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Thermal Arc
Welding System
POWERMASTER 500SP
Thermal Arc POWERMASTER 500SP Service Manual
146 pages
Manual
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PHASE
208
V
230
V
460
V
POWERMASTER
320SP
400SP
Service Manual
500SP
Revision:
AC
Issue Date:
March 3, 2008
Manual No.:
0-496
9
Operating Features:
A
r
t # A-07718
2
Table of Contents
Default Chapter
1
Service Manual
1
Table of Contents
4
Section 1
9
Safety Instructions and Warnings
9
Arc Welding Hazards
9
Principal Safety Standards
12
Symbol Chart
13
Precautions de Securite en Soudage a L'arc
14
Dangers Relatifs Au Soudage À L'arc
14
Principales Normes de Securite
17
Graphique de Symbole
18
Section 2
19
Introduction
19
How to Use this Manual
19
Equipment Identification
19
Receipt of Equipment
19
Machine Components (500SP, 400SP, and SP4000W)
20
Machine Components (400SP Compact Model)
21
Machine Components (320SP Compact Model)
22
Lifting Points
23
Power Supply Specifications (Part 1)
24
Power Supply Specifications (Part 2)
25
Wire Feeder Specifications
26
Features and Benefits Common to All Powermaster SP Systems
27
Section 3
29
Installation
29
Location
29
Transportation and Positioning
29
Fitting the Mains Cable into the Cable Gland
29
Voltage Change-Over
30
Connecting 3-Phase Input Power to 400SP or 500SP
31
Connecting Single-Phase Input Power to 320SP or 400SP or 500SP
33
Section
35
Quick Start Set up
35
Recommended Setup for MIG
35
TWECO PULSEMASTER PMA5512 500 AMP Weld Gun
39
Installing a New Wire Conduit
40
Section 4
41
Operation
41
General Safety Precautions
41
Welding Controls
42
Menu Structure
44
Main Menu
45
Special Functions
48
Smart GMAW, Pulse GMAW & Twinpulse Programs
49
Welding Setting Selection Guide
50
Section 5
53
Manual Gmaw Welding
53
Types of Weld Transfer Modes
53
Holding and Manipulating the Torch
54
Basics of Pulsed Arc Welding
56
Pulsed Arc Welding Parameters
57
Smart, Pulse or Twinpulse GMAW Welding
58
Conventional Manual GMAW/FCAW Welding
58
SMAW/STICK Welding
59
Section 6
61
Basic Service
61
Maintenance
61
System Troubleshooting Guide
62
Welding Process Troubleshooting Guide
63
Section 7
65
Advanced Service
65
Safety Precautions
65
Multivoltage Principle
66
Inverter Principle
67
Common Logic Functions
68
Gas Test
68
Pump Test
68
Reset Adjustments
68
Master Reset
68
Torque Setting(S)
68
Error Codes and Troubleshooting Guide
69
Overview of Mains Voltage Limits
69
Flowchart: Soft Power-Up Cycle at Switch on
70
Power-Up Schematic
71
Flowchart: Voltage Monitoring
72
Monitoring Bus Voltage
73
DP-MAPRO PC Board
74
MAPRO Connector Descriptions & Measuring Points
75
MV-MAPRO Diagram
79
DMR PC Board
80
DMR Connector Descriptions & Measuring Points
80
DMR Diagram
82
DMR Schematic
83
DS20BF PC Board
84
DS20BF Diagram
84
DS20BF Display Test
84
MVDRV / MVMDRV PC Board
85
MVMRV / MVMDRV Connector Descriptions & Measuring Points
87
MVDRV Schematic
88
MVMDRV Schematic
88
MVDRV Diagram
89
MVMDRV Diagram
90
MVPWRUP PC Board
91
MVPWRUP Connector Descriptions & Measuring Points
91
MVPWRUP Diagram
91
DK-GLCL PC Board
92
DK-GLCL PC Board Diagram
92
DP-UFI-BO PC Board
93
DP-UFI-BO PC Board Diagram
93
DP-EMV PC Board
94
DP-EMV Connector Descriptions & Measuring Points
94
DP-EMV PC Board Diagram
94
DS-VA PC Board
95
DS-VA Connector Descriptions & Measuring Points
95
DS-VA PC Board Diagram
95
DP-S3NEFI PC Board
95
Current Sensor VAC
96
Current Sensor VAC Connector Descriptions & Measuring Points
96
Current Sensor VAC Diagram
96
Control Transformer
97
Measuring Temperature
97
PCB Connection Diagram
98
Supply Voltages
99
Measuring Welding Current
100
Measuring the Flow Rate of the Cooling System
100
Measuring Output Voltage
101
Overcurrent Protection
101
Encoding Power Units
102
Parts List
103
Equipment Identification
103
How to Use this Parts List
103
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 List
112
Powermaster 500SP Remote, Water Exploded View Parts List
114
Powermaster 400SP Power Module
116
Powermaster 500SP Power Module
117
Powermaster SP Water Cooling System
118
Powermaster SP HR911 Remote Pendant
119
Powermaster SP4000W Wire Feeder (Part 1 of 2)
120
Powermaster SP4000W Wire Feeder (Part 2 of 2)
122
Powermaster SP4000W Feed Plate Assembly
124
Appendix 1: Options and Accessories
127
Appendix 2: Feed Roll Information
128
Drive Roll Kits
128
Ordering Information
128
Appendix 3: Mounting the Torch Holder
129
Appendix 4: Sp-Series Block Diagram
130
Appendix 5: Powermaster 320P Power Schematic
132
Appendix 6: Powermaster 400Sp Power Schematic
134
Appendix 7: Powermaster 400Sp Compact Power Schematic
136
Appendix 8: Powermaster 500Sp Power Schematic
138
Appendix 9: Rectifier Diode Data Sheet
140
Appendix 10: Mosfet Data Sheet
141
Limited Warranty
142
Warranty Schedule
143
Global Customer Service Contact Information
145
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Thermal Arc POWERMASTER 500SP Specifications
General
Brand
Thermal Arc
Model
POWERMASTER 500SP
Category
Welding System
Language
English
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