Thermal Arc POWERMASTER 400SP Service Manual Download Page 1

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Art # A-07790

POWERMASTER

400SP

Service Manual

500SP

Revision:

Issue Date:

Octobe

30, 2008

Manual No.:

0-4971B

Operating Features:

AUTOMATION

Summary of Contents for POWERMASTER 400SP

Page 1: ...Art A 07790 POWERMASTER 400SP Service Manual 500SP Revision AB Issue Date October 30 2008 Manual No 0 4971B Operating Features AUTOMATION...

Page 2: ......

Page 3: ...ing 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 wr...

Page 4: ...g 3 Phase Input Power to 400SP or 500SP 3 2 3 04 Connecting Single Phase Input Power to 400SP or 500SP 3 4 3 05 Quick Start Set Up 3 6 3 06 Recommended Setup for MIG 3 6 3 07 Pulsemaster PMA512S 3545...

Page 5: ...2 7 03 Welding Process Troubleshooting Guide 7 3 7 04 Error Codes 7 4 SECTION 8 ADVANCED SERVICE 8 1 8 01 Safety Precautions 8 1 8 02 Inverter Principle 8 2 8 03 Common Logic Functions 8 3 8 04 Gas Te...

Page 6: ...er SP HR911 Remote Pendant 9 9 9 09 PowerMaster SP 4000R Wire Feeder 9 10 9 10 PowerMaster SP4000R Feed Plate Assembly 9 12 APPENDIX 1 OPTIONS AND ACCESSORIES A 1 APPENDIX 2 FEED ROLL INFORMATION A 2...

Page 7: ...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 weldin...

Page 8: ...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 weldin...

Page 9: ...om 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 n...

Page 10: ...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...

Page 11: ...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...

Page 12: ...Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser tra ner par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de couran...

Page 13: ...ans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Ass...

Page 14: ...ileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquag...

Page 15: ...Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour t...

Page 16: ...t de Courant Tension Hertz cycles sec Fr quence N gatif Positif Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art A 07639...

Page 17: ...f the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 01 How To Use Th...

Page 18: ...T06 Robotic Interface Cable 8 INT06 Robotic Interface Connection Plug 9 Remote Pendant Interconnect Cable 1 14 16 2 3 12 13 8 4 5 11 10 Art A 07791 15 9 6 7 10 Wheeling Gear 11 Remote Pendant Operatin...

Page 19: ...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...

Page 20: ...460 208 230 400 460 Input Power S1 at 100 Duty Cycle 1 Phase kVA 13 14 13 13 13 14 13 13 Input Power S1 at 60 Duty Cycle 1 Phase kVA 15 15 15 15 15 15 15 15 Input Power S1 at Maximum Output 1 Phase k...

Page 21: ...num in 035 1 16 035 3 32 Wirefeed Speed IPM 4 984 4 984 Wire feed 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...

Page 22: ...POWERMASTER 400SP 500SP AUTOMATION 2 6 October 30 2008...

Page 23: ...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 WARNING Do not al...

Page 24: ...ke 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 Fuse A 45 40 25 20 70 60 35 30...

Page 25: ...elief and tighten screws Connect input conductors as shown in illustration Connect green or green yellow grounding conductor to welding power supply grounding terminal first Then connect input conduct...

Page 26: ...ake 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 Fuse A 100 90 50 45 100 90 50...

Page 27: ...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 o...

Page 28: ...ent by a qualified electrical trades person A Where equiped place the gas cylinder on the power supply cylinder tray and secure with the two safety chains If unit is not equiped with this option thene...

Page 29: ...t 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 eart...

Page 30: ...than the pressure adjustment next to the outlet guide this will ensure that the wire will be located correctly in the wire feed unit Press the inch switch button until the wire appears approximately 3...

Page 31: ...pe torch and wire diameter Please refer to the torch spare parts list H How To Refill The Cooling Fluid Only use original MIG TIG coolant for refill It provides protection against frost down to 4 F 20...

Page 32: ...ervice Art A 07922 1 2 3 4 5 6 7 TWECO Pulsemaster PMA5512 500 AMP Weld Gun Item Description Part No Qty 1 HEAVY DUTY NOZZLE HD24LP 62 A 1 2 CONTACT TIP 16RZ XX A 1 3 HEAVY DUTY GAS DIFFUSER MS5416SW...

Page 33: ...nduit stop meets the end of the con nector plug and the new raw end extends through the end of the conductor tube on the welding gun tighten the Allen screw in the connector plug onto the conduit to p...

Page 34: ...POWERMASTER 400SP 500SP AUTOMATION 3 12 October 30 2008...

Page 35: ...tective 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 prec...

Page 36: ...aving a welding job 48 Gas type push button For selection of the gas to be used The push button is also used for the increment function e g to increase the value of a sec ondary parameter 49 Tiptronic...

Page 37: ...ss 59 Arc length LED indication Indicates the degree of the trim in SmartGMAW Pulse MIG TwinPulse process OR Wire speed LED indication Indicates the wire speed in ManualGMAW process When the uppermost...

Page 38: ...ame 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 num...

Page 39: ...ation Operating hour counter Welding programs Operating system Process Operating system Master 0 normal 1 on Select language Flow rate cooling system 2 off 2 Diagnoses 1 Machine data 5 Mode cooling sy...

Page 40: ...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 push buttons 44 and 48 or with the smart torch ro...

Page 41: ...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 als...

Page 42: ...condary 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 uncha...

Page 43: ...0 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...

Page 44: ...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 20 18 16 14 12 10 8...

Page 45: ...F 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 Cra...

Page 46: ...4 12 October 30 2008 POWERMASTER 400SP 500SP AUTOMATION...

Page 47: ...are put out to the INT06 interface The INT06 is potentially separated from the machine The analog and digital inputs are not potentially separated from each other All inputs and outputs are available...

Page 48: ...rameter corresponds to the range which is selectable at the front panel The settings can be monitored at the displays of the welding machine The factory default assignment is Input Harting socket Pin...

Page 49: ...0 X3 12 X3 13 X3 11 X3 9 X3 14 X3 15 X3 16 X3 17 X3 18 X3 19 X4 24 X4 23 X4 22 X4 21 X4 20 X4 19 X4 18 X4 11 X4 12 X4 10 X4 26 X3 3 X3 5 X3 4 X4 2 X4 9 X4 7 X4 8 X4 5 X4 6 X4 9 X4 10 X4 11 X4 12 X4 13...

Page 50: ...ve 0 4 green power source ok off relay RE2 is off output power source ok is not active open 5 green polarity digital signals IN NPN on relay RE6 is on digital inputs are low active working with GND of...

Page 51: ...D16 LED4 650 5282 x INT06 RP367 1 D00 0110 0 00 Art A 07940 Connector Description X1 CAN connector X2 Internal programming connector X3 Flat ribbon connector to 42 pin Harting socket digital and analo...

Page 52: ...POWERMASTER 400SP 500SP AUTOMATION 5 6 October 30 2008 5 06 42 Pin Harting Socket 1 2 8 Art A 07827...

Page 53: ...initialisation after the machine is switched on between 12 and 13 machine is operable 0 between 13 and 14 welding current on is active contact closed 13 14 d o welding current on Potential free output...

Page 54: ...0 10V for the welding current 10V DC max welding current of p s 0V 60 of the programmed value 5V DC neutral position no correction 24 a i arc length wire speed Control voltage 0 10V for the korrectio...

Page 55: ...ent change Control voltage 0 10V for the twinpulse current change The operating mode twinpulse must be active 10V DC 50 of welding current 0V 20 twinpulse relation Control voltage 0 10V for the twinpu...

Page 56: ...27 Off analog input is disabled On analog input is enabled corresponds with DIP switch 6 set to ON Opt06 AnalogIn6 28 Off analog input is disabled On analog input is enabled corresponds with DIP switc...

Page 57: ...The actual states of the digital inputs are shown in the upper part of the program window In the lower part of the program window different parameters inputs can be enabled or disabled by click ing on...

Page 58: ...0100111 72 1001000 6 0000110 40 0101000 73 1001001 7 0000111 41 0101001 74 1001010 8 0001000 42 0101010 75 1001011 9 0001001 43 0101011 76 1001100 10 0001010 44 0101100 77 1001101 11 0001011 45 010110...

Page 59: ...rc 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...

Page 60: ...ng 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 i...

Page 61: ...ober 30 2008 6 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...

Page 62: ...es 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 r...

Page 63: ...lection 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 j...

Page 64: ...Shielding gas Eg 98 Argon 2 CO2 Thickness Press button to select material thickness B Set Torch trigger operation 2T Normal Operation 4T Trigger Latch C Set Base material thickness 250 Use left hand...

Page 65: ...up for SMAW STICK welding TT Save TT Sauver Enter Entrer Tiptronic END FIN TT Enter TT Entrer Process Processus SMAW STICK 120 A B C Art A 07869 A Set Process Process Processes To SMAW STICK B Press B...

Page 66: ...POWERMASTER 400SP 500SP AUTOMATION 6 8 October 30 2008...

Page 67: ...ed 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...

Page 68: ...ort circuit between contact tip and gas nozzle Spatter built up inside the gas nozzle Remove it with special pliers Unstable arc Wrong diameter contact tip or worn out Change contact tip The Control P...

Page 69: ...ngth 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...

Page 70: ...rocess 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 Pro...

Page 71: ...asis to avoid accidents while working with this machine WARNING Only qualified workers who are knowledgeabel and have been trained to work safely with test instruments and equipment on energized circu...

Page 72: ...ION 8 2 October 30 2008 8 02 Inverter Principle inductor secondary rectifier transformer clock pulse 80 kHz primary switch soft power up dc link voltage mains rectifier mains filter mains switch 3 pha...

Page 73: ...st 1 Press the buttons arrow up and material type at the same time 2 The cooling pump is activated for one minute 3 A countdown is shown in the display 4 Press button material type again to end the te...

Page 74: ...8V 0 18V 0 18V 42V 4A 0 42V 18V 1A 18V 0 4A 18V 0 4A 0 400V 1 0 42V 42V 3 5A 400V 2 Pos 4 3 7 8 Pos 20V 3A 0 20V 5 6 primary secondary 5 11 655 8021 0 3 1 2 10 4 8 9 12 13 14 15 5 9 12 10 11 13 15 14...

Page 75: ...half freq of LED5 CPLD processor ok 2 red off Digital Signal Processor DSP ok 3 green on supply voltage 3 3V DC ok 4 red off micro controller ok 5 green flashing DSP is working 6 green flashing micro...

Page 76: ...reducing start up peak current for capacitors supply and safeguarding of control transformer 8 14 DP S3NEFI PB Board The DP S3NEFI pc board is the mains filter and power up board for the 320SP Functi...

Page 77: ...er J1 jumper J2 setting machine type 0 0 240 A 400SP 0 1 270 A 320SP 1 0 300 A 500SP 1 1 reserved 0 contact open 1 contact closed If DIP switches are used instead of jumpers 0 OFF 1 ON Normal LED Disp...

Page 78: ...rrent 8 20 DS VA PC Board The DS VA pc board is the digital volt and ampere display Functions display nominal and actual values of welding voltage and welding current hold function of the last welding...

Page 79: ...equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permane...

Page 80: ...79 4 1 Quick disconnect Gas Female SP W7004135 5 1 Gas Hose 6ft 5 8 18UNF SP W7000094 6 1 Socket Panel 8Pin SP W7000060 7 1 Terminal Output SP W7000051 8 1 QuickDisconnect Red Female SP W7004134 9 1 Q...

Page 81: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 9 3 8 9 13 6 4 5 7 14 3 2 1 10 11 12 Art A 08599...

Page 82: ...34 23 1 Cap CAN Socket SP W7000096 24 1 Castor Swivel 125 SP W7004121 25 1 Label 50x25mm SP W7004132 26 2 Terminal Output SP W7000051 27 1 Castor Swivel Brake 125 SP W7000084 28 1 Remote Control HR 91...

Page 83: ...TER 400SP 500SP AUTOMATION October 30 2008 9 5 Sa ve Sa ve Ente r Ente r Tipt ron ic Tipt ron ic EN D EN D Ente r Ente r 17 27 22 20 32 38 36 16 25 35 19 18 15 21 23 37 31 34 30 29 26 24 39 33 28 Art...

Page 84: ...3 2 Fuse 4A 320 400 500SP F4 F5 W6000010 4 2 PCB Primary Capacitor 400 500SP A3 W7000027 5 1 Inductor 400SP L1 W7000056 6 1 Transformer Main 400SP T2 W7000057 7 1 Rectifier 3PH 1600V 175A SP A2 W7000...

Page 85: ...3 2 Fuse 4A 320 400 500SP F4 F5 W6000010 4 2 PCB Primary Capacitor 400 500SP C1 W7000027 5 1 Inductor 500SP L1 W7000068 6 1 Transformer Main 500SP T2 W7000067 7 1 Rectifier 3PH 1600V 175A SP A2 W7000...

Page 86: ...nnect Blue Female SP W7004133 3 1 QuickDisconnect Red Female SP W7004134 4 1 Radiator 390x130x66 SP W7004136 5 1 Tank Coolant 640 x 80 SP W7004137 6 1 Connector hose R1 4 SP W7004138 7 1 Connector hos...

Page 87: ...5 Display Cover HR911 SP W7004167 5 2 Refer to W7004167 N A 8 2 Refer to W7004167 N A 9 1 Refer to W7004167 N A 10 1 Strain Relief Nut HR911 W7004168 11 1 Refer to W7004167 N A 12 2 Knob Encoder 9 x1...

Page 88: ...or Flange Tweco No4 SP W7000021 11 4 Rivet Plastic 5x7 5 SP W7000022 12 1 Capillar tube 58mm SP4000R W7004161 13 1 Disconnect Gas Male 1 8 SP W7004147 14 1 QuickDisconnect Blue Female SP W7004133 15 1...

Page 89: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 9 11 2 3 4 5 6 2 3 4 5 6 10 10 10 10 9 10 11 8 22 1 7 12 3 5 25 23 2 6 26 4 20 24 21 16 13 18 19 17 14 15 Art A 08601...

Page 90: ...A 9 Guide Intermideate 023 1 16 SP W6000512 10 Tension adjust rod Mechafin SP W7004177 11 Pin Tension adjust Mechafin SP W7004178 12 Shaft PressureArm Mechafin SP W7004179 13 Spacer PressureArm Mechaf...

Page 91: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 9 13 Art A 08371...

Page 92: ...POWERMASTER 400SP 500SP AUTOMATION 9 14 October 30 2008...

Page 93: ...15ft Gun PMA515 3545 Heavy Duty 500 Amp Rated Suits 320SP 400SP 500SP Options Interconnect Cable Assy 3ft Long W4000603 3 0 Welding Cable Water Cooled Hoses Gas Hose Suits 400SP 500SP Interconnect Ca...

Page 94: ...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 Part No Description W6000500 DRIVE RL KIT 2RL 023 030 DS V W60005...

Page 95: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 A 3 APPENDIX 3 MOUNTING THE TORCH HOLDER Art A 07728...

Page 96: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 A 4 APPENDIX 4 SP SERIES BLOCK DIAGRAM Art A 07729...

Page 97: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 A 5 Art A 07729...

Page 98: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 A 6 APPENDIX 5 POWERMASTER 400SP POWER SCHEMATIC Art A 08555 PowerMaster 400SP Automation Schematic S00 0023 4 00...

Page 99: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 A 7 Refer to pages 8 12 and 8 13 for ordering information of parts shown in this schematic Art A 08555...

Page 100: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 A 8 APPENDIX 6 POWERMASTER 500SP POWER SCHEMATIC Art A 08557 PowerMaster 500SP Automation Schematic S00 0023 6 00...

Page 101: ...POWERMASTER 400SP 500SP AUTOMATION October 30 2008 A 9 Refer to pages 8 18 and 8 19 for ordering information of parts shown in this schematic Art A 08557...

Page 102: ...0 10VDC analog 0 10VDC analog 0 10VDC analog 0 10VDC analog 0 10VDC analog 0 10VDC analog 0 10VDC analog 0 10VDC analog X32 X33 X34 X35 X36 X37 X38 X39 X40 X41 X42 X3 10 X3 12 X3 13 X3 11 X3 9 X3 14 X...

Page 103: ...pF Inductance 5 nH FEATURES AND BENEFITS t i n U e u l a V r e t e m a r a P l o b m y S VRRM Repetitive peak reverse voltage 1000 V IFRM Repetitive peak forward current tp 5 s F 1kHz 700 A IF RMS RMS...

Page 104: ...C CONVERTERS FOR WELDING EQUIPMENT AND UNINTERRUPTIBLE POWER SUPPLIES AND MOTOR DRIVER ABSOLUTE MAXIMUM RATINGS Pulse width limited by safe operating area TYPE VDSS RDS on ID STE53NC50 500V 0 08 53 A...

Page 105: ......

Page 106: ...g 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 repre...

Page 107: ...l 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 1 yea...

Page 108: ......

Page 109: ...trict 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 Eh...

Page 110: ...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...

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