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PAK MASTER ® 100XL 200 VAC Air Plasma

1. Be TP6 o 9 D as 000000000 00 bo e i QTO bo 28 ES o o O m O 1 D34 TT Elm 582 adr s 525 tel 209909 Bose czs cza EG J4 2 oo zU dE L of oo TO T a U 28 31 loga 5 EIERE o 33 AROGR A og Eed Ho El o Bl ELL Berg S 09 ol F o 8000000 pao goo os 0 SENS c20 0 0 o000 RS ACT Ta E 00000000 sf 00000005 al 5660000 on jobo mo O le g Oss E lo GEES 00 e D Im O a Die EE da DO TP3 59 gb o o be er De EE o ou IO ol 06000000 0050000000005 50000000 00 O Ojo O Ojo J17 A BR dm 0000000 docto oodwooo al m jm Lun Le OG ses lo
2. J13 CGND ME PILOT OUTPUT PCB o 000 ol E_OOQO0000000h assy 19x185 d A a O E27 000 og od Lo z A 3 9 o fo b ui EE E E O m O ol oP og z Q Q l R a O D C3 8 O BB E p O Oe O O Oo E24 RE Od O O i O u 5 E O a BZ m 0 0 0 FG SEG V og or LL E23 Oo O O E a E7 O U mu R O O O war on JO OJ o E9 E10 E2 A 01389 E8 S Pilot Output PC Board Signals J12 1 Torch Switch Filter in from J22 3 Torch Control J12 2 Not Used J12 3 Torch Switch Filter Return from J22 4 Torch Control J12 4 Not Used J12 5 Pilot Return Shield to J22 1 Torch Control J12 6 Torch Switch Shield to J22 2 Torch Control J12 7 Not Used J12 8 OK to Move TO J22 12 Torch Control OK to Move J12 9 Not Used J12 10 OK to Move RTN TO J22 14 Torch Control OK to Move RTN J13 1 Torch Switch Filter out to J5 8 Logic Board Torch Sw J13 2 Torch Switch Filter gnd out to J5 9 Logic Board Torch Sw gnd J13 3 OK to Move Relay Coil to Logic PCB J5 10 OK to Move J13 4 OK to Move Relay Coil to Logic PCB J5 11 25V J13 5 PS to Logic Board J5 12 Outp
3. E ER 6 oo 22 We 238 bebe O ee oo S New Style Hele e Logic PC R rn Board A 01202 G H 2 A A 01550 b Connect a jumper between TP1 and one of the following points depending on the style of the Rogie PE Beard im ETE This will cause the gas to flow continuously NOTE and the DC indicator on the front panel to turn ON To determine the style of the Logic PC Board note the location of R22 or TP8 Style 1 Use Lower side of R22 WARNING Connection Point R22 At End Of R22 Connector J11 on the CD PC Board must be dis connected to prevent electrical damage to measur ing equipment when testing the open circuit volt age OCV c Press and hold the hand torch switch Logic PC Board Torch Switch Enable indicator D5 turns ON d Measure open circuit voltage between E29 to E7 at the Pilot Output PC Board If volt age is low each FET Heatsink Assembly should be tested individually Old Style Logic PC Board TP1 GND 401413
4. e poo ola 000000000 45 13x188 iO s ooo offo o 2 ba und O OP S DIT du ues 38 CU of PIE a BO A o on SER LJ o o e E oo p O BE J12 lo A 01399 O o O O a O 5 O O Hal Pin3 O pni go en UI E xw E 4 07 Pilot Arc Problems Locate your symptom below A AC indicator ON No gas flow GAS and DC indicators OFF Torch Switch must be pressed 1 RUN SET switch in SET position a Place RUN SET switch to RUN position 2 Faulty RUN SET switch a Check switch and replace if necessary 3 Faulty hand torch parts or Logic PC Board Check torch switch enable indicator D5 on the Logic PC Board a If indicator D5 is ON torch shield cup and switch are okay b If Torch Switch Enable indicator D5 on Logic PC Board is OFF check the following Check Pilot Output PC Board for 12 VDC between J12 pin 1 to pin 3 with torch switch pressed e If voltage is correct replace Torch parts as needed per appropriate Torch Instruction Manual Manual 0 2668 e If voltage is incorrect replace Logic PC Board 5 Faulty Logic PC Board Check CD enable indicator D15 on the Logic PC Board If OFF on Logic PC Board check for 12 VDC between J5 pins 8 to 9 with torch switch pressed a Replace Logic PC Board if less than 1
5. D3 D5 D15 D31 POWER ENABLE 1 J5 116 10000000000000 o Oi lo ol lol 0 ad old D35 D gt gap Meg AE 0000 do GND 32000050 oo D909 Sede 200 IO poe Oto ATI Ilke 2900 mina Fa A 01200 T TADOROR A 2000 99209 60 000000 EE E a r Tome Em S E ski SS RRE EP E TMM GM Logic PC Jal Tr Board kor Gate Driver PC Board U D Ge ke PTT Indicator 3 Power Enable When ON PWM Torch Switch Enable When ON Enable received from the Logic indicates torch switch is pressed PC Board CD Enable Initiates spark gap on Reset Indicator will blink if CD PC Board Indicator should primary over current is detected come ON then go OFF after a pilot when torch switch is pressed arc has been established ENS Indicates main cutting arc is 1 No DC Output D31 P established An open circuit voltage of approximately 280 to 325 VDC depending on input power selected is pro D Pilot ON Indicates that a true pilot duced when switching transistors in the FET 33 arc has started OFF during cutting Heatsink Assemblies are turned ON by a PWM En able signal from the Logic PC Board A circuit on the Logic PC Board monitors the output voltage When AC OK When ON indicates that AC the out
6. CD PC Board gm 3 1 io 3 1 Logic PC 12VDC Board Circuit J4 J9 1 1 OUT 36 VAC J1 3 3 OUT 3 5 5 GND Voltage 1 S 7 7 l Check Auxiliary 36 VAC 4 4 IN Circuit Transformer 5 2 2 Outputs 2 8 8 IN 115 VAC 6 EL re 6 Gate Drive PC Board J3 3 1 2 4 STO 0 ON OFF ER Switch APPENDIX 66 Manual 0 2668 Manual 0 2668 67 APPENDIX APPENDIX XIII SYSTEM SCHEMATIC SOLENOID GAS 1521 1591 15 Y MC 1551 581 SV FANI 1541 1571 FAN2 1531 561 151 681 LOGIC CONTROL PCB AE CURRENT SENSE RELAY AA A G R GND O su co en TEMP SWITCH PRESS SWITCH PSR BLACK 289 RED e BLUE 5 Es 5 YELLOW ji DRAG B 151 WHITE YELLOW Jk sa Ja 2 12345 6 789100 12 13 4 135 1341 eleicleelzi lz 1531 sj S sls ojo ojoj o 1321 12345578 m A gt LED PEB e RUN SET N F TEMP ku amp CURRENT ES CONTROL pe na D I D DI E31 Fi 5 8 84 STM FNO R 8 18 1 ES 115 141 1 A 4 2 R IMEI INPUT 208 VAC A A 3 PHASE i m H aci Sol 12 121 ACZ 120 d IT INPUT PCB 13 Gi aca 130 d 1 1 1 na 17 A 01872 APPENDIX 68 Manual 0
7. FET MODULE B M LOWER E17 OUT E12 E13 e fai E258 E12 E13 L ak I Je REV REVISIONS By DATE rev REVISIONS BY PATE THERMAL DYNAMICS INDUSTRIAL PARK 2 RR T 2724 WEST LEBANON NH 83784 CSS Ei e268 T T T A EC7757 ue 27 CORPORATION ea car NESSES INFORMATION PROPRIETARY TO THERMAL DYNAMICS DJ SUPERSEDED CAP BOARD B CORPORATION NOT FOR RELEASE OM DISTRIBUTION Fe ES Nore my REFERENCE UNLESS OTHERWISE SPECIFIED RESISTORS RE IN FIS OMS 1 44 5 CAPACITORS ARE IN MICROF ARADSIUF 1 om Jer t t TITLE 2 200V 192 SYSTEM SCHEMATIC 42x996 6 7 8 3 10 A 01872 Manual 0 2668 69 APPENDIX APPENDIX 70 Manual 0 2668
8. 1 Op A 01407 Manual 0 2668 4 09 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 Allow 2 minutes for discharge time Voltage measured on input capacitors must be zero before performing service on the power supply Do Not touch electrical components with any part of the human body when power is applied 3 Keep away from any moving parts Hot surfaces can cause severe burns Allow equip ment to cool before servicing 5 Electrostatic discharge can damage printed circuit board assemblies Transport printed circuit boards in proper anti static shielded packages Use proper grounding techniques with wrist strap before handling printed circuit boards Misaligned plugs can cause printed circuit board dam age Be sure plugs are properly aligned and com pletely seated Excessive pressure can damage printed circuit board Use only minimal pressure and gentle movement when disconnecting or connecting printed circuit board plugs B Opening Power Supply Enclosure The left side panel of the Power Supply must be removed to gain access to the input power connections and the input voltage selection Disconnect primary power at the source before as sembling or disa
9. Oil moisture in air lines a Purge system If problem corrected add filters in line with air source Incorrect torch parts a Refer to appropriate Torch Instruction Manual Faulty leads a Check continuity per appropriate Torch Instruc tion Manual Faulty torch a Check continuity per appropriate Torch Instruc tion Manual Faulty connection of wire 16 or 17 to Pilot Output PC Board a Check wiring connection Pilot Output PC Board ope H000000000 s Ass 19x88 IO La 8 ol ooo ojno o re LE o Q o d o o 10 Op O E pe Q i 5 o oa O x e 8 o o O Ou gt D o lt T Cat 210 OK ver E Oj N a O On A 01400 E24 o Wire 16 O O Tez P Wire 17 f N Faulty Logic PC Board Measure for 15 VDC on Logic PC Board from J5 6 to J5 7 SERVICE TROUBLESHOOTING a If voltage is less than 10 VDC replace Logic PC Board 8 Faulty PCR Relay Install a jumper between wires 12 and 14 Re try piloting again a If torch pilots with jumper installed replace PCR Relay 4 08 Main Arc Problems Locate your symptom below A Main cutting arc will not initiate 1 Work cable not connected a Connect work cable 2 Faulty current sensor Check the following indicators inside the Power Supply e Pilot indicator D33 on the Logic PC Board is ON during pilot then OFF during main arc transfer e CSR indicator D31 on the Logic PC Board is OFF during pilot then ON during main arc tra
10. Parts XL Plus Series amp Parts Parts PAK Units Power Supplies CutMaster 80XL Cougar Drag Gun All 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 All 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 Effective May 6 1999 GENERAL INFORMATION 8 Date 6 22 99 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This manual provides Service Instructions for Thermal Dynamics PAK Master 100XL 200 VAC Air Plasma Power Supply Refer to Operating Manual 0 266
11. WS 605477 LOGIC PCB 000600000000000 Ta T T i 42 Eus J2 A 01403 SERVICE TROUBLESHOOTING G AC indicator ON Gas flows GAS and DC indicators ON Arc in torch without pressing torch switch 1 Faulty torch switch a Refer to appropriate Torch Instruction Manual and check continuity 2 Faulty torch leads a Refer to appropriate Torch Instruction Manual and check continuity 3 Faulty Logic or Pilot PC Board Disconnect the Torch Control Cable from the J22 connector Check for de voltage from Logic PC Board J5 pin 8 to J5 pin 9 a Replace Logic PC Board if voltage is 15 vdc J5 Ping Ping A w 116 000000660000000 s 0000101010 Dojo oof oo 000 el o bx b r O oj IEJQ OJO Tt dc O 5 gen Logic PC Board RO 4 Faulty Pilot Output PC Board Remove power from the power supply Discon nect J12 and J13 from the Pilot PC Board Check for an open between J12 pin 1 to J12 pin 3 on the Pilot Output PC Board a Replace Pilot Output PC Board if continuity is present SERVICE TROUBLESHOOTING Pilot Output PC Board PILOT OUTPUT PCB e
12. eae nana 1 1 03 lee o EE des 2 1 04 Note Attention et Avertissement oocccccconnccnncconoconocononnnnnnnononanonnonaranonnnnaranns 3 1 05 Precautions De Securite Importantes nn 3 1 06 Documents De Reference ss 5 1 07 Declaration of Conformity conan nn naar nn nn rn 7 1 08 Statement of Warranty iii 8 SECTION 2 INTRODUCTION BEE 9 2 01 Scope Of Manual iii 9 2 02 General Service Philosophy ss 9 2 03 Service Responsibilities A 9 SECTION 3 DESCRIPTION a A o ea ee 11 3 01 Scope of Manual sue 11 3 02 General Description 11 3 03 Specifications Design Features sanita 11 3 04 Power Supply Options and Accessories ii 12 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS ui 13 4 01 Introduction EEN AW AAA Rai ALA HAIR IR 13 4 02 Periodic Inspection Procedures rrenan 13 4 03 Common Operating Problems raras 13 4 04 Troubleshooting Guide General Information 14 4 05 Circuit Fault Isolation easier areas 15 4 06 Main Input and Internal Power Problems AA 16 4 07 Pilot Arc Problems iii 18 4 08 Main Arc Problems eeoa aa EAEEREN AAAS EE AEREE 20 4 09 Test Procedures ins 21 SECTION 5 REPAIRS amp REPLACEMENT PROCEDURES siens 29 5 01 Introduction ge ii al 29 5 02 Anti Static Handling Procedures serrana 29 5 03 Parts Replacement General Information 29 5 04 Majo
13. 5 02 Anti Static Handling Procedures A General me 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 B Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Manual 0 2668 2 Unroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil to a convenient and exposed electrical ground 4 Connect the equipment primary cable ground to the same electrical ground as the wrist strap 5 Open the equipment enclosure see instruction manual for the appropriate equipment and re move the failed PC board ON Carefully open the ESD protective bag and remove the replacement PC b
14. 55 N cover Co ragpeee ENABLE e I RI f jm GD FL I 248 Siem E se c5 c6 Cum lt m el u3 2 E 5 5 on feid a R E q A P at Si Al ras m TT U 7 va fez gg 3 5 4 IE 03 LES T ge sll e s Ep Tr TR re it il dee ICT 1D ERER a T Ba A 01205 TP6 Gate Drive PC Board Signals J7 1 12 VDC to FET PC Boards J6 1 J7 2 Return for 12 VDC to FET PC Boards J6 2 J7 3 PWM Output A to FET PC Boards J6 3 J7 4 PWM Return to FET PC Boards J6 4 J7 5 Primary Current Sense from FET PC Boards J6 5 J7 6 Primary Current Sense Return from FET PC Boards J6 6 J7 7 Secondary Current Sense from FET PC Boards J6 7 J7 8 Secondary Current Sense Return from FET PC Boards J6 8 J7 9 Over Temperature Sense from FET PC Boards J6 9 J7 10 Over Temperature Sense from FET PC Boards J6 10 J8 1 12 VDC to FET PC Boards J6 1 J8 2 Return for 12 VDC to FET PC Boards J6 2 J8 3 PWM Output A to FET PC Boards J6 3 J8 4 PWM Return to FET PC Boards J6 4 J8 5 Primary Current Sense from FET PC Boards J6 5 J8 6 Primary Current Sense Return from FET PC Boards J6 6 J8 7 Secondary Current Sense from FET PC Boards J6 7 J8 8 Secondary Current Sense Return from FET PC Boards J6 8 J8 9 Over Temperature Sense from FET PC Boards J6 9 J8 10 Over Temperature Sense from FET PC Boards J6 10 APPENDIX 56 Manual 0 2668 J9 1 J9 2 J9 3 J9 4 J9 5 J9 6 J9
15. Heatsink Assembly REPLACEMENT PROCEDURES Connection Description Main Transformer Primary Main Transformer Primary Main Transformer Secondary Output Output Main Transformer Secondary From Input Section Assembly From Input Section Assembly 5 Disconnect the wiring from wire lug connections on the Capacitor PC Board at and terminals 6 Remove the two screws securing the Heatsink Mounting Bracket to the chassis 7 Lift up on the middle where the two FET Heatsink Assemblies come together and remove the Mount ing Bracket 8 Slide the FET Heatsink Assembly out and up to remove the FET Heatsink Assembly from the unit 9 Install the replacement FET Heatsink Assembly by reversing the above procedure NOTE Be sure that the top groove in the FET Heatsink Assembly is properly seated over the cutout in the chassis 5 08 Rear Panel Parts Replacement NOTE Refer to Section 6 07 for parts list and overall de tail drawing A Two Stage Air Line Filter Replacement NOTE This part is an option and may not be installed on all units 1 Disconnect the gas supply hose from the IN side of the Two Stage Filter Assembly 2 Pull the Two Stage Filter Assembly out of the mounting bracket REPLACEMENT PROCEDURES 3 Disconnect the output hose from the OUT side of the assembly 4 Install the replacement Two Stage Filter Assembly by reversing the above procedure Pres
16. Remove the Right Side Panel per Section 5 04 C Manual 0 2668 3 Disconnect the gas tube connected to the bottom of the T fitting at the Solenoid Valve Assembly 4 Remove the Air Line Regulator Bracket per para graph D above 5 Pull the Air Line Regulator away from the Rear Panel far enough to disconnect the plumbing joint between the reducer and elbow fitting 6 Remove the elbow fitting from the old assembly 7 Install the replacement Air Line Regulator Assem bly by reversing the above procedure and noting the following e Apply pipe thread sealant to the fitting before reassembling 5 09 Right Side Internal Component Parts Replacement NOTE Refer to Section 6 08 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 C NOTES Before removing any 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 Pilot Output PC Board Assembly 3 Remove the four screws and washers securing the PC Board to the standoffs 4 Install the replacement Pilot Output PC Board As sembly by reversing the above procedure B CD PC Board Assembly Replacement 1 Remove the Right Side Panel per Secti
17. clicks after AC indicator stops blinking e TEMP indicator OFF GAS indicator ON e Gas flows e Fans will operate e DC Indicator is OFF Set the Power Supply RUN SET switch to the RUN posi tion and note the following Gas indicator goes OFF e Gas flow stops This completes the Main Input and Internal Power Tests If the above are all correct then proceed to paragraph C If the above does not function as noted then note the symptom and proceed to Section 4 06 Main Input and Internal Power Problems C Pilot Arc Test Press the torch switch to establish a pilot arc and note the following e 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 Ifthe above are all cor rect then proceed to paragraph D If the above does not function as noted then note the symptom and proceed to Section 4 07 Pilot Arc Problems SERVICE TROUBLESHOOTING D Main Arc Test Press the Torch Switch 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 e Pilot arc turns OFF This completes the Main Arc Test If the above are all correct then the equipment should be operating properly If problems still persist then contact Technical Services If the above does not function as noted then note the symptom and proceed
18. e Cutting current too low 2 Main Arc Extinguishes a Cutting speed too slow b Torch standoff too high from workpiece c Cutting current too high d Work cable disconnected e Worn torch parts 3 Excessive Dross Formation a Cutting speed too slow b Torch standoff too high from workpiece c Worn torch parts d Improper cutting current 4 Short Torch Parts Life a Oil or moisture in air source b Exceeding system capability material too thick c Excessive pilot arc time d Air flow too low incorrect pressure e Improperly assembled torch f Incorrect torch parts for the operation g Non Genuine Thermal Dynamics parts used SERVICE TROUBLESHOOTING 4 04 Troubleshooting Guide General Information A WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot ing techniques cl A Troubleshooting and Repair Troubleshooting and repair of this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment B Advanced Troubleshooting For basic troubleshooting and parts replacement procedures refer to Pak Master 100XL Operating Manual 0 2581 The advanced troubleshooting covered in this Service Manual requires Power Supply disassembly and live mea surements Itis helpful for solving many of the common
19. 2668 CURRENT U SENSE PCB T7 o Lu E EZ 1461 M A 4 4 1471 sn CD PCB 3 usi 3 1481 5 1821 2 2 J2 5 1631 1 1491 U 8 201 PILOT OUTPUT 15 PCB 1a Gu e 1361 5 E7 171 1371 14 7 EB a 1381 5 El n 1391 428 20d D I 40 1a vel 3 EA 1411 S gt Eag 1421 16 n 8 1 E24 ON tf U gt 1431 czs Liz 6 1944 E22 E28 E27 14 34 uz Le 4 2 PCR 7 6 ua 4 LI TORCH CONTROL 1 b OUTPUT 9 z INDUCTOR ES 3 gt WH E25L CAP BOARD J 2 14 o 17 E26L ft 13 R c E13 E12 16 I H 1 1 1 E18 N A C OUT 112 A EUR FET MODULE A a OUT UPPER E17 Wm LJ E15 E14 El6 E19 18 SEC PRI 18 PIN M RIBBON CABLE CURRENT SENSE D 37 Ti LLUIS MAIN TXFR Kam 20 EIN 13 GATE DRIVE PCB ENABLE RIBBON CABLE J8 12 PIN RIBBON CABLE CURRENT SENSE 16 PRIM SEC E El4 El5 E16 Ela QUT EUR hh EB 112
20. 2668 Meter Meter Open Open L1 T1 L2 T2 L3 T3 If any test has resistance then replace the Main Contac tor also E Main Contactor MC1 Test Open Reconnect power and observe proper start up procedure Indicator D34 on the Logic PC Board should be ON If indicator D34 is OFF there is no voltage to the Power Supply or an overvoltage condition exists Logic PC Board EII d K N Q TA o O 1 ms oso ba of Go 01405 0 I 0000000000000 e H AR N a dh og D34 A 01409 If indicator D34 is OFF check for proper AC input volt age per the following e Three Phase Units check L1 L2 and L3 Main Contactor MC1 L3 Li Coil Wire 55 Wire 59 A 01195 Measure voltage on coil of contactor approximately 117 VAC between wires 55 and 59 Manual 0 2688 e If voltage is correct replace Main Contactor e If voltage is incorrect replace Logic PC Board F Temperature Circuit Test Test the temperature circuit per the following 1 Place the front panel ON OFF switch to the OFF position 2 Disconnect ribbon cable from the Upper FET Heatsink Assembly at J6 A 01410 FET Heatsink and Capacitor PC Board Assembly J6 Place the front panel ON OFF switch to ON B w Check status of the
21. 7 J9 8 J9 9 J9 10 J9 11 J9 12 J9 13 J9 14 J9 15 J9 16 J9 17 J9 18 J9 19 J9 20 TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 D3 D31 36 VAC from Logic PC Board J4 1 36 VAC from Logic PC Board J4 2 36 VAC from Logic PC Board J4 3 36 VAC from Logic PC Board J4 4 Return from Logic PC Board J4 5 36 VAC from Logic PC Board J4 6 Return from Logic PC Board J4 7 36 VAC from Logic PC Board J4 8 Over Temperature Sense from FET PC Boards to Logic PC Board J4 9 Over Temperature Sense from FET PC Boards Boards to Logic PC Board J4 10 Return for Master Enable Signal to Logic PC Board J4 11 Master Enable Signal from Logic PC Board J4 12 Return for PWM Enable Signal to Logic PC Board J4 13 PWM Enable Signal from Logic PC Board J4 14 Return for PSR Signal from Logic PC Board J4 15 PSR Signal to Logic PC Board J4 16 Return for Demand Signal to Logic PC Board J4 17 Demand Signal from Logic PC Board J4 18 Return for Demand Signal from Logic PC Board J4 19 Not Used Logic Ground 12 VDC 12 VDC 5 VDC Not Used Not Used Not Used Not Used Not Used 6 VDC Not Used Not Used Not Used Power Enable Indicator Reset Indicator Manual 0 2668 57 APPENDIX APPENDIX VI PILOT OUTPUT PC BOARD LAYOUT
22. Current Knob per paragraph A above e ON OFF Switch per paragraph B above e RUN SET Switch per paragraph C above Pot LED PC Board per paragraph D above 3 Remove the two nuts and washers securing the Access Panel to the Right Side Panel 4 Install the replacement Access Panel by reversing the above procedure 5 06 Front Panel Parts Replacement NOTE Refer to Section 6 05 for parts list and overall de tail drawing A Work Cable Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Work Cable connection from the lower FET Heatsink Assembly at E18 OUTPUT termi nal 3 Remove the Work Cable strain relief from the Front Panel 4 Pull the Work Cable from the unit 5 Install the replacement Work Cable by reversing the above procedure B Current Sensor Replacement 1 Remove the Work Cable per paragraph A above 2 Disconnect the ribbon cable from the Current Sen sor at J17 of the Logic PC Board 3 Remove the four screws securing the sensor to the standoffs at the rear of the Front Panel behind the Work Cable Strain Relief 4 Install the replacement Current Sensor by revers ing the above procedure 31 REPLACEMENT PROCEDURES C Main Contactor Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Note the orientation of all the wires and then dis connect the input and output wiring from the Main Contactor Assembly 3 Remove the two nuts and wash
23. J5 9 Torch Switch Return to Pilot Output PC Board J13 2 J5 10 OK To Move Signal to Pilot Output PC Board J13 4 J5 11 18 vdc to Pilot Output PC Board J13 3 J5 12 Return J5 13 Not Used J5 14 From Pilot Output PC Board to Sense Drag Cutting J5 15 Not Used J5 16 From Pilot Output PC Board to Sense DC J10 1 Inrush Signal to Input PC Board J16 1 J10 2 18 VDC to Input PC Board for Relays J16 2 J17 1 CSR Signal from Current Sensor J17 2 Return for CSR Signal J17 3 4120 VDC to Current Sensor TP1 Logic Ground TP2 18 VDC TP3 18 VDC TP4 Not Used D5 Torch Switch Enable Indicator TP5 Not Used D15 CD Enable Indicator TP6 12 VDC D31 CSR Indicator TP7 Not Used D33 Pilot On Indicator TP8 Not Used On Newer PC Boards Only D34 AC OK Indicator D35 Drag On Indicator Manual 0 2668 55 APPENDIX APPENDIX V GATE DRIVE PC BOARD LAYOUT TP1 DSI GND RESE TP1 TP9 p TP11 TP12 J9 POWER ENABLE SCH Gi gt
24. PRACTICE FOR RESPIRA TORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement No mom Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme suit 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 syst me mo ATTENTION Toute proc dure pouvant r sulter Vendommagement du mat riel en cas de non respect de la proc dure en question Date 6 22 99 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 pr s d une application l arc au jet de plasma devrait consulter leur
25. TEMP indicator If indicator has gone OFF then remove power and replace the Upper FET Heatsink Assembly 5 Place the front panel ON OFF switch to the OFF position 6 Disconnect ribbon cable from the Lower FET Heatsink Assembly at J6 N Place the front panel ON OFF switch to ON Oo Check status of the TEMP indicator If indicator has gone OFF then remove power and replace the Lower FET Heatsink Assembly 9 Place the front panel ON OFF switch to the OFF position 10 Disconnect wiring cable from the Logic PC Board at J2 15 SERVICE TROUBLESHOOTING A 01411 Logic PC Board i sk pocococococococg o Ojo S o o Olojn000000 o olo o O o o 00D47 o LOGIC PCB 000000000000000 16 J2 11 Place the front panel ON OFF switch to ON 12 Check status of the TEMP indicator If indicator has gone OFF then remove power and replace the Temperature Switch Assembly next to the input bridge diode Left Side 5 Places 13 Reconnect the ribbon cables to the Upper and Lower FET Heatsink Assemblies at J6 14 If the front panel TEMP indicator is still ON re place the Logic PC Board G Gas Solenoid Circuit Test Make the following voltage checks per the circuit dia gram and replace the faulty part as required SER
26. 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 80XL 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 80XL 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 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
27. Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales Ameri can National Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de I American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI Z49 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de I American National Standards Institute 1430 Broadway New York NY 10018 7 Norme A6 0 de l 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 I Association Am ricaine pour la Pro tection contre les Incendies NFPA LES SYSTEMES A GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROCEDES ASSOCIES disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NA TIONAL disponible aupres de la National Fire Pro tection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROCEDES DE COUPE ET DE SOUDAGE disponible aupres de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA
28. and in structions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions Date 6 22 99 As 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 e Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases e 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 e Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health e 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 e Use special equipment such as water or down draft cutting tables to capture fumes and gases e Do not use the plasma torch in an area where com bustible or explosive gases or materials are located Phosgene a toxic gas is
29. following hardware REPLACEMENT PROCEDURES a Two mounting nuts from Main Contactor As sembly b Nut and wire from ground stud A Bottom two screws securing Rear Panel to Base Front Assembly d On the right side remove the two screws secur ing the Pilot Panel to the Base Front Panel Assembly e On the right side remove the three nuts and washers securing the internal chassis to the bot tom of the unit 7 At the front panel remove the two screws securing the Base Front Panel to the internal chassis 8 Carefully slide the internal components up back and out of the Base Front Assembly 9 Install the replacement Base Front Assembly by reversing the above procedure 5 07 Left Side Internal Component Parts Replacement NOTE Refer to Section 6 06 for parts list and overall de tail drawing A Fuse Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Fuse from the fuse holder 3 Replace the Fuse with 0 8A 600V fuse 4 Reinstall the Left Side Panel Fuse Holder Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Fuse from the holder 3 Disconnect the two wires connected to the Fuse Holder 3 Remove the two small screws securing the Fuse Holder to the chassis 4 Install the replacement Fuse Holder by reversing the above procedure Input PC Board Assembly Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove
30. must be torqued to 35 in lbs when reinstalled Logic PC Board Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Carefully remove all cable connections from the Logic PC Board noting the location of each 3 Remove the four screws securing the Logic PC Board to the standoffs Manual 0 2668 4 Install the replacement Logic PC Board by revers ing the above procedure Gate Driver PC Board Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Logic PC Board per paragraph E above 3 Carefully remove all cable connections to the Gate Driver PCB Assembly noting the location of each per the following chart Connection Description of Cable Ribbon Cable from Logic PC J9 Board J8 Ribbon Cable from Top FET Heatsink Assembly J7 Ribbon Cable from Bottom FET Heatsink Assembly 4 Remove the four screws securing the Gate Driver PC Board to the four standoffs 5 Reinstall the replacement Gate Driver PCB Assem bly by reversing the above procedure FET Heatsink Assembly Replacement NOTE The two FET Heatsink Assemblies are identical and are removed in the same manner 1 Remove the Left Side Panel per Section 5 04 B 2 Place the unit on its right side 3 Remove the Ribbon Cable plug 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 4 Disconnect all the wire lug connections to the FET
31. pres sure for the type gas being used C Smart Cart Steel cart on easy rolling 10 pneumatic tires to pro vide maximum mobility for the power supply Handle is 3 4 tubing with hooks for storage of torch leads A tie down strap is also included DESCRIPTION Interface Cable NOTE This accessory can be used only with the PCM 100XL Torches The interface cable is available in two lengths 25 ft 7 6 m and 50 ft 15 2 m The cable is used to inter face the power supply with an auxiliary control de vice to provide OK To Move and ON OFF signals Manual 0 2668 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 4 01 Introduction This Section provides service diagnostics for the Pak Master 100XL 200VAC Power Supply allowing the Tech nician to isolate any faulty Subassemblies Refer to Sec tion 5 Repairs amp Replacement Procedures for parts re placement 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 troubleshooting 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 This subsection describes inspection procedures which should be performed at periodic intervals as required A Physical Inspection Chec
32. 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 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 travail e Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs e Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites 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 Docu ments U S Government Printing Office Washing ton 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 LV ARC ET AU GAZ disponible aupr s du Superin tendent of Documents U S Government Printing Office Washington D C 20402 Date 6 22 99 4 Norme ANSI
33. 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 Assem bly to check the output rectifier resistance to ground The meter should indicate gt 1 meg ohms Replace the FET Heatsink Assembly if any of the above tests are open or shorted FET Output Clamp Diodes Check Use an ohmmeter to check the resistance of the out put clamp diodes out E17 and out E18 per the following procedure 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 meg ohms Replace the FET Heatsink Assembly if any of the above tests are open or shorted Manual 0 2668 SECTION 5 REPAIRS amp REPLACEMENT PROCEDURES 5 01 Introduction This Section describes parts replacement procedures and all cable repairs which may be performed on the Pak Master 100XL 200VAC 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
34. 64 Manual 0 2668 A e Y NOTE Old style panels had only holes no studs New Style Relay A 01378 Manual 0 2668 49 PARTS LISTS 6 09 Options and Accessories PARTS LISTS Qty 1 Description Smart Cart Interface Cable For Use With Machine Torches Only 25 foot 7 62m 50 foot 15 24m 1 Circle Cutting Attachment 50 Catalog 7 7777 8 5557 8 5558 7 7501 Manual 0 2668 APPENDIX I INPUT WIRING REQUIREMENTS Input Power Input 3 Ph Current 3 Ph Suggested Sizes See Notes Voltage Volts Freq Hz KVA Amps Fuse Amps Wire AWG 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 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 K5 Flexible cab
35. 7 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 0 2667 thoroughly A complete understanding of the capabili ties and functions of the equipment will assure obtaining the performance for which it was designed 2 02 General Service Philosophy Several key points are essential to properly support the application and operation of this equipment A Application The equipment should satisfy the customer s require ments as supplied and as described in Section 3 of this manual Be sure to confirm that the equipment is capable of the application desired B Modifications No physical or electrical modifications other than selec tion of standard options and Accessories are to be made to this equipment C Customer Operator Responsibilities It is the customer operators responsibility to maintain the equipment and peripheral Accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual and to protect the equipment from accidental or mali cious damage D Repair Restrictions The electronics consists of Printed Circuit Board Assem blies which must be carefully handled and must be re placed as units No replacemen
36. ACEMENT PROCEDURES REPLACEMENT PROCEDURES 4 Remove the four screws which hold the mounting plate to the bottom chassis 5 Carefully remove the mounting plate with the Main Transformer Assembly from the unit 6 Install the replacement Main Transformer Assem bly by reversing the above procedure NOTE The four screws securing the mounting plate to the chassis should have a maximum of 2 to 5 threads protruding through the left side of the chassis Output Inductor Assembly Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Right Side Panel per Section 5 04 C 3 Disconnect the lead wire on terminal E7 of the Pi lot Output PC Board 4 Disconnect the lead wire on terminal E17 of the top FET Heatsink Assembly 5 Remove the four mounting screws securing the Out put Inductor Assembly to the chassis 6 Remove the Output Inductor Assembly from the unit 7 Install the replacement Output Inductor Assembly by reversing the above procedure NOTE The four screws securing the mounting plate to the chassis should have a maximum of 2 to 5 threads protruding through the left side of the chassis Auxiliary Transformer Assembly Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Right Side Panel per Section 5 04 C 3 Disconnect the single pin connector on the white wire coming from the Auxiliary Transformer As sembly 4 On the voltage selection panel remove the p
37. BEL INPUT POWER CONNECTIONS BRACKET REGULATOR MOUNTING 10 32X 5 PPH SWAGEFORM STL ZN PARKER KALON BRACKET LAMAN FILTER MOUNTING TWO STAGE AIR LINE FILTER KIT OPTIONAL DUAL STAGE AIR FILTER ASSEMBLY REPLACEMENT FIRST STAGE FILTER REPLACEMENT SECOND STAGE FILTER ASSEMBLY HOSE FILTER TO REGULATOR PANEL MOUNTING NUT 46 Catalog 9 1044 8 3370 9 7514 8 6307 9 2184 8 0352 9 2023 9 7524 9 7525 9 1045 9 7606 Manual 0 2668 PARTS LISTS Manual 0 2668 6 08 Right Side Internal Component Replacement Parts List Item D N O O RR N r 9 10 11 12 13 14 15 16 17 M HA EP HP PE SN M M e M rh EP Nemme Description BULKHEAD ADAPTER O2B 1 8 NPT 9 16 1 8 JAM NUT HEATSINK INPUT BRIDGE CHASSIS CENTER PANEL PILOT ASSEMBLY MOUNTING BRACKET BULKHEAD MOUNTING INSULATOR BULKHEAD PCR Relay Old Style Relay Use PCR Relay Field Reftrofit Kit New Style Relay Use DPST 20A 125VDC 12VDC COIL TRANSFORMER AUX IEC BOBBIN ASSEMBLY MAIN TRANSFORMER ASSEMBLY OUTPUT INDUCTOR FITTING 1 8 NPT X 1 4 TUBE STR COIL CD TRANSFORMER SECONDARY COIL PILOT INDUCTOR ASS Y CD PCB ASS Y PILOT OUTPUT PCB DUST COVER PCR RELAY NOTE 1 Item shown for illustration purposes only PARTS LISTS 48 Catalog 9 4045 8 2149 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 7 3535 8 3163 9 7541 9 7599 9 7598 8 3360 9 7597 9 7591 9 7517 9 7518 8 31
38. E Refer to Section 6 03 for parts list and overall de tail drawing A Lifting Handle Replacement 1 Remove the two allen screws securing the ends of the handle to the top of the unit 2 Remove the Lifting Handle from the two end mounting blocks 3 Place the replacement Lifting Handle into the mounting blocks 4 Secure the Lifting Handle to the top of the unit with the two allen screws B Left Side Panel Replacement 1 Using a phillips head screwdriver remove the five screws which secure the Left Side Panel to the Frame Assembly Left Side A 01869 5 Places 2 Carefully pull the Left Side Panel up and away from the unit far enough to gain access to the ground wire connection on the inside of the panel 3 Remove the nut from the ground stud on the side panel and remove the ground wire 4 Remove the four screws securing the Leads Wrap to the old Left Side Panel REPLACEMENT PROCEDURES 5 Install the replacement Left Side Panel by revers ing the above procedure noting the following e Leads Wrap must be installed on the replace ment Left Side Panel before panel is installed e Place the Left Side Panel onto the frame and slide the top edge under the lip on the top of the Right Side Panel C Right Side Panel Replacement 1 Remove the Lifting Handle per paragraph A above 2 Unlock the latch for the Access Panel 3 Using a phillips head screwdriver remove the five screws which s
39. E TROUBLESHOOTING A 00307 0 75 Forward Bias Diode Conducting bb Diode Test Symbol VR COM A Anode HS Cathode Testing Diode Forward Bias 6 Reverse the meter leads across the diode for reverse bias testing refer to following figure A properly functioning diode will block in the reverse bias direc tion and depending on the meter function will indi cate an open or OL A 00306 OL Reverse Bias Diode Not Conducting I VR COM A Cathode O Anode Testing Diode Reverse Bias 7 If a diode checks bad replace the diode module 8 Reconnect all cables to proper terminals D Input PC Board Test Check Input PC Board for shorted input diode SERVICE TROUBLESHOOTING 22 A 01408 O R2 G o o e 8 000 o o o o o o O o o an co 6 5 RZ e Alt 3 88 0 00000 AC1 AC2 AC3 Input PC Board Remove AC power and with an ohmmeter set on the di ode range make the following checks Diode Drop Meter Open Diode Drop Open Diode Drop Open Open Diode Drop Open Diode Drop Open Diode Drop The meter should indicate a diode drop in one direction and an open in the other direction for each check If Input Bridge Diode is shorted make the following checks with an ohmmeter at the Main Contactor Manual 0
40. IHERMAL DYNAMICS A THERMADYNE Company PAK MASTER 100XL 200 VAC Air Plasma Cutting Power Supply for Japan Service Manual August 11 1999 Manual No 0 2668 WARNING WARNING Read and understand this entire Service Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Service Manual repre sents our best judgement Thermal Dynamics Corporation assumes no liability for its use Pak Master 100XL 200 VAC Air Plasma Cutting Power Supply Service Manual for Japan Number 0 2668 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1998 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liabil ity to any party for any loss or damage caused by any error or omission in the Pak Master 100XL 200 VAC Air Plasma Cutting Power Supply Service Manual whether such error results from negligence accident or any other cause Printed in the United States of America August 11 1999 SECTION 1 GENERAL INFORMATION weta ora ada 1 1 01 Notes Cautions and Warnings ooooccccnnnnncocccnnnonnonncnnnnnnonnncnnnnnnnnoncnnnnannnncnnnos 1 1 02 Important Safety Precautions
41. MANIPULATION SANS RISQUE DES GAZ COMPRIMES EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA W117 2 CODE DE SECURITE POUR LE SOUDAGE ET LA COUPE disponible aupres de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 ivret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de I Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 GENERAL INFORMATION 14 Norme AWSF4 1 de I Association Am ricaine de Soudage RECOMMANDATIONS DE PRA TIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTEC TION RESPIRATOIRE disponible aupres de l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION 6 Date 6 22 99 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address Industrial Park 42 West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Direc tive European Council Directive 73 23 EEC as amended
42. NEL 38 Catalog 9 7505 9 7506 9 7610 9 7609 9 7611 Manual 0 2668 PARTS LISTS 39 Manual 0 2668 6 04 Access Panel Replacement Parts List Item NB PARTS LISTS Qty 1 1 N NN r RP Rp Description ASSEMBLY POT LED PCB Replacement Kit PC Board amp Knob KNOB INNER CONCENTRIC Current Pot Shaft Diameter 1 8 inch Order Kit Current Pot Shaft Diameter 1 4 inch Knob Only ON OFF ROCKER SWITCH DPST SWITCH ROCKER SPST PANEL ACCESS Includes PANEL ACCESS OVERLAY ACCESS PANEL LABEL ACCESS PANEL DZUS STUD DZUS RETAINING RING POT PROTECTOR KIT Includes Handles Screws Star Washers 40 Catalog 9 7014 9 7014 9 8007 8 3258 9 1042 9 7608 9 4346 9 4347 7 7575 Manual 0 2668 A 01065 Manual 0 2668 41 PARTS LISTS 6 05 Front Panel Replacement Parts List Item Qty Description Catalog 1 1 BASE FRONT UNIT Includes 9 7607 BASE FRONT UNIT GROUND TAG 8 4243 USA LABEL 1 3 4 X 3 8 3216 OVERLAY FRONT PANEL 2 1 CONTACTOR 4 POLE 40 FLA 120 VAC 9 7507 3 1 STRAIN REFIEF 325 360 DIA 8 5537 4 2 FAN 115V 50 60HZ 95 115CFM W 187 TABS 8 3209 5 1 CABLE WORK 6AWG W CLAMP 15 9 7540 6 1 PANEL FAN GUARD 9 7620 7 1 ASSEMBLY CURRENT SENSOR PCB 9 7602 PARTS LISTS 42 Manual 0 2668 A 01376 Manual 0 2668 43 PARTS LISTS 6 06 Left Side Internal Component Rep
43. P3 Not Used El CD output E2 CD Output APPENDIX 60 Manual 0 2668 APPENDIX VIII INPUT PC BOARD LAYOUT Solder Side Of PC Board Component Side Of PC Board J16 R2 G ze 0 00 o p Bor ooo lo 000 o 3 3 o 00 Ow P E31 A P NE OG FO e P gt E O E Lo o ob o 01 Ho Of ri fool Lo O O O4 FO R5 RZ o de o o ee m2 gr Mt No pe RB R7 RI R6 Du R3 o a O a e o a 2 oo Zb lo lo lo lo SR D CGND R404 po Og poo FORIZ o O E so oof Jo of Jo A o O C4 c5 3 O O O 5 A 01417 AC1 AC2 AC3 CGND Input PC Board Signals J16 1 Gate Drive Relay Rtn from Logic Board J10 1 J16 2 Gate Drive Relay Pos from Logic Board J10 2 J16 3 Not used J16 4 Not used J16 5 Not used CGND Chassis Ground to Chassis Ground R2 Rectifier to Rectifier G SCR Gate to SCR Gate SCR Cathode Module Output to the Inrush Choke Assembly Rectifier Module Output to the Cap Board E26 AC1 AC Input Phase 1 from the contactor T1 and T4 AC2 AC Input Phase 2 from the contactor T2 AC3 AC Input Phase 3 from the contactor T3 E31 Output
44. PPENDIX X CAPACITOR PC BOARD LAYOUT iii 64 APPENDIX XI CURRENT SENSOR PC BOARD LAYOUT eee ooo aaa ena a aaa een acne 65 APPENDIX XII 36VAC CIRCUIT DIAGRAM 2 eee eee eee eee aaa aaa aaa nn nan aaa aaa nana 66 APPENDIX XIII SYSTEM SCHEMATIC ire 68 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 MM CAUTION A procedure which if not properly followed may cause damage to the equipment Ae G Tt A procedure which ifnot properly followed may cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN GEROUS AND 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
45. R PC BOARD LAYOUT E13A El2A E13B E12B E26 Af C1 cz c3 CAPACITOR PCB ASSY 19X1257 A E13B E12B olo 0 E25 E13 A 01418 E12 E13C E12C Capacitor PC Board Signals E12 Positve Ra l to FET Board E12A Positve Rail to FET Board E12B Positve Rail to FET Board E12C Positve Rail to FET Board E13 Negative Rail to FET Board E13A Negative Rail to FET Board E13B Negative Rail to FET Board E13C Negative Rail to FET Board E25 Positive Input from Input Board SCR Cathode E26 Negative Input from Input Board Rectifier APPENDIX 64 Manual 0 2668 APPENDIX XI CURRENT SENSOR PC BOARD LAYOUT ASSY 19X1 o o D Ol O O o IL a a J15 or OO OO e OC o O O o a O gt el Ul o o A 01419 Current Sensor PC Board Signals J15 1 Work Cable Sense J15 2 Ground J15 3 12 VDC Manual 0 2668 65 APPENDIX APPENDIX XII 36VAC CIRCUIT DIAGRAM
46. RI van en SE SLP SRG o 000 GES 00 00 oo oo O o 000 o O o o o MAIN XFMR SEC o 0000 oo 00 oS 3 o ooo 8 o o o O El6 o 0O O e ES o o o o 9 o oo O O Or OUTPUT o o o o o o o o O o O o O o o o O O O 00 O OO O O 000 OOO o o o o o o o o o FET PCB ASSY A 00479 Solder Side Of PC Board E18 E16 J6 APPENDIX 62 Manual 0 2668 FET PC Board Signals Upper and Lower Assemblies J6 1 J6 2 J6 3 J6 4 J6 5 J6 6 J6 7 J6 8 J6 9 J6 10 El E14 E15 E16 E17 E18 E19 12V from the Gate Drive Board upper J7 1 Lower J8 1 12V RTN from the Gate Drive Board upper J7 2 Lower J8 2 Pwm Output from the Gate Drive Board upper J7 3 Lower J8 3 Pwn 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 to the Gate Drive Board upper J7 9 Lower J8 9 OVER TEMP 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 E9 on Output Board and pin 8 PCR MAIN XFMR SEC from MAIN XFMR SEC E19 Manual 0 2668 63 APPENDIX APPENDIX X CAPACITO
47. SERVICE TROUBLESHOOTING 26 Manual 0 2668 2 3 Pilot Output PC Board A 01401 oft HO000000000 aen 19x188 off o o ooo O ooo o o 4 Poooo00000je ofofo o cs Ic Se 6 a ta Get O_O ES Q z o O 5 O LI un u L a lO S 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 open or shorted in both direc tions then the faulty Fet Heatsink Assembly should be replaced MOSFET Resistance Checks The Power Supply contains two identical FET Heatsink 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 MOSFET s per the following procedure a Locate Q1 and Q6 on the FET Heatsink Assembly Manual 0 2688 27 06 FET Heatsink and Capacitor PC Board Assembly A 01414 b Place the met
48. VDC is present B AC indicator ON Gas flows GAS indicator ON DC indicator blinks Small arc may be visible in torch 1 Faulty Pilot Output PC Board or Shorted Torch a Test per Section 4 09 H repair as necessary 2 Faulty FET Heatsink Assembly a Check per Section 4 09 I repair as necessary 3 Faulty torch a Check torch per appropriate Torch Instruction Manual C AC indicator ON Gas flows GAS and DC indicators ON No arc in torch No arc at spark gap on CD PC Board CD enable indicator D15 on CD PC Board ON 1 Faulty CD PC Board Measure DC voltage between J11 4 to J11 5 on CD PC Board a If voltage is less than 2 vdc replace CD PC Board CD PC Board ge ze Jii Pin 4 O pi3 o Di4 HHocoooooc E E RE 04 Fo o ora o o a z al 2022 0 s o RZBj oof___ oR33 e Pin 5 o ojo C5 A 01188 J11 ir 85 1 u3 Manual 0 2688 D ACindicator ON Gas flows GAS and DC indicators ON Spark atgap on CD PC Board and CD enable indicator D15 on Logic PC Board ON No arc or intermittent arc in torch 1 d Gas pressure s set incorrectly too high a Refer to appropriate Torch Manual
49. VICE TROUBLESHOOTING Wire 56 4 Logic PC Gas J2 Solenoid pond Wire 52 19 A 01198 1 Check for 115 VAC from Wire 56 to wire 52 at the gas solenoid If approximately 115 VAC replace solenoid If no voltage is present proceed to Step 2 2 Measure for 115 VAC from J2 4 to J2 10 at the Logic PC Board If voltage is not correct replace Logic PC Board H Pilot Arc Circuit 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 17 and 16 removed I FET Heatsink Circuit Tests 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 both the Logic PC Board and the Gate Drive PC Board to help in troubleshooting The indicators on the Logic PC Board as follows 24 Manual 0 2668 The indicators on the Gate Drive PC Board as follows
50. WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS TIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Date 6 22 99 CO NFPA 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 NFPA Standard 70 NATIONAL ELECTRICALCODE obtainable from the National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Pro tection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Ca nadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRA PHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWSF4 1 REC OMMENDED SAFE PRACTICES FOR THE PREPA RATION FOR WELDING AND CUTTING OF CON TAINERS 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
51. 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 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 from a 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 nar row bead along the bottom of the cut edge and is very difficult to remove When cutting a troublesome steel SERVICE TROUBLESHOOTING it is sometimes useful to reduce the cutting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding F Common Cutting Faults 1 Insufficient Penetration a Cutting speed too fast b Torch tilted too much c Metal too thick d Worn torch parts
52. be ordered in various con figurations with various options factory installed Pak Master 100XL Power Supply OS Work Cable 7 NS With Clamp PCH M 100XL Torch and Leads A 01345 Figure 2 1 Pak Master 100XL Power Supply The power supply is designed to work with the Model PCH M 100XL Plasma Torches Torches will provide a maximum 1 inch 25 4 mm cut capacity Hand torches are available in 70 and 90 con figurations Machine torches are available only in Model PCM 100XL and include a rack and pinion mounting as Manual 0 2668 sembly Torch leads are available in 25 ft 7 6 m or 50 ft 15 2 m lengths with fittings for simple installation The torch includes a spare parts kit which provides an assort ment of replacement torch parts NOTE Refer to Section 3 04 for list of power supply op tions and accessories 3 03 Specifications Design Features A Power Supply Technical Specifications The following specifications apply to the Power Supply only 1 Front Panel Controls ON OFF Switch RUN SET Switch and Output Cur rent Control 2 Front Panel LED Indicators AC TEMP GAS DC 3 Rear Panel Input power cable strain relief gas connection Gas Regulator Filter Assembly 4 Input Power Available for the following input power 200 VAC 10 50 60 Hz Single or Three Phase Note Unit is supplied with 7 ft 2 1 m Input Power Cable 5 Output Power Continuously variable from 15 to 70 Am
53. by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and 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 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories 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 responsible representative Steve Ward Director of Operations Thermadyne UK Chorley England Date 6 22 99 7 GENERAL INFORMATION 1 08 Statemen
54. c transfer Pilot arc off ACTION Open external disconnect RESULT No power to system A 000926 Manual 0 2668 APPENDIX Ill POT LED PC BOARD LAYOUT J14 D4 10000000 y m aod Fo o 6a gt o O o3 1 FO Ole D7 a Oj o Lo 48 D5 g m5 DB LO o x R1 R4 0 eo Di x oT eet FO ES R2 R3 A 01206 D6 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 Current Control to Logic PC Board J3 8 Return for Current Control from Logic PC Board J3 9 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 J3 12 Signal for TEMP Indicator to Logic PC Board J3 13 Signal for DC Indicator to Logic PC Board J3 14 Front Panel AC Indicator Front Panel TEMP Indicator Front Panel DC Indicator Front Panel GAS Indicator Manual 0 2668 53 APPENDIX APPENDIX IV LOGIC PC BOARD LAYOUT D31 D35 D33
55. d indicate between 0 4 to 0 6 volts us ing the diode function d Reverse the meter leads and the indication should be a capacitor charging If the indication is a short then replace the FET Heatsink Assembly 5 FET Output Rectifier Check Use a digital meter diode or ohms function to check the forward and reverse bias of the output rectifiers on the FET Heatsink Assemblies per the following procedure a Remove the wire from E16 and E18 on the Upper and Lower FET 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 SERVICE TROUBLESHOOTING 28 should indicate between 0 3 to 0 6 volts using the diode function or 100K ohms using the ohms func tion c Place the meter lead on E18 and the meter lead on El6 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 func tion e Place the meter 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
56. e l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons ultra vio lets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne 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 parois lat rales ou des lu nettes de protection ou une autre sorte de protec tion oculaire e 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 e Maintenez votre casque et vos lunettes de protec tion 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 Date 6 22 99 e Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent ANSI ASC Z49 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 tre utilis s quand l arc est cach par moiceau de travail BRUIT Le bruit peut provoquer une perte permanente de louie Les proc d
57. ecure the Right Side Panel to the Frame Assembly NOTE The three bottom screws need only be loosened to allow the panel to be removed 4 Carefully pull the Right Side Panel up and away from the unit far enough to gain access to the wire connections on the inside of the Access Panel 5 Disconnect the LED POT PC Board wiring con nector from J3 at the Logic PC Board 6 Remove the two nuts securing the Access Panel to the Right Side Panel 4 Install the replacement Right Side Panel by revers ing the above procedure noting the following a Install the Access Panel onto the replacement Right Side Panel b Place the Right Side Panel onto the frame and slide the lip on the top edge over the edge on the top of the Left Side Panel D Leads Wrap Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the four screws securing the Leads Wrap to the Left Side Panel 4 Install the replacement Leads Wrap by reversing the above procedure 30 Manual 0 2668 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 clock wise and note the location of the pointer on the knob 2 Loosen the screw securing the Current Knob to the potentiometer shaft 3 Remove the old knob 4 Place the replacement Current Knob on to the po tentiometer shaft with the location of the pointe
58. ent replace the Logic PC Board 10 Faulty ribbon cable Refer to Appendiv XI 36 VAC Circuit Diagram and check for continuity on thepins a If any line between pins is open replace the ribbon cable 11 Faulty Gate Drive PC Board refer to Appendix XI 36 VAC Circuit Diagram Measure for 36 VAC on Gate Drive PC Board from J9 1 to J9 3 e If voltage is not present replace the Gate Drive PC Board e If voltage is present replace Logic PC Board AC indicator ON TEMP indicator ON System will not pilot 1 Air flow through unit is restricted a Provide adequate air flow Refer to Operating Manual 0 2581 Section 3 02 2 Exceeded duty cycle of Power Supply a Wait for fans to cool unit and refer to Operating Manual 0 2581 Section 2 03 for proper Duty Cycle Manual 0 2668 3 Faulty Fan or Logic PC Board Measure for 115 VAC on the Logic PC Board from J2 2 to J2 8 and J2 3 to J2 9 e If voltage is correct replace Fan Assembly e If voltage is incorrect replace Logic PC Board 4 Faulty temperature circuit a Check temperature circuit per Section 4 09 F repair as necessary D AC indicator ON TEMP indicator ON System will pilot RUN SET switch must be in RUN 1 Open Ribbon Cable or faulty FET Heatsink Assembly Check continuity on Logic Ribbon Cable from J4 10 Logic PC Board to J6 10 FET Heatsink As sembly e If cable has open replace ribbon cable If cable has continuity replace FET Hea
59. er 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 Source A 00553 Drain c Place the meter lead on drain lead of Q1 and meter lead on source lead of Q1 The meter should indicate gt 100K ohms NOTES Make measurements near the body of each MOSFET Be sure that the meter lead probes penetrate the protective coating on the MOSFET d Place the meter lead on drain lead of Q1 and meter lead to the heatsink The meter should indicate gt 1 meg ohms e Place the 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 SERVICE TROUBLESHOOTING 4 FET Reset Diode Check Use an ohmmeter set to the diode function and check the reset diode per the following procedure a Place the meter lead on E14 and the meter lead on E25 of the FET Heatsink Assembly Ca pacitor PC Board to check the reset diode The meter should indicate between 0 4 to 0 6 volts us ing the diode function b Reverse the meter leads and the indication should be a capacitor charging c Place the meter lead on E14 and the meter lead on E26 of the FET Heatsink Assembly Ca pacitor PC Board to check the reset diode The meter shoul
60. erify that unit is 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 inter nal components for signs of over heating fractures and damage 4 05 Circuit Fault Isolation NOTE Follow all instructions as listed and complete each in the order presented This section is to help isolate the defective circuit before troubleshooting identify symptoms and test the unit for proper operation Follow the instructions as given to iden tify the possible symptom s and the defective circuit After repairs are complete then run the following tests again to verify that the unit is fully operational A Initial Setup Conditions Connect gas supply to rear of Power Supply Turn on gas supply and adjust Power Supply Gas Regu lator to 70 psi 4 8 BAR Manual 0 2688 Set the Power Supply controls as follows ON OFF switch to OFF RUN SET switch to SET 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 following e AC indicator blinks for six seconds then steady ON e Main Contactor energizes clicks while AC indica tor is blinking Relay on Input PC Board energizes
61. ers securing the Main Contactor to the bottom of the unit 4 Install the replacement Main Contactor Assembly by reversing the above procedure Fan Replacement 1 Remove the Left Side Panel per Section 5 04 B NOTE The Top and Bottom Fan Assemblies are replaced in the same manner 2 Remove the four screws one each corner securing the Fan Guard to the Front Panel 3 Pull the Fan Guard and Fan Assemblies from the Front Panel far enough to locate the wiring to the Fans 4 Note the orientation of the Fan Assembly wiring push on connectors 5 Carefully pull the wiring connectors from the lugs on the Fan Assembly 6 Locate and remove the four phillips head screws securing the Fan Assembly to the Fan Guard 7 Carefully pull the Fan Assembly from the Fan Guard Oo Install the replacement Fan Assembly by reversing the above procedure see NOTE NOTE The mounting holes in the replacement Fan As sembly are not tapped Using one of the screws removed in Step 6 above turn the screw into the mounting holes of the new Fan Assembly This will make the reassembly of the unit easier Unit Base Front Replacement Remove the Left Side Panel per Section 5 04 B Remove the Right Side Panel per Section 5 04 C 1 2 3 Remove the Work Cable per paragraph A above 4 Remove the Torch from the unit 5 Remove the two Fan Assemblies from the Base Front Panel Assembly per paragraph D above 6 Remove the
62. essure Switch J2 15 Over Temperature Switch on Input Bridge J2 16 Over Temperature Switch Return APPENDIX 54 Manual 0 2668 J4 1 36 VAC from Gate Driver PC Board J9 1 J4 2 36 VAC to Gate Drive PC Board J9 2 J4 3 36 VAC from Gate Drive PC Board J9 3 J4 4 36 VAC to Gate Drive PC Board J9 4 J4 5 Ground to Gate Drive PC Board J9 5 J4 6 36 VAC to Gate Drive PC Board J9 6 J4 7 Ground to Gate Drive PC Board J9 7 J4 8 36 VAC to Gate Drive PC Board J9 8 J4 9 Return for Temperature Switch from Gate Drive PC Board J9 9 J4 10 Over Temperature Logic Level from Gate Drive PC Board J9 10 J4 11 Return for Master Enable Signal from Gate Drive PC Board J9 11 J4 12 Logic Level Master Enable Signal to Gate Driver PC Board J9 12 J4 13 PWM Enable Return to Gate Drive PC Board J9 13 J4 14 Logic Level PWM Enable Signal to Gate Drive PC Board J9 14 J4 15 PSR Return from Gate Drive PC Board J9 15 J4 16 PSR Signal from Gate Drive PC Board J9 16 J4 17 Return for Demand to Gate Drive PC Board J9 17 J4 18 Demand Signal to Gate Drive PC Board J9 18 J4 19 Return for Demand to Gate Drive PC Board J9 19 J4 20 Not Used J5 1 36 VAC to CD PC Board J11 1 J5 2 Return to CD PC Board J11 2 J5 3 36 VAC to CD PC Board J11 3 J5 4 CD Enable Signal to CD PC Board J11 4 J5 5 CD Enable Return to CD PC Board J11 5 J5 6 18 vdc to PCR Relay J5 7 PCR Signal to PCR Relay J5 8 Torch Switch to Pilot Output PC Board J13 1
63. f 000 lo 0000000 o GO00000 8 wohl J10 os 290000 QE 00 d8000 an posa LEN J 5 LOGIC PCB 2 1 T Il ze MES 00000000 3521555 288808 de A migo A ei ER EEE a TP4 A 01416 TP2 GND Logic PC Board Signals J1 1 36 VAC from Auxiliary Transformer J3 1 36 VAC to ON OFF Switch J1 2 115 VAC from Auxiliary Transformer J3 2 36 VAC from ON OFF Switch to Logic PC Board J1 3 Center Tap from Auxiliary Transformer J3 3 36 VAC to ON OFF Switch J1 4 Not Used J3 4 36 VAC from ON OFF Switch to Logic PC Board J1 5 36 VAC from Auxiliary Transformer J3 5 From RUN SET Switch on Front Panel J1 6 115 VAC Return from Auxiliary Transformer J3 6 From RUN SET Switch on Front Panel J3 7 10 vdc to Front Panel Current Control Pot J14 1 J2 1 115 VAC Return to Contactor J3 8 From Front Panel Current Control Pot Wiper J14 2 J2 2 115 VAC Return to Fan 1 J3 9 To Current Control Pot J14 3 Return J2 3 115 VAC Return to Fan 2 J3 10 18 VDC to Front Panel J14 4 J2 4 115 VAC Return to Solenoid J3 11 Logic Level for AC Indicator on Front Panel J14 5 J2 5 Not Used J3 12 Logic Level for GAS Indicator on Front Panel J14 6 J2 6 Not Used J3 13 Logic Level for TEMP Indicator on Front Panel J14 7 J2 7 115 VAC to Contactor J3 14 Logic Level for DC Indicator on Front Panel J14 8 J2 8 115 VAC Return to Fan 1 J3 15 Not Used J2 9 115 VAC Return to Fan 2 J3 16 Not Used J2 10 115 VAC Return to Solenoid J2 11 Not Used J2 12 Not Used J2 13 Pressure Switch Signal J2 14 Return from Pr
64. from Inrush Choke Assembly to Cap Board E25 Manual 0 2668 61 APPENDIX APPENDIX IX FET PC BOARD LAYOUT E14 E15 E17 E19 R33 o o O R32 o O R37 o o D5 O O Ob O O Olor OOO O O OM s3 of Lora o OL7 of oz 01 0rR2 oy OR7 01 ronn FET PCB ASSY R180 ca E12A E13A OR17 ORI 1 OR 2 OR 3 3 T r d no o o o pi4 1 bog 014015018 019 c14 O O Lo non 2390 O 66 60 607 Mie o mers e 500 no o DS no Do noklol of fo Ol A b amelie ro 50 66 66 60 ES no D O Ig a ro Do no Bo no bollolC 1 a 90 dos 00 OR25 0 O 012 013 016 017 c12 ocs Off go R26 O O in E12C E13C 050 o E12 E13 00 R23023 O O O1 0R4 rta of tos offers of 805 og 10 o o ola 000 00005 O opte 00 00 O O R34 OR39 o OR35 OR4 01 D2 o 0000000009 o Component Side Of PC Board E18 E16 o o o o o o o o o O OO O O 000 OOO o o o o o o o o o o o o o o o o O 000 oo oo oo o 000 E14 A 5 S o E15 MAIN XFMR P
65. generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors Lio SHOCK Electric Shock can injure or kill The 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 e Never touch any parts that are electrically live or hot e Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding cir cuit e Repair or replace all worn or damaged parts e Extra care must be taken when the workplace is moist or damp GENERAL INFORMATION Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publica tions Disconnect power source before performing any ser vice or repairs Read and follow all the instructions in the Operat ing Manual Ay AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable mate rial in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace e Do not cut or weld on containers that may have held combustibles e Provide a fire watch when working in an area where fire hazards may exist e Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut under water or while using a water
66. in 13 from connectors J19 black wire J20 orange wire and J21 brown wire using a pin removal tool 5 Disconnect the secondary wires by unplugging the J15 connector from the Logic PC Board 36 6 Remove the four mounting screws securing the Auxiliary Transformer Assembly to the chassis 7 Remove the Auxiliary Transformer Assembly from the unit 8 Install the replacement Auxiliary Transformer As sembly by reversing the above procedure noting the following e Brown wire to 460V selector connector J21 on the voltage selection panel Orange wire to 380V selector connector J20 on the voltage selection panel e Black wire to 220V selector connector J19 on the voltage selection panel G Bulkhead Adapter Replacement 1 Remove the Right Side Panel per Section 5 04 C 2 Remove Torch connection at the Bulkhead Adapter 3 Disconnect the gas tube from the fitting at the end of the Bulkhead Adapter 4 Remove the fitting 5 Remove the first nut from the Bulkhead Adapter 6 Carefully remove the wire from the Bulkhead Adapter that comes from the CD Transformer Coil 7 Remove the second nut securing the Bulkhead Adapter to the bulkhead 8 Install the replacement Bulkhead Adapter by re versing the above procedure Manual 0 2668 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts lists provide a breakdown of all replaceable components The parts lists are arranged a
67. k that all cable connections are secure B Cleaning Unit should be cleaned as described in Operating Manual 0 2667 4 03 Common Operating Problems A GS Disconnect primary power at the source before dis assembling the power supply torch or torch leads Frequently review the Important Safety Precau tions page 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 AE Manual 0 2688 m CAUTION Sparks from the cutting process can cause damage 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 E Piloting is harder on parts life than actual cutting be cause 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 torch tip at the edge of the workpiece not touching at the point where the cut is to start
68. lacement Parts List Item O oF ON N 10 11 12 13 14 15 16 17 Qty NFP RP k H M e A ME M e M MH Description INSULATOR INPUT PCB CABLE ASSEMBLY 10 CIR RIBBON 15 LG CABLE 20 CIRCUIT RIBBON LOGIC CONTROL PCB ASSEMBLY ASSEMBLY GATE DRIVER PCB ASSEMBLY FET HEATSINK Includes ASSEMBLY FET HEATSINK DUST COVER FET ASSEMBLY FUSE BLOCK FUSE 0 8A 600V 13 32 DIA BUSHING STANDOFF 10 32 X 3 8 HEX X 2 LG AL DIODE BRIDGE ASSEMBLY Includes DIODE BRIDGE 1600V 75A THERMAL PAD OUL INPUT MODULE ASSEMBLY INPUT PCB BRACKET HEATSINK MOUNTING CABLE 2 CIRCUIT ASSEMBLY INRUSH CHOKE NOTE 1 Item shown for illustration purposes only PARTS LISTS 44 Catalog See Note 1 9 5922 9 7510 9 7601 9 7562 9 7015 9 5562 9 7526 See Note 1 See Note 1 9 7604 9 7600 See Note 1 See Note 1 9 7616 Manual 0 2668 A 02027 PARTS LISTS 45 Manual 0 2668 6 07 Rear Panel Replacement Parts List Item Qty AN O O FP WN r Am o 12 13 14 15 16 17 PARTS LISTS p HE HE M RE RE R RE HE ME HM M HA PERE me N M Description PRESSURE SWITCH 35 PSI VALVE SOLENOID 1 8 NPT REGULATOR AIR LINE FLEX CONNECTOR 1 4 NPT STREET ELBOW 1 8 NPT STR TEE 1 4 1 8 NPT REDUCER FITTING 1 8 NPT X 2 LONG NIPPLE BRASS FITTING 1 8 NPT X 1 4 TUBE 90 PRESSURE GAUGE PANEL REAR Includes PANEL REAR LABEL GAS SUPPLY LA
69. le must have an outside diameter of 0 69 inches 17 5 mm or greater Manual 0 2668 51 APPENDIX APPENDIX II SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION Close external disconnect switch RESULT Power to system ACTION Protect eyes and activate torch RESULT Gas flows 2 seconds After gas pre flow DC indicator on Pilot relay closes Pilot arc established ACTION ACTION ACTION ON OFF switch to ON RUN SET switch to SET RESULT RESULT AG indicator blinks for 8 seconds then steady on Fans on Power circuit ready Gas solenoid open gas flows to set pressure GAS indicator on PILOT ARC 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 ACTION 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 ON OFF switch to OFF RESULT All indicators off Power supply fans off 52 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 ar
70. 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 U Au 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 sante e Eloignez toute fum e et gaz de votre zone de respi ration Gardez votre t te hors de la plume de fum e provenant du chalumeau e Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz GENERAL INFORMATION Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir 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 e Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient
71. nsfer D31 D33 Lo 0000099 D55 T og TORS 69 2000060000 Ch P 8 lo Iesel EE a Logic PC Board A 01405 While trying to transfer measure voltage at J17 1 to J17 2 on the Logic PC Board SERVICE TROUBLESHOOTING 20 Pin 1 Pin 2 on o veel ol 000 l0000000000000000 CA ET S 7 Logic PC Board A 01406 If voltage is approximately 12 vdc replace the current sensor If voltage is less than 2 vdc replace the Logic PC Board When operating at amperages over 35 amps the amperage drops off after main cutting arc initiates Check the following indicator inside the Power Sup ply Drag indicator D35 on the Logic PC Board is ON when the torch tip comes in contact with the workpiece 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 indi cator D35 on the Logic PC Board is still ON then replace the Logic PC Board Logic PC Board
72. oard 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 except for filter replacement require that the Power Supply be disassembled The part to be replaced will determine to what extent the Power Supply must be disassembled NOTES Before removing any connection mark each wire with the connection designation When reassem bling make sure the wires go to the proper termi nals Note the routing of wires and make sure the wires are put back in the same place when reassembling the unit Each Subsection is referenced to Section 6 for parts lists and overall detailed drawing A WARNING Disconnect primary power from the source before opening or disassembling the power supply Make sure AC indicator on the Power Supply front panel is OFF 29 REPLACEMENT PROCEDURES Before disassembling any part of the Power Supply first read the procedure for the part to be replaced then pro ceed with the disassembly 5 04 Major External Parts Replacement NOT
73. on 5 04 C Manual 0 2668 NOTES Before removing any 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 PC Board Assembly 3 Remove the four screws and washers securing the PC Board to the standoffs 4 Install the replacement CD PC Board Assembly by reversing the above procedure Relay Replacement 1 Remove the Right Side Panel per Section 5 04 C NOTES Before removing any 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 Relay Assembly 3 Remove the two screws securing the Relay Assem bly to the Pilot Panel 4 Install the replacement Relay Assembly by revers ing the above procedure Main Transformer Assembly Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Right Side Panel per Section 5 04 C 3 Remove the following terminal connections from the two FET Heatsink Assemblies noting the lo cation of each wire Connection Description MAIN XFMR PRI XFMR PRI MAIN XFMR SEC XFMR SEC REPL
74. problems that can arise with the Pak Master 100XL Power Supply 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 Sub section 4 09 includes specific test procedures and LED status identification tables The sub section is referenced by the troubleshooting guide for the specific test to be performed The troubleshooting guide has six sub sections as follows Section 4 05 Circuit Fault Isolation Section 4 06 Main Input and Internal Power Prob lems Section 4 07 Pilot Arc Problems Section 4 08 Main Arc Problems Section 4 09 Test Procedures 14 Manual 0 2668 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 guide is set up in the following manner 1 Perform operational check s on the equipment to iso late problem to possible circuit s per Section 4 05 Circuit Fault Isolation 2 Determine symptom and isolate to defective assembly using the following format X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Check Remedy Text Type 3 Locate your symptom in the appropriate Sub Section 4 Check the causes easiest listed first for the symptom 5 Check the remedies listed for each cause 6 Repair as needed being sure to v
75. ps maximum 6 Duty Cycle 40 Duty Cycle amp 108V output with 60 Hz input 40 Duty Cycle amp 108V output with 50 Hz input 7 Cut Capacity 1 inch 25 4 mm 1 1 4 inch 31 8 mm severance 8 Pilot Circuitry High Frequency HF Pulsed DC 9 Weight 79 lbs 35 8 kg 11 DESCRIPTION 10 Overall Dimensions 18 9 480 mm High x 13 330 mm Wide x 25 5 648 mm Long Overall dimensions are with handle lead wrap bracket and Gas Regulator Filter Assembly installed B Gas Regulator Filter Assembly Specifications The following specifications apply to the Gas Regulator Filter Assembly only 1 Gas regulator maximum gauge pressure 160 psi 11 BAR or 11 03 kPa 2 Maximum input gas pressure 125 psi 8 6 BAR or 861 kPa 3 Filter Coalescent type filter 3 04 Power Supply Options and Accessories NOTE Refer to Section 6 Parts Lists for part numbers and ordering information The following are accessories that are available for this power supply A Two Stage Air Line Filter An optional two stage air line filter is available The 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 The filter assembly is pre assembled at the factory and need only be attached to the power supply B High Pressure Regulators High pressure regulators are available for air and ni trogen The regulators are used to set the proper
76. put voltage drops below 60 VDC indicating a Input voltage is okay problem exists the Logic PC Board sends a signal which turns OFF the PWM Enable signal to the Gate Drag On When ON indicates that Drive PC Board Because this happens in less than 50 the torch tip is making contact with milliseconds itis not easy to take voltage readings to the workpiece find the source of the problem When the unit is at idle the AC OK indicator D34 should be ON The Torch Switch Enable indicator D5 turns ON when the torch switch is pressed At Manual 0 2688 25 SERVICE TROUBLESHOOTING this point the gas begins to flow When the preflow NOTE time is over the PWM Enable signal is given and the DC indicator at the front panel turns ON When the pilot arc is established the Pilot On indicator D33 turns ON e Style 2 Use TPS The conformal coating must be removed from the lead of R22 for the jumper to make a good contact If the PWM Enable indicator D3 does not come ON then replace the Logic PCB If the PWM Enable indicator D3 turns ON then OFF immediately the following test should be performed a Disconnect J11 from the CD PC Board to dis able the CD signal CD PC Board
77. r the same as noted in step 1 5 Tighten the screw to secure the knob to the poten tiometer shaft B ON OFF Switch Replacement 1 Unlatch the Access Panel to gain access to the rear of the ON OFF Switch 2 Disconnect all the wiring to the ON OFF Switch 3 Squeeze the top and bottom of the switch while pulling it out of the Access Panel 4 Install the replacement ON OFF Switch by revers ing the above procedure C RUN SET Switch Replacement 1 Unlatch the Access Panel to gain access to the rear of the RUN SET Switch 2 Disconnect all the wiring to the RUN SET Switch 3 Squeeze the top and bottom of the switch while pulling it out of the Access Panel 4 Install the replacement RUN SET Switch by re versing the above procedure D Pot LED PC Board Assembly Replacement 1 Turn the CURRENT adjustment fully counter clock wise and note the location of the pointer on the knob 2 Loosen the screw securing the Current Knob to the potentiometer shaft 3 Remove the Current Knob 4 Unlatch the Access Panel to gain access to the Pot LED PC Board Manual 0 2668 5 Remove the Pot LED PC Board from the four stand offs 6 Disconnect the connector at J14 of the Pot LED PC Board 7 Install the replacement Pot LED PC Board by re versing the above procedure E Access Panel Replacement 1 Remove the Right Side Panel per Section 5 04 C 2 Remove the following components from the Ac cess Panel
78. r External Parts Replacement nenn 30 5 05 Access Panel Parts Replacement a 31 5 06 Front Panel Parts Replacement a 31 5 07 Left Side Internal Component Parts Replacement en 32 5 08 Rear Panel Parts Replacement rea 34 5 09 Right Side Internal Component Parts Heplacement ss 35 TABLE OF CONTENTS TABLE OF CONTENTS continued SECTION 6 PARTS LS TS a as 37 BAR RL dree ren EE 37 6 02 Ordering Information 37 6 03 Major External Replacement Parts List 38 6 04 Access Panel Replacement Parts List 40 6 05 Front Panel Replacement Parts List 42 6 06 Left Side Internal Component Replacement Parts List 44 6 07 Rear Panel Replacement Parts List 46 6 08 Right Side Internal Component Replacement Parts List 1 48 6 09 Options and Accessories seessseeeseeesiiesirsssrnsstnttttntsttrnttintssrnnsnn nenun nnt 50 APPENDIX I INPUT WIRING REQUIREMENTS ui 51 APPENDIX II SEQUENCE OF OPERATION BLOCK DIAGRAM nennen 52 APPENDIX III POT LED PC BOARD LAYOUT ire 53 APPENDIX IV LOGIC PC BOARD LAwOUT eee eee ee aaa aaa aaa aaa aaa aaa enie 54 APPENDIX V GATE DRIVE PC BOARD LAYOUT iii 56 APPENDIX VI PILOT OUTPUT PC BOARD LAYOUT issue 58 APPENDIX VII CD PC BOARD LAYOUT ire 60 APPENDIX VIII INPUT PC BOARD LAYOUT eee eee aaa aaa aaa aaa aaa aaa aaa acc ea 61 APPENDIX IX FET PC BOARD LAYOUT iii 62 A
79. s as suggested in the following per ANSI ASC Z49 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 Documents U S Government Printing Office Wash ington D C 20402 2 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH SAFETY AND HEALTH IN ARC WELD ING AND GAS WELDING AND CUTTING obtain able from the Superintendent of Documents U S Government Printing Office Washington D C 20402 4 ANSI Standard Z87 1 SAFE PRACTICES FOR OC CUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 5 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broad way New York NY 10018 6 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Insti tute 1430 Broadway New York NY 10018 7 AWS Standard A6 0
80. s follows Section 6 03 Major External Replacement Parts List Section 6 04 Access Panel Replacement Parts List Section 6 05 Front Panel Replacement Parts List Section 6 06 Left Side Internal Component Re placement Parts List Section 6 07 Rear Panel Replacement Parts List Section 6 08 Right Side Internal Component Replacement Parts List 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 Thermal Dynamics product must be returned for ser vice contact your Thermal Dynamics distributor Mate rials returned to Thermal Dynamics without proper au thorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the torch Address all inquiries to your autho rized Thermal Dynamics distributor Manual 0 2668 37 PARTS LISTS 6 03 Major External Replacement Parts List Item Oty 1 2 1 4 1 5 1 PARTS LISTS Description TUBE LIFTING HANDLE 1 125 OD 11 85 LG MOUNT LIFTING HANDLE COVER LEFT SIDE Includes COVER LEFT SIDE 2X2976 LABEL USER WARNING ENGLISH COVER RIGHT SIDE Includes COVER RIGHT SIDE OVERLAY RIGHT SIDE PANEL LABEL USER WARNING FRENCH LEADS WRAP Includes PANEL LEADS WRAP OVERLAY LEFT SIDE PA
81. ssembling the Power Supply torch parts or torch and leads assemblies 1 Using a phillips head screw driver remove the five screws which secure the left side panel viewed from front of unit to the frame assembly Manual 0 2688 Left Side A 01869 Screws gt Ground Wire 5 Places 2 Carefully pull the left side panel from the Power Sup ply a short distance see note NOTE There is a ground wire attached to the side panel 3 Remove the nut securing the ground wire to the side panel 4 Close the enclosure by reversing the above steps 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 Using the Figures for each test check each diode in the module Fach diode must be checked in forward bias plus to negative and reverse bias negative to plus direction 5 Connect the volt ohmmeter positive lead to the an ode of the diode and the negative lead to the cath ode of the diode for forward bias testing refer to following figure A properly functioning diode will conduct in the forward bias direction and indicate be tween 0 3 to 0 9 volts 21 SERVIC
82. sure Switch Replacement 1 Remove the Right Side Panel per Section 5 04 C 2 Disconnect the two wires connected to the Pres sure Switch Assembly 3 Remove the assembly from the T fitting 4 Install the replacement Pressure Switch Assembly by reversing the above procedure and noting the following e Apply pipe thread sealant to the fitting before reassembling Solenoid Valve Replacement 1 Remove the Right Side Panel per Section 5 04 C 2 Disconnect the two wires connected to the Pres sure Switch Assembly 3 Disconnect the two wires connected to the Sole noid Valve Assembly 4 Disconnect the gas tube connected to the bottom of the T fitting 5 Remove the T fitting and gas fitting from the Sole noid Valve Assembly 6 Remove the Solenoid Valve Assembly from the straight brass fitting 7 Install the replacement Solenoid Valve Assembly by reversing the above procedure Air Line Regulator Bracket Replacement 1 Disconnect the gas input hose from the input of the Air Line Regulator Assembly 2 Remove the nut securing the Air Line Regulator to the mounting bracket 3 Remove the four screws securing the Air Line Regu lator Bracket to the Rear Panel 4 Pull the bracket from the unit 5 Install the replacement Air Line Regulator Bracket by reversing the above procedure Air Line Regulator Replacement 1 Disconnect the gas input hose from the input of the Air Line Regulator Assembly 2
83. t au Code lectrique national des Etats Unis Voir la page 5 article 9 e D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration e Lisez et respectez toutes les consignes du Manuel de consignes GENERAL INFORMATION A INCENDIE 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 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 e 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 e Procurez une bonne a ration de toutes les fum es inflammables ou explosives e Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles e 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 pieces 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 explosera si enflamm m RAYONS D ARC DE PLASMA Les rayons provenant d
84. t 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 IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by
85. t of printed circuit sol der mounted components is allowed except as noted in this manual If to be returned the replaced Printed Circuit Board As semblies must be properly packaged in protective mate rial and returned intact per normal procedures Manual 0 2668 2 03 Service Responsibilities The Service Technician should be familiar with the equip ment and its capabilities He should be prepared to rec ommend arrangements of components which will pro vide the most efficient layout utilizing the equipment to its best possible advantage Maintenance work should be accomplished in a timely manner If problems are encountered or the equipment does not function as specified contact Technical Services Department at West Lebanon for assistance 9 INTRODUCTION INTRODUCTION 10 Manual 0 2668 SECTION 3 DESCRIPTION 3 01 Scope of Manual The information in this section has two purposes e To familiarize the service technician with the capa 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 General Description The power supply provides 70 amp maximum outputand includes all control circuitry electrical and gas inputs and outputs pilot circuitry torch leads receptacle and a work cable with clamp Machine torch systems also include a remote hand ON OFF pendant NOTE The power supply can
86. 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 Apo Noise can cause permanent hearing loss Plasma arc pro 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 e Noise levels 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 manual m 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 GENERAL INFORMATION To protect your eyes always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear e 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 e Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of len
87. the five screws securing the wiring to the Input PC Board Manual 0 2668 3 Remove the clear Input PC Board Insulator sheet 4 Remove the two screws at Ri and CG 5 Carefully pull the Input PC Board from the unit far enough to disconnect the wiring connections to the component side of the PC board 6 Install the replacement Input PC Board by revers ing the above procedure noting the following NOTE Failure to properly tighten the seven screws secur ing the Input PC Board to the Diode Bridge will cause damage to the unit The five screws securing the wiring and Input PC Board to the Diode Bridge must be tight enough to prevent the wires from moving e The two screws securing the Input PC Board to the Diode Bridge at R2 and G must be tight Input Diode Bridge Assembly Replacement 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the Right Side Panel per Section 5 04 C 3 Remove the Input PC Board per paragraph C above 4 Remove the two nuts securing the Input Diode Bridge to the Center Chassis 5 Remove the Input Diode Bridge Assembly from the unit eh Remove the Thermal Pad from the Center Chassis N Remove the Input Heatsink on the right side of the unit Oo Remove the Thermal Pad from the Input Heatsink No Install the replacement Input Diode Bridge Assem bly and new Thermal Pad by reversing the above procedure see Note NOTE The two nuts removed in Step 3
88. to Section 4 08 Main Arc Prob lems 4 06 Main Input and Internal Power Problems Locate your symptom below A Main power line fuses blow as soon as main disconnect is closed 1 Faulty Input PC Board a Test Input PC Board per Section4 09 D repair as necessary B AC indicator 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 Replace input power cable 5 Fuse blown inside Power Supply a Replace internal Fuse 1 FU 6 Faulty Auxiliary Transformer refer to Appendix XI 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 SERVICE TROUBLESHOOTING 7 Faulty Logic PC Board refer to Appendix XI 36 VAC Circuit Diagram Measure for 36 VAC on Logic PC Board from J3 1 to J3 3 a If voltage is not present replace the Logic PC Board 8 Faulty ON OFE switch refer to Appendix XI 36 VAC Circuit Diagram Measure for 36vac on the Logic PC Board between J3 2 to J3 4 a If voltage is not present replace the ON OFF switch 9 Faulty Logic PC Board refer to Appendix XI 36 VAC Circuit Diagram Measure for 36 VAC on Logic PC Board from J4 2 to J4 6 or J4 4 to J4 8 a If voltage is not pres
89. 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 e 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 e 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 combustibles ou explosifs e Le phosgene un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e A CHOC ELECTRIQUE Les chocs 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 par ties du circuit de soudage e R parez ou remplacez toute pi ce us e ou endommag e e Prenez des soins particuliers lorsque la zone de tra vail est humide ou moite e Montez et maintenez le mat riel conform men
90. tsink Assembly 2 Defective Logic PC Board On Logic PC Board jumper J4 pin 9 to J4 pin 10 a If TEMP indicator stays ON then replace Logic PC Board E AC indicator ON TEMP indicator OFF No gas flow GAS and DC indicators OFF 1 RUN SET switch in RUN position a Switch to SET position 2 Gas supply not connected to unit a Connect to gas supply 3 Gas supply not turned on a Turn gas supply on 4 Faulty RUN SET switch a Check continuity 5 Faulty gas solenoid circuit a Test gas solenoid circuit per Section 4 09 G re pair as necessary E AC indicator ON GAS indicator OFF Gas flows DC indicator OFF 1 Gas pressure to low a See torch manual for operating pressures Manual 0 2688 17 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 a If 12vdc and pressure is above 50 PSI replace gas pressure switch Rear Panel Pu Gas Solenoid A 01184 5 Faulty Wiring or Logic PC Board Check for DC voltage from Logic PC Board J2 13 to TP1 GND e If less than a volt replace Logic PC Board TP1 GND Logic PC Board o GO on E oo ol e O 100 PE Olopnoooooo R72 OOO O O O o oo
91. ut Sense Gnd J13 6 Not Used J13 7 Tip Voltage Sense to Logic Board J5 14 Drag Sense J13 8 Not Used J13 9 PS Sense to Logic Board J5 16 PS Sense DC and Off the Plate J13 10 Not Used APPENDIX 58 Manual 0 2668 CGND Chassis Gnd E7 PS Stud from Output Inductor L1 to CD Xfmr ES PS C4 Rtn for Pilot Voltage Twisted with Pilot RTN to E23 E9 PS to E18 Upper Fet Module E10 PS to E18 Upper Fet Module E20 From E22 to PCR Pin 2 E22 From Pilot Choke to E20 E23 C4 Rtn for Pilot Voltage Twisted with Pilot RTN from E8 E24 Pilot RTN from Standoff on bulk head and Torch Cable E27 Pilot RTN to Pilot Choke E29 PS Stud from Work lead Through Current Sense To E18 Fet Modules E30 PS to CSR 8 Manual 0 2668 59 APPENDIX APPENDIX VII CD PC BOARD LAYOUT TP2 TP1 o O o o O o o El o o o SIG O om TS o J11 ooco D 19 SS D A Hi geen 2 o 45 E o a O Zeen u O I 1 go o S TP3 A 01208 CD PC Board Signals J11 1 36 VAC from Logic PC Board J5 1 J11 2 Return from Logic PC Board J5 2 J11 3 36 VAC from Logic PC Board J5 3 J11 4 CD Enable Signal from Logic PC Board J5 4 J11 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 T

PAK MASTER ® 100XL 200 VAC Air Plasma

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PAK MASTER &reg; 100XL 200 VAC Air Plasma

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PAK MASTER ® 100XL 200 VAC Air Plasma