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2428 C & CR Pgs - Victor Technologies

1. PIN SIG FROM TO 1 SEC PRESS _______ D L 2 GETI ee D L 3 RUN ___________ D L 5 LED 1 0 6 GAS LED L D 7 UE LEE i L D COMMONS AND SPARES NOT SHOWN PILOT LED L D 11 DISPLAY C50 ______ D A FROM TO P PILOT 13 PIP ESD A L D L LOGIC 15 REMOTE _________ _ 16 PREVIEW__________ A D Ae ANALOG 18 DISPLAY SIG COMM _ A D D DISPLAY a 19 DISPLAY SIG ______ A D R REMOTE Front Panel LEDs 22 CSD POT WIPER D A PM POWER MODULE AC 23 PDT LOW o 0 24 MAIN POT WIPER ___ D A GAS 25 HIGH A D DC 27 0 L D 28 SBVAC Lee L D PILOT 31 PLASMA PRESS _____ D L 33 LATOR D L 34 HIGH TRANSFER ____ D L cM c2 118 ASSY 19X915 oo 9 00000000000000000 Ml w ORZRIO 9 a _ 10000000000000000 33 en n ES 5 C4 O 0800 0018012011 00 at n Ut 1 T D ol LI L CTZ TEMP e 06 105 517 00000000 0000000 m 00 015 E UR Ol R11 R33 R18 N 10 O O4 F
2. 1 LEDs for READY RUN START TP3 TP2 TP1 PS ENABLE PSR CSR 4 9 10 LEDs for 70A 140A 11 12 13 14 LOGIC TO DISPLAY RIBBON DISPLAY RIBBON CABLE 320 PIN SEC PRESS FROM TO SIG SET RUN GAS LED DC LED PILOT LED __ DISPLAY CSD PIP ESD REMOTE PREVIEW DISPLAY DISPLAY CSD POT POT LOW MAIN POT WIPER POT HIGH PLASMA 55 HIGH TRANSFER J21LOGIC TORCH SIG CONN J25 Signal PIP START Torch ID A Torch ID Torch ID C ID Common Shield Return PCB Shield Return PCB A 00135 XIGNAddV SNOILO3NNOO 49d 919071 ANALOG PCB CONNECTIONS APPENDIX III 9 100 V 50141 Jo equunN 0 7777 H3dSNvHl HIIH EE 21 1 EE Gs 55Hd VNSvV Id JE BC 9 JVASE ZZ HIIH 109 Sc 777 H3dIM 10 NIVW pz Mona 10 EZ 7777 H3dIM 104 052 zz rr 915 AV1dSIO 7 WADI SIS AVIASIO 8 DE ANN E M3IA38d SI 310038 SI v 052 did El ON 055 5 Sarnen 031 10114 6 Me secs 031 20 24
3. Manual 0 2428 5 Defective Display Ribbon Cable or Logic PCB Check for DC voltage from Logic J20 1 to TP1 GND for secondary or J20 33 to TP1 GND for plasma a If less than a volt replace Logic PCB b If higher than a volt replace ribbon cable 1 GND J20 soe 31 A 00119 Logic PCB _ 4 07 Purge Problems Locate your symptom below A AC indicator ON TEMP indicator ON green Gas flows GAS indicator ON or OFF DC and PILOT indicators OFF 1 RUN PURGE SET switch in PURGE or SET posi tion a Move to RUN position 2 Defective RUN PURGE SET switch a Check continuity 3 Defective secondary single gas solenoid a Replace if secondary single gas flows and volt age between wire 26 to wire 110 measures 0 vac Solenoid Secondary A 00082 Solenoid Manual 0 2428 4 Defective plasma gas solenoid a Replace if plasma gas flows and voltage between wire 25 to wire 110 measures 0 vac 5 Defective Pilot PCB a Disconnect Pilot Ribbon Cable from Pilot PCB at J5 Replace if gas still flows 6 Defective Pilot Ribbon Cable Reconnect Pilot Ribbon Cable to Pilot PCB at J5 a Disconnect Pilot Ribbon Cable to Analog PCB at J14 and Logic PCB at J18 Replace if gas still flows Reconnect Pilot Ribbon Cable to Analog PCB at J14 and Logic PCB at J18 7 Defective Logic P
4. 50 834 39W3483 1NI FINGOW H3MOd SLP NA s ds olo ooo Bed 228 20 10 2 ER d ONVN30 10114 A 9015 3 EE Saa 1 4 LE ASJ LE 7 318YN3 385 OZH EE 4 MOI4 1 1002 52 1 10718 62 V 1 H O3VIVISNI 3LON38 42 ES de d 1 AW138 1 1002 82 ys en QIVASE SZ ERS EN ER ENT Ge V d 1 5 1 HJIH SZ Ha En eqvags EZ dy an en Gaye d 1 03 Z 1 13 QVASE 12 ei v 1 03395 MOTZIH BI Hey 109 61 es soil ON TER d 1 Av33H VASVIS Bl res AW1dSIO MY 41 Warren HAASNVEL 358 21 tee El WAOD 133130 GOW JO 4 0 3 B EEE V d JHL 440 El 10d Z Ad don Meg 11 ebene dOlS 1HviS Wd 1 GOW 10714 IT HSI Gases MONTE 338YN3 d 1 238 8 D ME S A39Hnd NDH Wt ee 853 9 01 NOH4 SIS Nid ET e e oso 1 IVNOLLdO SLOWSH 1 Ser e Ree T 1 H3u01 VSE x01 WAOHd SIS NId 401 AOHd SIS Nid dI8VvO
5. 1 YEAR 1 YEAR 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS iere 180 DAYS 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS 22 2 22 90 5 90 DAYS NONE Warranty repairs or replacement claims under this limited warranty must be submitted by authorized Thermal Arc repair facility within thirty 30 days of the repair Authorized Thermal Arc repair facilities are authorized distributors and authorized Thermal Arc Service Centers No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal warranties Thermal Arc is a Registered Trademark of Thermal Dynamics Effective February 1 1995 GENERAL INFORMATION 6 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This Manual provides Service Instructions for Thermal Dynamics STAK Control Module Model 6032 Refer to Operating Manual 0 2463 for individual oper ating procedures Information in this edition is therefore particularly applicable to the Troubleshooting and Repair of the equipment and is intended for
6. YNAMICS Il May 30 1996 WARNING WARNING Read and understand this entire Service Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Service Manual repre sents our best judgement Thermal Dynamics Corporation assumes no liability for its use STAK II Control Module Service Manual Number 0 2428 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1996 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in the STAK PAK II Control Module Service Manual whether such error results from negligence accident or any other cause Printed in the United States of America May 30 1996 TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION as
7. 89 LOlld vir 319v9 NO8SIH APPENDIX 47 Manual 0 2428 8 8cvc 0 lENUEW J5 PILOT RIBBON CABLE PIN t 516 FROM TO 1 3BVACa _____ _ P A L DENE oues 5 36VACb _ 6 36VACb __ 8 8 11 SEC RELAY CS gt DRAG _ 13 OFF THE PLATE Pore ee 17 PSR _ Bp 18 PLASMA RELAY 19 AT LOW SPEED J1 High Water Flow 21 ED ENABLE cc Shield Optional 25 HIGH TRANSFER Pin Signal 28 COOLANT RELAY 29 PILOT ENABLE 1 115 VAC Return 31 OVERTEMP W44 W48 W39A P1 2 4 115 CSR W50 J2 J3 W39 wa2 W49 E gt gt gt gt gt gt gt urrrrrr 7070707U TP7 2 00137 Al XIQNAddV SNOILO3NNOO 89d 412 PS2 8 RUN PURGE SET Switch Pin Signal APPENDIX V DISPLAY PCB CONNECTIONS J10 DISPLAY PCB RIBBON CABLE
8. Back of STANDARD LATCH HI TRANSFER Switch A 00123 Figure 5 10 STANDARD LATCH HI TRANSFER Switch Assembly REPLACEMENT PROCEDURES K Pressure Gauge Assembly Replacement NOTE Both the Plasma and Secondary gauges are replaced in the same manner 1 Open the Control Module as described in paragraph A above 2 Disconnect the wiring tho the desired Pressure Switch 3 Remove the Pressure Switch from the desired Pres sure Gauge Assembly 4 Carefully remove the feeder line T connector nut and clamp from the Pressure Gauge Assembly 5 Slide the Pressure Gauge out of the Front Panel As sembly 6 Reinstall the replacement Pressure Gauge Assembly by reversing the above procedure Pressure Switch Assembly Gauge Clamp Pressure Gauge JN JN Y EN A 2 A v w t g ES 9 7 Ao 00124 Figure 5 11 Pressure Gauge Assembly L Pressure Switch Replacement NOTE Both the Plasma and Secondary Pressure Switch Assemblies are replaced in the same manner 1 Open the Control Module as described in paragraph above 2 Disconnect the wiring from the desired Pressure Switch 3 Remove the Pressure Switch from the Pressure Gauge Assembly REPLACEMENT PROCEDURES 34 4 Reinstall the replacement Pressure Switch Assembly by reversing the above procedure
9. Control and Power Components Operating Manual 0 2463 The advanced troubleshooting covered in this Servive Manual requires control module disassembly and live measurements It is helpful for solving many of the com mon problems that can arise with the Stak Pak Plasma Cutting System If major complex subassemblies are faulty the unit must be returned to an authorized service center for repair Follow all instructions as listed and complete each in the order presented Specific test procedures and LED status identification tables have been grouped together and are referenced by the troubleshooting guide The guide has seven sections as follows Section 4 04 Circuit Fault Isolation Section 4 05 Main Input Power Problems Section 4 06 Internal Power Problems Section 4 07 Purge Problems Section 4 08 Pilot Arc Problems Section 4 09 Main Arc Problems Section 4 10 Test Procedures C How to use this Guide The following information is a guide to help the Service Technician determine the most likely causes for various symptoms This guide is set up in the following manner 1 Perform operational check s on the equipment to iso late problem to possible circuit s SERVICE TROUBLESHOOTING 2 Determine symptom and isolate to defective assembly using the following format X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Check Remedy Text Type 3 Locate your sympto
10. Pressure Switch A 00125 Figure 5 12 Pressure Switch Assembly M Plasma or Secondary Regulator Solenoid Assembly Replacement 1 Open the Control Module as described in paragraph A above NOTE Both the Plasma and Secondary Regulator Sole noid Assemblies are replaced in the same manner Disconnect the wiring from the desired Regulator Solenoid Assembly Carefully remove the input and output feeder lines to the assembly On the Front Panel remove the securing nut for the Regulator Solenoid Assembly Slide the Regulator Solenoid Assembly out of rear of the Front Panel Remove the output elbow connector from the old as sembly Reinstall the replacement Regulator Solenoid Assem bly by reversing the above procedure Manual 0 2428 Regulator Solenoid Assembly 00126 P di Securing Nut Figure 5 13 Regulator Solenoid Assembly N Capacitive Discharge CD Transformer Assembly Replacement 1 Open the Control Module as described in paragraph A above 2 Disconnect the two connections to the Pilot PCB As sembly at P1 and P2 3 Remove the winding connection from the power Fe male Blade Connector 5 Remove the winding connection to the Secondary Quick Disconnect Socket Assembly 6 Remove the two screws securing the assembly to the bottom of the Control Module 7 Reinstall the replacement Capacitive Discharge Trans former Assembly by reversing
11. amp L3 118 12 L L2 W JUMPER 12 13 FU 31 J3 C v 1281 gt 33 MX PILOT DRAG Pp 17 m PILOT SW ty esla J38 v ES J4 61 sav e B JUMPER GND 328 6 36VACaly 135 39 33 g m iae 3412 215v EM 24 RD 138 to OV _ BL 18 INSIDE CM I 18VAC TO POWER NEAR REAR CONNECT 230 TO RD 5 Np igen Vs F MODULES PANEL FOR 200 240V BLADE 1308 FOR 380 415V a TRA Swi CONNECTORS J3 C FOR 4607 ON OFF FRONT PANEL A 00133 1 APPENDIX 52 Manual 0 2428 RIBBON CABLES DISPLAY RIBBON CABLE 418 416 NOTE FAN ome SSTG 320 COMPONENTS LOCATION 1 SEC PRESS _ D L IDENTICAL HARNESS 2 SET __ D L USED FOR RUN D L 49 AND J12 TEMP OVERTEMP LED L D 510 EXTERNAL WIRING 6 GAS LED L D ET 538v SERT A FER 7 LED 1 0 1FU 2 AMP 688 VOLT E2 E J 9 PILOT LED L D DISPLAY NA
12. des pi ces sous tension solez vous du courant de coupe et de la terre Remplacer toute pi ce isolante fendue ou endom mag e y compris le corps de torche et les c bles Couper l alimentation avant la depose du chalumeau Couper l alimentation avant d intervenir sur la torche y compris pour changer la buse ou l lectrode Avant d utilisere le chalumeau s assurer que l ecran de protection est en place Soyez particuli rement vigilant lorsque vous coupez avec un appariel de coupe au plasma dans un endroit humide encendie Les Etincelles et les scories peuvent provoquer UN ENCENDIE Oter tout combustible de l aire de coupe ou installer un d tecteur de flammes GENERAL INFORMATION Ne pas couper de r cipient ayant contenu des com bustibles Tout mat riel inflammable ou combus tible pouvant tre allum par une tincelle doit tre enlev de l aire de coupe Aye BRUIT Le bruit peut causer la surdit Prot des protecteurs auditifs Assur que tous les autres sont prot g du bruit de gaz comprimes LES R SERVOIRS DE GAZ SONT DANGEREUX Se r f rer aux directives du constructeur pour une bonne utilisation 1 05 Les publications LES PUBLICATIONS suivantes contiennent des renseignements suppl mentaires sur les pr cautions prendre pour garantir la s curit A Bulletin No C5 2 83 Recommended Safe Prac tices for Plasma Arc Cutting
13. 4 7 A usan 2 3 READY RUN START PS PSR CSR 2 gt ct ENABLE 79 21 gt 36VACa 22 gt 6 4 a la 24 gt START STOP 25 gt 148 26 gt REMOTE INSTALLED 27 gt 29 gt AT LOW SPEED 315 J 314 J J19 218 421 _ 4 _ 2 5 6 7 J gt RUN PURGE i Ir 32 gt 250 A 2 a 33 gt SIGNAL RIBBON CABLE 36 E STOP v 37 34 PILOT RIBBON CABLE SHIELB 31 gt RE TURN 28 gt 23 gt 19 gt NEG 18 2 9 iG mest 8 68 ad 638v 7 gt t2 gt 6 4 5 PART or 5 REMOTE OPTION 23 x 110 J2 1 1 1 3 J5 J J27 D 3 126 POWER MODULE En 8 INTERFACE dos 4 ee z zo 2 iu E Ze zz 19 711 COL OK TO T OK TO lec D 5 lt MOVE MOVE Sum 2 5 2 u Elx 55 566 el Su 33 lo k gt 4 z 330 25 15 PCB A of jn 0 uU O lt gt 2w B lt S 306 lh b ER P ak ko Cal PEPYS sou PLAS eee se SEB p ageer B Rd SAN LL 1252 6 8 8 106 8 15 9 CSR CONTACTS 26 18 gt TXEDIS PARK 50 2 SEC SEC ET hs Em BAS X en REAR PANEL El E2 27 24 224 LT gt gt INPUT VN AC 2 REVERSE 208 468 VAC ww mm SELECT ES 1 OR 3 PHASE 1 PHASE L
14. 13 STANDARD 1 OTSPLAYCSG EN E 2 14 sw oF 13 8 A L D LATCH 15 REMOTE 3 15 uf PILOT INDUCTOR F6 N HIGH 16 PREVIEW A D 5 16 TRANSFER 18 DISPLAY SIG COMM A D LTI AMBER NEON Psi 19 DISPLAY SIG 0 SG 2475 PLASMA 22 CSD POT WIPER D A PS1 PLASMA PRESSURE SW 35 PSI 7 23 POT LOW A D PS2 SECONDARY PRESS SW 35 PSI B7 CURRENT 24 MAIN POT WIPER D A 25 POT HIGH A D R 2 75K IW Ezi J12 27 BYVAL Pn R3 188 2W PART OF OPTIONAL 06 A RUN 23 6 70 R4 200 55W 502 HARNESS EB NI 2 14 sw 0 31 PLASMA PRESS D L R5 10 55W csp 9 0 PURGE 33 Aon la D L N 3 151 34 HIGH TRANSFER D L Ie x rA an ol SET 1 54 Na us ES PILOT RIBBON CABLE J5 J14 J18 Set SPARE 15 FIXED ES Nas 17 Bee PIN SIG FROM TO SW ON OFF DPST ROCKER 1 38VACa P A L SW2 STANDARD LATCH HI TRANSFER 7 2 36VACa P A L SW SP3T ROCKER SCS VOLT 5 36VACb P A L 543 RUN PURGE SET SP3T ROCKER 87 J8 UPVIUER 6 36VAC P A TORCH CONTROL PCB J 24 jb PART OF 8 gt 120 SIG k 8 8 SEC RELAY L P 5011 PLASMA SOLENOID 115VAC 03 DUICK CONNECT 2 VAC SR P A L 50 2 SINGLE SECONDARY SOLENOID E3 _ gt lt SIG 11 DRAG _ P A 115VAC J25 13 OFF THE PLATE T AUX TRANS 215 395 46 PRI F3 15 Dem P L 120 amp 36V CT SEC 3 4 START 4 A
15. E j PL a If voltage is approximately 15 VDC replace Logic Pilot PCB A 00096 PEB b If voltage measures less than 12 VDC replace IS Pilot Ribbon Cable 2 Defective Pilot PCB or Torch 10 With wires attached check across W39A to W48 at the J18 Pilot PCB There should be a diode drop across W39A 15500 600 080 0 00 899819 to W48 direction and open in the other If shorted remove and check again a Ifshorted from W39A to W48 replace Pilot PCB b Defective Torch Assembly Refer to appropri ate Torch Instruction Manual 3 Defective Logic PCB Refer to Section 4 10 D No DC Output Re place if PS Enable LED on Logic PCB does not flash on or stay on after preflow delay 00098 Logic PCB E AC indicator ON TEMP indicator ON green Gas flows GAS indicator ON DC and PILOT indica tors ON No arc in torch No arc at spark gap on D AC indicator ON TEMP indicator ON green Gas Pilot PCB PSR LED on Logic OFF flows GAS indicator ON DC indicator ON PILOT indicator OFF No arc in torch Top Power Module DC indicator ON and fans operate Display indicates 00 and decimal points OFF CSR LED on Logic PCB ON 1 Defective Pilot PCB or Pilot Ribbon Cable 1 Defective Pilot PCB Measure DC voltage between J5 21 to 5 22 on Pilot PCB a If voltage is less than 2 vdc replace Pilot PCB J5 22 Measure DC voltage between J5 9 to TP1 GND on ET DEE
16. Pilot PCB 21 If voltage measures less than 2 VDC remove ribbon cable from J5 a If voltage measures less than 2 VDC replace Pilot PCB b If voltage is greater than 2 VDC replace Pilot Ribbon Cable SERVICE TROUBLESHOOTING 20 Pilot PCB A 00099 Manual 0 2428 2 Defective Logic PCB Measure DC voltage between J18 21 to TP1 GND on Logic PCB a If voltage is more than 8 vdc replace Logic 1 GND oc 2000000 21 00100 Logic AC indicator ON TEMP indicator ON green Gas flows GAS DC and PILOT indicators ON Spark at gap and PSR LED on Logic PCB OFF No arc or intermittent arc in torch Top Power Module DC indicator ON and fans operate 1 Gas pressure s set incorrectly too high a Refer to appropriate Torch Manual 2 Oil moisture in air lines a Purge system If problem corrected add filters in line with air source 3 Incorrect torch parts a Refer to appropriate Torch Instruction Manual 4 Defective leads a Check continuity per appropriate Torch Instruc tion Manual 5 Defective torch a Check continuity per appropriate Torch Instruc tion Manual 6 Faulty connection of wire 48 or 39A to Pilot PCB a Check wiring connection Manual 0 2428 W42 W48 W39A B 5 AE 21 DET ed 3 PE E Pilot PCB 7 Faulty Pilot PCB Lo
17. Washington D C 20210 D CSA Standard W117 2 Safety in Welding Cut ting and Allied Processes obtainable from The Canadian Standards Association 178 Rexdale Blvd Toronto Ontario MOWTR3 Canada NG Read and understand this instruction manual and your employer s safety practices 1 04 PR CAUTIONS SEMENT La mise en oeuvre et l entretien de tout quipement plasma implique des dangers potentiels Le per sonnel doit etre mis en garde contre les risques suivants et toutes les pr cautions doivent etre prises pour eviter de prendre des risques pour la sant qi Ay gaz et les fumees Les gaz et les fumees peuvent etre dangereux et constit uer un risque pour votre sante La ventilation doit tre suffisante pour vacuer les fum es lors de la coupe Dans la publication A page 4 vous trouverez la fa on de mesurer les quantit s permettant d affirmer que la ventilation est ad quate ainsi que les valeurs limites ne pas d passer Les vapeurs de solvants chlor s peuvent former un gaz toxique le Phosg ne lorsqu elles sont expos es aux radiations ultraviolettes mises par l arc lec trique Tous les solvants d graissants et sources potentielles de ces vapeurs doivent tre enlev s de l aire de coupe Evacuer toutes les fum es et les gaz de l aire de respiration Utiliser un tabli de coupe tirage vers le bas pour attirer les fum es et les gaz Util
18. Wire Canada Volts 3 Ph 1 Ph 3 Ph 1 Ph 3 Ph A 5 D D SD OD Lin o En Lin 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 8 7 17 16 27 26 41 39 Requires Transformer Module Line Voltages with Recommended Circuit Protection and Wire Sizes Based on Table 310 16 1987 National Electric Code and Table 4 Canadian Electrical Code Manual 0 2428 51 APPENDIX APPENDIX VIII SYSTEM SCHEMATIC 2 3 4 DISPLAY RIBBON CABLE 111 REMOTE I OPTIONAL REMOTE RIBBON CABLE OPTIONAL gt DEMAND 24 LUA 3 gt AMP DISPLAY gt J13 J16 J17 4 gt Ok TO MOVE N e 5 ANALOG LOGIC 11 gt 1 TORCH 12 gt START LED ID 13 gt PS OFF A 14 HIGH OF 2 35 4 15 gt 5 POWER 4 Le La La 4 16 gt LOW MODULES as 4
19. gas flows GAS DC and PILOT indicators OFF Digital display OFF 1 Remote cable connected a Normal Remove remote cable from J11 on Rear Panel if not being used 2 Defective Display PCB a Check DC voltage at J20 15 to TP1 GND on Logic PCB If less than 2vdc replace Display PCB GND 5 J20 22 15 Logic 00089 SERVICE TROUBLESHOOTING E CURRENT control adjustment does not change digital display All three decimal points are ON indicating corner slowdown 1 Dust debris blocking sensor on Display PCB a Clean PCB 2 Defective Display PCB a Check for DC voltage between J20 11 to 12 on Logic PCB If voltage is less than 10vdc replace Display PCB J20 A 00090 Log ic PCB 3 Corner slowdown CSD from remote ON if used Disconnect remote interface cable from J11 on Con trol Module rear panel a If decimals go OFF problem is in remote sys tem Disconnect remote ribbon cable from Analog 13 and Logic PCB J17 b If decimals go out replace Remote Interface Assembly 4 Defective Analog PCB a Check for DC voltage between J20 13 to TP1 GND on Logic PCB If Voltage is less than 2vdc replace Analog PCB GND J20 Logic PCB A 00091 5 Defective Display Ribbon Cable a Check for DC voltage between J20 13 to TP1 GND on Logic PCB If Voltage is less than 2vd
20. the torch When operating plasma arc cutting equipment in a damp or wet area extra care should be taken Use this equipment for plasma cutting and goug ing only Itis not designed for any other cutting or welding process Use only the torches specified in this instruction manual Ay FIRE can be caused by hot slag and sparks Remove combustibles from working area or pro vide a fire watch Do not cut containers that have held combustibles Remove all flammable and combustible materials in the operating area that may be ignited by sparks Do not mount this equipment over combustible surfaces Noise can cause permanent hearing loss Wear proper protective ear muffs or plugs Make sure others in the operating area are protected from noise GAS CYLINDERS Compressed gas cylinders are potentially danger ous Refer to suppliers for proper handling procedures 1 03 Publications The following publications provide additional informa tion on safety precautions A Bulletin No C5 2 83 Recommended Safe Prac tices for Plasma Arc Cutting B American National Standard ANSI Z49 1 1983 Safety in Welding and Cutting Both publications are available from GENERAL INFORMATION American Welding Society Inc 2501 Northwest 7th Street Miami Florida 33125 Telephone 305 443 9353 OSHA Safety and Health Standards 29CFR1910 available from The U S Department of Labor
21. American National Standard ANSI 749 1 1983 Safety Welding and Cutting Vous pouvez vous les procurer toutes les deux aupres de American Welding Society Inc 2501 Northwest 7th Street Miami Florida 33125 U S A T l phone 305 443 9353 C OSHA Safety and Health Standards 29CFR 1910 disponible aupr s du U S Department of Labor Washington DC 20210 USA D Norme de l ACNOR W117 2 Safety in Welding Cutting and Allied Processes que l on peut obtenir aupr s de L Association Canadienne Des Normes 178 Rexdale Blvd Toronto Ontario Canada MOW 1R3 GENERAL INFORMATION SSEMENT Lire et comprendre ce manuel d instructions ainsi que les pratiques sur la securite emises par votre employeur 1 06 Declaration Of Conformity Manufacturer Thermal Dynamics Corporation Address Industrial Park 2 West Lebanon New Hampshire 03784 USA Description ofequipment Plasma Cutting Equipment Namely Pak2XT Pak Master 25 Pak Master 50 Pak Master 100 Stak Pak Signature 625 Signature 1250XR 15 Pak44 Pak 45 TA 500 TA 1000 and associated accessories Plasma Welding Equipment Namely WC100B HE150 Weld Sequencer PS3000 and associated accessories Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture equipment conforms to all applicable aspects and regulations of the Low
22. Bes 070 Or E A 615141312 1 p 1 108 7 ASSY 19X888 455 33 00000000000000000 34 00000000000000000 427 POWER MODULE INTERFACE PCB RIBBON CABLE PIN SIG FROM TO 1 TORCH ooo L A 3 FOR TORCH ee dee L A TORCH ________ _ L A 7 OUTPUT CURRENT SIG ___ PM A 9 CSR TRANSFER 222 _ A L PM MOD ENABLE 11 PILOT MOD ENABLE L PM 13 OF MOD DETECT PM A 15 H20 SEC SELECTED PM L 17 OF MOD DETECT COMM HIGH TRANSFER _____ A PM 19 NO SEC OXYGEN zeini PM L Bi 23 3BEYACBr Inc A PM 25 MASTER ENABLE L PM 27 OVERTEMR gt tots PM L A 00138 28 COOLANT FLOW OK PM L 33 H20 SEC ENABLE _ L PM 34 DEMAND _____________ A PM APPENDIX 50 J26 Power Supply Connector Pin Signal 1 MOD DET 2 MOD DET COM 3 NOSEC OXYGEN 4 TO COMMON 5 OVERTEMP 6 COMMON 7 H20 SEC 8 36 VACa 9 36 VACb 10 COOLANT FLOW 11 COMMON 12 PILOT MOD ENABLE 13 COMMON 14 PM ENABLE 15 COOLANT ENABLE 16 36 VACct 17 TRANSFER MOD ENABLE 19 COMMON 20 115 VAC RET 21 OUTPUT CURRENT SIG 22 COMMON 23 TO COMMON 24 DEMAND 25 20 SEC ENABLE COMMONS AND SPARES SHOWN FROM TO P PILOT L LOGIC A ANALOG D DISPLAY R REMOTE PM POWER MODULE Manual 0 2428 APPENDIX VII INPUT WIRING REQUIREMENTS Recommended Sizes Fuse Amps Wire AWG
23. Measure the voltage between J5 15 to J5 16 Ifthe volt age is 15 VDC replace the Pilot PCB If the voltage is less than 2 VDC then continue to Step 7 7 Measure the voltage between 18 15 to 18 16 If the voltage is 15 VDC replace pilot ribbon cable If the voltage measures less than 2 VDC then replace Logic PCB E Power Module Checks 1 Input Bridge Check Separate each Power Module in the stack With an ohm meter set on 1 check continuity between the four in put power stakes on each Power Module Each stake when checked to the other three should measure open circuit no continuity If continuity is found then the Power Module should be repaired refer to Power Module Service Manual 0 2456 or send the unit to an authorized repair facility No Continuity Between Input Power Stakes Ohmmeter Using Rx1 A 00110 Manual 0 2428 2 Output Diode Check Separate each Power Module With an ohmmeter set on the diode range check between the two output power stakes This should indicate a diode drop in one direc tion and open in the other If the checks indicate open or shorted in both directions then the Power Module should be repaired refer to Power Module Service Manual 0 2456 or send the unit to an authorized repair facility Diode Drop In One Direction And Open In Other Direction Between Output Power Stakes Ohmmeter Using Diode Range A 00111 Manual 0 2428 27 SERVICE TROUBLESHOOTING SERVICE T
24. PROCEDURES 29 5 01 ANtrOGUGCU ORG dents ISTITUTI UMEN 29 5 02 Anti Static Handling 29 5 03 Disassembly amp Replacement enn 29 SECTION 6 ES fetal Ab 39 6 01 Introduetion u as 39 6 02 Ordering Information 1 eene nenne 39 6 03 Control Module Front Panel Assembly 40 6 04 Control Module 42 6 05 Control Module Rear Panel nn 44 TABLE OF CONTENTS continued APPENDIX REMOTE PCB INTERFACE CONNECTIONS 45 APPENDIX LOGIC PCB CONNECTIONS inner 46 APPENDIX ANALOG PCB CONNECTIONS ire 47 APPENDIX IV PILOT 22 48 APPENDIX V DISPLAY PCB CONNECTIONS 49 APPENDIX VI POWER MODULE INTERFACE PCB CONNECTIONS 50 APPENDIX VII INPUT WIRING REQUIREMENTS 51 APPENDIX VIII SYSTEM 70 52 SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions And Warnings Throughout this manual notes cautions and warnings are used to highlight important information These high lights are catego
25. Torch 35A PCH M 35 70A PCH M 70 PCH M 140 or 145 23 SERVICE TROUBLESHOOTING Logic PCB A 00107 The identity of the torch is determined by the voltages found between J21 5 J21 6 and J21 7 to J21 8 on the Logic PCB Each torch has jumper wires inside the 14 pin con nector inside the torch quick disconnect One or more of the identifying pins J21 5 21 6 or J21 7 are connected to 21 8 common via the jumpers If the torch idenity is correct continuity will be found at J25 connector part of TORCH connector for the following pins J25 Pins Model Torch 11 and 12 PCH M 35 9 and 12 PCH M 70 9 10 and 12 PCH M 140 9 10 11 and 12 PCH M 145 A 00473 7 200099 9000 es 100000 9 SERVICE TROUBLESHOOTING The torch ID inputs which normally are 15 VDC with respect to J21 8 will be 0 VDC depending on the torch used as follows Model Torch J21 Pins PCH M 35 PCH M 70 PCH M 140 9 and 10 PCH M 145 9 10 and 11 If the voltages for the torch ID at the J21 connector are correct but the torch identification LED is incorrect then replace the Logic PCB If the torch identification LED is correct then the torch ID signal from the Logic PCB to the Analog PCB should be checked atJ19 on the Logic PCB These pins are normally 15 VDC with respect to TP1 GND Depending o
26. Torch Leads at the quick disconnect at the Front Panel 3 Remove the feeder lines at the fitting of the socket to be removed inside the unit per the following a Push down and hold the quick release on the con nector with a screwdriver b Pull the hose out from the connector 4 Remove the wiring for the socket per one of the fol lowing a On the Plasma Socket remove the heavy gage wire at the socket b On the Secondary Socket remove the wiring at its connection to the Logic PCB Assembly W48 Remove the snap ring on the Socket Assembly inside the Quick Disconnect Body Push the socket out of the Quick Disconnect Body Reinstall the replacement Quick Disconnect Socket Assembly by reversing the above procedure and not ing the following a The Secondary Socket has the large feeder line and must be installed to the left as viewed from the outside of the Front Panel b The wiring lug on the Secondary must be turned to the left as viewed from the outside of the Front Panel and parallel to the unit base Plasma Socket Assembly Secondary Socket S A 00130 Figure 5 17 Quick Disconnect Socket Assemblies Manual 0 2428 T Quick Disconnect Body Replacement 1 Open the Control Module as described in paragraph above 2 Remove the Secondary and Plasma Gas Quick Dis connect Socket Assemblies per paragraph S above 3 Remove the two white pins holding the electrical con n
27. of the Control Module that are used as a visual indicator of the number of Power Modules in the Stak system Only one LED will be on at a time as shown in the following table LED Indicator Number of Power Modules The number of Power Module units determines the re sistance value measured between J15 13 and J15 17 on the Analog PCB in the Control Module Each Power Module has a 10 ohm resistor connected between J26 1 to J26 2 When each Power Module is connected to the system the 10 K ohm resistors are connected in parallel If the modules are correctly installed the resistance mea sured at the Analog PCB between J15 13 to 17 is as fol lows Number of Power J15 Pin 13 to 17 Modules Resistance Reading 10K ohms 5K ohms 3 3K ohms 2 5K ohms Manual 0 2428 053 1 5657 992 053 OD 3 A 060 694 MOD A 00106 Analog PCB 1 If the resistance is correct for the number of Power Mod ule units connected but the module identification LED is incorrect then replace the Analog PCB If the resistance is incorrect then seperate the Power Mod ules and check for 10 K ohm resistance on each unit be tween J26 1 to J26 2 A 00472 B Torch Identification Three light emitting diodes LEDs on the Logic PC Board indicate which torch is connected to the Control Module Only one LED will be on at a time per the following table Indicator ON Model
28. peel the liner from the copper foil at the opposite end 3 Attach the copper foil to a convenient and exposed electrical ground 4 Connect the power supply primary cable ground to the same electrical ground as the wrist strap a Open the power supply enclosure see instruction manual for the power supply and remove the failed PC board ON Carefully open the ESD protective bag and remove the replacement PC board 7 Install the replacement PC board in the power supply and make all necessary connections 99 Place the failed PC board in the ESD protective bag and seal for return shipping 9 Reassemble the power supply enclosure see instruc tion manual for the power supply 10 Remove the grounding wrist strap from your wrist and from the electrical ground connection before re connecting primary power to the power supply 5 03 Disassembly amp Replacement WARNING Disconnect primary power at the source before as sembling or disassembling stacked modules indi vidual modules torch parts or torch and leads as semblies A Removal of Control Module Cover 1 Remove the two module assembly pins from the rear of the Control Module 29 REPLACEMENT PROCEDURES 2 Lift the upper enclosure cover from the lower enclo 3 Slide the PCB up and out of the board holders located sure to gain access to the interior of the unit in the bottom of the unit 3 Close the unit reversing the above procedu
29. replacement Analog PCB Assembly by 2 Carefully remove all cable connections to the Logic reversing the above procedure and noting the follow PCB Assembly noting the location of each 1ng REPLACEMENT PROCEDURES 30 Manual 0 2428 Connector Description of Cable Ribbon cable from optional J11 Remote Interface if installed and the Logic PCB J13 Ribbon cable from Logic and Pilot 5 J15 Ribbon cable from Power Module Interface and Logic PCB Ribbon cable from Logic and Display PCBs J16 2 M ess es 2 500116 Analog Figure 5 4 Analog Assembly Connections Pilot PCB Assembly Replacement 1 Open the Control Module as discribed in paragaph above 2 Press together the sides of the two plastic pins secur ing the Control Module Baffle which covers part of the Pilot PCB and the fan Manual 0 2428 A 00121 Figure 5 5 Control Module Baffle Removal 3 Remove the Control Module Baffle 4 Carefully remove the all cable connections to the Pilot PCB Assembly noting the location of each There is a large wire in the lower front corner of the PCB This wire is the plus power connection and runs through a current senor on the PCB The wire goes to the WORK connector on the Front Panel Assembly and the other end goes to the plus Power Module Stake connection Note which end of the wire goes to which location MT W42 waa W39A W50 W39 U
30. the above procedure NOTE Do not bend any of the wiring or winding leads when installing the replacement They are formed to the proper angles and must be installed as sup plied P1 5 4 P2 gt i Secondary l QD Socket O CD Transformer A 00127 Figure 5 14 CD Transformer Assembly Manual 0 2428 O Pilot Inductor Assembly Replacement 1 Open the Control Module as described in paragraph A above 2 Remove the Control Module Baffle as described in paragraph 2 above 3 Disconnect the two connections to the Pilot PCB As sembly at W49 and W50 4 Remove the two screws securing the assembly to the bottom of the Control Module 5 Reinstall the replacement Pilot Inductance Assembly by reversing the above procedure To W50 on Pilot PCB Mounting Screws on Pilot PCB A 00128 Pilot Inductor Assembly Figure 5 15 Pilot Inductance Assembly P Auxiliary Transformer Assembly Replacement 1 Open the Control Module as described in paragraph A above 2 Disconnect 7 at the Pilot PCB Assembly 3 Disconnect the input connector to the transformer 4 Remove the four screws and washers securing the Aux iliary Transformer Assembly to the bottom of the Con trol Module 5 Reinstall the replacement Auxiliary Transformer As sembly by reversing the above procedure Q Plasma or Secondary Gas Input Fitting Replacement NOTE Both the Plasma and Secondary Ga
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32. 1 1 01 Notes Cautions And Warnings 1 1 02 Important Safety Precautions 2 1 1 03 PUDIICANONS ii ma de UE 2 1 04 PRECAUTIONS 25 darle 3 1 05 Les publications sus na nel een 4 1 06 Declaration 5 1 07 Statement Of Warranty iii 6 SECTION 2 INTRODUCTION E as 7 2 01 Scope Of Manual iii 7 2 02 General Service 7 2 03 Service 7 SECTION 3 DESCRIPTION E 9 3 01 INTRODUCTION irren 9 3 02 General sis 9 3 03 Technical 9 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 2 11 4 01 Introduction ent AAA area nant ri 11 4 02 Periodic Inspection amp 11 4 03 Troubleshooting Guide 11 4 04 Circuit Fault Isolation 12 4 05 Main Input Power Problems 13 4 06 Internal Power Problems eene en nnn nnn 13 4 07 Purge Probl me nt I eite 17 4 08 Pilot Arc Probl ms nt teet rr vct adas 19 4 09 Main Arc Problems iii 22 4 10 Test ie rr ene d e e P ERR E E e RT 23 SECTION 5 REPAIRS 8 REPLACEMENT
33. 16 1 8 6241 RF Filter PC Board Assembly The following parts are not shown 1 8 6245 Upper Enclosure 1 8 3338 Overlay Upper Right Side Panel 1 8 3339 Overlay Upper Left Side Panel 2 8 3340 Overlay Lower Side Panel 1 8 6244 Label Personal Warning 1 8 6223 Label Pin Installation 1 8 3343 Label Voltage Warning 1 8 3344 Label Lifting 1 8 6242 Inductor Torch Signal PARTS LISTS 42 Manual 0 2428 Exploded View Of Control Module Main Assembly SK NA 24 L SX TEN s 8 Ve E Y 4 A AV ty Y 00053 PARTS LISTS 43 Manual 0 2428 6 05 Control Module Rear Panel Assembly Item Catalog No Oty Number Description 8 4319 Rear Panel Without Overlays 8 6235 Rear Panel Overlay Auxiliary Connections 8 4321 Rear Panel Overlay Gases 8 3209 Fan Assembly 9 6232 Adaptor Fitting Inert to 1 4 Female with Ring Groove 8 6236 Plasma Adaptor Fitting 1 4 NPT to 1 4 Tube 9 6230 Secondary Single Gas Adaptor Fitting 1 4 NPT to 3 8 Tube N qM A 00054 PARTS LISTS 44 Manual 0 2428 APPENDIX REMOTE INTERFACE CONNECTIONS 411 to Remote Ribbon Cable J28 PIN t SIG 1 RUN PURGE _______ R L
34. 3 HI LOW SPEED _____ R L START STOP _______ R L 7 POT LOW 2222 A R 9 DEMAND ________ __ R A 13 START LED ________ L R 17 AMP DISPLAY_______ 19 POT HIGH 22222222 21 ct _________ L R 23 SBEACa ___ L R 25 __________ L R 27 REMOTE INSTALLED __R L 31 CSD R A 33 E STOP R L COMMONS AND SPARES SHOWN J28 REMOTE RIBBON CABLE Manual 0 2428 OO OO OO OO OO OO OO OO OO OO OO OO Qu OO OO OO 34 3 3 C1 4 1 OGO Q OOOO 49 2800000023 330000 029 37 34 REMO ASSY 139x943 45 FRI M TI R REMOTE 0 Remote Ribbon Cable J28 to Analog PCB J13 Logic PCB J17 411 PANEL a A REMOTE 00134 APPENDIX 8cvc 0 lENUEW LOGIG TO PILOT RIBBON SIG FROM TO P A L 3BVADR P A L JOVALD zes P A L 38VACb P A L SEC RELAY ___L CSR ae eee P A L DRAG _______ _ P OFF THE PLATE Date PSR ER PLASMA RELAY L HI LOW SPEED L L 5 ED ENABLE HIGH TRANSFER COOLANT RELAY PILOT ENABLE OVERTEMP PILOT 118 LOGIC TO POWER MODULE RIBBON PIN SIG FROM TO 1 TORCH _
35. 7 A TORCH 5 T 5A TORCH ____ 7 OUTPUT CURRENT SIG 9 CSR TRANSFER ______ 19 21 23 25 27 29 33 MOD ENABLE PILOT MOD ENABLE OF MOD DETECT H20 SEC SELECTED PM L OF MOD DETECT COMM HIGH TRANSFER NO SEC OXYGEN 36VACa 36VACb MASTER ENABLE OVERTEMP COOLANT FLOW OK H20 SEC ENABLE DEMAND FROM TO P PILOT L LOGIC A ANALOG D DISPLAY R REMOTE COMMONS AND SPARES NOT SHOWN PM POWER MODULE J20 J18 PIN amp 1 2 5 217 LOGIC TO REMOTE RIBBON OPTIONAL 5 PIN 516 FROM TO E 1 RUN PURGE ______ R L m 3 HI LOW SPEED _____ R L 15 5 START STOP _______ R L Hs 7 POT LOW ________ A R 9 DEMAND __ R A 15 13 START LED L R D 17 AMP DISPLAY_____ A R Ji 19 POT HIGH ________ 21 ct L R 23 _ _L R 25 36VACb L R REMOTE R L rs L rd c24 Ha C41 4 00000 1520 C45 CA7
36. 8 Remove the four wires from the ON OFF Switch Carefully press down on the tab holding the switch to the Front Panel Assembly Pull the switch from the panel Reinstall the replacement ON OFF Switch Assembly by reversing the above procedure making sure to con nect the wiring to the correct switch power tabs Back Of ON OFF Switch A 00112 Figure 5 8 ON OFF Switch Assembly RUN SET PURGE Switch Replacement Open the Control Module as described in paragraph A above Remove the three wires from the RUN SET PURGE Switch Carefully press down on the tab holding the switch to the Front Panel Assembly Pull the switch from the panel Reinstall the replacement RUN SET PURGE Switch Assembly by reversing the above procedure making sure to connect the wiring to the correct switch power tabs A 00122 Back of RUN SET PURGE Switch Figure 5 9 RUN SET PURGE Switch Assembly J STANDARD LATCH HI TRANSFER Switch 3 4 33 Replacement Open the Control Module as described in paragraph above Remove the three wires from the STANDARD LATCH HI TRANSFER Switch Carefully press down on the tab holding the switch to the Front Panel Assembly Pull the switch from the panel Reinstall the replacement STANDARD LATCH HI TRANSFER Switch Assembly by reversing the above procedure making sure to connect the wiring to the correct switch power tabs
37. 8 be 18VAC 00077 SW1 ON O FRONT PANEL AC indicator ON TEMP indicator ON red System will not pilot 1 Air flow through unit is restricted a Provide adequate air flow Refer to Operating Manual 0 2463 Section 3 02 2 Defective Power Module Disconnect ribbon cable from Logic PCB at J19 At the ribbon cable connector check for normally open condition from pin 26 to 27 If shorted then disconnect unstack all Power Module s and let unit cool Check each Power Module for normally open ther mal switch at J26 pin 5 to 6 a Replace Power Module if shorted A 00079 SERVICE TROUBLESHOOTING 3 Defective Pilot PCB or Pilot Ribbon Cable Disconnect Pilot Ribbon Cable from Logic PCB at J18 At the ribbon cable connector check for normally open thermal switch contacts from pin 31 to 33 2 00000000 AA 34 00 3 1 100000000000 Pilot Ribbon Cable A 00078 Connector J18 If shorted then disconnect rest of cable from J5 Pilot and J14 Analog a short remains then replace ribbon cable b If no short then replace Pilot PCB 4 Defective Logic PCB With ribbon cable in place check voltage at J18 pin 31 to 33 a If voltage measured is approximately 15vdc then replace Logic PCB AC indicator ON TEMP indicator ON red System will pilot RUN PURGE SET switch must be in RUN 1 Open Display Ribbon Cable or defective
38. CB a Replace if voltages as follows J20 2 to com mon 15 vdc J20 3 to common 0 TP1 GND J20 A 00087 Logic PCB 8 Defective Display Ribbon Cable a Replace if J20 3 Logic connector to J10 3 Display PCB connector is open b Replace if Logic PCB connector J20 pin 2 is shorted to pin 1 or 3 B AC indicator ON TEMP indicator ON green Gas flows GAS DC and PILOT indicators ON Arc in torch without pressing torch switch 1 Defective torch switch a Refer to appropriate Torch Instruction Manual and check continuity 2 Defective torch leads a Refer to appropriate Torch Instruction Manual and check continuity 17 SERVICE TROUBLESHOOTING 3 Defective Logic PCB a Replace if voltages are as follows J21 pin 3 to 4 15 vdc J17 pin 5 to 4 15 vdc 5 J17 33 00000000000000000 34 Logic AC indicator ON indicator ON green No gas flows GAS DC and PILOT indicators OFF Digital display indication is incorrect 00088 1 Defective Analog PCB a Refer to Section 4 10 A Module Identification 2 Defective Power Module a Refer to Section 4 10 A Module Identification 3 Defective Logic PCB a Refer to Section 4 10 B Torch Identification 4 Defective Display PCB a Refer to Section 4 10 C Potentiometer Scaling D ACindicator ON TEMP indicator ON green No
39. Display PCB Check continuity on Display Ribbon Cable from J20 5 Logic PCB to J10 5 Display PCB a If cable has open replace cable b If cable has continuity replace Display PCB 2 Defective Logic PCB Jumper pin 4 to 5 at J20 Logic PCB a If TEMP indicator turns green then replace Logic PCB AC indicator ON TEMP indicator ON green No gas flow Gas DC and PILOT indicators OFF Two left decimal points on digital display flash ing Disconnect Torch from Control Module and check for short between J25 pins 1 to 6 in the torch quick dis connect If shorted problem is in Control Module If open problem is in torch Manual 0 2428 1 Torch quick disconnect not tight a Tighten quick disconnect connection at Control Module 2 Shield cup loose or not installed Tighten or install shield cup 3 Parts In Place PIP pin missing or damaged a Refer to appropriate Torch Instruction Manual and replace pin 4 Faulty PIP wire in torch shell enclosure a Refer to appropriate Torch Instruction Manual and repair fault 5 Open PIP wire in torch leads a Refer to appropriate Torch Instruction Manual and repair torch leads 6 J25 connector 14pin in quick disconnect loose a Install Signal Connector Retrofit Kit Catalog 9 5848 per instructions with kit 7 Defective Logic PCB With Torch connected measure v
40. N OPTIONAL y8 0118 115VAC RTN 2 21 318 LOGIG TO PILOT RIBBON 148 LOGIC TO POWER SUPPLY RIBBON x 23 36VACb 6212 SEBSVADSESH lt 3 25 ENABLE L PM 228 LOGIC TO DISPLAY RIBBON 2 53 115VAC HOT 4 27 OVERTENP De de PM L J21 LOGIC TORCH SIG CONN J25 7 4 29 COOLANT FLOW PM L 122 REAR PANEL HFWS PRAI MW ze 33 AZO SEC ENABLE ____ L PM 2232 NOT USED tip R3 100 2W 7 34 A PM 124 REAR PANEL STANDOFF CONN OPTIONAL 3 56 S 125 TORCH SIG CONN PS 2 7 AAA lt 8 REMOTE RIBBON CABLE 428 POWER SUPPLY SIG CONN 1 208 55W OPTIONAL J13 417 J28 427 POWER SUPPLY SIG PCB TO RIBBON LS eee SE PIN 8 516 FROM TO 128 REMOTE CONN PCB TO RIBBON W46 46 1 RUN PURGE R L 128 AUX TRANSFORMER PRI 471 3 HI LOW SPEED R L 130 VOLTAGE SELECT WAT AT 5 START STOP R L 134 WORK LEAD T2 1 1 45 7 POT LOW 39 39 GC DEMAND Ci REX 13 START LED L R 15 AMP DISPLAY _ A R E 19 POT HIGH A R 21 ct L R 23 5 L R T 25 38VACb L R 27 REMOTE INSTALLED R L A 31 250 R A ws 33 E STOP __ R L 3 POWER 2 wsa 50 SUPPLY 131 COMMONS AND SPARES NOT SHOWN CURRENT ut FROM TO P PILOT L LOGIC A ANALOG SENSOR R REMOTE PM POWER MODULE D DISPLAY REv REVISIONS DATE REV REVISIONS DATE THERMAL DYNAMICS pare 2 Pca N A 212 assy A 6781 A CORPORATION bs o
41. O ule un cs Of FO Lr15 04 FO o4 C gt um 7 126 a oe0o000 000000000 2 5 2 7 re o LEDI LED2 LED3 2 9 4 T o GND noooono4oolnoooo o OOls23 o c23 aie e Q4 Lo H g Od Fo al a us Soy R24 1290 92 rn WHY Z 24 o ii o 022 5 m B SH OF e o Olezs 22740 E o 24 lo O o HOR38 O4 Koma O ON B o 127 A 2525 D 5 5 E CITATUS DISPLAY TA 1 RUN Side of RUN PURGE SET Switch 2 Center of RUN PURGE SET Switch 3 SET Side of RUN PURGE SET Switch 5 One Side of Secondary Pressure Switch PS2 6 Normally Open Side of Secondary Pressure Switch PS2 A 00139 Manual 0 2428 Display Modules J9 PS1 amp STANDARD LATCH HI TRANSFER Switch Pin 1 2 3 5 6 49 Signal STANDARD Side of STANDARD LATCH HI TRANSFER Switch Center of STANDARD LATCH HI TRANSFER Switch HI TRANSFER Side of STANDARD LATCH HI TRANSFER Switch One Side of Plasma Pressure Switch PS1 Normally Open Side of Plasma Pressure Switch PS1 APPENDIX APPENDIX VI POWER MODULE INTERFACE PCB CONNECTIONS O V OO OE Or QV c e amp O O PNA Le 2 J26 ES
42. PCB J5 pin 18 to TP1 GND for plasma sole noid e If higher than 8 VDC replace Logic PCB pin 10 to 18 on Pilot PCB for secondary solenoid f If not approximately 115 VAC replace Pilot PCB J4 pin 9 to 15 on Pilot PCB for plasma solenoid g Ifnot approximately 115 VAC replace Pilot PCB ES p 18 gt TP1 GND 9 Pilot PCB 10 2 9 A 00083 J4 5 SERVICE TROUBLESHOOTING AC indicator ON TEMP indicator ON green GAS indicator OFF Gas flows DC and PILOT indicators OFF 1 Gas pressure to low a See torch manual for operating pressures 2 Both gas supply hoses not connected a PCH M 70 140 and 145 torches require both plasma and secondary 3 Defective pressure switch Measure for DC voltage from wire 16 to wire 17 at the secondary pressure switch at the rear of the Front Panel Assembly a If 15vdc and pressure is above 40 PSI replace secondary pressure switch Wire 16 Plasma Pressure Switch Secondary 2o 4 SL A 00084 Pressure Switch Measure for DC voltage from wire 16 to wire 17 at the plasma pressure switch at the rear of the Front Panel Assembly b If 15vdc and pressure is above 40 PSI replace plasma pressure switch when using torch other than PCH M 35 4 Loose or bad connection a Check connections at J9 plasma and J12 sec ondary on the Display PCB Assembly A 00085
43. READY LEDs on Logic PCB should be ON a Replace if voltage on Logic PCB between J21 3 to 4 measures 0 vdc when torch switch pressed A 00095 B AC indicator ON TEMP indicator ON green Gas flows GAS indicator ON DC indicator OFF PILOT indicator ON momentarily 1 High input line voltage a Refer to Operating Manual 0 2463 Section 3 05 for proper input voltage C AC indicator ON TEMP indicator ON green Gas flows GAS indicator ON DC indicator OFF PILOT indicator blinks Power Module DC indicators may OFE flicker or blinking Small arc may be visible in torch 1 Defective Pilot PCB or Power Module With wires attached check across W39 to W42 at the Pilot PCB There should be a diode drop across W39 to W42 in one direction and an open in the other If shorted remove the wires at W39 W42 at the Pilot PCB and check again a Replace Pilot PCB if shorted from W39 to W42 with wires 39 and 42 removed b Defective Power Module Refer to Section 4 10 D No DC Output and Section 4 10 E 2 Out put Diode Check SERVICE TROUBLESHOOTING W39 W42 W48 W39A us E wi o OD JW3 vo R21 O4 F1 TE 2 E 1 GND En Pilot PCB A 00097 2 Defective Logic or pilot ribbon cable Measure DC voltage between J18 9 to J18 10 on Logic eq
44. ROUBLESHOOTING 28 Manual 0 2428 SECTION 5 REPAIRS amp REPLACEMENT PROCEDURES 5 01 Introduction This Section describes parts replacement procedures and all cable repairs which may be performed on the STAK Control Module Under not circumstances are field repairs to be attemped on Printed Circuit or other Subassemblies of this unit Evidence of unauthorized repairs may void the factory warranty 5 02 Anti Static Handling Procedures A General CAUTION PC boards can be irreparably damaged by improper handling due to electrostatic discharge ESD Replacement PC boards are shipped in a protective en closure to prevent damage from electrostatic discharge ESD during shipping Included with each replacement board is a ground strap to prevent static damage during installation WARNINGS Read and understand these instructions and the instructions on the grounding wrist strap package before opening the power supply enclosure or re moving the replacement PC board from its protec tive enclosure Disconnect primary power to the system before dis assembling the torch torch leads or power supply enclosure Do not operate the power supply or test equipment under power while wearing the grounding wrist strap U B Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Manual 0 2428 2 Unroll the rest ofthe band and
45. St 6 14 17 __ A L P K 4 7 gt LOGIC 18 PLASMA RELAY 1 T2 TRANSFORMER E7 6 PILOT 19 HI LOW SPEED L A ih 1 gt KARC 21 ED ENABLE L P IK 1 25 HIGH TRANSFER L P A 9 TORCH ID 28 COOLANT RELAY L P CONNECTORS lt 9 lt 29 PILOT ENABLE L P 18 ID B 31 OVERTENF ____P L 21 HIGH FLOW WATER SHIELD lt 19 lt PILOT 42 OK TO MOVE TO REMOTE 33 OK TO MOVE SELECT 12 ID COMM POWER MODULE SIGNAL CONTACTS OR PILOT lt 12 1404 RIBBON CABLE 415 419 427 14 115VAC SIGS FROM RELAYS PCB 113 354 70 a 5 PIN SIG FROM TO amp TO ON OFF SW 114 SEX TORCH 35 PILOT RIBBON CABLE gt lt 14 TORCA 37 AUX TRANSFORMER SEC 114 D RE 18 STANDOFF CONTROL 122 2 TPUT CURRENT PE 28 FRONT PANEL TO DISPLAY 118 k A HEWS 8 d ee vs PM 318 DISPLAY PCB RIBBON 8 OPTIONAL MOD ENABLE 114 REAR PANEL REMOTE OPTIONAL 3 11 PILOT ENABLE L PM 142 FRONT PANEL TO DISPLAY mn A 13 OF MOD DETECT PM 313 ANALOG TO REMOTE RIBBON OPTIONAL a OPTIONAL STANDOFF 15 AZO SEC SELECTED ____ PM L 314 ANALOG TO PILOT RIBBON CONTROL CONNECTOR 17 470 NOO DETECT COMM 315 ANALOG TO POWER SUPPLY RIBBON 124 SHOWN FOR SC2 024 1 HIGH TRANSFER 316 ANALOG TO DISPLAY RIBBON D JB FOR SC5 SEE ABOVE lt 1 18 RO SEC 317 LOGIC REMOTE RIBBO
46. T FEM X 1 4 Tube 90 Wire Assembly Pilot Return 48 10 1 8 6332 Quick Disconnect Socket Assembly Secondary includes Spring Canted Coil Bracket Q D H F Coil Nut 9 16 18 W 3 4 Flats Fitting 1 4 NPT FEM X 3 8 Tube 90 Fitting Console Female To 9 16 18 amp 1 4 11 1 8 6337 Display PC Board 12 4 8 707 Hole Plug 1 4 in diameter 13 1 9 4146 Current Control Knob 15 1 8 6243 Display Ribbon Cable 16 1 8 6219 Cable Clamp 17 2 8 0312 Female Tee Fitting 1 8 NPT 18 2 9 1044 Pressure Switch 35 psi 19 2 8 3360 Adaptor 1 8 NPT to 1 4 Tube 20 1 8 4333 Regulator Solenoid Assembly Plasma 21 1 8 4334 Regulator Solenoid Assembly Secondary PARTS LISTS 40 Manual 0 2428 Exploded View Of Control Module Front Panel A 00052 Manual 0 2428 41 PARTS LISTS 6 04 Control Module Main Assembly Item Catalog No Qty Number Description 1 1 8 6247 Lower Enclosure 2 2 8 620 Wire Harness Clip 1 2 in ID 3 6 8 2188 Female Blade Connector 4 3 8 2189 Blade Connector Cover 5 4 8 2190 Input Power Connector Power Lugs 6 2 8 6220 Fuse Clip 7 1 9 3861 Fuse 2 amp 600V 8 1 8 3335 Auxiliary Transformer Assembly 9 1 8 6238 Transformer Assembly Capacitive Discharge 10 1 8 6239 Pilot Inductor Assembly 11 1 8 6240 Divider Panel Assembly 12 1 8 6237 Pilot PC Board Assembly 13 1 86232 Analog PC Board Assembly 14 1 8 6233 Logic Control PC Board Assembly 15 1 8 6231 Module Interconnect PC Board Assembly
47. Voltage Directive Directive 73 23 as recently changed in Directive93 63EU and to the National legislation for the enforcement of this Directive National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are CSA Canadian Standards Association standard C22 2 number 60 M1990 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used IEC 974 1 BS 638 PT10 EN 60 974 1 applicable to welding equipment anassociated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process to ensure the product is safe and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermal Dynamics has been manufacturing products that perform in a safe manner for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative David Ashworth Vice President amp Managing Director Thermadyne Europe Chorley England 5 GENERAL INFORMATION 1 07 Statement Of Warranty LIMITED WARRANTY Thermal Dynamics Corporation hereinafter Thermal warrants that its products will be free of defects in workmanship or material Shou
48. ackaged in protective mate rial and returned intact per normal procedures Manual 0 2428 2 03 Service Responsibilities TheService Technician should be familiar with the equip ment and its capabilities He should be prepared to rec ommend arrangements of components which will pro vide the most efficient layout utilizing the equipment to its best possible advantage Maintenance work should be accomplished in a timely manner If problems are encountered or the equipment does not function as specified contact Technical Services Department at West Lebanon for assistance 7 INTRODUCTION INTRODUCTION 8 Manual 0 2428 SECTION 3 DESCRIPTION 3 01 Introduction The information in this Section has two purposes To fimilarize the Service Technician with the capabilities and limitations of the equipment and to provide him with an overall understanding which will allow him in turn to properly train the customer s operating personnel 3 02 General Description STAK Control Module contains all operator con trols electrical and gas inputs and outputs pilot circuitry and the torch leads receptacle A spare parts compart ment is built into the top enclosure The Control Module must have at least one Power Mod ule connected to it for it to operate Each power module provides 1 2 inch cut capacity Up to four can be easily stacked under each control module to provide up to 2 inch cutting capability with the appropriat
49. c replace Display Ribbon Cable Manual 0 2428 4 08 Pilot Arc Problems Locate your symptom below A AC indicator ON TEMP indicator ON green No gas flow GAS DC and PILOT indicators OFF 1 RUN PURGE SET switch not in RUN or defective a Check RUN and READY LEDs on Logic PCB If READY on and off check RUN PURGE SET switch If remote is used check for RUN setting LEDs Logic PCB 2 Defective hand torch parts leads switch or quick dis connect A 00093 Check START LED on Logic PCB If ON torch parts are Okay If OFF on Logic PCB check for approximately 10K ohms between J21 pins 3 to 4 with torch switch pressed a Replace Torch parts as needed per appropriate Torch Instruction Manual if no continuity 3 Defective Logic PCB Check START LED on Logic PCB If OFF on Logic PCB check for approximately 10K ohms between J21 pins 3 to 4 with torch switch pressed a Replace Logic PCB if zero ohms or small read ing 4 Remote Cable Disconnected RC6045 Remote Acces sory used a Check READY LED on Logic PCB If READY LED is off check remote E STOP 5 Coolant flow low if PCH M 145 Torch is used a Check for DC voltage on Logic PCB between J19 29 to TP1 GND If voltage is more than 2vdc coolant flow low coolant module defec tive or check for plugged torch Manual 0 2428 GND ES A 00094 5 Defective Logic PCB RUN and
50. e J1 J2 J3 J5 J8 Var ts AE D E 47 N Pilot PCB Figure 5 6 Pilot PCB Assembly Connections 31 REPLACEMENT PROCEDURES 5 Remove the screw securing the brace to the Pilot PCB 6 Slide the PCB up and out of the board holders located in the bottom of the unit 7 Reinstall the replacement Pilot PCB Assembly by re versing the above procedure and noting the follow ing Connector Description of Cable m Cable from optional High Flow Water Shield if installed Cable from optional Remote Interface if J2 installed Remove jumper from old PCB if not on replacement and install same as on old PCB OK to Move Select contacts or 36 Cables to the fan plasma secondary solenoids Power Module Interface and ON OFF switch J5 Ribbon cable from Analog and Logic 5 Cable from Auxiliary Transformer Cable from optional Standoff Control if installed Connect each wire to it s corresponding ING wire terminal CAUTION Make sure the ends of the large wire on the Pilot PCB get connected to the proper place F Display PCB Assembly Replacement 1 Open the Control Module as described in paragraph A above 2 Loosen the screw securing the current control knob and remove the knob 3 Remove the ribbon cable from the cable clamp 4 Remove the four screws securing the Display PCB to the Front Panel Assembly 5 Carefully remove the Display PCB far enough to
51. e the Analog PCB If the potentiometer high and low voltages are correct but the display is incorrect then replace the Display Manual 0 2428 D No DC Output An open circuit voltage of approximately 280 to 380 VDC depending on input power selected is produced when switching transistors in the Power Module are turned ON by an enable signal from the Control Module Logic PCB A circuit on the Pilot PCB monitors the output volt age When the output voltage drops below 60 VDC in dicating a problem exists the Pilot PCB sends a signal back to the Logic PCB which turns OFF the enable sig nal to the Power Module Because this happens in less than 50 milliseconds it is not easy to take voltage read ings to find the source of the problem 00093 Logic PCB The following light emitting diodes LED s on the Logic PCB will help in troubleshooting Indicator READY Meaning Indicatesthat E STOP TEMP switches coolant flow and parts in place circuits are satisfied This signal must be ON to allow RUN to come ON Indicates that the RUN PURGE SET or remote RUN PURGE switch is in the RUN position Signal must be ON to allow PS Enable to come ON Indicates a start signal froma hand torch switch CNC remote panelor pendant is being supplied START PS ENABLE Indicates the enable signal to the top Power Module isON Indicates that at least 4 ampsof DC curent is being supplied from Powe
52. e torch A Base Plate provides a secure mounting surface and pro tects the power and logic signal receptacles on the bot tom module Options and accessories are available as required A 00076 Figure 2 1 STAK Control Module Manual 0 2428 3 03 Technical Specifications A Controls Switch Output Current Control RUN PURGE SET Switch STANDARD LATCH HI TRANSFER Switch Secondary Single Gas Regulator Plasma Gas Regulator Corner Slowdown Adjustment B Control Indicators TEMP GAS DC and PILOT LED s Secondary Single Gas and Plasma Pressure Gauges Digital Ammeter with Output Preview Corner Slowdown Preview and Display PIP Circuit Status Display C Input Power 200 to 460 VAC 10 50 or 60 Hz Single or Three Phase Amps depends on input voltage phase amp number Power Modules used Refer to Appendix VII D Output Power Potentiometer Minimum Output 14 amps Maximum 35 amps per Power Module Total of 140 Amps with Four Power Modules E Pilot Circuitry CD Constant DC Pilot Modes Auto Restart Pre Flow Delay Recycle G CNC Signals Start Stop OK to Move Corner Slowdown Full CNC Available with Remote H Dimensions 9 1 0 23 m High x 16 0 41 m Wide x 22 0 56 m Long 9 Weight 37 5 Ibs 17 kg 9 DESCRIPTION DESCRIPTION 10 Manual 0 2428 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 4 01 This Section provides service diagnostics for the STAK Contro
53. ector into the Quick Disconnect Body Assembly White Pins Figure 5 18 Pin Removal 4 Carefully press the tabs down on the electrical con nector and remove the connector out the back of the Quick Disconnect Body 3 Carefully lift the right side of the Front Panel from the base NOTE The Front Panel must be pulled up on the right side to allow access to the snap ring on the Quick Disconnect Body 5 Remove the snap ring on the Quick Disconnect Body 6 Slide the connector body out the front of the Front Panel Assembly 7 Reinstall the replacement Quick Disconnect Body As sembly by reversing the above procedure Manual 0 2428 Socket Assembly 37 Plasma Socket Assembly 4 Retaining lt Ring Washer Secondary A700131 Snap Rings Figure 5 19 Quick Disconnect Body REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES 38 Manual 0 2428 SECTION 6 PARTS LISTS 6 01 Introduction Parts List Breakdown The parts list provides a breakdown of all replaceable components Control modules are field serviceable so a complete breakdown of parts is provided Power mod ules must be returned to an authorized Thermal Arc dis tributor for service The parts lists are arranged as fol lows Section 6 03 Control Module Front Panel Assembly Section 6 04 Control Module Main Assembly Section 6 05 Control Module Rear Panel Assembly NOTE Parts listed without item numbers are not illus trat
54. ed but may be ordered by the catalog numbers shown B Returns Ifa Thermal Dynamics product must be returned for ser vice contact your Thermal Dynamics distributor Mate rials returned to Thermal Dynamics without proper au thorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the de scription column of the Parts List Also include the model and serial number of the machine as shown on the plate attached to the front panel of the unit Address all inquir ies to your authorized Thermal Dynamics distributor Manual 0 2428 39 PARTS LISTS 6 03 Control Module Front Panel Assembly Item Catalog No Qty Number Description 1 1 8 4315 Front Panel 2 1 8 3372 Front Panel Overlay 3 2 8 4313 Pressure Gauge 0 100 psi bar 4 1 8 3258 ON OFF Switch 5 1 83259 RUN SET PURGE Switch SPDT 6 1 8 3259 STANDARD LATCH HI TRANSFER Switch SPDT 7 1 8 4316 Work Lead Connector Female 8 1 95834 Quick Disconnect Body Replacement Kit includes Body Quick Disconnect Console 2 PI Washer Q D Body Wave Spring Clip Q D Body Retaining Ring Retaining Ring Ext 55 9 16 Shaft 2 each Bumper Locking Tab Signal Connector 2 each 9 1 83373 Quick Disconnect Socket Assembly Plasma includes Fitting O D Console Female To 9 16 18 amp 1 4 Spring Canted Coil Nut 9 16 18 W 3 4 Flats Fitting 1 4 NP
55. gic PCB or Pilot Ribbon Cable A 00096 Measure DC voltage between J5 29 to TP1 GND on Pilot PCB a If voltage measures less than 2 VDC replace Pilot PCB TP1 GND TS ECER Pilot PCB Measure DC voltage between 18 29 to J18 30 on Logic PCB A 00102 a Replace if voltage is 15 VDC Logic PCB b If problem still exists replace Pilot Ribbon Cable 8 Faulty CD Transformer A 00101 Shorted secondary check for arc jumping across windings SERVICE TROUBLESHOOTING a If arc is present across the windings then re place CD Transformer b If arc is not present across windings then re place CD Transformer as it could be damaged internally 9 Contaminated Coolant PCH M 145 torch only a Drain system and replace coolant 4 09 Main Arc Problems Locate your symptom below A Main cutting arc will not initiate PILOT indicator stays ON Right most decimal point stays ON Top A0049 Analog PCB Power Module DC indicator ON a Replace Analog PCB if voltage measures less than 2 VDC 1 Work cable not connected C When operating at amperages over 46 amps the a Connect work cable digital display drops to 46 amps after main 2 Defective Pilot PCB cutting arc initiates Check for continuity between W42 to W48 on Pilot pieh PCB a Maintain standoff distance 1 8 3 8 between a Replace Pilot PCB if shorted or low ohms Sut pana work
56. he above are all correct then proceed to paragraph If the above does not function as noted then note the symptom and proceed to Section 4 05 Main Input Power Problems C Internal Power Test Set the Control Module ON OFF switch to ON and note the following e ACindicator ON TEMP indicator ON green GAS indicator ON Both plasma and secondary gas flow except when used with the PCH M 35 where only the second ary single gas will flow Fan will operate DC and PILOT Indicators are OFF Display indicates current as set by CURRENT con trol Display indicates preview Right most decimal point is ON This completes the Internal Power Test If the above are all correct then proceed to paragraph D If the above does not function as noted then note the symptom and proceed to Section 4 06 Internal Power Problems D Purge Test Set the Control Module ON OFF switch to OFF Set the RUN PURGE SET switch to RUN position Set the Control Module ON OFF switch to ON and note the following GAS indicator ON Fan operates Gas flows and stops 10 40 seconds depending on post flow setting after power on GAS indicator goes OFF e Fan stops This completes the Purge Test Ifthe above are all correct then proceed to paragraph If the above does not function as noted then note the symptom and proceed to Section 4 07 Purge Problems 12 Manual 0 2428 E Pilot Arc Test Press the torch s
57. he goods upon which such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS The limited warranty periods for Thermal products shall be as follows with the exception of STAK PAK II A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of sale by such distributor to the Purchaser and with the following further limitations on such two 2 year period The limited warranty period for STAK PAK II shall be as follows A maximum of four 4 years from date of sale to an authorized distributor and a maximum of three 3 years from date of sale by such distributor to the Purchaser and with the following further limitations on such three 3 year period PAK UNITS POWER SUPPLIES STAK PAK II LABOR MAIN POWER MAGNETICS 22 3 YEARS 2 1 YEAR ORIGINAL MAIN POWER RECTIFIER ss I VEARS 2 YEARS 1 YEAR CONIROLPGBOANRD ttt ttr ter i a ete an S YEARS 2 YEARS c 1YEAR ALL OTHER CIRCUITS AND COMPONENTS TXYEAR aene 1YEAR INCLUDING BUT NOT LIMITED TO STARTING CIRCUIT CONTACTORS RELAYS SOLENOIDS PUMPS POWER SWITCHING SEMI CONDUCTORS CONSOLES CONTROL EQUIPMENT HEAT
58. iser un masque aves arriv e d air si la ventila tion n est pas suffisante pour liminer tous les gaz et fum es e De l huile ou de la graisse en contact avec l oxyg ne peuvent s enflammer et br ler avec violence Nettoyez tous cylindres valves connecteurs r gulateurs boyaux et autres appareils afin d viter toute trace d huile ou de graisse e Ne jamais manipuler les cylindres ou l quipement oxyg ne avec des mains ou des gants graisseux Evitez que l oxyg ne entre en contact avec des sur faces huileuses ou graisseuses Nepas utiliser l oxyg ne pour remplacer l asair com press m Les rayons de l arc LES RAYONS DE L ARC peuvent abimer les yeux et bruler la peau Utiliser un cran de soudage muni d un filtre num ro 4 ou plus sombre en coupant au contact ou num ro 10 ou plus sombre en coupant dis tance Porter des v tements protecteurs ad quats Assurez vous que les autres personnes ne soient pas atteintes par les rayons De electrique Une DECHARGE ELECTRIQUE peut tuer Faire l installation et l entretien de l appariel selon les normes du Code Electrique des Etats Unis Norme NEC USA Standard C1 ou celles en vigueur dans votre pays e faut appliquer les proc dures de mise la terre sp cifiques l utilisation de dispositifs de coupe au plasma La pi ce ou le m tal sur lequel une per sonne coupe doit tre reli e une bonne prise de terre Ne pas toucher
59. l Module Assembly CM6032 allowing the Technician to islolate any faulty Subassemblies Refer to Section 5 Repairs amp Replacement Procedures for parts replacement instructions Introduction Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other Subassemblies of this unit Evidence of unauthorized repairs will void the fac tory warranty NOTE The troubleshooting contained in this manual is for the Control Module CM 6032 only Trouble shooting other parts of the system is covered in the seperate manuals for that product 4 02 Periodic Inspection 8 Procedures This subsection describes inspection procedures which should be performed at periodic intervals as required A Physical Inspection Check that all cable connections are secure B Cleaning Unit should be cleaned as described in Operating Manual 0 2463 4 03 Troubleshooting Guide A Troubleshooting and Repair Troubleshooting and repairing the this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment Manual 0 2428 WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot ing techniques B Advanced Troubleshooting For basic troubleshooting and parts replacement procedures refer to STAK
60. ld any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below Thermal shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal s specifications instructions recommen dations and recognized standard industry practice and not subject to misuse repair neglect alteration accident correct such defects by suitable repair or replacement at Thermal s sole option of any components or parts of the product determined by Thermal to be defective THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of t
61. m in the appropriate Sub Section 4 Check the causes easiest listed first for the symptom 5 Check the remedies listed for each cause 6 Repair as needed being sure to verify that unit is fully operational after any repairs NOTE Many signals are transfered between Printed Circiut Board Assemblies on Ribbon Cables If these cables become faulty they can then cause vari ous problems Do not forget about these cables when troubleshooting 4 04 Circuit Fault Isolation NOTE Before beginning troubleshooting visually inspect the internal components for signs of over heating fractures and damage This section is to help isolate the defect circuit before troubleshooting identify symptoms and test the unit for proper operation Follow the instructions as given to iden the possible symptom s and the defective circuit After repairs are complete then run the following tests again to verify that the unit is fully operational A Initial Setup Conditions Set the Control Module switches as follows ON OFF to OFF RUN PURGE SET to SET STANDARD LATCH HI TRANSFER to STAN DARD Set the CURRENT control potentiometer to maximum B Main Input Power Test Connect the main AC power to the unit and note the fol lowing AC indicators on the back of each power module should be ON Fans should not be operating SERVICE TROUBLESHOOTING Front panel LED s should be OFF This completes the Main Input Power Test If t
62. n the torch used the voltage will be as follows Model Torch J19 Pins Volts DC PCH M 35 PCH M 70 PCH M 140 or 145 A 00109 If the torch identification signals to the Analog PCB are incorrect then replace the Logic PCB 24 Manual 0 2428 C Potentiometer Scaling The Control Module Analog PC Board receives the torch and module identification signals which then provides the high and low voltages for the current control potenti ometer The total current output is divided equally be tween all Power Module s and is set not to exceed the torch rating The potentiometer high and low voltage with respect to PCB common TP 1 on Logic PCB are as fol lows Pot Low J16 23 Volts DC Number of Power Modules Pot High J16 25 Volts DC Model Torch PCH M 35 PCH M 70 PCH M 140 PCH M 145 PCH M 35 PCH M 70 PCH M 140 PCH M 145 PCH M 35 PCH M 70 PCH M 140 PCH M 145 PCH M 35 PCH M 70 PCH M 140 PCH M 145 This chart shows the normal potentiometer voltages sup plied by the Analog PCB at J16 The checks should be made in preview mode with CUR RENT control potentiometer and corner slow down CSD trimpot set to maximum The digital display should indicate the potentiometer setting and the deci mal point on the right side of the display should be ON If the torch and module identification signals to the Ana log PCB are correct and the output potentiometer high and low voltages are incorrect replac
63. nect is closed 1 Power Module input shorted a Refer to Section 4 10 E 1 Input Bridge Check 2 Input power cable installed incorrectly a Refer to Operating Manual 0 2463 Section 3 05 and connect input cable 3 Single phase jumper wire installed incorrectly a Refer to Operating Manual 0 2463 Section 3 05 and install jumper wire 4 06 Internal Power Problems Locate your symptom below A All front panel indicators on Control Module are off Control Module fan does not operate 1 Improper input power line connections inside Control Module a Refer to Operating Manual 0 2463 Section 3 05 and correct if needed 2 Fuse blown inside Control Module a Replace Fuse 1 FU 3 Auxiliary transformer primary plug connected incor rectly a Refer to Operating Manual 0 2463 Section 3 06 and correct as needed If unit still does not operate measure output voltages at J7 on the transformer for the following Pins Voltage Level 115vac 36vac 18vac b Replace transformer if incorrect 4 Faulty ON OFF switch Measure for 36vac on the Pilot PCB between J4 1 to j4 3 a If voltage is not present replace the ON OFF switch SERVICE TROUBLESHOOTING Pilot PCB CONTROL XEMR 1 J7 F YL 2 J 4 N 3 35 tv 18VAC VAC 1 36 Nh RD 18VAC z 22137 a R 4 l D _ 5 3
64. oltage between J21 pin 1 to pin 2 at Logic PCB a Replace Logic PCB if 0 volts Manual 0 2428 Logic PCB A 00080 AC indicator ON TEMP indicator ON green No gas flow Gas DC and PILOT indicators OFF 1 RUN PURGE SET switch in RUN position a Switch to SET position 2 Gas supply not connected to unit a Connect to gas supply 3 Gas supply not turned on a Turn gas supply on 4 Defective RUN PURGE SET switch a Check continuity 5 Defective gas solenoid circuit s Make the following voltage checks per the circuit dia gram and replace the faulty part as required Control Secondary Transformer Solenoid Plasma Solenoid WH BK OR BN Wire Wire Wire 110 26 110 z Wire 25 tv YL 115 M ee eu 6 2 10 18 9 15 u 115 VAC Pilot PCB 8 J5 18 A 00081 lt 8VDC lt 8VDC Secondary Plasma Enable Enable SERVICE TROUBLESHOOTING Wire 26 to wire 110 at the secondary solenoid a If approximately 115vac replace solenoid Wire 25 to wire 110 at the plasma solenoid not used with PCH M 35 Torch b If approximately 115vac replace solenoid Solenoid Secondary Solenoid A 00082 Check Pilot PCB J18 2 to TP1 GND for 0 VDC c If higher than 0 VDC replace Display Ribbon Cable Pilot PCB J5 pin 8 to TP1 GND for secondary sole noid d If higher than 8 VDC replace Logic PCB Pilot
65. pice Check CSR LED on Logic PCB Indicator should be ON during main arc transfer a Refer to appropriate Torch Instruction Manual If indicator is OFF then using an analog meter mea 3 Defective Pilot PCB sure DC voltage between J5 9 to TP1 GND on Pilot PCB while attempting to transfer Measure for open or high ohms between W49 to W42 on Pilot PCB b Replace Pilot PCB if voltage measures less than 2 VDC Replace Pilot PCB if shorted low ohms Measure DC voltage between J5 11 to 12 on Pilot PCB while cutting and tip not on work b Replace Pilot PCB if voltage is less than 2 vdc 12 J5 Pilot PCB A 00097 Fr B Cutting arc transfers may sputter when torch is rene very close to work piece but is weak Digtal Pilot PCB A 00105 display indicates current set by CURRENT control 3 Defective Analog PCB and right most decimal point is OFF Measure DC voltage between J5 11 to 12 on Pilot 3 Defective Analog PCB PCB Measure DC voltage between TP2 to TP1 GND on Analog PCB a Replace Analog PCB if voltage measures 15 vdc SERVICE TROUBLESHOOTING 22 Manual 0 2428 D Low cutting power Digital display indicates amperage less than preview current 1 Defective Power Module a Test each Power Module seperately 4 10 Test Procedures A Module Identification There are four light emitting diodes LED located on the Analog Board
66. r Module It isused to indicate when a true pilot arc has started Indicates main cutting arc is established 25 SERVICE TROUBLESHOOTING When the unit is at idle the RUN and READY LED should be on The START LED turns on when start sig nal is given At this point the gas or gases begin to flow When the preflow time is over the PS Enable signal is given and the DC LED on the top Power Module turns ON When the pilot arc is established the PSR LED turns ON If the PS Enable LED does not come ON then replace the Logic PCB If the PS Enable LED turns ON then OFF immediatly the following test should be performed 1 Jumper Logic PCB TP3 to TP1 to disable capacitive discharge CD 2 Connect a jumper between TP1 and TP2 test points on the Logic PCB This will cause the gas or gases to flow continuously and the DC indicator on the Con trol Module to turn ON V Logic PCB 5 00113 3 Press hand torch switch or send remote start signal START LED turns ON 4 After preflow delay the PS Enable LED turns ON and the top Power Module DC indicator turns ON 5 Measure open circuit voltage between wire 39 to 42 at the Pilot PCB If voltage is low each Power Mod ule should be tested individually If voltage iscorrect then continue to Step 6 SERVICE TROUBLESHOOTING 26 A 00114 6
67. re move the ribbon cable from J10 REPLACEMENT PROCEDURES 32 6 Remove the connection from J9 STANDARD LATCH HI TRANSFER switch and J12 RUN PURGE SET switch J10 a c gt es om 6 STATUS DISPLAY E AQU Display PCB J9 Figure 5 7 Connections on Display PCB Assembly 7 Remove the Display PCB from the unit 8 Reinstall the replacement Display PCB Assembly by reversing the above procedure CAUTION Make sure that all cables are inserted into the proper connectors G Fan Assembly Replacement 1 Open the Control Module as described in paragraph above 2 Remove the Control Module Baffle as described in paragraph E 2 above 3 Lift the Rear Panel Assembly out of it s slots on the bottom and side panels Turn the panel to gain ac cess to the Fan Assembly 4 Remove the four screws securing the Fan to the Rear Panel 5 Disconnect the two wires going to the fan power tabs 6 Reinstall the replacement Fan Assembly by reversing the above procedure NOTE When reinstalling the Rear Panel Assembly into it s holding slots be sure that no wiring is in the slots and that all wiring is inside the unit H ON OFF Switch Replacement 1 Open the Control Module as described in paragraph above Manual 0 2428 Manual 0 242
68. re 4 Set the switches on the replacement PCB the same as the one removed Module Assembly Pins NOTE Upper Enclosure Be sure that the switches on the replacement PCB are set the same as the old 5 Reinstall the replacement Logic PCB Assembly by re versing the above procedure and noting the follow ing Connector Description of Cable Ribbon cable from optional J11 J17 Remote Interface if installed and the Analog PCB J18 Ribbon cable from Analog and Pilot Figure 5 1 Removing Control Module Cover PCBs J19 Ribbon cable from Power Module B Fuse Replacement Interface and Analog PCB 1 Open the Control Module as described in paragraph Ribbon cable from Analog and A above Display PCBs 2 Locate and remove the old fuse Wiring harness from Quick Disconnect Front Panel 3 Install the replacement fuse and close up the Control DENTS Module by reversing the procedure in Step 1 A 00049 J17 J18 J19 J20 x TEE Logic PCB J21 Figure 5 3 Logic PCB Assembly Connections 00120 D Analog PCB Assembly Replacement 1 Open the Control Module as discribed in paragaph A above Figure 5 2 Fuse Location 2 Carefully remove all cable connections to the Analog PCB Assembly noting the location of each Es Loge PCE Assembly Replacement 3 Slide the PCB up and out of the board holders located 1 Open the Control Module as described in paragraph in the bottom of the unit A above 4 Reinstall the
69. rized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system m CAUTION A procedure which if not properly followed may cause damage to the equipment G A procedure which if not properly followed may cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions G Operation and maintenance of plasma arc equip ment involves potential hazards operators and personnel should be alerted to possible haz ards and precautions should be taken to prevent possible injury AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Ventilation must be adequate to remove gases and fumes during operation Threshold limit values and how to measure the amounts to assure ade quate ventilation are found in publication A page 2 Vapors of chlorinated solvents can form the toxic gas phosgene when exposed to ultraviolet radia tion from an electric arc Solvents degreasers and potential sources of these vapors must be removed from the cutting area Keep all fumes and gases from the breathing area Use a downdraft cutting table or water table to cap ture fumes and gases Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases Oil or grease in
70. s fittings are replaced in the same manner 1 pen the Control Module as described in paragraph A above 2 Turn off any gas supply 35 REPLACEMENT PROCEDURES 3 Disconnect the external supply line to the fitting being replaced at the Rear Panel 4 Remove the adapter fitting screwed into the fitting 5 Remove the internal feed line to the fitting being re placed 6 Remove the C clip from the fitting on the inside of the Rear Panel 7 Pull the fitting from the Rear Panel 8 Reinstall the replacement Plasma or Secondary Gas Input Fitting Assembly by reversing the above proce dure Plasma Adapter Fitting C Clips Secondary Adapter Fitting Z N Adapter Fitting A 00129 Inserts Rear Panel Figure 5 16 Plasma Or Secondary Gas Input Fitting R RF Filter PCB Assembly Replacement 1 Open the Control Module as described in paragraph above 2 Remove the nut securing the RF Filter PC Assembly to the Blade Connector near the front of the unit 3 Carefully pullthe RF Filter Assembly up off the blade lug and remove the wiring connections on the bottom side 4 Reinstall the replacement RF Filter PCB Assembly by reversing the above procedure S Quick Disconnect Socket Replacement NOTE Both the Plasma and Secondary sockets are replaced in the same manner 1 Open the Control Module as described in paragraph A above REPLACEMENT PROCEDURES 36 2 Disconnect the
71. the presence of oxygen may ignite and burn violently Keep cylinders valves cou plings regulators hoses and other apparatus clean and free from oil and grease Oxygen cylinders and apparatus should not be handled with oily hands or gloves Do not allow an oxygen stream to contact oily or greasy surfaces Do not use oxygen as a substitute for compressed air m ARC RAYS Arc rays can injure eyes and burn skin Use a welding shield with proper filter 4 filter or darker is recommended for drag cutting A 10 filter or darker is recommended when cutting with a standoff Wear proper protective clothing Make sure others in the operating area are protected from arc rays A SHOCK Electric shock can kill Install and maintain equipment according to USA Standard C1 National Electric Code Proper grounding procedures must be adhered to when using plasma arc cutting equipment The workpiece must be grounded to a solid electrical ground Do not contact electrically live parts Do not touch torch parts when input power is present in the power supply Insulate yourself and others from the workpiece and ground Replace any cracked or damaged insulating parts including torches hoses and leads GENERAL INFORMATION Disconnect power source before disassembling the torch Turn off primary power before working on torch parts including changing cups and tips The shield cup must be installed prior to operating
72. u cux anne gt N A GNO 2 ADDED COMMON 126 pg INFORMATION PROPRIETARY TO THERMAL DYNAMICS mm aus CORPORATION NOT FOR RELEASE OR DISTRIBUTION 18 08 93 NOTE REFERENCE UNLESS OTHERWISE SPECIFIED RESISTORS ARE IN PJB OHS 1 4 CAPACITORS ARE IN MICROFARADSIUF POWER Lor 1 SUPPLY STAK 2 CONTROL SYS 420837 2837 51A N 6 7 8 9 10 00133 Manual 0 2428 53 APPENDIX
73. use by properly trained Service Technicians familiar with this equipment Read this Manual and the Operating Manual 0 2463 thoroughly A complete understanding of the capabili ties and functions of the equipment will assure obtaining the performance for which it was designed 2 02 General Service Philosophy Several key points are essential to properly support the application and operation of this equipment A Application The equipment should satisfy the customer s require ments as supplied and as described in Section 3 of this manual Be sure to confirm that the equipment is capable of the application desired B Modifications No physical or electrical modifications other than selec tion of standard options and Accessories are to be made to this equipment C Customer Operator Responsibilities It is the customer operators responsibility to maintain the equipment and peripheral Accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual and to protect the equipment from accidental or mali cious damage D Repair Restrictions The electronics consists of Printed Circuit Board Assem blies which must be carefully handled and must be re placed as units No replacement of printed circuit sol der mounted components is allowed except as noted in this manual If to be returned the replaced Printed Circuit Board As semblies must be properly p
74. witch and note the following Both gases flow secondary single only for the PCH M 35 GAS indicator turns ON Control Module fan operates After preflow delay DC and PILOT indicators turn ON Top Power Module DC indicator ON and fans op erate This completes the Pilot Arc Test If the above are all cor rect then proceed to paragraph F If the above does not function as noted then note the symptom and proceed to Section 4 08 Pilot Arc Problems F Main Arc Test Bring the torch to within 1 8 3 8 of the work piece to establish a pilot arc and note the following Main cutting arc initiates and the pilot arc turns OFF PILOT indicator turns OFF Digital display indicates maximum as set by CUR RENT control Right most decimal point turns OFF This completes the Main Arc Test If the above are all correct then the equipment should be operating properly If problems still persist then contact Technical Services If the above does not function as noted then note the symptom and proceed to Section 4 09 Main Arc Prob lems 4 05 Main Input Power Problems Locate your symptom below A AC indicator on rear panel of power module s is noton 1 Main power disconnect not closed a Close main power disconnect 2 Main power line fuses blown a Replace Fuses 3 Defective input power cable a Replace input power cable Manual 0 2428 B Main power line fuses blow as soon as main discon

2428 C & CR Pgs - Victor Technologies

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2428 C &amp; CR Pgs - Victor Technologies

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2428 C & CR Pgs - Victor Technologies