POWERMASTER 500, 500P, 350, 350P
March 17, 2006
6-3
3. Machine powers up but fans do not run.
A. Fans should normally run when the machine is first
powered up or whenever the OUTPUT CONTACTOR
is ON.
B. With CONTROL POWER switch ON check for 120
VAC power on the rear duplex.
C. Check wiring to all three fans.
D. Check wiring to main control board – J9.
E. Possible defective main control board.
F. Possible defective fan/s.
4. CONTROL POWER circuit breaker trips off.
A. Check for shorts or overload on either rear duplex,
14 pin receptacle or 19 pin receptacle and cables.
B. Check for internal short circuit, check wiring to both
contactors, all three fans and to main control board
– J9.
C. Check internal wiring to rear duplex, amphenol
board and small control transformer.
D. Possible defective front panel circuit breaker.
E. Possible defective small control transformer or aux.
transformer.
5a.Machine powers up but no output or incorrect
output (Power-Master 500 and 350 only).
A. Check for open circuit voltage (see how to test open
circuit voltage below).
B. Check for shorted output diode (see how to check
output diodes below).
C. Check front panel controls:
1) Adjust ranges:
To check the output adjust range make sure that
the REMOTE/LOCAL control is set to local. For
GTAW, SMAW and CAG modes the Meter Amps/
Volts switch must be in the AMPS position. For
GMAW mode, the switch must be in the VOLTS
position.
a) GTAW range: 5 - 560 (AMPS display)
b) SMAW range: 5 - 560 (AMPS display)
c) CAG range: 5 - 560 (AMPS display)
d) GMAW range: 0 - 44.0 (VOLTS display)
2) CONTACTOR control:
Whenever the CONTACTOR switch is ON the
indicator LED should also be on. Anytime the
CONTACTOR is on, there should be open circuit
voltage present on the output terminals of the
power source. Open circuit voltage should be
approximately 50 - 70 volts for all operating
modes of the power source except GMAW. For
checking open circuit voltage in GMAW mode,
use an external CONTACTOR control.
NOTE:
For load testing the machine or welding in GMAW
mode it will be necessary to use an external
CONTACTOR signal, otherwise the machine will
NOT produce the correct output voltage.
D. Possible defective main control board.
E. Possible defective IGBT or input rectifier module
(See how to check these parts below).
F. Check internal wiring to control board and
current sensor.
G. Possible defective current sensor.
5b.Machine powers up but no output or incorrect
output (Power-Master 500P and 350P only).
A. Check for open circuit voltage (see how to test open
circuit voltage below).
B. Check for shorted output diode (see how to check
output diodes below).
C. Check front panel controls:
NOTE
If some of the controls appear not to function
as described below, they may have been locked
out or restricted using the programming
software. In this case it will be necessary to
connect a computer to the programmer
interface on the power source and use the
programming software to re-enable these
controls.
1) MODE SELECT:
Each time the mode switch is pressed and
released the power source should advance to
the next mode as indicated by one of the LEDs.
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