A THERMADYNE
®
Company
INVERTER
ARC
WELDER
MODEL 400MSTW CC/CV
• STICK•TIG - Lift Start•MIG - Short Circuit
- Globular
- Spray
OPERATING MANUAL
July 1, 2001
Manual No. 430429-490
Page 1: ...A THERMADYNE Company INVERTER ARC WELDER MODEL 400MSTW CC CV STICK TIG Lift Start MIG Short Circuit Globular Spray OPERATING MANUAL July 1 2001 Manual No 430429 490...
Page 2: ......
Page 3: ...2 05 Specifications 19 2 06 Duty Cycle 20 3 0 OPERATOR CONTROLS 21 3 01 400MSTW Front Rear Panels 21 3 02 Setup for Operation 23 3 02 1 Selection of Welding Mode 23 3 02 2 Shielded Metal Arc Welding S...
Page 4: ...OTING 51 5 01 Common Welding Operation Faults 51 5 02 Specific Problems 51 5 03 Error Code List 54 6 0 PARTS LIST 55 APPENDIX A REMOTE 14 Pin CONNECTIONS 59 APPENDIX B ACCESORIES 60 APPENDIX C INTERCO...
Page 5: ...Operating Manual Number 430429 490 Published by Thermal Arc INC 2200 CORPORATE DRIVE TROY OHIO 45373 1085 USA 937 440 0100 Copyright 2001 by Thermal Arc INC All rights reserved Reproduction of this wo...
Page 6: ...ese highlights are categorized as follows NOTE An operation procedure or background information which requires additional emphasis or is helpful in efficient operation of the system CAUTION A procedur...
Page 7: ...ch may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data...
Page 8: ...o combustible or flammable material in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containe...
Page 9: ...protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing t...
Page 10: ...iety 550 N W LeJeune Rd Miami FL 331 26 8 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Q...
Page 11: ...op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me ATTENTION Toute proc dure pouvant r sulter l endommage...
Page 12: ...asma d pendent du genre de m taI utills des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plus...
Page 13: ...l de consignes INCENDIE ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma prodult du m tal des tincelles d...
Page 14: ...en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en foumissant des cablnes ou des c...
Page 15: ...American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Assoclahon Am ncaine pour la Protechon contre les Incendms NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAG...
Page 16: ...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 THERMAL ARC S SOLE JUDG...
Page 17: ...MANUAL 430429 490 13 INTRODUCTION PAGE LEFT INTENTIONALY BLANK...
Page 18: ...Arc Welding SMAW Gas Metal Arc Welding GMAW and Gas Tungsten Arc Welding GTAW processes A digital amperage voltage meter is standard Figure 1 400MSTW model Volt Ampere curve NOTE Volt Ampere curves sh...
Page 19: ...al Sensor Output Transformers Output Diode Transformer CT 1 Current Coupling Coil Control Transformer Drive Circuit Voltage Sensor DC Power Supply for Control Circuit To each control circuit 12VDC 20V...
Page 20: ...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 break...
Page 21: ...hat complies with all applicable electrical codes 2 Connect ends of line 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch 3 Use Table 1 below as a guide to select lin...
Page 22: ...n the Power Control Assembly PCA will turn on after the input capacitors have charged to full operating voltage after approximately 5 seconds NOTE Note the available input power Damage to the PCA coul...
Page 23: ...Data 80V 50 60Hz Dimensions Weight Width Height Length Weight 8 3 in 210 mm 16 9 in 430 mm 16 5 in 420 mm kg Output at Rated Load Output Amperes Output Volts Duty Cycle KVA KW 400A 36V 25 22 6 16 9 3...
Page 24: ...NING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature Continua...
Page 25: ...ss the button the mode changes in the following order STICK LIFT TIG HF TIG SCRACH MIG Save Key Used to store the welding parameter into the internal memory of the welding machine Load Key Used to rec...
Page 26: ...tch Placing the Primary Power Switch circuit breaker located on the rear panel to the ON position energizes the welding power source Voltage Selector Manual slide switch selects the proper input volta...
Page 27: ...sulating gloves and clothing 3 Turn on MCB Apply the power The indication of LCD PANEL changes from LINK to Pre Charge and after about 7 seconds it displays CONTACTOR OFF 4 Pressing the PROCESS KEY wi...
Page 28: ...hed the last time Setting of the Welding Parameter 1 Pressing the SELECT KEY will illuminate the LCD DISPLAY 10 2 Press the SELECT KEY until the desired parameter is displayed 3 Press the UP DOWN KEY...
Page 29: ...electrode holder For the majority of electrodes in use the electrode holder is connected to the POSITIVE output terminal 6 Wear welding helmet with proper filter lens according to ANSI Z49 1 7 Place...
Page 30: ...time when the arc is initiated Selectable from10ms to 1000ms Default 600ms 4 Hot Cur Sets the hot current amperage when the arc is initiated Selectable from 0A to 100A Default 30A 5 Arc Control Sets...
Page 31: ...MANUAL 430429 490 31 SAVE LOAD OPERATION DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP SELECT SELECT SELECT SELECT SELECT Figure 6 STICK Mode Operation Diagram...
Page 32: ...sten electrode and insert into torch For the majority of electrodes in use the electrode is connected to the NEGATIVE output terminal 4 Wear dry insulating gloves and clothing 5 Connect TIG torch 6 Co...
Page 33: ...rc When it is short circuit the output current is fixed 15A 15 Begin welding WARNING HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill Shut off gas supply when not in use Modifiable Parame...
Page 34: ...ets the desired base current of the pulse output This parameter is only displayed and available for modification when the Pulser parameter listed previously is set to ON Selectable from 0 to 100 Defau...
Page 35: ...or modification when the Sloper parameter listed previously is set to ON Selectable from 0 sec to 60 sec Default 3 sec 11 Down Slope Sets the desired down slope fall time time This parameter is only d...
Page 36: ...OWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SEL...
Page 37: ...ngsten electrode and insert into torch For the majority of electrodes in use the electrode is connected to the NEGATIVE output terminal 4 Wear dry insulating gloves and clothing 5 Connect TIG torch 6...
Page 38: ...to work and lift quickly to start arc 15 Begin welding WARNING HIGH CONCENTRATION OF SHIELDING GAS can impair health or kill Shut off gas supply when not in use Modifiable Parameters 1 Contactor Selec...
Page 39: ...ts the desired base current of the pulse output This parameter is only displayed and available for modification when the Pulser parameter listed previously is set to ON Selectable from 0 to 100 Defaul...
Page 40: ...or modification when the Sloper parameter listed previously is set to ON Selectable from 0 sec to 60 sec Default 3 sec 11 Down Slope Sets the desired down slope fall time time This parameter is only d...
Page 41: ...N UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELEC...
Page 42: ...ece For the majority of electrodes in use the work clamp is connected to POSITIVE terminal 4 Select proper electrode 5 Insert electrode into torch For the majority of electrodes in use the torch is co...
Page 43: ...Default Current controlled by a remote switch ON Current available 2 A V Set the desired welding current with the Amperage Voltage control 1 or with a remote device PANEL Default A V set with Amperage...
Page 44: ...o the POSITIVE output terminals 3 Wear dry insulating gloves and clothing 4 Turn on shielding gas supply and set desired flow rate 5 Wear welding helmet with proper filter lens according to ANSI Z49 1...
Page 45: ...vailable 2 A V Set the desired welding current with the Amperage Voltage control 1 or with a remote device PANEL Default A V set with Amperage voltage control REMOTE A V set with a remote device 3 Ind...
Page 46: ...SETUP FOR OPERATION 46 MANUAL 430429 490 DOWN UP DOWN UP DOWN UP DOWN UP DOWN UP SELECT SELECT SELECT Figure 10 MIG Mode Operation Diagram...
Page 47: ...MANUAL 430429 490 47 SAVE LOAD OPERATION 3 02 7 Shutdown Operation 1 Stop welding 2 Move the PRIMARY POWER switch 18 to the OFF position 3 Turn off the shielding gas and water supplies if applicable...
Page 48: ...oyed Tungsten Red Band 0 010 in 0 25mm 0 020in 0 51mm 0 040in 1 02mm 1 16 in 1 59mm 3 32 in 2 38mm 1 8 in 3 18mm 5 32 in 3 97mm 3 16 in 4 76mm 1 4 in 6 35mm 1 25 15 40 25 85 50 160 135 235 250 400 400...
Page 49: ...s not require batteries etc Therefore you do not have to worry about a battery going dead You can record a maximum of Five welding parameters When the power is cut off the welding parameter will be re...
Page 50: ...uring a SAVE operation To SAVE perform the following steps 1 Press the SAVE KEY 6 2 Choose a save memory location No 1 5 by pressing the UP DOWN KEY 8 3 Press the SAVE KEY again 4 After a short delay...
Page 51: ...eration To LOAD a previously saved program perform the following steps 1 Press the LOAD KEY 6 2 Choose a load memory location No 1 5 by pressing the UP DOWN KEY 8 3 Press the LOAD KEY again 4 After a...
Page 52: ...ed as well When a SAVEd program is LOADed all parameters for other modes of operation are loaded as well The operator may have to press the PROCESS KEY 5 to return to the desired mode Table 4 SAVE LOA...
Page 53: ...te device if used 3 Contactor On Off The contactor On Off condition prior to a SAVE operation is not saved When a program is LOADed the contactor will automatically be set in the OFF condition Automat...
Page 54: ...arameter A V PANEL Hot Start 600ms Hot Cur 30A STICK MODE Arc Control 10 A V PANEL Pulser OFF Pulse Freq 100 0Hz Pulse Width 50 Back Cur 30 Sloper OFF Init Cur 30 Final Cur 30 Up Slope 3sec LIFT TIG M...
Page 55: ...in wrong position B Poor Weld Wrong polarity Wrong electrode used Electrode not properly prepared Incorrect welding amperage setting Speed too slow or too fast Incorrect switch settings for intended...
Page 56: ...per size and type of cable see Table 3 section 3 02 8 3 Improper input connections a Refer to Section 2 04 Electrical Input Connections 4 Poor electrode condition a Replace electrode 5 If using a wire...
Page 57: ...Faulty Remote Control Device a Operate LCD panel Set A V to PANEL and turn CONTACTOR on Under that condition if you can adjust output current by Amperage Voltage Control 1 please replace the remote c...
Page 58: ...tage E14 AC UVR2 Input Under Voltage Apply correct input voltage E21 DC OVR1 Input Over Voltage Apply correct input voltage E22 DC UVR1 Input Over Voltage Apply correct input voltage E23 DC OVR2 Input...
Page 59: ...horized Thermal Arc distributor If a Thermal Arc product must be returned for service contact your Thermal Arc distributor Materials returned to Thermal Arc without proper authorization will not be ac...
Page 60: ...14 LCD1 Liquid crystal Display WM C1602M 2GLY 1 49111000100 10 6575 15 MCB1 Molded Case Circuit Breaker EA103B 3P AC690V 100AF 75AT 1 25303004404 10 6576 16 MCB2 Molded Case Circuit Breaker TBC5071 2...
Page 61: ...4643 Supper Position Control 1 P0A464300 10 6587 29 Q1 2 KIT Transistor CM100DU24F 1200V 100A 2 43401009900 10 6592 30 R2 3 Resistor ERG 3ANJ 220 3W 22 6 40305122000 10 2213 31 R7 Resistor ERG 3ANJ 4...
Page 62: ...80600 1 E1B280600 10 6598 20 Panel Cover Holder Pin Wave shaped spring pin 2 50801118810 10 6599 21 PCB Sheet E6A490100 1 E6A490100 10 5419 22 Rear Panel E0C183900 1 E0C183900 10 5521 23 Rubber Foot E...
Page 63: ...GLY 1 49111000100 10 6575 13 MCB1 Molded Case Circuit Breaker DBE103B 3P 460V 75AT 1 25850002000 10 6322 14 MCB2 Molded Case Circuit Breaker TBC5071 20 1420 1P 125V 10AT CSA UL 1 25720000300 10 2235 1...
Page 64: ...1 2 KIT Transistor CM100DUS12F 600V 100A 2 43401008500 10 6623 27 R2 3 Resistor ERG 3ANJ 220 3W 22 6 40305122000 10 2213 28 R7 Resistor ERG 3ANJ 472 3W 4 7 1 40305147200 10 5010 29 S2 Switch SDKGA4 A...
Page 65: ...E1B280600 10 6598 19 Panel Cover Holder Pin Wave shaped spring pin 2 50801118810 10 6599 20 PCB Sheet E6A490100 1 E6A490100 10 5419 21 Rear Panel E0C183900 1 E0C183900 10 5521 22 Rubber Foot E6A181600...
Page 66: ...1 49111000100 10 6575 13 MCB1 Molded Case Circuit Breaker DBE103B 3P 460V 75AT 1 25850002000 10 6322 14 MCB2 Molded Case Circuit Breaker TBC5071 20 1420 1P 125V 10AT CSA UL 1 25720000300 10 2235 15 MC...
Page 67: ...100A 2 43401008500 10 6623 26 R2 3 Resistor ERG 3ANJ 220 3W 22 6 40305122000 10 2213 27 R7 Resistor ERG 3ANJ 472 3W 4 7 1 40305147200 10 5010 28 T1 2 Transformer F2A291000 2 F2A291000 10 6620 29 T3 Tr...
Page 68: ...1B280600 10 6598 19 Panel Cover Holder Pin Wave shaped spring pin 2 50801118810 10 6599 20 PCB Sheet E6A490100 1 E6A490100 10 5419 21 Rear Panel E0C183900 1 E0C183900 10 5521 22 Rubber Foot E6A181600...
Page 69: ...crystal Display WM C1602M 2GLY 1 49111000100 10 6575 13 MCB1 Molded Case Circuit Breaker EA53B 3P AC690V 50AF 50AT 1 25303006400 9 1076 14 MCB2 Molded Case Circuit Breaker TBC5071 20 1420 1P 125V 10A...
Page 70: ...0A336605 10 6586 25 Q1 2 KIT Transistor CM100DU24F 1200V 100A 2 43401009900 10 6592 26 R2 3 Resistor ERG 3ANJ 220 3W 22 6 40305122000 10 2213 27 R7 Resistor ERG 3ANJ 472 3W 4 7 1 40305147200 10 5010 2...
Page 71: ...0 1 E1B280600 10 6598 19 Panel Cover Holder Pin Wave shaped spring pin 2 50801118810 10 6599 20 PCB Sheet E6A490100 1 E6A490100 10 5419 21 Rear Panel E0C183900 1 E0C183900 10 5521 22 Rubber Foot E6A18...
Page 72: ...is provided between Sockets A and B to energize the solid state contactor C Amperage remote control MAXIMUM input command signal 10V for maximum D Amperage remote control MINIMUM PC board common use...
Page 73: ...in Female 14 Pin Male 14 Pin Female 14 Pin Male 14 Pin Female 14 Pin Male 14 Pin Female LENGTH 25 7 6m 25 7 6m 25 7 6m 25 7 6m 25 7 6m 25 7 6m 15 4 6m 3 90cm 15 4 6m 25 7 6m 50 15 2m 75 22 8m 100 30 4...
Page 74: ...N1 1 2 4 5 CN8 1 2 4 5 CN9 TB 3 TB 4 TB 5 TB 6 TB 1 TB 2 C1 E2 C2E1 C1 E2 C2E1 2 3 1 CN1 1 2 3 CN28 2 1 CN10 FAN1 1 3 CN36 1 2 3 4 CN6 1 2 CN4 CN63 CN62 CN51 CN50 CN62 CN63 CN50 CN51 1 3 CN7 1 3 CN1 1...
Page 75: ...F E 1 2 3 4 5 6 T2 PCB6 PCB5 PCB7 LCD1 R2 C2 R3 C3 D2 D3 CT1 L2 FCH D4 D5 PCB13 TB4 TB2 TB3 TB1 C6 C5 C8 R7 OUTPUT FILTER NETWORK Terminal Output Detect Terminal Output Detect Ground 12VDC 12VDC Outp...
Page 76: ...3 TB 4 TB 5 TB 6 TB 1 TB 2 C1 E2 C2E1 C1 E2 C2E1 2 3 1 CN1 1 2 3 CN28 2 1 CN10 FAN1 1 3 CN36 1 2 3 4 CN6 1 2 CN4 CN63 CN62 CN51 CN50 CN62 CN63 CN50 CN51 1 3 CN7 1 3 CN1 1 2 CN3 5 6 CN5 TH1 Input Diod...
Page 77: ...L N H D M G F E 1 2 3 4 5 6 T2 PCB6 PCB5 PCB7 LCD1 R2 C2 R3 C3 D2 D3 CT1 FCH C6 C5 C8 R7 OUTPUT FILTER NETWORK Terminal Output Detect Terminal Output Detect Ground 12VDC 12VDC Output Current Detect 0...
Page 78: ...CN1 1 2 4 5 CN8 1 2 4 5 CN9 TB 3 TB 4 TB 5 TB 6 TB 1 TB 2 C1 E2 C2E1 C1 E2 C2E1 1 2 3 CN28 2 1 CN10 FAN1 1 3 CN36 1 2 3 4 CN6 1 2 CN4 CN63 CN62 CN51 CN50 CN62 CN63 CN50 CN51 1 3 CN7 1 3 CN1 1 2 CN3 5...
Page 79: ...L N H D M G F E 1 2 3 4 5 6 T2 PCB6 PCB5 PCB7 LCD1 R2 C2 R3 C3 D2 D3 CT1 FCH C6 C5 C8 R7 OUTPUT FILTER NETWORK Terminal Output Detect Terminal Output Detect Ground 12VDC 12VDC Output Current Detect 0...
Page 80: ...9 TB 3 TB 4 TB 5 TB 6 TB 1 TB 2 C1 E2 C2E1 C1 E2 C2E1 1 2 3 CN28 2 1 CN10 FAN1 1 3 CN36 1 2 3 4 CN6 1 2 CN4 CN63 CN62 CN51 CN50 CN62 CN63 CN50 CN51 1 3 CN7 1 3 CN1 1 2 CN3 5 6 CN5 TH1 In put D iode B...
Page 81: ...L N H D M G F E 1 2 3 4 5 6 T2 PCB6 PCB5 PCB7 LCD1 R2 C2 R3 C3 D2 D3 CT1 FCH C6 C5 C8 R7 OUTPUT FILTER NETWORK Terminal Output Detect Terminal Output Detect Ground 12VDC 12VDC Output Current Detect 0...
