Thermal Dynamics Pak Master 75XL Plus, Service Manual

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TROUBLESHOOTING 4-2 Manual 0-2747
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. Cutting current too low
f. Non-Genuine Thermal Dynamics parts used
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
f. Non-Genuine Thermal Dynamics parts used
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-Genuine Thermal Dynamics parts used
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
4.04 Troubleshooting Guide -
General Information
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot-
ing techniques.
A. Troubleshooting and Repair
Troubleshooting and repair of this unit should be under-
taken only by those familiar with high voltage high power
electronic equipment.
B. Advanced Troubleshooting
For basic troubleshooting and parts replacement proce-
dures refer to Pak Master 75XL PLUS Operating Manual
0-2746.
The advanced troubleshooting covered in this Service
Manual requires Power Supply disassembly and live mea-
surements. It is helpful for solving many of the common
problems that can arise with the Pak Master 75XL PLUS
Power Supply.
If major complex subassemblies are faulty, the faulty sub-
assembly must be returned for repair.
NOTE
Follow all instructions as listed and complete each
in the order presented.
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 sub-sections as follows:
Section 4.05 - Circuit Fault Isolation
Section 4.06 - Main Input and Internal Power Prob-
lems
Section 4.07 - Pilot Arc Problems
Section 4.08 - Main Arc Problems
Section 4.09 - Test Procedures