400 MST ®

ARCMASTER
INVERTER ARC WELDER

Art # A-07368

Service Manual
Version No: AA.03 Issue Date: May 22, 2006 Manual No.: 0-4944B

460 CC
Operating Features: V CV DC
INVERTER
1/3 50 Hz 208 230
GMAW
FCAW SMAW CAG GTAW PHASE 60 V V
 WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.

ArcMaster 400 MST Inverter Arc Welder

Service Manual Number 0-4944B for:
Part Number 10-3072

Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711

www.thermalarc.com

Copyright 2006 by
Thermadyne Corporation

All rights reserved.

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 Manual, whether such error
results from negligence, accident, or any other cause.

Publication Date: May 22, 2006

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

i
 CONTENTS

1 GENERAL INFORMATION
1 Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
2 Important Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
3 Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
4 Note, Attention et Avertissement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
5 Precautions De Securite Importantes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
6 Documents De Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

2 INTRODUCTION AND DESCRIPTION

1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2 Functional Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
3 Transporting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
4 Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
4. 1 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
4. 2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
5 Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
5. 1 Electrical Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
5. 2 Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
7 Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

3 OPERATOR CONTROLS
1 400 MST Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
2 Weld Parameter Descriptions for 400MST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3 Weld Process selection for the 400MST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
4 Weld Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
4. 1 WELD (V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
4. 2 INDUCTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
4. 3 HOT START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
4. 4 WELD (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
4. 5 ARC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
4. 6 Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
4. 7 Power Source Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

4 SEQUENCE OF OPERATION
1 Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
2 LIFT TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
3 MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

5 ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 BASIC TROUBLE SHOOTING

1 Solving MIG Problems Beyond the Welding Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
1. 1 Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
1. 2 Inconsistent Wire Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
2 MIG Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
3 TIG Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
4 Stick Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
5 Power Source Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
7 VOLTAGE REDUCTION DEVICE (VRD)
1 VRD Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
2 VRD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
3 Switching VRD On/Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

8 POWER SOURCE ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 ADVANCED TROUBLESHOOTING
1 System-Level Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
1. 1 Opening the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
1. 2 Verification and Remedy to the Indicated Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
1.2. 1 E01 "Over-Temperature at the primary side" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
1.2. 2 E02 "Over-Temperature at the secondary side" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
1.2. 3 E03 "Primary Over-Current Failure" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
1.2. 4 E11 "High Input Voltage Failure" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
1.2. 5 E12 "Low Input Voltage Failure" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
1.2. 6 E14 "Low Input Voltage Warning". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
1.2. 7 E81 "Abnormal Input Voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
1.2. 8 E82 "Rated voltage selection circuit abnormality". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
1.2. 9 E83 "Abnormal mains supply voltage" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
1.2. 10 E85 "Pre-Charge Error". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
1.2. 11 E94 "Thermistor Failure" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
1.2. 12 E99 "Initial Power Receiving" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
1. 3 Verification and Remedy to Failures without Indication Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
1.3. 1 "Cooling Fan Failure"
(Fan is not rotating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
1.3. 2 "Wire feeding failure or inconsistent wire delivery" (Wire feeder does not work) . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
1.3. 3 "No weld output" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
1.3. 4 "Operating Panel Failure" (LED's do not light properly or weld settings cannot be establish.) . . . . . . . . . . . . . . 9–10
1. 4 Fault Isolation Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
1.4. 1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
1.4. 2 Verification of the Power Input Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
1.4. 3 Power Supply Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
1.4. 4 Verification of the Cooling Fan, FAN1, Drive Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
1.4. 5 Verification of the primary Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13
1.4. 6 Verification of the secondary Diode (D2-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
1.4. 7 Verification of the primary IGBT (Q1-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–14
1.4. 8 Verification of No-load Voltage (No OCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
2 Subsystem Test and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
2. 1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
2. 2 Test and Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
2. 3 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
2.3. 1 Tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
2.3. 2 Notes of disassembly and assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–21
2. 4 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–22
2.4. 1 PCB1 (WK-5493) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–22
2.4. 2 PCB2 (WK-5597) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–23
2.4. 3 PCB3 (WK-5548), PCB7 (WK-5689) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–24
2.4. 4 PCB4 (WK-4819) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26
2.4. 5 PCB5 (WK-5696) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–26
2.4. 6 PCB6 (WK-5688) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–27
2.4. 7 PCB8 (WK-5479) and PCB9 (WK-5479) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–27
2.4. 8 PCB10 (WK-5479), PCB11 (WK-5479) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–28
2.4. 9 PCB12 (WK-5527) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–28
2.4. 10 PCB13 (WK-5528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–29
2.4. 11 PCB14 (WK-5594) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–30
2.4. 12 PCB15 (WK-5606) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–31
2.4. 13 PCB16 (WK-4917) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–32
2.4. 14 PCB17 (WK-5699) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–33
2.4. 15 PCB18 (WK-5499) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–33
2.4. 16 Inductor (FCH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–34
2.4. 17 Thermistor (TH1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–35
2.4. 18 Thermistor (TH2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–36
2.4. 19 Fan (FAN1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–36
2.4. 20 Switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–37
2.4. 21 Switch (S2 and S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–38
 CONTENTS

2.4. 22 Current Sensor (HCT1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–39

2.4. 23 Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–39
2.4. 24 Diode (D2, D4, D5, and D7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–40
2.4. 25 Current Transformer (CT2 and CT3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–41
2.4. 26 Reactor (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–41
2.4. 27 Molded Case Circuit Breaker (MCB1 and MCB2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–42
2.4. 28 Resistor (R2 and R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–43
2.4. 29 Transformer (T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–44
2.4. 30 14-Pin Receptacle (CON1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–47
2.4. 31 19-Pin Receptacle (CON2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–48

APPENDIX 1 SPARE PARTS LIST

1 Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
2 How To Use This Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

APPENDIX 2 CONNECTION WIRING GUIDE

APPENDIX 3 INTERCONNECT DIAGRAM

APPENDIX 4 DIODE TESTING BASIC

 ARCMASTER 400 MST

1.0 SAFETY INSTRUCTIONS AND WARNINGS

! WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards 7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.

WARNING 9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.
ELECTRIC SHOCK can kill. 11. Do not touch electrode while in contact with the work (ground)
circuit.
Touching live electrical parts can cause fatal shocks or 12. Use only well-maintained equipment. Repair or replace damaged
severe burns. The electrode and work circuit is electrically parts at once.
live whenever the output is on. The input power circuit
and machine internal circuits are also live when power 13. In confined spaces or damp locations, do not use a welder with
is on. In semiautomatic or automatic wire welding, the AC output unless it is equipped with a voltage reducer. Use
wire, wire reel, drive roll housing, and all metal parts equipment with DC output.
touching the welding wire are electrically live. Incorrectly
14. Wear a safety harness to prevent falling if working above floor
installed or improperly grounded equipment is a hazard.
level.

1. Do not touch live electrical parts. 15. Keep all panels and covers securely in place.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats
or covers. WARNING
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch ARC RAYS can burn eyes and skin; NOISE can damage
open, or remove line fuses so power cannot be turned on hearing. Arc rays from the welding process produce
accidentally. intense heat and strong ultraviolet rays that can burn
5. Properly install and ground this equipment according to its Owner’s eyes and skin. Noise from some processes can damage
Manual and national, state, and local codes. hearing.

6. Turn off all equipment when not in use. Disconnect power to 1. Wear a welding helmet fitted with a proper shade of filter (see
equipment if it will be left unattended or out of service. ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.

1
ARCMASTER 400 MST
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
WARNING
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
WELDING can cause fire or explosion.
5. Use approved ear plugs or ear muffs if noise level is high.
Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
WARNING contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.

FUMES AND GASES can be hazardous to your health.

1. Protect yourself and others from flying sparks and hot metal.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health. 2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
1. Keep your head out of the fumes. Do not breath the fumes. If this is not possible, tightly cover them with approved covers.

2. If inside, ventilate the area and/or use exhaust at the arc to remove 4. Be alert that welding sparks and hot materials from welding can
welding fumes and gases. easily go through small cracks and openings to adjacent areas.

3. If ventilation is poor, use an approved air-supplied respirator. 5. Watch for fire, and keep a fire extinguisher nearby.

4. Read the Material Safety Data Sheets (MSDSs) and the 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
manufacturer’s instruction for metals, consumables, coatings, and can cause fire on the hidden side.
cleaners.
7. Do not weld on closed containers such as tanks or drums.
5. Work in a confined space only if it is well ventilated, or while
8. Connect work cable to the work as close to the welding area as
wearing an air-supplied respirator. Shielding gases used for
practical to prevent welding current from traveling long, possibly
welding can displace air causing injury or death. Be sure the
unknown paths and causing electric shock and fire hazards.
breathing air is safe.
9. Do not use welder to thaw frozen pipes.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to 10. Remove stick electrode from holder or cut off welding wire at
form highly toxic and irritating gases. contact tip when not in use.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.
Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter
Torch soldering 2 Gas metal-arc
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14

2
 ARCMASTER 400 MST
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
WARNING

FLYING SPARKS AND HOT METAL can cause injury. WARNING

Chipping and grinding cause flying metal. As welds cool,

they can throw off slag. ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Wear approved face shield or safety goggles. Side shields
recommended.
1. Stop engine before checking or adding fuel.
2. Wear proper body protection to protect skin.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
WARNING 3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
CYLINDERS can explode if damaged. 4. Do not overfill tank — allow room for fuel to expand.
Shielding gas cylinders contain gas under high pressure. 5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to treat
them carefully. WARNING

1. Protect compressed gas cylinders from excessive heat, mechanical

shocks, and arcs. MOVING PARTS can cause injury.

2. Install and secure cylinders in an upright position by chaining

Moving parts, such as fans, rotors, and belts can cut fingers and hands
them to a stationary support or equipment cylinder rack to prevent
and catch loose clothing.
falling or tipping.
1. Keep all doors, panels, covers, and guards closed and
3. Keep cylinders away from any welding or other electrical circuits.
securely in place.
4. Never allow a welding electrode to touch any cylinder.
2. Stop engine before installing or connecting unit.
5. Use only correct shielding gas cylinders, regulators, hoses, and 3. Have only qualified people remove guards or covers for
fittings designed for the specific application; maintain them and maintenance and troubleshooting as necessary.
associated parts in good condition.
4. To prevent accidental starting during servicing, disconnect
6. Turn face away from valve outlet when opening cylinder valve. negative (-) battery cable from battery.
7. Keep protective cap in place over valve except when cylinder is in 5. Keep hands, hair, loose clothing, and tools away from moving
use or connected for use. parts.
8. Read and follow instructions on compressed gas cylinders, 6. Reinstall panels or guards and close doors when servicing
associated equipment, and CGA publication P-1 listed in Safety is finished and before starting engine.
Standards.

! WARNING WARNING

Engines can be dangerous. SPARKS can cause BATTERY GASES TO EXPLODE;

BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

WARNING 1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
ENGINE EXHAUST GASES can kill.
3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases. 4. Do not use welder to charge batteries or jump start vehicles.
1. Use equipment outside in open, well-ventilated areas. 5. Observe correct polarity (+ and –) on batteries.

3
ARCMASTER 400 MST
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
WARNING
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S. Government Printing Office, Washington, D.C.
face, eyes, and skin. 20402.
The coolant in the radiator can be very hot and under Recommended Safe Practices for the Preparation for Welding and
pressure. Cutting of Containers That Have Held Hazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding
1. Do not remove radiator cap when engine is hot. Allow engine to cool. Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

2. Wear gloves and put a rag over cap area when removing cap. National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
3. Allow pressure to escape before completely removing cap.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1, from Compressed Gas Association, 1235 Jefferson Davis Highway,

! WARNING
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
This product, when used for welding or cutting, produces Boulevard, Rexdale, Ontario, Canada M9W 1R3.
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some Safe Practices for Occupation and Educational Eye and Face Protec-
cases, cancer. (California Health & Safety code Sec. tion, ANSI Standard Z87.1, from American National Standards Insti-
25249.5 et seq.) tute, 1430 Broadway, New York, NY 10018.

NOTE Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your
doctor for complete information.

4
 ARCMASTER 400 MST
1.03 Precautions de Securite en Soudage à l’Arc

! MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de
sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.04 Dangers Relatifs au Soudage à l’Arc 6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
AVERTISSEMENT
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
L’ELECTROCUTION PEUT ETRE MORTELLE.
9. N’enroulez pas de câbles électriques autour de votre corps.

Une décharge électrique peut tuer ou brûler gravement. 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
L’électrode et le circuit de soudage sont sous tension la pièce à souder.
dès la mise en circuit. Le circuit d’alimentation et les 11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
circuits internes de l’équipement sont aussi sous ten- soudage (terre).
sion dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou 12. N’utilisez que des équipements en bon état. Réparez ou remplacez
la bobine de fil, le logement des galets d’entrainement aussitôt les pièces endommagées.
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement 13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
inadéquatement installé ou inadéquatement mis à la terre de courant alternatif, à moins qu’il soit muni d’un réducteur de
est dangereux. tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
1. Ne touchez pas à des pièces sous tension.
15. Fermez solidement tous les panneaux et les capots.
2. Portez des gants et des vêtements isolants, secs et non troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.

5
ARCMASTER 400 MST

AVERTISSEMENT AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX LES VAPEURS ET LES FUMEES SONT DANGEREUSES
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. POUR LA SANTE.
L’arc de soudage produit une chaleur et des rayons Le soudage dégage des vapeurs et des fumées
ultraviolets intenses, susceptibles de brûler les yeux et dangereuses à respirer.
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe. 1. Eloignez la tête des fumées pour éviter de les respirer.

1. Portez une casque de soudeur avec filtre oculaire de nuance 2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour ou que les fumées et les vapeurs sont aspirées à l’arc.
vous protéger le visage et les yeux lorsque vous soudez ou que 3. Si la ventilation est inadequate, portez un respirateur à adduction
vous observez l’exécution d’une soudure. d’air approuvé.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux 4. Lisez les fiches signalétiques et les consignes du fabricant rela-
sont recommandés. tives aux métaux, aux produits consummables, aux revêtements
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger et aux produits nettoyants.
les autres des coups d’arc ou de l’éblouissement; avertissez les 5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
observateurs de ne pas regarder l’arc. portez un respirateur à adduction d’air. Les gaz protecteurs de
4. Portez des vêtements en matériaux ignifuges et durables (laine et soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
cuir) et des chaussures de sécurité. malaises ou la mort. Assurez-vous que l’air est propre à la respi-
ration.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé. 6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 6.2-73)
Dimension d'électrode ou Dimension d'électrode ou
Opération de coupage Nuance de Opération de coupage Nuance de
Epiasseur de métal ou Epiasseur de métal ou
ou soudage filtre oculaire ou soudage filtre oculaire
Intensité de courant Intensité de courant
Brassage tendre Soudage á l'arc sous gaz
toutes conditions 2
au chalumeau avec fil plein (GMAW)
Brassage fort
toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11
au chalumeau
Oxycoupage métaux ferreux toutes conditions 12
Soudage á l'arc sous gaz avec
mince moins de 1 po. (25 mm) 3 ou 4 toutes conditions 12
électrode de tungstène (GTAW)
Soudage á l'hydrogène
moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5 toutes conditions 12
atomique (AHW)
Soudage á l'arc avec
épais plus de 6 po. (150 mm) 5 ou 6 toutes conditions 12
électrode de carbone (CAW)
Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12
Gougeage Air-Arc avec
mince moins de 1/8 po. (3 mm) 4 ou 5
électrode de carbone
moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12
épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14
Soudage á l'arc avec
électrode enrobees moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)
(SMAW)
5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9
plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12
épais plus de 400 amperès 14

6
 ARCMASTER 400 MST
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que si
AVERTISSEMENT
l’espace est bien ventilé; si nécessaire portez un respirateur à ad-
duction d’air. Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du
LES ETINCELLES ET LES PROJECTIONS BRULANTES
soudage.
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
AVERTISSEMENT métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE 1. Portez un écran facial ou des lunettes protectrices
EXPLOSION approuvées. Des écrans latéraux sont recommandés.
L’arc produit des étincellies et des projections. Les 2. Portez des vêtements appropriés pour protéger la peau.
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
AVERTISSEMENT
peut provoquer des étincelles, un échauffement ou un
incendie.
LES BOUTEILLES ENDOMMAGEES PEUVENT
1. Protégez-vous, ainsi que les autres, contre les étincelles et du EXPLOSER
métal chaud.
Les bouteilles contiennent des gaz protecteurs sous
2. Ne soudez pas dans un endroit où des particules volantes ou des haute pression. Des bouteilles endommagées peuvent
projections peuvent atteindre des matériaux inflammables. exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées. 1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures 2. Enchainez verticalement les bouteilles à un support ou à un cadre
ou fissures. fixe pour les empêcher de tomber ou d’être renversées.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la 3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
main.
4. Empêchez tout contact entre une bouteille et une électrode de
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, soudage.
une cloison ou une paroi peut enflammer l’autre côté.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril. des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
8. Connectez le câble de soudage le plus près possible de la zone maintenus en bon état.
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie. 6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
9. Ne dégelez pas les tuyaux avec un source de courant.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-con- lorsque raccordé pour utilisation.
tact lorsqu’inutilisé après le soudage.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
11. Portez des vêtements protecteurs non huileux, tels des gants en comprimé et aux équipements connexes, ainsi que la publication
cuir, une chemise épaisse, un pantalon revers, des bottines de P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
sécurité et un casque.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

7
ARCMASTER 400 MST
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien Les accumulateurs contiennent de l’électrolyte acide et
ventilées. dégagent des vapeurs explosives.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin 1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
des prises d’air du bâtiment. 2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.

AVERTISSEMENT 3. N’utilisez que des outils anti-étincelles pour travailler sur un

accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE un accumulateur ou survolter momentanément un véhicule.
EXPLOSION.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de

faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles AVERTISSEMENT
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
de carburant ou d’en vérifier le niveau au début du soudage. BRULANT SOUS PRESSION PEUVENT BRULER LA
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace PEAU ET LES YEUX.
pour son expansion. Le liquide de refroidissement d’un radiateur peut être
5. Faites attention de ne pas renverser de carburant. Nettoyez tout brûlant et sous pression.
carburant renversé avant de faire démarrer le moteur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
AVERTISSEMENT
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
bouchon.
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des 1.05 Principales Normes De Securite
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples. Safety in Welding and Cutting, norme ANSI Z49.1, American Weld-
ing Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
1. Assurez-vous que les portes, les panneaux, les capots et les Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
protecteurs soient bien fermés. Documents, U.S. Government Printing Office, Washington, D.C.
20402.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
Recommended Safe Practices for the Preparation for Welding and
3. Seules des personnes qualifiées doivent démonter des protecteurs
Cutting of Containers That Have Held Hazardous Substances, norme
ou des capots pour faire l’entretien ou le dépannage nécessaire.
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
4. Pour empêcher un démarrage accidentel pendant l’entretien, FL 33128.
débranchez le câble d’accumulateur à la borne négative.
National Electrical Code, norme 70 NFPA, National Fire Protection
5. N’approchez pas les mains ou les cheveux de pièces en Association, Batterymarch Park, Quincy, MA 02269.
mouvement; elles peuvent aussi accrocher des vêtements amples
Safe Handling of Compressed Gases in Cylinders, document P-1,
et des outils.
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
6. Réinstallez les capots ou les protecteurs et fermez les portes après 501, Arlington, VA 22202.
des travaux d’entretien et avant de faire démarrer le moteur.
Code for Safety in Welding and Cutting, norme CSA W117.2 Asso-
ciation canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.

AVERTISSEMENT Safe Practices for Occupation and Educational Eye and Face Protec-
tion, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN Cutting and Welding Processes, norme 51B NFPA, National Fire Pro-
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU- tection Association, Batterymarch Park, Quincy, MA 02269.
LATEUR PEUT BRULER LA PEAU ET LES YEUX.
8
SYMBOL LEGEND
STICK
Amperage (Shielded Metal Arc SMAW)

Voltage Pulse Current Function

Hertz (frequency) Spot Time (GTAW)

t

Remote Control
SEC Seconds (Panel/Remote)

% Percent Remote Function

DC (Direct Current) Arc Control (SMAW)

AC (Alternating Current) Gas Post-Flow

t2

Standard Function Gas Pre-Flow

t1

Voltage Reduction Device

Slope Function VRD Circuit

Slope W/Repeat Function Negative

Spot Function Positive

Impulse Starting
Gas Input
(High Frequency GTAW)

Touch Start
(Lift Start TIG circuit GTAW) Gas Output
2 INTRODUCTION AND DESCRIPTION
1 Description INTRODUCTION AND DESCRIPTION

The Thermal Arc™ 400MST is a single & three-phase DC arc welding power source with Constant Current
(CC) and Constant Voltage (CV) output characteristics. This unit is equipped with a Digital Volt/Amperage, lift
arc starter for use with Gas Tungsten Arc Welding (GTAW), Arc Control and Hot Start for Shielded Metal Arc
Welding (SMAW), Inductance Control for Gas Metal Arc Welding (GMAW) processes. The power source is
totally enclosed in an impact resistant, flame resistant and non-conductive plastic case.
(V) (V) (V)
OCV OCV OCV

34V
10V

18V
10V
160A
5A 400A 420A (A) 25A 400A (A) 5A 400A 480A (A)

STICK Process LIFT-TIG Process MIG Process

Figure 2-1: Model 400MST volt-ampere curve

NOTE
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power
source. Curves of other settings will fall between the curves shown.

2 Functional Block Diagrams

Figure 2-2 illustrates the functional block diagram of the 400MST-power supply.
Input Hall Current
Main Input IGBT Main Output
Capacitor
Circuit Diode Inverter Transformers Diodes Transformer
Power Switch DC Power Thermal (T1) Thermal (HCT1)
Filter Primary Detector Detector
Voltage
Sensor Output
Inductor

Down To each control circuit Drive Thermal Stick Mode Lift Tig Mode
Transformers +/-15VDC +18VDC Circuit Sensor VRD Output Short
AC115V,AC24V +24VDC +5VDC Circuit Sensing Sensing
(T3) Circuit Circuit

Trouble Primary
Over Sensing Circuit
Current Circuit Sensor
Protect
14PIN
Receptacle Sequence Fan Control
Fan
(CON1) Control Circuit
19PIN
Receptacle
(CON2)
Current Reference 14PIN-19PIN
Adjustment Adjustment & Select Switch
Circuit Mode select Switch (S3)
Panel Circuit Board

Figure 2-2: 400MST Model functional block diagram

2–1
 400MST 2 INTRODUCTION AND DESCRIPTION
3 Transporting Methods 4.2 Location
Be sure to locate the welder according to the fol-
These units are equipped with a handle for carrying lowing guidelines:
purposes.  In areas, free from moisture and dust.
 Ambient temperature between 0 degrees C to
WARNING 40 degrees C.
ELECTRIC SHOCK can kill. DO NOT TOUCH live  In areas, free from oil, steam and corrosive
electrical parts. Disconnect input power conductors gases.
from de-energized supply line before moving the  In areas, not subjected to abnormal vibration or
welding power source. shock.
 In areas, not exposed to direct sunlight or rain.
WARNING  Place at a distance of 12" (304.79mm) or more
from walls or similar that could restrict natural
FALLING EQUIPMENT can cause serious per- airflow for cooling.
sonal injury and equipment damage.

Lift unit with handle on top of case. WARNING

Use handcart or similar device of adequate capac- Thermal Arc advises that this equipment be electri-
ity. cally connected by a qualified electrician.
If using a fork lift vehicle, place and secure unit on
a proper skid before transporting.
5 Electrical Input Connec-
4 Installation Recommenda- tions
tions
WARNING
4.1 Environment ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input power.
The 400MST is designed for use in hazardous
environments. DO NOT TOUCH live electrical parts.
Examples of environments with increased hazard- SHUT DOWN welding power source, disconnect
ous environments are - input power employing lockout/tagging procedures.
a. In locations in which freedom of movement is Lockout/tagging procedures consist of padlocking
restricted, so that the operator is forced to per- line disconnect switch in open position, removing
form the work in a cramped (kneeling, sitting or fuses from fuse box, or shutting off and red-tagging
lying) position with physical contact with con- circuit breaker or other disconnecting device.
ductive parts;
b. In locations which are fully or partially limited 5.1 Electrical Input Requirements
by conductive elements, and in which there is Operate the welding power source from a single or
a high risk of unavoidable or accidental contact three-phase 50/60 Hz, AC power supply. The input
by the operator, or voltage must match one of the electrical input volt-
c. In wet or damp hot locations where humidity or ages shown on the input data label on the unit
nameplate. Contact the local electric utility for infor-
perspiration considerably reduces the skin
mation about the type of electrical service avail-
resistance of the human body and the insula-
able, how proper connections should be made, and
tion properties of accessories.
inspection required.
Environments with hazardous environments do not The line disconnect switch provides a safe and
include places where electrically conductive parts convenient means to completely remove all electri-
in the near vicinity of the operator, which can cause cal power from the welding power supply whenever
increased hazard, have been insulated. necessary to inspect or service the unit.

2–2
400MST 2 INTRODUCTION AND DESCRIPTION
NOTE 5.2 Input Power
These units are equipped with a three-conductor Each unit incorporates an INRUSH circuit and input
with earth power cable that is connected at the voltage sensing circuit. When the MAIN SWITCH is
welding power source end for single or three-phase turned on, the inrush circuit provides a pre-charg-
electrical input power. ing of the input capacitors. At this point, the Bus
Voltages are checked and the welder is enabled
Do not connect an input (WHITE, BLACK or RED)
after the input capacitors have charged to full
conductor to the ground terminal.
operating voltage (after approximately 5 seconds).
Do not connect the ground (GREEN) conductor to
an input line terminal. NOTE
Refer to Figure 2-3 and: Note the available input power. Damage to the
1. Connect end of ground (GREEN) conductor to welder could occur if 575VAC or higher is applied.
a suitable ground. Use a grounding method
that complies with all applicable electrical The following 208-230/460V Primary Current rec-
codes. ommendations are required to obtain the maximum
welding current and duty cycle from this welding
2. Connect ends of line 1 (BLACK) and line 2
equipment:
(WHITE) and line 3 (RED) input conductors to
a de-energized line disconnect switch. Minimum Current & Duty Cycle
3. Use Table 1 and Table 2 as a guide to select Primary Primary
Model Supply Current
line fuses for the disconnect switch.
Lead Size Circuit Size MIG TIG STICK

NOTE (Vin/Amps)
208/63 - -
For Single-Phase operation connect the GREEN, 400A@
BLACK and WHITE input conductors. Insulate the 230/57 - -
25%
RED Conductor, it is not used for Single-phase 460/29 - -
operation. 8/4 AWG 208/49 - -
minimum 400A@
3φ 230/44 - -
(Factory 25%
Fitted) 460/22 - -
Input Voltage Fuse Size
208/67 - -
208 VAC 100 Amps 400A@
230/61 - -
230 VAC 75 Amps 400MST 25%
460/31 - -
460 VAC 50 Amps
208/88 300A@ - -
Table 2-1: Electrical Input Connections 230/79 25% - -
8/3 AWG 208/67 - 300A@ -
1φ
NOTE minimum 230/60 - 25% -
Fuse size is based on not more than 200 percent of 208/97 - - 300A@
the rated input amperage of the welding power 230/87 - - 25%
source (Based on Article 630, National Electrical
Table 2-2: Primary Current Circuit sizes to achieve max-
Code). imum current

Figure 2-3: Electrical input connections

2–3
 400MST 2 INTRODUCTION AND DESCRIPTION
6 Specifications notice. Such updates or changes do not entitle the
buyer of equipment previously sold or shipped to
the corresponding changes, updates, improve-
Parameter 400MST
ments or replacement of such items.
Rated Output
Amperes 400
Volts
Duty Cycle
36
25%
7 Duty Cycle
400A / 26V@25%
The duty cycle of a welding power source is the
TIG 300A / 22V@60%
percentage of a ten (10) minute period that it can
200A / 18V@100%
be operated at a given output without causing over-
400A / 36V@25%
heating and damage to the unit. If the welding
Duty Cycle STICK 300A / 32V@60%
amperes decrease, the duty cycle increases. If the
200A / 28V@100%
welding amperes are increased beyond the rated
400A / 34V@25%
output, the duty cycle will decrease.
MIG 300A / 29V@60%
200A / 24V@100%
Output Current TIG WARNING
5-400A
Range STICK Exceeding the duty cycle ratings will cause the
Output Voltage thermal overload protection circuit to become ener-
MIG 5-36V
Range gized and shut down the output until the unit has
Open Circuit Voltage 65V cooled to normal operating temperature.
Dimensions
Width 8.27" (210mm)
CAUTION
Height 16.89" (420mm)
Continually exceeding the duty cycle ratings can
Length 17.72" (450mm)
cause damage to the welding power source and
Weight 55.1 lb. 25.0 kg will void the manufactures warranty.
Output@Rated Load Three-phase Single-phase
Rated Input Voltage 208-230/460V 208-230V
NOTE
Output Amperes 400A 300A
Due to variations that can occur in manufactured
Output Volts 36V 32V
products, claimed performance, voltages, ratings,
Duty Cycle 25% 25%
all capacities, measurements, dimensions and
KVA 24.0 20.0 weights quoted are approximate only. Achievable
KW 18.0 12.0 capacities and ratings in use and operation will
Output@No Load depend upon correct installation, use, applications,
KVA 0.5 maintenance and service.
KW 0.13
Input Volts Single Amperage Draw
No Load
Phase @Rated Load
208V 97 2.4
230V 87 2.2
Input Volts Three
Phase
208V 67 1.4
230V 61 1.3
460V 31 0.7

Thermal Arc continuously strives to produce the

best product possible and therefore reserves the
right to change, improve or revise the specifica-
tions or design of this or any product without prior

2–4
3 OPERATOR CONTROLS
1 400MST Controls OPERATOR CONTROLS

1. Control Knob
This control sets the selected weld parameter,
rotating it clockwise increases the parameter
and is indicated on the digital meter. Pushing
the knob in previews the actual welding volt-
age while welding.
2. Remote Control Socket
The 14 pin Remote Control Socket is used to
connect remote current control devices to the
welding Power Source. To make connections,
align keyway, insert plug, and rotate threaded
collar fully clockwise.
Socket
Function
Pin
A 24VAC auxiliary high side.
Input to energize solid state contactor (Contact
B
closure between pin A and pin B).
5k ohm (maximum) connection to 5k ohm
C
remote control potentiometer.
Zero ohm (minimum) connection to 5k ohm
D
remote control potentiometer.
Wiper arm connection to 5k ohm remote control
E
potentiometer.
F Current feedback Ifb = 100Amps/Volt
24/115 VAC circuit common, also connected to
G
chassis.
H Voltage Feedback Vfb = 10 Arc Volts/Volt
I 115 VAC auxiliary high side.
115 VAC input to energize solid state contactor
J
(Contact closure between pin I and pin J).
K Chassis ground.
L Not used.
M Current Detect.
N Current Detect.

3. Positive Terminal
Welding current flows from the Power Source
via heavy duty Dinse type terminal. It is essen-
tial, however, that the male plug is inserted and
turned securely to achieve a sound electrical
connection.
4. Negative Terminal
Welding current flows from the Power Source
via heavy duty Dinse type terminal. It is essen-
Figure 3-1: 400MST Power Source tial, however, that the male plug is inserted and
turned securely to achieve a sound electrical
connection.

3–1
 400MST 3 OPERATOR CONTROLS
8. Voltage Input Select Switch (Smart Logic
CAUTION
Switch)
Loose welding terminal connections can cause User selectable switch.
overheating and result in the male plug being fused A manual slide switch selects the proper input
in the bayonet terminal and /or melting of the hous- voltage range. If this slide switch is not set to
ing (case). the position that matches the input line voltage,
the Smart Logic will inhibit the welding power
5. Remote Control Socket
source from turning on and a warning indica-
The 19 pin Remote Control Socket is used to
tion will be displayed.
connect remote current control devices to the
welding Power Source. To make connections,
align keyway, insert plug, and rotate threaded WARNING
collar fully clockwise. Do not alter the position of the Voltage Input Select
Switch when the ON/OFF Switch is in the ON posi-
Socket
Function tion and the unit is powered up.
Pin
A Contactor circuit (+15 Volts).
9. 14/19 Pin Remote Control Select Switch
Contactor circuit in, (closure between pin A and
B User selectable switch.
Pin B will energize output.).
Position this switch for the remote control
Scaled output voltage signal: Vfb = 10 Arc Volts/
C device socket to be utilized. The unselected
Volt
Remote Control Socket is disabled at this time
D 24 VAC auxiliary power high side.
and cannot be utilized. Do not alter the posi-
E 115 VAC auxiliary power high side. tion of this switch while one of the Remote
G Chassis ground. Control Sockets is being utilized.
H Remote control maximum. 10. 24VAC Remote Device C/B
J Remote control wiper (0 - 10 Volts). Push to reset. Controls the 24VAC power
K Remote Control minimum. source for the wire feeders controlled through
J Remote control wiper (0 - 10 Volts). the Remote Control Sockets.
L Control circuit common. 11. 115VAC Remote Device C/B
M Arc Establish = +12 Volts Push to reset. Controls the 115VAC power
N Control Circuit common. source for the wire feeders controlled through
P 24 VAC auxiliary power high side. the Remote Control Sockets.
R 24/115 VAC neutral
S
T
N/C
N/C
2 Weld Parameter Descrip-
U Scaled output signal: Ifb = 100 Amps/Volt tions for 400MST
V N/C

6. ON/OFF Switch
This switch connects the Primary supply volt-
age to the inverter when in the ON position.
This enables the Power Supply.

WARNING
When the welder is connected to the Primary sup-
ply voltage, the internal electrical components
may be at 720V potential with respect to earth.

7. Input Cable
The input cable connects the Primary supply Figure 3-2: 400MST Front Panel with Parameter Description
voltage to the equipment.

3–2
400MST 3 OPERATOR CONTROLS

Parameter Description
3 Weld Process selection for
This parameter provides a suitable the 400MST
short circuit current in STICK
welding to improve electrode sticking
ARC CONTROL and arc stability. Weld Mode
This parameter operates in STICK Weld LIFT
STICK MIG Description
weld mode and is used to improve Parameter TIG
the start characteristics for stick Weld voltage MIG
WELD (V) 8 9 8
electrodes. e.g. low hydrogen Mode.
HOT START
electrodes. It sets the peak start INDUCT- Inductance control
current on top of the (WELD) 8 9 8
ANCE in MIG Mode.
current.
Start current in
Weld Current (Amperage)- when lit HOT
DC (A) 9 8 8 amps is added to
parameter knob sets the STICK and START
the WELD (A).
TIG WELD current.
WELD (A) current
Weld Voltage (Volt) - when lit WELD (A) 9 8 9 for STICK or LIFT
DC (V)
parameter knob sets the MIG TIG.
voltage.
Adjusts percentage
Contactor operation in Stick Mode. increase in welding
ARC
9 8 8 current and is
CONTROL
proportional to arc
length (arc voltage).
Table 3-2: Weld Process selection verses Weld Mode
Contactor ON/OFF
Selects mode of operation: Panel or
Remote.
4 Weld Parameter Descrip-
tions
Operation
PANEL / REMOTE 4.1 WELD (V)
This parameter, similar to the ARC This parameter sets the MIG weld arc voltage in
CONTROL in STICK mode, allows
MIG mode.
for the adjustment of the dynamic
INDUCTANCE property of the arc. As the
inductance is increased the output 4.2 INDUCTANCE
voltage may need to be adjusted to This parameter sets the INDUCTANCE when MIG
achieve the desired weld
welding. It controls the dynamic properties of the
characteristics.
arc in dip transfer welding mode. When this param-
The SAVE/LOAD buttons are used
eter is set to 0%, ie minimum inductance, the arc
SAVE LOAD to save and retrieve a total number
of 5 programs into the 400MST has a fast response with a resulting crisp arc noise
SAUVEGARDER CHARGER memory. and coarse spatter. When this parameter is set to
Table 3-1: Weld Parameter Descriptions for 400MST 100%, ie maximum inductance, the arc has a slow
response with a resulting soft arc and fine spatter.

NOTE
As the INDUCTANCE is increased, the WELD (V)
may need to be adjusted to achieve the desired
weld characteristic.

3–3
 400MST 3 OPERATOR CONTROLS
4.3 HOT START i) Root runs
This parameter operates in STICK mode and During root runs the weld pool forms a "keyhole"
improves the start characteristics for stick elec- shape. If too much weld current is used, the hole
trodes. e.g. low hydrogen electrodes. It sets the blows out and the weld collapses. If too little
peak start current on top of the WELD current. weld current is used, the hole closes up and
penetration is lost. The size of the hole also
e.g. HOT START current = 150 amps when Weld determines the arc length; ie as the hole gets
Current = 100 amps & HOT START = 50A bigger, the arc gets longer.
4.4 WELD (A) If arc force is used, the increase in the arc
length causes the weld current to decrease until
This parameter sets the STICK & Lift TIG weld cur- the hole starts to close up but if the hole closes
rent. up to much then the arc length decreases which
causes the weld current to increase. Too little or
4.5 ARC CONTROL too much arc force makes this process unstable.
This parameter operates in STICK mode only and The operator must adjust the arc force until a
is used to adjust percentage increase in welding happy medium is reached.
current and is proportional to arc length (arc volt- ii) Vertical up welding
age). This control provides an adjustable amount of When welding vertical up with arc force on, the
arc control (or dig). This feature can be particularly operator can control the amount of current by
beneficial in providing the operator with the ability changing arc length, ie voltage. Weld metal is
to compensate for variability in joint fit up in certain deposited by "digging" the electrode into the
situations with particular electrodes, eg cellulose side of the base metal joint and then increasing
and hydrogen controlled electrodes. In all welding the arc length with a flicking motion, to allow the
processes, the amount of penetration obtained is weld pool to freeze, before digging the electrode
dependent on the welding current; ie the greater into the other side of the base metal joint.
the penetration, the greater the current.
Without arc force, increasing the arc length does
not decrease the weld current sufficiently and
Current Increase
Arc Force Effect on Welding the operator has to manually decrease the cur-
when Arc Voltage is
Position Performance rent via a remote current control to freeze the
less than 18V
weld pool. This welding current reduction also
Minimum Soft arc, Low spatter,
0A reduces the penetration.
(0) Low penetration
Normal arc, Improved The arc force allows the weld pool to freeze during
Medium the "flick" phase without decreasing the amount of
32A fusion characteristics,
(20%)
Normal penetration weld current available during the "dig" phase thus
Maximum Hard arc, Deep maximizing penetration.
160A
(100%) penetration

Table 3-3: Weld Parameter Descriptions

In general, having the ARC CONTROL set at 100%

(maximum) allows greater penetration control to be
achieved. With the ARC CONTROL set at 0%
(minimum) the Power Source has a constant cur-
rent characteristic. In other words, varying the arc
length does not significantly effect the welding cur-
rent. When the ARC CONTROL set to 100%, it is
possible to control the welding current by varying
the arc length. This is very useful for controlling
penetration on root runs and side wall wash on ver-
tical up fillet welds.

3–4
400MST 3 OPERATOR CONTROLS
4.6 Weld Parameters Feature Description
Control Knob  For the selected weld parameter,
Weld Mode rotating the knob clockwise
Weld Parameter Factory Units of
Parameter Range Setting Increment STICK MIG LIFT increases the parameter.
TIG  Rotating the knob counter clock-
WELD (V) 10.0 to wise decreases the parameter.
17.0V 0.1V 8 9 8  A selected weld parameter value
MIG 36.0V DC
can be adjusted at any time even
INDUCT-
0 to 100% 10% 1% 8 9 8 while welding.
ANCE
 Pushing the knob in sets the
HOT selected parameter then displays
0 to 70A 20A 1A 9 8 8
START the next parameter.
WELD (A) Self Diagnosis  An error code is displayed on the
1 to 400A
TIG or 80A 1A 9 8 9 Using Error Digital Meter when a problem
DC
STICK Codes occurs with Mains supply voltage or
ARC internal component problems.
0 to 100% 10% 1% 9 8 8
CONTROL
Save/Load  A total number of 5 programs can
function be saved into the 400MST memory.
Table 3-4: Weld Parameters
SAVE the Current Weld Parameters
into Memory
4.7 Power Source Features  Press the SAVE button.
 Select a memory location by rotat-
Feature Description ing the control knob, 1 to 5 is dis-
played on the meter.
New Digital  All welding parameters are adjust-
Control able.
 After selecting the desired memory
location (ie. 1 to 5), press the
Touch Panel  Touch switches eliminate mechani- parameter button and the machine
Switches cal damage. give a beep to confirm the weld
Front Control  Protects front panel controls. parameters from the control panel
Cover are saved.
LOAD (retrieve) a Program to
Digital Meter Volt  Displays selected weld parameter
Control Panel
& Ammeter value.
 Press the LOAD button.
 Displays average weld current  Select a memory location by rotat-
when welding.
ing the control knob, 1 to 5 is dis-
 Displays average weld current for played on the meter.
20 seconds after weld has been
After selecting the desired memory
completed.
location (ie. 1 to 5), press the
 A selected weld parameter value
parameter button and the machine
can be adjusted at any time even
give a beep to confirm the weld
while welding.
parameters are loaded onto the
Intelligent Fan  The intelligent cooling system is control panel.
Control designed to reduce dust and for-
eign material build-up, while provid-
ing optimum cooling.
 Fan speed reduces approximately
30 seconds after machine is turned
on.
 Fan speed increases when internal
components reach operating
temperature.
ON/OFF switch  Mains ON/OFF switch located on
rear panel.
Voltage  VRD fully complies to IEC 60974-1.
Reduction Device  VRD light is ON and operational
(VRD) when in STICK mode.

3–5
 400MST 3 OPERATOR CONTROLS

PAGE LEFT INTENTIONALLY BLANK

3–6
4 SEQUENCE OF OPERATION
NOTE: Parameter Buttons are used to select the
SEQUENCE OF OPERATION

1 Stick Welding
parameters to be set. The LED's show which func-
tion is being adjusted on the weld sequence graph.  Connect work lead to negative terminal.
Refer to Symbols Table located in the front of the  Connect electrode lead to positive terminal.
manual for Symbol descriptions.
 Switch machine on.
 Set weld current.
 Set Contactor.
1  Connect remote control device if required.
7 Use the Scroll Buttons to move to the parameter to
2 be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the
4 control knob to adjust each parameter.
 Set HOT START .
3  Set ARC CONTROL.
 Set WELD current .
Commence welding.
5 6

Figure 4-1: 400MST Front Panel

2 LIFT TIG Welding
1. Contactor function - Pressing this button
enables Contactor functions.  Connect work lead to positive terminal.
2. Remote functions - Pressing this button  Connect TIG torch to negative terminal.
enables remote current functions.  Switch machine on.
3. Digital LED displays - Welding amperage, Volt-  Set weld current.
age and parameter values are displayed in this  Connect remote control device if required.
window. Internal warnings such as over tem-
perature, low or high input voltage applied are Use the Scroll Buttons to move to the parameter to
signaled to the operator by a warning sound be set. The LED will show which function is being
and error message on the screen. adjusted on the weld sequence graph. Use the
control knob to adjust each parameter.
4. Save/Load Buttons -By using the Save & Load
buttons the operator can easily save up to 5 Commence welding.
welding parameter programs.
5. Control knob - Allows the operator to adjust the
output amperage/voltage within the entire 3 MIG Welding
range of the power source, also used to set
each parameter value.  Connect work lead to negative terminal.
 Connect electrode lead to positive terminal.
6. Process Button - This button selects between
STICK, Lift TIG, and MIG modes. MIG modes  Switch machine on.
include MS for mild steel and SS for stainless  Set weld voltage.
steel.  Set Inductance.
7. Parameter Button. - This button selects  Connect Wire feeder.
between HOT START, WELD CURRENT, and  Set wire feed speed (IPM).
ARC CONTROL while in STICK and Lift TIG
modes and selects between WELD VOLTAGE Use the Scroll Buttons to move to the parameter to
and INDUCTANCE CONTROL while in MIG be set. The LED will show which function is being
mode. This button is also used in conjunction adjusted on the weld sequence graph. Use the
with the Save/Load buttons to save and load control knob to adjust each parameter.
welding programs. Commence welding.

4–1
5 ROUTINE MAINTENANCE
ROUTINE MAINTENANCE

The only routine maintenance required for the

power supply is a thorough cleaning and inspec-
tion, with the frequency depending on the usage
and the operating environment.

WARNING
Disconnect primary power at the source before
opening the enclosure. Wait at least two minutes
before opening the enclosure to allow the primary
capacitors to discharge.

To clean the unit, open the enclosure (refer to

'Opening the Enclosure' section 9.1.1) and use
a vacuum cleaner to remove any accumulated dirt
and dust. The unit should also be wiped clean, if
necessary; with solvents that are recommended for
cleaning electrical apparatus.

CAUTION
Do not blow air into the power supply during clean-
ing. Blowing air into the unit can cause metal parti-
cles to interfere with sensitive electrical
components and cause damage to the unit.

5–1
6 BASIC TROUBLE SHOOTING
5. Welding dirty, oily, painted, oxidized or greasy plate.
BASIC TROUBLE SHOOTING

WARNING
Clean contaminates off the plate.
There are extremely dangerous voltages and
power levels present inside this product. Do not 6. Distance between the MIG torch nozzle and the
attempt to open or repair unless you are an work piece.
Accredited Thermal Arc Service Agent and you Keep the distance between the MIG torch
have had training in power measurements and nozzle and the work piece to a minimum.
troubleshooting techniques.
7. Maintain the MIG torch in good working order.
If major complex subassemblies are faulty, then Ensure that the gas holes are not blocked
the Welding Power Source must be returned to an and gas is exiting out of the torch nozzle.
Accredited Thermal Arc Service Agent for repair. Do not restrict gas flow by allowing spatter
The basic level of troubleshooting is that which can to build up inside the MIG torch nozzle.
be performed without special equipment or knowl- Check that the MIG torch O-rings are not
edge. damaged.

1 Solving MIG Problems WARNING

Beyond the Welding Termi- Disengage the drive roll when testing for gas flow
by ear.
nals
The general approach to fix Gas Metal Arc Welding 1.2 Inconsistent Wire Feed
(GMAW) problems is to start at the wire spool then
Checking the following points can reduce wire-
work through to the MIG torch. There are two main
feeding problems:
areas where problems occur with GMAW:
1. Wire spool brake is too tight.
1.1 Porosity Feed roller driven by motor in the cabinet
When there is a gas problem the result is usually will slip.
porosity within the weld metal. Porosity always
stems from some contaminant within the molten 2. Wire spool brake is too loose.
weld pool which is in the process of escaping dur- Wire spool can unwind and tangle.
ing solidification of the molten metal.
3. Worn or incorrect feed roller size.
Contaminants range from no gas around the weld-
ing arc to dirt on the work piece surface. Porosity Use 'U' groove drive feed roller matched to
can be reduced by checking the following points: the aluminium wire size you are welding.
1. Gas cylinder contents and flow meter. Use 'V' groove drive feed roller matched to
the steel wire size you are welding.
Ensure that the gas cylinder is not empty
and the flow meter is correctly adjusted to Use 'knurled V' groove drive feed roller
25 cubic feet per hour. matched to the flux cored wire size you are
welding.
2. Gas leaks.
Check for gas leaks between the regulator/ 4. Misalignment of inlet/outlet guides.
cylinder connection and in the gas hose to Wire will rub against the misaligned guides
the Wire Feeder. Internal gas hose in the and reduce wire feedability.
Wire Feeder.
5. Liner blocked with wire debris.
3. Internal gas hose in the Wire Feeder.
Wire debris is produced by the wire passing
Ensure the hose from the solenoid valve to through the feed roller, if excessive pressure
the MIG torch adapter has not fractured and is applied to the pressure roller adjuster.
that it is connected to the MIG torch adapter.
Wire debris can also be produced by the
4. Welding in a windy environment. wire passing through an incorrect feed roller
Shield the weld area from the wind or groove shape or size.
increase the gas flow.

6–1
 400MST 6 BASIC TROUBLE SHOOTING
Wire debris is fed into the liner where it heated. A contact tip designed for soft elec-
accumulates thus reducing wire feedability. trode wires should be used.
6. Incorrect or worn contact tip. 7. Poor work lead contact to work piece.
The contact tip transfers the weld current to If the work lead has a poor electrical contact
the electrode wire. If the hole in the contact to the work piece then the connection point
tip is to large then arcing may occur inside will heat up and result in a reduction of
the contact tip resulting in the electrode wire power at the arc.
jamming in the contact tip.
8. Bent liner.
When using soft electrode wire such as alu-
This will cause friction between the wire and
minium it may become jammed in the con-
the liner thus reducing wire feedability.
tact tip due to expansion of the wire when

2 MIG Welding Problems

Description Possible Cause Remedy
1 Undercut. A Welding arc voltage too high. A Reduce WELD (V) control or increase the
B Incorrect torch angle. wire feed speed.
C Excessive heat input. B Adjust angle.
C Increase the torch travel speed and/or
reduce welding current by reducing the
WELD (V) control or reducing the wire
feed speed.
2 Lack of penetration. A Welding current too low. A Increase welding current by increasing
B Joint preparation too narrow or gap too wire feed speed and increasing WELD
tight. (V) control.
B Increase joint angle or gap.
C Shielding gas incorrect.
C Change to a gas which gives higher
penetration.
3 Lack of fusion. Voltage too low. Increase WELD (V) control.
4 Excessive spatter. A Voltage too high. A Lower the voltage by reducing the WELD
B Voltage too low. (V) control or increase wirespeed control.
B Raise the voltage by increasing the
WELD (V) control or reduce wirespeed
control.
5 Irregular weld shape. A Incorrect voltage and current settings. A Adjust voltage and current by adjusting
Convex, voltage too low. Concave, the WELD (V) control and the wirespeed
voltage too high. control.
B Wire is wandering. B Replace contact tip.
C Incorrect shielding gas. C Check shielding gas.
D Insufficient or excessive heat input. D Adjust the wirespeed control or the
voltage selection switches.
6 Weld cracking. A Weld beads too small. A Decrease travel speed.
B Weld penetration narrow and deep. B Reduce current and voltage and increase
C Excessive weld stresses. MIG torch travel speed or select a lower
penetration shielding gas.
D Excessive voltage.
C Increase weld metal strength or revise
E Cooling rate too fast. design.
D Decrease voltage by reducing the WELD
(V) control.
E Slow the cooling rate by preheating part
to be welded or cool slowly.

6–2
400MST 6 BASIC TROUBLE SHOOTING
Description Possible Cause Remedy
7 Cold weld puddle. A Faulty rectifier unit. A Have an Accredited Thermal Arc Service
B Loose welding cable connection. Agent to test then replace the faulty
component.
C Low Primary Voltage.
B Check all welding cable connections.
C Contact supply authority.
8 Arc does not have a The MIG torch has been connected to the Connect the MIG torch to the positive (+)
crisp sound, that short wrong voltage polarity on the front panel. welding terminal for solid wires and gas
arc exhibits, when the shielded flux cored wires. Refer to the
wirefeed speed and electrode wire manufacturer for the correct
voltage are adjusted polarity.
correctly.

3 TIG Welding Problems

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and
proper welding technique.
Description Possible Cause Remedy
1 Excessive beard build- Welding current is too low. Increase weld current and/or faulty joint
up or poor penetration preparation.
or poor fusion at edges
of weld.
2 Weld bead too wide Welding current is too high. Decrease weld current.
and flat or undercut at
edges of weld or
excessive burn through.
3 Weld bead too small or Travel speed too fast. Reduce travel speed.
insufficient penetration
or ripples in bead are
widely spaced apart.
4 Weld bead too wide or Travel speed too slow. Increase travel speed.
excessive bead build up
or excessive
penetration in butt joint.
5 Uneven leg length in Wrong placement of filler rod. Re-position filler rod.
fillet joint.
6 Electrode melts when A Electrode is connected to the '+' terminal. A Connect the electrode to the '-' terminal.
arc is struck.
7 Dirty weld pool. A Electrode contaminated through contact A Clean the electrode by grinding off the
with work piece or filler rod material. contaminates.
B Gas contaminated with air. B Check gas lines for cuts and loose fitting
or change gas cylinder.
8 Electrode melts or A No gas flowing to welding region. A Check the gas lines for kinks or breaks
oxidizes when an arc is B Torch is clogged with dust. and gas cylinder contents.
struck. B Clean torch. Replace gas hose.
C Gas hose is cut.
D Disconnect gas hose from torch then
D Gas passage contains impurities.
raise gas pressure and blow out
E Gas regulator turned off. impurities.
F Torch valve is turned off. E Turn on.
G The electrode is too small for the welding F Turn on.
current. G Increase electrode diameter or reduce
the welding current.

6–3
 400MST 6 BASIC TROUBLE SHOOTING
Description Possible Cause Remedy
9 Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas line for gas
flow problems.
10 Arc flutters during TIG A Tungsten electrode is too large for the A Select the right size electrode. Refer to
welding. welding current. Basic TIG Welding guide.
B Absence of oxides in the weld pool. B Refer Basic TIG Welding Guide for ways
to reduce arc flutter.
11 Welding arc can not be A Work clamp is not connected to the work A Connect the work clamp to the work
established. piece or the work/torch leads are not piece or connect the work/torch leads to
connected to the right welding terminals. the right welding terminals.
B Torch lead is disconnected. B Connect it to the '-' terminal.
C Gas flow incorrectly set, cylinder empty C Select the right flow rate, change
or the torch valve is off. cylinders or turn torch valve on.
12 Arc start is not smooth. A Tungsten electrode is too large for the A Select the right size electrode. Refer to
welding current. Basic TIG Welding Guide.
B The wrong electrode is being used for the B Select the right electrode type. Refer to
welding job. Basic TIG Welding Guide.
C Gas flow rate is too high. C Select the correct rate for the welding job.
D Incorrect shielding gas is being used. Refer to Basic TIG Welding Guide.
E Poor work clamp connection to work D Select the right shielding gas. Refer to
piece. Basic TIG Welding Guide.
E Improve connection to work piece.

4 Stick Welding Problems

Description Possible Cause Remedy
1 Gas pockets or voids in A Electrodes are damp. A Dry electrodes before use.
weld metal (Porosity). B Welding current is too high. B Reduce welding current.
C Surface impurities such as oil, grease, C Clean joint before welding.
paint, etc.
2 Crack occurring in weld A Rigidity of joint. A Redesign to relieve weld joint of severe
metal soon after B Insufficient throat thickness. stresses or use crack resistance
solidification electrodes.
C Cooling rate is too high.
commences. B Travel slightly slower to allow greater
build up in throat.
C Preheat plate and cool slowly.
3 A gap is left by failure A Welding current is too low. A Increase welding current.
of the weld metal to fill B Electrode too large for joint. B Use smaller diameter electrode.
the root of the weld.
C Insufficient gap. C Allow wider gap.
D Incorrect sequence. D Use correct build-up sequence.

Incorrect sequence
Insufficient gap

Figure 6-1: Example of insufficient gap or incorrect sequence

6–4
400MST 6 BASIC TROUBLE SHOOTING
Description Possible Cause Remedy
4 Portions of the weld run A Small electrodes used on heavy cold A Use larger electrodes and pre-heat the
do not fuse to the plate. plate.
surface of the metal or B Welding current is too low. B Increase welding current.
edge of the joint.
C Wrong electrode angle. C Adjust angle so the welding arc is
D Travel speed of electrode is too high. directed more into the base metal.
E Scale or dirt on joint surface. D Reduce travel speed of electrode.
E Clean surface before welding.

Lack of fusion caused by dirt,

electrode angle incorrect, rate
of travel too high

Lack of inter-run Fusion

Lack of side fusion, scale Lack of Root Fusion

dirt, small electrode,
amperage too low

Figure 6-2: Example of lack of fusion

Description Possible Cause Remedy

5 Non-metallic particles A Non-metallic particles may be trapped in A If bad undercut is present, clean slag out
are trapped in the weld undercut from previous run. and cover with a run from a smaller
metal (slag inclusion). B Joint preparation too restricted. diameter electrode.
C Irregular deposits allow slag to be B Allow for adequate penetration and room
trapped. for cleaning out the slag.
D Lack of penetration with slag trapped C If very bad, chip or grind out irregularities.
beneath weld bead. D Use smaller electrode with sufficient
E Rust or mill scale is preventing full fusion. current to give adequate penetration.
Use suitable tools to remove all slag from
F Wrong electrode for position in which
corners.
welding is done.
E Clean joint before welding.
F Use electrodes designed for position in
which welding is done, otherwise proper
control of slag is difficult.

Not cleaned, or Slag trapped in

incorrect electrode undercut
Slag trapped in root

Figure 6-3: Examples of slag inclusion

6–5
 400MST 6 BASIC TROUBLE SHOOTING
5 Power Source Problems
Description Possible Cause Remedy
1 The welding arc cannot A The Primary supply voltage has not been A Switch ON the Primary supply voltage.
be established. switched ON. B Switch ON the Welding Power Source.
B The Welding Power Source switch is C Have an Accredited Thermal Arc Service
switched OFF. Agent repair the connection.
C Loose connections internally.
2 Maximum output Defective control circuit. Have an Accredited Thermal Arc Service
welding current can not Agent inspect then repair the welder.
be achieved with
nominal Mains supply
voltage.
3 Welding current Poor work lead connection to the work piece. Ensure that the work lead has a positive
reduces when welding. electrical connection to the work piece.
4 No gas flow when the A Gas hose is cut. A Replace gas hose.
torch trigger switch is B Gas passage contains impurities. B Disconnect gas hose from the rear of
depressed. Power Source then raise gas pressure
C Gas regulator turned off.
and blow out impurities.
D Torch trigger switch lead is disconnected
or switch/cable is faulty. C Turn gas regulator on.
D Reconnect lead or repair faulty switch/
cable.
5 Gas flow won't shut off. A Weld Mode (STD, SLOPE, REPEAT or A Strike an arc to complete the weld cycle.
SPOT) was changed before POST-FLOW OR Switch machine off then on to reset
gas time had finished. solenoid valve sequence.
B Gas valve is faulty. B Have an Accredited Thermal Arc Service
C Gas valve jammed open. Agent replace gas valve.
D POST-FLOW control is set to 60 sec. C Have an Accredited Thermal Arc Service
Agent repair or replace gas valve.
D Reduce POST-FLOW time.
6 The TIG electrode has The Weld Process Mode (STICK, HF TIG or Do not change Weld Process Mode before
been contaminated due LIFT TIG) was changed before POST-FLOW the POST-FLOW gas time had finished.
to the gas flow shutting gas time had finished.
off before the
programmed POST-
FLOW time has elapse.

6–6
7 VOLTAGE REDUCTION DEVICE (VRD)
1 VRD Specification Voltage Reduction Device (VRD)

3 Switching VRD On/Off

ArcMaster Switch the machine Off.
Description Notes
400MST a. Remove the clear plastic cover from the control
Open circuit voltage panel (see Figure 7-1).
VRD Open 15.3 to
between welding  Lift up the cover so it rests on the top of the
Circuit Voltage 19.8V
terminals.
unit.
The required resistance
148 to 193 between welding
 Place a small flat bladed screw driver between
VRD Resistanc. the cover hinge on the front panel.
ohms terminals to turn ON the
welding power.  Gently lift the cover hinge out of the front cover
The time taken to turn mounting hole.
VRD Turn OFF 0.2 to 0.3 OFF the welding power  Remove the control's clear plastic cover.
Time seconds once the welding current
has stopped.

2 VRD Maintenance 2 2

Routine inspection and testing (power source)

An inspection of the power source, an insulation
resistance test and an earth resistance test shall
be carried out. 3
a. For transportable equipment, at least once
every 3 months 1
b. For fixed equipment, at least once every 12
months.
The owners of the equipment shall keep a suitable Figure 7-1: VRD ON/OFF Step A
record of the periodic tests.
b. Remove four mounting screws from the control
NOTE
panel (see Figure 7-2).
A transportable power source is any equipment
c. Access the VRD control by gently prying back
that is not permanently connected and fixed in the
the front panel controls to reveal the VRD on/
position in which it is operated. off potentiometer (see Figure 7-2).

In addition to the above tests and specifically in CAUTION

relation to the VRD fitted to this machine, the fol- Do not pull back the front panel with excessive
lowing periodic tests should also be conducted by force as this will unplug control PCB. Plugging the
an accredited Thermal Arc service agent. control PCB back into the front panel controls can
Description IEC 60974-1 Requirements
only be achieved by removing the side covers.
VRD Open Less than 20V; at Vin=230V or 460V
Circuit Voltage 1
VRD Turn ON Less than 200 ohms 1
Resistance
VRD Turn OFF Less than 0.3 seconds
Time 2
1
1
If this equipment is used in a hazardous location or
environments with a high risk of electrocution then
the above tests should be carried out prior to enter-
ing this location. Figure 7-2: VRD ON/OFF Step B,C

7–1
 400MST 7 Voltage Reduction Device (VRD)
d. Turning the VRD ON/OFF (see Figure 7-3).
 To turn VRD ON: rotate the trim potentiometer
(VR1) on the display PCB fully clockwise.
When VRD is turned ON check that it operates
as per VRD Specifications on page 7-1.
 To turn VRD OFF: rotate the trim potentiometer
(VR1) on the display PCB fully counter clock-
wise.

WARNING
The VRD ON/OFF trim potentiometer MUST ONLY
be positioned fully clockwise OR fully counter
clockwise as the VRD function will be unknown for
every other position.

Figure 7-3: VRD ON/OFF Step D

7–2
8 POWER SOURCE ERROR CODES
Power Source Error Codes

Description Possible Cause Remedy Remarks

1 E01 error code displayed A The Welding Power A Let Power Source cool Weld current ceases.
Temperature sensor TH1 Source's duty cycle has down then keep within its Buzzer sounds constantly.
(protects IGBTs) is been exceeded. duty cycle. Fan operates at max speed.
greater than 80°C for B Fan ceases to operate. B Have an Accredited E01 resets when TH1
about 1 second. C Air flow is restricted by Thermal Arc Service decreases to 70°C for about
vents being blocked. Agent investigate. 30 seconds.
C Unblock vents then let
Power Source cool down.
2 E02 error code displayed A The Welding Power A Let Power Source cool Weld current ceases.
Temperature sensor TH2 Source's duty cycle has down then keep within its Buzzer sounds constantly.
(protects secondary been exceeded. duty cycle. Fan operates at max speed.
diodes) is greater than B Fan ceases to operate. B Have an Accredited E02 resets when TH1
80°C for about 1 second. C Air flow is restricted by Thermal Arc Service decreases to 70°C for about
vents being blocked. Agent investigate. 30 seconds.
C Unblock vents then let
Power Source cool down.
3 E03 error code displayed A Primary current is too A Reduce length of welding Weld current ceases.
Primary (input) current high because welding arc arc. Buzzer sounds constantly.
too high. is too long. B Have an Accredited Switch machine off then on to
B Mains supply voltage is Thermal Arc Service reset E03 error.
more than 10% below Agent or a qualified
nominal voltag. electrician check for low
Mains voltage.
4 E11 error code displayed Primary supply voltage is Have an Accredited Thermal Weld current ceases.
Over Primary supply greater than the nominal Arc Service Agent or a Buzzer sounds constantly.
(input) voltage at primary voltage plus 10%. qualified electrician check Error code E11 automatically
capacitors is exceeded the Primary voltage. will reset when the voltage
for one second. reduces.
5 E14 error code displayed Mains supply voltage is less Have an Accredited Thermal Weld current available.
Under mains supply than the nominal operating Arc Service Agent or a Buzzer sounds intermittently.
(input) voltage warning voltage less 10%. qualified electrician check Error code E14 automatically
primary capacitors is the Mains voltage. will reset when the voltage
reduced for one second. increases.
6 E12 error code displayed Mains supply voltage is Have an Accredited Thermal Weld current ceases.
Under mains supply down to a dangerously low Arc Service Agent or a Buzzer sounds constantly.
(input) voltage primary level. qualified electrician check Error code E12 automatically
capacitors is reduced for the Mains voltage. will reset when the voltage
one second. increases.
7 E81 error code displayed When 3 phase machine is Have an Accredited Thermal No weld current is available.
Wrong Primary supply first turned on with the wrong Arc Service Agent or a Buzzer sounds constantly.
(input) voltage Primary supply (input) qualified electrician check Switch machine off.
connected. voltage connected. the Mains voltage.
8 E82 error code displayed Link switch plug not Have an Accredited Thermal No weld current is available.
Link switch plug not connected. Arc Service Agent check Buzzer sounds constantly.
connected. connector plug on input PCB. Switch machine off.
9 E83 error code displayed The Primary supply (input) Have an Accredited Thermal No weld current is available.
CPU checks mains voltage fluctuates and is not Arc Service Agent check Buzzer sounds constantly.
supply (input) voltage stable. connector plug on input PCB Switch machine off then on to
when the on/off switch and the Mains voltage. reset E83 error.
on rear panel of machine
is turned ON.

8–1
 400MST 8 Power Source Error Codes
Description Possible Cause Remedy Remarks
10 E93 error code displayed Memory chip (EEPROM) Have an Accredited Thermal Weld current ceases.
Memory chip (EEPROM) error. Arc Service Agent check the Buzzer sounds constantly.
on control PCB can not control PCB. Switch machine off.
read/write weld
parameter.
11 E94 error code displayed The Welding Power Source's Have an Accredited Thermal Weld current ceases.
Temperature sensor TH1 temperature sensors have Arc Service Agent check or Buzzer sounds constantly.
for IGBTs or sensor TH2 malfunctioned. replace the temperature Switch machine off.
for secondary diodes are sensors.
open circuit.
12 E99 error code displayed A Main on/off switch on A Turn on/off switch on. Weld current ceases.
Mains supply (input) machine has been turned B Have an Accredited Buzzer sounds constantly.
voltage has been turned off. Thermal Arc Service Must switch machine off then
off but control circuit has B Mains supply (input) Agent or a qualified on to reset E99 error.
power from the primary voltage has been turned electrician check the
capacitors. off. Mains voltage and fuses.

8–2
9 ADVANCED TROUBLESHOOTING
If you are here, all of the troubleshooting sugges- Under no circumstances are field repairs to be
ADVANCED TROUBLESHOOTING

tions in Section 7 Basic Troubleshooting have attempted on printed circuit boards or other subas-
either failed to resolve the faulty operation or have semblies of this unit. Evidence of unauthorized
indicated that one or more of the subsystems repairs will void the factory warranty. If a subas-
within the power supply are defective. This section sembly is found to be defective by executing any of
provides the information needed to take live mea- the procedures in this Service Manual, the subas-
surements on the various subsystems within the sembly should be replaced with a new one. The
power supply, and replace those subsystems that faulty subassembly should then be returned to
prove faulty. Thermal Arc through established procedures.
CAUTION
Troubleshooting and repairing this unit is a pro- WARNING
cess, which should be undertaken only by those Disconnect primary power at the source before dis-
familiar with high voltage/high power electronic assembling the power supply. Frequently review
equipment. the "Principal Safety Standards" in section 1.02.
Be sure the operator is equipped with proper
gloves, clothing and eye and ear protection. Make
WARNING sure no part of the operator's body comes into con-
There are extremely dangerous voltage and power tact with the work piece or any internal components
levels present inside this unit. Do not attempt to while the unit is activated.
diagnose or repair unless you have training in
power electronics, measurement and troubleshoot-
ing techniques.

1 System-Level Fault Isolation

If none of the suggestions provided in Section 7 have solved the problem or corrected the faulty operation,
the next step is to isolate one or more of the internal subassemblies that may be defective.

CAUTION
Perform all steps in each procedure, in sequence. Skipping portions of procedures, or performing steps out
of sequence can result in damage to the unit, and possible injury, or worse, to the operator.

1.1 Opening the Enclosure

1) Confirm that the switch on the power supply and the switch on the switchboard (distribution panel) are all OFF.

9–1
 400MST 9 ADVANCED TROUBLESHOOTING
CAUTION
The capacitors inside the power supply will slowly discharged after you turn off the switch of the power sup-
ply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete.

2) Remove all screws and nuts on the side covers.

3) Loosen the screws on the front panel and the rear panel by turning them approximately two turns CCW.

NOTE
DO NOT remove the screws completely.

9–2
400MST 9 ADVANCED TROUBLESHOOTING
4) Pull the front panel slightly forward and pull the rear panel slightly backward.
The interlocking hooks of the side case covers can now be disengaged from the front and rear panels.

5) Remove the side covers.

6) Remove protection cover sheet by removing the plastic tabs.

NOTE
When you re-assemble the parts, conduct the above process backwards.

9–3
 400MST 9 ADVANCED TROUBLESHOOTING
1.2 Verification and Remedy to 1.2.1 E01 "Over-Temperature at the
the Indicated Error Codes primary side"
NOTE Cause
The capacitors inside the power supply will slowly Occurs when an over-temperature condition of the
discharged after you turn off the switch of the primary IGBT is detected.
power supply or the switch at the breaker box (dis-
tribution panel). Wait at least 5 minutes for the dis- Verification/Remedy
charge to complete and then remove the cases to
a) Unit may be in thermal shutdown mode.
continue your inspection and repair (or mainte-
nance) inside the power supply. As for the removal  Review the rated duty cycle of the unit per
and installation of the case, refer to section page 2-4. Exceeding the duty cycle
9.1.1. can damage the unit and void the warranty.
Refer also to section 2.7 for addi-
tional information.
NOTE
b) Verify the ventilating condition.
During the "Verification/Remedy" procedures
below, follow the alphabetical sequence (a, b, c...)  Maintain a clear and unobstructed distance
and proceed with your verification and confirma- of more than 12 in. in the front and more that
tion. 20 in. in the rear of the unit for ventilation pur-
poses.
NOTE  Verify and maintain clean, dust free, front and
rear airflow paths. Cleaning and removing
After you confirm and replace all spare parts and
dust from the front and rear panels once
components, confirm that there are no damaged
every six months in a normal working envi-
harnesses or connectors, uninstalled or loose
ronment is recommended. Extremely dusty
screws.
environments will require more frequent
cleanings.
c) Verify the operation of the cooling fan, FAN1,
and replace it if necessary.
 Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing any abnormal sounds.
 If broken or cracked FAN1 blades, or abnor-
mal sounds are emanating from FAN1,
replace FAN1.
 Refer to section 9.2.4.19 for the replacement
of FAN1.
 Refer to section 9.1.4.4 for additional FAN1
tests.
 Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section 9.1.4.4.
d) Replace PCB3 (WK-5548).
 Refer to section 9.2.4.3 for the replacement
of PCB3.

9–4
400MST 9 ADVANCED TROUBLESHOOTING
1.2.2 E02 "Over-Temperature at the 1.2.3 E03 "Primary Over-Current Failure"
secondary side"
Cause
Cause Occurs when excessive current is detected flow-
Occurs when an over-temperature condition of the ing into the primary side of the main transformer.
secondary IGBT and diode are detected.
Verification/Remedy
Verification/Remedy a) Confirm the operation of the machine within
a) Unit may be in thermal shutdown mode. the rated specification.
 Review the rated duty cycle of the unit per  Refer to the specification data sheet in Sec-
section 2.6. Exceeding the duty cycle tion 2.6.
can damage the unit and void the warranty. b) Verify the secondary diode (D2, D3, D4, D5,)
Refer also to section 2.7 for addi-
tional information.  Refer to section 9.1.4.6 for the test and
b) Verify the ventilating condition. replacement of D2 and to section 9.2.4.24 for
 Maintain a clear and unobstructed distance D3, D4, D5.
of more than 12 in. in the front and more that c) Replace the Hall CT, HCT1.
20 in. in the rear of the unit for ventilation pur-
poses. NOTE
 Verify and maintain clean, dust free, front and Pay special attention to installed direction of HCT1.
rear airflow paths. Cleaning and removing The Hall CT will not function properly if installed in
dust from the front and rear panels once the incorrect direction.
every six months in a normal working envi-
ronment is recommended. Extremely dusty  Refer to section 9.2.4.22 for the replacement of
environments will require more frequent HCT1.
cleanings.
c) Verify the operation of the cooling fan, FAN1,
and replace it if necessary. 1.2.4 E11 "High Input Voltage Failure"
 Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that Cause
FAN1 is not producing any abnormal sounds. Occurs when the input voltage is more than
 If broken or cracked FAN1 blades or abnor- approximately 275VAC (at input voltage 230V) or
mal sounds are emanating from FAN1, 520VAC (at input voltage 460V) (=1/1.41 of the
replace FAN1. maximum value of the sinusoidal wave).
 Refer to section 9.2.4.19 for the replacement
of FAN1. Verification/Remedy
 Refer to section 9.1.4.4 for additional FAN1 a) Verify input voltage.
tests.  Follow the instruction in section 9.1.4.2.
 Verify the operation of the cooling fan and b) Replace PCB4 (WK-4819).
replace it if the condition of FAN1 is inactive.
 If the voltage and current available is deter-
Follow the instruction in section 9.1.4.4.
mined to be sufficient, replace PCB4.
d) Replace PCB3 (WK-5548).
 Refer to section 9.2.4.4 for the replacement
 Refer to section 9.2.4.3 for the replacement of PCB4.
of PCB3.

9–5
 400MST 9 ADVANCED TROUBLESHOOTING
1.2.5 E12 "Low Input Voltage Failure"  Contact the manufacturer if you find any bro-
ken connectors or damaged wiring har-
Cause nesses.
Occurs when the input voltage is less than c) Verify PCB4 (WK-4819) for burned or discol-
approximately 150VAC (=1/1.41 of the maximum ored components or printed circuit board.
value of the sinusoidal wave).  Confirm that the PCB is securely fastened in
place. (No loose screws).
Verification/Remedy  Refer to section 9.2.4.4 for the replacement
a) Verify input voltage. of PCB4.
 Follow the instruction in section 9.1.4.2.
b) Replace PCB4 (WK-4819). 1.2.8 E82 "Rated voltage selection cir-
 If the voltage and current available is deter- cuit abnormality"
mined to be sufficient, replace PCB4.
Cause
 Refer to section 9.2.4.4 for the replacement
of PCB4. Failure detected by the input voltage detection cir-
cuit, etc.

1.2.6 E14 "Low Input Voltage Warning" Verification/Remedy

Cause a) Verify the wiring harness and connection of
CN4 on PCB4 (WK-4819).
Occurs when the input voltage is less than
approximately 173VAC (=1/1.41 of the maximum  Confirm a secure connection of CN4 on
value of the sinusoidal wave). PCB4.
 Contact the manufacturer if you find any bro-
Verification/Remedy ken connectors or damaged wiring har-
nesses.
a) Verify input voltage.
b) Verify PCB4 (WK-4819) for burned or discol-
 Follow the instruction in section 9.1.4.2.
ored components or printed circuit board.
b) Replace PCB4 (WK-4819).
 Confirm that the PCB is securely fastened in
 If the voltage and current available is deter- place. (No loose screws).
mined to be sufficient, replace PCB4.
 Refer to section 9.2.4.4 for the replacement
 Refer to section 9.2.4.4 for the replacement of PCB4.
of PCB4.

1.2.9 E83 "Abnormal mains supply

1.2.7 E81 "Abnormal Input Voltage" voltage"
Cause Cause
Failure detected by the input voltage detection cir- Failure detected by the input voltage detection cir-
cuit, etc. cuit, etc.

Verification/Remedy Verification/Remedy
a) Verify the AC input voltage using a voltmeter. a) Verify the AC input voltage using a voltmeter.
 Follow the instruction in section 9.1.4.2.  Follow the instruction in section 9.1.4.2.
b) Verify the wiring harness and connection of b) Verify the wiring harness and connection of
CN1 on PCB16 (WK-4917) and CN2 on PCB3 CN1 on PCB16 (WK-4917) and CN2 on PCB3
(WK-5548). (WK-5548).
 Confirm a secure connection of the harness  Confirm a secure connection of the harness
between CN1 on PCB16 and CN2 on PCB3.

9–6
400MST 9 ADVANCED TROUBLESHOOTING
between CN1 on PCB16 and CN2 on PCB3. • Confirm a secure connection of the harness
• Contact the manufacturer if you find any bro- wired between CN8 and CN9 on PCB6 and
ken connectors or damaged wiring har- TH1 and TH2 and re-install the harnesses
nesses. with a secure connection.
c) Verify PCB4 (WK-4819) for burned or discol- • Contact the manufacturer if you find any bro-
ored components or printed circuit board. ken connectors or damaged wiring har-
nesses.
• Confirm that the PCB is securely fastened in
place. (No loose screws). b) Replace thermistors, TH1 and TH2.
• Refer to section 9.2.4.4 for the replacement • Refer to section 9.2.4.17 and 9.2.4.18 for the
of PCB4. replacement of TH1 and TH2.
c) Replace PCB6 (WK-5688).
1.2.10 E85 "Pre-Charge Error" • Refer to section 9.2.4.6 for the replacement
of PCB6.
Cause
Occurs, after you apply power, when a failure is 1.2.12 E99 "Initial Power Receiving"
detected during the preliminary charging of the
capacitors. Cause
Occurs when the initial AC power-received signal
Verification/Remedy has not reached the CPU.
a) Verify the AC input voltage and the Capacitor
NOTE
Bus Voltage on PCB2 (WK-5597).
This error occurs normally during the power "OFF"
• Follow the instruction in section 9.1.4.2. sequence of the unit.
b) Verify the input diode, D1.
• Refer to section 9.1.4.5 for the test and
replacement of D1. Verification/Remedy
c) Verify the IGBT, Q1-Q24. a) Verify the wiring harness and connection of
CN1 on PCB16 (WK-4917) and CN2 on PCB3
• Refer to section 9.1.4.7 for the test and
(WK-5548).
sections 9.2.4.7 and 9.2.4.8 for replacement of
Q1, Q2, ..., Q23, and Q24. • Confirm a secure connection of the harness
d) Replace PCB2 (WK-5597) and PCB4 (WK- wired between CN1 on PCB21 and CN2 on
4819). PCB3 and re-install the harness with a
secure connection.
• If the tests in the above sections (a, b, c) are
within expected results and the unit is still • Contact the manufacturer if you find any bro-
defective, replace PCB2 and PCB4. ken connectors or a damaged wiring harness.
• Refer to section 9.2.4.2 and 9.2.4.4 for the b) Verify and replace PCB4 (WK-4819).
replacement of PCB2 and PCB4. • During the installation of PCB4 and PCB3,
confirm that the PCB's are securely fastened
1.2.11 E94 "Thermistor Failure" in place. (No loose screws).
Cause • Refer to section 9.2.4.4 for the replacement
of PCB4.
Occurs when the thermistor for the temperature
c) Replace PCB6 (WK-5688).
detection circuitry is open.
• Refer to section 9.2.4.6 for the replacement
Verification/Remedy of PCB6.

a) Verify the wiring harness and connection

between CN8 and CN9 on PCB6 (WK-5688)
and thermistors TH1 and TH2.

9–7
 400MST 9 ADVANCED TROUBLESHOOTING
1.3 Verification and Remedy to 1.3.2 "Wire feeding failure or inconsis-
Failures without Indication tent wire delivery" (Wire feeder
Codes does not work)
Refer to Notes on Page 9-4. Cause
Power Source: Faulty or damaged 14-pin recepta-
1.3.1 "Cooling Fan Failure" cle and 19-pin receptacle, tripped or damaged
(Fan is not rotating) the circuit breaker (MCB1, MCB2), blown down-
transformer, associated wiring.
Cause
Wire Feeder: Feeder gear failure. Refer to the
Occurs when the cooling fan is defective, dam- wire feeder operator manual, supplied by the
aged or the driving voltage is incorrect. wire feeder manufacturer, for additional informa-
tion.
Verification/Remedy
a) Verify the cooling fan, FAN1. Verification/Remedy
• Inspect the condition of the fan blades and all a) Confirm wire setting.
peripheral parts. Clean the fan blades and all
b) Verify CON1 of 14-pin receptacle (CON2 of 19-
peripheral parts if covered with dust. Clean-
pin receptacle). * Applies to MIG mode.
ing and removing dust from the fan blades
once every 6 months in a normal environ- • Confirm the wiring harness and connections
ment is recommended. Extremely dusty envi- between CON1 of 14-pin receptacle (or
ronments will require more frequent cleanings. CON2 of 19-pin receptacle) and the wire
feeder device are secure.
• Verify that there are no wiring harnesses
entangled inside the fan, confirm that the har- • Confirm the wiring harness and connections
nesses do not have any brakes in the wire or between CON1 of 14-pin receptacle (or
damaged connectors. CON2 of 19-pin receptacle) and PCB17 (WK-
5699).
• Contact the manufacturer if you find any
broken connectors or damaged wiring harn- • Contact the manufacturer if you find any bro-
esses. ken connectors or damaged wiring harn-
esses.
• Replace the fan if there are any broken,
cracked or missing fan blades. • Confirm that the voltage between pin "I" and
pin "G" of the 14-pin CON1 receptacle is
• Refer to section 9.2.4.19 for replacement of
AC115V (AC100~125V).
FAN1.
• Confirm that the voltage between pin "E" and
b) Verify the wiring harness between the cooling
fan (FAN1) and CN11 on PCB3 (WK-5548). pin "F" of the 19-pin CON2 receptacle is
AC115V (AC100~125V).
• Confirm a secure connection of the harness
to CN11 on PCB3.
• Contact the manufacturer if you find any
broken connectors or damaged wiring harn-
esses.
c) Cooling fan voltage tests and replacement of
the cooling fan (FAN1).
• Follow the instruction in section 9.1.4.4.

9–8
400MST 9 ADVANCED TROUBLESHOOTING
• Confirm the pin-out numbers of the 14-pin 1.3.3 "No weld output"
receptacle (or 19-pin receptacle) located on
the wire feeder equipment. (Refer to section Cause
3.1.) Occurs when the 14-pin receptacle (19-pin recep-
• Confirm the wiring and connections on the tacle) or associated circuitry is defective, dam-
14-pin receptacle (or 19-pin receptacle) aged, or the TIG torch cable is defective and Wire
located on the wire feeder equipment. feeder Abnormality.
c) Verify the circuit breaker used for the wire
feeder equipment power supply, MCB1 and Verification/Remedy
MCB2.
CAUTION
• Confirm whether MCB1 or MCB2 has tripped
Read and understand this entire section before
or not. (When the MCB trips, the yellow knob
proceeding. Extreme personal harm and test
will be exposed.)
equipment damage will occur if the procedures are
NOTE not performed accurately.
If the circuit breaker of the wire feeder power sup-
a) Verify the 14-pin receptacle. * Applies to LIFT
ply has tripped, there are other possible failures TIG and MIG mode.
that must be considered. For example, the capacity
of the wire feeder equipment motor is large, or • Confirm a secure connection between CON1
there are some other problems in the wire feeder of the 14-pin receptacle and the wire feeder.
equipment. Before continuing onto the next sec- • Confirm a secure connection between CON1
tion, verify and eliminate the above possible failure of the 14-pin receptacle and the remote
conditions. Refer the operating manual supplied by device.
the wire feeder manufacture. • Confirm a secure connection of the harness
and the connections between CON1 and
• Press the yellow knob down AFTER the PCB17 (WK-5699) are all correct and there
faults in the wire feeder equipment are are no open circuit.
resolved. • Contact the manufacturer if you find any bro-
• If the wire feeder equipment still does not ken connectors or damaged wiring har-
operate, verify MCB1 and MCB2. Replace nesses.
them if necessary. • Confirm the proper pin-outs of the 14-pin
• Refer to section 9.2.4.27 for the replacement receptacle on the wire feeder side. (Refer to
of MCB1 and MCB2. section 3.1.)
d) Verify the transformer, T1, and replace it if nec- • Confirm the proper pins-outs of the 14-pin
essary. receptacle on the remote device side. (Refer
• Refer to section 9.2.4.29 for the replacement to section 3.1.)
of T1. • Confirm that the wire feeder has no open
e) Verify the wire feeder equipment, and replace circuit on the 14-pin receptacle at the remote
it if necessary. device side.
b) Verify the condition and connect the connec-
• Refer to the operating manual supplied by the
tions of the welding cable, the stick rod holders
wire feeder manufacture before any work is
and the base metal cables. * Applies to STICK
performed on the wire feeder.
and LIFT TIG mode.
• Confirm a secure connection of the welding
cable, stick rod holders, base metal cables
and dinse connectors and there are no open
circuits.
c) Verify the cables connected to the wire feeder
equipment including welding and base metal
cables. * Applies to MIG mode only.

9–9
 400MST 9 ADVANCED TROUBLESHOOTING
 Confirm the connections of the required  Confirm a secure connection of the harness
cables; control cable for the wire feeder and the connections between CN21 on PCB6
equipment, cable for welding, and a cable for and CN2 on PCB12.
the base metal are all secured.  Contact the manufacturer if you find any broken
 Confirm that there are no connection errors connectors or damaged wiring harnesses.
or broken wires of the required cables; con- b) Verify the connection between PCB5 (WK-
trol cable for the wire feeder equipment, cable 5696) and PCB6 (WK-5688).
for welding, and a cable for the base metal.
 Confirm that all three connectors between
d) Verify the no-load voltage (OCV). *Applies to PCB5 and PCB6 are tightly connected.
STICK and MIG mode.
 Confirm the condition of the pins on the con-
 Refer to section "Verification of No-Load volt- nectors and the connectors themselves. If
age (OCV)" in the section 9.1.4.8 first bent pins or damaged connectors are found,
before continuing this section. replace the suspected PCB.
 If performing the "No-Load Voltage Failure"  Refer to section 9.2.4.5 and 9.2.4.6 for the
procedure does not rectify the failure, per- replacement and installation of PCB5 and
form the following tests in the sequence PCB6.
below. Replace any defective components
c) Replacement of PCB6 (WK-5688) and PCB12
found.
(WK-5527).
1) Diode, D2, D3, D4 and D5. (Refer to the
 Refer to section 9.2.4.6 for the replacement
Section 9.1.4.6)
and installation of PCB6 and section 9.2.4.9
2) Reactor, FCH. Confirm the connection of for PCB12.
FCH and PCB14 (WK-5594). (Refer to the
Section Appendix 3)
1.4 Fault Isolation Tests
3) PCB8, PCB9, PCB10, PCB11 (WK-5479).
(Refer to the Section 9.2.4.7 and 9.2.48) 1.4.1 Preparation
4) Hall CT, HCT1. Confirm the connection of The following initial conditions must be met prior to
FCT1 and PCB6 (WK-5688). (Refer to the starting any of the procedures in this section
Section 9.2.4.22) (9.1.4).
e) Verify the wire feeder equipment, and replace 1) Connect the appropriate input voltage. (Check
it if necessary. the name plate on the rear of the power supply for
 Refer to the operating manual supplied by the the proper input voltage.)
wire feeder manufacture before any work is NOTE
performed on the wire feeder.
Operate at ALL input voltages as noted on the
nameplate on the rear panel when testing the
1.3.4 "Operating Panel Failure" (LED's power supply.
do not light properly or weld set-
tings cannot be established.) 2) Close primary power source wall disconnect
switch or circuit breaker.
Cause 3) Place power supply MAIN CIRCUIT SWITCH
(S1) on rear of unit in the ON position.
Occurs when there is a connection failure among
PCB3 (WK-5548), PCB6 (WK-5688) and PCB12
(WK-5527) or PCB3, PCB6 and PCB12 are defec- WARNING
tive. Dangerous voltage and power levels are present
inside this unit. Be sure the operator is equipped
Verification/Remedy with proper gloves, clothing and eye and ear pro-
a) Verify the PCB connection between CN21 on tection. Make sure no part of the operator's body
comes into contact with the workpiece or any inter-
PCB6 (WK-5688) and CN2 on PCB12 (WK-
nal components while the unit is activated.
5527).

9 – 10
400MST 9 ADVANCED TROUBLESHOOTING
1.4.2 Verification of the Power Input using a single-phase connection, the voltage
Circuitry can be verified only between U2 and V2.
1) Verify the AC input voltage using an AC volt- 4) If this voltage is out of the operating range,
meter which is ±10% (187~253/414~506 VAC) of the
Verify input voltage (Phase-to Phase) using an rated voltage (208, 230/460V), replace S1 fol-
AC voltmeter. (The capability of the voltmeter lowing the process in section 9.2.4.20.
should be more than 600VAC). Measure the 5) Verify the rectified output voltage of the input
point between lines U1 and V1 on the input diode, D1 using a DC voltmeter. (The capabil-
switch, S1. ity of the voltmeter should be more than
Measure the point between lines U1 and W1 1000VDC.)
on the input switch, S1. Measure the point Using a DC voltmeter, measure between the
between lines V1 and W1 on the input switch, points 1 (P) [+] and 2 (N) [-] on D1.
S1. Points 1 (P) and 2 (N) are on D1.
The location of points U1, V1 and W1 on switch See Figure 9-2.
S1 are indicated in Figure 9-1.
The measured voltage should be approxi-
When using a single-phase connection, the mately 1.4 times larger than input voltage mea-
voltage can be verified only between U1 and sured in #1 above. Replace diode D1 if the
V1. calculated measurement is not within the cor-
responding range (260~360/580~720VDC) fol-
lowing the process in section 9.2.4.23.
S1 U2
U1
V2
W2
V1
W1

0
Figure 9-1: Check points U1, U2, V1, V2, W1 and W2
D1 1
2) If the input voltage is out of the operating range 2
of the unit, which is ±10% (187~253/414~506
VAC) of the rated voltage (208, 230/460V),
verify the available power capacity at the
installed site. Figure 9-2: The check points 1 (P) and 2 (N)
If the input voltage is within the operating
6) Verify bus voltage (the voltage of the electro-
range, recheck the input voltage while welding,
lytic capacitor after rectification) using a DC
as welding may cause the input voltage to
voltmeter. (The capability of the DVM
decrease to a value below the operating range
should be more than 1000VDC.)
of the unit.
Using a DC voltmeter, measure between the
3) Verify input voltage after the input switch (S1)
output studs C and E on PCB8 (WK-5479),
using an AC voltmeter. (The capability of the
PCB9 (WK5479), PCB10 (WK-5479) and PCB11
voltmeter should be more than 600VAC.)
(WK5479).
• Using an AC voltmeter, measure between the
See Figure 9-2.
points U2 and V2 on the input switch, S1.
The measured voltage should be approxi-
• Using an AC voltmeter, measure between the
mately 1.4 times larger than the input voltage
points U2 and W2 on the input switch, S1.
measured in #1 above, except when running at
• Using an AC voltmeter, measure between the 460V where the bus voltage will be shared across
points V2 and W2 on the input switch, S1. all boards, ie, each board receiving 0.7 times the
The location of points U2, V2 and W2 on input voltage measured in step 1 above. Replace
switch S1 are indicated in Figure 9-1. When diode D1 if the

9 – 11
 400MST 9 ADVANCED TROUBLESHOOTING
calculated measurement is not within the cor-
responding range (260~360/580~720VDC) fol-
lowing the process in section 9.2.4.23.
PCB3
TB1(P)
CN18
TB4(N)
PCB2

PIN 1
Figure 9-3: The check points TB1(P) and TB4(N) PIN 3

7) After the replacement of D1, if the above volt-

age is still abnormal, replace PCB1 (WK-
5493).

1.4.3 Power Supply Voltage Test

Connect the power supply to a source of rated
input voltage. (Check the name plate on the rear of Figure 9-5: The check points PIN1-PIN3 of CN18 on
the power supply for the proper input voltage.) PCB3

Apply power to the unit and place the switch of the Test Point Reference
ACCEPTABLE
power supply to the ON position. (CN18 on PCB3; (CN18 on PCB3;
VALUE
WK-5548) WK-5548)
On the PCB6 (WK-5549) and PCB3 (WK-5548),
PIN1 PIN3 +24VDC
measure the voltages according to the following
table. The test point and the reference are obtain- If any of these voltages are not present or are
able on the parts side of PCB6 (WK-5549) and below a 10% tolerance, replace PCB3 (WK-5548).
PCB3 (WK-5548).
The location of points TP0-3 are indicated in Figure 1.4.4 Verification of the Cooling Fan,
9-4.
FAN1, Drive Circuitry
The location of points PIN1-PIN3 of CN18 on
Verify the condition of the cooling fan, FAN1, using
PCB3 are indicated in Figure 9-5.
a DC voltmeter. (The capability of the voltmeter
should be more than 50VDC.)
Using a DC voltmeter, measure between PIN 1[+]
TP3 and PIN 2[-] of CN11 on PCB3 (WK-5548).
TP0
The location of connector CN11 of PCB3 (WK-
PCB6 TP1
5548) is indicated in Figure 9-6.
TP2
NOTE
When you measure the above voltage, do not
remove the connector. Conduct the measurement
while the connector plug and receptacle are still
Figure 9-4: The check points TP0-3
connected.
Test Point Reference ACCEPTABLE
(PCB6;WK-5688) (PCB6;WK-5688) VALUE
TP1 TP0 +15VDC
TP2 TP0 +5VDC
TP3 TP0 –15VDC

9 – 12
400MST 9 ADVANCED TROUBLESHOOTING
NOTE
When verifying the voltage, confirm that the AC
input voltage remain within the operating range of
PCB3
the unit. (The AC input does not drop below
180VAC).
CN11

1.4.5 Verification of the primary Diode

(D1)
CAUTION
PIN1
PIN2
Before performing any portion of the procedure
below, make certain unit is placed in the initial set
up condition as described in section 9.1.4.1
"Preparation".

1. Verify the characteristic of the primary diode,

D1, using a diode tester.
2. Refer to Table 9-1 and Figure 9-7, 9-8 for the
Figure 9-6: The location of connector CN11 of PCB3 checkpoints on D1.
(WK-5548)
TERMINALS
Using the measurement taken above, follow the COMPONENT ACCEPTABLE
TESTED Positive Negative VALUE
chart below for possible failure modes. lead lead
Voltage 3, 4, 5 0 0.3 to 0.5V
Diode of D1
Fan measurement 0 3, 4, 5 Open
Remedy 3, 4, 5 2 Open
Status (PIN1-PIN2 of Diode of D1
CN11 on PCB3) 2 3, 4, 5 0.3 to 0.5V
Case1 Rotating DC 18~25V Fan drive circuit is normal. 0 1 Open
Thyristor of D1
1 0 Open
Replace PCB3 (WK-
Case2 Rotating Below DC 18V 5548). (Refer to section Table 9-1: Tester checkpoints in the primary diode (D1)
9.2.4.3)
Replace PCB3 (WK-
5548). (Refer to section
9.2.4.3)
↓
Case3 Inactive Below DC 18V
Conduct the
"Verification of the
power input circuitry" in
section 9.1.4.2.
Replace FAN1. (Refer
Case4 Inactive DC 18~25V
to section 9.2.4.19)

NOTE
This welding unit has a feature that will slow the
rotational speed of the cooling fan during low out-
put current and while in standby. Under these con-
ditions, the voltages in the above table will be
inaccurate; therefore, when verifying the voltage,
do so during the failure condition.

9 – 13
 400MST 9 ADVANCED TROUBLESHOOTING
1. Verify the characteristic of the secondary
diode, D2, D3, D4, and D5 using a
diode tester.
2. Refer to Table 9-2 and Figure 11 for the
checkpoints on D2, D3, D4, and D5.

TERMINALS
COMPONENT ACCEPTABLE
D1 TESTED Positive Negative VALUE
lead lead
Diode 1 of D2, D3, Anode Cathode 0.2 to 0.3V
D4, D5 Cathode Anode Open
Diode 2 of D2, D3, Anode Cathode 0.2 to 0.3V
3 4 5 67 D4, D5 Cathode Anode Open
Table 9-2: Tester checkpoints in the secondary diode
(D2, D3, D4, D5)

D5

Anode Anode
D4
D3
2 1 0
D2 Cathode Cathode

Figure 9-7: Tester checkpoints in the primary diode (D1)

0 6 7

Figure 9-9: Tester checkpoints in the secondary diode

1 (D2-7)

1.4.7 Verification of the primary IGBT

5
(Q1-24)
4
3 CAUTION
Before performing any portion of the procedure
2
below, make certain the unit is placed in the initial
Figure 9-8: The primary diode (D1) interconnection set up condition as described in section 9.1.4.1
diagrams "Preparation".

1. Check whether there are any abnormalities on

1.4.6 Verification of the secondary the appearance of PCB8 and PCB9.
Diode (D2-5) 2. Verify the characteristic of the primary IGBT
CAUTION (Q1-24), using a diode tester.
Before performing any portion of the procedure 3. Refer to Table 9-3 and Figure 9-10 for the
below, make certain the unit is placed in the initial checkpoints on PCB8 and PCB9.
set up condition as described in section 9.1.4.1
"Preparation".

9 – 14
400MST 9 ADVANCED TROUBLESHOOTING
1.4.8 Verification of No-load Voltage
TERMINALS
COMPONENT ACCEPTABLE (OCV)
TESTED Positive Negative VALUE
lead lead a) Verify the no-load voltage in STICK mode.
Collector-Emitter 1) STICK welding mode, mark and then turn
C CE Open
of Q1-24 with
CE C 0.2 to 0.5V
potentiometer VR1 on PCB6 (WK-5688)
PCB8 and PCB9 fully counter clockwise to turn off the
Collector-Emitter electric shock protector function (Voltage-
CE E Open
of Q1-24 with Reduction-Device, VRD).
E CE 0.2 to 0.5V
PCB8 and PCB9
2) Contactor function is put into the state of
Table 9-3: Tester checkpoints in the primary IGBT "ON" by pushing the Function button.

CAUTION
Electric shock hazard. The unit will generate OCV
immediately when contactor function is put into the
PCB10 PCB11 state of “ ON” pushing Function button enabling
STICK mode.
C CE E
3) Verify the no-load voltage using a DC volt-
meter. (The capability of the voltmeter
should be more than 100VDC.)
TRO_0031
4) The normal no-load voltage is approxi-
mately 65V.
b) Verify the no-load voltage in MIG mode.
1) Confirm a secure connection between
CON1 of the 14-pin receptacle (or CON2
of the 19-pin receptacle) and the remote
PCB8 PCB9 device.
2) Confirm a secure connection of the har-
C CE E ness and the connections between CON1
(or CON2) and PCB17 (WK-5699) are all
correct and there are no open circuits.
3) Contact the manufacturer if you find any
broken connectors or damaged wiring har-
nesses.
4) Contactor function is put into the state of
Figure 9-10: Tester checkpoints in the primary IGBT
(Q1-24) on pushing Function button.

CAUTION
Electric shock hazard. The unit will generate OCV
immediately when contactor function is put into the
state of “ON” pushing Function button enabling MIG
mode.

5) The normal no-load voltage is approxi-

mately 65V.
6) Return potentiometer VR1 to the original
position.

9 – 15
THIS PAGE LEFT INTENTIONALLY BLANK
400MST 9 ADVANCED TROUBLESHOOTING
2 Subsystem Test and Replacement Procedures
2.1 Preparation
This section provides specific procedures for verifying the operation and replacement of each subsystem
within the power supply.
Before undertaking any of these procedures, eliminate the obvious first-visually inspect the suspect sub-
system for physical damage, overheating, and loose connections.

2.2 Test and Replacement Parts List

9
3

2
4
5

6
1
7
8

No. DWG No. Parts name Reference page Part No.

1 PCB2 Print Circuit Board (WK-5597) 9-23 W7001313
2 PCB3 Print Circuit Board (WK-5548) 9-24 W7001314
3 PCB4 Print Circuit Board (WK-4819) 9-26 10-6635
4 PCB5 Print Circuit Board (WK-5696) 9-26 W7001315
5 PCB7 Print Circuit Board (WK-5689) 9-24 W7001317
6 PCB12 Print Circuit Board (WK-5527) 9-28 W7001319
7 PCB13 Print Circuit Board (WK-5528) 9-29 W7001320
8 PCB14 Print Circuit Board (WK-5594) 9-30 W7001321
9 PCB16 Print Circuit Board (WK-4917) 9-32 10-6740

9 – 17
 400MST 9 ADVANCED TROUBLESHOOTING

2
6

4
1
3

No. DWG No. Parts name Reference page Part No.

1 PCB1 Print Circuit Board (WK-5493) 9-22 W7001312
2 PCB6 Print Circuit Board (WK-5688) 9-27 W7001742
3 PCB8 (Q1-Q6) Print Circuit Board (WK-5479) 9-27 W7001318
4 PCB9 (Q7-Q12) Print Circuit Board (WK-5479) 9-27 W7001318
5 PCB10 (Q13-Q18) Print Circuit Board (WK-5479) 9-28 W7001318
6 PCB11 (Q19-Q24) Print Circuit Board (WK-5479) 9-28 W7001318
7 PCB15 Print Circuit Board (WK-5606) 9-31 W7001322
8 PCB17 Print Circuit Board (WK-5699) 9-33 W7001323
9 PCB18 Print Circuit Board (WK-5499) 9-33 W7001324

9 – 18
400MST 9 ADVANCED TROUBLESHOOTING

10
11

12
9
8
3

6
1
4
5

13

No. DWG No. Parts name Reference page Part No.

1 CON1 14-PIN Receptacle 9-47 W7001302
2 CON2 19-PIN Receptacle 9-48 W7001303
3 D1 Diode 9-39 10-6769
4 D2 Diode 9-40 10-6629
5 D4 Diode 9-40 10-6629
6 D5 Diode 9-40 10-6629
8 MCB1 Circuit Breaker 9-42 W7001310
9 MCB2 Circuit Breaker 9-42 10-2235
10 S1 Switch 9-37 10-6857
11 S2 Switch 9-38 10-5222
12 S3 Switch 9-38 10-5222
13 T1 Transformer 9-44 W7001326

9 – 19
 400MST 9 ADVANCED TROUBLESHOOTING

6
7
2
8

9
5 10

No. DWG No. Parts name Reference page Part No.

1 CT2 Current Trans 9-41 W7001304
2 CT3 Current Trans 9-41 W7001304
3 FAN1 Cooling Fan 9-36 W7001307
4 FCH1 Inductor 9-34 W7001308
5 HCT1 Current Sensor 9-39 10-5003
6 L1 Reactor 9-41 W7001309
7 R2 Resistor 9-43 W7001325
8 R3 Resistor 9-43 W7001325
9 TH1 Thermistor 9-35 10-5228
10 TH2 Thermistor 9-36 10-5228

9 – 20
400MST 9 ADVANCED TROUBLESHOOTING
2.3 Service Tools
2.3.1 Tools and parts
The tools and parts to be used for maintenance are shown by icons.

Spanner Philips Head Long Nose C-Ring Pliers Silicon

Snap Band
Screwdriver Pliers Compound
(5.5, 8, 10, 17mm)

2.3.2 Notes of disassembly and assembly

NOTE
When removing the locking type connectors and board supporters, disengage the locking mechanism first
and then disconnect them.
Locking type connectors and board supporters are indicated in this manual using the following symbols;
black star marks for locking connectors and white star marks for locking board supports.

NOTE
During your maintenance or repair, please cut any tie-wraps necessary. However, after your maintenance or
repair, please reassemble and tie-wrap all components and wiring in the same manner as before the mainte-
nance or repair.

CAUTION
Please note that you remove each connector, grasp and pull out by the connector part only. Do not pull the
harness (cable) part.

WARNING
The capacitors inside the power supply will slowly discharged after you turn off the switch of the power sup-
ply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete.

9 – 21
 400MST 9 ADVANCED TROUBLESHOOTING
2.4 Replacement Procedure
2.4.1 PCB1 (WK-5493) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB2 (WK-5597). [Reference page: 9-23]
3) Remove the diode (D1). [Reference page: 9-39]
4) Remove the current transformers (CT2 and CT3). [Reference page: 9-41]
5) Remove two screws and three terminals from PCB1 (WK-5493).

6) Remove the reactor (L1). [Reference page: 9-41]

7) Disconnect one connector and remove four terminals.

purple Blue
orange brown

8) Remove 18 screws and remove PCB1 (WK-5493).

9 – 22
400MST 9 ADVANCED TROUBLESHOOTING
2.4.2 PCB2 (WK-5597) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB6 (WK-5688). [Reference page: 9-27]
3) Remove one screw and three ground terminals. Disconnect 13 connectors.
CN22 CN10 CN4
CN23

2
CN11 CN7 CN3
CN2
2
CN1

CN21 CN9
CN20 CN11

4) Loosen two screws. Rotate the resistors (R2 and R3) to expose two screws on PCB3 (WK-5548).

5) Disconnect five connectors.

CN1
2 CN15
CN16
CN2

1
CN13

9 – 23
 400MST 9 ADVANCED TROUBLESHOOTING
6) Remove five screws, three terminals, and five connectors from PCB2 (WK-5597).

CN1

CN4

CN5

CN2
CN3

7) Cut off one snap band. Remove two board supports and then remove PCB2 (WK-5597) and the insulat-
ing sheet.

2.4.3 PCB3 (WK-5548), PCB7 (WK-5689) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB4 (WK-4819). [Reference page: 9-26]
3) Remove PCB6 (WK-5688). [Reference page: 9-27]
4) Remove PCB5 (WK-5696). [Reference page: 9-26]
5) Disconnect 11 connectors from PCB3 (WK-5548).

CN9 CN21
CN20

CN23
CN11 CN7 CN22

CN8

CN1

CN2
CN3

9 – 24
400MST 9 ADVANCED TROUBLESHOOTING
6) Loosen two screws. Rotate the resistors (R2 and R3) to expose two screws on PCB3 (WK-5548).

7) Remove one screw and three ground terminals. Remove four screws and remove PCB3 and PCB7. Dis-
connect five connectors from PCB7 (WK-5689).

1
2

CN13

CN1 CN16
CN2 CN15
3

8) Disconnect one connector and remove two screws and then remove PCB7 (WK-5689) from PCB3 (WK-
5548). Remove one screw and one ground terminal from PCB7 (WK-5689).

CN20

9 – 25
 400MST 9 ADVANCED TROUBLESHOOTING
9) Disconnect two connectors from PCB3 (WK-5548).

CN18

CN33

2.4.4 PCB4 (WK-4819) 

1) Remove the side cover. [Reference page: 9-1]
2) Disconnect three connectors. Remove two screws and disconnect three connectors, and then remove
PCB4 (WK-4819).

CN10
CN7 1

CN4
CN5

CN4 CN6

2.4.5 PCB5 (WK-5696) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB6 (WK-5688). [Reference page: 9-27]
3) Remove two screws and disconnect three connectors. Remove PCB5 (WK-5696).

CN30
CN31
CN32

9 – 26
400MST 9 ADVANCED TROUBLESHOOTING
2.4.6 PCB6 (WK-5688) 
1) Remove the side cover. [Reference page: 9-1]
2) Disconnect five connectors.

CN1

CN21 CN9
CN8

CN20

3) Remove three screws and disconnect six connectors, and then remove PCB6 (WK-5688).

CN3
CN27
CN18

CN30
CN31
CN32

2.4.7 PCB8 (WK-5479) and PCB9 (WK-5479) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove eight screws and four component clips. Disconnect four connectors and remove six screws,
and then remove PCB8 (WK-5479) and PCB9 (WK-5479).
 When reinstalling, remember to install new silicon rubber sheets.
CN1
CN2 2
2 CN1
CN2

Silicone Rubber Sheet

9 – 27
 400MST 9 ADVANCED TROUBLESHOOTING
2.4.8 PCB10 (WK-5479), PCB11 (WK-5479) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove eight screws and four component clips. Disconnect four connectors and remove six screws,
and then remove PCB10 (WK-5479) and PCB11 (WK-5479).
 When reinstalling, remember to install new silicon rubber sheets.

CN1 CN2 CN1

2 CN2
1

3 Silicone Rubber Sheet

2.4.9 PCB12 (WK-5527) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB13 (WK-5528). [Reference page: 9-29]
3) Release three hooks and remove PCB12 (WK-5527).

2 1

 Engage two hooks before reinstalling the unit.

9 – 28
400MST 9 ADVANCED TROUBLESHOOTING
2.4.10 PCB13 (WK-5528) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove the operation cover.

2
2

3) Remove the jog dial cap. Loosen the screw while pressing the jog dial and then remove the jog dial.

1mm

1
3

4) Disconnect one connector from PCB12 (WK-5527). Remove four screws and pull out the operation
panel and tilt it.

3 1
3
CN1

4
3
3

9 – 29
 400MST 9 ADVANCED TROUBLESHOOTING
5) Disconnect one connector and remove two screws, and then remove PCB13 (WK-5528).

3 CN1

2.4.11 PCB14 (WK-5594) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB17 (WK-5699). [Reference page: 9-33]
3) Remove the inductor (FCH1). [Reference page: 9-34]
4) Remove two screws from the front side and detach the bus bar.

5) Remove four screws and open the rear cabinet.

2
1

2 1

9 – 30
400MST 9 ADVANCED TROUBLESHOOTING
6) Remove two screws from PCB1 (WK-5477) and disconnect three terminals. Cut off two snap bands and
slide the insulating tube. Remove two screws, two nuts, and four terminals.

1 3

7) Remove four screws from the bottom and disconnect one terminal. Remove two screws from the rear
side and remove PCB14 (WK-5594) by pulling it out. Remove four screws and detach the bus bar.

1
2

2.4.12 PCB15 (WK-5606) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB17 (WK-5699). [Reference page: 9-33]
3) Remove the sheet and remove eight screws. Remove two board supports and remove PCB15 (WK-
5606).

3
1

3 2

9 – 31
 400MST 9 ADVANCED TROUBLESHOOTING
2.4.13 PCB16 (WK-4917) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove six screws from the switch (S1) and disconnect six terminals.

2 1

3) Remove four screws and open the rear board.

1
1

1
1

4) Disconnect the one connector. Remove the two screws and one ground terminal. Remove the PCB16
(WK-4917).

3
2

1
CN1

9 – 32
400MST 9 ADVANCED TROUBLESHOOTING
5) Remove the three screws and the bus bar from the PCB16 (WK-4917).

2.4.14 PCB17 (WK-5699) 

1) Remove the side cover. [Reference page: 9-1]
2) Disconnect 11 connectors and remove one terminal. Remove four screws and remove PCB17 (WK-
5699).

CN10
CN6
CN9
CN7
CN3
CN4
CN15
CN2
CN1
CN5
CN8

2.4.15 PCB18 (WK-5499) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB17 (WK-5699). [Reference page: 9-33]
3) Remove one screw and one terminal. Remove one bolt, one toothed washer, one washer, and one ter-
minal. Disconnect one connector. Remove one screw and one nut and detach the bus bar.

2
2

CN1
3 2 1

9 – 33
 400MST 9 ADVANCED TROUBLESHOOTING
4) Disconnect two connectors. Remove four board supports and remove PCB18 (WK-5499).

1 CN1

2.4.16 Inductor (FCH1) 

1) Remove the side cover. [Reference page: 9-1]
2) Disconnect one connector. Remove one screw and three ground terminals.

1
2

CN21

3) Remove two bolts and three terminals. Remove four screws and open the front cabinet.

2
1
2
3

9 – 34
400MST 9 ADVANCED TROUBLESHOOTING
4) Remove one screw, one terminal and one nut.

5) Remove four screws and remove the inductor (FCH1).

2.4.17 Thermistor (TH1)

1) Remove the side cover. [Reference page: 9-1]
2) Cut off one snap band and disconnect one connector. Remove one screw and remove the thermistor (TH1).

2
CN8

 When replacing the thermistor with a new one, apply an oil compound (SHINETSU SILICONE G-747
or equivalent) evenly to the base.

9 – 35
 400MST 9 ADVANCED TROUBLESHOOTING
2.4.18 Thermistor (TH2)
1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB17 (WK-5699).
3) Cut off three snap bands and disconnect one connector. Remove one screw and remove the thermistor (TH2).
 When replacing the thermistor with a new one, apply an oil compound (SHINETSU SILICONE G-747
or equivalent) evenly to the base.

1 CN9

1
3

2.4.19 Fan (FAN1) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove four screws and open the rear cabinet.

2
1

2 1

3) Cut off one snap band and disconnect one connector.

CN11

9 – 36
400MST 9 ADVANCED TROUBLESHOOTING
4) Remove two screws and remove the fan (FAN1).
 Pay attention to the installation direction of the fan.

ROTATION
AIR FLOW

2.4.20 Switch (S1) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove six screws and six terminals.

2 1

3) Remove two screws and remove the switch (S1). Remove three posts.

9 – 37
 400MST 9 ADVANCED TROUBLESHOOTING
2.4.21 Switch (S2 and S3) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove six screws and six terminals.

2 1

3) Remove four screws and open the rear panel.

1
1

1
1

4) Cut off one snap band and disconnect one connector from PCB4 (WK-4819). Remove two screws and
two nuts and remove the switch (S2). Disconnect one connector from the switch (S3). Remove two nuts
and remove the switch (S3).

4
1

CN4 3

9 – 38
400MST 9 ADVANCED TROUBLESHOOTING
2.4.22 Current Sensor (HCT1) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB17 (WK-5699). [Reference page: 9-33]
3) Remove one screw and one terminal. Remove one bolt and one terminal. Disconnect one connector.
Remove one screw and one nut and detach the bus bar.

2
2

CN1
3 2 1

4) Remove one screw and remove the current sensor (HCT1).

2.4.23 Diode (D1) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB3 (WK-5548). [Reference page: 9-24]
3) Remove six screws and 13 terminals. Remove two screws and remove the diode (D1).
 When replacing the diode with a new one, apply an oil compound (SHINETSU SILICONE G-747 or
equivalent) evenly to the base.

9 – 39
 400MST 9 ADVANCED TROUBLESHOOTING
2.4.24 Diode (D2, D3, D4, and D5) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB17 (WK-5699). [Reference page: 9-33]
3) Remove PCB15 (WK-5606). [Reference page: 9-31]
4) Remove one screw and one nut. Remove 20 screws and one terminal and detach the bus bar.

4 2

1 2

5) Remove eight screws and remove the diodes (D2, D3, D4, and D5).
 When replacing the diode with a new one, apply an oil compound (SHINETSU SILICONE G-747 or
equivalent) evenly to the base.
 Pay attention to the installation direction of the diode.

D5

D4

D3

D2

9 – 40
400MST 9 ADVANCED TROUBLESHOOTING
2.4.25 Current Transformer (CT2 and CT3) 
1) Remove the side cover. [Reference page: 9-1]
2) Remove PCB6 (WK-5688). [Reference page: 9-27]
3) Remove four screws and open the rear cabinet.

2
1

2 1

4) Cut off one snap band and disconnect one connector from PCB3 (WK-5548). Remove two screws and
two terminals from PCB1 (WK-5493). Cut off two snap bands and remove the current transformers (CT2
and CT3).

5 5 3
3

1 2
CN7

2.4.26 Reactor (L1) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove four screws and open the rear cabinet.

2
1

2 1

9 – 41
 400MST 9 ADVANCED TROUBLESHOOTING
3) Remove two screws and two terminals. Cut off one snap band and remove the reactor (L1).

1
3

2.4.27 Molded Case Circuit Breaker (MCB1 and MCB2) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove six screws and six terminals.

2 1

3) Remove four screws and open the rear panel.

1
1

1
1

9 – 42
400MST 9 ADVANCED TROUBLESHOOTING
4) Remove four terminals. Remove two nuts and remove the molded case circuit breakers (MCB1 and
MCB2).
purple Blue
orange brown

1 1 1 1

3
3

2 2

2.4.28 Resistor (R2 and R3) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove the switch (S1). [Reference page: 9-37]
3) Remove four screws and four terminals.

4) Remove two screws and the resistors (R2 and R3).

9 – 43
 400MST 9 ADVANCED TROUBLESHOOTING
2.4.29 Transformer (T1) 
1) Remove the side cover. [Reference page: 9-1]
2) Cut off one snap band and disconnect one connector. Remove one screw and three ground terminals.
Cut off two snap bands.

4
3

CN1

1 2

3) Cut the tap wires on the primary side of the transformer (T1), which are connected with the insulated ter-
minal.
 Incorrect wiring of each tap wire when reinstalling the transformer may damage the welding machine.
Check the electrical schematic diagram before connecting the tap wires.

9 – 44
400MST 9 ADVANCED TROUBLESHOOTING
4) Remove four screws and open the rear cabinet.

2
1

2 1

5) Cut off three snap bands.

 When reinstalling the transformer, secure the harnesses to the holders using snap bands.

6) Cut off one snap band. Cut off one snap band that ties together the harness of CN7 on PCB17 (WK-
5699) and the harness wired to the rear side. Cut off one snap band that ties together the harness on the
secondary side of the transformer (T1) and the harnesses of CN7/CN1 on PCB17 (WK-5699).

CN7

1
2

CN1

9 – 45
 400MST 9 ADVANCED TROUBLESHOOTING
7) Remove four terminals.

purple Blue
orange brown

8) Remove four screws and remove the transformer (T1).

9 – 46
400MST 9 ADVANCED TROUBLESHOOTING
2.4.30 14-Pin Receptacle (CON1) 
1) Remove the side cover. [Reference page: 9-1]
2) Disconnect three connectors. Remove one screw and three ground terminals. Cut off two snap bands.

CN10

1
3 CN9

2
1

CN8

3) Remove two bolts and three terminals. Remove four terminals and open the front cabinet.

2
1
2

3
2

4) Cut off five snap bands.

 When reinstalling the receptacle, bend both the harnesses of CN6/CN7/CN9/CN10 on PCB17 (WK-
5699) and the ones of N-pin/L-pin of 19-pin receptacle (CON2), and then use snap bands to tie
together the bent harnesses and the ones of CN1/CN5/CN8 on PCB17 (WK-5699).

CN7

CN10

CN6
CN9

CN1
CN5
CN8

9 – 47
 400MST 9 ADVANCED TROUBLESHOOTING
5) Remove two screws. Remove the cap and remove the 14-pin receptacle (CON1).

2.4.31 19-Pin Receptacle (CON2) 

1) Remove the side cover. [Reference page: 9-1]
2) Remove four screws and open the rear cabinet.

2
1

2 1

3) Cut off three snap bands.

 When reinstalling the receptacle, secure the harnesses to the holders using snap bands.

9 – 48
400MST 9 ADVANCED TROUBLESHOOTING
4) Cut off one snap band. Cut off one snap band that ties together the harness of CN7 on PCB17 (WK-
5699) and the harness wired to the rear side. Cut off one snap band that ties together the harness on the
secondary side of the transformer (T1) and the harness of CN7/CN1 on PCB17 (WK-5699).

CN7

1
2

CN1

5) Remove five snap bands.

 When reinstalling the receptacle, bend both the harnesses of CN6/CN7/CN9/CN10 on PCB17 (WK-
5699) and the ones of N-pin/L-pin of the 19-pin receptacle (CON2), and then use snap bands to tie
together the bent harnesses and the ones of CN1/CN5/CN8 on PCB17 (WK-5699).

CN7

CN10

CN6
CN9

CN1
CN5
CN8

9 – 49
 400MST 9 ADVANCED TROUBLESHOOTING
6) Disconnect three connectors. Remove one screw and three ground terminals. Cut off two snap bands.

1
CN7

CN6

3 1

1 CN5

7) Cut the harnesses of N-pin/L-pin of the 19-pin receptacle (CON2), which are connected with the insu-
lated terminals.

N L

8) Remove two screws. Remove the cap and remove the 19-pin receptacle (CON2).

9 – 50
 APPENDIX 1 PARTS LIST
1 Equipment Identification
All identification numbers as described in the Introduction chapter must be furnished when ordering parts or
making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to
include any dash numbers following the Part or Assembly numbers.

2 How To Use This Parts List

The Parts List is a combination of an illustration and a corresponding list of parts which contains a break-
down of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed
except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc., and per-
manently attached items which are soldered, riveted, or welded to other parts. The part descriptions may be
indented to show part relationships. To determine the part number, description, quantity, or application of an
item, simply locate the item in question from the illustration and refer to that item number in the correspond-
ing Parts List.
PART NUMBERS: ARC MASTER 400MST 10-3072

No. DWG No. Part No. Description Additional Information QTY.

1 CON1 W7001302 Socket, Remote, gen 3.1, IPS MS3102A20-27S (NIC) 14P (with Wiring 1
Assembly)
2 CON2 W7001303 Socket, Remote, gen 3.1, IPS MS3102A22-14S (NIC) 19P (with Wiring 1
Assembly)
3 CT1-2 W7001304 Transformer, gen 3.1, IPS F2A503001 CT 1:40 2
4 D1 10-6769 Diode, gen 3.1, IPS DFA100BA160 1
5 D2-5 10-6629 Diode, gen 3.1, IPS DBA200UA60 4
6 FAN1 W7001307 Fan, gen 3.1, IPS 109E5724H507 DC 24V 16.8W 1
7 FCH1 W7001308 Inductor, gen 3.1, IPS F3A207601 400A MIG FCH 1
8 HCT1 10-5003 Sensor, Current, gen 3.1, IPS HC-TN200V4B15M 200A 4V 1
9 L1 W7001309 Reactor, gen 3.1, IPS GP-7 1
10 MCB1 W7001310 Circuit Breaker, gen 3.1, IPS TBC5071-01-0820 1P 125V 2.5AT 1
11 MCB2 10-2235 Circuit Breaker, gen 3.1, IPS TBC5071-20-1420 1P 125V 10AT 1
12 PCB1 W7001312 PCB, gen 3.1, IPS WK-5493 U01 MAIN PCB 1
13 PCB2 W7001313 PCB, gen 3.1, IPS WK-5597 U01 LINK PCB 1
14 PCB3 W7001314 PCB, gen 3.1, IPS WK-5548 U01 DDC PCB 1
15 PCB4 10-6635 PCB, gen 3.1, IPS WK-4819 U01 DETECT PCB 1
16 PCB5 W7001315 PCB, gen 3.1, IPS WK-5696 U01 CONECT PCB 1
17 PCB6 W7001742 PCB, gen 3.1, IPS WK-5688 U03-2 MIG CTRL PCB 1
18 PCB7 W7001317 PCB, gen 3.1, IPS WK-5689 U01 FILTER PCB 1
19 PCB8-11 W7001318 PCB, gen 3.1, IPS WK-5479 U01 GATE PCB (with 4
20 PCB12 W7001319 PCB, gen 3.1, IPS WK-5527 U05 PANEL PCB 1
21 PCB13 W7001320 PCB, gen 3.1, IPS WK-5528 U01 ENCODER PCB 1
22 PCB14 W7001321 PCB, gen 3.1, IPS WK-5594 U01 TRANS PCB 1
23 PCB15 W7001322 PCB, gen 3.1, IPS WK-5606 U01 DIODE SNUBBER PCB 1
24 PCB16 10-6740 PCB, gen 3.1, IPS WK-4917 U04 INPUT FILTER PCB 1
25 PCB17 W7001323 PCB, gen 3.1, IPS WK-5699 U01 14/19 CONNECT PCB 1
26 PCB18 W7001324 PCB, gen 3.1, IPS WK-5499 U01 FILTER PCB 1
27 R2-3 W7001325 Resistor, gen 3.1, IPS MHS20A151JI 20W 150OHM 2
28 S1 10-6857 Switch, gen 3.1, IPS DCP-103SR100C-480V 3P-480V 1
29 S2 10-5222 Switch, gen 3.1, IPS SDKGA4-A-1-A 1
30 S3 10-5222 Switch, gen 3.1, IPS SDKGA4-A-1-A 1
31 T1 W7001326 Transformer, gen 3.1, IPS F3A216701 1
32 TH1, 2 10-5228 Thermistor, gen 3.1, IPS ERTA53D203 20kΩ/25°C B=3950K 2
1
No. DWG No. Part No. Description Additional Information QTY.
33 W7001328 Panel, Front, gen 3.1, IPS E0D006301 1
34 W7001329 Panel, Rear, gen 3.1, IPS E0D004901 1
35 W7001330 Label, Side, gen 3.1, IPS E0D005207 2
36 W7001331 Case, Front, gen 3.1, IPS E0C346000 1
37 W7001332 Board, Front, gen 3.1, IPS JEA496001 1
38 W7001333 Cover, Rear, gen 3.1, IPS JDA788900 1
39 W7001334 Cover, Protector, gen 3.1, IPS E0C299200 1
40 10-6791 Cover, Encoder, gen 3.1, IPS EBA514400 1
41 W7001336 Cover, PCB, gen 3.1, IPS E1B537600 (with Dustcover Sheet) 1
42 W7001718 Label, Name, gen 3.1, IPS N4A831400 (400MST) 1
43 W7001338 Label, Side, gen 3.1, IPS N4A785200 2
44 W7001339 Label, 1 Warning, gen 3.1, IPS N1B029700 1
45 W7001340 Label, 2 Warning, gen 3.1, IPS N1B029800 1
46 W7001341 Label, Output Terminal, gen 3.1, N4A178600 1
47 W7001342 Label, Switch, gen 3.1, IPS N4A146500 1
48 W7001343 Label, 14/19 Switch, gen 3.1, IPS N4A311800 1
49 W7001344 Label, MCB, gen 3.1, IPS N4A144200 1
50 W7001345 Label, VRD, gen 3.1, IPS N4A919100 1
51 W7001511 Label, VRD, gen 3.1, IPS N4A598700 1
52 10-6660 Terminal, Output, F, gen 3.1, IPS TRAK-BE35-70S 2
53 N/A Cable, Input, gen 3.1, IPS SOOW AWG8X4C L=3.4m 1
54 10-6795 Clamp, Input, gen 3.1, IPS EBA156800 1
55 W7001349 Heatsink, gen 3.1, IPS E1B895000 2
56 W7001350 Heatsink, gen 3.1, IPS E1B870100 1
57 W7001351 Spring Clip,IGBT, gen 3.1, IPS E1B850100 8
58 W7001352 Chassis, PCB1, gen 3.1, IPS J5B017500 1
59 W7001353 Chassis, gen 3.1, IPS J3C356600 1
60 10-6665 Knob, gen 3.1, IPS 2621603 1
61 10-6666 Knob Cap, gen 3.1, IPS 3021104 1
62 W7001356 Cover, Protector, gen 3.1, IPS N1B039200 1
63 W7001357 Sheet, Rubber, gen 3.1, IPS EDA227700 4
64 W7001358 Post, 1(M5), gen 3.1, IPS EBA643600 (M5-M5) 3
65 W7001359 Bus Bar, D, gen 3.1, IPS EDA761400 1
66 W7001360 Bus Bar, T-D, gen 3.1, IPS EDA003800 4
67 W7001361 Bus Bar, 1 D, gen 3.1, IPS EDA046900 1
68 W7001362 Bus Bar, 2 D, gen 3.1, IPS EDA047000 1
69 W7001363 Bus Bar, 3 D, gen 3.1, IPS EDA047100 1
70 W7001364 Bus Bar, 4 D, gen 3.1, IPS EDA047200 1
71 10-6868 Bus Bar, S1, gen 3.1, IPS ECA321000 3
72 W7001366 Bus Bar, Output, gen 3.1, IPS EDA761300 1
73 W7001367 Bus Bar, T-CC, gen 3.1, IPS EDA047300 1
74 W7001368 Post, Output, gen 3.1, IPS ECA867900 2
75 W7001369 Insulated Board, gen 3.1, IPS E1B872000 2
76 W7001370 Insulation Sheet, gen 3.1, IPS E1B859700 1
77 W7001371 Insulation Sheet, gen 3.1, IPS EDA079800 1
78 W7001372 Cover, Protector, gen 3.1, IPS E1B933900 1
79 W7001373 Cover, Protector, gen 3.1, IPS E1B933100 1
80 W7001374 Clip, gen 3.1, IPS #74 NATURAL 4
81 W7001375 Cover, CON1, gen 3.1, IPS 1070500-20 (with String) 1
82 10-6874 Cover, CON2, gen 3.1, IPS 97121-422R (with String) 1
83 W7001377 Edge Protect, gen 3.1, IPS EH18U 2
84 10-2020 Plug, Output, gen 3.1, IPS TRAK-SK50 1
85 300X4866 Operating Manual, gen 3.1, IPS Operating Manual 1

2
400MST PARTS LIST

47 49
38

44 48
29

43 41
28
10
11
64 24 30
35 71
64 71
80
54
34 53

21
20 40 37
36
62

6
60
61 42 50

51
39

35

42

33

81 45
74
43
74
82 52 2

52
46

3
 400MST PARTS LIST

17
3 9
4 83

83
15
3
16

14
12
18

76

13 57
58
57 19
55

19 55
27 63
77

63 19

59 32

75

19 57
22
57
27
56

7
73 75
5
5 66
5
26
66
59

78 67
68
69
31 32 70

65
72
79
8
23
83 25

4
APPENDIX 2 CONNECTION WIRING GUIDE
CONNECTION WIRING GUIDE
APPENDIX 2 Connection Wiring Guide

Destination Destination Destination

A PCB2 CN1 ↔ PCB4 CN7 PCB10 CN1 PCB17 CN1 ↔ T1 0V
J PCB3 CN23 ↔
B PCB2 CN2 ↔ PCB3 CN3 PCB11 CN2 T MCB1
C PCB2 CN3 ↔ D1 K PCB3 CN18 ↔ PCB7 CN20 MCB2
D PCB2 CN4 ↔ PCB4 CN10 L PCB3 CN33 ↔ PCB6 CN20 PCB17 CN5
D1 M PCB4 CN4 ↔ S2 U PCB17 CN6 ↔ CON2
E PCB2 CN5 ↔ T1 230V N PCB6 CN1 ↔ HCT1 PCB17 CN7
T1 460V O PCB6 CN21 ↔ PCB12 CN2 PCB17 CN8
F PCB3 CN2 ↔ PCB16 CN1 P PCB7 CN1 ↔ PCB17 CN3 V PCB17 CN9 ↔ CON1
PCB8 CN1 Q PCB7 CN2 ↔ PCB17 CN2 PCB17 CN10
G PCB3 CN20 ↔
PCB9 CN2 PCB7 CN13 PCB17 CN4 W PCB17 CN7 ↔ S3
PCB8 CN2 R PCB7 CN15 ↔
H PCB3 CN21 ↔
PCB9 CN1 PCB7 CN16
PCB10 CN2 S PCB12 CN1 ↔ PCB13 CN1
I PCB3 CN22 ↔
PCB11 CN1

5
 400MST CONNECTION WIRING GUIDE

CN1 CN1
CN1
CN2 N PCB6
PCB13 CN20
S2
I
PCB16
PCB12 CN21
CN7
CN4
MCB1
L
J M MCB2
CN1 CN10 CN1 S3
CN2 A
PCB4
CN1
PCB10 CN22 F
CN3
CN2 CN23
PCB11 C CN33 CN2
D
G

CN18 D1 H
PCB3 CN2
PCB7 CN1
CN21
CN2 CN2
CN20 CN1 PCB9
K
B CN20
CN1
CN15
PCB17 PCB8
CN3 CN1 CN16
CN2 CN13
CN4 CN5
W
R
PCB2 Q
CN2
CON1 CN4
P CN7
HCT1 CN3
V CN8
CN9 CN6 CN10
CN5

U
CON2 CN1
T1

APPENDIX 3 Interconnect Diagram

6
APPENDIX 3 INTERCONNECT DIAGRAM
INTERCONNECT DIAGRAM

CN3
2 C Q1 C Q13
TB13 C TB10 C
D1 UB3
+ TB14 CE G TB11 CE G
(1) P
TB15 E PCB8 E TB12 E PCB10 E
PCB1 C Q2 C Q14
K(7) IGBT IGBT
Main
G(6) Circuit Gate G Gate G
P Circuit E Circuit E
Board
[WK-5493] Board C Q3 Board C Q15
Line1 S1 R(3) TB1
TB1 [WK-5479] [WK-5479]
G G
(0) R2 G1 1 G4 1
E E

CN1

CN1
S(4) E1 2 C Q4 E4 2 C Q16
3 3
Line2 R2
G G
N
E E
Line3 T(5) - C Q5 C Q17
(2) G2 1 G3 1
N
2 2

CN2

CN2
E2 G E3 G
3 3
4 E 4 E
TB2 C Q6 C Q18
1 TB2
2 G G
CN5

3
230V

460V

+ Ground 4 TB3 E E
0V

5 TB3
E PCB16 T1 PCB2
Filter C Q7 C Q19
Link TB18 C TB5 C
115V

Circuit Board UB1

24V

Circuit Board
MCB2 0V

TB19 CE G TB6 CE G
[WK-4917] [WK-5597]
MCB1 TB20 E PCB9 E TB7 E PCB11 E
CN1 1 C Q8 C Q20
2 IGBT IGBT
SIDE CHASSIS 1
115V

TB4
CN2

Gate G Gate G
24V

1 2 TB4
0V

3
4 Circuit E Circuit E
REAR 5 Board C Q9 Board C Q21
PANEL [WK-5479] [WK-5479]
CN1 CN4 G G

1 2 3 1 2 G6 1 E G7 1 E
CN1

CN1
E6 2 C Q10 E7 2 C Q22
1 2 3 1 2 3 4 5 3 3
G G
N 1 CN2 CN3
2 E E
3 C Q11 C Q23
CN1

P 4 G5 1 G8 1
2 G 2 G
CN2

CN2
5 E5 E8
R2 6 1 2 3 1 2 3 E 3 E
PCB4 4 C 4 C
460V 1 Q12 Q24
Detect CN7 CN10
2
CN4

Circuit Board G G
S2 3 1 CT1
4 [WK-4819] E E
2
CN7

CT2
230V CN5 CN6 CN1 3 CT3
FAN1 CN5 CN6 CN4 4 CT4
- +
CN31 CN32 CN30
G1

G5

G2

G6

G7

G3

G8

G4
E1

E5

E2

E6

E7

E3

E8

E4

1 PCB3
CN31 CN32 CN30
CN11

2
PCB5 Control Souce
3
4 Conect Circuit Board Circuit Board
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
[WK-5696] [WK-5548]
CN20 CN21 CN22 CN23
CN131 CN132 CN130
CN131 CN132 CN130
PCB6
1 1
CN33

Control
CN20

2 2
3 3 Circuit Board
4 [WK-5688]
CN27 CN18 CN3
CN27 CN18 CN3
1 1 PCB7
CN18

CN20

2 2 Filter Circuit Board

3 3 CN1 CN13 CN15 CN16 CN2 CN19
[WK-5689]
1 2 3 4 5 6 7 1 2 3 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 1 2 3

1 2 3 4 5 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3
0V 1 PCB17
2 CN3 CN4 CN2 CN15
Socket Receptacle Circuit Board
24V 3
CN1

[WK-5699]
4
5 CN7 CN6 CN5 CN10 CN9 CN8
115V 6 TB1
1 2 3 4 5 6 7 8 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 6
19P
EC
S3 EC
14PCON2 S T V C U H J N K L A BMGR FD P E CON1 M N C D E H F N J B K G A I L

7
 400MST INTERCONNECT DIAGRAM

PCB15
DIODE Snubber
Circuit Board

GND
+15
SH.DET+

-15
IS
[WK-5606]
PCB14 D2
TRANS

AC1
Board 4
[WK-5594] TB35 123 TO1
TB7 +Output
AC2 Terminal
TB33 HCT1
CT1
CT2

TB21
TB34 D3
CT2
TB8
UB2

1 2 3 4 5 + Ground
L1
D4 CN1
1 PCB18

CN3
TB30 2
TB16 Filter Circuit
3 SIDE CHASSIS 3
UB4 Board
[WK-5499]
TB32

TB22
TB31
FCH1 TO2
-Output
D5
TB17 CT3 Terminal
AC4

SH.DET-
FRONT
CT3
CT4

PANEL
EB

+ Ground
R2
TH2 TH1 UB1 UB2

R3 SIDE CHASSIS 2
1 2 3 1 2 3 4 UB3 UB4

CN9 CN8

1
SH.DET+
SH.DET-

2 PCB12
3 Panel
CN17
EB

AC4

AC2

4 Circuit Board
5 [WK-5527]
6
7 PCB13
1 2 3 4 5 1 2 3 4 5 6 7 8 9 Encoder
Board
CN8 CN9 [WK-5528]
1 1
CN21

2 2
3 3
CN2

4 4
5 CN1
6
1 2 3 4
1 +15 CN1
CN1

2 -15
3 IS 1 2 3 4
4 GND

A M L A J
B N U K B K I
C P V T J C L N H
D R S H D M G
E F G E F

CON2 CON1

8
APPENDIX 4 DIODE TESTING BASICS
DIODE TESTING BASIC
APPENDIX 4 DIODE Testing Basic

Testing of diode modules requires a digital Volt/

Ohmmeter that has a diode test scale.
1. Locate the diode module to be tested.
2. Remove cables from mounting studs on diodes
to isolate them within the module.
3. Set the digital volt/ohm meter to the diode test
scale.
4. Using figure 1 and 2, check each diode in the
VR COM A
module. Each diode must be checked in both
the forward bias (positive to negative) and
Forward Bias
reverse bias (negative to positive) direction. Diode Conducting
5. To check the diode in the forward bias direc-
tion, connect the volt/ohm meter positive lead
to the anode (positive, +) of the diode and the
negative lead to the cathode (negative, –) of
the diode (refer to Figure 10-1). A properly
functioning diode will conduct in the forward Anode Cathode
bias direction, and will indicate between 0.3 Figure 10-1: Forward bias diode test
and 0.9 volts.
6. To check the diode in the reverse bias direc-
tion, reverse the meter leads (refer to Figure
10-1). A properly functioning diode will block
current flow in the reverse bias direction, and
depending on the meter function, will indicate
an open or "OL".
7. If any diode in the module tests as faulty,
replace the diode module.
8. Reconnect all cables to the proper terminals. VR COM A

Reverse Bias
Diode Not Conducting

Cathode Anode

Figure 10-2: Reverse bias diode test

9
 LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.

April 2006

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company ("Thermal Arc"),

warrants to customers of authorized distributors ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warranty
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair or
replacement, at Thermal Arc's sole option, of any components or parts of the product
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of
merchantability, fitness for any particular purpose, or other warranty of
quality, whether express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc with respect to any contract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whether
arising out of contract, tort, including negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.
This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchaser’s rights under this warranty
are void if the product is sold to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned goods
shall be at the Purchaser's risk and expense. This warranty dated April 1st 2006
supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered
Trademark of Thermal Arc, Inc.
 WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.

April 2006
ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years 3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year 1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer ............................................................. See the Engine’s Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................ 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year 1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year 1 year
PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years 3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year 1 year
SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year 1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year 1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year 1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year 1 year
GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR
Water Recirculators ....................................................................................................................... 1 year 1 year
Plasma Welding Torches.............................................................................................................180 days 180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil
Replacement repair parts .............................................................................................................90 days Nil
MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil
 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA Thermadyne Asia Sdn Bhd

2800 Airport Road Lot 151, Jalan Industri 3/5A
Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang
Telephone: (940) 566-2000 48000 Rawang Selangor Darul Ehsan
800-426-1888 West Malaysia
Fax: 800-535-0557 Telephone: 603+ 6092 2988
Email: sales@thermalarc.com Fax : 603+ 6092 1085

Thermadyne Canada Cigweld, Australia

2070 Wyecroft Road 71 Gower Street
Oakville, Ontario Preston, Victoria
Canada, L6L5V6 Australia, 3072
Telephone: (905)-827-1111 Telephone: 61-3-9474-7400
Fax: 905-827-3648 Fax: 61-3-9474-7510

Thermadyne Europe Thermadyne Italy

Europe Building OCIM, S.r.L.
Chorley North Industrial Park Via Benaco, 3
Chorley, Lancashire 20098 S. Giuliano
England, PR6 7Bx Milan, Italy
Telephone: 44-1257-261755 Tel: (39) 02-98 80320
Fax: 44-1257-224800 Fax: (39) 02-98 281773

Thermadyne, China Thermadyne International

RM 102A 2070 Wyecroft Road
685 Ding Xi Rd Oakville, Ontario
Chang Ning District Canada, L6L5V6
Shanghai, PR, 200052 Telephone: (905)-827-9777
Telephone: 86-21-69171135 Fax: 905-827-9797
Fax: 86-21-69171139
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: sales@thermalarc.com
www.thermalarc.com