THERMAL ARC 350 500 500P Powermaster CC/CV Power Source Instruction manual

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350

POWERMASTER

500

500P

CC/CV POWER SOURCE

Operating Manual

Version No: AB.01 Issue Date: March 17, 2006 Manual No.: 0-4749 Operating Features:

Art # A-07643

208

460

230

400

WE APPRECIA TE 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 Spec Number 100054A, 100096 (CCC) Power-Master 350 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

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 #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 Principal Safety Standards ............................................................................. 1-4

1.03 Symbol Chart ................................................................................................. 1-5

1.04 Precautions De Securite En Soudage à L’arc .................................................. 1-6

1.05 Dangers Relatifs Au Soudage à L’arc .............................................................. 1-6

1.06 Principales Normes De Securite ..................................................................... 1-9

1.07 Graphique De Symbole ................................................................................. 1-10

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 General: Power-Master 500 ............................................................................ 2-2

2.05 General: Power-Master 350 ............................................................................ 2-3

2.06 Power-Master 500 Specifications ................................................................... 2-4

2.07 Power-Master 350 Specifications ................................................................... 2-5

2.08 General: Power-Master 500P.......................................................................... 2-6

2.09 Power-Master 500P Specifications................................................................. 2-7

2.10 Standard Features .......................................................................................... 2-8

2.11 PM500P Programmable Features................................................................... 2-8

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Location ......................................................................................................... 3-1

3.02 Voltage Changeover........................................................................................ 3-1

3.03 Connection Instructions ................................................................................. 3-2

3.04 Connecting Welding Machine to Line Voltage ................................................ 3-2

3.05 Grounding ...................................................................................................... 3-4

3.06 Welding Leads ................................................................................................ 3-5

3.07 Configuration Settings .................................................................................... 3-6

SECTION 4:

OPERATION........................................................................................... 4-1

4.01 General Safety Precautions ............................................................................ 4-1

4.02 Power-Master 500 and 350 Controls.............................................................. 4-2

4.03 Power-Master 500P Controls ......................................................................... 4-4

4.04 Rear Panel (All Models) ................................................................................. 4-6

4.05 GTAW (Gas Tungsten Arc Welding) ................................................................ 4-8

4.06 SMAW (Shielded Metal Arc Welding) ............................................................. 4-8

4.07 CAG (Carbon Arc Gouging) ............................................................................ 4-9

4.08 GMAW (Gas Metal Arc Welding) .................................................................... 4-9

4.09 Pulsed GMAW (Power-Master 500P Only) ................................................... 4-10

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 5:

SERVICE .............................................................................................. 5-1

5.01 General Maintenance ...................................................................................... 5-1

5.02 Basic Troubleshooting Guide .......................................................................... 5-3

5.03 Troubleshooting Guide ................................................................................... 5-3

5.04 Power Source Problems ................................................................................. 5-4

SECTION 6:

PARTS LIST .......................................................................................... 6-1

6.01 Equipment Identification................................................................................. 6-1

6.02 How To Use This Parts List ............................................................................ 6-1

6.03 Lifting Eye Bushing......................................................................................... 6-2

6.04 Voltage Selection Strap .................................................................................. 6-3

6.05 Front Panel Parts (Power-Master 500 and 350) ............................................. 6-4

6.07 Rear Panel Parts ............................................................................................. 6-5

6.06 Front Panel Parts (Power-Master 500P)......................................................... 6-6

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.

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

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.

March 17, 2006

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.

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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

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.

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.

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

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen C utting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

March 17, 2006

WARNING

POWERMASTER 500, 500P, 350

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

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.

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.

WARNING

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

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.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

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.

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POWERMASTER 500, 500P, 350

1.02 Principal Safety Standards

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

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 P1, 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.

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-E63 (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:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

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March 17, 2006

1.03 Symbol Chart

Note that only some of these symbols will appear on your model.

POWERMASTER 500, 500P, 350

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

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

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.

Burnback Time

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

March 17, 2006

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

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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.

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.

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.

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March 17, 2006

POWERMASTER 500, 500P, 350

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.

AVERTISSEMENT

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.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

mince moins de 1 po. (25 mm) 2 ou 3

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

épais plus de 6 po. (150 mm) 5 ou 6

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec fil plein (GMAW)

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)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

March 17, 2006

1-7

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

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.

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.

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.

POWERMASTER 500, 500P, 350

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

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.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

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

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.

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.

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.

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

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.

March 17, 2006

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

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.

1-9

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

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Distant

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

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Torch de

Purge Du Gaz

Soudure Par Point

Duréc du Pulse

Appuyez pour dèruarer l’alimentation du fils et la soudure, le relâcher pour arrêter.

Maintenez appuyez pour pré-dèbit, relailez pour initier l'arc. Appuyez pour arrêter l'arc, et mainteuir pour pré-dèbit.

Durée de Pré-Dèbit

Durée de Post-Dèbit

Soudage

Mode Continu de Soudure

Détente à 2-Temps

Détente à 4-Temps

115V 15A

1-10

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de PriseSource Auxiliaire

Haute Température

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

IPM

MPM

Probléme de Terre

Pouces Par Minute

Mètres Par Minute

Art # A-07639

March 17, 2006

POWERMASTER 500, 500P, 350

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.

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.

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

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.

Volts

MIN.

MAX. ARC FORCE

MIN. ARC FORCE

100 200 300 400 500 600 700

Amps

MAX.

VOLT-AMP CURVE FOR CC-GTAW MODE

VOLT-AMP CURVE FOR CC-SMAW MODE

Volts

MIN.

Volts

100 200 300 400 500 600

Amps

VOLT-AMP CURVE FOR CV-GMAW MODE

MAX.

MIN.

MAX.

2-2

100 200 300 400 500 600 700

Amps

Art # A-04120

Figure 2-1: Power-Master 500 Power Source Volt-

Amp Characteristics

March 17, 2006

2.05 General: Power-Master 350

POWERMASTER 500, 500P, 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.

The graphs in Figure 2-1 show the output volt-amp characteristics of the Power-Master 500 power source.

Volts

MIN.

MAX. ARC FORCE

MIN. ARC FORCE

100 200 300 400 500 600 700

Amps

MAX.

VOLT-AMP CURVE FOR CC-GTAW MODE

VOLT-AMP CURVE FOR CC-SMAW MODE

MIN.

MAX.

Volts

100 200 300 400 500 600

Amps

VOLT-AMP CURVE FOR CV-GMAW MODE

MAX.

MIN.

100 200 300 400 500 600 700

Amps

Art #A-07352

rt # A-0412

Figure 2-2: Power-Master 350 Power Source Volt-Amp

Characteristics

March 17, 2006

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.

Input Data

Line Voltage Line Current kVA Eff. PF Output

208 VAC/3 Phase 68 Amps 24.5 89% 0.83 450A/38V/100% Duty Cycle 230 VAC/3 Phase 62 Amps 24.7 90% 0.82 450A/38V/100% Duty Cycle 380 VAC/3 Phase 40 Amps 23.7 89% 0.84 450A/38V/100% Duty Cycle 400 VAC/3 Phase 35 Amps 24.2 90% 0.84 450A/38V/100% Duty Cycle 460 VAC/3 Phase 30 Amps 23.9 91% 0.84 450A/38V/100% Duty Cycle

208 VAC/3 Phase 88 Amps 31.7 89% 0.88 500A/40.0/60% Duty Cycle 230 VAC/3 Phase 82 Amps 32.7 89% 0.87 500A/40.0/60% Duty Cycle 380 VAC/3 Phase 50 Amps 32.9 88% 0.87 480A/39.2/60% Duty Cycle 400 VAC/3 Phase 43 Amps 29.8 91% 0.86 480A/39.2/60% Duty Cycle 460 VAC/3 Phase 39 Amps 31.1 90% 0.88 500A/40.0/60% Duty Cycle

Line Frequency: 50/60 HZ Out put Current Range: 5 – 560 Amps Out put Voltage Range: 10 – 44 Volts Maximum Output Current: 600 Amps Maximum Open Circuit Voltage (OCV): 70 Volts (57 Volts for CCC) Operating Temperature Range: 32-104°F Input Line Variations: ± 10% Line Regulation: ± 1% Load Regulation: ± 1% Water Protection Class: IP23S

23.0 in / 58.4 cm

CONTACTOR

WARNING

POWER

10A

REMOTE

LOCAL

26.8 in /

25.5 in /

64.7 cm

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

350350

2.07 Power-Master 350 Specifications

changes, updates, improvements or replacement of such items.

Input Data

Line Voltage Line Current kVA Eff. PF Output

208 VAC/3 Phase 37 Amps 13.1 89% 0.83 300A/32V/100% Duty Cycle 230 VAC/3 Phase 33 Amps 13.1 89% 0.82 300A/32V/100% Duty Cycle 380 VAC/3 Phase 24 Amps 15.8 88% 0.82 300A/32V/100% Duty Cycle 400 VAC/3 Phase 19 Amps 13.1 89% 0.84 300A/32V/100% Duty Cycle 460 VAC/3 Phase 17 Amps 13.1 89% 0.84 300A/32V/100% Duty Cycle

208 VAC/3 Phase 43 Amps 15.4 89% 0.88 350A/34V/60% Duty Cycle 230 VAC/3 Phase 39 Amps 15.4 89% 0.87 350A/34V/60% Duty Cycle 380 VAC/3 Phase 28 Amps 18.4 88% 0.85 350A/34V/60% Duty Cycle 400 VAC/3 Phase 23 Amps 15.4 91% 0.86 350A/34V/60% Duty Cycle 460 VAC/3 Phase 20 Amps 15.4 90% 0.88 350A/34V/60% Duty Cycle

23.0 in / 58.4 cm

CONTACTOR

WARNING

POWER

10A

350350

REMOTE

LOCAL

26.8 in /

25.5 in /

64.7 cm

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.

Volts

MIN.

MAX. ARC FORCE

MIN. ARC FORCE

100 200 300 400 500 600 700

Amps

MAX.

VOLT-AMP CURVE FOR CC-GTAW MODE

VOLT-AMP CURVE FOR CC-SMAW MODE

Volts

MIN.

Volts

100 200 300 400 500 600

Amps

VOLT-AMP CURVE FOR CV-GMAW MODE

MAX.

MIN.

MAX.

2-6

100 200 300 400 500 600 700

Amps

Art # A-04120

Figure 2-4 Power-Master 500P Power Source Volt-Amp

Characteristics

March 17, 2006

POWERMASTER 500, 500P, 350

2.09 Power-Master 500P Specifications

changes, updates, improvements or replacement of such items.

Input Data

Line Voltage Line Current kVA Eff. PF Output

23.0 in / 58.4 cm

22.0 in / 55.9 cm

26.8 in /

68.0 cm

25.5 in /

64.7 cm

6.8 in /

172.7 mm

March 17, 2006

14.9 in / 378.5 mm

Art # A-06854

Net Weight: 154 lbs / 70 kg

Figure 2-5: Power-Master 500P Dimensions and Weight

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.

2.11 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.

1.1Mode Select Switch - Prevents changing of the mode of operation.

1.2Remote On Switch - Prevents changing of the remote control feature.

1.3Schedule 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.

2.1Amps 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.

2.2Volts 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.

2.3Pulse 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.

2-8

March 17, 2006

SECTION 3:

INSTALLATION

POWERMASTER 500, 500P, 350

400

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.

400 460

200 VOLT CONNECTION

230

Figure 3-1

400 460

230 VOLT CONNECTION

Figure 3-2

200

460

Art # A-04083

400

460

Art # A-04084

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.

DANGER

ELECTRIC SHOCK CAN KILL.

Open the main wall disconnect switch or breaker, before removing any covers or access panels on the welding machine. Live voltage is still present even with the front panel control switch OFF. Wait at least three full minutes after power has been removed before removing any covers or access panels to allow adequate time for internal capacitors to discharge.

230

380 / 400 VOLT CONNECTION

E4 E1

230

460 VOLT CONNECTION

200200 230

200

230

Figure 3-3

200

230

Figure 3-4

460

Art # A-04085

400

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.

CUSTOMER

INPUT

LINES

FRAME GROUND

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:

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.

Art # A-04100

Figure 3-5 Input Terminal Block

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.

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

Approx. Line

Fuse Size Amps Copper Line Wire Size*

208 88 100 6 AWG (16 mm 230 82 100 6 AWG (16 mm 380 50 60 10 AWG (6 mm 400 43 60 10 AWG (6 mm 460 39 60 10 AWG (6 mm

Table 3-1 Recommended Wire and Fuse Size Table For PowerMaster 500/500P

Line

Volts

Rated Line

Amps

Approx. Line

Fuse Size Amps Copper Line Wire Size*

208 58 60 10 AWG (6 mm 230 54 60 10 AWG (6 mm 380 31 40 12 AWG (4 mm 400 29 40 12 AWG (4 mm 460 26 40 12 AWG (4 mm

Table 3-2 Recommended Wire and Fuse Size Table For PowerMaster 350

Copper Gounding

Conductor Min. Size

) 6 AWG (16 mm2)

) 10 AWG (6 mm2)

Copper Gounding

Conductor Min. Size

) 10 AWG (6 mm2)

) 12 AWG (4 mm2)

*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

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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

Art # A-06856

GROUND STUD

3-4

Figure 3-6: Ground Stud Location

March 17, 2006

POWERMASTER 500, 500P, 350

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.

TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS

Avg. Welding

Amps

100

150

200

250

300

350

400

450

500

550

600

50 Feet (15.2 m) 100 Feet (30.5 m) 150 Feet (45.7 m) 200 Feet (61.0 m) 250 Feet (76.2 m)

#4 (20 mm

#3 (25 mm

#2 (35 mm

#1 (50 mm

#1/0 (50 mm

#2/0 (70 mm

#3/0 (95 mm

#4/0 (120 mm

) #4 (20 mm2) #2 (35 mm2) #1 (50 mm2) #1 (50 mm2)

) #3 (25 mm2) #1 (50 mm2) #1/0 (50 mm2) #2/0 (70 mm2)

)

) #1 (50 mm2) #2/0 (70 mm2) #3 /0 (95 mm2) #4/0 (120 mm2)

) #1/0 (50 mm2) #3/0 (95 mm2) #4/0 (120 mm2)

) #2/0 (70 mm2) #4/0 (120 mm2)

) #3/0 (95 mm2) #4/0 (120 mm2)

) #4/0 (120 mm2)

(ELECTRODE LEAD PLUS WORK LEAD)

#2 (35mm2)

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.

#1/0 (50 mm2) #2 /0 (70 mm2) #3/0 (95 mm2)

2 - #2/0

2 - (70 mm

2 - #2/0

2 - (70 mm

2 - #3/0

2 - (95 mm

2 - # 2/0

2 - (70 mm

2 - # 2/0

2 -(70 mm

)

2 - # 2/0

2 - (70 mm

)

2 - # 3/0

2 - (95 mm

)

2 - # 3/0

)

2 - (95 mm2)

2 - # 4/0

)

2 - (120 mm2)

2 - # 4/0

)

2 - (120 mm2)

2 - # 2/0

2 - (70 mm2)

2 - # 3/0

2 - (95 mm2)

2 - # 3/0

2 - (95 mm2)

2 - # 4/0

2 - (120 mm2)

2 - # 4/0

2 - (120 mm2)

2 - # 4/0

2 - (120 mm2)

)

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

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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

Art # A-04090

Figure 3-7 Main Control Board

March 17, 2006

POWERMASTER 500, 500P, 350

B. Wire-Sharpening for GMA W (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

Figure 3-8 Wire-Sharpening jumper plug

Art # A-04105

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 fourposition switch used to select the weld process. The four modes are as follows:

4.02 Power-Master 500 and 350 Controls

CONTACTOR

WARNING

POWER

10A

REMOTE

LOCAL

Figure 4-1: Power-Master 500 and 350 Front Panel

1. Control Power ON/OFF Switch: This circuit breaker/ switch activates the controls on the power source. When this switch is in the OFF position, the power source is in standby mode. There is still line voltage present 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.

Art # A-06857

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.

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March 17, 2006

POWERMASTER 500, 500P, 350

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.

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.

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.

March 17, 2006 4-3

POWERMASTER 500, 500P, 350

this control presets the welding voltage. For Pulse GMAW this control sets the pulse reference, which is similar in function to a voltage control.

4.03 Power-Master 500P Controls

PULSED

GMAW

PULSE SCHEDULE

PROGRAMMER

Art # A-06858

POWER

10A

GTAW SMAW GMAW

CONTACTOR REMOTE ON

POWERMASTERPOWERMASTER

MODE SELECT

Figure 4-2: Power-Master 500P Front Panel

1. Control Power ON/OFF Switch: This circuit breaker/ switch activates the controls on the power source. When this switch is in the OFF position, the power source is in standby mode. 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 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 PulsedGMAW 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

POWERMASTER 500, 500P, 350

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.

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 PULSEDGMAW 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

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.

4.04 Rear Panel (All Models)

St. Louis, MO USA

WELDING OUTPUT

75V

U1I

1MAX

1eff

ENERGY INPUT

208 V

50/60HZ3

230 V

IP23S

400 V

460 V

AUXILLARY POWER OUTPUT

10A

100%

120 V

50/60HZ1

10A

100%

24 V

MADE IN MALAYSIA

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)

Art # A-06859

Figure 4-3: Rear Panel

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

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).

POWERMASTER 500, 500P, 350

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.

March 17, 2006 4-7

POWERMASTER 500, 500P, 350

4.05 GTAW (Gas Tungsten Arc Welding)

13.To end the weld, release the foot pedal or turn off torch switch if being used. Turn off shielding gas supply.

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.

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.

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.

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March 17, 2006

POWERMASTER 500, 500P, 350

4.07 CAG (Carbon Arc Gouging)

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.

4.08 GMAW (Gas Metal Arc Welding)

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.

4-10

March 17, 2006

5.01 General Maintenance

POWERMASTER 500, 500P, 350

SECTION 5:

SERVICE

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:

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.

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.

March 17, 2006

5-1

POWERMASTER 500, 500P, 350

Warning! Disconnect input power before maintaining.

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Maintain more often if used under severe conditions

Each Use

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

Replace all broken parts

3 Months

Gas and air lines

6 Months

Visually check and use a vacuum to carefully

clean the interior

Clean exterior of power supply

O ACT T ON C

ING N R A

LOCA

POWER

A 0 1

5-2

Art # A-07433

March 17, 2006

POWERMASTER 500, 500P, 350

5.02 Basic 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.

5.03 Troubleshooting Guide

This guide should be used as an aid to determine the cause of a system malfunction or failure. It should be remembered that in most welding situations there can 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:

All signals referenced in the following troubleshooting guide can be measured with a digital multimeter (DMM).

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.

March 17, 2006

ELECTRIC SHOCK CAN KILL

5-3

POWERMASTER 500, 500P, 350

5.04 Power Source Problems

FAULT CAUSE REMEDY

1 Mains supply voltage is ON.

Digital meter if off and welding arc can not be established. .

2 Power Source blows input

fuse as soon as power is applied

Primary fuse is blown.

Broken connection in primary circuit.

Voltage links not set correctly

Control POWER switch is OFF

Control POWER switch is faulty

Possibly defective main control board or display board

Incorrect input wiring

Voltage links not set

correctly Control fuse blown

Internal wiring to terminal

block, input rectifier, IGBT’s, contactors or changeover board faulty

Possible defective input

rectifier, suppressor, IGBT, or capacitor board

Replace primary fuse.

Have an Accredited Thermal Arc Service Provider check primary circuit.

Correct voltage links

Turn switch ON

Have an Accredited Thermal Arc Service Provider replace the switch

Have an Accredited Thermal Arc Service Provider replace the board(s)

Correct input wiring

Correct voltage links

Replace

Have an Accredited Thermal Arc

Service Provider repair the wiring

Have an Accredited Thermal Arc

Service Provider replace the components(s) / board(s)

3 Power Source powers up

but fans do not run

4 Power Source powers up

but fans do not run

5-4

Control switch is OFF

No 120VAC on rear outlet

Faulty wiring

Defective main control pcb

Possible faulty fan(s)

Turn switch ON

Replace 20A fuse on rear panel

Have an Accredited Thermal Arc Service Provider repair the wiring to fans or main control board J9

Have an Accredited Thermal Arc Service Provider replace pcb

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

Short on the 120VAC rear outlets or 14 / 19 pin receptacles

Internal short circuit

Defective main circuit breaker

Defective control / auxiliary transformer

Check open circuit voltage is correct

Shorted Output Diode

Check front panel controls are correct

Defective main control pcb

Defective IGBT or input rectifier

Possible faulty wiring to current sensor, or faulty current sensor

Repair the external short circuit

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

Have an Accredited Thermal Arc Service Provider replace the circuit breaker

Have an Accredited Thermal Arc Service Provider replace the control / auxiliary transformer

Open Circuit Voltage should be between 55 – 70VDC

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

Have an Accredited Thermal Arc Service Provider replace pcb

Have an Accredited Thermal Arc

Service Provider replace the IGBT or input rectifier

Have an Accredited Thermal Arc

Service Provider check wiring to the current sensor, or replace faulty current sensor

March 17, 2006

Power Source Problems (con't)

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.

POWERMASTER 500, 500P, 350

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 (CSA) Part Number 100060A Power-Master 500P (CSA) Part Number 100054 Power-Master 350 (CSA) Part Number 100078

Power-Master 500 (CCC) Part Number 100097 Power-Master 500P (CCC) Part Number 100098 Power-Master 350 (CCC) Part Number 100103

March 17, 2006

6-1

POWERMASTER 500, 500P, 350

6.03 Lifting Eye Bushing

ItemItem

Item

ItemItem

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

1 1 Bushing, Lifting Eye, PM, IPS 12CW2170

Art # A-06916

6-2

March 17, 2006

6.04 Voltage Selection Strap

POWERMASTER 500, 500P, 350

ItemItem

Item

ItemItem

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

1 3 Strap, 220/440 Volts, PM, IPS CW811

March 17, 2006

Art # A-06917

6-3

POWERMASTER 500, 500P, 350

6.05 Front Panel Parts (Power-Master 500 and 350)

ItemItem

Item

ItemItem

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

1 2 Bushing, Insulator, PM, IPS 357654 2 1 Circuit, Breaker, 10A, 2 Pole 830362 3 2 Knob,Control,1/4" IDx1.6" 870696PKD 4 1 Knob,Control,1/4" IDx.57" 870734 5 2 Nut, Hex, 1/2"-13 400614-001 6 2 Screw,Hex HD,1/2"-13x1.75" 351505 7 2 Cover, Terminal 357655 8 2 Busbar, Cable Stud, PM, IPS 5CW974

POWER

10A

WARNING

CONTACTOR

REMOTE

LOCAL

Art # A-06918

6-4

March 17, 2006

6.07 Rear Panel Parts

POWERMASTER 500, 500P, 350

ItemItem

Item

ItemItem

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

1 1 Fuse,20A,600V,Bussman KTK 405093-002 2 1 Fuse Holder, PM, IPS 402151

Art # A-06921

March 17, 2006

6-5

POWERMASTER 500, 500P, 350

6.06 Front Panel Parts (Power-Master 500P)

ItemItem

Item

ItemItem

1 2 Knob,Control,1/4" ID x 1.6" 870696PKD 2 1 CIRCUIT BRKR 10A 2POLE 830362 3 1 LATCH SELF ADJUSTING, PM, IPS 830960 4 1 DOOR CONTROL ASSY, PM, IPS 830903WBLK 5 2 RIVET,1/8,BLIND STEEL See Note 1 6 3 Washer,4.4mm,Int Lock See Note 1 7 3 Nut, Hex M4X0.7, STZP See Note 1 8 3 SCREW PHCR BLINDING M4 x 12 See Note 1

9 2 SCREW PHCR #6-32 X 3/8 See Note 1 10 2 WASHER SPRING 3.5ID See Note 1 11 2 CAPACITOR ASSY 47N 630V, PM, IPS 707158 12 2 Screw,Hex HD,1/2"-13x1.75" 351505 13 4 WASHER SPRING 12.7ID See Note 1 14 2 WASHER FL M12x35 OD ST ZP See Note 1 15 4 WASHER INSULATING FLAT See Note 1 16 2 Pin, Roll 1/8" x 2", PM, IPS 831125PKD 17 2 BUSHING INSULATOR, PM, IPS 357654 18 2 SCREW HEX M12X1.75-30 ST ZP See Note 1 19 2 WASHER FL M12 ST ZP See Note 1 20 2 COVER,TERMINAL 357655 21 2 NUT,1/2-13,HEX FLANGE 400614-001 22 2 BUS STUD CABLE, PM, IPS 5CW974

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

Note 1:

This part is available at any hardware store

6-6

March 17, 2006

POWERMASTER 500, 500P, 350

Viewed from outside

Viewed from inside

19 13

Art # A-07642

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 MODEL SCHEMATIC AND CONNECTION DIAGRAM

100060A POWER-MASTER 500 830921

100097 830920

100054A POWER-MASTER 500P 830924

100098 830925

100078 POWER-MASTER 350 830921

100103 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

POWERMASTER 500, 500P, 350

NOTE: CENTER DIODE IN POWER-MASTER 500 ONLY

March 17, 2006

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 W3300001

Ultrafeed VA 4000 W3400001

Ultrafeed VA 4000D W3420001 Portafeed VS212 W3512002 15-100V DC, Heavy Duty, CC/CV operation, 2-roll wirefeeder,

.045” (1.2mm) drive rolls

GUNS

Spraymaster 12ft MS412-116 Gun assembly with 12ft cable, 450 Amp @ 80% Spraymaster 15ft MS415-116 Gun assembly with 15ft cable, 450 Amp @ 80% Supra XT 12ft SE400-4M1,6 Gun assembly with 12ft cable, 450 Amp @ 60% Supra XT 15ft SE400-5M1,6 Gun assembly with 15ft cable, 450 Amp @ 60% Tweco® No.4 12ft 412-116 Gun assembly with 12ft cable, 400 Amp @ 60% Tweco® No.4 15ft 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 0781-0353 SR311 flowmeter/regulator, CO2 Heavy Duty Roll Cage 831097 Protective roll cage Single Cylinder Running Gear 831096 Running gear, storage cable hook, single cylinder rack Dual Cylinder Running Gear 830457-001 Running gear, dual cylinder rack

Industrial TIG Kit

Industrial Stick Kit W4009400 Includes 15ft, 2/0 electrode and work lead with clamp Arcair® K4000 Gouging Torch 61082008 K4000 torch and 7ft cable, 1000 Amp @ 100%

Dual Feeder Interlock 870008-001

Front/Weather Security Cover 830470 Rear Weather Cover 830469 Keeps the weather out of the rear panel control sockets

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 374878-005 19 pin control cable for compatible wire feeders 15ft (4.6m) Control Cable 374878-015 25ft (7.6m) Control Cable 374878-025 15ft (4.6m) Extension Control Cable 170558-015 19 pin extension control cable 25ft (7.6m) Extension Control Cable 170558-025 50ft (15m) Extension Control Cable 170558-050 Work Lead 15ft W4009300 Work lead, 2/0 cable, 1/2” ID terminal, 500 Amp work clamp

PART NO. DESCRIPTION

110V, 50/60Hz, Heavy Duty 2-roll wirefeeder, .035”-.045” (0.9-1.2mm) drive rolls 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

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

Permits welding from two separate wire feeders from a single power source Ideal for securing machine controls plus protects the controls from the weather

W4009200 W4009201

W4009202

W4009203

2/0 welding cable & connections, gas hose & fitting, 19 pin control cable

A-10

March 17, 2006

POWERMASTER 500, 500P, 350

APPENDIX 7: POWERMASTER 500P OPTIONS & ACCESSORIES

WIREFEEDERS

Ultrafeed VA 2000 W3300001 110V, 50/60Hz, Heavy Duty 2-roll wirefeeder Ultrafeed VA 4000 W3400001 110V, 50/60Hz, Heavy Duty 4-roll wirefeeder

Ultrafeed VA 4000D W3420001 Portafeed VS212 W3512002 15-100V DC, Heavy Duty, CC/CV operation, 2-roll wirefeeder

GUNS

Tweco® Spraymaster 12ft MS412-116 Gun assembly with 12ft cable, 450 Amp @ 80% Tweco® Spraymaster 15ft MS415-116 Gun assembly with 15ft cable, 450 Amp @ 80% Tweco® Supra XT 12ft SE400-4M1,6 Gun assembly with 12ft cable, 450 Amp @ 60% Tweco® Supra XT 15ft SE400-5M1,6 Gun assembly with 15ft cable, 450 Amp @ 60% Tweco® No.4 12ft 412-116 Gun assembly with 12ft cable, 400 Amp @ 60% Tweco® No.4 15ft 415-116 Gun assembly with 15ft cable, 400 Amp @ 60%

ACCESSORIES

RS-232 Interface Cable 830969 Heavy Duty Roll Cage 831097 Protective roll cage

Single Cylinder Running Gear 831096 Running gear, storage cable hook, single cylinder rack Dual Cylinder Running Gear 830457-001 Running gear, dual cylinder rack

Industrial TIG Kit CK26V TIG torch with valve and 25ft cable hose, torch

Industrial Stick Kit W4009400 Includes 15ft, 2/0 electrode and work lead with clamp Arcair® K4000 Gouging Torch 61082008 K4000 torch and 7ft cable, 1000 Amp @ 100%

Dual Feeder Interlock 870008-001 Front/Weather Security Cover 830470 Rear Weather Cover 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

25ft (7.6m) Interconnection Cable Assembly W4009202 50ft (15m) Interconnection Cable Assembly W4009203 6ft (1.6m) Control Cable 374878-006 19 pin control cable for compatible wire feeders 15ft (4.6m) Control Cable 374878-015 25ft (7.6m) Control Cable 374878-025 15ft (4.6m) Extension Control Cable 170558-015 19 pin extension control cable 25ft (7.6m) Extension Control Cable 170558-025 50ft (15m) Extension Control Cable 170558-050 Work Lead 15ft W4009300 Work lead, 2/0 cable, 1/2” ID terminal, 500 Amp work clamp

PART NO. DESCRIPTION

110V, 50/60Hz, Heavy Duty, Dual Feed System 4-roll wirefeeder

Interface cable 6ft (1.8m) allows power source to PC connection

W4009500 Includes 15ft, 2/0 work lead with clamp, regulator/flowmeter

with 15ft gas hose,

consumable parts

Permits welding from two separate wire feeders from a single power source Ideal for securing machine controls plus protects the controls from the weather

2/0 welding cable & connections, gas hose & fitting, 19 pin control cable

March 17, 2006

A-11

POWERMASTER 500, 500P, 350

APPENDIX 8: POWERMASTER 350 OPTIONS & ACCESSORIES

WIREFEEDERS

Ultrafeed VA 2000 W3300001 110V, 50/60Hz, Heavy Duty 2-roll wirefeeder Ultrafeed VA 4000 W3400001 110V, 50/60Hz, Heavy Duty 4-roll wirefeeder Ultrafeed VA 4000D W3420001 110V, 50/60Hz, Heavy Duty, Dual Feed System 4-roll wirefeeder Portafeed VS212 W3512002 15-100V DC, Heavy Duty, CC/CV operation, 2-roll wirefeeder

GUNS

Tweco® Spraymaster 12ft MS312-116 Gun assembly with 12ft cable, 350 Amp @ 80% Tweco® Spraymaster 15ft MS315-3545 Gun assembly with 15ft cable, 350 Amp @ 80% Tweco® No.4 12ft 412-3545 Gun assembly with 12ft cable, 400 Amp @ 60% Tweco® No.4 15ft 415-3545 Gun assembly with 15ft cable, 400 Amp @ 60% Supra XT 12ft SE400-4M1,6 Gun assembly with 12ft cable, 450 Amp @ 60% Supra XT 15ft SE400-5M1,6 Gun assembly with 15ft cable, 450 Amp @ 60%

ACCESSORIES

Victor Regulator/Flowmeter Mixed Gases Victor Regulator/Flowmeter CO2 0781-0353 SR311 flowmeter/regulator, CO2 Heavy Duty Roll Cage 831097 Protective roll cage Single Cylinder Running Gear 831096 Running gear, storage cable hook, single cylinder rack Dual Cylinder Running Gear 830457-001 Running gear, dual cylinder rack

Industrial TIG Kit W4009500 CK26V TIG torch with valve and 25ft cable hose, torch

Industrial Stick Kit W009400 Includes 15ft, 2/0 electrode and work lead with clamp Arcair® K4000 Gouging Torch 61082008 K4000 torch and 7ft cable, 1000 Amp @ 100%

Dual Feeder Interlock 870008-001 Front/Weather Security Cover 830470 Rear Weather Cover 830469 Keeps the weather out of the rear panel control sockets

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 374878-006 19 pin control cable for compatible wire feeders 15ft (4.6m) Control Cable 374878-015 25ft (7.6m) Control Cable 374878-025 15ft (4.6m) Extension Control Cable 25ft (7.6m) Extension Control Cable 50ft (15m) Extension Control Cable Work Lead 15ft W4009300 Work lead, 2/0 cable, 1/2” ID terminal, 500 Amp work clamp

PART NO. DESCRIPTION

0781-3873

W4009200 W4009201

W4009202

W4009203

170558-015 19 pin extension control cable 170558-025

170558-050

HSR flowmeter/regulator, Argon - Argon/CO2 mix gases

Includes 15ft, 2/0 work lead with clamp, regulator/flowmeter with 15ft gas hose,

consumable parts

Permits welding from two separate wire feeders from a single power source Ideal for securing machine controls plus protects the controls from the weather

2/0 welding cable & connections, gas hose & fitting, 19 pin control cable

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 ("Purcha ser") that its products will be free of defects in workmanship or material. Should any failure to conform to this warrant 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, recommendat ions and recognized stan dard industry practic e, and not subject to misu se, repair, neglect, alteration, or damage, correct such defects by suitable repair o replacement, at Thermal Arc's sole option, of any components or parts of the produc determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty o merchantability, fitness for any particular purpose, or other warranty o quality, whether express, implied, or statutory.

Limitation of liability: Therma l Arc shall not under an y circumstances be lia ble 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 A rc with respect to any co ntract, 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, whethe arising out of contract, tort, in cluding 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 b 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 t his warrant 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

supersedes all previous Thermal Arc warranties. Thermal Arc

is a Registered

2006

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 WARRANTY PERIOD LABOR Scout, Raider, Ex p lorer

Original Main Power Stators and Inductors.................................................................................. 3 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

Engines and associated components are NOT warranted by Thermal Arc, although

most are warranted by the engine manufacturer............................................................. See the Engine’s Warranty for Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P; Excelarc 6045. Wire Feeders; Ultrafeed, Portafeed

Original Main Power Transformer and Inductor............................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors............................................................... ....1 year

GTAW (TIG) & MULTI-PR OCESS INVERT ER W ELDING EQUIPME N T WARRANTY PERIOD LABOR 160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics....................................................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors............................................................... ....1 year

PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years 3 years

Welding Console, Weld Con tr o lle r , Weld Timer.................... ............... ...................................... .. 3 y e ars 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 WARRANTY PERIOD LABOR Dragster 85

Original Main Power Magnetics.....................................................................................................1 year 1 year

Original Main Power Rectifiers, Con tr o l P.C. Boards......................................... ...........................1 year 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 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

GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR

Water Recirculators .......................................................................................................................1 year 1 year

Plasma Welding Torches.............................................................................................................180 days 180 days

Gas Regulators (Supplied with power sources) ..........................................................................180 days Nil

MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil

Replacement repair parts.............................................................................................................90 days Nil

MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil

3 years 3 years

1 year

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

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, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

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: sales@thermalarc.com

www.thermalarc.com

THERMAL ARC 350 500 500P Powermaster CC/CV Power Source Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.03 Symbol Chart

1.06 Principales Normes De Securite

1.07 Graphique De Symbole

2.01 How To Use This Manual

2.02 Equipment Identification

2.03 Receipt Of Equipment

2.04 General: Power-Master 500

2.05 General: Power-Master 350

2.06 Power-Master 500 Specifications

2.07 Power-Master 350 Specifications

2.08 General: Power-Master 500P

2.09 Power-Master 500P Specifications

2.10 Standard Features

2.11 PM500P Programmable Features

3.01 Location

3.02 Voltage Changeover

3.03 Connection Instructions

3.04 Connecting Welding Machine to Line Voltage

3.05 Grounding

3.06 Welding Leads

3.07 Configuration Settings

4.01 General Safety Precautions

4.02 Power-Master 500 and 350 Controls

4.03 Power-Master 500P Controls

4.04 Rear Panel (All Models)

4.05 GTAW (Gas Tungsten Arc Welding)

4.07 CAG (Carbon Arc Gouging)

4.08 GMAW (Gas Metal Arc Welding)

4.09 Pulsed GMAW (Power-Master 500P Only)

5.02 Basic Troubleshooting Guide

5.03 Troubleshooting Guide

5.04 Power Source Problems

6.01 Equipment Identification

6.02 How To Use This Parts List

6.03 Lifting Eye Bushing

6.04 Voltage Selection Strap

6.05 Front Panel Parts (Power-Master 500 and 350)

6.07 Rear Panel Parts

6.06 Front Panel Parts (Power-Master 500P)

APPENDIX 1: GENERAL INFORMATION

APPENDIX 2: PM500/350 CONNECTION DIAGRAM 1 OF 2

APPENDIX 3: PM500/350 CONNECTION DIAGRAM 2 OF 2

APPENDIX 4: PM500P CONNECTION DIAGRAM 1 OF 2

APPENDIX 5: PM500P CONNECTION DIAGRAM 2 OF 2

APPENDIX 6: POWERMASTER 500 OPTIONS & ACCESSORIES

APPENDIX 7: POWERMASTER 500P OPTIONS & ACCESSORIES

APPENDIX 8: POWERMASTER 350 OPTIONS & ACCESSORIES