Thermal Arc POWERMASTER 320SP - Service Manual

Thermal Arc POWERMASTER 320SP

146 pages

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PHASE

208

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230

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460

V

POWERMASTER

320SP

400SP

Service Manual

500SP

Revision: AC Issue Date: March 3, 2008 Manual No.: 0-4969

Operating Features:

Art # A-07718

Table of Contents

Default Chapter1
- Service Manual1
- Table of Contents4
Section 19
Safety Instructions and Warnings9
- Arc Welding Hazards9
- Principal Safety Standards12
- Symbol Chart13
- Precautions de Securite en Soudage a L'arc14
- Dangers Relatifs Au Soudage À L'arc14
- Principales Normes de Securite17
- Graphique de Symbole18
Section 219
Introduction19
- How to Use this Manual19
- Equipment Identification19
- Receipt of Equipment19
- Machine Components (500SP, 400SP, and SP4000W)20
- Machine Components (400SP Compact Model)21
- Machine Components (320SP Compact Model)22
- Lifting Points23
- Power Supply Specifications (Part 1)24
- Power Supply Specifications (Part 2)25
- Wire Feeder Specifications26
- Features and Benefits Common to All Powermaster SP Systems27
Section 329
Installation29
- Location29
- Transportation and Positioning29
- Fitting the Mains Cable into the Cable Gland29
- Voltage Change-Over30
- Connecting 3-Phase Input Power to 400SP or 500SP31
- Connecting Single-Phase Input Power to 320SP or 400SP or 500SP33
Section35
- Quick Start Set up35
- Recommended Setup for MIG35
- TWECO PULSEMASTER PMA5512 500 AMP Weld Gun39
- Installing a New Wire Conduit40
Section 441
Operation41
- General Safety Precautions41
- Welding Controls42
- Menu Structure44
- Main Menu45
- Special Functions48
- Smart GMAW, Pulse GMAW & Twinpulse Programs49
- Welding Setting Selection Guide50
Section 553
Manual Gmaw Welding53
- Types of Weld Transfer Modes53
- Holding and Manipulating the Torch54
- Basics of Pulsed Arc Welding56
- Pulsed Arc Welding Parameters57
- Smart, Pulse or Twinpulse GMAW Welding58
- Conventional Manual GMAW/FCAW Welding58
- SMAW/STICK Welding59
Section 661
Basic Service61
- Maintenance61
- System Troubleshooting Guide62
- Welding Process Troubleshooting Guide63
Section 765
Advanced Service65
- Safety Precautions65
- Multivoltage Principle66
- Inverter Principle67
- Common Logic Functions68
- Gas Test68
- Pump Test68
- Reset Adjustments68
- Master Reset68
- Torque Setting(S)68
- Error Codes and Troubleshooting Guide69
- Overview of Mains Voltage Limits69
- Flowchart: Soft Power-Up Cycle at Switch on70
- Power-Up Schematic71
- Flowchart: Voltage Monitoring72
- Monitoring Bus Voltage73
- DP-MAPRO PC Board74
- MAPRO Connector Descriptions & Measuring Points75
- MV-MAPRO Diagram79
- DMR PC Board80
- DMR Connector Descriptions & Measuring Points80
- DMR Diagram82
- DMR Schematic83
- DS20BF PC Board84
- DS20BF Diagram84
- DS20BF Display Test84
- MVDRV / MVMDRV PC Board85
- MVMRV / MVMDRV Connector Descriptions & Measuring Points87
- MVDRV Schematic88
- MVMDRV Schematic88
- MVDRV Diagram89
- MVMDRV Diagram90
- MVPWRUP PC Board91
- MVPWRUP Connector Descriptions & Measuring Points91
- MVPWRUP Diagram91
- DK-GLCL PC Board92
- DK-GLCL PC Board Diagram92
- DP-UFI-BO PC Board93
- DP-UFI-BO PC Board Diagram93
- DP-EMV PC Board94
- DP-EMV Connector Descriptions & Measuring Points94
- DP-EMV PC Board Diagram94
- DS-VA PC Board95
- DS-VA Connector Descriptions & Measuring Points95
- DS-VA PC Board Diagram95
- DP-S3NEFI PC Board95
- Current Sensor VAC96
- Current Sensor VAC Connector Descriptions & Measuring Points96
- Current Sensor VAC Diagram96
- Control Transformer97
- Measuring Temperature97
- PCB Connection Diagram98
- Supply Voltages99
- Measuring Welding Current100
- Measuring the Flow Rate of the Cooling System100
- Measuring Output Voltage101
- Overcurrent Protection101
- Encoding Power Units102
Parts List103
- Equipment Identification103
- How to Use this Parts List103
- Powermaster 320SP Exploded View Parts List (1 of 2)104
- Powermaster 320SP Exploded View Parts List (2 of 2)106
- Powermaster 400SP Compact Exploded View Parts List (1 of 2)108
- Powermaster 400SP Compact Exploded View Parts List (2 of 2)110
- Powermaster 400SP Remote, Water Exploded View Parts List112
- Powermaster 500SP Remote, Water Exploded View Parts List114
- Powermaster 400SP Power Module116
- Powermaster 500SP Power Module117
- Powermaster SP Water Cooling System118
- Powermaster SP HR911 Remote Pendant119
- Powermaster SP4000W Wire Feeder (Part 1 of 2)120
- Powermaster SP4000W Wire Feeder (Part 2 of 2)122
- Powermaster SP4000W Feed Plate Assembly124
Appendix 1: Options and Accessories127
Appendix 2: Feed Roll Information128
- Drive Roll Kits128
- Ordering Information128
Appendix 3: Mounting the Torch Holder129
Appendix 4: Sp-Series Block Diagram130
Appendix 5: Powermaster 320P Power Schematic132
Appendix 6: Powermaster 400Sp Power Schematic134
Appendix 7: Powermaster 400Sp Compact Power Schematic136
Appendix 8: Powermaster 500Sp Power Schematic138
Appendix 9: Rectifier Diode Data Sheet140
Appendix 10: Mosfet Data Sheet141
Limited Warranty142
- Warranty Schedule143
- Global Customer Service Contact Information145

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