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Thermal Arc Arcmaster 400 MST User Manual

Thermal Arc Arcmaster 400 MST
68 pages
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GTAWCAGSMAW
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400
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INVERTER
Operating Manual
ARCMASTER
®
Version No: 1 Issue Date: April 26, 2006 Manual No.: 0-4905
Operating Features:
INVERTER ARC WELDER
400 MST
Art # A-07368

Table of Contents

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Thermal Arc Arcmaster 400 MST Specifications

General IconGeneral
BrandThermal Arc
ModelArcmaster 400 MST
CategoryWelding System
LanguageEnglish

Summary

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS

1.01 Arc Welding Hazards

Details potential dangers associated with arc welding, including electric shock and fumes.

1.02 Principal Safety Standards

Lists key safety standards and regulations relevant to welding operations.

1.06 Declaration Of Conformity

Details compliance with relevant European Directives and national legislation.

SECTION 2: INTRODUCTION AND DESCRIPTION

2.01 How to Use This Manual

Explains how to navigate and interpret the manual's structure and warnings.

2.02 Equipment Identification

Details how to locate and record the unit's identification number (model, serial).

2.03 Receipt of Equipment

Instructions for checking equipment upon delivery for completeness and damage.

2.04 Description

Describes the ARC MASTER 400 MST as a DC arc welding power source.

2.05 Functional Block Diagram

Illustrates the internal functional block diagram of the 400 MST power supply.

2.06 Transporting Methods

Provides guidelines and warnings for safely lifting and transporting the welding unit.

SECTION 3: INSTALLATION RECOMMENDATIONS

3.01 Environment

Details the recommended environmental conditions for operating the welding equipment.

3.02 Location

Provides guidelines for selecting a suitable location for the welder, considering ventilation.

3.03 Electrical Input Connections

Explains how to safely connect the welding power source to the electrical input supply.

3.04 Electrical Input Requirements

Specifies AC power supply requirements, voltage matching, and fuse selection.

3.05 Input Power

Describes the unit's inrush circuit, voltage sensing, and primary current recommendations.

3.06 High Frequency Introduction

Emphasizes correct installation of HF equipment and potential interference issues.

3.07 High Frequency Interference

Explains how high frequency energy can be transmitted and cause interference.

3.08 Duty Cycle

Defines duty cycle and warns about exceeding ratings, which can cause shutdown.

3.09 Specifications

Lists detailed technical specifications of the ARC MASTER 400 MST welding equipment.

SECTION 4: OPERATOR CONTROLS

4.01 ARC MASTER 400 MST Controls

Identifies and describes the main controls on the front panel of the power source.

4.02 Weld Parameter Descriptions

Explains the function of each weld parameter and its effect on welding performance.

4.03 Weld Process Selection

Details how to select different weld modes (STICK, MIG, LIFT TIG) and their parameters.

Detailed Weld Parameter Descriptions

Provides detailed descriptions of specific weld parameters like WELD(V), INDUCTANCE, HOT START.

4.05 Weld Parameters

Presents a table summarizing weld parameters and their ranges for different welding modes.

4.06 Power Source Features

Highlights key features of the power source, including digital controls and cooling.

SECTION 5: SEQUENCE OF OPERATION

5.01 Stick Welding

Step-by-step guide on connecting and setting up for Stick welding operation.

5.02 LIFT TIG Welding

Instructions for connecting and setting up the machine for LIFT TIG welding.

5.03 MIG Welding

Procedure for connecting and setting up the machine for MIG welding operations.

5.04 Save-Load Operation

Explains how to save and retrieve welding parameter programs using Save/Load buttons.

SECTION 6: BASIC TIG WELDING GUIDE

6.01 Electrode Polarity

Explains how to connect TIG torch and work lead for direct current straight polarity.

6.02 Tungsten Electrode Current Ranges

Provides a table of current ranges for various tungsten electrode sizes.

6.03 Tungsten Electrode Types

Details electrode types, their applications, features, and color codes.

6.04 Guide for Selecting Filler Wire Diameter

Offers guidance on selecting filler wire diameter based on AC/DC current ranges.

6.05 Shielding Gas Selection

Lists recommended shielding gases for different metal alloys used in welding.

6.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Provides TIG welding parameters for steel pipe, including electrode type and filler rod.

6.07 Welding Parameters for Steel

Presents DC TIG welding parameters for steel based on thickness and joint type.

SECTION 7: BASIC STICK WELDING GUIDE

7.01 Electrode Polarity

Explains the correct electrode polarity connection for stick electrodes.

7.02 Effects of Stick Welding Various Materials

Discusses the effects of stick welding on different metal types and material properties.

SECTION 8.0 BASIC MIG WELDING GUIDE

8.01 Setting of the Power Source

Guides on setting Wirespeed and Voltage controls for optimal MIG welding.

8.02 Position of MIG Torch

Explains how MIG torch angle affects the weld run width.

8.03 Distance from the MIG Torch Nozzle to the Work Piece

Specifies the recommended electrode stick-out distance from the MIG torch nozzle.

8.04 Travel Speed

Discusses how travel speed influences weld width and penetration.

8.05 Electrode Wire Size Selection

Details factors influencing electrode wire size selection for MIG welding.

8.06 Deposition Rate Comparison

Compares deposition rates and productivity when using different electrode wire sizes.

SECTION 9: ROUTINE MAINTENANCE

Routine Maintenance Procedures

Outlines the cleaning and inspection procedures for the power supply unit.

SECTION 10: BASIC TROUBLESHOOTING

10.01 Solving MIG Problems beyond the Welding Terminals

Addresses common MIG welding issues like porosity and inconsistent wire feed.

10.02 MIG Welding Problems

Troubleshooting guide for common MIG welding defects and their causes/remedies.

10.03 TIG Welding Problems

Troubleshooting guide for common TIG welding issues affecting weld quality.

10.04 Stick Welding Problems

Identifies common problems in Stick welding and provides solutions.

10.05 Power Source Problems

Troubleshooting guide for issues related to the welding power source itself.

SECTION 11: VOLTAGE REDUCTION DEVICE (VRD)

11.01 VRD Specifications

Provides technical specifications for the Voltage Reduction Device (VRD).

11.02 VRD Maintenance

Outlines routine inspection and testing procedures for the VRD.

11.03 Switching VRD On/Off

Step-by-step instructions on how to enable or disable the VRD function.

SECTION 12: POWER SOURCE ERROR CODES

Error Code Descriptions and Remedies

Details common error codes displayed by the power source and their troubleshooting.

APPENDIX B - ARCMASTER 400 MST ACCESSORIES

Accessories List

Lists part numbers and descriptions for available accessories for the welder.

LIMITED WARRANTY AND SCHEDULE

Warranty Information

Details the warranty periods for welding equipment, cutting equipment, and accessories.

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Contact Information by Region

Provides contact details for Thermal Arc customer service worldwide.

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