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Thermal Dynamics PakMaster 50 XL Plus, Service Manual

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Thermal Dynamics PakMaster 50 XL Plus Service Manual Download Page 56

SECTION 6: PARTS LISTS

50

Manual 0-2745

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

M1, M2

8-3209

NOTE 1:  Item shown for illustration purposes only.

Summary of Contents for PakMaster 50 XL Plus

Page 1: ...Manual No 0 2745 August 12 1999 Service Manual A 02464 Air Plasma Cutting Power Supply...

Page 2: ...ermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1999 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole...

Page 3: ...Record Serial Numbers For Warranty Purposes...

Page 4: ......

Page 5: ...ies 12 SECTION 4 SERVICE TROUBLESHOOTING DIAGNOSTICS 13 4 01 Introduction 13 4 02 Periodic Inspection Procedures 13 4 03 Common Operating Problems 13 4 04 Troubleshooting Guide General Information 14...

Page 6: ...st 48 6 08 Right Side Internal Component Replacement Parts List 50 6 09 Options and Accessories 52 APPENDIX I INPUT WIRING REQUIREMENTS 53 APPENDIX II SEQUENCE OF OPERATION BLOCK DIAGRAM 54 APPENDIX I...

Page 7: ...ep 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 ki...

Page 8: ...yes always wear a welding hel met or 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...

Page 9: ...uit 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 ATTENTION Toute proc dure pouvant r sul...

Page 10: ...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 INCENDIE ET EXPLOSION Les incendies et les explos...

Page 11: ...ashington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l InstitutAm ricain des Normes Nationales Ameri can National...

Page 12: ...LAPR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2...

Page 13: ...andardsAssociation 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 9...

Page 14: ...roducts 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 yea...

Page 15: ...quipment 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 equi...

Page 16: ...SECTION 2 INTRODUCTION 10 Manual 0 2745...

Page 17: ...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...

Page 18: ...nd 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 C High Pressure Regulators High pressure...

Page 19: ...damage A Piloting 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 pi...

Page 20: ...t 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 is a...

Page 21: ...en 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...

Page 22: ...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 a Replace main powe...

Page 23: ...on 4 09 G re pair as necessary F 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...

Page 24: ...tween 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 If voltage is incorrect replace Logic Gate PC Board 2 Faulty...

Page 25: ...ds a Check continuity per appropriate Torch Instruc tion Manual 5 Faulty torch a Check continuity per appropriate Torch Instruc tion Manual 6 Faulty connection of wire 16 or 17 to Pilot Output PC Boar...

Page 26: ...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...

Page 27: ...h test check each diode in the module Each diode must be checked in forward bias plus to negative and reverse bias negative to plus direction 5 Connect the volt ohmmeter positive lead to the an ode of...

Page 28: ...ks with an ohmmeter at the Main Contactor Meter Meter Indication L1 T1 Open L2 T2 Open L3 T3 Open If any test has resistance then replace the Main Contac tor also E Main Contactor MC1 Test Reconnect p...

Page 29: ...connector from J2 12 Check for short on connector harness end be tween J2 15 16 If shorted Replace TS1 If no short replace Logic Gate PC Board A 02546 J2 TP1 GND Logic Gate PC Board G Gas Solenoid Ci...

Page 30: ...ates that the torch tip is m ak ing contact with the work piece A 02550 Logic Gate PC Board D1 D45 D39 D36 D20 D2 1 No DC Output An open circuit voltage of approximately 280 to 325 VDC depending on in...

Page 31: ...nect wire from E24 on the Pilot Output Board and recheck steps c d If voltage is okay then check torch leads If voltage is still low disconnect wires 11 12 from FET PCB to Pilot Output PCB If voltage...

Page 32: ...ds 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 Use a digital meter diode or ohms function to chec...

Page 33: ...es 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 r...

Page 34: ...SECTION 4 SERVICE TROUBLESHOOTING 28 Manual 0 2745...

Page 35: ...e 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 th...

Page 36: ...above procedure noting the following Leads Wrap must be installed on the replace ment Left Side Panel before panel is installed Place the Left Side Panel onto the frame and slide the top edge under t...

Page 37: ...ise 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 4 Unlatch the Access Panel to gain access to the...

Page 38: ...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 e On the right side remove the three nuts and was...

Page 39: ...on of each 3 Remove the four screws securing the Logic Gate PC Board to the standoffs 4 Remove the Work Cable per the following a Remove Right Side Panel per Section 5 04 C b Loosen the Work Cable end...

Page 40: ...ad sealant to the fitting before reassembling 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 Disc...

Page 41: ...e above procedure C Relay 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...

Page 42: ...3 from connectors J19 black wire J20 orange wire and J21 brown wire using a pin removal tool 5 Disconnect the secondary wires by unplugging the J15 connector from the Logic Gate PC Board 6 Remove the...

Page 43: ...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 wi...

Page 44: ...SECTION 5 REPLACEMENT PROCEDURES 38 Manual 0 2745...

Page 45: ...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...

Page 46: ...LIFTING HANDLE 1 125 OD 11 85 LG 9 7505 2 2 MOUNT LIFTING HANDLE 9 7506 3 1 COVER LEFT SIDE Includes 9 8001 COVER LEFT SIDE LABEL WARNING ENGLISH 4 1 LEADS WRAP Includes 9 8002 PANEL LEADS WRAP MOLDED...

Page 47: ...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 H Rubber Feet I 6 32x3 3 4 LG PH Screw J 10 32 Keput w Sta...

Page 48: ...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...

Page 49: ...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 H Rubber Feet I 6...

Page 50: ...em 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 3P 40 FLA 600V 115VAC COIL MC1 9 7554 3 1 STRAIN RELIEF FOR...

Page 51: ...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 H Rubber Feet I 6 32x3 3 4 LG PH Screw J 10...

Page 52: ...8A 600V 13 32 DIA F1 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 ASSY Includes 9 8011 DIODE BRIDGE 3 PHASE W SCR 40A 1600V 10...

Page 53: ...rm 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 Washer Note Ill...

Page 54: ...NPUT POWER CONNECTIONS 12 1 BRACKET 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...

Page 55: ...E A 10 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 S...

Page 56: ...ING 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 IN...

Page 57: ...t HARDWARE A 10 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...

Page 58: ...DRY AIR 9 7742 1 BRACKET LAMAN FILTER MOUNTING OPTIONAL 9 7535 1 TWO STAGE AIR LINE FILTER KIT OPTIONAL 7 7500 1 DUAL STAGE AIR FILTER ASSEMBLY 9 7527 1 REPLACEMENT FIRST STAGE FILTER 9 1021 1 REPLAC...

Page 59: ...tion and W ire S izes B ased on National E lectric Code and Canadian E lectrical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cabl...

Page 60: ...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 61: ...Board J3 9 J14 4 18VDC Unregulated VDC from Logic PC Board J3 10 J14 5 Logic Low Signal for AC OK Indicator to Logic PC Board J3 11 J14 6 Logic Low Signal for GAS Indicator to Logic PC Board J3 12 J14...

Page 62: ...Auxiliary Transformer J1 6 115 VAC Return from Auxiliary Transformer J2 1 115 VAC Return to K10 Relay Contactor MC1 J2 2 115 VAC Return to Fan 1 J2 3 115 VAC Return to Fan 2 J2 4 115 VAC Return to Sol...

Page 63: ...Relay J5 7 Logic Low PCR Signal to PCR Relay J5 8 Logic Low Torch Switch Input from Pilot Output PCB J13 1 J5 9 Torch Switch Return to Pilot Output PC Board J13 2 J5 10 Logic Low OK To Move Signal to...

Page 64: ...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 Return out to J5 9 Logic Board Torch Sw Return J13 3 Logic Low OK to...

Page 65: ...mr 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 Sta...

Page 66: ...d J5 1 J11 2 Return from Logic PC Board J5 2 36VAC centertap J11 3 36 VAC from Logic PC Board J5 3 J11 4 Logic Low CD Enable Signal from Logic PC Board J5 4 J11 5 Return for CD Enable Signal from Logi...

Page 67: ...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 AC1 AC Input Phase 1 from the contactor T1 and T4 AC2 AC I...

Page 68: ...APPENDIX 62 Manual 0 2745 APPENDIX VIII FET PC BOARD LAYOUT Component Side of PC Board Solder Side of PC Board A 02631 E16 E14 E17 E19 E18 E17 E15 E16 E18 E14 E19...

Page 69: ...te Board upper J7 6 Lower J8 6 J6 7 SEC CURRENT SENSE to the Logic Gate Board upper J7 7 Lower J8 7 J6 8 SEC CURRENT SENSE RTN to the Logic Gate Board upper J7 8 Lower J8 8 J6 9 OVER TEMP RTN to the L...

Page 70: ...Capacitor PC Board Signals E1B Positve Rail to FET Board E1C Positve Rail to FET Board E2B Negative Rail to FET Board E2C Negative Rail to FET Board E1A Positive Input from Input Board E2A Negative I...

Page 71: ...45 65 APPENDIX APPENDIX X 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 V...

Page 72: ...APPENDIX 66 Manual 0 2745 APPENDIX XI SYSTEM SCHEMATIC A 02503 9 13 16 J21 J20 J19 GAS SOL GAS INRUSH INRUSH...

Page 73: ...Manual 0 2745 67 APPENDIX A 02503 OK OK TO MOVE 8 11 99...

Page 74: ...APPENDIX 68 Manual 0 2745...

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