THERMAL ARC 400SP 500SP Powermaster Automation Instruction manual

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400SP 500SP

POWERMASTER

AUTOMATION

Art # A-07790

Operator Manual

Revision No: AC Issue Date: March 16, 2007 Manual No.: 0-4970 Operating Features:

460

400

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PHASE

208

230

WE APPRECIA TE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-752-7621, or visit us on the web at www.Thermalarc.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

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.

Operator Manual Number 0-4970 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 W4000101

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

www.thermadyne.com

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: March 16, 2007 Revision AC Date: May 23, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 Principal Safety Standards ............................................................................. 1-4

1.03 Symbol Chart ................................................................................................. 1-5

1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6

1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6

1.06 Principales Normes De Securite ..................................................................... 1-9

1.07 Graphique de Symbole ................................................................................. 1-10

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Machine Components..................................................................................... 2-2

2.05 Lifting Points .................................................................................................. 2-3

2.06 Power Supply Specifications (part 1) ............................................................. 2-4

2.07 Power Supply Specifications (part 2) ............................................................. 2-5

2.08 Wire Feeder Specifications ............................................................................. 2-6

2.09 Features and Benefits Common to all PowerMaster SP Systems # ................ 2-7

2.09 Features and Benefits Common to all PowerMaster SP Systems (con't) # .... 2-8

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Location ......................................................................................................... 3-1

3.02 Transportation and Positioning....................................................................... 3-1

3.03 Fitting the Mains Cable into the Cable Gland .................................................. 3-1

3.04 Voltage Changeover........................................................................................ 3-2

3.05 Connecting 3-Phase Input Power to 400SP or 500SP .................................... 3-3

3.06 Connecting Single-Phase Input Power to 400SP or 500SP ............................ 3-5

3.07 Quick Start Set Up .......................................................................................... 3-7

3.08 Recommended Setup for MIG ........................................................................ 3-7

3.09 Automation Weld Gun .................................................................................. 3-11

3.10 Pulsemaster PMA512S-3545 500 Amp Weld Gun (when welding by hand). 3-11

3.11 Installing A New Wire Conduit in the Pulsemaster PMA512S-3545 ............. 3-12

SECTION 4:

MANUAL OPERATION ............................................................................... 4-1

4.01 General Safety Precautions ............................................................................ 4-1

4.02 Welding Controls ............................................................................................ 4-2

4.03 Menu Structure .............................................................................................. 4-4

4.04 Special functions ............................................................................................ 4-8

4.05 Smart GMAW, Pulse GMAW & TwinPulse Programs ...................................... 4-9

4.06 Welding Setting Selection Guide .................................................................. 4-10

TABLE OF CONTENTS

SECTION 5:

ROBOTIC OPERATION............................................................................... 5-1

5.01 Robot Interface INT06 .................................................................................... 5-1

5.02 Digital Inputs and Outputs .............................................................................. 5-1

5.03 Analog Inputs ................................................................................................. 5-2

5.04 Robot Interface Schematic ............................................................................. 5-3

5.05 Robot Interface INT06 PC Board Schematic ................................................... 5-5

5.06 42-Pin Harting Socket .................................................................................... 5-6

5.07 Configuration at Front Panel Menu ............................................................... 5-10

5.08 Robot Tool Software Installation .................................................................. 5-11

5.09 Decimal-Binary Conversion .......................................................................... 5-12

SECTION 6:

MANUAL GMAW WELDING ........................................................................ 6-1

6.01 Types of Weld Transfer Modes ....................................................................... 6-1

6.02 Holding and Manipulating the Torch............................................................... 6-2

6.03 Basics of Pulsed Arc Welding ......................................................................... 6-4

6.04 Pulsed Arc Welding Parameters ..................................................................... 6-5

6.05 Smart, Pulse or TwinPulse GMAW Welding.................................................... 6-6

6.06 Conventional Manual GMAW/FCAW Welding.................................................. 6-6

6.07 SMAW/STICK Welding.................................................................................... 6-7

TABLE OF CONTENTS (continued)

SECTION 7:

SERVICE .............................................................................................. 7-1

7.01 Maintenance ................................................................................................... 7-1

7.02 System Troubleshooting Guide....................................................................... 7-2

7.03 Welding Process Troubleshooting Guide........................................................ 7-3

7.04 Error Codes .................................................................................................... 7-4

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES ...................................... A-1

APPENDIX 2: FEED ROLL INFORMATION............................................................... A-2

APPENDIX 3: MOUNTING THE TORCH HOLDER ....................................................... A-3

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

POWERMASTER 400SP, 500SP AUTOMATION

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: 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

WARNING

ELECTRIC SHOCK can kill.

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 live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

8. Do not use worn, damaged, undersized, or poorly spliced

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work

12. Use only well-maintained equipment. Repair or replace

13. In confined spaces or damp locations, do not use a welder

14. Wear a safety harness to prevent falling if working above

15. Keep all panels and covers securely in place.

SAFETY IN WELDING AND CUTTING. This publication

cables.

(ground) circuit.

damaged parts at once.

with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

floor level.

1. Do not touch live electrical parts.

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

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

March 16, 2007

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

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POWERMASTER 400SP, 500SP AUTOMATION

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

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 sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding

4. Be alert that welding sparks and hot materials from welding

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

arc. If this is not possible, tightly cover them with approved covers.

can easily go through small cracks and openings to adjacent areas.

can cause fire on the hidden side.

as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

WARNING

WELDING can cause fire or explosion.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

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POWERMASTER 400SP, 500SP AUTOMATION

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

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.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

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.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

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

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

March 16, 2007

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POWERMASTER 400SP, 500SP AUTOMATION

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

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 & 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 Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields 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 questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, 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.

To reduce magnetic fields in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

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POWERMASTER 400SP, 500SP AUTOMATION

1.03 Symbol Chart

Note that only some of these symbols will appear on your model.

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

Burnback Time

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

March 16, 2007

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

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POWERMASTER 400SP, 500SP AUTOMATION

1.04 Precautions De Securite En Soudage A L’arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.05 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semiautomatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

3 Isolez-vous de la pièce à souder et de la mise à la terre au

moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

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POWERMASTER 400SP, 500SP AUTOMATION

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER 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 brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

mince moins de 1 po. (25 mm) 2 ou 3

épais plus de 6 po. (150 mm) 5 ou 6

mince moins de 1/8 po. (3 mm) 4 ou 5

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec fil plein (GMAW)

Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydrogène atomique (AHW) Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

March 16, 2007

1-7

POWERMASTER 400SP, 500SP AUTOMATION

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitezles avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil au tubecontact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

1-8

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

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

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

1. Portez toujours un écran facial en travaillant sur un accumulateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

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

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

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 être brûlant et sous pression.

1. N’ôtez 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’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

1.06 Principales Normes De Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR PEUT BRULER LA PEAU ET LES YEUX.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

March 16, 2007

Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-9

POWERMASTER 400SP, 500SP AUTOMATION

1.07 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Sous Tension

Hors Tension

Tension dangereuse

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Fusible

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Distant

Facteur de Marche

Pourcentage

Panneau/Local

Soudage Arc Electrique Avec Electrode Enrobé (SMAW)

Soudage á L’arc Avec Fil Electrodes Fusible (GMAW)

Soudage á L’arc Avec Electrode Non Fusible (GTAW)

Decoupe Arc Carbone (CAC-A)

Courant Constant

Tension Constante Ou Potentiel Constant

Haute Température

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Torch de

Soudage

Purge Du Gaz

Mode Continu de Soudure

Soudure Par Point

Duréc du Pulse

Appuyez pour dèruarer l’alimentation du fils et la soudure, le relâcher pour arrêter.

Maintenez appuyez pour pré-dèbit, relailez pour initier l'arc. Appuyez pour arrêter l'arc, et mainteuir pour pré-dèbit.

Durée de Pré-Dèbit

Durée de Post-Dèbit

Détente à 2-Temps

Détente à 4-Temps

Probléme de Terre

115V 15A

1-10

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de PriseSource Auxiliaire

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

IPM

MPM

Pouces Par Minute

Mètres Par Minute

Art # A-07639

March 16, 2007

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 i.

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:

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

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 i 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 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 uncrate the unit.

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 downloaded 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

March 16, 2007

2-1

POWERMASTER 400SP, 500SP AUTOMATION

2.04 Machine Components

(15)

(14)

(13)

(12)

(11)

(16)

(1)

(2)

(3)

(4)

(10)

(9)

1. SP4000R Wire Feeder

2. MIG Torch Connection Socket

3. Handle

(5)

(6)

Art # A-07791

(7)

(8)

10. Wheeling Gear

11. Remote Pendant Operating Panel

12. Protective Cover, Operation Panel

4. Mains On/Off Switch

5. Air Intake

6. Negative Connection Socket for Work Lead

7. INT06 Robotic Interface Cable

8. INT06 Robotic Interface Connection Plug

9. Remote Pendant Interconnect Cable

2-2

13. Red = Hot coolant return

14. Control Cable Socket

15. Blue = Cool coolant to torch

16.

Shielding Gas Valve Inlet

17. Work Clamp (not shown)

18. Coolant Tank Cap (underneath Remote Pendant)

March 16, 2007

2.05 Lifting Points

POWERMASTER 400SP, 500SP AUTOMATION

Maximum

Art # A-07910

Lifting Points for 500SP and 400SP

March 16, 2007

2-3

POWERMASTER 400SP, 500SP AUTOMATION

2.06 Power Supply Specifications (part 1)

PowerMaster Power Source Part Numbers

Summary Specifications

Input Mains Voltage (50/60 Hz) V 208 230 400 460 208 230 400 460 Mains Voltage Tolerance Range % Max Recommended Circuit Breaker or Time-Delay Fuse 3 Phase A 45 40 25 20 70 60 35 30 Max Recommended Standard Normal Operating Fuse 3 Phase A 55 50 30 25 80 70 40 35 Max Recommended Circuit Breaker or Time-Delay Fuse 1 Phase A 100 90 50 45 100 90 50 45 Max Recommended Standard Normal Operating Fuse 1 Phase A 110 100 60 50 110 100 60 50 Power factor at Maximum Output cos Maximum Open Circuit Voltage OCV V Voltage Range for GMAW-P, GMAW, FCAW, MIG U 2min-U 2max V Current Range for GMAW-P, GMAW, FCAW, MIG I 2min-I 2max A Current Range for SMAW (Stick) I 2min-I 2max A Enclosure Protection Class to EN 60 529 Insulation Class Cooling Method Noise Emission dB (A)

Electrical Specifications for GMAW-P / GMAW / FCAW / MIG with Three-Phase Input Power

Welding Output

Duty Cycle 100% 3 Phase A Duty Cycle 60% 3 Phase A Duty Cycle at Maximum Current 3 Phase X

Inp ut Mains Power

Input Mains Voltage (50/60 Hz) 3 Phase V 208 230 400 460 208 230 400 460 Input Power S1 at 100% Duty Cycle 3 Phase kVA 11 11 12 12 16 16 16 17 Input Power S1 at 60% Duty Cycle 3 Phase kVA 13 13 14 14 24 23 23 24 Input Power S1 at Maximum Current 3 Phase kVA 17 16 17 17 24 23 23 24 Generator Requirement with Three Phase 3 Phase kVA Input Current I1 at 100% Duty Cycle 3 Phase A 32 29 18 16 45 40 23 21 Input Current I1 at 60% Duty Cycle 3 Phase A 37 33 20 17 66 59 34 30 Input Current I1 at Maximum Output 3 Phase A 46 41 24 21 66 59 34 30

400SP 500SP

W1000402 W1000602Automation Power Supply with Integrated Torch Water Cooling System

+/- 10

0.99 0.99 79

14.3 – 34 5 – 400

10-380

IP23

Fan Cooled

<70

400SP

320 350

50%@400A, 34V

25 35

+/- 10

14.3 – 39 5 – 500

10-480

IP23

Fan Cooled

<70

500SP

400 500

60%@500A, 39V

Electrical Specifications for GMAW-P / GMAW / FCAW / MIG with Single-Phase Input Power

Welding Output

Duty Cycle 100% 1 Phase A Duty Cycle 60% 1 Phase A Duty Cycle at Maximum Current 1 Phase X

Inp ut Mains Power

Input Mains Voltage (50/60 Hz) 1 Phase V 208 230 400 460 208 230 400 460 Input Power S1 at 100% Duty Cycle 1 Phase kVA 13 14 14 14 13 14 14 14 Input Power S1 at 60% Duty Cycle 1 Phase kVA 15 16 16 16 15 16 16 16 Input Power S1 at Maximum Output 1 Phase kVA 19 20 20 20 19 20 20 20 Generator Requirement with Single Phase 1 Phase kVA Input Current I1 at 100% Duty Cycle 1 Phase A 65 61 35 30 65 61 35 30 Input Current I1 at 60% Duty Cycle 1 Phase A 74 68 40 35 74 68 40 35 Input Current I1 Maximum Output 1 Phase A 92 85 50 43 92 85 50 43

400SP 500SP

320 350

50%@400A, 34V

320 350

50%@400A, 34V

2-4

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

2.07 Power Supply Specifications (part 2)

Electrical Specifications for SMAW / STICK with Three-Phase Input Power

Welding Ou tput

Duty Cycle 100% 3 Phase A Duty Cycle 60% 3 Phase A Duty Cycle at Maximum Current 3 Phase X

Inp ut Mains Power

Input Mains Voltage (50/60 Hz) 3 Phase V 208 230 400 460 208 230 400 460 Input Power S1 at 100% Duty Cycle 3 Phase kVA 10 10 11 11 16 16 17 17 Input Power S1 at 60% Duty Cycle 3 Phase kVA 12 12 12 12 23 22 22 23 Input Power S1 at Maximum Output 3 Phase kVA 16 16 16 17 23 22 22 23 Generator Requirement with Three Phase 3 Phase kVA Input Current I1 at 100% Duty Cycle 3 Phase A2726161344412522 Input Current I1 at 60% Duty Cycle 3 Phase A 33 30 17 15 63 56 32 29 Input Current I1 at Maximum Output 3 Phase A4440242163563229

Electrical Specifications for SMAW / STICK with Single-Pha se Input Power

Welding Ou tput

Duty Cycle 100% 1 Phase A Duty Cycle 60% 1 Phase A Duty Cycle at Maximum Current 1 Phase X

Inp ut Mains Power

Input Mains Voltage (50/60 Hz) 1 Phase V 208 230 400 460 208 230 400 460 Input Power S1 at 100% Duty Cycle 1 Phase kVA 13 14 13 13 13 14 13 13 Input Power S1 at 60% Duty Cycle 1 Phase kVA 15 15 15 15 15 15 15 15 Input Power S1 at Maximum Output 1 Phase kVA 19 19 19 19 19 19 19 19 Generator Requirement with Single Phase 1 Phase kVA Input Current I1 at 100% Duty Cycle 1 Phase A6459342964593429 Input Current I1 at 60% Duty Cycle 1 Phase A 73 66 38 33 73 66 38 33 Input Current I1 at Maximum Output 1 Phase A9083484190834841

400SP 500SP

300 380 330 480

50%@380A, 35.2V 60%@480A, 39.2V

400SP 500SP

300 300 330 330

50%@380A, 35.2V 50%@380A, 35.2V

30 30

Torch Cooling System (Where Fitted)

Standard Coolant Flow Rate gallon / min. Maximum Coolant Pressure Psi Pump Type

Dimensions and Weights

Power Supply Dimension (DxWxH) in Power Supply Weight lb

400SP

0.29 50

Centrifugal Pump

400SP 500SP

43.9x17.5x33.7 201

500SP

0.29 50

Centrifugal Pump

43.9x17.5x33.7 222

March 16, 2007

2-5

POWERMASTER 400SP, 500SP AUTOMATION

2.08 Wire Feeder Specifications

Wiref eeder P ar t Numbers SP4000W SP4000R

Wiref eed er suit s wat er cooled torch W3000102 – Wiref eed er suit s Automation Power S ou r c e – W300 0302

Welding Output

Weld able Wire Steel & Stainless Steel Ø i n .023 – .045 . 023 – 1/16 Weld able Wire A luminum Ø i n .03 5 - 1/16 .035 – 3/32 Wiref eed S pe ed IP M 4 – 984 4 – 984 Wir e f ee d unit Rollers 4 4

Dimensions and weights

Size of wire feed case (DxW xH) in 25.2x14x19.6 21.3x8.2x 7 Weig ht of wire feed c ase lb 44.4 18.7

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.

2-6

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

2.09 Features and Benefits Common to all PowerMaster SP Systems #

HARDW ARE (Standard)

Inverter Design: Heavy duty, highly efficient, environmentally toughened 80KHz design with exceptional dynamic welding performance.

Flow Through Tunnel: Designed to circulate air around components that require cooling and not over critical circuitry. This reduces metallic dust ingression and improves reliability.

Intelligent Heat Sensing Fan: Operates only as needed to cool components and further reduce airborne contaminants from being pulled through the power source.

Simple, multi-voltage design from 200 to 500V for maximum flexibility in a single power source.

Remote Control CAN-Bus Ports: Allow for easy data transfer and provide full function remote control capability.

4 Roll Drive Systems: All wire feeder drive systems are high precision, 4 roll systems manufactured to extremely tight tolerances for optimum feed-ability of both hard and soft wires. Refer to page 3-8.

Heavy Duty Running Gear: All running gear has been developed for manufacturing / production environments, built heavy-duty and designed to last.

Tweco

Guns and Accessories: Tweco® has a full line

of PulseMaster standard and PulseMaster Smart Guns with advanced digital controls optimized for the PowerMaster SP range. Gun connections are Tweco No. 4 and return leads are Tweco® MPC. Refer to page 3-10.

SOFTW ARE (St andard)

Links the wire feed speed, arc current and voltage to deliver the perfect welding parameters and eliminate the guesswork for achieving optimum performance. Refer to page 4-2 item 52.

Effortless TIG-like weld appearance up to seven times faster on aluminum and stainless steel than traditional TIG (GTAW).

High Definition Pulse is expertly tailored, optimized wave designs for perfect, digital microprocessor controlled, pulse performance.

Built-in hardware and software protection against accidental incorrect input voltage selection.

JobTool™ is a library of 100 independent, user-defined, job save programs. You can save and recall welding procedures from a PulseMaster SmartGun or from the front panel at any time. Refer to page 4-3 item 62.

Fresh Tip Treatment sharpens the wire at the end of the weld sequence ready for a perfect restart.

Recalls up to 100 personalized jobs with perfect repeatability from the push of a button. Refer to page 4-2 item 45 and 47 and to page 4-6 section C 1-7.

Pre Programmed: Up to 100 optimized SmartMIG™, PulseMIG and TwinPulse™ programs are standard, delivering optimal performance and versatility.

Down Slope (Crater Fill Mode): The digitally adjustable parameters reduce arc energy down eliminating any craters that could cause defects.

#Subject to change without notification.

March 16, 2007

2-7

POWERMASTER 400SP, 500SP AUTOMATION

2.09 Features and Benefits Common to all PowerMaster SP Systems (con't) #

PERFORMANCE (Standard)

Operating Platform: How would you like to use the machine? What is your primary parameter is it Inches per Minute or Amps? Would you rather just dial up the material thickness and let the machine do the rest? All can be accommodated.

One Touch Control: Delivers at your fingertips the perfect welding parameters by adjusting the total arc energy. Set material thickness then start welding.

Hot Start Ignition: The digitally adjustable start parameters combined with FTT™, creep feed speed and an amplified power level applied to the welding arc at the start of the weld bead ensures perfect fusion.

HARDWARE/SOFTW ARE (Options)

High Speed Pulse is specialized high speed

wave design for maximum productivity. Push / Pull Gun Capability: “Plug and Play” Python®

interface.

#Subject to change without notification.

2-8

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

(END)

(+)

Save

Enter

Mode

Tiptron

HOLD

Art # A-08325_AA

SECTION 3:

INSTALLATION

NOTE

Please refer to Sections 3.08 Recommended Equipment Setup and SECTION 4: Control Panels for explanations of the controls.

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) 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 Transportation and Positioning

3.03 Fitting the Mains Cable into the Cable Gland

Refer to the pictures below when connecting the mains cable to the cable gland.

Properly transporting and positioning the equipment is important for preventing injury. Move the equipment in an upright position and pick a flat welding surface.

Sav

t er

Tip

tro

n ic

(EN

)

o d

)

t er

O LD

WARNING

Art # A-08324_AA

WARNING

The mains cable has to be assembled into the cable gland as shown in the picture. The electrical technician has to make sure that the cable gland is adjusted to the external diameter of the mains cable and the mains cable is securely fastened in the cable gland according to IEC 60974-1.

Injury to the operator may occur if the machine’s maximum permissible angle of inclination is exceeded. The maximum permissible angle of inclination is 10°. Only transport or position the machine for welding on a flat and level surface.

March 16, 2007

3-1

POWERMASTER 400SP, 500SP AUTOMATION

3.04 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.

ELECTRIC SHOCK CAN KILL.

WARNING

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

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.

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 AC line voltage.

3. Secure the switch cover.

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.

WARNING

3-2

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

3.05 Connecting 3-Phase Input Power to 400SP or 500SP

WARNINGS

Installation must meet all National and Local Codes - have only qualified persons make this installation.

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

400SP 500SP

Input Mains Voltage (50/60 Hz) V 208 230 400 460 208 230 400 460 Max Recommended Circuit Breaker or Time-Delay Fuse A 45 40 25 20 70 60 35 30 Max Recommended Standard Normal Operating Fuse A 55 50 30 25 80 70 40 35 Min Input Conductor Size AWG 8 8 12 14 4 6 10 10 Min Input Conductor Size AWG 8 8 12 14 6 8 10 10 Suggested Input Cord Type

Carolprene® Jacketed Type SOOW

90°C 600 Volt UL/CSA Portable Cord

Ground Terminal

Art: A-07877

GND/PE

Ground Conductor

Line Disconnect Switch

Line Fuse

Primary Power Cable (customer supplied)

March 16, 2007

3-3

POWERMASTER 400SP, 500SP AUTOMATION

L1 L2 L3

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) Select 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

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.

Art # A-07858

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 L1, L2, and L3 to the

Line Disconnect Switch terminals. F. Select type and size of over-current protection

using table (fused Line Disconnect Switch shown). G. Close and secure door on Line Disconnect Switch. H. Remove lockout/tagout device, and place switch

in the On position.

Black

L1 L2 L3

White

Red

GND/PE GND/PE

Green & Yellow

3-4

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

3.06 Connecting Single-Phase Input Power to 400SP or 500SP

WARNINGS

Installation must meet all National and Local Codes - have only qualified persons make this installation.

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

400SP

Input Mains Voltage (50/60 Hz) V 208 230 400 460 208 230 400 460 Max Recommended Circuit Breaker or Time-Delay Fuse A 100 90 50 45 100 90 50 45 Max Recommended Standard Normal Operating Fuse A 110 100 60 55 110 100 60 55 Min Input Conductor Size AWG 4 4 8 10 4 4 8 10 Min Input Conductor Size AWG 6 6 8 10 6 6 8 10 Suggested Input Cord Type

Carolprene® Jacketed Type SOOW 90°C 600 Volt

UL/CSA Portable Cord

Single-Phase

500SP

Ground Terminal

Art# A-07883

GND/PE

Ground Conductor

Line Disconnect Switch

Line Fuse

Primary Power Cable (customer supplied)

March 16, 2007

3-5

POWERMASTER 400SP, 500SP AUTOMATION

WARNING

A. Input Power Conductors (Customer Supplied

Cord)

Select 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

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.

Art # A-07879

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 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. Select type and size of over-current protection

using table (fused Line Disconnect Switch shown). G. Close and secure door on Line Disconnect Switch. H. Remove lockout/tagout device, and place switch

in the On position.

1-Phase Input Power Connection PowerMaster 400SP,500SP

Black

L1 L2 L3

White

GND/PE GND/PE

Green & Yellow

3-6

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

3.07 Quick Start Set Up

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.

A. Where equipped, place the gas cylinder on the

power supply cylinder tray and secure with the two safety chains. If unit is not equipped with this option, then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position.

B. Remove screw cap from gas cylinder, if fitted, and

open gas cylinder valve briefly to remove

contaminants. C. Connect gas regulator to gas cylinder. D. Connect gas hose from power supply to gas

regulator and open gas cylinder valve.

3.08 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.

E. Connect input power, refer to previous WARNING

and the Connecting Input Power Section.

F. Connect work lead to Negative connection (–) and

attach Work clamp to workpiece.

G. Fit the correct size feed rollers to wire feeder then

fit the selected welding wire and set the pressure levers to position 2.

H. Connect torch (central socket, coolant connections

red-blue) and mount contact tip to fit welding wire

selected. I. Insert welding wire. J. Turn on main switch. K. Press push-button and push-button (gas type)

(solenoid valve is activated) and adjust gas amount

on the gas regulator. L. Keep the wire inch switch

pressed until the

welding wire protrudes approximately 3/8 inch (10

mm) out of the MIG torch nozzle.

Front Panel Access Hole

Trigger Receptacle

Hot coolant return (Red)

Cool coolant to torch (Blue)

Art # A-07851

NOTE

When disconnecting gun switch leads from the machine, loosen the locking ring and grab the connectors and pull. Do not pull on the wires.

March 16, 2007

6. To remove the gun, reverse these directions.

3-7

POWERMASTER 400SP, 500SP AUTOMATION

Negative Connection

Work Lead

L L L N E

Drive pin

Hub

Brake

Nut

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.

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

to adjust the

brake, the wire spool should not continue to run.

Art # A-06368

Connect the Work clamp tightly to the welding bench or to the workpiece.

D. How To Connect To The Mains

Refer to Connecting Input Power Section.

Art # A-06367

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.

3-8

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

F. Insertion Of The Wire Electrode

Screw out the contact tip in the MIG torch handset. Open the wire feed compartment lid on the power supply or wirefeed case.

The diameter of the wire should correspond to the 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.

Pressure lever

Inlet guide Feedroll

Outlet guide

Art # A-06369

Close the lever and fasten the pressure rollers.

Press the inch switch button

until the wire

appears approximately 3/4 inch (20 mm) out of the torch neck.

Screw in the contact tip corresponding to the wire diameter and cut off any wire sticking out.

G. How To Connect The Gas Cylinder

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.

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.

Lever

Pressure adjustment screw

Art # A-06370

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 rolls drive the wire consistently without slipping. The wire should not be deformed.

Art # A-06371

The quantity will be shown at the flowmeter. This should be approximately:

Wire Size (in) Gas Flow (CFH) .023 13 .030 17 .035 19 .040 21 .045 25 3/64 34

gas regulator

input gauge

gas cylinder valve

gas cylinder

bracket chain

2 33

output gauge

gas hose

Correct

Pressure

too High

Wrong Size

Feedrolls

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.

March 16, 2007

Art # A-06372

regulator valve

3-9

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.

CAUTION

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) Part No. W4001402 MIG/TIG Coolant 1 Quart (5 L) Part No. W4001400 MIG/TIG Coolant 5 Gallon (20 L) Part No. W4001401

I. 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 & .035 in. - Steel tube with red lining .045 & 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.

Coolant Tank Cap

Art # A-06373

3-10

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

3.09 Automation Weld Gun

The PowerMaster 400SP and 500SP Automation power supplies can be fitted with any number of TWECO aircooled or water-cooled robotic torches and accessories. Contact a TWECO representative or review their online literature to select the appropriate robotic torch and accessories for your application:

TWECO U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 TWECO International Customer Care: 905-827-9777 / FAX 905-827-9797 TWECO Web Site: www.tweco.com

3.10 Pulsemaster PMA512S-3545 500 Amp Weld Gun (when welding by hand)

For manual welding, Thermal Arc recommends the TWECO Pulsemaster PMA512S-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.

Art # A-07922

TWECO Pulsemaster PMA5512 500 AMP Weld Gun

Original Parts Installed

Item Desc ri pt ion Part No. Qty

1 HEAVY DUTY NOZZLE HD24LP-62-A 1 2 CONTAC T TI P 16 RZ-XX-A 1 3 HEAVY DUTY GAS DIFFUSER MS5416SW-F 1 4 MA CHINE D NO ZZLE INSUL ATOR 6 6J-3A 1 5 CONDUCTOR TUBE PMA65-45S-F 1 6 HANDLE ASSY N/A 1 7 TRIGGER ASSEMBLY PM95-F 1

TWECO Pulsemaster MIG guns may be fitted to many different types of manual 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.

March 16, 2007

3-11

POWERMASTER 400SP, 500SP AUTOMATION

3.11 Installing A New Wire Conduit in the Pulsemaster PMA512S-3545

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 removing 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 conduit 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 connector 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 conduit to prevent its backward movement.

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.

CAUTION

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.

CONDUIT LINER

ALLEN SCREW

REMOVE CONSUMABLES

ALLEN SCREW

CONDUIT LINER

CONDUCTOR TUBE

1 1/16" (27mm)

Art # A-07921

O-RINGS

CONNECTOR PLUG

3-12

March 16, 2007

POWERMASTER 400SP, 500SP 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.

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 and Warnings chapter included in this manual. Neglect of these precautions may result in personal injur

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.

March 16, 2007

4-1

POWERMASTER 400SP, 500SP AUTOMATION

(46) ”Welding wire diameter” push-button

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).

(47) “TT Enter” push-button

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.

For acknowledgment when saving a welding job.

a,b

(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

— Twin pulse GMAW with one

knob (53) control

SMAW/STICK

(44) “Material” push-button

For selection of the wire material to be welded. The push-button is also used for the “Decremental" (-) function, e. g., to reduce the value of a secondary parameter.

(45) “TT Save” push-button

For saving user-defined, frequently used welding job

— Stick electrode welding

Art # A-07864

(48) “Gas type” push-button

For selection of the gas

to be used. The push- button is also used for the “increment” (+) function, e. g., to increase the value of a secondary parameter.

(49) push-button

For switching the Tiptronic process on or off.

(50) Multi-function display

For indication of all parameter values and me

ssages.

(51)

and push-buttons (Enter)

For switching between the individual secondary parameters. Pressing both pushbuttons at the same time is used for acknowledgment (Enter).

(52a) “2 stroke (2T) / 4 stroke (4T)” push-button

For switching between 2T and 4T (Latch) operation process. A lit LED indicates currently selected operating process.

(52b) "Spot Welding Mode" push-button

Activate the Spot Welding Mode by pressing and holding the 2T/4T button for 2 seconds, at which point the 2T and 4T leds will both be lit. The "spot welding time" parameter can then be adjustedin the main display.

(53) “Smart Power” control knob

Sets weldi

ng current or material thickness or

wire speed in SmartGMAW, Pulse MIG,

process. OR

“Arc Voltage” control knob Sets welding arc voltage in ManualGMAW process.

(54) “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.

the

4-2

March 16, 2007

(55) “Primary parameter” indicator lights

These lights show which primary parameter is currently displayed in the multifunction display (54).

(56) “Primary parameter” push-button

For switching between welding current, material thickness, wire feed speed and arc length, as in

dicated in the digital multifunction

display (54).

(57) “Downslope” push-button

POWERMASTER 400SP, 500SP AUTOMATION

Art # A-06376

Switches 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, process,

OR "Wire speed/Inductan

ce" control knob. To adjust the wire speed or Inductance in Manual MIG process.

(59) “Arc length” LED indication

Indicates the degree of the trim in SmartGMAW, Pulse MIG, process.

OR ”Wire speed” LED indication Indicates the wire

speed in ManualGMAW process. When the uppermost center

programmed arc length/wire speed remains unchanged; “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.

LED is lit, the

(60) Smart Torch display

Indicates the welding current or arc length trim; material thickness or arc length trim; wire feed speed or arc length trim (Linked to the digital multifunction display (54)).

In process, the current job set and the current job number are displayed.

(61) Smart to

rch rocker

Changes the welding current, material thickness, arc length to the arc length (depending on which value is being displayed on the digital multifunction display (54)).

In process, the rocker can be used to switch between the active jobs or job sets.

(62) Smart torch push-button

Has

the same function as the “Primary

parameter” push-button (56) on the

Panel

. In process this push-button

Control

can be used to switch between job selection and job-set selection.

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 in

dicated. 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.

March 16, 2007

Art # A-07865

HOLD

TENIR

4-3

POWERMASTER 400SP, 500SP AUTOMATION

4.03 Menu Structure

Main Menu Level 1 “Extras” Level 2 Remark

Gas pre-flow 0 – 10 sec.; not in SMAW/STICK electrode process Start current 20 % – 200 % of the welding current Start current time 0 – 10 sec.; not in 4-stroke (4T) mode

Twin pulse frequency 0,5 – 5 Hz; only in TwinPulse mode Twin pulse current change 5 – 50 % of the welding current; only in TwinPulse process Twin pulse relation 20 % – 80 %; only in TwinPulse process Welding current Adjustment range depends on the selected material-wire-

Downslope 10 – 990 A/sec.; not in SMAW/STICK process, only when

Crater fill current 10 % – 200 % of the welding current; not in SMAW/STICK

Crater fill time 0 – 10 sec.; not in SMAW/STICK process, only for slope =

Wire burnback time 20 % – 300 % of the programmed value; not in

Gas post-flow 20 % – 200 % of the programmed value; not in

Arc length correction 60 % – 140 % of the programmed value Inductor effect 20 % – 200 % of the programmed value; only in

Arc dynamic arc force 0 % – 100 % of the programmed value; only in

Job selection, indication of set and job name

Edit mode for set and job

Extras

Set and job name are indicated only in Tiptronic mode upon

name

1 Machine data

2 Diagnosis

3 Language Selection of the menu language 4 Display contrast Contrast setting of the LCD display 5 Mode cooling system

6 Lock function

8 Robot interface Menu item is only visible when the machine is equipped

Operating system Master Version number, operating system Master Operating system Process Version number, operating system process Operating system DMRs Version number, motor assembly Welding program version Version number, welding programs Operating hour counter Indication of the welding duration in h, min, sec Configuration Machine type and the recognized power module (with max.

Last error message Indication of the last three error messages from the error

Module temperatures Temperatures of the power modules in °C Operating voltages Indication of the operating voltages (15 V / 24 V) of the

Flow rate, cooling unit Indication of the coolant flow rate in l/min

0 normal cooling unit switches on, as soon as an arc is ignited 1 on cooling unit runs constantly 2 off cooling unit is deactivated 0 All welding controls can be adjusted by user 1 Only Tiptronic on/off and job selection can be adjusted by

2 Tiptronic on/off, job selection free 3 All welding controls locked except menu selection, gas and

Voltage correct arc length with rotary pulse encoder (58) 7 Arc length control Wire correct wire speed with rotary pulse encoder (58)

gas combination

downslope = on

process, only when slope = on or in 4 (4T) stroke

SMAW/STICK process

ManualGMAW process (short arc)

SMAW/STICK process

actuation of the „TT Enter“ push-button (47) or the „Tiptronic“ push-button (49)

Move the cursor with the change the character with the pushbuttons (48) (+) and (44) (-)

current ) are indicated alternately

memory (0 = last error, 2 = oldest error)

assembly DPMAPRO

user

pump test

and push-buttons (51);

4-4

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

Level 1

Main Menu

Gas pre- ow

Start current

Start current time

win pulse frequency

win pulse current change

win pulse relation

Welding current

Downslope

Crater ll current

Crater ll time

“Extras”

Enter menu item by pressing both keys (51) at the same time

1 Machine data

Change between

menu items with

keys 48(+) & 44(-)

2 Diagnoses

Level 2

Operating system Master

Operating system Process

Operating system DMR

Welding programs

Operating hour counter

Conguration

Last error messages

Module temperatures

Operating voltages

Flow rate cooling system

Wire burnback time

Gas post-ow

Arc length correction

Inductance

Arc force

Job selection

Extras

Change between parameters with keys (51)

Art A-07726

3 Language

4 Display contrast

5 Mode cooling system

6 Lock function

7 Arc length control

11 Robot interface

Select language

0 normal

1 on

2 o

Voltage

Wire

March 16, 2007

4-5

POWERMASTER 400SP, 500SP AUTOMATION

A. Secondary Parameters (Menu Main

Level)

Art # A-07866

2. Selecting jobs:

With and (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.

b. Press the “TT Save” button (45) (Save LED flashes).

c. Select the target job number with the pushbuttons (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 afte

r 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.

a. Switch the Tiptronic function on by pressing “Tiptronic” (49) (associated LED comes on).

b. S

elect 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.

Push-button (44) (-) is used to r

educe 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 Extr

as 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

push-buttons (51) at the same time. Switching between the individual entries is also possible here with the push-buttons (44) (-) and (48) (+). To return, press push-button (46) (END).

The Tiptronic function provides you with 100 independent jobs (10 job set with 10 jobs each). A 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.

3. Setti

ng a job inactive:

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

for two 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 come 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).

c. Hold the “TT Enter” push-button (47) pressed for two seconds (the decimal point between the job set and the job number lights

up).

s on).

1. Save/Programming jobs: a. Determi

4-6

ne the optimal welding values.

March 16, 2007

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. c. Press the “TT Save” button (45) (Save LED

flashes). d. Press “TT Enter” button e. The Save and Enter LEDs flash briefly to

confirm that programming is terminated.

6. Copying jobs: a. Switch the Tiptronic function on by pressing

“Tiptronic” (49) and select a job for copying (see Selecting Jobs).

(47) to confirm.

POWERMASTER 400SP, 500SP AUTOMATION

f. The edit mode is ended by pressing pushbutton (46) (END) or by pressing the

and 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.

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) (S 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 ca

ncelled). 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 assign

identify it more clearly. a. Switch on the Tiptronic function with the

“Tiptronic” pushbutton (49).

ed to each job in order to

ave LED

b. Select the job number with the push-buttons (44) (-) and (48) (+).

c. Press the the same time (a flashing cursor appears in

the display (50)) in order to get into the edit mode.

d. The cursor is moved with the push-buttons (51). At the end of the line, the

cursor jumps to the respective next line. e. Select a character (number, letter or special

character) with push-buttons (44) (-) and (48) (+).

March 16, 2007

and push-buttons (51) at

and

4-7

POWERMASTER 400SP, 500SP AUTOMATION

D. Code lock function

The lock function in menu Extras is s ecured with a code lock. A three-digit code must be entered before the lock function can be changed. Only after the

4.04 Special functions

A. Gas test

Pressing the 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 ca terminated.

pushbutton (51) and the “Gas type”

n be

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” i

Procedure:

s the default (factory setting) number.

1. Switch to menu Extras, lock function

2. Press button (44) (-) or (48) (+) question “change parameter ?” is displayed

3. Acknowledge with button

(51)

B. Pump test (where fitted)

Pressing the 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 (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 cont

pushbutton (51) and the “Material”

pushbutton (51) and the “TT Enter”

rast, etc.) remain unchanged.

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)

8. If requested, set a new code number with buttons (44) (-) ,(48) (+) or encoder

9. Acknowledge the code number with button

(51)

(53)

4-8

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

4.05 Smart GMAW, Pulse GMAW & TwinPulse Programs

Material

Type Name Ar / CO2 / O2 / He in.min - max min - max min - max

M/ Steel 75 / 25 / 0 / 0 .030 1 40-288 N/A N/A M/ Steel 75 / 25 / 0 / 0 .035 2 52-332 N/A N/A M/ Steel 75 / 25 / 0 / 0 .045 3 64-436 N/A N/A

Mild Steel

ER70S-x

Flux Cored

ER70C-xx

Flux Cored

ER71-T1

Stainless

ER308/ER309

Stainless Steel

Steel

ER316

Aluminum

ER4043

Aluminum

ER5356

Aluminum

ER5183

Silicone

Bronze

M/ Steel 75 / 25 / 0 / 0 .052 4 72-468 N/A N/A M/ Steel 92 / 8 / 0 / 0 .030 5 48-292 24-292 24-292 M/ Steel 92 / 8 / 0 / 0 .035 6 52-360 28-360 28-360 M/ Steel 92 / 8 / 0 / 0 .045 7 68-440 32-448 32-448 M/ Steel 92 / 8 / 0 / 0 .052 8 72-468 48-476 48-476 M/ Steel 92 / 8 / 0 / 0 1/16 9 100-500 N/A N/A

FC Metal 75 / 25 / 0 / 0 .045 13 76-388 N/A N/A FC Metal 75 / 25 / 0 / 0 .052 14 84-440 N/A N/A

FC Metal 75 / 25 / 0 / 0 1/16 15 96-488 N/A N/A FC E71- T1 75 / 25 / 0 / 0 .045 16 96-340 60-360 60-360 FC E71- T1 75 / 25 / 0 / 0 1/16 17 144-480 120-460 120-460

S/S 308/309 81 / 1 / 0 / 18 .030 18 48-280 24-284 24-284 S/S 308/309 81 / 1 / 0 / 18 .035 19 52-320 28-320 28-320 S/S 308/309 81 / 1 / 0 / 18 .045 20 60-444 32-440 32-440 S/S 308/309 98 / 2 / 0 / 0 .030 21 48-280 24-280 24-280 S/S 308/309 98 / 2 / 0 / 0 .035 22 52-320 28-320 28-320 S/S 308/309 98 / 2 / 0 / 0 .045 23 60-432 32-428 32-428

S/S 316 81 / 1 / 0 / 18 .030 30 48-280 24-280 24-280 S/S 316 81 / 1 / 0 / 18 .035 31 52-320 28-320 28-320 S/S 316 81 / 1 / 0 / 18 .045 32 S/S 316 98 / 2 / 0 / 0 .030 33 48-280 24-280 24-280 S/S 316 98 / 2 / 0 / 0 .035 34 52-320 28-320 28-320 S/S 316 98 / 2 / 0 / 0 .045 35 60-428 32-420 32-420

Al 4043 100 / 0 / 0 / 0 .035 36 48-268 20-260 20-260 Al 4043 100 / 0 / 0 / 0 3/64 38 64-348 24-348 24-348 Al 4043 100 / 0 / 0 / 0 1/16 39 80-388 32-388 32-388 Al 4043 75 / 0 / 0 / 25 3/64 40 68-352 24-352 24-352 Al 4043 75 / 0 / 0 / 25 1/16 41 80-388 32-380 32-380 Al 5356 100 / 0 / 0 / 0 .035 42 64-228 24-232 24-232 Al 5356 100 / 0 / 0 / 0 3/64 44 88-340 28-328 28-328 Al 5356 100 / 0 / 0 / 0 1/16 45 100-388 36-380 36-380 Al 5356 75 / 0 / 0 / 25 3/64 46 88-340 28-328 28-328 Al 5356 75 / 0 / 0 / 25 1/16 47 92-388 36-384 36-384 Al 5183 100 / 0 / 0 / 0 .035 48 64-228 24-228 24-228 Al 5183 100 / 0 / 0 / 0 3/64 50 88-332 28-320 28-320 Al 5183 100 / 0 / 0 / 0 1/16 51 96-380 32-372 32-372 Al 5183 75 / 0 / 0 / 25 3/64 52 88-340 28-328 28-328 Al 5183 75 / 0 / 0 / 25 1/16 53 92-380 32-372 32-372

Si Bronze 100 / 0 / 0 / 0 .035 56 48-280 24-288 24-288 Si Bronze 100 / 0 / 0 / 0 .045 57 64-348 28-352 28-352

Shield

Gas

Wire

size

Program

Number

Smart GMAW

Current Range

60-436 32-432 32-432

Pulse GMAW

Current Range

TwinPulse

March 16, 2007

4-9

POWERMASTER 400SP, 500SP AUTOMATION

4.06 Welding Setting Selection Guide

Wire Gas Combinations

Material

Name

Mild Steel

ER70-S6

Flux Cored

E71-T1

Flux Cored

E70C-6M

Stainless

Steel

308-309

Stainless

Steel

316

Aluminum

4043

Aluminum

5356

Aluminum

5183

Silicon Bronze

Art # A-07907

Shield

Gas

75Ar/

25CO

90Ar/

10CO

92Ar/ 8CO

75Ar/

25CO

75Ar/

25CO

81Ar/ 18He/ 1CO

98Ar/ 2CO

81Ar/ 18He/ 1CO

98Ar/ 2CO

Argon

75Ar/

25He

Argon

75Ar/

25He

Argon

75Ar/

25He

Argon

Wire Size

.030” (0.8mm) .035” (0.9mm)

.045” (1.1mm) .052” (1.4mm)

.030” (0.8mm)

.035” (0.9mm) .045” (1.1mm) .052” (1.4mm)

.062” (1.6mm)

.045” (1.1mm) .062” (1.6mm)

.045” (1.1mm) .052” (1.4mm)

.062” (1.6mm)

.030” (0.8mm) .035” (0.9mm) .045” (1.1mm)

.030” (0.8mm) .035” (0.9mm)

.045” (1.1mm)

.030” (0.8mm) .035” (0.9mm)

.045” (1.1mm)

.030” (0.8mm) .035” (0.9mm)

.045” (1.1mm)

.035” (0.9mm) .045” (1.1mm) .047” (1.2mm) .062” (1.6mm)

.047” (1.2mm) .062” (1.6mm)

.035” (0.9mm) .045” (1.1mm) .047” (1.2mm) .062” (1.6mm)

.047” (1.2mm) .062” (1.6mm)

.035” (0.9mm) .045” (1.1mm) .047” (1.2mm)

.062” (1.6mm)

.045” (1.1mm) .047” (1.2mm) .062” (1.6mm)

.035” (0.9mm)

.045” (1.1mm)

320SP 400SP 500SP

Synergic

Smart

MIG

Pulse &Twin

Pulse

Synergic

Smart

MIG

Pulse

&Twin

Pulse

Synergic

Smart

MIG

Pulse

&Twin

Pulse

Base Material Thickness Guide

Decimal

Thickness

(Thous)

024 030 031 036 038

040 047 048 060 063

075 078 094 105 109

125 135 141 156 162

172 188 203 219 234

250 266 281 297 313

328 344 359 375 391

406 422 438 453 469

484 500 516 532 547

563 578 594 609 625

641 656 672 688 703

719 734 750 766 781

797 813 828 844 859

875 891 906 922 938

953 969 984

Fraction

Thickness

(Inches)

1/32

3/64

1/16

5/64 3/32

7/64

1/8

9/64 5/32

11/64

3/16

13/64

7/32

15/64

1/4

17/64

9/32

19/64

5/16

21/64 11/32 23/64

3/8 25/64

13/32 27/64

7/16 29/64 15/32

31/64

1/2 33/64 17/32 35/64

9/16 37/64 19/32 39/64

5/8

41/64 21/32 43/64 11/16 45/64

23/32 47/64

3/4 49/64 25/32

51/64 13/16 53/64 27/32 55/64

7/8 57/64 29/32 59/64 15/16

61/64 31/32 63/64 25.00

Gauge

Steel

24 22

18 16

Refer to Warranty Schedule

Decimal

Thickness

(mm)

0.61

0.76

0.79

0.91

0.97

1.02

1.19

1.21

1.52

1.59

1.91

1.98

2.38

2.66

2.78

3.18

3.42

3.57

3.97

4.11

4.37

4.76

5.16

5.56

5.95

6.35

6.75

7.14

7.54

7.94

8.33

8.73

9.13

9.53

9.92

10.32

10.72

11.11

11.51

11.91

12.30

12.70

13.10

13.50

13.89

14.29

14.68

15.08

15.48

15.88

16.27

16.67

17.07

17.46

17.86

18.26

18.65

19.05

19.45

19.84

20.24

20.64

21.03

21.43

21.83

22.23

22.62

23.02

23.42

23.81

24.21

24.61

4-10

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

A B C D

Three Steps To GMAW (MIG) Welding

1.Set Variables

A) Select Process :

B) Select Wire Type

C) Select Wire Size

D) Select Shielding Gas

MANUAL GMAW SMART GMAW PULSE GMAW TWIN PULSE

2.Set Function

E) Set Trigger to 2T or 4T. 4T= Latch

F) Set Crater fill on or off.

Now you are ready to weld

3.Set Thickness

.000”

G) Set LED to

H) Set material thickness Refer to Base Material Thickness Guide

March 16, 2007

Art # A-07907

4-11

POWERMASTER 400SP, 500SP AUTOMATION

4-12

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

SECTION 5:

ROBOTIC OPERATION

5.01 Robot Interface INT06

The Robot interface INT06 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 INT06 is poss

• The control panel of the power source

• A PC with CAN interface

The INT06 works as a participant of the internal CAN-Bus. Commands coming over the INT06 interface are converted into CAN-Bus messages and vice versa: actual values and status signals coming from the internal CAN-Bus (e.g. "welding curren

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 f

Art # A-07825

unctions (like gas monitoring) can be connected optionally.

ible via:

t on") are put out to the INT06 interface.

Power

Source

INT06

Robot Control

Analog

Digital

µP

Digital

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 INT06" 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 ar tors on Robot Interface INT06 PC Board" on page 5-3).

e displayed on the pc-board INT06 with two LEDs (see " Connec-

March 16, 2007

5-1

POWERMASTER 400SP, 500SP AUTOMATION

5.03 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:

Input

A1 23 welding current A2 24 arc length A3 25 start current A4 26 downslope A5 27 start current time A6 28 end current A7 29 end current time A8 30 twin pulse frequency

Harting socket

Pin no.

Standard Configuration

Parameter

Programming the analog inputs:

Programming 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

March 16, 2007

5.04 Robot Interface Schematic

Power Source

X14/1

X14/2

X14/3

X14/4

X1/1

X1/2

X1/3

X1/4

X4/9

X4/10

X4/11

X4/12

X4/13

X4/14

X4/15

X4/16

X4/17

X4/18

X4/19

X4/3

X4/5

X4/4

X3/24

X3/23

X3/22

X3/21

X3/20

X3/19

X3/18

X3/2

X3/11

X3/12

X3/9

X3/10

X3/7

X3/8

X3/5

X3/6

X3/26

POWERMASTER 400SP, 500SP AUTOMATION

GND 24VDC digital

+ 24VDC digital

(+24VDC digital)

(0...+10VDC analog)

X3/9

X3/10

X3/11

X3/12

X3/13

X3/14

X3/15

X3/16

X3/17

X3/18

X3/19

X3/3

X3/5

X3/4

X4/24

X4/23

X4/22

X4/21

X4/20

X4/19

X4/18

X4/2

X4/11

X4/12

X4/9

X4/10

X4/7

X4/8

X4/5

X4/6

X4/26

X32

X33

X34

X35

X36

X37

X38

X39

X40

X41

X42

Art # A-07832

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.

I > 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 + (1A = 10mV)

Secondary output current GND (1A = 10 mV)

Collision protection

Contact sensor

Gas monitoring (Option)

Gas monitoring

Secondary output voltage +

Secondary output voltage -

Air blast valve 24VDC

(Option)

March 16, 2007

S00.0024.0-00 INT06 Robotic Interface

5-3

POWERMASTER 400SP, 500SP AUTOMATION

LEDs on Robot Interface INT06 PC Board

LED Designation State Meaning

1 (red) malfunction

2 (green) supply voltage

+5V

3 (green) power source

ready

4 (green) power source ok

5 (green) polarity digital

signals "IN-NPN"

off relay RE6 is off : digital inputs are high-active 15

(green) off status not ok

status blinking status ok

lit weak Microcontroller not programmed blinking supply voltage not ok

off INT06 ok on

off internal supply voltage +5V DC is not ok on

off relays RE1 is off : output „I>0“ (welding current

on off relay RE2 is off : output „power source ok“ is not

on relay RE6 is on : digital inputs are low-active

internal supply voltage +5V DC is ok

relay RE1 is on : output „I>0“ (welding current on) is active (0 Ω)

on) is not active (open) relay RE2 is on : output „power source ok“ is

active (0 Ω) active (open) (working with GND) (working with +24V DC)

16 (green) off relay RE3 is off : output „Arc Sensing“ is not

17 (green) off relay RE4 is off : output „Wire Stick“ is not active

18 (green)

arc sensing "ARC-SENSE"

short circuit wire "W-STICK"

wire sensing "WSTATE"

on off

relay RE3 is on : output „Arc Sensing“ is active (0 Ω)

active (open) relay RE4 is on : output „Wire Stick“ is active (0 Ω)

(open) relay RE5 is on : output „Wire State“ is active (0 Ω) relay RE5 is off : output „Wire State“ is not active (open)

5-4

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

5.05 Robot Interface INT06 PC Board Schematic

LED2

LED3

LED16

LED18LED17

650.5282.x INT06 RP367/1

Connector Description

X1 CAN connector X2 Internal programming connector X3 Flat ribbon connector to 42 pin Harting socket (digital and analog inputs) X4 Flat ribbon connector to 42 pin Harting socket (digital in- and outputs) X5 Additional analog outputs (optional)

LED1

LED15

D00.0110.0-00

LED5

LED4

X3X4

Art # A-07940

March 16, 2007

Robot Interface PC Board Connectors

5-5

POWERMASTER 400SP, 500SP AUTOMATION

5.06 42-Pin Harting Socket

8 1 2

5-6

Art # A-07827

March 16, 2007

Harting Socket Pin Descriptions

POWERMASTER 400SP, 500SP AUTOMATION

machine is operable 12,13 d. o. power source ok Potential free output (relay contact): if the power source is operable the contact is

machine is operable

0V bit = 0

+24V DC bit = 1 1-7 d. i. job- / program no. These digital inputs are used to select a job no. The job no. has to be set into binary

0V Tiptronic mode off

+24V DC Tiptronic mode on 8 d. i. job select The Tiptronic mode is activated with this signal. A valid job no. has to be set at the

0V machine stops welding

+24V DC machine starts welding 9 d. i. welding on Start signal of the welding machine. This signal corresponds with a pressed torch

between

12 and 13

0? between

12 and 13

“welding current on” is not active

“welding current on” is active

0? between

(contact open)

(contact closed)

between

13 and 14

(“normal manual mode”)

0V internal mode

+24V DC external mode (“robot mode”) 15 d. i. set external By setting this signal, all inputs which are declared as “external“ are valid. That means

0V setup mode is not active

+24V DC setup mode is active 16 d. i. setup mode By setting this signal, the welding procedure can be started without starting the power

0V S lope is not active

+24V DC Slope is active 17 d. i. slope The downslope is activated with this signal.

s mode.

Type Designation Description Signal Function

Harting

Pin No.

March 16, 2007

code. When none of the inputs are set (program no. 0), a program selection can be

necessary, that valid values are present at the inputs at least 100ms before and

made at the front panel of the welding machine.

program no. (only when DIP switch 9 “program select“ is “ON“)

If the signal is not set, the signals at the digital inputs 1-7 are interpreted as welding

inputs 1-7 in binary code.

button. With PowerMaster SP range the wire feed unit 1 is activated.

closed, otherwise the contact is open (in case of an error or during initialisation after

the machine is switched on)

contact is closed, if no welding current (no arc) the contact is open

the machine switches from “normal manual mode“ to “robot mode“.

It is

front panel, but the actual values of the welding parameters are still displayed.

When activated, all parameters which are set as “external“ can’t be changed over the

after setting the signal.

Course corrections can be made in thi

INT04. The signals “set extern“, “setup mode“ and “welding on“ must be active .

source (“currentless welding“). The signal “welding current on“ is simulated by the

DIP switch 10 (operating mode selection) must be in “ON“ position

13,14 d. o. welding current on Potential free output (relay contact): if welding current flows (arc is ignited) the

d. i. : digital input

d. o. : digital output

a. i. : analog input

5-7

POWERMASTER 400SP, 500SP AUTOMATION

Harting Socket Pin Descriptions (Con't)

0,5 Hz

5 Hz

+24V DV pulse welding mode 18 d. i. mode pulse This signal activates the pulse welding mode (pluse welding mode = pulse-shaped

0V normal welding mode

+24V DC Twinpulse active 19 d. i. Twinpulse mode This signal activates the twinpulse welding mode (twinpuls mode = pulse-shaped

+24V DC wire feed on 20 d. i. wire feed This signal activates the wire feeder and corresponds with pressing the wire insert

0V Twinpulse not active

+24V DC solenoid valve on 21 d. i. gas test This signal is for checking the gas supply (solenoid valve opens) and corresponds

0V wire feed off

10V DC max. welding current of p.s.

0V min. welding current of p.s. 23 a. i. welding current Control voltage 0-10V for the welding current

0V 60% of the programmed value

5V DC neutral position (no correction)

0V solenoid valve off

10V DC 140% of the programmed value

0V 20% of welding current 25 a. i. start current Control voltage 0-10V for the start current

peed given by the characteristic is corrected by the

10V DC 99% (990 A/s)

0V 0,1% (10 A/s) 26 a. i. downslope Control voltage 0-10V for the downslope

0V 0 sec. 27 a. i. start current time Control voltage 0-10V for the start current time

0V 10% of welding current 28 a. i. final current Control voltage 0-10V for the final current

10V DC 10 sec.

10V DC 200% of welding current

10V DC 100% of welding current

10V DC 10 sec.

0V 0 sec. 29 a. i. final current time Control voltage 0-10V for the final current time

10V DC

5-8

Type Designation Description Signal Function

Harting

welding current). If the signal is not set, the machine operates in normal welding

mode (short circuit arc). DIP switch 10 (operating mode selection) must be in “ON“

position

The operating mode slope must be active.

welding current with two alternating energy levels). The signal “mode pulse“ must be

set. DIP switch 10 (operating mode selection) must be in “ON“ position

with pressing the gas test button. The signal “set extern“ is not necessary.

button. The signal „set extern„ is not necessary.

The function of this control voltage depends on the setting in menu “Extras, arc length

voltage : the programmed arc lenght given by the characteristic is corrected by the

correction“.

control voltage

wire : the programmed wire feed s

the start current is set as a percentage of the welding current.

control voltage

The final current is set as a percentage of the welding current.

The operating mode slope must be active.

The operating mode twinpulse must be active.

The operating mode slope must be active.

d. i. : digital input

d. o. : digital output

Pin No.

24 a.i. arc length / wire speed Control voltage 0-10V for the korrection of the arc length / wire speed

30 a. i. twinpulse frequency Control voltage 0-10V for the twinpulse frequency

March 16, 2007

a. i. : analog input

POWERMASTER 400SP, 500SP AUTOMATION

Other Analog Parameters

Designation Description Signal Function

0V 0 sec. pre gas time Control voltage 0-10V for the pre gas time.

10V DC 10 sec.

0V 20% gas post time Control voltage 0-10V for the gas post time.

10V DC 300%

0V 5% of welding current twinpulse current change Control voltage 0-10V for the twinpulse current change.

The operating mode twinpulse must be active.

10V DC 50% of welding current

0V 20% twinpulse relation Control voltage 0-10V for the twinpulse relation.

10V DC 80%

0V 20% of programmed value wire burnback time Control voltage 0-10V for the wire burnback time.

10V DC 300% of programmed value

0V 20% of programmed value inductor effect Control voltage 0-10V for the inductor effect.

10V DC 200% of programmed value

March 16, 2007

5-9

POWERMASTER 400SP, 500SP AUTOMATION

5.07 Configuration at Front Panel Menu

The INT06 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 n ot 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 "ProgIn1" to "ProgIn3". The selection of these welding programs is made over the digital inputs 1 and 2 (pin 1 and 2).

Menu Item Pin No. Setting Description

On analog input is enabled (corresponds with DIP switch 1 set to “ON”) Opt01(AnalogIn1) 23 Off analog input is disabled On analog input is enabled (corresponds with DIP switch 2 set to “ON”) Opt02(AnalogIn2) 24 Off analog input is disabled On analog input is enabled (corresponds with DIP switch 3 set to “ON”) Opt03(AnalogIn3) 25 Off analog input is disabled On analog input is enabled (corresponds with DIP switch 4 set to “ON”) Opt04(AnalogIn4) 26 Off analog input is disabled On analog input is enabled (corresponds with DIP switch 5 set to “ON”) Opt05(AnalogIn5) 27 Off analog input is disabled On analog input is enabled (corresponds with DIP switch 6 set to “ON”) Opt06(AnalogIn6) 28 Off analog input is disabled On analog input is enabled (corresponds with DIP switch 7 set to “ON”) Opt07(AnalogIn7) 29 Off analog input is disabled On analog input is enabled (corresponds with DIP switch 8 set to “ON”) Opt08(AnalogIn8) 30 Off analog input is disabled On program selection is enabled (corresponds with DIP switch 9 set to “ON”) Opt09(ProgSelect) Off program selection is disabled On operating mode selection is enabled (corresponds with DIP switch 10 set to “ON”) Opt10(OperMode) Off operating mode selection is disabled On “robot mode” is active (corresponds with the signal “set extern”) Opt11(Setextern) Off “manual hand mode” is active

Opt12(Job+Analog)

ProgIn1 = Prog (0-99) Assignment of a welding program

ProgIn2 = Prog (0-99) Assignment of a welding program

ProgIn3 = Prog (0-99) Assignment of a welding program

On 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 be altered with the control voltage at the analog input 1 [Opt01(AnalogIn1) must be set to “ON”]

Off Normal tiptronic mode, all welding parameters are stored in the job and can’t be changed over the

analog inputs.

welding program no. (0-99) set as program 1

welding program no. (0-99) set as program 2

welding program no. (0-99) set as program 3

5-10

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

5.08 Robot Tool Software Installation

1. Insert the Installation floppy disk into your "A" 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 INT06 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.

Start the software by double-clicking the icon on the Windows desktop.

The actual state

s of the digital inputs are shown in

the upper part of the program window. In the lower part of the program window, different

parameters/inputs can be enabled or disabled by click- ing on the buttons 1-10. A clicked button means enabled a released button means disabled.

In the right part of the p

rogram 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

Art # A-07831

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).

March 16, 2007

5-11

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 for the automation interface INT06 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.

Decimal Binary Decimal Binary Decimal Binary

0 0000000 34 0100010 67 1000011 1 0000001 35 0100011 68 1000100 2 0000010 36 0100100 69 1000101 3 0000011 37 0100101 70 1000110 4 0000100 38 0100110 71 1000111 5 0000101 39 0100111 72 1001000 6 0000110 40 0101000 73 1001001 7 0000111 41 0101001 74 1001010 8 0001000 42 0101010 75 1001011 9 0001001 43 0101011 76 1001100 10 0001010 44 0101100 77 1001101 11 0001011 45 0101101 78 1001110 12 0001100 46 0101110 79 1001111 13 0001101 47 0101111 80 1010000 14 0001110 48 0110000 81 1010001 15 0001111 49 0110001 82 1010010 16 0010000 50 0110010 83 1010011 17 0010001 51 0110011 84 1010100 18 0010010 52 0110100 85 1010101 19 0010011 53 0110101 86 1010110 20 0010100 54 0110110 87 1010111 21 0010101 55 0110111 88 1011000 22 0010110 56 0111000 89 1011001 23 0010111 57 0111001 90 1011010 24 0011000 58 0111010 91 1011011 25 0011001 59 0111011 92 1011100 26 0011010 60 0111100 93 1011101 27 0011011 61 0111101 94 1011110 28 0011100 62 0111110 95 1011111 29 0011101 63 0111111 96 1100000 30 0011110 64 1000000 97 1100001 31 0011111 65 1000001 98 1100010 32 0100000 66 1000010 99 1100011

33 0100001

5-12

March 16, 2007

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 an alternating.

The transition from the short circuit to spray arc depends on the wire diameter and the gas mixture.

B. T ransitional 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 a provides higher electrode melt rate and is more economic than welding at short circuit arc.

d the arcing period are constantly

NOTE

rc. Welding with transitional arc

E. Working range at GMAW welding

Wire

diameter

inches A V A V A

.030

.035

.045 or 3/64

1/16

Favorable welding characteristics are only possible if voltage and current are corr CO2requires an arc voltage approximately 3 V higher than gas mixtures with a high argon content.

Long arc /

Spray arc

140…

180

180…

250

220…

320

260…

320

ectly adjusted.

23…

24…

25…

26…

Transitional

arc

110…

18…

150

130…

18…

200

170…

19…

250

200…

22…

300

Short circuit

arc

50…

14…

130

70…

160

120…

200

150…

200

16…

17…

18…

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 weldi

ng. 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.

March 16, 2007

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-up, overhead and in horizontalvertical 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.

A. Length of the arc

Welding with a longer arc reduces the penetration, the welding bead is wide and flat with in creased

spattering. The welding material is transferred with slightly larger drops than welding with a shorter arc.

A lo

nger 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

Welding direction

pushing the weld

Art # A-06380

Welding direction

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.

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 wir

Long electrode stick out

e-feed speed remains the same.

Art # A-06382

Short electrode stick out

6-2

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

C. Material Transfer

Benefits:

•Controlled, short-circuit-proof material transfer without spatter

• Low thermal transfer due to low primary current

Art # A-06384

Disadvantages:

•Only shielding gases with low CO2 content can be used

March 16, 2007

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 controlled 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.

Spray Transfe

Current Range

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.

Wire electrode

Acceleration due

Acceleration due to gravity

to gravity

Wire electrode

Electromagnetic force

Electromagnetic force FL (pinch effect)

FL (pinch effect)

Surface

Surface tension S

tension S

Electrostatic

Electrostatic Forces

Forces

Workpiece

Viscosity

Constrict drops

Force of inertia

Forces of

Forces of repulsion (F

repulsion (F evaporating

evaporating material

material

Eddying forces

Eddying forces caused by

caused by plasma flow

plasma flow

Art # A-06385

) o

NOTE

The main force components for separating the drops are electromagnetic force (pinch effect).

6-4

March 16, 2007

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 IP.

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

Since welding with pulsed arc is based on the temporary utilization of the pinch effect, the dropseparating pulse current must always be large enough to exceed critical current intensity depending on wire diameter, wire material and shielding gas composition, 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

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 requ 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 welds or at high welding rates.

The time of drop separation can be affected by varying the ratio of primary current to pulse current. Nor 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

and pulse current I

and pulse frequency

ires

mally

increasing the primary current and reducing the pulse current at the same time. Remember that excessively high primary curre

nt 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.

• Spray transfer weldi

ng permitted at lower-than-

normal average weld currents.

• 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.

• High energy arc produced, that virtually eliminates the risk of lack of fusio

• Improved arc control for out-of-position welding and more effective welding of thin materials, with all the advantages of spray transfer.

• Optimized pulse programs for gas/wire combinations

•TwinPulse® capabilities.

• Exceptional out-of-position welding for non-

ferrous mate

rials, including aluminium.

• Effortless TIG-like weld appearance on aluminium and stainless steel

• Deeper weld penetration

• Accurate penetration on sheet metal

• Superior welding characteristics on hard-facing and high alloy steels

• The ability to use larger-than

-normal diameter wires on thin base material, providing a cost saving on wire

• Spray arc welding vertical up, giving smoother welds, better control and deeper penetration

•Improved edge wetting in Pulse GMAW process

At the lower end of the performance range the puls 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.

March 16, 2007

6-5

POWERMASTER 400SP, 500SP AUTOMATION

Process

Processes

197

17.0

6.05 Smart, Pulse or TwinPulse GMAW Welding

The following instructions explain how to set up for Smart GMAW or Pulse GMAW or TwinPulse welding.

Art # A-07867

Enter

TT Entrer

(END)

(FIN)

Tiptronic

(+ )

Enter

Entrer

Save

TT S auver

Pulse GMAW <P35> Ar/CO2

S/S 316 .035 98/2

Processes

Process

250

6.06 Conventional Manual GMAW/ FCAW Welding

The following instructions explain how to set up for conventional manual GMAW welding.

Save

TT S auver

Manual GMAW

Processes

Process

Enter

TT Entrer

(END) (FIN)

Tiptronic

(+ )

197

Art A-07868

Enter

Entrer

A Se t

B Se t

C Set

Process

Wire type

Wire size

Shielding gas

Thickness

Torch trigger operation

Base material thickness

Sma rtG MA W = One knob control non-pulse

Processes

Pul seG MA W = One knob control pulse

Process

Twi nPu ls e = One knob control twin pulse

Eg. Stainless Steel 316

Eg. .035 in diameter

Eg. 98% Argon / 2% CO2

Press button to select material thickness

2T = Normal Operation

4T = Trigger Latch

250

Art # A-07871

welding

Use left hand knob to dial

up base ma terial thickne ss

Eg. 250 = 0.250” (1/4”)

Set

Adjust

Process

Torch trigger opera tion

Wirefeed speed knob to the des i red IPM

Arc volta ge knob to the desire arc vol ta ge

To Manual GMAW

2T = Normal Operation OR

4T = Trigger Latch

Art # A-07870

6-6

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

6.07 SMAW/STICK Welding

The following instructions explain how to set up for SMAW/STICK welding.

Art # A-07869

Enter

(END)

Tiptronic

(FIN)

(+ )

Entrer

Enter

Save

TT S auver

SMAW/STICK

Processus

Process

TT Entrer

A Se t

B Press

C Set

Process

Button

Weld current

120

Processes

o SMAW/STICK

Process

To activate SMAW mode

120

Art # A-07872

To the suggested weld current. Refer to electrode manufacturer

March 16, 2007

6-7

POWERMASTER 400SP, 500SP AUTOMATION

6-8

March 16, 2007

7.01 Maintenance

POWERMASTER 400SP, 500SP AUTOMATION

SECTION 7:

SERVICE

Warning! Disconnect input power before maintaining.

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Each Use

Visual check of torch electrode and shield cup

Weekly

Visually inspect the cables and leads. Replace as needed

Maintain more often if used under severe conditions

Visually inspect the Wire feed mechanisms

Replace all broken parts

3 Months

Gas and air lines

6 Months

Visually check and Carefully clean the interior

Clean exterior of power supply

R O T

C A T N O C

G N I N R

O M E

L A C O L

R E W O P

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.

March 16, 2007

7-1

POWERMASTER 400SP, 500SP AUTOMATION

7.02 System Troubleshooting Guide

Symptom Cause Remedy

Torch too hot

No function when torch button is pressed

ular wire feeding

Irreg or wire welds to the contact tip Irregular wire feeding or no wire feeding

Unit switches off

Cooler, hoses or pump are damaged Arc or short circuit between contact tip and gas nozzle Unstable arcWrong diameter co The

Control Panel

completely blank No shielded gas

Shielded gas switches not off

Not enough shielded gas

Decreased welding performance

Hot plug of work lead Plug was not tightened by turning to the right Check Higher wire wear out at wire-feeding unit

Insufficient coolant through flow due to pollu tion in coolant Contact tip is not tight or the wrong size for the wire used Nut of the torch hose is not tight Tighten it No connection of the control cable in the torch hose C heck and change if necessar Overload of the unit and thermal protection operates Allow unit to cool down at no load Wire electrode is tight at the spool Check and change if necessary

Burr at the wire beginningCut burr from end of wire

Wrong contact pressure at the wire-feed rolls Adjust it as described in the manual Torch defective Check and change if necess No intermediate guide or is dirty Install or clean the intermediate guide Bad quality of weldi ng wire Check and change if necessary Rust formation on the welding wire C heck and change if necessary Torch liner is dirty inside Disconnect the torch from the machine, unscrew

Torch liner is defective Check and change if necessary Motor brake adjusted too strongAdjust as described in the manual Duty cycle overloaded Al low the machine to cool down Poor cooing of internal unit parts Check the air in and outlet F

rozen systems due to low concentration of recommended coolant i n re-circulator Spatter built up inside the gas nozz le Remove i t with special pliers

ntact tip or worn outChange contact tip

Primary power phase missing Check the unit at another power outlet. Check

Gas cylinder empty Replace it Defective torch Check and replace it Gas regulator dirty or defective Check and replace it Valve of gas cylinder defective Replace the gas cylinder Valve of gas cylinder dirty or does not close Remove torch and gas regulator and clean it

Incorrect setting of shielded gas Adjust as described in the manual Dirty gas regulator Check valve Torch, gas hose blocked or not air-tight Check and change if necessary Shielded gas Phase missing Check the unit at another power outlet. Check

Poor Work lead connection Ensure good el ectrical contact between Work

Work lead not plugged in right Fasten work lead by turning the plug to the right Defect tor

Wire rolls do not fit the wire di ameter Install correct wire rolls Wrong contact pressure at wire feeder Adjust as described in the manual

is blown away from draught Avoid draught

ch Repair or replace i t

Flush the coolant hoses of the torch in opposite direction Check it

ary

the contact tip and clean compressed air

Contact the nearest service facility

power cable and mains fuses/circuit breakers

with compressed air

power cable and mains fuses/circuit breakers

clamp and workpiece

the liner with

7-2

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

7.03 Welding Process Troubleshooting Guide

Symptom Cause Remedy

Poor edge wetting on stainless steel welds

Stanless steel weld has

a dark burnt finish Dirty al uminum welds

Weld performance is very poor or high spatter levels Poor weld starts

Varying arc length when welding

Gas mixture in the cylinder has separated due to lack of use

Wire is contaminated with oil or the wire quality is uncertain Work piece is contamin ated with grease or oil Degrease with mineral spirits, etc to remove

Poor current transfer to the wire at the contact tip Use a copper or brass jump liner in the

Arc length control (58) has been adjusted too high Reduce arc length, control (58)

Inadequate gas coverage Increase gas flow by 10% and check again.

Wire is contaminated with oil Contact wire manuafacturer / supplier.

Work piece is contamin ated with grease or oil Degrease with mineral spirits, etc to remove

Poor current transfer to the wire at the contact tip Use a copper or brass jump liner in the

Incorrect wire / gas combination selected Set the correct gas / wi re combination

Improper work lead connection Reconnect work lead Contact tip is worn with an oval shape hole or

contact tip i s bl ack Contact tip is loose Tighten contact tip Material build-up in torch liner Replace torch liner

Contact tip is worn or damaged Replace contact tip

Pl ace protective cap used for storage and transport on cyl inder then carefully disconnect the cylinder from the welder and lay it down on the floor. Carefu lly roll it back and forth to remix the Contact wire manuafacturer / supplier. Kee

contaminates

conductor tube to improve current transfer to the wire

Shield arc from drafts. Hold nozzle closer to the work. Replace the damaged nozzle to center contact tip in nozzle

Keep the wire covered

contaminates

condu the wire

Replace co

the w ire covered

ctor tube to improve current transfer to

ntact tip

March 16, 2007

7-3

POWERMASTER 400SP, 500SP AUTOMATION

7.04 Error Codes

In case of a malfunction, an error code is indicated on the digital multifunction display (54) and the corre- sponding error description appears on the LCD display (50). As long as an error code is indicated, welding operation is not possible.

Code Description Cause Remedy

E01 Thermal overload Thermal sensor of power unit measures a too

high temperature (>176°F)

E02 Mains overvoltage Mains voltage too high (24V supply > 36V) Check mains voltage and control E03 Secondary over-current Welding current is too high Notify an accredited Thermal Arc Service E04 Air cooling error Temperature sensor of the power unit

detects that the unit heats up too fast

E05 Cooling system error Flowrate of the cooling liquid is too low (< 0,3

l/min) Pump is not working

E06 Secondary overvoltage Master detects output voltage is too high

(>100V)

E07 EEProm checksum error No welding program stored or error during

reading from memory

E08 Wire feed / tacho Power consumption of wire feed motor too

high No tacho signal No CAN-Bus connection between MAPRO and DMR

E09 Error v/a measuring Measuring difference between Master and

Process

E11 Remote-control connection Short circuit between remote contr ol cables Check remote control and wiring of remote E12 Communication Process Process is not responding to Master Switch the machine off and on again E13 Temp. sensor error Temp. sensor is defective Notify an accredited Thermal Arc Service E14 Op. voltages error Supply voltage is too low (< 17V) Check mains voltage and control E16 Overcurrent protection1 Power consumption of power unti 1 is too

high

E17 Op. voltage 18V error 18 V from control transformer missing Check mains supply and control E18 overload protection Safety shutdown to protect electrical

components Temp. sensor is disconnected

E19 Power module error Chargeup time for capacitors >1 second Check mains input E20 Overvoltage sec. Proc ess reports a too high output voltage or

no voltage

E21 Output voltage/current External current/voltage or measure-

difference between Master and Process 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

high E25 Power module detection DIP-switch on pc-board MVDRV have been

set wrong E26 Error voltage symmetry DC-link voltage difference (>50V) between

power units E27 No program (DSP) Wrong material-wire-gas combination

Welding programs faulty or not available E30 Op. voltage 15V error Supply voltage is too low Check mains voltages

E31 Communication error Master is not responding to Process Switch the machine off and on again ? A “?“ is shown in the display The display board doesn’t get any data from

the MV-MAPRO

*1 Check module temperatures in menu Extras , Diagnosis > Module temperatures *2 Check supply voltages in menu Extras, Diagnosis > Operating voltages *3 Check the flow rate in menu Extras, Diagnosis > Flow rate cooling system

Let machine cool down in standby (*1) Check temperature sensor (short circuit)

transformer (*2) Provider for repair

Check fans and their wiring Check connectors of flow-meter, level of

cooling liquid and flowrate (*3) Check fuse SI7 (2,5A) on pc-board MVMAPRO Notify an accredited Thermal Arc Service Provider for repair Transfer welding programs to machine again, exchange MV-MAPRO if error still persists Blow out torch package with compressed air Check wire feed unit Check wiring of wire feed motor and PCboard DMR Check wiring of pc-board LSW, pc-board DP-EMV and PC-board DP-UFI-BO

control socket Optionally exchange PC-board DP-MAPRO Provider for repair transformer (*2)

Notify an accredited Thermal Arc Service Provider for repair

transformer Let machine cool down in standby Check temp. sensor

Check MVPWRUP board and it’s wiring Notify an accredited Thermal Arc Service Provider for repair Notify an accredited Thermal Arc Service Provider for repair

Notify an accredited Thermal Arc Service Provider for repair Notify an accredited Thermal Arc Service Provider for repair Notify an accredited Thermal Arc Service Provider for repair Select other material-wire-gas combination Transfer welding programs to machine again

Check the flat ribbon cable of the DS20BF Check interpass hose (only machines with separate wire feeder) and it’s connectors Check PC-boards DMR and MV-MAPRO

7-4

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES

Wirefeeders Part No. Feature

SP4000W SP4000R

MIG Guns Part No. Feature

PulseMaster 12ft Smart Gun

PulseMaster 15ft Smart Gun

PulseMaster 12ft Gun PulseMaster 15ft Gun

Python Gun 15ft W4011301 Python Gun 15ft, PM320SP Python Gun 25ft Python Gun 15ft W4011305 Python Gun 15ft, PM400/500SP Python Gun 25ft W4011306 Python Gun 25ft, PM400/500SP

Options

Interconnect Cable Assy, 3ft Long W4000603 3/0 Welding Cable, Water Cooled Hoses & Gas Hose. Suits

Interconnect Cable Assy, 16ft Long

Interconnect Cable Assy, 32ft Long

Remote Hand Control RC20 W4000000 Small Hand Pocket Pendant, Suits 320SP, Remote Hand Pendant HR 911 W4000101 Full Control Panel Pendant. Suits 320SP and 400SP/500SP via SP4000W Cart Swivel Unit K14 W4001000 Suits 400SP/500SP with SP4000W Wirefeeder MIG/TIG Coolant 1 Quart (1L) W4001402 all PM series SP welders MIG/TIG Coolant 5 Quart (5L) W4001400 all PM SP series welders MIG/TIG Coolant 5 Gal (20L) W4001401 all PM SP series welders

Mobile Cart w/Cylinder Rack W4000300 Mobile Cart w/Cylinder Rack, PM320SP Push/Pull Interface Kit W4010300 Push/Pull Interface Kit, all PM SP series welders Job Tool Software Work Lead 12ft 90940 Work Lead 12ft, PM320SP Work Lead 12ft 90941 Work Lead 12ft, PM400/500SP Pivot Mount W4001000 Pivot Mount, PM400/500SP

W3000202

W3000302

PMA512S-3545

PMA515S-3545

PMA512-3545

PMA515-3545

W4011302

W4000604 3/0 Welding Cable, Water Cooled Hoses & Gas Hose. Suits

W4000605

W4000001

W4010400

Water cooled connections, 4 Roll, suits 400SP/500SP Water cooled connections, 4 Roll suits 400SP/500SP Automation

Built in Remote Controls. Heavy Duty 500 Amp Rated. Suits 320SP/400SP/500SP

Heavy Duty 500 Amp Rated. Suits 320SP/400SP/500SP Heavy Duty 500 Amp Rated. Suits 320SP/400SP/500SP

Python Gun 25ft, PM320SP

400SP/500SP

400SP/500SP 3/0 Welding Cable, Water Cooled Hoses & Gas Hose. Suits

400SP/500SP

Rugged Construction, Accepts Full Size Cylinder. Suits 320SP

Job Tool Software, all PM SP series welders

March 16, 2007

A-1

POWERMASTER 400SP, 500SP AUTOMATION

APPENDIX 2: FEED ROLL INFORMATION

DRIVE ROLL KITS – 4 ROLLS

Description Style 1 Style 2 Style 3

Provides less wire friction in the MIG torch due to the straightening effect of the feed rolls system,

Top Drive Roll Flat Flat Flat

Bottom Drive Roll

Wire Type Aluminum (Soft) Wire Solid (Hard) Wire Flux Cored Wire

Wire Size

.023”, .030” / 0.6, 0.8mm – W6000500 –

.035” / 0.9mm – W6000501 –

.035”, .045” / 0.9, 1.2mm – W6000502 –

.045” / 1.2mm – W6000503 –

.052”, 1/16” / 1.4, 1.6mm – W6000504 –

.030”, .035” / 0.8, 0.9mm – – W6000505

.035”, .045” / 0.9, 1.2mm – – W6000506

.045” – .052”, 1/16” / 1.2 – 1.4, 1.6mm – – W6000507

.030”, .035” / 0.8, 0.9mm W6000508 – –

.035”, 3/64” / 0.9, 1.2mm W6000509 – –

3/64”, 1/16” / 1.2, 1.6mm W6000510 – –

Double “U” Double Smooth VEE Double Knurled VEE

A-2

March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATION

APPENDIX 3: MOUNTING THE TORCH HOLDER

March 16, 2007

Art # A-07728

A-3

LIMITED WARRANTY

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

April 2006

LIMITED WARRANTY: 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 warrant appear within the warranty period stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc's specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or damage, correct such defects by suitable repair o replacement, at Thermal Arc's sole option, of any components or parts of the produc determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty o merchantability, fitness for any particular purpose, or other warranty o quality, whether express, implied, or statutory.

, Inc., A Thermadyne Company ("Thermal Arc"),

Limitation of liability: Thermal Arc shall not under any circumstances be liable for special, indirect, incidental, or consequential damages, including but not limited to lost profits and business interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whethe 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 b 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 warrant are void if the product is sold to purchaser by unauthorized persons.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivere d the product to the authorized distributor.

Warranty r epairs or replacement claims un de r this limited war r an ty must be subm itted 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 r ep ai r fa c i li ty shall be the responsibility of the Pu r c ha s e r . All returned goods shall be at th e Pu rchaser's ris k and expense. This w arranty dated Apr il 1 supersedes all previous Thermal Arc warranties. Thermal Arc

is a Registered

2006

Trademark of Thermal Arc, Inc.

WARRANTY SCHEDULE

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

April 2006

ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout, Raider, Explorer

Original Main Power Stators and Inductors.................................................................................. 3 years

Original Main Power Rectifiers, Control P.C. Boards................................................................... 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

Engines and associated components are NOT warranted by Thermal Arc, although

most are warranted by the engine manufacturer............................................................. See the Engine’s Warranty for Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P, 320SP, 400SP, 500SP; Excelarc 6045. Wire Feeders; Ultrafeed, Portafeed, PowerMaster

Original Main Power Transformer and Inductor............................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year

GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR 160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year

PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years

Welding Console, Weld Controller, Weld Timer........................................................................... 3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors, Coolant Recirculator................................1 year

SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR Dragster 85

Original Main Power Magnetics.....................................................................................................1 year 1 year

Original Main Power Rectifiers, Control P.C. Boards....................................................................1 year 1 year

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

160S, 300S, 400S

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards................................................................... 3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR

Water Recirculators.......................................................................................................................1 year 1 year

Plasma Welding Torches.............................................................................................................180 days 180 days

Gas Regulators (Supplied with power sources) ..........................................................................180 days Nil

MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil

Replacement repair parts.............................................................................................................90 days Nil

MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil

3 years 3 years

1 year

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 Wyecroft 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 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 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 S. Giuliano Milan

, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

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

THERMAL ARC 400SP 500SP Powermaster Automation Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.03 Symbol Chart

1.06 Principales Normes De Securite

1.07 Graphique de Symbole

2.01 How To Use This Manual

2.02 Equipment Identification

2.03 Receipt Of Equipment

2.04 Machine Components

2.05 Lifting Points

2.06 Power Supply Specifications (part 1)

2.07 Power Supply Specifications (part 2)

2.08 Wire Feeder Specifications

2.09 Features and Benefits Common to all PowerMaster SP Systems #

2.09 Features and Benefits Common to all PowerMaster SP Systems (con't) #

3.01 Location

3.02 Transportation and Positioning

3.03 Fitting the Mains Cable into the Cable Gland

3.04 Voltage Changeover

3.05 Connecting 3-Phase Input Power to 400SP or 500SP

3.06 Connecting Single-Phase Input Power to 400SP or 500SP

3.07 Quick Start Set Up

3.08 Recommended Setup for MIG

3.09 Automation Weld Gun

3.10 Pulsemaster PMA512S-3545 500 Amp Weld Gun (when welding by hand)

3.11 Installing A New Wire Conduit in the Pulsemaster PMA512S-3545

4.01 General Safety Precautions

4.02 Welding Controls

4.03 Menu Structure

4.04 Special functions

4.05 Smart GMAW, Pulse GMAW & TwinPulse Programs

4.06 Welding Setting Selection Guide

5.01 Robot Interface INT06

5.02 Digital Inputs and Outputs

5.03 Analog Inputs

5.04 Robot Interface Schematic

5.05 Robot Interface INT06 PC Board Schematic

5.06 42-Pin Harting Socket

5.07 Configuration at Front Panel Menu

5.08 Robot Tool Software Installation

5.09 Decimal-Binary Conversion

6.01 Types of Weld Transfer Modes

6.02 Holding and Manipulating the Torch

6.03 Basics of Pulsed Arc Welding

6.04 Pulsed Arc Welding Parameters

6.05 Smart, Pulse or TwinPulse GMAW Welding

6.06 Conventional Manual GMAW/ FCAW Welding

6.07 SMAW/STICK Welding

7.01 Maintenance

7.02 System Troubleshooting Guide

7.03 Welding Process Troubleshooting Guide

7.04 Error Codes

APPENDIX 2: FEED ROLL INFORMATION

APPENDIX 3: MOUNTING THE TORCH HOLDER

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION