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POWERMASTER
320SP
400SP
Service Manual
500SP
Revision: AC Issue Date: March 3, 2008 Manual No.: 0-4969
Operating Features:
Art # A-07718
!
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.
i
Setrvice Manual Number 0-4969 for:
PowerMaster 320SP (US) W1000102
PowerMaster 400SP Bw (US) W1000202
PowerMaster 400SP (US) Compact W1000304
PowerMaster 500SP Bw (US) W1000502
Wirefeeder SP4000W Thermal Arc (US) W3000202
Wirefeeder SP4000R Thermal Arc (US) W3000302
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermadyne.com
Copyright 2008 by
Thermadyne Industries, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident,
or any other cause.
Original Publication Date: March 3, 2008
Revision AC Date: December 23, 2008
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________
TABLE OF CONTENTS (continued)
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
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 Start 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
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:
BASIC SERVICE ...................................................................................... 6-1
6.01 Maintenance ................................................................................................... 6-1
6.02 System Troubleshooting Guide....................................................................... 6-2
6.03 Welding Process Troubleshooting Guide........................................................ 6-3
SECTION 7:
ADVANCED SERVICE ................................................................................ 7-1
7.01 Safety Precautions ......................................................................................... 7-1
7.02 Multivoltage Principle ..................................................................................... 7-2
7.03 Inverter Principle ............................................................................................ 7-3
7.04 Common Logic Functions .............................................................................. 7-4
7.05 Gas Test.......................................................................................................... 7-4
7.06 Pump Test ...................................................................................................... 7-4
7.07 Reset Adjustments ......................................................................................... 7-4
7.08 Master Reset .................................................................................................. 7-4
7.09 Torque Setting(s)............................................................................................ 7-4
7.10 Error Codes and Troubleshooting Guide ......................................................... 7-5
7.11 Overview of Mains Voltage Limits .................................................................. 7-5
7.12 Flowchart: Soft Power-Up Cycle At Switch On................................................ 7-6
7.13 Power-Up Schematic ...................................................................................... 7-7
7.14 Flowchart: Voltage Monitoring........................................................................ 7-8
7.15 Monitoring Bus Voltage .................................................................................. 7-9
7.16 DP-MAPRO PC Board ................................................................................... 7-10
7.17 MAPRO Connector Descriptions & Measuring Points .................................. 7-11
7.18 MV-MAPRO Diagram ................................................................................... 7-15
7.19 DMR PC Board ............................................................................................. 7-16
7.20 DMR Connector Descriptions & Measuring Points....................................... 7-16
7.21 DMR Diagram............................................................................................... 7-18
7.22 DMR Schematic ........................................................................................... 7-19
7.23 DS20BF PC Board......................................................................................... 7-19
7.24 DS20BF Diagram .......................................................................................... 7-20
7.25 DS20BF Display Test .................................................................................... 7-20
7.26 MVDRV / MVMDRV PC Board ...................................................................... 7-20
7.27 MVMRV / MVMDRV Connector Descriptions & Measuring Points ............... 7-22
7.28 MVDRV Schematic ....................................................................................... 7-23
7.29 MVMDRV Schematic .................................................................................... 7-24
7.30 MVDRV Diagram .......................................................................................... 7-24
7.31 MVMDRV Diagram ....................................................................................... 7-26
TABLE OF CONTENTS (continued)
TABLE OF CONTENTS
7.32 MVPWRUP PC Board ................................................................................... 7-27
7.33 MVPWRUP Connector Descriptions & Measuring Points............................. 7-27
7.34 MVPWRUP Diagram..................................................................................... 7-27
7.35 DK-GLCL PC Board....................................................................................... 7-28
7.36 DK-GLCL PC Board Diagram ........................................................................ 7-28
7.37 DP-UFI-BO PC Board .................................................................................... 7-29
7.38 DP-UFI-BO PC Board Diagram ..................................................................... 7-29
7.39 DP-EMV PC Board ........................................................................................ 7-30
7.40 DP-EMV Connector Descriptions & Measuring Points ................................. 7-30
7.41 DP-EMV PC Board Diagram ......................................................................... 7-30
7.42 DS-VA PC Board ........................................................................................... 7-31
7.43 DS-VA Connector Descriptions & Measuring Points .................................... 7-31
7.44 DS-VA PC Board Diagram............................................................................. 7-31
7.45 DP-S3NEFI PC Board .................................................................................... 7-31
7.46 Current Sensor VAC ..................................................................................... 7-32
7.47 Current Sensor VAC Connector Descriptions & Measuring Points ............... 7-32
7.48 Current Sensor VAC Diagram ....................................................................... 7-32
7.49 Control Transformer ..................................................................................... 7-33
7.50 Measuring Temperature ............................................................................... 7-33
7.51 PCB Connection Diagram ............................................................................. 7-34
7.52 Supply Voltages............................................................................................ 7-35
7.53 Measuring Welding Current.......................................................................... 7-36
7.54 Measuring the Flow Rate of the Cooling System .......................................... 7-36
7.55 Measuring Output Voltage ............................................................................7-37
7.56 Overcurrent Protection ................................................................................. 7-37
7.57 Encoding Power Units .................................................................................. 7-38
SECTION 8:
PARTS LIST .......................................................................................... 8-1
8.01 Equipment Identification................................................................................. 8-1
8.02 How To Use This Parts List ............................................................................ 8-1
8.03 PowerMaster 320SP Exploded View Parts List (1 of 2) .................................. 8-2
8.04 PowerMaster 320SP Exploded View Parts List (2 of 2) .................................. 8-4
8.05 PowerMaster 400SP Compact Exploded View Parts List (1 of 2) ................... 8-6
8.06 PowerMaster 400SP Compact Exploded View Parts List (2 of 2) ................... 8-8
8.07 PowerMaster 400SP Remote, Water Exploded View Parts List .................... 8-10
8.08 PowerMaster 500SP Remote, Water Exploded View Parts List .................... 8-12
8.09 PowerMaster 400SP Power Module .............................................................8-14
8.10 PowerMaster 500SP Power Module .............................................................8-15
8.11 PowerMaster SP Water Cooling System ...................................................... 8-16
8.12 PowerMaster SP HR911 Remote Pendant ................................................... 8-17
8.13 PowerMaster SP4000W Wire Feeder (part 1 of 2) ....................................... 8-18
8.13 PowerMaster SP4000W Wire Feeder (part 2 of 2) ....................................... 8-20
8.14 PowerMaster SP4000W Feed Plate Assembly .............................................. 8-22
TABLE OF CONTENTS
APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1
APPENDIX 2: FEED ROLL INFORMATION............................................................... A-2
APPENDIX 3: MOUNTING THE TORCH HOLDER ....................................................... A-3
APPENDIX 4: SP-SERIES BLOCK DIAGRAM ............................................................ A-4
APPENDIX 5: POWERMASTER 320P POWER SCHEMATIC........................................... A-6
APPENDIX 6: POWERMASTER 400SP POWER SCHEMATIC ......................................... A-8
APPENDIX 7: POWERMASTER 400SP COMPACT POWER SCHEMATIC ........................... A-10
APPENDIX 8: POWERMASTER 500SP POWER SCHEMATIC ........................................ A-12
APPENDIX 9: RECTIFIER DIODE DATA SHEET ........................................................ A-14
APPENDIX 10: MOSFET DATA SHEET .................................................................. A-15
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
1-1
March 3, 2008
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 replace
damaged parts at once.
13. In confined spaces or damp locations, do not use a welder
with AC output unless it is equipped with a voltage reducer.
Use equipment with DC output.
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.
1-2
March 3, 2008
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 removed from
the weld area, the area is well ventilated, and if necessary,
while wearing an air-supplied respirator. The coatings and
any metals containing these elements can give off toxic fumes
if welded.
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) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
1-3
March 3, 2008
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 prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from
moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
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.
1-4
March 3, 2008
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 from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126.
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding
and Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face
Protection, ANSI Standard Z87.1, from American National
Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
1-5
March 3, 2008
POWERMASTER 320SP, 400SP, 500SP
1.03 Symbol Chart
Note that only some of these symbols will appear on your model.
1-6
March 3, 2008
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 Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires
à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de
ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
5. Veuillez à installer cet équipement et à le mettre à la terre
selon le manuel d’utilisation et les codes nationaux,
provinciaux et locaux applicables.
6. Arrêtez tout équipement après usage. Coupez l’alimentation
de l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais
plonger les porte-électrodes dans l’eau pour les refroidir. Ne
jamais les laisser traîner par terre ou sur les pièces à souder.
Ne touchez pas aux porte-électrodes raccordés à deux sources
de courant en même temps. Ne jamais toucher quelqu’un
d’autre avec l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la
terre de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit
de soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou
remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de
source de courant alternatif, à moins qu’il soit muni d’un
réducteur de tension. Utilisez plutôt une source de courant
continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
1.05 Dangers relatifs au soudage à l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler
gravement. L’électrode et le circuit de soudage sont
sous tension dès la mise en circuit. Le circuit
d’alimentation et les circuits internes de
l’équipement sont aussi sous tension dès la mise
en marche. En soudage automatique ou semiautomatique avec fil, ce dernier, le rouleau ou la
bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le
fil de soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à
la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre au
moyen de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou
arrêtez le moteur avant de l’installer ou d’en faire l’entretien.
Bloquez le commutateur en circuit ouvert ou enlevez les
fusibles de l’alimentation afin d’éviter une mise en marche
accidentelle.
1-7
March 3, 2008
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 antibruit ou des bouchons d’oreille
approuvés lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien
ventilée ou que les fumées et les vapeurs sont aspirées à
l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consummables, aux
revêtements et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz
protecteurs de soudage peuvent déplacer l’oxygène de l’air
et ainsi causer des malaises ou la mort. Assurez-vous que
l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir avec des vapeurs et former des gaz
hautement toxiques et irritants.
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 fort
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'hydrogène
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 enrobees
(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)
1-8
March 3, 2008
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 atteindre des matériaux
inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10,
7 mètres autour de l’arc, ou couvrez-les soigneusement avec
des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage
susceptibles de pénétrer dans des aires adjacentes par de
petites ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée
de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l’autre
côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un
baril.
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.
1-9
March 3, 2008
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 vérifier le niveau e
carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source
d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le
plein de carburant ou d’en vérifier le niveau au début du
soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez
tout carburant renversé avant de faire démarrer le moteur.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER
DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs,
des rotors et des courroies peuvent couper doigts
et mains, ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le
moteur.
3. Seules des personnes qualifiées doivent démonter des
protecteurs ou des capots pour faire l’entretien ou le
dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements
amples et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes
après des travaux d’entretien et avant de faire démarrer le
moteur.
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.
1-10
March 3, 2008
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
t
t1
t2
%
X
IPM
MPM
t
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
V
1.07 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
POWERMASTER 320SP, 400SP, 500SP
March 3, 2008
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 offers helpful information
concerning certain operating procedures.
Additional copies of this manual may be purchased
by contacting Thermal Arc at the address and phone
number listed in the inside back cover of this manual.
Include the Owner’s Manual number and equipment
identification numbers.
Electronic copies of this manual can also be 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
POWERMASTER 320SP, 400SP, 500SP
2-2
March 3, 2008
2.04 Machine Components (500SP, 400SP, and SP4000W)
(1)
(7)
(3)
(8)
(4)
(9)
(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)
POWERMASTER 320SP, 400SP, 500SP
March 3, 2008
2-3
2.05 Machine Components (400SP Compact Model)
(1)
(3)
(4)
(7)
(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
POWERMASTER 320SP, 400SP, 500SP
2-4
March 3, 2008
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)
POWERMASTER 320SP, 400SP, 500SP
March 3, 2008
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
POWERMASTER 320SP, 400SP, 500SP
2-6
March 3, 2008
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 Toleran ce 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 Circuit Voltage OCV V
Voltage Range for GMAW-P, GMAW, FCAW, MIG U 2min-U 2max V
Current Range for GMAW-P, GMAW, FCAW, MIG I 2min-I 2max A
Current Range for SMAW (Stick) I 2min-I 2max A
Enclosure Protection Class to EN 60 529
Insulation Class
Cooling Method
Noise Emission dB (A)
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 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 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
+/- 10
350
50%@400A, 34V
+/- 10
F
Fan Cooled
-
+/- 10
10-300
F
Fan Cooled
<70
40%@320A, 30V 50%@400A, 34V
79
400
500
5 – 500
14.3 – 39
IP23
<70
IP23
10-480
350
50%@400A, 34V
60%@500A, 39V
320
5 – 320
-
Input Mains Power
<70
IP23
F
Fan Cooled
5 – 400
10-380
-
Input Mains Power
320SP 400SP 500SP
Summary Specifications
320
79
280
W1000102 W1000304
350
Electrical Specifications for GMAW-P / GMAW / FCAW / MIG with Single-Phase Input Power
500SP
320
250
400SP
-
320SP
0.99 0.99 0.99
79
14.3 – 3414.3 – 30
W1000202 W1000502
3023
Electrical Specifications for GMAW-P / GMAW / FCAW / MIG with Three-Phase Input Power
25 35
320SP
400SP 500SP
30
PowerMaster Power Source Part Numbers
W1000402 W1000602
Remote Power Supply with Integrated Torch Water Cooling System
Compact Power Supply with Integrated Wirefeeder
Automation Power Supply with Integrated Torch Water Cooling System
POWERMASTER 320SP, 400SP, 500SP
March 3, 2008
2-7
2.09 Power Supply Specifications (part 2)
Welding Outp ut
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 Three 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 Outp ut
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 Pressure Psi
Pump Type
Dimensions and Weights
Power Supply Dimension (DxWxH) in
Power Supply Weight lb
25
43.9x17.5x33.7
222
Inp ut Mains Power
50
Centrifugal Pump
320SP
35-
400SP
320SP 400SP 500SP
500SP
0.29
77 201
-0.29
-
29.3x13.4x19.6
-50
Centrifugal Pump
43.9x17.5x33.7
22 30 30
40%@300A, 32V 50%@380A, 35.2V 50%@380A, 35.2V
Inp ut Mains Power
230 300 300
260 330 330
320SP 400SP 500SP
Electrical Specifications for SMAW / STICK with Single-Pha se Inp ut Power
50%@380A, 35.2V 60%@480A, 39.2V-
-330480
Electrical Specifications for SMAW / STICK with Three -Phase Input Power
-300380
320SP 400SP 500SP
POWERMASTER 320SP, 400SP, 500SP
2-8
March 3, 2008
2.10 Wire Feeder Specifications
Wiref eeder Part Numb ers SP4000W SP400 0R
Wir efeeder suits water cooled torc h W3000102 –
Wir efeeder suits Automation Powe r Source – W300030 2
Welding Output
Weldabl e Wire St ee l & S tainless St ee l Ø in .023 – . 045 .023 – 1/ 16
Weldabl e Wire 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 case (DxWxH) in. 25.2x14x19. 6 21.3x8.2x7
Weight of wire feed case 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.
POWERMASTER 320SP, 400SP, 500SP
March 3, 2008
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
are high precision, 4 roll systems manufactured to
extremely tight tolerances for optimum feed-ability of
both hard and soft wires. Refer to page 3-8.
Heavy Duty Running Gear: All running gear has been
developed for manufacturing / production
environments, built heavy-duty and designed to last.
Tweco
®
Guns and Accessories: Tweco® has a full line
of PulseMaster standard and PulseMaster Smart Guns
with advanced digital controls optimized for the
PowerMaster SP range. Gun connections are Tweco
®
No. 4 and return leads are Tweco® MPC. Refer to page
3-10.
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 perfect, digital
microprocessor controlled, pulse performance.
Built-in hardware and software
protection against accidental incorrect input voltage
selection.
JobTool™ is a library of 100 independent,
user-defined, job save programs. You can save and
recall welding procedures from a PulseMaster
SmartGun or from the front panel at any time. Refer
to page 4-3 item 62.
Fresh Tip Treatment sharpens the wire at the
end of the weld sequence ready for a perfect restart.
Recalls up to 100 personalized jobs with
perfect repeatability from the push of a button. Refer
to page 4-2 item 45 and 47 and to page 4-6 section
C 1-7.
Pre Programmed: Up to 100 optimized SmartMIG™,
PulseMIG and TwinPulse™ programs are standard,
delivering optimal performance and versatility.
Down Slope (Crater Fill Mode): The digitally
adjustable parameters reduce arc energy down
eliminating any craters that could cause defects.
#Subject to change without notification.
POWERMASTER 320SP, 400SP, 500SP
2-10
March 3, 2008
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.
HARDWARE/SOFTW ARE (Options)
High Speed Pulse is specialized high speed
wave design for maximum productivity.
Push / Pull Gun Capability: “Plug and Play” Python®
interface.
POWERMASTER 320SP, 400SP, 500SP
March 3, 2008
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.
(EN
D
)
(END)
(+
)
(+)
m
m
mm
Sav
e
Save
En
t
er
Enter
En
t
er
Enter
M
o
d
e
Mode
Tip
tro
n
ic
Tiptron
ic
V
H
O
LD
HOLD
A
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
POWERMASTER 320SP, 400SP, 500SP
3-2
March 3, 2008
!
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.
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