Amada MacGregor PA20P Series User manual

961-00035 rev11
Arc Welding Power Supply
PA20P-x, PA40P-x, PA60P-x, PA100P-x,
PA-200P-x
Single & Multi-output
DC TIG Welders
OPERATION MANUAL

Operating Instructions PA-xxP
961-00035 rev11 2/42 2020-04-15
Annex:
- Safety Regulations
- General References on Arc welding
- Contact addresses
Versions
Version Date Basis of Version
10 2018-10 Conversion to new layout
11 2020-04 Detail Update
Copyright  2020: Amada Weld Tech UK Ltd
All rights reserved.
The products named in this manual are only used for identification purposes and may be trademarks
or registered trademarks of the respective companies.

Operating Instructions PA-xxP
Table of Contents
961-00035 rev11 3/42
Table of Contents
1 General Information ...........................................................................................................5
2 Technical Description ........................................................................................................6
2.1 Technical Specification .....................................................................................................6
2.2 Introduction ........................................................................................................................7
3 Commissioning ..................................................................................................................8
3.1 Electrical Connections ......................................................................................................8
3.2 Shield Gas Connections ....................................................................................................9
3.3 Rear Panel Layout ........................................................................................................... 10
3.4 Getting Started ................................................................................................................ 12
3.4.1 Power on .......................................................................................................................... 12
3.4.2 The Default Menu Screen ............................................................................................... 12
3.4.3 Information Colour Coding Key ..................................................................................... 13
3.4.4 Memory Organisation ..................................................................................................... 14
3.4.4.1 Memory Locations (Profiles) ............................................................................................. 14
3.4.4.2 Scratchpad Memory .......................................................................................................... 14
3.5 Limit Functions ............................................................................................................... 15
3.5.1 Monitored Limit Parameters .......................................................................................... 15
3.5.2 High Voltage Limit .......................................................................................................... 15
3.5.3 Low Voltage Limit ........................................................................................................... 15
3.5.4 High Energy Limit ........................................................................................................... 15
3.5.5 Low Energy Limit ............................................................................................................ 15
3.6 Password Entry Screen (Log in/out) ............................................................................. 16
4 Setup (Man mode) ........................................................................................................... 17
4.1 Setup screen .................................................................................................................... 17
4.2 Setup (Man mode) Graph Screen .................................................................................. 19
4.3 Setup (Man mode) Load Screen .................................................................................... 20
4.4 Setup (Man mode) Save Screen .................................................................................... 21
5 Profile Editor .................................................................................................................... 22
5.1 Profile Editor screen ....................................................................................................... 22
5.2 Profile Editor Load Screen ............................................................................................. 24
5.3 Profile Editor Save Screen ............................................................................................. 25
6 Run (Auto Mode) ............................................................................................................. 26
6.1 Run (Auto Mode) Main Monitor Screen ........................................................................ 26
6.2 Run (Auto mode) Monitor Screen .................................................................................. 27
6.3 Run (Auto mode) Load Screen ...................................................................................... 30
7 Configuration Screen ..................................................................................................... 31
8 Gas Control Screen ........................................................................................................ 32
9 IO Monitor Screen ........................................................................................................... 33
10 Control Connections ...................................................................................................... 34

Operating Instructions PA-xxP
Table of Contents
961-00035 rev11 4/42
10.1 RS232 Port (9way D Type) .............................................................................................. 34
10.2 MWSBus ........................................................................................................................... 34
10.3 USB Port .......................................................................................................................... 34
10.4 AVM Voltage Output Terminals ..................................................................................... 35
10.5 Single Output Digital I/O (37way D Type) ..................................................................... 35
10.6 Multiple Output Digital I/O (37way D Type) .................................................................. 36
10.7 Remote Profile Select (15way D Type) .......................................................................... 37
11 Process Faults and Warnings ........................................................................................ 38
11.1 High Voltage Limit Fault ................................................................................................. 38
11.2 Low Voltage Limit Fault .................................................................................................. 38
11.3 High Energy Limit Fault .................................................................................................. 38
11.4 Low Energy Limit Fault .................................................................................................. 38
11.5 Additional Warnings ....................................................................................................... 38
12 Basic Trouble Shooting Guide ...................................................................................... 40
13 Index ................................................................................................................................. 42
13.1 Headword Index .............................................................................................................. 42

Operating Instructions PA-xxP
Table of Contents
961-00035 rev11 5/42
1 General Information
Information about safety regulations, symbols, copyrights, protection rights,
usage location conditions can be found in the back section of these operating
instructions.
Please read this information carefully before using these operating instructions.
These operating instructions should help you familiarize yourself with the system and
take advantage of its application possibilities when used as directed.
It contains important notes to help operate the unit safely, properly, and economically.
Observing the notes will help avoid risks, decrease repair costs and down times, and
enhance reliability and the service life of the unit.
It is a rule: Safety first!
Warning
Incorrect or inappropriate configuration, installation, settings, handling or use can cause
mechanical, electrical or thermal hazards, which may result in serious damage or injury.
Ensure the correct execution of these points and follow the respective notes in the
operating instructions.
Danger
Do not put the system into operation before you have read the operating instructions!
Danger Persons with cardiac pacemakers and metallic implants are prohibited from
approaching to within a radius of at least 5 m of welding equipment!
Crushing Hazard
There is a risk of crushing during the adjustment movement due to closing electrodes,
stops for limiting adjustment or stroke movement and the stop on the basic pincers unit
for limiting floating movement.
Warning
This Class A welding equipment is not supposed to be used in living quarters, where
the power supply is carried out by a public low voltage supply.
There it can be difficult to ensure electromagnetic compatibility because of conducted or
radiated disturbances.
Warning
Restrictions on use environment conditions
Use this equipment in an environment without conductive dust. If conductive dust
enters into equipment, it may cause failure, electric shock or ignition. If using
equipment in such environment, consult Amada Weld Tech.
Warning

Operating Instructions PA-xxP
961-00035 rev11 6/42
2 Technical Description
2.1 Technical Specification
PA-20P-x PA-40P-x PA-60P-x PA-100P-x PA-200P-x
Maximum Output
Current
20Amps 40Amps 60Amps 100Amps 200Amps
Output Voltage Main Supply
80V D.C.
Auxiliary
Starting Supply
200V D.C.
High Voltage
Starting Supply
12KV
Main Supply
70V D.C.
Auxiliary
Starting Supply
150V D.C.
High Voltage
Starting Supply
12KV
Main Supply
70V D.C.
Auxiliary
Starting Supply
150V D.C.
High Voltage
Starting Supply
12KV
Main Supply
45V D.C.
Auxiliary
Starting Supply
150V D.C.
High Voltage
Starting Supply
12KV
Main Supply
45V D.C.
Auxiliary
Starting Supply
150V D.C.
High Voltage
Starting Supply
12KV
Duty Cycle 100% 20Amps 25% 40Amps 5% 60Amps 5% 100Amps 5% 100Amps
RS232 baud rate 9600,38400 & 57600
Accuracy Within +/-1%
Cooling Air-cooled with over temperature protection
Data Retention Trend data/user password 100 days with fully
Charger lithium battery. (96 hour charge).
Profile/Calibration data 10 years.
Dimensions Depth
Width
Height
490mm 490mm 490mm 630mm 630mm
270mm 270mm 270mm 450mm 450mm
300mm 300mm 300mm 250mm 250mm
Weight 38Kg 38Kg 38Kg 40Kg 40Kg
Supply Rating 110-240vac
50/60Hz single
phase (factory
selected)
110-240vac
50/60Hz single
phase (factory
selected)
110-240vac
50/60Hz single
phase (factory
selected)
380-480vac
50/60Hz 3
phase (factory
selected)
380-480vac
50/60Hz 3
phase (factory
selected)
Please refer to machine serial number plate for power rating

Operating Instructions PA-xxP
961-00035 rev11 7/42
2.2 Introduction
Thank you for purchasing this MacGregor Arc welding power source.
This manual is designed to help the new user to understand and operate the equipment
quickly and safely. Please take a few moments to become familiar with the equipment
and this manual before attempting to use the equipment.
The following information covers the model you have purchased and others in the range
and should be kept for reference. This will also help you identify model specific features
mentioned in this manual.
All PA-xxP’s are comprised of a linear DC power unit controlled by a microprocessor and
colour touch screen interface.
It is the user's responsibility to ensure that their
installation is safe both electrically
and mechanically.
The PAxxP allows you to program the delivery of electrical energy into a weld by allowing
adjustment of time and amplitude. Typically, energy into the weld is gradually ramped up,
held at a peak and then reduced. The amount of energy will depend on the length of
these times together with the value of the peak amplitude achieved. In some cases it is
beneficial to use 2 pulses in a weld, usually with the first pulse acting as a means of pre-
conditioning the parts.
A weld profile that is used to make a satisfactory weld can be saved as a PROFILE in the
units memory.
The starting system of the PAxxP range has been optimised for low current use. The arc
is stuck by a 12KV impulse, which starts current flowing in the 5A unregulated supply
(rated at 200Vdc). Once the auxiliary current is detected, the main controlled current is
turned on. This lower voltage and higher current (up to 60Amps at 80V DC depending on
model), then controls the weld and the auxiliary system is switched off.
Unlike conventional arc welders, where this can take several milliseconds, the PAxxP
achieves this in under 700uS, giving more precise low current/power control.
8Amps
PAxxP Output 5Amps
Reduced uncontrolled
Energy in auxiliary.
700uS
10Amps
Conventional Welder
2 mS
PLEASE NOTE :- DUE TO THE REDUCED UNCONTROLLED AUXILIARY ENERGY,
IT MAY BE NECESSARY TO ADJUST YOUR SETTINGS IF REPLACING A
CONVENTIONAL WELDER.

Operating Instructions PA-xxP
961-00035 rev11 8/42
3 Commissioning
3.1 Electrical Connections
DO Use a properly rated Mains Service Supply
An identification plate on the rear panel specifies the input mains voltage
requirement.
DO Provide Proper Ventilation
DO Use Lifting Gear to Move the Unit
DO NOT Operate Machine Without Covers
DO NOT Operate With Suspected Failures
DO NOT Operate in an Explosive Atmosphere
DO NOT Operate in Wet/Damp Conditions
IF IN DOUBT, CONTACT YOUR DISTRIBUTOR
Inspect the unit for any shipping damage prior to connecting to the mains supply.
Ensure you use green safety goggles when operation unit.
Maximum inlet gas pressure : 0.03Mpa
Caution
This product MUST be connected to the correct mains supply voltage. Refer to the
identification plate located on the rear panel.
Single-Phase connections :
BROWN : Live
BLUE : Neutral
GREEN/YELLOW : Safety Earth / Ground
Three-Phase connections :
BLACK 1, BLACK2, BLACK3 : Phase colours
GREEN/YELLOW : Safety Earth / Ground
Ensure a good earth / ground connection is provided for operator safety. The internal
electrical circuits are earthed. To comply with Class 1 protection, the positive output
terminal should be earthed.
The unit must NOT be operated with any of the negative outputs grounded.
Ensure unused negative outputs have the supplied protection covers fitted.

Operating Instructions PA-xxP
961-00035 rev11 9/42
3.2 Shield Gas Connections
The recommended shielding gas is Argon.
This should be connected to the ‘GAS IN’
port on the rear of the welder.
Please ensure the Argon gas is shut off at the bottle, and that the pressure is a
maximum of 0.03MPa, before connecting to the welder.
Caution

Operating Instructions PA-xxP
961-00035 rev11 10/42
3.3 Rear Panel Layout
PA-100P and PA-200P
MWSBus PORT – NOT USED.
ISOLATED RS232 PORT – PC CONNECTION PORT FOR UP & DOWN LOADING OF
PARAMETERS, & DATA LOGGING.
USB PORT – REPROGRAMMING OF HMI.
POSITIVE/NEGATIVE OUTPUTS – OUTPUT FOR THE POWER CABLES TO THE
TORCHES/WORKPIECE.
EXTERNAL INPUT– FOR REMOTE PROGRAM SELECTION.
TRIGGER & FAULTS i/o PORT – EXTERNAL TRIGGER & FAULT SIGNALS PORT.
Cooling Fan Outlet
Keep clear
Positive Output
(workpiece)
Negative Connections
To Welding Torches.
Ensure any unused outputs have
the supplied protection covers
fitted.
Isolated RS232 Port
Trigger/faults i/o
Voltage monitor for AVM AUX drive fuse 2A
(T)
External Input /
Program select
Optional Gas inlet
and outlet
connections.

Operating Instructions PA-xxP
961-00035 rev11 11/42
PA-20P, PA-40P and PA-60P
MWSBus PORT – NOT USED.
ISOLATED RS232 PORT – PC CONNECTION PORT FOR UP & DOWN LOADING OF
PARAMETERS, & DATA LOGGING.
USB PORT – REPROGRAMMING OF HMI.
POSITIVE/NEGATIVE OUTPUTS – OUTPUT FOR THE POWER CABLES TO THE
TORCHES/WORKPIECE.
EXTERNAL INPUT– FOR REMOTE PROGRAM SELECTION.
TRIGGER & FAULTS i/o PORT – EXTERNAL TRIGGER & FAULT SIGNALS PORT.
Mains Cable
Cooling Fan Outlet
Keep clear
Positive Output
(workpiece)
USB
Port
Negative
Connections
To Welding
Torches.
Ensure any
unused outputs
have the
supplied
protection
covers fitted.
Isolated RS232
Port
Trigger/faults
i/o
Voltage monitor for AVM
AUX drive fuse 2A (T)
External Input /
Program select
Optional Gas
inlet and outlet
connections.
Chassis Earthing Point

Operating Instructions PA-xxP
961-00035 rev11 12/42
3.4 Getting Started
3.4.1 Power on
Ensure the unit is connected to a suitable mains lead and all the cables are properly
connected to the welding torch. Switch on. The Indicator LED below the left corner of
the screen will illuminate red, then flash orange (while system booting up), then go steady
green. The colour touch screen will display an initialisation screen.
3.4.2 The Default Menu Screen
The DEFAULT MENU SCREEN is the screen shown after power up.
SETUP (Man Mode) allows the user to setup and store weld profiles offline manually.
LOG IN/OUT provides password protection entry to allow access to varying levels of machine adjustment.
GAS allows the user to select how the gas valve is controlled.
RUN (Auto Mode) allows monitoring of the system when operated by a PLC on a production line.
I/O MONITOR provides a graphical view of the machine inputs and outputs with provision to test them.
PROFILE EDITOR allows weld profiles to be adjusted dynamically while the machine is operating under
external high speed control.
IO MONITOR
PROFILE EDITOR
CONFIG MENU
PASSWORD PROTECTED
SETUP (MAN MODE)
LOG IN/OUT GAS VALVE CONTROL
RUN (AUTO MODE)

Operating Instructions PA-xxP
961-00035 rev11 13/42
3.4.3 Information Colour Coding Key
All of the menus on the welder use the following colour code. Additionally the
background colour of the screen changes to indicate whether the welder is either in
SETUP (MAN MODE) black background or RUN (AUTO MODE) blue background.
- Pressing this key returns or exits the current screen.
- Data field where the user can change the value, touch to obtain
a keypad to enter value.
- Data field, not editable.
- Button.
- Illuminated button, OFF background is brown, ON background
is green.
- Indicator light, grey OFF, red ON
0.0
0.0

Operating Instructions PA-xxP
961-00035 rev11 14/42
3.4.4 Memory Organisation
3.4.4.1 Memory Locations (Profiles)
The PAxxP has 99 memory locations each of which is able to store the complete details
of either a single or double pulse weld profile. In order to identify the memories, each
location is given a number between 1 and 99.
The memory system uses a special memory location internally to store and display
temporary data. This is known as the scratchpad.
3.4.4.2 Scratchpad Memory
When a program is loaded, it is loaded into the scratchpad. This allows the parameters
to be changed without affecting the data in the original memory store.
Upon loading a profile from memory, the memory location will be displayed as PROFILE
x in the middle of the display. If the user changes this data, the PROFILE x value
background will change to red to indicate that the current Program is different to the
saved Program.
This indicates that the scratchpad now contains data which is different from that which
was originally loaded.
If the user wishes to save and use the modified data, the scratchpad memory must be
stored.

Operating Instructions PA-xxP
961-00035 rev11 15/42
3.5 Limit Functions
3.5.1 Monitored Limit Parameters
The PAxxP controls the weld current output. Since V=IxR (Ohms Law), as the arc
resistance changes, the voltage will reflect this change. Hence the PAxxP measures this
voltage parameter in real time as the weld occurs, thereby allowing the machine to react
to unexpected weld conditions.
Since arc current is controlled, the output circuit/arc voltage is monitored. Feedback
within the system ensures that the output current matches the demand set by the user.
As resistance increases, so does the circuit/arc voltage. This relationship can be used to
trip the machine at a particular voltage level. Since current is constant, the voltage
proportionally indicates the circuit/arc resistance.
3.5.2 High Voltage Limit
The High Voltage limit setting for a weld pulse provides a trip point. If the High Voltage
Limit is reached at any time during the weld, then a fault is indicated at the end of weld.
To set a High Limit, refer to the Main Monitor > Profile Editor for more information.
3.5.3 Low Voltage Limit
The Low Voltage limit setting is used for monitoring during the peak time for a weld pulse.
If for any reason the value set is not achieved during the peak period, a Low Voltage Limit
Fault will be caused.
This method maybe used to detect a weld condition in which not enough energy was
imparted to the weld. For example, if the circuit resistance is reduced, this will produce
less voltage. This can happen if electrode and work piece touch.
To set a Low Limit, refer to the Main Monitor > Profile Editor for more information.
3.5.4 High Energy Limit
The High Energy limit setting for a weld pulse provides a trip point. If the High Energy
Limit is exceeded at the end of the weld pulse, then a fault is indicated.
To set a High Limit, refer to the Main Monitor > Profile Editor for more information.
3.5.5 Low Energy Limit
The Low Energy limit setting for a weld pulse provides a trip point. If the Low Energy
Limit is exceeded at the end of the weld pulse, then a fault is indicated.
To set a Low Limit, refer to the Main Monitor > Profile Editor for more information.

Operating Instructions PA-xxP
961-00035 rev11 16/42
3.6 Password Entry Screen (Log in/out)
The password screen will appear whenever a password is required for the function that is
being accessed. There are three 4 digit passwords on the system.
USER. The factory default for this is 0000.
BACKUP. Maintained by Amada Weld Tech UK Ltd for each machine. Can be supplied
to customer if user password changed and then lost/forgotten.
MWS ENGINEER. For Amada Weld Tech engineers calibration use only.
To enter a password, touch the password field, a keypad appears. Type in the number
and press the ENT button.
Returns user
to password
protected
function, or
exits of
password
incorrect.
Touch to enter
password (4
digits).
Logout button
appears here,
once correct
password is
entered.
Press to
logout of
editing
modes, etc.
Save button
appears here,
once correct
password is
entered, to
enable change
of password.
Password Enable /
Disable button.

Operating Instructions PA-xxP
961-00035 rev11 17/42
4 Setup (Man mode)
4.1 Setup screen
The setup profile screen shows the currently selected profile for that particular output.
From this screen, it is possible to edit the profile data, save or load profile, trigger a test
weld, setup limits (both voltage and energy) or enter the monitor menu to view further
information about this output.
Profile time. There are three areas to a weld pulse, the upslope, peak and downslope
times.
To enter data, touch the appropriate field you wish to
change.
A numeric keypad pops-up, as shown opposite.
This shows the current value, and the minimum and
maximum values permited.
Use the number keys to enter the appropriate value.
CANCEL – exits keypad without changing value.
CLR – erases current value.
ENT – enters current value, and closes keypad.
BS – deletes character to the left of cursor.
DEL – deletes character under cursor.
<> - move cursor left and right.
Profile Current. The is labelled LEVEL (Amps). The data range is depends upon the
model. Data entry is carried out the same way as for profile time.
Voltage/Energy Limits. These fields can only be edited if they are turned on by pressing
the appropriate button at the top of the screen. Data entry is carried out in the same way
as for profile time.
Enable/Disable Energy limits Pulse 1. Turns
GREEN to indicate limits enabled/on.
Weld button. Press to fire weld on
this output, or STOP to terminate
Enable/Disable Voltage limits Pulse 1.
Turns GREEN to indicate limits
enabled/on.
Displays Current
Profile number
And name.
Turns RED on a
fault, press for
information.
Minimum and
Maximum voltage
measured during
peak period.
Measured
energy of
weld pulse.
Single/Double Pulse
Mode.
Display Weld Monitor Press to load or save
profiles.
Exit returns to
main monitor
display.

Operating Instructions PA-xxP
961-00035 rev11 18/42
The pulse 2 profile screen follows the format of the pulse 1 screen. From this screen, it is
possible to edit the profile data, trigger a test weld, setup limits (both voltage and energy)
or enter the graph menu to view further information about this output.
The setup procedure is the same as that for the first pulse.
Delay time. This is the delay between two weld pulses. The time is set in milli-seconds,
from 1 to 999ms.
Enable/Disable Energy limits Pulse 2. Turns
GREEN to indicate limits enabled/on.
Weld button. Press to fire
weld on this output.
Returns to the
pulse 1 screen.
Display Weld Monitor
Enable/Disable Voltage limits Pulse 2. Turns
GREEN to indicate limits enabled/on.
Displays Current
Profile number
and name.
Delay time
between pulse 1
and 2 in milli -
seconds.
Minimum and
Maximum voltage
measured during peak
period.

Operating Instructions PA-xxP
961-00035 rev11 19/42
4.2 Setup (Man mode) Graph Screen
Voltage Graph. This shows the voltage waveform for the selected profile (this is set on
this screen). The graph updates each time a weld is carried out on this profile, on this
output. If the voltage limits are enabled for this profile, then these are also displayed, as
red horizontal lines. The vertical scale is 0v to 100v. The time scale is the width of the
profile. The yellow vertical lines indicate the beginning and end of the peak period.
Energy Readout. This is the measured energy in the last weld.
Vmin/Vmax Readout. This is the measured minimum and maximum voltages
measured during the peak period. The peak period is indicated on the graph by the two
yellow lines.
Weld button. This triggers a weld on the selected output. The screen will update with
the arc voltage waveform at the end of weld.
Fault Light/button. This turns red to indicate a fault on the output. Pressing the button
shows the fault information display.
High Voltage Limit
Low Voltage Limit.
Exit returns to
monitor menu.
Yellow lines indicates peak period during
which the min and max readings are taken.
Press to fire weld
on this output.
Turns RED on a
fault. Press for
fault information
screen.
Minimum and
maximum voltage
measured during
the peak period
i.e. between the
yellow lines.
Energy measured
in the weld.
Current profile selected.
Blue background if stored.
Red background if edited and not stored.

Operating Instructions PA-xxP
961-00035 rev11 20/42
4.3 Setup (Man mode) Load Screen
This screen enables a profile to be loaded into setup mode for manual welding. The
boxes on the right hand side show 5 of the profile memory locations. Pressing the buttons
above and below these boxes scroll up and down the 99 profile memory locations. The
single arrows move 5 increments, and the double arrows move 10 increments.
To view the profile (before loading into the system), touch the appropriate profile from the
ones listed on the right. The data for this profile is then shown in the VIEW PROFILE
window. If this is the required data, to load the profile, touch the LOAD button.
View Profile Window. This details the data within the profile. Hi_V and Lo_V are the high
and low voltage limits. Hi_E and Lo_E are the high and low energy limits. If the limits are
turned off for this profile, then they are not displayed.
Moves in
increments of 10
profiles.
Moves in increments of
5 profiles.
Profile list. Shows
5 profiles. Press
one to view data in
VIEW PROFILE
window.
Moves in
increments of 10
profiles.
Returns to
previous screen.
Moves in increments of
5 profiles.
Enables profile to
be viewed before it
is loaded.
Loads profile into
the setup (man
mode ) editor.