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appendix 1 - Victor Technologies

1. J96 E Pu 1 J17 12 1 4 i J2 J1 m Z SE i zr zi z L o ooo S o oo o o fo opopo O 3 os 5 9 1 olo o o 2522552 iih OO as 6 o su ass Lo K Q 9 9 0000000 D SE er E E ir Sac 269 ra 9995999 po rang Ol J3 Te 5 lt ij gl 00000000 SWS E 23 oss d O J99 2 300 D bo a D 00000000 T sws 25 OT fs 2 85r 295 454 b d Lo Bonen 90900000 15210 O 18 e e E 0000000 0900000 oooooon 1 DE 00000000 O eS or s 047 2 Ilo E ae ss 9900000 D 90990000 099000904 0090000 1 re m 5 00000000 Qu co n Drs Or u hah i i 9 PNH Uh 55 00000000 ooooood 5 629 9 220 0000000 g E
2. ARC VOLTS CURRENT res START K CD ENAHLE SENSE in sur ion L CNC INTERFACE 5 T810 00000 CONNECTOR 123 FILTER VOLTAGE 722 192 7 DIVIDER 1 36 B 19 1712 105 5 3l START CD 4 19X1522 Sher v PS Bj SIG 5 VOLTS 7 ARC v 9 STAR B in series 36VACb 12 36VACa ENABLE 3 m IU SHIELD CAP PCB 19X1479 J28 79 IOPTIONAL NOT USED E24 NN 3 lt 17 E d SYM START E23 Hand Torch Oni PILOT 14 GND usi J PEN 22 27 F J7 amp B RIBBON CABLE 21 JL 1 12V COMMON L3 pan lt 2 COMMON 7 SECONDARY LI LL LS 227 PILOT IND 3 FET GATE DRIVE CURRENT 515 17 SHIELDED HAND 4 COMMON 8 9 COMMON m 5 PRI CURRENT SIG 10 SHIELD STUD 2 Lois EN GS cower FET MODULE A ENABLE Z 19X1256 D20 RESET 2 18 b le led n 5 123 Ea E26 1111 BOARD B 19 1257 11 Von i d Eh FET MODULE B 0UT D 19X1256 dour m 12 12 L2 OUTPUT INDUCTOR aan ng E25 E12 co bL l b ju T 1 4 E26 1 1 1 1 E16 SEC TAP BOARD C 19x1257 4 a FET MODULE C E15 PRIM
3. Current Sensor Board Signals J15 1 Active Low CSR Sense Signal J15 2 Ground J15 3 12 vdc Manual 0 2825 99999 O o O e a m L Lb 4 T T 1 OOOOOO On c 2739222 qm Do o o 01419 15 APPENDIX APPENDIX 12 36VAC CIRCUIT DIAGRAM CD PC Board Pilot Output PC Board 2 93 1 J11 14 15 16 _ J13 52 3 1171819 Logic PC Board J4 J9 J1 3 3 gt 5 5 5 7 7 7 Auxiliary 36 3 3 Transformer 1 2 2 Outputs 2 1 D 1 115 VAC 452944 6 Input Voltage Sense J3 3 1 24 ON OFF 19 Switch APPENDIX A 16 Gate Drive PC Board A 02325 Gate Drive PC Board Manual 0 2825 APPENDIX 13 RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS This schedule applies to all types of liquid cooled plasma cutting systems Some systems will not have all the parts listed and those checks need not be performed NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment Daily Operational Checks or Every Six Arc Hours 1 Check torch parts
4. A 01208 CD PC Board Signals J11 1 36 b from Logic PC Board J5 1 J11 2 36 VAC CT Return J5 2 J11 3 36 VAC a from Logic PC Board J5 3 J11 4 Active Low CD Enable Signal from Logic PC Board 5 4 11 5 Return for CD Enable Signal from Logic PC Board J5 5 J11 6 Not Used J11 7 Not Used J11 8 Not Used TP1 Logic Ground or Return TP2 12 vdc TP3 Not Used El CD output E2 CD Output APPENDIX A 10 Manual 0 2825 APPENDIX 8 INPUT BOARD LAYOUT f E5 E6 Component Side of PC Board Solder Side of PC Board 5 RIB 5 LT R5 5 2 RI 782 2 R3 LT1 30 198 7 79 e Eo 2 O O ASSY QO E4 je E3 E8 EB s ecu B C RS s 5 R7 i R8 c2 CGND oi 01 Fo of F o O Ria cs ro c3 o e O FORTS Input PC Board C B A Input 11 B AC Input L2 C AC Input L3 Rectifier Output Recti
5. 00553 Place the meter lead drain lead of Q1 meter lead on source lead of O1 The meter should indicate gt 100 ohms NOTES Make measurements near the body of each MOSFET Besure that the meter lead probes penetrate the pro tective coating on the MOSFET d Place the meter lead on drain lead of Q1 and meter lead to the heatsink The meter should indicate 1 meg ohms e Placethe meter lead on gate lead of Q6 and meter lead on source lead of Q6 The meter should indicate approximately 2 5K ohms f Place the meter lead on drain lead of Q6 and meter lead on source lead of Q6 The meter should indicate gt 100K ohms 4 18 4 FET Reset Diode Check Use an ohmmeter set to the diode function and check thereset diode as follows a Place the meter lead on E14 and the meter lead on E12 of the FET Heatsink Assembly Capaci tor PC Board to check the reset diode The meter should indicate between 0 4 to 0 6 volts using the diode function b Reversethe meter leads and the indication should bea capacitor charging c Place the meter lead on E14 and the meter lead on E13 of the FET Heatsink Assembly Capaci tor PC Board to check the reset diode The meter should indicate between 0 4 to 0 6 volts using the diode function d Reverse the meter leads and the indication should bea capacitor charging If the indication is a short th
6. c Pressand hold the hand torch switch Logic PC Board Start Indicator D26 turns ON d Measure open circuit voltage between 8 to E7 atthe Pilot Output PC Board If voltage is low each FET Heatsink Assembly should be tested individually FET Heatsink Output Diode Checks Remove input power from the unit Isolate each FET Heatsink Assembly by removing the red wire 12 at E18 and the black wire 11 at E17 on each FET Heatsink Assembly With an ohmmeter set on the diode range check between the two output studs E17 output to E18 output This should indicate a diode drop in one direction and open in the other If the checks indicate shorted or open in both direc tions then the faulty pair of FET Heatsink Assemblies should be replaced The FET Heatsink Assemblies are matched and balanced during production and must be replaced in pairs SERVICE SERVICE MOSFET Resistance Checks The Power Supply contains four identical FET Heat sink Assemblies On each assembly there are two MOSFET devices that must be checked Use an ohm meter to check for the proper resistance of the 5 as follows a Locate O1 and Q6 on the FET Heatsink Assembly 96 Q1 FET Heatsink and Capacitor PC Board Assembly A 01414 b Place the meter lead on gate lead of Q1 and meter lead on source lead of Q1 The meter should indicate approximately 2 5K ohms Spring Clip MOSFET Gate 3
7. KY POWER ENABLE D2 H reser E25 81 ld kd a h T TT T BOARD D 19X1257 EU FET MODULE D Z 256 BOTTOM 2 REV REVISIONS Rev REVISIONS BY DATE THERMAL DYNAMICS INDUSTRIAL PARK 2 assy AA ECO 2A16 CORPORATION Lane 298 571 AB ECO 2CFA OE INFORMATION PROPRIETARY TO THERMAL DYNAMICS TE s CORPORATION NOT FOR RELEASE OR DISTRIBUTION 3 00 gt ECO 363E asie 3 3 80 701 77 REFERENCE DAT AD 188874 HAS 742 o Ten 1786 AE 188398 8 ym FOR AUTOMATION SYSTEM 5 42 1075 7 8 10 02868 Manual 0 2825 A 25 APPENDIX APPENDIX 20 SYSTEM SCHEMATIC for Units Rev and Later m F2 F3 FSI INR LI L2 L3 4 PSI 2 5 soLz sw swz F 2 Ts2 68 59 1 156 2 1 7 OK 151 E 9 LOGIC CONTROL I 168 18X1488 5011 TS2 Ex n CURRENT SENSE f 2 Des RELAY PLASMA 1647 k so PREFLOW 5012 E 2 TIME GN DN OFF 27 25 ED 3 165 165 m OFF 33 mz Tz OFF OFF 4 69 26 START L lu 4 JH russ
8. Wheel PT Retaining Ring Axle NOTE Both support leg assemblies are removed and re placed in a similar manner Raise the unit off the floor far enough for the weight of the unit to be removed from the support legs Remove two screws securing support leg to front of base Install replacement support leg by reversing above step C Auxiliary Transformer T3 Assembly Replacement NOTE replacement Auxiliary Transformers Assem blies include two fuses Remove the Right Side Panel per Section 5 04 A Note orientation of all the wires connected to the Auxiliary Transformer Assembly Disconnect wires Remove the four flat washers and nuts securing the Auxiliary Transformer to the four base studs Remove Transformer from unit Install replacement Transformer by reversing the above procedure Manual 0 2825 D Motor 5 Fan Pump Replacement NOTE The simplest way to replace the Motor is to remove the Motor Fan and Pump together then replace the Motor The procedure below describes how to remove the Motor Fan Pump Assembly to replace the Motor To replace the Fan continue with the procedures outlined in Section 5 08 E Fan Assem bly Only Replacement To replace the Pump fol low the procedures outlined in Section 5 08 F Pump Assembly Replacement Remove the Right Panel per Section 5 04 A Disconnect the following NOTE Coolant may drain from the hoses It is recommended th
9. 5 H coor ant DRAE H ran J96 n FAN 295 NOT USED FOR SOME EARLY UNITS HAD OK TO MOVE 217 L 385 amp J97 CONNECTED 1571 11188 pod 120VAC ALSO NOT USED 2 us HS 3 120 VAC J99 8 398 15 REMOVED 8 FROM LATER UNITS i JU J3 J98 5 12356 12345 8 7 8 9101121314 1 ORANGE 28 PIN RIBBON CABLE NOTE 14 OPEN BETWEEN GATE DRIVE 5 ONLY TOP GETS PILOT ENABLE GATE DRIVE PCB 19X1487 TOP DRIVE PCB 19X1487 BOTTOM 432 238 ELT 432 3 FED CA 5138 1 BROWN 469 v BLUE imis 1721 ORANGE RED C oy 5 za esu RUN eer c BLACK 222 V ions 174 DFF e YELLOW 128vAC 1342 3315 YELLOW 120 CURRENT L aas AUX TRANSFORMER VOLTAGE CHANGEOVER 2008 240 220 380 415 UNITS HAVE 2 JIB A ONLY J31 A amp B ACCESSIBLE LED PCB a 188 388 4157 230 480 UNITS HAVE ONLY 19X1604 J31 A amp C ACCESSIBLE 189 450V gt J18 C Et 18 INPUT PCB 19 1497 ise M 14 POWER INDICATOR E INR 5 7 NA 1 m EB INPUT K 208 460 3 PHASE A I 4 4 12
10. POWER CEPR INDICATOR M m EB YX PIN 14 OPEN m a 4 BETWEEN DRIVE PCBS ter ONLY GETS INPUT o PILOT ENABLE D 200 460 VAC 3 PHASE CW A AT 141 m l 4 9 c 5 12 B 120 oo 4 9 s i i s ee di GND O 23 COMPONENTS LOCATION 122 Jia Fi FUSE BBBVAC FNO R 5 D2 m F2 F3 FUSE 25 MDL 5 22 FSI COOLANT FLOW SENSOR 0 2 GPM BB INR INRUSH CONTACTOR 128 COIL D4 4 POLE CONTACTS INPUT VOLTAGE Li L2 OUTPUT SMOOTHING INDUCTORS 081 SELECTION a L3 PILOT INDUCTOR 19X1487 4 FAN 4 120 821 r74 BOTTOM M5 COOLANT PUMP MOTOR 23 VAC 1811 1 3 50 60 HZ 1 PHASE 1 w MOTOR CONTROL CONTACTOR 272 2201 12 COIL 25A CONTACTS pa i 5 PLASMA PRESURE SW 35PSI 1A21 Q Q RI 2 RESISTOR OHM 55W 71 JiB SOL PLASMA CONTROL SOLENOID I20VAC 5012 SECONDARY CONTROL SOLENOID 128VAC azi swi ON OFF SWITCH DPST ROCKER C31 Jer 7 9 sw2 RUN SET SWITCH SPST ROCKER 1 41 2 MAIN POWER SWITCHING TRANSFORMERS D8 EB 73 AUX TRANSFORMER 220 380 460 VAC 1821 INPUT 238 120 36VAC CT OUTPUTS T4 CD TRANSFORMER 818 TS COOLANT TEMP SW 78 DEG C N O A2 152 INPUT BRIDGE TEMP SW 80 DEG A21 w MAIN POWER CONTACTOR 120 COIL 142 031 3 POLE 83A CONTACTS A 02
11. 11 S gt 0 487115 85 Lolo E J7 T 9 8 S TP 0 9 5 2 TP8 D20 7 9 TEX TP10 deg TP7 7 E S 90 A 14 Gate Drive Board Signals EMEN O 000 9 fos 9 cas Q Q Hi J7 1 J7 3 J7 4 J7 5 J7 6 J7 7 17 8 17 9 17 10 J8 1 J8 2 J8 3 J8 4 J8 5 J8 6 J8 7 J8 8 J8 9 J8 10 12 vdc to FET PC Boards J6 1 Return for 12 vdc to FET PC Boards J6 2 Output to FET PC Boards J6 3 PWM Return to FET PC Boards J6 4 Primary Current Sense from FET PC Boards J6 5 Primary Current Sense Return from FET PC Boards J6 6 Secondary Current Sense from FET PC Boards J6 7 Secondary Current Sense Return from FET PC Boards J6 8 Over Temperature Sense from FET PC Boards J6 9 Over Temperature Sense from FET PC Boards J6 10 Gate Drive PC Board A 02323 12 vdc to FET PC Boards J6 1 Return for 12 vdc to FET PC Boards J6 2 PWM Output B to FET PC Boards J6 3 PWM Return to FET PC Boards J6 4 Primary Current Sense from FET PC Boards J6 5 Primary Current Sense Return from FET PC Boards J6 6 Secondary Current Sense from FET PC Boards J6 7 Secondary Current Sense Return from FET PC Boards J6 8 Over Temperature Sense from FET PC Boards J6 9 Over Temperature Sense from FET PC Boards J6 10 APPENDIX A 6 Manual 0 2825 19 1
12. 120 1 1 134 c ae 4 GND 5 LOCATION PM S FUSE GBQVAC FNO R S D2 zm FUSE 258 MDL 5 C21 COOLANT FLOW SENSOR 0 2 GPM BB INRUSH CONTACTOR 120 COR 4 POLE CONTACTS INPUT VOLTAGE OUTPUT SMOOTHING INDUCTORS DB SELECTION PILOT INDUCTOR 17 380 45BV FAN 4 128 1821 COOLANT PUMP MOTOR 230VAC 1 3 HP 58 58 HZ 1 PHASE MOTOR CONTROL CONTACTOR len 120VAC CDL 254 CONTACTS PLASMA PRESURE SW 3SPSI 2 RESISTOR 10 OHM 55W 1471 PLASMA CONTROL SOLENOID I2BVAC an SECONDARY CONTROL SOLENOID 120 21 ON DFF SWITCH DPST ROCKER ica RUN SET SWITCH SPST ROCKER 27 MAIN POWER SWITCHING TRANSFORMERS AUX TRANSFORMER 2290 380 4560 VAL 182 INPUT 230 120 OUTPUTS CD TRANSFORMER COOLANT SW 78 DEG N O 21 INPUT BRIDGE TEMP SW BB DEG 1A21 MAIN POWER CONTACTOR 126 COR az 3 POLE 83A CONTACTS Art A 04332 1
13. 6 gt 255 POWER n 20 reser 7 26 E13 BOARD D 19 1257 FET MODULE D 4 _19x1256 rev REVISIONS REVISIONS sv DATE THERMAL DYNAMICS ECO 2415 hasl Sao CORPORATION eco zcra Jupe E ea rr ar AC ECO 363E 5 0 218 E AD 100074 sr tee Van Sie B NE SOMEN UI E AE Eco 100388 5 6 158XL FOR AUTOMATION 101549 228 SYSTEM SCHEMATIC 42 1076 7 8 9 Art A 04332
14. REPLACEMENT PROCEDURES 5 8 reversing the above procedure Manual 0 2825 F Coolant Filter Replacement 1 2 8 Remove Right Side Panel per Section 5 04 Remove the two coolant hose connections to the Filter Assembly NOTE Some residual coolant may drain from the In Line Filter It is recommended that a bucket rag or tow els be placed below the hose prior to removing Remove the two elbow fittings on each side of the Coolant Filter Assembly and remove the damaged Coolant Filter Assembly from the bracket Clean the old thread sealer from the threads of the elbow fittings Apply a thin coating of liquid Teflon thread sealer to the threads of the elbow fittings Place the replacement Coolant Filter Assembly in the bracket with the arrow pointing to the left and reinstall the two elbow fittings Reconnect the two coolant hoses to the Coolant Filter Assembly making sure that the hose to the Pump Assembly is on the output of the Coolant Filter Assembly Install Right Side Panel G Coolant Reservoir Replacement CAUTION Handle and dispose of the used coolant per recom mended procedures NOTE The Coolant Reservoir is removed by removing the rear panel Remove the Left and Right Side Panels per Sec tion 5 04 A Drain the coolant from the Coolant Reservoir as follows a Disconnect CoolantSupply Hose input con nection at the Coolant Filter Assembly The hose goes from the Cool
15. 4 9 F ACindicator ON GAS indicator OFF Gas flows DC indicator OFF 1 Gas pressure too low a Set pressures above 35 psi 2 4 bar limit of Plasma Pressure Switch 2 Faulty pressure switch Measure for DC voltage from wire 51 to wire 50 at the gas Pressure Switch at the rear of the Rear Panel Assembly If 12 vdcis present and pressure is above 35 psi 2 4 bar replace gas Pressure Switch Rear Panel ne Gas Solenoid A 01184 3 Lowor No Coolant Flow a Check for proper coolant level If low fill to cor rect level b Checkpump for proper operation running and replace pump if necessary 4 Clogged coolant filter and or in line coolant filter a Checkinternal and external coolant filters Clean or replace if necessary Flush the old coolant from the system 5 Clogged torch leads a Check torch and leads and replace if necessary Flush the old coolant from the system SERVICE 6 Faulty Flow Switch 251 or Logic PC Board a Checkthe coolant flow switch and Logic Board as follows The flow switch FS1 for the coolant is cali brated for 0 25 gpm When adequate coolant flow satisfies FS1 it closes connecting J99 1 on the Logic PC Board to 99 3 common Measure voltage between J99 pin 1 and J99 pin If J99 1 is greater than 2 volts FS1 or connec tions to FS1 are faulty If the voltage is less than 2vdc the Logic Board may be faulty Replace the flow switch or
16. E Air Line Regulator 5 Replacement 5 Removethe Regulator from the2 inch brass nipple connected to the Solenoid Assembly NOTE m on 6 Remove the elbow fitting from the old assembly There are two Air Line Regulator Brackets in this unit and both are replaced using this same proce 7 Install the replacement Air Line Regulator Assem dure bly by reversing the above procedure keeping in mind the following 1 Remove the nut securing the Air Line Regulator to the mounting bracket e Apply pipe thread sealant to the fitting before reassembling 2 Remove the four screws securing the Air Line Regulator Bracket to the Rear Panel G Filter Voltage Divider PC Board 3 Remove bracket from unit Replacement 4 Install the replacement Air Line Regulator Bracket by reversing the above procedure 2 Disconnect the two wiring connectors at J23 and F Air Line Regulator s Replacement 124 from the Filter Divider PC Board 3 If CNC wiring is connected to TB1 then remove _ NOTE _________ the TB1 from the PC Board terminal block is This unit has two Air Line Regulators one for plugged into a socket on the Filter Voltage Divider plasma gas and one for secondary gas This proce PC Board dure applies to both Regulators 4 Install thereplacement Filter Voltage Divider PC 1 Remove the Right Side Panel per Section 5 04 A Board making sure to reconnect any wiring
17. Remove the Right Side Panel per Section 5 04 A Locate the Radiator and carefully disconnect the Thermostat Switch solid state near the inlet port and slide out through hole in mounting bracket Remove ties as required Install the replacement Thermal Switch by revers ing the above procedure 5 09 Rear Panel Parts Replacement NOTE Refer to Section 6 08 for parts list and overall de tail drawing A Handle Replacement 1 Remove the four hex head screws securing the handle to the Rear Panel of the unit Remove the Handle from the Rear Panel To install the replacement Handle reverse the above procedure B Rear Panel Replacement 1 Remove the Left and RightSide Panels per Section 5 04 A Remove the Top Panel per Section 5 04 B Remove the two Regulators on the Rear Panel by completing the following a Disconnect the air line hose connected to the solenoid pressure switch assembly b Disconnect the air line hose connected to the solenoid assembly c Note the location of two blue wires connected to the solenoid assembly secondary and four blue wires connected to the solenoid pressure switch assembly plasma Secondary Gas Solenoid Brass Nipple L Fitting af Pressure Switch Gas Tubing Plasma Gas d Disconnect wires e Note solenoid orientation then remove the so lenoid assembly from the 2 inch long brass nipple and set assembly aside
18. Reservoir Panel must seat in corresponding center chassis slots The four screws securing the Inductor mount ing plate to the center chassis should have a maximum of 2 to 5 threads protruding through the left side of the chassis REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES K Main Transformer T1 amp T2 Assembly Replacement NOTES There are two Main Transformers in this unit Re placement instructions are the same for both The Main Transformer s are located behind the Reservoir Panel In order to access to the Out put Inductor s the Rear Panel of the unit must be removed and the internal Reservoir Panel disen gaged and moved out of the way Remove the Left and Right Side Panels per Sec tion 5 04 A Drain the coolant from the Coolant Reservoir as follows a Remove Reservoir from Reservoir b Disconnect the CoolantSupply Hose input con nection at the Coolant Filter Assembly The hose goes from the Coolant Filter Assembly to the bottom of the Reservoir c Place the end of the hose into a container to catch the coolant as it flows from the reservoir NOTE Do Not run the pump as the coolant will gravity feed from the reservoir Disconnect the Coolant Supply Hose output con nection from the bottom of the Reservoir Disconnect the In Line Filter Assembly where it connects to the Reservoir NOTE Some residual coolant may drain from the In Line Filter It is recommended t
19. Start signal from CNC same as J24 10 Start signal return from CNC same as J24 8 OK To Move signal relay contact from plasma power supply same as J24 3 OK To Move signal relay contact from plasma power supply same as J24 1 GND Output of SC 11 Standoff Control Voltage Divider Circuit 0 to 200 vdc arc volts 0 to 12 vdc signal Manual 0 2825 A 23 APPENDIX APPENDIX 19 SYSTEM SCHEMATIC for Units to Rev 1 2 3 4 5 TS 1601 1591 1 sn 59 12 J5 1551 1557 H L se 2 D47 AC OK 4 Psi 5 ser FT LOGIC CONTROL PCB A po s 62 19X1488 4 5011 52 565 CURRENT SENSE PLASMA L 1541 12 4 RELAY 1 521 5012 peu PREFLOW sw3 1 2 5 SECONDARY ON ON gt 28 eb 8 ji OFF ON 2 7 1551 165 ON OFF 3 3 16 152 M OFF OFF 4 ta 1891 1691 925 START 2 INRUSH 1881 4
20. 2 years from date of sale to an authorized distributor and a maximum of one 1 year from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below Parts XL Plus amp Parts Parts PAK Units Power Supplies CutMaster Series Cougar Drag Gun Others Labor Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year All Other Circuits And Components Including 1 Year 1 Year 1 Year 1 Year But Not Limited To Starting Circuit Contactors Relays Solenoids Pumps Power Switching Semi Conductors Consoles Control Equipment Heat 1 Year 1 Year 1 Year Exchanges And Accessory Equipment Torch And Leads Maximizer 300 Torch 1 Year 1 Year SureLok Torches 1 Year 1 Year 1 Year Other Torches 180 Days 180 Days 180 Days 180 Days Repair Replacement Parts 90 Days 90 Days 90 Days None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repair facility within thirty 30 days of the repair 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 Eff
21. SPST SW2 ON OFF ROCKER SWITCH DPST SW1 KNOB CURRENT CONTROL FOAM SEAL ASSEMBLY ACCESS PANEL w Overlay DZUS STUD DZUS RETAINING RING POT PROTECTION KIT includes Handles Screws Star Washers A 02368 6 3 Catalog 9 8004 9 1042 8 3258 9 8007 9 7821 9 4346 9 4347 7 7575 PARTS LISTS 6 05 Left Side Center Chassis Replacement Parts Item N ON D VI 10 Qty Ne ON Description FUSEBLOCK FUSE 5 AMP 600V DELAY FNQ R 5 INPUT PCB ASSEMBLY ASSEMBLY BRIDGE RECTIFIER 110A 3PH BRIDGE RECTIFIER 110A 3PH THERMALPAD INPUT MODULE THERMOSTAT CLOSES 80c RISING CONTACTOR 4 POLE 40 FLA 120 VAC In Rush Contactor LOGIC PCB ASSEMBLY GATE DRIVE PCB FET HEATSINK ASSEMBLY KIT includes FET HEATSINK ASSEMBLY MAIN CONTACTOR Location on current units The following parts are not shown PARTS LISTS 1 1 1 CABLE ASS Y 10 CIR RIBBON 15 LG CABLE 3 CIRCUIT CABLE ASSY 20 CIRCUIT RIBBON 20 LONG 6 4 Ref Fl 52 INR Catalog 9 5562 10 2274 9 7813 9 7824 9 7800 9 7895 9 7507 9 7812 9 7811 9 7015 9 1244 9 5922 9 7509 9 7804 Manual 0 2825 A 02274 Manual 0 2825 6 5 PARTS LISTS 6 06 Right Side Center Chassis Replacement Parts Item O amp
22. 2 115 Return to Plasma Solenoid 18 3 36 VAC to ON OFF Switch J2 3 Not Used J3 4 36 from ON OFF Switch J2 4 115 VAC to Main Contactor J3 5 RUN SET Switch on Front Panel 12V signal J2 5 Not Used J3 6 RUN SET Switch on Front Panel Return J2 6 115 VAC to Secondary Solenoid 3 7 Main Current Control Signal High 10 J2 7 Not Used J3 8 Main Current Control Pot Wiper J2 8 Not Used 18 9 Current Control Pot Low J2 9 Pressure Switch 12 vdc Signal J2 10 Pressure Switch Return APPENDIX 4 Manual 0 2825 J3 10 J3 11 J3 12 J3 13 J3 14 J3 15 J3 16 J4 1 J4 2 J4 3 J4 4 J4 5 J4 6 J4 7 J4 8 J4 9 J4 10 J4 11 J4 12 J4 13 J4 14 J4 15 J4 16 J4 17 J4 18 J4 19 1 2 3 4 J5 5 J5 6 J5 7 J5 8 J5 9 J5 10 J5 11 J5 12 J5 13 J5 14 J5 15 J5 16 J5 17 J5 18 J5 19 J5 20 J5 21 Manual 0 2825 12 vdc Active Low Signal for AC Indicator on Front Panel J14 5 Active Low Signal for GAS Indicator on Front Panel J14 6 Active Low Signal for TEMP Indicator on Front Panel J14 7 Active Low Signal for DC Indicator on Front Panel J14 8 Not Used Not Used 36 VAC b from Gate Driver PC Board J9 1 36 VAC a to Gate Drive PC Board J9 2 36 VAC a from Gate Drive PC Board J9 3 36 VAC b to Gate Drive PC Board J9 4 36 VAC CT Return PC Board Common Transfer Mod Enable Return 36 VAC CT Return PC Board Common Active Low Transfer Mod Enable Signal Return for Temp Switch
23. 3 m 460VAC 6AWG 10 ft 3 m B High Pressure Regulators High pressure regulators are available for air nitro gen and argon hydrogen The regulators are used to set proper pressure for the type of gas being used C 575V Transformer This 575 VAC to 460 VAC Step down Transformer al lows the Power Supply to operate on 575 VAC three phase input power D Standoff Control SC11 Optional Standoff Control automatically finds height and maintains torch standoff with a high speed torch lifter motor Refer to Standoff Control SC11 Manual 0 2556 for more information E Remote Pendant Control Control used to manually start and stop cutting op erations from a location up to 20 ft 6 1 m from the Plasma Power Supply 3 3 DESCRIPTION 2 05 Theory Operation Plasma Arc Cutting Gouging Plasma is a gas which is heated to an extremely high tem perature and ionized so that it becomes electrically con ductive The plasma arc cutting process uses this plasma gas to transfer an electric arc to a workpiece The metal to be cut is melted by the intense heat of the arc and then blown away by the flow of gas With a simple change of torch parts the system can also be used for plasma arc gouging Plasma arc gouging uses the same process to remove material to a controlled depth and width B Input and Output Power The unit converts AC input power to DC power for the main cutting arc The negative out
24. 36 b from Logic PC Board J4 1 19 2 36 a from Logic PC Board 4 2 19 3 36 from Logic PC Board 4 3 19 4 36 b from Logic PC Board J4 4 19 5 36 VAC CT Return from Logic PC Board J4 5 19 6 Return for Transfer Enable Jo 7 36 VAC CT Return from Logic PC Board J4 7 19 8 Active Low Transfer Enable Signal J9 9 Active Low Over Temperature Sense from FET PC Boards to Logic PC Board J4 9 19 0 Over Temperature Sense from FET PC Boards to Logic PC Board J4 10 19 1 Return for Master Enable Signal to Logic PC Board J4 11 J9 12 Active Low Master Enable Signal from Logic PC Board J4 12 19 3 Return for Pilot Enable Signal to Logic PC Board J4 13 J9 14 Active Low Pilot Enable Signal from Logic PC Board 14 19 55 Return for PSR Signal from Logic PC Board J4 15 19 6 Active Low PSR Signal to Logic PC Board J4 16 19 7 Return for Demand Signal to Logic PC Board J4 17 19 18 Demand Signal from Logic PC Board 18 19 9 Return for Demand Signal from Logic PC Board J4 19 10 20 Not Used TP1 Logic Ground TP2 12 vdc TP3 Active Low Transfer Mod Enable Signal 5vdc TP5 PWM Signal TP6 PWM Signal A IP7 Secondary Current Sense TP8 Primary Current Sense TP9 Active Low Reset Signal TP10 6 vdc TP11 Current Demand Signal TP12 Active Low Shutdown Signal TP13 Return for Secondary Current Sense TP14 12 vdc TP15 Active Low Pilot Enable Signal TP16
25. 9999 dl on 5 5555555 009090520 00909000 de 5 oL cz 93 52 036 ds _ e ododo 5 d 5 5 s Qu 9 5189 56 LS 9 r a en L 2 0 99 g g 0000000 0 0009000 EL a on iS 4 C2500066 D log 0800 nb 009080808 SAE suc SiS NIE Bo oo 2 173 5 ro 595 ae WE OS fies e 0 Lo 99555559 655 0000 DOO O gt 5 alo 20 of Loo Lo Olojo Ino lo 9 9n 9 5 zu og OO 0 020709050 00 lil 20 bb 58 0o u o o lob ngo 6 80 05050 0 1 FE 02310 Logic Board D31 Un 5 25 Logic Board Signals J2 11 Over Temp Sw Input Bridge Pilot Bd Radiator 12V J2 12 Over Temp Sw Input Bridge Pilot Bd Radiator Return 1 1 36 VAC from Auxiliary Transformer 2 13 Not Used 1 1 2 115 from Auxiliary Transformer 2 14 Not Used 1 3 Center from Auxiliary Transformer 2 15 Not Used P y 1 4 Not Used J2 16 Not Used J1 5 36 VAC from Auxiliary Transformer J1 6 115 VAC Return from Auxiliary Transformer J3 1 36 VAC to ON OFF Switch 2 1 115 Return to Contactor 3 2 36 ON OFF Switch 2
26. Active Low Master Enable Signal D4 Power Enable Indicator D20 Reset Indicator Manual 0 2825 A 7 APPENDIX APPENDIX 6 PILOT OUTPUT PC BOARD LAYOUT AND WIRING CONNECTION DIAGRAM Pilot Output PC Board o O PSI TE ci T tO 05 54 9 O E 0 O Ole 0 0 69 o al m E E ps TP5 00000000 O 19 r d PIND olo TP8 ED TP2 Fete S D GND TP6 4 o o E EI 3 TP3 i D D H 24 TP1 emen Ez il E ES D e 5 bd inei lo 2000000 B Fe j O 0 0 02 o lo ob Doooooo mo 2 cs O Fi O ojo OOOO PILOT OUTRUT ASS Y 24 POR 12 CIS OO OD 5 PS J13 Tp7 J12 Pilot
27. FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Govern ment Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCU PATION AND EDUCATIONAL EYE AND FACE PRO TECTION obtainable from American National Stan dards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the Ameri can National Standards Institute 1430 Broadway New York NY 10018 Date November 15 2004 6 ANSIStandard 749 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American NationalStandards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CON TAINERS WHICH HAVE HELD COMBUSTIBLES ob tainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 9 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Associa tion Batterymarch Park Quincy MA 02269 10 Standard 51B CUTTING AND WELDING CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDE
28. J24 4 24 5 24 6 7 J24 8 J24 9 J24 10 J24 11 J24 12 J24 13 J24 14 J24 15 J24 16 J24 17 J24 18 TB1 1 TB1 2 TB1 3 TB1 4 TB1 5 TB1 6 1 2 Signals Bias Power From Plasma Power Supply Negative Arc voltage input form plasma power supply Not Used Not Used Positive arc voltage system common connection work lead Printed Circuit Board PCB power supply common Printed Circuit Board PCB power supply 24 36 VAC C T or 20 24 vdc Printed Circuit Board PCB power supply 24 36 VAC C T or 20 24 vdc Start signal from CNC Start signal return Not Used Circuit common connection for SC11 Standoff Control Spare Not Used OK To Move relay contact in plasma power supply Not Used OK To Move relay contact in plasma power supply Signals To and From CNC OK To Move to CNC relay contact in plasma power supply Not Used OK To Move to CNC relay contact in plasma power supply Not Used Spare Circuit common connection to SC 11 Standoff Control Not Used Start signal return from CNC Not Used Start signal from CNC Not Used Arc voltage signal to SC 11 Standoff Control Not Used Arc voltage signal rtn to SC 11 Standoff Control Not Used Arc voltage Positive with 100K series resistor Not Used Arc voltage Negative with 100K series resistor ARC Volts Positive w ith 100K series resistor same as J24 16 ARC Volts Negative with 100K series resistor same as J24 18
29. Manual 0 2825 10 f Note solenoid pressure switch orientation then remove the solenoid pressure switch as sembly from the 2 inch brass nipple and set aside g Remove the four screws securing each regula tor to the rear panel and remove Regulators Remove reservoir cap from the reservoir Disconnect the following input power cable wires from Main Contactor L1 L2 amp L3 Ground connection to base panel Remove strain relief from rear panel Disconnect the two wiring connectors at J23 and 24 from the Filter Divider PC Board If wiring is connected to then remove the from the PC Board The terminal block is plugged into a socket on the Filter Voltage Divider PC Board Remove the Filter Voltage Divider PC Board from the Rear Panel Remove rear panel from unit by completing the following a Remove the two screws on near bottom of rear panel securing the panel to the base of the unit b Remove the two nuts and washers on the in side of rear panel connecting the panel to the center chassis c Remove screw located in the center of the rear panel securing the rear panel to the frame d Carefully lift the rear panel up over the reser voir and away from the power supply Install the replacement rear panel by reversing the above procedure C Pressure Switch PS1 Replacement 1 2 Remove the Right Side Panel per Section 5 04 A Disconnect the two wires connected t
30. ON OFF switch to OFF RESULT All indicators off Power supply fans off A 2 ACTION RUN SET switch to RUN RESULT Gas flow stops GAS indicator off ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc automatically restarts ACTION Torch moved within transfer distance of workpiece RESULT Main arc transfer Pilot arc off ACTION Open external disconnect RESULT No power to system A 02324 Manual 0 2825 APPENDIX 3 POT LED BOARD LAYOUT J14 04 20000000 6 914 S C3 05 D4 9 5 O 1 7 1 LO 05 R5 D8 e R4 C4 DB soot so 77 OL RODEO ee D6 A 01206 Pot LED PC Board Signals J14 1 J14 2 J14 3 J14 4 J14 5 J14 6 J14 7 J14 8 D4 D5 D6 D7 10 vdc from Logic PC Board J3 7 Potentiometer High Current Control to Logic PC Board J3 8 Potentiometer Wiper Return for Current Control from Logic PC Board J3 9 Potentiometer Low 12 vdc from Logic PC Board J3 10 Signal for AC OK Indicator to Logic PC Board J3 11 Signal for GAS Indicator to Logic PC Board 12 Signal for TEMP Indicator to Logic PC Board J3 13 Signal for DC Indicator to Logic PC Board 14 Front Panel AC Indicator Front P
31. Power Supply Under no circumstances are field repairs to be attempted on Printed Circuits 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 GS Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or remov ing the replacement PC Board from its protective enclosure Disconnect primary power to the system before dis assembling the torch torch leads or power supply enclosure Do not operate the equipment or test equipment under power while wearing the grounding wrist strap Manual 0 2825 1 the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist 2 Unrollthe rest of the band and peel the liner from the copper foil at the opposite end 3 Attachthe copper foil to a convenient and exposed electrical ground 4 Connect the equipment primary cable ground to the same electrical ground as the wrist strap
32. Repeat steps 1 8 for each FET Assembly If the TEMP Indicator is still on go to the next step Check the Temperature Switch at the Input Bridge Diode by completing the following a Make sure power is off at the wall disconnect b Remove one connection from the Temp switch located behind the Input PC Board c Turn the unit back on e Ifthe Temp Indicator is off remove power and replace Temp Switch If the Temp Indicator is still on go to the next step Check the Pilot Output Board a Remove power then disconnect J13 on Pilot Out put Board b Turn power back on and check the TEMP Indi cator If the Indicator has gone off replace Pilot Out put PC Board e Ifthe TEMP Indicator is still on continue with the next step Unplug J2 on the Logic Board Place the ON OFF switch in the ON position e If the TEMP indicator is off replace the Tem perature Switch on the Radiator e Ifthe TEMP indicator is still on replace the Logic Board Gas Solenoid Circuit Test NOTE Refer to the Appendix Pages for PC Board layouts as required Make the following voltage checks per the circuit dia gram and replace the faulty part as required 1 Place the RUN SET Switch in the SET position and check for 115 VAC from wire 56 to wire 52 at the plasma gas Solenoid If approximately 115 VAC replace Solenoid Ifno voltage is present proceed to Step 2 Measure for 115 VAC from J2 2 to J17 3 at the
33. and new style data tags that may be encounted The old style data tag has the revision letter s at the end of the serial number The new style data tag has the revision letter s in an area marked The parts lists may include references to the revision letter s for parts that are different between revisions 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the torch Address all inquiries to your autho rized distributor Manual 0 2825 6 1 PARTS LISTS 6 03 Major External Replacement Parts Item Description Catalog 1 1 RIGHT PANEL W LABELS 9 7819 2 1 LEFT SIDE PANEL W LABELS 9 7818 3 1 FRONT PANEL W LABELS 9 7816 4 1 REAR PANEL Refer to Section 6 08 for Parts List 5 1 TOP PANEL 9 7797 6 1 ACCESS PANEL Refer to Section 6 04 for Parts List 7 1 CABLE WORK 22 4 AWG W RING TERMINAL 9 7792 8 1 BOOT RUBBER 9 4210 The following is not shown 1 Torch Coolant 1 gal 3 78 liters Extra Cool Coolantfor Ambient Temperatures to 10 F 12 C 7 3580 Ultra Cool Coolant Ambient Temperatures to 27 F 33 C 7 3581 A 02273 PARTS LISTS 6 2 Manual 0 2825 6 04 Access Panel Replacement Parts Item 1 1 2 1 3 1 4 1 5 1 6 2 7 2 8 1 2 2 2 Manual 0 2825 Description Ref ASS Y POT LED PCB SWITCH ROCKER
34. chart Connection Description of Cable Ribbon Cable from di FET Heatsink Assembly Ribbon Cable from FET Heatsink Assembly J8 Ribbon Cable from logic J9 Board at J4 to both Gate Drives at J9 Twisted 3 wire harness from J11 on top Gate Drive Board Twisted 3 wire harness J11 from J10 on bottom Gate Drive Board J10 Remove the four screws securing the Gate Drive PC Board to the four standoffs Reinstall the replacement Gate Drive PCB Assem bly by reversing the above procedure REPLACEMENT PROCEDURES FET Heatsink Assembly Replacement The FET Heatsink Assemblies are matched and balanced during production and must be replaced in pairs The four FET Heatsink Assemblies are identical and are removed in the same manner Remove the Left Side Panel per Section 5 04 A Remove the Ribbon Cable plugs at J6 on the FET Heatsink Assembly To remove the cable push down on the locking tab and pull the cable plug out of the connector Disconnect all the wire lug connections to the FET Heatsink Assembly Connection Description Main Transformer Primary Main Transformer Primary Main Transformer Secondary Output Output Main Transformer Secondary Disconnect the wiring from wire lug connections on the Capacitor PC Board at E25 and E26 terminals Remove the two screws securing the Heatsink Mounting Bracket to the chassis To remove the Mounting Bracket lift up on
35. control bulkhead and rear panel as the interface A Logic PC Board Functions NOTE Refer to Appendix 4 for Logic PC Board layout The Logic PC Board controls the timing and sequencing of thesystem Itmonitors the pressure temperature and flow interlocks and controls the gas flow in run and setmodes by turning on the plasma and secondary solenoids The Logic PC Board also controls the power on the voltage selection and prepurge functions After the ON OFF switch is closed on the front panel the AC Indicator blinks and the GAS Indicator is ON steady The AC Indicator blinks for approximately 8 seconds then at that time it becomes steady and the inrush relay closes The GAS Indicator stays ON for approximately 20 seconds prepurge function then goes OFF and the gas stops flow ing TheSTART signal is activated by one of the following meth ods Connecting J22 3 to 22 4 at the rear panel CNC connector Connecting TB 1 pin 3 to TB 1 pin 4 on the Fil ter Voltage Divider PC Board When the START signal is activated D26 start Indi cator comes ON gas will flow for approximately 2 seconds before DC is established indicated on the front panel During this time D25 CD Enable will come ON and sends a logic signal to the CD Board which fires the spark gap and initiates the torch to pilot D25 should go OFF immediately if the pilot starts immediately When the torch is close to the workpiece the cutting arc tra
36. coolant as it flows from the reservoir Drain enough coolant so that the coolant level is below the Flow Switch Assembly connection to the reservoir tank NOTE Do Not run the pump as the coolant will gravity feed from the reservoir 3 Remove the hose connected to the bottom of the 3 Detach red wires at top end of Flow Switch where In Line Coolant Filter Assembly they connect to wire harness NOTE 4 DisconnectIn Line Filter from the bottom of Flow Some residual coolant will drain from the In Line Filter It is recommended that a bucket rag or tow els be placed below the hose prior to removing Switch Assembly NOTE Some residual coolant will drain from the In Line 4 Remove bowlon In Line Coolant Filter Filter It is recommended that a rag or towels be placed below the hose prior to removing 5 Remove filter body from Flow Switch 2 5 Remove fitting from bottom end of Flow Switch 6 Remove fittings from filter body Assembly 7 Install the replacement In Line Coolant Filter As 6 Disconnect Flow Switch from Reservoirand re sembly by reversing the above procedure move Switch from unit NOTE 7 Install the replacement Flow Switch Assembly by Use thread sealant on all the pipe threads when reversing the above steps keeping in mind the reinstalling following 8 Refill the Coolant Reservoir with the coolant re a The Flow Switch Assembly should be installed moved or add fresh Thermal Arc Torch Coolant ata slight ang
37. defective assembly using the following format X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Check Remedy Text Type a Locate your symptom in the appropriate sub section b Check the causes easiest listed first for the symptom c Checkthe remedies listed for each cause 3 Repair as needed being sure to verify that unitis fully operational after any repairs NOTES Many signals are transferred between Printed Cir cuit Board Assemblies on Ribbon Cables If these cables become faulty they can then cause various problems Do not forget about these cables when troubleshooting While troubleshooting visually inspect the internal components for signs of overheating fractures and damage Manual 0 2825 4 06 Circuit Fault Isolation This section is used before troubleshooting to help isolate the defective circuit identify symptoms and test the unit for proper operation NOTE Follow all instructions as listed and complete each in the order presented Follow the instructions as given to identify 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 Initial Setup Conditions Connect gas supply to rear of Power Supply Turnon gas supply and adjust the Plasma Gas Regulator to 65 psi 4 5 bar and the Secondary Gas Regulator to 60 psi 4 1 bar Set the Power Sup
38. manual provides advanced troubleshooting and parts replacement not covered in the basic troubleshoot ing section of the Operating Manual In most cases it requires Power Supply disassembly and live measure ments Troubleshooting and repair of this unitis a process which should be undertaken only by those familiar with high voltage high power electronic equipment If major complex subassemblies are faulty the faulty sub assembly must be returned for repair NOTE Follow all instructions as listed and complete each in the order presented Subsection 4 09 includes specific test procedures and LED status identification tables The subsection is referenced by the troubleshooting guide for the specific test to be performed SERVICE 4 6 The troubleshooting guide has six subsections as follows Section 4 06 Circuit Fault Isolation Section 4 07 Main Input and Internal Power Prob lems Section 4 08 Pilot Arc Problems Section 4 09 Main Arc Problems Section 4 10 Test Procedures C How to Use the Troubleshooting Guide The following information is a guide to help the Service Technician determine the most likely causes for various symptoms This guideisset up in the following manner 1 Perform operational check s on the equipment to iso late problem to possible circuit s per Section 4 06 Cir cuit Fault Isolation Refer to the Appendix Pages for PC Board layouts as necessary 2 Determine symptom and isolate to
39. motor connector Manual 0 2825 4 15 H Temperature Circuit Test The Power Supply has seven temperature sensing switches Oneon each FET Heatsink Assembly four total One located behind the Input Board near the Input Bridge Diode Oneon the Pilot Output Heatsink Oneon the Radiator If any one of these sense over temperature the Overtemp Indicator on the Access Panel will light and not allow DC output NOTE Refer to the Appendix Pages for PC Board Lay outs Test the temperature circuit as follows 1 Place the front panel ON OFF switch to the OFF position 2 Disconnect ribbon cable from the FET Heatsink Assembly at J6 A 01410 FET Heatsink and Capacitor PC Board Assembly J6 3 Placethe front panel ON OFF switch to ON 4 Checkthestatus of the TEMP indicator a Ifindicator has gone OFF then remove power and replace the corresponding pair of FET Heatsink Assemblies The FET Heatsink Assemblies are matched and balanced during production and must be replaced in pairs b Iftheindicator is still on goto the next step SERVICE 10 11 12 13 SERVICE Place the front panel ON OFF switch to the OFF position Disconnect ribbon cable from the next FET Heat sink Assembly at J6 Place the front panel ON OFF switch to ON Check status of the TEMP Indicator If Indicator is OFF remove power and replace the corresponding pair of FET Heatsink Assemblies
40. ni to ES Joos cus 2500 82300 55 OOD 9 2 4 o mE s 5 p ud no 01301 LE FE m OR25 012 013 016 017 12 oso 012 ug O 0 12 E13C o 1 1 1 y i O R ues 23023 R2004 o ORS 18 of 0 4 oE o OLS oq O O O Olas O 015 O opta 00 0 e So R34 OL 5 OT FOR40 01 02 of 1 0000000009 Component Side Of PC Board E16 E18 E14 0 0000 0000000000 FET PCB ASSY Solder Side Of PC Board E18 12 Manual 0 2825 FET Board Signals Upper Lower Assemblies J6 1 16 2 76 3 16 4 16 5 16 6 16 7 16 8 16 9 16 10 1 14 1 16 17 18 19 12 vdc from the Gate Drive Board upper J7 1 Lower J8 1 12 vdc RTN from the Gate Drive Board upper J7 2 Lower J8 2 PWM Output from the Gate Drive Board upper J7 3 Lower 8 3 PWM Output RTN J6 2 from the Gate Drive Board upper J7 4 Lower J8 4 PRI CURRENT SENSE to the Gate Drive Board upper J7 5 Lower J8 5 PRI CURRENT SENSE RTN to the Gate Drive Board upper J7 6 Lower J8 6 SEC CURRENT SENSE to the Gate Drive Board upper J7 7 Lower J8 7 SEC CURRENT SENSE RTN to the Gate Drive Board upper J7 8 Lower J8 8 OVER TEMP RTN t
41. producing the high voltage spark which starts the DC pilot arc When a pilot arc is sensed by the Gate Drive Board the PSR signal shuts off the CD enable SERVICE Gate Drive Board Functions NOTE Refer to Appendix 5 for Gate Drive PC Board lay out This board controls the amount of time the FETs are turned on This is done with a pulse width modulator PWM controlled by the demand signal from the Logic PC Board The longer the FETs are on the more output current If a short develops the primary overcurrent will shut down the gatedriveand notallow the power supply to power up and run The PSR signal senses any current in the secondary and determines what the PWM should do for a pulse width If there is current in the secondary the PSR signal will go back to the Logic PC Board and shut off the CD Enable signal Gate Drive PC Boards Meaning Power Enable When ON PWM 04 Enable received from the Logic PC Board Reset Normally ON goes out when torch switch is pressed Indicator will blink if primary over current is detected when torch switch is pressed D Pilot Output PC Board Functions NOTE Refer to Appendix 6 for Pilot Output PC Board layout This board has an IGBT which is turned on by the Logic Board for piloting This allows the DC to flow from the output through the pilot return tip to a Pilot Inductor and finally to the work This path is broken very quickly by the IGBT when th
42. produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res com bustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou in flammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail Procurez une bonne a ration de toutes les fum es inflammables ou explosives coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul exploserasi enflamm Date November 15 2004 RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infrarouge et des rayons ultra violets tr s forts Ces rayons d arc nuiront vos yeux etbr leront votre peau si vousne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de
43. sizes are based on flexible power cable with power plug installations For hard wired installations refer to local or national codes Cable conductor temperature used is 167 F 75 C An energy limiting fuse UL Class RK 1 examples BUSS LPS LPN RK or Gould Shawmut AZK A6K should be used to minimize damage to Plasma Cutting Welding or power distribution equipment NEVER use replaceable element fuses like UL Class H or one time fuses like UL Class 5 Manual 0 2825 1 APPENDIX APPENDIX 2 SEQUENCE OPERATION BLOCK DIAGRAM ACTION Close external disconnect switch ACTION ON OFF switch to ON RESULT RESULT AC indicator blinks for 8 seconds then steady on Fans on Power circuit ready Power to system ACTION Protect eyes and activate torch RESULT Gas flows 2 seconds After gas pre flow DC indicator on Pilot arc established ACTION Torch deactivated by torch switch release or by remote device RESULT Main arc stops Power supply enable signal removed Gas flows 15 seconds NOTE If torch is activated during post flow pilot arc will immediately restart If torch is within transfer distance 3 8 in of workpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off APPENDIX ACTION RUN SET switch to SET RESULT Gas solenoid open gas flows to set pressure GAS indicator on PILOT ARC ACTION
44. the Gate Drive PC Board If LED D20 does turn off D4 should flash on off once two seconds later fD4does not flash on off once measure for 12 vdcto drop to less than 2 vdc momentarily between J9 14 to J9 13 on the top Gate Drive PC Board Ifthe voltage does not drop momentarily then replace the Logic PC Board e Ifthe voltage does drop momentarily re place the Gate Drive PC Board e If D4 on the Gate PC Board does flash for two seconds after D20 turns off then go to the next step 5 Faulty Torch or Leads see note above a Remove wire 15 from Pilot Output PC Board ter minal E24 b Following the procedure detailed in 4 10 K 1 mea sure the output voltage at the FET Heatsink As sembly between E 17 amp E 18 If voltage is okay with wires disconnected repair or replace torch leads as required 6 Faulty Output Pilot PC Board see note above a Test per section 4 10 T repair as necessary b Disconnectand isolate wires from E8 on Pilot Out put PC Board c Following the procedure detailed in 4 10 K 1 mea sure the output voltage at the FET Heatsink as sembly between E 17 amp E 18 If voltage is okay with wires disconnected replace Output Pilot PC Board 7 Faulty FET PC Board a Check per section 4 10 K Repair or replace as necessary Manual 0 2825 B ACindicator ON Gas flows GAS indicator ON DC indicator blinks Small arc may be visible in torch 1 Shorted torch a Re
45. the top FET Heatsink Assembly and push down on the bottom FET Heatsink Assembly in the middle where the two FET Heatsink Assemblies come together Slide the FET Heatsink Assembly out and up to remove the FET Heatsink Assembly from the unit NOTE FET Heatsink Assemblies must be replaced in pairs per the following illustration Manual 0 2825 5 Install the replacement Main Contactor Assembly by reversing the above steps connecting wires as follows a Connect ground wire as shown Replace As a gt Pair lt gt gt Y AN Replace As Pair lt lt A 02584 A 02291 Main 8 Install the replacement FET Heatsink Assembly by Harness reversing the above procedure Ground NOTE b Attach main harness wires 55 and 59 to the Be sure that the top groove in the FET Heatsink coil of the Contactor Assembly is properly seated over the cutout in the chassis Main Contactor L3 J Main Contactor W Assembly Replacement MC1 NOTE 1 Coil The Main Contactor was located in the Base on Wire 55 earlier units and on the Center Chassis for current units 1 Remove the Left Side Panel per Section 5 04 A 2 Note orientation of the Main Contactor and loca tion of all wires and cables connected to the Contactor Assembly 3 Disconnect wires and cables at Main Contactor Wire 59 01195 4 Remove the two nuts securing the Contactor As sembly to the two mounting studs in the unit c Attach the
46. two FET Heatsink Assemblies 1 No DC Output An open circuit voltage of approximately 280 to 325 vdc depending on input power selected is produced when switching transistors in the FET Heatsink As semblies are turned ON by a PWM Enable signal from the Logic PC Board A circuit on the Logic PC Board monitors the output voltage When the output volt age drops below 60 vdc indicating a problem exists the Logic PC Board sends a signal which turns OFF the PWM Enable signal to the Gate Drive PC Board Because this happens in less than 50 milliseconds it is not easy to take voltage readings to find the source of the problem When the unit is at idle the OK indicator D47 should be ON The Torch Switch Enable indicator D26 turns ON when the torch switch is pressed At this point the gas begins to flow When the preflow time is over the PWM Enable signal is given and the DC indicator at the front panel turns ON Manual 0 2825 2 4 17 If the front panel DC Indicator turns ON then OFF im mediately the following test should be performed a Disconnect 11 from the CD PC Board to disable the CD signal b Connect a jumper between TP1 and TP8 on Logic PC Board This will cause the gas to flow continuously and the DC Indicator on the front panel to turn ON Connector J11 on the CD PC Board must be discon nected to preoent electrical damage to measuring equipment when testing the open circuit voltage OCV
47. 0 Ibs 158 8 kg 16 Used With Torch PCM 120 Automated Machine Torch Manual 0 2825 Gas Regulator Filter Assembly Specifications The following specifications apply to the Gas Regulator Filter Assembly only 1 Gas Regulator Maximum Gauge Pressure Plasma 160 psi 11 3 bar Secondary 160 psi 11 3 bar 2 Maximum Input Gas Pressure 125 psi 8 6 bar 3 Filter Coalescent type filter C Gas Requirements 1 Plasma Gases Compressed Air Nitrogen Argon Hydrogen Operating Pressure 65 psi 4 5 bar Cold Flow Cutting 50 78 scfh 23 6 36 8 Ipm Gouging 85 95 scfh 40 1 44 8 Ipm CAUTION Maximum input gas pressure must not exceed 125 psi 8 6 bar 2 Secondary Gases Compressed Air Carbon Dioxide Ni trogen Operating Pressure 60 psi 4 1 bar Cold Flow Cutting 340 scfh 160 4 Ipm Gouging 235 scfh 110 9 Ipm CAUTION Maximum input gas pressure must not exceed 125 psi 8 6 bar D Two Stage Air Line Filter The Two Stage Air Line Filter will remove moisture and contaminants from the air stream when using compressed air The filter is capable of filtering to at least 5 microns Manual 0 2825 3 04 Power Supply Options and Accessories The following accessories are available for the Power Supply Refer to Section 6 Parts Lists for part numbers and ordering information A Primary Input Power Cable The following input power cables are available e 230VAC 10 ft
48. 10 50 60Hz Three Phase 5 Refer to Appendix 1 for suggested input wiring size current ratings and circuit protection require ments Units using 575 VAC input power require instal lation of Optional 575V Transformer Assembly 5 Output Power Continuously variable from 30 to 120 amps 5 6 Duty Cycle 60 128 vdc output at 120 amps DESCRIPTION 3 2 7 CutCapacity on Carbon Steel Genuine Cut Capacity 1 1 2 inch 38 mm Severance Cut 1 3 4 inch 44 mm Pierce Rating 5 8 inch 15 9 mm 8 Pilot Circuitry Capacitive Discharge CD Pulsed DC 9 CNC Interface Signals Start Stop OK To Move and Arc Voltage 10 Coolant Pressure Internal Service Adjustable Factory Only 130 psi 8 8 bar at zero flow 120 125 psi 8 2 8 5 bar at 0 6 gpm 2 3 Ipm 11 Coolant Flow Rate 0 5 gpm 1 9 Ipm with 150 feet 45 7 m of total torch and torch leads at 70 F 21 C NOTE The flow rate varies with lead length torch con figuration ambient temperature amperage level etc 12 Cooling Capacity 4 000 to 10 000 BTU NOTE Maximum value based on free flow condition 13 Coolant Reservoir Capacity 2 gallons Use Thermal Arc coolant only Capable of handling a total of 150 feet 45 7 m of torch lead length 14 Overall Dimensions Height 45 3 8 inches 1 2 m Width 24 1 2 in 0 6 m Depth 35 inches 0 9 m 15 Weight Power Supply with Torch 275 lbs 125 kg Shipping Weight 35
49. 2 L3 T3 If any test has resistance then replace the Main Contactor also Manual 0 2825 E Main 1 Test Reconnect power and observe proper start up procedure Indicator D47 on the Logic PC Board should be ON If indicator D47 is OFF there is no voltage to the Power Sup ply or an overvoltage condition exists If indicator D47 is OFF check L1 L2 and L3 for proper AC input voltage Main Contactor MC1 L3 L1 Coil Wire 55 Ratios Wire 59 Measure voltage on coil of contactor approximately 115 VAC between wires 55 and 59 If voltage is correct replace Main Contactor If voltage is incorrect replace Logic PC Board NOTE The Main Contactor was located in the Base on ear lier units and on the Center Chassis for current units F Inrush Relay Test If after approximately 8 seconds the Inrush Relay does not engage measure for 115VAC on wires 68 and 69 If there is voltage replace Contactor If there is no voltage measure at Logic Board J17 4 to J17 8 If there is no volt age at the Logic Board replace Logic Board G Blown Fuse F1 Test 1 The voltage selector set to the wrong input volt age will cause F1 to fail a Verify input voltage with Voltage Selector 2 Ashorted or frozen pump motor will cause F1 to fail To check the motor a Replace F1 fuse and unplug J32 b Turn power on if fuse is okay Checkmotor connections e Check voltage to
50. 20 30 a e VZD 14 68 1431 17 voc ESTA 200v A MT EET Sl 1 PS 361 il ito 12V 92 B 4 1615 scu Tp VOLTS 1371 7 lt gt gt 7l 14 ARC Q Q 38i M 6 94 941 4 m 721 F STAR 1421 i m 1931 CENE af 73 in series m gt 12 gt ue JETAGE E 15 7 120 1201114 3 1741 12 ss 15 36vACa a cu 1211 16 NI 1771 414108 TO MOVE 2 lt 13 ENABLE 731 us 2 4 163 f 391 4 T 7 171 160 28 oy 5 161 25 1 21 12V 1851 5 B 23 En 23 PILOT OUTPUT 105 126 m r 19x1479 A 28 3 OPTIONAL USED w nnannnannanananannan 3 UUUUUUUUUUUUUUUUUUUH ST D5 a 125 PILOT eso Torch Oniy OGND p esa K 22 7 amp B RIBBON CABLE uzi 1621 1 12 COMMON L3 mm 183117 2 COMMON 7 SECONDARY LI IND PILOT IND INDUCTOR 12 SHIELDED HAND 3 FET BATE DRIVE CURRENT 816 zn TORCHES ONLY 4 COMMON 8 9 COMMON 5 PRI CURRENT SIG 18 o SHIELD STUD E25 C gt 8 5 E26 T 6 x CAP BOARD 19X1257 FET MODULE ENABLE P 7k 19x1256 r 20 RESET gt 8 25 e H t t t A IT 123 CAP BOARD 19X1257 FET MODULE D 19X1256 121 021 L2 OUTPUT INDUCTOR 1815 E25 E12 P dede dde CT on 191 5 2 CAP BOARD 19X1257 FET MODULE Oh _19x1256 E
51. 2STAGE FIRST STAGE FILTER REPLACEMENT SECOND STAGE FILTER REPLACEMENT BRKT FILTER MOUNTING 10 32 x 1 1 8 PPH Screw 1 4 NPT STREET ELBOW Adapter Fitting Barb NOTE Part can be purchased locally PARTS LISTS 6 10 Catalog 9 7822 9 1044 8 3370 9 7514 9 1045 9 5804 9 7589 9 3743 9 2034 9 3164 9 2391 9 7524 9 2023 9 2184 9 2186 9 4595 8 3360 8 0330 8 6465 9 7527 9 1021 9 1022 9 7535 See Note 9 2184 8 4264 Manual 0 2825 02930 PARTS LISTS 6 11 Manual 0 2825 6 09 Options Accessories PARTS LISTS Description 575V Transformer Module Primary Input Power Cable 10 ft 3 05 m 230VAC 2AWG 4 COND 600V 460VAC 6AWG 4 COND 600V Y Hose Assembly Kit Locking Caster Kit 2 Casters Remote Pendant Control 20 ft 6 1 m 6 12 Catalog 9 7700 9 7697 9 7696 9 7827 9 7868 7 3460 Manual 0 2825 APPENDIX 1 INPUT WIRING REQUIREMENTS _____ _____ Power Input Volts Hz Amps 3 Ph 3 Ph 3 Ph 208 78 220 75 230 74 240 72 380 44 415 41 460 37 Requires Transformer Module Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated based on the Duty Cycle of the equipment The suggested
52. 4 INRUSH 8 1871 2 3 zl 67 158 5 4 COOLANT DRAG s 58 ee 2 ran 7 166 154 21 157 J96 1 FAN 281 154 1531 4 185 NOT USED FOR 15 XL 3 120 SOME EARLY UNITS HAD OK TO MOVE J17 Lan J95 amp J97 CONNECTED 157 295 RIN TO I20VAC ALSO NOT USED 12 unc ds 2 lt L F 120 VAC 188 s B ME 2 198 15 REMOVED FROM LATER UNITS 7 6 128 JI 13 1861 JBE 1235 6 1 2345 6 7 B S 18 12 13 14 14 1 3 1 1871 1821 35 28 433 333 _ RIBBON 2 1 ORANGE 432 41 a 8 CABLE 238 I Ed FSI ORANGE J323 9 Su F2 men MAL un BROWN 468 BLUE 721 ORANGE 5 NP OEF 2 3BVACA BLACK 228 V VETUS 38 2 9 mti 3 L av 128Y C 1751 4 23112 sais WHITE YELLOW 92828 5 7 COMMON TXF MOD toss T dai AUX TRANSFORMER VOLTAGE CONTROL ENABLE E 1901 2202 242 228 388 415 V UNITS HAVE TENER BA ONLY J31 A amp B ACCESSIBLE LED oc 12 1881 380 415V JIB 238 468 V UNITS HAVE ONLY 19X1604 COMMON 118 8 1 amp ACCESSIBLE 12 MASTER 89 468V J18 C 13 COMMON W PEET TAREE GATE 15 COMMON DRIVE 16 PSR a PCB 17 COMMON m 18X1487 18 DEMAND 181 19 COMMON TOP INPUT PCB 2 Fi 19X1497 M 161 ui dE 225 BE
53. 5 Open the equipment enclosure see instruction manual for the appropriate equipment and re move the failed PC Board 6 Carefully open the ESD protective bag and remove the replacement PC Board 7 Install the replacement PC Board in the equipment and make all necessary connections 8 Place the failed PC Board in the ESD protective bag and seal for return shipping 9 Reassemble the equipment enclosure see instruc tion manual for the appropriate equipment 10 Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equipment 5 03 Parts Replacement General Information The parts replacement procedures described in this manual require that the Power Supply be disassembled The part to be replaced will determine to what extent the Power Supply must be disassembled Before disassembling any part of the Power Supply first read the procedure for the part to be replaced then pro ceed with the disassembly NOTES Before removing any electrical connection mark each wire with the connection designation When reassembling this makes sure the wires go to the proper terminals Note the routing of wires and make sure the wires are put back in the same place when reassembling the unit Turn OFF all gas inputs to the Power Supply at the source before disconnecting any gas Hose As semblies 5 1 REPLACEMENT PROCEDURES Each Subsection is referenced
54. 868 2 3 4 5 APPENDIX A 24 Manual 0 2825 RI uai ARC VOLTS XE 1481 1 S CURRENT res CD ENABLE 1461 iE CN SENSE in series h 8f CNC INTERFACE THIGOOOOO CONNECTOR 38 VACa 1471 T gt PSI I 1898 7281 _ FILTER VOLTAGE 722 181 12 FpivipER PCB 124 821 Z 491 es N 2 mag 9x7 18 166 i CD PCB i gt 3 188 3 um 5 1871 18 1522 PCR 144
55. Active Low Over Temp Signal Return for Master Enable Signal Active Low Master Enable Signal Return for Pilot Enable Active Low Pilot Enable Signal Return for PSR Signal Active Low PSR Signal Return for Demand Signal Demand Signal Return for Demand Signal 36 VAC b to CD PC Board 36 VAC CT Return to CD PC Board 36 VAC a to CD PC Board Active Low CD Enable Signal CD Enable Return Active Low Pilot Signal to Pilot Output Board Pilot Signal Return Active Low Torch Switch Signal Torch Switch Return Not Used Wire to J28 1 Not Used PS Not Used Drag Sensing Signal Voltage Tip Volts Not Used PS 36 VAC a to Pilot Output Board 36 VAC b to Pilot Output Board 36 VAC CT Return to Pilot Output Board Opt Remote Active Low ENABLE Signal Return for Optional Remote Enable Jumper 5 10 11 026 025 065 047 D31 Not Used Not Used 115VAC to Fans M3 amp M4 115VAC to Fans M1 amp M2 115VAC Fan Rtn for M3 amp M4 115VAC Fan Rtn for M1 amp M2 Not Used Not Used 115 VAC to Plasma Solenoid 115 VAC to Inrush Cont 115 VAC to Motor Cont Not Used 115 VAC Return Sec Solenoid 115 VAC Return Inrush Cont 115 VAC Return Motor Cont Not Used OK To Move Isolated Contact Closure OK To Move Isolated Contact Closure Active Low Coolant Flow Switch Signal Not Used Coolant Flow Switch Return Not Used Not Used Wire from J28 3 Active Low CSR Signal From Current Sense Boar
56. BSaeNRVRTRBRES 21 NotShown PARTS LISTS Qty H b N gt gt Description PILOT OUTPUTPCB ASSEMBLY RELAY DPST 25A MAX 120 AC Coolant Motor Relay RESISTOR INDUCTOR PILOT CD PCB ASSEMBLY COOLANTFILTER COOLANT RESERVOIR FILTER IN LINE FEMALE FLOW SWITCH ASSEMBLY 0 2 GPM MAIN TRANSFORMER OUTPUT INDUCTOR ASSEMBLY FAN 115V 50 60Hz 95 115CFMW 187 TABS ASS Y CURRENT SENSE PCB HOSE FILTER TO PUMP HOSE RADIATOR TOSMALLFILTER HOSE RESERVOIR TO FILTER ASSEMBLY CDCOIL DEIONIZER BAG DEIONIZER BASKET CAP COOLANT TANK OUTPUT INDUCTOR ASSEMBLY Field Update Kit for Units before Rev AJ Shield Return Capacitor Assembly Pilot Panel Ground Strap 6 6 Ref RLR2 FS1 T1 T2 1 Catalog 9 7809 8 3390 9 5843 9 7801 9 7814 8 4276 9 5948 8 3460 9 5937 9 7810 9 7815 8 3209 9 7602 9 7805 9 7807 9 7808 9 7825 8 3312 8 4410 8 5142 9 7872 9 8651 Manual 0 2825 Parts differ slightly from illustration NOTE PAN ZAN LS V SETZ WS A X Ze 74 px 4 px 2 29 4 L 5 PARTS LISTS 6 7 Manual 0 2825 6 07 Replacement Parts Item N PARTS LISTS Qty N H Q N N N gt Description Ref WHEEL 8 5579 AXLE SUPPORTLEG TRANSFORMER A
57. C Board to the standoffs Pilot Panel and remove Pilot Inductor from unit Install the replacement Pilot Output PC Board As 4 Install replacement Pilot Inductor by reversing the sembly by reversing the above procedure Refer to Appendix 6 for wiring connection diagram B Coolant Motor Relay MC1 Replacement Remove the Right Side Panel per Section 5 04 A NOTES Before removing any connection mark each wire with the connection designation When reassem bling this makes sure the wires 90 to the proper terminals Note the routing of wires and make sure the wires are put back in the same place when reassembling the unit above steps E CD PC Board Assembly Replacement 1 Remove the Right Side Panel per Section 5 04 A NOTES Before removing connection mark each wire with the connection designation When reassem bling this makes sure the wires go to the proper terminals Note the routing of wires and make sure the wires are put back in the same place when reassembling the unit 2 Disconnect all the wiring connections to the CD Mark all wirings connections then disconnect all PC Board Assembly the wiring connections to the Relay Assembly 3 Remove the four screws and washers securing the Remove the two screws securing the Relay Assem PC Board to the standoffs bly to the Reservoir Panel 4 Installthereplacement CD PC Board Assembly by Install the replacement Relay Assembly by revers ing the above procedure
58. ENDIX 13 RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS A 17 APPENDIX 14 TYPICAL MECHANIZED SYSTEM GROUNDING DIAGRAM A 18 APPENDIX 15 POWER SUPPLY CNC INTERFACE DIAGRAM WITHOUT STANDOFF CONTROL uu u tto nete rtv Ee dae ttr e tene tags A 19 APPENDIX 16 TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM A 20 APPENDIX 17 QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES A 21 TABLE CONTENTS Continued APPENDIX 18 FILTER VOLTAGE DIVIDER PC BOARD LAYOUT APPENDIX 19 SYSTEM SCHEMATIC for Units to Rev AH APPENDIX 20 SYSTEM SCHEMATIC for Units Rev AJ and Later 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 categorized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system CAUTION procedure which if not properly followed may cause damage to the equipment G aa F rr rs procedure which if not properly followed cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions GS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN GEROUS AND
59. ENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American Na tional Standards Institute 1430 Broadway New York NY 10018 7 Norme A6 0 del Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Pro tection contre les Incendies LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme70dela NFPA CODEELECTRIQUE NATIONAL disponible aupr s de la National Fire Protection Associa tion Batterymarch Park Quincy MA 02269 1 5 GENERAL INFORMATION 10 11 12 13 14 15 Norme 518 dela LES PROC D S DE COUPE ET DESOUDAGE disponible aupr s de la National Fire Pro tection Association Batterymarch Park Quincy MA 02269 BrochureGCAP 1 LAMANIPULATIONSANS RISQUE DESGAZ COMPRIM S EN CYLINDRES disponible aupr s del Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA22202 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Bou
60. HAZARDOUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Per sons who work near plasma arc cutting applica tions should consult their medical health profes sional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and in structions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions Date November 15 2004 1 1 amp AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any met als which may contain one or more of the follow ing Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are
61. IHERMAL DYNAMICS C A THERMADYNE Company Automated Plasma Cutting Power Supply PAK Master 150XL Service Manual November 18 2005 Manual No 0 2825 Read understand this entire Manual 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 Automated Plasma Cutting Power Supply Pak Master 150XL Service Manual Number 0 2825 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2000 by Thermal Dynamics Corporation rights reserved Reproduction of this work in whole or in part without written per mission 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 this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date November 18 2005 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial ff Torch Serial TABLE CONTENTS SECTION 1 GENERAL INFORMATION 2 aaa Lean Dus etre d
62. Logic PC Board Ifvoltage is not correct replace Logic PC Board Check for 115VAC from wire 64 to wire 65 at the secondary gas Solenoid Ifapproximately 115VAC is present replace So lenoid Ifno voltage is present proceed to step 4 Measure for 115VAC from 17 7 to J2 6 at the Logic Board If the voltage is not correct replace the Logic Board J Pilot Arc Circuit Test NOTE Refer to the Appendix Pages for PC Board Lay outs Check across E23 to E24 at the Pilot Output PC Board There should be a diode drop across E23 to E24 in one direction and an open in the other If shorted remove the wires at E23 and E24 at the Pi lot Output PC Board and check again Replace Pilot Output PC Board if shorted from E23 to E24 with wires removed 4 16 Manual 0 2825 K FET Heatsink Circuit Tests NOTE Refer to the Appendix Pages for PC Board Lay outs The FET Heatsink circuit tests require various checks to isolate the possible fault to the FET Heatsink Assembly There are several internal indicators LED s on the Logic PC Board Pilot Output PC Board and the Gate Drive PC Board to help in troubleshooting They are as fol lows NOTES The upper FET Assemblies provide the power for piloting and the main cutting arc The lower FET Assemblies are for main cutting arc only The upper Gate Drive Board controls the upper two FET Heatsink Assemblies and the lower Gate Drive Board controls the bottom
63. Logic Board as necessary AC Indicator ON GAS Indicator ON gas flows continually 1 RUN SET Switch in the SET position a PlaceSwitch in RUN position 2 Faulty Gas Solenoid s or Logic PC Board a Turn the ON OFF Switch to the OFF position e If the gas continues to flow check the air filters or replace Solenoid s Ifthe gas flow stops replace the Logic PC Board ACindicator ON Gas flows GAS and DC indica tors ON Arcin torch without activating START signal D26 START enable on Logic PC Board ON 1 Faulty Remote Pendant switch a Checkcontinuity 2 Faulty CNC Cable a Disconnect the CNC Cable from the J22 connec tor If the arc shuts off the controller is supply ing a START signal 3 Faulty Pilot Output Board a Turn unit off b Disconnect J12 and 13 from Pilot Output PC Board then check continuity at J12 pin 1 and pin3on the Pilot Output Board If shorted re place Output PC Board 4 Faulty Logic Board a Disconnect J5 connector from Logic PC Board If D26 stays on replace Logic PCB If D26 goes out check wiring to J5 connector from Pilot PC Board SERVICE 4 10 4 08 Pilot Arc Problems NOTE Refer to the Appendix Pages for PC Board Layouts Locate your symptom below A ACIndicator ON gas flows GAS Indicator ON when START signal is activated DC Indicator OFF or flashes once No spark or momentary spark at torch Measure for 320 vdc at Input PC Board between terminal E8 wir
64. Output PC Board Signals J12 1 J12 2 J12 3 J12 4 J12 5 J12 6 J12 7 J12 8 J12 9 J12 10 J12 11 J12 12 J12 13 J12 14 J12 15 J12 16 APPENDIX START Signal from 23 8 Filter Divider PC Board Shield to J26 1 START Signal from J23 9 Filter Divider PC Board Shield to J26 2 Not Used Not Used OK To Move To J23 14 Isolated Contacts from Logic PC Board OK To Move To J23 16 Isolated Contacts from Logic PC Board Enable Jumper Not Used Enable Jumper Not Used Not Used Return to J23 11 Not Used Return to J23 4 A 8 A 02311 Manual 0 2825 J13 1 J13 2 J13 3 J13 4 J13 5 J13 6 J13 7 J13 8 J13 9 J13 10 J13 11 J13 12 J13 13 J13 14 J13 15 J13 16 J13 17 J13 18 J13 19 J13 20 J13 21 J13 22 J13 23 J13 24 Twisted 3 Wire Harness Active Low START signal TP1 Ground START Signal Return TP2 15 vdc OK To Move Isolated Contacts from Logic PC Board TP3 Pilot Switch to Gate Drive PC Board OK To Move Isolated Contacts from Logic PC Board TP4 Pilot Drive Signal Ground TP5 Not Used Not Used TP6 Active Low Pilot Drive Signal Drag Voltage Sensing Tip Voltage Not Used Not Used TP8 Pilot Switch to Gate Drive PC Board PS Voltage Sensing Not Used D5 Pilot ON Indicator Enable Jumper Enable Jumper Not Used 36 VAC a from Logic PC Board 36 VAC b from Logic PC Board 36 VAC CT Common Return for Pilot Signal Active Low Pilot Signal Not Used Active Low Overtemp Signal
65. RS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELD ING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa tion 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWSF4 1 MENDED SAFE PRACTICES FOR THE PREPARA TION FOR WELDING AND CUTTING OF CONTAIN ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Hau Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations a caract re important Ces mises en relief sont classifi es comme suit Date November 15 2004 NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du systeme ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en questio
66. Return for Overtemp Signal Active Low CSR Sense Signal J98 1 Return for CSR Sense Signal J98 2 12 to Current Sense Board J98 3 Stiff CD Coil Wire Wire 13 To Resistors Output Inductor Lead Output Inductor Lead Gq Wire 17 Black Wrapped Around Wire 15 TA Wire From Transformer Wire 14 To Resistors Ground Green Wire Wire 15 Red lo From Bulkhead Wire From Transformer dp Wire 17 Black Wrapped Around Wire 15 uta O 3 lo 8000000 L 2200000 d 5000000 amp oou 5 From Current Sensor 24 12 00000000 Work Cable 1 1 1 PS PSAI A 02558 J13 J12 4 Wires 12 Red From FET Heatsink Assemblies Manual 0 2825 A 9 APPENDIX APPENDIX 7 BOARD LAYOUT TP2 TP1
67. UXILIARY 220 395 460 T3 Fuse 5A 250V Delay MDL in Torch Spare Parts Kit FAN MEDIUM PRESSURE 8 DIA MOTOR 1 3 HP 1425 1725 RPM 115 230 V 50 60HZ M5 PUMP ROTARY VANETYPE RADIATOR ASSY INCLUDES 6 GROMMETS HOSE TORCH DISCONNECT TO RADIATOR FOOT RUBBER 1 50 DIA X 0 63 HIGH 6 JIC 3 8 NPTSTRADAPTER 6 JIC 3 8 X90 DEG ADAPTER 3 8NPTCLOSENIPPLE 3 8NPTHEXHEADPLUG 3 8NPTFEMTEE 3 8NPT STREET ELBOW VALVE CHECK 3 8 NPT FEM BRASS THERMALSWITCH TS1 CLAMP PUMP V BRAND 6 8 Catalog 9 7891 9 7892 9 7802 9 8109 9 7893 9 5932A 9 6164 9 5941 9 7806 9 7894 8 0348 9 3077 9 2384 9 4583 9 2385 9 2365 9 1402 9 5967 9 5942 Manual 0 2825 4 p A 02929 Manual 0 2825 6 9 PARTS LISTS 6 08 Rear Panel Replacement Parts Item BON 18 19 20 21 Qty N Ne gt e e ON S NNN N Description Ref HANDLE WITH SCREWS PRESSURE SWITCH 35 PSI PS1 VALVE SOLENOID 1 8 NPT SOL1 SOL2 AIR REGULATOR FILTER ASSEMBLY AIR LINE REGULATOR PRESSURE GAUGE PANEL MOUNTING NUT BRACKET REGULATOR MOUNTING HOSE 1 4 NPT FEM TEET STRAIN RELIEF ONE TOUCH 90 DEG 1 8 FITTING 1 8 NPT X 2 LONG NIPPLE BRASS 1 4 1 8 NPT REDUCER 1 4 NPT STREET ELBOW NIPPLE CLOSE 1 4 NPT 1 4 NPT 1 4 NPT FEM ELBOW FITTING 1 8 NPT X 1 4 TUBE STR FITTING ADAPTER 1 4NPT INERT B R H Filter Voltage Divider PC Board FILTER AIR
68. anel TEMP Indicator Front Panel DC Indicator Front Panel GAS Indicator Manual 0 2825 A 3 APPENDIX APPENDIX 4 LOGIC BOARD LAYOUT TP1 Ground
69. anel to gain access to the rear of the RUN SET Switch 2 Disconnect all the wiring to the RUN 5 Switch 5 3 Wiring is as follows Run Set Switch wire 31 02284 Squeeze the top and bottom of the switch while pulling it out of the Access Panel Install the replacement RUN SET Switch by re versing the above procedure REPLACEMENT PROCEDURES D Pot LED PC Board Assembly Replacement 1 Turn the CURRENT adjustment fully counter clockwise and note the location of the pointer on the knob Loosen the screw securing the Current Knob to the potentiometer shaft Remove the Current Knob Unlatch the Access Panel to gain access to the Pot LED PC Board Remove the Pot LED PC Board from the four standoffs Disconnect the wire harness on Pot LED PC Board Install the replacement Pot LED PC Board by re versing the above procedure E Access Panel Replacement 1 Turn the two Dzus studs 1 4 turn each to unlatch Access Panel from Front Panel Lift Access Panel straight up then down until the side hinges lock into place Disconnect the ground wire on the Access Panel Remove the following components from the Ac cess Panel by referring to ON OFF Switch per paragraph 5 05 B RUN SET Switch per paragraph 5 05 C Current Knob and Pot LED PC Board per paragraph 5 05 D To remove the Access Panel lift up and pull straight out to disengage the Access Panel side hinges and remove
70. ant Filter Assembly to the bottom of the reservoir Place the end of the hose into a container to catch the coolant as it flows from the reservoir NOTE Do Not run the pump as the coolant will gravity feed from the reservoir Manual 0 2825 5 9 10 1 12 13 Remove Coolant Reservoir then remove the Deionizer Basket and Deionizer Bag from the Coolant Reservoir filler hole Disconnect the Coolant Supply Hose output con nection from the bottom of the reservoir Disconnect the In Line Coolant Filter Assembly where it connects to the reservoir NOTE Some residual coolant may drain from the In Line Filter It is recommended that a bucket rag or tow els be placed below the hose prior to removing Disconnect two air lines connected to the two so lenoid assemblies Remove the two bottom screws on Rear Panel Remove the two nuts and washers on the inside of rear panel connecting the panel to the center chassis Remove the screw located in the center of the rear panel which secures the rear panel to the reser voir panel Carefully slide the rear panel out and away from the unit Remove the four nuts and washers two top and two bottom securing the coolant tank to the res ervoir panel Remove the coolant reservoir from the rear panel Reinstall the replacement Coolant Reservoir by re versing the above steps keeping in mind the fol lowing Use thread sealant on all fittings wh
71. ast b Torch tilted too much c Metal too thick d Worn torch parts e Cutting current too low f Drag cutting above 35 amps Tip Saver Circuit Main Arc Extinguishes a Cutting speed too slow b Torch standoff too high from workpiece c Cutting current too high d Work cable disconnected or bad connection e Worn torch parts Excessive Dross Formation a Cutting speed too slow b Torch standoff too high from workpiece c Worn torch parts d Improper cutting current e Improper gas selection for cutting material SERVICE 4 Short Torch Parts Life moisture in air source b Exceeding system capability material too thick c Excessive pilot arc time d Airflow too low incorrect pressure e Improperly assembled torch f Incorrect torch parts for the operation 8 Non Genuine Thermal Dynamics parts used 4 05 Troubleshooting Guide General Information G 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 Basic Troubleshooting For basic troubleshooting and parts replacement refer to Operating Manual This manual should be your first re source for troubleshooting If the problem cannot be rem edied using the Operating Manual refer to the advanced troubleshooting in this Service Manual B Advanced Troubleshooting This
72. at a bucket rags or towels be placed below the hose prior to removing a Radiator to In Line Filter Hose disconnect at Filter b Radiator to Torch Hose disconnect at Bulk head c Pump to Coolant Filter Hose disconnect at Pump d Pump to Torch Hose disconnect at Bulkhead e Remove tie wraps as necessary Note connection of all wires to Motor then discon nect wires Remove four nuts and washers securing the Mo tor Mount to the base and remove Motor Pump Fan Assembly Replace Fan and Pump per procedures in Sections 5 08 E and 5 08 F respectively if required Install the replacement Motor with pump and fan by reversing the above procedure see NOTE NOTE Before installing the replacement Motor check that the internal wiring of the Motor is set for the proper input voltage per the information on the Motor nameplate Manual 0 2825 E Fan Assembly Only Replacement 1 Remove Motor Fan Pump Assembly from unit per procedure in 5 08 D Loosen the fan locking screw securing the Fan to the Motor Assembly shaft and remove the Fan Install the replacement Fan by reversing the above procedure noting the following a The fan locking screw is facing the motor and aligned with flat of shaft The motor assembly shaft must be flush with the front part of the Fan Bushing b Apply Loctite to the fan screw before tighten ing F Pump Assembly Replacement 5 15 1 Remove the Motor Fan Pum
73. d Retum 12 vdc Logic Ground 18 vdc Unregulated 18 vdc Unregulated 10 vdc Demand Signal to Gate PC Board 12 vdc Drag CRT DC Sense Active Low PSR Signal Active Low CSR Signal Current Control Demand Pot Wiper Torch Switch Enable Indicator CD Enable Indicator CSR Indicator AC OK Indicator Drag On Indicator APPENDIX APPENDIX 5 DRIVE BOARD LAYOUT J11 J9 TP16 TP15 TP3 di DRIVE ack A 7 28 0 ee 3 n 4 19 B d 02 n m R 8 808 8 E MEI 8 way e O 36 d o o B 9 leo o TP4 03204 0 5 ca 9 5 5 ARS Ojcs e TP6 oi oe
74. d details description parts used to manufacture a unit and date of manufacture 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 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 50192 EN50078 applicable to plasma cutting equipment and associated accessories CENELEC EN50199 EMC Product Standard for Arc Welding Equipment environments with increased hazard of electrical shock Power Supplies bearing the 5 mark conform to PP 5 EN50192 when used in conjunction with hand torches with exposed tips if equipped with properly installed stand off guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards 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 for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers res
75. designed to cut most metals up to 1 1 2 inches 38 mm using air nitrogen or argon hydrogen as the plasma gas This system is also capable of satisfy ing many mechanized gouging applications The Automated Power Supply provides 120 amp maxi mum output current and includes all control circuitry electrical and gas inputs and outputs pilot circuitry torch leads receptacle and a 20 ft 6 1 m work cable with ring lug The torch used with the Power Supply is available in the following configuration 180 Machine Torch Head PCM with 1 3 8 inch 34 mm diameter Mounting Tube with Rack and Pinion Assembly Automated system include a machine torch with shielded leads and a CNC Interface Cable NOTES The power supply can be ordered in various con figurations with various options factory installed Refer to the supplied Torch Instruction Manual for more information on the Torch Refer to Section 3 04 for list of Power Supply Op tions and Accessories Manual 0 2825 3 1 Power Supply Torch amp Leads Work Cable With Ring Lug Figure3 1 Automated Pak Master 150XL System The Extra Cool Coolant supplied with the Power Supply be used in ambient temperatures down to 10 F 12 C For lower temperatures Ultra Cool Coolant should be used This coolantcan be used in areas where the ambient temperature drops to 27 F 33 A Typical System A typical system configuration wil
76. e f 120VAC is not present replace the Logic PC Board If120VAC is present check wiring 4 12 4 Faulty Current Sensor PC Board Check the following a While trying to initiate main cutting arc mea sure the voltage at J99 6 to J99 7 or TP 10 to Gnd indicators inside the Power Supply If voltage is approximately 12 vdc replace the Current Sensor Ifvoltage is less than 2 replace the Logic PC Board 5 Faulty Transfer Mod Enable Signal a Test this Signal by measuring J4 6 to J4 8 Ifvoltage approximately 12 vdc replace Logic Board IfOvdc replace Gate Drive Board Whenoperating atamperages over 35 amps the amper age drops off after main cutting arc initiates Check whether Drag indicator 031 on the Logic PC Board is ON when the torch tip comes in contact with the work piece 1 Cutting tip in contact with the workpiece a Maintain standoff distance 1 8 3 8 between cutting tip and workpiece 2 Faulty Logic PC Board If torch tip is off the workpiece and the drag indica tor D31 on the Logic PC Board is still ON then replace the Logic PC Board Standoff Control Not Working Correctly Refer to Troubleshooting in the Standoff Control In struction Manual Manual 0 2825 4 10 Test Procedures The test procedures in this subsection are referenced in the troubleshooting section A Safety Precautions 1 Significant DC Voltage exists after removal of input power All
77. e 48 to wire 9 If voltage is present go to 4 Faulty Logic or Gate PC Board 1 Faulty Input W Contactor a If Input Contactor is not closing then mea sure the coil for 120VAC between wires 55 amp 59 Ifvoltageisnot present go to the next step If voltage is okay then replace Input W Con tactor 2 Faulty Logic PC Board a Measure for 120VAC at the Logic PC Board con nector J2 1 and J2 4 Ifvoltage is present then check connections to W coil If voltage is not present measure for 120VAC input to the Logic PC Board between J1 2 and J1 6 If voltage is present replace the Logic Ifvoltage is not present continue to next step 3 Faulty Auxiliary Transformer T3 a Measure for 120VAC between T3 connector J30 2 to J30 6 Ifvoltage is okay check connections to Logic PC Board If voltage is not present replace the T3 Aux iliary Transformer NOTE For 4 through 6 below J 11 should be disconnected and isolated from the CD PC Board and the torch switch will need to be closed Manual 0 2825 4 Faulty Logic Board Gate Board see note above a Close the torch switch The LED D20 on the top Gate PC Board should turn off e If LED D20 does not turn off measure for 12 vdc to drop to less than 2 vdc between J9 12 to J9 11 Ifvoltage does not drop replace the Logic PC Board Ifvoltage drops to less than 2 vdc replace
78. e main cut ting arc is initiated This board also filters the torch shield back to the torch through the Capacitor Pilot PC Board Indicator IGBT is turned on from the logic signal coming from the Logic Board PCR J5 6 NOTE This LED is on during piloting it is off during cutting D5 SERVICE E Current Sense PC Board Functions NOTE Refer to Appendix 11 for Current Sense PC Board layout This board senses current in the work lead approxi mately 3 amps When this happens it sends a signal backto the Logic Board This in turn tells the Logic to change demand levels from pilot current to main cut ting current Filter Voltage Divider PC Board Functions NOTE Refer to Appendix 18 for Filter Voltage Divider PC Board Diagram The Filter Voltage Divider PC Board provides com mon mode inductors for all the Remote J22 CNC sig nals that require filtering These inductors in series with the control signals work with the capacitance between the control signal lines of the CNC remote control cable and the cable shield to form an LC in ductive capacitive lowpass filter To obtain the re quired capacitance for the lowpass filter to work the CNC cable shield must be terminated to ground grounded chassis at the cutting machine end of the cable The Filter Voltage Divider PC Board also contains the voltage divider circuit for the SC11 Standoff Control The voltage divider converts and filters the high ne
79. ective November 15 2001 GENERAL INFORMATION 1 8 Date November 15 2004 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This Manual provides Service Instructions for Thermal Dynamics PAK Master 150XL Automated Plasma Power Supply Refer to Operating Manual 0 2824 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 use by properly trained Service Technicians familiar with this equipment Read this manual and the Operating Manual thoroughly A complete understanding of the capabilities and func tions of the equipment will assure obtaining the perfor mance 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 operator s responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined
80. em bly to check the output rectifier resistance to ground The meter should indicate 1 meg ohms Replace the appropriate pair of FET Heatsink Assem bliesifany ofthe above tests are open or shorted EN The FET Heatsink Assemblies are matched and balanced during production and must be replaced in pairs Manual 0 2825 6 4 19 FET Output Clamp Diodes Check NOTE Refer to the Appendix Pages for PC Board Lay outs Use an ohmmeter to check the resistance of the out put clamp diodes out E17 and out E18 as fol lows NOTE The wires on E16 and E18 should still be discon nected from both FET Heatsink Assemblies a Place the meter lead on E17 and the meter lead on E18 of the FET Heatsink Assembly to check the output clamp diode resistance The meter should indicate gt 1 meg ohms b Place the meter lead on E18 and the meter lead on E17 of the FET Heatsink Assembly to check the output clamp diode resistance The meter should indicate gt 1 megohms Replace the appropriate pair of FET Heatsink Assemblies if any of the above tests are open or shorted The FET Heatsink Assemblies are matched and balanced during production and must be replaced in pairs SERVICE SERVICE 4 20 Manual 0 2825 SECTION 5 REPLACEMENT PROCEDURES 5 01 Introduction This section describes parts replacement procedures and all cable repairs which may be performed on the Auto mated Pak Master 150XL
81. en rein stalling Refill the Coolant Reservoir with the coolant removed or fresh Thermal Arc Torch Coolant Place the Deionizer Basket and Bag into the Cool ant Reservoir filler hole and install the Coolant Reservoir Cap REPLACEMENT PROCEDURES H In Line Coolant Filter Assembly Replacement Flow Switch FS1 Assembly Replacement 1 2 Remove the Right Side Panel Section 5 04 CAUTION Handle and dispose of the used coolant per recom mended procedures Partially drain the coolant from the Coolant Res ervoir as follows a Disconnect the Reservoir to Coolant Filter As sembly hose at the Coolant Filter Assembly b Place the end of the hose into a container to catch the coolant as it flows from the reservoir Only enough needs to be removed so that the level is below the In Line Filter Flow Switch Assembly hole located on the end of the reser voir NOTE Do Not run the pump as the coolant will gravity feed from the reservoir 1 Remove the Right Side Panel per Section 5 04 A CAUTION Handle and dispose of the used coolant per recom mended procedures Partially drain the coolant from the Coolant Res ervoir until the coolant level is below where the Flow Switch connects to the Reservoir Drain cool ant as follows a Disconnect the Reservoir to Coolant Filter As sembly hose at the Coolant Filter Assembly b Place the end of the hose into a container to catch the
82. en replace the FET Heatsink Assembly FET Output Rectifier Check NOTE Refer to the Appendix Pages for PC Board Lay outs Use a digital meter diode or ohms function to check the forward and reverse bias of the output rectifiers on the FET Heatsink Assemblies as follows a Removethe wire from E16 and E18 on the Upper and LowerFET Heatsink Assemblies b Place the meter lead on E16 and the meter lead on E18 of the FET Heatsink Assembly to check the output rectifier forward bias The meter should indicate between 0 3 to 0 6 volts using the diode function or 100K ohms using the ohms function Manual 0 2825 c Place the meter lead on E18 and the meter lead on E16 of the FET Heatsink Assembly to check the output rectifier reverse bias The meter should indicate OL using the diode function or 100K ohms using the ohms function d Place the meter lead on E17 and the meter lead on E19 of the FET Heatsink Assembly to check the output rectifier forward bias The meter should indicate between 0 3 to 0 6 volts using the diode function or 100K ohms using the ohms function e Place the meter 4 lead on E19 and the meter lead on E17 of the FET Heatsink Assembly to check the output rectifier reverse bias The meter should indicate OL using the diode function or 100K ohms using the ohms function f Place the meter lead on E18 and the meter lead on the heatsink of the FET Heatsink Ass
83. ent Parts 6 3 6 05 Left Side Center Chassis Replacement 6 4 6 06 Right Side Center Chassis Replacement Parts 6 6 6 07 Base Replacement Parts ere enit a 6 8 6 08 Rear Panel Replacement Parts 6 10 6 09 Options and Accessories 2 04 4400000 01 6 12 APPENDIX 1 INPUT WIRING 44 1002 11 nnne nnne nnn nnns A 1 APPENDIX 2 SEQUENCE OF OPERATION BLOCK DIAGRAM A 2 APPENDIX 3 POT LED PC BOARD LAYOUT 3 12 2 tion Pet y tet encor eet A 3 APPENDIX 4 LOGIC PC BOARD LAYOULI nennen nennen nennen nennen nnn 4 APPENDIX 5 GATE 6 APPENDIX 6 PILOT OUTPUT PC BOARD LAYOUT AND WIRING CONNECTION DIAGRAM 8 APPENDIX 7 CD PC BOARD LAYOUT luu arcere d opa el A A 10 APPENDIX 8 INPUT PC BOARD A 11 APPENDIX 9 FET PC BOARD LAYOU ierit t ie LY oper ue A 12 APPENDIX 10 CAPACITOR PC BOARD A 14 APPENDIX 11 CURRENT SENSOR PC BOARD LAYOUT A 15 APPENDIX 12 36VAC CIRCUIT A 16 APP
84. ery day at the rear panel coolant gauge If the coolant in the reservoir is more than 2 inches 50 mm from the top of the reservoir then add Torch Coolant 2 Coolant Conductivity The coolant conductivity level should be checked if the pilot doesn t start Check the condition of the deionizer bag in the reser voir basket if the bag is yellowish brown straw color replace the bag and coolant see NOTE NOTE To accurately measure the coolant conductivity it is recommended to use a Conductivity Sensor simi lar to Thermal Dynamics Model TDS 73 Catalog 7 2844 SERVICE G Draining and Replacing Coolant Remove the old coolant from the Power Supply reservoir as follows 1 Remove the right side panel from the Power Sup ply 2 Disconnect the coolant input hose to the Coolant Filter Assembly 3 Carefully lower the hose out the right side of the Power 42 Supply and drain the coolant into an acceptable con tainer CAUTION Handle and dispose of the used coolant per recom mended procedures Assembly Coolant Reservoir Coolant Input Hose Figure 5 3 Draining Coolant From Reservoir Reconnect the hose to the Coolant Filter Assembly Remove Coolant Reservoir lid and install new cool ant and deionizer bag Reinstall the right side panel Manual 0 2825 4 03 System Theory The system is designed for mechanized automated cut ting operations using the torch
85. fier Output Rectifier Output Power Indicator E1 Rectifier Output to INR E2 Rectifier Output to INR E3 Rectifier Output to Capacitor PC Boards A amp C and Input Voltage Selection E4 Rectifier Output to Capacitor PC Boards A amp C and Input Voltage Selection E5 AC Input L1 for 11 E6 AC Input L2 for LT1 E7 Rectifier from INR E8 Rectifier to Capacitor PC Boards B amp D and Input Voltage Selection CGND Chassis Ground Manual 0 2825 A 11 APPENDIX APPENDIX 9 FET BOARD LAYOUT E1 oR o R31 R36 R32 0 R37 oo D5 O O Olas O O Olaz p oor o OL6 2 of OL7 O FORS oi Tron2 O FET ASSY R1801 OR17 OR 2 Et 128 138 T TE O O 5 BB B o 014015018 019 c14 n N T pag R27 04 oo l o
86. g Guide General Information 4 6 4 06 Circuit Fault Isolation 2 222 100000 4 7 4 07 Main Input and Internal Power Problems 4 8 4 08 Pilot Arc Problems Rc 4 10 4 09 Main Cutting Arc Problems 4 12 4 10 4 13 SECTION 5 REPLACEMENT PROCEDURES sidas 5 1 5 01 uum Z a 5 1 5 02 Anti Static Handling Procedures 2 5 1 5 03 Parts Replacement General Information 2 5 1 5 04 Major External Parts Replacement 5 2 5 05 Access Panel Parts Replacement 5 8 5 06 Left Side Center Chassis Parts Replacement 5 4 5 07 Right Side Center Chassis Parts 5 8 5 08 Base Parts Replacement uuu inedite tue uie ate eu 5 13 5 09 Rear Panel Parts 5 16 TABLE CONTENTS Continued SECTION 6 PARTS LIS TS ncm 6 1 uu IL 6 1 6 02 Ordering 6 1 6 03 Major External Replacement 6 2 6 04 Access Panel Replacem
87. ga tive arc voltage to a lower positive signal used by the SC 11 Standoff Control Arc voltage plus and mi nus with 100K ohm series resistors are also pro vided for use by certain other standoff controls Manual 0 2825 4 04 Common Operating Problems GS Disconnect primary power at the source before dis assembling the power supply torch or torch leads Frequently review the Important Safety Precau tions in Section 1 Be sure the operator is equipped with proper gloves clothing eye and ear protec tion Make sure no part of the operator s body comes into contact with the workpiece while the torch is activated CAUTION Sparks from the cutting process can cause dam age to coated painted and other surfaces such as glass plastic and metal NOTE Handle torch leads with care and protect them from damage A Piloting Piloting reduces parts life more than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to improve parts life Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also significantly affect the bevel angle Reducing standoff generally results in a more square cut Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the to
88. hat a bucket rag or tow els be placed below the hose prior to removing Disconnect two air lines where they connect to the two Solenoid assemblies Remove the Rear Panel per procedures in Section 5 09 B Locate the two nuts on the base which secure the Reservoir Panel to the base Remove nuts NOTE It may be necessary to disconnect some wiring in order to have enough room to work Note wire con nections so that wires can be reconnected again properly 10 11 12 Slide reservoir panel up and out of the T slots on the center chassis and move panel to provide ac cess to main transformers Carefully remove all wire connections to the FET PCB Assembly noting the location of each per the following chart FET PCB Connection Cable NOTES Make sure white 19 wires are looped around and connected from the right side Transformer leads are marked A amp B Group is wired to the top heatsink and group B is wired to the bottom heatsink Wires are placed belly up Note orientation of Main Transformer Assembly then remove four lock nuts securing Transformer to the center chassis Install the replacement Transformer Assembly by reversing the above procedure keeping in mind the following Reservoir Panel must seat in corresponding center chassis slots The four screws securing the output inductor mounting plate to the center chassis should have a maximum of 2 to 5 threads protrudi
89. he Side Panel B Top Panel Replacement 1 2 Remove the Left Side Panel per Section 5 04 A Remove the screws securing the Top Panel to the side and rear panels Locate and remove the nut securing the Top Panel to the center chassis Slide the Top Panel stud out of the center chassis hole Install the replacement Top Panel by reversing the above procedure E Front Panel Replacement 1 Remove the Left and Right Side Panels per Sec tion 5 04 A Remove the Work Cable from the unit per G be low Remove the Torch from the unit per H below Remove the two bolts at the bottom of the Front Panel Remove the nuts on the inside of unit securing the Front Panel to the two studs on the center chassis Carefully remove Front Panel from the unit Install the replacement Front Panel by reversing the above procedure C Work Cable Replacement 5 2 1 2 Remove Right Side Panel per Section 5 04 A Remove the work cable strain relief from the Front Panel Disconnect work cable connection from E8 on Pi lot Output PC Board Pull the work cable through the Current Sense Board and then through the Front Panel then re move from unit Install the replacement work cable by reversing the above procedure Manual 0 2825 D Torch amp Leads Assembly Replacement 1 2 Open the Access Panel Section 5 05 Disconnect all hoses and the cable from the bulk head Disconnect Shie
90. ignal from CNC or press the torch switch on the Remote Pendant to establish a pilot arc and note the following Gas flows e GAS indicator turns ON e After preflow delay DC indicator turns ON e Pilot arc established This completes the Pilot Arc Test If the above are all cor rect then proceed to the Main Arc Test below Ifthe above does not function as noted then note the symptom and proceed to Section 4 08 Pilot Arc Problems 4 7 SERVICE D Main Arc Test Activate START signal from CNC or press the torch switch on the Remote Pendant to establish a pilot arc Bring the torch to within 1 8 3 8 3 2 9 5 mm of the workpiece to establish the main cutting arc and note the following Main cutting arc initiates 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 07 Main Input and Internal Power Problems NOTES The Input PC Board has a neon light on the upper left hand corner If AC power is present on L1 L2 L3 of the Main Contactor the light will be on Refer to the Appendix Pages for PC Board Lay outs as required Locate your symptom below A Main power line fuses blow as soon as main disconnect is closed 1 Input power cable installed incorrectly a Refer to Opera
91. 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 Printed Circuit Board Assemblies to be returned must be properly packaged in protective material and returned intact per normal procedures Manual 0 2825 2 03 Service Responsibilities The Service Technician should be familiar with the equip ment and its capabilities and 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 2 1 INTRODUCTION INTRODUCTION 2 2 0 2825 SECTION 3 DESCRIPTION 3 01 Scope of Manual The information in this section has two purposes To familiarize the service technician with the bilities and limitations of the equipment To provide an overall understanding which will al low the technician in turn to properly train customer s operating personnel 3 02 Power Supply General Description Power Supply is
92. ise rite 1 1 1 01 Notes Cautions and Warnings 1 1 1 02 Important Safety Precautions 1 1 1 03 D 1 2 1 04 Note Attention et Avertissement 1 3 1 05 Precautions De Securite Importantes 1 1 3 1 06 Documents De Reference 0 4 1 5 1 07 Declaration of Conformity UU L UU aaa aa nennen 1 7 1 08 Statement of Warranty us 1 8 SECTION 2 INTRODUCTION T 1 2 01 Scope Of Manual ces casts 1 2 02 General Service Philosophy su 1 2 03 Service Responsibilities 2 2 1 0000 1 SECTION 3 DESCRIPTION EE 3 1 3 01 Scope of Man al t rt ttes se REA arem neue 3 1 3 02 Power Supply General Description 3 1 3 03 Specifications Design Features 3 2 3 04 Power Supply Options and Accessories 3 3 2 05 Theory Of Operation eicit nnno cinta it ebur eR sa RR RA du 3 3 SECTION 4 SERVICE 2 a cathare 4 1 4 01 INWOdUCHON M CE 4 1 4 02 Periodic Inspection amp Procedures 4 1 4 09 System TEO Tm 4 3 4 04 Common Operating Problems 4 5 4 05 Troubleshootin
93. item 9 in Subsection 1 03 Publica tions Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operat ing Manual A AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Besure there is no combustible or flammable ma terial in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles Provide a fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut under water or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dis sipated Trapped hydrogen gas that is ignited will cause an explosion Noise cause permanent hearing loss Plasma arc cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent per manent loss of hearing To protect your hearing from loud noise wear pro tective ear plugs and or ear muffs Protect others in the workplace Noiselevels should be measured to be sure the deci bels sound do not exceed safe levels e For information on how to test for noise see item 1 in Subsection 1 03 Publications in this man
94. l contain the follow ing Automated Power Supply e 20 ft 6 1 m Work Cable with Ring Lug PCM Torch with 25 ft 7 6 m or 50 ft 15 2 m Leads length as ordered PCM Torch Spare Parts Kit CNC Interface Cable 25 ft 7 6 m or 50 ft 15 2 m length as ordered Standard Thermal Arc Coolant 3 gallons 11 4 li ters NOTE Refer to Section 3 04 for complete list of Power Sup ply Options and Accessories B Requirements to Complete System To complete the system the user needs to provide the following Primary Input Power Cable GasSupplies DESCRIPTION 3 03 Specifications Design Features A Power Supply Specifications The following specifications apply to the Power Supply only 1 Front Panel Controls ON OFF and RUN SET Switches Output Current Control Work Cable Connection Torch Leads Connection 2 Front Panel LED Indicators e AC GAS Pressure Coolant Flow e DC Output 3 Rear Panel Primary Input Power Cable Strain Relief e Plasma Gas Supply Connection e Plasma Gas Regulator Filter Assembly with Gas Pressure Gauge and Pressure Adjustment Secondary Gas Supply Connection e Secondary Gas Regulator Filter Assembly with Gas Pressure Gauge and Pressure Adjustment Two Stage Air Line Filter CNC Control Connector 4 Input Power see NOTES 208 230 460 10 50 60 Hz Three Phase 220 380 415 10 50 60 Hz Three Phase 575 VAC
95. ld Wire from Shield Stud if present on Torch Lead Install the replacement Torch Assembly by revers ing the above procedure keeping in mind the fol lowing a Connect the bottom hoses first b The two fittings on the right side of the bulk head when viewed from the front of unit are for left hand hoses the two fittings on the left are for right hand hoses 5 05 Access Panel Parts Replacement NOTE Refer to Section 6 04 for parts list and overall de tail drawing A CURRENT Knob Replacement 1 Turn the CURRENT adjustment fully counter clockwise and note the location of the pointer at the 30 on the knob Loosen the screw securing the Current Knob to the potentiometer shaft Remove knob Place the replacement Current Knob on to the po tentiometer shaft with the location of the pointer the same as noted in step 1 Tighten the screw to secure the knob to the poten tiometer shaft Manual 0 2825 B ON OFF Switch SW1 Replacement 1 1 Unlatch the Access Panel to gain access to the rear of the ON OFF Switch Disconnect all the wiring to the ON OFF Switch Wiring is as follows On Off Switch o I vire 34 wire 32 58 An wire 35 wire 33 A 02285 Squeeze the top and bottom of the switch while pulling it out of the Access Panel Install the replacement ON OFF Switch by revers ing the above procedure C RUN SET Switch SW2 Replacement Unlatch the Access P
96. le to allow room for hose attach ment with the filter pointing away from the tank b Usethread sealant on all the pipe threads when reinstalling 8 Refill the Coolant Reservoir to the full level refer REPLACEMENT PROCEDURES to label on coolant tank with either the coolant that was removed or add fresh Thermal Arc Torch Coolant Manual 0 2825 J Output Inductor L1 4 L2 Assembly Replacement NOTES There are two Output Inductors in this unit Re placement instructions are the same for both The Output Inductor s are located behind the res ervoir panel To gain access to the Output Inductor s the rear panel of the unit is removed then the internal reservoir panel is disengaged and moved out of the way 1 Remove the Left and Right Side Panels per Sec tion 5 04 A 2 Drain the coolant from the Coolant Reservoir as follows a Remove Reservoir Cap from Reservoir b Disconnect the Coolant Supply Hose input con nection at the Coolant Filter Assembly The hose goes from the Coolant Filter Assembly to the bottom of the reservoir c Place the end of the hose into a container to catch the coolant as it flows from the reservoir NOTE Do Not run the pump as the coolant will gravity feed from the reservoir 3 Disconnect the Coolant Supply Hose output con nection from the bottom of the reservoir 4 Disconnect the In Line Filter Assembly where it connects to the reservoir NOTE Some residual coola
97. levard Rexdale Ontario Canada MOW 183 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s del Association Nationale de Fournitures deSoudage National Welding Supply As sociation 1900 ArchStreet Philadelphia PA 19103 Norme AWSF4 1 del Association Am ricaine deSoudage RECOMMANDATIONSDE PRATIQUESSURES POUR LAPR PARATION LACOUPE ET AU SOUDAGE DE CONTENEURSETTUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s dela Ameri Welding Society 550 N W LeJeune Miami FL 33126 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION Date November 15 2004 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address 82 BenningStreet West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive Euro pean Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment an
98. lity 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 the 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 XL Plus Series CutMaster Series Cougar and DRAG GUN 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 further limitations on such two 2 year period see chart below The limited warranty period for XL Plus Series and CutMaster Series 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 further limitations on such three 3 year period see chart below The limited warranty period for Cougar and DRAG GUN shall be as follows A maximum of two
99. ls are off inspect the wiring in the unit Look for any frayed wires or loose connections that should be corrected D Coolant Filter Assembly The Coolant Filter Screen should be cleaned periodically To gain access to the Coolant Filter Assembly remove the right side panel when viewed from front of unit Remove the Filter Screen by unscrewing the filter holder from the Coolant Filter Assembly Clean the filter screen by rins ing with hot soapy water Remove soap residue by rins ing with clean hot water Be sure that all the soap has been removed and the screen is dry of water before rein stalling in the Coolant Filter Assembly Filter Holder 02152 Figure 5 1 Coolant Filter Assembly 4 1 SERVICE E In Line Coolant Filter Assembly The In line Coolant Filter Screen should be cleaned periodi cally To gain access to the In Line Coolant Filter Assembly remove the right side panel when viewed from the front of unit Remove the Filter Screen by unscrewing the Filter Holder from the In Line Coolant Filter Assembly Clean the Filter Screen by rinsing with hot soapy water Remove soap residue by rinsing with clean hot water Be sure that all the soap has been removed and the screen is dry of water before reinstalling in the In Line Coolant Filter Assembly Filter Filter Holder A 02153 Figure5 2 In Line Coolant Filter Assembly F Coolant Level and Conductivity 1 CoolantLevel The coolant level should be checked ev
100. main harness wires 4 amp 5 to the inner prong of L1 amp L2 respectively of the main contactor d Connect cables 1 2 and 3 to T1 T2 and T3 respectively Manual 0 2825 5 7 REPLACEMENT PROCEDURES C Pilot Resistor R1 4 R2 Replacement NOTE 5 07 Right Side Center Chassis Parts Replacement This unit has two Pilot Resistors The replacement instructions are the same for both NOTE Refer to Section 6 06 for parts list and overall de tail drawing A Pilot Output PC Board Assembly Replacement 1 Remove the Right Side Panel per Section 5 04 B 2 Remove all wiring connections to the Pilot Out put PC Board Assembly noting the location of each 3 Remove two nuts securing Pilot Resistor to Pilot NOTES Panel Before removing any connection mark each wire 4 Remove Pilot Resistor from studs ee 5 Install replacement Resistor by reversing the above wires go to the proper terminals when reassembling Also note the routing of wires and make sure the wires are put back in the same place when reas sembling the unit procedure D Pilot Inductor L3 Replacement 1 Remove the Right Side Panel per Section 5 04 A Mark all wirings connections then disconnect all the wiring connections to the Pilot Output PC 2 Remove all wire connections to the Pilot Inductor Board Assembly noting the location of each Remove the four screws and washers securing the 3 Remove four nuts securing Pilot Inductor to the P
101. movetorch from bulkhead connections Mea sure between Pilot Return Lead and Torch If the meter doesn t show an open repair torch 2 Faulty Pilot Output PC Board a Test per Section 4 10 J repair as necessary 3 Faulty FET Heatsink Assembly a Check perSection 4 10 K repair as necessary ACindicator ON Gas flows GAS and DC indicators ON No arc in torch No arc at spark gap on CD PC Board CD enable indicator D25 on Logic Board ON 1 Faulty CD PC Board Measure DC voltage between 11 4 to J11 5 on CD PC Board a If voltageisless than 2 vdc replace CD PC Board ACindicator ON Gas flows GAS and DC indicators ON Spark at gap on CD PC Board and CD enable indicator 025 on Logic PC Board ON No arc intermittent arc in torch 1 Gas pressure s set incorrectly too high a Check gas pressures Plasma Gas Pressure should be 65 psi 4 5 bar and Secondary Gas Pressure should be 60 psi 4 1 bar 2 Oil moisture in air lines a Purgesystem If problem corrected add filters in line with air source 3 Incorrect torch parts a Refer to appropriate Torch Instruction Manual 4 Faulty leads a Check continuity per appropriate Torch Instruc tion Manual 5 Faulty torch a Check continuity per appropriate Torch Instruc tion Manual 6 Faulty connection of wire 15 or 17 to Pilot Output PC Board or pilot inductor wires reversed with wire 17 a Check wiring connection SERVICE 7 Faulty Pilot O
102. n SSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes SSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pres d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il faut communiquer aux op rateurs et au person nel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions 1 3 GENERAL INFORMATION etGAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respiratio
103. n Gardez votre t te hors dela plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Lessortesdegazet de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvantsur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvantcontenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz e N utilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combus tibles ou explosifs Lephosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produit
104. nctioning diode will conduct in the forward bias direction and indicate between 0 3 to 0 9 volts SERVICE Art A 00307 0 75 Forward Bias Diode Conducting ph gt Diode Test Symbol VR COM lt Cathode Testing Diode Forward Bias 6 Reverse the meter leads across the diode for reverse bias testing refer to following figure A properly func tioning diode will block in the reverse bias direction and depending on the meter function will indicate an open OL Art A 00306 OL Reverse Bias Diode Not Conducting Cathode Anode Testing Diode Reverse Bias 7 Ifadiode checks bad replace the diode module 8 Reconnect all cables to proper terminals SERVICE 4 14 D Input PC Board Input Bridge Rectifier Test Locate the Input PC Board and check for shorted input diode NOTE Refer to the Appendix Pages for PC Board Layouts Remove AC power and with an ohmmeter set on the diode range make the following checks A Open Open Open Diode Drop Diode Drop Diode Drop Open The meter should indicate a diode drop in one direction andan open in the other direction for each check If Input Bridge Rectifier diode s shorted make the follow ing checks with an ohmmeter at the Main Contactor Open Open Open L1 T1 L2 T
105. nd then lift up to remove the panel from the Power Supply a short distance see NOTE NOTE There is a ground wire connection to the Side Panel on the inside of the unit Manual 0 2825 4 13 5 Remove the nut securing the ground wire to the side panel and remove the ground wire 6 Remove Side Panel from unit and set aside NOTE Art may differ from actual unit 37 7 Reinstall the Side Panel as follows a Reconnect the ground wire to the Side Panel if disconnected b Place the Side Panel onto the frame and slide the top edge under the lip on the Top Panel c Reinstall all the screws to secure the Side Panel C Diode Testing Basics Testing of diode modules requires a digital volt ohmme ter that has a diode test scale Remember that even if the diode module checks good it may still be bad If in doubt replace the diode module 1 Locate the diode module to be tested 2 Remove cables from mounting studs on diodes to iso late the module 3 Set digital volt ohmmeter to diode test scale 4 Usingthe Figures for each test check each diode in the module Each diode must be checked in forward bias plus to negative and reverse bias negative to plus direction 5 Connectthe volt ohmmeter positive lead to the anode of the diode and the negative lead to the cathode of the diode for forward bias testing refer to follow ing figure A properly fu
106. ng through the left side of the chassis Manual 0 2825 L Pilot Panel Fan 1 M4 Replacement NOTE There are four Fans mounted to the Pilot Fan Panel Replacement instructions are the same for all Fans Remove Front Panel per Section 5 04 E Remove the two screws securing the Fan to the two tabs on the Pilot Fan Panel Turn the fan sideways and pull gently out of unit to where the wires can be disconnected Carefully note wiring connections then disconnect wires Install replacement Fan s by reversing the above steps noting the following a Piggyback tabs face outside b Label faces inside unit c Position Fan so that Air Flow Rotation Label molded into the Fan Housing is positioned as shown in the following illustration Air Flow Rotation Label Molded Into Fan Housing gt Air Flow Arrow Direction Air Flow Rotation Label Direction A 02290 de Manual 0 2825 M Current Sense PC Board Assembly Replacement Remove the Work Cable per Section 5 04 C Disconnect the ribbon cable from the Current Sen sor at J17 on the Logic PC Board Remove the Sensor by prying off standoffs at the rear of the Bulkhead behind the Work Cable Strain Relief Install the replacement Current Sensor PC Board by reversing the above procedure N CD Coil T4 Assembly Replacement NOTE Prior to removal note the location and orientation of the CD Coil Assembly and all its connectio
107. ng contained in this manual is for the Power Supply only Troubleshooting other parts of the system is covered in the separate manu als for that product 4 02 Periodic Inspection amp Procedures NOTE Refer to Appendix 13 for a recommended mainte nance schedule for water cooled plasma cutting systems 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 Fan Motor and Pump Lubrication The fan motor and pump in the power supply should be oiled twice per year or once for each 100 hours of operation To oil the motor remove one side panel and add two or three drops of 20 SAE oil to the front and rear oil holes on the motor NOTE Some units may utilize a sealed motor design which does not require lubrication Manual 0 2825 C Power Supply Cleaning To clean the unit open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean If necessary solvents that are recommended for cleaning electrical apparatus may be used Do NOT blow air into the power supply during cleaning make sure to always blow air out of the unit Blowing air into the unit can cause metal particles to interfere with sensitive electrical com ponents and cause damage to the unit pnm While the side pane
108. ns Remove the Left and Right Side Panels per Sec tion 5 04 A Remove the Top Panel per Section 5 04 B Disconnect the coolant hose from the fitting at the end of the bulkhead adapter Drain coolant from hose into bucket Remove the first nut and washer from the bulk head adapter Disconnect CD Coil Leads at E1 amp E2 on the CDPC Board Disconnect stiff CD Coil Wire from PS on Pilot Output Board Remove two screws in Ferrite U Core attaching it to the bulkhead chassis and remove CD Coil As sembly from unit Install the replacement CD Coil Assembly by re versing the above procedure REPLACEMENT PROCEDURES 5 08 Parts Replacement Wheel Axle Assembly Replacement B Support Leg s Assembly Replacement REPLACEMENT PROCEDURES Wheel Replacement NOTE Both Wheels are removed and replaced in the same manner 1 Raise the unit off the floor far enough for the weight of the unit to be removed from the axle and wheels 2 For the wheel to be replaced remove retaining ring washer wheel and second washer from end of axle 3 Install the replacement wheel s by reversing above procedure Axle Replacement 1 Raise the unit off the floor far enough for the weight of the unit to be removed from the axle and wheels 2 Remove both wheels from the axle 3 Slide the faulty axle out of base 4 Install the replacement axle by reversing above procedure 02307
109. nsfers tothe work Also if thetip touches the work piece the current is automatically folded back to approxi mately 35 amps to save the tip from being blown out Manual 0 2825 The resulting current is sensed by the Current Sense PC Board resulting in the demand level changing from pilot current to whatever the main current control is set at During the transfer the CSR Indicator D65 comes ON and the transfer enable signal goes low al lowing the bottom gate drive and FET modules to come up and start running Also at this time D5 located on the Pilot Output PC Board shuts off and at this time the main cutting arc is initiated If the torch is removed from the workpiece the pilot arc will automatically restart if the START signal is still active Logic PC Board START Signal Enable When ON start indicates START signal is active CD Enable Initiates spark gap on D CD PC Board Indicator should come ON then go OFF after a pilot arc has been established CSR Indicates main cutting arc is D established D AC OK When ON indicates that AC Input voltage is okay Drag When ON indicates that the D torch tip is making contact with the workpiece 26 25 65 47 31 B CD Capacitive Discharge PC Board 4 3 Functions NOTE Refer to Appendix 7 for CD PC Board layout The CD Board functions are initiated by the CD Enable signal from the Logic PC Board The CD arc starting circuit fires the spark gap
110. nt may drain from the In Line Filter It is recommended that a rag or towels be placed below the hose prior to removing 5 Disconnect two air lines where they connect to the two solenoid assemblies 6 Remove the two bottom screws on rear panel 7 Remove the two nuts and washers on the inside of rear panel connecting the panel to the center chassis 8 Remove the rear panel from the unit by removing the screw located in the center of the rear panel which secures the rear panel to the reservoir panel 9 Carefully slide the rear panel out and away from the unit Manual 0 2825 10 Locate the two nuts on the base which secure the reservoir panel to the base then remove nuts NOTE It may be necessary to disconnect some wiring in order to have enough room to work Note wire con nections so that wires can be reconnected again properly 11 12 13 14 Slide reservoir panel up and out of the T slots on the center chassis and move panel to provide ac cess to main transformers Complete the following a Disconnect single leg orange wire from E17 on the FET Heatsink Assembly and slide wire back through adjacent bushing hole in center chassis b Disconnect orange wire at E3 on Pilot Output Board Note orientation of Inductor then remove four lock nuts securing Transformer to center chassis Install the replacement Output Inductor by revers ing the above procedure keeping in mind the fol lowing
111. o the Gate Drive Board upper J7 9 Lower J8 9 Active Low OVER TEMP Signal to the Gate Drive Board upper J7 10 Lower J8 10 HEATSINK GND To HEAT SINK MAIN XFMR PRI to MAIN XFMR PRI E14 MAIN XFMR PRI to MAIN XFMR PRI E15 MAIN XFMR SEC from MAIN XFMR SEC E16 OUTPUT to OUTPUT INDUCTOR L1 OUTPUT to Current Sense Transformer and E8 on Output Board MAIN XFMR SEC from MAIN XFMR SEC E19 Manual 0 2825 13 APPENDIX APPENDIX 10 CAPACITOR BOARD LAYOUT Ei3A 12 E26 E13B E12B E2 C E26 APACITOR 55 19X1257 b E13B E12B 2 E13 Capacitor Board Signals E12 E12A E12B E12C E13 E13B E13C E25 E26 Positve Rail to FET Board Positve Rail to FET Board Positve Rail to FET Board Positve Rail to FET Board Negative Rail to FET Board Negative Rail to FET Board Negative Rail to FET Board Negative Rail to FET Board Positive Input from E8 on Input PC Board Negative Input from E3 amp 4 Input PC Board APPENDIX A 14 A 01418 E13C 12 Manual 0 2825 APPENDIX 11 CURRENT SENSOR BOARD LAYOUT ASSY 19X11 20
112. o the Pres sure Switch Assembly see Figure below Remove the Pressure Switch Assembly from the T fitting Install the replacement Pressure Switch Assembly by reversing the above procedure keeping in mind the following Apply pipe thread sealant to the fitting before reassembling Manual 0 2825 D Solenoid Valve SOL1 amp SOL2 5 17 Replacement NOTE There are two Solenoid Valve Assemblies in this unit one for plasma gas and one for secondary gas as labeled on rear panel The Solenoid Assembly for secondary gas has a Pressure Switch which must be removed before the Solenoid can be removed Fol lowing the instructions as they pertain to the Sole noid Valve being replaced Remove the Right Side Panel per Section 5 04 A Locate theSolenoid Assembly to be replaced Parts are assembled as shown below Secondary Gas Solenoid Brass Brass Nipple L Fittin 4 Pressure Switch Gas Tubing Plasma Gas Note the location of all wires then disconnect the following a Disconnect the gas tubing at the solenoid or L fitting b Disconnect blue wires Disconnect the Pressure Switch from the Plasma Gas L fitting if applicable Note the orientation of the Solenoid Valve Assem bly then remove the Solenoid s from the two inch brass regulator fitting s Install the replacement Solenoid Valve Assembly by reversing the above procedure REPLACEMENT PROCEDURES
113. ositions T1 amp T2 NOTE Refer to reverse side of replacement board for con nection identification Remove the clear insulator sheet from the Input Board Remove the three screws in top holes connecting the Input Board to the Bridge Rectifier Install the replacement Input PC Board by revers ing the above procedure noting the following The three screws securing the wiring In put PC Board to the Bridge Rectifier must be tight enough to prevent the wires from mov ing NOTE Failure to properly tighten the three screws secur ing the Input PC Board to the Bridge Rectifier will cause damage to the unit Prior to making cable connections peel pro tective coating off insulator sheet and place in sulator sheet on replacement input board Manual 0 2825 D a Input Bridge Rectifier Replacement Remove the Left Side Panel per Section 5 04 A Remove the Input PC Board per Section 5 06 C Remove the two nuts securing the Bridge Recti fier to the Heatsink Remove the Bridge Rectifier Assembly from the unit Remove the Thermal Pad Install the replacement Input Diode Bridge Assem bly including Thermal Pad by reversing the above procedure noting the following Clean Heatsink and back of Bridge Rectifier surface with a clean rag and alcohol The two nuts removed in Step 3 must be torqued to 35 in Ibs when reinstalled Install Rectifier with A B C terminals away from the Thermo
114. ow 2 minutes for discharge time Voltage measured on input capacitors must be zero before performing service on the power supply 2 Do Not touch electrical components with any part of the humanbody when poweris applied Keep away from any moving parts 4 Hotsurfaces can cause severe burns Allow equipment to cool before servicing 5 Electrostatic discharge can damage printed circuitboard assemblies Transport printed circuitboards in proper anti static shielded packages Use proper grounding techniques with wrist strap before handling printed circuit boards 6 Misaligned plugs can cause printed circuit board damage Besure plugs are properly aligned and completely seated 7 Excessive pressure can damage printed circuit board Use only minimal pressure and gentle movement when discon necting or connecting printed circuit board plugs B Opening Power Supply Enclosure Theleftside panel of the Power Supply must be removed to gain access to the input power connections and the input volt age selection A G Disconnect primary power at the source before as sembling or disassembling the Power Supply torch parts or torch and leads assemblies 1 Remove input power from the unit 2 Loosen the two bottom screws in the slotted holes of the desired Side Panel viewed from the front of the unit 3 Remove the remaining screws which secure the Side Panel to the Power Supply 4 Pull the top of the Side Panel out a
115. p Assembly per pro cedure in 5 08 D Loosen the Pump Clamp securing the Pump As sembly to the Motor Assembly Note the orientation of the Pump Assembly to the Motor Assembly Pull the Pump Assembly from the Motor Assembly Disassemble the Pump Assembly in the sequence shown below beginning with 1 To Coolant Filter To Bulkhead A 02286 REPLACEMENT PROCEDURES 7 8 Install the replacement Pump Assembly by revers ing the above steps noting the following a Proper orientation of the Pump Assembly to the Motor Assembly b Install check valve with the flow marking to wards the bottom as shown above c Use thread sealant on all pipe threads Loctite thread sealant 565 or equivalent Refill Coolant Reservoir Connect primary power and turn on unit G Radiator Assembly Replacement NOTE The Front Panel Right Side Panel and Motor Fan Pump Assembly must be removed first in order to remove the Radiator Remove the Right Side Panel per Section 5 04 A Remove the Front Panel per Section 5 04 E Remove the Motor Fan Pump Assembly per Sec tion 5 08 D Carefully disconnect Thermal Switch solid state near the inlet port and slide it out through hole in mounting bracket Remove ties as required Remove 6 screws securing Radiator to frame Install the replacement Radiator by reversing the above procedure H Thermal Switch TS1 Replacement 1 2 REPLACEMENT PROCEDURES
116. parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent ANSI ASC 749 1 Nuance Minimum Nuance Sugger e Courant Arc Protective Num ro Num ro Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent utilis s quand l arc est cach par moiceau de travail Le bruit peut provoquer une perte permanente l ou e Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d 4ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ou e Pour prot ger votre ou e contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de tra
117. ply controls as follows ON OFF switch to OFF RUN SET switch toSET CURRENT control potentiometer to maximum B Main Input and Internal Power Tests Connect main AC power to the unit Set the Power Supply ON OFF switch to ON and note the fol lowing e AC indicator blinks for eight 8 seconds then steady ON Main Contactor energizes clicks once while AC Indi cator is blinking e Inrush Relay energizes clicks once after AC Indi cator stops blinking TEMP Indicator OFF e GAS Indicator ON Gas flows e Fans operate DC Indicator OFF Manual 0 2825 Set the Power Supply RUN SET switch to the RUN posi tion and note the following e Gas Indicator goes OFF Gas flow stops NOTE This unit has a 20 second pre purge feature which begins when the unit is turned As long as the RUN SET Switch is in the SET position the gas will flow indefi nitely However once the RUN SET Switch is placed in the RUN position the gas will stop flowing after ap proximately 20 seconds The 20 seconds begins from the time the unit is turned on not from when the unit was put in the RUN position This completes the Main Input and Internal Power Tests If the unit functions as described above and all correct then proceed to the Pilot Arc Test below If the unit does not function as noted then note the symp tom and proceed to Section 4 07 Main Input and Inter nal Power Problems C Pilot Arc Test Activate START s
118. ponsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX Date November 15 2004 1 7 GENERAL INFORMATION 1 08 Statement of Warranty LIMITED WARRANTY Thermal Dynamics Corporation hereinafter Thermal warrants that its products will be free of defects in workmanship or material Should 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 recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or 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 ISIN 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 liabi
119. put is connected to the torch electrode through the negative torch lead and the positive output connects to the workpiece through the work cable C Pilot Arc When the torch is activated there is a 2 second service adjustable gas pre flow followed by an uninterrupted pulsed DC pilot arc established between the electrode and tip The pilot arc is initiated by a momentary high fre quency pulse from the Power Supply The pilot creates a path for the main arc to transfer to the work When the main arc is established the pilot arc shuts off The pilot automatically restarts when the main arc stops as long as the torch remains activated D Main Cutting Arc The power supply converts the AC input power to DC power for the main cutting arc The negative output is connected to the torch electrode through the negative torch lead The positive output is connected to the work piece via the work cable and clamp connection E RF Shielding Automated systems using CNC Interface Cables are shielded to minimize radio frequency RF interference which results from the high frequency arc initiation These shielded systems are designed with features such as a wire for establishing an earth ground and shielded torch and control leads The CNC control signals are filtered on an internal PC Board DESCRIPTION 3 4 F Interlocks The system has several built in interlocks to provide safe and efficient operation When an interlock shuts down
120. rch tip at the edge of the workpiece not touching at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal Establish the cutting arc as quickly as possible Direction of Cut The plasma gas stream swirls as it leaves the torch The purpose of the swirl is to maintain a smooth col umn of gas The swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left Manual 0 2825 E Dross When dross is present on carbon steel it is commonly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate distance Top dross is normally very easy to remove and can often be wiped off with a welding glove Slow speed dross is normally present on the bottom edge of the plate It can vary froma light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom ofthe cut edge and is very difficultto remove When cutting a troublesome steel it is sometimes useful to reduce the cut ting speed to produce slow speed dross Any resultant cleanup can beaccomplished by scraping not grinding Common Cutting Faults Insufficient Penetration a Cutting speed too f
121. re moved 2 Disconnect the gas input hose from the inert B fit ting input located on the right side of the Air Line Regulator Assembly Gas Pressure Gas Input Regulator LES Filter AK TE Assemblies ji PEU Input Hoses A 02327 3 Remove the four screws securing the Regulator to the Rear Panel 4 Pull the Air Line Regulator away from the Rear Panel far enough to disconnect the plumbing joint between the Reducer and Elbow Fitting REPLACEMENT PROCEDURES 5 18 Manual 0 2825 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts lists provide a breakdown of all replaceable components Parts are organized as follows Section 6 03 Major External Replacement Parts Section 6 04 Access Panel Replacement Parts Section 6 05 Left Side Center Chassis Replacement Parts Section 6 06 Right Side Center Chassis Replacement Parts Section 6 07 Base Component Replacement Parts Section 6 08 Rear Panel Replacement Parts Section 6 09 Options and Accessories NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your authorized distributor Materials returned without proper authorization will not be accepted C Product Improvements Improvements to the product since release is denoted by a revision letter s located on the data tag of the unit There are old style
122. replace if damaged 2 Check plasma and secondary supply and pressure flow 3 Purge plasma gas line to remove any moisture build up 4 Check deionizer bag cartridge replace if color is predominantly yellow 5 Check coolant pressure 100 120 psi Weekly or Every 30 Arc Hours 1 Check fan for proper operation and adequate air flow 2 Blow or vacuum dust and dirt out of the entire machine CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit Six Months or Every 720 Arc Hours 1 Remove and clean in line filter screens 2 Check cables and hoses for leaks or cracks replace if necessary 3 Check all contactor points for severe arcing or pits replace if necessary 4 Check all pillow blocks and bearings clean and lubricate if necessary 5 Check fan pump and pulley belts for wear or cracking replace if necessary Twelve Months or Every 1500 Arc Hours 1 Drain coolant fill with distilled water turn on main power switch and let machine run for approximately 30 minutes WARNING DO NOT energize the Torch Drain distilled water and replace with Thermal Arc Coolant Use Extra Cool Coolant Catalog 7 3580 or Ultra Cool Coolant Catalog 7 3581 for environments below 10 12 C 2 Check radiator fins clean and comb out if necessary 3 Repeatsix mon
123. rol I Torch Torch Lifter L OR Assembly J100 3 Phase Input Earth Ground Med APPENDIX A 20 Manual 0 2825 Manual 0 2825 APPENDIX 17 QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES dentifier Description Remote Standoff Control Cable 50 ft 15 2 m 75 ft 22 9 m 100 ft 5 Wok cable 224 67 Lifter Motor cse 10 ft 3 0 m 15 ft 4 6 m 20 ft 6 1 m 25 ft 7 6 m 40 ft 12 2 m 50 ft 15 2 m CNC Control me is SC11 50 ft A 2 k 9 5652 Bl CNC Control Cable Wm SC11 L F 5 ft 1 5 m 9 4483 Other Lenghts Available See SC11 Manual 48 Power Supply Power Cord 9 9025 APPENDIX APPENDIX 18 FILTER VOLTAGE DIVIDER BOARD LAYOUT J23 TB1 J24 TB1 J23 4 15 O O fa 2 _ 95 gt o 9 O lt NI Z e B S E x E N O O BOARD Filter Voltage Divider PC Board A 02872 TP2 APPENDIX A 22 Manual 0 2825 Filter Voltage Divider Board Signals J23 J23 1 J23 2 J23 3 J23 4 J23 5 J23 6 J23 7 J23 8 J23 9 J23 10 J23 11 J23 12 J23 13 J23 14 J23 15 J23 16 J24 J24 1 J24 2 J24 3
124. s de nettoyage chlor s Eliminez toute source de telle fum e Ceproduit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit desant en Californieet la code s curit Sec 25249 5 etseq GENERAL INFORMATION 14 A mm Leschocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail e Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit de soudage R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de tra vail est humide ou moite e Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes A o ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma
125. stat E Thermostat TS2 Replacement 1 2 3 F 5 5 Remove the Left Side Panel per Section 5 04 A Remove the Input PC Board per Section 5 06 C Remove two screws securing the Thermostat to the Heatsink Install replacement Thermostat by reversing the above procedure In Rush Contactor INR Assembly Replacement Remove the Left Side Panel per Section 5 04 A Note orientation of all the wires connected to the Contactor Assembly and label them Disconnect the wires from the Contactor Assem bly terminals Remove the two nuts and washers securing the Contactor Assembly to the internal chassis of the unit Install the replacement Contactor Assembly by re versing the above steps keeping in mind the fol lowing Install Contactor with T1 T4 side towards heatsinks REPLACEMENT PROCEDURES Logic Board Replacement 1 2 Remove the Left Side Panel per section 5 04 Carefully remove all cable connections from the Logic PC Board noting the location of each Remove the five screws securing the Logic PC Board to the standoffs Install the replacement Logic PC Board by revers ing the above procedure H Gate Drive PC Board s Replacement NOTE The two Gate Drive Boards are identical and are removed in the same manner Remove the Left Side Panel per Section 5 04 A Carefully remove all cable connections to the Gate Drive PCB Assembly noting the location of each per the following
126. tage is not present replace the ON OFF switch 10 Faulty Logic PC Board refer to Appendix 12 36 VAC Circuit Diagram Measure for 36 VAC on Logic PC Board from J5 1 to 5 3 a If voltage is not present replace the Logic PC Board 4 8 Manual 0 2825 D ACindicator ON TEMP indicator RUN SET Switch is in RUN position System will not pilot 1 Air flow through unit is restricted a Provide adequate air flow refer to Operating Manual Section 3 02 2 Exceeded duty cycle of Power Supply a Waitfor fans to cool unit refer to Section 3 03 for proper Duty Cycle 3 Fans not operating Measure for 115 VAC on the Logic PC Board from 196 1 to J96 3 and J96 2 to J96 4 fvoltageis correct replace Fan Assembly If voltage is incorrect replace Logic PC Board 4 Faulty temperature circuit a Check temperature circuit per Section 4 10 H repair as necessary 5 Defective Logic PC Board On Logic PC Board remove J4 and J2 connectors a If TEMP Indicator stays ON then replace Logic PC Board E ACindicator ON TEMP indicator OFF No gas flow GAS and DC indicators OFF 1 5 switch in RUN position a Switch to SET position 2 Gas supply not connected to unit a Connectto gassupply 3 Gas supply not turned on a Turn gas supply on 4 Faulty RUN SET switch a Check continuity 5 Faulty gas solenoid circuit a Test gas solenoid circuit per Section 4 10 I re pair as necessary Manual 0 2825
127. th maintenance Manual 0 2825 A 17 APPENDIX APPENDIX 14 TYPICAL MECHANIZED SYSTEM GROUNDING DIAGRAM Connection for Systems Without Standoff Control piece us CNC Control Earth Ground Plasma Power Supply Work Cable Workpiece Earth Ground A 02883 NOTE Work Cable must connect direct to workpiece DO NOT connect Work Cable to earth ground and then to workpiece APPENDIX A 18 Manual 0 2825 APPENDIX 15 POWER SUPPLY INTERFACE DIAGRAM WITHOUT STANDOFF CONTROL NOTE Cable connections from Cutting Machine Controller CNC to Plasma Power Supply without any Standoff Control Accessory Cutting Machine CNC Cable Power Supply 77 422 11 oo 3 START STOP i Start 4 5 Signal 5 11 l 6 I I 7 0 Arc V w 100K in Series TT 9 i 8 12 Start Motion OK To Move 14 13 Shield must terminated Shield a at the Cutting Machine 03740 Manual 0 2825 19 APPENDIX APPENDIX 16 TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM NOTE Refer to Appendix XVII for com plete data on the Cables and Hoses External 48 vdc 120 220 VAG 41 CONTROL 440 5 11 Standoff C With Standoff Control J42 Control CNC CONTROL I I Without Standoff Cont
128. the panel from the unit Install the replacement Access Panel by reversing the above procedure REPLACEMENT PROCEDURES 5 06 Left Side Center Chassis Parts Replacement NOTE Refer to Section 6 05 for parts list and overall de tail drawing A Fuse F1 Replacement HE Remove power from unit Remove the Left Side Panel per Section 5 04 A Remove Fuse from the fuse holder Replace Fuse 5 amp 600V Reinstall Left Side Panel B Fuse Holder Replacement 5 4 1 2 3 4 Remove the Left Side Panel per Section 5 04 A Remove Fuse from Fuse Holder Disconnect two wires connected to Fuse Holder Remove the two small screws securing Fuse Holder to the chassis Install the replacement Fuse Holder by reversing the above procedure Manual 0 2825 Input Board Assembly Replacement Remove the Left Side Panel per Section 5 04 A Disconnect all cable lug connections to Input Board removing star washers and nuts where applicable Connection Description of Cable Cable 1 from W Contactor B Cable 2 from W Contactor C Cable 3 from W Contactor Wire 8 from Voltage Selection Base Wires 8E from INR Contactor Positions L3 amp L4 Wire 8 from Voltage Selection E2 Base Wires 8E from INR Contactor Positions L1 amp L2 E3 Wire 9 From Voltage Selection Base Wire 9 from Voltage Selection E4 Base E7 Wires 8E from INR Contactor Positions T3 amp T4 E8 Wires 8E from INR Contactor P
129. the system the fault condition must be remedied and the system recycled using the applicable control device 1 Parts In Place PIP Interlock The Power Supply has a built in parts in place in terlock that prevents accidental torch starting when torch parts are not properly installed A flow switch on the coolant return lead detects reduced coolant flow caused by improper torch assembly If not satisfied the switch interrupts power to the tip and electrode 2 Gas Pressure Interlock A pressure switch acts as an interlock for the plasma gas supply If the plasma gas supply pres sure falls below minimum requirements the pres sure switch will open shutting off the power to the contactors and the GAS indicator will go out When adequate plasma supply pressure is avail able the pressure switch will close allowing power to be resumed for cutting NOTE There is no gas pressure interlock for secondary gas Manual 0 2825 SECTION 4 SERVICE 4 01 Introduction This Section provides service diagnostics for the Auto mated Pak Master 150XL Power Supply allowing the Tech nician to isolate any faulty subassemblies Refer to Sec tion 5 Repairs amp Replacement Procedures for parts replacement instructions 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 troubleshooti
130. ting Manual Section 3 07 Input Power Cable Connections and connect input cable B Main power line fuses blow when unit is pow ered on 1 Input Bridge Faulty a Test Input Bridge Rectifier per Section 4 10 D repair as necessary 2 Faulty FET Heatsink Assembly a Check per Section 4 10 K repair as necessary 3 Faulty Input PC Board a Test Input PC Board per Section 4 10 D repair as necessary SERVICE C ACindicator on front panel of power supply is OFF 1 Front Panel ON OFF switch in OFF position a Place switch to ON position 2 Main power disconnect not closed a Close main power disconnect 3 Main power line fuses blown a Replace main power line Fuses 4 Defective input power cable a Replaceinput power cable 5 Improper input power line connections inside Power Supply a Refer to Operating Manual Section 3 07 Input Power Cable Connections and correct connec tions if necessary 6 Fuse blown inside Power Supply a Replace internal Fuse F1 7 Voltage selection plug connected incorrectly a Refer to Operating Manual Section 3 06 and correct as needed 8 Faulty Auxiliary Transformer refer to Appendix 12 36 VAC Circuit Diagram Measure for 36 VAC on Logic PC Board from J1 1 to J1 5 a If voltage is not present replace the Auxiliary Transformer 9 Faulty ON OFF switch refer to Appendix 12 36 VAC Circuit Diagram Measure for 36VAC on the Logic PC Board be tween J3 2 to J3 4 a If vol
131. to Section 6 for parts lists and overall detailed drawing Disconnect primary power from source before opening or disassembling the power supply Make sure AC indicator on the Power Supply front panel is OFF 5 04 Major External Parts Replacement NOTE Refer to Section 6 03 for parts list and overall de tail drawing A Left or Right Side Panel Replacement 1 Remove input power from the unit 2 Loosen the two bottom screws in the slotted holes of the desired Side Panel viewed from the front of the unit 3 Remove the remaining screws which secure the Side Panel to the Power Supply 4 Pull the top of the Side Panel out and then lift up to remove the panel from the Power Supply a short distance see NOTE NOTE There is a ground wire connection to the Side Panel on the inside of the unit 5 Remove the nut securing the ground wire to the side panel and remove the ground wire 6 Remove Side Panel from unit and set aside NOTE Art may AN from actual unit die TER 4 Figure 5 1 Side Panel Removal A 02074 REPLACEMENT PROCEDURES 7 Install the replacement Side Panel by reversing the above procedure doing the following a Reconnect the ground wire to the Side Panel if disconnected b Place the Side Panel onto the frame and slide the top edge under the lip on the Top Panel c Reinstall all the screws to secure t
132. ual GENERAL INFORMATION PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding hel metor shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC 749 1 Minimum Protective Suggested Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the work piece 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Docu ments U S Government Printing Office Washington D C 20402 ANSI Standard 249 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding So ciety 550 N W LeJeune Rd Miami
133. using These MSDSs will give you the in formation regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where com bustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth de fects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq Electric Shock injure kill plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the op erator or others in the workplace Never touch any parts that are electrically live or hot GENERAL INFORMATION e Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp e Install and maintain equipment according to NEC code refer to
134. utput Board D5 on the Pilot PC Board should turn on two seconds after the START signal is activated IfD5 does turn ON install a jumper between E22 and E8 on the Pilot PC Board If unit will pilot with jumper installed replace the Output PC Board e f D5 does not turn ON measure the 12 vdc to drop to less than 2 vdc between J13 18 amp J13 17 two seconds after START signal is ac tivated If voltage does drop then measure for 36 VAC between J13 14 amp J13 15 If 36VAC is found then replace the Pilot Out put PC Board 8 Faulty Logic PC Board a If the voltage between 13 18 amp J13 17 on the Pilot Output PC Board does not drop to less than 2 vdc two seconds after the START signal is activated replace the Logic PC Board 4 09 Main Cutting Arc Problems NOTE Refer to the Appendix Pages for PC Board Layouts Locate your symptom below A Main cutting arc will not initiate 1 Workcable not connected a 2 Faulty INR Inrush Contactor a Connect work cable While attempting to transfer measure for 0 vdc at input PC Board between 1 and 8 If the voltage is correct then replace the INR Inrush Contactor If voltage is not 0 vdc then measure for 120VAC at INR inrush contactor coil wires 68 and 69 3 Faulty Logic PC Board a SERVICE If 120VAC is not found at INR Inrush Contactor wires 68 and 69 measure for 120VAC at the Logic PC Board between J17 4 to J17 8
135. vail Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 Date November 15 2004 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites a celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 2 Norme ANSI Z49 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superin tendent of Documents 0 5 Government Printing Office Washington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRA VAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American Na tional Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI 241 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI Z49 2 PR V

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