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Thermal Dynamics PAK Master 150XL, Service Manual

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PLASMA CUTTING

POWER SUPPLY

CE PAK Master

®

 150XL™

Service Manual

September 15, 2003

Manual No. 0-2728

TM

TM

A-03044

Summary of Contents for PAK Master 150XL

Page 1: ...PLASMA CUTTING POWER SUPPLY CE PAK Master 150XL Service Manual September 15 2003 Manual No 0 2728 TM TM A 03044...

Page 2: ......

Page 3: ...this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date September 15 2003 Record the following information for Warr...

Page 4: ...ories 3 3 3 05 Theory Of Operation 3 3 SECTION 4 SERVICE TROUBLESHOOTING 4 1 4 01 Introduction 4 1 4 02 Periodic Inspection Procedures 4 1 4 03 System Theory 4 3 4 04 Common Operating Problems 4 4 4 0...

Page 5: ...ATION BLOCK DIAGRAM A 2 APPENDIX 3 POT LED PC BOARD LAYOUT A 3 APPENDIX 4 LOGIC PC BOARD LAYOUT A 4 APPENDIX 5 GATE DRIVE PC BOARD LAYOUT A 6 APPENDIX 6 PILOT OUTPUT PC BOARD LAYOUT AND WIRING CONNECT...

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Page 7: ...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...

Page 8: ...ns in this manual PLASMAARC RAYS PlasmaArc 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 eye...

Page 9: ...able 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 e...

Page 10: ...er ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres pe...

Page 11: ...ue 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 suiva...

Page 12: ...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 M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA...

Page 13: ...elding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 P...

Page 14: ...as follows with the exception of XL Plus Series CutMaster Series Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date o...

Page 15: ...t will assure obtaining the perfor mance for which it was designed 2 02 General Service Philosophy Several key points are essential to properly support the application and operation of this equipment...

Page 16: ...INTRODUCTION 2 2 Manual 0 2728...

Page 17: ...hine torch systems with unshielded leads include a Remote Hand ON OFF Pendant machine torches with shielded leads include a CNC Interface Cable NOTES The power supply can be ordered in various con fig...

Page 18: ...le will be reduced if the primary in put voltage AC is low or the DC voltage is higher than shown in the chart Ambient Temperature 104 F 40 C 104 F 40 C Duty Cycle 60 100 Current 120 Amps n a Amps DC...

Page 19: ...High pressure regulators are available for air nitro gen and argon hydrogen The regulators are used to set the proper pressure for the type of gas being used B CNC Interface Cable NOTE Accessory is f...

Page 20: ...ielded to minimize radio frequency RF interference which results from the high frequency arc initiation These shielded systems are designed with features such as a wire for establishing an earth groun...

Page 21: ...side panel and add two or three drops of 20 SAE oil to the front and rear oil holes on the motor NOTE Some units may utilize a sealed motor design which does not require lubrication C Power Supply Cl...

Page 22: ...oolant Conductivity The coolant conductivity level should be checked if the pilot doesn t start Check the condition of the deionizer bag in the reservoir basket if the bag is yellowish brown straw col...

Page 23: ...at During the transfer the CSR Indicator D65 comes on and the transfer enable signal goes low allowing the bottom gate drive and FET mod ules to come up and start running Also at this time D5 located...

Page 24: ...torch leads Frequently review the Important Safety Precau tions in Section 1 Be sure the operator is equipped with proper gloves clothing eye and ear protec tion Make sure no part of the operator s bo...

Page 25: ...rkpiece c Worn torch parts d Improper cutting current e Improper gas selection for cutting material 4 Short Torch Parts Life a Oil or moisture in air source b Exceeding system capability material too...

Page 26: ...mblies 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 co...

Page 27: ...g arc and note the following Main cutting arc initiates This completes the Main Arc Test If the above are all correct then the equipment should be operating properly If problems still persist then con...

Page 28: ...or fans to cool unit and Refer to Section 2 03 for proper Duty Cycle 3 Fans not operating Measure for 115 VAC on the Logic PC Board from J96 1 to J96 3 and J96 2 to J96 4 If voltage is correct replace...

Page 29: ...air fil ters or replace Solenoid s If the gas flow stops replace the Logic PC Board H AC indicator ON Gas flows GAS and DC indica tors ON Arc in torch without pressing torch switch D26 Torch Switch E...

Page 30: ...oltage does drop momentarily re place the Gate Drive PC Board If D4 on the Gate PC Board does flash for two seconds after D20 turns off then go to the next step 5 Faulty Torch or Leads see note above...

Page 31: ...36 VAC between J13 14 J13 15 If 36VAC is found then replace the Pilot Out put PC Board 8 Faulty Logic PC Board a If the voltage between J13 18 J13 17 on the Pilot Output PC Board does not drop to less...

Page 32: ...t 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 hum...

Page 33: ...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...

Page 34: ...the Power Supply or an overvoltage condition exists If indicator D47 is OFF check L1 L2 and L3 for proper AC input voltage L1 L2 L3 Main Contactor MC1 A 02453 Coil Wire 59 Coil Wire 55 Measure voltage...

Page 35: ...er and replace the upper or lower pair of FET Heatsink Assemblies 9 Repeat steps 1 8 for each FET Assembly If the TEMP Indicator is still on go to the next step 10 Check the Temperature Switch at the...

Page 36: ...ls the bottom two FET Heat sink Assemblies 1 No DC Output An open circuit voltage of approximately 280 to 325 vdc depending on input power selected is produced when switching transistors in the FET He...

Page 37: ...ter lead on source lead of Q1 The meter should indicate 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...

Page 38: ...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 th...

Page 39: ...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...

Page 40: ...nel onto the frame and slide the top edge under the lip on the Top Panel c Reinstall all the screws to secure the Side Panel B Top Panel Replacement 1 Remove the Left Side Panel per Section 5 04 A 2 R...

Page 41: ...ement 1 Unlatch theAccess Panel to gain access to the rear of the ON OFF Switch 2 Disconnect all the wiring to the ON OFF Switch Wiring is as follows On Off Switch wire 32 wire 33 wire 34 wire 35 4B 5...

Page 42: ...the Ac cess Panel by referring to ON OFF Switch per paragraph 5 05 B RUN SET Switch per paragraph 5 05 C STANDARD LATCH Switch per paragraph 5 05 D Current Knob and Pot LED PC Board per paragraph 5 0...

Page 43: ...nections peel pro tective coating off insulator sheet and place insulator sheet on replacement input board D Input Bridge Rectifier Replacement 1 Remove the Left Side Panel per Section 5 04 A 2 Remove...

Page 44: ...rd at J4 to both Gate Drives at J9 J10 Twisted 3 wire harness from J11 on top Gate Drive Board J11 Twisted 3 wire harness from J10 on bottom Gate Drive Board 3 Remove the four screws securing the Gate...

Page 45: ...TES Before removing any connection mark each wire with the connection designation to ensure that wires go to the proper terminals when reassembling Also note the routing of wires and make sure the wir...

Page 46: ...sing the above procedure F Coolant Filter Replacement 1 Remove Right Side Panel per Section 5 04 A 2 Remove the two coolant hose connections to the Filter Assembly NOTE Some residual coolant may drain...

Page 47: ...oir with the coolant removed or fresh Thermal Arc Torch Coolant 14 Place the Deionizer Basket and Bag into the Cool ant Reservoir filler hole and install the Coolant Reservoir Cap H In Line Coolant Fi...

Page 48: ...e full level refer to label on coolant tank with either the coolant that was removed or add fresh ThermalArc Torch Coolant J Output Inductor Assembly L1 L2 Replacement NOTES There are two Output Induc...

Page 49: ...nel In order to gain access to the Main Transformer s the Rear Panel of the unit must be removed and the internal Reservoir Panel disen gaged and moved out of the way 1 Remove the Left and Right Side...

Page 50: ...Replacement NOTE There are four Fans mounted to the Pilot Fan Panel Replacement instructions are the same for all Fans 1 Remove Front Panel per Section 5 04 E 2 Remove the two screws securing the Fan...

Page 51: ...r wheel and second washer from end of axle 3 Install the replacement wheel s by reversing above procedure Axle Replacement 1 Raise the unit off the floor far enough for the weight of the unit to be re...

Page 52: ...Motor Fan and Pump together then replace the Motor The procedure below describes how to remove the Mo tor Fan PumpAssembly to replace the Motor To replace the Fan continue with the procedures outline...

Page 53: ...oting the following a Proper orientation of the Pump Assembly to the Motor Assembly b Install check valve with the flow marking to wards the bottom as shown above c Use thread sealant on all pipe thre...

Page 54: ...orientation then remove the Solenoid Pressure SwitchAs sembly from the two inch brass nipple and set aside g Remove the four screws securing each Regu lator to the rear panel and remove Regulators 4 T...

Page 55: ...Wires L Fitting Brass Nipple Brass Nipple 3 Note the location of all wires then complete the following a Disconnect the gas tubing at the solenoid fitting s b Disconnect blue wires 4 Remove the Press...

Page 56: ...remove the panel This will make it easier to remove wiring 6 Note how the nomex shield is installed around the Filter Assembly then unwrap the shield from around the Filter Assembly 7 Note the locatio...

Page 57: ...urned for service contact your authorized distributor Materials returned without proper authorization will not be accepted C Product Improvements Improvements to the product since release is denoted b...

Page 58: ...ier 9 7817 Top Panel for Units Revision J or later 9 7797 6 1 Access Panel With Labels Screws Access Panel for Units Revision AQ or earlier 9 7821 Access Panel for Units Revision AR or later 9 9034 7...

Page 59: ...sion H or earlier 9 7014 Pot LED Assembly for Units Revision I or later 9 8004 2 1 RUN SET Switch SPST SW2 9 1042 3 1 ON OFF Switch DPST SW1 8 3258 4 1 Knob CURRENT Control With Foam Seal 9 8007 5 2 D...

Page 60: ...s 80 C Rising TS2 9 7895 6 1 Contactor 4 Pole 40 FLA 120 VAC In Rush Contactor INR 9 7507 7 1 Logic PC Board Assembly 9 7812 8 2 Gate Drive PC Board Assembly 9 7811 9 1 FET Heatsink Assembly Kit Inclu...

Page 61: ...Manual 0 2728 6 5 PARTS LISTS 7 1 2 6 3 A 02580 8 5 4 10 9 9...

Page 62: ...Reservoir 9 5948 8 1 Filter In Line Female 8 3460 9 1 Flow Switch Assembly 0 2 GPM FS1 9 5937 10 2 Main Transformer T1 T2 9 7810 11 1 Output Inductor Assembly L1 9 7815 12 4 Fan 115VAC 50 60Hz 95 115...

Page 63: ...Manual 0 2728 6 7 PARTS LISTS A 02275 6 8 7 3 9 4 1 5 2 17 13 12 14 16 10 10 11 21 15 20 18 19 NOTE Parts may differ slightly from illustration...

Page 64: ...sure 8 inch 203 mm Diameter 9 7893 7 1 Motor 1 3 HP 1425 1725 RPM 115 230 V 50 60 Hz M5 9 5932A 8 1 Pump 9 6164 9 1 Radiator Assembly Includes 6 Grommets 9 5941 10 1 Hose Torch Disconnect To Radiator...

Page 65: ...Manual 0 2728 6 9 PARTS LISTS 1 3 4 2 A 02278 7 8 5 6 23x4274 11 13 12 16 17 18 19 14 15 20 9 10 21...

Page 66: ...9 2034 7 1 One Touch 90 1 8 NPT 9 2391 8 2 Fitting 1 8 NPT x 2 Long Nipple Brass 9 7524 9 2 1 4 1 8 NPT Reducer 9 2023 10 2 1 4 NPT Street Elbow 9 2184 11 2 Nipple Close 1 4 NPT 1 4 NPT 9 2186 12 2 1...

Page 67: ...Manual 0 2728 6 11 PARTS LISTS 8 9 10 4 14 5 6 5 8 9 10 4 14 12 11 2 13 7 3 3 1 20 19 15 17 16 18 21 A 02387...

Page 68: ...Elements 1 First Stage 9 1021 1 Second Stage 9 1022 1 Mounting Bracket 9 7535 CNC Interface Control Cable Used With Shielded PCM Machine Torch 1 25 ft 7 6 m 8 5557 1 50 ft 15 2 m 8 5558 1 Y Hose Assem...

Page 69: ...tor 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 distribu...

Page 70: ...ter post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power to system ACTION Close external disconnect switch RESULT Power to system ACTION RUN S...

Page 71: ...urn for Current Control from Logic PC Board J3 9 Potentiometer Low J14 4 12 vdc from Logic PC Board J3 10 J14 5 Signal for AC OK Indicator to Logic PC Board J3 11 J14 6 Signal for GAS Indicator to Log...

Page 72: ...Not Used J2 9 Pressure Switch 12 vdc Signal J2 10 Pressure Switch Return J2 11 Over Temp Sw Input Bridge Pilot Bd Radiator 12V J2 12 Over Temp Sw Input Bridge Pilot Bd Radiator Return J2 13 Not Used J...

Page 73: ...9 Torch Switch Return J5 10 Active Low Torch Sw Signal to LATCH Sw J5 11 Not Used J5 12 PS J5 13 Not Used J5 14 Drag Sensing Signal Voltage Tip Volts J5 15 Not Used J5 16 PS J5 17 36 VAC a to Pilot O...

Page 74: ...Sense from FET PC Boards J6 9 J7 10 Over Temperature Sense from FET PC Boards J6 10 J8 1 12 vdc to FET PC Boards J6 1 J8 2 Return for 12 vdc to FET PC Boards J6 2 J8 3 PWM Output B to FET PC Boards J...

Page 75: ...13 Return for Pilot Enable Signal to Logic PC Board J4 13 J9 14 Active Low Pilot Enable Signal from Logic PC Board J4 14 J9 15 Return for PSR Signal from Logic PC Board J4 15 J9 16 Active Low PSR Sig...

Page 76: ...22 4 Torch Control J12 4 Shield to J22 2 J12 5 Not Used J12 6 Not Used J12 7 OK To Move To J22 12 Isolated Contacts from Logic PC Board J12 8 OK To Move To J22 14 Isolated Contacts from Logic PC Board...

Page 77: ...emp Signal J13 21 Return for Overtemp Signal J13 22 Active Low CSR Sense Signal J98 1 J13 23 Return for CSR Sense Signal J98 2 J13 24 12 vdc to Current Sense Board J98 3 TP1 Ground TP2 15 vdc TP3 Pilo...

Page 78: ...J5 2 J11 3 36 VAC a from Logic PC Board J5 3 J11 4 Active Low CD Enable Signal from Logic PC Board J5 4 J11 5 Return for CD Enable Signal from Logic PC Board J5 5 J11 6 Not Used J11 7 Not Used J11 8...

Page 79: ...Output to INR E2 Rectifier Output to INR E3 Rectifier Output to Capacitor PC Boards A C E4 Rectifier Output to Capacitor PC Boards A C E5 AC Input L1 for LT1 E6 AC Input L2 for LT1 E7 Rectifier from...

Page 80: ...PC BOARD LAYOUT Solder Side Of PC Board A 00479 Component Side Of PC Board XFMR SEC E17 E18 E19 OUTPUT OUTPUT E15 MAIN XFMR PRI MAIN XFMR PRI E14 E16 MAIN XFMR SEC FET PCB ASSY 10 1 J6 T3 E19 E17 E18...

Page 81: ...SE RTN to the Gate Drive Board upper J7 6 Lower J8 6 J6 7 SEC CURRENT SENSE to the Gate Drive Board upper J7 7 Lower J8 7 J6 8 SEC CURRENT SENSE RTN to the Gate Drive Board upper J7 8 Lower J8 8 J6 9...

Page 82: ...d E12C Positve Rail to FET Board E13 Negative Rail to FET Board E13A Negative Rail to FET Board E13B Negative Rail to FET Board E13C Negative Rail to FET Board E25 Positive Input from E8 on Input PC B...

Page 83: ...Manual 0 2728 A 15 APPENDIX APPENDIX 11 CURRENT SENSOR PC BOARD LAYOUT Current Sensor PC Board Signals J15 1 Active Low CSR Sense Signal J15 2 Ground J15 3 12 vdc J15 A 01419...

Page 84: ...rmer Outputs 115 VAC J1 1 2 3 5 6 36 VAC J3 3 1 2 4 ON OFF Switch 1 3 2 J5 CD PC Board 3 J4 5 7 2 Logic PC Board 3 J9 5 7 4 Gate Drive PC Board 1 3 2 J11 A 02325 Pilot Output PC Board 14 15 16 17 18 1...

Page 85: ...he entire machine CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage t...

Page 86: ...APPENDIX A 18 Manual 0 2728 APPENDIX 14 SYSTEM SCHEMATIC Unit Rev AQ or Earlier A 02329...

Page 87: ...Manual 0 2728 A 19 APPENDIX NOTE Transformer T3 in earlier product does not have fuses as part of the Transformer Assembly A 02329...

Page 88: ...APPENDIX A 20 Manual 0 2728 APPENDIX 14 SYSTEM SCHEMATIC Unit Rev AR or Later A 03054...

Page 89: ...Manual 0 2728 A 21 APPENDIX NOTE Transformer T3 in earlier product does not have fuses as part of the Transformer Assembly A 03054...

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