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CUSTOMER/OPERATOR SERVICE

60

Manual 0-2470

5.07 POWER SUPPLY TROUBLESHOOTING (continued)

SYMPTOM

POSSIBLE CAUSE

REMEDY

C. (continued)

D. AC indicator lit, TEMP

indicator green, PIP
indicator lit, GAS indicator
not lit

E. When power is applied to

unit, GAS indicator
remains lit for more than
20 seconds

F. Torch will not pilot when

torch switch is activated

5. Faulty LDD board*

1. Gas not connected or

pressure too low

2. Faulty pressure switch*

3. Faulty regulator*

4. Faulty LDD board*

1. RUN/SET switch in SET

position

2. Faulty LDD board*

3. Faulty solenoid*

1. Switch activated during 20

second pre-flow

2. Faulty torch parts

3. Gas pressure too high

4. Faulty high frequency

trigger circuit*

5. Check and replace if

necessary. See Service
Procedures (page 66)

1. Check source for at least

70 psi (4.8 BAR). In SET
position, adjust gas pres-
sure to 70 psi

2. Check and replace if

necessary. See Service
Procedures (page 65)

3. Check and replace if

necessary. See Service
Procedures (page 65)

4. Check and replace if

necessary. See Service
Procedures (page 65)

1. Set switch to RUN position

2. Check and replace if

necessary. See Service
Procedures (page 65)

3. Check and replace if

necessary. See Service
Procedures (page 65)

1. Release switch and wait at

least 20 seconds before
activating switch again

2. Inspect torch parts and

replace if necessary (see
Replacing Consumable
Torch Parts, page 44)

3. Set pressure to 70 psi (4.8

BAR)

4. Check spark gap assembly

(see Service Procedures,
page 65)

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Summary of Contents for CE CutMaster 50

Page 1: ...pany Manual No 0 2470 October 20 1997 Air Plasma Cutting Power Supply Instruction Manual R The System Includes Pak Master 50 Power Supply PCH M 35 Smart Torch with Leads Optional Input Power Cable Work Cable with Clamp ...

Page 2: ... Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1995 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omis...

Page 3: ...NSTALLATION 18 3 06 ELECTRICAL CONNECTIONS 20 3 07 WORK CABLE AND GROUND CONNECTIONS 23 3 08 GAS CONNECTIONS 24 SECTION 4 OPERATION 27 4 01 OPERATING CONTROLS 27 4 02 GETTING STARTED 29 4 03 SEQUENCE OF OPERATION 30 4 04 TORCH PARTS SELECTION 31 4 05 CUT QUALITY 32 4 06 OPERATING THE SYSTEM 34 4 07 OPERATING WITH A HAND TORCH 36 4 08 OPERATING WITH A MACHINE TORCH 37 4 09 RECOMMENDED CUTTING SPEED...

Page 4: ...COMPONENTS 71 6 04 REGULATOR SOLENOID ASSEMBLY 72 6 05 BASE PANEL COMPONENTS 73 6 06 CHASSIS COMPONENTS 74 6 07 REAR PANEL COMPONENTS 76 6 08 REPLACEMENT TORCHES AND LEADS 77 5 9 TORCH HEADS AND SPLIT HOLDERS 78 5 10 CONSUMABLE TORCH PARTS 79 6 11 TORCH OPTIONS AND ACCESSORIES 80 6 12 TORCH SPARE PARTS KITS 82 APPENDIX I SYSTEM SCHEMATIC 84 ...

Page 5: ...ing or welding any met als which may contain one or more of the follow ing Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the informa tion regarding the kind and amount of fumes and gases that may...

Page 6: ...ped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as recommended in Subsec tion 1 03 item 4 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 ingt...

Page 7: ...NT L OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ Il faut communiquer aux opérateurs et au person nel TOUS les dangers possibles Afin d éviter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les précautions de sécurité et toutes les consignes avant d utiliser le matériel Composez l...

Page 8: ...eneursayant pu renfermer des matières combustibles Prévoyez une veille d incendie lors de tout travail dans une zone présentant des dangers d incendie Le gas hydrogène peut se former ou s accumuler sous les pièces de travail en aluminium lorsqu elles sont coupées 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 à moins que le gas hydrogène...

Page 9: ...ITSCOMBUSTIBLES disponibleauprèsde laAmericanWeldingSociety 550N W LeJeuneRd Miami FL 33126 8 Norme 51 de l Association Américaine pour la Pro tectioncontrelesIncendies NFPA LESSYSTEMES À GAZ AVEC ALIMENT ATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROCÉDÉS ASSOCIÉS disponible auprès de la National Fire ProtectionAssociation Batterymarch Park Quincy MA02269 9 Norme 70 de la NFP A CODE ELECTRI...

Page 10: ...g them are CSA Canadian Standards Association standard C22 2 number 60 M1990 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used IEC 974 1 BS 638 PT10 EN 60 974 1 applicable to welding equipment and associated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine desi...

Page 11: ...REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS The limited warranty periods for Thermal products shall be as follows with the exception of STAK PAK II Amaximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of...

Page 12: ...GENERAL INFORMATION 8 ...

Page 13: ...vides a maximum 1 2 inch 12 mm cut capacity Hand torches are available in 70 and 90 configurations which include a handle and multi position switch assembly Machine torches include a rack and pinion mounting assembly A phenolic plastic pinch block mounting assembly is optional Torch leads are available in 12 5 25 or 50 ft 3 8 7 6 or 15 2 m lengths with a quick disconnect torch leads fitting for si...

Page 14: ...1 1 Wide x 21 7 Long 470 x 282 x 551 mm Controls Panel Indicators Input Power Output Power Cut Capacity Pilot Circuitry CNC Capability Weight Dimensions Configurations Current Rating Duty Cycle Cutting Range Pierce Rating Transfer Distance Consumable Parts Gases Pressure Requirements Flow Requirements Available Leads Lengths 70 or 90 Hand Torch 180 Machine Torch 35 amps Maximum DC Straight Polarit...

Page 15: ...mensions 3 09 in 78 mm 9 59 in 244 mm 1 06 in 27 mm 8 95 in 227 mm 1 06 in 27 mm 2 95 in 75 mm 1 38 in 35 mm 0 20 in 5 mm 6 21 in 158 mm Min 14 72 in 374 mm Max 16 60 in 422 mm 1 06 in 27 mm A 00009 PCM 35 Machine Torch with Rack and Pinion MountingAssembly PCH 35 70 HandTorch PCH 35 90 HandTorch ...

Page 16: ...maging moisture and contaminants from the air stream when using compressed air 575V Transformer Unit Cat No 9 6211 For operating standard systems with 575V three phase input Spare Parts Kit MaximumLife Cat No 5 6001 Spare Parts Kit Gouging Cat No 5 6015 Kits contain replacement front end torch parts see detailed description of spare parts kit contents on page 80 Leads Extension Kit PCH 35 25 ft 7 ...

Page 17: ... is 1 PCH M 35 Torch with Shield Cup Tip Electrode and Gas Distributor Installed 1 Torch Leads with Quick Disconnect Attached 1 Torch Handle Assembly For Hand Torches or 1 Machine Torch Mounting Assembly For Machine Torches 1 MaximumLife Cutting Spare Parts Kit Includes 1 Shield Cup Attachment Cat No 9 6503 5 Tips Standoff Cutting Cat No 9 6500 3 Tips Drag Cutting Cat No 9 6501 5 Electrodes Cat No...

Page 18: ...st not be obstructed Provide at least 2 feet 0 61 m of clearance in the rear Provide at least 6 inches 0 15 m clearance on each side Provide sufficient clearance in front of the unit to allow access to front panel controls minimum 6 in or 0 15 m Operation without proper air flow will inhibit proper cooling and reduce duty cycle Review Important Safety Precautions at the front of this Manual to be ...

Page 19: ... back approximately 2 inches 51 mm and rotate the handle assembly 180 do not rotate beyond 180 To position the control switch in the rear position 1 Locate the tab on the back of the switch track closure Gently press in on the tab and carefully pry the closure upward 2 Remove the switch track insert and the torch control switch 3 Reinstall the switch track insert then the switch then the switch tr...

Page 20: ...Parts Selection page 23 Metal mounting tubes with rack and pinion assemblies are standard for machine torches Phenolic plastic mounting tubes with pinch blocks are optional see Torch Options and Accesso ries page 80 1 Mount the torch assembly on the cutting table Refer to Figure 3 B and 2 To obtain a clean vertical cut use a square to align the torch perpendicular to the surface of the workpiece U...

Page 21: ... with the PCH M 35 torch only Do not connect any other torch to this power supply 1 Check the torch for proper assembly refer to Torch Parts Selection page 31 2 Connect the torch leads fitting onto the receptacle marked TORCH on the front panel of the power supply Figure 3 C Torch Connections Torch Leads Connector WORK TO RCH ON OFF AC TE MP PIP GAS DC PILOT CS D GAS PRESSURE RUN SET CURR Quick Di...

Page 22: ...which hold together the two halves of the power supply enclosure Lay the power supply on its side with the screw heads facing UP Remove all eight mounting screws and carefully lift the upper half of the enclosure from the unit Lift the unit from the lower half of the enclosure and set the unit in upright position on a secure working surface continued on next page RC Wire Harness WARNING Remove the...

Page 23: ...o the chassis Then lift the unit and set it down on its side with the case half down 9 Before installing the other case half make sure the edges of the bottom middle and top chassis panels are fully inserted into the slots in the case Look for gaps between the front and rear panels and the edge of the case Look into the case to see that the notches in the top corners of the front and rear panels a...

Page 24: ...ve the voltage selection access panel 2 Connect the 9 circuit plug on the rear panel to the receptacle which corresponds with the actual primary input voltage HIGH for 380 415 460V or LOW for 200 220V 3 Connect the single circuit plug on the rear panel to the receptacle which corresponds to the actual primary input voltage 460V 380 415V or 200 220V 4 Replace the voltage selection access panel Figu...

Page 25: ...ctly to a properly fused disconnect or by using a plug which conforms to the recommended ratings The primary power source power cable and plug all must conform to local electric code and the recommended circuit protection and wiring requirements see Table 3 A page 22 2 Before connecting the replacement input power cable strip back the outer covering approximately 3 inches 76 mm to expose the indiv...

Page 26: ...0 14 50 60 35 20 10 16 8 12 240 7 5 28 13 50 60 35 15 12 12 8 12 380 7 5 18 8 50 60 25 10 14 18 10 12 460 7 5 14 7 50 60 20 10 16 18 10 12 506 7 5 13 6 50 60 15 8 16 18 12 12 Table 3 A Line Voltages with Recommended Circuit Protection and Wire Sizes Based on Table 310 16 1987 National Electric Code and Table 4 Canadian Electrical Code Figure 3 F Input Power Cable Connections Ground Wire REMOTE CON...

Page 27: ...required will vary depending on location Locate the rod as close as possible to the power supply The work table should be connected to the same earth ground 2 Connect the control device CNC to a separate earth ground The ground cable should be at least 12 gauge wire 3 To minimize RF interference position torch leads as far as possible at least 1 ft or 0 3 m from any CNC components control cables o...

Page 28: ... 4 NPT gas input fitting A quick disconnect coupling 1 4 NPT to 6 barb is supplied with the unit Refer to the manufacturer s specifications for installation and maintenance procedures for high pressure gas regulators Do not use an air line filter with high pressure gas cylinders To use air or nitrogen from a high pressure gas cylinder 1 Examine the cylinder valves to be sure they are clean and fre...

Page 29: ...required when using air from a compressor to insure that moisture and debris from the supply hose does not enter the torch The LeMan two stage air line filter kit is recommended for most applications Follow the installation instructions for this kit on page 18 Air Line Filter Kit Two Stage Cat No 7 3340 CAUTION Using Shop Air Figure 3 H Gas Connections Quick Disconnect Fitting 1 4 NPT Rear Panel F...

Page 30: ...r with bracket to the power supply with the 1 2 in pan head screws 3 Connect the 1 4 NPT male coupling of the gas hose assembly to the power supply first then connect the female JIC fitting to the air filter Tighten both fittings with a 9 16 in wrench Supply hoses must be at least 6 hose 3 8 in or 9 5 mm I D Installing Air Line Filter NOTE Rear Panel Fitting 1 4 NPT Air Filter Assembly Nylon Screw...

Page 31: ... 6 bar psi WORK TORCH ON OFF AC TEMP PIP GAS DC PILOT CSD GAS PRESSURE CURRENT RUN SET RUN SET Switch ON OFF Switch AC Indicator TEMP Indicator PIP Parts In Place Indicator CSD Control Current Control PILOT Indicator DC Indicator GAS Indicator WORK Cable Gas Pressure Gauge Gas Pressure Control TORCH Receptacle SECTION 4 OPERATION ...

Page 32: ...dicates proper torch assembly Light goes out if the shield cup is not fully seated against the PIP pins in the torch body Yellow LED light with RUN SET switch in SET position indicates gas pressure is above the minimum 42 psi or 2 9 BAR to the torch Light goes out in RUN position until torch is activated Yellow LED light indicates adequate DC power output for main arc when the torch is activated Y...

Page 33: ...the workpiece 4 Select desired gas air or nitrogen Make sure gas sources meet pressure and flow requirements see Gas Connections page 16 Check connections and turn gas supply on 5 Move the ON OFF switch to ON position When the unit is switched on an automatic 20 second pre flow gas purge will remove any moisture that may have accumulated in the torch and leads while the system was shut down The to...

Page 34: ...FF switch to OFF RESULT All indicators off Power supply fan off Figure 4 B Sequence of Operation ACTION Torch moved within transfer distance of workpiece RESULT Main arc transfer Pilot arc off PILOT indicator off DC indicator still on ACTION Protect eyes and activate torch RESULT Gas flows GAS indicator on After gas pre flow DC indicator on Power supply enabled HF relay closes Pilot arc establishe...

Page 35: ...9 6501 Electrode MaximimLife 9 6506 Gas Distributor MaximimLife 9 6507 Do not use MaximimLife parts with standard parts MaximimLife shield cup attachment No 9 6503 must be installed over the standard shield cup Torch Parts Selection MaximumLife Parts CAUTION A 00017 Standard Shield Cup Catalog No 9 6003 Crown Shield Cup Catalog No 9 6004 Standoff Cutting Tip 031 in Catalog No 9 6000 Drag Cutting T...

Page 36: ... surface of the plate A perfectly perpen dicular cut would result in a 0 bevel angle Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece Dross is molten material which is not blown out of the cut area and re solidifies on the plate Top spatter is dross which accu mulates on the top surface of the workpiece Excessive dross may require seconda...

Page 37: ... tip orifice diameter little or no dross smooth cut surface Good Slight bevel 0 10 slightly wider kerf 2 1 2 x tip orifice diameter some dross easily removed medium smooth cut surface slight top edge rounding Fair Excessive bevel over 10 wide kerf over 2 1 2 x tip orifice diameter medium to heavy dross rough cut surface top edge rounding Cut quality depends heavily on set up and parameters such as...

Page 38: ...ch allows the operator to keep the torch in contact with the workpiece during operation Drag cutting also requires special cutting tips For edge starts hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of t...

Page 39: ... Life Possible Cause 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Cutting current too low 1 Cutting speed too slow 2 Torch standoff too high from workpiece 3 AC line too low reduce output current 4 Work cable disconnected 5 Worn torch parts 1 Cutting speed too slow bottom dross Easily removed 2 Cutting speed too fast bottom dross Tight bead Difficult to r...

Page 40: ...remain on until the cutting arc starts 5 Once on the main arc remains on as long as the control switch is held down unless the torch is withdrawn from the work or torch motion is too slow If the cutting arc is inter rupted the pilot arc comes back on automatically 6 To shut off the torch simply release the control switch When the switch is released a ten second post flow will occur If the torch sw...

Page 41: ...wn eliminates excessive metal removal in corners Normally open NO contacts supplied by the control device close when the torch travel speed decreases through a corner When the contacts close power supply output drops to a preset current level Small Standard Slotted Head Screwdriver The corner slowdown adjustment is located on the upper front panel see Figure 4 A page 27 CSD output is a percentage ...

Page 42: ...E below and 1 Use a square to align the torch perpendicular to the work piece to obtain a clean vertical cut see Setting Up the Torch page 20 2 To start a cut at the plate edge position the center of the torch along the edge of the plate Figure 4 E Machine Torch Set up and Operation Standoff Distance Straight Arc Trailing Arc Leading Arc Direction of Torch Travel Shown with Optional Rack and Pinio...

Page 43: ...de to side in search of metal for transfer Travel speed also affects the bevel angle of a cut When cutting in a circle or around a corner slowing down the travel speed will result in a squarer cut The power supply has a corner slowdown feature which reduces output for this purpose see Corner Slow down Operation page 37 To pierce with a machine torch the arc should be started with the torch positio...

Page 44: ... 6 6 1 8 1 8 9 6000 Air 102 35 75 1 9 1 8 1 4 9 6000 Air 108 35 45 1 1 1 8 3 8 9 6000 Air 115 35 22 0 6 1 8 1 2 9 6000 Air 120 35 12 0 3 1 8 Table 4 D PCM 35 Cutting Speeds Air Plasma on Mild Steel Thickness Tip Gas es Voltage Amperage Speed Per Minute Standoff Inches Cat No Volts Amps Inches Meters Inches 1 16 9 6000 Air 100 35 250 6 3 1 8 1 8 9 6000 Air 118 35 100 2 5 1 8 1 4 9 6000 Air 124 35 2...

Page 45: ... torch leads or power supply Gouging performance depends on parameters such as torch travel speed current level lead angle the angle between the torch and workpiece and the distance between the torch tip and workpiece standoff Optimum torch travel speed for gouging is between 20 and 120 inches per minute 0 5 and 3 0 meters per minute Travel speed is dependent on current setting lead angle and mode...

Page 46: ... or loss of transferred main arc Slag generated by gouging on materials such as carbon and stainlesss steels nickels and alloyed steels can be removed easily in most cases Slag does not obstruct the gouging process if it accumulates to the side of the gouge path However slag build up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc The...

Page 47: ... power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensi tive electrical components and cause damage to the unit To clean the unit open the enclosure see Service Procedures page 62 and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean If necessary solvents that are recommended for cleaning electrical ap...

Page 48: ...se parts from falling out when the cup is removed Refer to Figure 5 A and 1 Unscrew and remove the shield cup from the torch Inspect the cup for damage Wipe it clean or replace if damaged 2 Remove the tip Check for excessive wear indicated by an elongated or oversized orifice Clean and replace the tip if necessary 3 Remove the gas distributor and check for excessive wear plugged gas holes or disco...

Page 49: ...taken to use only clean air with a torch eventually the inside of the torch becomes coated with residue This buildup can affect the pilot arc initiation and the overall cut quality of the torch Disconnect primary power to the system before disassembling the torch leads or power supply DO NOT touch any internal torch parts while the AC indicator light on the front panel of the power supply is lit T...

Page 50: ...stem before disassembling the torch leads or power supply DO NOT touch any internal torch parts while the AC indicator light on the front panel of the power supply is lit Refer to Figure 5 A page 44 and 1 Remove the shield cup tip gas distributor and electrode from the torch Disconnect the torch leads from the power supply to isolate the torch from power supply circuits 2 Using an ohmmeter set to ...

Page 51: ...crew the retaining nut from the mounting tube and slide the mounting assembly up over the leads 2 Pull the mounting adaptor from the torch head assembly Slide the mounting assembly back over the leads to expose the negative plasma lead connection pilot lead connection and two PIP parts in place circuit connectors 3 Disconnect the negative plasma and pilot leads and the PIP connectors to allow remo...

Page 52: ...s It is not necessary to disconnect the PIP connectors 2 Remove the switch closure from the torch handle by carefully pressing in on the switch closure tab and gently prying the closure upward Remove the switch insert Slide the switch out of the track on the torch handle 3 Push the torch switch connectors through the end of the torch handle to allow removal of the torch switch It may be necessary ...

Page 53: ...d pilot leads and the PIP connectors to allow removal of the torch head Refer to Figure 5 E page 50 and 1 Remove the two O rings from the back of the torch head assembly 2 Remove the shield cup tip gas distributor and electrode if necessary see Figure 5 A page 44 3 Remove the two assembly screws which secure the split holder and separate the two halves of the holder to allow removal of the torch h...

Page 54: ...amage to holder and or PIP pin receptacles may occur 3 Install replacement PIP pin assemblies by positioning the square solder post of the PIP pin receptacle in the retention slot in the split holder and sliding the assembly up into place Position the flange on the PIP pin receptacle flush with the front face of the split holder 4 Route the PIP wires around the strain relief bosses as shown Push t...

Page 55: ...pin assemblies PIP leads and the negative plasma and pilot leads are properly positioned Do not force the holder together Damage to the insulation on the leads will cause torch head failure The PIP leads must be posi tioned correctly to allow reassembly of the torch head Refer to Figure 5 E page 50 and 1 Install the two assembly screws to secure the split holder and reinstall the O rings on the ba...

Page 56: ...e removing or reinstalling the switch assembly 4 Install the switch insert and switch closure 5 Reattach the torch switch leads connectors if necessary and connect the torch switch leads Slide the protective boot forward to cover the end of the handle Refer to Figure 5 B page 47 and 1 Connect the two PIP lead connectors and the negative plasma and pilot leads On a machine torch the control leads a...

Page 57: ...e the locking tabs from the signal connector plug 7 Gently push the tabs in toward the center on the front of the signal connector plug Carefully push the connector out through the back of the quick disconnect body 8 Disconnect the negative plasma and pilot lead fittings 9 Remove the inner retaining ring from the boot Remove both the outer retaining nut and inner retaining ring from the leads The ...

Page 58: ...uick disconnect items Rotate outer retaining ring to access all three set screws Outer Retaining Nut Set Screw Three Gently press tabs inward and remove connector Reverse View Slide boot and retaining ring back over leads to expose leads connections Negative Plasma Lead Connection Pilot Lead Connection Quick Disconnect Body Torch End Signal Pin Connector Outer Retaining Nut Signal Pin Connector In...

Page 59: ...ICING TORCH LEADS COMPONENTS continued Figure 5 H Torch Quick Disconnect Fitting Front End View Pins 3 4 1 6 13 14 A B Description Torch Switch Parts In Place PIP Shield GND Pilot Return Positive Negative Gas A B 10 11 12 13 14 1 2 3 4 5 6 7 8 9 A 00018 ...

Page 60: ...istance between negative cathode body of the torch head where the electrode seats and the positive anode body of the torch head the outer threads where the shield cup seats Infinite resistance no continuity should be measured be tween negative and positive sections of the torch head If any current can flow through the center insulator the torch head is faulty and must be replaced If the torch head...

Page 61: ... and the negative plasma lead fitting If continuity is found replace the torch leads If no continuity is found the torch leads are okay 7 Recheck the torch head leads and quick disconnect assembly to confirm proper measurements If each component is found to be okay there is an assembly problem Carefully reas semble the torch leads and quick disconnect and return to step 2 Checking the Torch Leads ...

Page 62: ...urement and troubleshooting techniques Two levels of troubleshooting are covered in the troubleshooting guide The first basic level of troubleshooting are those which can be performed without special equipment or knowledge and without removing the plastic enclosure from the unit The second advanced level of troubleshooting provides procedures for replacing components and subassemblies which will a...

Page 63: ...nd properly connected see Electrical Connections page 20 2 Check actual line voltage vs voltage selection on rear panel see Electrical Connections page 20 3 Check fuse on inside of rear panel If blown doublecheck voltage selection and replace fuse If fuse blows again return unit to a service station 4 Check and replace if necessary see Service Procedures page 66 1 Make sure the unit has not been o...

Page 64: ...sure too high 4 Faulty high frequency trigger circuit 5 Check and replace if necessary See Service Procedures page 66 1 Check source for at least 70 psi 4 8 BAR In SET position adjust gas pres sure to 70 psi 2 Check and replace if necessary See Service Procedures page 65 3 Check and replace if necessary See Service Procedures page 65 4 Check and replace if necessary See Service Procedures page 65 ...

Page 65: ...oil or moisture in torch 1 Release switch and wait at least 20 seconds before activating switch again 2 Check DC output see Section 5 08 page 68 1 Hold torch 1 8 inch 3 mm from workpiece 2 Make sure work lead is connected securely check continuity if necessary 3 Check D23 indicator on LDD board If not lit send unit to an authorized service center 1 Increase current setting 2 Reduce cutting speed s...

Page 66: ...pping damage or the unit being dropped Minor chips are normal If any burning or arcing is visible on the main transformer return the unit to an authorized service center To remove the transformer 1 Remove the two mounting nuts on the FET board and the four mounting nuts on the pilot board which fasten the transformer leads to the PC boards 2 Remove current sensor plugs from pilot and LDD PC boards...

Page 67: ...rom one lead of the pilot inductor and the connecting copper link from the other lead 2 Turn the unit on its side to access the two mounting nuts and lockwashers which attach it to the chassis Remove the inductor from the unit 3 Install the replacement inductor by reversing the above procedure To avoid damaging the core of the replacement inductor do not force it into place Pilot Inductor L4 Main ...

Page 68: ...component from the unit 3 Install the replacement main output choke by reattaching the mounting and terminal hardware To replace the auxiliary transformer 1 Disconnect the single pin connector on the white wire coming from the auxiliary transformer 2 Using a pin removal tool remove the pins from connectors J14 A J14 B and J14 C on the voltage selection panel 3 Disconnect the secondary wires by unp...

Page 69: ...ap assembly and the torch connecting lug Keep it away from other compo nents and sheet metal as it has very high voltages on it and it can emit electrical interference into critical circuitry 2 Install a replacement HF inductor and connect To check the solenoid measure for 115 VAC between wires 18 and 21 If 115 VAC is present replace the solenoid 1 Disconnect the two connecting hoses by pushing th...

Page 70: ...b 4 Gently squeeze the top of the two rear plastic mounting standoffs to release the board Lift the rear end of the board just enough to clear the locking tabs 5 Squeeze the tops of the two front standoffs and lift the board enough to clear the locking tabs By lifting the rear of the board gently remove it taking care not to get it caught on the front panel holes for the switches or current contro...

Page 71: ...sembly in gently so that the foam seal doesn t catch and seals tightly against the heatsinks 6 Place the fan guard on the outside of the unit and reinstall the four fan mounting screws and nuts 7 Connect the two wires back onto the fan terminals polarity doesn t matter 8 Put the top panel onto its mounting studs and make sure the studs on the bottom of the panel enter the holes in the top of the h...

Page 72: ...panels are fully inserted into the slots in the case Look for gaps between the front and rear panels and the edge of the case and look into the case to see that the notches in the top corners of the front and rear panels are flush against the plastic stops of the case It may take some lifting and re settling of the chassis to get this all lined up 3 Once the chassis is properly aligned in one case...

Page 73: ...d complete de scription of the part or assembly as listed in the description column of the Parts List Also include the model and serial number of the torch Address all inquiries to your authorized Thermal Dynamics distributor If a Thermal Dynamics product must be returned for service contact your Thermal Dymanics distributor Materials returned to Thermal Dynamics without proper authorization will ...

Page 74: ...256 Pak Master 50 with PCM 35 Machine Torch and 25 ft 7 6 m Leads 1 1 6257 Pak Master 50 with PCM 35 Machine Torch and 50 ft 15 2 m Leads Complete 575V Systems Only Complete 575V systems include power supply with work lead 575 VAC transformer assembly PCH M 35 torch with leads and torch spare parts kit Machine torch systems include metal mounting tube and pinion assembly and remote pendant control...

Page 75: ... Quick Disconnect Retaining Ring Clip 5 1 Quick Disconnect Body Wave Spring Washer 6 2 9 4488 Socket Retaining Ring Clip 7 1 9 6237 RF Filter PC Board Assembly PCB 8 1 9 6221 Socket Assembly Plasma 9 1 8 6332 Socket Assembly Secondary 10 2 8 7071 Hole Plug 1 4 11 2 9 6240 Bumper Locking Tab Signal Connector 12 1 8 4249 Strain Relief Work Cable 13 1 8 4247 Work Cable with Clamp 10 ft 1 8 5560 Work ...

Page 76: ...or Solenoid Assembly Includes 1 1 8 4382 Regulator 2 1 8 3370 Solenoid Valve 1 8 NPT SOL 3 1 8 5533 Pressure Switch 42 psi PS 4 1 8 0354 Fitting 1 8 NPT Close Nipple 5 1 8 3369 Reducer Bushing 6 1 9 6220 Gauge 0 100 PSI BAR 7 1 9 6230 Fitting 1 4 NPT x 3 8 Tube Straight 8 1 9 2023 Fitting 1 4 1 8 NPT Reducer 6 1 8 4 7 3 5 5 1 2 A 00764 ...

Page 77: ...Frequency Transformer Assembly T2 5 1 9 6205 Spark Gap Assembly 6 1 9 6229 Single Circuit Receptacle 7 1 9 6200 Main Transformer T3 8 1 9 6201 Pilot Inductor Assembly L4 9 1 9 6213 Base Panel 10 2 9 3133 Fiber Washer 11 1 9 6214 Resistor 10 ohm 12 watt R 12 1 8 4243 Ground Tag 13 1 8 4281 Male Adaptor 14 1 9 5770 Disc Capacitor C 15 1 9 6239 Bracket Inductor Lead Connection 16 1 9 6203 HF Inductor...

Page 78: ...att 12 2 9 6226 Resistor 6k ohm 50 watt 13 8 9 6227 Resistor Mounting Clip 14 1 9 6222 Top Chassis Panel 15 4 9 6223 PC Board Support 16 1 8 4243 Ground Tag 17 1 9 6276 Input OVP Board The following parts sre not shown 4 8 0381 Rubber Feet 1 9 6248 Ribbon Cable Assembly 34 Circuit 1 9 6249 Ribbon Cable Assembly Dual 10 20 Circuit 1 9 6250 Access Panel Input Voltage Connection 1 9 6251 Access Panel...

Page 79: ...Manual 0 2470 75 PARTS LIST 1 2 3 5 6 8 15 13 14 7 10 11 12 9 16 A 00775 ...

Page 80: ...nger Guard 7 2 9 6231 Nine Circuit Receptacle 8 1 9 3861 Fuse 2 amp 600V 9 3 Retaining Ring 300 inch I D 10 1 9 5562 Fuse Holder IEC Internal Style Only 11 1 9 6232 Adaptor Inert B to 1 4 NPT Female 12 1 9 6233 Retaining Ring 75 inch I D 13 1 9 6234 Hole Plug 14 1 8 6214 Amber Lamp 15 1 9 6247 Adaptor Rear Panel Fitting 16 1 9 6235 Fan Heatsink Gasket The follwing part is not shown 1 8 4243 Label ...

Page 81: ...achine Torch 25 ft 7 6 m Leads Spare Parts Kit 1 2 6009 PCM 35 Machine Torch 50 ft 15 2 m Leads Spare Parts Kit Replacement Torches with Leads Only 1 2 6052 PCH 35 70 Hand Torch 12 5 ft 3 8 m Leads 1 2 6053 PCH 35 70 Hand Torch 25 ft 7 6 m Leads 1 2 6054 PCH 35 70 Hand Torch 50 ft 15 2 m Leads 1 2 6055 PCH 35 90 Hand Torch 12 5 ft 3 8 m Leads 1 2 6056 PCH 35 90 Hand Torch 25 ft 7 6 m Leads 1 2 605...

Page 82: ...ne Torch 4 1 9 6259 Split Holder Two Parts PCH 35 70 Hand Torch 1 9 5856 Split Holder Two Parts with PIP Parts PCH 35 70 Hand Torch 5 1 9 6260 Split Holder Two Parts PCH 35 90 Hand Torch 1 9 5857 Split Holder Two Parts with PIP Parts PCH 35 90 Hand Torch 6 1 9 6261 Split Holder Two Parts PCM 35 Machine Torch 1 9 5858 Split Holder Two Parts with PIP Parts PCM 35 Machine Torch 7 1 9 6103 PIP Pin Wir...

Page 83: ...6 MaximimLife Electrode 1 9 6507 MaximimLife Gas Distributor A 00017 Standard Shield Cup Catalog No 9 6003 Crown Shield Cup Catalog No 9 6004 Standoff Cutting Tip 031 in Catalog No 9 6000 Drag Cutting Tip 031 in Catalog No 9 6001 Gouging Tip 046 Catalog No 9 6002 Electrode Catalog No 9 6006 Gas Distributor Catalog No 9 6007 Heavy Duty Drag Tip 036 in Catalog No 9 6120 CAUTION Do not use MaximimLif...

Page 84: ... 35 Machine Torch 50 ft 15 2 m 1 1 8 4305 Torch Handle 2 1 8 4304 Torch Handle Boot 3 1 8 4303 Switch Track Closure 4 1 8 4302 Switch Track Insert 5 1 8 4301 Switch Assembly 1 8 5170 Switch Lever Kit Includes items 6 1 Switch Lever 7 2 Switch Lever Mounting Bracket 1 8 5172 PCH 35 Handle Extension Kit 1 7 3253 Machine Torch Mounting Tube Kit Metal Includes 8 1 8 4306 Adaptor Tube 9 1 7 3207 Metal ...

Page 85: ...Manual 0 2470 81 PARTS LIST 6 7 5 4 3 1 2 8 9 11 10 12 13 ...

Page 86: ...aximimLife Drag Cutting Tip 15 9 6506 MaximimLife Electrode 2 9 6507 MaximimLife Gas Distributor 5 6015 Spare Parts Kit PCH M 35 Gouging Includes 2 9 6003 Shield Cup Standard 6 9 6002 Tip Gouging 5 9 6006 Electrode 2 9 6007 Gas Distributor 5 6021 Spare Parts Kit PCH M 35 Drag Cutting Includes 1 9 6004 Crown Cup Attachment 10 9 6000 Tip Standoff Cutting 10 9 6001 Tip Drag Cutting 10 9 6120 Tip Drag...

Page 87: ...Manual 0 2470 83 APPENDIX This Page Left Blank ...

Page 88: ...APPENDIX 84 Manual 0 2470 APPENDIX I SYSTEM SCHEMATIC A 00804 ...

Page 89: ...Manual 0 2470 85 APPENDIX A 00804 ...

Page 90: ...APPENDIX 86 Manual 0 2470 ...

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