Thermal Dynamics Pak Master 75XL Plus Service Manual Download Page 2

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Summary of Contents for Pak Master 75XL Plus

Page 1: ...PLASMA CUTTING POWER SUPPLY Pak Master 75XL Plus Service Manual September 15 2003 Manual No 0 2747 A 02464...

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Page 3: ...n 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 War...

Page 4: ...Options and Accessories 3 2 Section 4 TROUBLESHOOTING 4 1 4 01 Introduction 4 1 4 02 Periodic Inspection Procedures 4 1 4 03 Common Operating Problems 4 1 4 04 Troubleshooting Guide General Informatio...

Page 5: ...ernal Component Replacement Parts 6 10 6 09 Options and Accessories 6 12 APPENDIX 1 INPUT WIRING REQUIREMENTS A 1 APPENDIX 2 SEQUENCE OF OPERATION BLOCK DIAGRAM A 2 APPENDIX 3 POT LED PC BOARD LAYOUT...

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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: ...tion standard C22 2 number 60 forArc 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 E...

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: ...quipment will assure obtaining the per formance for which it was designed 2 02 General Service Philosophy Several key points are essential to properly support the application and operation of this equ...

Page 16: ...INTRODUCTION 2 2 Manual 0 2747...

Page 17: ...tings for simple installation Spare Parts Kits are available which provide an assortment of replacement torch parts NOTE Refer to Section 3 04 for list of power supply op tions and accessories 3 03 Sp...

Page 18: ...ilter for use on compressed air shop systems Filters moisture and particulate mat ter from the air stream to at least 5 0 microns C High Pressure Regulators High pressure regulators are available for...

Page 19: ...from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to improve parts life B Torch Standoff Improper standoff the distance between the torch tip a...

Page 20: ...empt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot ing techniques A Troubleshooting and Repair Troubleshooting and repair of this unit should be...

Page 21: ...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 possib...

Page 22: ...fuses blow when unit is pow ered on 1 Input voltage selection incorrect for the main input volt age a Refer to Operating Manual 0 2746 Section 3 06 and select proper input voltage 2 Single phase jump...

Page 23: ...rom 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 temperature circuit per Section 4...

Page 24: ...ck continuity 2 Faulty torch leads a Refer to appropriate Torch Instruction Manual and check continuity 3 Faulty Pilot PC Board Remove power from power supply Disconnect J12 and J13 from the Pilot PC...

Page 25: ...Assembly a Check per Section 4 09 I repair as necessary 3 Faulty torch a Check torch per appropriate Torch Instruction Manual C No arc in torch Gas flows AC indicator ON TEMP indicator off GAS and DC...

Page 26: ...e following indicators inside the Power Supply Pilot indicator D39 on the Logic Gate PC Board is ON during pilot then OFF during main arc transfer CSR indicator D20 on the Logic Gate PC Board is OFF d...

Page 27: ...rd plugs B Opening Power Supply Enclosure The left side panel of the Power Supply must be removed for access to the input power connections and the input voltage selection WARNING Disconnect primary p...

Page 28: ...onducting _ Testing Diode Reverse Bias 7 If a diode checks bad replace the diode module 8 Reconnect all cables to proper terminals D Input PC Board Test Check Input PC Board for shorted input diode In...

Page 29: ...t replace Main Contactor If voltage is incorrect replace Logic PC Board F Temperature Circuit Test Test the temperature circuit per the following 1 Place the front panel ON OFF switch to the OFF posit...

Page 30: ...wires at E23 and E24 at the Pi lot Output PC Board and check again Replace Pilot Output PC Board if shorted from E23 to E24 with wires 17 and 16 removed If Pilot Output PCB is not shorted check for s...

Page 31: ...he 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 rep...

Page 32: ...rted in both direc tions then the FET Heatsink Assemblies should be replaced CAUTION The FET Heatsink Assemblies are matched and balanced during production and must be replaced in pairs 3 MOSFET Resis...

Page 33: ...balanced during production and must be replaced in pairs 5 FET Output Rectifier Check Use a digital meter diode or ohms function to check the forward and reverse bias of the output rectifiers on the F...

Page 34: ...ce of the out put clamp diodes out E17 and out E18 as fol lows NOTE The wires on E16 and E18 should still be discon nected from both FET Heatsink Assemblies a Place the meter lead on E17 and the meter...

Page 35: ...oil 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 manualfor...

Page 36: ...Unlock the latch for the Access Panel 3 Using a Phillips head screwdriver remove the two screws and loosen the three bottom screws which secure the Right Side Panel to the FrameAssembly 4 Carefully p...

Page 37: ...tch per paragraph B above RUN SET LATCH Switch per paragraph C above Pot LED PC Board per paragraph D above 3 Remove the two nuts and washers securing the Ac cess Panel to the Right Side Panel 4 Insta...

Page 38: ...lacement FollowtheAnti StaticHandlingProceduresinSection5 02 1 Remove the Left Side Panel per Section 5 04 B 2 Remove the five screws securing the wiring to the Input PC Board Connection Qty Descripti...

Page 39: ...StaticHandlingProceduresinSection5 02 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...

Page 40: ...d canbescrewedback into the Regulator body by compressing the spring on the spool Tighten firmly by hand Regulator Filter Assembly Spool Bowl Spring Filter Element Baffle Ring A 02988 Standard Filter...

Page 41: ...4 C 4 Disconnect the two wires connected to the Pres sure Switch Assembly 5 Remove the assembly from the T fitting 6 Install the replacement Pressure Switch Assembly by reversing the above procedure A...

Page 42: ...irewith theconnectiondesignation Whenreassemblingthis 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...

Page 43: ...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 the chassis should have a maximu...

Page 44: ...Bulkhead Adapter by re versing the above procedure H Fan Replacement Refer to Section 6 for parts list and overall detail drawing and replacement parts catalog numbers The Top and Bottom Fan Assemblie...

Page 45: ...nt Parts Section 6 08 Right Side Internal Component Re placement Parts Section 6 09 Options and Accessories NOTE Partsed without item numbers are not shown but may be ordered by the catalog number sho...

Page 46: ...ight Side Overlay RH Side Panel Labels Label Warning French 5 1 Leads Wrap Includes 9 8017 Panel Leads Wrap Overlay LH Side Panel HARDWARE A 10 32 Regular Nylon Lock Nut B 10 32 x 2 PPH HDMS C 10 32 x...

Page 47: ...0 Torch 9 8018 Overlay Access Panel Label Access Panel For Units With PCH M 102 Torch 9 6693 Overlay Access Panel Label Access Panel NOTE Illustration may vary slightly from actual unit A 02532 1 2 3...

Page 48: ...w H Rubber Feet I 6 32x3 3 4 LG PH Screw J 10 32 Keput w Star Washer NOTE Illustration may vary slightly from actual unit 6 05 Front Panel Replacement Parts Item Qty Description Ref Catalog 1 1 Panel...

Page 49: ...Manual 0 2747 6 5 REPLACEMENT PARTS This page left blank...

Page 50: ...se Block 9 5562 6 1 Fuse 0 8A 600V 13 32 Dia 9 7526 7 1 Bushing Plastic Snap 1 3 8 ID See Note 1 8 4 Standoff 10 32 X 3 8 Hex X 2 Lg AL See Note 1 9 1 Diode Bridge Ass y 9 8011 Diode Bridge 3 Phase 40...

Page 51: ...PPH Sw ageform Stl Zn Screw D 1 4 20 x 3 Screw Soc HD E 6 32 x 3 1 2 THD Screw F 10 32 x 3 4 PPH Sw ag Screw G 6 32x3 8 PPH STL ZN Screw H Rubber Feet I 6 32x3 3 4 LG PH Screw J 10 32 Keput w Star Was...

Page 52: ...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 8022...

Page 53: ...Manual 0 2747 6 9 REPLACEMENT PARTS NOTE Illustration may vary slightly from actual unit A 02535 1 2 3 4 5 6 7 8 9 10 13 11 12 Part of 4 N 14...

Page 54: ...kt Bulkhead Mounting See Note 1 7 1 Insulator Bulkhead See Note 1 8 1 PCR Relay Replacement Kit PCR 8 3163a 9 1 Transformer Aux IEC Bobbin T2 9 7541 10 1 Ass y Main Transformer T1 9 7520 11 1 Ass y Ou...

Page 55: ...0 32 Regular Nylon Lock Nut B 10 32 x 2 PPH HDMS C 10 32 x 0 5 PPH Sw ageform Stl Zn Screw D 1 4 20 x 3 Screw Soc HD E 6 32 x 3 1 2 THD Screw F 10 32 x 3 4 PPH Sw ag Screw G 6 32x3 8 PPH STL ZN Screw...

Page 56: ...nting Not shown 9 7535 1 Two Stage Air FilterAssembly 9 7527 1 Replacement First Stage Filter 9 1021 1 Replacement Second Stage Filter 9 1022 Computer Control Cable CNC 1 25 Foot 7 6 M 8 5557 1 50 Foo...

Page 57: ...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...

Page 58: ...in arc will transfer After 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...

Page 59: ...rd J3 9 J14 4 18VDC Unregulated from Logic Gate PC Board J3 10 J14 5 Active Low Signal for AC OK Indicator to Logic Gate PC Board J3 11 J14 6 Active Low Signal for GAS Indicator to Logic Gate PC Board...

Page 60: ...er Temperature Switch on Input Bridge J2 16 Over Temperature Switch Return J3 1 36 VAC to ON OFF Switch J3 2 36 VAC from ON OFF Switch to Logic Gate PC Board J3 3 36 VAC to ON OFF Switch J3 4 36 VAC f...

Page 61: ...h Return to Pilot Output PC Board J13 2 J5 10 Logic Low OK To Move Signal to Pilot Output PC Board J13 3 J5 11 Unregulated 18 VDC for OK To Move CSR Relay on Pilot Output PC Board J13 4 J5 12 PS from...

Page 62: ...J12 9 Not Used J12 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 gnd out to J5 9 Logic Board Torch Sw gnd J13 3 OK to...

Page 63: ...23 E9 PS to E18 Upper Fet Module E10 PS to E18 Upper Fet Module E20 From E22 to PCR Pin 2 E22 From Pilot Choke to E20 E23 C4 Rtn for Pilot Voltage Twisted with Pilot RTN from E8 E24 Pilot RTN from Sta...

Page 64: ...36 VAC from Logic PC Board J5 1 J11 2 Return from Logic PC Board J5 2 J11 3 36 VAC from Logic PC Board J5 3 J11 4 CD Enable Signal from Logic PC Board J5 4 J11 5 Return for CD Enable Signal from Logic...

Page 65: ...und R2 Rectifier to Rectifier G SCR Gate to SCR Gate SCR Cathode Module Output to the Inrush Choke Assembly Rectifier Module Output to the Cap Board E26 AC1 AC Input Phase 1 from the contactor T1 and...

Page 66: ...APPENDIX A 10 Manual 0 2747 APPENDIX 8 FET PC BOARD LAYOUT A 02630 Component side of PC Board Solder Side of PC Board E1 E14 E16 E19 E17 E15 E18 E19 E17 E18 E16 E14 E15 E12B E13C...

Page 67: ...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 OVER TEMP RTN to the Gate...

Page 68: ...to FET Board E12B Positive Rail to FET Board E12C Positive 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 Bo...

Page 69: ...7 A 13 APPENDIX APPENDIX 10 36VAC CIRCUIT DIAGRAM Auxiliary Transformer 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 Logic Gate Drive PC Board 1 3 2 J11 A 02527 12...

Page 70: ...pressure flow 4 Purge plasma gas line to remove any moisture build up 5 Inspect input power cable for damage or exposed wires replace if necessary Weekly or Every 30 Cutting Hours 1 Check fan for pro...

Page 71: ...Manual 0 2747 A 15 APPENDIX Notes...

Page 72: ...APPENDIX A 16 Manual 0 2747 APPENDIX 12 SYSTEM SCHEMATIC A 02503...

Page 73: ...Manual 0 2747 A 17 APPENDIX A 02503...

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