Thermal Arc PowerMaster 250 Operating Manual
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Thermal Arc PowerMaster 250 Operating Manual

Cc/cv power source
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350
500
500P

Operating Manual

POWERMASTER
CC/CV POWER SOURCE
Version No: AB.01
Operating Features:
Issue Date: March 17, 2006
Art # A-07643
Manual No.: 0-4749
208
230
V
V
400
460
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V

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Summary of Contents for Thermal Arc PowerMaster 250

  • Page 1: Operating Manual

    POWERMASTER CC/CV POWER SOURCE 500P Art # A-07643 Operating Manual Version No: AB.01 Issue Date: March 17, 2006 Manual No.: 0-4749 Operating Features:...
  • Page 2 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.
  • Page 3 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)

  • Page 4: Table Of Contents

    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 ..............
  • Page 5 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 .................

  • Page 7: Safety Instructions And Warnings

    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.
  • Page 8 POWERMASTER 500, 500P, 350 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. WELDING can cause fire or explosion.
  • Page 9 POWERMASTER 500, 500P, 350 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 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: Symbol Chart

    POWERMASTER 500, 500P, 350 1.03 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- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas...

  • Page 12: Precautions De Securite En Soudage À L'arc

    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.
  • Page 13 POWERMASTER 500, 500P, 350 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 dangereuses à...
  • Page 14 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 AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.

  • Page 15: Principales Normes De Securite

    POWERMASTER 500, 500P, 350 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. fumées d’échappement doivent être envoyées à...

  • Page 16: Graphique De Symbole

    POWERMASTER 500, 500P, 350 1.07 Graphique De Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension Tri-Phase Statique Soudage Torch de Tension dangereuse...

  • Page 17: 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 18: General: Power-Master 500

    POWERMASTER 500, 500P, 350 2.04 General: Power-Master 500 The Power-Master 500 is a primary inverter DC power VOLT-AMP CURVE FOR CC-SMAW MODE 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.

  • Page 19: General: Power-Master 350

    POWERMASTER 500, 500P, 350 2.05 General: Power-Master 350 VOLT-AMP CURVE FOR CC-SMAW MODE 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.

  • Page 20: Power-Master 500 Specifications

    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.

  • Page 21: Power-Master 350 Specifications

    2.07 Power-Master 350 Specifications Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

  • Page 22: General: Power-Master 500P

    POWERMASTER 500, 500P, 350 2.08 General: Power-Master 500P The Power-Master 500 Pulse is a primary inverter DC VOLT-AMP CURVE FOR CC-SMAW MODE 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.

  • Page 23: Power-Master 500P Specifications

    2.09 Power-Master 500P Specifications Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding...

  • Page 24: Standard Features

    POWERMASTER 500, 500P, 350 2.10 Standard Features 2.11 PM500P Programmable Features 1. Short-Circuit Protection – The output of the power 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 so they operation.

  • Page 25: Installation

    POWERMASTER 500, 500P, 350 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 200 VOLT CONNECTION Art # A-04083 sure that the ventilator openings are not obstructed.

  • Page 26: Connection Instructions

    POWERMASTER 500, 500P, 350 3.03 Connection Instructions 3.04 Connecting Welding Machine to 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 POWERMASTER 500, 500P, 350 Line Rated Line Approx. Line Copper Gounding Volts Amps Fuse Size Amps Copper Line Wire Size* Conductor Min. Size 6 AWG (16 mm 6 AWG (16 mm 6 AWG (16 mm 6 AWG (16 mm 10 AWG (6 mm 10 AWG (6 mm 10 AWG (6 mm 10 AWG (6 mm...

  • Page 28: Grounding

    POWERMASTER 500, 500P, 350 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 29: Welding Leads

    POWERMASTER 500, 500P, 350 3.06 Welding Leads Refer to Table 3-3 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 30: Configuration Settings

    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.
  • Page 31 POWERMASTER 500, 500P, 350 B. Wire-Sharpening for GMAW (Power-Master 500P) The power source is configured from the factory with the Wire-Sharpening circuit active for GMAW. This feature improves arc starting by reducing the size of the ball on the wire at the end of the weld. To disable this feature proceed as follows: 1.
  • Page 32 POWERMASTER 500, 500P, 350 March 17, 2006...

  • Page 33: Operation

    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).

  • Page 34: Power-Master 500 And 350 Controls

    POWERMASTER 500, 500P, 350 2. Mode Select Switch: The mode select switch is a four- position switch used to select the weld process. The four modes are as follows: GTAW mode: In this mode the power source 4.02 Power-Master 500 and 350 Controls operates in constant current mode with a lift arc starting circuit activated and arc force/inductance disabled.
  • Page 35 POWERMASTER 500, 500P, 350 6. Meter Display: The digital meter is used to preset the 10.Arc Force/Inductance Control: This control 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 controls the amount of arc force or "dig"...

  • Page 36: Power-Master 500P Controls

    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. This control becomes inactive if REMOTE control is 4.03 Power-Master 500P Controls selected, except for GTAW mode.
  • Page 37 POWERMASTER 500, 500P, 350 circuit limits the “touch” current to a low value and 7. Arc Force/Inductance Control: When the SMAW mode then switches to the preset current after the arc is is selected this control is activated and allows struck.

  • Page 38: Rear Panel (All Models)

    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) F) Scaled output current signal: Ifb = 100 Amps/Volt G) 24/115 VAC neutral...
  • Page 39 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.

  • Page 40: Gtaw (Gas Tungsten Arc Welding)

    POWERMASTER 500, 500P, 350 13. To end the weld, release the foot pedal or turn off torch switch if being used. Turn off shielding gas supply. 4.06 SMAW (Shielded Metal Arc Welding) 4.05 GTAW (Gas Tungsten Arc Welding) 1. Connect the welding leads to the output terminals of 1.

  • Page 41: Cag (Carbon Arc Gouging)

    POWERMASTER 500, 500P, 350 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 the control cable to the 19-pin receptacle or the 14- connect to the negative lead and the electrode holder pin receptacle on the rear of the power source.

  • Page 42: Pulsed Gmaw (Power-Master 500P Only)

    POWERMASTER 500, 500P, 350 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.

  • Page 43: Service

    POWERMASTER 500, 500P, 350 SECTION 5: SERVICE 5.01 General Maintenance Periodically clean the inside of the welding power source If this equipment does not operate properly, stop work by using clean dry compressed air of not over 25 psi as immediately and investigate the cause of the malfunction.
  • Page 44 POWERMASTER 500, 500P, 350 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 45: Basic Troubleshooting Guide

    POWERMASTER 500, 500P, 350 5.02 Basic Troubleshooting Guide 5.03 Troubleshooting Guide This guide should be used as an aid to determine the cause A. Scope: of a system malfunction or failure. It should be The troubleshooting guide is intended to be used by remembered that in most welding situations there can be qualified service technicians.

  • Page 46: Power Source Problems

    REMEDY 1 Mains supply voltage is ON. Primary fuse is blown. Replace primary fuse. Digital meter if off and Broken connection in Have an Accredited Thermal Arc welding arc can not be primary circuit. Service Provider check primary established. circuit.
  • Page 47 Repair the external short circuit breaker trips OFF outlets or 14 / 19 pin receptacles Internal 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...
  • Page 48 POWERMASTER 500, 500P, 350 March 17, 2006...

  • Page 49: Parts List

    POWERMASTER 500, 500P, 350 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.

  • Page 50: Lifting Eye Bushing

    POWERMASTER 500, 500P, 350 6.03 Lifting Eye Bushing Item Item Item Item Item Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Bushing, Lifting Eye, PM, IPS 12CW2170 Art # A-06916 March 17, 2006...

  • Page 51: Voltage Selection Strap

    POWERMASTER 500, 500P, 350 6.04 Voltage Selection Strap Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Strap, 220/440 Volts, PM, IPS CW811 Art # A-06917 March 17, 2006...

  • Page 52: Front Panel Parts (Power-Master 500 And 350)

    POWERMASTER 500, 500P, 350 6.05 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 Bushing, Insulator, PM, IPS 357654 Circuit, Breaker, 10A, 2 Pole 830362...

  • Page 53: Rear Panel Parts

    POWERMASTER 500, 500P, 350 6.07 Rear Panel Parts Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Fuse,20A,600V,Bussman KTK 405093-002 Fuse Holder, PM, IPS 402151 Art # A-06921 March 17, 2006...

  • Page 54: Front Panel Parts (Power-Master 500P)

    POWERMASTER 500, 500P, 350 6.06 Front Panel Parts (Power-Master 500P) Item Item Item Item Item Qty..Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Knob,Control,1/4" ID x 1.6" 870696PKD CIRCUIT BRKR 10A 2POLE 830362 LATCH SELF ADJUSTING, PM, IPS...
  • Page 55 POWERMASTER 500, 500P, 350 Viewed from inside Art # A-07642 Viewed from outside March 17, 2006...
  • Page 56 POWERMASTER 500, 500P, 350 March 17, 2006...

  • Page 57: Appendix 1: General Information

    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...

  • Page 58: Appendix 2: Pm500/350 Connection Diagram 1

    POWERMASTER 500, 500P, 350 APPENDIX 2: PM500/350 CONNECTION DIAGRAM 1 OF 2 Art # A-06861 March 17, 2006...
  • Page 59 POWERMASTER 500, 500P, 350 NOTE: CENTER DIODE IN POWER-MASTER 500 ONLY Art # A-06861 March 17, 2006...

  • Page 60: Appendix 3: Pm500/350 Connection Diagram 2

    POWERMASTER 500, 500P, 350 APPENDIX 3: PM500/350 CONNECTION DIAGRAM 2 OF 2 Art # A-06862z March 17, 2006...
  • Page 61 POWERMASTER 500, 500P, 350 Art # A-06862 March 17, 2006...

  • Page 62: Appendix 4: Pm500P Connection Diagram 1

    POWERMASTER 500, 500P, 350 APPENDIX 4: PM500P CONNECTION DIAGRAM 1 OF 2 Art # A-06864 March 17, 2006...
  • Page 63 POWERMASTER 500, 500P, 350 Art # A-06864 March 17, 2006...

  • Page 64: Appendix 5: Pm500P Connection Diagram 2

    POWERMASTER 500, 500P, 350 APPENDIX 5: PM500P CONNECTION DIAGRAM 2 OF 2 Art # A-06865 March 17, 2006...
  • Page 65 POWERMASTER 500, 500P, 350 Art # A-06865 March 17, 2006...

  • Page 66: Appendix 6: Powermaster 500 Options & Accessories

    POWERMASTER 500, 500P, 350 APPENDIX 6: POWERMASTER 500 OPTIONS & ACCESSORIES WIREFEEDERS PART NO. DESCRIPTION 110V, 50/60Hz, Heavy Duty 2-roll wirefeeder, .035”-.045” Ultrafeed VA 2000 W3300001 (0.9-1.2mm) drive rolls 110V, 50/60Hz, Heavy Duty 4-roll wirefeeder, .045” (1.2mm) Ultrafeed VA 4000 W3400001 drive rolls 110V, 50/60Hz, Heavy Duty, Dual Feed System 4-roll...

  • Page 67: Appendix 7: Powermaster 500P Options & Accessories

    POWERMASTER 500, 500P, 350 APPENDIX 7: POWERMASTER 500P OPTIONS & ACCESSORIES WIREFEEDERS PART NO. DESCRIPTION Ultrafeed VA 2000 W3300001 110V, 50/60Hz, Heavy Duty 2-roll wirefeeder Ultrafeed VA 4000 W3400001 110V, 50/60Hz, Heavy Duty 4-roll wirefeeder 110V, 50/60Hz, Heavy Duty, Dual Feed System 4-roll Ultrafeed VA 4000D W3420001 wirefeeder...

  • Page 68: Appendix 8: Powermaster 350 Options & Accessories

    POWERMASTER 500, 500P, 350 APPENDIX 8: POWERMASTER 350 OPTIONS & ACCESSORIES WIREFEEDERS PART NO. DESCRIPTION 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...

  • Page 70: 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 71 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. Boards ..............3 years...
  • Page 73 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 Telephone: 603+ 6092 2988 Fax: 800-535-0557...
  • Page 74 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...

This manual is also suitable for:

Powermaster 500Powermaster 500pPowermaster 350

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