Thermal Arc POWERMASTER 320SP User manual

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POWERMASTER
320SP
400SP
Service Manual
500SP
Revision: AC Issue Date: March 3, 2008 Manual No.: 0-4969
Operating Features:
Art # A-07718

!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
i
Setrvice Manual Number 0-4969 for:
PowerMaster 320SP (US) W1000102
PowerMaster 400SP Bw (US) W1000202
PowerMaster 400SP (US) Compact W1000304
PowerMaster 500SP Bw (US) W1000502
Wirefeeder SP4000W Thermal Arc (US) W3000202
Wirefeeder SP4000R Thermal Arc (US) W3000302
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermadyne.com
Copyright 2008 by
Thermadyne Industries, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident,
or any other cause.
Original Publication Date: March 3, 2008
Revision AC Date: December 23, 2008
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________

TABLE OF CONTENTS (continued)
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ...................................................................................... 1-1
1.02 Principal Safety Standards ............................................................................. 1-4
1.03 Symbol Chart ................................................................................................. 1-5
1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6
1.05 Dangers relatifs au soudage à l’arc................................................................. 1-6
1.06 Principales Normes De Securite ..................................................................... 1-9
1.07 Graphique de Symbole ................................................................................. 1-10
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment..................................................................................... 2-1
2.04 Machine Components (500SP, 400SP, and SP4000W) .................................. 2-2
2.05 Machine Components (400SP Compact Model)............................................. 2-3
2.06 Machine Components (320SP Compact Model)............................................. 2-4
2.07 Lifting Points .................................................................................................. 2-5
2.08 Power Supply Specifications (part 1) ............................................................. 2-6
2.09 Power Supply Specifications (part 2) ............................................................. 2-7
2.10 Wire Feeder Specifications ............................................................................. 2-8
2.11 Features and Benefits Common to all PowerMaster SP Systems # ................ 2-9
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Location ......................................................................................................... 3-1
3.02 Transportation and Positioning....................................................................... 3-1
3.03 Fitting the Mains Cable into the Cable Gland .................................................. 3-1
3.04 Voltage Change-over ...................................................................................... 3-2
3.05 Connecting 3-Phase Input Power to 400SP or 500SP.................................... 3-3
3.06 Connecting Single-Phase Input Power to 320SP or 400SP or 500SP ............ 3-5
3.07 Quick Start Set Up .......................................................................................... 3-7
3.08 Recommended Setup for MIG ........................................................................ 3-7
3.09 TWECO PULSEMASTER PMA5512 500 AMP Weld Gun .............................. 3-11
3.10 Installing A New Wire Conduit ...................................................................... 3-12
SECTION 4:
OPERATION........................................................................................... 4-1
4.01 General Safety Precautions ............................................................................ 4-1
4.02 Welding Controls ............................................................................................ 4-2
4.03 Menu Structure .............................................................................................. 4-4
4.04 Special functions ............................................................................................ 4-8
4.05 Smart GMAW, Pulse GMAW & TwinPulse Programs ...................................... 4-9
4.06 Welding Setting Selection Guide .................................................................. 4-10

TABLE OF CONTENTS
SECTION 5:
MANUAL GMAW WELDING ........................................................................ 5-1
5.01 Types of Weld Transfer Modes ....................................................................... 5-1
5.02 Holding and Manipulating the Torch ............................................................... 5-2
5.03 Basics of Pulsed Arc Welding ......................................................................... 5-4
5.04 Pulsed Arc Welding Parameters ..................................................................... 5-5
5.05 Smart, Pulse or TwinPulse GMAW Welding.................................................... 5-6
5.06 Conventional Manual GMAW/FCAW Welding.................................................. 5-6
5.07 SMAW/STICK Welding.................................................................................... 5-7
SECTION 6:
BASIC SERVICE ...................................................................................... 6-1
6.01 Maintenance ................................................................................................... 6-1
6.02 System Troubleshooting Guide....................................................................... 6-2
6.03 Welding Process Troubleshooting Guide ........................................................ 6-3
SECTION 7:
ADVANCED SERVICE ................................................................................ 7-1
7.01 Safety Precautions ......................................................................................... 7-1
7.02 Multivoltage Principle ..................................................................................... 7-2
7.03 Inverter Principle ............................................................................................ 7-3
7.04 Common Logic Functions .............................................................................. 7-4
7.05 Gas Test.......................................................................................................... 7-4
7.06 Pump Test ...................................................................................................... 7-4
7.07 Reset Adjustments ......................................................................................... 7-4
7.08 Master Reset .................................................................................................. 7-4
7.09 Torque Setting(s)............................................................................................ 7-4
7.10 Error Codes and Troubleshooting Guide ......................................................... 7-5
7.11 Overview of Mains Voltage Limits .................................................................. 7-5
7.12 Flowchart: Soft Power-Up Cycle At Switch On................................................ 7-6
7.13 Power-Up Schematic ...................................................................................... 7-7
7.14 Flowchart: Voltage Monitoring........................................................................ 7-8
7.15 Monitoring Bus Voltage .................................................................................. 7-9
7.16 DP-MAPRO PC Board................................................................................... 7-10
7.17 MAPRO Connector Descriptions & Measuring Points .................................. 7-11
7.18 MV-MAPRO Diagram ................................................................................... 7-15
7.19 DMR PC Board ............................................................................................. 7-16
7.20 DMR Connector Descriptions & Measuring Points....................................... 7-16
7.21 DMR Diagram............................................................................................... 7-18
7.22 DMR Schematic ........................................................................................... 7-19
7.23 DS20BF PC Board......................................................................................... 7-19
7.24 DS20BF Diagram .......................................................................................... 7-20
7.25 DS20BF Display Test .................................................................................... 7-20
7.26 MVDRV / MVMDRV PC Board ...................................................................... 7-20
7.27 MVMRV / MVMDRV Connector Descriptions & Measuring Points............... 7-22
7.28 MVDRV Schematic ....................................................................................... 7-23
7.29 MVMDRV Schematic .................................................................................... 7-24
7.30 MVDRV Diagram .......................................................................................... 7-24
7.31 MVMDRV Diagram ....................................................................................... 7-26

TABLE OF CONTENTS (continued)
TABLE OF CONTENTS
7.32 MVPWRUP PC Board ................................................................................... 7-27
7.33 MVPWRUP Connector Descriptions & Measuring Points............................. 7-27
7.34 MVPWRUP Diagram..................................................................................... 7-27
7.35 DK-GLCL PC Board....................................................................................... 7-28
7.36 DK-GLCL PC Board Diagram ........................................................................ 7-28
7.37 DP-UFI-BO PC Board .................................................................................... 7-29
7.38 DP-UFI-BO PC Board Diagram ..................................................................... 7-29
7.39 DP-EMV PC Board ........................................................................................ 7-30
7.40 DP-EMV Connector Descriptions & Measuring Points ................................. 7-30
7.41 DP-EMV PC Board Diagram ......................................................................... 7-30
7.42 DS-VA PC Board ........................................................................................... 7-31
7.43 DS-VA Connector Descriptions & Measuring Points .................................... 7-31
7.44 DS-VA PC Board Diagram............................................................................. 7-31
7.45 DP-S3NEFI PC Board.................................................................................... 7-31
7.46 Current Sensor VAC ..................................................................................... 7-32
7.47 Current Sensor VAC Connector Descriptions & Measuring Points ............... 7-32
7.48 Current Sensor VAC Diagram ....................................................................... 7-32
7.49 Control Transformer ..................................................................................... 7-33
7.50 Measuring Temperature ............................................................................... 7-33
7.51 PCB Connection Diagram ............................................................................. 7-34
7.52 Supply Voltages............................................................................................ 7-35
7.53 Measuring Welding Current.......................................................................... 7-36
7.54 Measuring the Flow Rate of the Cooling System .......................................... 7-36
7.55 Measuring Output Voltage............................................................................ 7-37
7.56 Overcurrent Protection ................................................................................. 7-37
7.57 Encoding Power Units .................................................................................. 7-38
SECTION 8:
PARTS LIST .......................................................................................... 8-1
8.01 Equipment Identification................................................................................. 8-1
8.02 How To Use This Parts List ............................................................................ 8-1
8.03 PowerMaster 320SP Exploded View Parts List (1 of 2).................................. 8-2
8.04 PowerMaster 320SP Exploded View Parts List (2 of 2).................................. 8-4
8.05 PowerMaster 400SP Compact Exploded View Parts List (1 of 2)................... 8-6
8.06 PowerMaster 400SP Compact Exploded View Parts List (2 of 2)................... 8-8
8.07 PowerMaster 400SP Remote, Water Exploded View Parts List .................... 8-10
8.08 PowerMaster 500SP Remote, Water Exploded View Parts List .................... 8-12
8.09 PowerMaster 400SP Power Module ............................................................. 8-14
8.10 PowerMaster 500SP Power Module ............................................................. 8-15
8.11 PowerMaster SP Water Cooling System ...................................................... 8-16
8.12 PowerMaster SP HR911 Remote Pendant ................................................... 8-17
8.13 PowerMaster SP4000W Wire Feeder (part 1 of 2) ....................................... 8-18
8.13 PowerMaster SP4000W Wire Feeder (part 2 of 2) ....................................... 8-20
8.14 PowerMaster SP4000W Feed Plate Assembly.............................................. 8-22

TABLE OF CONTENTS
APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1
APPENDIX 2: FEED ROLL INFORMATION ............................................................... A-2
APPENDIX 3: MOUNTING THE TORCH HOLDER ....................................................... A-3
APPENDIX 4: SP-SERIES BLOCK DIAGRAM ............................................................ A-4
APPENDIX 5: POWERMASTER 320P POWER SCHEMATIC ........................................... A-6
APPENDIX 6: POWERMASTER 400SP POWER SCHEMATIC ......................................... A-8
APPENDIX 7: POWERMASTER 400SP COMPACT POWER SCHEMATIC ........................... A-10
APPENDIX 8: POWERMASTER 500SP POWER SCHEMATIC ........................................ A-12
APPENDIX 9: RECTIFIER DIODE DATA SHEET ........................................................ A-14
APPENDIX 10: MOSFET DATA SHEET .................................................................. A-15
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

1-1
March 3, 2008
POWERMASTER 320SP, 400SP, 500SP
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive
roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed
or improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water
to cool it or lay it down on the ground or the work surface.
Do not touch holders connected to two welding machines at
the same time or touch other people with the holder or
electrode.
8. Do not use worn, damaged, undersized, or poorly spliced
cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or replace
damaged parts at once.
13. In confined spaces or damp locations, do not use a welder
with AC output unless it is equipped with a voltage reducer.
Use equipment with DC output.
14. Wear a safety harness to prevent falling if working above
floor level.
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can
damage hearing. Arc rays from the welding process
produce intense heat and strong ultraviolet rays that
can burn eyes and skin. Noise from some processes
can damage hearing.
1. Wear a welding helmet fitted with a proper shade of filter
(see ANSI Z49.1 listed in Safety Standards) to protect your
face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS
KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL
BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator
does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study
and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply
to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication
and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL
INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1-2 March 3, 2008
POWERMASTER 320SP, 400SP, 500SP
WARNING
FUMES AND GASES can be hazardous to your
health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
and cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can react
with vapors to form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from
the weld area, the area is well ventilated, and if necessary,
while wearing an air-supplied respirator. The coatings and
any metals containing these elements can give off toxic fumes
if welded.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, overheating,
or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding
arc. If this is not possible, tightly cover them with approved
covers.
4. Be alert that welding sparks and hot materials from welding
can easily go through small cracks and openings to adjacent
areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area
as practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire
at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter
Torch soldering 2 Gas metal-arc
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.