Thermal Arc POWERMASTER 400SP User manual

Art # A-07790
POWERMASTER
400SP
Service Manual
500SP
Revision: AB Issue Date: October30, 2008 Manual No.: 0-4971B
Operating Features:
AUTOMATION

!
WARNINGS
Read and understand this entire Manual and youremployer’s safety practices before installing,
operating, orservicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturerassumes no liability forits use.
i
Service Manual Number0-4971B for:
PowerMaster500SP Automation Bw Robotic (US) W1000602
PowerMaster400SP Automation Bw Robotic (US) W1000402
SP4000R Automation Wire Feeder(US) W3000302
Remote Operation Panel Pendant W4001001
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 orin part, without written permission of the publisheris prohibited.
The publisherdoes not assume and hereby disclaims any liability to any party forany loss ordamage
caused by any errororomission in this Manual, whethersuch errorresults from negligence, accident,
orany othercause.
Original Publication Date: October30, 2008
Revision AB Date: December23, 2008
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________

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..................................................................................... 2-2
2.05 PowerSupply Specifications (part 1) ............................................................. 2-3
2.06 PowerSupply Specifications (part 2) ............................................................. 2-4
2.07 Wire FeederSpecifications ............................................................................. 2-5
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Location ......................................................................................................... 3-1
3.02 Voltage Changeover........................................................................................ 3-1
3.03 Connecting 3-Phase Input Powerto 400SP or500SP.................................... 3-2
3.04 Connecting Single-Phase Input Powerto 400SP or500SP ............................ 3-4
3.05 Quick Start Set Up .......................................................................................... 3-6
3.06 Recommended Setup forMIG ........................................................................ 3-6
3.07 PulsemasterPMA512S-3545 500 Amp Weld Gun (when welding by hand). 3-10
3.08 Installing A New Wire Conduit ...................................................................... 3-11
SECTION 4:
MANUAL 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
SECTION 5:
ROBOTIC OPERATION ............................................................................... 5-1
5.01 Robot Interface INT06 .................................................................................... 5-1
5.02 Digital Inputs and Outputs .............................................................................. 5-1
5.03 Analog Inputs ................................................................................................. 5-2
5.04 Robot Interface Schematic ............................................................................. 5-3
5.05 Robot Interface INT06 PC Board Schematic................................................... 5-5
5.06 42-Pin Harting Socket .................................................................................... 5-6
5.07 Configuration at Front Panel Menu ............................................................... 5-10
5.08 Robot Tool Software Installation .................................................................. 5-11
5.09 Decimal-Binary Conversion .......................................................................... 5-12

TABLE OF CONTENTS (continued)
TABLE OF CONTENTS
SECTION 6:
MANUAL GMAW WELDING ........................................................................ 6-1
6.01 Types of Weld TransferModes ....................................................................... 6-1
6.02 Holding and Manipulating the Torch ............................................................... 6-2
6.03 Basics of Pulsed Arc Welding ......................................................................... 6-4
6.04 Pulsed Arc Welding Parameters ..................................................................... 6-5
6.05 Smart, Pulse orTwinPulse GMAW Welding.................................................... 6-6
6.06 Conventional Manual GMAW/FCAW Welding.................................................. 6-6
6.07 SMAW/STICK Welding.................................................................................... 6-7
SECTION 7:
BASIC SERVICE ...................................................................................... 7-1
7.01 Maintenance ................................................................................................... 7-1
7.02 System Troubleshooting Guide ....................................................................... 7-2
7.03 Welding Process Troubleshooting Guide ........................................................ 7-3
7.04 ErrorCodes .................................................................................................... 7-4
SECTION 8:
ADVANCED SERVICE ................................................................................ 8-1
8.01 Safety Precautions ......................................................................................... 8-1
8.02 InverterPrinciple ............................................................................................ 8-2
8.03 Common Logic Functions .............................................................................. 8-3
8.04 Gas Test.......................................................................................................... 8-3
8.05 Pump Test ...................................................................................................... 8-3
8.06 Reset Adjustments ......................................................................................... 8-3
8.07 MasterReset .................................................................................................. 8-3
8.08 Torque Setting(s)............................................................................................ 8-3
8.09 Control Transformer....................................................................................... 8-4
8.10 DP-MAPRO PC Board..................................................................................... 8-5
8.11 DMR PC Board ............................................................................................... 8-6
8.12 DS20BF PC Board........................................................................................... 8-6
8.13 DK-PWRUP04 PC Board ................................................................................ 8-6
8.14 DP-S3NEFI PB Board...................................................................................... 8-6
8.15 DK-DCDRV / DK-S3DRV PC Board ................................................................. 8-7
8.16 DK-GLCL PC Board......................................................................................... 8-8
8.17 DP-UFI-BO PC Board ...................................................................................... 8-8
8.18 DP-EMV PC Board .......................................................................................... 8-8
8.19 LSW PC Board................................................................................................ 8-8
8.20 DS-VA PC Board ............................................................................................. 8-8
8.21 DS-ERW PC Board ......................................................................................... 8-8

TABLE OF CONTENTS
SECTION 9:
PARTS LIST .......................................................................................... 9-1
9.01 Equipment Identification................................................................................. 9-1
9.02 How To Use This Parts List ............................................................................ 9-1
9.03 PowerMaster 400SP & 500SP Robotic Exploded View Parts List (1 of 2) ..... 9-2
9.04 PowerMaster 400SP & 500SP Robotic Exploded View Parts List (2 of 2) ..... 9-4
9.05 PowerMaster 400SP Power Module ............................................................... 9-6
9.06 PowerMaster 500SP Power Module ............................................................... 9-7
9.07 PowerMaster SP Water Cooling System ........................................................ 9-8
9.08 PowerMaster SP HR911 Remote Pendant ..................................................... 9-9
9.09 PowerMaster SP 4000R Wire Feeder ........................................................... 9-10
9.10 PowerMaster SP4000R Feed Plate Assembly ............................................... 9-12
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 400SP POWER SCHEMATIC ......................................... A-6
APPENDIX 6: POWERMASTER 500SP POWER SCHEMATIC ......................................... A-8
APPENDIX 7:ROBOTIC INTERFACE DIAGRAM ........................................................ A-10
APPENDIX 8: RECTIFIER DIODE DATA SHEET ........................................................ A-11
APPENDIX 9: HYBRID ESBT DATA SHEET ............................................................. A-12
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

1-1
October30, 2008
POWERMASTER 400SP, 500SP AUTOMATION
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
orsevere burns. The electrode and work circuit is
electrically live wheneverthe output is on. The input
powercircuit and machine internal circuits are also
live when poweris 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
orimproperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Weardry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats orcovers.
4. Disconnect input powerorstop engine before installing or
servicing this equipment. Lock input powerdisconnect switch
open, orremove line fuses so powercannot 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 powerto
equipment if it will be left unattended orout of service.
7. Use fully insulated electrode holders. Neverdip holderin water
to cool it orlay it down on the ground orthe work surface.
Do not touch holders connected to two welding machines at
the same time ortouch otherpeople with the holderor
electrode.
8. Do not use worn, damaged, undersized, orpoorly spliced
cables.
9. Do not wrap cables around yourbody.
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. Repairorreplace
damaged parts at once.
13. In confined spaces ordamp locations, do not use a welder
with AC output unless it is equipped with a voltage reducer.
Use equipment with DC output.
14. Weara safety harness to prevent falling if working above
floorlevel.
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. Weara welding helmet fitted with a propershade of filter
(see ANSI Z49.1 listed in Safety Standards) to protect your
face and eyes when welding orwatching.
2. Wearapproved safety glasses. Side shields recommended.
3. Use protective screens orbarriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wearprotective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved earplugs orearmuffs 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 ordeath, ordamage to otherequipment orproperty, 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 powerlines; otherpractices 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 otherguides 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 October30, 2008
POWERMASTER 400SP, 500SP AUTOMATION
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 yourhead out of the fumes. Do not breathethe fumes.
2. If inside, ventilate the area and/oruse 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 formetals, consumables, coatings,
and cleaners.
5. Work in a confined space only if it is well ventilated, orwhile
wearing an air-supplied respirator. Shielding gases used for
welding can displace aircausing injury ordeath. Be sure the
breathing airis safe.
6. Do not weld in locations neardegreasing, 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 orexplosion.
Sparks and spatterfly 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 orwelding
wire to metal objects can cause sparks, overheating,
orfire.
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 coverthem 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 forfire, and keep a fire extinguishernearby.
6. Be aware that welding on a ceiling, floor, bulkhead, orpartition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks ordrums.
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 welderto thaw frozen pipes.
10. Remove stick electrode from holderorcut 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 orcutting Electrode Size FilterWelding orcutting Electrode Size Filter
Torch soldering 2 Gas metal-arc
Torch brazing 3 or4 Non-ferrous base metal All 11
Oxygen Cutting Ferrous base metal All 12
Light Under1 in., 25 mm 3 or4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or5 (TIG) All12
Heavy Over6 in., 150 mm 5 or6Atomichydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under1/8 in., 3 mm 4 or5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or6 Carbon arc air gouging
Heavy Over1/2 in., 12 mm 6 or8 Light 12
Shielded metal-arc Under5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Over1/4 in., 6.4 mm 14 Light Under300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over400 Amp 14
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.

1-3
October30, 2008
POWERMASTER 400SP, 500SP AUTOMATION
1. Wearapproved face shield orsafety goggles. Side shields
recommended.
2. Wearproperbody protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas underhigh
pressure. If damaged, a cylindercan explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support orequipment cylinderrack to
prevent falling ortipping.
3. Keep cylinders away from any welding orotherelectrical
circuits.
4. Neverallow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses,
and fittings designed forthe specific application; maintain
them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylindervalve.
7. Keep protective cap in place overvalve except when cylinder
is in use orconnected foruse.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in
Safety Standards.
!
WARNING
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and
away from any building airintakes.
WARNING
ENGINE FUEL can cause fire orexplosion.
Engine fuel is highly flammable.
1. Stop engine before checking oradding fuel.
2. Do not add fuel while smoking orif unit is nearany sparks or
open flames.
3. Allow engine to cool before fueling. If possible, check and
add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room forfuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and
hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing orconnecting unit.
3. Have only qualified people remove guards orcovers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from
moving parts.
6. Reinstall panels orguards and close doors when
servicing is finished and before starting engine.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always weara face shield when working on a battery.
2. Stop engine before disconnecting orconnecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welderto charge batteries orjump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
STEAM AND PRESSURIZED HOT COOLANT can
burn face, eyes, and skin.
The coolant in the radiatorcan be very hot and under
pressure.

1-4 October30, 2008
POWERMASTER 400SP, 500SP AUTOMATION
1. Do not remove radiatorcap when engine is hot. Allow engine
to cool.
2. Weargloves and put a rag overcap area when removing cap.
3. Allow pressure to escape before completely removing cap.
!
WARNING
This product, when used forwelding orcutting,
produces fumes orgases which contain chemicals
know to the State of California to cause birth defects
and, in some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of
Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Sec-
tion of the U.S. Congress, Office of Technology Assessment, Bio-
logical Effects of PowerFrequency Electric & Magnetic Fields -
Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Gov-
ernment Printing Office, May 1989): “...there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields and interact with,
and produce changes in, biological systems. While most of this
work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the
evidence in a single coherent framework. Even more frustrating,
it does not yet allow us to draw definite conclusions about ques-
tions of possible risk orto offerclearscience-based advice on
strategies to minimize oravoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close togetherby twisting ortaping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil ordrape cable around the body.
4. Keep welding powersource and cables as faraway from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also
normally recommended forpacemakerwearers.
Consult yourdoctorforcomplete information.
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126.
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Recommended Safe Practices forthe Preparation forWelding
and Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code forSafety in Welding and Cutting, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices forOccupation and Educational Eye and Face
Protection, ANSI Standard Z87.1, from American National
Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.