Thermal Arc 500 - User Manual

POWERMASTER
W
A
R
N
IN
G
P
O
W
E
R
1
0
A
R
E
M
O
T
E
L
O
C
A
L
C
O
N
T
A
C
T
O
R
P
U
L
S
E
S
C
H
E
D
U
L
E
P
R
O
G
R
A
M
M
E
R
G
T
AW
S
M
A
W
G
M
A
W
P
U
L
S
E
D
G
M
A
W
MODE SELECT
CONTACTOR
REMOTE ON
P O W E R M A S T E R
P O W E R M A S T E R
POWER
10A
A
V
Art # A-07556
400
V
460
V
230
V
208
V
CC/CV POWER SOURCE
500
500P
350
350P
Service Manual
Version No: AB.01 Issue Date: March 17, 2006 Manual No.: 0-4938B
Operating Features:

Summary

POWERMASTER 500, 350, 350 P Service Manual

WARNINGS

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS

1.01 Arc Welding Hazards

Details hazards associated with arc welding, including electrical shock.

1.02 Principal Safety Standards

Lists key safety standards and publications for welding and cutting.

SECTION 2: INTRODUCTION

2.01 How To Use This Manual

Guide on interpreting manual symbols, warnings, and cautions.

2.05 General: Power-Master 500 & 350

Overview of the Power-Master 500/350 inverter DC power sources and their capabilities.

2.06 Power-Master 500 Specifications

Detailed specifications for the Power-Master 500, including input data and dimensions.

SECTION 3: INSTALLATION

3.01 Location

Specifies requirements for unit placement to ensure proper operation and airflow.

3.02 Voltage Changeover

Procedure for setting the voltage changeover board for incoming AC line voltage.

3.05 Grounding

Details grounding requirements for personnel safety and overcurrent protection.

SECTION 4: OPERATION

4.01 General Safety Precautions

Emphasizes using protective clothing and eye safeguards before operating the machine.

4.02 Power-Master 500 and 350 Controls

Explanation of the front panel controls for Power-Master 500 and 350 models.

4.03 Power-Master 500 P and 350 P Controls

Explanation of the front panel controls for Power-Master 500P and 350P models.

4.05 GTAW (Gas Tungsten Arc Welding)

Procedure for operating the machine in GTAW mode.

4.06 SMAW (Shielded Metal Arc Welding)

Procedure for operating the machine in SMAW mode.

4.08 GMAW (Gas Metal Arc Welding)

Procedure for operating the machine in GMAW mode.

SECTION 5: MAINTENANCE

Periodic Cleaning and Inspection

Outlines routine maintenance tasks like cleaning and checking components.

SECTION 6: TROUBLESHOOTING

6.01 General

Overview of troubleshooting purpose and general advice.

6.03 Troubleshooting Guide

Guide for diagnosing malfunctions by checking front panel lights and causes.

6.04 Power-Master 500 and 350 Block Diagram

Visual representation of internal components and interconnections for specific models.

6.05 Power-Master 500 P and 350 P Block Diagram

Visual representation of internal components and interconnections for P models.

6.06 Control Board Connector Signals

Details signals and functions of connectors on the main control board.

6.07 Power Circuit Tests

Procedures for testing rectifiers, IGBTs, and output diodes using a multi-meter.

6.08 Semiconductor Replacement Requirements

Guidelines for safely replacing power semiconductors like diodes and IGBT modules.

6.11 Calibration Procedure

Steps for calibrating voltage and current feedback signals using a load bank.

SECTION 7: REPAIR PROCEDURES

7.01 Output Diode Replacement

Step-by-step guide for replacing failed output diode modules.

7.02 IGBT Module Replacement

Procedure for replacing IGBT modules, including cleaning and thermal compound.

SECTION 8: PARTS LIST

8.01 Equipment Identification

Instructions on how to identify equipment using model and specification numbers.

8.03 External Panels

Lists external panels of the welding machine and their part numbers.

8.04 Base Parts

Lists components and hardware related to the base assembly of the machine.

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

Lists parts specific to the front panel of the 500 and 350 models.

8.06 Front Panel Parts (Power-Master 500 P and 350 P)

Lists parts specific to the front panel of the 500P and 350P models.

8.07 PC Board Parts

Lists various printed circuit boards used in the equipment.

8.08 Rear Panel Parts (Power-Master 500 and 350)

Lists parts located on the rear panel of the 500 and 350 models.

8.09 Rear Panel Parts (Power-Master 500 P and 350 P)

Lists parts located on the rear panel of the 500P and 350P models.

8.10 Center Chassis Parts

Lists components and hardware located in the center chassis assembly.

APPENDIX 1: GENERAL INFORMATION

APPENDIX 2: PM-500;350 SCHEMATIC DIAGRAM

APPENDIX 3: PM500;350 CONNECTION DIAGRAM - 1 OF 2

APPENDIX 4: PM500;350 CONNECTION DIAGRAM - 2 OF 2

APPENDIX 5: PM-500 P;350 P SCHEMATIC DIAGRAM

APPENDIX 6: PM500 P;350 P CONNECTION DIAGRAM - 1 OF 2

APPENDIX 7: PM500 P;350 P CONNECTION DIAGRAM - 2 OF 2

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermal Arc 500 Specifications

General

Brand	Thermal Arc
Model	500
Category	Welding System
Language	English