Tweco 500SP PowerMaster Automation Manuel d'utilisateur

1/3PHASE208V230V460V400VPOWERMASTER400SPOperator Manual500SPRevision No: AD Issue Date: March 16, 2007 Manual No.: 0-4970Operating Features:AUTOMATIO

1-4March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION1. Do not remove radiator cap when engine is hot. Allow engineto cool.2. Wear gloves and put a rag

1-5March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION1.03 Symbol ChartNote that only some of these symbols will appear on your model.Gas Tungsten Arc W

1-6March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION1.04 Precautions De Securite En Soudage A L’arc! MISE EN GARDELE SOUDAGE A L’ARC EST DANGEREU

1-7March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION AVERTISSEMENTLE RAYONNEMENT DE L’ARC PEUT BRÛLER LESYEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGERL’OU

1-8March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION7. Ne soudez des tôles galvanisées ou plaquées au plomb ouau cadmium que si les zones à souder ont

1-9March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION AVERTISSEMENTLE CARBURANT PEUR CAUSER UN INCENDIE OUUNE EXPLOSION.Le carburant est hautement in

1-10March 16, 2007POWERMASTER 400SP, 500SP AUTOMATIONSoudage á L’arc AvecElectrode Non Fusible(GTAW)Decoupe Arc Carbone(CAC-A)Courant ConstantTension

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20072-1SECTION 2:INTRODUCTION2.02 Equipment IdentificationThe unit’s identification number (specification

POWERMASTER 400SP, 500SP AUTOMATION2-2March 16, 20072.04 Machine Components1. SP4000R Wire Feeder2. MIG Torch Connection Socket3. Handle4. Mains On/Of

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20072-32.05 Lifting PointsArt # A-07910MaximumLifting Points for 500SP and 400SP

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Thermal Arc product. We are proud tohave you as our customer and will strive to provide you wi

POWERMASTER 400SP, 500SP AUTOMATION2-4March 16, 20072.06 Power Supply Specifications (part 1)Input Mains Voltage (50/60 Hz) V 208 230 400 460 208 230

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20072-52.07 Power Supply Specifications (part 2)Welding OutputDuty Cycle 100% 3 Phase ADuty Cycle 60% 3 P

POWERMASTER 400SP, 500SP AUTOMATION2-6March 16, 20072.08 Wire Feeder SpecificationsWirefeeder Part Numbers SP4000W SP4000RWirefeeder suits water coole

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20072-72.09 Features and Benefits Common to all PowerMaster SP Systems #HARDWARE (Standard)Inverter Desig

POWERMASTER 400SP, 500SP AUTOMATION2-8March 16, 20072.09 Features and Benefits Common to all PowerMaster SP Systems (con't) #PERFORMANCE (Standar

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20073-1SECTION 3:INSTALLATIONNOTEPlease refer to Sections 3.08 RecommendedEquipment Setup and SECTION 4:

POWERMASTER 400SP, 500SP AUTOMATION3-2March 16, 20073.04 Voltage ChangeoverFor proper operation and to prevent damage to themachine, the Voltage Input

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20073-33.05 Connecting 3-Phase Input Power to 400SP or 500SP !WARNINGSInstallation must meet all Nationa

POWERMASTER 400SP, 500SP AUTOMATION3-4March 16, 2007!WARNINGNever connect the safety ground screw toone of the three line phases. This wouldrepresent

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20073-53.06 Connecting Single-Phase Input Power to 400SP or 500SP ! WARNINGSInstallation must meet all Na

! WARNINGSRead and understand this entire Manual and your employer’s safety practices before installing,operating, or servicing the equipment.While th

POWERMASTER 400SP, 500SP AUTOMATION3-6March 16, 2007 !WARNINGNever connect the safety ground screw toone of the three line phases. This wouldrepresen

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20073-73.08 Recommended Setup for MIGA. Torch Connection (TWECOPulseMaster PMA5 shown as anexample)1. Ope

POWERMASTER 400SP, 500SP AUTOMATION3-8March 16, 2007B. How To Connect The Work leadConnect the work lead to the Negative connection andfasten it by

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20073-9F. Insertion Of The Wire ElectrodeScrew out the contact tip in the MIG torch handset.Open the wire

POWERMASTER 400SP, 500SP AUTOMATION3-10March 16, 2007I. How To Configure The Power SupplyFor Aluminium WeldingChange the feedrolls to U groove for alu

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20073-113.09 Automation Weld GunThe PowerMaster 400SP and 500SP Automation power supplies can be fitted w

POWERMASTER 400SP, 500SP AUTOMATION3-12March 16, 20073.11 Installing A New Wire Conduit inthe Pulsemaster PMA512S-35451. Be sure the MIG gun cable is

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20074-1SECTION 4:MANUAL OPERATION4.01 General Safety PrecautionsRead and understand the safety instructio

POWERMASTER 400SP, 500SP AUTOMATION4-2March 16, 2007(46) ”Welding wire diameter” push-buttonFor diameter selection of the wire to bewelded. The push-

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20074-3(55) “Primary parameter” indicator lightsThese lights show which primary parameteris currently dis

TABLE OF CONTENTSSECTION 1:SAFETY INSTRUCTIONS AND WARNINGS ... 1-11.01 Arc Welding Hazards ...

POWERMASTER 400SP, 500SP AUTOMATION4-4March 16, 20074.03 Menu StructureMain Menu Level 1 “Extras” Level 2 Remark Gas pre-flow 0 – 10 sec.; not in

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20074-5Twin pulse relationWelding currentDownslopeTwin pulse current changeTwin pulse frequencyStart curr

POWERMASTER 400SP, 500SP AUTOMATION4-6March 16, 2007A. Secondary Parameters (Menu MainLevel)Art # A-07866With and (51) push-buttons you can switch

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20074-75. Re-saving/Re-programming jobs:a. Switch the Tiptronic function on by pressing“Tiptronic” (49) a

POWERMASTER 400SP, 500SP AUTOMATION4-8March 16, 20074.04 Special functionsA. Gas testPressing the pushbutton (51) and the “Gas type”pushbutton (48) at

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20074-94.05 Smart GMAW, Pulse GMAW & TwinPulse ProgramsShieldGasWiresizeProgram NumberSmart GMAW Curr

POWERMASTER 400SP, 500SP AUTOMATION4-10March 16, 20074.06 Welding Setting Selection GuideFraction(Inches)Thickness DecimalThickness (Thous)DecimalThic

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20074-11Three Steps To GMAW (MIG) WeldingNow you are ready to weldA B C DEGHF1.Set VariablesB) Select Wir

POWERMASTER 400SP, 500SP AUTOMATION4-12March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20075-1SECTION 5:ROBOTIC OPERATION5.01 Robot Interface INT06The Robot interface INT06 is for connection b

TABLE OF CONTENTS (continued)TABLE OF CONTENTSSECTION 5:ROBOTIC OPERATION ...

POWERMASTER 400SP, 500SP AUTOMATION5-2March 16, 20075.03 Analog InputsThe eight analog inputs are designed for a voltage of 0 to +10V DC. Programming

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20075-35.04 Robot Interface Schematic12345678910111213141516171819202122232425262728293031323334353637383

POWERMASTER 400SP, 500SP AUTOMATION5-4March 16, 2007LEDs on Robot Interface INT06 PC Board LED Designation State Meaning lit weak Microco

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20075-55.05 Robot Interface INT06 PC Board SchematicX2LED2X1LED15LED1X3X4X5LED5LED18LED17LED3LED16LED4650

POWERMASTER 400SP, 500SP AUTOMATION5-6March 16, 20075.06 42-Pin Harting Socket128Art # A-07827

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20075-7d. i. : digital inputd. o. : digital outputa. i. : analog inputHarting Socket Pin Descriptions Har

POWERMASTER 400SP, 500SP AUTOMATION5-8March 16, 2007Harting Socket Pin Descriptions (Con't)d. i. : digital inputd. o. : digital outputa. i. : ana

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20075-9Other Analog ParametersDesignation Description Signal Function 0V 0 sec. pre gas time Control v

POWERMASTER 400SP, 500SP AUTOMATION5-10March 16, 20075.07 Configuration at Front Panel MenuThe INT06 can also be programmed at the front panel in menu

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20075-115.08 Robot Tool Software Installation 1. Insert the Installation floppy disk into your "A&qu

POWERMASTER 400SP, 500SP AUTOMATION5-12March 16, 20075.09 Decimal-Binary ConversionThe following table shows the conversion between decimal and binary

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20076-1SECTION 6:MANUAL GMAW WELDING6.01 Types of Weld Transfer ModesA. Dip transfer mode (short circuit

POWERMASTER 400SP, 500SP AUTOMATION6-2March 16, 2007Art # A-06381 Long Arc Short Arc B. Length of the wire electrodeThe distance between the torch and

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20076-3C. Material TransferArt # A-06384Benefits:•Controlled, short-circuit-proof material transfer witho

POWERMASTER 400SP, 500SP AUTOMATION6-4March 16, 20076.03 Basics of Pulsed Arc WeldingA. Current and voltage pulsesMaterial transfer is achieved by cur

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20076-56.04 Pulsed Arc Welding ParametersA. Pulse period tPThe pulse period for separating the droplet is

POWERMASTER 400SP, 500SP AUTOMATION6-6March 16, 20076.05 Smart, Pulse or TwinPulseGMAW WeldingThe following instructions explain how to set up forSmar

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20076-76.07 SMAW/STICK WeldingThe following instructions explain how to set up forSMAW/STICK welding.TTSa

POWERMASTER 400SP, 500SP AUTOMATION6-8March 16, 2007

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20077-1Warning! Disconnect input power before maintaining.Each UseVisual check of regulator and pressureV

1-1March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION1.01 Arc Welding Hazards WARNINGELECTRIC SHOCK can kill.Touching live electrical parts can cause

POWERMASTER 400SP, 500SP AUTOMATION7-2March 16, 20077.02 System Troubleshooting GuideSymptom Cause RemedyInsufficient coolant through flow due to poll

POWERMASTER 400SP, 500SP AUTOMATIONMarch 16, 20077-37.03 Welding Process Troubleshooting GuideSymptom Cause RemedyGas mixture in the cylinder has sepa

POWERMASTER 400SP, 500SP AUTOMATION7-4March 16, 20077.04 Error CodesIn case of a malfunction, an error code is indicated on the digital multifunction

March 16, 2007A-1POWERMASTER 400SP, 500SP AUTOMATIONAPPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLESWirefeeders Part No. Feature SP4000W W3000202 Wa

March 16, 2007A-2POWERMASTER 400SP, 500SP AUTOMATIONAPPENDIX 2: FEED ROLL INFORMATION DRIVE ROLL KITS – 4 ROLLS Description Style 1 Style 2 S

March 16, 2007A-3POWERMASTER 400SP, 500SP AUTOMATIONAPPENDIX 3: MOUNTING THE TORCH HOLDERArt # A-07728

LIMITED WARRANTYThis information applies to Thermal Arc products that were purchased in the USA and Canada.April 2006 LIMITED WARRANTY: Thermal Arc®,

WARRANTY SCHEDULEThis information applies to Thermal Arc products that were purchased in the USA and Canada.April 2006 ENGINE DRIVEN WELDERS WARRANT

Thermadyne USA2800 Airport RoadDenton, Tx 76207 USATelephone: (940) 566-2000800-426-1888Fax: 800-535-0557Email: [email protected] Canada

1-2March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION WARNINGFUMES AND GASES can be hazardous to yourhealth.Welding produces fumes and gases. Brea

World HeadquartersThermadyne Holdings CorporationSuite 300, 16052 Swingley Ridge RoadSt. Louis, MO 63017Telephone: (636) 728-3000FAX: (636) 7

1-3March 16, 2007POWERMASTER 400SP, 500SP AUTOMATION1. Wear approved face shield or safety goggles. Side shieldsrecommended.2. Wear proper body protec