Tweco ARCMASTER 401S, Operating Manual

Page 1: ...Tweco com Art A 12546_AB ARCMASTER 401S 3163339 Revision AC Issue Date November 11 2014 Manual No 0 5345 Operating Manual...

Page 2: ...stinguish 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...

Page 3: ...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 publish...

Page 4: ...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 G...

Page 5: ...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...

Page 6: ...This Page Intentionally Blank...

Page 7: ...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 1...

Page 8: ...ide 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...

Page 9: ...ause sparks overheating or fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7...

Page 10: ...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 MOVING PARTS can cause injury Movin...

Page 11: ...ic findings based on experiments at the cel lular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with and produce changes in biologi...

Page 12: ...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 Pa...

Page 13: ...tive Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wir...

Page 14: ...ARCMASTER 401S POWER SOURCE SAFETY INSTRUCTIONS AND WARNINGS 1 8 Manual 0 5345 This Page Intentionally Blank...

Page 15: ...back cover of this manual Include all equipment identification numbers as de scribed above along with a full description of the parts in error Move the equipment to the installation site before un cra...

Page 16: ...t 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 equipmen...

Page 17: ...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 mi...

Page 18: ...0A 3 phase Effective Input Current I1eff note2 40A 208V 1 phase 38 1A 230V 1 phase 20A 460V 1 phase 26 6A 208V 3 phase 24 6A 230V 3 phase 14 3A 460V 3 phase Maximum Input Current I1max 84 7A 208V 1 ph...

Page 19: ...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 Dut...

Page 20: ...ARCMASTER 401S POWER SOURCE INTRODUCTION 2 6 Manual 0 5345 This Page Intentionally Blank...

Page 21: ...onments with increased hazard of electric shock are 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...

Page 22: ...ctrical 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...

Page 23: ...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 canno...

Page 24: ...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...

Page 25: ...tions 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 meta...

Page 26: ...ARCMASTER 401S POWER SOURCE INSTALLATION OPERATION AND SETUP 3 6 Manual 0 5345 3 08 ArcMaster 401S Power Source Controls Indicators and Features Art A 12453_AB 1 2 4 3 7 6 5 11 12 13 8 9 Figure 3 2...

Page 27: ...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...

Page 28: ...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 esse...

Page 29: ...ply D Remote ctrl ground common min Also control circuit common E Remote Input 0 Vin 10V F n c 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...

Page 30: ...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 weld...

Page 31: ...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 h...

Page 32: ...cting 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 s...

Page 33: ...trode 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 connec...

Page 34: ...10 to 300 A 1 phase 100 10 to 400 A 3 phase Table 3 8 STICK Welding Current E Arc ignition Briefly touch the workpiece at the point to be welded using the electrode and lift the electrode a little Th...

Page 35: ...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...

Page 36: ...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 c...

Page 37: ...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 Conn...

Page 38: ...y 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 in...

Page 39: ...able 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 preheatin...

Page 40: ...es 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...

Page 41: ...16 to 4 8mm 3 16 depending on plate thickness Joint Open Square Butt 1 6mm 1 16 max 1 6mm 1 16 Single Vee Butt Joint Not less than 70 Double Vee Butt Joint 1 6mm 1 16 Lap Joint Tee Joints Fillet both...

Page 42: ...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...

Page 43: ...Weld 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 I...

Page 44: ...job and strike the arc in the corner of the fillet The electrode needs to be about 10 from the horizontal to enable a good bead to be deposited Refer Figure 4 15 Use a short arc and do not attempt to...

Page 45: ...ccur 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 approximatel...

Page 46: ...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...

Page 47: ...C Figure 4 22 Reduction of Distortion by Preheating Art A 07709 Figure 4 23 Examples of Distortion Art A 07710_AB 1 Block Sequence The spaces between the welds are filled in when the welds are cool 2...

Page 48: ...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 restricte...

Page 49: ...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 an...

Page 50: ...en 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...

Page 51: ...stainless steel and copper Excellent arc starting Long life High current carrying capacity Red Zirconated 1 High quality AC welding of aluminium magnesium and their alloys Self cleaning Long life Main...

Page 52: ...es 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 Operatin...

Page 53: ...by contact with work piece or filler rod material A Clean the electrode by grinding off the contaminates B Work piece surface has foreign material on it B Clean surface C Gas contaminated with air C...

Page 54: ...ARCMASTER 401S POWER SOURCE This Page Intentionally Blank BASIC WELDING GUIDE 4 16 Manual 0 5345...

Page 55: ...t 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 trouble free...

Page 56: ...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 e...

Page 57: ...25 Idle Generator Idle generator faulty Take to an accredited Tweco Service Center for repair E30 Error Configuration Faulty or wrong pc board wrong software system installed Take to an accredited Twe...

Page 58: ...re 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 sh...

Page 59: ...19 7 17 9 10 25 33 13 12 40 8 11 11 Art A 12460_AB Figure 6 1 ArcMaster 401S Spare Parts ArcMaster 401S Spare Parts Item Description Des Ref Quantity Part Number 1 Side Panel Left 1 W7006700 2 Side Pa...

Page 60: ...DP10 PCB PCB 6 1 W7006722 25 Front Panel PCB PCB 4 1 W7006752 26 Main Power PCB PCB 2 1 W7006724 27 Input PCB PCB 1 1 W7006725 28 Main Transformer T1 1 W7006727 29 ON OFF Switch SW1 1 W7006728 30 Brid...

Page 61: ...X8 1 X1 X1 F1 1 4 3 X10 1 X10 2 M2 M A4 DRV04 X7 1 X7 2 X7 3 X7 6 X7 4 X7 5 X7 7 X7 8 X7 9 X7 10 X6 1 X6 2 X6 3 X6 4 X6 6 X6 7 X6 8 X6 5 X2 3 X5 8 X5 6 X2 2 X7 1 X7 2 X5 1 X5 2 LP8 LP6 LP1 X2 4 X5 7 L...

Page 62: ...AL 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 an...

Page 63: ...ts 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 p...

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