Document Outline

• SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS
• 1.01 Arc Welding Hazards
• 1.02 Principal Safety Standards
• 1.03 Symbol Chart
• 1.04 Precautions De Securite En Soudage A L'arc
• 1.05 Dangers relatifs au soudage à l'arc
• 1.06 Principales Normes De Securite
• 1.07 Graphique de Symbole
• SECTION 2: INTRODUCTION
• 2.01 How To Use This Manual
• 2.02 Equipment Identification
• 2.03 Receipt Of Equipment
• 2.04 Machine Components
• 2.05 Lifting Points
• 2.06 Power Supply Specifications (part 1)
• 2.07 Power Supply Specifications (part 2)
• 2.08 Wire Feeder Specifications
• 2.09 Features and Benefits Common to all PowerMaster SP Systems #
• 2.09 Features and Benefits Common to all PowerMaster SP Systems (con't) #
• SECTION 3: INSTALLATION
• 3.01 Location
• 3.02 Transportation and Positioning
• 3.03 Fitting the Mains Cable into the Cable Gland
• 3.04 Voltage Changeover
• 3.05 Connecting 3-Phase Input Power to 400SP or 500SP
• 3.06 Connecting Single-Phase Input Power to 400SP or 500SP
• 3.07 Quick Start Set Up
• 3.08 Recommended Setup for MIG
• 3.09 Automation Weld Gun
• 3.10 Pulsemaster PMA512S-3545 500 Amp Weld Gun (when welding by hand)
• 3.11 Installing A New Wire Conduit in the Pulsemaster PMA512S-3545
• SECTION 4: MANUAL OPERATION
• 4.01 General Safety Precautions
• 4.02 Welding Controls
• 4.03 Menu Structure
• 4.04 Special functions
• 4.05 Smart GMAW, Pulse GMAW & TwinPulse Programs
• 4.06 Welding Setting Selection Guide
• SECTION 5: ROBOTIC OPERATION
• 5.01 Robot Interface INT06
• 5.02 Digital Inputs and Outputs
• 5.03 Analog Inputs
• 5.04 Robot Interface Schematic
• 5.05 Robot Interface INT06 PC Board Schematic
• 5.06 42-Pin Harting Socket
• 5.07 Configuration at Front Panel Menu
• 5.08 Robot Tool Software Installation
• 5.09 Decimal-Binary Conversion
• SECTION 6: MANUAL GMAW WELDING
• 6.01 Types of Weld Transfer Modes
• 6.02 Holding and Manipulating the Torch
• 6.03 Basics of Pulsed Arc Welding
• 6.04 Pulsed Arc Welding Parameters
• 6.05 Smart, Pulse or TwinPulse GMAW Welding
• 6.06 Conventional Manual GMAW/FCAW Welding
• 6.07 SMAW/STICK Welding
• SECTION 7: SERVICE
• 7.01 Maintenance
• 7.02 System Troubleshooting Guide
• 7.03 Welding Process Troubleshooting Guide
• 7.04 Error Codes
• 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