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350
500
POWERMASTER
CC/CV POWER SOURCE
500P
Art # A-07643
Operating Manual
Version No: AB.01
Issue Date: March 17, 2006
Operating Features:
Manual No.: 0-4749
208
V
230
V
460
V
400
V
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call
1-800-752-7621, or visit us on the web at www.Thermalarc.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.
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
Instruction Manual Number 0-4749 for:
Power-Master 500 Spec Number 100060A, 100095 (CCC)
Power-Master 500P
Power-Master 350
Spec Number 100054A, 100096 (CCC)
Spec Number 100078, 100101 (CCC), 100099 (CSA)
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711 www.thermalarc.com
Copyright 2006 by
Thermadyne Industries Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Publication Date: March 17, 2006
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:
___________________________________
___________________________________
___________________________________ i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.04 Connecting Welding Machine to Line Voltage ................................................ 3-2
SECTION 4:
OPERATION ........................................................................................... 4-1
4.09 Pulsed GMAW (Power-Master 500P Only) ................................................... 4-10
SECTION 5:
SERVICE .............................................................................................. 5-1
5.01 General Maintenance ...................................................................................... 5-1
SECTION 6:
PARTS LIST .......................................................................................... 6-1
6.05 Front Panel Parts (Power-Master 500 and 350) ............................................. 6-4
APPENDIX 1: GENERAL INFORMATION ................................................................. A-1
APPENDIX 2: PM500/350 CONNECTION DIAGRAM 1 OF 2 .......................................... A-2
APPENDIX 3: PM500/350 CONNECTION DIAGRAM 2 OF 2 .......................................... A-4
APPENDIX 4: PM500P CONNECTION DIAGRAM 1 OF 2 .............................................. A-6
APPENDIX 5: PM500P CONNECTION DIAGRAM 2 OF 2 .............................................. A-8
APPENDIX 6: POWERMASTER 500 OPTIONS & ACCESSORIES .................................... A-10
APPENDIX 7: POWERMASTER 500P OPTIONS & ACCESSORIES .................................. A-11
APPENDIX 8: POWERMASTER 350 OPTIONS & ACCESSORIES .................................... A-12
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
POWERMASTER 500, 500P, 350
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01
Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground) circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor level.
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
March 17, 2006
POWERMASTER 500, 500P, 350
3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
WARNING
WARNING
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
1-2
Welding or cutting
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Electrode Size Filter Welding or cutting
Torch soldering
Torch brazing
2
3 or 4
Oxygen Cutting
Light Under 1 in., 25 mm 3 or 4
Medium 1 to 6 in., 25-150 mm 4 or 5
Heavy Over 6 in., 150 mm 5 or 6
Gas welding
Light Under 1/8 in., 3 mm 4 or 5
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6
Heavy Over 1/2 in., 12 mm
Shielded metal-arc
Under 5/32 in., 4 mm
6 or 8
10
5/32 to 1/4 in.,
Over 1/4 in., 6.4 mm
12
14
Electrode Size Filter
Gas metal-arc
Non-ferrous base metal
Ferrous base metal
Gas tungsten arc welding
(TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
All
All
All
All
All
All
Plasma arc cutting
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp
12
14
9
12
14
11
12
12
12
12
12
March 17, 2006
POWERMASTER 500, 500P, 350
2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
WARNING
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
WARNING
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.
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open flames.
3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
WARNING
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety
Standards.
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 before starting engine.
Engines can be dangerous.
WARNING
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
March 17, 2006
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.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
POWERMASTER 500, 500P, 350
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.
WARNING
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 & 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, Biological Effects of Power
Frequency Electric & 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 and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about 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:
1.02
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code 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 Protection,
ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
1-4 March 17, 2006
1.03
Symbol Chart
Note that only some of these symbols will appear on your model.
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
115V 15A
Receptacle Rating-
Auxiliary Power
March 17, 2006
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
Single Phase
Three Phase
Three Phase Static
Frequency Converter-
Transformer-Rectifier
Remote
X
%
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
V
Voltage Input
POWERMASTER 500, 500P, 350
Art # A-04130
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
t1
t
Spot Time
Preflow Time
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
POWERMASTER 500, 500P, 350
1.04
Precautions De Securite En Soudage à L’arc
MISE EN GARDE
LE SOUDAGE A 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 STIMULATEUR 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 procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.05
Dangers Relatifs Au Soudage à L’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez 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’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.
1-6
6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
March 17, 2006
POWERMASTER 500, 500P, 350
AVERTISSEMENT
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.
Opération de coupage ou soudage
Brassage tendre au chalumeau
Brassage fort au chalumeau
Oxycoupage
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de filtre oculaire
Opération de coupage ou soudage
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de filtre oculaire toutes conditions 2
Soudage á l'arc sous gaz avec fil plein (GMAW) toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11 toutes conditions 12
Soudage aux gaz mince moyen
épais mince moins de 1 po. (25 mm) de 1 á 6 po. (25 á 150 mm) plus de 6 po. (150 mm) moins de 1/8 po. (3 mm) moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais plus de 1/2 po. (12 mm)
Soudage á l'arc avec
électrode enrobees
(SMAW) moins de 5/32 po. (4 mm)
5/32 á 1/4 po. (4 á 6.4 mm) plus de 1/4 po. (6.4 mm)
2 ou 3
4 ou 5
5 ou 6
4 ou 5
5 ou 6
6 ou 8
10
12
14 métaux ferreux
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plasma (PAW)
Gougeage Air-Arc avec
électrode de carbone mince
épais
Coupage á l'arc Plasma (PAC) mince moyen toutes conditions toutes conditions toutes conditions toutes dimensions moins de 300 amperès de 300 á 400 amperès
épais plus de 400 amperès
12
12
12
12
12
14
9
12
14
March 17, 2006
POWERMASTER 500, 500P, 350
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du soudage.
AVERTISSEMENT
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
1-8
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
March 17, 2006
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.
EXPLOSION.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
Le carburant est hautement inflammable.
POWERMASTER 500, 500P, 350
Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.
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 être brûlant et sous pression.
AVERTISSEMENT
1. N’ôtez 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’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
1.06
Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American
Welding 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
Association canadienne de normalisation, Standards Sales, 276
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face
Protection, norme ANSI Z87.1, American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-
LATEUR PEUT BRULER LA PEAU ET LES YEUX.
March 17, 2006
POWERMASTER 500, 500P, 350
1.07
Graphique De Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension
Hors Tension
Tension dangereuse
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Fusible
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
Courant Continue (DC)
Terre de Protection
Ligne
Connexion de la Ligne
1-10
Source Auxiliaire
115V 15A
Classement de Prise-
Source Auxiliaire
Mono Phasé
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur
Transformateur-Redresseur
Distant
X
%
Facteur de Marche
Pourcentage
Panneau/Local
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Decoupe Arc Carbone
(CAC-A)
Courant Constant
Tension Constante
Ou Potentiel Constant
Haute Température
Force d'Arc
Amorçage de L’arc au
Contact (GTAW)
Inductance Variable
V
Tension
Déroulement du Fil
Alimentation du Fil Vers la Pièce de Fabrication
Hors Tension
Torch de
Soudage
Purge Du Gaz
Mode Continu de
Soudure
Soudure Par Point
t1 t
Duréc du Pulse
Durée de Pré-Dèbit
t2 t
Durée de Post-Dèbit
Détente à 2-Temps
Appuyez pour dèruarer l’alimentation du fils et la soudure, le relâcher pour arrêter.
Détente à 4-Temps
Maintenez appuyez pour pré-dèbit, relailez pour initier l'arc. Appuyez pour arrêter l'arc, et mainteuir pour pré-dèbit.
Probléme de Terre
IPM
Pouces Par Minute
MPM
Mètres Par Minute
Art # A-07639
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 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:
!
WARNING
A WARNING gives information regarding possible personal injury.
!
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
POWERMASTER 500, 500P, 350
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. Record 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 uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.
March 17, 2006 2-1
POWERMASTER 500, 500P, 350
2.04 General: Power-Master 500
The Power-Master 500 is a primary inverter DC power source 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 500
Amps/40 Volts at 60% duty cycle. The power source also provides 24VAC and 120VAC auxiliary outputs both 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)/Flux Cored Arc Welding (FCAW). An ArcForce/
Inductance control is also provided to allow adjustment of the arc stiffness for SMAW.
The graphs in Figure 2-1 show the output volt-amp characteristics of the Power-Master 500 power source.
2-2
VOLT-AMP CURVE FOR CC-SMAW MODE
70
40
30
60
50
MIN.
20
MAX. ARC FORCE
10
0
0
MIN. ARC
FORCE
100 200 300
Amps
400 500
MAX.
600 700
VOLT-AMP CURVE FOR CC-GTAW MODE
70
60
50
40
30
20
MIN.
10
0
0 100 200 300
Amps
400
MAX.
500 600
VOLT-AMP CURVE FOR CV-GMAW MODE
70
40
30
60
50
20
10
0
0
MIN.
MAX.
100 200 300
Amps
400 500 600 700
Art # A-04120
Figure 2-1: Power-Master 500 Power Source Volt-
Amp Characteristics
March 17, 2006
POWERMASTER 500, 500P, 350
2.05 General: Power-Master 350
The Power-Master 350 is a primary inverter DC power source that can be used for constant voltage and constant current weld processes. The Power-Master 350 output is rated at 350 Amps/34 Volts at 100% duty cycle and 425
Amps/37 Volts at 60% duty cycle. The power source also provides 24VAC and 120VAC auxiliary outputs both 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)/Flux Cored Arc Welding (FCAW). An ArcForce/
Inductance control is also provided to allow adjustment of the arc stiffness for SMAW.
The graphs in Figure 2-1 show the output volt-amp characteristics of the Power-Master 500 power source.
VOLT-AMP CURVE FOR CC-SMAW MODE
70
60
50
40
MIN.
30
20
MAX. ARC FORCE
10
0
0
MIN. ARC
FORCE
100 200 300
Amps
400
MAX.
500 600 700
VOLT-AMP CURVE FOR CC-GTAW MODE
70
60
50
40
30
20
MIN.
10
0
0
100 200 300
Amps
400
MAX.
500 600
VOLT-AMP CURVE FOR CV-GMAW MODE
70
60
50
40
30
20
10
0
0
MIN.
MAX.
100 200 300
Amps
400 500 600 700
Art #A-07352
Art # A-04120
March 17, 2006
Figure 2-2: Power-Master 350 Power Source Volt-Amp
Characteristics
2-3
POWERMASTER 500, 500P, 350
2.06 Power-Master 500 Specifications
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
Line Voltage
208 VAC/3 Phase
230 VAC/3 Phase
380 VAC/3 Phase
400 VAC/3 Phase
460 VAC/3 Phase
Line Current
68 Amps
62 Amps
40 Amps
35 Amps
30 Amps
24.5
24.7
23.7
24.2
23.9
Input Data kVA Eff.
PF Output
89% 0.83 450A/38V/100% Duty Cycle
90% 0.82 450A/38V/100% Duty Cycle
89% 0.84 450A/38V/100% Duty Cycle
90% 0.84 450A/38V/100% Duty Cycle
91% 0.84 450A/38V/100% Duty Cycle
208 VAC/3 Phase
230 VAC/3 Phase
380 VAC/3 Phase
400 VAC/3 Phase
460 VAC/3 Phase
88 Amps
82 Amps
50 Amps
43 Amps
39 Amps
31.7
32.7
32.9
29.8
31.1
89% 0.88 500A/40.0/60% Duty Cycle
89% 0.87 500A/40.0/60% Duty Cycle
88% 0.87 480A/39.2/60% Duty Cycle
91% 0.86 480A/39.2/60% Duty Cycle
90% 0.88 500A/40.0/60% Duty Cycle
Line Frequency:
Out put Current Range:
Out put Voltage Range:
Maximum Output Current:
Maximum Open Circuit Voltage (OCV):
Operating Temperature Range:
Input Line Variations:
Line Regulation:
Load Regulation:
Water Protection Class:
50/60 HZ
5 – 560 Amps
10 – 44 Volts
600 Amps
70 Volts (57 Volts for CCC)
32-104°F
± 10%
± 1%
± 1%
IP23S
23.0 in / 58.4 cm
WARNING
REMOTE
CONTACTOR
LOCAL
POWER
10A
25.5 in /
64.7 cm
26.8 in /
68.0 cm
2-4
14.9 in /
378.5 mm
22.5 in / 57.1 cm
Net Weight: 154 lbs / 70 kg
Figure 2-3: Power-Master 500 Dimensions and Weight
Art # A-06852
March 17, 2006
POWERMASTER 500, 500P, 350
2.07 Power-Master 350 Specifications
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
Line Voltage
208 VAC/3 Phase
230 VAC/3 Phase
380 VAC/3 Phase
400 VAC/3 Phase
460 VAC/3 Phase
Line Current
37 Amps
33 Amps
24 Amps
19 Amps
17 Amps
13.1
13.1
15.8
13.1
13.1
Input Data kVA Eff.
PF Output
89% 0.83 300A/32V/100% Duty Cycle
89% 0.82 300A/32V/100% Duty Cycle
88% 0.82 300A/32V/100% Duty Cycle
89% 0.84 300A/32V/100% Duty Cycle
89% 0.84 300A/32V/100% Duty Cycle
208 VAC/3 Phase
230 VAC/3 Phase
380 VAC/3 Phase
400 VAC/3 Phase
460 VAC/3 Phase
43 Amps
39 Amps
28 Amps
23 Amps
20 Amps
15.4
15.4
18.4
15.4
15.4
89% 0.88 350A/34V/60% Duty Cycle
89% 0.87 350A/34V/60% Duty Cycle
88% 0.85 350A/34V/60% Duty Cycle
91% 0.86 350A/34V/60% Duty Cycle
90% 0.88 350A/34V/60% Duty Cycle
Line Frequency:
Out put Current Range:
Out put Voltage Range:
Maximum Output Current:
Maximum Open Circuit Voltage (OCV):
Operating Temperature Range:
Input Line Variations:
Line Regulation:
Load Regulation:
Water Protection Class:
50/60 HZ
5 – 560 Amps
10 – 44 Volts
600 Amps
70 Volts (57 Volts for CCC)
32-104°F
± 10%
± 1%
± 1%
IP23S
23.0 in / 58.4 cm
WARNING
REMOTE
CONTACTOR
LOCAL
POWER
10A
25.5 in /
64.7 cm
26.8 in /
68.0 cm
March 17, 2006
14.9 in /
378.5 mm
22.5 in / 57.1 cm
Net Weight: 154 lbs / 70 kg
Figure 2-4: Power-Master 350 Dimensions and Weight
Art # A-06853
2-5
POWERMASTER 500, 500P, 350
2.08 General: Power-Master 500P
The Power-Master 500 Pulse is a primary inverter DC power source 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 500 Amps/40 Volts at 60% duty cycle. The power source also provides 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.
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.
VOLT-AMP CURVE FOR CC-SMAW MODE
70
60
50
40
MIN.
30
20
MAX. ARC FORCE
10
0
0
MIN. ARC
FORCE
100 200 300
Amps
400 500
MAX.
600 700
VOLT-AMP CURVE FOR CC-GTAW MODE
70
60
50
40
30
20
MIN.
10
0
0
100 200 300
Amps
400
MAX.
500 600
VOLT-AMP CURVE FOR CV-GMAW MODE
70
60
50
40
30
20
10
0
0
MIN.
MAX.
100 200 300
Amps
400 500 600 700
Art # A-04120
2-6
Figure 2-4 Power-Master 500P Power Source Volt-Amp
Characteristics
March 17, 2006
POWERMASTER 500, 500P, 350
2.09 Power-Master 500P Specifications
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items
.
Line Voltage
208 VAC/3 Phase
230 VAC/3 Phase
380 VAC/3 Phase
400 VAC/3 Phase
460 VAC/3 Phase
Line Current
68 Amps
62 Amps
40 Amps
35 Amps
30 Amps
24.5
24.7
23.7
24.2
23.9
Input Data kVA Eff.
PF Output
89% 0.83 450A/38V/100% Duty Cycle
90% 0.82 450A/38V/100% Duty Cycle
89% 0.84 450A/38V/100% Duty Cycle
90% 0.84 450A/38V/100% Duty Cycle
91% 0.84 450A/38V/100% Duty Cycle
208 VAC/3 Phase
230 VAC/3 Phase
380 VAC/3 Phase
400 VAC/3 Phase
460 VAC/3 Phase
88 Amps
82 Amps
50 Amps
43 Amps
39 Amps
31.7
32.7
32.9
29.8
31.1
89% 0.88 500A/40.0/60% Duty Cycle
89% 0.87 500A/40.0/60% Duty Cycle
88% 0.87 480A/39.2/60% Duty Cycle
91% 0.86 480A/39.2/60% Duty Cycle
90% 0.88 500A/40.0/60% Duty Cycle
Line Frequency:
Out put Current Range:
Out put Voltage Range:
Maximum Output Current:
Maximum Open Circuit Voltage (OCV):
Operating Temperature Range:
Input Line Variations:
Line Regulation:
Load Regulation:
Water Protection Class:
50/60 HZ
5 – 560 Amps
10 – 44 Volts
600 Amps
70 Volts (57 Volts for CCC)
32-104°F
± 10%
± 1%
± 1%
IP23S
23.0 in / 58.4 cm
22.0 in / 55.9 cm
26.8 in /
68.0 cm 6.8 in /
172.7 mm
25.5 in /
64.7 cm
March 17, 2006
14.9 in / 378.5 mm
Net Weight: 154 lbs / 70 kg
Figure 2-5: Power-Master 500P Dimensions and Weight
Art # A-06854
2-7
POWERMASTER 500, 500P, 350
2.10 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.
2. Output Overload Protection – The overload protection
feature will limit the continuous weld current to the maximum value listed in the specifications for any of the modes of operation. The machine will continue to operate but the current will be limited to this maximum value.
3. Cooling Fan Control – The cooling fans are designed
to operate only when required. They will come on whenever the output contactor control of the machine is on. The fans will come on for several minutes when the machine is first turned on and will normally stay on for several minutes after the output contactor control has been switched off. The fans will turn off after several minutes of inactivity, to minimize the amount of dirt being drawn into the machine, as well as lengthen the life of the fans.
4. Over-temperature Protection – If the machine
overheats because of blocked air flow, excessive ambient temperatures, failed fan, or other causes, the over-temperature protection will disable the output of the power source until it has cooled down. If the overtemperature protection circuit operates, it will turn on the over-temperature indicator light on the front panel and the fans should continue to run until the machine cools. The overtemperature circuit will reset itself automatically once the machine has cooled.
5. Multi-Voltage Operation – The power source is
designed to operate from a wide range of input line voltages as given in the specifications. The machine can be reconfigured for the different line voltages with a simple, rugged voltage changeover panel (refer to
Section 3 Installation for detailed instructions).
6. Multi-Process Operation – The machine has built in
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. Each mode of operation has a dedicated electronic control which has been optimized for that particular process.
2-8
2.11 PM500P Programmable Features
1. Lockout features: Any or all of the following controls
can be locked out on the Power-Master 500P 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.
1.1 Mode Select Switch - Prevents changing of the mode of operation.
1.2 Remote On Switch - Prevents changing of the remote control feature.
1.3 Schedule Select Switches - Prevents changing of the pulse mig schedule.
2. Restricted output adjustment: The range of
adjustment of the output of the power source can be restricted for the various modes of operation.
2.1 Amps Adjust Range Locked: A high and low amperage limit can be programmed which will limit the output amperage adjust range. This amperage adjust range is in effect for both GTAW and SMAW modes.
2.2 Volts Adjust Range Locked: A high and low voltage limit can be programmed for GMAW mode which will limit the voltage adjust range of the power source.
2.3 Pulse Reference Range Locked: A high and low pulse reference limit can be programmed which will limit the adjust range of the output of the machine for the Pulsed-GMAW mode.
3. Pulse Parameters: All 24 of the Pulsed GMAW
schedules can be modified, to allow for a very flexible design of the optimum pulse waveform. In addition the arc starting conditions, and arc end conditions can be modified.
4. Wire sharp: Both GMAW and Pulsed GMAW modes
provide a wire sharpening sequence at the end of the weld to condition the end of the wire. The wire sharpening time and voltage can be modified.
5. Meter Functions: The meter hold feature and meter
refresh rate can both be modified if desired.
6. 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.
March 17, 2006
POWERMASTER 500, 500P, 350
SECTION 3:
INSTALLATION
E4
E1
3.01 Location
Adequate air circulation is needed at all times in order to assure proper operation. Provide a minimum 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 AC line voltage. Remove the left side panel of the machine to gain access to the voltage changeover board. Set the links to agree with one of the four available voltage settings. (See Figures 3-1 through 3-4).
The four settings are:
200 VAC 230 VAC
400VAC / 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.
E2
400
460
E3
E4
E2
E4
200
230
E2
400
460
200 VOLT CONNECTION
Figure 3-1
E3
E1
E1
200
230
E3
400
230 460
200
400
460
230 VOLT CONNECTION
Figure 3-2
200
230
460
Art # A-04083
Art # A-04084
DANGER
380 / 400 VOLT CONNECTION
Figure 3-3
Art # A-04085
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.
E4
200
230
E2
E1
200
230
E3
200
400
230
460 VOLT CONNECTION
Figure 3-4
Art # A-04086
March 17, 2006
3-1
POWERMASTER 500, 500P, 350
3.03 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.
3.04 Connecting Welding Machine to
Line Voltage
The input power should be connected to the unit through a fused disconnect switch, or other suitable disconnecting means furnished by the user. Access is provided in the rear panel of the machine for the entry of the input conductors.
DANGER:
CUSTOMER
INPUT
LINES
FRAME GROUND
L1
L2
L3
Figure 3-5 Input Terminal Block
Art # A-04100
WARNING:
Never connect the safety ground screw to one of the three line phases. This would represent a serious electrical shock hazard. The wiring to this machine should be performed by a qualified person only.
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.
Tables 3-1 and 3-2 provide 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.
3-2
March 17, 2006
POWERMASTER 500, 500P, 350
Line
Volts
Rated Line
Amps
208 88
230
380
400
460
82
50
43
39
Approx. Line
Fuse Size Amps Copper Line Wire Size*
100
100
60
60
60
6 AWG (16 mm
2
)
6 AWG (16 mm
2
)
10 AWG (6 mm
2
)
10 AWG (6 mm
2
)
10 AWG (6 mm
2
)
Copper Gounding
Conductor Min. Size
6 AWG (16 mm
2
)
6 AWG (16 mm
2
)
10 AWG (6 mm
2
)
10 AWG (6 mm
2
)
10 AWG (6 mm
2
)
Table 3-1 Recommended Wire and Fuse Size Table For PowerMaster 500/500P
Line
Volts
Rated Line
Amps
208
230
58
54
380
400
460
31
29
26
Approx. Line
Fuse Size Amps Copper Line Wire Size*
60 10 AWG (6 mm
2
)
60 10 AWG (6 mm
2
)
40
40
40
12 AWG (4 mm
2
)
12 AWG (4 mm
2
)
12 AWG (4 mm
2
)
Copper Gounding
Conductor Min. Size
10 AWG (6 mm
2
)
10 AWG (6 mm
2
)
12 AWG (4 mm
2
)
12 AWG (4 mm
2
)
12 AWG (4 mm
2
)
Table 3-2 Recommended Wire and Fuse Size Table For PowerMaster 350
*Conductor size shall be modified as required for line voltage and ambient temperature. Sizes listed are based on
194°F (90°C) conductor insulation, designated as FEP, FEPB, RHH, and THHN.
March 17, 2006
3-3
POWERMASTER 500, 500P, 350
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 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.
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 Tables
3-1 and 3-2 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
INPUT POWER
TERMINAL
BLOCK
GROUND
STUD
3-4
Figure 3-6: Ground Stud Location
Art # A-06856
March 17, 2006
3.06 Welding Leads
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 current capacity 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.
POWERMASTER 500, 500P, 350
Refer to Table 3-3 as a basic guideline to the required copper cable sizes.
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
Amps
100
150
200
250
300
350
400
450
500
550
600
50 Feet (15.2 m)
#4 (20 mm
2
)
#3 (25 mm
2
)
#2 (35 mm
2
)
#1 (50 mm
2
)
#1/0 (50 mm
#2/0 (70 mm
#3/0 (95 mm
#3/0 (95 mm
2
2
2
2
)
)
)
)
#4/0 (120 mm
2
)
#4/0 (120 mm
2
)
#4/0 (120 mm
2
)
TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS
(ELECTRODE LEAD PLUS WORK LEAD)
100 Feet (30.5 m) 150 Feet (45.7 m) 200 Feet (61.0 m) 250 Feet (76.2 m)
#4 (20 mm
2
)
#3 (25 mm
2
)
#2 (35mm2)
#1 (50 mm
2
)
#1/0 (50 mm
#2/0 (70 mm
#3/0 (95 mm
#3/0 (95 mm
#4/0 (120 mm
#4/0 (120 mm
#4/0 (120 mm
2
2
2
2
2
2
2
)
)
)
)
)
)
)
#2 (35 mm
2
)
#1 (50 mm
2
)
#1/0 (50 mm
2
)
#2/0 (70 mm
2
)
#3/0 (95 mm
#4/0 (120 mm
#4/0 (120 mm
#4/0 (120 mm
2 - #2/0
2 - (70 mm
2 - #2/0
2 - (70 mm
2 - #3/0
2 - (95 mm
2
2
)
2
)
2
)
2
2
2
)
)
)
)
#1 (50 mm
2
)
#1/0 (50 mm
2
)
#2/0 (70 mm
2
)
#3/0 (95 mm
2
)
#4/0 (120 mm
2 - #2/0
2 -(70 mm
2
2 - #2/0
2 - (70 mm
2
2 - #3/0
2 - (95 mm
2
2 - #3/0
2 - (95 mm
2
2 - #4/0
2 - (120 mm
2 - #4/0
2 - (120 mm
)
2
)
)
)
)
2
)
2
)
#1 (50 mm
2
)
#2/0 (70 mm
2
)
#3/0 (95 mm
2
)
#4/0 (120 mm
2
)
2 - #2/0
2 - (70 mm
2
)
2 - #2/0
2 - (70 mm
2
)
2 - #3/0
2 - (95 mm
2
)
2 - #3/0
2 - (95 mm
2
)
2 - #4/0
2 - (120 mm
2
)
2 - #4/0
2 - (120 mm
2
)
2 - #4/0
2 - (120 mm
2
)
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 3-3 Lead Circuit Lengths by Welding Amps
March 17, 2006
3-5
POWERMASTER 500, 500P, 350
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 if 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.
3-6
Figure 3-7 Main Control Board
Art # A-04090
March 17, 2006
POWERMASTER 500, 500P, 350
B. Wire-Sharpening for GMAW (Power-Master 500P)
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 at the end of the weld. To disable this feature proceed as follows:
1. 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. To disable Wire-Sharpening place jumper plug JP1 in the OFF position (pins 3 to 4 shorted).
5. To re-enable Wire-Sharpening place jumper plug JP1 back in the ON position (pins 1 to 2 shorted).
6. Replace board and panels.
JP1
Art # A-04105
Figure 3-8 Wire-Sharpening jumper plug
March 17, 2006
3-7
POWERMASTER 500, 500P, 350
3-8
March 17, 2006
POWERMASTER 500, 500P, 350
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.
!
WARNING:
Make all connections to the power source including electrode and work cables, as well as remote control cables, with the power source turned off. These connections could be electrically live with the power switch ON.
March 17, 2006 4-1
POWERMASTER 500, 500P, 350
2. Mode Select Switch: The mode select switch is a four-
position switch used to select the weld process. The four modes are as follows:
4.02 Power-Master 500 and 350 Controls
1
10
11
2
POWER
10A
3
WARNING
REMOTE
CONTACTOR
LOCAL
4
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 internal 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
120 VAC power in the case of an overload.
5
6
8
7
9
12
Art # A-06857
Figure 4-1: Power-Master 500 and 350 Front Panel
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 Section 3.07 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 disabled.
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 Section 3.07 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.
4. 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.
4-2
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 or CAG, place meter Amps/Volts switch in the Amps position and adjust the main Amps/Volts control to the desired current. To preset output volts for GMAW, place the meter Amps/Volts switch in the
Volts position and adjust the main Amps/Volts control 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.
7. 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.
8. 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 GTAW 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.
9. Amps/Volts Control: This control 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 pot. is used to set the maximum weld current available to a foot 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 should be in the amps position). Place the LOCAL/
REMOTE switch in the REMOTE mode to activate foot pedal control.
POWERMASTER 500, 500P, 350
10.Arc Force/Inductance Control: This control is
active for SMAW (Stick) and GMAW (MIG). In SMAW mode, this 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 midrange as a good starting point.
11.Output Negative Terminal: Connection point for
negative welding lead.
12.Output Positive Terminal: Connection point for
positive welding lead.
March 17, 2006 4-3
POWERMASTER 500, 500P, 350
4.03 Power-Master 500P Controls
1
6
7
8
14
9
2
POWER
10A
GTAW SMAW GMAW PULSED
GMAW
MODE SELECT
CONTACTOR REMOTE ON
3
A
V
PULSE SCHEDULE
PROGRAMMER
Figure 4-2: Power-Master 500P Front Panel
4
5
10
11
12
13
15
Art # A-06858
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. 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.
2. 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.
This control becomes inactive if REMOTE control is 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 condition should be investigated and resolved before continuing.
4. 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.
5. 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.
6. 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
Section 3.07 7for jumper 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
4-4
March 17, 2006
circuit limits the “touch” current to a low value and then switches to the preset current after the arc is struck.
SMAW mode: In this mode the power sources operates in constant current mode. 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 wiresharpening 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 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.
POWERMASTER 500, 500P, 350
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 indicator 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: Connection point for
negative welding lead.
15.Output Positive Terminal: Connection point for
positive welding lead.
March 17, 2006 4-5
POWERMASTER 500, 500P, 350
4.04 Rear Panel (All Models)
6
St. Louis, MO USA
F1
F2
WELDING OUTPUT
5
S
75V
ENERGY INPUT
3 50/60HZ
IP23S
208 V
230 V
400 V
460 V
I
1MAX
88
82
43
39
68
64
33
30
AUXILLARY POWER OUTPUT
1 50/60HZ
120 V
24 V
10A
10A
100%
100%
MADE IN MALAYSIA
Figure 4-3: Rear Panel
1
2
4
5
Art # A-06859
3
1. 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 of the power source, and remote output control.
The pinout is as follows:
A) 24 VAC auxiliary power high side
B) 24 VAC Contactor circuit, (closure between pin A and pin B will energize output).
C) Remote control maximum (top side of remote control)
D) Control circuit common
E) Remote control in (wiper of remote pot., 0 to 10
Volts). CV mode: 0 to 10 Volts gives 10 – 44 Volts of output. CC mode: 0 to 10 Volts gives 5 – 560
Amps of output.
F) Scaled output current signal: Ifb = 100 Amps/Volt
G) 24/115 VAC neutral
H) Output voltage signal: 10 Volts/Volt
I) 115 VAC auxiliary power high side
J) 115 VAC Contactor circuit, (closure between pin I and pin J will energize output).
K) Chassis ground
L) N/C
M) N/C
N) N/C
2. 19 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 of the power source, and remote output control.
The pinout is as follows:
A) Contactor circuit (+15 Volts)
B) Contactor circuit in, (closure between pin A and pin B will energize output).
C) Scaled output voltage signal: Vfb = 10 Arc Volts/
Volt
D) 24 VAC auxiliary power high side
E) 115 VAC auxiliary power high side
F) 24/115 VAC neutral
G) Chassis ground
H) Remote control maximum (top side of remote pot.)
J) Remote control in (wiper of remote pot., 0 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
4-6
March 17, 2006
P) 24 VAC auxiliary power high side (same as pin D)
R) 24/115 VAC neutral (same as pin E)
S) N/C
T) N/C
U) Scaled output current signal: Ifb = 100 Amps/Volt
V) N/C
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.
3. Duplex Receptacle: This receptacle can provide up to
10 amps of 120 VAC auxiliary power for powering wire feeders, water circulators, etc.
4. Fuse: This fuse protects the control transformer in the
power source. If the fuse opens it should be replaced with a like amperage and voltage, (20 amps, 600VAC).
5. 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.
6. CAN Port (PowerMaster 500P): This serial port is used
for connection to a CAN compatible Thermal Arc wire feeder or other auxilliary device. All of the programmable features of the power source can be accessed via this port.
POWERMASTER 500, 500P, 350
March 17, 2006 4-7
POWERMASTER 500, 500P, 350
13. To end the weld, release the foot pedal or turn off torch switch if being used. Turn off shielding gas supply.
4.05 GTAW (Gas Tungsten Arc Welding)
4.06 SMAW (Shielded Metal Arc
Welding)
1. Connect the work lead to the positive terminal and the torch to the negative terminal of the power source
(normal connection for DCEN).
2. Provide suitable shielding gas connections and controls to the torch. The power source does not provide connections for the shielding gas.
3. Select the proper tungsten size and type for the job.
4. 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.
5. 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.
6. Set the front panel mode switch to GTAW.
7. 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.
8. If a foot 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.
9. 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.
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).
2. If a remote control is being used, connect to the 14 or
19-pin remote receptacle on the rear of the power source.
3. 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.
4. Set the front panel mode switch to SMAW.
5. 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.
6. 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.
7. 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.
8. 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.
9. The power source is now ready to weld.
4-8
March 17, 2006
4.07 CAG (Carbon Arc Gouging)
POWERMASTER 500, 500P, 350
4.08 GMAW (Gas Metal Arc Welding)
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).
2. If a remote control is being used, connect to the 14 or
19-pin remote receptacle on the rear of the power source.
3. 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.
4. Set the front panel mode switch to CAG.
5. 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.
6. 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.
7. 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.
8. 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.
1. Connect the wire feeder to the power source. Connect the control cable to the 19-pin receptacle or the 14pin 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 should be activated.
3. Set the front panel mode switch to GMAW.
4. 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.
5 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.
6. 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 welding. For globular or spray transfer modes the inductance control has minimal effect.
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 4-9
POWERMASTER 500, 500P, 350
4.09 Pulsed GMAW (Power-Master 500P
Only)
1. 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.
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 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. If the 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.
4-10
March 17, 2006
POWERMASTER 500, 500P, 350
SECTION 5:
SERVICE
5.01 General Maintenance
If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction.
Maintenance work must be performed by 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.
DANGER:
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. Check warning labels on the machine for readability; replace if necessary. Check input and output connections as well as frame ground connections to the machine to insure that they are tight and the wires are not frayed or overheated. Inspect internal wiring of machine for loose or frayed connections; tighten or repair as necessary. It would also be advisable to check connections to wire feeders, fixtures, etc., at this time. Any damaged cables or hoses should be replaced.
HIGH VOLTAGE is present internally even with the control power switch in the OFF position.
Before inspecting, cleaning, or servicing disconnect and lock out input power to the power source.
March 17, 2006
5-1
POWERMASTER 500, 500P, 350
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Visual check of regulator and pressure
Weekly
Visual check of torch
Consumable parts
Replace all broken parts
Visually inspect the torch body and consumables
3 Months
Visually inspect the cables and leads.
Replace as needed
Gas and air lines
6 Months
Clean exterior of power supply
Visually check and use a vacuum to carefully clean the interior
POW ER
10A
RN WA ING
RE MO
LOCA
TAC TO
CON
5-2
Art # A-07433
March 17, 2006
5.02 Basic Troubleshooting Guide
POWERMASTER 500, 500P, 350
5.03 Troubleshooting Guide
A. Scope:
The troubleshooting guide is intended to be used by qualified service technicians. The troubleshooting guide contains information which can be used to diagnose and correct unsatisfactory operation or failure of the various components of the power source.
B. Safety:
To ensure safe operation and service, read this entire manual before attempting to service or repair this machine.
The service technician may be asked to check voltage levels while the machine is turned ON; to assure safety, use care and follow all instructions accordingly!
C. Troubleshooting Hints:
Examine connections for proper assembly and contact before replacing a component. Wire lugs should be in tight contact with the lead’s conductor and should be crimped to the lead’s insulation. The mating surfaces of the connection should be clean and free of oxidation. Faulty connections or wiring problems are often the cause of an equipment malfunction!
Do not pull on wires to disassemble connections. Firmly grasp each lug or connector when disconnecting. Pulling on wires for disassembly can damage the integrity of the connection and cause future malfunctions.
Prior to disassembly or servicing of the machine, note the wiring and connections in the machine. Reassembling should place the wires in the same location and routing as received from the factory. Keep wires and leads away from hot parts and sharp objects.
All signals referenced in the following troubleshooting guide can be measured with a digital multimeter (DMM).
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 be 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, consummable 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 (located under the control panel door):
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.
DANGER:
ELECTRIC SHOCK CAN KILL
WARNINGS
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.
ALL SERVICE SHOULD BE PERFORMED BY
TRAINED PERSONNEL ONLY.
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
5-3
POWERMASTER 500, 500P, 350
5.04 Power Source Problems
5-4
FAULT CAUSE REMEDY
1 Mains supply voltage is ON.
Digital meter if off and welding arc can not be established.
.
A Primary fuse is blown.
B Broken connection in primary circuit.
C Voltage links not set correctly
D Control POWER switch is
OFF
E Control POWER switch is faulty
F Possibly defective main control board or display board
A Replace primary fuse.
B Have an Accredited Thermal Arc
Service Provider check primary circuit.
C Correct voltage links
D
Turn switch ON
E Have an Accredited Thermal Arc
Service Provider replace the switch
F Have an Accredited Thermal Arc
Service Provider replace the board(s)
2 Power Source blows input fuse as soon as power is applied
3 Power Source powers up but fans do not run
4 Power Source powers up but fans do not run
A Incorrect input wiring
B Voltage links not set correctly
C Control fuse blown
D Internal wiring to terminal block, input rectifier,
IGBT’s, contactors or changeover board faulty
E Possible defective input rectifier, suppressor, IGBT, or capacitor board
A Correct input wiring
B Correct voltage links
C Replace
D Have an Accredited Thermal Arc
Service Provider repair the wiring
E Have an Accredited Thermal Arc
Service Provider replace the components(s) / board(s)
A Control switch is OFF
B No 120VAC on rear outlet
C Faulty wiring
A
B
Turn switch ON
Replace 20A fuse on rear panel
C Have an Accredited Thermal Arc
Service Provider repair the wiring to fans or main control board J9
D Defective main control pcb
E Possible faulty fan(s)
D Have an Accredited Thermal Arc
Service Provider replace pcb
E Have an Accredited Thermal Arc
Service Provider replace the fan(s)
March 17, 2006
POWERMASTER 500, 500P, 350
FAULT CAUSE REMEDY
5 Control Power circuit breaker trips OFF
6 Power Source powers up but no output or incorrect output
A Short on the 120VAC rear outlets or 14 / 19 pin receptacles
B Internal short circuit
C Defective main circuit breaker
D Defective control / auxiliary transformer
A Repair the external short circuit
B Have an Accredited Thermal Arc
Service Provider check and repair wiring to both contactors, fans, main pcb, rear 120VAC outlets, 14 / 19 pin receptacles and small control transformer
C Have an Accredited Thermal Arc
Service Provider replace the circuit breaker
D Have an Accredited Thermal Arc
Service Provider replace the control / auxiliary transformer
A Check open circuit voltage is correct
B Shorted Output Diode
C Check front panel controls are correct
D Defective main control pcb
E Defective IGBT or input rectifier
F Possible faulty wiring to current sensor, or faulty current sensor
A Open Circuit Voltage should be between 55 – 70VDC
C
B Have an Accredited Thermal Arc
Service Provider replace diode
Set Remote / Local to Remote
Check range of main control
500/500P 350
GTAW 5–560A 5–425A
SMAW 5–560A 5–425A
CAG 5–560A 5–425A
GMAW 10–44V 10–38V
Check contactor control
When the contactor is ON the indicator LED should be ON.
When the contactor is ON there should be open circuit voltage on the output terminals
E
D Have an Accredited Thermal Arc
Service Provider replace pcb
Have an Accredited Thermal Arc
Service Provider replace the
IGBT or input rectifier
F
Have an Accredited Thermal Arc
Service Provider check wiring to the current sensor, or replace faulty current sensor
Power Source Problems (con't)
March 17, 2006
5-5
POWERMASTER 500, 500P, 350
5-6 March 17, 2006
SECTION 6:
PARTS LIST
6.01 Equipment Identification
All identification numbers as described in the Introduction 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 Assembly numbers.
6.02 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. All parts of the equipment are listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc., and permanently attached 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.
PART NUMBERS:
Power-Master 500
Power-Master 500P
Power-Master 350
Power-Master 500
Power-Master 500P
Power-Master 350
(CSA) Part Number 100060A
(CSA) Part Number 100054
(CSA) Part Number 100078
(CCC) Part Number 100097
(CCC) Part Number 100098
(CCC) Part Number 100103
POWERMASTER 500, 500P, 350
March 17, 2006
6-1
POWERMASTER 500, 500P, 350
6.03 Lifting Eye Bushing
Item Qty
1 1 Bushing, Lifting Eye, PM, IPS
1
Art # A-06916
12CW2170
6-2
March 17, 2006
6.04 Voltage Selection Strap
Item Qty
1 3 Strap, 220/440 Volts, PM, IPS
POWERMASTER 500, 500P, 350
CW811
1
Art # A-06917
March 17, 2006
6-3
POWERMASTER 500, 500P, 350
6.05 Front Panel Parts (Power-Master 500 and 350)
Item Qty
7
8
5
6
3
4
1
2
2
2
2
2
2
1
2
1
Bushing, Insulator, PM, IPS
Circuit, Breaker, 10A, 2 Pole
Knob,Control,1/4" IDx1.6"
Knob,Control,1/4" IDx.57"
Nut, Hex, 1/2"-13
Screw,Hex HD,1/2"-13x1.75"
Cover, Terminal
Busbar, Cable Stud, PM, IPS
357654
830362
870696PKD
870734
400614-001
351505
357655
5CW974
3
4
2
10A
POWER
WA
RNING
REMOTE
CONT
ACT
OR
LOCAL
6
7
5
8
1
Art # A-06918
6-4
March 17, 2006
6.07 Rear Panel Parts
Item Qty
1
2
1
1
Fuse,20A,600V,Bussman KTK
Fuse Holder, PM, IPS
POWERMASTER 500, 500P, 350
405093-002
402151
Art # A-06921
1
2
March 17, 2006
6-5
POWERMASTER 500, 500P, 350
6.06 Front Panel Parts (Power-Master 500P)
Item Qty
18
19
20
21
22
13
14
15
16
17
8
9
10
11
12
3
4
5
1
2
6
7
2
2
2
2
2
4
2
4
2
2
3
2
2
2
2
1
1
2
2
1
3
3
Knob,Control,1/4" ID x 1.6"
CIRCUIT BRKR 10A 2POLE
LATCH SELF ADJUSTING, PM, IPS
DOOR CONTROL ASSY, PM, IPS
RIVET,1/8,BLIND STEEL
Washer,4.4mm,Int Lock
Nut, Hex M4X0.7, STZP
SCREW PHCR BLINDING M4 x 12
SCREW PHCR #6-32 X 3/8
WASHER SPRING 3.5ID
CAPACITOR ASSY 47N 630V, PM, IPS
Screw,Hex HD,1/2"-13x1.75"
WASHER SPRING 12.7ID
WASHER FL M12x35 OD ST ZP
WASHER INSULATING FLAT
Pin, Roll 1/8" x 2", PM, IPS
BUSHING INSULATOR, PM, IPS
SCREW HEX M12X1.75-30 ST ZP
WASHER FL M12 ST ZP
COVER,TERMINAL
NUT,1/2-13,HEX FLANGE
BUS STUD CABLE, PM, IPS
Note 1:
This part is available at any hardware store
870696PKD
830362
830960
830903WBLK
See Note 1
See Note 1
See Note 1
See Note 1
See Note 1
See Note 1
707158
351505
See Note 1
See Note 1
See Note 1
831125PKD
357654
See Note 1
See Note 1
357655
400614-001
5CW974
6-6
March 17, 2006
1
POWERMASTER 500, 500P, 350
2
Viewed from outside
Viewed from inside
22
21
20
19
13
18
8
7
6
Art # A-07642
3
4
5
16
15
17
14
13
12
11
10
9
March 17, 2006
6-7
POWERMASTER 500, 500P, 350
6-8
March 17, 2006
POWERMASTER 500, 500P, 350
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.
• Use only those diagrams and instructions that are applicable.
SPECIFICATION NUMBER
100060A
100097
100054A
100098
100078
100103
MODEL
POWER-MASTER 500
POWER-MASTER 500P
POWER-MASTER 350
SCHEMATIC AND CONNECTION DIAGRAM
830921
830920
830924
830925
830921
830920
March 17, 2006
A-1
POWERMASTER 500, 500P, 350
APPENDIX 2: PM500/350 CONNECTION DIAGRAM 1 OF 2
Art # A-06861
A-2
March 17, 2006
March 17, 2006
POWERMASTER 500, 500P, 350
NOTE: CENTER DIODE IN
POWER-MASTER 500 ONLY
,
Art # A-06861
A-3
POWERMASTER 500, 500P, 350
APPENDIX 3: PM500/350 CONNECTION DIAGRAM 2 OF 2
Art # A-06862z
A-4
March 17, 2006
POWERMASTER 500, 500P, 350
March 17, 2006
,
Art # A-06862
A-5
POWERMASTER 500, 500P, 350
APPENDIX 4: PM500P CONNECTION DIAGRAM 1 OF 2
Art # A-06864
A-6
March 17, 2006
POWERMASTER 500, 500P, 350
March 17, 2006
Art # A-06864
A-7
POWERMASTER 500, 500P, 350
APPENDIX 5: PM500P CONNECTION DIAGRAM 2 OF 2
Art # A-06865
A-8
March 17, 2006
POWERMASTER 500, 500P, 350
March 17, 2006
,
Art # A-06865
A-9
POWERMASTER 500, 500P, 350
APPENDIX 6: POWERMASTER 500 OPTIONS & ACCESSORIES
WIREFEEDERS
Ultrafeed VA 2000
Ultrafeed VA 4000
Ultrafeed VA 4000D
Portafeed VS212
GUNS
Spraymaster 12ft
W3512002 15-100V DC, Heavy Duty, CC/CV operation, 2-roll wirefeeder,
.045” (1.2mm) drive rolls
MS412-116 Gun assembly with 12ft cable, 450 Amp @ 80%
MS415-116 Gun assembly with 15ft cable, 450 Amp @ 80% Spraymaster 15ft
Supra XT 12ft
Supra XT 15ft
Tweco® No.4 12ft
Tweco® No.4 15ft
SE400-4M1,6 Gun assembly with 12ft cable, 450 Amp @ 60%
SE400-5M1,6 Gun assembly with 15ft cable, 450 Amp @ 60%
412-116 Gun assembly with 12ft cable, 400 Amp @ 60%
415-116 Gun assembly with 15ft cable, 400 Amp @ 60%
ACCESSORIES
Victor Regulator/Flowmeter Mixed Gases 0781-3873 HSR flowmeter/regulator, Argon - Argon/CO2 mix gases
Victor Regulator/Flowmeter CO2
Heavy Duty Roll Cage
Single Cylinder Running Gear
Dual Cylinder Running Gear
0781-0353 SR311 flowmeter/regulator, CO2
831097 Protective roll cage
831096 Running gear, storage cable hook, single cylinder rack
830457-001 Running gear, dual cylinder rack
W4009500 Includes 15ft, 2/0 work lead with clamp, regulator/flowmeter
Industrial TIG Kit
PART NO. DESCRIPTION
W3300001
110V, 50/60Hz, Heavy Duty 2-roll wirefeeder, .035”-.045”
(0.9-1.2mm) drive rolls
W3400001
W3420001
110V, 50/60Hz, Heavy Duty 4-roll wirefeeder, .045” (1.2mm) drive rolls
110V, 50/60Hz, Heavy Duty, Dual Feed System 4-roll wirefeeder, .045” (1.2mm) drive rolls
Industrial Stick Kit
Arcair® K4000 Gouging Torch
Dual Feeder Interlock
Front/Weather Security Cover
Rear Weather Cover
6ft (1.8m) Interconnection Cable
Assembly
15ft (4.6m) Interconnection Cable
Assembly with 15ft gas hose, CK26V TIG torch with valve and 25ft cable hose, torch consumable parts
W4009400 Includes 15ft, 2/0 electrode and work lead with clamp
61082008 K4000 torch and 7ft cable, 1000 Amp @ 100%
Permits welding from two separate wire feeders from a
870008-001 single power source
Ideal for securing machine controls plus protects the
830470 controls from the weather
830469 Keeps the weather out of the rear panel control sockets
W4009200
W4009201
2/0 welding cable & connections, gas hose & fitting, 19 pin control cable
25ft (7.6m) Interconnection Cable
Assembly
50ft (15m) Interconnection Cable
Assembly
W4009202
W4009203
6ft (1.6m) Control Cable
15ft (4.6m) Control Cable
25ft (7.6m) Control Cable
15ft (4.6m) Extension Control Cable
25ft (7.6m) Extension Control Cable
50ft (15m) Extension Control Cable
Work Lead 15ft
374878-005 19 pin control cable for compatible wire feeders
374878-015
374878-025
170558-015 19 pin extension control cable
170558-025
170558-050
W4009300 Work lead, 2/0 cable, 1/2” ID terminal, 500 Amp work clamp
A-10
March 17, 2006
POWERMASTER 500, 500P, 350
APPENDIX 7: POWERMASTER 500P OPTIONS & ACCESSORIES
WIREFEEDERS
Ultrafeed VA 2000
Ultrafeed VA 4000
PART NO. DESCRIPTION
W3300001 110V, 50/60Hz, Heavy Duty 2-roll wirefeeder
W3400001 110V, 50/60Hz, Heavy Duty 4-roll wirefeeder
Ultrafeed VA 4000D
Portafeed VS212
GUNS
Tweco® Spraymaster 12ft
Tweco® Spraymaster 15ft
Tweco® No.4 15ft
ACCESSORIES
W3420001
110V, 50/60Hz, Heavy Duty, Dual Feed System 4-roll wirefeeder
W3512002 15-100V DC, Heavy Duty, CC/CV operation, 2-roll wirefeeder
MS412-116 Gun assembly with 12ft cable, 450 Amp @ 80%
MS415-116 Gun assembly with 15ft cable, 450 Amp @ 80%
SE400-4M1,6 Gun assembly with 12ft cable, 450 Amp @ 60% Tweco® Supra XT 12ft
Tweco® Supra XT 15ft
Tweco® No.4 12ft
Victor Regulator/Flowmeter Mixed Gases
Victor Regulator/Flowmeter CO2
GUS Graphical User Software
RS-232 Interface Cable
SE400-5M1,6 Gun assembly with 15ft cable, 450 Amp @ 60%
412-116 Gun assembly with 12ft cable, 400 Amp @ 60%
415-116 Gun assembly with 15ft cable, 400 Amp @ 60%
0781-3873 HSR flowmeter/regulator, Argon - Argon/CO2 mix gases
0781-0353 SR 311 flowmeter/regulator, CO2
830970 Simple to use software for accessing programmable features
830969
Interface cable 6ft (1.8m) allows power source to PC connection
831097 Protective roll cage Heavy Duty Roll Cage
Single Cylinder Running Gear
Dual Cylinder Running Gear
Industrial TIG Kit
Industrial Stick Kit
Arcair® K4000 Gouging Torch
831096 Running gear, storage cable hook, single cylinder rack
830457-001 Running gear, dual cylinder rack
W4009500 Includes 15ft, 2/0 work lead with clamp, regulator/flowmeter with 15ft gas hose,
CK26V TIG torch with valve and 25ft cable hose, torch consumable parts
W4009400 Includes 15ft, 2/0 electrode and work lead with clamp
61082008 K4000 torch and 7ft cable, 1000 Amp @ 100%
Dual Feeder Interlock
Front/Weather Security Cover
Rear Weather Cover
870008-001
830470
Permits welding from two separate wire feeders from a single power source
Ideal for securing machine controls plus protects the controls from the weather
830469 Keeps the weather out of the rear panel control sockets
6ft (1.8m) Interconnection Cable Assembly W4009200
15ft (4.6m) Interconnection Cable Assembly W4009201
2/0 welding cable & connections, gas hose & fitting, 19 pin control cable
25ft (7.6m) Interconnection Cable Assembly W4009202
50ft (15m) Interconnection Cable Assembly W4009203
6ft (1.6m) Control Cable
15ft (4.6m) Control Cable
25ft (7.6m) Control Cable
15ft (4.6m) Extension Control Cable
25ft (7.6m) Extension Control Cable
50ft (15m) Extension Control Cable
Work Lead 15ft
374878-006 19 pin control cable for compatible wire feeders
374878-015
374878-025
170558-015 19 pin extension control cable
170558-025
170558-050
W4009300 Work lead, 2/0 cable, 1/2” ID terminal, 500 Amp work clamp
March 17, 2006
A-11
POWERMASTER 500, 500P, 350
APPENDIX 8: POWERMASTER 350 OPTIONS & ACCESSORIES
WIREFEEDERS
Ultrafeed VA 2000
Ultrafeed VA 4000
Ultrafeed VA 4000D
Portafeed VS212
GUNS
Tweco® Spraymaster 12ft
Tweco® Spraymaster 15ft
Tweco® No.4 12ft
Tweco® No.4 15ft
Supra XT 12ft
Supra XT 15ft
ACCESSORIES
Victor Regulator/Flowmeter
Mixed Gases
Victor Regulator/Flowmeter CO2
Heavy Duty Roll Cage
Single Cylinder Running Gear
Dual Cylinder Running Gear
Industrial TIG Kit
Industrial Stick Kit
Arcair® K4000 Gouging Torch
PART NO. DESCRIPTION
W3300001 110V, 50/60Hz, Heavy Duty 2-roll wirefeeder
W3400001 110V, 50/60Hz, Heavy Duty 4-roll wirefeeder
W3420001 110V, 50/60Hz, Heavy Duty, Dual Feed System 4-roll wirefeeder
W3512002 15-100V DC, Heavy Duty, CC/CV operation, 2-roll wirefeeder
MS312-116 Gun assembly with 12ft cable, 350 Amp @ 80%
MS315-3545 Gun assembly with 15ft cable, 350 Amp @ 80%
412-3545 Gun assembly with 12ft cable, 400 Amp @ 60%
415-3545 Gun assembly with 15ft cable, 400 Amp @ 60%
SE400-4M1,6 Gun assembly with 12ft cable, 450 Amp @ 60%
SE400-5M1,6 Gun assembly with 15ft cable, 450 Amp @ 60%
0781-3873
HSR flowmeter/regulator, Argon - Argon/CO2 mix gases
0781-0353 SR311 flowmeter/regulator, CO2
831097 Protective roll cage
831096 Running gear, storage cable hook, single cylinder rack
830457-001 Running gear, dual cylinder rack
Includes 15ft, 2/0 work lead with clamp, regulator/flowmeter
W4009500 with 15ft gas hose,
CK26V TIG torch with valve and 25ft cable hose, torch consumable parts
W009400 Includes 15ft, 2/0 electrode and work lead with clamp
61082008 K4000 torch and 7ft cable, 1000 Amp @ 100%
870008-001
Permits welding from two separate wire feeders from a single power source
830470
830469 Keeps the weather out of the rear panel control sockets
2/0 welding cable & connections, gas hose & fitting, 19 pin
W4009200 control cable
W4009201
Ideal for securing machine controls plus protects the controls from the weather
Dual Feeder Interlock
Front/Weather Security Cover
Rear Weather Cover
6ft (1.8m) Interconnection Cable
Assembly
15ft (4.6m) Interconnection
Cable Assembly
25ft (7.6m) Interconnection
Cable Assembly
50ft (15m) Interconnection
Cable Assembly
6ft (1.6m) Control Cable
15ft (4.6m) Control Cable
25ft (7.6m) Control Cable
15ft (4.6m) Extension Control
Cable
25ft (7.6m) Extension Control
Cable
50ft (15m) Extension Control
Cable
Work Lead 15ft
W4009202
W4009203
374878-006 19 pin control cable for compatible wire feeders
374878-015
374878-025
170558-015 19 pin extension control cable
170558-025
170558-050
W4009300 Work lead, 2/0 cable, 1/2” ID terminal, 500 Amp work clamp
A-12
March 17, 2006
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
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 Arc's 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 defective.
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 product. 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. All returned goods shall be at the Purchaser's risk and expense. This warranty dated April 1 st
2006 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.
April 2006
ENGINE DRIVEN WELDERS
Scout, Raider, Explorer
W
ARRANTY
P
ERIOD
Original Main Power Stators and Inductors .................................................................................. 3 years
L
ABOR
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year
Engines and associated components are NOT warranted by Thermal Arc, although most are warranted by the engine manufacturer .............................................................
1 year
See the Engine’s Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
W
ARRANTY
P
ERIOD
L
ABOR
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, electric motors................................................................... 1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
W
ARRANTY
P
ERIOD
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 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
Ultima 150
W
ARRANTY
P
ERIOD
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 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
W
ARRANTY
P
ERIOD
Original Main Power Magnetics..................................................................................................... 1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years
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 .......................................... 1 year
GENERAL ARC EQUIPMENT W
ARRANTY
P
ERIOD
Water Recirculators ....................................................................................................................... 1 year
Plasma Welding Torches.............................................................................................................180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
MIG and TIG Torches (Supplied with power sources)..................................................................90 days
Replacement repair parts .............................................................................................................90 days
MIG, TIG and Plasma welding torch consumable items...................................................................Nil
3 years
1 year
L
ABOR
3 years
3 years
1 year
L
ABOR
3 years
3 years
3 years
1 year
L
ABOR
1 year
1 year
1 year
3 years
3 years
1 year
L
ABOR
1 year
180 days
Nil
Nil
Nil
Nil
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: [email protected]
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Europe
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
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 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 S. 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
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: [email protected]
www.thermalarc.com
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