To Next PageTo Next PageWhy is my Thermal Arc Inverter weld bead too wide or excessive bead build up or excessive penetration in butt joint?
If the weld bead is too wide, there's excessive bead build-up, or excessive penetration in a butt joint when using your Thermal Arc Inverter, the travel speed is likely too slow. Increase the travel speed to resolve this.
What to do if my Thermal Arc Inverter welding current reduces when welding?
If the welding current reduces during welding, first, check and tighten all welding cable connections. Ensure you are using the proper size and type of cable. Also, replace the electrode if it is in poor condition and verify the output torch connections to confirm correct welding polarity.
Why does my Thermal Arc Inverter have gas pockets or voids in weld metal (Porosity)?
Porosity, or gas pockets in the weld metal, can occur for a few reasons. The electrodes might be damp; dry them before use. The welding current could be too high; reduce it. Also, surface impurities like oil, grease, or paint can cause this; clean the joint before welding.
What to do if my Thermal Arc Inverter electrode melts when arc is struck?
If the electrode melts when the arc is struck, it could be due to two main reasons. First, check if the electrode is connected to the '+' terminal and connect it to the '–' terminal instead. Second, if the WAVE BALANCE is greater than 50%, reduce it to below 50% or increase the electrode size.
What to do if my Thermal Arc Inverter welding arc can not be established?
If a welding arc cannot be established, first ensure that the work clamp is properly connected to the workpiece, or that the work/torch leads are connected to the correct welding terminals. If using a torch lead, connect it to the '–' terminal. Finally, check the gas flow rate, ensure the cylinder isn't empty, and verify that the torch valve is on. Select the right flow rate, change cylinders or turn torch valve on.
Why is there no gas flow when the torch trigger switch is depressed on my Thermal Arc Inverter?
If there's no gas flow when the torch trigger is depressed, several issues could be the cause. Check if the gas hose is cut and replace it if necessary. Impurities in the gas passage can also be a problem; disconnect the gas hose from the rear of the Power Source, then raise the gas pressure and blow out any impurities. Ensure the gas regulator is turned on. Finally, the torch trigger switch lead might be disconnected, or the switch/cable could be faulty; reconnect the lead or repair the faulty switch/cable.
What causes crack occurring in weld metal soon after solidification commences with my Thermal Arc Inverter?
If cracks occur in the weld metal soon after solidification, it could be due to a few reasons. The rigidity of the joint might be a factor; redesign the joint to relieve severe stresses or use crack-resistant electrodes. Insufficient throat thickness can also contribute; travel slightly slower to allow greater build-up in the throat. Finally, a cooling rate that is too high can cause cracking; preheat the plate and allow it to cool slowly.
Why the welding arc cannot be established with my Thermal Arc Inverter?
If the welding arc cannot be established, first ensure that the primary supply voltage is switched ON. Next, check that the Welding Power Source switch is also switched ON.
Why is my Thermal Arc Inverter weld bead too small or insufficient penetration or ripples in bead are widely spaced apart?
If the weld bead is too small, penetration is insufficient, or ripples in the bead are widely spaced when using your Thermal Arc Inverter, the travel speed is likely too fast. Reduce the travel speed to correct this.
What causes a dirty weld pool in my Thermal Arc Inverter?
A dirty weld pool can result from a couple of issues. The electrode might be contaminated through contact with the workpiece or filler rod material; clean the electrode by grinding off the contaminants. Alternatively, the gas could be contaminated with air; check the gas lines for cuts and loose fittings or change the gas cylinder.
Electrical shock hazards, arc rays, fumes, and fire risks associated with arc welding.
Lists key safety standards and regulations for welding operations and equipment.
Explains how to navigate and use the service manual effectively.
Details how to identify the welding unit by its specifications and serial numbers.
Provides a reference for symbols used on the model's controls and displays.
Describes the features and capabilities of the ARC MASTER welder models.
Illustrates the internal workings and connections of the power supply units.
Provides instructions and safety precautions for moving the welding equipment.
Details suitable and adverse environmental conditions for operation.
Guidelines for placing the welder for proper ventilation and cooling.
Instructions for connecting the power source to the electrical supply.
Specifies the required AC power supply voltage and frequency.
Explains the INRUSH circuit and input voltage sensing for power activation.
Importance of correct installation for high frequency welding.
Ways interference is transmitted and how to mitigate it.
Defines duty cycle and its impact on welder performance and lifespan.
Provides technical specifications for the welder models.
Overview of front panel controls, including knob, remote socket, and terminals.
Table explaining selection of STICK, HF TIG, LIFT TIG modes and their descriptions.
Explanation of parameters like PRE-FLOW, HOT START, WELD CUR, and PULSE settings.
Tables detailing parameter ranges and settings for different welding modes.
Details features like digital meter, fan control, VRD, and control knob.
Connecting work lead and electrode, adjusting current based on electrode type.
Ensure power is OFF before connecting clamp; remove packaging and do not block vents.
Overview of controls like Pulse, Remote Current, TIG Modes, LED display, Save/Load, knob, Process, Scroll Buttons, Contactor.
Step-by-step guide for performing stick welding operations.
Procedure for performing High Frequency TIG welding.
Procedure for performing Lift TIG welding.
Sequence of operations for slope mode welding.
Operation of the repeat function during the down slope cycle.
Controls for managing heat input in pulse welding.
Disconnect power before opening; avoid blowing air into the unit during cleaning.
Common TIG welding issues, possible causes, and remedies.
Common stick welding issues, possible causes, and remedies.
Troubleshooting issues related to the power source itself.
Specifications and requirements for the Voltage Reduction Device.
Routine inspection and periodic testing procedures for the VRD.
Procedure for turning the VRD function on and off.
Over-temperature condition detected on the primary IGBT.
Over-temperature condition detected on the secondary IGBT and diode.
Excessive current detected flowing into the primary side of the main transformer.
Error related to combined length of torch and work cables being too long.
Main supply voltage exceeds specified limits (over voltage).
Main supply voltage is below specified limits (under voltage).
Error indicating incorrect main supply voltage connection.
Abnormality in the rated voltage selection circuitry.
Abnormalities detected in the mains supply voltage detection circuit.
Primary capacitors are not charging correctly.
Thermistors for component temperature detection malfunctioned.
Error when initial AC power signal is not received by the CPU.
Troubleshooting procedures for issues without specific error codes.
Isolating defective internal subassemblies when basic troubleshooting fails.
Steps to safely open the unit for inspection and repair.
Procedures for verifying and resolving specific error codes.
Troubleshooting procedures for issues without specific error codes.
Tests to isolate faults and preparation steps required.
Verifying AC input voltage and rectified output voltage.
Verifying cooling fan operation and its drive circuitry.
Verifying gas valve operation and its drive circuitry.
Verifying characteristics of primary/secondary diodes and IGBTs.
Verifying no-load voltage in STICK and HF TIG modes.
Lists maintenance items and their reference pages for components.
Lists required tools, parts, and notes for disassembly and assembly.
Step-by-step guides for replacing various components like PCBs and diodes.
Information needed to identify equipment for ordering parts.
Explanation of how to navigate and utilize the parts list and illustration.
Table mapping PCB connections to their destinations for wiring.
Diagram showing electrical connections within the 300/400TS model.
Diagram showing electrical connections within the 300/400S model.
Basic principles for testing diodes using a digital volt/ohm meter.
Details warranty coverage, limitations, and exclusions for Thermal Arc products.
Table outlining warranty periods and labor coverage for different welder types.
General| Output Current Range | 5-400A |
|---|---|
| Input Current | 32A |
| Rated Output | 400A/36V |
| Duty Cycle | 60% @ 400A |
| Welding Processes | TIG, MMA |
| Weight | 84 lbs (38 kg) |
