POWERMASTER 400SP Service Manual 500SP AUTOMATION
Contents
1. 6 6 6 06 Conventional Manual GMAW FCAW 6 6 6 07 SMAW S TICK Welding rc 6 7 SECTION 7 BEN eege 7 1 7 1 7 02 System Troubleshooting Guide 7 2 7 03 Welding Process Troubleshooting Guide 7 3 1 04 Error Codes NP PP TM 7 4 SECTION 8 anne 8 1 8 01 Safety PCA 9 1 5 02 Inverter 0 2 8 03 Common Logic Functions ntt reme nam rra 0 3 8 04 Gas 8 3 0 00 PUD MES 8 3 8 3 8 07 Master EE 8 3 FORE a 8 3 8 09 Control Transformer tan tasten 8 4 8 10 8 5 8 11 DMR PC Board 8 6 0 12 DS20BF PG a 8 6 DIO DK PWRUPO4 PG 8 6 0 14 BA o exe 8 6 8 15 DK DCDRV DK S3DRV east 8 7 8 10 DR A PA 8 8 8 17 DP UFI BO PC Board enuncia dolce 8 8 a 8 8 6 19 LOW PG BOUG NT 8 8 0 20 DS PC BOJO EN 8 8 AA PO BOI ee 8 8 TABLE OF CONTENTS SECTION 9 PARTS LIST WE 9 1 9 01 EQUIDIMENE EIERE cada dat 9 1 9 1 9 03 PowerMaster 4005 amp 5005 Robotic Exploded View Parts List 1 of 2 9 2 9 04 PowerMaster 4005 amp 5005 Robotic Exploded View Parts List 2 of2. aSo SoSo fesse Or lt lt lt lt ISIS IS Art A 07907 4 10 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION Three Steps To GMAW MIG Welding Cau Sa dence Head ios a We Gol Now you are ready to weld Art A 07907 October 30 2008 4 11 POWERMASTER 400SP 500SP AUTOMATION 4 12 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION SECTION 5 ROBOTIC OPERATION 5 01 Robot Interface 06 The Robot interface INTO6 is for connection between the PowerMaster 400SP 500SP Automation power sources and the robot control There are different analog and digital in outputs available to allow an individual adaptation between welding power source and robot control Configuration of the INTO6 is possible via e The control panel of the power source e APC with CAN interface The INTO6 works as a participant of the internal CAN Bus Commands coming over the 06 interface are converted into GAN Bus messages and vice versa actual values and status signals coming from the internal CAN Bus e g welding current on are put out to the INTOG interface The INT06 is potentially separated from the machine The analog and digital inputs are not potentially separated from each other All inputs and outputs are available at the 42 pin Harting socket at the rear side of the welding power source Additional signals and functions
3. wiro mmm Art A 07729 October 30 2008 A 5 POWERMASTER 400SP 500SP AUTOMATION APPENDIX 5 POWERMASTER 400SP POWER SCHEMATIC E 8 84 IS SI 77771 a BELT N ra gt lt gt lt AAA J E Le th B M ro re e IN gt lt FREE _ gt Gil m one EC gt lt gt Im at gt bn lt lt IS 2 ies Ny gt gt B gt lt L d e rm 1 SS ES x a gt e gt lt gt lt gt lt gt lt gt lt lt gt Art 08555 PowerMaster 4005 Automation Schematic S00 0023 4 00 October 30 2008 A 6 X14 1 X14 2 x X8 1 8 2 8 3 X8 4 AP E d xn liem ssepe gt lt vi October 30 2008 POWERMASTER 400SP 500SP AUTOMATION Refer to pages 8 12 and 8 13 for ordering information of parts shown in this schematic ze el E 1 robot wire feeder 3 1 mu 20 mn 029 X
4. 00 11 LI BE SEE 4H 17 16 19 18 Art A 08601 9 11 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 9 10 PowerMaster SP4000R Feed Plate Assembly 9 12 Item NN OO N L c Qty Description Ref Feedplate 4R Mechafin SP Pressure Arm Right Mechafin SP Pressure Arm Left Mechafin SP shaft for Feedroll Mechafin SP Gear Driveroll Mechafin SP Drive Gear Mechafin SP Screw Washer Driveroll M4x6 SP Refer to W7004169 Refer to W7004169 Guide Intermideate 023 1 16 SP Tension adjust rod Mechafin SP Pin Tension adjust Mechafin SP Shaft PressureArm Mechafin SP Spacer PressureArm Mechafin SP Spring PressureArm Mechafin SP Shaft PressureRoll Mechafin SP Refer to W7004182 Refer to W7004182 Refer to W7004182 Guide Inlet 023 1 16 5P Pressure Roll Flat SP Circlip 6F Mechafin SP Screw Kit AR Mechafin SP Refer to W7004185 Refer to W7004185 Refer to W7004185 Refer to W7004182 Refer to W7004185 N A Part Number W7004170 W7004171 W7004172 W7004173 W7004174 W7004175 W7004169 FN A FN A W6000512 W7004177 W7004178 W7004179 W7004180 W7004181 W7004182 N A N A N A W6000511 004183 W7004184 W7004185 FN A FN A FN A FN A FN A FN A October 30 2008 POWERMASTER 400SP 500SP AUTOMATION October 30 2008 Art A 08371 9 13 POWERMASTER 400SP 500SP AUTOMATION 9 14 October 30 2008
5. Inside Rear Cover POWERMASTER 400SP 500SP AUTOMATION SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS A 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 249 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 8 Do not use worn damaged undersized or poorly spliced cables 9 Do not wrap cables around your bo
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7. 24VDC digital 10VDC analog 10VDC analog 10VDC analog 10VDC analog 10VDC analog 10VDC analog 10VDC analog 10VDC analog Option Option Option Option Option Option Option Option Option Option Option 9 3 POWERMASTER 400SP 500SP AUTOMATION LEDs on Robot Interface 06 PC Board Designation meani 1 red malfunction blinking 2 green supply voltage 5V on 3 green 4 green polarity digital 5 green signals IN NPN green arc sensing green ARC SENSE short circuit wire green W STICK power source ready power source ok wire sensing W green STATE 5 4 Microcontroller not programmed supply voltage not ok INTO6 ok internal supply voltage 5V DC is ok internal supply voltage 5V DC is not ok relay RE1 is on output I gt 0 welding current on is active 0 relays RE1 is off output I gt 0 welding current on is not active open relay RE2 is on output power source ok is active 0 relay RE2 is off output power source ok is not active open relay is on digital inputs are low active working with GND relay is off digital inputs are high active working with 24V DC status ok status not ok rei RE3 is on output Arc Sensing is active m RE3 is a output Arc Sensing is not active open m RE4 is on outpu
8. 7 5 CONDUCTOR TUBE 65456 1 7 6 HANDLEASSY 7 TRIGGER ASSEMBLY PMF 1 TWECO Pulsemaster MIG guns may be fitted to many different types of MIG welding Power Supplies so that your whole shop can be converted to TWECO Pulsemaster Not only will this give greater reliability and hence greater productivity but it will reduce stockholding of consumable parts See your Thermal Arc distributor for details 3 10 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 3 08 Installing A New Wire Conduit 1 Be sure the MIG gun cable is arranged in a straight line free from twists when installing or removing a wire conduit Remove the old conduit by first re moving the MIG gun nozzle contact tip insulator and gas diffuser Then loosen Allen screws in the conductor tube and connector plug and pull the old wire conduit out of the cable assembly from the connector plug end 2 To install a new conduit first inspect the o ring gas seal on the conduit for cuts or damage Start from the connector plug end of the assembly and begin pushing the conduit through the connector plug cable assembly and into the gun If the con duit should lodge along the way gently whip or work the cable assembly to aid forward movement When the conduit stop meets the end of the con nector plug and the new raw end extends through the end of the conductor tube on the welding gun tighten the Allen screw in the connector plug onto the co
9. it s wiring no voltage Provider for repair difference between Master and Process Provider for repair E22 Mains undervoltage 1 Power unit 1 reports mains voltage too low Check mains voltage and mains rectifier E23 Mains overvoltage Power unit reports mains voltage too high Check mains voltage E24 Overcurrent protection2 Power consumption of power unti 2 is too Notify an accredited Thermal Arc Service high Provider for repair set wrong Provider for repair DC link voltage difference gt 50V between Notify an accredited Thermal Arc Service power units Provider for repair No program DSP Wrong material wire gas combination Select other material wire gas combination Welding programs faulty or not available Transfer welding programs to machine again E30 Op voltage 15V error Supply voltage is too low Check mains voltages E31 Master is not responding to Process Switch the machine off and on again 2 is shown in the display The display board doesn t get any data from Check the flat ribbon cable of the DS20BF the MV MAPRO Check interpass hose only machines with E E E09 E11 E12 E13 E14 E16 E17 E18 E19 E20 E21 25 26 27 E separate wire feeder and it s connectors Check PC boards DMR and MV MAPRO 1 Check module temperatures in menu Extras Diagnosis gt Module temperatures 2 Check supply voltages in menu Extras Diagnosis gt Operating voltages 3 Check the flow rate in menu Extras Diagnosis gt Flow
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11. Digital multifunction display Displays the primary parameters such as welding current material thickness in 001 wire feed speed in inches min or arc length trim October 30 2008 POWERMASTER 4005 500SP 55 Primary parameter indicator lights These lights show which primary parameter is currently displayed in the multifunction dis play 54 56 Primary parameter push button For switching between welding current ma terial thickness wire feed speed and arc length as indicated in the digital multifunc tion display 54 57 Downslope push button owitches the downslope function on or off A lit LED next to the push button indicates that the downslope is on 58 Arc length control knob To adjust the arc length in SmartGMAW PulseGMAW TwinPulse process OR Wire speed Inductance control knob To ad just the wire speed or Inductance in Manual MIG process 59 Arc length LED indication Indicates the degree of the trim in SmartGMAW Pulse MIG TwinPulse process OR Wire speed LED indication Indicates the wire speed in ManualGMAW process When the uppermost centre LED is lit the pro grammed arc length wire speed remains un changed 0 is indicated in the multifunction display 54 Turn the rotary control knob 58 left to shorten the arc length wire speed turn the rotary control knob 58 right to lengthen the arc length wire speed October 30 2008
12. nana 3 11 SECTION 4 MANUAL OPERATION 4 1 4 01 General Safety Precautions conan 4 1 4 02 Welding 4 2 4 03 Menu Structure secret eege Aen te ese ans 4 4 4 04 Special TUNENONS iris 4 8 4 05 Smart GMAW Pulse GMAW A TwinPulse 4 9 4 06 Welding Setting Selection Guide 0 4 10 SECTION 5 ROBOTIC OPERATION e ri eaa iba Ra Rr rit eh a 5 1 5 01 Robot Interface INTOG 9 1 5 02 Digital Inputs and Outputs EE 5 1 OO ose tcs 5 2 5 04 Robot Interface Schematic EE 5 3 5 05 Robot Interface 06 PC Board 5 5 5 06 42 Pin Harting Socket NENNEN 5 6 5 07 Configuration at Front Panel Menu 5 10 5 08 Robot Tool Software Installation e e 5 11 5 09 Decimal Binary Conversion iii 5 12 TABLE OF CONTENTS SECTION 6 MANUAL GMAW WELDING ea a ne 6 1 6 01 Types of Weld Transfer Modes 6 1 6 02 Holding and Manipulating the Torch nano 6 2 6 03 Basics of Pulsed Arc Welding 244 02 2 01 41 6 4 6 04 Pulsed Arc Welding 2 hix e butt tutu ite te 6 5 6 05 Smart Pulse or TwinPulse GMAW
13. October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 8 03 Common Logic Functions Component Function fan power unit power module temperature over 40 power module temperature below 40 fan cooling system after detection welding current after welding process two minutes post cooling time pump after detection welding current after welding process two minutes post cooling time 8 04 Gas Test Sh N 8 05 Sh N 8 06 PB N 8 07 9 08 Press the buttons arrow up and gas type at the same time The gas valve is activated for 30 sec countdown is shown in the display Press button gas type again to end the test manually Pump Test Press the buttons arrow up and material type at the same time The cooling pump is activated for one minute countdown is shown in the display Press button material type again to end the test manually Reset Adjustments Press the buttons arrow up and TT Enter at the same time All secondary parameters are reset to their default values If Tiptronic is active the settings of the current job are reset to their programmed values All adjustments of the Extras menu remain unchanged Master Reset Press the buttons arrow up and together for about five sec The display shows Master Reset The machine is reset completely to factory settings
14. 91 82 93 94 95 8 88 91 92 93 94 99 1000100 1000101 1000110 1000111 1001000 1001001 1001010 1001011 1001100 1001101 1001110 1001111 1010000 1010001 1010010 1010011 1010100 1010101 1010110 1010111 1011000 1011001 1011010 1011011 1011100 1011101 1011110 1011111 96 97 1100000 1100001 1100010 1100011 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION SECTION 6 MANUAL GMAW WELDING 6 01 Types of Weld Transfer Modes A Dip transfer mode short circuit arc This type of arc is especially suitable for thin materials and positional welding due to a relative cool welding pool welded with very short arc low arc voltage and low current The surface tension of the welding pool helps to draw the drop into the bath and to reignite the arc This cycle is repeated again and again so the Short circuit and the arcing period are constantly alternating NOTE The transition from the short circuit to Spray arc depends on the wire diameter and the gas mixture B Transitional arc The transitional arc is especially suitable for medium thickness sheet metals and for vertical down welding The transfer of the electrode to the workpiece takes place partly in short circuit and in free flight Due to fewer short circuits the welding pool is hotter than at the short circuit arc Welding with transitional arc provides higher electrode melt rate and is more economic than welding at short circuit
15. Robot interface not active Bob rt version 030206 03 Art A 07831 POWERMASTER 400SP 500SP AUTOMATION 5 09 Decimal Binary Conversion The following table shows the conversion between decimal and binary numbering system The conversion is used the automation interface 06 for the job selection all series and for the selection of the external program number The table shows the connection between job program no decimal and the digital inputs pins 1 to 7 binary Example job no 9 0001001 pins 1 and 4 logic high pins 2 3 5 6 and 7 logic low 9 12 o 3 4 5 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2 28 000000 0000001 0000010 0000011 0000100 0000101 000011 0000111 000100 0001001 000101 0001011 000110 0001101 000111 0001111 001000 0010001 001001 0010011 001010 0010101 001011 0010111 001100 0011001 001101 0011011 0011100 29 30 31 0011101 001111 0011111 0100000 0100001 39 36 37 30 39 40 41 42 43 44 45 46 47 48 49 90 91 92 03 94 99 96 08 99 61 62 0100011 0100100 0100101 0100110 0100111 0101000 0101001 0101010 0101011 0101100 0101101 0101110 0101111 0110000 0110001 0110010 0110011 0110100 0110101 0110110 0110111 0111000 0111001 0111010 0111011 0111100 0111101 0111110 63 64 0111111 1000000 1000001 1000010 70 71 12 73 74 15 76 11 78 79
16. loosen the locking ring and grab the connectors and pull Do not pull on the wires 6 To remove the gun reverse these directions October 30 2008 POWERMASTER 400SP 500SP AUTOMATION B How To Connect The Work lead Connect the work lead to the Negative connection and fasten it by turning the connector to the right Connect the Work clamp to the workpiece or the welding table Art A 06366 C Where to connect the Work Clamp Fasten the Work clamp shown as 2 below near the welding location this avoids stray current flow through mains earthing system BS U 852 N E Connect the Work clamp tightly to the welding bench or to the workpiece A WARNING Do not place the Work clamp on the welding power supply or gas cylinder as welding current may be conducted via the mains earth and will burn it out D How To Connect To The Mains Refer to Connecting Input Power Section October 30 2008 E How To Install The Wire Spool Open the wire feed compartment lid on the power supply or wirefeed case and un screw the nut from the wire support coil hub Place wire spool on the hub and ensure that the drive dog pin engages the mating hole in the wire spool Press then release the inch switch g to adjust the brake the wire spool should not continue to run Drive pin Art A 06368 3 7 POWERMASTER 400SP 500SP AUTOMATION F Insertion Of The Wire Electrode Press the inc
17. of free airspace on all sides of the unit Make sure that the ventilator openings are not obstructed Ventilation airflow is from rear to side 3 02 Voltage Changeover For proper operation and to prevent damage to the machine the Voltage Input Select Switch must be set according to the incoming AC line voltage If this switch is not set to the position that matches the input line voltage the Smart Logic will inhibit the welding power source from turning on The Voltage Input Select Switch is located on the rear panel Art A 07878 To set the Voltage Input Select Switch 1 Rotate the locking screw 90 degrees 2 Lift up the switch cover and set the switch to the in coming AG line voltage 3 Secure the switch cover October 30 2008 N WARNING Do not alter the position of the Voltage Input Select Switch when the ON OFF Switch is in the ON position as this will cause two internal auxiliary fuses to rupture These fuses will have to be replaced before the machine can operate N WARNING ELECTRIC SHOCK KILL Open the main wall disconnect switch or breaker before removing any covers or access panels on the welding machine Live voltage is still present even with the front panel control switch OFF Wait at least 10 full minutes after power has been removed before removing any covers or access panels to allow adequate time for internal capacitors to discharge 3 1 POWERMASTER 400SP 500SP A
18. the cursor jumps to the respective next line e selecta character number letter or special character with push buttons 44 and 48 f The edit mode is ended by pressing pushbutton 46 END or by pressing the and W push buttons 51 at the same time If you press the Tiptronic pushbutton 49 in edit mode Tiptronic is switched off then the text entries will not be saved 6 Copying jobs a Switch the Tiptronic function on by pressing Tiptronic 49 and select a job for copying see Selecting Jobs Texts can be programmed both for the job set upper line in display 50 as well as for the job bottom line in display 50 b Press the TT Save button 45 Save LED flashes c Select the target job number with the push buttons 44 and 48 and confirm with the TT Enter pushbutton 47 if the Enter pushbutton is not actuated the Save LED goes out 10 seconds after the last pushbutton actuation and the saving procedure is cancelled If the target job number has not been occupied with a job yet it is indicated by the display flashing d The Save and Enter LEDs flash briefly to confirm that programming is terminated The user defined job texts are also copied onto the new target job number 7 Assigning descriptive text to a job Text can be assigned to each job in order to identify it more clearly a Switch on the Tiptronic function with the Tiptronic pushbutton
19. 2 9 4 9 05 PowerMaster 4005P Power Module 9 6 9 06 PowerMaster 500SP Power Module 9 7 9 07 PowerMaster SP Water Cooling System 9 8 9 08 PowerMaster SP HR911 Remote Pendant 9 9 9 09 PowerMaster SP 4000R Wire Feeder 9 10 9 10 PowerMaster SP4000R Feed Plate 4 9 12 APPENDIX 1 OPTIONS AND ACCESSORIES A 1 APPENDIX 2 FEED ROLL A 2 APPENDIX 3 MOUNTING THE TORCH HOLDER A 3 APPENDIX 4 SP SERIES BLOCK DIAGRAM ener HH nn nn nn nn ann nn nn nun 4 APPENDIX 5 POWERMASTER 400SP POWER SCHEMATIC A 6 APPENDIX 6 POWERMASTER 500SP POWER SCHEMATIC 8 APPENDIX 7 ROBOTIC INTERFACE DIAGRAM A 10 APPENDIX 8 RECTIFIER DIODE DATA SHEET A 11 APPENDIX 9 HYBRID ESBT DATA SHEET A 12 LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
20. 49 b Select the job number with the push buttons 44 and 48 c Press the and W push buttons 51 at the same time a flashing cursor appears in the display 50 in order to get into the edit mode October 30 2008 4 7 POWERMASTER 400SP 500SP AUTOMATION 4 04 Special functions A Gas test Pressing the pushbutton 51 and the Gas type pushbutton 48 at the same time activates the gas test function The solenoid valve of the system is activated and the gas flow rate can be checked adjusted The function remains active for 30 seconds and is then ended automatically By pushing the Gas type pushbutton 48 again the gas test can be terminated B Pump test where fitted Pressing the pushbutton 51 and the Material pushbutton 44 at the same time activates the pump test function The coolant pump is switched on and runs for approximately one minute By pushing the Material pushbutton 44 the pump test can be terminated C Resetting Adjustments Pressing the pushbutton 51 and the Enter pushbutton 47 at the same time resets all secondary parameters to the Factory set values When the Tiptronic process is active the settings of the current job are reset All adjustment in the Extras menu language display contrast etc remain unchanged 4 8 D Code lock function The lock function in menu Extras is secured with a code lock three digi
21. 54 and the corre sponding error description appears on the LCD display 50 As long as an error code 15 indicated welding operation is not possible Code standby 7 high temperature gt 176 Check temperature sensor short circuit transformer 2 Provider for repair detects that the unit heats up too fast Cooling system error Flowrate of the cooling liquid is too low lt 0 3 Check connectors of flow meter level of l min cooling liquid and flowrate 3 E02 E03 E04 0 E05 Pump is not working Check fuse SI7 2 5A on pc board MV MAPRO Secondary overvoltage Master detects output voltage is too high Notify an accredited Thermal Arc Service gt 100V Provider for repair EEProm checksum error No welding program stored or error during Transfer welding programs to machine reading from memory again exchange MV MAPRO if error still persists Wire feed tacho Power consumption of wire feed motor too Blow out torch package with compressed high air No tacho signal Check wire feed unit No CAN Bus connection between MAPRO Check wiring of wire feed motor and PC and DMR board DMR Error v a measuring Measuring difference between Master and Check wiring of pc board LSW pc board control socket Optionally exchange PC board DP MAPRO E06 207 E08 Provider for repair transformer 2 high Provider for repair transformer components Check temp sensor Temp sensor is disconnected Check MVPWRUP board
22. Assurez vous que Pair est propre la respiration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Dimension d lectrode ou Op ration de coupage Nuance de Epiasseur de m tal ou Intensit de courant ou soudage filtre oculaire m taux ferreux toutes toutes conditions toutes conditions E toutes toutes conditions 25 sous 0 7 avec lectrode de tungst ne GTAW Soudage l hydrog ne de146 25 150 mm 4 ou 5 Soudage l arc avec 1 5 ou 6 toutes conditions Soudage aux gaz EE 72 22088 Soudage l arc Soudage l arc Plasma PAW PAW toutes toutes dimensions mince moins de 1 8 po 3 mm BEE lectrode de carbone de 1 8 4 1 2 po 12 5006 mine 12 plus de 1 2 po 12 mm 608 4 Soudage l arc avec lectrode enrobees moins de 5 32 po 4 mm Coupage l arc Plasma PAC SMAW D 8824 1A po 4 464 mm mons de 300 amperes 9 piss de 1A po 64 mm de 300 4 400 amper s plus de 400 amper October 30 2008 1 7 POWERMASTER 400SP 500SP AUTOMATION 7 10 1 9 Ne soudez des 10165 galvanis es ou plaqu es au plomb ou au cadmium que si les zones a souder ont t gratt es fond que si l espace est bien ventil si n cessaire
23. CPLD processor is not working P on DSP is not working 3 green i supply voltage 3 3V DC is missing check 18V AC of control transformer X2 1 and X2 2 4 red on micro controller is not working DSP not working 6 green micro controller is not working CAUTION if the LEDs are indicating a malfunction which can not be relieved by switching the machine off and on again it is recommended that the pc board DP MAPRO is exchanged DIP Switch Settings If the machine is to be programmed via the serial port the DIP switches 1 3 has to be set to ON In normal operation they has to be set to OFF If the pc board is used in a 320SP the DIP switch 4 has to be set to ONT For the use in 4005 or 5005 DIP switch 4 has to be set to OFF mode serial programming mode normal operation mode serial programming mode normal operation mode serial programming configuration 320SP configuration 400SP 500SP Fuses on DP MAPRO PC Board fuse value A safeguarding fans power unit cooling pump October 30 2008 8 5 POWERMASTER 400SP 500SP AUTOMATION 8 11 DMR PC Board The DMR pc board is the wire feed motor control of the machine Functions e control and monitoring wire feed motor e driving solenoid valve e control and monitoring of operating elements DS20BF remote control torch buttons e monitoring wire insert button e supply PP9OR pc board Push Pull Normal LED Dis
24. F6 W6000208 9 1 Pump Motor Coolant 230V SP WM 7000039 10 3 Fan 230V 119x119x38 400 500SP M1 M6 W6000209 Art A 08367 9 0 October 30 2008 9 08 PowerMaster SP HR911 Remote Pendant Item 3 4 9 9 10 11 12 13 14 15 18 13 12 18 October 30 2008 Qty 4 4 POWERMASTER 400SP 500SP AUTOMATION Description Foot Rubber 20x10 w stud HR91 1 Starlock Cap Shaft 4mm HR91 1 Display Cover HR911 SP Refer to W7004167 Refer to W7004167 Refer to W7004167 Strain Relief Nut HR911 Refer to W7004167 Knob Encoder 9 x1 4 shaft SP Cap Knob Grey Ou SP PCB Volt Amp Meter SP PCB Front Panel SP Shoulder Washer 1 1 8x3 8x1 4 Part Number W7004162 W7004163 W7004167 N A N A N A W7004168 N A W7004164 W7004165 W7000024 W6000003 W7000037 9 9 POWERMASTER 400SP 500SP AUTOMATION 9 09 PowerMaster SP 4000R Wire Feeder 9 10 Item N O RA O N Qty 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4 2 2 Description Ref Adaptor 1 8 id x hose 5mm SP switch PB Wi
25. POWERMASTER 400SP 500SP AUTOMATION APPENDIX 1 OPTIONS AND ACCESSORIES Wirefeeders SP4000W SP4000R MIG Guns PulseMaster 12ft Smart Gun PulseMaster 15ft Smart Gun PulseMaster 12ft Gun PulseMaster 15ft Gun Interconnect Cable Assy 3ft Long Part No W3000202 W3000302 Part No PMA512S 3545 5155 3545 512 3545 515 3545 W4000603 Feature Water cooled connections 4 Roll suits 4005 5005 Water cooled connections 4 Roll suits 400SP 500SP Automation Feature Built in Remote Controls Heavy Duty 500 Amp Rated Suits 3205 4005 5005 Built in Remote Controls Heavy Duty 500 Amp Rated Suits 320SP 400SP 500SP Heavy Duty 500 Amp Rated Suits 3205 4005 5005 Heavy Duty 500 Amp Rated Suits 3205P 4005P 5005P 3 0 Welding Cable Water Cooled Hoses Gas Hose Suits 4005 5005 Interconnect Cable Assy 16ft Long Interconnect Cable Assy 32ft Long W4000604 W4000605 3 0 Welding Cable Water Cooled Hoses amp Gas Hose Suits 4005 5005 3 0 Welding Cable Water Cooled Gas Hose Suits 4005 5005 MIG TIG Coolant 1 Quart 1L MIG TIG Coolant 5 Quart 5L MIG TIG Coolant 5 Gal 20L October 30 2008 W4001402 W4001400 W4001401 A 1 POWERMASTER 400 500 AUTOMATION APPENDIX 2 FEED ROLL INFORMATION Description Stylet 92 Styles Provides less wire friction in the MIG torch due to the straightening effect of th
26. Sensor 500A 2000 1 VAC W7000042 12 4 spacer PCB 3 4 SP W7004130 13 2 Thermal sensor 320 400 500SP F3 W6000000 ELE Art A 08366 9 6 October 30 2008 Item gt W N i O A Alt Qty E O 6 1 4 2 11 IT POWERMASTER 400SP 500SP AUTOMATION 9 06 PowerMaster 500SP Power Module Description PCB Output Diode SP PCB Input Relay SP Fuse 320 400 5005 PCB Primary Capacitor 400 500SP Inductor 500SP Transformer Main 500SP Rectifier 3PH 1600V 175A SP Fan 230V 119x119x38 400 500SP MOSFET N Channel 500V 50A SP Diode 400V 2x100A 320SP Current Sensor 500A 2000 1 VAC Spacer PCB 3 4 SP Thermal sensor 320 400 500SP IR RRRS XXE RE S CH October 30 2008 Schematic Ref Part Number 11 1 FO C1 L1 T2 A2 M1 A12 A14 F3 W6000007 W7000026 W6000010 W7000027 W7000068 W7000067 W7000035 W7004142 W7000040 W7000041 W7000042 W7004130 W6000000 Art A 08366 POWERMASTER 400SP 500SP AUTOMATION 9 07 PowerMaster SP Water Cooling System Item Qty Description Ref Part Number 1 1 Cap Water Tank M33x2 SP W7000014 2 1 QuickDisconnect Blue Female SP W7004133 3 1 QuickDisconnect Red Female SP W7004134 4 1 Radiator 390x130x66 SP W7004136 5 1 Tank Coolant 640 x 80 SP W7004137 6 1 Connector hose R1 4 SP W7004138 7 1 Connector hose elbow R1 4 SP W7004139 8 1 Flowmeter 400 500SP
27. as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire 6 Do not weld in locations near degreasing cleaning or hazard spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases 9 Do not use welder thaw frozen pipes 7 Do not weld on coated metals such as galvanized lead or 10 Remove stick electrode from holder or cut off welding wire cadmium plated steel unless the coating is removed from at contact tip when not in use the weld area the area is well ventilated and if necessary Ah WARNING while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes FLYING SPARKS AND HOT METAL can cause injury WARNING If welded NV Chipping and grinding cause flying metal As welds cool they can throw off slag WELDING can cause fire or explosion Eye protection filter shade selector for welding or cutting goggles or helmet from AWS A6 2 73 Torhsoldeing 3 2 Gasmetatare Torch brazing 304 Nonferrous base metal Al 11 Oxygen Cutting Ferrous base metal Al 12 Gaswelding__ 1 Carbon arc welding Al 12 a Light Under 1 8 in 4or5 Plasmaarcwelding 2 Medium 1 8 10 1 2 in 3 12 mm 50r6 Carbon arc air gouging Heavy Ovrt2in 2mm 6 __ g 22 Shielded
28. au 91421900 SI 921005 aug 19e u09 110100 991 ejue od yo 921005 JaMod 0 p Gulpjam 50015 A SI ay IULI JS Jejse y49Mog UONG Gulpjam suejs euiuoeu 19101 passed e Spuods21109 eubis siu jo eubis HLS uo Hulpjam S 12998 ure1604d 6 YOUMS Ajuo ou se sindui ey Je sjeubis au 19 JOU si EUPIS au JO 510 414 NO 9 ul sindul uo y 198 94 0 seu ou y SIU UU si oul 19919s qol 1 3y JO jaued 1u0JJ 3y Je 0 19 AO 94 ued 01129 95 e 0 ou ure1604d 19 SinduI ay jo euou uauM 9 02 LG Sa Apc 01 195 aq 01 seu ou qof au ou qof e 12995 0 pesn edu esau L ou qof del October 30 2008 POWERMASTER 400SP 500SP AUTOMATION Harting Socket Pin Descriptions Con t Hoyeue 1 nd no Jeubip 0 jndurjeubip 1 OAI eq ISNW esinduim ay Aouanb31 esinduiw 94110 AQ L 0 0 1407 AS 24 A0 HD 22 9950 90 AD 9uenbaJJ 99
29. et cuir et des chaussures de s curit Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev Dimension d lectrode ou Op ration de coupage Nuance de Epiasseur de m tal ou Intensit de courant Brassage tendre toutes conditions au chalumeau Brassage fort toutes conditions 3 ou 4 chalumeau ou soudage filtre oculaire Owcoupage SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux toutes conditions CEN AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer AAA AAA AA l Eloignez la t te des fum es pour viter de les respirer l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate portez un respirateur ad duction d air approuv Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ne travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort
30. eubis 00110112890 uoneu isaq ad L UNAS October 30 2008 9 0 POWERMASTER 400SP 500SP AUTOMATION Other Analog Parameters Designation Control voltage 0 10V for the pre gas time Control voltage 0 10V for the twinpulse current change OV 5 of welding current gas post time Control voltage 0 10V for the gas post time The operating mode twinpulse must be active 10V DC 50 of welding current twinpulse relation Control voltage 0 10V for the twinpulse relation The operating mode twinpulse must be active 10V DC Control voltage 0 10V for the wire burnback time 20 of programmed value 300 of programmed value Control voltage 0 10V for the inductor effect 20 of programmed value 200 of programmed value October 30 2008 9 9 POWERMASTER 400SP 500SP AUTOMATION 5 07 Configuration at Front Panel Menu The INTO6 can also be programmed at the front panel in menu Extras Robot Interface The eight analog inputs can be enabled or disabled So it is not necessary to open the machine and set the DIP switches If there are not enough digital outputs available at the robot control to select a welding program it is possible to select three different pre defined welding programs with only two digital outputs Those welding programs can be set at menu items Proglnt to ProgIn3 The selection of these welding programs is made over the dig
31. flow 4 Display contrast Arc length correction Inductance Arc force Job selection 6 Lock function Last error messages Module temperatures Operating voltages Flow rate cooling system Select language 0 normal O ER Change between m Extras parameters with keys 51 7 Arc length control Voltage 11 Robot interface Wire Art A 07726 October 30 2008 Ge POWERMASTER 400SP 500SP AUTOMATION 1 Save Programming jobs A Secondary Parameters Menu Main Level 4344 45 46 47 48 49 50 51 0 1 0 45 d e With and W 51 push buttons you can switch to the secondary parameters The currently selected parameter is indicated in the display 50 The Gas Pre Flow 0 1 value is pre loaded at the Factory but the user has increased it to 0 4s using 48 push button Push button 44 is used to reduce the indicated parameter and push button 48 is used to increase the value of the indicated parameter Pressing the push button 46 END saves the parameter and the system switches back to the material wire gas combination display B Extras menu In addition to the secondary parameters the Extras menu item is also available it offers the following functions Push buttons 44 and 48 are used to switch between the menu items The different entries of the menu items are called up by pressing the and y push buttons 51 at the same time Switching between
32. like gas monitoring can be connected optionally Art A 07825 Power Source Robot Control Analog CAN Bus 5 02 Digital Inputs and Outputs The 18 digital inputs are designed for a voltage of 24V DC For some of the digital inputs LEDs are showing the state of the inputs see Overview LEDs Robot interface INTO6 on page 4 The two digital outputs are designed as potential free relays contact The power rating of the contacts is max 1A at 48V The state of the digital outputs are displayed on the pc board 06 with two LEDs see Connec tors on Robot Interface 06 PC Board on page 5 3 CAN Bus October 30 2008 5 1 POWERMASTER 400SP 500SP AUTOMATION 9 03 Analog Inputs The eight analog inputs are designed for a voltage of 0 to 10V DC Programming the analog inputs assign ment to welding parameters is made with a PC with CAN interface see PC Program Robot Tool or directly at the power source over the front panel menu Extras Robot Interface The selectable range of a welding parameter corresponds to the range which is selectable at the front panel The settings can be monitored at the displays of the welding machine The factory default assignment is Harting socket Standard Configuration Pin no Parameter welding current arc length 5 2 rt current time A 28 mamm M 3 domm H8 30 him ule frequency Programming the analog inputs Progra
33. portez un respirateur adduction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage De m de LESOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION AVERTISSEMENT L arc produit des tincellies et des projections Les particules volantes le metal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un echauffement ou un incendie Protegez vous ainsi que les autres contre les tincelles et du metal chaud Ne soudez pas dans un endroit des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre cote Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le cou
34. rate cooling system 7 4 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION SECTION 6 ADVANCED SERVICE 8 01 Safety Precautions Requirement WARNING AN Use and maintenance of welding and cutting machines can be dangerous Follow the safety precautions in Section 1 of this manual to avoid injuries Welding and cutting machines must be used by properly trained personel Please review the safety precautions and regulations on a regular basis to avoid accidents while working with this machine WARNING AN Only qualified workers who are knowledgeabel and have been trained to work safely with test instruments and equipment on energized circuits shall be permitted to perform testing work on electrical circuits or equipment where there is danger of injury from accidental contact with energized parts or improper use of the test instruments and equipment CAUTION Use only original spare parts Immediately replace any components that are not in perfect condition CAUTION Please follow the current safety regulations corresponding to your country Norms October 30 2008 8 1 POWERMASTER 400SP 500SP AUTOMATION 8 02 Inverter Principle 3 phases 50 Hz mains switch mains filter soft power up mains rectifier dc link voltage primary switch clock pulse 80 kHz transformer secondary rectifier inductor 8 2 11213 4 Cer rt A 07732
35. secs et non trou s continu 3 Isolez vous de la pi ce souder et de la mise la terre au 14 Portez un harnais de s curit si vous travaillez en hauteur moyen de tapis isolants ou autres 15 Fermez solidement tous les panneaux et les capots 4 D connectez la prise d alimentation de l quipement ou arr tez 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 viter une mise en marche accidentelle 1 6 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION AR A AVERTISSEMENT 9 LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE L arc de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager l ouie Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI Z49 indiqu e ci apres pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc Portez des v tements en mat riaux ignifuges et durables laine
36. the individual entries is also possible here with the push buttons 44 and 48 To return press push button 46 END C Tiptronic The Tiptronic function provides you with 100 independent jobs 10 job set with 10 jobs each job stores all the settings and corrections on the operating panel The best way to use the Tiptronic function is to assign job numbers to frequently recurring welding tasks or save the settings which individual welders use specifically for their jobs 4 6 a Determine the optimal welding values b Press the TT Save button 45 Save LED flashes c Select the target job number with the push buttons 44 and 48 or with the smart torch rocker and confirm with the TT Enter push button 47 if you do not press Enter the Save LED goes out after 10 seconds after the last keystroke and the save operation is aborted d The Save and Enter LEDs flash briefly to confirm that programming is terminated 2 Selecting jobs a Switch the Tiptronic function on by pressing Tiptronic 49 associated LED comes on b Select the job number with the smart torch rocker alternatively the job number can be selected with the push buttons 44 and 48 c To exit the Tiptronic process press Tiptronic 49 Tiptronic LED goes out The parameters are reset to the values that existed before you switched on the Tiptronic process 3 oetting a job inactive
37. up overhead and in horizontal vertical position When horizontal welding hold the torch vertical to the workpiece neutral torch position or up to 30 pushing the torch For best depth of penetration and shielding gas coverage hold the torch in the neutral position Please note that if the torch is tilted too far it is possible that air will be sucked into the shielded gas and may result in porosity For vertical or overhead welding a slight pushing motion is required Vertical down welding is most used for thin materials hold the torch at the neutral or slightly dragging position Some experience is required as the welding pool could run ahead of the arc and cause weld defects There is a danger of lacks of fusion with thicker material due to the welding pool being very liquid from high voltage Welding direction pushing the weld dragging the weld Avoid extreme side to side movements as it can cause the weld pool to dam up in front of the arc This can cause lacks of fusion due to the welding pool flowing ahead of the welding arc The side to side motion should only be used as wide as is necessary to reach both sides of the joint If the joint is too wide you should weld two parallel weld beads When vertical up welding the side to side motion should follow the shape of an open triangle 6 2 Art A 06880 Welding direction A Length of the arc Welding with a longer arc reduces the penetration the we
38. 0 MIG TIG Coolant 5 Gallon 20 L Part No W4001401 l How To Configure The Power Supply For Aluminium Welding Change the feedrolls to U groove for aluminium wire refer to the Options and Accessories list in the Appendix Change the torch liner to a nylon or teflon liner refer to the Options and Accessories list in the Appendix and to the next section 3 07 Installing a New Wire Conduit Use the correct size outlet guide to suit the wire diameter 030 4 035 in Steel tube with red lining 045 amp 3 64 in Use steel tube with black lining 1 16 in Use clear teflon tube Fasten the torch and insert the wire electrode NOTE The parts required for the torch depends on the type torch and wire diameter Please refer to the torch spare parts list 3 9 POWERMASTER 400SP 500SP AUTOMATION 3 07 Pulsemaster 5125 3545 500 Amp Weld Gun when welding by hand For manual welding Thermal Arc recommends the TWECO Pulsemaster PMA512 3545 500 AMP gun Fitted to the PowerMaster it offers robust construction unparalleled reliability and easy replacement of consumable parts The TWECO Pulsemaster gun has an operating capacity in excess of the capacity of the PowerMaster and can be expected to give trouble free service 1 Art A 07922 TWECO Pulsemaster PMA5512 500 AMP Weld Gun Original Parts Installed HEAVY DUTY NOZZLE HD24LP 62 A CONTACT TIP 16RZ XX A 7 4 MACHINED NOZZLE INSULATOR 6834 1
39. 03 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters Thermadyne Holdings Corporation suite 300 16052 Swingley Ridge Road St Louis MO 63017 Telephone 636 728 3000 FAX 636 728 3010 Email sales thermalarc com www thermalarc com By THERMADYNE IHERMAL A RC
40. 2 _ 029 6 Wu R mat 80 EE 0 J n M5 mum nn mun WO 1 2 2 2 1 ML zen MI contact sensor MA 5 on ZE L pe tE collision protection E we te ot we 1 7 poo 3 34 BCE collision protection ME _ d PP 2 ME 1 A eer HI 146 wg SA Xn _ Ivan X10 Pol Ho xa EN I 8 249 1 2 DE _ 7 xe 8 wm XT 4 d ab Loft yg g X 1 X8 7 17 X9 7 xy di 3 X8 6 16 X9 6 NE wen A XT X8 5 15 5 X9 5 p ABS A qi M7 Du 1 4 Lut o XM wn A 3 3 1 3 3 X93 qi t X8 3 _ X8 2 12 2 1 1 1 FC r di ee t X8 1 Y Ch Art A 08555 A 7 POWERMASTER 400SP 500SP AUTOMATION APPENDIX 6 POWERMASTER 500SP POWER SCHEMATIC 1213 power source 0 230 gt lt gt lt gt lt M el C m 12 EA A EE Hi II d 8 84 ISSI pp lt lt Io Le a nr gt lt 522271 D Y gt lt CN gt lt e a e only at watercooled machines Art A 08557 PowerMaster 500SP Automation Schematic S00 0023 6 00 October 30 2008 A 8 POWERMASTER 400SP
41. 500SP AUTOMATION Refer to pages 8 18 and 8 19 for ordering information of parts shown in this schematic 07 robot wire feeder 42 gt K en Ss 5 D P j X9 4 d 7 D ci r E B x Ss 5S I ER IIIA 222g bridge X9 1 to X9 4 only at air cooled machine R nd dE Ce Fee 7 Wm N ML o Y NET we i 54 E oro d x I lt contact sensor wm p 9 pp X1 584 org EE collision protection X14 2 0 6 v2 8 D 44 Oa ih y collision protection on NENNEN 13 r 20 1 mu qk yy BE VUE ah XL AN G JJ pin 4 42 Ab X4 1 1 EN Lo m Ai N d UE D T H 90 12 mode nt m msn Ir Cl dm BA 80 14 1 MEN ZE 18 81 8 BI me do 9 Or 63 M ben en dy MA X 6 di ag b we 15 5 1x5 ii 55 o ha 8 5 YA o M7 N A j b 4 X 1 Y o e wu A X3 13 3 X93 s 53 o tp X8 3 8 2 2 2 02 1 il aaa M A ze SE od b mu Ak EE E X2 d uu Art A 08557 October 30 2008 A 9 POWERMA
42. 72 21 1 Socket 4Pin SP W7000052 22 1 Switch On Off 100A 400 500SP W7000034 23 1 Cap CAN Socket SP W7000096 24 1 Castor Swivel 125 SP W7004121 25 1 Label 50x25mm SP W7004132 26 2 Terminal Output SP W7000051 27 1 Castor Swivel Brake 0125 SP W7000084 28 1 Remote Control HR 911 W4000101 29 1 PCB Output Filter SP W7000044 30 1 PCB Filter SP W7000045 31 2 Label Mains Connection 30 SP 7004114 32 1 Label Warning SP W7004116 oo 1 PCB Robot Interface 06 1 5 W7000025 34 1 Terminal Block Input 4 Way SP W7000058 35 2 Castor Fixed 0125 SP 7000011 36 1 Panel Side RH 4005P amp 500SP 7004120 37 1 Strain Relief M40 030 SP W7000018 38 1 PCB Master Control SP W7000029 38 1 Fuse 320 400 5005 W6000012 38 1 Fuse 2 5A 320 400 5005 W6000011 39 6 Spacer PCB 3 8 SP W7000099 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION Art A 08600 9 5 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 9 05 PowerMaster 400SP Power Module Item Qty Description Schematic Ref Part Number 2 2 PCB Output Diode SP A11 W6000007 3 1 PCB Input Relay SP 1 7000026 3 2 Fuse 4 320 400 5005 F4 F5 W6000010 4 2 PCB Primary Capacitor 400 5005 A3 W7000027 5 1 Inductor 400SP L1 W7000056 6 1 Transformer Main 400SP T2 W7000057 7 1 Rectifier 3PH 1600V 175A SP A2 W7000035 8 2 Fan 230V 119x119x38 400 500SP M1 W7004142 9 16 MOSFET N Channel 500V 50A SP W7000040 10 6 Diode 400V 2x100A 320SP A12 A14 W7000041 11 1 Current
43. A SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 2 Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries EM C x WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure a POWERMASTER 400SP 500SP AUTOMATION 1 Donotremove radiator cap when engine is hot Allow engine to cool 2 Wear gloves and puta rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap A WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Sec tion of the U S Congress Office of Technology Assessment Bio logical Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC
44. AW B Set Torch trigger a 2T Normal Operation OR operation AT Trigger Latch C Adjust Wirefeed speed knob to the desired Art 07871 SmartGMAW One knob control non pulse A Set Process Processes welding PulseGMAW One knob control pulse welding TwinPulse One knob control twin pulse welding PN Process Wire type Eg Stainless Steel 316 Wire size Eg 035 in diameter D Adjust Arc voltage knob to the desire arc Thickness voltage L 000 O p 5 Set Torch trigger 8 2T Normal Operation operation 21 4T 4T Trigger Latch Set Base material Use left hand knob to dial thickness up base material thickness Es 250 0 250 1 4 Shielding gas 69 Eg 98 Argon 2 CO2 Press button to select material thickness 6 6 October 30 2008 6 07 SMAW STICK Welding POWERMASTER 400SP 500SP AUTOMATION The following instructions explain how to set up for SMAW STICK welding Art A 07869 Pruden ors A Lisez le Manuel d Op rateurs Process the suggested weld current Refer to electrode manufacturer October 30 2008 6 7 POWERMASTER 400SP 500SP AUTOMATION 6 8 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION SECTION 7 BASIC SERVICE 7 01 Maintenance Maintain more often Warning if used under severe Disconnect input power before maintaining conditions Each Use Visual check of Visual check of torch regulator and p
45. AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protec tion Association Batterymarch Park Quincy MA 02269 oafe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 As sociation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 oafe Practices for Occupation and Educational Eye and Face Pro tection norme ANSI Z87 1 American National Standards Insti tute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 POWERMASTER 400SP 500SP AUTOMATION 1 07 Graphique de Symbole Seulement certains de ces symboles apparaitront sur votre modele Sous Tension Hors Tension Tension dangereuse Augmentez Diminuer gt O O Disjoncteur Source AC Auxiliaire Intensit de Courant V Tension Hertz cycles sec Fr quence Len ESL Terre de Protection Courant Continue DC DD Connexion de la Ligne Source Auxiliaire Classement de Prise No Source Auxiliaire Tri Phase Statique Fr quence Convertisseur Transformateur Redresseur Distant Facteur de Marche Pourcentage Panneau Local Soudage Arc Electrique Avec
46. Air Carbon Arc welding release to stop Cutting 9 4 Step Trigger 02 Operation Press and hold for preflow release Positive Constant Voltage to start arc Press to stop arc and Or Constant Potential hold for preflow Direct Current DC High Temperature Bumback Time Fault Indication Ground Inches Per Minute Line Arc Force Meters Per Minute Auxiliary Power Wire Feed Function Wire Feed Towards Workpiece With 4 Output Voltage Off Welding Gun Purging Of Gas Continuous Weld Ke Mode Spot Weld Mode Spot Time Receptacle Rating Auxiliary Power October 30 2008 1 5 POWERMASTER 400SP 500SP AUTOMATION 1 04 Precautions De Securite En Soudage A L arc N MISE EN GARDE 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 LE SOUDAGE A L ARC EST DANGEREUX Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et a la propri t si l utilisateur n adh re pas strictement a toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En
47. CAUTION All Tiptronic jobs are deleted Torque Setting s All power semi conductors and mounting screws should be tightened with a torque wrench to 1 5 Nm October 30 2008 0 3 POWERMASTER 400SP 500SP AUTOMATION 8 09 Control Transformer 655 8021 0 655 8023 0 primary secondary 8 4 Pos 4 HE AE 5 0 42V 2 230V 2 5A i 18V 1A 11 0 18V te 18V 0 4A 13 0 18V 14 18V 0 4A 15 0 18V 0 400V Pos 2 Pos 0 42V 400V secondary 2 42V 3 5A primary Secondary 20V 3A 0 400V 1 gt Art A 07733 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 8 10 DP MAPRO PC Board The DP MAPRO pc board is responsible for the welding sequence and is managing the process control of the machine MAPRO MAster PROcess Functions e driving coolingpump e Logicfunctions of the welding process e monitoring flowmeter e generating and monitoring supply voltages monitoring mains and output voltage driving powerup relays generating signal welding current driving power unit units e managing communications between and e monitoring control and operating elements machine DS20BF remote control torch buttons managing and storage of all welding e driving fans parameters e CAN bus Normal LED Displays LED 7 jdesignaion micro controller ok DSP is working micro controller is working Malfunction LED Displays HED State aooo designation
48. Current voltage display The actual welding voltage and welding current values are indicated during welding After the welding procedure the Hold LED illuminates and the last welding voltage and welding current values are indicated When the operator changes certain welding adjustments e g thickness program job the Hold LED goes out and the preview values for current and voltage are displayed 4 3 POWERMASTER 400SP 500SP AUTOMATION A 4 03 Menu Structure O 10 sec notin SMAWISTICK electrode process Start rent 20 200 ofthe welding curent Sancie _________ JO 10560 notin stroke AT mode Twin pulse frequency SHzoWiwmusemoe pulse current change 5 50 of the welding current only in TwinPulse process Twin puise relation 0 80 onyin TwinPulse process Welding current Adjustment range depends on the selected material wire gas combination Downslope 10 990 A sec not in SMAW STICK process only when downslope on Crater fill current 10 200 of the welding current not in SMAW STICK process only when slope on or in 4 4T stroke Crater fill time 0 10 sec not SMAW STICK process only for slope on Wire burnback time 20 300 of the programmed value not in SMAW STICK process Gas post flow 20 200 of the programmed value not in SMAW STICK process Arc length correction 60 140 of the programmed value Inductor effec
49. ER LA PEAU ET LES YEUX Les accumulateurs contiennent l lectrolyte acide et d gagent des vapeurs explosives AAA er October 30 2008 1 Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule Utilisez la polarit correcte et de l accumulateur e m d AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression Et 1 N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant doter compl tement le bouchon 1 06 Principales Normes De Securite Safety in Welding and Cutting norme ANSI 749 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superinten dent of Documents U S Government Printing Office Washing ton D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme
50. Electrode Enrob SMAW Soudage L arc Avec Fil Electrodes Fusible GMAW Soudage L arc Avec Electrode Non Fusible GTAW Decoupe Arc Carbone CAC A Courant Constant Tension Constante Ou Potentiel Constant Haute Temp rature Amorcage de L arc au Contact GTAW Inductance Variable Tension Deroulement du Fil Alimentation du Fil Vers la Piece de Fabrication Hors Tension Torch de Soudage Purge Du Gaz Mode Continu de Soudure Soudure Par Point Durec du Pulse Dur e de Pr Debit Dur e de Post Debit Detente a 2 Temps fa Appuyez pour deruarer Palimentation du fils et la soudure le rel cher pour arr ter D tente a 4 Temps yy Maintenez appuyez pour pr debit relailez pour initier l arc Appuyez pour arr ter l arc et mainteuir pour pr debit Probl me de Terre Pouces Par Minute Metres Par Minute Art A 07639 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION SECTION 2 INTRODUCTION 2 01 How To Use This Manual This Owner s Manual applies to just specification or part numbers listed on page 1 To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognised as follows A WARNING A WARNING giv
51. IHERMAL A RC POWERMASTER AUTOMATION Art A 07790 ervice Manual Revision AB Issue Date October 30 2008 Manual No 0 4971B Operating Features AAA Se AMP IHERMAL A RC A 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 Service Manual Number 0 4971B for PowerMaster 500SP Automation Bw Robotic US W1000602 PowerMaster 400SP Automation Bw Robotic US W1000402 SP4000R Automation Wire Feeder US W3000302 Remote Operation Panel Pendant W4001001 Published by Thermadyne Industries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermadyne com Copyright 2008 by Thermadyne Industries Inc 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 Original Publication Date October 30 2008 Revision AB Date December 23 2008 Record the following information for Warranty purposes Where P
52. STER 400SP 500SP AUTOMATION APPENDIX 7 ROBOTIC INTERFACE DIAGRAM A 10 Power Source Art A 07832 1 E Program orjobsettingbit2 mu lt 2 e Program or job setting bit2 NN 3 1 A Program or job setting bit2 NI 4 A Program or job setting bit2 NN Program or job setting bit2 NY 6 gt Program or job setting bit2 mu lt IL Program or job setting bit2 NY BL A Job setting NI 9 A Welding on wire feed unit 1 mu I 10 E Welding on wire feed unit 2 mu lt 11 A GND 24VDC digital mu X DAMEN Power source o k Le 13 gt mu lt 14 gt 0 signal welding current on L 5 1 2 Set extern NY 16 A Set up mode mu lt Wl A Set slope NY 18 A Set puls mu lt gt Set twinpuls NY 20 A Wire feed mu ST 21 A Gas test mu SH 22 E GND 24 VDC digital mu I 23 A Energ mu X 24 A Arc length mu I 23 A Start current NI 26 A Downslope mu SH 27 Start time NY 28 A Final current mu X 29 A Final current time mu lt 30 gt Twin puls frequence mu TI 31 gt GND 10 VDC analog mu I 3 ln Secondary output current 10mV 33 Secondary output current GND 1A 10 mV 34 A Collision protection NY 35 Collision protection mu gt 64 Contact sensor L 37 gt Gas monitoring mu lt 3 N Gas monitoring L 39 Secondary output voltage 40 M Secondary output voltage mu gt 41 Air blast valve 24VDC 2 40 42 Air blast valve 24VDC S00 0024 0 00 IN
53. TO6 Robotic Interface pe board MAPRO 2 2 3 X 1 2 709 0153 0 fuse 1 0A TR 5X20 X GND 24VDC digital 24VDC digital 24VDC digital 24VDC digital 0 10VDC analog 10VDC analog 10VDC analog 10VDC analog 10VDC analog 1 analog 10VDC analog 10VDC analog Option Option Option Option Option Option Option Option Option Option Option October 30 2008 POWERMASTER 400SP 500 AUTOMATION APPENDIX 8 RECTIFIER DIODE DATA SHEET BYT230PIV 1000 J BYT231PIV 1000 FAST RECOVERY HECTIFIER DIODES K2 A2 K1 A1 BYT231PIV 1000 BYT230PIV 1000 MAIN PRODUCT CHARACTERISTICS da ___ 1000 V TE FEATURES AND BENEFITS VERY LOW REVERSE RECOVERY TIME a VERY LOW SWITCHING LOSSES a LOW NOISE TURN OFF SWITCHING INSULATED PACKAGE ISOTOP Insulation voltage 2500 Vrms Capacitance 45 pF Inductance 5 nH Plastic DESCRIPTION Dual high voltage rectifier devices are suited for free wheeling function in converters and motor control circuits Packaged in ISOTOP they are intended for use in Switch Mode Power Supplies ABSOLUTE RATINGS limiting values per diode Sm 30 Surge non repetitive forward current tp 10 ms Sinusoidal Storage temperature
54. TROCUTION PEUT ETRE MORTELLE de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode 8 N utilisez pas de c bles lectriques us s endommag s mal Une d charge lectrique peut tuer ou br ler piss s ou de section trop petite gravement L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit 9 N enroulez pas de c bles lectriques autour de votre corps d alimentation et les circuits internes de 8 l quipement sont aussi sous tension d s la mise 10 N utilisez qu une bonne prise de masse pour la mise a la en marche En soudage automatique ou semi terre de la piece a souder automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement 12 N utilisez que des quipements en bon tat R parez ou inad quatement install ou inad quatement mis remplacez aussit t les pi ces endommag es la terre est dangereux 1 Ne touchez pas des pi ces sous tension 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant 2 Portez des gants et des v tements isolants
55. U S Gov ernment 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 and 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 ques tions 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 Arrange cables to one side and away from the operator Do not coil or drape cable around the body Xe gt 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 1 4 1 02 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 449 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washi
56. UTOMATION 3 03 Connecting 3 Phase Input Power to 400SP or 500SP AN WARNINGS Installation must meet all National and Local Codes have only qualified persons make this instal lation Disconnect and lockout tagout input power before connecting input conductors from unit Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal Make input power connections to the welding power source first Three Phase Three Phase Min Input Conductor Size Min Input Conductor Size GND PE Ground Ground Conductor NN Line lt Disconnect Switch Art A 07877 Line Fuse en Power Cable customer supplied 3 2 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION AN WARNING Never connect the safety ground screw to one of the three line phases This would represent a serious electrical shock hazard The wiring to this machine should be performed by a qualified person only A Input Power Conductors Customer Supplied Cord oelect size of conductors using table Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size B Welding Power Source Input Power Connections Pure rr Remove the side panel next to the strain relief Route conductors cord through strain relief and Art A 07858 tighten screws Connect input con
57. W1000602 SP4000R Automation Wire Feeder US W3000302 Remote Operation Panel Pendant W4000101 October 30 2008 9 1 POWERMASTER 400SP 500SP AUTOMATION 9 03 PowerMaster 400SP amp 500SP Robotic Exploded View Parts List 1 of 2 Ui Description Schematic Ref Part Number 1 1 PCB Harting Adaptor 42P W7000064 2 42 Socket Contacts Harting 42 SP W7000078 2 1 Socket Tray Harting 42 SP W7000077 3 1 Housing Harting 42P 43x93 DP W7000079 4 1 Quick disconnect Gas Female SP W7004135 5 1 Gas Hose 6ft 5 8 18UNF SP W7000094 6 1 Socket Panel 8Pin SP W7000060 1 Terminal Output SP W7000051 8 1 QuickDisconnect Red Female SP W7004134 9 1 QuickDisconnect Blue Female SP W7004133 10 1 Cable robot control 42pin 10m W4000700 11 1 Hinge 40x40 Black Plastic SP W7000093 12 1 switch Multi Voltage 3205P W7000048 13 1 Panel Control Cover 400 500SP W7004140 13 1 Panel Cover 400 500SP W7004141 13 Screw Kit 320SP 400SP 500SP W7004186 14 1 Panel Plastic Feed Motor SP W7000091 9 2 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION POWERMASTER 400SP 500SP AUTOMATION 9 04 PowerMaster 400SP 500SP Robotic Exploded View Parts List 2 of 2 9 4 Item Qty Description Schematic Ref Part Number 15 1 Panel Side LH 400SP A 500SP W7004131 16 1 Mat Rubber 560x350mm SP W7004122 17 1 Transformer 208 460 20 42 5 W7000031 18 1 Handle Left Side Molded SP W7000071 19 1 Handle Tube 30nmx397mm 5005 W7000070 20 1 Handle Right Side Molded SP W70000
58. _ 3 Phase A 25 80 70 40 35 Max Recommended Standard Normal Operating Fuse __1 Phase 110 100 60 50 110 100 60 50 Max Recommended Circuit Breaker or Time Delay Fuse 1 Phase A 100 90 50 45 100 90 50 45 Current Range for SMAW Stick 2min 2max 10 380 10 480 Power factor at Maximum Output Jos Maximum Open Circuit Voltage 20 Jy 9 79 5 500 Electrical Specifications for GMAW P GMAW FCAW MIG with Three Phase Input Power Wein Output 400SP 500 P Duty Cycle 100 3 Phase Duty Cycle at Maximum Current 3 Phase 50 400 34V 60 500 39V Input Power 51 at 100 Duty Cycle 3 Phase kVA Input Current 11 at60 Duty Cycle Phase 37 33 20 17 66 59 34 30 Input Current 11 at Maximum Output 3 Phase A 46 41 24 21 66 59 34 30 Welding Output Duty Cycle 100 1 Phase Duty Cycle at Maximum Current 1 Phase X 50 04004 34V 50 400 34V 230 400 460 Generator Requirement with Single Phase 1 Phase 30 Input Current at 100 Duty Cycle 1 Phase Input Current 11 at 60 Duty Cycle 1 Phase 68 40 35 74 68 40 35 Input Current 11 Maximum Output 1 Phase 92 BEE lt gt gt i N gt O Elle October 30 2008 2 3 POWERMASTER 400SP 500SP AUTOMATION 2 06 Power Supply Specifications part 2 lectrical Specifications for SMAW STICK with Three Phase In
59. a Switch the Tiptronic function on by pressing Tiptronic 49 associated LED comes on b Select job number with the smart torch rocker 61 or with the push buttons 44 and 48 an active job is indicated in the smart torch display 60 and in digital multifunction display 54 with a decimal point between the job set and the job number c Hold the Enter push button 47 pressed fortwo seconds the decimal point in the smart torch display 60 and in the digital display 54 goes out 4 Setting a job active a Switch the Tiptronic function on by pressing Tiptronic 49 associated LED comes on b Select the job number with the push buttons 44 and 48 with an inactive job the decimal point between job set and job number Is missing October 30 2008 POWERMASTER 400SP 500SP AUTOMATION Hold the Enter push button 47 pressed for two Seconds the decimal point between the job set and the job number lights 5 Re saving Re programming jobs a Switch the Tiptronic function on by pressing Tiptronic 49 and select a job see Selecting Jobs b Change the settings as required Press the Save button 45 Save LED flashes d Press TT Enter button 47 to confirm e The Save and Enter LEDs flash briefly to confirm that programming is terminated d The cursor is moved with the and y push buttons 51 At the end of the line
60. additional wire feeder Functions e switching between wire feeder 1 and wire feeder 2 e driving gas valve e driving water valve Normal LED Displays 41 green wire feed unit 1 is active wire feed unit 2 is active 8 8 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION SECTION 9 PARTS LIST 9 01 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 Specification or Assembly numbers 9 02 How To Use This Parts List The Parts List is acombination of an illustration and a corresponding list of parts which contains a breakdown 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 permanently 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 ques tion from the illustration and refer to that item number in the corresponding Parts List SYSTEM CATALOG NUMBERS PowerMaster 400 Automation Bw Robotic US W1000402 PowerMaster 500 Automation Bw Robotic US
61. an be dangerous WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Za Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes y 7 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable October 30 2008 1 2 Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine we WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and Securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when Servicing is finished and before starting engine WS WARNING
62. arc C Long arc Long arcs are typically at a higher ampere range under carbon dioxide and gases with a high CO2 content It is not particularly suitable for positional welding In this type of arc large drops are formed which falls into the welding pool mainly by force of gravity This results in occasionally short circuits occurring which increases the current at the moment of the short circuit and high spatter levels when the arc is reignited D Spray arc The spray arc is not suitable for positional welding due to the extremely liquid nature of the welding pool The spraying arc forms by welding at the higher range of ampere using inert gas or mixtures with high argon content The most typical characteristic of the spray arc is the transfer of extremely fine molten metal droplets across the arc October 30 2008 E Working range at GMAW welding Wire Long arc Transitional diameter Spray are arc 180 28 150 22 130 18 250 30 200 24 160 19 220 25 170 19 120 17 320 34 300 28 200 21 Favorable welding characteristics are only possible if voltage and current are correctly adjusted CO2requires an arc voltage approximately 3 V higher than gas mixtures with a high argon content 6 1 POWERMASTER 400SP 500SP AUTOMATION 6 02 Holding and Manipulating the Torch NOTE Metal shielded gas welding can be welded in all positions horizontal vertical down vertical
63. chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication 1 de la CGA identifi e dans la liste de docu ments ci dessous f e AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs 1 2 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es 51 vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es a l ext rieur loin des prises d air du b timent October 30 2008 POWERMASTER 400SP 500SP AUTOMATION f 47 AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable EE 1 Arr tez le moteur avant de v rifier le niveau carburant ou de faire le plein 2 Ne faltes pas le plein en fumant ou proche d une source d
64. ct type and size of over current protection using table fused Line Disconnect Switch shown Greens vaou PP PE G Close and secure door on Line Disconnect Switch H Remove lockout tagout device and place switch in the On position October 30 2008 3 9 POWERMASTER 400 500SP AUTOMATION 3 05 Quick Start Set Up 3 6 UJ U c TI TI E NOTE Please refer to Sections 3 04 Recommended Equipment Setup and SECTION 4 Control Panels for explanations of the controls WARNING Thermal Arc advises that a suitable Mains Plug be fitted to this equipment by a qualified electrical trades person Where equiped place the gas cylinder on the power supply cylinder tray and secure with the two safety chains If unit is not equiped with this option then ensure thatthe gas cylinder is secured to a building pillar wall bracket or otherwise securely fixed in an upright position Remove screw cap from gas cylinder if fitted and open gas cylinder valve briefly to remove contaminants Connect gas regulator to gas cylinder Connect gas hose from power supply to gas regulator and open gas cylinder valve Connect input power refer to previous WARNING and the Connecting Input Power Section Connect work lead to Negative connection and attach Work clamp to workpiece Fit the correct size feed rollers to wire feeder then fit the selected welding wire and set the pr
65. cturer supplier uncertain Keep the wire covered contaminates Poor current transfer to the wire at the contact tip Use a copper or brass jump liner in the conductor tube to improve current transfer to the wire Stanless steel weld has Arc length control 58 has been adjusted too high Reduce arc length control 58 a dark burnt finish Dirty aluminum welds Inadequate gas coverage Increase gas flow by 10 and check again Shield arc from drafts Hold nozzle closer to the work Replace the damaged nozzle to center contact tip in nozzle Keep the wire covered Work piece is contaminated with grease or oil Degrease with mineral spirits etc to remove MR Poor current transfer to the wire at the contact tip Use a copper or brass jump liner in the conductor tube to improve current transfer to the wire Weld performance 15 Incorrect wire gas combination selected Set the correct gas wire combination very poor or high spatter levels Poor weld starts Improper work lead connection Reconnect work lead Contact tip is worn with an oval shape hole or Replace contact tip contact tip is black Contact tip is loose Tighten contact tip Varying arc length Material build up in torch liner Replace torch liner when welding Contact tip is worn or damaged Replace contact tip October 30 2008 1 3 POWERMASTER 400SP 500SP AUTOMATION 7 04 Error Codes In case of a malfunction an error code is indicated on the digital multifunction display
66. d 75Ar 045 1 1 Y 71 1 25C02 062 1 6mm 045 1 1mm FluxCored 79AU 052 1 4 E70C 6M 25C02 062 1 6 030 0 8mm Stainless Soe 035 09mm y 08 309 045 1 1mm y DARE 030 0 8mm Y r 99 oco 035 09 045 1 1mm y 030 0 8mm 035 0 9mm y 316 045 1 1mm 930 0 8mm r 53 oco 035 0 9mm EUM 035 0 9mm 045 1 1 Y 047 1 2 Y lt lt lt lt lt lt 4 4 4 lt lt lt amp 441444444 48444 lt 31 64 33 64 17 32 35 64 37 64 19 32 39 64 41 64 21 32 672 43 64 11 16 45 64 23 32 734 47 64 49 64 781 25 32 197 51 64 13 16 828 53 64 844 27 32 55 64 875 57 64 29 32 59 64 15 16 61 64 31 32 984 63 64 25 00 Refer to Warranty Schedule 484 lt lt lt lt 547 78 75Ar 047 1 2mm Y 25 1 062 1 6mm 062 1 6mm NA 75Ar 047 1 2mm Y 25He 062 1 6 AA 045 1 Y lt D Co elen ON NN lt lt O1 C9 C AO lt mr zmm 062 1 6 045 1 1mm 75 062 1 6mm Silicon 035 Y 045 1 1mm lt Aluminum 5183 lt lt lt tee
67. ductors as shown in illustration Connect green or green yellow grounding conductor to welding power supply grounding terminal first Then connect input conductors L1 L2 and L3 to welding power supply line terminals Reinstall side panel onto welding power supply C Turn the Line Disconnect Switch off D Connect the green or green yellow grounding conductor to the Line Disconnect Switch ground terminal first E Connect input conductors 11 L2 and L3 to the AT Line Disconnect Switch terminals ZC Black F Select type and size of over current protection Ivey White using table fused Line Disconnect Switch shown NE G Close and secure door on Line Disconnect Switch H Remove lockout tagout device and place switch in the On position GND PE GND PE Green amp Yellow October 30 2008 3 3 POWERMASTER 400SP 500SP AUTOMATION 3 04 Connecting Single Phase Input Power to 400SP or 500SP N WARNINGS Installation must meet all National and Local Codes have only qualified persons make this instal lation Disconnect and lockout tagout input power before connecting input conductors from unit Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal Make input power connections to the welding power source first Single Phase Single Phase Carolprene Jacketed Type SOOW 90 C 600 Volt UL CSA Portable Cord GND PE Ground Ter
68. dy 10 Ground the workpiece to a good electrical earth ground WARNING 11 Do not touch electrode while in contact with the work ground circuit ELECTRIC SHOCK can kill 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also 14 Wear a safety harness to prevent falling if working above live when power is on In semiautomatic or floor level automatic wire welding the wire wire reel drive roll housing and all metal parts touching the 15 Keep all panels and covers securely in place welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Anh EU 1 Do not touch live electrical parts A WARNING 9 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself from work and ground using dry insulating RAYS can burn eyes and skin NOISE can mats or covers damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that 4 Disconnect input power or stop engine before installing or can burn eyes and skin Noise fro
69. e feed rolls system Solid Hard Wire Wire Size 023 030 0 6 0 8mm 035 0 9mm W6000500 W6000501 052 1 16 1 4 1 6mm 030 035 0 8 0 9mm W6000504 W6000505 035 045 0 9 1 2mm W6000502 045 1 2mm W6000503 W6000506 O 045 052 1 16 12 14 16 W6000507 0307 035 0 8 0 9mm W6000508 Il 035 3 64 0 9 1 2mm W6000509 Il y 3 64 1 16 1 2 1 6mm W6000510 ____ PartNo Description 0 2 2 October 30 2008 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION APPENDIX 3 MOUNTING THE TORCH HOLDER Art A 07728 3 APPENDIX 4 SP SERIES BLOCK DIAGRAM POWERMASTER 400SP 500SP AUTOMATION bo Com UK GLCL lI LL eee Lee Art A 07729 October 30 2008 4 POWERMASTER 400SP 500SP AUTOMATION pr 71 1 fan my EE pan EEN Less flowmeter r alternative c Firm 0520 socket RIDERS alternative pe board DS VA socket ES 1 pom con ue DS208F La DS VA MENS ege ec viet mg wire feed wie a ue qu mE mE 4 torch switch 2 boe ah Lg
70. e program window different parameters inputs can be enabled or disabled by click ing on the buttons 1 10 A clicked button means en abled a released button means disabled In the right part of the program window all voltage levels of the analog inputs are displayed as sliders and their actual value The version of the operating system of the robot in terface is displayed in the status line below With the Drop Down lists next to the buttons 1 through 8 any parameter can be assigned to the eight analog inputs Those assignments are also saved per manently into the machine Assigning one parameter to several inputs is not possible When assigning the parameters notice that some parameters are only usable in certain operating modes e g twinpulse frequency on PowerMaster SP Range is only available when the twinpulse mode is active October 30 2008 le Gaztest Setup mode Wie feed Stick check RobotTool Robot interface tool Start Start Program Job Welding mode Jobsetting Slopes pulse No Pulse P X Welding current 1 Kutten 2 conection VI Fam Dowsipe noo v Crater fil current 7 8 8 Twin pulse frequeney Program External 10 Wielding mode External i Set External On EE Job Analag input lt
71. ed Portafeed PowerMaster Original Main Power Transformer and Inductor Original Main Power Rectifiers Control P C Boards power switch semi conductors All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors GTAW TIG 8 MULTI PROCESS INVERTER WELDING EQUIPMENT 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards power switch semi conductors All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors PLASMA WELDING EQUIPMENT Ultima 150 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards power switch semi conductors Welding Console Weld Controller Weld Timer All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year SMAW Stick WELDING EQUIPMENT Dragster 85 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 160S 300S 400S Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original c
72. es information regarding possible personal injury CAUTION CAUTION refers to possible equipment damage NOTE NOTE offers helpful information concerning certain operating procedures Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number listed in the inside back cover of this manual Include the Owner s Manual number and equipment identification numbers Electronic copies of this manual can also be down loaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link http www thermalarc com October 30 2008 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container Record these numbers on the bottom of page for future reference 2 03 Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims
73. essure levers to position 2 Connect torch central socket coolant connections red blue and mount contact tip to fit welding wire selected Insert welding wire Turn on main switch Press push button and push button gas type solenoid valve is activated and adjust gas amount on the gas regulator Keep the wire inch switch pressed until the welding wire protrudes approximately 3 8 inch 10 mm out of the MIG torch nozzle 3 06 Recommended Setup for MIG A Torch Connection Tweco PulseMaster PMA5 shown as an example 1 Open the door panel to the machine by turning the release knobs and pulling the cover outward and up 2 Route the gun cable through the access hole in the front panel 3 Locate the thumbscrew on the gun adapter inside the unit Loosen the thumbscrew and insert the gun cable end into the gun adapter as far as it will go Tighten the thumbscrew 4 Align the keyways of the gun switch connector with the trigger receptacle next to the gun cable and plug them together Secure by turning the locking ring to the right clockwise 5 If a coolant cooling system is installed connect the coolant hoses of the torch with the coolant sockets on the front panel Be sure to connect the red fittings together and the blue fittings together Front Panel Access Hole Trigger Receptacle Hot coolant return Red Cool coolant to torch When disconnecting gun switch leads from the machine
74. gh signal welding current from LSW pc board Encoding Power Unit 3 p 3 o 0 contact open 1 contact closed If DIP switches are used instead of jumpers 0 1 Normal LED Displays LED designation Malfunction LED Displays LED state reson O 1 red primary current is too high power unit has been switched off 2 green no drive level low side 4 green DC link voltage is too high e g mains overvoltage 5 green no drive level high side 6 green DC link voltage is too low e g mains voltage too low October 30 2008 8 7 POWERMASTER 400SP 500SP AUTOMATION 8 16 DK GLCL PC Board The DK GLCL pc board is for wiring the secondary rectifier diodes Functions e wiring e pulse smoothing 8 17 DP UFI BO PC Board Functions e wiring welding sockets e providing output voltage 8 18 DP EMV PC Board Functions EMC filter 8 19 LSW PC Board LSW pc board is a potential free current sensor Functions e measuring welding current 8 20 DS VA PC Board The DS VA pc board is the digital volt and ampere display Functions e display nominal and actual values of welding voltage and welding current e hold function of the last welding values Normal LED Displays LED state designation 1 green lon holf function active 8 21 DS ERW PC Board The DS ERW pc board is the extension pc board for machines with
75. h switch button until the wire Screw out the contact tip in the MIG torch handset appears approximately 3 4 inch 20 mm out of the Open the wire feed compartment lid on the power torch neck supply or wirefeed case Screw in the contact tip corresponding to the wire The diameter of the wire should correspond to the diameter and cut off any wire sticking out diameter of the feedrolls The wire size is on the face of the feedrolls Open the pressure lever and thread the wire through the inlet guide and the outlet guide If the Wheeling Kit option has been installed position a gas cylinder on the rear tray and lock securely to the Power Source cylinder bracket with the chains provided If this arrangement is not used then ensure that the gas cylinder is secured to a building pillar wall bracket or otherwise securely fixed in an upright position G How To Connect The Gas Cylinder Open the gas valve once to blow out possible dirt particles Connect the gas regulator to the gas cylinder valve Connect the gas hose to the gas regulator Open the gas cylinder valve and adjust the gas flow on the gas regulator while pressing the torch trigger switch The quantity will be shown at the flowmeter This should be approximately Switch on power supply at main switch stretch torch cable out straight and press the inch switch button in the wire feed compartment Adjust the pressure at the pressure adjustment screws so the wire feed ro
76. he cursor with the Wand push buttons 51 change the character with the pushbuttons 48 and 44 Version number operating system Master Version number operating system process Version number motor assembly Version number welding programs Indication of the welding duration in h min sec Module temperatures Flow rate cooling unit 3 Language 4 Display contrast 5 Mode cooling system O normal 2 off 6 Lock function 7 Arc length contro Voltage PO m CH O e gt gt S EJE 5 O 2 lt keen e 5 O 3 o lt e CH 5 8 Robot interface 4 4 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION Level Extras Enter menu item by pressing both keys 51 at the same time 1 Machine data Change between menu items with Main Menu Gas pre flow Operating system Master system Operating system Master Start current Operating system Process system Operating system Process Start current time Operating system DMR system Operating system DMR keys 48 amp 44 Twin pulse frequency Welding programs programs Twin pulse current change Operating hour counter Operating hour counter counter Twin pulse relation Configuration Welding current Downslope Crater fill current Crater fill time Wire burnback time Gas post
77. inless steel e Deeper weld penetration e Accurate penetration on sheet metal e Superior welding characteristics on hard facing and high alloy steels e The ability to use larger than normal diameter wires on thin base material providing a cost saving on wire e Spray arc welding vertical up giving smoother welds better control and deeper penetration e Improved edge wetting in Pulse GMAW process At the lower end of the performance range the pulsed arc cannot fully replace the dip transfer The reason is the continuous arc that occurs in the primary current phase This phenomenon does not exist with the short circuiting arc An exception to this is when welding aluminium and aluminium alloys Normally these materials can only be reliably welded using a pulsed arc In the upper performance range the pulsed arc is preferable to the sprayer arc in particular for welding aluminium materials and high alloy steels 6 5 POWERMASTER 400SP 500SP AUTOMATION 6 05 Smart Pulse or TwinPulse 6 06 Conventional Manual GMAW GMAW Welding FCAW Welding The following instructions explain how to set up for The following instructions explain how to set up for Smart GMAW or Pulse GMAW or TwinPulse welding conventional manual GMAW welding Art A 07867 Art A 07868 r Ter Pruden cd i 4 Prudence Lisez le Manuel d A e 5 Lisez le Manuel Manual Op rateurs Op rateurs Art A 07870 Processes A Set Manual GM
78. ircuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors GENERAL ARC EQUIPMENT Water Recirculators Plasma Welding Torches 180 days Gas Regulators Supplied with power sources 180 days MIG and TIG Torches Supplied with power sources Replacement repair parts MIG TIG and Plasma welding torch consumable items WARRANTY PERIOD LABOR 3 years 3 years 1 year 3 years 3 years 1 year LABOR 3 years 3 years 1 year LABOR 3 years 3 years 3 years 1 year LABOR 1 year 1 year 1 year 3 years 3 years 1 year LABOR 1 year 180 days Nil Nil Nil Nil IHERMAL A RC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wvecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jin Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 6
79. ital inputs 1 and 2 pin 1 and 2 LIMITS EE NEN Opt01 Analogln1 analog input is enabled corresponds with DIP switch 1 set to ON an Ea analog input is disabled Opt02 Analogin2 analog input is enabled corresponds with switch 2 set to ONT d analog input is disabled OptO3 Analogln3 analog input is enabled corresponds with DIP switch 3 set to ONT analog input is disabled Opt04 Analogin4 analog input is enabled corresponds with DIP switch 4 set to ONT analog input is disabled mm a analog input is enabled corresponds with DIP switch 5 set to ON analog input is disabled analog input is enabled corresponds with switch 6 set to ONT analog input is disabled analog input is enabled corresponds with switch 7 set to ONT analog input is disabled analog input is disabled program selection is enabled corresponds with switch 9 set to ONT program selection is disabled operating mode selection is enabled corresponds with DIP switch 10 set to ONT operating mode selection is disabled robot mode is active corresponds with the signal set extern manual hand mode is active When using job selection tiptronic mode it is possible during the welding to change enabled parameters over the analog inputs For example during the welding process the welding current can Opt11 Setextern be altered with the control voltage at the analog input 1 Opt01 Analog n1 must be set to ONT Op
80. jects can cause sparks overheating FUMES AND GASES can be hazardous to your or fire health 5555255555535 1 Protect yourself and others from flying sparks and hot metal Welding produces fumes and gases Breathing and gases be hazardous to your 2 Donotweld where flying sparks can strike flammable material ealth 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved 1 Keep your head out of the fumes Do not breathe the fumes N 2 Ifinside ventilate the area and or use exhaust at the arc to 4 Be alert that welding sparks and hot materials from welding remove welding fumes and gases can easily go through small cracks and openings to adjacent 3 If ventilation is poor use an approved air supplied respirator areas 4 Read the Material Safety Data Sheets MSDSs and the gt Watch for fire and keep a fire extinguisher nearby manufacturer s instruction for metals consumables coatings 6 Be aware that welding on a ceiling floor bulkhead or partition and cleaners can cause fire on the hidden side 5 Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be surethe 8 Connect work cable to the work as close to the welding area 7 Donot weld on closed containers such as tanks or drums breathing air is safe
81. lding bead is wide and flat with increased spattering The welding material is transferred with slightly larger drops than welding with a shorter arc A longer arc is useful for welding a fillet weld to form a flat or concave seam Welding with a shorter arc at the same amperage increases the penetration the welding bead is narrow and high with reduced spattering The welding material is transferred with smaller droplets Art A 06381 Long Arc Short Arc B Length of the wire electrode The distance between the torch and the workpiece should be 10 12 times the diameter of the wire Altering the distance of the torch will influence the electrode stick out A longer electrode stick out reduces the amperage and the penetration A shorter electrode stick out increases the amperage if the wire feed speed remains the same Art A 06382 Long electrode stick out Short electrode stick out October 30 2008 POWERMASTER 400SP 500SP AUTOMATION C Material Transfer in DI 10 00 ms Art A 06384 8 10 12 14 t ms 18 Benefits e Controlled short circuit proof material transfer without spatter e Low thermal transfer due to low primary current Disadvantages e Only shielding gases with low 602 content can be used October 30 2008 6 3 POWERMASTER 400SP 500SP AUTOMATION 6 03 Basics of Pulsed Arc Welding A Current and voltage pulses Material transfer is achieved by current and voltage pulses control
82. led at the same rate as the pulse frequency The arc power is changed by the ratio between background and pulses current the pulse duty cycle and the pulse frequency Art A 06383 B Forces acting during material transfer A number of forces come into play which influences the resulting molten metal drop formation and separation Acceleration due Wire electrode to gravity Electromagnetic force F pinch effect A L Constrict drops tension S Geh Force of inertia Forces of repulsion Fg of evaporating material Electrostatic Forces Eddying forces caused by Workpiece lasma flow NOTE The main force components for separating the drops are electromagnetic force pinch effect 6 4 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 6 04 Pulsed Arc Welding Parameters A Pulse period t The pulse period for separating the droplet is between 1 5 and 3 0 ms depending on wire diameter and the pulse current setting If the pulse period is too long material transfer only takes place during the pulse phase Arc formation and drop rate can be affected by additional pulse stages B Pulse voltage U and pulse current Since welding with pulsed arc is based on the temporary utilization of the pinch effect the drop separating pulse current must always be large enough to exceed critical current intensity depending on wire diameter wire material and shielding gas comp
83. lls drive the wire consistently without slipping The wire should not be deformed gas regulator C gt input gauge nam Art A 06371 0 e gas cylinder valve output gauge Correct Pressure Wrong Size CN A Pressure too High Feedrolls Vt A 0637 Art A 06370 gas cylinder bracket chain Adjust the pressure adjustment next to the inlet guide to a lower pressure less than the pressure adjustment next to the outlet guide this will ensure that the wire will be located correctly in the wire feed unit 3 0 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION H How To Refill The Cooling Fluid Only use original MIG TIG coolant for refill It provides protection against frost down to 4 F 20 C If using other coolants the coolant pump could be damaged Coolant circulation has to be checked at regular intervals Reliable coolant return flow is essential to ensure the coolant is not lost and the coolant cooled MIG torch is not damaged Check the level of the coolant every day before operating The coolant must be visible when the tank cap 37 Is removed Remove the pin from the breather hole in the cap of the coolant tank as leaving the pin in the cap may cause a coolant flow error MIG TIG Coolant 1 Quart 1 L MIG TIG Coolant 1 Quart 5 L October 30 2008 Part No W4001402 Part No W400140
84. m some processes servicing this equipment Lock input power disconnect switch can damage hearing open or remove line fuses so power cannot be turned on LL accidentally 1 Wear a welding helmet fitted with a proper shade of filter 5 Properly install and ground this equipment according to its see ANSI 249 1 listed in Safety Standards to protect your Owner s Manual and national state and local codes face and eyes when welding or watching 6 Turn off all equipment when not in use Disconnect powerto 2 Wear approved safety glasses Side shields recommended equipment if it will be left unattended or out of service 3 Use protective screens or barriers to protect others from flash 7 Usefully insulated electrode holders Never dip holder in water and glare warn others not to watch the arc to cool it or lay it down on the ground or the work surface 4 Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode 5 Use approved ear plugs or ear muffs if noise level is high Wear protective clothing made from durable flame resistant material wool and leather and foot protection October 30 2008 1 1 POWERMASTER 400SP 500SP AUTOMATION Sparks and spatter fly off from the welding arc The 9 flying sparks and hot metal weld spatter hot WARNING workpiece and hot equipment can cause fires and SCH Q2 burns Accidental contact of electrode or welding Wire to metal ob
85. metal arc Under 5 32 in 4 mm 10 O y 52014 12 Plasmaarccuting 4mm 14 Lightf Under300Amp 9 1 2 October 30 2008 1 2 POWERMASTER 400SP 500SP AUTOMATION Wear approved face shield or safety goggles Side shields recommended Wear proper body protection to protect skin gt WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards N WARNING Engines c
86. minal low Ground Conductor 5 Line a Disconnect n 2 Switch Art A 07883 Line Fuse Ns Power Cable customer supplied 3 4 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION AN WARNING Never connect the safety ground screw to one of the three line phases This would represent a serious electrical shock hazard The wiring to this machine should be performed by a qualified person only A Input Power Conductors Customer Supplied Cord oelect size of conductors using table Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Art A 07879 B Welding Power Source Input Power Connections Remove the side panel next to the strain relief Route conductors cord through strain relief and tighten screws Connect input conductors as shown in illustration Connect green or green yellow grounding conductor to welding power supply grounding terminal first Then connect input conductors L1 and L2 to welding power supply line terminals Reinstall side panel onto welding power supply C Turn the Line Disconnect Switch off 1 Phase Input Power Connection PowerMaster 400SP 500SP D Connect the green or green yellow grounding conductor to the Line Disconnect Switch ground terminal first E Connect input conductors L1 and L2 to the Line Disconnect Switch terminals F Sele
87. mming the analog inputs assignment to welding parameters is made with a PC with CAN interface see section 5 09 Robot Tool Software Installation 5 2 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 5 04 Robot Interface Schematic Power Source October 30 2008 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 37 38 V Y Y A Y Y A Y Y AAAA ZN ZN VN Ah AAA A AAA YA V AA Ah A Art A 07832 Program or job setting bit 2 Program or job setting bit 2 Program or job setting bit 2 Program or job setting bit 2 Program or job setting bit 2 Program or job setting bit 2 Program or job setting bit 2 Job setting Welding on wire feed unit 1 Welding on wire feed unit 2 GND 24VDC digital Power source o k gt 0 signal welding current on Set extern Set up mode Set slope Set puls Set twinpuls Wire feed Gas test GND 24 VDC digital Energy Arc length Start current Downslope Start time Final current Final current time Twin puls frequence GND 10 VDC analog Secondary output current 1 10mV Secondary output current GND 1A 10 mV Collision protection Collision protection Contact sensor Gas monitoring Gas monitoring Secondary output voltage Secondary output voltage Air blast valve 24VDC Air blast valve 24VDC 500 0024 0 00 INTO6 Robotic Interface GND 24VDC digital 24VDC digital 24VDC digital
88. nd Warnings chapter included in this manual Neglect of these precautions may result in personal injury A WARNING Make all connections to the power source including electrode and work cables as well as remote control cables with the power source turned off These connections could be electrically live with the power switch ON October 30 2008 4 1 POWERMASTER 400SP 500SP AUTOMATION 4 02 Welding Controls This section explains the displays and buttons in the secondary Control Panel and Primary Control Panel items 3 and 4 see page 2 2 4344 45 46 47 48 49 50 51 Art A 07864 Caution Prudence Read Operators Lisez le Manuel d Manual Op rateurs K 52a b 53 54 55 56 57 58 59 43 Process push button For switching between the operation processes ManualGMAW Conventional GMAW with separate Voltage and Wirespeed controls SmartGMAW Non pulse GMAW with one knob 53 control PulseGMAW Pulse GMAW with one knob 53 control TwinPulse Twin pulse GMAW with one knob 53 control SMAW STICK Stick electrode welding 44 Material push button For selection of the wire material to be welded The push button is also used for the Decre mental function g to reduce the value of a secondary parameter 45 TT Save push button Tiptronic For saving user defined frequently used weld ing jobs 4 2 46 Welding wire diameter push butt
89. nduit to prevent its backward movement TUBE E ASE 1 16 Q CONDUIT LINER ALLEN SCREW REMOVE CONSUMABLES 0 ALLEN SCREW B CONDUIT LINER October 30 2008 gt Ai NOTE When the conduit is fully inserted into the cable assembly and the conduit stop is firmly against the Connector Plug the raw end of the conduit will protrude out of the open end of the gun conductor tube Trim the conduit as shown below The trimmed end which seats in the Gas Diffuser must be filed and reamed smooth on the inside and outside radii so wire feed will not be obstructed 3 Replace Gas Diffuser Contact Tip Insulator and Nozzle 4 Tighten the Allen screw in the conductor tube Ae UTION Do not over tighten the conductor tube screw as this action will result in the distortion of the conduit and will lead to wire feedability problems Dun a Lemoz KIN 9 0224 A 07921 dH re 3 11 POWERMASTER 400SP 500SP AUTOMATION 3 12 October 30 2008 POWERMASTER 400SP 500 AUTOMATION SECTION 4 MANUAL OPERATION 4 01 General Safety Precautions Read and understand the safety instructions at the beginning of this manual prior to operating this machine A WARNING be sure to put on proper protective clothing and eye safeguards welding coat apron gloves and welding helmet with proper lenses installed See Safety Instructions a
90. ngton D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 1 03 Symbol Chart Note that only some of these symbols will appear on your model D Three Phase Static Dangerous Voltage Frequency Converter Transformer Rectifier e AS O O Circuit Breaker X Duty Cycle Shielded Metal CG Gas Metal Arc Gas Tungsten Arc 2 Step Trigger AL Hertz cycles sec Welding GTAW V Operation Press to initiate wirefeed and
91. nless Steel BS 308209 817170718 045 20 eosa 3240 32440 ER308 ER309 55308309 9872 0 0 035 22 52 320 2830 2320 9530830 98727070 05 23 6042 3248 32408 55316 81 1 0 18 os s1 5230 2830 28320 Stainless Stel 55216 817170718 045 32 60498 3242 32432 _ ER316 35316 98 2 0 0 0 s4 5230 2830 2320 38316 98 2 0 0 fous 35 50428 3240 3242 CA14043 100707070 05 36 20200 20290 tim 75 0 0 25 364 40 6832 24382 24392 LAG 757070725 Vi6 a 80388 3238 32380 C856 100707070 035 42 64228 2422 24232 ie 100707070 035 48 242 242 aluminum A5183 100 0 0 0 aa 50 88332 28 320 28370 EE Silicon Bronze SBrwe 100 0 0 0 ot 57 1 2832 28952 October 30 2008 4 9 POWERMASTER 400SP 500SP AUTOMATION 4 06 Welding Setting Selection Guide Wire Gas Combinations 059 Base Material Thickness Guide Synergic Pulse Synergic Pulse Synergic Pulse Decimal Fraction Decimal Material Shield Wire Size Smart amp Twin Smart amp Twin Smart amp Twin Thickness Thickness Thickness Name Gas Pulse MG Pulse MG Pulse thous inches 030 0 8mm Y 035 0 9mm 045 1 1mm Mild Steel un 70 56 030 0 8mm 035 0 9 Y 045 1 1mm Y 052 1 4mm pum Flux Core
92. on For diameter selection of the wire to be welded The push button is also used for the End function with which you can move back to the previous menu level 47 Enter push button Tiptronic For acknowledgment when saving a welding job 48 Gas type push button For selection ofthe gas to be used The push button is also used for the increment function e 0 to increase the value of a sec ondary parameter 49 Tiptronic push button For switching the Tiptronic process on or off 50 Multi function display For indication of all parameter values and mes sages 51 A and Y push buttons Enter For switching between the individual second ary parameters Pressing both push buttons atthe same time is used for acknowledgment Enter 52a 2 stroke 2T 4 stroke 4T push button For switching between 21 and 4T Latch op eration process lit LED indicates the cur rently selected operating process 52b Spot Welding Mode push button Activate the Spot Welding Mode by pressing and holding the 21 4T button for 2 seconds at which point the 2T and 41 leds will both be lit The spot welding time parameter can then be adjustedin the main display 53 Smart Power control knob sets welding current or material thickness or wire speed in SmartGMAW Pulse MIG TwinPulse process OR Arc Voltage control knob Sets welding arc voltage in ManualGMAW process 54
93. or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 25 POWERMASTER 400SP 500SP AUTOMATION 2 04 Machine Gomponents 16 SP4000R Wire Feeder MIG Torch Connection Socket Handle Mains On Off Switch Air Intake Negative Connection Socket for Work Lead INTOG Robotic Interface Cable INTOG Robotic Interface Connection Plug N O A N Remote Pendant Interconnect Cable 2 2 Art A 07791 Wheeling Gear Remote Pendant Operating Panel Protective Cover Operation Panel Red Hot coolant return Control Cable Socket Blue coolant to torch Shielding Gas Valve Inlet Work Clamp not shown Coolant Tank Cap underneath Remote Pendant October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 2 05 Power Supply Specifications part 1 PowerMaster Power Source Part Numbers 400SP 5005 Automation Power Supply with Integrated Torch Water Cooling System W1000402 W1000602 ummary Specifications Mains Voltage Tolerance Range 10 20 70 60 35 30 Max Recommended Standard Normal Operating
94. ore 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 1 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 Scout Raider Explorer Original Main Power Stators and Inductors Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors Engines and associated components are NOT warranted by Thermal Arc although most are warranted by the engine manufacturer GMAW FCAW MIG WELDING EQUIPMENT Fabricator 131 181 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P 320SP 400SP 500SP Excelarc 6045 Wire Feeders Ultrafe
95. osition etc If this value is not achieved material transfer takes place completely or partially in the short circuit with possible spatter C Wire feed speed v and pulse frequency f P The main condition for a controlled material transfer with one drop per pulse is to set a defined drop volume The volume of the melted drop must then be identical with the volume of the wire electrode fed in each pulse period The necessary wire feed speed v results from the product of pulse frequency fP and the wire length L melted in each pulse period From this relationship you see that a change in wire feed speed requires a linear change in pulse frequency A rise in electrode melt rate by increasing wire feed speed needs a higher pulse frequency The objective drop diameter should be about 045 1 2mm with a wire diameter of 045 1 2mm D Primary current Arc length ionization must be maintained during the primary current phase whose period results from the selected frequency and pulse period This requires currents ranging between 25 and 80 A depending on wire diameter material and material thickness The primary current can also be used to affect the arc and material transfer At a constant ratio of wire feed speed and pulse frequency the arc length can be changed by varying the primary current and the associated voltage Reducing the primary current causes a shorter arc This can be used to counteract arc deflection with fillet
96. plays LED designation______________ 1 red off microcontroller ok 2 green supply voltage 5V ok Malfunction LED Displays state designation__________________ 1 red LED red 8 12 DS20BF PC Board The DS20BF pc board is the front panel with all buttons rotary impulse encoder and all displays Functions e operating setup the machine e display of all welding parameters e display error messages e display machine parameters version operating system actual values etc 8 13 DK PWRUP04 PC Board PWRUP04 pc board is the power up board of the 4005 and 5005 Functions e reducing start up peak current for capacitors e supply and safeguarding of control transformer 8 14 DP S3NEFI PB Board The DP S3NEFI pc board is the mains filter and power up board for the 320SP Functions e mains filter e reducing start up peak current for capacitors e supply and safeguarding for control transformer 0 6 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 8 15 DK DCDRV DK S3DRV PC Board The DK DCDRV pc board is managing the primary drive level of the power unit 4005 500SP The DK S3DRV pc board is managing the primary drive level of the power unit 320SP Functions e encoding power unit e connection temperature sensor of heat sink e supply pc board LSW e monitoring DC link voltage and supply voltage e safety shut down of power unit e passthrough signal powerup relais e passthrou
97. put Power Welding Output 400SP 5005 Duty Cycle 10096 3 Phase 300 380 Duty Cycle 60 3 Phase 330 480 lt BEE Duty Cycle at Maximum Current 3 Phase X 150 380A 35 2V 60 04804 39 2 Input Mains Power Input Mains Voltage 50 60 Hz 3 Phase No O N I O I O RO O Ka O I O lt lt gt i O i 9 Input Power 51 at 100 Duty 3 Phase Input Current 11 at Maximum Output 3 Phase lt lt gt bh DIM o o NI Im NO n5 n5 m m m lt gt m S m gt IS NS N A po Co ID N NS al O O o gt lectrical Specifications for SMAW STICK with Single Phase Input Power Welding Output 40 5 Duty Cycle 100 1 Phase 330 Duty Cycle at Maximum Current 1 Phase X 50 380 35 2V150 380A 35 2 Input Power S1 at 100 Duty Cycle 1 Phase Generator Requirement with Single Phase 1 Phase gt gt El RO O NO I O O I O lt gt co co Input Current 11 at 100 Duty Cycle 1 Phase Input Current 11 at 60 Duty Cycle 1 Phase Input Current at Maximum Output 1 Phase Torch Cooling S
98. range 40 to 150 Maximum operating junction temperature Art A 07789 V A C Average forward current 55 0 5 October 30 2008 A 11 POWERMASTER 400 500 AUTOMATION APPENDIX 9 HYBRID ESBT DATA SHEET 77 STE53NC50 N CHANNEL 500V 0 0700 53A ISOTOP PowerMesh MIl MOSFET TYPICAL Rps on 0 07 Q EXTREMELY HIGH dv dt CAPABILITY 100 AVALANCHE TESTED sn NEW HIGH VOLTAGE BENCHMARK e GATE CHARGE MINIMIZED ISOTOP DESCRIPTION The PowerMESH MII is the evolution of the first generation of MESH OVERLAY M The layout re finements introduced greatly improve the Ron area figure of merit while keeping the device at the lead ing edge for what concerns swithing speed gate INTERNAL SCHEMATIC DIAGRAM charge and ruggedness APPLICATIONS HIGH CURRENT HIGH SPEED SWITCHING SWITH MODE POWER SUPPLIES SMPS DC AC CONVERTERS FOR WELDING EQUIPMENT AND UNINTERRUPTIBLE POWER SUPPLIES AND MOTOR DRIVER 3604590 2 ABSOLUTE MAXIMUM RATINGS Vos Drain source Voltage Vas 0 VDGR Drain gate Voltage Ras 20 Drain Current continuos at 25 53 Drain Current continuos at Tc 100 C 33 Drain Current pulsed 212 Total Dissipation at 25 460 Factor 3 68 dv dt 1 Peak Diode Recovery voltage slope Viso Insulation Winthstand Voltage AC RMS 2500 Tstg Storage Temperatu
99. rant de suivre un long parcours inconnu et pr venir ainsi les risques d electrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube contact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque Ah AVERTISSEMENT 2 LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau TD y LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp
100. re 59 to 150 Max Operating Junction Temperature 150 Pulse width limited by safe operating area 1 5 lt 53A di dt lt 100 Aus lt 24V Tj lt Tjmax A 07788_AB 12 October 30 2008 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 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 incl
101. re Inch SP Guide Inlet 023 1 16 SP Motor 42V 240rpm SP Feed Plate 4 Roll SP owitch PB Wire Inch SP Hinge 40x32mm SP4000R Panel Cover SP4000R Torch Connection Euro SP4000R Insulator Flange Tweco No4 SP Rivet Plastic 5x7 5 SP Capillar tube 58mm SP4000R Disconnect Gas Male 1 8 SP QuickDisconnect Blue Female SP QuickDisconnect Red Female SP Disconnect Gas Male 1 8 SP Disconnect Gas Female 1 8 SP Quick Disconnect Male Blue SP Quick Disconnect Male Red SP Terminal Male 500A SP Clamp Cable SP4000R Latch Quarter Turn 031 SP PCB Motor Driver SP spacer PCB M4 12mm SP Connector Gas 1 8 x4mm SP solenoid valve 24VDC SP4000 Part Number W7004158 W7000047 W6000511 W6000008 W7000095 W7000047 W7004159 W7004156 W7004160 W7000021 W7000022 W7004161 W7004147 004133 W7004134 W7004147 W7004146 W7000009 W7000010 W7000062 W7004157 W7000013 W6000006 W7004128 W7004152 W7000038 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 12 15 14 19 23 24 26 25 1 Le co ICH f
102. ressure electrode and shield cup h Weekly Visually inspect the torch body and consumables Visually inspect the cables and leads Visually inspect the Wire feed mechanisms GN Gel 3 Months Replace all lt el broken parts Gas and Pen air lines exterior of power supply 6 Months Visually check and Garefully clean the interior Art A 07725 NOTE For units with integrated coolers check the fluid levels and refill as needed Check torch connec tions for leaks and then check for return flow of coolant to the resevoir October 30 2008 7 1 POWERMASTER 400SP 500SP AUTOMATION 7 02 System Troubleshooting Guide Torch too hot Insufficient coolant through flow due to pollution in Flush the coolant hoses of the torch in opposite coolant direction Contact tip is not tight or the wrong size for the wire Check it used No function when torch Nut of the torch hose is not tight Tighten it button is pressed No connection of the control cable in the torch hose Check and change if necessary Overload of the unit and thermal protection operates Allow unit to cool down at no load Irregular wire feeding Wire electrode is tight at the spool Check and change if necessary contact tip irregular wire feeding or no wire feeding Torch liner is dirty inside Disconnect the torch from the machine unscrew the contact tip and clean the liner with compressed air Torch liner is defective Check and change if neces
103. sary Motor brake adjusted too strong Adjust as described in the manual Unit switches off Duty cycle overloaded Allow the machine to cool down Poor cooing of internal unit parts Check the air in and outlet Cooler hoses or pump Frozen systems due to low concentration of Contact the nearest service facility are damaged recommended coolant in re circulator Arc or short circuit opatter built up inside the gas nozzle Remove it with special pliers between contact tip and gas nozzle The Control Panel is Primary power phase missing Check the unit at another power outlet Check Bel eet shielded gas Gas regulator dirty or defective Check and replace it Valve of gas cylinder defective Replace the gas cylinder Shielded gas switches Valve of gas cylinder dirty or does not close Remove torch and gas regulator and clean it not off with compressed air Not enough shield gas performance power cable and mains fuses circuit breakers clamp and workpiece Higher wire wear out wire feeding unit 7 2 October 30 2008 POWERMASTER 400 500SP AUTOMATION 7 03 Welding Process Troubleshooting Guide Poor edge wetting on Gas mixture in the cylinder has separated due to lack Place protective cap used for storage and stainless steel welds transport on cylinder then carefully disconnect the cylinder from the welder and lay it down on the floor Carefully roll it back and forth to re mix the Contact wire manuafa
104. soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 749 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez connaitre avant d utiliser cet quipement sont pr sent s a la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 05 Dangers relatifs au soudage l arc 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais AVERTISSEMENT plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser tra ner par terre ou sur les pieces a souder Ne touchez pas aux porte lectrodes raccord s a deux sources L ELEC
105. t Wire Stick is active 0 si REA is off output Wire Stick is not active open Ge is on output Wire State is active 0 is off output Wire State is not active open October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 5 05 Robot Interface 06 PC Board Schematic D19 B Ol SERS B RRE R43 P R24 C34 C34 C31 B Bp EP B T REI C54 241 RELIJ E55 108 REIS 253 LEDS zl 650 5282 INTO6 RP367 1 D00 0110 0 00 Art A 07940 Connector Description CAN connector Internal programming connector Flat ribbon connector to 42 pin Harting socket digital and analog inputs Flat ribbon connector to 42 pin Harting socket digital in and outputs Additional analog outputs optional Robot Interface PC Board Connectors October 30 2008 5 5 POWERMASTER 400SP 500SP AUTOMATION 5 06 42 Pin Harting Socket 9 6 Art A 07827 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION Harting Socket Pin Descriptions indui ojeue jndino indu 9AI 9 100 SI 9 A uonisod NO Ul eq 15 01129 95 OL YOUMS 90 Av2 euDis SIU UJIM pajeAnoe si ado sumop 141 ue SU0I 991109 9S1NON 9AI 9 ISNW uo Bulpjem pue 1195 19 195 SIeU IS 991 OAI JOU SI
106. t 20 200 of the programmed value only in ManualGMAW process short arc 0 100 of the programmed value only in SMAW STICK process Job selection indication of set and job name Machine type and the recognized power module with max Extras 1 Machine data perating system Master perating system Process perating system DMRs perating hour counter current are indicated alternately 2 Diagnosis Last error message Indication of the last three error messages from the error memory 0 last error 2 oldest error Temperatures of the power modules in C Indication of the operating voltages 15 V 24 V of the assembly DPMAPRO Indication of the coolant flow rate in l min election of the menu language ontrast setting of the LCD display cooling unit switches on as soon as an arc is ignited cooling unit runs constantly cooling unit is deactivated All welding controls can be adjusted by user Only Tiptronic on off and job selection can be adjusted by User Tiptronic on off job selection free All welding controls locked except menu selection gas and pump test correct arc length with rotary pulse encoder 58 correct wire speed with rotary pulse encoder 58 Menu item is only visible when the machine is equipped Set and job name are indicated only in Tiptronic mode upon actuation of the Enter push button 47 or the Tiptronic push button 49 Edit mode for set and job name Move t
107. t code must be entered before the lock function can be changed Only after the correct code is entered the lock function can be altered After leaving the menu a new code number can be set or the old code number is acknowledged Code 000 is the default factory setting number Procedure 1 Switch to menu Extras lock function 2 Press button 44 or 48 question change parameter is displayed 3 Acknowledge with button 51 4 set three digit code number with button 44 48 or encoder 53 5 Acknowledge the code number with button 51 6 Set desired lock function number with buttons 44 or 48 7 Leave menu with button 46 END requested set a new code number with buttons 44 48 or encoder 53 9 Acknowledge the code number with button A 51 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 4 05 Smart GMAW Pulse GMAW amp TwinPulse Programs Material Shield ire Program Smart Pulse GMAW TwinPulse Gas i Number Current Range Current Range Current Range Ar 02 02 in min max 757257070 os 2 5232 wa ma mt Lean 9278 0 0 5 4822 242 2429 CurStee 92 8 0 0 oss 6 52 360 283 2830 9278 0 0 ose 8 72408 48476 48 476 92 8 0 0 we 9 100500 wa NA Fox Core mn 55308909 817170718 096 19 Sram 28320 2320 Stai
108. t12 Job Analog LE analog inputs Assignment of a welding program welding program 0 99 set as program 1 ES Assignment of a welding program welding program no 0 99 set as program 2 AAA Assignment of a welding program welding program no 0 99 set as program 3 Opt09 ProgSelect Opt10 OperMode or __ _ Of _ Of On _ Of On Of On _ Off On _ Of LEM m analog input is enabled corresponds with DIP switch 8 set to ON Of On Of On Of On 5 10 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 5 08 Robot Tool Software Installation 1 Insert the Installation floppy disk into your disk drive or the Robot Tool CD into your CD drive 2 Click on Start and then click on Run and type in the command printed on the disk label and click on OK 3 Follow the instructions given by the program which installs the software A new Robot Tool icon will be created on the Windows desktop Program Description The Robot Tool software is to control and monitor the 06 interface The CAN interface must first be installed and functional If not please install the CAN interface first For instructions refer to the Thermal Arc Install section otart the software by double clicking the icon on the Windows desktop The actual states of the digital inputs are shown in the upper part of the program window In the lower part of th
109. tincelles ou d une flamme nue 3 Sic est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage 4 Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 9 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pieces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un systeme arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur Ww D AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRUL
110. u18ua ay Jo 1011981103 94110 AQ L 0 peeds S d Jo 1u911N9 AOL S d JO uano NO 1491109 eui JO AQ L 0 041002 1u811n9 IR ez UO SAJEA 1009 05 A 8599 0 100 SI 191 9 195 eubis ay 1591 526 ay 55918 UO PIOUAJOS Jd Spuods91109 pue suado prougjos Ajddns seb ay 29 2 10 si eubis gQopeggalM w 125 999 100 SI U19 X9 195 eubis au uoynq Opa WSU eu Duisseid uir pue JIM ay euis E uonisod NO Ul eq snw 01129 95 OL UIIMS 195 9 1198 JOU aSINduUIM snw asind jeubis ay 5 OM JIM Juano 90 Atc pedeus es nd sinduim asindulm3 ay sajeAroe eufis siu as nduiM 4011504 NO eq snw 01129 95 OL YMS de WOU 1404 sajeJedo au 19 jou si Jeu Is au Guan es nd Arz podeus asind 95 asind ay 1 jeubis siu asind 00112014
111. uding 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 m
112. urchased Purchase Date Equipment Serial 7 TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 Arc Welding sonitono etapa tala cadencia ee local 1 1 1 02 Principal Safety Standards nano nann cnn nao n cn ne 1 4 e A A 1 5 1 04 Precautions De Securite En Soudage 4 40242 1 6 1 05 Dangers relatifs au soudage Al Alk un ee nn 1 6 1 06 Principales Normes De Securite VU 1 9 1 07 Graphique d SYD OS re 1 10 SECTION 2 INTRODUCTION ea P 2 1 2 01 How Use This RAR A 2 1 2 02 Equipment Identification aa ae 2 1 2 03 Receipt Of EQUIPE eme tacitis canica atea 2 1 2 04 Machine Components in nana nnns 2 2 2 05 Power Supply Specifications part 1 or metn 2 3 2 06 Power Supply Specifications part 2 2 4 2 07 Wire Feeder Specifications ee aan 2 5 SECTION 3 INSTALLATION WE 3 1 3 01 Location 3 1 3 02 Voltage Changeover EN 3 1 3 03 Connecting 3 Phase Input Power to 400SP or 5005 3 2 3 04 Connecting Single Phase Input Power to 400SP or 5009P 3 4 3 05 Quick Start Set 3 6 3 06 Recommended Setup for MIG EE 3 6 3 07 Pulsemaster 5125 3545 500 Amp Weld Gun when welding by hand 3 10 3 08 Installing A New Wire Conduit
113. welds or at high welding rates The time of drop separation can be affected by varying the ratio of primary current to pulse current Normally the objective is to separate the drop just after the current pulse in the primary current phase in the third pulse current phase This can be achieved by October 30 2008 increasing the primary current and reducing the pulse current at the same time Remember that excessively high primary current will melt the free wire end too quickly This will form very large drops which can lead to spatter during the transition to the welding pool E Pulse MIG applications The main application for pulse MIG is for precision MIG welding of aluminium stainless steel steel and other weldable materials e Spray transfer welding permitted at lower than normal average weld currents e No spatter or undercut in the majority of welding applications Precise control of welding power to assure bead shape and root penetration rivalling TIG welding e High energy arc produced that virtually eliminates the risk of lack of fusion e Improved arc control for out of position welding and more effective welding of thin materials with all the advantages of spray transfer e Optimized pulse programs for gas wire combinations e TwinPulse capabilities e Exceptional out of position welding for non ferrous materials including aluminium e Effortless TIG like weld appearance on aluminium and sta
114. ystem Where Fitted Standard Coolant Flow Rate gallon min Psi Pump Type ______ Dimensions and Weights 500680 in 43 9 17 5 33 7 201 222 O 2 4 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION 2 07 Wire Feeder Specifications Wirefeeder Part Numbers SP4000W SPaooor Wirefeeder suits water cooledtorch W3000102 Wirefeeder suits Automation Power Source 3000302_ Welding Output Ion Wirefeed Speed Dimensions andweights J T Weightorwreteedcase 44 187 NOTE Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are approximate only Achievable capacities and ratings in use and operation will depend upon correct installation use applications maintenance and service October 30 2008 2 5 POWERMASTER 400SP 500SP AUTOMATION 2 6 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION SECTION 3 INSTALLATION NOTE Please refer to Sections 3 04 Recommended Equipment Setup and SECTION 4 Control Panels for explanations of the controls N WARNING Thermal Arc advises that a suitable Mains Plug and cable be fitted to this equipment by a qualified electrical trades person 3 01 Location Adequate air circulation is needed at all times in order to assure proper operation Provide a minimum of 12 inches 305 mm
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