Thermal Arc POWERMASTER 320SP User manual

Service Manual
PowerMaster
320SP / 400SP / 500 SP
999.9997.9-97

page 2
Contents
Safety precautions........................................................... 3
Common Logic Functions................................................ 4
Inverter Principle.............................................................. 5
Troubleshooting guide ..................................................... 6
Pc-board DP-MAPRO...................................................... 7
Pc-board DMR............................................................... 10
Pc-board DS20BF ......................................................... 12
Pc-board DK-DCDRV / DK-S3DRV............................... 14
Pc-board PWRUP04...................................................... 19
Pc-board DP-S3NEFI .................................................... 20
Pc-board DP-UFI-BO..................................................... 22
Pc-board DP-EMV......................................................... 22
Pc-board LSW ............................................................... 23
Current Sensor VAC ...................................................... 23
Pc-board DS-VA ............................................................ 24
Pc-board PP-90R .......................................................... 24
Control Transformer....................................................... 25
Temperature Monitoring................................................. 26
Supply Voltages............................................................. 27
Monitoring Welding Current........................................... 28
Cooling Unit................................................................... 29
Welding voltage monitoring ........................................... 30
Control and monitoring wire feed motor ........................ 31
Remote control interface ............................................... 32
Monitoring primary current............................................. 33
Power-up cycle.............................................................. 34
Monitoring bus voltage .................................................. 35
Identification power units............................................... 36
Testing MOSFETs.......................................................... 37
Inside Diagram Diodes .................................................. 38

page 3
Safety precautions
Requirement
Use and maintenance of welding and cutting machines can be dangerous. Please draw user´s attention to
follow the safety precautions to avoid injuries. Welding and cutting machines must be used appropriately
and only by qualified/trained staff. Please follow safety regulations and use safety precautions in order to
prevent accidents when working with these machine.
Only qualified workers who are knowledgeabel and have been trained to work safely with test instruments and
equipment on energized circuits shall be permitted to perform testing work on electrical circuits or equipment were
there is danger of injury from accidental contact with energized parts or improper use of the test instruments and
equipment.
Use only original spare parts
Replace immediately any components that are not in perfect condition.
Norms
IEC 60974-4 In-service inspection and testing
Testing Transmig machines according to IEC 60974-4
it is not necessary to disconnect any components of the power unit for the test-
it is recommended to disconnect the torch at water cooled machines-
the machine has to be cleaned properly before the test-
switch to MMA mode (stick electrode)-

page 4
Common Logic Functions
component function cause
fan (power unit) on power modul temperature over 30°C
fan (power unit) off power modul temperature below 30°C
fan (cooling system) on after detection „welding current on“
fan (cooling system) off after welding process, two minutes post-cooling time
pump on after detection „welding current on“
pump off after welding process, two minutes post-cooling time
Gas test
press the buttons- (arrow up) and “gas type“ (+) at the same time
the gas valve is activated for 30 sec.-
a countdown is shown in the display-
press button “gas type“ (+) again to end the test manually-
Pump test
press the buttons- (arrow up) and “material type“ (-) at the same time
the cooling pump is activated for one minute-
a countdown is shown in the display-
press button “material type“ (-) again to end the test manually-
Reset adjustments
press the buttons- (arrow up) and
TT
Enter “TT Enter“ at the same time
all secondary parameters are reset to their default values-
if Tiptronic is active, the settings of the current job are reset to their programmed values-
all adjustments of the Extras menu remain unchanged-
Master reset
press the buttons- (arrow up) and
Mode
“Mode“ together for about five sec.
the display shows “Master Reset“-
the machine is reset completely to factory settings-
!!! CAUTION : all Tiptronic jobs are deleted after a Master Reset !!!

page 5
Inverter Principle
A welding inverter is a electronically controlled welding power source. At conventional transformer based ma-
chines, the mains voltage with 50/60 Hz is directly switched to the welding transformer. At a welding inverter the
mains voltage is rectified first and with electronic power switches (MOSFETs or IGBTs) chopped into a frequency
of 80 kHz. This allows a very small construction of the welding transformer, because it‘s driven at this high fre-
quency. The basic structure of a welding inverter is always the same:
mains rectifier-
primary inverter-
transformer-
secondary rectifier-
mains-
filter
3 phase mains
power-
up
primary
rectifier
primary
driver switch
transformer
secondary
rectifier

page 6
Troubleshooting guide
code description reason removal
E 00 no program no welding parameters available for selected
material-wire-gas combination (no reasonable
combination)
select other material-wire-gas combination
E 01 thermal overload thermal sensor of power unit measures a too high
temperature
let machine cool down in standby (*1)
E 02 mains overvoltage mains voltage too high (24V supply > 36V) check mains voltage and control transformer (*2)
E 03 secondary overcurrent welding current is too high check current sensor
E 04 air cooling error Temp. sensor of the power unit detects that the
unit heats up too fast
check fan and air flow
E 05 cooling system error flowrate of the cooling liquid is too low (< 0,3 l/
min)
pump is not working
check connectors of flow-meter, level of cooling
liquid and flowrate (*3)
check fuse SI7 (2,5A) on pc-board DP-MAPRO
E 06 secondary overvoltage Master detects output voltage is too high (>100V) check wiring of power unit
E 07 EEProm checksum error no welding program stored or error during rea-
ding from memory
switch the machine off and on again, if necessary
transfer the welding programs to machine again
E 08 wire feed / tacho power consumption of wire feed motor too high
no tacho signal
no CAN-Bus connection between pc-board
MAPRO and pc-board DMR
blow out torch package with compressed air
check wire feed unit
check wiring of wire feed motor and pc-board
DMR
E 09 error v/a measuring measuring difference between Master and
Process
check wiring of current sensor and pc-board DK-
UFI
E 11 remote-control conn. short circuit between remote control cables check remote control and wiring of remote control
socket
E 12 Communication Process Process is not responding to Master switch the machine off and on again
optionally exchange pc-board DP-MAPRO
E 13 Temp. sensor error Temp. sensor is faulty check resistor value and wiring of the sensor
E 14 Op. voltages error supply voltage is too low (24V supply < 17V) check mains voltage and control transformer (*2)
E 16 primary overcurrent
protection1
power consumption of power unti 1 is too high check MOSFETs and pc-board DCDRV
E 18 overload protection safety shutdown to protect electrical components
temp. sensor is disconnected
let machine cool down in standby
check temp. sensor
E 20 Overvoltage sec. Process reports a too high output voltage or no
voltage can be measured
check wiring of power unit, especially wiring from
output sockets to pc-baord DP-MAPRO
E 21 Output voltage/current external current/voltage or measure-difference
between Master and Process
check wiring of current sensor and pc-board DK-
UFI
E 22 Mains undervoltage 1 power unit 1 reports mains voltage too low check mains voltage, mains rectifier and pc-board
PWRUP
E 23 Mains overvoltage power unit reports mains voltage too high check mains voltage
E 24 Overcurrent protection2 power consumption of power unti 2 is too high check MOSFETs and pc-board DK-DCDRV
E 25 Power module detection Jumper on pc-board DK-DCDRV have been set
wrong
check DIP switch on pc-board DK-DCDRV
E27 no program (DSP) invalid material-wire-gas combination selected
welding programs faulty or not available
select other material-wire-gas combination
transfer welding programs to machine again
E 30 Mains undervoltage 2 power unit 2 reports mains voltage too low check mains voltage, mains rectifier and pc-board
PWRUP
E 31 Communication error Master is not responding to Process switch the machine off and on again
optionally exchange pc-board DP-MAPRO
the display only shows
a “?“
the display doesn‘t get any data to show no CAN bus connection between pc-board DMR
and pc-board DP-MAPRO
check flat ribbon cable and/or interpass hose
package
(*1) display the module temperatures in menu Extras > Diagnosis > Module temperatures
(*2) display the supply voltages in menu Extras > Diagnosis > Operating voltages
(*3) display the flow rate in menu Extras > Diagnosis > Flow rate cooling system

page 7
Pc-board DP-MAPRO
The pc-board DP-MAPRO is responsible for the welding sequence and is managing the process control of the
PowerMaster. (MAPRO = MAster-PROcess)
Functions
Logicfunctions of the welding process-
generating and monitoring supply voltages-
driving powerup-relays-
driving power unit/units-
monitoring control and operating elements (DS20BF, remote control, torch buttons)-
driving fans-
driving coolingpump-
monitoring flowmeter-
monitoring mains- and output voltage-
generating signal „welding current on“ (arc established)-
managing communications between PC and machine-
managing and storage of all welding parameters-
CAN-bus communication-
LED displays :
normal
LED state designation
1 (green) flashing (half freq. of LED5) CPLD-processor ok
2 (red) off Digital Signal Processor (DSP) ok
3 (green) on supply voltage 3,3V DC ok
4 (red) off micro controller ok
5 (green) flashing DSP is working
6 (green) flashing micro controller is working
malfunction
LED state designation
1 (green) never on CPLD-processor is not working
2 (red) on DSP is not working
3 (green) off supply voltage 3,3V DC is missing
check 18V~ AC of control transformer X2/1 X2/2
4 (red) on micro controller is not working
5 (green) never on DSP is not working
6 (green) never on micro controller is not working
If the LEDs are indicating a malfunction which can not be relieved by switching the machine off and on again, it is
recommended that the pc-board DP-MAPRO is exchanged.
Overview fuses DP-MAPRO
fuse value [A] Safeguarding
Si 6 1 fans (power unit)
Si 7 2,5 cooling pump

page 8
Settings DIP Switch
If the machine is to be programmed via the serial port, the DIP switches 1-3 has to be set to “ON“. In normal ope-
ration they has to be set to “OFF“.
If the pc-board is used in a 320SP, the DIP switch 4 has to be set to “ON“. For the use in a 400SP or 500SP, DIP
switch 4 has to be set to “OFF“.
DIP switch ON OFF
1 mode serial programming mode normal operation
2 mode serial programming mode normal operation
3 mode serial programming mode normal operation
4 configuration 320SP configuration 400SP, 500SP
Measuring points
designation measure point result
solenoid valve X10/1
X10/2
+
gnd
+24V DC
supply voltage
control transformer
X6/1
X6/3
~
~
230V AC
supply voltage
fan group 1
X7/1
X7/2
~
~
230V AC
supply voltage
fan group 2
X25/1
X25/2
~
~
230V AC
supply voltage
cooling pump
X13/1
X13/2
~
~
230V AC
output voltage
control transformer
X2/1
X2/2
~
~
18V AC
X2/3
X2/4
~
~
42V AC
supply voltage
flow meter
X9/1
X9/3
+
gnd
+15V DC
supply voltage
CAN bus
X8/1
X8/2
gnd
+ +15V DC
X14/1
X14/2
gnd
+ +15V DC
X20/1
X20/2
gnd
+ +15V DC

page 9
Picture Pc-board DP-MAPRO
Overview connectors Pc-board DP-MAPRO
connector designation
X1 connector to power uint 1
X2 connector control transformer (supply of pc-board)
X3 connector to pc-baord DS-ERW (not used in Transmig machines)
X4 connector to power uint 2
X5 connector to Interpass hose package
X6 230V supply fans/cooling unit (from control transformer)
X7 connector fan group 1
X8 CAN connector
X9 connector flow meter
X10 connector gas valve (only used when TIG option is installed)
X11 connector front panel
X13 connector cooling unit
X14 CAN connector
X15 connector TIG torch button
X16 connector volt/amp display
X17 connector output voltage (to pc-board DP-UFI-BO)
X18 connector remote control
X19 connector gas test button
X20 CAN connector
X21 connector JTAG interface (internal programming port)
X22 connector JTAG interface (internal programming port)
X23 connector serial Interface (RS232: internal programming port)

page 10
Pc-board DMR
The pc-board DMR is the wire feed motor control of the machine.
Functions
control and monitoring wire feed motor-
driving solenoid valve-
control and monitoring of operating elements (DS20BF, remote control, torch buttons)-
monitoring wire inch button-
supply pc-board PP90R (Push-Pull)-
LED displays
normal
LED state designation
1 (red) off microcontroller ok
2 (green) on supply voltage 5V ok
malfunction
LED state designation
1 (red) is lit weak microcontroller not programmed
flashes malfunction CAN bus
2 (green) off supply voltage 5V not ok
Measuring points
designation measure point result
solenoid valve X6/1
X6/2
+
gnd
+24V DC
supply voltage tacho X5/1
X5/3
+
gnd
5V DC
drive level for pc-board PP90R
(Push-Pull)
X7/1
X7/3
+
gnd
+24V DC
wire insert button
(when button pressed)
X1/1
X1/2
0Ω
supply wire feed motor X10
X11
-
+ 0-42V DC
supply voltage
CAN bus
X20/1
X20/2
gnd
+ +15V DC

page 11
Picture Pc-board DMR
Overview connectors Pc-board DMR
connector designation
X1 torch trigger switch
X2 front panel
X3 volt/amp display
X4 wire insert button
X5 tacho
X6 gas valve
X7 pc-board PP90R (Push-Pull option)
X8 Interpass hose package
X10 wire feed motor “-“ (minus)
X11 wire feed motor “+“ (plus)
X12 welding potential
X18 remote control interface

page 12
Pc-board DS20BF
The pc-board DS20BF is the front panel with all buttons, rotary impulse encoder and all displays.
Functions
- operating/setup the machine
- display of all welding parameters
- display error messages
- display machine parameters (version operating system, actual values etc.)
Picture Pc-board DS20BF
X1
LED10LED11
S2
LED12
LED13
LED16
LED17
LED18
LED7 LED8
LED9
LED1
LED4LED3LED2
S1
LED5 LED6
LED14 LED15
At a machine with separated front panels, the pc-boards DS21BF and DS22BF are used.
S2
LED7 LED8
LED1
LED4LED3LED2
S1
LED5 LED6
X1
LED9
LED10
LED11 LED12 LED13
LED14
LED15
650.1244.0 DS21BF RP327
D00.0068.9-00

page 13
X1
LED10LED11
LED9
650.1243.0 DS22BF RP326
D00.0069.0-00
Display test
The display has an internal function test. To execute the test press the buttons “arrow down“ (TA13) and
“mode“
Mode
(TA4) at the same time.
At a machine with seperatd front panels, the test can also be executed at the DS21BF with the buttons
“2-stroke/4-stroke“ (TA2) and “slope“ (TA3).
Now the LC-Display shows „Display Test“ and the version number of the operating system. Press any button to
start the first test, where all LEDs and the LC-Display are turned on and off alternately. The LC-Display shows
„LEDs on, Backlight off“.
Press any button to go to the next test. In this test all buttons are checked, by pressing all 12 buttons one after
another. The button which is to be pressed, is indicated by a lit LED. After that the rotary impulse encoders are
checked. The LC-Display shows a cursor which can be moved by the rotary impulse encoders. At first the cursor
has to be moved to the left with the left rotary impulse encoder then to the right. After that the cursor has to be
moved to the left and right with the right rotary impulse encoder.
Then the test are completed and the LC-Display shows „End of Tests“ and the machine goes back into normal
mode, which was displayed before the display test was executed.

page 14
Pc-board DK-DCDRV / DK-S3DRV
The pc-board DK-DCDRV is managing the primary drive level of the power unit 400SP and 500SP.
The pc-board DK-S3DRV is managing the primary drive level of the power unit 320SP.
!!! CAUTION !!!: there had been several changes at the boards, please read the detailed informations about the-
se changes on page 17.
Functions
- encoding power unit
- connection temperature sensor of heat sink
- supply current sensor
- monitoring bus voltage and supply voltage
- safety shut-down of power unit
- passthrough signal powerup relays
- passthrough signal „welding current on“ (from current sensor)
Encoding Power Unit
The type of the power unit is set via the DIP switch.
DIP 1 DIP 2 setting machine type
OFF OFF 240 A 400SP
OFF ON 270 A 320SP
ON OFF 300 A 500SP
ON ON reserved
LED displays
normal
LED state designation
1 (red) off primary overcurrent shut down
2 (green) on drive level of low-side is ok
4 (green) on bus voltage max is ok
5 (green) on drive level of high-side is ok
6 (green) on bus voltage min is ok
malfunction
LED state reason
1 (red) on primary current is too high, power unit has been switched off
2 (green) never on no drive level low-side
4 (green) off bus voltage is too high (e.g. mains overvoltage)
5 (green) never on no drive level high-side
6 (green) off bus voltage is too low (e.g. mains voltage too low)
Measuring Points
designation measure point result
supply voltage current sensor X2/1
X2/6
+
gnd
+15V DC
supply voltage current sensor X2/3
X2/6
-
gnd
-15V DC
temperature sensor X3/1
X3/2
gnd
+
10kΩat 25°C
(about +2V DC)

page 15
Picture Pc-board DK-DCDRV / DK-S3DRV
X3
X2
X1 S1
LED6
LED4
LED1
LED2
LED5
T
TT
T
T
TT
T
D
D00.0050.6-01
T = MOSFET (power transistor)
D = diode

page 16
Overview connectors pc-baord DCDRV
connector designation
X1 connector to pc-board DP-MAPRO
X2 connector current sensor and pc-board PRWUP
X3 connector temperature sensor
Primary Driver
The pc-board DCDRV is the primary driver board for the transformer. It is a classical half bridge design. The sup-
ply is provided via pins 1, 2 and 3 of the flat ribbon cable and the PWM signals (PWM = Pulse Width Modulation)
for driving the MOSFETs are at pin 5 (low side) and pin 6 (high side).
Schematic
+Ubus
-Ubus

page 17
Changeover to new MOSFETs and new pc-board DK-DCDRV
Over the time there had been some changes at the power units. Important is to make sure, that the different versi-
ons are not mixed up (do not combine “old“ with “new“).
Since september 2006 the MOSFET (711.2606.0) was replaced by a new type (711.2608.0). In this context the•
pc-boards DK-DCDRV/DK-S3DRV were replaced by DCDR-01 and DCDR-03.
Since December 2007 additional diodes had been added to the pc-boards (change from DCDR0x to DCDR1x)•
Since April 2008 a new driver circuit was used (change from DCDR1x to DCDR2x)•
type part. no. designation picture
„old“ MOSFET 711.2606.0 E26NA90
„new“ MOSFET 711.2608.0 IXFN26N90
The new pc-boards DCDR-01 and DCDR-03 can be easily distinguished from the „old“ pc-board DK-DCDRV. At
the „new“ pc-boards the gate resistors have a small toroidal core:
The main difference between the DCDR0x and DCDR1x is an additional diode:
DCDR0xDCDR1x
with additional diode

page 18
320SP:
pc-board part no. serial no. date identification
MOSFET toroidal core diode driver ic
DK-S3DRV 650.1274.x old no no old
DCDR03 650.5256.x N630001 A W1000101 21.09.2006 new yes no old
DCDR13 650.5366.x T821001 A W1000101 30.11.2007 new yes yes old
DCDR23 650.5373.x R802001 A W1000101 02.04.2008 new yes yes new
400SP:
pc-board part no. serial no. date identification
MOSFET toroidal core diode driver ic
DK-DCDRV 650.1274.x old no no old
DCDR01 650.5258.x N627001 A W1000201
N630001 A W1000301
R718001 A W1000401
20.09.2006 new yes no old
DCDR11 650.5364.x E807001 A W1000201
C730001 A W1000301
H814001 A W1000401
30.11.2007 new yes yes old
DCDR21 650.5371.x E812001 A W1000201
E812001 A W1000301
E812001 A W1000401
12.03.2008 new yes yes new
500SP:
pc-board part no. serial no. date identification
MOSFET toroidal core diode driver ic
DK-DCDRV 650.1274.x old no no old
DCDR01 650.5258.x N627001 A W1000501
Y620001 A W1000601
20.09.2006 new yes no old
DCDR11 650.5364.x C730001 A W1000501
C730001 A W1000601
30.11.2007 new yes yes old
DCDR21 650.5371.x E825001 A W1000501
E812001 A W1000601
12.03.2008 new yes yes new
!!! CAUTION !!! : the new MOSFETs are not compatible with the old type. The new MOSFETs must only be used
with the new pc-boards DCDRxx. The new parts must not be mixed with the old parts, under no circumstances !
Especially at the machines with double power units (400SP and 500SP) it must be ensured, that both power units
are equipped completely with only one version.
old driver ic: JC429CPA DCDR2x with new
driver ic: TC4429

page 19
Pc-board PWRUP04
The pc-board DK-PWRUP is the power up-circuit of the 400SP and 500SP.
Functions
- reducing start-up peak current for capacitors
- supply and safeguarding of control transformer
Measuring Points
designation measure point result
mains input L1 X1 ~
400V ACmains input L2 X2 ~
mains input L3 X3 ~
mains output L1 X11 ~
400V ACmains output L2 X12 ~
mains output L3 X13 ~
supply voltage control transformer X10/1
X10/2
~
~
400V AC
drive level relay X4/1 and 3
X4/2 and 4
+
-
+24V DC
Picture Pc-board PWRUP04
X10
X4
X1 X3 X2
SI2
SI1
X11
X13
X12
650.1252.x PWRUP04DKL RP397/1
D00.0090.8-01
Fuses
Safeguarding the control transformer via Si1, Si2 : each 4A, 400V (slow)

page 20
Pc-board DP-S3NEFI
The pc-board DP-S3NEFI is the mains filter and power up board of the 320SP.
Functions
- mains filter
- reducing start-up peak current for capacitors
- supply and safeguarding for control transformer
Measuring Points
designation measure point result
mains input L1 LP1 ~
400V ACmains input L2 LP2 ~
mains input L3 LP3 ~
drive level power-up relays X4/1 and 3
X4/2 and 4
+
-
+24V DC
supply control transformer X10/1
X10/2
~
~
400V AC
mains output L1 LP4 ~
400V ACmains output L2 LP5 ~
mains output L3 LP6 ~
Picture pc-board DP-S3NEFI
X4
X10
SI3
SI4
LP1
LP2
LP3
LP4
LP6
LP5
LP7
650.1281.x DP-S3NEFI RP359/1
D00.0107.0-00
Fuses
Safeguarding the control transformer via Si1, Si2 : each 4A, 400V (slow)