MAGNATECH Pipemaster 515 Manual

6 Kripes Road - PO Box 260 - East Granby, CT 06026 USA
Fax: [phone] E-Mail: [email protected]
Phone: [phone] Web: www.MagnatechLLC.com
Operating and Maintenance
Instruction Manual
For
Pipemaster Digital Power Source
(Model 515)
S/N PM515AB1014 to Current
&
Water Circulator
(Model 905)
Rev March 8, 2012

PIPEMASTER DIGITAL POWER SOURCE
(MODEL 515)
OPERATION MANUAL
TABLE OF CONTENTS
Section Title Page #
INTRODUCTION........................................................................................................................................................1
COPYRIGHT NOTICE...............................................................................................................................................1
1.0 DESCRIPTION AND OPERATION OF CONTROLS - POWER SUPPLY AND PENDANT.......................2
1.1 Power Source Description..............................................................................................................2
1.2 Pendant Controls (Figure 1.1)........................................................................................................2
1.3 Front Panel Controls.......................................................................................................................4
1.4 Rear Panel (Figure 1.4)....................................................................................................................5
2.0 PIPEMASTER WELDING SYSTEM - MODEL 515 COMPONENT INVENTORY.......................................6
3.0 SAFETY INSTRUCTIONS AND WARNINGS FOR OPERATION AND ARC WELDING EQUIPMENT ....7
3.1 Important Notice..............................................................................................................................7
3.2 Obligations Of Owner/Operator ...................................................................................................12
3.3 Shock Prevention ..........................................................................................................................12
3.4 Burn Prevention.............................................................................................................................13
3.5 Toxic Fume Prevention.................................................................................................................14
3.6 Compressed Gas Cylinder Handling...........................................................................................14
3.7 Equipment Warning Labels ..........................................................................................................14
3.8 Alterations To The Power Supply................................................................................................14
3.9 Spares And Expendable Parts .....................................................................................................15
3.10 Particular Danger Spots................................................................................................................15
3.11 Calibration Of Power Supply........................................................................................................15
3.12 Safety Precautions At The Installation Location........................................................................15
3.13 Safety Precautions In Normal Operation ....................................................................................15
3.14 Turn Power Off Before Connecting/Disconnecting Cables.......................................................15
3.15 Safety Inspection...........................................................................................................................15
3.16 Additional Safety And Health Information ..................................................................................15
4.0 WARRANTY AND SUPPORT....................................................................................................................17
4.1 Warranty.........................................................................................................................................17
4.2 Support Contacts...........................................................................................................................20
5.0 INSTALLATION TO ELECTRICAL AND GAS SERVICES. WELD HEAD CONNECTION. ...................21
5.1 General Assembly Instructions....................................................................................................21
5.2 Filling Model 905 Cooling Module with Coolant.........................................................................21
5.3 Connecting Power Source to Input Power..................................................................................21
5.4 Connecting Pipemaster Power Source to Gas Supply..............................................................21
5.5 Install Interconnect Power Cable - Pipemaster to Water Circulator.........................................22
5.6 Connect Weld Head.......................................................................................................................22
5.7 Ready for Welding - Power Switch on.........................................................................................22
5.8 Pipemaster Specifications............................................................................................................23
5.9 Fault Conditions ............................................................................................................................23
6.0 MAIN MENU ...............................................................................................................................................24
6.1 Start-up...........................................................................................................................................24
6.2 Main Screen/Main Menu................................................................................................................24
6.3 Navigating ......................................................................................................................................25
7.0 LIBRARY - TO RUN, REVIEW EXISTING PROGRAM.............................................................................26
7.1 Run a Weld.....................................................................................................................................26
7.2 Weld in Progress ...........................................................................................................................27

TABLE OF CONTENTS Continued
Section Title Page#
8.0 USING AUTOPROGRAM...........................................................................................................................30
8.1 For D-Head Model 420, Quickclamp Heads Model 432, 433.....................................................30
8.2 For C-Series Models (819A - 823A); 800 Series Model (810 - 860); and R-Heads Models (427A
- 429A).............................................................................................................................................34
8.3 Using Autotack for 800 Series, C-Series, and R-Heads.............................................................34
9.0 ALPHANUMERIC LABELING ...................................................................................................................35
9.1 Using the Floating Keyboard........................................................................................................35
9.2 Entering Text..................................................................................................................................35
10.0 MANUAL PROGRAMMING .......................................................................................................................36
10.1 Create New Weld Program............................................................................................................36
10.2 Weld Number Selection.................................................................................................................36
10.3 Manually Set Parameters..............................................................................................................36
10.4 Enter Prepurge and Upslope........................................................................................................38
10.5 Pass Screen ...................................................................................................................................38
10.6 Pass 1, Level 1...............................................................................................................................39
10.7 Downslope Screen.........................................................................................................................40
10.8 Save Weld/Next Weld ....................................................................................................................41
10.10 Weld Notes.....................................................................................................................................42
10.11 Programs Notes.............................................................................................................................42
10.12 How to Observe Programmed Oscillation Width (Without Striking an Arc)............................42
11.0 EDITING A WELD PROGRAM ..................................................................................................................44
11.1 Select Weld Number to Edit..........................................................................................................44
11.2 Edit Weld Parameters....................................................................................................................44
11.3 Adding/Removing a Pass .............................................................................................................44
11.4 Save Weld/Next Weld ....................................................................................................................45
11.5 Scaling A Weld...............................................................................................................................45
12.0 MENU..........................................................................................................................................................46
12.1 Copy Welds (Power Source Internal Memory)............................................................................46
12.2 Copy/Transfer Files to Data Key..................................................................................................46
12.3 Delete Welds ..................................................................................................................................47
12.4 Print Welds.....................................................................................................................................47
12.5 Transfer Print Files to Data Key...................................................................................................48
12.6 QC Settings and Printout..............................................................................................................48
12.7 Tungsten Calc................................................................................................................................49
13.0 OPTIONS: MAINTENANCE - OPTIONS MENU.......................................................................................50
13.1 Setting the Weld Counter..............................................................................................................50
13.2 Set Password.................................................................................................................................50
13.3 Operator Name...............................................................................................................................51
13.4 Set Date/Time.................................................................................................................................51
13.5 Set Language.................................................................................................................................51
13.6 Units................................................................................................................................................51
13.7 Set Calibration Time......................................................................................................................51
13.8 Test Mode.......................................................................................................................................51
14.0 WELD HEAD OPTIONS.............................................................................................................................52
14.1 Programming Mode.......................................................................................................................52
14.2 Start Method...................................................................................................................................52
14.3 Arc Length Mode ...........................................................................................................................52
15.0 PRINTER OPERATION/MAINTENANCE ..................................................................................................53
15.1 Installing Paper in the Printer.......................................................................................................53

TABLE OF CONTENTS Continued
Section Title Page #
16.0 MODEL 905 WATER CIRCULATOR.........................................................................................................54
16.1 Filling Water Circulator with Coolant ..........................................................................................54
16.2 Connecting Water Circulator to the Pipemaster ........................................................................54
16.3 Operation of the Water Flow Switch............................................................................................54
16.4 Shipment of Water Circulator.......................................................................................................54
16.5 Periodically Clean the Filters .......................................................................................................54
16.6 Circuit Breaker...............................................................................................................................54
17.0 CALIBRATION ...........................................................................................................................................55
17.1 Arc Voltage.....................................................................................................................................55
17.2 Weld Current ..................................................................................................................................55
17.3 Wire Feed........................................................................................................................................55
17.4 Travel ..............................................................................................................................................56
18.0 BILL OF MATERIALS - DRAWINGS - SCHEMATICS..............................................................................57

1
PIPEMASTER MODEL 515 POWER SOURCE
FOR USE WITH GTAW PROCESS WELD HEADS
INTRODUCTION
The Pipemaster, Model 515, is a digital power source designed to be used with Magnatech D-Head®, T-Head®,
Quickclamp Head®, 424/425/426® model weld Heads. Internal memory and removable data media used for
program transfer are solid state. The Power Source is operated from a Remote Pendant, containing all controls.
Take Inventory. After receiving your system, please take an inventory of parts using the Packing List, or the
general inventory list detailed in Section 2.0.
READ AND OBSERVE WARNINGS BEFORE PROCEEDING WITH INSTALLATION!!
Read all warnings listed in Section 3.0 before connecting the Pipemaster to input power or attempting any welding!
Contact Magnatech technical staff if any questions exist concerning proper installation procedures.
COPYRIGHT NOTICE
This manual and the information contained herein is the property of Magnatech LLC. It is proprietary and shall not
be copied in whole or in part without the prior express written permission of Magnatech LLC.
Information and instructions in this document are subject to change and Magnatech LLC reserves the right to
change specifications and data without notice.
This document is based on the latest design version at the time of publication. Some deviations in actual operation,
from this document, are possible depending on the production generation of a particular machine.
Edition publication date – March 22, 2011. Copyright 2011 by Magnatech LLC all rights reserved.

2
1.0 DESCRIPTION AND OPERATION OF CONTROLS - POWER SUPPLY AND PENDANT
1.1 Power Source Description
The Remote Pendent (Figure 1.1) provides controls necessary to develop, save and call up
welding programs. Programming is selectable position or time-based.
Each program can consist of a maximum of 100 levels. Any and all welding parameters may be
changed at each of the 100 levels. Downslope will occur following completion of the final level
time period.
While welding, the operator can immediately override the programmed parameters within preset
limits.
1.2 Pendant Controls (Figure 1.1)
1.2.1 LCD Display
A color LCD display is used to display information. When powered up,
approximately 12 seconds is required for the microprocessor to boot, and the display
will remain blank.
1.2.2 Cursor Up Switch
Moves cursor up display.
1.2.3 Cursor Down Switch
Moves cursor down display.
1.2.4 Enter Switch
Enters item highlighted by cursor.
1.2.5 Soft Keys (Four)
Used to select menu items. These items/functions change depending on operation
mode (i.e., setup, programming, operation).
1.2.6 Home Position Switch
Depressing this switch will cause the weld Head to rotate until it reaches a Home
position, at which point rotation will cease. (Home Position for the D-Head/T-Head is
one of 6 locations located 60° apart around the Guide Ring.) Active only when no
arc is present, this switch causes the Head to move forward until one of the position
notches on the guide ring is found. When using Autorewind, the weld Head will
rotate in reverse until finding the Home location.
1.2.7 Start Weld/Start Downslope
Used to start a weld, or to initiate downslope if a weld is in progress.
1.2.8 Emergency Stop Switch
Used to immediately terminate the weld cycle and all weld Head functions.
ATTENTION: In nonwelding operation, this switch is used as an “Escape” back
to the Start Up screen/Main Menu.

3
Figure 1.1
Img Ref 637
Function Switches
The following -/+ switches (1.2.9 thru 1.2.19) perform multiple functions depending on the operating
conditions.
•During programming, these serve to directly input the desired parameter values.
•During “Run Program” mode, these serve as JOG switches, when no arc is present.
•During welding, they serve as override switches for each function, within the preset limits of
the % override screen.
1.2.9 Current Switches
Used to decrease/increase welding current level in both programming and welding
modes.
1.2.10 Travel Switches
Used to decrease/increase welding travel (rotation) speed in both programming and
welding modes.
1.2.11 Wire Switches
Used to decrease/increase welding wire speed in both programming and welding
modes.

4
1.2.12 Arc Length Switches
Used to decrease/increase welding arc length (and therefore arc voltage) in both
programming and welding modes.
1.2.13 Oscillation Speed Switches
Used to decrease/increase welding oscillation speed in both programming and
welding modes.
1.2.14 Oscillation Amplitude Switches
Used to decrease/increase oscillation amplitude (torch weave width) during both
programming and welding modes.
1.2.15 AGC Stop Switch
This switch and the Wire Stop are used primarily in weld repairs. Depressing this
switch causes the AGC operation to cease. While the AGC is disabled, a warning
indicator is displayed on the LCD. Depressing the switch a second time causes the
function to once again become active.
When the AGC Stop switch is on, the two AGC Switches can be used to jog the
torch up/down.
1.2.16 Wire Stop Switch
Operation of this switch is similar to that previously described, except that the
function interrupted is wire feed.
When the WIRE STOP switch is depressed, filler wire feed will be interrupted until
the switch is again depressed. A warning indicator is displayed. When the WIRE
STOP switch is actuated, the two wire switches can be used to jog wire.
1.2.17 Rotary Encoder
This multifunction control can be used to increase/decrease any parameter that has
been selected during programming. During welding, this is used to “steer” the torch
in the seam, and adjust the center point of the oscillation strokes.
1.2.18 Inner & Outer Oscillation Dwell
During programmed and welding modes, the four soft keys adjust the inner and outer
dwell times. Oscillation dwell is the time period that the torch remains stationary at
either stroke end points. (“Inner” refers to the location where the Torch is closer to
the weld Head body, “Outer” the reverse.)
1.2.19 USB Port (At Top of Pendent)
A standard digital “data key” connects to the USB port. This allows program transfer
between power sources, program archiving, and QC data downloading. Weld
parameters can be downloaded for subsequent print out on a PC equipped with a
printer.
1.3 Front Panel Controls
1.3.1 Emergency Stop Switch
Used to immediately terminate the weld cycle and all weld Head functions. Will also
“reboot” the system.

5
1.4 Rear Panel (Figure 1.4)
All connections are made on the Rear Panel.
Figure 1.4 - Rear Panel
1.4.1 Water Circulator Connector
A connector is provided to power the Water Circulator and to provide to provide
Water Flow Switch protection. (A Water Flow Switch is mounted in the Water
Circulator.)
The water flow switch is factory calibrated. Interruption in water flow will result in
termination of welding and a warning message on the display.
1.4.2 Gas Flow Switch
The Pipemaster Power Source is equipped with a Gas Flow Switch that is factory
preset. Shielding gas must be flowing to the weld Head in order to be able to initiate
a welding arc. If gas flow to the weld Head is insufficient, depressing the START
WELD switch will not initiate a welding arc. If the gas flow is interrupted during
welding, the flow switch will immediately cause the arc to be extinguished. If gas
flow is interrupted, a warning message will be displayed.

6
2.0 PIPEMASTER WELDING SYSTEM - MODEL 515 COMPONENT INVENTORY
Each Pipemaster comes equipped with the following:
•1 Power Source
•Printer (Installed), P/N 515PR
•1 Input Power Cable
•1 Gas Hose (P/N 102990)
•1 Manual
•1 Data Key, P/N 51773
•1 Work Cable 8m (25') P/N 515-66
•1 Water Circulator Model 905
•Circulator Coolant Fluid, P/N 7280
Options
•Rolls, Printer Paper, P/N 41004
•Cart with Bottle Rack
•Extension Cable Set - 8m (25'), P/N 515EX-25
•Extension Cable Set - 15m (50'), P/N 515EX-50
•Shipping Case - Power Source
•Shipping Case - Water Circulator