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Thermal Arc PowerMaster 350, 350P, 500, 500P Service Manual_(0

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2. POWERMASTER 500 500P 350 350P 6 15 Art 07548 Main Control Board Figure 6 4 Ground
3. MC2 n R1 50 OHM 50 WATT RV4 RV5 RV6 CUSTOMER INPUT CONNECTION H d HH alo Ole 208V 230V 400V 460V TB1 CHASSIS bi E1 c2 E2 IB 2 MC1 d 3 1 F6 n GND STUD 1 RV1 RV2 C1 C2 F1 20A E1 208 230V 400 460V 208 230V lt 5 E4 Q VOLTAGE CHANGEOVER 10A CB1 XFMR 115V 2 24V y DIODE d 77 1 5 9 IGBT CHASSIS 115 E GFCI Ka GND STUD contactor iv 7 Ole contactor em Ole ves nom REMOTE INTERFACE PCB AMPHENOL PCB Qno zan svac Ole crassis ano GND STUD remote 7 REMOTE IN 0 10v Ofk remore min Ch eo uto 15 Pos arc ESTABLISHED 164 contro common anisvacrerunn gt 28 e 1 e 28 2 4 8 8 8 28 2 o x 5 QOOOOOQOQOO 14 POS REMOTE INTERFACE RECEPTICLE Art 08275 March 17 2006 POWERMASTER 500 500 350 350P A
4. T4 3 L1 10 55W 047 2o E1 2 R2 C1 p A CAP PCB at crop 7 m 8 E i 047 400V 3 B1 A sol em cR4 1 4 1 5 1 ca 2 cst aS 0 84 ds 047 CURRENT SENSOR 047 400V E2 6 10 55W R Ge Q2 BOTTOM O e ra ser 22 O 23 O CONTROL BOARD e eo a sw ON INPUT HEATSINK sw2 ON OUTPUT HEATSINK 26 POS RIBBON DISPLAY sk MAIN OUTPUT CONTROL BOARD 8 POS SERIAL INTERFACE Rev Revisions By Dae No m RELEASE EO 1002s ms 053106 THERMAL RC EE E Eco ssss RWH 02 06 07 A TNERMADYNE WEST LEBANON NH 09784 eco GAC 10 31 07 Supersedes TON Proprietary to THERMAL ARC CORPORATION Not For Release Reproduction or Distribution without Written Consent Tuesday March 28 2006 NOTE UNLESS OTHERWISE SPECIFIED D 2007 E OHMS X CAPACITOR VALUES ARE me be Sheet TME SCHEMATIC pus Last Modifie
5. Ch contactor MC2 mi R1 50 OHM 50 WATT RV4 RV5 RV6 CUSTOMER INPUT CONNECTION d rh CR1 2 208V 230V 400V 460V TB1 d H EE E1 2 E3 AA MC1 d d e F 5 u m GND STUD RVI C1 2 1 20 208 230V El 400 460V lt Q gt 208 230V lt Ed VOLTAGE CHANGEOVER d Ti 10A CB1 y XFMR 400V 4 X3 115V 230V 3 lo 24V en g DIODE 200V 2 X1 COM 77 1 CHASSIS y IGBT 115 VAC 20 GFCI a 8 12 GND STUD Art A 08278 Ob contactor vee own REMOTE INTERFACE PCB AMPHENOL PCB aanisvac chassis Ok remote max Ob remore m neuore CH contor common Ch common zurt svac RETURN 2 4 8 m Is 478 5 SZ 5 Ob raum EB Eg 8 5 9 8 8 o 8 5 9 sa52555 88 8 8 8 22 o n uu p or 000000000 14 POS REMOTE INTERFACE RECEPTICLE GND STUD E 210 16 Pos RIBBON March 17 2006 POWERMASTER 50
6. 3 1 3 02 Voltage Ile TE 3 1 3 03 Connecting Welding Machine to Line Voltage 3 2 3 04 Connection INSIRBELONE zn ae 3 2 303 ee ee 3 3 300 Welding Less en ei 3 4 3 07 Configuration Settings are 3 5 SECTION 4 OPERATION ect 4 1 401 General Safety Precautions euer 4 1 402 Power Master 500 and 350 Controls sss 4 2 403 Power Master 500P and Controls 4 4 404 Rear Panel ee 4 6 405 Gas Tungsten Are Welding nen nn 4 8 4 06 SMAW Shielded Metal Arc Welding 4 8 AO CAG Carbon Arc GOUGING na a 4 9 408 GMAW Gas Metal Arc Welding 4 9 4 09 Pulsed GMAW Power Master 500P 350P Only 4 10 TABLE OF CONTENTS SECTION 5 LU lisse tee 5 1 SECTION 6 TROUBLESHOOTING u cc a 6 1 REN 6 1 6 02 Basic Troubleshooting sse 6 1 6 03 Troubleshooting Guide 62 6 04 Power Master 500 and 350 Block Diagram 6 6 6 05 Power Master 500P and 350P Block Diagram 6 8 6 06 Control Board Connector Signals For 830894 Main Control Board
7. CUSTOMER L2 INPUT Q LINES L3 FRAME GROUND Art A 04100 Figure 3 5 Input Terminal Block A WARNING Never connect the safety ground screw to one ofthe three line phases This would represent a serious electrical shock hazard The wiring to this machine should be performed by a qualified person only Line Rated Line Approx Line Fuse Copper Gounding Volts Amps Size Amps Copper Line Wire Size Conductor Min Size 88 82 8 50 43 39 460 39 60 No6 t6mm 400 4 60 No 10 6 mm 60 10 6 mm No 6 16 mm No 6 16 mm 230 8 100 No6 t6mm 6 16 5 No 6 16 mm No 10 6 mm No 10 6 mm Table 3 1 Recommended Wire and Fuse Size Table Conductor size shall be modified as required for line voltage and ambient temperature Sizes listed are based on 90 conductor insulation designated as FEP FEPB RHH and THHN 32 March 17 2006 3 05 Grounding The frame of this welding machine should be grounded for personnel safety and to assure operation of the overcurrent protection The grounding method and the equipment grounding conductor size and type shall conform to local and national codes For the National Electrical Code the equipment grounding conductor shall be green green with a yellow stripe or bare If flexible power cable is used use a cable assembly which
8. 6 10 uunc qe I e 6 13 6 08 Semiconductor Replacement Requirements 6 14 5 09 Control Board u 6 15 6 10 TESTS T 6 16 ana en 6 24 SECTION 7 REPAIR PROCEDURES eege ee eege 7 1 7 01 Output Diode Replacement 7 1 7 02 IGBT Module Replacement 7 2 SECTION 8 ee 8 1 TORIC AMOI suco een eeh AE 8 1 02 8 1 8 03 Exleitt l Panels Ee 8 2 9 04 Falls an a aa ane oies 8 4 8 05 Front Panel Parts Power Master 500 and 350 8 5 8 06 Front Panel Parts Power Master 500P and 350P 8 6 9 07 PG BOAT POS nn denses 8 8 8 08 Rear Panel Parts Power Master 500 and 350 8 9 8 09 Rear Panel Parts Power Master 500P and 350P 8 10 840 Center Chassis Parts nnne nnns 8 12 TABLE OF CONTENTS APPENDIX 1 GENERAL INFORMATION ii 1 APPENDIX 2 PM 500 350 SCHEMATIC DIAGRAM 2 APPENDIX 3 PM500 350 CONNECTION DIAGRAM 2 OF 2 A 4 APPENDIX 4 PM 500P SCHEMATIC
9. 4 2 GND 21 VAC L1 to L3 42 VAC L1 21VAC Art A 07550 DALL PRECAUTIONS L4 R21 REQUIRED R230 R229 R231 ou 923 062 RC C125 R22 Ua 15 16 17 1 076 4 R249 073 075 4 C123 RD a o5 mt OI e L1 gt 2 N 00000 5 L3 21VAC Figure 6 6 AC Power Check March 17 2006 6 17 POWERMASTER 500 500 350 350P 2 Reference Circuit Set front panel to LOCAL Remote off control and mode to GMAW Measure 10V Ref as main A V control pot on front panel is varied min to max 2 1 to TP4 2 2 27 to 10 0 VDCVolts display on front panel reads 10 to 44 Volts B For GTAW SMAW modes TP2 1 to TP4 2 0 1 to 10 0 VDC Amps display on front panel reads 4 to 560 Amps C For PULSE GMAW mode TP2 1 to 4 2 0 1 to 10 0 VDC Volts Display on front panel reads 4 to 440 Ref In UUUUUUL 6 D4 21 ces 056 86 057 C91 R236 R238 R240 069 C12 RU2 Q19 RU4 RUS R258 R261 R263 R284 9 pin input 14 pin input Ref Min Remote Max U ST uuuuu UU UU Q13 BI 022 R28 c148 Bes R289 d p If TP2 1 reads OK but front panel display is wrong then the problem is with the front panel board or ribbon cable inter connect If TP2 1 is not OK then make the following checks See Figure 6 7 be
10. Original Main Power Rectifiers Control P C Boards 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors Engines and associated components are NOT warranted by Thermal Arc although most are warranted by the engine manufacturer GMAW FCAW MIG WELDING EQUIPMENT WARRANTY PERIOD Fabricator 131 181 140 180 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P 320SP 400SP 5005 Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor 5 years 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year GTAW TIG amp MULTI PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150 Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards power
11. VOLT AMP CURVE FOR CC GTAW MODE 0 100 200 300 400 500 600 Amps VOLT AMP CURVE FOR CV GMAW MODE 70 eo 50 40 Volts 30 20 0 0 100 200 300 400 500 600 700 Amps Art A 04120 Figure 2 1 Power Master 500 Power Source Volt Amp Characteristics 2 3 POWERMASTER 500 500P 350 350P 2 06 Power Master 500 Specifications Input Data 208 VAC 3 Phase 68 Amps 450A 38V 100 Duty Cycle 230 VAC 3 Phase 62 Amps 450A 38V 100 Duty Cycle 380 VAC 3 Phase 40 Amps 450W38V 100 Duty Cycle 400 VAC 3 Phase 35 Amps 450A 38V 100 Duty Cycle 460 VAC 3 Phase 450A 38V 100 Duty Cycle i 500A 40 0V 60 Duty Cycle 500A 40 0V 60 Duty Cycle 480A 39 2V 60 Duty Cycle 480A 39 2V 60 Duty Cycle 500A 40 0V 60 Duty Cycle Line Frequency 50 60 HZ Output Current Range 5 560 Amps Output Voltage Range 10 44 Volts Maximum Output Current 600 Amps Maximum Open Circuit Voltage OCV 70 Volts 57 Volts for CCC Operating Temperature Range 0 40C Input Line Variations 10 Line Regulation 1 Load Regulation 1 Water Protection Class 1235 RE ur ok D E T o 26 8 in 68 0 c
12. G De energize the output by removing the gun switch signal H Setthe machine to GMAW mode Presetthe output to 24 0 Volts J Energize the output using the gun switch input The contactor switch on the front panel can not be used or the voltage readings will be off K Verify the voltage reading on the front panel display is 24 0 0 2 volts L Adjust the output voltage control on the front panel of the Power Master until the voltage display reads exactly 24 0 volts M Verify the output terminal volts directly on the copper bus bar of the output terminal using the external digital meter reading average volts Voltage should be 24 0 0 5 Volts N If the voltage is out of calibration it can be adjusted with R68 on the main control board 6 24 March 17 2006 SECTION 7 REPAIR PROCEDURES 1 01 Output Diode Replacement The following procedure should be used for replacing a failed output diode module Step 1 Remove the two nuts securing the transformer bus bars to the diode bus bars Step 2 Loosen the bolts on the other end of the two trans former bus bars These bolts do not need to be removed Pivot the two transformer bus bars to the side out of the Step 3 Remove the six bolts holding the diode bus bars to the diodes Letthe bus bars hang free on the snubber wires It is not necessary to remove the wires Step 4 Identify the failed diode module s POWERMASTER 500 500P 350 350P Step 5
13. J1 23 0 to 10V Reference output J1 24 0 to 13 5V Pulse or CAG control input J1 25 Common Signal common J1 26 0 to 10V Reference input to main board J2 4 pin connector to current sensor J2 1 15V Power supply to current sensor J2 2 15V Power supply to current sensor J2 3 0 to 5V Output current 4 500 Amps J2 4 Common Signal common for current sensor J3 2 pin connector for output voltage feedback J3 1 0 to Positive output terminal voltage J3 2 0 to 60V Negative output terminal voltage March 17 2006 POWERMASTER 500 500 350 350P Connector Voltage Description 4 12 position connector header for optional wire stick detect circuit 34 3 to 34 10 5 5 position to primary current transformer 35 1 Current transformer secondary 35 2 Current transformer secondary 5 3 _ 5 4 O O 6 1 ee 7 8 position to IGBT gate drive 7 1 to J7 5 7 4 to J7 8 8 1 to 8 5 8 4toJ8 8 10 0 14 Gate drive signal 4 March 17 2006 POWERMASTER 500 500 350 350P 6 06 Control Board Connector Signals For 830894 Main Control Board con t Connector jVoltage 10 16 position ribbon to amphenol board 10 1 10 2 10 8 urrent feedback 100 Amps Volt 10 9 ontrol circuit common 10 10 emote control input from 14 pin 10 11 oltage feedback for 14 pin remote 10V Volt 10 12 to J10 16 NC 11 4 position voltage to board 11 1 21VAC upply voltage 1
14. Description PCB Control PM IPS Cable Ribbon 26 P 13 PM IPS Cable Ribbon 16P 20 PM IPS Contactor 30A 2 Pole PM IPS Resistor 50 Ohm 50w QC PM IPS Resistor 10 Ohm 55W PM IPS Transformer Control PM IPS Rivet 4mmx6 4 BLIND STEEL Screw PHCR M4 7x30mm STZP Rivet 4mmx6 4 BLIND STEEL Nut Hex 7 STZP Rivet 4mmx6 4 BLIND STEEL Screw Hex HD M5 1 4x13 STZC Nut Hex M4x 7 STZP Washer 4 4mm Int Lock Art A 06934 Part Number 830894 204038 002 204038 012 406240 002 830394 830345 830336 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 March 17 2006 POWERMASTER 500 500P 350 350P 8 08 Rear Panel Parts Power Master 500 and 350 Nem Qty Description Part Number 1 1 PCB Amphenol PM IPS 830427 2 1 Fuse Holder PM IPS 402151 3 1 Fuse 20A 600V Bussman 405093 002 4 1 Receptacle 120V 10A PM IPS 402670 5 4 Screw PHCR M4 7x16mm STZP See Note 1 6 4 Nut Hex M4x 7 STZP See Note 1 7 8 Screw PHCR 6x3 8 self tap See Note 1 8 2 Washer 3 5mm Int Lock See Note 1 Note 1 This part is available at most hardware stores Art A 06935 March 17 2006 8 9 POWERMASTER 500 500P 350 350P 8 09 Rear Panel Parts Power Master 500P and 350P Nem Description Part Number 1 1 PCB Amphenol PM IPS 830427 2 1 Cap Can Port PM IPS 830961 3 1 Fuse Holder PM IPS 402151 4 1 Fuse 20A 600V Bussman KTK 405093 002 5 1 Harness C
15. POWERMASTER 500 500P 350 350P 3 07 Configuration Settings A Lift Arc GTAW The power source is configured from the factory with the Lift Arc starting circuit active for GTAW This feature should be disabled if an external high voltage arc starter is being used to start the arc To disable the lift arc feature proceed as follows 1 Turn off the power to the power source at the main disconnect 2 Remove the top panel to gain access to the main control board see Figure 3 7 3 To disable Lift Arc place jumper plugs JP1 and JP2 in the OFF position pins 2 to 3 shorted 4 To re enable Lift Arc place jumper plugs JP1 and JP2 back in the ON position 1 to 2 shorted 5 Replace the top panel JUMPERS SHOWN IN THE ON POSITION Art A 04090 Figure 3 7 Main Control Board March 17 2006 3 5 POWERMASTER 500 500P 350 350P B Wire Sharpening for GMAW Power Master 500P and 350P Only The power source is configured from the factory with the Wire Sharpening circuit active for GMAW This feature improves arc starting by reducing the size of the ball on the wire the end of the weld To disable this feature proceed as follows 1 3 6 Turn off the power to the power source at the main disconnect 2 Remove the top and side panels to gain access to the display board see Figure 3 8 3 Remove the knobs and hardware from the front panel to allow removal of the display board 4 5 6 To disable Wire Sharpening
16. Roll 1 8 x 2 PM IPS Overlay Front Controls PM500 Overlay Front Controls PM350 Overlay Front Controls PM500P Washer Insulation Flat PM IPS Part Number 12CW2170 204036 830963 831132 831131PKD 831130PKD 831118CLAPKD 831111BLKPKD 831122BLKPKD See Note 1 831125PKD 831073PKD 831138PKD 831098PKD 5CW976A March 17 2006 POWERMASTER 500 500 350 350P N o lt 8 3 March 17 2006 POWERMASTER 500 500P 350 350P 8 04 Base Parts Rem 1 1 2 1 9 1 4 3 5 d 6 3 1 8 20 9 14 10 13 11 13 12 4 13 4 14 5 15 2 16 2 17 2 18 4 19 2 20 6 21 3 Note 1 This part is available at most hardware stores 84 Description Board Volt Selection PM IPS Bracket Input Line PM IPS Reactor Assy 560A PM IPS Connector 2 0 14Block PM IPS Insulation Input Line PM IPS Strap 220 440 Volts PM IPS Transformer Control PM IPS Washer 6 4mm Flat Nut Hex 1 4 20 Keps Nut Hex M6 1 STZP Washer 6 4mm Int Lock Washer 6 4mm IDx19mm OD Flat Washer 6 4mm Ext Lock Screw Hex M6 1 0x30 STZP Washer 5 4mm Ext Lock Terminal QC 1 4 Screw PHCR 10 24x1 2 Screw Hex HD M8 1 25x12 STZC Washer 8 4mm Ext Lock Screw Hex HD 1 4 20x1 0 Screw Hex HD M6 1 0x20 STZP Part Number 830941 830966 830942 830968 830967 CW811 830928 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note
17. includes the equipment grounding conductor If metallic armored cable or conduit is used the metal sheathing or conduit must be effectively grounded per local and national codes POWERMASTER 500 500P 350 350P Rubber tire mounted equipment shall be grounded to conform to local and national codes The grounding assists in providing protection against line voltage electrical shock and static shock The grounding serves to discharge the static electric charge which tends to build up on rubber tire mounted equipment This static charge can cause painful shock and lead to the erroneous conclusion that an electrical fault exists in the equipment If a system ground is not available consult the electrical code enforcement body for instructions The welding machine should be connected to an adequate driven ground rod or to a water pipe that enters the ground not more than 10 feet 3 meters from the machine The equipment grounding conductor size is listed in Table 3 1 as a guide if no local or national code is applicable Attach the equipment grounding conductor to the stud provided on the yoke panel Determine that the ground wire size is adequate before the machine is operated VOLTAGE CHANGEOVER BOARD Art A A 06974 Figure 3 6 Ground Stud Location March 17 2006 3 3 POWERMASTER 500 500 350 350P 3 06 Welding Leads Refer to Table 3 2 as a basic guideline to the required copper cable s
18. polarity wire feeding problem liner feed rolls tip guides etc Torch to work distance incorrect travel speed torch angle etc March 17 2006 POWERMASTER 500 500P 350 350P 6 02 Basic Troubleshooting There are two general types of problems or failures which can occur with the Power Master The first would relate to afailure within the power circuit and the second would be a control type problem Power Circuit failure Typical symptoms Blown line fuses e No output e Visual damage to power components Diagnostics e Check input rectifier Check IGBT modules Check output diodes Check capacitor boards Check input contactors for damaged contacts Control circuit failure Typical symptoms e Lack of output control e mproper operation e Erratic welding rule out external causes first Diagnostics Refer to block diagram control board signal information and specific control tests to pinpoint trouble A WARNING Disconnect the power source from the input power source before carrying out any service or repair work Hazardous voltages can be present in the machine whenever input power is connected A WARNING ALL SERVICE SHOULD BE PERFORMED BY TRAINED PERSONNEL ONLY 6 1 POWERMASTER 500 500 350 350P 6 03 Troubleshooting Guide This guide should be used as an aid to determine the cause of a system malfunction or failure It should be remembered that in most welding situations there can b
19. 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 Art A 06928 March 17 2006 POWERMASTER 500 500 350 350P 8 05 Front Panel Parts Power Master 500 and 350 Nem 1 1 2 2 3 2 4 2 5 2 6 2 7 1 8 2 9 1 10 2 11 2 12 1 12 1 13 4 March 17 2006 Description PCB Non PulseDisplay PM IPS Capacitor 47nF 630V PM IPS Bushing Insulator PM IPS Bus Stud Cable PM IPS Nut Hex 1 2 13 Screw Hex HD 1 2 13x1 75 Circuit Breaker 10A 2 Pole Knob Control 1 4 IDx1 6 Knob Control 1 4 IDx 57 Cover Terminal Pin Roll 1 8 x 2 PM IPS Overlay Front Controls PM500 Overlay Front Controls PM350 Washer Insulation Flat PM IPS Part Number 830906 707158PKD 357654 707665 400614 001 351505 830362 870696PKD 870734 357655 831125PKD 831073PKD 831138PKD 5CW976A ies 8 5 POWERMASTER 500 500P 350 350P 8 06 Front Panel Parts Power Master 500P and 350P Hem Qiy 1 1 2 10 3 1 4 4 5 2 6 2 7 2 8 2 9 4 10 2 11 4 12 2 13 2 14 2 15 2 16 2 17 2 18 2 19 1 2 1 21 3 22 1 23 2 24 1 25 1 3 2 3l 1 32 3 33 3 35 1 36 1 3 11 38 11 39 Note 1 Description Overlay Weld Schedule PM500P Spacer 141Dx 5 Nylon PM IPS PCB Pulse PM500P IPS Circuit Breaker 10A 2 Pole Bushing Insulator PM IPS Cover Terminal Pin Roll 1 8 x 2 PM IPS Bus Stud Cable PM IPS Washer Insulation Flat PM IPS Washer 13
20. 2 Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein 2 Nefaites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue 3 Sic est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage 4 Nefaites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples a 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage
21. 2 14 01 FULL CHECKED JPPROVED RECORDS DO NOT SCALE DRAWING apy 8 2 14 01 CONFDENTAL This drowing Including d Information sr SHEET 2 contained thereon the excksise and confidential property of 2 Thermal Arc Corporation of Troy Ohio 45373 This drawing D not to be copled reproduced or disclosed to others THERMADYNE Company 830925 In whole or In port except with express witten permission TROY USA 6 T 5 T 4 3 T 2 1 Art 06946 March 17 2006 A 9 LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada November 2007 LIMITED WARRANTY Thermal Arc Inc A Thermadyne Company Thermal Arc warrants to customers of authorized distributors Purchaser that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the warranty period stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or damage correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be def
22. 4 06 SMAW Shielded Metal Arc Welding Connect the welding leads to the output terminals of the power source Normally the work lead should connect to the negative lead and the electrode holder to the positive terminal DCEP or reverse polarity Ifaremote control is being used connect to the 14 19 pin remote receptacle on the rear of the power Source Turnthe control power switch ON located on the front panel of the power source The digital display on the power source should be activated Setthe front panel mode switch to SMAW Presetthe weld amperage using the front panel amps volts control by placing the meter amps volts switch in the amps position and the local remote switch in the local position Ifaremote control is being used place the local remote switch in the remote position The remote control will have full control of the output of the power source from minimum to maximum Set the arc force control to the desired setting Fully counter clockwise is off full clockwise is maximum Higher arc force settings will give the arc more dig or drive by increasing the short circuit current available Energize the output of the power source with either the front panel output contactor ON OFF switch or by the switch on the remote control if one is being used Open circuit voltage will now be present on the output terminals of the power source The power source is now ready to w
23. Capacitor BD Top IGBT Input Rectifier C2E1 E2 C1 Bottom IGBT B C2E1 C E2 D C1 Capacitor BD Art A 04091 A Figure 6 1 Input Rectifier IGBT Modules 7 Howto check the IGBT modules A Refer to Figure 6 1 and or Appendix 3 Connection Diagram Using diode checker on digital VOM make the following checks all should read in the range of 0 3 to 0 6 volts 1 Top IGBT Positive meter lead on terminal C2E1 negative meter lead on terminal C1 2 Top IGBT Positive meter lead on terminal E2 H negative meter lead on terminal C2E1 3 Bottom IGBT Positive meter lead on terminal C2E1 negative meter lead on terminal C1 4 Bottom IGBT Positive meter lead on terminal E2 negative meter lead on terminal C2E1 March 17 2006 Disconnect the weld cables from output terminals With diode checker setting on DVM measure across output terminals with positive meter lead on negative output terminal Diode checker should indicate 0 2 to 0 6 volts If diode checker indicates short then one or more of the output diodes is shorted Disconnect the weld cables from output terminals 9 How to check output open circuit voltage A Place front panel mode switch in SMAW Setto LOCAL mode and turn OUTPUT CONTACTOR switch ON Measure output terminal voltage should read approximately 55 to 70 VDC 10 Erratic arc Check for loose or incorrect polarity connection to electrode and work
24. Coupage l arc Plasma PAC SMAW D 882414 po HABA mm 300 9 nis de T po 64 mm de 300 4 400 ampors pus de 400 ampers 1 6 March 17 2006 Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur ad duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie M 5l Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes matieres inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertur
25. DIAGRAM A 6 APPENDIX 5 PM500P 350P CONNECTION DIAGRAM 20F2 8 LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Inside Rear Cover POWERMASTER 500 500P 350 350P SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 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 249 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 safe
26. Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jin Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 5 Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters IHERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE St Louis MO 63017 Telephone 636 728 3000 FAX 636 728 3010 Email sales thermalarc com www thermalarc com
27. T 5 T Kee 9 A D f gn 1 1 Ree 0000 T 09 R16 c9 e e md 9 5 S Tig DISP LE Un n T2 J2 C10 C12 R28 R30 R32 R33 GC GGG S OPAniitataorota 0Rsne 017 C20 52 D18 01388 ABbAS C26 fl fl 1 1 4 e 1 23 196 ve m cos T R29 C14 C18R34 R4 R49 R50 RSI R53 54 cm od mn R99 R62 R63 C28 C29 R67 870 R7202 EA E E nee as 634895 5 1 d 1 1 1 A S ses mo 05 06 dr 09 oi 012 0 0 GER UI GE T T GAIN DISRBLE Y T 1 ls Te s ll i Mus Mie C27 R64 RES R66 R69 R71 m de hEr onguan o m ow dm des u R1 1 C37 C39 c40 C41 coc 9 25889020 Son 228 1 m g 1 1 1 1 H Y OFF ON T m sysya JP3 T Trizg T 538 TTT UIT KKK TITI WIRE SHARP 5 NOI 5 Sno UU 029 102 958858 Ue 859849299 R118 ER SS reg 2 o oip 9126 Jt 130 C53 C54 R133 CSS 638 OgEkEkCI U C48 C51 SES LI us Ds D 1249 166 o 00110 N A F
28. The capacitor banks should have the follow voltage readings when power is applied to the unit by switching the front panel CONTROL POWER switch ON NOTE The voltage must be checked with the OUTPUT CONTACTOR control OFF C1 4 to C2E1 top IGBT 140 to 180 VDC C2E1 to E2 top IGBT 140 to 180 VDC C1 4 to C2E1 bottom IGBT 140 to 180 VDC 2 1 to E2 bottom IGBT 140 to 180 VDC All readings should be within 15 VDC of each other A DANGER Use extreme caution when making measurements internal to the machine Primary voltage is present inside the machine even with the CONTROL POWER switch in the OFF position Do not touch exposed metal or wiring connections if the main wall disconnect is activated After power has been removed allow 2 minutes for the voltage to decay on the capacitor banks 6 14 6 08 Semiconductor Replacement Requirements The following guidelines must be followed when replacing one of the power semiconductors This includes the input rectifier module output diode or IGBT module 1 Remove the failed component and thoroughly clean the heat sink area where the part mounts 2 Apply a thin layer of heat sink thermal compound to the semiconductor module 3 Tighten and torque the mounting screws and terminals per the chart below NOTE It is important to follow the torque requirements to avoid possible damage to the component Component Torque Output Diode Center mounting
29. This receptacle allows the power source to interface with wire feeders and remote controls such as a foot pedal This receptacle provides auxiliary power contactor control for energizing the output of the power source and remote output control The pinout is as follows A Contactor circuit 15 Volts Contactor circuit in closure between pin A and pin B will energize output Scaled output voltage signal Vfb 10 Arc Volts Volt D 24 auxiliary power high side E 115 auxiliary power high side 24 115 VAC neutral G Chassis ground H Remote control maximum top side of remote pot J Remote control in wiper of remote pot O to 10 Volts CV Mode 0 to 10 Volts gives 0 44 Volts of output CC Mode 0 to 10 Volts gives 0 560 Amps of output K Remote control minimum bottom side of remote pot L Control circuit common M Arc Established 12 Volts N Control circuit common P 24 VAC auxiliary power high side same as pin D R 24 115 VAC neutral same as pin E S NC NC March 17 2006 0 Scaled output current signal 100 Amps Volt V NC If a remote control is plugged into both the 14 pin and 19 pin receptacles the device plugged into the 19 pin receptacle will have control over the output current or voltage Either device can control the output contactor circuit Duplex Receptacle This receptacle can provide up to 10 amps of 120 VAC auxiliary power for
30. accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces mouvement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives 1 Porteztoujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur A N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez polarit correcte et de l accumulateur P AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression 1 N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant d te
31. des bouchons d oreille approuv s lorsque le niveau de bruit est lev 6 Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Op ration de coupage DIMENSION d Nuance de Op ration de coupage Dimensione electrode ou Nuance de Epiasseur de m tal ou Epiasseur m talou soudage filtre oculaire soudage filtre oculaire Intensit de courant Intensit de courant Brassage tendre Soudage l arc sous gaz toutes conditions au chalumeau 2 avec fil plein GMAW Brassage fort toutes conditions 4 m taux non ferreux toutes conditions 5 chalumeau Oycoupage metaux ferreux toutes conditions toutes conditions Soudage sous gaz avec mince moins de 1 po 25 mm lu lectrode de tungst ne GTAW toutes conditions E Soudage l hydrog ne moyen de 1 46 po 25 amp 150 mm 40u5 toutes toutes conditions EEES atomique AHW toutes conditions Souda e 4 l arc avec Soudage aux gaz Soudage m toutes toutes dimensions lectrode de carbone EE Soudage avec lectrode enrobees moins de 5 32 po 4 mm
32. high 2 WARNING m 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 lfinside 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 7T 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 Torch soldering Oxygen Cutting Over 1 2 in 12 mm 64 mm goggles or helmet from AWS A6 2 73 Torch brazing 13041 Nomterous mase melf 1 Gaswelding Carbo
33. internal capacitors to discharge 6 2 1 Unit is completely inoperative digital display is off fans are off no output A Check for blown input fuse or fuses Check to make sure that voltage setting on changeover board is correct 1 Check all of the LINKS to make sure they are set right 2 Check fuse on the rear panel C Check wiring to the input terminal block and ground screw D Is front panel CONTROL POWER switch circuit breaker ON E With CONTROL POWER switch ON and power applied to the machine check for 115 VAC power on the rear duplex F Check the following internal to the machine 1 All connections to the control boards 2 Wiring to the small control transformer mounted underneath the control board G Possible defective circuit breaker switch on front panel H Possible defective main control board L Possible defective display board 2 Machine blows input fuse as soon as power is applied Check wiring to input terminal block and ground screw Check to make sure that voltage setting on changeover board is correct 1 Check the LINKS to make sure they are set right 2 Check fuse on the rear panel C Check internal wiring to terminal block input rectifier IGBTs contactors and changeover board D Possible defective input rectifier module and or suppressors See how to check the input rectifier module below Possible defective IGBT modules See how to check I
34. operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows A WARNING A WARNING gives information regarding possible personal injury A CAUTION A CAUTION refers to possible equipment damage NOTE A NOTE offers helpful information concerning certain operating procedures Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual Include the Owner s Manual number and equipment identification numbers Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link http www thermalarc com March 17 2006 POWERMASTER 500 500P 350 350P 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the rear panel In some cases the nameplate may be attached to the control panel Equipment which does not have a name plate such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container Re
35. screw 15 in Ibs Outer mounting screws 35 in Ibs Terminal screws 35 in Ibs Input Rectifier Mounting Screws 27 in Ibs Terminal Screws 27 in Ibs IGBT Module Mounting Screws 35 in Ibs Terminal Screws 27 in Ibs Table 6 2 Semiconductor Torque Requirements March 17 2006
36. switch semi conductors 3 years 3 years Welding Console Weld Controller Weld Timer 3 years 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year SMAW Stick WELDING EQUIPMENT Dragster 85 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1608 300S 4008 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors GENERAL ARC EQUIPMENT LABOR Water Recirculators 1 year Plasma Welding Torches 180 days 180 days Gas Regulators Supplied with power sources 180 days Nil MIG and TIG Torches Supplied with power sources Nil Replacement repair parts Nil MIG TIG and Plasma welding torch consumable items i Nil 1 year IHERMAL GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe
37. 0 350P 2 09 Power Master 500P Specifications Input Data 208 VAC 3 Phase 68 Amps 450W38V 100 Duty Cycle 230 VAC 3 Phase 62 Amps 450A 38V 100 Duty Cycle 380 VAC 3 Phase 40 Amps 4504 38V 100 Duty Cycle 400 VAC 3 Phase 35 Amps 450A 38V 100 Duty Cycle 460 VAC 3 Phase 450W38V 100 Duty Cycle 500A 40 0V 60 Duty Cycle 500 40 0V 60 Duty Cycle 480W39 2V 60 Duty Cycle 480A 39 2V 60 Duty Cycle 500A 40 0V 60 Duty Cycle Line Frequency 50 60 HZ Output Current Range 5 560 Amps Output Voltage Range 10 44 Volts Maximum Output Current 600 Amps Maximum Open Circuit Voltage OCV 70 Volts 57 Volts for Operating Temperature Range 0 40C Input Line Variations 10 Line Regulation 1 Load Regulation 190 Water Protection Class 235 23 0 in 58 4 le 22 0 55 9 1 26 8 in 68 0 cm 6 8 in DE 172 7 FEDT MEN P P 25 5 in Art 06854 14 9 378 5 Figure 2 5 Power Master 500 Dimensions Net Weight 154 105 70 kg March 17 2006 2 7 POWERMASTER 500 500 350 350P 2 10 Power Master 350P Specifications Input Data enen wa em Pr 300A 32V 100 Duty Cycle 300A 32V 100 Duty Cycle 300A 32V 100 Duty Cycle 300A 32V 100 Duty Cycl
38. 0 350P 2 08 General Power Master 500 amp 350P The Power Master 500 Pulse and 350 Pulse are primary inverter DC power sources that can be used for constant voltage and constant current weld processes The Power Master 500 Pulse output is rated at 450 Amps 38 Volts at 100 duty cycle and 560 Amps 42 4 Volts at 60 duty cycle The Power Master 350 Pulse output is rated at 300 Amps 32 Volts at 100 duty cycle and 350 Amps 34 Volts at 60 duty cycle Both power source also provide 24VAC and 120VAC auxiliary outputs rated at 10 Amps Controls are built into the power source for Gas Tungsten arc welding GTAW Shielded Metal arc welding SMAW Gas Metal arc welding GMAW and Pulsed Gas Metal Arc Welding P GMAW An Arc Force Inductance control is also provided to allow adjustment of the arc characteristics for SMAW and GMAW welding processes The graphs in Figure 2 4 show the output volt amp characteristics of the power source for the SMAW GTAW and GMAW modes of operation 2 6 VOLT AMP CURVE FOR CC SMAW MODE Volts MAX ARC FORCE 0 0 100 200 300 400 500 600 700 Amps VOLT AMP CURVE FOR CC GTAW MODE 0 100 200 300 400 500 600 Amps VOLT AMP CURVE FOR CV GMAW MODE Volts Amps Art A 04120 Figure 2 4 Power Master 500P Power Source Volt Amp Characteristics March 17 2006 POWERMASTER 500 500P 35
39. 0 500P 350 350P A CAP PCB i T4 1 L1 B1 B b 10 55W 047 1 2 R2 C1 win J A CAP PCB O Aer AB a 8 T8 OT 8 j Y Y Les RES CAP PCB 047 400V ee 3 E Bt m cre cra El 4 E Hf d 5 C4 A c2 CS1 ST il 9 047 CURRENT SENSOR 047 400V E24 6 10 55W 05 CONTROL BOARD wi ON INPUT HEATSINK sw2 ON OUTPUT HEATSINK 26 POS RIBBON DISPLAY BOARD Rev visions AA INITIAL RELEASE IHERMAL mS References AB 100035 RWH 5 20 05 A THERMADYNE Company AC GAC 11142007 Scale Supersedes Information Proprietary THERMAL ARG CORPORATION Not For Release Reproduction or Distribution without Written Consent Tuesday March 28 2006 NOTE UNLESS OTHERWISE SPECIFIED prec Pan 4 2007 E CAPACITOR VALUES ARE EXPRESSED IN MCROFAMDS uh Pe er pes To 1 Art A 08278 TE SCHEMATIC sza wars Lauter Wednes
40. 1 2 21VAC upply voltage 11 3 Common ircuit common for supply voltages 12 5 position option connector 12 1 upply voltage 12 2 upply voltage 25 6 12 March 17 2006 6 07 PowerCircuit Tests A DANGER HIGH VOLTAGE is present internally even with the control power switch in the OFF position Before inspecting cleaning or servicing disconnect and lock out the input power to the power source The following test must be performed with power disconnected from the machine These tests require a DVM with a diode checker NOTE Normally a good diode will check in the range of 0 2 to 0 9 Volts in the forward direction depending on the particular diode Input Rectifier Test see Figure 6 3 and connection diagram Terminal 4 4 to terminal 1 Open Terminal 4 4 to terminal 2 Open Open Terminal 4 4 to terminal 3 0 2 0 9 to terminal 1 4 0 2 0 9 0 2 0 9 Terminal 4 to terminal 3 Terminal 4 Terminal 4 to terminal 2 0 2 0 9 0 2 0 9 0 2 0 8 Open Terminal 5 to terminal 1 Terminal 5 to terminal 2 Terminal 5 to terminal 3 Terminal 5 Open to terminal 1 Terminal 5 to terminal 2 Open Terminal 5 to terminal 3 Art A 07546 Figure 6 2 Input Rectifier March 17 2006 POWERMASTER 500 500P 350 350P IGBT Test See Figu
41. 2 C133 K2 YTTI Tenio T 233 Um 1 nani EE J R228 112 U 15U AAT Ross em C125 R242 21 95 916 Q18 TITI mash d T D73 led i R227 076 U 068 A236 8238 240 069 C129 C131 071 gt 20 i A D73 075 R252 C12 8254 078 a RU2 DCH RUS RUS si 5a 1 1 1 1 8258 R261 8263 R264 R266 R294 A o HGS e R243 1 1 u32 09 7 gt J m OH 8245 R246 R248 C124 074 126 8253 R255 R256 TS T TTT D82 R268 d R25 R259 J R262 R265 R295 R293 V 134 8 M T Be R286 GND R283 C145 C R270 R272 R274 R276 C142 R279 R281 L3 4 lt 1 TT LS TEST cal SH 2 R267 081 083 084 U29 S R284 R28 287 TTUT C146 Dec nodi 12345678901 bss R269 8271 R273 R275 R277 R278 R280 R282 4 031 15 9 N 33 ei RS pe Ei 2830 1 dis S tom 8288 085 C147 6290 2 Hs C148 150 6 09 Main Control Board March 17 2006 POWERMASTER 500 500P 350 350P 6 10 Control Circuit Tests Most of the control circuit measurements can be made on the main control board See Figure 6 5 Connect primary power to the machine and turn the CONTROL POWER switch ON to power up the control NOTE Unless sta
42. 212 1 DV R171 Ri41 8141 8142 R144 ttt Remote 100 T 0 0 d 178 R172 n GMAW Dive _ R199 R200 C100 C103 1000 9197 1110 1 C98 99 R201 101 9 starie starie SENSITIVE Pu Ise neiitece Art A 07554 Figure 6 10 March 17 2006 POWERMASTER 500 500 350 350P 8 Relay Checks K2 controls the main contactor K3 controls the precharge inrush contactor and K4 controls the fans Measure the continuity at J9 when power is first applied to the board B J9 3to J9 5 checks shorted when power is first applied to the board open after approximately 7 seconds This drives the inrush contactor 6 22 066 R224 R226 1065 223 R225 D Br 32 C133 K2 R241 D 9 R266 R294 R265 R295 R293 R286 C145 C121 lt lt 144 d R289 29287 K3 K4 I R292 D88 47 R290 Art A 07555 Figure 6 11 C J9 1 to J9 5 checks open when power is first applied checks shorted after approximately 4 seconds This drives the main contactor D J9 7 to J9 5 checks open before power is applied to the board checks shorted as soon as power is applied This drives the fans J9 1 Main Contactor J9 3 Inrush Contactor J9 5 Common J9 7 Fans March 17 2006 9 Current Feedback Ifb Verification of the Ifb signal requires putting a load on the ma
43. AMPS VOLTS control by placing the meter amps volts switch in the amps position and the LOCAL REMOTE switch inthe LOCAL position If afoot pedal or torch amperage control is being used place the local remote switch in the remote position after presetting the maximum desired amperage The digital meter will now display the foot torch control amperage Until the foot pedal is pressed the meter will display the minimum amperage If a remote control is not being used it will be necessary to turn the output contactor ON OFF switch to the ON position to energize the output of the machine Open circuit voltage will now be present on the output terminals of the power source 10 Gently rest the torch cup on the workpiece 11 Press the foot pedal or torch switch to energize the output if being used 12 Rock the torch until the tungsten briefly touches the workpiece This will initiate the LIFT ARC feature Lift or rock the tungsten back off of the work to initiate the arc During the time the tungsten is touching the work the power source will automatically limit the weld current to around 20 amps Once the arc is initiated the weld amperage will change to the preset value or foot pedal value To minimize heating of the end of the tungsten it should be left in contact with the workpiece only briefly 13 To end the weld release the foot pedal or turn off torch 48 switch if being used Turn off shielding gas supply
44. ASTER 500 500P 350 350P Note If the current sensor is unplugged from the board or the signal line is broken then the machine will not produce any output and Ifb will measure approximately 14 Volts all the time 10 Voltage Feedback Vfb Verification of the Vfb signal requires putting a load on the machine Make sure that all connectors are plugged into the board Note The following test is intended as a simple verification that the circuit is functioning To verify the calibration ofthe current and voltage feedback signals see the calibration test later in this chapter Connect to a load bank set for approximately 200 amps at 24 volts B Set machine for GMAW mode Set to Local control and preset the output to 24 0 volts C With no load on the machine Vfb should read 0 volts D Energize the output using the GUN SWITCH input jumper A B on the 19 pin amphenol receptacle on the rear panel The gun switch must be used instead of the front panel contactor switch or the voltage will not read correct E TP2 4 should read 2 4 Volts and the front panel volts display should read approximately 24 volts IfTP2 4is ok but the front panel display is wrong then verify both current feedback and arc established signals G If TP2 4 is not correct then verify that the output terminal voltage is coming up to the main control board at J3 1 plus to J3 2 minus 6 23 POWERMASTER 500 500P 350 350P 11 Arc estab
45. B Check for good gas flow and correct mixture C Is wire feeding smoothly Check feed rolls liner tip nozzle etc Check welding wire for excess lubrication or improper cast Is electronic inductance set correctly see Operation chapter of manual Check voltage and wire speed settings G Torch to work distance too great Possible defective main control board 6 5 POWERMASTER 500 500 350 350P 6 04 Power Master 500 and 350 Block Diagram INPUT DUPLEX RECEPTACLE 115 URC 14 19 PIN RECEPTRCLES 247115 URC Art A 07544 6 6 PRECHRRGE IGBT OUERTEMP THERMOSTRT RUX TRRNSFORMER 24 115VAC PRECHARGE CONTROL CIRCUIT FAN GATE DRIVE OUERTEMP CONTROL TRRNSFORMER SHUTDOWN CONTROL CIRCUIT CIRCUIT CIRCUIT POWER CKT BREAKER CONTROL i POWER TRANSFORMER i SUPPLIES INVERTER 36 VAC 8150 150 CONTROL 5U CIRCUIT UOLTRGE DETECTION CIRCUIT 830894 CONTROL BORRD March 17 2006 POWERMASTER 500 500 350 350P INVERTER OUTPUT FILTER TRANSFORMER DIODES OUTPUT PRIMARY DIODE CURRENT OVERTEMP TRANSFORMER THERMOSTAT OUTPUT CURRENT SENSOR IFB 188A V PRIMARY OVERCURRENT CIRCUIT WELD CONTROL CIRCUIT 14719 PIN RECEPTRCLES GUN MODE OUTPUT SWITCH SELECT REFERENCE CIRCUIT LOGIC CIRCUIT CIRCUIT OUTPUT RE
46. GBT module below Possible defective capacitor board s March 17 2006 3 Machine powers up but fans do not run A Fans should normally run when the machine is first powered up or whenever the OUTPUT CONTACTOR is ON With CONTROL POWER switch ON check for 115 VAC power on the rear duplex Check wiring to all three fans Check wiring to main control board J9 Possible defective main control board Possible defective fan s 4 CONTROL POWER circuit breaker trips off A Check for shorts or overload on either rear duplex 14 pin receptacle or 19 pin receptacle and cables Check for internal short circuit check wiring to both contactors all three fans and to main control board J9 Check internal wiring to rear duplex amphenol board and small control transformer D Possible defective front panel circuit breaker Possible defective small control transformer or aux transformer Machine powers up but no output or incorrect output Power Master 500 and 350 only A Check for open circuit voltage see how to test open circuit voltage below Check for shorted output diode see how to check output diodes below Check front panel controls 1 Adjust ranges To check the output adjust range make sure that the REMOTE LOCAL control is set to local For GTAW SMAW and CAG modes the Meter Amps Volts switch must be in the AMPS position For GMAW mode the switch must be in the VOLTS po
47. IHERMAL m gilt POWERMASTER 900 POWER SOURCE 900 Art 07556 ervice Manual Revision AD Issue Date March 17 2006 Manual No 0 4938B 208 230 V 500 460 400 Saal amp oc 2 SE Operating Features 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 Power Master Inverter Welding Power Supply Service Manual Number 0 4938B for Power Master 500 Part Number 100060 100095 CCC Power Master 500P Part Number 100054 100096 CCC Power Master 350 Part Number 100078 100101 CCC 100099 CSA Power Master 350P Part Number 100079 100102 CCC 100100 CSA Published by Thermadyne Industries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 2008 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher 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 Publ
48. LATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme Z49 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 04 Dangers Relatifs au Soudage l Arc 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipeme
49. MOTE OUTPUT CONTACTOR LOCAL CONTROL SWITCH SWITCH POTENTIOMETER CIRCUIT METER DISPLAY 830906 FRONT PANEL DISPLAY BOARD March 17 2006 6 7 POWERMASTER 500 500 350 350P 6 05 Power Master 500P and 350P Block Diagram IGBT INPUT TERMINAL PRECHARGE en INUERTER IGBT OUERTEMP THERMOSTRT RUX TRRNSFORMER sing tet EE 24 11SURC PRECHARGE CONTROL CIRCUIT FAN GATE DRIVE OVERTEMP CONTROL TRANSFORMER SHUTDOWN CONTROL CIRCUIT CIRCUIT CIRCUIT POWER CKT BREAKER DUPLEX RECEPTACLE 11S VAC CONTROL POWER TRANSFORMER SUPPLIES INVERTER 15U 15U CONTROL 50 CIRCUIT 36 14 19 PIN RECEPTACLES 24 115 URC VOLTAGE DETECTION CIRCUIT 830894 CONTROL BOARD SCHEDULE SCHEDULE DISPLAY DISPLAY DRIVER PANEL MICROCONTROLLER CONTROLS UOLTS DISPLAY DISPLAY DRIVER DRIVER CAN RS 232 PORT DRIVER DRIVER CIRCUIT CAN RS 232 VOLTS BS DISPLRY PORT CONNECTOR CONNECTOR D SUB9 830838 DISPLAY BOARD 6 8 March 17 2006 INVERTER TRANSFORMER PRIMARY CURRENT TRANSFORMER PRIMARY OVERCURRENT CIRCUIT GUN SWITCH CIRCUIT OUTPUT CONTACTOR CONTROL March 17 2006 DIODE OVERTEMP THERMOSTAT WELD CONTROL CIRCUIT MODE OUTPUT SELECT REFERENCE LOGIC CIRCUIT OUTPUT FILTER DIODES CHOKE POWERMASTER 500 500P 350 350P OUTPUT CURRENT SENSOR ESTABLISHED CIRCUIT OUTPUT MODE CONTROL CI
50. RCUIT PULSE CONTROL LOGIC ARC DETECT CIRCUIT PULSE WELDING CONTROL 830831 PULSE CONTROL BOARD ie Seve ere ce Sees ss LES 14719 PIN RECEPTACLES Art 07545 POWERMASTER 500 500P 350 350P 6 06 Control Board Connector Signals For 830894 Main Control Board 6 10 Connector Voltage Description J1 26 pin ribbon cable to front panel board J1 1 1V or 14V GTAW mode select 1V GTAW selected J1 2 1V or 14V SMAW mode select 1V SMAW selected J1 3 1V or 14V or PULSE mode selected 1V CAG or PULSE selected J1 4 1V or 14V GMAW mode selected 1V GMAW selected J1 5 Arc force pot high side in SMAW mode J1 6 Inductance pot high side in all modes except SMAW J1 7 Arc force pot low side in SMAW mode J1 8 Inductance pot low sidein all modes except SMAW J1 9 1V or 14V Remote Local 1V remote selected J1 10 15V Power supply J1 11 or 13 5V Contactor input 13 5 inverter on J1 12 10V High side reference for front panel control pot J1 13 0 07V or 2 22V Low side of front panel pot 2 22 for GMAW 07 for other modes J1 14 0 to 10V Wiper input from front panel control pot J1 15 0 to 6V Current feedback 100Amps volt J1 16 0 to 6V Voltage feedback 10Volts volt J1 17 0 or 14V Arc established signal 14V arc established J1 18 0 or 15V Gun Switch signal 15V gun switch on J1 19 15V Power supply J1 20 Common Signal common J1 21 5V Power Supply J1 22 Over temperature light drive
51. REQ ADJUST ur 7 016 25 RI92 f cse S Sonn 0808 89880 C74 R143 C75 C77 85888 25588 9 9 8 54 8 164 8167 C72 1 UI 1 cd Eh gogo 8147 045 1 1 1 AN 1 AN 014 020 i So 0 952 C76 018 8176 R177 R179 C83 C84 D46 280 R169 ids U21 r ge 013 28 FRE END 1 053 8181 C85 C88 C89 066 022 Sagar Goo 0 8175 8184 8186 05 91 R196 Y d AA a d AA CULTU LU d ST T R170 R172 174 80 U19 C82 R178 T 1 n R198 niss ciga 79 C103 d j 7 105 DBT R207 nud Lay Hoa 1135 CSP Eege 054 R210 212 R215 217 6185 R187 C9 RIOS 22092 059 10 1 P R208 1 1 6 ey A u25 U26 819711111 8214 066 c98 C99 R201 C101 C102 Deet LIT EA 8224 R226 CAUTION TTT TT T IT CHE WEN R203 205 068 R206 Rosaali 216 1 1 DEUICES HRNDLING 218 7 D64 PRECRUT IONS LA Y TT REQUIRED R230 023 T C108 22918231 c D62 R221 C11 4065 R223 R225 1 C109 4 f R232 T U28 29 Q 1 N 115 072 N 067 R237 R239 C128 C130 C13
52. Remove the three mounting screws holding the diode to the heatsink Step 6 Clean the heatsink area where the diode mounts Step 7 Apply a thin layer of thermal compound to the back of the diode Step 8 Mount diode on heatsink and hand tighten mount ing screws DO NOT TORQUE YET Step 9 Attach bus bars to diodes and hand tighten Step 10 Torque the diode mounting screws See Figure 7 1 Torque the center mounting screw first and then the two outer screws Step 11 Torque the six screws holding the bus bars to the diodes See Figure 7 1 Step 12 Reconnect the transformer bus bars Step 5 35 IN LBS le PLACES See steps 10 amp 11 TORQUE TO 15 IN LBS 3 PLACES See step 10 Art A 07542 Figure 7 1 Output Diode Assembly March 17 2006 7 1 POWERMASTER 500 500P 350 350P 1 02 IGBT Module Replacement The following procedure can be used to replace one ofthe IGBT modules The IGBT can be replaced without remov ing the capacitor boards if the capacitor boards are still ok 7 2 Step 1 Remove the screws holding the transformer leads to the IGBT modules Remove the transformer leads from both modules so they can be positioned out ofthe way Step 2 Remove the thermostat so it can be posi tioned out of the way Step 3 Disconnect the gate drive connector from the IGBT module being replaced Step 4 Remov
53. an Assembly PM IPS 830937 6 1 Receptacle 120V 10A PM IPS 402670 7 4 Screw PHCR M4 7x16mm STZP See Note 1 8 4 Nut Hex M4x 7 STZP See Note 1 9 8 Screw PHCR 6x3 8 self tap See Note 1 10 2 Washer 3 5mm nt Lock See Note 1 11 4 Screw PHCR M3 0 5x10mm STZP See Note 1 12 4 Nut Hex M3x 5 STZP See Note 1 Note 1 This part is available at most hardware stores Art A 06936 8 10 March 17 2006 March 17 2006 POWERMASTER 500 500 350 350P THIS PAGE HAS NEEN LEFT INTENTIONALLY BLANK 8 11 POWERMASTER 500 500 350 350P 8 10 Center Chassis Parts Hem gt 10 11 12 13 14 15 16 17 18 19 21 o gt O 00 c NO 4 gt SBSRBNSRRBB Note 1 This part is available at most hardware stores Description PCB Capacitor Neg B PM IPS PCB Capacitor Pos B PM IPS Capacitor Snubber 2x47nF IPS Contactor 40A 2 Pole PM IPS Diode Dual 320A 400V PM IPS Fan Cooling 6 PM IPS Fan Transformer 4 PM IPS Heatsink IGBT PM IPS IGBT Module Assembly PM IPS Rectifier 1600V 100A PM IPS Sensor Current 500A PM IPS KIT Suppressor MOV Assy PM500 Thermostat Assy 85 C PM IPS Transformer Current PM IPS Transformer Inverter PM IPS Thermostat Assy 85 C PM IPS Screw PHCR M4 7x50 STZC Nut Hex 1 4 20 Keps Nut Hex 1 4 20 conical washer Screw He
54. by using the programmer interface PULSED GMAW mode In this mode the power source uses the built in pulse control for pulsed GMAW welding The pulse control is factory programmed with 24 different pulse weld schedules The active pulse schedule is shown on the pulse schedule display The label on the inside of the control door shows the pulse schedules as shipped from the factory Schedules 1 12 are programmed as standard non AVC and schedules 13 24 are programmed as AVC schedules The AVC schedules provide for control of the arc length as the torch to work distance is varied In the pulsed GMAW mode the front panel output control is used to preset a pulse reference for the pulse control circuit The pulse schedules can be modified by using the programmer interface March 17 2006 POWERMASTER 500 500P 350 350P 7 Arc Force Inductance Control When the SMAW mode is selected this control is activated and allows adjustment of the amount of arc force or dig Maximum arc force is full clockwise full counter clockwise is zero arc force For GMAW mode this control can be used to adjust the amount of inductance in the circuit Higher inductance settings make the arc softer with less spatter Lower inductance settings give a stronger driving arc Generally the inductance control can be set at mid range as a good starting point For GTAW and PULSED GMAW modes this control is not active 8 Contactor On Indicator This indicat
55. cessive voltage drop which may degrade welding performance Check control cable connections to the power source and wire feeder or other controls Damaged cables can cause intermittent problems which are often difficult to troubleshoot Cables should be repaired or replaced if damage is evident Check all control switches and potentiometers If any of the controls are damaged or broken they should be replaced Most of the controls on this machine are integral components to a circuit board and will require replacement of the board Inspect internal wiring of the welding machine for loose or frayed connections tighten or repair as necessary Check internal connections including circuit board connectors Any loose or corroded connections should be repaired 5 1 POWERMASTER 500 500P 350 350P Maintain more often if used under severe conditions Warning Disconnect input power before maintaining Each Use Visual check of Visual check of torch regulator and pressure Consumable parts h Weekly Visually inspect the torch body and consumables Visually inspect the cables and leads Replace as needed 3 Montlis I E Replace all Ke broken parts Gas and Clean air lines exterior of power supply 6 Months Visually check and use a vacuum to carefully clean the interior Art A 07433 5 2 March 17 2006 SECTION 6 TROUBLESHOOTING 6 01 General T
56. ch mode of operation has a dedicated electronic control which has been optimized for that particular process March 17 2006 can be locked out on the Power Master 500P 350P so they will have no affect on the operation of the machine The machine will remain in whatever mode or condition it is in before the feature is locked out 2 Output Overload Protection The overload protection 1 1 Mode Select Switch Prevents changing of the feature will limit the continuous weld current to the mode of operation maximum value listed in the specifications for any of the modes of operation The machine will continue to DN EE EES operate butthe current will be limited to this maximum value 1 3 Schedule Select Switches Prevents changing of 3 Cooling Fan Control The cooling fans are designed the pulse mig schedule to operate only when required They will come on Restricted output adjustment The range of whenever the output contactor control of the machine adjustment of the output of the power source can be is on The fans will come on for several minutes when restricted for the various modes of operation the machine is first turned on and will normally stay on for several minutes after the output contactor 2 1 Amps Adjust Range Locked A high and low control has been switched off The fans will turn off amperage limit can be programmed wign wili after several minutes of inactivity to minimize the rnit me GUIDUE adjust ra
57. chine Make sure that all connectors are plugged into the board Nole The following test is intended as a simple verification that the circuit is functioning To verify the calibration of the current and voltage feedback signals see the calibration test later in this chapter Connect to a load bank set for approximately 200 amps at 24 volts B Set machine for SMAW mode set Force to minimum Set for LOCAL and preset to 200 amps on front panel C With no load on the machine Ifb should read 0 volts D Energizethe output of the machine using the front panel contactor switch E 2 5 should read 2 Volts and the amps display on the front panel should read approximately 200 amps If TP2 5 is ok but the meter does not read actual amps correctly then check the voltage feedback as well as the arc established signal G If TP2 5 is not correct then verify the functionality and connection of the current sensor device It connects to J2 on the main control board H With the plug disconnected at the current sensor and power off of the machine the sensor should show the following resistance Pin 1 to pin 4 1 meg Pin 2 to pin 4 gt 1 meg Pin 3 to pin 4 approximately 22K With the sensor plugged in and power applied the sensor should have the following voltages Pin 1 15V supply Pin 2 15V supply Pin 3 0 to 4 volts feedback signal Pin 4 circuit common same as 4 2 March 17 2006 POWERM
58. cord these numbers on the bottom of page i for future reference 2 03 Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 1 POWERMASTER 500 500P 350 350P 2 04 Symbol Chart Note that only some of these symbols will appear on your model Wire Feed Towards Off 3 2 Three Phase Workpiece With Output Voltage Off Three Phase Static Dangerous Voltage CD BE Frequency Converter Welding Gun Transformer Rectifier AEN Continuous Weld Circuit Breaker X Duty Cycle Mode Shielded Metal Gas Metal Arc Gas Tungsten Arc 2 Step Trigger Hertz cycles sec Welding GTAW V 4 Operation Press to initiate wirefeed and Air Carbon Arc welding release to stop mcum FT a Press and hold for preflow release Positive Constant Voltage to start arc Press to stop arc a
59. d GMAW mode In this mode the power source operates in constant voltage mode with the inductance control enabled A Wire Sharpening circuit is also active to help condition the end of the wire when the weld is complete to improve the arc start on the next weld The Wire Sharpening feature can be disabled if desired See configuration settings under Installation instructions chapter of this manual for an explanation of how to disable the Wire Sharpening feature 3 Output Contactor Indicator This green light will be ON whenever the output of the welding machine is energized Output Contactor Switch This switch is used to energize the output of the machine 5 Overtemp Indicator This amber light will be ON whenever an overtemperature condition has been detected internal to the machine This light will remain on with the fans running until the unit cools down If this light is on the output of the machine will be disabled Once the machine cools down this light will go off and the overtemperature condition will automatically reset March 17 2006 6 Meter Display The digital meter is used to preset the output voltage or current when the power source is not welding and to display the actual amps or volts while welding To preset output current amps for GTAW SMAW CAG place meter Amps Volts switch inthe Amps position and adjust the main Amps Volts control potentiometer to the desired current To preset output
60. d Thursday November 200 Art 08275 14402 POWER MASTER 500 0 830924 17 2006 7 POWERMASTER 500 500P 350 350P APPENDIX 5 PM500P 350P CONNECTION DIAGRAM 2 OF 2 53 CONTROL PC BOARD Mr OL i 0 2 2 Ce 92 BLK RED 22 22 BK 5 4 4 22 595 J4 J3 emm TWISTED BLK PAIRS LN BLK BLK ALK 43 35 BLK 42 RED 26 29 25 RED i 24 BLK S 23 RED g 2A9A21 212323 22 BLK 10 8 21 RED 20 1 19 RED io A Art A 06946 12 11 10 9 8 7 A 8 March 17 2006 POWERMASTER 500 500 350 350P 35 m DISPLAY 34 PULSE PC BOARD 9o 9 B 9 S WA ci b RED 1 BLK 1 J5 5 BLK 1 TWISTED PAIRS Le O D CHANGE RECORD FINISH CODE PER EC No DATE ARE mme REFUCED REPUCES 83092552 2 14 01 UNLESS OTHERWISE SPECIFIED QUANTUM COMM CLS WATERAL SPEC TRE CONNECTION DIAGRAM DESCRIPTIVE DATA POWER MASTER 5 PN 359P DESIGNED DRAG ONE SRE BN DBB
61. day November 2007 f br POWER MASTER 350 500 830920 March 17 2006 3 POWERMASTER 500 500P 350 350P APPENDIX 3 PM500 350 CONNECTION DIAGRAM 2 OF 2 2 o 53 CONTROL PC BOARD 95 J2 BLK 22 al RED BLK 22 7 BRN 55 43 TWISTED PAIRS ELSE 21 26 BLK 25 RED 24 BLK 23 RED 22 BLK 1 9 RED 10 20 19 RED lt 10 1 9 21 21 2323 43 32 42 RED 29 Art A 06943 12 10 4 March 17 2006 POWERMASTER 500 500 350 350P OD DISPLAY PC BOARD H H z OUTSDE OSTR DISTRIBUTION TABLE CHANGE RECORD FINISH CODE PER TIE WWE BUT eme FERRED BY 83092152 2 14 01 UNLESS OTHERWISE SPECIFIED CONNECTION DIAGRAM DESCRIPTIVE DATA POWER MASTER PN 588 PN 35 MASTER e ee EE un BN 2 14 01 FULL EN E Gi ay 2714 0 Tan Age 12 2 Ce el D Sg 820921 A 6 5 4 3 2 1 Art A 06943 March 17 2006 AS POWERMASTER 500 500P 350 350P APPENDIX 4 PM 500P SCHEMATIC DIAGRAM
62. ding For globular or spray transfer modes the inductance control has minimal effect The power source is now ready to weld To end the weld release the torch switch while holding the torch in place at the end of the weld This will allow the wire sharpening circuit in the power source to condition the end of the wire for the next weld The wire sharpening circuit will tend to leave a very small ball on the end of the wire thus making the next start easier 49 POWERMASTER 500 500P 350 350P 4 09 Pulsed GMAW Power Master 500P 4 10 and 350P Only 1 Connect the wire feeder to the power source Connectthe control cable to the 19 pin receptacle or the 14 pin receptacle on the rear of the power source Connect the electrode cable from the wire feeder to the output terminal of the power source normally positive for DCEP Connect the other output terminal of the power source to the workpiece 2 Turn the control power switch ON located on the front panel of the power source The digital display on the power source will be activated 3 Select Pulsed GMAW mode using the mode select switch located on the control panel under the door 4 Select the desired pulse schedule based on the wire size and type The label on the inside of the door shows the default factory pulse schedules Schedules 1 12 are standard pulse schedules schedules 13 24 are AVC type pulse schedules The AVC schedules provide for greater control of the arc
63. duct Purchaser s rights under this warranty are void if the product is sold to purchaser by unauthorized persons The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shall pay no transportation costs of any kind under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser returned goods shall be at the Purchaser s risk and expense This warranty dated July 1 2007 supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermal Arc Inc WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada November 2007 SAFETY EQUIPMENT WARRANTY PERIOD LABOR Auto Darkening Welding Helmet Electronic Lens 1 year 1 year Harness Assembly 1 Month 1 Month ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout Raider Explorer Original Main Power Stators and Inductors 3 years
64. e 460 VAC 3 Phase 3004 32V 100 Duty Cycle ee 350A 34V 60 Duty Cycle 350A 34V 60 Duty Cycle 350A 34V 60 Duty Cycle 350A 34V 60 Duty Cycle 350A 34V 60 Duty Cycle Line Frequency 50 60 HZ Output Current Range 5 560 Amps Output Voltage Range 10 44 Volts Maximum Output Current 600 Amps Maximum Open Circuit Voltage OCV 70 Volts 57 Volts for CCC Operating Temperature Range 0 40C Input Line Variations 10 Line Regulation 1 Load Regulation 1 Water Protection Class IP23S 23 0 58 4 g 22 0 in 55 9 m 6 81 172 7 IHERMAL Art 06855 Net Weight 154 Ibs 70 kg Figure 2 6 Power Master 350P Dimensions 2 8 March 17 2006 POWERMASTER 500 500 350 350P 2 12 500 350 Programmable Features 1 Lockout features Any or all of the following controls 2 11 Standard Features 1 Short Circuit Protection The output of the power source can be short circuited in any of the modes of operation This protection feature will instantly limit the output current to a safe value to assure reliable operation of the power source electronic controls which have been optimized for most welding processes The following controls are standard GTAW with Lift Start SMAW CAG GMAW FCAW including the short arc globular and spray transfer modes Ea
65. e a large number of variables which can affect the overall system performance These variables often include several pieces of equipment interconnect cables weld cables Shielding gas systems grounding consumable wire or electrodes part preparation etc It is important to check all aspects of the welding system and environment when troubleshooting a problem or malfunction Explanation of front panel lights OUTPUT CONTACTOR ON GREEN This light indicates that either the OUTPUT CONTACTOR switch on the front panel is on or the remote GUN SWITCH is on via either the 14 pin or 19 pin remote receptacle Whenever this green light is on the machine should be producing output OVERTEMPERATURE AMBER This light indicates that the machine has overheated and shut itself off When this light is on the machine will be disabled and not produce any output After the machine has cooled this light will automatically turn off and the machine will no longer be disabled The following guide lists several potential problems and lists a number of items to check or possible causes A DANGER ELECTRIC SHOCK CAN KILL Open the main wall disconnect switch or breaker before removing any covers or access panels on the welding machine Live voltage is still present even with the front panel control switch OFF Wait at least three full minutes after power has been removed before removing any covers or access panels to allow adequate time for
66. e the four mounting screws holding the IGBT to the heatsink Step 5 Remove the two screws connecting the ca pacitor boards to the IGBT Remove the brass spacer from underneath the capacitor board lead Step 6 Slide the IGBT up or down to clear the bus bars on the capacitor boards and remove the IGBT Step 7 Clean the area of the heatsink where the IGBT mounts This area must be free of contaminations which would prevent the IGBT from mounting flush to the heatsink Step 8 Apply a thin layer of thermal compound to the back of the new IGBT module Step 9 Slide the new IGBT back in place Step 10 Reassemble in reverse order of removal TORQUE MOUNTING SCREWS TO 35 IN LBS AND TERMINAL SCREWS TO 27 IN LBS Art A 07543 Step 1 Step 4 Figure 7 2 IGBT Replacement March 17 2006 SECTION 8 PARTS LIST 8 01 Equipment Identification identification numbers as described in the Introduc tion chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assem bly
67. ealth Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can 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 for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion ANSI Standard Z87 1 from American National Standards Insti tute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 March 17 2006 POWERMASTER 500 500 350 350P 1 03 Precautions de Securite en Soudage l Arc N MISE EN GARDE LE SOUDAGE L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMU
68. ective This warranty is exclusive and in lieu of any warranty of merchantability fitness for any particular purpose or other warranty of quality whether express implied or statutory Limitation of liability Thermal Arc shall not under any circumstances be liable for special indirect incidental or consequential damages including but not limited to lost profits and business interruption The remedies of the purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty and Thermal Arc shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or accessories which in Thermal Arc s sole judgment impaired the safety or performance of any Thermal Arc pro
69. eld March 17 2006 4 07 CAG Carbon Arc Gouging 1 Connect the welding leads to the output terminals of the power source Normally the work lead should connect to the negative lead and the electrode holder to the positive terminal DCEP or reverse polarity If a remote control is being used connect to the 14 or 19 pin remote receptacle on the rear of the power Source Turn the control power switch ON located on the front panel of the power source The digital display on the power source should be activated Set the front panel mode switch to CAG Preset the weld amperage using the front panel amps volts control by placing the meter amps volts switch in the amps position and the local remote switch in the local position If a remote control is being used place the local remote switch in the remote position The remote control will have full control of the output of the power source from minimum to maximum Energize the output of the power source with either the front panel output contactor ON OFF switch or by the switch on the remote control if one is being used There will now be open circuit voltage present on the output terminals of the power source The power source is now ready to arc gouge NOTE For CAG mode the arc force inductance control is not active The optimum arc characteristics are built into the power source March 17 2006 POWERMASTER 500 500P 350 350P 4 08 GMAW Gas Metal Arc Weldin
70. er to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use uM Light 12 Light Under 300 Amp 9 March 17 2006 WARNING FLYING SPARKS AND HOT METAL can cause injury V Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin A gt J warme CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and fol
71. es ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque March 17 2006 POWERMASTER 500 500P 350 350P ah gt 4 AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau he Z LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endo
72. g Connect the wire feeder to the power source Connect the control cable to the 19 pin receptacle or the 14 pin receptacle on the rear of the power source Connect the electrode cable from the wire feeder to the output terminal of the power source normally positive for DCEP Connect the other output terminal of the power source to the workpiece Turn the control power switch ON located on the front panel of the power source The digital display on the power source should be activated Set the front panel mode switch to GMAW Preset the weld voltage using the front panel amps volts control by placing the meter amps volts switch in the volts position and the local remote switch in the local position If the wire feeder has remote voltage control place the local remote switch on the front of the power source in the remote position This will allow the wire feeder to control the preset voltage of the power source Set the inductance control to the desired inductance setting Full clockwise is maximum inductance Higher inductance settings make the arc softer with less spatter Lower inductance settings give a stronger driving arc The inductance should be set according to the type of wire and gas and desired arc characteristics desired Generally the inductance control can be set at mid range as a good starting point NOTE The inductance control is primarily used for the short circuiting transfer mode of MIG wel
73. his manual is intended to be used by qualified trained service technicians It s purpose is to give the service technician an enhanced detailed understanding of the welding machine This troubleshooting section is intended to help determine which component or sub assembly is faulty This manual only provides information to the point of determining whether a circuit board is defective it does not provide information to troubleshoot and repair a circuit board There are many outside influences on the overall welding process which can often point towards a defective welding power source It is important to make sure that these outside influences are not the actual cause of a complaint or faulty operation before troubleshooting the welding power source Some common things to look for are listed below Input Power Incorrect voltage blown fuses loose connections improper voltage changeover setting Improper Operation Incorrect switch positions remote local mode trigger hold voltage or wire feed setting inductance setting pulse schedule etc Loose damaged or missing control or weld connections NOTE The Power Master 500P has a number of programmable features including the ability to disable front panel switches and limit the output range of the machine These features can be programmed using an optional software package GUS Poor Welding Or Starting Shielding gas type flow or contamination incorrect weld
74. ication Date March 17 2006 Revision AC Date October 30 2008 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 191 sense 1 1 1 02 Principal Safety Standards nn 1 4 1 03 Precautions de Securite en Soudage 1 5 1 04 Dangers Relatifs au Soudage 1 5 1 05 Principales Normes De Securite san ee 1 8 SECTION 2 INTRODUCTION 2 1 201 How To Use This Manual nee 2 1 2 02 Equipment Identification u 2 1 2 03 Receipt Of Equipment 2 1 204 ein E 2 2 2 05 General Power Masier 500 amp 350 nn 2 3 2 06 Power Master 500 Specifications sess 2 4 207 Power Master 350 Specifications 2 5 2 08 General Power Master 500 A 350P 2 6 2 09 Power Master 500P Specifications 2 7 2 10 Power Master 350P Specifications anne 2 8 211 standard KEREN essen 2 9 212 500P 350P Programmable Features u 2 9 SECTION 3 INSTALLATION ce 3 1 Pee M
75. in board is providing the correct voltage at see Figure 6 7 for remote max This voltage should be 10VDC all the time for GMAW mode and should vary from 0 1 to 10VDC for GTAW mode as the front panel control is varied from min to max Arc Established POWERMASTER 500 500P 350 350P If is ok then verify that the remote signal is making it to the main board from the amphenol board The input from the 19 pin remote is at R269 and the input from the 14 pin remote is at R276 See Figure 6 7 7T Mode Checks The following checks can be done to verify that the correct signals are coming from the front panel board to the main control board If a signal is not correct it most likely indicates a problem with either the front panel board or the ribbon cable inter connect Forthe following if the mode is selected the signal should read around 1 Volt if it is not selected it should read around 14 Volts A GTAW mode check at R133 See Figure 6 10 B SMAW mode check at R145 See Figure 6 10 C GMAW mode check at R198 See Figure 6 10 D CAG PULSE mode check at R200 See Figure 6 10 E Check REMOTE LOCAL mode at R173 See Figure 6 10 LOCAL 14 Volts REMOTE 1 Volt u R100 R101 C37 gt gt 4 RI C36 2 6 029 R102 R138 C5 54 du gt c3 LILI TORQ uc SMAW ui 25 C52 R131 H 4 R143 A i 1
76. ing the programming software In this case it will be necessary to connect a computer to the programmer interface on the power source and use the programming software to re enable these controls 1 MODE SELECT Each time the mode switch is pressed and released the power source should advance to the next mode as indicated by one of the LEDs 6 3 POWERMASTER 500 500P 350 350P 2 REMOTE LOCAL control Each time the REMOTE ON switch is pressed and released the associated indicator LED should toggle between ON and OFF Ifthe LED is ON this indicates that the power source is set for remote control 3 Schedule UP and DOWN controls gt a Each time the switch next to the UP arrow is pressed the PULSE SCHEDULE should increase by one until it reaches 24 and rolls back over to 1 The switch next to the DOWN arrow should work in a similar way except that the PULSE SCHEDULE should decrease Adjust ranges To check the output adjust range make sure that the REMOTE LOCAL control is set to local the indicator LED should be OFF a GTAW range 5 560 AMPS display b SMAW range 5 560 AMPS display c GMAW range 10 44 VOLTS display d PULSED GMAW range 0 440 VOLTS display CONTACTOR control Whenever the CONTACTOR switch is ON the indicator LED should also be on Anytime the CONTACTOR is on there should be open circuit voltage present on the output terminals of the power source Open circu
77. ion point for negative welding lead 15 Output Positive Terminal Connection point for positive welding lead 45 POWERMASTER 500 500 350 350P 4 00 RearPanel All Models 46 AAAAAA 200000 DOD 2 D Uy J J J V J J V JJ Ee SI Art A 06859 Figure 4 3 Rear Panel 14 Pin Receptacle This receptacle allows the power source to interface with wire feeders and remote controls such as a foot pedal This receptacle provides auxiliary power contactor control for energizing the output ofthe power source and remote output control The pinout is as follows A 24 auxiliary power high side 24 Contactor circuit closure between pin A and pin B will energize output C Remote control maximum top side of remote pot D Control circuit common E Remote control in wiper of remote pot 0 to 10 Volts CV mode Otto 10 Volts gives 10 44 Volts of output CC mode 0 to 10 Volts gives 5 560 Amps of output Scaled output current signal 100 Amps Volt G 24 115 VAC neutral H Scaled output voltage signal 10 Volts Volt 115 auxiliary power high side J 115 Contactor circuit closure between pin and pin J will energize output K Chassis ground L NC M NC N NC 19 Pin Receptacle
78. it voltage should be approximately 50 70 volts for all operating modes of the power source except GMAW For checking open circuit voltage in GMAW mode use an external CONTACTOR control NOTE For load testing the machine or welding in GMAW mode it will be necessary to use an external CONTACTOR signal otherwise the machine will NOT produce the correct output voltage D Possible defective main control board E Possible defective IGBT or input rectifier module see how to check these parts below F Check internal wiring to contro board and current sensor G Possible defective current sensor 6 How to check the input rectifier module A See Figure 6 1 and or Appendix 3 Connection Diagram Check all six internal diodes as follows with diode checker on DVM all should read in the range of 0 3 to 0 6 volts 1 Positive meter lead on AC terminal A 1 negative meter lead on terminal D 4 Positive meter lead on AC terminal B 2 negative meter lead on terminal D 4 Positive meter lead on AC terminal C 3 negative meter lead terminal D 4 Positive meter lead on terminal F 5 negative meter lead on AC terminal A 1 Positive meter lead on terminal F 5 negative meter lead on AC terminal B 2 Positive meter lead on terminal F 5 negative meter lead on AC terminal C 3 March 17 2006 POWERMASTER 500 500P 350 350P 8 How to check the output diodes A B
79. izes Connect the welding leads to the output bus bar terminals of the power source Selection of the proper size of welding leads should be based upon both the rated ampacity of the wire as well as the voltage drop on the cable When considering voltage drop the entire loop electrode plus work lead must be considered As a general rule the welding cables should be kept as short as possible and placed close together Try to avoid coiling up the cables if possible A damaged or frayed cable should not be used and all connections must be properly tightened Avg Welding ELECTRODE LEAD PLUS WORK LEAD z gt 2 2 0 300 1 0 50 mm 1 0 50 mm 3 0 95 mm 4 0 120 mm 2 T0 mm 850 2 0 70 mm 42 0 70 mm 2 42 0 2 42 0 70 70 mm 120 2 470 mm 400 3 0 95 mm 3 0 95 mm 4 0 120 mm 95 mm 95 mm 120 mm 2 70 mm 2 95 mn 450 43 0 95 mm 83 0 95 mm 84 0 120 mm 2 3 0 2 43 0 pum 95 mm 2 95 mm m 2 42 0 2 43 0 2 4 0 um am 2 70 95 mm 120 mm 4 0 120 4 0 120 ped 2 84 0 2 4 0 an mm 2 70 120 mm 120 mm potus 2 43 0 2 4 0 2 4 0 m 2 95 mm 120 mm 120 mm NOTE Lead size shown is for 194 F 90 C cable insulation 86 F 30 C ambient and not over 4 5 volts lead drop Table 3 2 Lead Circuit Lengths by Welding Amps 3 4 March 17 2006
80. l Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government 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 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 questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS EIC cc c A The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 1 02 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 749 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and H
81. length as the torch to work distance varies NOTE Any or all of the pulse schedules can be modified using the programmer interface and the programming software 5 Preset the pulse reference The reference can be between 0 and 440 This is just a reference to the pulse control circuit and is not a preset of the actual arc voltage or amperage The reference controls the pulse rate The pulse rate can be considered similar to voltage for conventional GMAW A higher reference gives a longer arc with higher voltage and heat input As with conventional GMAW the power source must be adjusted to correspond with the correct heat input for a given wire feed speed 6 Ifthe wire feeder has remote voltage control place the power source in remote mode using the remote switch located on the control panel under the door This will allow the wire feeder to control the preset voltage of the power source 7 The power source is now ready to weld 8 To end the weld release the torch switch while holding the torch in place at the end of the weld This will allow the wire sharpening circuit in the power source to condition the end of the wire for the next weld The wire sharpening circuit will tend to leave a very small ball on the end of the wire thus making the next start easier March 17 2006 If this equipment does not operate properly stop work immediately and investigate the cause ofthe malfunction Maintenance work must be performed b
82. lished circuit 6 11 Calibration Procedure a the arc established signal at R132 See Figure Voltage and current feedback calibration procedure The following procedure be used to check the A WEEN on the machine established should calibration of the Power Master A resistive load bank set for approximately 100Amps 24 Volts is required A resistive external shunt and digital meter set to read average millivolts is required to check B With any load greater than approximately 4 amps and 4 volts arc established should read approximately 14 Win the current A digital meter set to read average DC volts Note is required to read the machine output voltage Arc established should also be present on pin Setthe Power Masterto SMAW LOCAL and arc force of 19 pin remote receptacle on the rear setto minimum poner B Preset the output amperage to 100 C Energize the output using the gun switch input jumper A B on the 19 pin remote D Verify the amperage reading on the Power Master is 100 4 amps E Adjust the output amperage control of the Power Master 500 until the amperage display reads exactly 100 Verify the actual load amps using the external shunt Load amps should be 100 4 amps There is no calibration adjustment if the calibration is off then either the current sensor or the control board is out of calibration At 100 amps of load current the current sensor output should be 0 80 Volts dc
83. low A R195 top side 10 all the time with or without J1 plugged in Min ref RV2 bottom side 0 07 VDC for SMAW GTAW or PULSE 2 22 VDC for GMAW or with J1 unplugged Ref in to main control board at R222 top side 0 07 to 10 VDC for GTAW min to max 2 22 10 VDC min to max for GMAW This is the reference input from the front panel 10V niga 052 FREQ GND ar SOS i 8195 a d 058 C68 R192 gt C95 gt R163 8193 gt ol e d n zu Gun Switch Input Art A 07551 Figure 6 7 Reference Circuit 6 18 March 17 2006 3 Gun Switch Circuit This is the gun switch from the 19 14 pin remote receptacle To activate gun switch short Pins amp B on 19 pin remote A Gun switch input D85 Anode 15VDC for gun switch on OV for gun switch off See Figure 6 7 B Gun switch output R131 15VDC for gun switch on OV for gun switch off See Figure 6 8 If gun switch input is not present to main control board that most likely indicates a problem with either the amphenol board or the J10 ribbon cable Ifthe gun switch input is present but the gun switch output is not correct then the problem is with the main control board Note J1 must be plugged in for this circuit to work 4 Output Contactor circuit The contactor signal comes from the front panel board to the main control board It is based on the gun switch output sig
84. low instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards Engines can be dangerous 9 WARNING ENGINE EXHAUST GASES can kill POWERMASTER 500 500P 350 350P If used in a closed area vent engine exhaust outside and away from any building air intakes Vt WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine we 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 or connecting unit 3 Have only qualified people remove guards or covers 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 or guards and close doors when servicing is finished and bef
85. m 64 7 a D 4 D N D D N N D NA D A D 22 5 in 57 1 uM 378 5 mm Net Weight 154 Ibs 70 kg Art A 06852 Figure 2 2 Power Master 500 Dimensions 2 4 March 17 2006 POWERMASTER 500 500P 350 350P 2 07 Power Master 350 Specifications L 460 VAC 3 Phase 3004 32V 100 Duty Cycle ine Voltage Line Current KVA ER PF 3004 32V 100 Duty Cycle 300A 32V 100 Duty Cycle 3004 32V 100 Duty Cycle 300A 32V 100 Duty Cycle 350A 34V 60 Duty Cycle 350A 34V 60 Duty Cycle 350A 34V 60 Duty Cycle 350A 34V 60 Duty Cycle 350A 34V 60 Duty Cycle Line Frequency 50 60 HZ Output Current Range 5 560 Amps Output Voltage Range 10 44 Volts Maximum Output Current 600 Amps Maximum Open Circuit Voltage OCV 70 Volts 57 Volts for CCC Operating Temperature Range Input Line Variations Line Regulation Load Regulation Water Protection Class 26 8 in 68 0 cm 14 9 T I amp 22 5 in 57 1 378 5 mm March 17 2006 Net Weight 154 Ibs 70 kg Art A 06853 Figure 2 3 Power Master 350 Dimensions 2 5 500 500P 35
86. mm Hat GT Zb Washer 13mm Spring Screw Hex 1 2 13 1 75 Capacitor 47nF 630V PM IPS Washer 3 5mm Spring Screw PHCR 6 32x3 8 Nut Hex 1 2 18 Washer 13mm Flat STZP Screw Hex HD M12 1 75x30 STZP PCB Display PM IPS Door Control Assy PM IPS Screw PHCR M4x12mm Blinding Harness Control Pot PM IPS Knob Control 1 4 IDx1 6 Cable Ribbon 10P 6 PM IPS Cable D SUN Assy PM IPS Rivet 1 8 BLIND STEEL Latch Self Adjusting PM IPS Washer 4 4mm Int Lock Nut Hex M4X0 7 STZP Nut 3 8 32 Lock PM IPS Reducer Shaft Hole Washer 3 5mm Ext Lock Nut Hex M3X0 5 STZP Overlay Pulse Control PM500P This part is available at most hardware stores 8 6 Part Number 831114PKD 204600 001 830831 830362 357654 357655 831125PKD 707665PKD 5CW976A See Note 1 See Note 1 351505 707158PKD See Note 1 See Note 1 400614 001 See Note 1 See Note 1 830838 830903WBLKPKD See Note 1 830935 870696PKD 171370 005 830936 See Note 1 830960 See Note 1 See Note 1 402663 404454 See Note 1 See Note 1 831103PKD March 17 2006 POWERMASTER 500 500 350 350P 06952 from outside March 17 2006 8 7 POWERMASTER 500 500 350 350P 8 07 PC Board Parts Aa O N il mb el eck C gt D gt D HK Note 1 This part is available at most hardware stores 8 8
87. mmag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin Hace M M ai Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci dessous AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs POWERMASTER 500 500 350 350P 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es
88. mper settings The lift arc circuit allows the arc to be initiated by momentarily touching the tungsten to the work and then lifting or rocking the tungsten off the work The lift arc circuit limits the touch current to a low value and then switches to the preset current after the arc is struck March 17 2006 SMAW mode In this mode the power sources operates in constant currentmode The front panel control can be used to preset the desired welding amperage The arc force control is activated for SMAW mode allowing the amount of dig or arc force to be set by the arc force control Maximum arc force is full clockwise full counter clockwise is zero arc force GMAW mode In this mode the power source operates in constant voltage mode The front panel control can be used to preset the desired welding voltage The inductance control is activated for GMAW mode The inductance control allows the arc characteristics to be adjusted Maximum inductance is full clockwise Higher inductance settings make the arc softer with less spatter Lower inductance settings give a stronger driving arc Generally the inductance control can be set at mid range as a good starting point The GMAW mode also has a built in wire sharpening circuit to help condition the end of the wire at the end of the weld This feature reduces the size of the ball on the end of the wire to improve the next arc start The wire sharp settings can be modified or disabled
89. n arc welding Al 12 Light Underif in 3mm 40751 Plasmaarcwelding i 8101 2in 3 12mm 5or6 Carbon arc air gouging Shielded metal arc Under 5 32 4 mm 10 14 5 32 to 1 4 in Plasma arc cutting 300 to 400 Over 400 Amp 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 Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums 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 Do not use weld
90. nal This is the signal which actually turns the inverter on and off Gun Switch Output Vi Figure 6 8 March 17 2006 POWERMASTER 500 500P 350 350P With gun switch on jumper A B on 19 pin remote R175 is 13 6 VDC with gun switch off R175 is OVDC See Figure 6 8 Output contactor switch on front panel should give the same results With R175 at 13 6 VDC D10 Cathode should also be high 15VDC with R175 at 0 D10 Cathode should also below See Figure 6 10 With R175 at 413 6VDC D10 Anode should be around 12VDC with R175 at 0 D10 Anode should be 0 7 D10 Anode is the ON OFF control signal to the PWM controller chip If D10 Cathode is right but the Anode side is not then check J5 4 to J5 5 jumper to make sure it is in place and also make sure power supplies are ok Also make sure the thermostat light is not on Any one of these conditions can inhibit the inverter circuit from running by keeping D10 Anode low R101 C3 C3 C36 A 029 R102 1 C52 R131 R132 R134 C56 C 4 R143 C 5 R146 C C 8 Contactor Input Signal 8141 R141 8142 R144 8145 M 8146 C76 _ R170 R172 R174 C88 R198 R199 R200 100 c81 c79 C103 NE C98 99 R201 C101 C102 CAUTION STATIC SENSITIVE Art 07552 6 19 POWERMASTER 500 500 350 350P 5 Gate Signal Checks C Use the CONTACTOR switch on the front panel to activa
91. nal to the machine but the controls are not energized In the ON position the control power is applied and the controls are energized In the ON position the digital display should be on This circuit breaker switch also protects the auxiliary 24 VAC and 115 VAC power in the case of an overload If circuit breaker trips determine cause of overload before resetting Allow breaker time to cool before resetting 42 Mode Select Switch Ihe mode select switch Is a four position switch used to select the weld process The four modes are as follows GTAW mode In this mode the power source operates in constant current mode with a lift arc starting circuit activated and arc force inductance disabled The lift arc circuit allows the arc to be initiated by momentarily touching the tungsten to the work and then lifting The lift arc circuit limits the touch current to a low value and then switches to preset current after lifting The lift arc feature can be disabled if desired to allow scratch starting by moving two jumpers internal to the machine on the main control board See configuration settings under Installation instructions chapter of this manual for an explanation of how to disable the lift arc feature SMAW mode In this mode the power source operates in constant current mode with the arc force control enabled CAG mode In this mode the power source operates in constant current mode with arc force inductance control disable
92. nd Or Constant Potential hold for preflow Direct Current DC High Temperature Burnback Time Protective Earth Fault Indication Ground NEE Inches Per Minute Line Arc Force Meters Per Minute Line Connection Touch Start GTAW Auxiliary Power Variable Inductance Receptacle Rating Auxiliary Power 04130 2 2 17 2006 2 05 General Power Master 500 amp 350 The Power Master 500 and 350 are primary inverter DC power sources that can be used for constant voltage and constant current weld processes The Power Master 500 output is rated at 450 Amps 38 Volts at 100 duty cycle and 560 Amps 42 4 Volts at 6096 duty cycle The Power Master 350 output is rated at 300 Amps 32 Volts at 100 duty cycle and 350 Amps 34 Volts at 60 duty cycle Both power source also provide 24VAC and 120VAC auxiliary outputs rated at 10 Amps Controls are built into the power source for Gas Tungsten arc welding GTAW Shielded Metal arc welding SMAW Carbon arc gouging CAG and Gas Metal arc welding GMAW An ArcForce Inductance control is also provided to allow adjustment of the arc stiffness or drive for SMAW and GMAW welding processes The graphs in Figure 2 1 show the output volt amp characteristics of the Power Master 500 power source March 17 2006 POWERMASTER 500 500P 350 350P VOLT AMP CURVE FOR CC SMAW MODE Volts MAX ARC FORCE 0 100 200 300 400 500 600 700
93. nge This amount of dirt being drawn into the machine as well amperage adjust range is in effect for both GTAW as lengthen the life of the fans and SMAW modes 4 Overtemperature Protection If the machine 22 Volts Adjust Range Locked A high and low overheats because of blocked air flow excessive voltage uu can be programmed 97 NIA ambient temperatures failed fan or other cause the modes which will limit the voltage adjust range of overtemperature protection will disable the output of the power source the power source until it has cooled down If the 23 Pulse Reference Range Locked A high and low overtemperature protection circuit operates it will turn pulse reference limit can be programmed which on the indicator light on the front panel and the fans will limit the adjust range of the output of the should continue to run until the machine cools The machine for the Pulsed GMAW mode overtemperature circuit will reset itself automatically once the machine has cooled Pulse Parameters All 24 of the Pulsed GMAW schedules can be modified to allow for a very flexible 9 Multi Voltage Operation The power source is design of the optimum pulse waveform In addition designed to operate from a wide range of input line the arc starting conditions and arc end conditions voltages as given in the specifications The machine can be modified can be reconfigured for the different line voltages with simple rugged voltage changeover panel refer
94. nt s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser tra ner par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilisez pas de c bles lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT MORTELLE 9 pas de c bles lectriques autour de votre corps 10 N utilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique peut tuer ou br ler gravement la piece souder L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de circuits internes de l quipement sont aussi sous ten soudage terre sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou 12 N utilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatemen
95. numbers 8 02 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded to other parts The part descriptions may be indented to show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List POWER SUPPLY NUMBERS Power Master 500 100085 Power Master 500P 100086 Power Master 350 100078 Power Master 350P 100079 March 17 2006 POWERMASTER 500 500P 350 350P 8 1 POWERMASTER 500 500 350 350P 8 03 External Panels eoanounson f le cd Note 1 This part is available most hardware stores 82 Bo ap Waa um Description Bushing Lifting Eye PM IPS Label Precaution Arc Equip Label Volt Changeover PM IPS Label Warning Lifting PM IPS Panel Left Side PM IPS Panel Right Side PM IPS Panel Top PM IPS Chassis Support Front PM IPS Chassis Support Side PM IPS Screw Hex HD M5 1 4x13 STZC Pin
96. on should be investigated and resolved before continuing Amps Display The top display shows preset amperage for GTAW and SMAW modes when not welding This display shows the actual welding current for all modes while welding For GMAW and Pulsed GMAW modes the meter will hold the last value at the end of the weld for up to 5 seconds Volts Display The bottom display shows preset voltage for GMAW and preset pulse reference for Pulsed GMAW when not welding The display will show actual welding voltage for all modes while welding For GMAW and Pulsed GMAW modes the meter will hold the last value at the end of the weld for up to 5 seconds Mode Select Switch The mode select switch is used to select one of the four built in operating modes of the power source One of the four indicator lights located above the switch should be on at all times indicating the mode which is currently selected The four modes are as follows GTAW mode In this mode the power source operates in constant current mode The front panel control can be used to preset the welding amperage If a foot pedal or other remote control is used then the front panel control is used to set the maximum welding current available to the foot pedal For GTAW mode the arc force control is not active A lift arc circuit is automatically activated for GTAW mode unless disabled internally by jumper selections on the control board See installation chapter for ju
97. one ofthe four available voltage settings See Figures 3 1 through 3 4 The four settings are 200 VAC 230 400VAC and 380VAC 460 VAC 1 Check the name plate of the machine for proper line voltage 2 Move the voltage links by loosening the nuts securing the links in place For 200 and 230 VAC settings place the two links in the 200 230V positions For 380 400 and 460 VAC settings place the two links directly on top of each other in the 400 460V position See figures 3 1 through 3 4 Make sure that the connections are properly tightened A DANGER ELECTRIC SHOCK CAN KILL Open the main wall disconnect switch or breaker before removing any covers or access panels on the welding machine Live voltage is still present even with the front panel control switch OFF Wait at least three full minutes after power has been removed before removing any covers or access panels to allow adequate time for internal capacitors to discharge March 17 2006 POWERMASTER 500 500P 350 350P 200 VOLT CONNECTION Figure 3 1 Art A 04083 230 VOLT CONNECTION Figure 3 2 Art A 04084 380 400 VOLT CONNECTION Figure 3 3 Art A 04085 200 400 555 m 460 VOLT CONNECTION Figure 3 4 Art A 04086 3 1 POWERMASTER 500 500 350 350P 3 03 Connecting Welding Machine to Line Voltage The input power should be connected to the unitthr
98. oot pedal or hand control To preset maximum output for GTAW place the LOCAL REMOTE switch in the LOCAL mode and set the maximum desired amperage on the digital meter The meter amps volts switch must be in the amps position Place the LOCAL REMOTE switch in the REMOTE mode to activate foot pedal control March 17 2006 POWERMASTER 500 500P 350 350P 10 Arc Force Inductance Control This control pot is 11 active for SMAW Stick and GMAW MIG In SMAW mode this potentiometer controls the amount of arc force or dig that the arc has Maximum arc force is full clockwise full counter clockwise is zero arc force In GMAW mode this becomes an inductance control Maximum inductance is full clockwise Higher inductance settings make the arc softer with less spatter Lower inductance settings give a stronger driving arc The inductance should be set according to the type of wire and gas and desired arc characteristics desired Generally the inductance control can be set at mid range as a good starting point Output Negative Terminal Connection point for negative welding lead 12 Output Positive Terminal Connection point for positive welding lead 43 POWERMASTER 500 500 350 350P 4 03 Fouer Master 500P and 350P Controls iS Control becomes active REMOTE contro 1S 13 15 2 Art A 06858 Figure 4 2 Power Master 500P and 350P Front Panel 1 44 Control Power ON OFF Switch Thi
99. or light is on whenever the output of the power source is energized either by the contactor switch on the front panel or by the remote gun switch signal 9 Contactor Switch This switch can be used to energize the output of the power source when a remote gun switch is not being used This switch would primarily be used for SMAW welding or GTAW welding without a remote pendant or foot pedal 10 Pulse Schedule Display This two digit display shows the current selected pulse GMAW welding schedule The current schedule can be changed by using the schedule up and down select buttons 11 Pulse Schedule Select Buttons These two buttons can be used to select one of the built in pulse GMAW welding schedules These buttons can only be used to change the pulse schedule when the output contactor is off see description 8 above 12 Remote On Selector This button allows the selection of either remote control of the output or local front panel control of the output The indicator light next to the switch will be on if remote control is selected and off if local control is selected Remote control is via either the 19 pin or 14 pin receptacle on the rear panel of the power source 13 Programmer Port This port allows the connection of the power source to a computer for accessing the programmable features of the power source This port is configured for direct connection to a serial port on a computer 14 Output Negative Terminal Connect
100. ore starting engine 5 WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Engines produce harmful exhaust gases Do not use welder to charge batteries or jump start vehicles N 1 Use equipment outside in open well ventilated areas Observe correct polarity and on batteries March 17 2006 13 POWERMASTER 500 500P 350 350P AT P WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure 1 Do not remove radiator cap when engine is hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp 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 Section of the U S Congress Office of Technology Assessment Biologica
101. ough a fused disconnect switch or other suitable disconnecting means furnished by the user Access is provided in the rear panel ofthe machine for the entry of the input conductors A DANGER ELECTRIC SHOCK CAN KILL Open the disconnect switch or breaker and determine that no voltage is present before connecting wires between welding machine and power supply CAUTION The method of installation conductor size and overcurrent protection shall conform to the requirements of the local electrical code the National Electrical Code or other national codes as applicable All installation wiring and machine reconnection shall be done by qualified persons Table 3 1 provides minimal information for selection of line conductors fuses and the equipment grounding conductor This information is from the National Electrical Code NFPA 70 1981 Edition Install this equipment per the latest edition available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 3 04 Connection Instructions 1 Remove left side panel to gain access to the input terminal block and ground screw 2 Connect the three phase power line to the terminal block as shown in Figure 3 5 3 Connect the power system safety ground to the screw labeled FRAME GROUND located on the base of the machine near the input terminal block as shown in Figure 3 5 4 Replace side panel
102. parts level 15 Keep all panels and covers securely in place 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself from work and ground using dry insulating mats or covers WARNING d el es 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch ARC RAYS can burn eyes and skin NOISE can damage open or remove line fuses so power cannot be turned on hearing Arc rays from the welding process produce accidentally intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage 5 Properly install and ground this equipment according to its Owner s Manual and national state and local codes hearing 6 Tum off all equipment when not in use Disconnect power to 1 Wear a welding helmet fitted with a proper shade of filter see equipment if it will be left unattended or out of service ANSI 749 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended March 17 2006 14 POWERMASTER 500 500 350 350P 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
103. pirer la peau Le bruit caus par certains proc d s peut mmm endommager 1 Eloignez la t te des fum es pour viter de les respirer 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI 249 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que 3 Silaventilation est inadequate portez un respirateur adduction vous observez l ex cution d une soudure d air approuv 2 A l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc 2 Portez des lunettes de s curit approuv es Des crans lat raux Lisez les fiches signal tiques et les consignes du fabricant rela sont recommand s tives aux m taux aux produits consummables aux rev tements 3 Entourez l aire de soudage de rideaux ou de cloisons pour prot ger et aux produits nettoyants les autres des coups d arc ou de l blouissement avertissez les 5 Netravaillez dans un espace confin que s il est bien ventil sinon observateurs de ne pas regarder l arc portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respi ration 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou
104. place jumper plug JP1 in the OFF position pins 3 to 4 shorted To re enable Wire Sharpening place jumper plug JP1 back in the ON position pins 1 to 2 shorted Replace board and panels Art A 04105 Figure 3 8 Wire Sharpening jumper plug March 17 2006 SECTION 4 OPERATION 4 01 General Safety Precautions Read and understand the safety instructions at the beginning of this manual prior to operating this machine WARNING Be sure to put on proper protective clothing and eye safeguards welding coat apron gloves and welding helmet with proper lenses installed See Safety Instructions and Warnings chapter included in this manual Neglect of these precautions may result in personal injury P s Pow gt Make all connections to the power source including electrode and work cables as wellas remote control cables with the power source turned off These connections could be electrically live with the power switch ON March 17 2006 POWERMASTER 500 500P 350 350P 4 POWERMASTER 500 500 350 350P 4 022 Power Master 500 and 350 Controls Art A 06857 Figure 4 1 Power Master 500 and 350 Front Panel 1 Control Power ON OFF Switch This circuit breaker switch activates the controls on the power source When this switch is in the OFF position the power source is in standby mode There is still line voltage present inter
105. powering wire feeders water circulators etc Fuse This fuse protects the control circuit in the power source If the fuse opens it should be replaced with a like amperage and voltage 20 amps 600VAC Input Power Access This opening provides access to the input terminal block for the input cable Refer to the installation chapter of this manual for detailed instructions CAN Port PowerMaster 500P and 350P only This serial port is used for connection to a CAN compatible Thermal Arc wire feeder or other auxilliary device All ofthe programmable features of the power source can be accessed via this port March 17 2006 POWERMASTER 500 500P 350 350P 47 POWERMASTER 500 500P 350 350P 4 05 GTAW Gas Tungsten Arc Welding 1 Connectthe work lead to the positive terminal and the torch to the negative terminal of the power source normal connection for Provide suitable shielding gas connections and controls to the torch The power source does not provide connections for the shielding gas Select the proper tungsten size and type for the job If a foot pedal or torch control is being used connect to the 14 or 19 pin remote receptacle on the rear of the power source Turn the control power switch ON located on the front panel of the power source The digital display on the power source should be activated Set the front panel mode switch to GTAW Presetthe weld amperage using the front panel
106. r compl tement le bouchon 1 05 Principales Normes De Securite Safety in Welding and Cutting norme ANSI 749 1 American Weld ing Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Pro tection Association Batterymarch Park Quincy MA 02269 March 17 2006 SECTION 2 INTRODUCTION 2 01 How To Use This Manual This Owner s Manual applies to just specification or part numbers listed on page i To ensure safe
107. re 6 4 and connection diagram NOTE Because of the capacitor boards connected across the IGBTs they may initially show a short circuit when using the diode checker until the capacitors charge up Check both IGBTs as follows E2 4 to C2E1 0 2 0 9 E2 to C2E1 Open See Note above C2E1 to C1 0 2 0 9 C2E1 to C1 4 Open See Note Above Art A 07547 Figure 6 3 IGBT Module Output Diode test Check the output diodes at the output weld terminals as follows Positive terminal to Negative terminal Open Positive terminal to Negative terminal 0 2 0 9 6 13 POWERMASTER 500 500P 350 350P Capacitor Board tests The capacitors can be checked using the diode checker function with the power disconnected from the machine A good capacitor will initially show a short and then go to an open circuit as the capacitor charges up If the meter leads are then reversed the capacitor will again show a short and go to an open as the capacitor charges with the opposite polarity NOTE Check the IGBTs and input rectifier first If an IGBT is shorted it will have to be disconnected from the capacitor board before the capacitor can be checked Check the four capacitor banks using the diode checker function on the meter with power disconnected from the machine as follows C1 to C2E1 top IGBT C2E1 to E2 top IGBT C1 to C2E1 bottom IGBT C2E1 to E2 bottom IGBT
108. s circuit breaker switch activates the controls on the power source When this switch is in the OFF position the power source is in standby mode Line voltage is still present internal to the machine but the controls are not energized In the ON position power is applied to the control circuit of the power source Whenever the switch is in the ON position the digital meter displays are activated This circuit breaker also protects the auxiliary 24 VAC and 115 VAC power in case of an overload If the circuit breaker trips determine the cause of the overload before resetting Output Control This control is used to set the output voltage or amperage depending on the operating mode of the power source For GTAW and SMAW modes this control is used to preset the amperage For GMAW this control presets the welding voltage For Pulse GMAW this control sets the pulse reference which is similar in function to a voltage control selected except for GTAW mode In GTAW mode this control is used to set the maximum welding current available to the remote control 3 Overtemp Indicator This indicator light will be on if the power source has overheated Whenever this light is on the power source will be disabled from welding but the fans will continue to run to cool the unit Once the power source cools down this light will automatically go off and the unit will be ready to weld If this light comes on the cause of the overheating conditi
109. sition GTAW range 5 560 AMPS display b SMAW range 5 560 AMPS display c CAG range 5 560 AMPS display d GMAW range 0 44 0 VOLTS display March 17 2006 POWERMASTER 500 500P 350 350P 2 CONTACTOR control Whenever the CONTACTOR switch is ON the indicator LED should also be on Anytime the CONTACTOR is on there should be open circuit voltage present on the output terminals of the power source Open circuit voltage should be approximately 50 70 volts for all operating modes of the power source except GMAW For checking open circuit voltage in GMAW mode use an external CONTACTOR control NOTE For load testing the machine or welding in GMAW mode it will be necessary to use an external CONTACTOR signal otherwise the machine will NOT produce the correct output voltage D Possible defective main control board E Possible defective IGBT or input rectifier module See how to check these parts below Check internal wiring to control board and current sensor Possible defective current sensor 5b Machine powers up but no output or incorrect output Power Master 500P and 350P only A Check for open circuit voltage see how to testopen circuit voltage below Check for shorted output diode see how to check output diodes below Check front panel controls NOTE If some of the controls appear not to function as described below they may have been locked out or restricted us
110. t install ou inad quatement mis la terre est dangereux 14 Portez un harnais de s curit si vous travaillez en hauteur 1 Netouchez pas des pi ces sous tension 18 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables March 17 2006 15 POWERMASTER 500 500 350 350P 9 7 a AVERTISSEMENT AVERTISSEMENT LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX LES VAPEURS ET LES FUMEES SONT DANGEREUSES ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE POUR LA SANTE L arc de soudage produit une chaleur et des rayons Le soudage d gage des vapeurs et des fum es ultraviolets intenses susceptibles de br ler les yeux et dangereuses res
111. te the gate drive With CONTACTOR on the gate voltage should be approximately 14 5 VAC at 17KHz Remove jumper from pins A amp B of 19 pin with the CONTACTOR off the gate voltage should read amphenol if it is still in place 0 volts A Set machine for SMAW LOCAL preset A V for 100 D Measure all four gate drive signals J7 1 to J7 5 J7 4 amps to J7 8 J8 1 to J8 5 and J8 4 to J8 8 B Check gate drive voltages using digital meter set for AC volts Gate Drive Signals OFF ON WIRE SHARP NN a 3 034uxo R118 H e e e e MER C50 D37 US C48 C49 51 6 8186 Art 07553 us _ FREQ ADJUST AE R120 R121 Figure 6 9 6 20 March 17 2006 6 Remote Control Checks A Jumper pins H and J together at 19 pin remote receptacle on rear panel Select GMAW mode and REMOTE on front panel TP2 1 10V Ref should measure 10VDC all the time Switch to GTAW mode TP2 1 should vary from 0 1 to 10 as the front panel A V control is varied from min to max Remove jumper from pins and J of 19 pin remote and jumper pin C to E on 14 pin remote receptacle on the rear panel G In GTAW mode TP2 1 should vary from 0 2 to 10 VDC as the front panel control is varied from min to max H In GMAW mode TP2 1 should read 10 all the time If either of these are not correct then verify that the ma
112. ted otherwise use 4 2 as the ground or common connection when making measurements on the control circuits A DANGER The gate drive signals T1 T2 R24 R27 J7 and J6 are all connected to the primary circuit and are live whenever power is applied to the machine even if the CONTROL POWER switch is in the OFF position Switch off power at main disconnect before unplugging J7 and J8 NOTE Disconnect connectors J7 J8 and J9 from the control board before making the following checks This will keep the input contactors off and keep from firing the gates on the IGBTs circuit 6 16 1 Power Supplies TP2 6 to TP4 2 GND 15 VDC TP2 3 to TP4 2 GND 15 VDC TP2 2 to TP4 2 GND 5 VDC If the power supplies do not check ok then disconnect the ribbon cable from J1 to isolate the main control board from the front panel board s dir gt D oc SP Tx R13 53 w s CS2 R131 n 00 C74 us Cep AO j J1 1 n IW n Rizr R173 81691 p U17 n R198 Ku C100 C103 R197 ee Gees 1 1 9 state SENSITIVE Art A 07549 WORKING Figure 6 5 Power Supply Test Points March 17 2006 POWERMASTER 500 500P 350 350P If the power supplies still do not check ok verify that the proper AC voltage is coming up to the board L1 to TP4 2 GND 21 VAC L3 to
113. to Wire sharp Both GMAW and Pulsed GMAW modes Installation chapter for detailed instructions provide a wire sharpening sequence at the end of the weld to condition the end of the wire The wire 6 Multi Process Operation The machine has built in sharpening time and voltage can be modified Meter Functions The meter hold feature and meter refresh rate can both be modified if desired Software Control In addition to the programmable features of the Power Master 500P the power source can be controlled through either the programmer port or the CAN port This includes complete control of the power source such as mode pulse schedule pulse parameters remote local control etc Most of the features of the power source can be controlled in real time under live arc conditions 2 9 POWERMASTER 500 500 350 350P 2 10 17 2006 SECTION 3 INSTALLATION 3 01 Location Adequate air circulation is needed at all times in order to assure proper operation Provide aminimum of 12 inches 305 mm of free airspace on all sides of the unit Make sure that the ventilator openings are not obstructed Ventilation air flow is from rear to side 3 02 Voltage Changeover For proper operation and to prevent damage to the machine the voltage changeover must be set according to the incoming line voltage Remove the left side panel ofthe machine to gain access to the voltage changeover board Setthe links to agree with
114. ty precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 00 Arc Welding Hazards 7 Usefully 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 52 time or touch other people with the holder or electrode 8 Donot use worn damaged undersized or poorly spliced cables WARNING 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground ELECTRIC SHOCK can kill 11 Do not touch electrode while in contact with the work ground circuit Touching live electrical parts can cause fatal shocks or 12 Use only well maintained equipment Repair or replace damaged severe burns The electrode and work circuit is electrically parts at once live whenever the output is on The input power circuit and machine internal circuits are also live when power 13 In confined spaces or damp locations do not use a welder with is on In semiautomatic or automatic wire welding the AC output unless it is equipped with a voltage reducer Use wire wire reel drive roll housing and all metal parts equipment with DC output touching WITE Are EIeCIIGANY 14 Wear a safety harness to prevent falling if working above floor installed or improperly grounded equipment is a hazard E 1 not touch live electrical
115. volts for GMAW place the meter Amps Volts switch in the Volts position and adjust the main Amps Volts control potentiometer to the desired voltage The meter will automatically switch over to actual amps or volts while welding depending on the position of the meter Amps Volts switch Meter Amps Volts Switch This two position toggle switch is used to select whether the digital meter will display amps or volts To preset weld amperage for GTAW SMAW or CAG place this switch in the AMPS position To preset weld voltage for GMAW place this switch in the VOLTS mode After an arc has been initiated this switch allows either actual weld amps or weld volts to be displayed on the meter Remote Local Switch The remote local toggle switch is used to select either front panel control of output amps volts LOCAL mode or remote control of output amps volts through the 19 pin or 14 pin receptacles located on the rear panel REMOTE mode For mode the maximum output current must be preset by the front panel Amps Volts control pot For all other modes the remote control is full output of the machine Amps Volts Control This control potentiometer sets the output amps or volts depending on the weld process Clockwise is increasing output For all modes except GTAW this control is only active when the LOCAL REMOTE switch is in the LOCAL mode For GTAW this control potentiometer is used to set the maximum weld current available to a f
116. x M8 1 25x20 STZP Screw PHCR M5 8x20mm blinding Screw Hex HD M5 1 4x13 STZC Screw PHCR M5 8x50 STZP Screw Hex HD 1 4 20x 5 Screw SHC 1 4 20x5 8 Screw PHCR M6 1 0x16mm STZP Screw PHCR 10 32x3 4 Bracket IGBT Fan PM IPS Heatsink Output Diodes PM IPS Bracket Diode Fan ID Art A 06940 Part Number 830413 830414 707159PKD 406241 002 830358 830353 830360 707107 830962 830911 205018 001 707618 9 830934 830351 830912 831194 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 830898 830896 830806 March 17 2006 POWERMASTER 500 500 350 350P Art A 06937 NAKI 8 13 March 17 2006 POWERMASTER 500 500 350 350P 8 14 17 2006 POWERMASTER 500 500P 350 350P APPENDIX 1 GENERAL INFORMATION Note the model and specification number shown on the equipment nameplate Locate these numbers in the model and specification number columns below Useonly those diagrams and instructions that are applicable SPECIFICATION NUMBER MODEL SCHEMATIC AND CONNECTION DIAGRAM 100085 POWER MASTER 500 830921 830920 100086 POWER MASTER 500P 830924 830925 100078 POWER MASTER 350 830921 100079 POWER MASTER 350P 830924 17 2006 1 POWERMASTER 500 500P 350 350P APPENDIX 2 500 350 SCHEMATIC DIAGRAM
117. y an experienced qualified person only Any electrical work must be performed by an electrician or other person properly trained in servicing electrical equipment Do not permit untrained persons to inspect clean or repair this equipment Use only recommended replacement parts when servicing this machine WARNING Danger HIGH VOLTAGE is present internally even with the control power switch in the OFF position Before inspecting cleaning or servicing disconnect and lock out the input power to the power source T Periodically clean the inside of the welding power source by using clean dry compressed air of not over 25 psi as normal preventive maintenance At the time of the cleaning a full inspection of the welding machine and setup should be performed March 17 2006 POWERMASTER 500 500P 350 350P SECTION 5 MAINTENANCE The following checklist can be used as a guide for routine maintenance Check warning labels for readability Check sheet metal panels all screws and fasteners should be firmly secured heavily corroded panels and fasteners or damaged panels should be replaced Check primary input power wiring to the machine including ground Repair or replace any wires that have cracked or damaged insulation or frayed connections Check output weld connections including any connections to wire feeders fixtures etc Loose or frayed connections can cause overheating of the output terminals or ex

Thermal Arc PowerMaster 350, 350P, 500, 500P Service Manual_(0

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