Thermal Arc 400MSTW CC User manual

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

TABLE OF CONTENTS

1.0 GENERAL INFORMATION ...................................................2

1.01 Notes, Cautions and Warnings ...............................................2

1.02 Important Safety Precautions .................................................3

1.03 Publications ............................................................................6

1.04 Note, Attention et Avertissemen ............................................7

1.05 Precautions De Securite Importantes .....................................8

1.06 Documents De Reference .....................................................11

1.07 Statement of Warranty .............................................................12

2.0 INTRODUCTION AND DESCRIPTION .............................14

2.01 Description ...........................................................................14

2.02 Functional Block Diagrams .................................................15

2.03 Transporting Methods ..........................................................16

2.04 Electrical Input Connections ................................................16

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 (SMAW) .........................25

3.02.3 Gas Tungsten Arc Welding (GTAW) Lift Start .............28

3.02.4 Gas Tungsten Arc Welding (GTAW) Scratch Start .......33

3.02.5 Carbon Arc Cutting (CAC) ...........................................38

3.02.6 Gas Metal Arc Welding (GTAW) ..................................40

3.02.7 Shutdown Operation ......................................................43

3.02.8 Electrode Selection Guide .............................................44

3.02.9 Welding Cable Selection Guide ....................................44

4.0 SAVE/LOAD OPERATION ...................................................45

4.01 Outline ......................................................................…..........45

4.02 SAVE Operation ......................................................................46

4.03 LOAD Operation .....................................................................47

4.04 SAVE/LOAD Data ..................................................................48

4.05 Initial Parameter Settings ........................................................50

5.0 BASIC TROUBLESHOOTING .............................................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 - INTERCONNECTION DIAGRAMS ..............61

MANUAL 430429-490 1 GENERAL

WARNING Read and understand this entire Operating Manual and your employer's safety

practices before installing, operating, or servicing the equipment.

WARNING While the information contained in this Operating Manual represents

our best judgement, Thermal Arc INC. assumes no

liability for its use.

Thermal Arc Models 400MSTW CC/CV Welder

Operating Manual Number 430429-490

Published by:

Thermal Arc INC.

2200 CORPORATE DRIVE

TROY, OHIO 45373-1085, USA

(937) 440-0100

Thermal Arc INC.

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

Operating Manual, whether such error results from negligence,

accident, or any other cause.

Printed in the United States of America

July 1, 2001

GENERAL 2 MANUAL 430429-490

1.0 GENERAL INFORMATION

1.01 NOTES, CAUTIONS AND WARNINGS

Throughout this manual, notes, cautions, and warnings are used to

highlight important information. These 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 procedure which, if not properly followed, may cause damage to the

equipment.

WARNING A procedure which, if not properly followed, may cause injury to the

operator or others in the operating area.

MANUAL 430429-490 3 GENERAL

WARNING

1.02 IMPORTANT SAFETY PRECAUTIONS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT

CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

To prevent possible injury, read, understand and follow all warnings, safety precautions and

instructions before using the equipment. Call 1-937-440-0100 or your local distributor if you have any

questions.

GASES AND FUMES Gases and fumes produced during the plasma welding process can be

dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out

of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove

all fumes and gases.

• The kinds of fumes and gases from the plasma arc depend on the kind

of metal being used, coatings on the metal, and the different

processes. You must be very careful when cutting or welding any

metals which 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 Sheets (MSDS) that should be

supplied with the material you are using. These MSDS’s will give you

the information regarding the kind and mount of fumes and gases

that may be dangerous to your health.

• For information on how to test for fumes and gases in your

workplace, refer to item I in the Publications Section in this manual.

Use special equipment, such as water or down draft cutting tables, to

capture fumes and gases.

• Do not use the plasma torch in an area where combustible or

explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated

solvents and cleansers. Remove all sources of these vapors.

WARNING:

This product, when used for welding or cutting, produces

fumes or gases which contain chemicals known to the State of California

to cause birth detects and, in some cases, cancer.

(California Health & Safety Code Section 25249.5 et seq.)

GENERAL 4 MANUAL 430429-490

IMPORTANT SAFETY PRECAUTIONS (CONTINUED)

ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc process uses and

produces high voltage electrical energy. This electric energy can cause

severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically "live" or "hot."

• Wear dry gloves and clothing. Insulate yourself from the work piece

or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 4

in the Publications section of this manual.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no 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 containers that may have held combustibles.

• Provide a fire watch when working in an area where fire hazards may

exist.

• Hydrogen gas may be formed and trapped under aluminum

workpieces when they are cut underwater or while using a water

table. DO NOT cut aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dissipated. Trapped

hydrogen gas that is ignited will cause an explosion.

NOISE Noise can cause permanent hearing loss. Plasma arc processes can cause

noise levels to exceed safe limits. You must protect your ears from loud

noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs

and/or ear muffs Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do

not exceed safe levels.

• For information on how to test for noise, see item 1 in the Publications

section of this manual.

MANUAL 430429-490 5 GENERAL

IMPORTANT SAFETY PRECAUTIONS (CONTINUED)

PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma

arc process produces very bright ultra violet and infra red light. These

arc rays will damage your eyes and bum your skin if you are not

properly 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 to protect your skin from

the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses

when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective

booths, screens or shields.

• Use the shade of lens as recommended in the Operating Manual.

GENERAL 6 MANUAL 430429-490

1.03 PUBLICATIONS

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American

Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETYAND HEALTH IN ARC WELDING AND GASWELDING AND CUTTING,

obtainable from the Superintendent of Documents, U.S. Government Printing Office,

Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND

FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway,

New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN'S SAFETY-TOE FOOTWEAR, obtainable from the

American National Standards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING

PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York,

NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD

COMBUSTIBLES, obtainable from American Welding Society, 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,

Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 5lB, CUTTING AND WELDING PROCESSES, obtainable from the National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-l, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable

from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard Wl17.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the

Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,

Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding

Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE

PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE

HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from

American National Standards Institute, 1430 Broadway, New York, NY 10018

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