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MAGNATECH Pipemaster 515 Operating And Maintenance Instruction Manual Download Page 1

 

 

6 Kripes Road - PO Box 260 - East Granby, CT 06026 USA 

Fax: (860) 653-0486 

 

E-Mail: [email protected] 

Phone:  (860) 653-2573 

 

 

Web: 

www.MagnatechLLC.com

 

 

Operating and Maintenance 

Instruction Manual 

For 

 
 

Pipemaster Digital Power Source 

(Model 515) 

S/N PM515AB1014  to Current 

 

& 

 

Water Circulator 

(Model 905) 

 
 
 
 

Rev March 8, 2012

Summary of Contents for Pipemaster 515

Page 1: ...ax 860 653 0486 E Mail info MagnatechLLC com Phone 860 653 2573 Web www MagnatechLLC com Operating and Maintenance Instruction Manual For Pipemaster Digital Power Source Model 515 S N PM515AB1014 to C...

Page 2: ...5 3 11 Calibration Of Power Supply 15 3 12 Safety Precautions At The Installation Location 15 3 13 Safety Precautions In Normal Operation 15 3 14 Turn Power Off Before Connecting Disconnecting Cables...

Page 3: ...Observe Programmed Oscillation Width Without Striking an Arc 42 11 0 EDITING A WELD PROGRAM 44 11 1 Select Weld Number to Edit 44 11 2 Edit Weld Parameters 44 11 3 Adding Removing a Pass 44 11 4 Save...

Page 4: ...Connecting Water Circulator to the Pipemaster 54 16 3 Operation of the Water Flow Switch 54 16 4 Shipment of Water Circulator 54 16 5 Periodically Clean the Filters 54 16 6 Circuit Breaker 54 17 0 CA...

Page 5: ...ore connecting the Pipemaster to input power or attempting any welding Contact Magnatech technical staff if any questions exist concerning proper installation procedures COPYRIGHT NOTICE This manual a...

Page 6: ...sor Down Switch Moves cursor down display 1 2 4 Enter Switch Enters item highlighted by cursor 1 2 5 Soft Keys Four Used to select menu items These items functions change depending on operation mode i...

Page 7: ...itches when no arc is present During welding they serve as override switches for each function within the preset limits of the override screen 1 2 9 Current Switches Used to decrease increase welding...

Page 8: ...re feed will be interrupted until the switch is again depressed A warning indicator is displayed When the WIRE STOP switch is actuated the two wire switches can be used to jog wire 1 2 17 Rotary Encod...

Page 9: ...will result in termination of welding and a warning message on the display 1 4 2 Gas Flow Switch The Pipemaster Power Source is equipped with a Gas Flow Switch that is factory preset Shielding gas mus...

Page 10: ...nput Power Cable 1 Gas Hose P N 102990 1 Manual 1 Data Key P N 51773 1 Work Cable 8m 25 P N 515 66 1 Water Circulator Model 905 Circulator Coolant Fluid P N 7280 Options Rolls Printer Paper P N 41004...

Page 11: ...this equipment is to be considered Hazardous UNTIL READING THIS MANUAL has made an operator aware of these potential hazards The lightening flash symbol indicates that there are potential electrical...

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Page 16: ...son To protect against shock have a competent electrician verify that the equipment is adequately grounded do not make contact with terminals and parts that are electrically HOT The body s electrical...

Page 17: ...ets safety shoes welding helmet and other articles needed to shield the skin and to prevent injury from arc burns Wear earplugs if welding overhead or in a confined space Wear a hard hat if others are...

Page 18: ...reasing cleaning or spraying operations The heat and rays from the arc react with the vapors to form highly toxic PHOSGENE Work in a confined space only if it is being adequately ventilated and if ven...

Page 19: ...er supply if all its protective features are fully functional Before switching power on to the power supply ensures that nobody can be injured At least once a week check the power supply for any damag...

Page 20: ...SHA Standard 29 CFR Part 1910 Subpart Q WELDING CUTTING AND BRAZING Order from Superintendent of Documents U S Government Printing Office Washington DC 20402 3 16 6 NFPA Standard 51B CUTTING AND WELDI...

Page 21: ...any party other than Magnatech nor to products which have not been installed and operated in accordance with applicable industry standards or to products which have been used other than under usual c...

Page 22: ...ny express warranty not provided herein and any implied warranty guaranty or representation as to performance and any remedy for breach of contract tort or any other legal theory which but for this pr...

Page 23: ...arts are supplied service bulletins reach the correct person and provide a contact person for service Product Name S N Product Name S N Product Name S N Product Name S N Company Name Company Address D...

Page 24: ...Sales Ext 17 jnettleton MagnatechLLC com Jeff Schwirz Sr Technician Design Eng g Ext 23 jschwirz Magnatechllc com Yuchi Liu Controls Engineer Ext 38 yliu MagnatechLLC com Dave Richard Vice President...

Page 25: ...cooling fluid required will depend on the cable length of the weld Head It will be necessary to check the level of coolant after several minutes of first turning on power to top up the coolant level...

Page 26: ...ource to prevent possible damage to the electrical circuitry 5 6 1 Connect the Head Control Cable at the end of the Head umbilical assembly to the receptacle on the side panel of the Pipemaster marked...

Page 27: ...0 Duty Cycle 125A Output at 60 Duty Cycle 175A Open Circuit Voltage max 80V Type of Cooling Air F 5 9 Fault Conditions Certain fault conditions will cause the arc to be immediately terminated or preve...

Page 28: ...6 2 1 Press Library Soft Key Programs are listed Use up down cursor to scroll through programs Select program using Select soft key The following choices are displayed Weld Number XX Run Review Param...

Page 29: ...To select an item use the Up Down Keys to red highlight move the cursor the desired item To change a numerical value select yes no or select an item from a drop down menu use the rotary Encoder To mo...

Page 30: ...Soft Key Note Only Weld Numbers 001 to 099 are used for programs to be stored in internal memory Weld Number 100 and above are used when exporting weld programs to a Data key for transfer to other Po...

Page 31: ...27 7 1 2 Press Start Weld to initiate weld Or press Purge Soft Key to a purge gas lines when first connecting a weld Head to Power Source 7 2 Weld in Progress 7 2 1 7 2 2...

Page 32: ...28 7 2 3 7 2 4 Note These screens will sequentially change with the start of each new Level and Pass 7 2 5...

Page 33: ...29 7 2 6...

Page 34: ...it is generated The Autoprogram feature will only create a maximum of 5 passes rotations around the pipe which should allow weld thicknesses up to 12 7mm 0 5 to be programmed For heavier walls create...

Page 35: ...rrect Guide Ring Factor GRF based on the OD If the OD is not a standard tube or pipe size i e 2 333 instead of 2 375 the system will default to 8 0 for the GRF If your OD is not standard or you are us...

Page 36: ...example but be prevented from modifying the original program outside of specified heat input limitations for example The override limits are saved with each weld thus allowing for different override v...

Page 37: ...33 Program Notes Use Cursor to select line for additional notes Save if all program selections completed or Back to make corrections Completion of Programming Press Main to exit out to Main Menu...

Page 38: ...ce is that programming is Time based and each program is created in 4 levels 8 3 Using Autotack for 800 Series C Series and R Heads Tack welding is useful when welding larger diameter tubes Autotack w...

Page 39: ...cted number into the line The Left shown as and Right shown as keys will move the highlighted character to the left or right along the line Replacing a letter already typed can be accomplished by movi...

Page 40: ...an select each parameter and technique to be used If Password Protection has been applied you will be asked for your password to allow you to continue 10 1 Create New Weld Program Select No with Encod...

Page 41: ...TORS REF 102176 102189 D HEAD GUIDE RING SPEED FACTORS REF 102176 102189 5 19 2004 GUIDE RING SIZE PIPE TUBE NOM OD GUIDE RING FACTOR DN GRF 1 3 4 TUBE 1 750 7 5 1 1 2 PIPE 1 900 8 0 2 TUBE 2 000 8 5...

Page 42: ...Used to establish penetration Start Amps Current level at which arc is initiated Start Delay Arc Gap Control or AVC operation Start Delay in seconds after arc initiated Wire Start Delay Wire Feed Ope...

Page 43: ...ion Indexes operation with pulsed current When off the Arc Gap Control function will be operational during both high and low pulse time periods When on the Arc Gap Control function will operate during...

Page 44: ...u move to a subsequent pass the parameters will not be copied from the previous pass 10 7 Downslope Screen Move Cursor and enter values with Encoder Press Next Downslope Delay Downslope of weld curren...

Page 45: ...ram Press Next when finished 10 9 Parameter Override Screen Use Cursor to select item Encoder to modify Override Limit Function The welder may override any of the preprogrammed values but only within...

Page 46: ...Mode For an existing program cycle the program to a level in which oscillation is being used and has a programmed value Press the Oscillation Width key one time This will cause the oscillator to weave...

Page 47: ...modes press the AGC Inhibit key in the left hand bottom corner of the Pendant one time This will oscillate the torch for any level in which oscillation is being used Be sure to press the AGC Inhibit...

Page 48: ...Use Cursor to select item Modify with Encoder Note Certain items may not be modified The Cursor will bypass these items Use Next to move through Levels Editing them as you go Use Enter switch to copy...

Page 49: ...rite the original program if the same Weld Number is selected To create a new program select an unused program number 11 5 Scaling A Weld Welds may be edited by scaling current or travel speed up down...

Page 50: ...To Copy a weld program the Source Weld and Destination Weld Program Numbers must be entered Select the Source or Destination weld by using the arrow keys and then press Enter Use the Encoder to chang...

Page 51: ...f the Key has been installed and initialized Program on the Data Key will be numbered 100 and higher Note Only existing weld programs are displayed in the Delete screen 12 4 Print Welds Select Weld To...

Page 52: ...e side of the key will slowly pulse When it is ready it will blink rapidly 5 times If no Data Key is installed or it has not yet finished initializing an Error message will appear on the display Press...

Page 53: ...49 12 7 Tungsten Calc To determine the optimum cut length for tungsten refer to this screen For C Heads tungsten length will be calculated based on tube O D...

Page 54: ...particular Weld ID Number Operator Name Time and Date will be stored and can be printed out The Weld Number will sequentially increase by one digit each weld The Counter can be set reset to any speci...

Page 55: ...rved in conjunction with the change of the various levels of the program on the display It is a useful diagnostic tool if a suspected malfunction is occurring during the weld mode The service technici...

Page 56: ...14 2 Start Method High Frequency or Touch Start can be selected Touch Start only available on weld Heads equipped with Arc Gap Arc Voltage Control 14 3 Arc Length Mode Allows selections of Arc Gap Co...

Page 57: ...nd of the paper on the new roll to remove any ragged edges Insert the tip of the paper into the insertion slot and press the Paper Feed switch NOTE The roll should be oriented so that the paper is fee...

Page 58: ...r as well as to provide the water flow switch signal to the Pipemaster 16 3 Operation of the Water Flow Switch The water flow switch has a factory preset trip point that is not adjustable 0 91 min or...

Page 59: ...o within the acceptable tolerances Tools required verifying Weld Current Certified DMM and Certified shunt 100 mV 200 Amps 17 2 2 Write a simple test program using nonpulsed current at the desired tes...

Page 60: ...ounted on pipe scribe a start position on the pipe Position weld head so that the tungsten is over the scribe mark 17 4 3 From the main menu screen on the remote pendant select Menu 17 4 4 Scroll down...

Page 61: ...Key Sheet 104058 104460 2 104460 20 104653 B 104653 BP 104653 BPX 104653 BX 104657 1 104790 1 104823 10 104932 10 104904 1 104906 1 104915 1 104925 XXYY 104927 105239 105313 X 105337 105630 105661 2...

Page 62: ...MESTIC COLORS 1 5150BPBAH0 PIPEMASTER 515 BEMF 115 230 PRINTER INTERNATIONAL 1 104653 BP PIPEMASTER ASSY MODEL 515 BEMF 115 230 PRINTER 1 1000273 PENDANT ASSEMBLY DIGITAL TIG 1 PART NUMBER DESCRIPTION...

Page 63: ...TIONS MODEL 515 DESCRIPTION QTY 105313 2 SPARES LIST MODEL 515 BEMF SHORT LIST 1 104928 1 ADAPTOR CABLE 514 T C TO 515 BEMF 1 105239 2 HAND TORCH ASSEMBLY 515 125 AMPS GAS COOLED 25 FT 1 105360 1 ADAP...

Page 64: ...104058 79W 104058 66T AND 104058 66W 04 16 09 IE XXXXX XXXXX 1 2 3 2 4 Redrawn from MJ 09 25 2000 BILL OF MATERIALS CABLE ASSEMBLY EXTENSION CABLE AND CONNECTOR ASSEMBLY 104058 XX SEE TABLE PART DESCR...

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Page 66: ...13 1 14 13 16 1 17 1 18 1 22 13 24 4 25 7 24 4 25 4 25 4 20 1 26 4 15 2 21 1 19 1 23 5 MAGNATECH LIMITED PARTNERSHIP EAST GRANBY CT 06026 USA PENDANT ASSY DIGITAL PROGRAM TIG W OUT APPLICATION PROGRA...

Page 67: ...DANT 1 ASSEMBLY 11 104816 1 CONNECTOR PIGTAIL ASSEMBLY DIGITAL PENDANT 1 ASSEMBLY 12 104817 1 CONNECTOR PIGTAIL ASSY USB A DIGITAL PENDANT 1 ASSEMBLY 13 104818 2 KEYPAD COVER W GLASS TIG 1 ASSEMBLY 14...

Page 68: ...3 4 14 3 15 4 16 4 18 4 17 4 15 2 10 2 13 2 14 18 12 1 1 1 11 1 17 6 18 4 17 4 MAGNATECH LIMITED PARTNERSHIP EAST GRANBY CT 06026 USA PIPEMASTER ASSEMBLY MODEL 515 BACK EMF 115 230 VAC 104653 B Sht 1...

Page 69: ...1 ASSEMBLY 9 104912 1 PANEL BLANKING PRINTER 1 PART 10 104933 1 CABLE ASSEMBLY RIBBON 20 PINS DRIVER TO SLAVE 2 ASSEMBLY 11 104934 1 CABLE ASSEMBLY RIBBON 40 PINS MASTER TO SLAVES 1 ASSEMBLY 12 105337...

Page 70: ...4 3 15 4 16 4 18 4 17 4 15 2 10 2 13 2 14 18 12 1 1 1 11 1 17 6 18 4 17 4 MAGNATECH LIMITED PARTNERSHIP EAST GRANBY CT 06026 USA PIPEMASTER ASSEMBLY MODEL 515 BACK EMF 115 230 VAC PRINTER 104653 BP Sh...

Page 71: ...T TO 104653 MODEL 515 W 115 220 VAC 1 ASSEMBLY 10 104933 1 CABLE ASSEMBLY RIBBON 20 PINS DRIVER TO SLAVE 2 ASSEMBLY 11 104934 1 CABLE ASSEMBLY RIBBON 40 PINS MASTER TO SLAVES 1 ASSEMBLY 12 105337 PCB...

Page 72: ...15 4 16 4 18 4 17 4 15 2 10 2 14 18 13 2 12 1 1 1 11 1 17 6 18 4 17 4 MAGNATECH LIMITED PARTNERSHIP EAST GRANBY CT 06026 USA PIPEMASTER ASSEMBLY MODEL 515 BACK EMF 230 400 460 VAC PRINTER 104653 BPX...

Page 73: ...MODEL 515 230 400 460 1 ASSEMBLY 10 104933 1 CABLE ASSEMBLY RIBBON 20 PINS DRIVER TO SLAVE 2 ASSEMBLY 11 104934 1 CABLE ASSEMBLY RIBBON 40 PINS MASTER TO SLAVES 1 ASSEMBLY 12 105337 PCB ASSY DRIVER B...

Page 74: ...14 3 15 4 16 4 18 4 17 4 15 2 10 2 13 2 14 18 12 1 1 1 11 1 17 6 18 4 17 4 MAGNATECH LIMITED PARTNERSHIP EAST GRANBY CT 06026 USA PIPEMASTER ASSEMBLY MODEL 515 BACK EMF 230 400 460 VAC 104653 BX Sht...

Page 75: ...0 460 1 ASSEMBLY 9 104912 1 PANEL BLANKING PRINTER 1 PART 10 104933 1 CABLE ASSEMBLY RIBBON 20 PINS DRIVER TO SLAVE 2 ASSEMBLY 11 104934 1 CABLE ASSEMBLY RIBBON 40 PINS MASTER TO SLAVES 1 ASSEMBLY 12...

Page 76: ...2 38 4 43 2 43 4 14 1 15 1 28 1 45 2 42 3 22 2 35 4 35 4 35 4 47 6 7 1 12 1 25 1 30 1 36 4 40 4 41 1 43 2 39 2 27 1 37 1 48 1 42 2 42 5 42 4 40 1 17 2 18 2 19 2 31 1 32 1 34 2 MAGNATECH LIMITED PARTNE...

Page 77: ...X 3 4 X 1 16 1 PART 26 41016 LABEL WHITE ON RED VINYL TURN OFF 1 PART 27 50355 CLAMP MOUNTING CAPACITOR 1 3 8 DIA 1 PART 28 51608 CAPACITOR CYLINDRICAL 18 000 UF 50 V 1 PART 29 51848 CIRCUIT BREAKER 3...

Page 78: ...1 104842 1 RABBIT RCM3400 PROGRAMMED MODEL 515 SLAVE 1 1 104842 2 RABBIT RCM3400 PROGRAMMED MODEL 515 SLAVE 2 1 105204 2 USB KEYCHAIN PROGRAMMED MODEL 515 BEMF 1 104790 3 UPDATE KIT SOFTWARE MODEL 516...

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Page 84: ...OQUIP FD 45 F 1 104914 1M ADAPTOR ASSEMBLY OBAC 25F X AEROQUIP FD 45 M 1 05 05 06 04 07 06 DATE MAGNATECH LIMITED PARTNERSHIP BILL OF MATERIALS EAST GRANBY CONNECTICUT 06026 5 5 2006 104915 1 PART NUM...

Page 85: ...LY EXTENSION PIPELINER PIPEMASTER 1 104058 50T CABLE ASSEMBLY EXTENSION 2 0 TORCH 1 104058 50W CABLE ASSEMBLY EXTENSION 2 0 WORK 1 104925 25 PW EXTENSION CABLE KIT PIPELINER 25 WOF PNEUMATIC 1 104927...

Page 86: ...BLE ASSEMBLY IN Ft P WITH PNEUMATIC LINE PW WITH PNEUMATIC AND WIRE DRIVE CONTROL LINES MISSING NO PNEUMATIC AND WIRE DRIVE CONTROL LINES BILL OF MATERIALS CABLE ASSEMBLY EXTENSION PIPELINER PIPEMASTE...

Page 87: ...Ft 2 Ft 25 Ft REF 1 2 4 3 6 5 7 8 9 WIRE LIST WIRE COLOR 52142 CONNECTOR TERMINAL RED E BLACK N BILL OF MATERIALS HAND TORCH ASSEMBLY 514 125 AMPS GAS COOLED 25 Ft 105239 1 REV PART DESCRIPTION QTY TY...

Page 88: ...SSEMBLY 515 125 AMPS GAS COOLED 25 Ft 105239 2 REV PART DESCRIPTION QTY TYPE 1 50187 CONNECTOR 41 CONTACT MALE KPT 06J 20 41P 1 PART 2 10129 LOCK WASHER INTERNAL TOOTH 8 SCREW SIZE 2 PART 3 5353 SCREW...

Page 89: ...LY GAS 1 51720 RELAY WATER COOLER 1 104460 2 PENDANT ASSEMBLY 515 1 104939 25 PENDANT CABLE ASSEMBLY 1 PAGE 1 OF 1 25 Jul 08 MAGNATECH LIMITED PARTNERSHIP EAST GRANBY CONNECTICUT 06026 SPARES LIST MOD...

Page 90: ...DPDT RL3 50598 2 Transistor TIP41C Q2 Q3 50619 2 CM Filter 2 mh CM1 CM2 50710 2 Latch For J1 50716 3 Spacer For LED1 LED3 50890 2 IC MCT9001 IC1 IC3 50960 2 Transistor FET IRF540 Q1 Q4 51036 2 Heat si...

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Page 92: ...EMASTER 105661 2 Sht 1 of 1 19 Nov 09 105661 2 PL PART DESCRIPTION QTY TYPE 1 105661 20 PENDANT ASSY DIGITAL PROGRAM TIG W OUT APPLICATION PROGRAM 1 ASSEMBLY CHANGE DESCRIPTION BY DATE INITIAL RELEASE...

Page 93: ...13 1 14 13 16 1 17 1 18 1 22 13 24 4 25 7 24 4 25 4 25 4 20 1 26 4 15 2 21 1 19 1 23 5 MAGNATECH LIMITED PARTNERSHIP EAST GRANBY CT 06026 USA PENDANT ASSY DIGITAL PROGRAM TIG W OUT APPLICATION PROGRA...

Page 94: ...PENDANT 1 ASSEMBLY 11 104816 1 CONNECTOR PIGTAIL ASSEMBLY DIGITAL PENDANT 1 ASSEMBLY 12 104817 1 CONNECTOR PIGTAIL ASSY USB A DIGITAL PENDANT 1 ASSEMBLY 13 104818 2 KEYPAD COVER W GLASS TIG 1 ASSEMBLY...

Page 95: ...11 9 2006 KEY SHEET MODEL 905 WATER COOLER MOUNTS UNDER 515 PIPEMASTER PART NUMBER DESCRIPTION QTY 104643 1 WATER COOLER ASSEMBLY MODEL 905 OPTIONS 104983 2 SHIPPING CASE MODEL 905 1 7 2850 COOLANT P...

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Page 98: ...GNATECH LIMITED PARTNERSHIP EAST GRANBY CT 06026 USA TANK FITTINGS ASSEMBLY 905 WATER COOLER 104647 1 Sht 1 of 2 31 Mar 10 104647 1 PL Rev AA NOTE INSTALL NPT FITTINGS W 5953 TEFLON TAPE 5 PLACES INST...

Page 99: ...2 PART 4 38462 FITTING 90 DEG EL BRASS 1 4 NPT X 1 4 BARB 2 PART 5 38480 FITTING ELBOW 1 4 MNPT X 3 8 BARB 1 PART 6 38526 SEAL NEOPRENE 1 5 16 X 1 1 2 X 1 16 1 PART 7 38527 CHECKVALVE BRASS 10 32F M 1...

Page 100: ...PART 5 105664 1 FAN AND ADAPTOR PLATE ASSEMBLY 904 AND 905 WATER COOLER 1 ASSEMBLY 6 M101 04C 12 3 SCREW SHC M4 0 X 70 X 12MM 4 PART 7 M102 04C 06 3 SCREW BUTHD M4 X 70 X 6MM 14 PART 8 M501 04C FA 3 W...

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