undesirable.

45° from vertical

60° - 70° from line of weld accumulate in the centre of the weld. Figure

4-16 illustrates multi-run technique and Figure

4-17 shows the effects of pausing at the edge of weave and of weaving too rapidly.

Art # A-07701

Art # A-07699_AB

Figure 4-13: Electrode Position for HV Fillet Weld

Art # A-07700_AB

6

3

1

5

2 4

Figure 4-15: Single Run Vertical Fillet Weld

Art # A-07702

Figure 4-`14: Multi-runs in HV Fillet Weld

C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron to your work bench in an upright position. Use a electrode and set the current at 100 amps.

Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet. The electrode needs to be about 10º from the horizontal to enable a good bead to be deposited. Refer Figure 4-15. Use a short arc, and do not attempt to weave on the first run.

When the first run has been completed de-slag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necessary to cover the first run and obtain good fusion at the edges. At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will

BASIC WELDING GUIDE 4-6

Figure 4-16: Multi Run Vertical Fillet Weld

Art # A-07703

Figure 4-17: Examples of Vertical Fillet Welds

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2. Vertical Down

The electrode makes welding in this position particularly easy. Use a electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about

45º.

3. Overhead Welds

Apart from the rather awkward position necessary, overhead welding is not much more difficult that downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-18). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead fillet welds. Deposit the first run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.

Art # A-07704

Figure 4-18: Overhead Fillet Weld

Distortion

Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.

The Cause of Distortion

Distortion is caused by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to flow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint in imperial dimensions sheet, the contracting weld metal may cause the sheet to become distorted.

B. Expansion and Contraction of Parent Metal in the Fusion Zone:

While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or "along the weld", it meets considerable resistance, and to fulfil the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset". When the weld area begins to

Manual 0-5345 4-7 BASIC WELDING GUIDE

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cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal.

Several things can then happen.

The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain "locked-up" stresses in the job. Figures 4-19 and 4- 20 illustrate how distortion is created.

Art # A-07705_AB

Weld

Upsetting

Hot Hot

Expansion with compression

Cool

Figure 4-19: Parent Metal Expansion

Art # A-07706_AC

Weld

Permanent Upset

Contraction with tension

Figure 4-20: Parent Metal Contraction

Overcoming Distortion Effects

There are several methods of minimizing distortion effects.

A. Peening

This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.

B. Distribution of Stresses

Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-20 through 4-23 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack welds are methods employed with this in view.

D. Presetting

It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment. A simple example is shown in Figure 4-21.

E. Preheating

Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-22 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

BASIC WELDING GUIDE 4-8 Manual 0-5345

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Art # A-07707

Preheat

Figure 4-21: Principle of Presetting

Art # A-07708

B

Weld

C

Preheat

Dotted lines show effect if no preheat is used

Figure 4-22: Reduction of Distortion by Preheating

Art # A-07709

Art # A-07428_AB

Figure 4-26: Chain Intermittent Welding

Art # A-07713_AB

Figure 4-27: Staggered Intermittent Welding

Figure 4-23: Examples of Distortion

1

2

3

Art # A-07710_AB

Block Sequence.

The spaces between the welds are filled in when the welds are cool.

Figure 4-24: Welding Sequence

1

2

3

4

Art # A-07711_AB

Figure 4-25: Step back Sequence

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4.02 Stick (SMAW) Welding Troubleshooting

FAULT

1 Welding current fluctuations

CAUSE

ARC FORCE parameter is set at a value that causes the welding current to vary excessively with the arc length.

REMEDY

Reduce the ARC FORCE parameter until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig” the electrode into the workpiece.

2 A gap is left by failure of the weld metal to fill the root of the weld.

A Welding current too low A Increase welding current.

B Electrode too large for joint.

B Use smaller diameter electrode.

C Insufficient gap.

C Allow wider gap.

3 Non-metallic particles are trapped in the weld metal.

A Non-metallic particles may be trapped in undercut from previous run.

A If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode.

B Joint preparation too restricted.

B Allow for adequate penetration and room for cleaning out the slag.

C Irregular deposits allow slag to be trapped.

C If very bad, chip or grind out irregularities.

D Lack of penetration with slag trapped beneath weld bead.

D Use smaller electrode with sufficient current to give adequate penetration. Use suitable tools to remove all slag from comers.

E Clean joint before welding.

E Rust or mill scale is preventing full fusion.

F Wrong electrode for position in which welding is done.

F Use electrodes designed for position in which welding is done, otherwise proper control of slag is difficult.

Art: A-04971

Figure 1-Example of insufficient gap or incorrect sequence

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FAULT CAUSE REMEDY

4 A groove has been formed in the base metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut).

A Welding current is too high.

C Angle of the electrode is incorrect.

A Reduce welding current.

B Welding arc is too long.

B Reduce the length of the welding arc.

C Electrode should not be inclined less than 45° to the vertical face.

D Joint preparation does not allow correct electrode angle.

D Allow more room in joint for manipulation of the electrode.

E Electrode too large for joint.

E Use smaller gauge electrode.

F Insufficient deposit time at edge of weave.

F Pause for a moment at edge of weave to allow weld metal buildup.

5 Portions of the weld run do not fuse to the surface of the metal or edge of the joint.

A Small electrodes used on heavy cold plate.

A Use larger electrodes and preheat the plate.

B Welding current is too low. B Increase welding current.

C Wrong electrode angle.

C Adjust angle so the welding arc is directed more into the base metal.

D Travel speed of electrode is too high.

E Scale or dirt on joint surface.

D Reduce travel speed of electrode.

E Clean surface before welding.

Art: A-04972

6 Gas pockets or voids in weld metal (porosity)

Figure 2: Example of Lack of Fusion

A High levels of sulphur in steel.

B Electrodes are damp.

C Welding current is too high.

A Use an electrode that is designed for high sulphur steels.

B Dry electrodes before use.

C Reduce welding current.

D Surface impurities such as oil, grease, paint, etc.

D Clean joint before welding.

E Shield the weld area from the wind.

E Welding in a windy environment.

F Electrode damaged ie flux coating incomplete.

F Discard damaged electrodes and only use electrodes with a complete flux coating.

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FAULT

7 Crack occurring in weld metal soon after solidification commences

CAUSE

A Rigidity of joint.

B Insufficient throat thickness.

REMEDY

A Redesign to relieve weld joint of severe stresses or use crack resistance electrodes.

B Travel slightly slower to allow greater build up in throat.

C Weld current is too high. C Decrease welding current.

Art: A-04973

Figure 3: Example of Slag Inclusion

Table 4-1: Welding Problems SMAW (Stick)

4.03 TIG (GTAW) Basic Welding Technique

Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas which is generally Argon. A filler metal may also be added manually in some circumstances depending on the welding application.

Art # A-09658_AC

Work Piece

Can Be Any Commercial

Metal

Gas Cup

Either Ceramic,

High-lmpact or

Water Cooled

Metal

Tungsten Electrode

Non-Consumable

Welds Made With or Without

Addition of Filler Metal

Inert Gas

Shields Electrode and Weld Puddle

Figure 4-28: TIG Welding Application Shot

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Tungsten Electrode Current Ranges

Electrode Diameter

0.040” (1.0mm)

1/16” (1.6mm)

3/32” (2.4mm)

1/8” (3.2mm)

5/32” (4.0mm)

3/16” (4.8mm)

DC Current (Amps)

30-60

60-115

100-165

135-200

190-280

250-340

Table 4-2: Current Ranges for Various Tungsten Electrode Sizes

Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)

1/16” (1.6mm)

3/32” (2.4mm)

1/8” (3.2mm)

3/16” (4.8mm)

20-90

65-115

100-165

200-350

Table 4-3: Filler Wire Selection Guide

Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

Welding Application Features

DC welding of mild steel, stainless steel and copper

High quality AC welding of aluminium, magnesium and their alloys.

Excellent arc starting, Long life, High current carrying capacity

Self cleaning, Long life, Maintains balled end, High current carrying capacity.

AC & DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys

Longer life, More stable arc,

Easier starting, Wider current range, Narrower more concentrated arc.

Table 4-4: Tungsten Electrode Types

Colour Code

Red

White

Grey

TIG Welding Filler Rods

Manual 0-5345

AWS Std

ER70S-4

ER70S-6

ER70S-2

Type/Application

For mild-medium strength steels.

Pipes, tubing, roll cages, etc.

ER80S-B2

ER90S-B3

ER308L

ER309L

ER316L

For welding of high strength Cr-Mo steels used at elevated temperatures.

For stainless steels. Stainless pipes, tubing, architectural uses, etc.

Table 4-5: TIG Welding Filler Rods

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Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm

1/16”

1.6mm

1/8”

3.2mm

3/16”

4.8mm

1/4”

6.4mm

DC Current for Mild

Steel

35-45

40-50

45-55

50-60

60-70

70-90

80-100

90-115

115-135

140-165

160-175

170-200

DC Current for Stainless

Steel

20-30

25-35

30-45

35-50

40-60

50-70

65-85

90-110

100-125

125-150

135-160

160-180

Tungsten

Electrode

Diameter

0.040”

1.0mm

0.040”

1.0mm

Filler Rod

Diameter (if required)

1/16”

1.6mm

1/16”

1.6mm

1/16”

1.6mm

1/16”

1.6mm

1/16”

1.6mm

3/32”

2.4mm

3/32”

2.4mm

1/8”

3.2mm

1/8”

3.2mm

Table 4-6: Welding Rate

5/32”

4.0mm

Argon Gas

Flow Rate

CFH

11-15

11-15

15

15

21

21

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

TIG Welding is generally regarded as a specialized process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www.tweco.com or contact Tweco.

4.04 TIG (GTAW) Welding Problems

FAULT

1 Excessive bead build up or poor penetration or poor fusion at edges of weld.

2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through.

3 Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart.

4 Weld bead too wide or excessive bead build up or excessive penetration in butt joint.

5 Uneven leg length in fillet joint

CAUSE

Welding current is too low

Welding current is too high

Travel speed too fast

Travel speed too slow

Wrong placement of filler rod

REMEDY

Increase weld current and/or faulty joint preparation.

Decrease weld current.

Reduce travel speed.

Increase travel speed.

Re-position filler rod.

BASIC WELDING GUIDE 4-14 Manual 0-5345

ARCMASTER 401S POWER SOURCE

FAULT

6 Electrode melts or oxidizes when an arc is struck.

CAUSE

A Torch lead connected to positive welding terminal.

B No gas flowing to welding region.

C Torch is clogged with dust or dirt.

D Gas hose is cut.

A Connect torch lead to negative welding terminal.

B Check the gas lines for kinks or breaks and gas cylinder contents.

C Clean torch.

REMEDY

D Replace gas hose.

7 Dirty weld pool

E Gas passage contains impurities.

F Gas regulator turned off.

G The electrode is too small for the welding current.

H Power source is set for

STICK welding.

A Electrode contaminated by contact with work piece or filler rod material.

E Disconnect gas hose from the rear of

Power Source then raise gas pressure and blow out impurities.

F Turn on.

G Increase electrode diameter or reduce the welding current.

H Set Power Source to a GTAW operating mode.

A Clean the electrode by grinding off the contaminates.

B Work piece surface has foreign material on it.

B Clean surface.

8 Poor weld finish

C Gas contaminated with air.

Inadequate shielding gas.

9 Arc start is not smooth.

A Tungsten electrode is too large for the welding current.

C Check gas lines for cuts and loose fitting or change gas cylinder.

Increase gas flow or check gas line for gas flow problems.

A Select the right size tungsten electrode.

Refer to Table 4-3 Tweco Tungsten Electrode Selection Chart.

B Select the right tungsten electrode type. B The wrong electrode is being used for the welding job.

C Gas flow rate is too high.

C Select the right rate for the welding job.

Refer to Table 4-6.

D Incorrect shielding gas is being used.

D Select the right shielding gas.

10 Arc flutters during TIG welding.

E Poor work clamp connection to work piece.

Tungsten electrode is too large for the welding current.

Table 4-7

E Improve connection to work piece.

Select the right size tungsten electrode.

Manual 0-5345 4-15 BASIC WELDING GUIDE

ARCMASTER 401S POWER SOURCE

This Page Intentionally Blank

BASIC WELDING GUIDE 4-16 Manual 0-5345

ARCMASTER 401S POWER SOURCE

SECTION 5:

POWER SOURCE PROBLEMS AND ROUTINE SERVICE

REQUIREMENTS

5.01 Maintenance and Repair

!

WARNING

There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson and you have had training in power measurements and troubleshooting techniques.

If major complex subassemblies are faulty, then the Welding Power Source must be returned to an accredited

Tweco Service Provider for repair. The basic level of troubleshooting is that which can be performed without special equipment or knowledge. Refer also to section 4 for solving welding problems.

The machine requires a minimum of care and maintenance. Only a few items need to be checked to ensure troublefree long-term operation.

Check the following points for damage before starting up the welding machine,

–– Mains plug and cable

–– Welding torch and connections

–– Keyboard membrane and control panel

Check the dust filter every two months.

–– Switch the machine off

–– Disconnect the mains plug

–– Unscrew the ventilation grid on the rear side

––Check the dust filter for pollution

––Replace the dust filter if it is polluted (dust filter)

Use only original TWECO spare parts for maintenance and repair.

If you experience problems or need repairs, contact a dealer authorised by Victor. Never make repairs or technical changes yourself. In this case the manufacturer's warranty is no longer valid.

Manual 0-5345 5-1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

ARCMASTER 401S POWER SOURCE

5.02 Power Source Status Messages

An error code is displayed in the digital displays in the event of a malfunction. You can switch over between error code and sub-error (sub code) in the digital displays by pressing Process Selection Button.

After the message has been displayed, the machine will only function to a limited extent; the error must be corrected as quickly as possible.

The status message can be deleted by pressing Encoder Control.

Code

H08

H30

Note

Short-circuit

Cause

Short-circuit in the output circuit

Possible Remedy

Eliminate the short-circuit (pick up electrode holder, ...)

Configuration Component group recognition faulty Take to an accredited Tweco Service

Center for repair

Table 5-1 Power Source Status Messages

5.03 Error Messages

!

WARNING

There are extremely dangerous voltage and power levels present inside this Inverter Power Source.

Do not attempt to open or repair unless you are an accredited Tweco Service Provider. Disconnect the

Welding Power Source from the Mains Supply Voltage before disassembling.

An error code is displayed in the digital displays in the event of a malfunction. You can switch over between error code and sub-error (sub code) in the digital displays by pressing any button. As long as there is an error code on display welding is not possible.

Code

E01

E02

E06

E07

E08-1

E08-2

E08-3

E08-10

E08-11

E08-13

Error Cause Possible Remedy

Excessive Temperature Duty cycle exceeded Allow switched-on machine to cool down for a few minutes

Overvoltage

Overvoltage Secondary

EEPROM

Wirefeeder Motor

Dust filter contaminated

Mains voltage too high

Initial voltage too high

Communication with EEPROM defec tive

Replace dust filter

Check mains voltage

Take to an accredited Tweco Service

Center for repair

Switch machine off and on again, ex ecute master reset

Excess Wirefeeder Voltage Wirefeeder voltage too high Take to an accredited Tweco Service

Center for repair

Error in Wirefeeder Motor Take to an accredited Tweco Service

Center for repair

Overcurrent on Wirefeeder Wirefeeder current continuously too high

Torch Connection Torch/torch connection error

Reduce motor load

Check torch and torch connection.

Switch the equipment off and on again

V/I Acquisition

CAN Identification

Voltage/current measuring systems faulty

Take to an accredited Tweco Service

Center for repair

Unknown device connected Check connected devices and CAN connections

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-2 Manual 0-5345

E39

E40

E41

E31

E32

E33

E34

E18

E22

E25

E30

Code

E09

E12

E13

E14

E15

E47

Error Cause

ARCMASTER 401S POWER SOURCE

Possible Remedy

Output Voltage

Power Section

Temperature Sensor

Supply Voltage

Current Detection

Overload Protection

Mains Undervoltage

Idle Generator

Error Configuration

Communications Fault

FPGA

Power Section

Fans

Protective Earth Conductor

Monitoring

Voltage Detection

Phase Loss

Undefined Mains

Voltage measuring system faulty

Take to an accredited Tweco Service

Center for repair

Power section start-up faulty Take to an accredited Tweco Service

Center for repair

Temperature sensor not ready for operation

Take to an accredited Tweco Service

Center for repair

Internal supply voltage too low Check mains voltages

Error during current measurement

Safety switch device to protect elec trical components

Mains voltage on power unit is too low

Idle generator faulty

Take to an accredited Tweco Service

Center for repair

Take to an accredited Tweco Service

Center for repair

Check mains voltages

Faulty or wrong pc-board, wrong software system installed

CAN bus communication faulty

FPGA faulty

Power module not symmetrical

Fan current faulty

Take to an accredited Tweco Service

Center for repair

Take to an accredited Tweco Service

Center for repair

Switch the equipment off and on again

Take to an accredited Tweco Service

Center for repair

Take to an accredited Tweco Service

Center for repair

Take to an accredited Tweco Service

Center for repair

Connect the welding earth lead Fault current to protective earth con ductor

Voltage measurement faulty at the socket

The primary DSP detected a loss of at least one phase of the mains.

Mains voltage between permitted ranges

Take to an accredited Tweco Service

Center for repair

Take to an accredited Tweco Service

Center for repair

Check mains

Table 5-2 Power Source Error Messages

Manual 0-5345 5-3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS

ARCMASTER 401S POWER SOURCE

5.04 Routine Inspection, Testing & Maintenance

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

A. Testing Schedule

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.

A transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated.

B. General Maintenance Checks

Welding equipment should be regularly checked by an accredited Tweco Service Provider to ensure that:

1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition.

2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit.

3. The Welding System is clean internally, especially from metal filing, slag, and loose material.

C. Accessories

Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall not be used.

D. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited

Tweco Service Provider.

5.05 Cleaning the Welding Power Source

!

WARNING

There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal filings, slag and loose material. Keep the surfaces clean.

POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5-4 Manual 0-5345

ARCMASTER 401S POWER SOURCE

SECTION 6:

KEY SPARE PARTS

6.01 401S Power Source Spare Parts

43

8

16

3

1

36

21

24

20

13

10

33

25

19

6

4

37

42

41

18

32

11

29

12

11

26

28

27

35

30

14

15

2

5

17

7

9

31

23

22

40

34

38

Figure 6-1 ArcMaster 401S Spare Parts

39

Art # A-12460_AB

8

9

6

7

3

4

1

2

5

Item

ArcMaster 401S Spare Parts

Description

Des. Ref.

Quantity Part Number

Side Panel Left

Side Panel Right

Top Panel with Display Sheet

Front Panel

Rear Panel

1

1

1

1

1

W7006700

W7006701

W7006702

W7006703

W7006704

Front Grill

Rear Grill

Handle Tube

Mains Label

1

1

1

1

W7006705

W7006706

W7006707

W7006708

Manual 0-5345 6-1 KEY SPARE PARTS

Item

38

39

40

41

42

43

44

33

34

35

36

37

28

29

30

31

32

23

24

25

26

27

18

19

20

21

22

13

14

15

16

17

10

11

12

ARCMASTER 401S POWER SOURCE

Description

Des. Ref.

Quantity Part Number

Display Panel Overlay

Cover black AD 10,3 LD 9,5

Strain relief

Foam Spacer

Foam inlay

Foam inlay

Foam Plate Self-adhesive

Rear Filter

Wire Gauze

Knob Body

Knob Cap

Control PCB

Capacitor PCB

Output PCB

ADP10 PCB

Front Panel PCB

Main Power PCB

Input PCB

PCB 5

PCB 3

PCB 7

PCB 6

PCB 4

PCB 2

PCB 1

T1

SW1

BR1

Main Transformer

ON/OFF Switch

Bridge Rectifier

Input Mains Cable

14 pin Remote Socket with Harness

Insulating Bush

Insulation Foil

Insulation Foil

Shunt

50 mm Dinse Output Terminal

Output Diode

Unit Thermal Sensor

Cooling Fan

Label +/- Tweco

Label 401S

Warning Sticker

D1, D2, D3

TS1

M1

Sticker Tweco 261 x 93 (not shown)

Table 6-1 ArcMaster 401S Spart Parts

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

3

2

2

1

1

1

W7006749

W7006751

W7006710

W7006732

W7006733

W7006734

W7006735

W7006739

W7006740

W7006741

W7006742

W7006744

W7006750

W7006746

W7006748

W7006711

W7006712

W7006713

W7006714

W7006715

W7006716

W7006717

W7006718

W7006719

W7006720

W7006721

W7006722

W7006752

W7006724

W7006725

W7006727

W7006728

W7006729

W7006730

W7006753

KEY SPARE PARTS 6-2 Manual 0-5345

ARCMASTER 401S POWER SOURCE

APPENDIX A: CIRCUIT DIAGRAM

X3/13

X3/14

X3/11

X3/12

X2/3

X2/4

X2/1

X2/2

Manual 0-5345

LP4

LP3

LP2

LP1

LP7

LP9

LP6

LP8

B

A

+

X5/4

X5/3

X5/2

X5/1

X7/2

X7/1

4

1

3

2

X6/7

X6/6

X6/8

X6/4

X6/3

X6/5

X6/2

X6/1

X1

X7/7

X7/5

X7/6

X7/3

X7/4

X7/2

X7/1

X7/9

X7/8

X7/10

X1

X5/8 X5/6

A-1 APPENDIX

TWECO - LIMITED WARRANTY TERMS

LIMITED WARRANTY: Tweco ®, Inc, A Victor Technologies Company, warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Tweco products as stated below, Tweco shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Tweco’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Tweco’s sole option, of any components or parts of the product determined by Tweco to be defective.

TWECO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU

OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR

ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: TWECO SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDI-

RECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTER-

RUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of Tweco with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Tweco whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of

Tweco is authorized to change this warranty in any way or grant any other warranty.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE

USED WHICH IN TWECO’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY TWECO

PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PUR-

CHASER BY NON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Tweco delivered the product to the authorized distributor.

WARRANTY SCHEDULE

5 Years Parts* / 3 Years Labor

ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster

Portafeed, Ultrafeed, Ultima 150, WC 100B

* 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards.

* 3 years on Power Supply Components

2 Years Parts and Labor Unless specified

Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy

Victor Regulator for Fabricator 141i (No labor)

1 Years Parts and Labor Unless specified

95S, Water recirculators

All Plasma Welding consols (i.e WC-1 Controller, WT Timer,

WF-100 Capstain Feeder, etc)

180 days parts and Labor Unless specified

Plasma Welding Torch and leads packages

Gas Regulators "Supplied with power sources" (No Labor)

90 days parts / No Labor

Remote Controls

MIG and TIG Torches (Supplied with power sources)

Replacement repair parts

30 days parts / No Labor

MIG Torch for Fabricator 141i

5-2-1 years Parts / No Labor

FirePower® Welders

5 Years Parts / No Labor

Victor® Professional

Victor Technologies limited warranty shall not apply to:

Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that fail due normal wear

* Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized VICTOR TECHNOLOGIES® repair facility within thirty (30) days of the repair.

* No employee, agent, or representative of VICTOR TECHNOLOGIES® is authorized to change this warranty in any way or grant any other warranty, and VICTOR TECHNOLOGIES® shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of VICTOR TECHNOLOGIES®’s obligations to purchaser with respect to the product.

* This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in VICTOR

TECHNOLOGIES®'s sole judgment, impaired the safety or performance of any VICTOR TECHNOLOGIES® product. Purchaser’s rights under this warranty are void if the product is sold to purchaser by unauthorized persons.

THE AMERICAS

Denton, TX USA

U.S. Customer Care

Ph 1-800-426-1888 (tollfree)

Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph 1-940-381-1212

Fax: 1-940-483-8178

Miami, FL USA

Sales Office, Latin America

Ph 1-954-727-8371

Fax: 1-954-727-8376

Oakville, Ontario, Canada

Canada Customer Care

Ph 1-905-827-4515

Fax: 1-800-588-1714 (tollfree)

EUROPE

Chorley, United Kingdom

Customer Care

Ph +44 1257-261755

Fax: +44 1257-224800

Milan, Italy

Customer Care

Ph +39 0236546801

Fax: +39 0236546840

ASIA/PACIFIC

Cikarang, Indonesia

Customer Care

Ph 6221-8990-6095

Fax: 6221-8990-6096

Rawang, Malaysia

Customer Care

Ph +603 6092-2988

Fax: +603 6092-1085

Melbourne, Australia

Australia Customer Care

Ph 1300-654-674 (tollfree)

Ph 61-3-9474-7400

Fax: 61-3-9474-7391

International

Ph 61-3-9474-7508

Fax: 61-3-9474-7488

Shanghai, China

Sales Office

Ph +86 21-64072626

Fax: +86 21-64483032

Singapore

Sales Office

Ph +65 6832-8066

Fax: +65 6763-5812

I N N O V A T I O N T O S H A P E T H E W O R L D ™

U.S. Customer Care: 800-426-1888 / FAX 800-535-0557

Canada Customer Care: 905-827-4515 / FAX 800-588-1714

International Customer Care: 940-381-1212 / FAX 940-483-8178

© 2012 Victor Technologies International, Inc. www.victortechnologies.com

Printed in Germany

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