Thermal Arc POWERMASTER 320SP, POWERMASTER 500SP, POWERMASTER 400SP Operator's Manual

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POWERMASTER

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Operator Manual

500SP

Version No: AD Issue Date: March 16, 2007 Manual No.: 0-4968 Operating Features:

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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 Ther mal 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 P

recautions. 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.

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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 0-4968 for:

PowerMaster 320SP Compact W1000102 PowerMaster 400SP with Integrated Water Cooler W1000202 PowerMaster 400SP Compact W1000304 PowerMaster 500SP with Integrated Water Cooler W1000502 Wirefeeder SP4000W (Enclosed spool) W3000202 Wirefeeder SP4000R (Automation) W3000302

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 AD Date: December 23, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

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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 (500SP, 400SP, and SP4000W) .................................. 2-2

2.05 Machine Components (400SP Compact Model)............................................. 2-3

2.06 Machine Components (320SP Compact Model)............................................. 2-4

2.07 Lifting Points .................................................................................................. 2-5

2.08 Power Supply Specifications (part 1) ............................................................. 2-6

2.09 Power Supply Specifications (part 2) ............................................................. 2-7

2.10 Wire Feeder Specifications ............................................................................. 2-8

2.11 Features and Benefits Common to all PowerMaster SP Systems # ................ 2-9

2.11 Features and Benefits Common to all PowerMaster SP Systems (con't) # .. 2-10

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 Change-over ...................................................................................... 3-2

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

3.06 Connecting Single-Phase Input Power to 320SP or 400SP or 500SP ............ 3-5

3.07 Quick Sta

rt Set Up .......................................................................................... 3-7

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

3.09 TWECO PULSEMASTER PMA5512 500 AMP Weld Gun .............................. 3-11

3.10 Installing A New Wire Conduit ...................................................................... 3-12

SECTION 4:

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

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TABLE OF CONTENTS (continued)

TABLE OF CONTENTS

SECTION 5:

MANUAL GMAW WELDING ........................................................................ 5-1

5.01 Types of Weld Transfer Modes ....................................................................... 5-1

5.02 Holding and Manipulating the Torch............................................................... 5-2

5.03 Basics of Pulsed Arc Welding ......................................................................... 5-4

5.04 Pulsed Arc Welding Parameters ..................................................................... 5-5

5.05 Smart, Pulse or TwinPulse GMAW Welding.................................................... 5-6

5.06 Conventional Manual GMAW/FCAW Welding.................................................. 5-6

5.07 SMAW/STICK Welding.................................................................................... 5-7

SECTION 6:

SERVICE .............................................................................................. 6-1

6.01 Maintenance ................................................................................................... 6-1

6.02 System Troubleshooting Guide....................................................................... 6-2

6.03 Welding Process Troubleshooting Guide........................................................ 6-3

6.04 Error Codes .................................................................................................... 6-4

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

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POWERMASTER 320SP, 400SP, 500SP

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.

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.

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

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 (ground) circuit.

12. Use only well-maintained equipment. Repair or r eplace damaged parts at once.

13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

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

15. Keep all panels and covers securely in place.

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.

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:

SAFETY IN WELDING AND CUTTING. This publication

and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL

INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

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POWERMASTER 320SP, 400SP, 500SP

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 r

emoved 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.

WARNING

WELDING can cause fire or explosion.

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.

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

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

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

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

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

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

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

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) All12

Heavy Over 6 in., 150 mm 5 or 6Atomic 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

Eye protection filter shade selector for welding or cutting

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

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POWERMASTER 320SP, 400SP, 500SP

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.

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.

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 pr event accidental star ting 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

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.

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POWERMASTER 320SP, 400SP, 500SP

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.”

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 f

rom 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 ar e among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

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, fr om 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 Standar d 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.

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POWERMASTER 320SP, 400SP, 500SP

1.03 Symbol Chart

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

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

Voltage Input

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Dangerous Voltage

Off

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle RatingAuxiliary Power

Art # A-04130

115V 15A

IPM

MPM

Fuse

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld Mode

Press to initiate wirefeed and welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

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

4 Step Trigger Operation

2 Step Trigger Operation

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POWERMASTER 320SP, 400SP, 500SP

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 Standa

rd, 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.

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’élect

rode 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.

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 inter nes 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.

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POWERMASTER 320SP, 400SP, 500SP

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 antibr uit ou des bouchons d’oreille appr

ouvés 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’intér ieur, 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 pulvé

risation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

Opération de coupage

ou soudage

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

Nuance de

filtre oculaire

Brassage tendre au chalumeau

toutes conditions 2

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

Brassage for t au chalumeau

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

Oxycoupage métaux ferreux toutes conditions 12

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

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

toutes conditions 12

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

Soudage á l'hydr ogène atomique (AHW)

toutes conditions 12

épais plus de 6 po. (150 mm) 5 ou 6

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

toutes conditions 12

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

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

Gougeage Air-Arc avec électrode de carbone

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

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14 Soudage á l'arc avec électrode enr obees (SMAW)

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

épais plus de 400 amperès 14

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

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

Page 14

1-8

March 16, 2007

POWERMASTER 320SP, 400SP, 500SP

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 atteindr e des matér iaux 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.

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. 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.

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.

Page 15

1-9

March 16, 2007

POWERMASTER 320SP, 400SP, 500SP

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vér ifier 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.

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 protecteur s 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.

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.

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

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.

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.

Page 16

1-10

March 16, 2007

POWERMASTER 320SP, 400SP, 500SP

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

Decoupe Arc Carbone (CAC-A)

Courant Constant

Tension Constante Ou Potentiel Constant

Haute Température

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Tension dangereuse

Hors Tension

Sous Tension

Panneau/Local

Soudage Arc Electrique Avec Electrode Enrobé (SMAW)

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

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Distant

Facteur de Marche

Pourcentage

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de PriseSource Auxiliaire

Art # A-07639

115V 15A

IPM

MPM

Fusible

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Durée de Pré-Dèbit

Durée de Post-Dèbit

Duréc du Pulse

Soudure Par Point

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

Purge Du Gaz

Mode Continu de Soudure

Pouces Par Minute

Mètres Par Minute

Torch de

Soudage

Probléme de Terre

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

Détente à 4-Temps

Détente à 2-Temps

1.07 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Page 17

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

2-1

SECTION 2:

INTRODUCTION

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.

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 recognized as follows:

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offer s helpful infor mation concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be 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

Page 18

POWERMASTER 320SP, 400SP, 500SP

2-2

March 16, 2007

2.04 Machine Components (500SP, 400SP, and SP4000W)

(1)

(7)

(3)

(8)

(4)

(9)

(10)

(2)

(16)

(15)

(13)

(12)

(11)

(14)

Art # A-07717

(5)

(6)

(17)

1. External Wire Feeder (N/A with compact models)

2. Protective Cover, Operation Panel

3. Secondary Control Operating Panel

4. Primary Control Operating Panel

5. Preview and actual welding current and voltage

6. MIG Torch Connection

7. Red = Hot coolant return

8. Blue = Cool coolant to torch

9. Lifting Points (refer to Section 2.07)

10. Handle

11. Mains On/Off Switch

12. Coolant Tank Cap

13. Air intake

14. Wheeling Gear

15. Positive Connection Socket for Work Lead

16. Negative Connection Socket for Work Lead

17. Gas Cylinder Tray

18. Work Clamp (not shown)

19. MIG Torch (not shown)

Page 19

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

2-3

2.05 Machine Components (400SP Compact Model)

(1)

(3)

(4)

(7)

(8)

(2)

(12)

(11)

(10)

(9)

(15)

Art # A-07884

(5)

(6)

1. Wire Feeder Door Panel

2. Protective Cover, Operation Panel

3. Secondary Control Operating Panel

4. Primary Control Operating Panel

5. Preview and actual welding current and voltage

6. MIG Torch Connection

7. Lifting Points (refer to Section 2.07)

8. Handle

9. Mains On/Off Switch

10. Air intake

11. Positive Connection Socket for Work Lead

12. Negative Connection Socket for Work Lead

13. Work Clamp (not shown)

14. MIG Torch (not shown)

15. Wheeling Gear

Page 20

POWERMASTER 320SP, 400SP, 500SP

2-4

March 16, 2007

2.06 Machine Components (320SP Compact Model)

1. Wire Feeder Door Panel

2. Carrying Handle

3. Protective Cover, Operation Panel

4. Handle

5. Torch Holder

6. Secondary Control Operating Panel

7. Primary Control Operating Panel

8. Preview and actual welding current and voltage

(1)

(4)

(7)

(2), (10)

(13)

(14)

(5)

(9)

Art # A-07908

(3)

(8)

(6)

9. MIG Torch Connection

10. Lifting Point (refer to Section 2.07)

11. Mains On/Off Switch (in rear)

12. Air intake (in rear)

13. Negative Connection Socket for Work Lead

14. Positive Connection Socket for Work Lead

13. Work Clamp (not shown)

14. MIG Torch (not shown)

15. Wheeling Gear (in rear)

Page 21

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

2-5

2.07 Lifting Points

Art # A-07909

Lifting Point for 320SP and 400SP Compact

Art # A-07910

Maximum

Lifting Points for 500SP and 400SP

Page 22

POWERMASTER 320SP, 400SP, 500SP

2-6

March 16, 2007

2.08 Power Supply Specifications (part 1)

Input Mains Voltage (50/60 Hz) V 208 230 400 460 208 230 400 460 208 230 400 460 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 70 60 40 35 100 90 50 45 100 90 50 45 Max Recommended Standard Normal Operating Fuse 1 Phase A 80 70 45 40 110 100 60 50 110 100 60 50 Power factor at Maximum Output cos Maximum Open Cir cuit 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)

Welding Output

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

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

Welding Output

Duty Cycle 100% 1 Phase A Duty Cycle 60% 1 Phase A Duty Cycle at Maximum Cu

rrent 1 Phase X

Input Mains Voltage (50/60 Hz) 1 Phase V 208 230 400 460 208 230 400 460 208 230 400 460 Input Power S1 at 100% Duty Cycle 1 Phase kVA 9 9 10 10 13 14 14 14 13 14 14 14 Input Power S1 at 60% Duty Cycle 1 Phase kVA 11 11 12 12 15 16 16 16 15 16 16 16 Input Power S1 at Maximum Output 1 Phase kVA 14 13 15 15 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 44 40 26 23 65 61 35 30 65 61 35 30 Input Current I1 at 60% Duty Cycle 1 Phase A 52 47 31 26 74 68 40 35 74 68 40 35 Input Current I1 Maximum Output 1 Phase A 70 58 38 32 92 85 50 43 92 85 50 43

Powe rM aster Po wer So urce Part Numb ers

W1000402 W1000602

Remote Power Supply with Integr ated Tor ch Water Cooling System

Compact Power Supply with In tegrated Wirefeeder

Automation Power Supply with Integrated Tor ch Water Cooling System

W1000502

3023

Ele ctr ica l Specifica tio ns for GMAW-P / GM AW / F CAW / MIG with Three -Pha se Inpu t Power

25 35

320SP

400SP 500SP320SP

0.99 0.99 0.99 79

14.3 – 3414.3 – 30

W1000202

Input Mains Power

320SP 400SP 500SP

Summary Specifications

320

280

W1000102 W1000304

Fan Cooled

5 – 400

10-380

500SP

320

400SP

350

50%@400A, 34V

60%@500A, 39V

320

Input Mains Power

350

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

250

40%@320A, 30V 50%@400A, 34V

400 500

5 – 500

14.3 – 39

IP23

<70

IP23

+/- 10

10-300

Fan Cooled

<70

5 – 320

+/- 10

350

50%@400A, 34V

+/- 10

Fan Cooled

10-480

<70

IP23

Page 23

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

2-7

2.09 Power Supply Specifications (part 2)

Welding Ou tpu t

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

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 Thr ee Phase 3 Phase kVA Input Current I1 at 100% Duty Cycle 3 Phase A - - - - 27 26 16 13 44 41 25 22 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 A - - - - 44 40 24 21 63 56 32 29

Welding Ou tpu t

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

Input Mains Voltage (50/60 Hz) 1 Phase V 208 230 400 460 208 230 400 460 208 230 400 460 Input Power S1 at 100% Duty Cycle 1 Phase kVA 10 10 12 12 13 14 13 13 13 14 13 13 Input Power S1 at 60% Duty Cycle 1 Phase kVA 12 12 14 13 15 15 15 15 15 15 15 15 Input Power S1 at Maximum Output 1 Phase kVA 14 13 15 15 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 A 49 45 29 25 64 59 34 29 64 59 34 29 Input Current I1 at 60% Duty Cycle 1 Phase A 57 52 34 28 73 66 38 33 73 66 38 33 Input Current I1 at Maximum Output 1 Phase A 67 57 38 32 90 83 48 41 90 83 48 41

Torch Cooling System (Where Fitted)

Standard Coolant Flow Rate gallon / min. Maximum Coolant PressurePsi Pump Type

Dimensions and Weights

Power Supply Dimension (DxWxH) in Power Supply Weight lb

43.9x17.5x33.7 222

Inp ut Ma ins Power

Centrifugal Pump

320SP

35-

400SP

320SP 400SP 500SP

500SP

0.29

77 201

-0.29

29.3x13.4x19.6

-50 Centrifu gal Pump

43.9x17.5x33.7

22 30 30

40%@300A, 32V 50%@380A, 35.2V 50%@380A, 35.2V

Inp ut Ma ins Power

230 300 300 260 330 330

320SP 400SP 500SP

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

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

-330480

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

-300380

320SP 400SP 500SP

Page 24

POWERMASTER 320SP, 400SP, 500SP

2-8

March 16, 2007

2.10 Wire Feeder Specifications

Wiref eeder P ar t Numbers SP4000W SP4000R

Wir efeeder suits water c ool ed tor c h W 3 000102 – Wir efeeder suits Automation P owe r Sourc e – W3000302

Welding Output

Weldabl e Wir e St eel & Stainless Steel Ø in .023 – .045 .023 – 1/ 1 6 Weldabl e Wir e Aluminum Ø in .035 - 1/16 .035 – 3/32 Wir efeed Speed IP M 4 – 984 4 – 984 Wir e f ee d unit Rollers 4 4

Dimensions and weights

Size of wire feed c ase (DxWxH) in. 25.2x14x19.6 21.3x8.2x7 Weight of wi re 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.

Page 25

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

2-9

2.11 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 a

re 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 manufactur ing / pr oduction 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.

SOFTWARE (Standard )

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 per fect, digital microprocessor controlled, pulse performance.

Built-in hardwar e 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.

Page 26

POWERMASTER 320SP, 400SP, 500SP

2-10

March 16, 2007

2.11 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.

#Subject to change without notification.

HARDW ARE/SOFTW ARE (Options)

High Speed Pulse is specialized high speed

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

interface.

Page 27

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

3-1

SECTION 3:

INSTALLATION

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 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

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

( E

N D

)

( E ND)

( + )

S a v

Save

E n

t e r

Enter

E n

t e

Enter

o d

Mode

T i p

t r o

n i c

T ipt

r on

i c

O L

HOLD

Art # A-08324_AA

WARNING

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.

3.03 Fitting the Mains Cable into the Cable Gland

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

Art # A-08325_AA

Page 28

POWERMASTER 320SP, 400SP, 500SP

3-2

March 16, 2007

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.

3.04 Voltage Change-over

For proper operation and to prevent damage to the machine, the Voltage Input Select Switch must be set according to the incoming AC line voltage.

If this switch is not set to the position that matches the input line voltage, the Smart Logic will inhibit the welding power source from turning on. The Voltage Input Select Switch is located on the rear panel.

Art # A-07856

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 incoming AC line voltage.

3. Secure the switch cover.

WARNING

Do not alter the position of the Voltage Input Select Switch when the ON/OFF Switch is in the ON position as this will cause two internal auxiliary fuses to

rupture. These fuses will have to be replaced before the machine can operate.

WARNING

ELECTRIC SHOCK CAN KILL.

Open the main wall disconnect switch or breaker, before removing any covers or access panels on the welding machine. Live voltage is still present even with the front panel control switch OFF. Wait at least 10 full minutes after power has been removed before removing any covers or access panels to allow adequate time for internal capacitors to discharge.

Page 29

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

3-3

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.

Input Mains Voltage (50/60 Hz) V 208 230 400 460 208 230 400 460 Max Recommended Circuit Breaker or Time-Delay FuseA 4540252070603530 Max Recommended Standard Normal Operating Fuse A 5550302580704035 Min Input Conductor Size AWG8 812144 61010 Min Input Conductor Size AWG8 812146 81010 Suggested Input Cord Type

Carolprene® Jacketed Type SOOW

90°C 600 Volt UL/CSA Portable Cord

Three-Phase Three-Phase

400SP 500SP

Art: A-07857

Primary Power Cable (not supplied)

Line Fuse

Line Disconnect Switch

Ground Conductor

Ground Terminal

GND/PE

Page 30

POWERMASTER 320SP, 400SP, 500SP

3-4

March 16, 2007

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. Connect green or gr een/yellow gr ounding

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

conducto

r 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.

GND/PE GND/PE

Art # A-07858

Black

White

Red

Green & Yellow

Page 31

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

3-5

3.06 Connecting Single-Phase Input Power to 320SP or 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.

Input Mains Voltage (50/60 Hz) V 208 230 400 460 Max Recommended Circuit Breaker or Time-Delay Fuse A 70 60 40 35 Max Recommended Standard Normal Operating Fuse A 90704540 Min Input Conductor Size AWG 6 6 10 12 Min Input Conductor Size AWG 8 8 10 12 Suggested Input Cord Type

Carolprene® Jacketed Type

SOOW 90°C 600 Volt

UL/CSA Portable Cord

Single-Phase

320SP

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 AWG4481044810 Min Input Conductor Size AWG6681066810 Suggested Input Cord Type

Single-Phase

Carolprene® Jacketed Type SOOW 90°C 600 Volt

UL/CSA Portable Cord

400SP

Single-Phase

500SP

Art: A-07859

Primary Power Cable

Line Fuse

Line Disconnect Switch

Ground Conductor

Ground Terminal

GND/PE

Page 32

POWERMASTER 320SP, 400SP, 500SP

3-6

March 16, 2007

Connect input conductors as shown in illustration.

Connect green or green/yellow gr ounding

conductor to welding power supply grounding

terminal first.

Then connect input conductors T1 and T2 to

welding power supply line terminals.

On the 320SP, push the terminal block back on

the switch shaft and pull the red level toward you.

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 T1 and T2 to the Line

Disconnect Switch terminals.

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

1-Phase Input Power Connection PowerMaster 320SP

GND/PE GND/PE

GND/PE

Black

White

Green & Yellow

Art # A-07862

WARNING

Never connect the safety ground screw to one of the three line phases. This would repr esent 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 the compression fitting.

On the 320SP, disconnnect the terminal block from

the switch shaft by pushing the small red lever

away from you (see below).

Push red lever away from you to release the terminal block

Art # A-07920

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.

Page 33

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

3-7

3.08 Recommended Setup for MIG

A. Torch Connection

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.

Art # A-07851

Trigger Receptacle

Front Panel Access Hole

Hot coolant return (Red)

Cool coolant to torch (Blue)

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. 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 in. (10 mm) out of the MIG torch nozzle.

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.

6. To remove the gun, reverse these directions.

Page 34

POWERMASTER 320SP, 400SP, 500SP

3-8

March 16, 2007

B. How T o 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

Negative Connection

Work Lead

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.

Art # A-06367

L L L N E

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

WARNING

Do not place the Work clamp on the welding power supply or gas cylinder as welding current may be conducted via the mains earth and will burn it out.

D. How To Connect To The Input Power

Refer to Connecting Input Power Section.

E. How T o 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 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

Drive pin

Hub

Brake

Nut

Page 35

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

3-9

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.

Art # A-06369

Pressure lever

Outlet guide

Inlet guide Feedroll

Close the lever and fasten the pressure rollers.

Art # A-06370

Lever

Pressure adjustment screw

Switch on power supply at main switch (item #11 see page 2-2), 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 wirefeed rolls drive the wire consistently without slipping. The wire should not be deformed.

Correct

Pressure

too High

Wrong Size

Feedrolls

Art # A-06371

Adjust the pressure adjustment knob next to the inlet guide to a lower pressure less than the pressure adjustment knob next to the outlet guide. This will ensure that the wire will be located correctly in the wirefeed unit.

Press the inch switch button

until the wire

appears approximately 3/4 in. (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 tr

igger switch. 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

gas cylinder valve

gas cylinder

bracket chain

input gauge

output gauge

gas hose

regulator valve

Art # A-06372

2 33

Page 36

POWERMASTER 320SP, 400SP, 500SP

3-10

March 16, 2007

H. How T o 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 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 Gallon (5 L) Part No. W4001400 MIG/TIG Coolant 5 Gallon (20 L) Part No. W4001401

I. How T o Configure The Power Supply

For Aluminum Welding

Change the feedrolls to U groove for aluminum 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.

Art # A-06373

Coolant Tank Cap

Page 37

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

3-11

3.09 TWECO PULSEMASTER PMA5512 500 AMP Weld Gun

The TWECO Pulsemaster PMA5512 500 AMP gun fitted to the PowerMaster 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

Item De sc ript i o n Part No. Qt y

1 HEAVY DUTY NOZZLE HD24LP-62-A 1 2 CON TACT TIP 16 R Z-XX-A 1 3 HEAVY DUTY GAS DIFFUSER MS5416SW-F 1 4 MA CHINE D NO ZZLE INSUL A TOR 66J-3A 1 5 CONDUCTOR TUBE PMA65-45S-F 1 6 HANDLE ASSY N/A 1 7 TRIGGER ASSEMBLY PM95-F 1

Original Parts Installed

TWECO Pulsemaster MIG guns may be fitted to many different types of MIG welding Power Supplies so that your whole shop can be converted to TWECO Pulsemaster. Not only will this give greater reliability (and hence greater productivity) but it will reduce stockholding of consumable parts. See your Thermal Arc distributor for details.

Page 38

POWERMASTER 320SP, 400SP, 500SP

3-12

March 16, 2007

3.10 Installing A New Wire Conduit

1. Be sure the MIG gun cable is arr anged 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.

CONDUCTOR TUBE

CONDUIT LINER

1 1/16" (27mm)

Art # A-07921

REMOVE CONSUMABLES

ALLEN SCREW

O-RINGS

ALLEN SCREW

CONNECTOR PLUG

Page 39

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

4-1

SECTION 4:

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 injury.

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.

Page 40

POWERMASTER 320SP, 400SP, 500SP

4-2

March 16, 2007

(46) ”Welding wire diameter” 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.

(47) “TT Enter” push-button

For acknowledgment when saving a welding job.

(48) “Gas type” push-button

For selection of the gas to be used. The pushbutton 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 messages.

(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 the 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 welding 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 cu

rrent, material thickness (in .001), wire feed speed (in inches/min) or arc length trim.

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).

Art # A-07864

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 — Stick electrode welding

(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 jobs.

Page 41

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

4-3

(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 indicated in the digital multifunction display (54).

(57) “Downslope” push-button

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/Inductance" control knob. To

adjust the wire speed or Inductance in Manual MIG process.

(59) “Arc length” LED indication

Indicates the degree of the tr im in SmartGMAW, Pulse MIG, process.

OR ”Wire speed” LED indication Indicates the wire

speed in ManualGMAW process. When the uppermost center LED is lit, the

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.

Art # A-06376

(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 torch 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

Control

Panel

. In process this push-button can be used to switch between job selection and job-set selection.

Current / voltage display

The actual welding voltage and welding current values ar e indicated during welding. After the welding procedure, the “Hold” LED illuminates and the last welding voltage and welding current values are indicated. When the operator changes certain welding adjustments (e. g. thickness, program, job), the “Hold” LED goes out and the preview values for current and voltage are displayed.

HOLD

TENIR

Art # A-07865

Page 42

POWERMASTER 320SP, 400SP, 500SP

4-4

March 16, 2007

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-

gas combination

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

downslope = on

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

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

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

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

SMAW/STICK process

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

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

ManualGMAW process (short arc) Arc dynamic arc force 0 % – 100 % of the programmed value; only in

SMAW/STICK process Job selection, indication of

set and job name

Set and job name are indicated only in Tiptronic mode upon

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

„Tiptronic“ push-button (49) Edit mode for set and job

name

Move the cursor with the

and push-buttons (51); change the character with the pushbuttons (48) (+) and (44) (-)

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

1 Machine data

Configuration Machine type and the recognized power module (with max.

current ) are indicated alternately

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

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

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

assembly DPMAPRO

2 Diagnosis

Flow rate, cooling unit Indication of the coolant flow rate in l/min 3 Language Selection of the menu language 4 Display contrast Contrast setting of the LCD display

0 normal cooling unit switches on, as soon as an arc is ignited

1 on cooling unit runs constantly

5 Mode cooling system

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

user

2 Tiptronic on/off, job selection free

6 Lock function

3 All welding controls locked except menu selection, gas and

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

Extras

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

Page 43

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

4-5

win pulse relation

Welding current

Downslope

win pulse current change

win pulse frequency

Start current time

Start current

Gas pre- ow

Job selection

Extras

Arc force

Inductance

Gas post-ow

Wire burnback time

Crater ll current

Last error messages

Module temperatures

Operating voltages

Conguration

Operating hour counter

Welding programs

Operating system Process

Operating system Master

0 normal

1 on

Select language

Flow rate cooling system

2 o

2 Diagnoses

1 Machine data

5 Mode cooling system

6 Lock function

4 Display contrast

3 Language

7 Arc length control

11 Robot interface

Voltage

Wire

Crater ll time

Arc length correction

Operating system DMR

Main Menu

Level 2

Change between menu items with

keys 48(+) & 44(-)

Level 1 “Extras”

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

Change between parameters with keys (51)

Art A-07726

Page 44

POWERMASTER 320SP, 400SP, 500SP

4-6

March 16, 2007

A. Secondary Parameters (Menu Main

Level)

Art # A-07866

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) pushbutton.

Push-button (44) (-) is used to reduce the indicated parameter and push-button (48) (+) is used to increase the value of the indicated parameter. Pressing the push-button (46) (END) saves the parameter and the system switches back to the material-wire-gas combination display.

B. Extras menu

In addition to the secondary parameters, the Extras menu item is also available; it offers the following functions:

Push-buttons (44) (-) and (48) (+) are used to switch between the menu items. The different entries of the

menu items are called up by pressing the

and

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.

1. Save/Programming jobs: a. Determine the optimal welding values.

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 after 10 seconds after the last keystroke and the save operation is aborted).

d. The Save and Enter LEDs flash briefly to confirm that programming is terminated.

2. Selecting jobs: a. Switch the Tiptronic function on by pressing

“Tiptronic” (49) (associated LED comes on). b. Select the job number with the smart torch

rocker (alternatively the job number can be selected with the push-buttons (44) (-) and (48) (+)).

c. To exit the Tiptronic process, pr ess “Tiptronic” (49) (Tiptronic LED goes out). The parameters are reset to the values that existed before you switched on the Tiptronic process.

3. Setting 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 comes on). b. Select the job number with the push-buttons

(44) (-) and (48) (+) (with an inactive job, the decimal point between job set and job number is missing).

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).

Page 45

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

4-7

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 (47) to confirm. 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).

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

c. Select the target job number with the pushbuttons (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 procedur e is cancelled). If the target job number has not been occupied with a job yet, it is indicated by the display flashing.

d. The Save and Enter LEDs flash briefly to confirm that programming is terminated.

The user-defined job texts are also copied

onto the new target job number.

7. Assigning descriptive text to a job: Text can be assigned to each job in order to

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

“Tiptronic” pushbutton (49). b. Select the job number with the push-buttons

(44) (-) and (48) (+).

c. Press the

and push-buttons (51) at

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

and

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) (+).

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)).

Page 46

POWERMASTER 320SP, 400SP, 500SP

4-8

March 16, 2007

4.04 Special functions

A. Gas test

Pressing the

pushbutton (51) and the “Gas type”

pushbutton (48) at the same time activates the gas test function. The solenoid valve of the system is activated and the gas flow rate can be checked / adjusted. The function remains active for 30 seconds and is then ended automatically. By pushing the “Gas type” pushbutton (48) again, the gas test can be terminated.

B. Pump test (where fitted)

Pressing the

pushbutton (51) and the “Material”

pushbutton (44) at the same time activates the pump test function. The coolant pump is switched on and runs for approximately one minute. By pushing the “Material” pushbutton (44), the pump test can be terminated.

C. Resetting Adjustments

Pressing the

pushbutton (51) and the “TT Enter”

pushbutton (47) at the same time resets all secondary parameters to the Factory set values. When the Tiptronic process is active, the settings of the current job are reset. All adjustment in the Extras menu (language, display contrast, etc.) remain unchanged.

D. Code lock function

The lock function in menu Extras is secured with a code lock. A three-digit code must be entered before the lock function can be changed. Only after the correct code is entered, the lock function can be altered. After leaving the menu, a new code number can be set or the old code number is acknowledged. Code “000” is the default (factory setting) number.

Procedure:

1. Switch to menu Extras, lock function

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

3. Acknowledge with button

(51)

4. Set three-digit code number with button (44) (-),(48) (+) or encoder (53)

5. Acknowledge the code number with button (51)

6. Set desired lock function number with buttons (44) (-) or (48) (+)

7. Leave menu with button (46) (END)

8. If requested, set a new code number with buttons (44) (-) ,(48) (+) or encoder (53)

9. Acknowledge the code number with button

(51)

Page 47

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

4-9

4.05 Smart GMAW, Pulse GMAW & TwinPulse Programs

Shield

Gas

Wire

size

Program

Number

Smart GMAW

Current Range

Pulse GMAW

Current Range

TwinPulse

Current Range

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 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 60-436 32-432 32-432 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

Silicone

Bronze

Stainless Steel

ER316

Aluminum

ER4043

Aluminum

ER5356

Aluminum

ER5183

Stainless Steel

ER308/ER309

Material

Mild Steel

ER70S-x

Flux Cored

ER70C-xx

Flux Cored

ER71-T1

Page 48

POWERMASTER 320SP, 400SP, 500SP

4-10

March 16, 2007

4.06 Welding Setting Selection Guide

Fraction

(Inches)

Thickness

Decimal

Thickness

(Thous)

Decimal

Thickness

(mm)

Steel

Gauge

1/32

1/16

5/64 3/32

9/64 5/32

11/64

3/16

9/32

19/64

5/16

21/64 11/32

7/16 29/64 15/32

31/64

1/2

19/32 39/64

5/8

41/64 21/32

0.61

0.76

0.79

0.91

0.97

1.59

1.91

1.98

2.38

3.57

3.97

4.11

4.37

4.76

7.14

7.54

7.94

8.33

8.73

11.11

11.51

11.91

12.30

12.70

15.08

15.48

15.88

16.27

16.67

024 030 031 036 038

3/64

1.02

1.19

1.21

1.52

040 047 048 060 063

075 078 094

7/64

1/8

2.66

2.78

3.18

3.42

105 109

125 135 141 156 162

172 188

13/64

7/32

15/64

1/4 17/64

5.16

5.56

5.95

6.35

6.75

203 219 234

250 266 281 297 313

328 344

23/64

3/8 25/64

13/32 27/64

9.13

9.53

9.92

10.32

10.72

359 375 391

406 422 438 453 469

484 500

33/64 17/32 35/64

9/16

37/64

13.10

13.50

13.89

14.29

14.68

516 532 547

563 578 594 609 625

641 656

43/64 11/16 45/64

23/32 47/64

17.07

17.46

17.86

18.26

18.65

672 688 703

719 734

3/4 49/64 25/32

51/64 13/16

19.05

19.45

19.84

20.24

20.64

750 766 781

797 813

7/8

53/64 27/32 55/64

57/64

21.03

21.43

21.83

22.23

22.62

828 844 859

875 891

29/32 59/64 15/16

61/64 31/32

23.02

23.42

23.81

24.21

24.61

906 922 938

953 969

63/64 25.00

984

24 22

18 16

Base Material Thickness Guide

Refer to Warranty Schedule

Art # A-07907

320SP 400SP 500SP

Wire Size

Shield

Material

Name

Gas

Wire Gas Combinations

Silicon Bronze

.035” (0.9mm)

.045” (1.1mm)

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

.062” (1.6mm)

Aluminum

5183

75Ar/

25CO

75Ar/

25CO

Argon

81Ar/ 18He/ 1CO

90Ar/

10CO

92Ar/ 8CO

75Ar/

25CO

98Ar/ 2CO

75Ar/

25He

75Ar/

25He

75Ar/

25He

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

Aluminum

5356

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

.047” (1.2mm) .062” (1.6mm)

Aluminum

4043

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

.047” (1.2mm) .062” (1.6mm)

Flux Cored

E71-T1

Flux Cored

E70C-6M

.045” (1.1mm) .062” (1.6mm)

Stainless

Steel

316

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

Stainless

Steel

308-309

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

.045” (1.1mm) .052” (1.4mm) .062” (1.6mm)

.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)

Mild Steel

ER70-S6

Synergic

Smart

MIG

Pulse &Twin

Pulse

Synergic

Smart

MIG

Pulse

&Twin

Pulse

Synergic

Smart

MIG

Pulse

&Twin

Pulse

Page 49

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

4-11

Three Steps To GMAW (MIG) Welding

Now you are ready to weld

A B C D

1.Set Variables

B) Select Wire Type

C) Select Wire Size

D) Select Shielding Gas

A) Select Process :

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.

3.Set Thickness

H) Set material thickness Refer to Base Material Thickness Guide

G) Set LED to

.000”

Art # A-07907

Page 50

POWERMASTER 320SP, 400SP, 500SP

4-12

March 16, 2007

Page 51

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

5-1

SECTION 5:

MANUAL GMAW WELDING

5.01 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 poll helps to draw the drop into the bath and to reignite the arc. This cycle is repeated again and again so the short circuit and the arcing period are constantly alternating.

NOTE

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

B. Transitional arc

The transitional arc is especially suitable for medium thickness sheet metals and for vertical-down welding. The transfer of the electrode to the workpiece takes place partly in short circuit and in free flight. Due to fewer short circuits, the welding pool is hotter than at the short circuit arc. Welding with transitional arc provides higher electrode melt rate and is more economic than welding at short circuit arc.

C. Long arc

Long arcs are typically at a higher ampere range under carbon dioxide and gases with a high CO2 content. It is not particularly suitable for positional welding. In this type of arc large drops are fo

rmed 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.

E. Working range at GMAW welding

Wire

diameter

inches A V A V A

.030

140…

180

23…

110…

150

18…

50…

130

14…

.035

180…

250

24…

130…

200

18…

70…

160

16…

.045 or 3/64

220…

320

25…

170…

250

19…

120…

200

17…

1/16

260…

320

26…

200…

300

22…

150…

200

18…

Long arc /

Spray arc

Transitional

arc

Short circuit

arc

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

Page 52

POWERMASTER 320SP, 400SP, 500SP

5-2

March 16, 2007

Art # A-06381

Long Arc

Short Arc

B. Length of the wire electrode

The distance between the torch and the workpiece should be 10 – 12 times the diameter of the wire. Altering the distance of the torch will influence the electrode stick out.

A longer electrode stick out reduces the amperage and the penetration.

A shorter electrode stick out increases the amperage if the wire-feed speed remains the same.

Art # A-06382

Long electrode stick out

Short electrode stick out

5.02 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.

Art # A-06380

Welding direction

pushing the weld

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 verticalup welding, the side to side motion should follow the shape of an open triangle.

A. Length of the arc

Welding with a longer arc reduces the penetration, the welding bead is wide and flat with increased spattering. The welding material is transferred with slightly larger drops than welding with a shorter arc. A longer arc is useful for welding a fillet weld to form a flat or concave seam. Welding with a shorter arc (at the same amperage) increases the penetration, the welding bead is narrow and high with reduced spattering. The welding material is transferred with smaller d

roplets.

Page 53

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

5-3

C. Material Transfer

Art # A-06384

Benefits:

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

• Low thermal transfer due to low primary current

Disadvantages:

• Only shielding gases with low CO2 content can be used

Page 54

POWERMASTER 320SP, 400SP, 500SP

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March 16, 2007

5.03 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.

Art # A-06383

Spray Transfe

Current Range

B. Forces acting during material transfer

A number of forces come into play which influences the resulting molten metal drop formation and separation.

Electrostatic Forces

Workpiece

Surface tension S

Acceleration due

Electromagnetic force FL (pinch effect)

Eddying forces caused by

Forces of repulsion (F

) o

evaporating

Force of inertia

Constrict drops

Viscosity

Wire electrode

to gravity

material

plasma flow

Electrostatic Forces

Workpiece

Surface tension S

Acceleration due

Electromagnetic force FL (pinch effect)

Eddying forces caused by

Forces of repulsion (F

) o

evaporating

Force of inertia

Constrict drops

Viscosity

Wire electrode

to gravity

material

plasma flow

Art # A-06385

NOTE

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

Page 55

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

5-5

5.04 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

and pulse current I

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

and pulse frequency

The main condition for a controlled material transfer with one drop per pulse is to set a defined drop volume. The volume of the melted drop must then be identical with the volume of the wire electrode fed in each pulse period. The necessary wire feed speed v

results from the product of pulse frequency fP and the wire length “L” melted in each pulse period. From this relationship you see that a change in wire feed speed requires a linear change in pulse frequency. A rise in electrode melt rate by increasing wire feed speed needs a higher pulse frequency. The objective drop diameter should be about .045" (1.2mm) with a wire diameter of .045" (1.2mm).

D. Primary current

Arc length ionization must be maintained during the primary current phase, whose period results from the selected frequency and pulse period. This requires currents ranging between 25 and 80 A depending on wire diameter, material and material thickness. The primary cu

rrent 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. Normally the objective is to separate the drop just after the current pulse in the primary current phase (in the third pulse current phase). This can be achieved by

increasing the primary curr

ent and reducing the pulse current at the same time. Remember that excessively high primary current will melt the free wire end too quickly. This will form very large drops which can lead to spatter during the transition to the welding pool.

E. Pulse MIG applications

The main application for pulse MIG is for precision MIG welding of aluminum, stainless steel, steel and other weldable materials.

•Spray transfer welding 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 rivaling TIG welding.

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

• 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 nonferrous materials, including aluminum.

• Effortless TIG-like weld appearance on aluminum 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 PulseGMAW process

At the lower end of the performance range the pulsed arc cannot fully replace the dip transfer. The reason is the continuous arc that occurs in the primary current phase. This phenomenon does not exist with the short-circuiting arc. An exception to this is when welding aluminum and aluminum 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 aluminum materials and high-alloy steels.

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POWERMASTER 320SP, 400SP, 500SP

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March 16, 2007

5.05 Smart, Pulse or TwinPulse GMAW Welding

The following instructions explain how to set up for SmartGMAW or PulseGMAW or TwinPulse welding.

Save

TT S auver

Enter

Entrer

Tiptronic

(END)

(FIN)

(+ )

Enter

TT Entrer

Process

Processes

Pulse GMAW <P35> Ar/CO2 S/S 316 .035 98/2

250

Art # A-07867

A Se t

Process

Pro ce ss

Pro ce sses

Sma rtG MAW = One knob control non-pulse

welding

Pul seG MA W = One knob control pulse

welding

Twi nPu ls e = One knob control twin pulse

welding

Wire type

Eg. Stainless Steel 316

Wire size

Eg. .035 in diameter

Shielding gas

Eg. 98% Argon / 2% CO2

Thickness

Press button to select material thickness

B Se t

Torch trigger operation

2T = Normal Operation

4T = Trigger Latch

C Se t

Base material thickness

250

Use left hand knob to dial

up base mat erial thickness

Eg. 250 = 0.250” (1/4”)

Art # A-07871

5.06 Conventional Manual GMAW/ FCAW Welding

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

Save

TT S auver

Enter

Entrer

Tiptronic

(END) (FIN)

(+ )

Enter

TT Entrer

Process

Processes

Manual GMAW

197

Art A-07868

Set

Process

Processes

To Manual GMAW

Set

Torch trigger opera tion

2T = Normal Operation OR

4T = Trigger Latch

Adjust

Wirefeed speed knob to the des i red IPM

197

Adjust

Arc vol tage knob to the desire a rc vol ta ge

17.0

Art # A-07870

Page 57

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

5-7

5.07 SMAW/STICK Welding

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

Save

TT S auver

Enter

Entrer

Tiptronic

(END) (FIN)

(+ )

Enter

TT Entrer

Process

Processus

SMAW/STICK

120

Art # A-07869

A Se t

Process

Pro ce ss

Pro ce sses

o SMAW/STICK

B Press

Button

To activate SMAW mode

C Se t

Weld current

120

To the suggested weld current. Refer to electrode manufacturer

Art # A-07872

Page 58

POWERMASTER 320SP, 400SP, 500SP

5-8

March 16, 2007

Page 59

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

6-1

Warning! Disconnect input power before maintaining.

Each Use

Visual check of regulator and pressure

Visual check of torch electrode and shield cup

Weekly

Visually inspect the torch body and consumables

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

6 Months

Replace all broken parts

Visually check and Carefully clean the interior

Maintain more often if used under severe conditions

Gas and air lines

Art # A-07725

Visually inspect the Wire feed mechanisms

SECTION 6:

SERVICE

6.01 Maintenance

NOTE

For units with integrated coolers, check the fluid levels and refill as needed. Check torch connections for leaks and then check for return flow of coolant to the reservoir.

Page 60

POWERMASTER 320SP, 400SP, 500SP

6-2

March 16, 2007

6.02 System Troubleshooting Guide

Symptom Cause Remedy

Insufficient coolant through flow due to pollution in coolant

Flush the coolant hoses of the torch in opposite

direction Contact tip is not tight or the wrong size for the wire used

Check it

Nut of the torch hose is not tight Tighten it No connection of the control cable in the torch hose Check and change if necessary Overload of the unit and thermal protection operates Allow unit to cool down at no load Wire electrode is tight at the spool Check and change if necessary

Burr at the wire beginning Cut 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 necessary No intermediate guide or is dirty Install or clean the intermediate guide Bad quality of welding wire Check and change if necessary Rust formation on the welding wire Check and change if necessary To

rch liner is dirty inside Disconnect the torch from the machine, unscrew

the contact tip and clean the liner with

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

Cooler, hoses or pump are damaged

Frozen systems due to low concentration of recommended coolant in re-circulator

Contact the nearest service facility

Arc or short circuit between contact tip and gas nozzle

Spatter built up inside the gas nozzle Remove it with special pliers

Unstable arcWrong diameter contact tip or worn out Change contact tip The

Control Panel

completely blank

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

power cable and mains fuses/circuit breakers 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

Shielded gas switches not off

Valve of gas cylinder dirty or does not close Remove torch and gas regulator and clean it

with compressed air 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 is blown away from draft Avoid draft One of the three phase input power is missing Check the unit at another power outlet. Check

power cable and mains fuses/circuit breakers Poor Work lead connection Ensure good electrical contact between Work

clamp and workpiece Work lead not plugged in right Fasten work lead by turning the plug to the right Defect torch Repair or replace it

Hot plug of work lead Plug was not tightened by turning to the right Check

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

Torch too hot

No function when torch button is pressed

Irregular wire feeding or wire welds to the contact tip Irr

egular wire feeding

or no wire feeding

Higher wire wear out at wire-feeding unit

Unit switches off

No shielded gas

Not enough shielded gas

Decreased welding performance

Page 61

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

6-3

6.03 Welding Process Troubleshooting Guide

Symptom Cause Remedy

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

Place protective cap used for storage and transport on cylinder then carefully disconnect the cylinder from the welder and lay it down on the floor. Carefully roll it back and for th to re- mix the

as Wire is contaminated with oil or the wire quality is uncertain

Contact wire manufacturer / supplier. Kee

the wire covered

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

contaminates

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

conductor tube to improve current transfer to

the wire Stainless steel weld has a dark burnt finish

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.

Shield arc from drafts.

Hold nozzle closer to the work.

Replace the damaged nozzle to center contact

tip in nozzle

Wire is contaminated with oil Contact wire manufacturer / supplier.

Keep the wire covered

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

contaminates

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

conductor tube to improve current transfer to

the wire Weld performance is very poor or high spatter levels

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

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

contact tip is black

Replace contact tip

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

Varying arc length when welding

Poor edge wetting on stainless steel welds

Dirty aluminum welds

Poor weld starts

Page 62

POWERMASTER 320SP, 400SP, 500SP

6-4

March 16, 2007

6.04 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.

*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

Code Description Cause Remedy

E01 Thermal overload Thermal sensor of power unit measures a too

high temperature (>176°F)

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

E02 Mains overvoltage Mains voltage too high (24V supply > 36V) Check mains voltage and control

transformer (*2)

E03 Secondary over-current Welding current is too high Notify an accredited Thermal Arc Service

Provider for repair

E04 Air cooling error Temperature sensor of the power unit

detects that the unit heats up too fast

Check fans and their wiring

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

l/min) Pump is not working

Check connectors of flow-meter, level of cooling liquid and flowrate (*3) Check fuse SI7 (2,5A) on pc-board MVMAPRO

E06 Secondary overvoltage Master detects output voltage is too high

(>100V)

Notify an accredited Thermal Arc Service Provider for repair

E07 EEProm checksum error No welding program stored or error during

reading from memory

Transfer welding programs to machine again, exchange MV-MAPRO if error still persists

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

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

Blow out torch package with compressed air Check wire feed unit Check wiring of wire feed motor and PCboard DMR

E09 Error V/A measuring Measuring difference between Master and

Process

Check wiring of pc-board LSW, pc-board DP-EMV and PC-board DP-UFI-BO

E11 Remote-control connection Short circuit between remote control cables Check remote control and wiring of remote

control socket

E12 Communication Process Process is not responding to Master Switch the machine off and on again

Optionally exchange PC-board DP-MAPRO

E13 Temp. sensor error Temp. sensor is defective Notify an accredited Thermal Arc Service

Provider for repair

E14 Op. voltages error Supply voltage is too low (< 17V) Check mains voltage and control

transformer (*2)

E16 Overcurrent protection1 Power consumption of power unti 1 is too

high

Notify an accredited Thermal Arc Service Provider for repair

E17 Op. voltage 18V error 18 V from control transformer missing Check mains supply and control

transformer

E18 overload protection Safety shutdown to protect electrical

components Temp. sensor is disconnected

Let machine cool down in standby Check temp. sensor

E19 Power module error Chargeup time for capacitors >1 second Check mains input

Check MVPWRUP board and it’s wiring

E20 Overvoltage sec. Process reports a too high output voltage or

no voltage

Notify an accredited Thermal Arc Service Provider for repair

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

difference between Master and Process

Notify an accredited Thermal Arc Service

Provider for repair E22 Mains undervoltage 1 Power unit 1 reports mains voltage too low Check mains voltage and mains rectifier E23 Mains overvoltage Power unit reports mains voltage too high Check mains voltage E24 Overcurrent protection2 Power consumption of power unti 2 is too

high

Notify an accredited Thermal Arc Service

Provider for repair E25 Power module detection DIP-switch on pc-board MVDRV have been

set wrong

Notify an accredited Thermal Arc Service

Provider for repair E26 Error voltage symmetry DC-link voltage difference (>50V) between

power units

Notify an accredited Thermal Arc Service

Provider for repair E27 No program (DSP) Wrong material-wire-gas combination

Welding programs faulty or not available

Select other material-wire-gas combination

Transfer welding programs to machine

again 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

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

Page 63

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

A-1

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES

Wirefeeders Part No. Feature

SP4000W

W3000202

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

SP4000R W3000302 Water cooled connections, 4 Roll suits 400SP/500SP Automation

MIG Guns Part No. Feature

PulseMaster 12ft Smart Gun PMA512S-3545 Built in Remote Controls. Heavy Duty 500 Amp Rated. Suits

320SP/400SP/500SP

PulseMaster 15ft Smart Gun PMA515S-3545 Built in Remote Controls. Heavy Duty 500 Amp Rated. Suits

320SP/400SP/500SP

PulseMaster 12ft Gun PMA512-3545 Heavy Duty 500 Amp Rated. Suits 320SP/400SP/500SP

PulseMaster 15ft Gun PMA515-3545 Heavy Duty 500 Amp Rated. Suits 320SP/400SP/500SP Python Gun 15ft W4011301 Python Gun 15ft, PM320SP Python Gun 25ft W4011302 Python Gun 25ft, PM320SP 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 400SP/500SP

Interconnect Cable Assy, 16ft Long

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

400SP/500SP

Interconnect Cable Assy, 32ft Long

W4000605

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

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

W4000001

Rugged Construction, Accepts Full Size Cylinder. Suits 320SP

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

W4010400

Job Tool Software, all PM SP series welders

Work Lead 12ft

90940

Work Lead 12ft, PM320SP

Work Lead 12ft

90941

Work Lead 12ft, PM400/500SP

Pivot Mount W4001000 Pivot Mount, PM400/500SP

Page 64

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

A-2

APPENDIX 2: FEED ROLL INFORMATION

Part No. Description

W6000500 DRIVE RL KIT,2RL,023-030,DS V W6000501 DRIVE RL KIT,2RL,035-035,DS V W6000502 DRIVE RL KIT,2RL,035-045,DS V W6000503 DRIVE RL KIT,2RL,045-045,DS V W6000504 DRIVE RL KIT,2RL,052-1/16,DS V W6000505 DRIVE RL KIT,2RL,035-035,DK V W6000506 DRIVE RL KIT,2RL,035-045,DK V W6000507 DRIVE RL KIT,2RL,045-1/16,DK V W6000508 DRIVE RL KIT,2RL,030-035,DU W6000509 DRIVE RL KIT,2RL,035-045,DU W6000510 DRIVE RL KIT,2RL,045-1/16,DU W6000511 Guide,Inlet,023-1/16,SP W6000512 Guide,Intermideate,023-1/16,SP W6000513 Guide,Outlet,023-035,SP W6000514 Guide,Outlet,035-045,SP W6000515 Guide,Outlet,045-1/16,SP

ORDERING 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 Double “U” Double Smooth VEE Double Knurled VEE

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 – –

Page 65

POWERMASTER 320SP, 400SP, 500SP

March 16, 2007

A-3

APPENDIX 3: MOUNTING THE TORCH HOLDER

Art # A-07728

Page 66

LIMITED WARRANTY

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

April 2006

LIMITED WARRANTY: Thermal Arc

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

warrants to customers of authorized distributors ("Purchaser") that its products will be free

of defects in workmanship or material. Should any failure to conform to t

his warranty

appear within the warranty period stated below, Thermal Arc shall, upon notification

thereof and substantiation that the product has been stored, installed, operated, and

maintained in accordance with Thermal Arc's specifications, instruction

recommendations and recognized standard industry practice, and not subject to misuse,

repair, neglect, alteration, or damage, correct such defects by suitable repair or

replacement, at Thermal Arc's sole option, of any components or parts of the product

determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty of

merchantability, fitness for any particular purpose, or other warranty of

quality, whether express, implied, or statutory.

Limitation of liability: Ther mal A

rc shall not under any circumstances be liable for special,

indirect, incidental, or consequential damages, including but not limited to lost profits and

business i nterrupt ion. The remedies of the pu rchaser s et forth herein are exclusive, and

the liability of Thermal A

rc 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 A

rc, whether

aris

ing 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 ch

ange this

warranty in any way or grant any other warranty, and Thermal A

rc shall not be bound by

any such attempt. Correction of non-

conformities, in the manner and time provided

herein, constitutes fulfillment of thermal’s obligations to purchaser with r

espect to the

product.

This warranty is void, and seller bears no liability hereunder, if purchaser used

replacement parts or accessories which, in Thermal A

rc's sole judgment, impaired the

safety or performance of any Therma l Arc product. Purchaser’s rig

hts under this warranty

are void if the product is sold to purchaser by unauth orized persons.

The warranty is effective for the time stated below beginning on the date that the

authorized distributor delivers the products to the Purchaser. Notwithstanding

the

foregoing, in no event shall the warranty period extend more than the time stated plus

one year from the date Thermal Arc delivered the product to the authorized distributor. Warranty r ep airs or replacement claims under this l im i ted warrant y mu st be submitte d 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 rep ai r facility shal l be the re s p onsibility of the Purchaser. All r eturned goods shall be at the Purchaser' s ri sk an d expense. This w ar ranty dated Apr il 1

2006

supersedes all previous Thermal Arc warranties. Thermal Arc

is a Registered

Trademark of Thermal Arc, Inc.

Page 67

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

3 years All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semi-conductors

.............................

1 year

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

most are warranted by the engine manufacturer................................

..............................

See the Engine’s Warranty for Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P, 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

Page 68

Page 69

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, China

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

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - 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 International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Page 70

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 POWERMASTER 320SP, POWERMASTER 500SP, POWERMASTER 400SP Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual