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Service Manual - Victor Technologies

1. 17 19 14 16 18 2 L2 L3 091 5 004 O
2. 7 8 9 10 CURRENT SENSE 5 CD ENABLE AL ee 1 ual A n CD PCB PILOT 3 3 481 19 1664 OUTRUT 5 1621 2 2 a 1631 19 1663 6 1 1 1281 L ki 1 25 T gu t 1381 8 NEG 22 7 7 14 371 7 TIP SENSE 2 381 5 WORK E9 418 un d an un 5 2 30 Ha z nnnm nmgmnnnh a UUUUUUUUUUUUUU 7 1441 L2 D i B E27 a EZB PILOT PO INDUCTOR 17 D a q 1 12V DD 21 COM c5 TORCH CONTROL 31 PW PCI a pazzj m 4 COM ri L2 51 PRI OUTPUT a CURRENT INDUCTOR M SIGNAL c5 6 COM a S 979 71 SEC 3 5 CURRENT E25 2 CAP BOARD q PM58XL PLUS 19X1289 cp 2 kie il L PM75XL PLUS 19x928 D SIOVER 0 TEMP 191 E26 D R 1a COM 1 1 ide q 161 2 N 2 E13 E12 OUT 2 5 o FET MODULE sos OUT UPPER E
3. 17 TP1 GND 0 2166 re u cml SERRE 12 LOGI GATE DRIVE Pca 2 4 pa Logic Gate Board UN K02545 ACindicator 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 Pilot Output PC Board Remove power from the power supply Discon nect J12 and 13 from the Pilot PC Board Check for an open between J12 pin 1 to J12 pin 3 on the Pilot Output PC Board SECTION 4 SERVICE TROUBLESHOOTING a Replace Pilot Output PC Board if reading is not 4 07 Pilot Arc Problems open Locate your symptom below A AC indicator ON TEMP indicator off No gas Pilot Output PC Board flow GAS and DC indicators OFF Torch Switch PILOTZOUTPUT PCB ooo sg 2000000009 Assy 19x188 iO must be pressed ola o o ds 1 Faulty hand torch parts or Logic Gate PC Board 8 9 9 oO OF p 5 j Check start indicator DI on Logic Gate o 5 Board
4. o a If start indicator D1 is ON replace Logic Gate tee PCB a Ob al cl FETE b Ifstart indicator DI on Logic Gate PC Board is OFF check the following O Check Pilot Output PC Board for 12 VDC between J12 pin 1 to pin 3 with torch switch pressed If voltage is correct check Torch Switch and PIP as needed per appropriate torch manual J12 4 If voltage is incorrect replace Logic Gate PC Board Pin 3 Pin 7 A 2 Faulty Logic Gate PC Board Measure for 12VDC on Logic Gate PC Board be tween J5 8 J5 9 If voltage is less than 2VDC replace Logic Gate PC Board 4 Faulty Logic Gate or Pilot PC Board B AC indicator ON TEMP indicator off Gas flows Check for DC voltage from Logic Gate PC Board GAS indicator ON DC indicator blinks Small arc J5 pin 8 to J5 pin 9 may be visible in torch a Replace Logic Gate PC Board if voltage is 1 Faulty Pilot Output PC Board or Shorted Torch 12VDC a Test per Section 4 09 H repair as necessary J5 2 Faulty FET Heatsink Assembly a Check per Section 4 09 1 repair as necessary 3 Faulty torch a Check torch per appropriate Torch In
5. E24 C4 J12 0000000001 C2 1 O O g D2 C6 5 a PLOTS o 9 M em 5 m i amp _ 8 8 1 E E s se 9 10 29 20 22 01389 8 E30 Pilot Output PC Board Signals JI2 1 Torch Switch Filter in from J22 3 Torch Control JI2 2 Not Used 12 3 Torch Switch Filter Return from J22 4 Torch Control JI2 4 Not Used J12 5 Pilot Return Shield to J22 1 Torch Control J12 6 Torch Switch Shield to J22 2 Torch Control JI2 7 Not Used J12 8 OK to Move TO J22 12 JI2 9 Not Used 12 10 OK to Move RTN TO J22 14 Torch Control J13 1 Torch Switch Filter out to J5 8 Logic Board Torch Sw J13 2 Torch Switch Filter Return out to J5 9 Logic Board Torch Sw Return 13 3 Logic Low OK to Move Relay Coil to Logic PCB J5 10 OK to Move 13 4 OK to Move Relay Coil to Logic PCB J5 11 Unregulated 18VDC J13 5 5 to Logic Board J5 12 Output Sense Gnd J13 6 Not Used J13 7 Tip Voltage Sense to Logic Board J5 14 Drag Sense J13 8 Not Used 139 PS Sense to Logic Board J5 16 PS Sense DC and Off
6. 14 04 10000000 _ Fo 9 6o gt O 1 u OJ 1 Lo 05 R5 D8 LO R1 R4 C4 06 o 07 R2 R3 A 01206 06 Pot LED PC Board Signals 114 1 142 114 3 114 4 114 5 114 6 147 114 8 D4 D5 D6 D7 10 vdc from Logic PC Board 7 Current Control to Logic PC Board J3 8 Return for Current Control from Logic PC Board 9 18VDC Unregulated VDC from Logic PC Board 10 Logic Low Signal for AC OK Indicator to Logic PC Board J3 11 Logic Low Signal for GAS Indicator to Logic PC Board J3 12 Logic Low Signal for TEMP Indicator to Logic PC Board J3 13 Logic Low Signal for DC Indicator to Logic PC Board 3 14 Front Panel AC Indicator Front Panel TEMP Indicator Front Panel DC Indicator Front Panel GAS Indicator Manual 0 2745 55 APPENDIX APPENDIX IV LOGIC GATE PC BOARD LAYOUT TP24 TP25 dis Ne T TPS TP8 TP7 TP23 ci ca SARI 1 e228 2 O ETE D WT 1 1 sac pa N xk pra 5 LE lej al nm E
7. IHERMAL DYNAMICS ETS A THERMADYNE Company aster ak 50 XL PLUS Air Plasma Cutting Povver Supply Service Manual August 12 1999 Manual No 0 2745 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 50XL PLUS Air Plasma Cutting Power Supply Service Manual Number 0 2745 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1999 by Thermal Dynamics Corporation 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 50XL PLUS 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 1999 Record Serial Numbers For VVarranty Purposes SECTION 1 GENERAL INFORMATION erii bes sit lat shuk sui ee pone teen 1 1 01 Notes Cautio
8. 1 Front Panel Controls ON OFF Switch RUN SET LATCH Switch and Output Current Control 2 Front Panel LED Indicators AC TEMP GAS DC 3 Rear Panel Input Power Cable Gas Connection Gas Regulator Filter Assembly 208 230 240V single phase units include a 50 amp in put cable and plug 4 Input Power Available for the following input power 208 230 240 410 50 60 Hz Single or Three Phase 380 415 21096 50 60 Hz Three Phase 460 VAC 10 50 60 Hz Single or Three Phase 575 VAC can be utilized with the addition of the op tional transformer unit 5 Output Power Continuously variable from 15 to 40 Amps maximum 6 Duty Cycle 100 duty cycle at 40 Amps 7 Cut Capacity 1 2inch 12 7 mm 3 4 inch 19 mm severance 8 Pilot Circuitry Capacitive Discharge CD Pulsed DC 9 Weight 62 lbs 28 kg w work lead only 66 lbs 30 kg w work lead and torch amp lead 11 SECTION 3 DESCRIPTION 10 Overall Dimensions Overall dimensions are with Handle Lead Wrap Bracket and Gas Regulator Filter Assembly installed 19 482 mm High x 13 330 mm Wide x 24 8 63 m Long 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 2 Maximum input gas pressure 125 psi 8 6 bar 3 Filter Coalescent type filter 3 04 Power Supply Options and Acc
9. 48 6 08 Right Side Internal Component Replacement Parts List 50 6 09 Options and Accessories 2 APPENDIX I INPUT WIRING REQUIREMENTS iii 53 APPENDIX SEQUENCE OF OPERATION BLOCK DIAGRAM 54 APPENDIX IIl POTILED PC BOARD LAYOUT 55 APPENDIX IV LOGIC GATE PC BOARD LAYOUT 56 APPENDIX V PILOT OUTPUT PC BOARD LAYOUT sieur 58 APPENDIX VI PC BOARD LAYOUT iris 60 APPENDIX VII INPUT PC BOARD 61 APPENDIX VIII FET PC BOARD LAYOUT iii 62 APPENDIX IX CAPACITOR PC BOARD 64 APPENDIX X 36VAC CIRCUIT DIAGRAM 65 APPENDIX XI SYSTEM 5 66 SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and VVarnings 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 wmm CAUTION A procedure which if not properly followed may cause damage to the equipment G E A procedure which if not properly followed may cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions OPERATION AND MAINTENANCE OF PLASMA ARC E
10. 904 Foo 0 0 hu 9 O 01 T 02 R34 D2 cag o ERN o me 2224 2 ES O D2104 a o joo FOnza QO QO m 9 019 Lo d FO aia ais o 825 R23 CZ O4 Fo XS z pag OL ce og o4 Lo 6 O4 Cpe T2 R430 0 O4 OOou O4 225 59 RI2 O10 m OO R8 EI3A O Lol o otsa o o LO O of LO R28 9 FET PCB ASSY 19 1259 REV Component Side of PC Board E19 o ONO O O 00 17 OUTPUT E17 6 UJ i S 5 qo EISXFMR 566 e 9 u O no E14 sod 5 O e o O o o OF O Et4 MAIN XFMR PRI o E15 Hg 9 e Q o 8 9 0 OI o 9 15 0000 9 MAIN XFMR PRI ej o oo o ra o EE on o E16 eo E 5 E16 o o MAIN XFMR SEC B OO E 8 18 O 2 OO OO GO oo mo EIB OUTPUT o o 00 00 Cy pO OO Og 99 02631 Solder Side of Board APPENDIX 62 Manual 0 2745 FET PC Board Signals Upper and Lower Assemblies J6 1 12VDC from Logic Gate PCB upper J7 1 lower J8 1 6 2 common GND from Logic Gate PCB
11. WHITE 3 E amp xia Dc IN LINE 12 CONNECTOR n p 102 12345 6 7 8 9 1 1 12 1 12V 35 21 COM 1341 a lg ajelslelalsla s 31 33 a 41 51 PRI 1 2 34 5 8 7 8 T CURRENT LED PCB SIGNALE 19 1604 COM AC 71 SEC V SER CURRENT ON 7 OFF TEMP SIGNAL 81 COM RUN GIOVER TEMP 181 COM CURRENT G CONTROL G 1761 n uj 1581 525 13 16 Ci 12 1701 m INRUSH 141 5 1 D 2 151 1 75XLPLUS USE 4 POLE INPUT PCB CONTACTOR 18 1592 INPUT 9 200 400 VAC 1781 1 OR 3 PHASE USE LI 4 L2 FOR SINGLE PHASE INPUT Li 1 aci 2 12 021 AC2 ta ui 8 N GND CGND Q JUMPER L2 inb TO L3 FOR SINGLE PHASE ONLY 5 XLPLUS USE 3 POLE CONTACTOR 0000000000000 000000000000 0000000000000 2 3 45 78 9 21 1 2 3 4 5 6 7 8 3 2 3 4 5 amp 7 8 n 1 2 TO J25 12 TO 325 9 21 468 J20 380 208 280 J19 at TOSACI 2 3 4 5 5 7 892 rit AUR TO L2 12 TO AC2 5 a F TO L3 TO at I 191 151 APPENDIX 66 Manual 0 2745
12. isolate the possible fault to the FET Heatsink Assembly There are several internal indicators LED s on the Logic Gate PC Board to help in troubleshooting The indicators on the Logic Gate PC Board as follows S orc vvitc nable VVhen ON indicates torch switch is pressed CD Enable Initiates spark gap on CD PC Board Indicator should come ON then go OFF after a pilot arc has been establis hed Indicates main cutting arc D 2 is established 4 Pilot ON Indicates that Relay drive is active OFF D D D during cutting D PWM Enable indicates PWM IC which provides Gate Drive signal to FET PCB is active Drag On When ON indicates D that the torch tip is making contact with the workpiece 15 2 0 39 5 36 ECTION 4 SERVICE TROUBLESHOOTING D20 039 UR Fe 24 02550 Logic Gate Board 1 No DC Output An open circuit voltage of approximately 280 to 325 VDC depending on input power selected is pro duced when switching transistor
13. 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 4 Place the meter lead on drain lead of 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 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 E1B of the FET Heatsink Assembly 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 E2B 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 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 4 FET Output Rectifier Check SECTION 4 S
14. upper J7 2 lowerJ8 1 103 Output from the Logic Gate Board upper J7 3 Lower J8 3 16 4 Pun Output J6 2 from the Logic Gate Board upper J7 4 Lower J8 4 165 PRI CURRENT SENSE to the Logic Gate Board upper J7 5 Lower J8 5 166 PRI CURRENT SENSE to the Logic Gate Board upper J7 6 Lower J8 6 J6 7 SEC CURRENT SENSE to Logic Gate Board upper J7 7 Lower J8 7 J 8 SEC CURRENT SENSE to the Logic Gate Board upper J7 8 Lower J8 8 J6 9 OVER TEMP RTN to the Logic Gate Board upper 7 9 Lower J8 9 J6 10 Logic Low OVER TEMP to the Logic Gate Board upper J7 10 Lower J8 10 E14 MAIN XFMR PRI to MAIN XFMR PRI E14 E15 MAIN XFMR PRI to MAIN XFMR PRI E15 E16 MAIN XFMR SEC from MAIN XFMR SEC E16 E17 OUTPUT to OUTPUT INDUCTOR L1 E18 OUTPUT to Current Sense Transformer E9 on Output Board and pin 8 PCR E19 MAIN XFMR SEC from MAIN XFMR SEC E19 G1 HEATSINK GND To HEAT SINK G2 HEATSINK GND To HEAT SINK Manual 0 2745 63 APPENDIX APPENDIX IX CAPACITOR BOARD LAYOUT E2B E2A E1C E1A 4 114X228 REV 1 2 Capacitor Board Signals E1B Positve Rail to FET Board Positve Rail to FET Board E2B Negative Rail to FET Board E2C Negative Rail to FET Board Positive Input from Input Board E2A Negative Input from Input Board Rectifier APPENDIX 64 Manual 0 2745 APPE
15. 1 Item shown for illustration purposes only SECTION 6 PARTS LISTS 50 Manual 0 2745 NOTE Illustration may vary slightly from actual unit Manual 0 2745 51 L A 02618 HARDWARE 10 32 Regular Nylon Lock Nut 6 32X3 3 4 LG PH Screw 6 20X3 8 PPH THD Screw SECTION 6 PARTS LISTS 6 09 Options Accessories Qty HA Hi Description SMART CART 575V TRANSFORMER CUTTING GUIDE KIT FILTER KIT DRY AIR INCLUDES FILTER AND OPTIONAL REPLACEMENT FILTER BODY DRY AIR REPLACEMENT FILTER ELEMENT DRY AIR REPLACEMENT FILTER HOSE DRY AIR BRACKET LAMAN FILTER MOUNTING OPTIONAL TWO STAGE AIR LINE FILTER KIT OPTIONAL DUAL STAGE AIR FILTER ASSEMBLY REPLACEMENT FIRST STAGE FILTER REPLACEMENT SECOND STAGE FILTER COMPUTER CONTROL CABLE CNC 25 FOOT 7 6 m 50 FOOT 15 2 m HAND PENDANT CONTROL WITH 25 ft 15 2 m CABLE HAND PENDANT EXTENSION CABLE 25 ft 15 2 m METAL MOUNTING TUBE WITH PINION ASSEMBLY Housing 5 Filter Element Spring Cover Barbed Fitting Assembled Filter SECTION 6 PARTS LISTS 52 Catalog 7 7777 9 7500 7 8910 7 7507 9 7740 9 7741 9 7742 9 7535 7 7500 9 7527 9 1021 9 1022 8 5557 8 5558 7 3114 7 7744 7 7745 Manual 0 2745 APPENDIX INPUT VVIRING REQUIREMENTS Input Power Input Current
16. Board to the Diode Bridge must be tight enough to prevent the wires from moving The two screws securing the Input PC Board to the Diode Bridge at R2 and G must be tight nput Diode Bridge Assembly Replacement Remove the Left Side Panel per Section 5 04 B Remove the Input PC Board per paragraph C above Remove the two nuts securing the Input Diode Bridge to the Center Chassis Remove the Input Diode Bridge Assembly from the unit Remove the Thermal Pad from the Center Chassis 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 must be torqued to 35 in lbs when reinstalled E Logic Gate Drive PC Board Replacement 1 2 Man Remove the Left Side Panel per Section 5 04 B Carefully remove all cable connections from the Logic Gate PC Board noting the location of each Remove the four screws securing the Logic Gate PC Board to the standoffs Remove the Work Cable per the following a Remove Right Side Panel per Section 5 04 C b Loosen the Work Cable end at the terminal on the Output PC Board c Remove the Work Cable end from the Output PC Board terminal Remove the tie wrap holding the Work Cable to the CD Coil Lead e Carefully pull the Work Cable out through the Bushing in the Center Chassis f Continue pulling the Work Cable down through the current sensor mounted on
17. 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 PRACTICE FOR RESPIRA TORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations a caract re important Ces mises en relief sont classifi es comme suit 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 wmm ATTENTION Toute proc dure pouvant r sulter l endommagement 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 quest
18. 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 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 SECTION 4 SERVICE TROUBLESHOOTING 4 04 Troubleshooting Guide General Information VVARNING 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 ET 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 50XL PLUS Oper ating Manual 0 2744 The advanced troubleshooting covered in this Service Manual requires Power Supply disassembly and live mea surements Itis helpful for solving many of the
19. E E El E l el eee ce 89 RE 4 1 na R44 a kr c s Re ni 52 8 8 78 71 In 10778 es 1 F DB GCG na 3 CDI wr Logic Gate PC Board A 02528 Logic Gate PC Board Signals J1 1 36 VAC from Auxiliary Transformer J1 2 115 VAC from Auxiliary Transformer J1 3 Center Tap from Auxiliary Transformer 36VAC 11 4 Not Used J1 5 36 VAC from Auxiliary Transformer J1 6 115 VAC Return from Auxiliary Transformer J2 1 115 VAC Return to K10 Relay Contactor MC1 2 2 115 VAC Return to Fan 1 2 3 115 VAC Return to Fan 2 J2 4 115 VAC Return to Solenoid 2 5 Not Used J2 6 Not Used J2 7 115 VAC to K10 Relay MC1 Contactor J2 8 115 VAC to Fan 1 J2 9 115 VAC to Fan 2 J2 10 115 VAC to Solenoid J2 11 Not Used J2 12 Not Used J2 13 Logic Low Pressure Switch Signal J2 14 Return from Pressure Switch J2 15 Logic Low Over Temperature Switch on Input Bridge J2 16 Over Temperature Switch Return APPENDI
20. SIDE Includes COVER LEFT SIDE LABEL WARNING ENGLISH LEADS WRAP Includes PANEL LEADS VVRAP MOLDED OVERLAY LH SIDE PANEL COVER RIGHT SIDE Includes COVER RIGHT SIDE OVERLAY RH SIDE PANEL LABEL WARNING FRENCH SECTION 6 PARTS LISTS 40 Catalog 9 7505 9 7506 9 8001 9 8002 9 8003 Manual 0 2745 02615 NOTE Illustration may vary slightly from actual unit Manual 0 2745 41 B Wo32xzPPHHNS D 4 20x 8 Screw SocHO T 32x3 34 LG PH Scron SECTION 6 PARTS LISTS 6 04 Access Panel Replacement Parts List Items Description Ref Catalog 1 1 ASSEMBLY POT LED PCB 9 8004 2 1 KNOB INNER CONCENTRIC 9 8007 3 1 SWITCH ROCKER SPST CENTER OFF 8 3259 4 1 ON OFF ROCKER SWITCH DPST 8 3258 5 1 PANEL ACCESS Includes 9 8005 PANEL ACCESS OVERLAY ACCESS PANEL LABEL ACCESS PANEL SECTION 6 PARTS LISTS 42 Manual 0 2745 02532 HAROWARE 10 32 Regular Nylon Lock Nut B HO32xZ 1 4 20 x 3 Screw Soc HD D 110 32 x 3 4 PPH Sw ag Screw Manual 0 2745 43 SECTION 6 PARTS LISTS 6 05 Front Panel Replacement Parts List Item Qty Description Ref Catalog 1 1 PANEL BASE FRONT Includes 9 8006 BASE FRONT UNIT GROUND TAG OVERLAY FRONT PANEL W USA LABEL 2 1 CONTACTOR 40 FLA 600V 115VAC MCI 9 7554 3 1 STRAIN RELIEF FOR 6 STRANDED WIRE 8 5537 4 1 WORK CABL
21. Suggested Sizes See Notes Voltage 1 Ph 3 Ph 1 Ph 3 Ph Fuse Amps Wire AWG Wire Canada Volts Hz kVA Amps Amps 1 Ph 3 Ph 1 Ph 3 Ph 1 Ph 3 Ph 8 2 45 25 8 10 10 8 2 45 25 8 10 10 8 3 45 25 8 10 10 9 9 30 20 10 14 14 9 9 30 20 10 14 14 9 9 25 20 14 14 Requires Module Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated based on the Duty Cycle of the equipment The suggested 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 cable must have an outside diameter of 0 69 inches 17 5 mm or greater Manual 0 2745 53 APPENDIX APPENDIX SEQUENCE OF OPERATION BLOCK DIAGRAM POTION ACTION ACTION ACTION Close external ON OFF switch RUN SET LATCH switch RUN SET LATCH disconnect switch to ON to SET switch to RUN RESUL
22. 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 Do not cut or weld on containers that may have held combustibles Provide a fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut under water or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dis sipated Trapped hydrogen gas that is ignited will cause an explosion 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 yo
23. 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 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 SECTION 4 SERVICE TROUBLESHOOTING itis 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 e
24. cabines ou des crans de protection Date 6 22 99 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 l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d 4ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie l our prot ger votre ouie 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 Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 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 d
25. 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 A Disconnect primary power at the source before as sembling or disassembling 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 2745 Left Side Screws 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 Each diode must be checked in forward bias plus to negative and
26. 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 wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Manual 0 2745 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 Carefully open the ESD protective bag and remove the replacement PC board 7 Install the replacement PC board in the equipment and make all necessary connections 8 Place the failed PC boardin the ESD
27. 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 Parts XL Plus Series amp Parts Parts PAK Units Power Supplies CutMaster 80XL Cougar Drag Gun Others Labor Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year 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 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 transpo
28. indicator If indicator peme aC replace has gone OFF then remove power and replace the If no voltage is present proceed to Step 2 Lower FET Heatsink Assembly 2 Measure for 115 VAC from J2 4 to J2 10 at the Logic 9 Place the front panel ON OFF Switch to the OFF Gate PC Board position If voltage is not correct replace Logic Gate PC 10 Remove power from unit Board 11 Disconnect connector from J2 H Pilot Arc Circuit 12 Check for short on connector harness end be 1 Check across E23 to E24 at the Pilot Output PC tween 2 15 amp 16 Board There should be a diode drop across E23 If shorted Replace 191 to E24 in one direction and an open in the other If shorted remove the wires at E23 and E24 at If hort replace L Gate PC Board 4 id the Pilot Output PC Board and check again Replace Pilot Output PC Board if shorted from E23 to E24 with wires 17 and 16 removed Check for shorted torch Pilot Output PCB is not shorted Check for short between E8 and E22 Manual 0 2745 23 SECTION 4 SERVICE TROUBLESHOOTING If shorted replace Pilot Output PCB 2 Measure between E9 to E8 and E24 on Pilot Out put PC Board If shorted remove wires on E8 E9 and E24 and re check PCB If shorted replace Pilot Output PCB If no longer measures shorted check for short in torch or leads FET Heatsink Circuit Tests The FET Heatsink circuit tests require various checks to
29. 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 SECTION 5 REPLACEMENT PROCEDURES Before disassembling any part of the Power Supply first 4 Remove the four screws securing the Leads read the procedure for the part to be replaced then pro to the old Left Side Panel i j ie 5 Install the replacement Left Side Panel by revers 5 04 Maj or External Parts ing the above procedure
30. the Logic Gate PC Board ual 0 2745 F 33 5 Install the replacement Logic Gate PC Board 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 FETA Heatsink Assembly Connection Description Main Transformer Primary Main Transformer Primary Main Transformer Secondary Output Output Main Transformer Secondary From Input Section Assembly From Input Section Assembly SECTION 5 REPLACEMENT PROCEDURES 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 ch
31. the front panel ON OFF switch to the OFF position CE Up T 1 2 Disconnect ribbon cable from the Upper FET jq Heatsink Assembly at J6 TIT ii Ark L O or FET Heatsink and D hop eilg 26 2 Capacitor Board EJ Assembly DO d d E 14 zl Q Logic Gate PC Board D J2 G Gas Solenoid Circuit Test J6 Make the following voltage checks per the circuit dia gram and replace the faulty part as required 3 Place the front panel ON OFF switch to ON VVire 56 4 4 Check status of the TEMP indicator If indicator Logic PC has gone OFF then remove power and replace the Gas J2 Board Upper FET Heatsink Assembly Solenoid 5 Place the front panel ON OFF switch to the OFF Wire 52 m position A 01198 6 Disconnect ribbon cable from the Lower FET Heatsink Assembly at J6 1 Check for 115 VAC from Wire 56 to wire 52 at the 7 Place the front panel ON OFF switch to ON Eno solenoid 8 Check status of the TEMP
32. this section has two purposes To familiarize the service technician with the capa bilities and limitations of the equipment lo 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 40 amp maximum output and includes all control circuitry electrical and gas inputs and outputs pilot circuitry torch leads receptacle and a work cable with clamp 208 230 240V single phase units also include a 50 amp input cable and plug NOTE The power supply can be ordered in various con figurations with various options factory installed Work Cable and Clamp Figure 2 1 Pak Master 50XL PLUS Power Supply The power supply is designed to work with the Model PCH M 40 Plasma Torches Torches will provide a maximum 1 2 inch 12 7 mm cut capacity Hand torches are available in both 70 and 90 configurations Machine torches are available in a 180 configuration Torch leads are available in 25 ft 7 6 m or 50 ft 15 2 m lengths with fittings for simple installa tion Spare Parts Kits which provide an assortment of re placement torch parts are available for the torches Manual 0 2745 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
33. C Board J13 3 Unregulated 18 VDC for OK To Move CSR Relay on Pilot Output PC Board J13 4 PS from Pilot Outut PCB to sense Positive Output Voltage Not Used From Pilot Output PC Board to Sense Drag Cutting Tip Not Used PS From Pilot Output PC Board to Sense negative DC Output Voltage Logic Low 1 Contactor to Input PC Board 16 1 Unregulated 18 to Input PC Board for K11 Relay on Input PCB Logic Low CSR Signal from Current Sensor Return for CSR Signal 12 VDC to Current Sensor LED Description Logic Ground Unregulated 18 VDC DI Start Unregulated 18 VDC D2 CD Enable Not Used D20 CSR 12 VDC 412 VDC D36 Drag On Drag Circuit Disable jumper to TP1 D39 Pilot Negative Voltage Sensing jumper to TP1 to override 045 PWM Enabled Logic Low Primary Overcurrent Shutdovyn momentary Logic Low CSR input Current Demand Signal Gate Drive Signal A Gate Drive Signal B Manual 0 2745 57 APPENDIX APPENDIX V PILOT OUTPUT BOARD LAYOUT J13 2 15 PILOTZOUTPUT PCB of ASSY 19 O n0 FO OK CGND E27 DI O RB 82 1 D6 2 O FO R4 U 3 O O E24 E27 c9 FO C3
34. CD PC Board and CD enable indicator D2 on Logic Gate PC Board ON No arc or intermittent arc in torch 1 Gas pressure s set incorrectly too high a Refer to appropriate Torch Manual 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 Manual 0 2745 5 213 PILOTZOUTPUT PCB e Assy 19x188 50 s d 5 9 AO eng rs 10 ti 55 Lo o 8 x gt sp B JO 8 A 01400 E24 Wire 16 0 JE N N 7 Faulty Logic Gate PC Board Check D39 amp D2 on the Logic Gate PC Board E23 Wire 17 a If D39 amp D2 are not on replace Logic Gate Board Measure for 12 vdc on Logic Gate PC Board from J5 6 to J5 7 a If voltage is low then replace Logic Gate 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
35. D above Ground Wire 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 Right Side Panel per Section 5 04 C 3 Loosen the Work Cable end at the terminal on the Output PC Board 4 Remove the Work Cable end from the Output PC Board terminal 5 Remove the tie wrap holding the Work Cable to the CD Coil Lead 6 Carefully pull the Work Cable out through the Bush ing in the Center Chassis 7 Continue pulling the Work Cable down through the current sensor mounted on the Logic Gate PC Board 8 Remove the Work Cable strain relief from the Front Panel 31 SECTION 5 REPLACEMENT PROCEDURES 9 Pull the VVork Cable from the unit 10 Install the replacement VVork Cable by reversing the above procedure B Main Contactor Replacement 1 2 Remove the Left Side Panel per Section 5 04 B Note the orientation of all the wires and then dis connect the input and output wiring from the Main Contactor Assembly Remove the two nuts and washers securing the Main Contactor to the bottom of the unit Install the replacement Main Contactor Assembly by reversing the above procedure C Fan Replace
36. D LAYOUT 16 2 position connector Solder Side of PC Board Component Side of PC Board VET 2 o o Os shej ro 2 fo 000 o zu 225 INPUT PCB ASSY 19 1592 AC2 AC3 looooooooooooooon az 5 c 19 lo lo CEND ae 40 to 04 bo of Fon O4 O4 C3 C4 cs o on Input Board A 02551 1 2 CGND Input PC Board Signals 16 1 Logic low inrush signal from Logic PCB J10 1 J16 2 Unregulated 18VDC to inrush Relay K11 J16 3 Not used J16 4 Not used J16 5 Not used CGND Chassis Ground to Chassis Ground Output to the Cap Board E25 Rectifier Module Output to the Cap Board E26 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 Manual 0 2745 61 APPENDIX APPENDIX FET BOARD LAYOUT
37. E 6 AWG WCLAMP 20 FT 9 8008 5 1 CLAMP 9 8120 SECTION 6 PARTS LISTS 44 Manual 0 2745 NOTE Illustration may vary slightly from actual unit Manual 0 2745 45 A 02533 J HARDWARE 10 32 Regular Nylon Lock Nut 10 32 x 2 PPH HDMS 10 32 x 0 5 PPH Sw ageform Stl Zn Screw 1 4 20 x 3 Screw Soc HD 6 32 x 3 1 2 THD Screw 10 32 x 3 4 Sw ag Screw 6 32x3 8 PPH STL ZN Screw Rubber Feet 6 32x3 3 4 LG PH Screw 10 32 Keput w Star Washer SECTION 6 PARTS LISTS 6 06 Left Side Internal Component Replacement Parts List Item 1 1 2 2 3 4 2 5 1 6 1 7 1 8 4 9 1 10 11 1 12 1 13 1 14 1 15 1 16 1 17 1 Description Ref INSULATOR INPUT PCB CABLE ASS Y 10 CIR RIBBON 151 1 LOGIC GATE DRIVE PCB ASSEMBLY ASS Y FET HEATSINK ASSEMBLY FET HEATSINK PCB DUST COVER FET ASS Y FUSE BLOCK FUSE 0 8A 600V 13 32 DIA F1 BUSHING PLASTIC SNAP 1 3 8 ID STANDOFF 10 32 X 3 8 HEX X 2 LG AL DIODE BRIDGE ASSY Includes DIODE BRIDGE 3 PHASE W SCR 40A 1600V THERMAL PAD Q3 INPUT MODULE ASSEMBLY INPUT PCB BRKT HEATSINK MOUNTING PM50XL HARNESS INRUSH CONTROL HARNESS CAP BD VOLTAGE SELECT HARNESS VOLTAGE SELECT VOLTAGE SELECTION LABEL TEMPERATURE SWITCH 151 Note 1 Item shown for illustration purposes only SECTION 6 PARTS LISTS 46 Catalog See Note 1 9 5922 9 8010 9 8009 9 5562 9 7526 See Note 1 See Note 1 9 8011 9 8012 Se
38. ERVICE TROUBLESHOOTING 26 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 A 01423 b Place the meter lead on E16 and the meter lead on E18 of the FET Heatsink Assembly to check the output rectifier forward bias The meter should indicate between 0 3 to 0 6 volts using the diode function or 100K ohms using the ohms func tion c Place the meter lead on E18 and the meter lead on E16 of the FET Heatsink Assembly to check the output rectifier reverse bias The meter should indicate OL using the diode function or 100K ohms using the ohms function d Place the meter lead on E17 and the meter lead on E19 of the FET Heatsink Assembly to check the output rectifier forward bias The meter should indicate between 0 3 to 0 6 volts using the diode function or 100K ohms using the ohms 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 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 ind
39. ILTER TO REGULATOR 9 7513 21 1 PANEL MOUNTING NUT 9 5804 N S 1 220V SINGLE PHASE INPUT POWER CABLE 6 ft 1 8 m 8 4384 NOTE 1 Item can be purchased locally N S Not Shown SECTION 6 PARTS LISTS 48 Manual 0 2745 18 Part of 4 02535 B 10 32 x 2 PPH HDMS D 14 20 3 6 32x3 8 PPH STL ZN Screw Rubber Feet 6 32 3 3 4 LG PH Screw 10 32 Keput w Star Washer NOTE Illustration may vary slightly 46 32 Regular Nylon Lock Nut from actual unit 6 32X3 3 4 LG PH Screw 6 20X3 8 PPH THD Screw 10 32x1 1 8 PPH Screw Manual 0 2745 49 SECTION 6 PARTS LISTS 6 08 Right Side Internal Component Replacement Parts List Item Qty Description Ref Catalog 1 1 BULKHEAD ADAPTER O2B 1 8 NPT 9 4045 2 2 9 16 18 JAM NUT BRASS 8 2149 3 1 CHASSIS CENTER See Note 1 4 1 PANEL PILOT ASS Y MOUNTING See Note 1 5 1 BRKT BULKHEAD MOUNTING See Note 1 6 1 INSULATOR BULKHEAD See Note 1 7 1 PCR RELAY DPST NO 25A 250V 12VDC COIL PCR 9 7508 8 1 TRANSFORMER AUX IEC BOBBIN T2 9 7541 9 1 ASS Y MAIN TRANSFORMER T1 9 7567 10 1 ASS Y OUTPUT INDUCTOR L1 9 7595 11 2 FITTING 1 8 NPT X 1 4 TUBE STR 8 3360 12 1 COIL PILOT INDUCTOR L2 9 7596 13 1 COIL CD XFMR SECONDARY T3 9 7618 14 1 ASS Y CD PCB 9 7517 15 1 ASS Y PILOT OUTPUT PCB 9 7518 16 2 FAN 115V 50 60HZ 95 115CFM W 187 TABS MI M2 8 3209 NOTE
40. NDIX X 36VAC CIRCUIT DIAGRAM CD PC Board J1112 3 4 952 31 Logic Gate 42 VDC Drive PC Circuit Board J1 3 a 1 Auxiliary 36 VAC Transformer 5 Outputs 2 115 VAC J3 11 3 4 2 A 02527 Switch Manual 0 2745 65 APPENDIX APPENDIX XI SYSTEM SCHEMATIC 1891 esi 15 1581 sv FAN 1 INRUSH A 58 3 FAN 15 045 PWM LOGIC GATE DRIVE PCB 2 d PM5 XL PLUS 19 1593 CURRENT SENSE 4641 232 PM75XL PLUS 19X1594 RELAY 561 el 02 gt GAS 1611 m 7 36 VAC A A A at 50 TEMP SWITCH BROWN 458 7 PRESS SWITCH 3 BLUE Di START ORANGE 388 RED 2 llt B BLACK 228 YELLOW 22 AT OVERTEMF 51
41. NSI 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 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 Standard 51 OXYGEN FUEL GAS SYSTEMS FOR VVELDING CUTTING AND ALLIED PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND VVELDING 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
42. OCEDURES SECTION 5 REPLACEMENT PROCEDURES 38 Manual 0 2745 SECTION 6 PARTS LISTS 6 01 Introduction Parts List Breakdown The parts lists provide a breakdovyn of all replaceable components The parts lists are arranged as 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 Ifa Thermal Dynamics product must be returned for ser vice contact your Thermal Dynamics distributor Mate rials returned to Thermal Dynamics without proper au thorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the 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 2745 39 SECTION 6 PARTS LISTS 6 03 Major External Replacement Parts List Item 1 2 3 Qty 1 2 1 Description TUBE LIFTING HANDLE 1 125 OD 11 85 LG MOUNT LIFTING HANDLE COVER LEFT
43. 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 19 SECTION 4 SERVICE TROUBLESHOOTING 2 Faulty Logic Gate Check the following indicators inside the power supply Pilot Indicator D39 on the Logic Gate PC Board is ON during the pilot then OFF during the main arc transfer CSR indicator 020 on the Logic Gate PC Board is OFF during the pilot then ON during the main arc transfer While trying to transfer measure voltage If D20 on the Logic Gate PC Board does not turn on replace Logic Gate PCB DI D2 J5 gt PR n SE e o MERE E D 32 VIL E 7119 Fr 1i i EH 1 3 2 medo 02548 Logic Gate Board VYhen operating at amperages over 35 amps amperage drops off after the main cutting arc initiates Check the following indicator inside the Power Sup ply Drag indicator D36 on the Logic Gate PC Board is ON when the torch tip comes in con
44. QUIPMENT 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 prevent possible injury read understand and follow all warnings safety precautions and in structions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions QI Date 6122199 Ae AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any met als which may contain one or more of the follow ing Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Alwaysread the Material Safety Data Sheets MSDS that should be supplied wi
45. T RESULT RESULT RESULT Power to system AC indicator blinks for 8 Gas solenoid open Gas flow stops seconds then steady on gas flows to set pressure GAS indicator off Fans on Povver ready GAS indicator on ACTION ACTION Torch moved away Protect eyes and from work while activate torch still activated RESULT RESULT PILOT ARC Gas flows 2 seconds Main arc stops Pilot arc automatically restarts After gas pre flow DC indicator on Pilot relay closes Pilot arc established ACTION Torch moved within transfer distance of workpiece RESULT ACTION Torch Switch ACTION can be released Main arc transfer Torch deactivated by torch switch Pilot arc off release or by remote device RESULT RESULT Transfer will continue until torch is removed from workpiece 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 ACTION workpiece main arc will transfer ON OFF switch Open external After post flow eh Gas solenoid closes gas flovv stops RESULT RESULT GAS indicator off All indicators off N i i o power to system Power supply fans off APPENDIX 54 Manual 0 2745 APPENDIX III POT LED PC BOARD LAYOUT
46. TION 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 Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne 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
47. TION OF LIABILITY Thermal shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of 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
48. X 56 Manual 0 2745 3 1 J3 2 J3 3 J3 4 J3 5 J3 6 J3 7 J3 8 J3 9 J3 10 J3 11 J3 12 J3 13 J3 14 J3 15 J3 16 J5 1 J5 2 J5 3 J5 4 5 5 5 6 J5 7 J5 8 5 9 5 10 5 11 5 12 5 13 5 14 5 15 5 16 10 1 710 2 17 1 117 2 717 3 1 2 TP3 4 5 TP6 TP7 TP8 TP20 TP26 TP22 TP25 TP24 36 VAC to ON OFF Switch 36 VAC from ON OFF Switch to Logic Gate PC Board 36 to ON OFF Switch 36 VAC from ON OFF Switch to Logic Gate PC Board Logic Low From RUN SET LATCH Switch on Front Panel RUN PCB Common 10 vdc to Front Panel Current Control Pot J14 1 From Front Panel Current Control Pot Wiper J14 2 To Current Control Pot J14 3 Return Unregulated 18 VDC to Front Panel 14 4 Logic Low for Indicator on Front Panel 714 5 Logic Low for GAS Indicator on Front Panel 14 6 Logic Lovy for TEMP Indicator on Front Panel 714 7 Logic Low for DC Indicator on Front Panel 714 8 Not Used Logic Low From RUN SET LATCH Switch on Front Panel LATCH 36 VAC to CD PC Board J11 1 36VAC Centertap to CD PC Board 11 2 36 VAC to CD PC Board 11 3 Logic Low CD Enable Signal to CD PC Board J11 4 CD Enable Return to CD PC Board J11 5 Unregulated 18 vdc to PCR Relay Logic Low PCR Signal to PCR Relay Logic Low Torch Switch Input from Pilot Output PCB J13 1 Torch Switch Return to Pilot Output PC Board J13 2 Logic Low OK Io Move Signal to Pilot Output P
49. alve Assembly by reversing the above procedure D 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 Remove the Right Side Panel per Section 5 04 C 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 Apply pipe thread sealant to the fitting before reassembling Manual 0 2745 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
50. andard options and Accessories are to be made to this equipment Customer Operator Responsibilities It is the customer operator s responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual and to protect the equipment from accidental or mali cious damage D Repair Restrictions The electronics consists of Printed Circuit Board Assem blies which must be carefully handled and must be re placed as units No replacement of printed circuit sol der mounted components is allowed except as noted in this manual If to be returned the replaced Printed Circuit Board As semblies must be properly packaged in protective mate rial and returned intact per normal procedures Manual 0 2745 2 03 Service Responsibilities TheService Technician should be familiar with the equip ment and its capabilities and should be prepared to rec ommend arrangements of components which will pro vide the most efficient layout utilizing the equipment to its best possible advantage Maintenance work should be accomplished in a timely manner If problems are encountered or the equipment does not function as specified contact the Technical Ser vices Department at West Lebanon for assistance 9 SECTION 2 INTRODUCTION SECTION 2 INTRODUCTION 10 Manual 0 2745 SECTION 3 DESCRIPTION 3 01 Scope The information in
51. assis 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 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 B Pressure 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 Apply pipe thread sealant to the fitting before reassembling SECTION 5 REPLACEMENT PROCEDURES C 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 V
52. common problems that can arise with the Pak Master 50XL PLUS Povver 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 Subsection 4 09 includes specific test procedures and LED status identification tables The subsection is referenced by the troubleshooting guide for the specific test to be performed The troubleshooting guide has six subsections 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 2745 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 follovving 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
53. e Note 1 See Note 1 See Note 1 See Note 1 See Note 1 See Note 1 Manual 0 2745 HARDWARE 10 32 Regular Nylon Lock Nut B 10 32 x 2 PPHHDMS 10 32 x 0 5 PPH Sw ageform Stl Zn Screw Note Illustration may vary slightly from D 174 20x 3 Screw Soc HD actual unit fe3 8841GPHScew Manual 0 2745 47 SECTION 6 PARTS LISTS 6 07 Rear Panel Replacement Parts List Item Qty Description Ref Catalog 1 1 PRESSURE SWITCH 35 PSI PS1 9 1044 2 1 VALVE SOLENOID 1 8 NPT SOL 8 3370 3 1 REGULATOR AIR LINE 9 7514 4 1 FLEX CONNECTOR 8 4289 5 1 1 4 NPT STREET ELBOW 9 2184 6 1 1 8 NPT STR TEE 8 0352 7 1 1 4 1 8 NPT REDUCER 9 2023 8 1 FITTING 1 8 NPT X 2 LONG NIPPLE BRASS 9 7524 9 1 FITTING 1 8 NPT X 1 4 TUBE 90 9 7525 10 1 PRESSURE GAUGE 9 1045 11 1 PANEL REAR Includes 9 8013 PANEL REAR LABEL GAS SUPPLY LABEL INPUT POWER CONNECTIONS 12 1 BRACKFT REGULATOR MOUNTING 9 7589 13 2 10 32X 5 PPH FORM STL ZN PARKER KALON 9 7590 14 1 FILTER KIT DRY AIR INCLUDES FILTER AND HOSE OPTIONAL 7 7507 15 1 REPLACEMENT FILTER ELEMENT DRY AIR 9 7741 16 1 REPLACEMENT FILTER HOSE DRY AIR 9 7742 17 1 REPLACEMENT FILTER BODY DRY AIR 9 7740 18 1 BRACKET LAMAN FILTER MOUNTING OPTIONAL 9 7535 19 1 TWO STAGE AIR LINE FILTER KIT OPTIONAL 7 7500 DUAL STAGE AIR FILTER ASSEMBLY 9 7527 REPLACEMENT FIRST STAGE FILTER 9 1021 REPLACEMENT SECOND STAGE FILTER 9 1022 20 1 ASSEMBLY HOSE F
54. e secure B Cleaning Unit should be cleaned and maintained as described in Operating Manual 0 2744 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 Manual 0 2745 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 13 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 When starting
55. ear 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 RUN SET LATCH Switch Replacement 1 Unlatch the Access Panel to gain access to the rear of the RUN SET LATCH Switch 2 Disconnect all the wiring to the RUN SET LATCH Switch 3 Squeeze the top and bottom of the switch while pulling it out of the Access Panel 4 Install the replacement RUN SET LATCH Switch by reversing the above procedure 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 Manual 0 2745 4 Unlatch the Access Panel to gain access to the Pot LED PC Board 5 Remove the Pot LED PC Board from the four stand offs 6 Disconnect the connector at J14 of the Pot LED Board 7 Install the replacement Pot LED PC Board by re versing the above procedure Access Panel Replacement 1 Remove the Right Side Panel per Section 5 04 C 2 Remove the follovving components from the Ac cess Panel Current Knob per paragraph A above ON OFF Switch per paragraph B above RUN SET Switch per paragraph C above Pot LED PC Board per paragraph
56. es not function as noted then note the symptom and proceed 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 Input power cable installed incorrectly a Refer to Operating Manual 0 2744 Section 3 07 and connect primary input power cable 2 Input voltage selection incorrect for the main input volt age a Refer to Operating Manual 0 2744 Section 3 06 and select proper input voltage B Main power line fuses blow 3 6 seconds after the ON OFF Switch is turned on 1 Faulty Input PC Board and Rectifier a Test Input PC Board Rectifier per Section 4 09 D repair as necessary 2 Faulty FET PC Board a Test FET PC Board per Section 4 09 I repair as necessary C AC indicator on front panel of power supply is OFF Fan does not operate 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 SECTION 4 SERVICE TROUBLESHOOTING 16 a Replace main power line Fuses 4 Defective input power cable a Replace input power cable 5 Improper input power line connections inside Power Supply a Refer to Operating Manual 0 2744 Section 3 07 and correct if needed 6 Fuse blown inside Power Supply a Replace internal Fuse 1 FU 7 Line voltage above 10 tolerance over v
57. essories NOTE Refer to Section 6 Parts Lists for part numbers and ordering information The following are some of the accessories that are avail able for this power supply Refer to Section 6 09 for a complete list A Dry Air In Line Filter Kit An optional in line filter for use on compressed air shop systems Highly effective at removing moisture and particulate matter from the air stream to at least 85 microns B Two Stage Air Line Filter An alternative to the Dry Air Filter this optional two stage air line filter is for use on compressed air shop systems The filter will remove moisture and contami nants from the air stream to at least 5 0 microns The filter assembly is pre assembled at the factory and need only be attached to the power supply SECTION 3 DESCRIPTION C High Pressure Regulators High pressure regulators are available for air and ni trogen The regulators are used to set the proper pres sure for the type gas being used D 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 tie down strap is also included E 575V Transformer This step down transformer allows the power sup ply to operate with 575 VAC three phase input power F Computer Control Cable CNC NOTE This accessory is for use with PCM 40 Torches only This interface cable is available in two lengt
58. g Relay energizes pulling in MC1 after AC light stops blinking TEMP indicator OFF GAS indicator ON Gas flows Fans will operate DC Indicator is OFF 3 Set the Power Supply RUN SET LATCH switch to the RUN position and note the following Gas indicator goes OFF Gas flow stops This completes the Main Input and Internal Power Tests If the above are all correct then proceed to paragraph If the above does not function as noted then note the symptom and proceed to Section 4 06 Main Input and Internal Power Problems C Pilot Arc Test 1 Press the torch switch to establish a pilot arc and note the following Gas flows GAS indicator turns ON After preflow delay DC indicator turns ON Pilot arc established This completes the Pilot Arc Test If the 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 15 SECTION 4 SERVICE TROUBLESHOOTING D Main Arc Test Press the Torch Switch to establish 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 Pilot Relay opens 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 do
59. g LOCATION FUSE 8A 6 8V FNOR 8 18 a MC CONTACTOR 20V COIL El USE 3 POLE CONTACTOR FOR Pam SGXLPLUS USE 4 POLE PM5 XL PLUS E CONTACTOR FOR 75XLPLUSI PARDJE US 1951693 EE gen ON OFF SWITCH DPST C4 4B SEC RUN SET LATCH SWITCH C4 PRIM 2 I20V FAN 2 GAS SOLENOID 1287 2 PIN RIBBON CABLE PS PRESSURE SWITCH B2 TS TEMP SWITCH B2 EMERENE ORENSE T2 AUX TRANSFORMER B2 TI MAIN TRANSFORMER D8 D fi PCR PILOT CONTROL RELAY B7 VAIN T3 CD TRANSFORMER LI OUTPUT INDUCTOR B8 PIN RIBBON CABLE CURRENT SENSE J6 PRIM SEC E EM EIB EIS OUT EUR hh 2 FET MODULE B LOWER mi PM5 XL PLUS 19X1628 um E12 PM75XL PLUS 19X1599 OUT 1 I 181 25 Visi 1 de de REV REVISIONS By REVISIONS BY DATE THERMAL DYNAMICS INDUSTRIAL PARK 2 doit sr LE exo 171 E26 8202 px P3426 CORPORATTON aon 8260 85718 INFORMATION PROPRIETARY TO THERMAL DYNAMICS m CAP BOARD EAEI CORPORATION NOT FOR RELEASE DISTRIBUTION as 25 52 PM5 XL PLUS 19X1289 8323 HAS 799 Note REFERENCE PM75XL PLUS 19X928 VAN CAPACITORS Are MEROPARAOSLI per tort me PMSOXL PLUS PM75XL PLUS SYSTEM SCHEMATIC 42X1831 6 7 8 9 12 A 02503 Manual 0 2745 67 APPENDIX APPENDIX 68 Manual 0 2745
60. g Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTEC TION RESPIRATOIRE disponible aupr s 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 2 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 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
61. he 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 5 Places 2 Remove the four screws securing the Leads Wrap to the Left Side Panel 3 Install the replacement Leads Wrap by reversing 2 Carefully pull the Left Side Panel up and away the above procedure 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 SECTION 5 REPLACEMENT PROCEDURES 30 Manual 0 2745 5 05 Access Panel Parts Replacement NOTE Refer to Section 6 04 for parts list and overall detail draw ing 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 screvy 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 vrith the location of the pointer the same as noted in step 1 5 Tighten the screvy to secure the knob to the poten tiometer shaft ONJOFF Switch Replacement 1 Unlatch the Access Panel to gain access to the r
62. hs 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 G Cutting Guide Kit Easy add on attachments to allow for straight line circle or bevel cutting H Hand Pendant Control A hand pendant control with 25 ft 7 6m cable which provides ON OFF signals to the power supply Also offered is a 25 ft 7 6m extension cable which can be added to the hand Pendant Control cable to provide a total length of 50 ft 15 2m 12 Manual 0 2745 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 4 01 Introduction This section provides service diagnostics for the Pak Master 50XL PLUS Power Supply allowing the Techni cian to isolate any faulty subassemblies Refer to Section 5 Repairs amp Replacement Procedures for parts replace ment 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 vvarranty 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 those products 4 02 Periodic Inspection amp Procedures This subsection describes inspection procedures which should be performed at periodic intervals as required A Physical Inspection Check that all cable connections ar
63. icate 1 meg ohms Manual 0 2745 Replace the FET Heatsink Assembly if any of the above tests are open or shorted 5 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 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 1 meg ohms Replace the FET Heatsink Assembly if any of the above tests are open or shorted Manual 0 2745 27 SECTION 4 SERVICE TROUBLESHOOTING SECTION 4 SERVICE TROUBLESHOOTING 28 Manual 0 2745 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 50XL PLUS Power Supply Under no circumstances are field repairs to be attempted on Printed Circuits or other Subassemblies of this unit Evidence of unauthorized repairs may void the factory warranty 5 02 Anti Static Handling Procedures A General Em CAUTION PC boards can be irreparably damaged by improper handling due to
64. ies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NA TIONAL disponible aupr s de la National Fire Pro tection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S 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 S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada MOW 1R3 13 ivret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 GENERAL INFORMATION 14 Norme AWSF4 1 de l 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 Weldin
65. ion 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 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 __ et GAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respi ration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz GENERAL INFORMA
66. isponible 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 L 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 787 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 l 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 l 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 l Association Am ricaine pour Pro tection contre les Incend
67. ks Diode Drop 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 SECTION 4 SERVICE TROUBLESHOOTING Indication Meter Meter If any test has resistance then replace the Main Contac tor also E Main Contactor MC1 Test Reconnect power and observe proper start up procedure AC LED Indicator on the Front Panel should be ON If indicator is OFF there is no voltage to the Power Supply or an overvoltage condition exists 9 01395 Ifindicator AC LED Indicator on Front Panel is OFF check for proper AC input voltage per the following Single Phase Units check at L1 and L2 e Three Phase Units check L1 L2 and L3 Main Contactor MC1 L3 L2 L1 Coil Wire 455 A 01379 Wire 59 Measure voltage on coil of contactor approximately 117 between wires 70 and 75 If voltage is correct replace Main Contactor If voltage is incorrect replace Logic Gate PC Board 22 Manual 0 2745 F Temperature Circuit Test Test the temperature circuit per the following 1 Place
68. 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 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 R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de tra vail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes GENERAL INFORMATION INCENDIE 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 Soyez certain qu aucune mati re combustible ou in flammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail Procurez une bonne a ration de toutes les fum es inflammables ou explosives Ne coupez pas et ne soudez pas
69. les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm m RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re 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 Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de 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
70. ll 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 2 3 4 Remove the Left Side Panel per Section 5 04 B Remove the Fuse from the fuse holder Replace the Fuse with 0 8A 600V fuse Reinstall the Left Side Panel B Fuse Holder Replacement 1 2 3 3 Remove the Left Side Panel per Section 5 04 B Remove the Fuse from the holder Disconnect the two wires connected to the Fuse Holder 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 2 Remove the Left Side Panel per Section 5 04 Remove the five screws securing the wiring to the Input PC Board Remove the clear Input PC Board Insulator sheet Remove the two screws at R2 and Carefully pull the Input PC Board from the unit far enough to disconnect the wiring connections to the component side of the PC board Install the replacement Input PC Board by revers ing the above procedure noting the following Manual 0 2745 D 1 2 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
71. llowing procedure a Locate Q1 and on the FET Heatsink Assembly 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 FET Heatsink and Capacitor PC Board Assembly c Press and hold the hand torch switch Logic Gate PC Board Start indicator D1 turns ON After 2 seconds D45 turns on Logic Gate PCB If D45 does not turn on replace Logic Gate PBB d Measure open circuit voltage between E29 to E7 at the Pilot Output PC Board e If voltage is low disconnect wire from E24 on the Pilot Output Board and recheck steps c d If voltage is okay then check torch amp leads If voltage is still low disconnect wires 11 12 from FET PCB to Pilot Output PCB If voltage ap proximately 325 check torch amp leads A 01422 b Place the meter lead on gate lead of Q1 and Make sure wires 11 amp 12 which connect the meter lead on source lead of Q1 The meter FET assemblies to each other remain con should indicate approximately 2 5K ohms nected Check for output voltage between E17 amp E18 If voltage is OV replace both FET As semblies if voltage is approximately 325 VDC replace Pilot Output PC Board Manual 0 2745 25 SECTION 4 SERVICE TROUBLESHOOTING 3 Spring Clip MOSFET Gate Source A 00553 Drain c Place the meter lead on drain lead of Q1 and meter
72. ltage selection panel Bulkhead Adapt Orange wire to pin 13 of the middle connector 120 on the voltage selection panel Black wire to pin 13 of the lower connector 719 on the voltage selection panel SECTION 5 REPLACEMENT PROCEDURES 36 Manual 0 2745 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 vvire 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 H 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 center chassis by following the proce dure in Section 5 06 C 3 Locate the wiring to the Fans and note the orienta tion of the Fan Assembly wiring push on connec tors 4 Carefully pull the wiring connectors from the lugs on the Fan Assembly 5 Locate and remove the four phillips head screws securing the Fan Assembly to the internal chassis 6 Carefully pull the Fan Assembly from the internal chassis 7 Install the replacement Fan Assembly by reversing the above procedure NOTE Refer to Section 6 08 for parts list and overall de tail drawing Manual 0 2745 37 SECTION 5 REPLACEMENT PR
73. ment 1 2 Remove the Left Side Panel per Section 5 04 B Note the orientation of the Fan Assembly wiring push on connectors Carefully pull the wiring connectors from the lugs on the Fan Assembly Locate and remove the four phillips head screws securing the Fan Assembly to the Front Panel As sembly Carefully pull the Fan Assembly from the Front Panel Assembly Install the replacement Fan Assembly by reversing the above procedure D Unit Base Front Replacement 1 2 3 4 5 SECTION 5 REPLACEMENT PROCEDURES Remove the Left Side Panel per Section 5 04 B Remove the Right Side Panel per Section 5 04 C Remove the Work Cable per paragraph A above Remove the Torch from the unit Remove the two Fan Assemblies from the Base Front Panel Assembly per paragraph C above Remove the following hardware a Two mounting nuts from Main Contactor As sembly b Nut and wire from ground stud c 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 32 e On the right side remove the three nuts and washers securing the internal chassis to the bot tom of the unit 7 Atthe front panel remove the two screws securing the Base Front Panel to the internal chassis 8 Carefully slide the internal components up back 9 and out of the Base Front Assembly Insta
74. mperature circuit per Section 4 09 repair as necessary E AC indicator ON TEMP indicator OFF No gas flow GAS and DC indicators OFF 1 RUN SET LATCH switch in RUN or LATCH posi tion 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 Gas supply inlet presure too high a aa gas supply inlet pressure between 100 110 PSI 5 Faulty RUN SET LATCH switch a Check continuity 6 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 too low a See torch manual for operating pressures 2 Faulty pressure switch Measure for DC voltage from wire 51 to wire 50 at the gas pressure switch at the rear of the Rear Panel Assembly a If 12vdc and pressure is above 50 PSI replace gas pressure switch Manual 0 2745 Rear Panel Gas Solenoid A 01184 5 Faulty Wiring or Logic Gate PC Board Check for DC voltage from Logic Gate PC Board J2 13 to TP1 GND If less than a volt replace Logic Gate PC Board If 12 VDC check wiring to PS1
75. noting the following Replacement Leads Wrap must be installed on the replace ment Left Side Panel before panel is installed NOTE Place the Left Side Panel onto the frame and Refer to Section 6 03 for parts list and overall de slide the top edge under the lip on the top of tail drawing the Right Side Panel A Lifting Handle Replacement C Right Side Panel Replacement 1 Remove the two allen screws securing the ends of 1 Remove the Lifting Handle per paragraph A the handle to the top of the unit above 2 Remove the Lifting Handle from the two end 2 Unlock the latch for the Access Panel mounting blocks 3 Using a phillips head screwdriver remove the five 3 Place the replacement Lifting Handle into the screws which secure the Right Side Panel to the mounting blocks Frame Assembly 4 Secure the Lifting Handle to the top of the unit NOTE with the two allen screws The three bottom screws need only be loosened to B Left Side Panel Replacement 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 Gate PC Board 1 Using a phillips head screwdriver remove the five screws which secure the Left Side Panel to the Frame Assembly 6 Remove the two nuts securing the Access Panel to Left Side the Right Side Panel 4 Install t
76. ns and Warnings 1 1 02 Important Safety Precautions sse 1 1 09 Publications oiii e Hee a ee de a te ees 2 1 04 Note Attention et Avertissement 3 1 05 Precautions De Securite Importantes sse 3 1 06 Documents De Reference ss 5 1 07 Declaration of Conformity 7 1 08 Statement of Warranty iii 8 SECTION 2 INTRODUCTION ot e e I t ee lest ia oe 9 2 01 Scope Of Manual iii 9 2 02 General Service Philosophy ss 9 2 03 Service Responsibilities enne 9 SECTION 3 5 en duet 11 3 01 SCOPE a dd 11 3 02 General Description 11 3 03 Specifications Design 11 3 04 Power Supply Options and Accessories 12 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS ui 13 4 01 Introduction oie ERR e a eet 13 4 02 Periodic Inspection amp 13 4 03 Common Operating 13 4 04 Troubleshooting Guide General 14 4 05 Circuit Fault Isolation eseve rere eee eee vete nnns 15 4 06 Main Input and Internal Power 16 4 07 Pilot A
77. oard 01401 Logic Gate PC Board in the unit 5 PILOTZOUTPUT PCB 919 00000000 Assy 19x188 a o m Before pressing the trigger make sure no faults were found on the Pilot Board and in the torch 22 HO000000001 Un P i __08 UU fe U 8 aL 8 kaq poo we al a Q Q o 52 9 9 x A 02552 E29 ogic Gate PC Board 2 MOSFET Resistance Checks This will cause the gas to flow continuously and the DC indicator on the front panel to turn ON 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 A MOSFET s per the fo
78. oltage protec tion a Reduce line supply 8 Voltage selection plug connected incorrectly a Refer to Operating Manual 0 2744 Section 3 06 and correct as needed 9 Faulty Auxiliary Transformer refer to Appendix X 36 VAC Circuit Diagram Measure for 36 VAC on Logic Gate PC Board from J1 1 to J1 5 a If voltage is not present replace the Auxiliary Transformer 10 Faulty Logic Gate PC Board refer to Appendix X 36 VAC Circuit Diagram Measure for 36 VAC on Logic Gate PC Board from J3 1 to J3 3 a If voltage is not present replace the Logic Gate PC Board 11 Faulty ON OFF switch refer to Appendix X 36 VAC Circuit Diagram Measure for 36vac on the Logic Gate PC Board between J3 2 to J3 4 a If voltage is not present replace the ON OFF switch b If voltage is present replace Logic Gate PCB 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 2744 Section 3 02 2 Exceeded duty cycle of Power Supply Manual 0 2745 a Wait for fans to cool unit and refer to Operating Manual 0 2744 Section 2 03 for proper Duty Cycle 3 Faulty Fan or Logic Gate PC Board Measure for 115 VAC on the Logic Gate PC Board from J2 2 to J2 8 and J2 3 to J2 9 If voltage is correct replace Fan Assembly If voltage is incorrect replace Logic Gate PC Board 4 Faulty temperature circuit a Check te
79. 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 Statement of VVarranty LIMITED VARRANTY 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 LIMITA
80. rc Problems iii 18 4 08 Main Arc Problems 19 4 09 Test Procedures ins 20 SECTION 5 REPAIRS amp REPLACEMENT PROCEDURES siens 29 cie ete Lei LL da 29 5 02 Anti Static Handling 29 5 03 Parts Replacement General Information 29 5 04 Major External Parts 8 30 5 05 Access Panel Parts 31 5 06 Front Panel Parts Replacement sse 31 5 07 Left Side Internal Component Parts 32 5 08 Rear Panel Parts Replacement 34 5 09 Right Side Internal Component Parts 35 TABLE OF CONTENTS TABLE OF CONTENTS continued SECTION 6 PARTS LISTS ani contia tuia shnet tre ht ar nte sete 39 6 01 Introduction EE 39 6 02 Ordering Information 39 6 03 Major External Replacement Parts 40 6 04 Access Panel Replacement Parts 42 6 05 Front Panel Replacement Parts List 44 6 06 Left Side Internal Component Replacement Parts List 46 6 07 Rear Panel Replacement Parts List
81. 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 CD 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 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 Manual 0 2745 35 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 rea
82. 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 Manual 0 2745 A 00307 0 75 Forward Bias Diode Conducting DE Diode Test Symbol VR COM A Anode 1 H Testing Diode Forward Bias Reverse the meter leads across the diode for reverse bias testing refer to follovving 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 DE VR COM A Anode Testing Diode Reverse Bias 7 If a diode checks bad replace the diode module 8 Reconnect all cables to proper terminals 21 SECTION 4 SERVICE TROUBLESHOOTING D Input PC Board Input Diode Test Check Input PC Board for shorted input diode Solder Side of PC Board 1 e INPUT PCB ASSY 19 1592 ACI AC2 AC3 Input PC Board A 02563 Remove AC power and with an ohmmeter set on the di ode range make the following chec
83. rtation 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 50XL PLUS Air Plasma Power Supply Refer to Operating Manual 0 2744 for individual oper ating procedures Informationin 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 vvith this equipment Read this Manual and the Operating Manual 0 2744 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 equipmentis capable of the application desired B Modifications No physical or electrical modifications other than selec tion of st
84. s in the FET Heatsink Assemblies are turned ON by a PWM En able signal from the Logic Gate PC Board A circuit on the Logic Gate PC Board monitors the output volt age When the output voltage drops below 60 indicating a problem exists the Logic Gate PC Board sends a signal which turns OFF the PWM Enable sig nal to the Logic Gate Drive PC Board Because this happens in less than 50 milliseconds it is not easy to take voltage readings to find the source of the prob lem The Torch Switch Enable indicator D1 turns ON when the torch switch is pressed At this point the gas be gins to flow When the preflow time is over the PWM Enable signal is given PWM turns on and the DC indicator at the front panel turns ON When the PCR Drive Pilot On Indicator D39 turns ON If the PWM Enable indicator D45 does not come ON then replace the Logic Gate PCB If the PWM Enable indicator D45 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 Es ses Jit 82 04 HFoR33 o 5 looooooou n A 01202 M 1 u3 Manual 0 2745 b Connect a jumper between TP1 and TP8 on the Pilot Output PC B
85. ssembling 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 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 see NOTE 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 SECTION 5 REPLACEMENT PROCEDURES 4 Disconnect the lead wire on terminal E17 of the top FET Heatsink Assembly 5 Remove the four mounting screws securing the Out 460 put Inductor Assembly to the chassis brov
86. struction P Manual TU ZEE indicator ON TEMP indicator off Gas flows LL Sh f 4 GAS and DC indicators No arcin torch j 3x4 LH 7 te ees mee arc at spark gap on oard enable 3 pi nike park gap on CD PC Board CD enabl e E PE tme m indicator D2 ON Logic Gate PC Board 02547 J2 1 Faulty CD PC Board Measure for 36VAC betvven J11 1 and J11 3 Measure DC voltage between J11 4 to J11 5 on CD PC Board SECTION 4 SERVICE TROUBLESHOOTING 18 Manual 0 2745 If voltage is less than 2VDC replace CD Board CD PC Board Pilot Output PC Board ge e ewe 928 ro 833 5 8 n n o R35 loooeeoocu le o 9d s n A 01188 J11 922 ci2 O oy 1 D AC indicator ON TEMP indicator off Gas flows GAS and DC indicators ON Spark at gap on
87. sure to verify 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 1 Connect gas supply to rear of Power Supply 2 Turn on gas supply and adjust Power Supply Gas Regu lator to 70 psi 4 8 bar Manual 0 2745 3 Set the Power Supply controls as follows ON OFF switch to OFF RUN SET LATCH switch to SET CURRENT control potentiometer to maximum B Main Input and Internal Power Tests 1 Connect main AC power to the unit 2 Set Power Supply ON OFF switch to ON and note the following AC indicator blinks for six seconds then steady ON Relay K10 on Input PC Board energizes clicks while AC indicator is blinkin
88. tact with the workpiece 1 Cutting tip in contact with the workpiece a Maintain standoff distance 1 8 3 8 between cutting tip and workpiece See SW 1 Drag Dis able 2 Faulty PCR Relay a With power off measure for continuity between wires 12 and 14 If continuity is found re place PCR 3 Faulty Logic Gate PC Board If torch tip is off the workpiece and the drag indi cator D36 on the Logic Gate PC Board is still ON then replace the Logic Gate PC Board SECTION 4 SERVICE TROUBLESHOOTING 20 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 2 Do Not touch electrical components with any part of the human body when power is applied 3 Keep away from any moving parts 4 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 6 Misaligned plugs can cause printed circuit board dam age Be sure plugs are properly aligned and com pletely seated 7 Excessive pressure can
89. th 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 For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch an area where com bustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors A 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 Never touch any parts that are electrically live or hot VVear dry gloves and clothing Insulate yourself from the vvork piece or other parts of the vvelding cir cuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp GENERAL INFORMATION Install and maintain equipment according to 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
90. the Plate J13 10 Not Used APPENDIX 58 Manual 0 2745 CGND Chassis E7 PS C4 Rtn for Pilot Voltage Twisted with Pilot RTN to E23 E8 PS Stud from Output Inductor L1 to CD Xfmr 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 E7 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 2745 59 APPENDIX APPENDIX VI BOARD LAYOUT TP2 sh ma nama D L 1 1 o o 5 330 a n o pa FA o om J11 o a E5 Eg SGI o OO TP3 A 01208 CD PC Board Signals J11 1 36 VAC from Logic PC Board 5 1 J11 2 Return from Logic PC Board 5 2 36VAC centertap J11 3 36 VAC from Logic PC Board 5 3 JIL4 Logic Low CD Enable Signal from Logic PC Board J5 4 115 Return for CD Enable Signal from Logic PC Board J5 5 11 6 Not Used J11 7 Not Used J11 8 Not Used TP1 Logic Ground or Return TP2 12 VDC TP3 Not Used 1 CD output E2 CD Output APPENDIX 60 Manual 0 2745 APPENDIX VII INPUT BOAR
91. ur skin if you are not properly protected GENERAL INFORMATION To protect your eyes always wear a welding hel metor shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC 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 A
92. vn vvire 6 Remove the Output Inductor Assembly from the unit 7 Install the replacement Output Inductor Assembly by reversing the above procedure see NOTE NOTE The four screws securing the mounting plate to 220V the chassis should have a maximum of 2 to 5 threads black wire protruding through the left side of the chassis F Auxiliary Transformer Assembly 380 415V Replacement orange wire 1 Remove the Left Side Panel per Section 5 04 B View of Voltage Selector Connectors 2 Remove the Right Side Panel per Section 5 04 C from the Left Side of Center Chassis 3 Disconnect the single pin connector on the white wire coming from the Auxiliary Transformer As sembly G Bulkhead Adapter Replacement 4 On the voltage selection panel remove the pin 13 1 Remove the Right Side Panel per Section 5 04 C from connectors J19 black wire J20 orange wire and J21 brown wire using a pin removal tool 2 Remove Torch connection at the Bulkhead Adapter 5 Disconnect the secondary wires by unplugging the J15 connector from Logic Gate PC Board 6 Remove the four mounting screws securing the Auxiliary Transformer Assembly to the chassis Gas 7 Remove the Auxiliary Transformer Assembly from T ube Fitting the unit Nut 8 Install the replacement Auxiliary Transformer As Bracket sembly by reversing the above procedure noting the following Brown wire to pin 13 of the top connector J21 on the vo

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