Thermal Arc POWERMASTER 350P Service Manual
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Thermal Arc POWERMASTER 350P Service Manual

Thermal Arc POWERMASTER 350P Service Manual

Powermaster cc/cv power source
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350
350P
500
500P

Service Manual

POWERMASTER
CC/CV POWER SOURCE
Version No: AB.01
Operating Features:
Art # A-07556
Issue Date: March 17, 2006
Manual No.: 0-4938B
208
230
V
V
460
400
V
V

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Summary of Contents for Thermal Arc POWERMASTER 350P

  • Page 1: Service Manual

    350P POWERMASTER CC/CV POWER SOURCE 500P Art # A-07556 Service Manual Version No: AB.01 Issue Date: March 17, 2006 Manual No.: 0-4938B Operating Features:...
  • Page 3 Part Number 100060, 100095 (CCC) Power-Master 500P Part Number 100054, 100096 (CCC) Power-Master 350 Part Number 100078, 100101 (CCC), 100099 (CSA) Power-Master 350P Part Number 100079, 100102 (CCC), 100100 (CSA) Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermalarc.com...

  • Page 4: Table Of Contents

    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 and 350P Only) ........4-10...
  • Page 5 8.04 Base Parts ...................... 8-4 8.05 Front Panel Parts (Power-Master 500 and 350) ..........8-5 8.06 Front Panel Parts (Power-Master 500P and 350P) ......... 8-6 8.07 PC Board Parts ....................8-8 8.08 Rear Panel Parts (Power-Master 500 and 350) ..........8-9 8.09 Rear Panel Parts (Power-Master 500P and 350P) ........
  • Page 6 APPENDIX 4: PM500/350 CONNECTION DIAGRAM - 2 OF 2 ......... A-6 APPENDIX 5: PM-500P/350P SCHEMATIC DIAGRAM..........A-8 APPENDIX 6: PM500P/350P CONNECTION DIAGRAM - 1 OF 2 ........A-10 APPENDIX 7: PM500P/350P CONNECTION DIAGRAM - 2 OF 2 ........A-12 LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......

  • Page 7: Safety Instructions And Warnings

    POWERMASTER 500, 500P, 350, 350P 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.
  • Page 8 POWERMASTER 500, 500P, 350, 350P 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
  • Page 9 POWERMASTER 500, 500P, 350, 350P 2. If used in a closed area, vent engine exhaust outside and away from any building air intakes. WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

  • Page 10: Principal Safety Standards

    POWERMASTER 500, 500P, 350, 350P 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S.

  • Page 11: Precautions De Securite En Soudage À L'arc

    POWERMASTER 500, 500P, 350, 350P 1.03 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).
  • Page 12 POWERMASTER 500, 500P, 350, 350P AVERTISSEMENT AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX POUR LA SANTE. ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. Le soudage dégage des vapeurs et des fumées L’arc de soudage produit une chaleur et des rayons...
  • Page 13 POWERMASTER 500, 500P, 350, 350P 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 AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.

  • Page 14: Principales Normes De Securite

    POWERMASTER 500, 500P, 350, 350P Les accumulateurs contiennent de l’électrolyte acide et 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. dégagent des vapeurs explosives. 2. Si vous utilisez ces équipements dans un endroit confiné, les 1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

  • Page 15: Introduction

    Include the Owner’s Manual number and equipment identification numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link: http://www.thermalarc.com March 17, 2006...

  • Page 16: Symbol Chart

    POWERMASTER 500, 500P, 350, 350P 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter-...
  • Page 17 POWERMASTER 500, 500P, 350, 350P 2.05 General: Power-Master 500 & 350 The Power-Master 500 and 350 are primary inverter DC VOLT-AMP CURVE FOR CC-SMAW MODE power sources that can be used for constant voltage and constant current weld processes. The Power-Master 500 output is rated at 450 Amps/38 Volts at 100% duty cycle and 560 Amps/42.4 Volts at 60% duty cycle.

  • Page 18: Power-Master 500 Specifications

    POWERMASTER 500, 500P, 350, 350P 2.06 Power-Master 500 Specifications Input Data Line Voltage Line Current Eff. Output 208 VAC/3 Phase 68 Amps 24.5 0.83 450A/38V/100% Duty Cycle 230 VAC/3 Phase 62 Amps 24.7 0.82 450A/38V/100% Duty Cycle 380 VAC/3 Phase 40 Amps 23.7...

  • Page 19: Power-Master 350 Specifications

    POWERMASTER 500, 500P, 350, 350P 2.07 Power-Master 350 Specifications Input Data Line Voltage Line Current Eff. Output 208 VAC/3 Phase 37 Amps 13.1 0.83 300A/32V/100% Duty Cycle 230 VAC/3 Phase 33 Amps 13.1 0.82 300A/32V/100% Duty Cycle 380 VAC/3 Phase 24 Amps 15.8...

  • Page 20: General: Power-Master 500P & 350P

    POWERMASTER 500, 500P, 350, 350P 2.08 General: Power-Master 500P & 350P VOLT-AMP CURVE FOR CC-SMAW MODE The Power-Master 500 Pulse and 350 Pulse are primary inverter DC power sources that can be used for constant voltage and constant current weld processes. The Power- Master 500 Pulse output is rated at 450 Amps/38 Volts at 100% duty cycle and 560 Amps/42.4 Volts at 60% duty...

  • Page 21: Power-Master 500P Specifications

    POWERMASTER 500, 500P, 350, 350P 2.09 Power-Master 500P Specifications Input Data Line Voltage Line Current Eff. Output 208 VAC/3 Phase 68 Amps 24.5 0.83 450A/38V/100% Duty Cycle 230 VAC/3 Phase 62 Amps 24.7 0.82 450A/38V/100% Duty Cycle 380 VAC/3 Phase 40 Amps 23.7...

  • Page 22: Power-Master 350P Specifications

    POWERMASTER 500, 500P, 350, 350P 2.10 Power-Master 350P Specifications Input Data Line Voltage Line Current Eff. Output 208 VAC/3 Phase 37 Amps 13.1 0.83 300A/32V/100% Duty Cycle 230 VAC/3 Phase 33 Amps 13.1 0.82 300A/32V/100% Duty Cycle 380 VAC/3 Phase 24 Amps 15.8...

  • Page 23: Standard Features

    1. Lockout features: Any or all of the following controls source can be short circuited in any of the modes of can be locked out on the Power-Master 500P/350P operation. This protection feature will instantly limit so they will have no affect on the operation of the the output current to a safe value, to assure reliable machine.
  • Page 24 POWERMASTER 500, 500P, 350, 350P 2-10 March 17, 2006...

  • Page 25: Installation

    POWERMASTER 500, 500P, 350, 350P SECTION 3: INSTALLATION 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...

  • Page 26: Connecting Welding Machine To Line Voltage

    POWERMASTER 500, 500P, 350, 350P 3.03 Connecting Welding Machine to 3.04 Connection Instructions Line Voltage 1. Remove left side panel to gain access to the input terminal block and ground screw. The input power should be connected to the unit through a fused disconnect switch, or other suitable 2.

  • Page 27: Grounding

    POWERMASTER 500, 500P, 350, 350P 3.05 Grounding Rubber-tire mounted equipment shall be grounded to conform to local and national codes. The grounding The frame of this welding machine should be grounded assists in providing protection against line voltage for personnel safety, and to assure operation of the electrical shock and static shock.

  • Page 28: Welding Leads

    POWERMASTER 500, 500P, 350, 350P 3.06 Welding Leads Refer to Table 3-2 as a basic guideline to the required copper cable sizes. Connect the welding leads to the output bus bar As a general rule, the welding cables should be kept as terminals of the power source.

  • Page 29: Configuration Settings

    POWERMASTER 500, 500P, 350, 350P 3.07 Configuration Settings A. Lift-Arc GTAW The power source is configured from the factory with the Lift-Arc starting circuit active for GTAW. This feature should be disabled if an external high voltage arc starter is being used to start the arc. To disable the lift arc feature proceed as follows: 1.
  • Page 30 POWERMASTER 500, 500P, 350, 350P B. Wire-Sharpening for GMAW (Power-Master 500P and 350P Only) The power source is configured from the factory with the Wire-Sharpening circuit active for GMAW. This feature improves arc starting by reducing the size of the ball on the wire at the end of the weld. To disable this feature proceed as follows: 1.

  • Page 31: Section 4: Operation

    POWERMASTER 500, 500P, 350, 350P 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).

  • Page 32: Power-Master 500 And 350 Controls

    POWERMASTER 500, 500P, 350, 350P 4.02 Power-Master 500 and 350 Controls 2. Mode Select Switch: The mode select switch is a four- position switch used to select the weld process. The four modes are as follows: GTAW mode: In this mode the power source...
  • Page 33 POWERMASTER 500, 500P, 350, 350P 6. Meter Display: The digital meter is used to preset the 10.Arc Force/Inductance Control: This control pot. is output voltage or current when the power source is active for SMAW (Stick) and GMAW (Mig). In SMAW not welding, and to display the actual amps or volts mode, this pot.

  • Page 34: Power-Master 500P And 350P Controls

    One of the four indicator lights Figure 4-2: Power-Master 500P and 350P Front Panel located above the switch should be on at all times, indicating the mode which is currently selected. The 1.
  • Page 35 POWERMASTER 500, 500P, 350, 350P SMAW mode: In this mode the power sources 7. Arc Force/Inductance Control: When the SMAW mode operates in constant current mode. The front panel is selected this control is activated and allows control can be used to preset the desired welding adjustment of the amount of arc force or “dig”.

  • Page 36: Rear Panel (All Models)

    POWERMASTER 500, 500P, 350, 350P 4.04 Rear Panel (All Models) 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).
  • Page 37 Refer to the installation chapter of this manual for detailed instructions. 6. CAN Port (PowerMaster 500P and 350P only): This serial port is used for connection to a CAN compatible Thermal Arc wire feeder or other auxilliary device. All of the programmable features of the power source can be accessed via this port.

  • Page 38: Gtaw (Gas Tungsten Arc Welding)

    POWERMASTER 500, 500P, 350, 350P 4.05 GTAW (Gas Tungsten Arc Welding) 4.06 SMAW (Shielded Metal Arc Welding) 1. Connect the work lead to the positive terminal and the torch to the negative terminal of the power source 1. Connect the welding leads to the output terminals of (normal connection for DCEN).

  • Page 39: Cag (Carbon Arc Gouging)

    POWERMASTER 500, 500P, 350, 350P 4.07 CAG (Carbon Arc Gouging) 4.08 GMAW (Gas Metal Arc Welding) 1. Connect the welding leads to the output terminals of 1. Connect the wire feeder to the power source. Connect the power source. Normally the work lead should...

  • Page 40: Pulsed Gmaw (Power-Master 500P And 350P Only)

    POWERMASTER 500, 500P, 350, 350P 4.09 Pulsed GMAW (Power-Master 500P 8. To end the weld, release the torch switch while holding the torch in place at the end of the weld. and 350P Only) This will allow the wire sharpening circuit in the power source to condition the end of the wire for 1.

  • Page 41: Maintenance

    POWERMASTER 500, 500P, 350, 350P SECTION 5: MAINTENANCE If this equipment does not operate properly, stop work The following checklist can be used as a guide for routine immediately and investigate the cause of the malfunction. maintenance. Maintenance work must be performed by an experienced, •...
  • Page 42 POWERMASTER 500, 500P, 350, 350P Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch Visual check of Consumable parts regulator and pressure Weekly Visually inspect the torch Visually inspect the body and consumables cables and leads.

  • Page 43: Troubleshooting

    POWERMASTER 500, 500P, 350, 350P SECTION 6: 6.02 Basic Troubleshooting TROUBLESHOOTING There are two general types of problems or failures which can occur with the Power-Master. The first would relate to a failure within the power circuit, and the second would 6.01 General...

  • Page 44: Troubleshooting Guide

    POWERMASTER 500, 500P, 350, 350P 6.03 Troubleshooting Guide 1. Unit is completely inoperative – digital display is off, fans are off, no output. This guide should be used as an aid to determine the cause A. Check for blown input fuse or fuses.
  • Page 45 D. Possible defective front panel circuit breaker. 5b.Machine powers up but no output or incorrect E. Possible defective small control transformer or aux. output (Power-Master 500P and 350P only). transformer. A. Check for open circuit voltage (see how to test open 5a.Machine powers up but no output or incorrect...
  • Page 46 POWERMASTER 500, 500P, 350, 350P 2) REMOTE/LOCAL control: 6. How to check the input rectifier module. Each time the REMOTE ON switch is pressed A. See Figure 5-1 and/or Appendix 3 Connection Diagram. and released the associated indicator LED should toggle between ON and OFF. If the LED B.
  • Page 47 POWERMASTER 500, 500P, 350, 350P 8. How to check the output diodes. A. Disconnect the weld cables from output terminals. Capacitor BD B. With diode checker setting on VOM, measure across Top IGBT output terminals with positive meter lead on negative output terminal.

  • Page 48: Power-Master 500 And 350 Block Diagram

    POWERMASTER 500, 500P, 350, 350P 6.04 Power-Master 500 and 350 Block Diagram Art # A-07544 March 17, 2006...
  • Page 49 POWERMASTER 500, 500P, 350, 350P March 17, 2006...

  • Page 50: Power-Master 500P And 350P Block Diagram

    POWERMASTER 500, 500P, 350, 350P 6.05 Power-Master 500P and 350P Block Diagram March 17, 2006...
  • Page 51 POWERMASTER 500, 500P, 350, 350P Art # A-07545 March 17, 2006...

  • Page 52: Control Board Connector Signals For 830894 Main Control Board

    POWERMASTER 500, 500P, 350, 350P 6.06 Control Board Connector Signals For 830894 Main Control Board Connector Voltage Description J1: 26 pin ribbon cable to front panel board J1-1 1V or 14V GTAW mode select, 1V = GTAW selected J1-2 1V or 14V...
  • Page 53 POWERMASTER 500, 500P, 350, 350P Connector Voltage Description J4: 12 position connector header for optional wire stick detect circuit J4-1 Power supply to wire detect circuit J4-2 Common Signal common J4-3 to J4-10 J4-11 0 to +60V Positive output terminal...
  • Page 54 POWERMASTER 500, 500P, 350, 350P 6.06 Control Board Connector Signals For 830894 Main Control Board (con't) Connector Voltage Description J10: 16 position ribbon to amphenol board J10-1 +15V Voltage supply to remote gun switch J10-2 0 or +15V Gun switch input, +15V = Gun switch on...

  • Page 55: Power Circuit Tests

    POWERMASTER 500, 500P, 350, 350P 6.07 Power Circuit Tests IGBT Test: (See Figure 6-4 and connection diagram). Note: Danger: Because of the capacitor boards connected across the IGBTs they may initially show a short HIGH VOLTAGE is present internally even with circuit when using the diode checker, until the the control power switch in the OFF position.

  • Page 56: Semiconductor Replacement Requirements

    POWERMASTER 500, 500P, 350, 350P 6.08 Semiconductor Replacement Capacitor Board tests: Requirements The capacitors can be checked using the diode checker function on a digital multi-meter, with the power The following guidelines must be followed when replacing disconnected from the machine. A good capacitor will one of the power semiconductors.

  • Page 57: Main Control Board

    POWERMASTER 500, 500P, 350, 350P 6.09 Main Control Board Ground Art # A-07548 Figure 6-4: Main Control Board March 17, 2006 6-15...

  • Page 58: Control Circuit Tests

    POWERMASTER 500, 500P, 350, 350P 6.10 Control Circuit Tests 1. Power Supplies: TP2-6 to TP4-2 (GND): +15 VDC Most of the control circuit measurements can be made on the main control board. (See Figure 6-5) TP2-3 to TP4-2 (GND): -15 VDC...
  • Page 59 POWERMASTER 500, 500P, 350, 350P If the power supplies still do not check ok, verify that the proper AC voltage is coming up to the board. L1 to TP4-2 (GND): 21 VAC L3 to TP4-2 (GND): 21 VAC L1 to L3: 42 VAC...
  • Page 60 POWERMASTER 500, 500P, 350, 350P 2. Reference Circuit If TP2-1 reads OK but front panel display is wrong then the problem is with the front panel board or Set front panel to LOCAL (Remote off) control and mode ribbon cable inter-connect.
  • Page 61 POWERMASTER 500, 500P, 350, 350P 3. Gun Switch Circuit A. With gun switch on (jumper A-B on 19 pin remote), R175 is 13.6 VDC, with gun switch off, R175 is 0VDC. This is the gun switch from the 19/14 pin remote (See Figure 6-8) receptacle.
  • Page 62 POWERMASTER 500, 500P, 350, 350P 5. Gate Signal Checks: C. Use the CONTACTOR switch on the front panel to activate the gate drive. With CONTACTOR on the gate Note: voltage should be approximately 14.5 VAC (at 17KHz), with the CONTACTOR off, the gate voltage should read Remove jumper from pins A &...
  • Page 63 POWERMASTER 500, 500P, 350, 350P 6. Remote Control Checks: If RV3 is ok, then verify that the remote signal is making it to the main board from the amphenol board. The input A. Jumper pins H and J together at 19 pin remote from the 19 pin remote is at R269, and the input from the receptacle on rear panel.
  • Page 64 POWERMASTER 500, 500P, 350, 350P 8. Relay Checks: C. J9-1 to J9-5 checks open when power is first applied, checks shorted after approximately 4 seconds. This K2 controls the main contactor. K3 controls the precharge drives the main contactor. inrush contactor, and K4 controls the fans.
  • Page 65 POWERMASTER 500, 500P, 350, 350P Note: 9. Current Feedback Ifb: Verification of the Ifb signal requires putting a load on the If the current sensor is unplugged from the board or the signal line is broken then the machine. Make sure that all connectors are plugged into the board.

  • Page 66: Calibration Procedure

    POWERMASTER 500, 500P, 350, 350P 11. Arc established circuit: 6.11 Calibration Procedure Measure the arc established signal at R132 (See Figure Voltage and current feedback calibration procedure: 6-11). The following procedure can be used to check the A. With no load on the machine, arc established should calibration of the Power-Master.

  • Page 67: Repair Procedures

    POWERMASTER 500, 500P, 350, 350P SECTION 7: Step 4: Identify the failed diode module/s. Step 5: Remove the three mounting screws holding the REPAIR PROCEDURES diode to the heatsink. Step 6: Clean the heatsink area where the diode mounts. 7.01 Output Diode Replacement: Step 7.

  • Page 68: Igbt Module Replacement

    POWERMASTER 500, 500P, 350, 350P 7.02 IGBT Module Replacement: Step 5: Remove the two screws connecting the ca- pacitor boards to the IGBT. Remove the brass spacer The following procedure can be used to replace one of the from underneath the capacitor board lead.

  • Page 69: Parts List

    POWERMASTER 500, 500P, 350, 350P SECTION 8: PARTS LIST 8.01 Equipment Identification All identification numbers as described in the Introduc- tion chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Specification or Assem- bly numbers.

  • Page 70: External Panels

    POWERMASTER 500, 500P, 350, 350P 8.03 External Panels Item Item Description Description Part Number Part Number Item Item Item Description Description Description Part Number Part Number Part Number Bushing, Lifting Eye, PM, IPS 12CW2170 Label, Precaution, Arc Equip 204036 Label,Volt Changeover, PM, IPS...
  • Page 71 POWERMASTER 500, 500P, 350, 350P Art # A-06927 March 17, 2006...

  • Page 72: Base Parts

    POWERMASTER 500, 500P, 350, 350P 8.04 Base Parts Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Board,Volt Selection, PM, IPS 830941 Bracket,Input Line, PM, IPS...

  • Page 73: Front Panel Parts (Power-Master 500 And 350)

    POWERMASTER 500, 500P, 350, 350P 8.05 Front Panel Parts (Power-Master 500 and 350) Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number PCB,Non-PulseDisplay, PM, IPS...

  • Page 74: Front Panel Parts (Power-Master 500P And 350P)

    POWERMASTER 500, 500P, 350, 350P 8.06 Front Panel Parts (Power-Master 500P and 350P) Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Overlay,Weld Schedule,PM500P 831114PKD Spacer,.14IDx.5 Nylon, PM, IPS...
  • Page 75 POWERMASTER 500, 500P, 350, 350P 24 2 38 37 19 Viewed from inside A-06952 Viewed from outside March 17, 2006...

  • Page 76: Pc Board Parts

    POWERMASTER 500, 500P, 350, 350P 8.07 PC Board Parts Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number PCB, Control, PM, IPS 830894 Cable,Ribbon,26 P,13", PM, IPS 204038-002 Cable,Ribbon,16P,20", PM, IPS...

  • Page 77: Rear Panel Parts (Power-Master 500 And 350)

    POWERMASTER 500, 500P, 350, 350P 8.08 Rear Panel Parts (Power-Master 500 and 350) Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number PCB, Amphenol, PM, IPS...

  • Page 78: Rear Panel Parts (Power-Master 500P And 350P)

    POWERMASTER 500, 500P, 350, 350P 8.09 Rear Panel Parts (Power-Master 500P and 350P) Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number PCB, Amphenol, PM, IPS...
  • Page 79 POWERMASTER 500, 500P, 350, 350P THIS PAGE HAS NEEN LEFT INTENTIONALLY BLANK 8-11 March 17, 2006...

  • Page 80: Center Chassis Parts

    POWERMASTER 500, 500P, 350, 350P 8.10 Center Chassis Parts Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number PCB,Capacitor,Neg,“B”, PM, IPS 830413 PCB,Capacitor,Pos,“B”, PM, IPS...
  • Page 81 POWERMASTER 500, 500P, 350, 350P Art # A-06937 8-13 March 17, 2006...
  • Page 82 POWERMASTER 500, 500P, 350, 350P March 17, 2006 8-14...

  • Page 83: Appendix 1: General Information

    POWERMASTER 500, 500P, 350, 350P APPENDIX 1: GENERAL INFORMATION • Note the model and specification number shown on the equipment nameplate. • Locate these numbers in the model and specification number columns below. • Use only those diagrams and instructions that are applicable.

  • Page 84: Appendix 2: Pm-500/350 Schematic Diagram

    POWERMASTER 500, 500P, 350, 350P APPENDIX 2: PM-500/350 SCHEMATIC DIAGRAM Art # A-06941 March 17, 2006...
  • Page 85 POWERMASTER 500, 500P, 350, 350P NOTE: CR3 CIRCUIT IN POWER-MASTER 500 ONLY Art # A-06941 March 17, 2006...

  • Page 86: Appendix 3: Pm500/350 Connection Diagram - 1

    POWERMASTER 500, 500P, 350, 350P APPENDIX 3: PM500/350 CONNECTION DIAGRAM - 1 OF 2 Art # A-06942 March 17, 2006...
  • Page 87 POWERMASTER 500, 500P, 350, 350P NOTE: CENTER DIODE IN POWER-MASTER 500 ONLY Art # A-06942 March 17, 2006...

  • Page 88: Appendix 4: Pm500/350 Connection Diagram - 2

    POWERMASTER 500, 500P, 350, 350P APPENDIX 4: PM500/350 CONNECTION DIAGRAM - 2 OF 2 Art # A-06943 March 17, 2006...
  • Page 89 POWERMASTER 500, 500P, 350, 350P Art # A-06943 March 17, 2006...

  • Page 90: Appendix 5: Pm-500P/350P Schematic Diagram

    POWERMASTER 500, 500P, 350, 350P APPENDIX 5: PM-500P/350P SCHEMATIC DIAGRAM Art # A-06944 March 17, 2006...
  • Page 91 POWERMASTER 500, 500P, 350, 350P NOTE: CR3 CIRCUIT IN POWER-MASTER 500P ONLY Art # A-06944 March 17, 2006...

  • Page 92: Appendix 6: Pm500P/350P Connection Diagram - 1

    POWERMASTER 500, 500P, 350, 350P APPENDIX 6: PM500P/350P CONNECTION DIAGRAM - 1 OF 2 Art # A-06945 March 17, 2006 A-10...
  • Page 93 POWERMASTER 500, 500P, 350, 350P NOTE: CENTER DIODE IN POWER-MASTER 500P ONLY Art # A-06945 A-11 March 17, 2006...

  • Page 94: Appendix 7: Pm500P/350P Connection Diagram - 2

    POWERMASTER 500, 500P, 350, 350P APPENDIX 7: PM500P/350P CONNECTION DIAGRAM - 2 OF 2 Art # A-06946 March 17, 2006 A-12...
  • Page 95 POWERMASTER 500, 500P, 350, 350P Art # A-06946 A-13 March 17, 2006...

  • Page 96: Limited Warranty

    No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt.

  • Page 97: Warranty Schedule

    WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. April 2006 ENGINE DRIVEN WELDERS ARRANTY ERIOD ABOR Scout, Raider, Explorer Original Main Power Stators and Inductors................3 years 3 years Original Main Power Rectifiers, Control P.C.

  • Page 99: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 100 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...

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