CARBONE PowerMaster256, Operator'S Manual

C-1                            MAINTENANCE                                    C-1 

SAFETY PRECAUTIONS 

ELECTRIC SHOCK can kill.   

●

Only qualified personnel 

should per-form this 
maintenance.  
 

●

 Turn the input power OFF at 

the disconnect switch or fuse 

box before working on this equipment.   
   

●

 Do not touch electrically hot parts.   

INPUT FILTER CAPACITOR 

 DISCHARGE PROCEDURE  

The machine has internal capacitors which are 
charged to a high voltage during power-on 
conditions. This voltage is dangerous and must 
be discharged before the machine can be 
serviced. Discharging is done automatically by 
the machine each time the power is switched off. 
However, you must allow the machine to sit for 
at least 5 minutes to allow time for the process 
to take place.

To avoid receiving a high frequency shock, keep 
the TIG torch and cables in good condition.   
ROUTINE AND PERIODIC MAINTENANCE   

1 Disconnect power supply lines to machine before 
performing periodic maintenance.   
2. Periodically clean the inside of the machine with 
a low pressure air system. Be sure to clean the 
following components thoroughly.   
   Main Transformer  
   Electrode/Gas Output Receptacle  
      Polarity Switch   
   Rectifier Assembly  
   Arc Starter/Spark Gap Assembly  
   PC Boards  
   Fan Blades  
3 Inspect welder output and control cables for 
fraying, cuts, and bare spots.   
4    Keep TIG torch and cables in good condition.   
5 Clean air louvers to ensure proper air flow and 
cooling.  
6 The fan motor has sealed ball bearings which 
require no maintenance.   

7 

SPARK GAP ADJUSTMENT 

The spark gap .020(.5mm) is set at the factory to a 
gap of 0.015 inches (0.4mm) See Figure D.1. This 
setting is adequate for most applications. Where 
less high frequency is desired, the setting can be 
reduced to 0.015 inches (0.4mm).   

Use extreme caution when working with circuit 
of the high frequency. The high voltages 
developed can be lethal. Turn the input power 
off using the disconnect switch or fuse box 
before working inside machine. This is 
particularly important when working on the 
secondary circuit of the high voltage 
transformer (T3) because the output voltage is 
dangerously high.   

Refer to figure D.1. Note in highly dirty 
environments where there is an abundance of 
conductive contaminants, use a low pressure air 
stream or a firm piece of paper to clean the spark 
gap. Do not disturb the factory setting.   
To check the spark gap:   
-Turn off input power as specified above.   
-Remove the right side panel from the machine, the 
spark gap box is located on the lower right side.   
-Check the spark gap with a feeler gauge. If 
adjustment is needed:   
-Adjust the gap by loosening the head screw in one 
of the aluminum blocks, near the front of the unit 
and tighten the screw in the new position.   
If the gap is correct:   
-Replace the wraparound.   
8    Inspect gas hose and inlet fitting for cracks or 
leaks.  
9    Replace any unreadable labels or decals.   
10 Verify that the machine and welding circuit is 
properly grounded.   

FIGURE D.1 SPARK GAP   

FAN MOTOR OR FAN BLADE REPLACEMENT   

When installing a new fan blade or fan motor be 
sure to maintain proper shaft spacing. 

0.5mm