Thermal Arc POWERMASTER 500SP Manuals

Manuals and User Guides for Thermal Arc POWERMASTER 500SP. We have 4 Thermal Arc POWERMASTER 500SP manuals available for free PDF download: Service Manual, Operator's Manual

Thermal Arc POWERMASTER 500SP Service Manual (146 pages)

Brand: Thermal Arc | Category: Welding System | Size: 9 MB

Service Manual
1
Table of Contents
4
Section 1

9
Safety Instructions and Warnings

9
Section 2

19
Introduction

19
Section 3

29
Installation

29
Section

35
Section 4

41
Operation

41
- General Safety Precautions
  41
- Welding Controls
  42
- Menu Structure
  44
- Main Menu
  45
- Special Functions
  48
- Smart GMAW, Pulse GMAW & Twinpulse Programs
  49
- Welding Setting Selection Guide
  50
Section 5

53
Manual Gmaw Welding

53
Section 6

61
Basic Service

61
Section 7

65
Advanced Service

65
- Safety Precautions
  65
- Multivoltage Principle
  66
- Inverter Principle
  67
- Common Logic Functions
  68
- Gas Test
  68
- Pump Test
  68
- Reset Adjustments
  68
- Master Reset
  68
- Torque Setting(S)
  68
- Error Codes and Troubleshooting Guide
  69
- Overview of Mains Voltage Limits
  69
- Flowchart: Soft Power-Up Cycle at Switch on
  70
- Power-Up Schematic
  71
- Flowchart: Voltage Monitoring
  72
- Monitoring Bus Voltage
  73
- DP-MAPRO PC Board
  74
- MAPRO Connector Descriptions & Measuring Points
  75
- MV-MAPRO Diagram
  79
- DMR PC Board
  80
- DMR Connector Descriptions & Measuring Points
  80
- DMR Diagram
  82
- DMR Schematic
  83
- DS20BF PC Board
  84
- DS20BF Diagram
  84
- DS20BF Display Test
  84
- MVDRV / MVMDRV PC Board
  85
- MVMRV / MVMDRV Connector Descriptions & Measuring Points
  87
- MVDRV Schematic
  88
- MVMDRV Schematic
  88
- MVDRV Diagram
  89
- MVMDRV Diagram
  90
- MVPWRUP PC Board
  91
- MVPWRUP Connector Descriptions & Measuring Points
  91
- MVPWRUP Diagram
  91
- DK-GLCL PC Board
  92
- DK-GLCL PC Board Diagram
  92
- DP-UFI-BO PC Board
  93
- DP-UFI-BO PC Board Diagram
  93
- DP-EMV PC Board
  94
- DP-EMV Connector Descriptions & Measuring Points
  94
- DP-EMV PC Board Diagram
  94
- DS-VA PC Board
  95
- DS-VA Connector Descriptions & Measuring Points
  95
- DS-VA PC Board Diagram
  95
- DP-S3NEFI PC Board
  95
- Current Sensor VAC
  96
- Current Sensor VAC Connector Descriptions & Measuring Points
  96
- Current Sensor VAC Diagram
  96
- Control Transformer
  97
- Measuring Temperature
  97
- PCB Connection Diagram
  98
- Supply Voltages
  99
- Measuring Welding Current
  100
- Measuring the Flow Rate of the Cooling System
  100
- Measuring Output Voltage
  101
- Overcurrent Protection
  101
- Encoding Power Units
  102
Parts List

103
Appendix 1: Options and Accessories

127
Appendix 2: Feed Roll Information

128
- Drive Roll Kits
  128
- Ordering Information
  128
Appendix 3: Mounting the Torch Holder

129
Appendix 4: Sp-Series Block Diagram

130
Appendix 5: Powermaster 320P Power Schematic

132
Appendix 6: Powermaster 400Sp Power Schematic

134
Appendix 7: Powermaster 400Sp Compact Power Schematic

136
Appendix 8: Powermaster 500Sp Power Schematic

138
Appendix 9: Rectifier Diode Data Sheet

140
Appendix 10: Mosfet Data Sheet

141
Limited Warranty

142
- Warranty Schedule
  143
- Global Customer Service Contact Information
  145

Thermal Arc POWERMASTER 500SP Service Manual (110 pages)

Powermaster Automation

Brand: Thermal Arc | Category: Welding System | Size: 7 MB

Service Manual
1
Table of Contents
4
Safety Instructions and Warnings

7
Introduction

17
- How to Use this Manual
  17
- Equipment Identification
  17
- Receipt of Equipment
  17
- Machine Components
  18
- Power Supply Specifications (Part 1)
  19
- Power Supply Specifications (Part 2)
  20
- Wire Feeder Specifications
  21
Installation

23
Manual Operation

35
- General Safety Precautions
  35
- Welding Controls
  36
- Menu Structure
  38
- Main Menu
  39
- Special Functions
  42
- Smart GMAW, Pulse GMAW & Twinpulse Programs
  43
- Welding Setting Selection Guide
  44
Robotic Operation

47
- Robot Interface INT06
  47
- Digital Inputs and Outputs
  47
- Analog Inputs
  48
- Robot Interface Schematic
  49
- Robot Interface INT06 PC Board Schematic
  51
- 42-Pin Harting Socket
  52
- Configuration at Front Panel Menu
  56
- Robot Tool Software Installation
  57
- Decimal-Binary Conversion
  58
Manual Gmaw Welding

59
Basic Service

67
- Maintenance
  67
- System Troubleshooting Guide
  68
- Welding Process Troubleshooting Guide
  69
- Error Codes
  70
Advanced Service

71
- Safety Precautions
  71
- Inverter Principle
  72
- Common Logic Functions
  73
- Gas Test
  73
- Pump Test
  73
- Reset Adjustments
  73
- Master Reset
  73
- Torque Setting(S)
  73
- Control Transformer
  74
- DP-MAPRO PC Board
  75
- DMR PC Board
  76
- DS20BF PC Board
  76
- DK-PWRUP04 PC Board
  76
- DP-S3NEFI PB Board
  76
- DK-DCDRV / DK-S3DRV PC Board
  77
- DK-GLCL PC Board
  78
- DP-UFI-BO PC Board
  78
- DP-EMV PC Board
  78
- LSW PC Board
  78
- DS-VA PC Board
  78
- DS-ERW PC Board
  78
Section 9

79
Parts List

79
Appendix 1: Options and Accessories

93
Appendix 2: Feed Roll Information

94
Appendix 3: Mounting the Torch Holder

95
Appendix 4: Sp-Series Block Diagram

96
Appendix 5: Powermaster 400Sp Power Schematic

98
Appendix 6: Powermaster 500Sp Power Schematic

100
Appendix 7:Robotic Interface Diagram

102
Appendix 8: Rectifier Diode Data Sheet

103
Appendix 9: Hybrid Esbt Data Sheet

104
Limited Warranty

106
Warranty Schedule

107
Global Customer Service Contact Information

109

Thermal Arc POWERMASTER 500SP Operator's Manual (70 pages)

Brand: Thermal Arc | Category: Welding System | Size: 3 MB

Operator Manual
1
Table of Contents
4
Safety Instructions and Warnings

7
Introduction

17
Installation

27
Operation

39
- General Safety Precautions
  39
- Welding Controls
  40
- Menu Structure
  42
- Main Menu
  43
- Special Functions
  46
- Smart GMAW, Pulse GMAW & Twinpulse Programs
  47
- Welding Setting Selection Guide
  48
Section 5

51
Section 6

59
- Service
  
  59
- Maintenance
  59
- System Troubleshooting Guide
  60
- Welding Process Troubleshooting Guide
  61
- Error Codes
  62
Appendix 1: Optional Accessories and Consumables

63
Appendix 2: Feed Roll Information

64
Appendix 3: Mounting the Torch Holder

65
Limited Warranty

66
Warranty Schedule

67
Global Customer Service Contact Information

69

Thermal Arc POWERMASTER 500SP Service Manual (40 pages)

Brand: Thermal Arc | Category: Welding System | Size: 2 MB

Table of Contents
2
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
Identifi Cation Power Units
36
Testing Mosfets
37
Inside Diagram Diodes
38

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Welding System Inverter

Power Supply

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Thermal Arc POWERMASTER 500SP Manuals

Thermal Arc POWERMASTER 500SP Service Manual (146 pages)

Table of Contents

Section 1

Safety Instructions and Warnings

Section 2

Introduction

Section 3

Installation

Section

Section 4

Operation

Section 5

Manual Gmaw Welding

Section 6

Basic Service

Section 7

Advanced Service

Parts List

Appendix 1: Options and Accessories

Appendix 2: Feed Roll Information

Appendix 3: Mounting the Torch Holder

Appendix 4: Sp-Series Block Diagram

Appendix 5: Powermaster 320P Power Schematic

Appendix 6: Powermaster 400Sp Power Schematic

Appendix 7: Powermaster 400Sp Compact Power Schematic

Appendix 8: Powermaster 500Sp Power Schematic

Appendix 9: Rectifier Diode Data Sheet

Appendix 10: Mosfet Data Sheet

Limited Warranty

Thermal Arc POWERMASTER 500SP Service Manual (110 pages)

Table of Contents

Safety Instructions and Warnings

Introduction

Installation

Manual Operation

Robotic Operation

Manual Gmaw Welding

Basic Service

Advanced Service

Section 9

Parts List

Appendix 1: Options and Accessories

Appendix 2: Feed Roll Information

Appendix 3: Mounting the Torch Holder

Appendix 4: Sp-Series Block Diagram

Appendix 5: Powermaster 400Sp Power Schematic

Appendix 6: Powermaster 500Sp Power Schematic

Appendix 7:Robotic Interface Diagram

Appendix 8: Rectifier Diode Data Sheet

Appendix 9: Hybrid Esbt Data Sheet

Limited Warranty

Warranty Schedule

Global Customer Service Contact Information

Thermal Arc POWERMASTER 500SP Operator's Manual (70 pages)

Table of Contents

Safety Instructions and Warnings

Introduction

Installation

Operation

Section 5

Manual Gmaw Welding

Section 6

Service

Appendix 1: Optional Accessories and Consumables

Appendix 2: Feed Roll Information

Appendix 3: Mounting the Torch Holder

Limited Warranty

Warranty Schedule

Global Customer Service Contact Information

Thermal Arc POWERMASTER 500SP Service Manual (40 pages)

Table of Contents

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