Thermal Dynamics CE Pak Master 100XL Plus Service Manual

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PLASMA CUTTING

POWER SUPPLY

CE Pak Master® 100XL™ Plus

A-02464

Service Manual

September 15, 2003 Manual No. 0-2785

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WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply CE PakMaster® 100XL™ Plus Service Manual Number 0-2785

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

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 omission in 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 W arranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

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TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMA TION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.0 2 Important Safety Precautions....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

1.0 4 Note, Attention et Avertissement.................................................................. 1-3

1.0 5 Precautions De Securite Importantes ........................................................... 1-3

1.06 Documents De Reference............................................................................. 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

1.08 Statement of Warranty .................................................................................. 1-8

SECTION 2:

INTRODUCTION ............................................................................................................... 2-1

2.01 Scope Of Manual ......................................................................................... 2-1

2.02 General Service Philosophy......................................................................... 2-1

2.03 Service Responsibilities............................................................................... 2-1

SECTION 3:

DESCRIPTION.................................................................................................................. 3-1

3.01 Scope of Manual.......................................................................................... 3-1

3.02 General Description of System .................................................................... 3-1

3.03 Specifications/Design Features ................................................................... 3-1

3.04 Pow er Supply Options and Accessories....................................................... 3-2

SECTION 4:

SERVICE TR OUBLESHOOTING ....................................................................................... 4-1

4.01 Introduction................................................................................................... 4-1

4.0 2 Periodic Inspection & Procedures ................................................................. 4-1

4.03 Common Operating Problems....................................................................... 4-1

4.04 Troubleshooting Guide - General Information................................................. 4-2

4.0 5 Circuit Fault Isolation.................................................................................... 4-3

4.0 6 Main Input and Internal Power Problems....................................................... 4-4

4.0 7 Pilot Arc Problems........................................................................................ 4-6

4.0 8 Main Arc Problems ....................................................................................... 4-8

4.09 Test Procedures............................................................................................ 4-8

SECTION 5:

REPLACEMENT PROCEDURES ...................................................................................... 5-1

5.01 Introduction................................................................................................... 5-1

5.02 Anti-Static Handling Procedures ................................................................... 5-1

5.03 P arts Replacement - General Information ..................................................... 5-1

5.04 Major External P arts Replacement ............................................................... 5-2

5.0 5 Access Panel P arts Replacement................................................................. 5-2

5.06 F ront Panel Parts Replacement..................................................................... 5-3

5.0 7 Left Side Internal Parts Replacement ........................................................... 5-4

5.08 Rear P anel Parts Replacement ..................................................................... 5-6

5.09 Right Side Internal Parts Replacement ......................................................... 5-8

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TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS ................................................................................................................... 6-1

6.01 Introduction.................................................................................................. 6-1

6.02 Ordering Information .................................................................................... 6-1

6.03 Major External Replacement Parts............................................................... 6-2

6.04 Access Panel Replacement Parts................................................................ 6-3

6.05 Front P anel Replacement Parts.................................................................... 6-4

6.06 Left Side Internal Component Replacement Parts ........................................ 6-6

6.07 Rear Panel Replacement P arts .................................................................... 6-8

6.08 Right Side Internal 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: PO T/LED PC BO ARD LAYOUT.......................................................................... A-3

APPENDIX 4: LOGIC/GATE PC BOARD LAYOUT.................................................................... A-4

APPENDIX 5: PILO T OUTPUT PC BO ARD LAYOUT ...............................................................A-6

APPENDIX 6: CD PC BOARD LAYOUT.................................................................................... A-8

APPENDIX 7: INPUT PC BO ARD LAYOUT ..............................................................................A-9

APPENDIX 8: FET PC BO ARD LAYOUT ................................................................................A-10

APPENDIX 9: CAPACITOR PC BO ARD LAYOUT...................................................................A-12

APPENDIX 10: CURRENT SENSOR PC BO ARD LA YOUT .................................................... A-13

APPENDIX 11: 36VAC CIRCUIT DIAGRAM ...........................................................................A-14

APPENDIX 12: MAINTENANCE SCHEDULE ......................................................................... A-15

APPENDIX 13: SYSTEM SCHEMATIC................................................................................... A-16

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SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEAL TH.

Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep 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 of metal being used, coatings on the metal, and the different pr ocesses. Y ou must be very careful when cutting or welding any metals which may contain one or more of the following:

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 information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

Date: No v ember 15, 2001 1-1 GENERAL INFORMATION

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• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

• Provide a fire watch when working in an area where fire hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. T rapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. Yo u must protect your ears from loud noise to prevent permanent loss of hearing.

• T o protect your hearing from loud noise, wear pr otective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.

PLASMA ARC RA YS

Plasma Arc 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 eyes and burn your skin if you are not properly pr otected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12 400 - 800* 10 14

* These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEAL TH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY -TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Date: Nov ember 15, 2001

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6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standar d A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W1 17.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American W elding Society Standar d A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable fr om the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ATTENTION

Toute procédur e pouvant r ésulter l’endommagement du matériel en cas de nonrespect de la procédur e en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

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.

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATOR Y PROTECTION, obtainable 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 utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.

Date: No v ember 15, 2001 1-3 GENERAL INFORMATION

Il faut communiquer aux opérateurs et au personnel 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 le + 603-298-5711 ou votr e distributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

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• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différ ents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer . (La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (V oir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant 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 peut s’échapper ou se dissiper . Le gas hydrogène accumulé explosera si enflammé.

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’éner gie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

GENERAL INFORMATION 1-4 Date: Nov ember 15, 2001

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons

RAYONS D’ARC DE PLASMA

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ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur . Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculair e.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12 400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L ’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAV AIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. V ous dú4ez vous pr otéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS A YANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymar ch Park, Quincy, MA 02269

Date: No v ember 15, 2001 1-5 GENERAL INFORMATION

Page 12

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13.Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRA TIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-6 Date: Nov ember 15, 2001

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1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street

W est Lebanon, New Hampshire 03784 USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requir ements. Among them ar e:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.

* CENELEC EN50199 EMC Product Standard for Ar c W elding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192

when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative: Giorgio Bassi

Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy

Date: No v ember 15, 2001 1-7 GENERAL INFORMATION

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1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF 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 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 of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Y ears 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year Control PC Board 3 Y ears 1 Year 2 Years 1 Year All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year

But Not Limited To, Starting Circuit, Contactors, Relays, Solenoids, Pumps, Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year SureLok T orches 1 Y ear 1 Y ear 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective August 6, 2001

GENERAL INFORMATION 1-8 Date: Nov ember 15, 2001

Page 15

SECTION 2:

2.03 Service Responsibilities

INTRODUCTION

2.01 Scope Of Manual

This manual provides service Instructions for Thermal Dynamics CE P AK Master® 100XL™ PLUS Plasma Power Supply.

Refer to Operating Manual (0-2784) for individual operating procedures. Information in this edition is therefore particularly applicable to the T roubleshooting and Repair of the equipment, and is intended for use by properlytrained Service T echnicians familiar with this equipment.

Read this manual and the Operating Manual thoroughly . A complete understanding of the capabilities and functions of the equipment 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 equipment.

A. Application

The Service T echnician should be familiar with the equipment and its capabilities and should be prepared to recommend arrangements of components which will provide the most efficient layout, utilizing the equipment to its best possible advantage.

Maintenance work should be accomplished in a timely manner . If problems ar e encountered, or the equipment does not function as specified, contact the Technical Service Department for assistance.

The equipment should satisfy the customer ’s requirements as supplied and as described in Section 3 of this manual. Be sure to confirm that the equipment is capable of the application desired.

B. Modifications

No physical or electrical modifications other than selection of standard options and Accessories are to be made to this equipment.

C. Customer/Operator Responsibilities

It is the customer/operators’ responsibility to maintain the equipment and peripheral Accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual, and to protect the equipment from accidental or malicious damage.

D. Repair Restrictions

The electronics consists of Printed Circuit Board Assemblies which must be carefully handled, and must be replaced as units. No replacement of printed circuit solder-mounted components is allowed except as noted in this manual.

Printed Circuit Board Assemblies to be returned must be properly packaged in protective material and returned intact per normal procedures.

Manual 0-2785 2- 1 INTRODUCTION

Page 16

INTRODUCTION 2-2 Manual 0-2785

Page 17

SECTION 3:

3.03 Specifications/Design Features

DESCRIPTION

3.01 Scope of Manual

The information in this section has two purposes:

• To familiarize the service technician with the capabilities and limitations of the equipment

• T o pr ovide an overall understanding which will allow the technician, in turn, to properly train customer's operating personnel.

3.02 General Description of System

The Pak Master® 100XLTM PLUS (CE) System includes a power supply, torch & leads, work cable & clamp and input power cable.

The power supply provides 80 amp maximum output and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle, and work cable with clamp.

The power supply can be ordered in various configurations with various options factory installed. Refer to Section 3.04 for list of power supply options and accessories.

A. Power Supply Technical Specifications

The following specifications apply to the Power Supply only:

1. Front Panel Controls

ON/OFF Switch, RUN/SET/LATCH Switch and Output Current Control

2. Front Panel LED Indicators

AC , TEMP , GAS , DC

3. Rear Panel

Input Power Cable, Gas Connection, Gas Regulator/ Filter Assembly

4. Input Power

Configured for the following input power: 380/415 VAC (±10%), 50/60 Hz, Three-Phase

5. Output Power

Continuously variable from 15 to 80 Amps maximum

6. Duty Cycle (see NOTE)

NOTE

XL PLUS Power Supply

A-02462

Work Cable and Clamp

Torch and Leads

Figure 2-1 Pak Master® 100XLTM PLUS (CE) System

The torch provides a maximum 1 inch (25.4 mm) cut capacity. The hand torch is available in a 70°and 90° configuration and the machine torch 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 installation. Spare Parts Kits are available for the torch which provide an assortment of replacement torch parts.

The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher than shown in the chart.

Power Supply Duty Cycle

Ambient

Tem

erature

Duty Cy cle

Current

DC Voltage

7. Cut Capacity (Mild Steel)

1 inch / 25.4 mm; 1-1/4 inch / 31.8 mm severance

8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

9. Weight

75 lbs /34 kg with work lead, & input power cable 82 lbs / 37.2 kg with work lead, torch & lead, & input

power cable

104° F

(40° C)

40% 60% 100%

80 Amps n/ a 60 Amps

112 vdc n/a 112 vdc

104° F

(40° C)

104° F

(40° C)

Manual 0-2785 3-1 DESCRIPTION

Page 18

10. Overall Dimensions

E. Computer Control Cable (CNC)

Overall dimensions are with handle, lead wrap bracket, and gas regulator/filter assembly installed.

19" /482 mm High x 13" / 330 mm Wide x 24.6" /0.63 m Long

B. Gas Regulator/Filter Assembly

Specifications

The following specifications apply to the Gas Regulator/ Filter Assembly only:

1. Gas regulator maximum gauge pressure

160 psi / 11 bar

2. Maximum input gas pressure

125 psi / 8.6 bar

3. Filter

Coalescent type filter

3.04 Power Supply Options and Accessories

The following accessories are available for this power supply. Refer to Section 6, Parts Lists, for part numbers and ordering information.

NOTE

This accessory is for use with PCM (Machine) Torches only.

The interface cable is available in two lengths, 25 ft (7.6 m) and 50 ft (15.2 m). The cable is used to interface the power supply with an auxiliary control device to provide OK-To-Move and ON/OFF signals.

F. Cutting Guide Kit

Easy add-on attachments to allow for straight line, circle, or bevel cutting.

G. Standoff Cutting Guide

Simple, push-on guide attachment to allow for torch dragging without risk of touching tip.

H. Hand Pendant Control

A hand pendant contr ol with 20 ft / 6.1 m cable which provides ON/OFF signals to the power supply.

Also offered is a 25 ft / 7.6m extension cable which can be added to the hand Pendant Control cable to provide a total length of 50 ft / 15.2m.

A. Single Stage Air Line Filter Kit

A Single Stage In-Line Air Filter for use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 0.85 microns.

B. Two Stage Air Line Filter

A Two Stage In-Line Air Filter for use on compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 5.0 microns.

C. High Pressure Regulators

High pressure regulators ar e available for air and nitrogen. The regulators are used to set the pr oper pressure for the type gas being used.

D. Multi-Purpose Cart

Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for the power supply and can also serve as a display cart. Top shelf is 12 " / 305 mm x 20 / 508 mm. Steel handle is 30" / 762 mm high.

DESCRIPTION 3-2 Manual 0-2785

Page 19

SECTION 4:

SERVICE

TROUBLESHOOTING

4.01 Introduction

This section provides service diagnostics for the Pak Master® 100XLTM PLUS (CE) Power Supply , allowing the T echnician to isolate any faulty subassemblies. Refer to Section 5, Repairs & Replacement Procedures, for parts replacement instructions.

Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other subassemblies of this unit. Evidence of unauthorized repairs will void the factory warranty .

NOTE

The troubleshooting contained in this is for the Power Supply only. Troubleshooting other parts of the system is covered in the separate manuals for that product.

4.02 Periodic Inspection & Procedures

This subsection describes inspection procedures which should be performed at periodic intervals as required.

A. Physical Inspection

Check that all cable connections are secure.

B. Cleaning

Unit should be cleaned per Appendix 12, Maintenance Schedule.

4.03 Common Operating Problems

W ARNINGS

Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.

Frequently review the Important Safety Precautions (Section 1). Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

Handle torch leads carefully and protect them from damage.

A. Piloting

Piloting is harder on parts life than actual cutting because the pilot arc is directed 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 and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff generally results in a more square cut.

C. Edge Starting

For edge starts, hold the torch perpendicular to the workpiece with the front of the torch tip at the edge of the workpiece, not touching, 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 the metal. Establish the cutting arc as quickly as possible.

D. Direction of Cut

The plasma gas stream swirls as it leaves the torch. The purpose of the swirl is to maintain a smooth column of gas. The swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.

E. Dross

When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance. "Top dross" is normally very easy to remove and can often be wiped off with a welding glove. "Slow speed dross" is normally present on the bottom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not grinding.

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

Manual 0-2785 4- 1 SERVICE TROUBLESHOO TING

Page 20

F. Common Cutting Faults

1. Insufficient Penetration

a. Cutting speed too fast

4.04 Troubleshooting Guide General Information

b. T or ch 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. Tor ch standoff too high fr om 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. Tor ch standoff too high fr om workpiece c. Worn torch parts d. Improper cutting current e. Non-genuine Thermal Dynamics parts used

4. Short T orch 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

W ARNING

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 troubleshooting techniques.

A. Troubleshooting and Repair

T roubleshooting and repair of this unit should be under taken only by those familiar with high voltage high power electronic equipment.

B. Advanced Troubleshooting

NOTE

For basic troubleshooting and parts replacement procedures refer to Pak Master 100XL PLUS (CE) Operating Manual 0-2784.

The advanced troubleshooting covered in this Service Manual requires Power Supply disassembly and live measurements. It is helpful for solving many of the common problems that can arise with the Pak Master® 100XL PLUS (CE) Power Supply .

If major complex subassemblies are faulty , the faulty subassembly 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 subsections 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

SERVICE TROUBLESHOO TING 4- 2 Manual 0-2785

Page 21

C. How to Use the Troubleshooting Guide

3. Set the Power Supply controls as follows:

The following information is a guide to help the Service Technician determine the most likely causes for various symptoms. This guide is set up in the following manner:

1. Perform operational check(s) on the equipment to isolate problem to possible circuit(s) per Section 4.05, Circuit Fault Isolation.

2. Determine symptom and isolate to defective assembly using the following format:

X. Symptom (Bold Type)

Any Special Instructions (T ext T ype)

1. Cause (Italic T ype)

a. Check/Remedy (T ext T ype)

3. Locate your symptom in the appropriate subsection.

4. Check the causes (easiest listed first) for the symptom.

5. Check the remedies listed for each cause.

6. Repair as needed being sure to verify that unit is fully operational after any repairs.

NOTES

Many signals are transferred between Printed Circuit Board Assemblies 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 internal components for signs of over heating, fractures and damage.

ON/OFF switch to OFF RUN/SET/LA TCH switch to SET CURRENT control potentiometer to maximum

B. Main Input and Internal Power Tests

1. Connect main AC power to the unit.

2. Set the Power Supply ON/OFF switch to ON and note the following:

• AC indicator blinks for six seconds, then steady ON.

• Relay K10 on Input PC Board energizes (clicks) before AC indicator is blinking.

• Relay K11 energizes pulling in main contactor (MC1) after AC light stops blinking.

• TEMP indicator OFF

• GAS indicator ON

• Gas flows.

• Fans will operate.

• DC lndicator is OFF.

3. Set the Power Supply RUN/SET/LATCH switch to the RUN position and note the following:

• Gas indicator goes OFF

• Gas flow stops

4.05 Circuit Fault Isolation

Follow all instructions as listed and complete each in the order 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 identify 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 gas supply to rear of Power Supply.

2. T urn on gas supply and adjust Power Supply Gas Regulator to 70 psi (4.8 bar).

Manual 0-2785 4- 3 SERVICE TROUBLESHOO TING

This completes the Main Input and Internal Power T ests. If the above are all correct then proceed to paragraph 'C'.

If the above does not function as noted then note the symptom and proceed to Section 4.06, Main Input and Internal Power Problems.

C. Pilot Arc Test

1. Press the torch switch to establish a pilot arc and note the following:

• Gas flows

• GAS indicator turns ON

• After preflow delay DC indicator turns ON

• Pilot arc established

This completes the Pilot Arc Test. If the above are all correct then proceed to paragraph 'D'.

If the above does not function as noted then note the symptom and proceed to Section 4.07, Pilot Arc Problems.

Page 22

D. Main Arc Test

Press the Torch Switch to establish a pilot ar c. Bring the torch to within 1/8"-3/8" (3-9 mm) of the work-

piece to establish the main cutting arc, and note the following:

• Main cutting arc initiates

• Pilot Relay opens

This completes the Main Arc Test. If the above are all correct then the equipment should be operating properly. If problems still persist then contact T echnical Services.

C . Fan does not operate; AC indicator on front panel of

power supply is OFF

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 power line Fuses.

4. Defective input power cable

If the above does not function as noted then note the symptom and proceed to Section 4.08, Main Arc Problems.

4.06 Main Input and Internal Power Problems

Locate your symptom below:

A. Main power line fuses blow as soon as main

disconnect is closed

1. Input power cable installed incorrectly

a. Refer to Operating Manual 0-2784, Section 3.07

and connect input cable.

B. Main power line fuses blow when unit is powered

1. Input voltage selection incorrect for the main input voltage

a. Refer to Operating Manual 0-2784, Section 3.06

and select proper input voltage.

2. Single phase jumper wire installed incorrectly

a. Refer to Operating Manual 0-2784, Section 3.07

and check jumper wire installation.

3. Faulty Input PC Board

a. Test Input PC Board per Section 4.09-D; repair

as necessary.

4. Faulty Input Bridge

a. Test Input Bridge Rectifier per Section 4.09-D;

repair as necessary.

5. FET/Heatsink Assembly faulty

a. Replace input power cable.

5. Improper input power line connections inside Power Supply

a. Refer to Operating Manual 0-2784, Section 3.07

and correct if needed.

6. Fuse blown inside Power Supply

a. Replace internal Fuse. See Section 5.

7. Line Voltage above 10% tolerance (over voltage protection)

a. Reduce line supply .

8. V oltage selection plug connected incorrectly

a. Refer to Operating Manual 0-2784, Section 3.06

and correct as needed.

9. Faulty Auxiliary Transformer (refer to Appendix 11, 36 VAC Circuit Diagram)

Measure for 36 V AC on Logic/Gate PC Board fr om J1-1 to J1-5.

a. If voltage is not present, replace the Auxiliary

Transformer.

10. Faulty Logic/Gate PC Board (refer to Appendix 11, 36 VAC Circuit Diagram)

Measure for 36 V AC on Logic/Gate PC Board fr om J3-1 to J3-3.

a. If voltage is not present, replace the Logic/Gate

PC Board.

11. Faulty ON/OFF switch (refer to Appendix 1 1, 36 VAC Circuit Diagram)

a. Check per Section 4.09-I; repair as necessary .

SERVICE TROUBLESHOO TING 4- 4 Manual 0-2785

Measure for 36VAC on the Logic/Gate PC Board between J3-2 to J3-4.

a. If voltage is not present replace the ON/OFF

switch.

b. If voltage is present, replace Logic/Gate PCB.

Page 23

D. System will not pilot; AC indicator ON, TEMP

indicator ON

1. Air flow through unit is restricted

a. Provide adequate air flow (Refer to Operating

Manual 0-2784, Section 3.02).

Rear Panel

2. Exceeded duty cycle of Power Supply

a. Wait for fans to cool unit and refer to Operating

Manual 0-2784, Section 2.03, for proper Duty Cycle.

3. Faulty Fan or Logic/Gate PC Board

Measure for 1 15 V AC on the Logic/Gate PC Board from 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 4.09-F;

repair as necessary.

E. No gas flow; AC indicator ON; TEMP indicator

OFF; GAS and DC indicators OFF

1. RUN/SET/LATCH switch in RUN (or LATCH) position

a. Switch to SET position.

Gas Solenoid

Gas Pressure Switch

Wire #51

Wire #50

A-01184

5. Faulty Wiring or Logic/Gate PC Board

Check for DC voltage from Logic/Gate PC Board J2-13 to TP1 (GND).

• If less than a volt, replace Logic/Gate PC Board.

TP1 (GND)

2. Gas supply not connected to unit

a. Connect to gas supply.

3. Gas supply not turned on

a. Turn gas supply on.

4. Faulty RUN/SET/LA TCH switch

a. Check continuity.

5. Faulty gas solenoid circuit

a. Test gas solenoid circuit per Section 4.09-G; r e-

pair as necessary.

F . Gas flows; AC indicator ON; GAS indicator OFF;

DC indicator OFF

1. Gas pressure to low

a. See torch manual for operating pressures.

2. Faulty pressure switch

Measure for DC voltage from wire #51 to wire #50 at the gas pressure switch at the rear of the Rear Panel Assembly .

a. If 12vdc and pressure is above 50 psi, replace

gas pressure switch.

Logic/Gate PC Board

G. Arc in torch without pressing torch switch; Gas

flows; AC indicator ON; GAS and DC indicators ON

1. Faulty torch switch

a. Refer to appropriate Tor ch Instruction Manual

and check continuity.

2. Faulty torch leads

a. Refer to appropriate Tor ch Instruction Manual

and check continuity.

A-02546

Manual 0-2785 4- 5 SERVICE TROUBLESHOO TING

Page 24

3. Faulty Pilot Output PC Board

A-02548

Logic/Gate PC Board

Remove power from the power supply. Disconnect J12 and J13 from the Pilot PC Board.

Check for an open between J12 pin 1 to J12 pin 3 on the Pilot Output PC Board.

a. Replace Pilot Output PC Board if continuity is

present.

Pilot Output PC Board

Top

4.07 Pilot Arc Problems

Locate your symptom below:

A. No gas flow; AC indicator ON; TEMP indicator off;

GAS and DC indicators OFF (T orch Switch must be pressed)

1. Faulty RUN/SET/LATCH switch a. Check switch and replace if necessary .

2. Faulty hand torch parts or Logic/Gate PC Board

Check start indicator, D1, on the Logic/Gate PC Board.

a. If start indicator D1 is ON, replace Logic/Gate

PCB.

b. If start indicator D1 on Logic/Gate PC Board is

OFF check the following:

J12

Pin 3

Pin 1

A-01399

4. Faulty Logic/Gate or Pilot PC Board

Check for DC voltage from Logic/Gate PC Board J5 pin 8 to J5 pin 9.

a. Replace Logic/Gate PC Board if voltage is ap-

proximately 12vdc.

Check Pilot/Output PC Board for 12 vdc between J12 pin 1 to pin 3 with torch switch pressed.

• If voltage is correct, check T orch Switch and PIP as needed per appropriate Torch Instruction Manual.

• If voltage is incorrect, replace Logic/Gate PC Board.

B. Small arc may be visible in torch; Gas flows; AC

indicator ON; TEMP indicator off; GAS indicator ON; DC indicator blinks

1. Faulty Pilot Output PC Board or Shorted T orch

a. Test for 36VAC at J11-1 to J1 1-3.

2. Faulty FET/Heatsink Assembly

a. Check per Section 4.09-I; repair as necessary .

3. Faulty torch

Logic/Gate PC Board

SERVICE TROUBLESHOO TING 4- 6 Manual 0-2785

A-02547

a. Check torch per appropriate Torch Instruction

Manual.

Page 25

C . No arc in torch; No arc at spark gap on CD PC

Board; Gas flows; AC indicator ON; T emp indicator off; GAS and DC indicators ON; CD enable indicator (D2) ON

1. Faulty CD PC Board

a. Test for 36VAC at J11-1 to J1 1-3.

• If voltage is present, proceed to step B.

• If voltage is not present, test for voltage at J5-1 to J5-3.

If no voltage is present, replace Logic/Gate PCB.

b. Measure DC voltage between J11-4 to J11-5 on

CD PC Board.

• If voltage is less than 2 vdc replace CD PC Board.

• If voltage is approximately 12vdc, replace Logic PCB.

5. Faulty torch

a. Check continuity per appropriate T or ch Instruc-

tion Manual.

6. Faulty connection of wire #16 or #17 to Pilot Output PC Board

a. Check wiring connection.

Pilot Output PC Board

Top

CD PC Board

Pin 4

Pin 5

A-01188

J11

D. No arc or intermittent arc in torch; Gas flows; AC

indicator ON; TEMP indicator off; GAS and DC indicators ON; Spark at gap on CD PC Board and CD enable indicator (D2) on Logic/Gate PC Board ON

1. Gas pressure(s) set incorrectly (too high)

a. Refer to appropriate Torch Manual.

2. Oil/moisture in air lines

a Purge system. If problem corrected add filters in

line with air source.

3. Incorrect torch parts

A-01400

E24

Wire #16

E23

Wire #17

7. Faulty Logic/Gate PC Board

Check D39 & D20 on the Logic/Gate Board a. If D39 & D20 are not on, replace Logic/Gate PCB. Measure for 12 vdc on Logic/Gate PC Board from

J5-6 to J5-7.

a. If voltage is greater than 2 vdc, replace Logic/

Gate PC Board.

8. Faulty PCR Relay

Install a jumper between wires #12 and #14. Retry piloting again.

a. If torch pilots with jumper installed, replace PCR

Relay.

a. Refer to appropriate Torch Instr uction Manual.

4. Faulty leads

a. Check continuity per appropriate T or ch Instruc-

tion Manual.

Manual 0-2785 4- 7 SERVICE TROUBLESHOO TING

Page 26

4.08 Main Arc Problems

Locate your symptom below:

A. Main cutting arc will not initiate

2. Faulty PCR Relay

a. With power off, measure for continuity between

wires #12 and #14. If continuity is found, replace PCR.

1. Work cable not connected.

a. Connect work cable.

2. Faulty current sensor

Check the 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 during pilot then ON during main arc transfer .

While trying to transfer , measure voltage at J17-1 to J17-2 on the Logic/Gate PC Board.

If voltage is approximately 12 vdc replace the Current Sensor .

If voltage is less than 2 vdc replace the Logic/ Gate PC Board.

D36

A-02549

D20

D39

3. Faulty Logic/Gate PC Board

If torch tip is off the workpiece and the drag indicator , D36, on the Logic/Gate PC Board is still ON, then replace the Logic/Gate PC Board.

4.09 Test Procedures

The test procedures in this 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 capacitors must be zero before performing service on the power supply .

2. Do Not touch electrical components with any part of the human body when power is applied.

3. Keep away from any moving parts.

4. Hot surfaces can cause severe burns. Allow equipment to cool before servicing.

5. Electrostatic discharge can damage printed circuit board assemblies. T ransport printed cir cuit boards in proper anti-static shielded packages. Use proper grounding techniques with wrist strap before handling printed circuit boards.

Logic/Gate PC Board

Pin 1 Pin 2

B. When operating at amperages over 35 amps, the

amperage drops off after main cutting arc initiates

Check the following indicator inside the Power Supply:

• Drag indicator (D36) on the Logic/Gate PC Board is ON when the torch tip comes in contact with the workpiece.

1. Cutting tip in contact with the workpiece.

a. Maintain standoff distance 1/8"-3/8" (3-9 mm)

between cutting tip and workpiece. (See SW-1 Drag Disable.)

J17

6. Misaligned plugs can cause printed circuit board damage. Be sure plugs are properly aligned and completely seated.

7. Excessive pressure can damage printed circuit boards. Use only minimal pressure and gentle movement when disconnecting or connecting printed circuit board plugs.

SERVICE TROUBLESHOO TING 4- 8 Manual 0-2785

Page 27

B. Opening Power Supply Enclosure

C. Diode Testing Basics

The left side panel of the Power Supply must be removed for access to the input power connections and the input voltage selection.

W ARNING

Disconnect primary power at the source before assembling or disassembling the Power Supply, torch parts, or torch and leads assemblies.

1. Remove the screws securing the left side panel (viewed from front of unit) to the main assembly.

Left Side Panel

T esting of diode modules requires a digital volt/ohmmeter that has a diode test scale. Remember that even if the diode module checks good, it may still be bad. If in doubt, replace the diode module.

1. Locate the diode module to be tested.

2. Remove cables from mounting studs on diodes to isolate 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 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 anode (+) of the diode and the negative lead to the cathode (-) of the diode for forward bias testing (refer to following figure). A properly functioning diode will conduct in the forward bias direction and indicate between 0.3 to 0.9 volts.

A-00307

0.75

A-02640

Ground

Screws (5 places)

Wire

2. Carefully pull the left side panel from the Power Supply a short distance (see note).

NOTE

There is a ground wire attached to the side panel.

3. Remove the nut securing the ground wire to the side panel.

4. Close the enclosure by reversing the above steps.

Forward Bias

Diode Conducting

Diode T est Symbol

Anode

Cathode

COM

Testing Diode Forward Bias

6. Reverse the meter leads across the diode for reverse bias testing (refer to following figure). A properly functioning diode will block in the reverse bias direction and depending on the meter function will indicate an open or “OL”.

Manual 0-2785 4- 9 SERVICE TROUBLESHOO TING

Page 28

A-00306

Remove AC power and with an ohmmeter set on the diode range make the following checks:

M et er (+ ) M et er (-) I n dica ti on

Reverse Bias

Diode Not Conducting

Cathode

Anode

COM

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

Locate the Input PC Board and check for shorted input diode.

Solder Side of PC Board

AC1 (-) Op e n AC2 (-) Op e n AC3 (-) Op e n

(-) AC 1 D io d e D ro p (-) AC 2 D io d e D ro p

(-) AC 3 D io d e D ro p (+) A C1 Op en (+) A C2 Op en (+) A C3 Op en

AC1 (+) Diode Drop AC2 (+) Diode Drop AC3 (+) Diode Drop

The meter should indicate a diode drop in one direction and an open in the other direction for each check.

If Input Bridge Diode is shorted, make the following checks with an ohmmeter at the Main Contactor:

Input PC Board

M et er (+ ) M et er (-) I n dica ti on

L1 T1 O pen L2 T2 O pen L3 T3 O pen

If any test has resistance, then replace the Main Contactor also.

A-02563

SERVICE TROUBLESHOOTING 4-10 Manual 0-2785

Page 29

E. Main Contactor (MC1) Test

Reconnect power and observe proper start-up procedure. With the ON/OFF fr ont panel switch in the ON position, the AC LED should be blinking. If AC LED is not blinking, there is either no power to the unit or an overvoltage condition exists.

Check L1, L2, and L3 for proper AC input voltage.

From EMC

Filter Assembly

Main Contactor

(MC1)

Coil

Wire #55

A-01939

Coil

Wire #59

Measure voltage on coil of contactor, approximately 117 VAC between wires #70 and #75.

• If voltage is correct, replace Main Contactor .

• If voltage is incorrect, replace Logic/Gate PC Board.

A-01410

FET/Heatsink and

Capacitor PC Board

Assembly

3. Place the front panel ON/OFF switch to ON.

4. Check status of the TEMP indicator. If indicator has gone OFF , then remove power and r eplace the FET/Heatsink Assemblies.

5. Place the front panel ON/OFF switch to the OFF position.

6. Disconnect ribbon cable from the Lower FET/ Heatsink Assembly at J6.

7. Place the front panel ON/OFF switch to ON.

8. Check status of the TEMP indicator. If indicator has gone OFF , then remove power and r eplace the FET/Heatsink Assemblies.

F. Temperature Circuit Test

T est the temperature circuit per the following:

1. Place the front panel ON/OFF switch to the OFF position.

2. Disconnect ribbon cable from the Upper FET/Heatsink Assembly at J6.

9. Place the front panel ON/OFF switch to the OFF position.

10. Remove power from unit.

11. Disconnect Connector from J2.

12. Check for short on Connector (harness end) between J2-15 & 16.

If shorted, replace TS1. If no short is found, replace Logic/Gate PC Board.

CAUTION

The FET/Heatsink Assemblies are matched and balanced during production and must be replaced in pairs.

Manual 0-2785 4-11 SERVICE TROUBLESHOOTING

Page 30

TP1 (GND)

I. FET/Heatsink Circuit Tests

The FET/Heatsink circuit tests require various checks to isolate the possible fault to the FET/Heatsink Assembly. There are several internal indicators (LED's) on the Logic/ Gate PC Board to help in troubleshooting.

The indicators on the Logic/Gate PC Board as follows:

Indicator Meaning

Logic/Gate PC Board

A-02546

G. Gas Solenoid Circuit Test

Make the following voltage checks per the circuit diagram and replace the faulty part as required.

Wire #56

Gas

Solenoid

Wire #52

A-01198

1. Check for 1 15 V AC fr om W ire #56 to wire #52 at the gas solenoid.

If approximately 1 15 V AC r eplace solenoid. If no voltage is present proceed to Step 2.

2. Measure for 1 15 V AC from J2-4 to J2-10 at the Logic/ Gate PC Board.

Logic PC

Board

D20

D39

D45

D36

Start - when ON indicates torch swit ch is p resse d

CD Enable - Initiates spark gap on CD PC Board. Indicator should come ON then g o OF F after a pilot arc has been established.

CS R - I nd icat es m ain cut ting arc is established.

Pilot ON - Indicates PCR Relay Drive is active. OF F during cutting.

PWM - Indicates the pulse width modulator IC chip is running

Drag On - W hen ON indicates that the torch tip is making contact with the workpiece.

If voltage is not correct replace Logic/Gate PC Board.

D45

D20

D36

D39

H. Pilot Arc Circuit

Check across E23 to E24 at the Pilot Output PC Board. There should be a diode drop across E23 to E24 in one direction and an open in the other .

If shorted remove the wires at E23 and E24 at the Pilot Output PC Board and check again.

Replace Pilot Output PC Board if shorted from E23 to E24 (with wires #17 and #16 removed).

Logic/Gate PC Board

If Pilot Output PCB is not shorted, check for shorted torch. Check for short between E8 and E22. If shorted, replace Pilot/Output PCB.

SERVICE TROUBLESHOOTING 4-12 Manual 0-2785

A-02550

Page 31

1. No DC Output

A-02552

Logic/Gate PC Board

TP8D1

TP1

An open circuit voltage of approximately 280 to 325 vdc (depending on input power selected) is produced when switching transistors in the FET/Heatsink Assemblies are turned ON by a PWM (Pulse Width Modulation) Enable signal from the Logic/Gate PC Board. A circuit on the Logic/Gate PC Board monitors the output voltage. When the output voltage drops below 60 vdc, indicating a problem exists, the Logic/Gate PC Board sends a signal which turns OFF the PWM Enable signal to the Logic/Gate PC Board. Because this happens in less than 50 milliseconds, it is not easy to take voltage readings to find the source of the problem.

When the unit is at “idle” the AC OK indicator, on front Access Panel, should be ON. The start indicator , D1, turns ON when the torch switch is pressed. At this point the gas begins to flow . When the preflow time is over the 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 replace the Logic/Gate PCB.

This will cause the gas to flow continuously and the DC indicator on the front panel to turn ON.

W ARNING

Connector J11 on the CD PC Board must be disconnected to prevent electrical damage to measuring equipment when testing the open circuit voltage (OCV).

If the PWM Enable indicator , D45, turns ON then OFF immediately , the following test should be performed:

a. Disconnect J11 fr om the CD PC Board to disable

the CD signal.

CD PC Board

J11

A-01202

b. Connect a jumper between TP1 and TP8 on

Logic/Gate PC Board in the unit:

NOTE

Before pressing the trigger , make sure no faults wer e found on the Pilot Board and in the torch.

c. Press and hold the hand torch switch. Logic/

Gate PC Board Start indicator D45 turns on after 2 seconds. If D45 does not turn on, replace the Logic/Gate PCB.

d. Measure open circuit voltage between E29 (+)

to E7 (-) at the Pilot Output PC Board.

e. If voltage is okay , check torch & leads. If voltage

is low, disconnect wire from E24 on Pilot Output Board and recheck steps c-d. If voltage is still low , disconnect wires 1 1-12 (from FET PCB to Pilot Output PCB).

Make sure wires #11 & #12 which connect the FET Assemblies to each other remain connected. Check for output voltage between E17 & E18. If voltage is OV- then replace both FET Assemblies.

Manual 0-2785 4-13 SERVICE TROUBLESHOOTING

Page 32

3. MOSFET Resistance Checks

Pilot Output PC Board

Top

2. FET/Heatsink Output Diode Checks

Remove input power from the unit.

A-01401

E29

The Power Supply contains two identical FET/Heatsink Assemblies. On each assembly there are two MOSFET devices that must be checked. Use an ohmmeter to check for the proper resistance of the MOSFET's as follows:

a. Locate Q1 and Q6 on the FET/Heatsink Assembly.

FET/Heatsink and

Capacitor PC Board

Assembly

A-02560

Isolate each FET/Heatsink Assembly by removing the red wire #12 at E18 and the black wire #11 at E17 on each FET/Heatsink Assembly. With an ohmmeter set on the diode range, check between the two output studs, E17 (- output) to E18 (+ output). This should indicate a diode drop in one direction and open in the other.

If the checks indicate open or shorted in both directions then the faulty Fet/Heatsink Assemblies should be replaced.

b. Place the meter (+) lead on gate lead of Q1 and meter

(-) lead on source lead of Q1. The meter should indicate approximately 2.5K ohms.

Spring

Clip

MOSFET

Gate

A-00553

Drain

Source

c. Place the meter (+) lead on drain lead of Q1 and

meter (-) 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 pro-

tective coating on the MOSFET .

SERVICE TROUBLESHOOTING 4-14 Manual 0-2785

Page 33

d. Place the meter (+) lead on drain lead of Q1 and

meter (-) lead to the heatsink. The meter should indicate >1 meg ohms.

e. Place the meter (+) lead on gate lead of Q7 (located

at bottom right corner of FET/Heatsink) and meter (-) lead on source lead of Q7. The meter should indicate approximately 2.5K ohms.

f. Place the meter (+) lead on drain lead of Q7 and

meter (-) lead on source lead of Q7. The meter should indicate >100K ohms.

4. FET Reset Diode Check

Use an ohmmeter set to the diode function and check the reset diode as follows:

a. Place the meter (+) lead on E14 and the meter (-)

lead on E25 of the FET/Heatsink Assembly Capacitor PC Board to check the reset diode. The meter should indicate between 0.4 to 0.6 volts using the diode function.

b. Reverse the meter leads and the indication should

be a capacitor charging.

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 FET/Heatsink Assemblies as follows:

a. Remove the wire from E16 and E18 on the Upper

and Lower FET/Heatsink Assemblies.

A-01415

E14

E15

E19

c. Place the meter (-) lead on E14 and the meter (+)

lead on E26 of the FET/Heatsink Assembly Capacitor PC Board to check the reset diode. The meter should indicate between 0.4 to 0.6 volts using the diode function.

d. Reverse the meter leads and the indication should

be a capacitor charging.

If the indication is a short, then replace the FET/ Heatsink Assemblies.

E17

E18

E16

b. Place the meter (+) lead on E16 and the meter (-)

lead on E18 of the FET/Heatsink Assembly to check the output rectifier forward bias. The meter should indicate between 0.3 to 0.6 volts using the diode function or 100K ohms using the ohms function.

c. Place the meter (+) lead on E18 and the meter (-)

lead on E16 of the FET/Heatsink Assembly to check the output rectifier reverse bias. The meter should indicate 'OL' using the diode function or 100K ohms using the ohms function.

d. Place the meter (+) lead on E17 and the meter (-)

lead on E19 of the FET/Heatsink Assembly to check the output rectifier forward bias. The meter should indicate between 0.3 to 0.6 volts using the diode function or 100K ohms using the ohms function.

Manual 0-2785 4-15 SERVICE TROUBLESHOOTING

Page 34

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 the diode function or 100K ohms using the ohms function.

f. Place the meter (+) lead on E18 and the meter (-)

lead on the heatsink of the FET/Heatsink Assembly to check the output rectifier resistance to ground. The meter should indicate >1 meg ohms.

Replace the FET/Heatsink Assemblies if any of the above tests are open or shorted.

6. FET Output Clamp Diodes Check

Use an ohmmeter to check the resistance of the output clamp diodes, (+ out) E17 and (- out) E18, as follows:

NOTE

The wires on E16 and E18 should still be disconnected 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 resistance. The meter should indicate >1 meg ohms.

b. Place the meter (+) lead on E18 and the meter (-)

lead on E17 of the FET/Heatsink Assembly to check the output clamp diode resistance. The meter should indicate >1 meg ohms.

Replace the FET/Heatsink Assemblies if any of the above tests are open or shorted.

This completes the test procedures.

SERVICE TROUBLESHOOTING 4-16 Manual 0-2785

Page 35

SECTION 5:

REPLACEMENT

PROCEDURES

5.01 Introduction

4. Connect the equipment primary cable ground to the same electrical ground as the wrist strap.

5. Open the equipment enclosure (see instruction manual for the appropriate equipment) and remove the failed PC Board.

6. Carefully open the ESD protective bag and remove the replacement PC board.

This section describes parts replacement procedures and all cable repairs which may be performed on the Pak Master® 100XL

Under no circumstances are field repairs to be attempted on Printed Circuits or other subassemblies of this unit. Evidence of unauthorized repairs may void the factory warranty.

PLUS (CE) Power Supply .

5.02 Anti-Static Handling Procedures

A. General

Replacement PC boards are shipped in a protective enclosure to prevent damage from electrostatic discharge (ESD) during shipping. Included with each replacement board is a ground strap to prevent static damage during installation.

W ARNINGS

Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or removing the replacement PC Board from its protective enclosure.

Disconnect primary power to the system before disassembling the torch, torch leads, or power supply enclosure.

Do not operate the equipment or test equipment under power while wearing the grounding wrist strap.

PC Boards can be irreparably damaged by improper handling due to electrostatic discharge (ESD).

7. Install the replacement PC Board in the equipment and make all necessary connections.

8. Place the failed PC board in the ESD protective bag and seal for return shipping.

9. Reassemble the equipment enclosure (see instruction manual for the appropriate equipment).

10. Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equipment.

5.03 Parts Replacement - General Information

The parts replacement procedures described in this manual, except for filter replacement, require that the Power Supply be disassembled. The part to be replaced will determine to what extent the Power Supply must be disassembled.

W ARNING

Disconnect primary power from the source before opening or disassembling the power supply. Make sure AC Indicator on the Power Supply front panel is OFF .

NOTES

Before removing any connection mark each wire with the connection designation. When reassembling make 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 the unit.

B. Procedure

1. Open the wrist strap and unwrap the first two folds of the band. W rap the adhesive side firmly around your wrist.

2. Unroll the rest of the band and peel the liner from the copper foil at the opposite end.

3. Attach the copper foil to a convenient and exposed electrical ground.

Manual 0-2785 5- 1 REPLACEMENT PROCEDURES

Each subsection is referenced to Section 6 for parts lists and overall detailed drawing.

Before disassembling any part of the Power Supply first read the procedure for the part to be replaced, then proceed with the disassembly .

Page 36

5.04 Major External Parts Replacement

C. Right Side Panel Replacement

1. Remove the Lifting Handle per paragraph 'A' above.

Refer to Section 6.03 for parts list and overall detail drawing.

A. Lifting Handle Replacement

1. Remove the two screws securing the ends of the handle to the top of the unit.

2. Remove the Lifting Handle from the two end mounting blocks.

3. Place the replacement Lifting Handle into the mounting blocks.

4. Secure the Lifting Handle to the top of the unit with the two screws.

B. Left Side Panel Replacement

1. Remove the two side screws and loosen the three bottom screws securing the Left Side Panel to the Frame Assembly .

Left Side Panel

2. Remove screw securing the Access Panel to the Front Panel.

3. Remove the two side screws and loosen the three bottom screws which secure the Right Side Panel to the Frame Assembly .

4. Carefully pull the Right Side Panel up and away from the unit to gain access to the wire connections on the inside of the Access Panel.

5. Disconnect the LED/POT PC Board wiring connector from J3 at the Logic PC Board.

6. Remove the two nuts securing the Access Panel to the Right Side Panel.

7. Install the replacement Right Side Panel by reversing the above procedure noting the following:

a. Install the Access Panel onto the replacement

Right Side Panel.

b. Place the Right Side Panel onto the frame and

slide the lip on the top edge over the edge on the top of the Left Side Panel.

D. Leads Wrap Replacement

A-02640

Ground

Screws (5 places)

Wire

2. Carefully pull the Left Side Panel up and away from the unit far enough to gain access to the ground wire connection on the inside of the panel.

3. Remove the nut from the ground stud on the side panel and remove the ground wire.

4. Remove the four screws securing the Leads W rap to the Left Side Panel.

5. Install the replacement Left Side Panel by reversing the 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 three bottom

screws and slide the top edge under the lip on the top of the Right Side Panel.

1. Remove the Left Side Panel per Section 5.04-B.

2. Remove the four screws securing the Leads W rap to the Left Side Panel.

3. Install the replacement Leads Wrap by reversing the above procedure.

5.05 Access Panel Parts Replacement

Refer to Section 6.04 for parts list and overall drawing.

A. CURRENT Knob Replacement

1. Turn the CURRENT adjustment fully counter clockwise 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 old knob.

4. Place the replacement Current Knob on to the potentiometer shaft with the location of the pointer the same as noted in step 1.

5. Tighten the screw to secure the knob to the potentiometer shaft.

REPLACEMENT PROCEDURES 5-2 Manual 0-2785

Page 37

B. ON/OFF Switch Replacement

E. Access Panel Replacement

1. Disconnect input power from the power supply .

2. Unlatch the Access Panel to gain access to the rear of the ON/OFF Switch.

3. Disconnect all the wiring to the ON/OFF Switch.

4. Squeeze the top and bottom of the switch while pulling it out of the Access Panel.

5. Install the replacement ON/OFF Switch by reversing the above procedure.

C. RUN/SET/LATCH Switch Replacement

1. Disconnect input power from the power supply .

2. Remove the screw securing the Access Panel to gain access to the rear of the RUN/SET/LA TCH Switch.

3. Disconnect all the wiring to the RUN/SET/LATCH Switch.

4. Squeeze the top and bottom of the switch while pulling it out of the Access Panel.

5. Install the replacement RUN/SET/LATCH Switch by reversing the above procedure.

D. Pot/LED PC Board Assembly Replacement

Follow the anti-static procedures in Section 5.02.

1. Disconnect input power from the power supply .

2. Turn the CURRENT adjustment fully counter clockwise and note the location of the pointer on the knob.

3. Loosen the screw securing the Current Knob to the potentiometer shaft.

4. Remove the Current Knob and bushing.

5. Unlatch the Access Panel to gain access to the Pot/ LED PC Board.

6. Remove the Pot/LED PC Board from the four standoffs.

7. Disconnect the connector at J14 of the Pot/LED PC Board.

8. Install the replacement Pot/LED PC Board by reversing the above procedure.

1. Disconnect input power from the power supply .

2. Remove the Right Side Panel per Section 5.04-C.

3. Remove the following components from the Access Panel:

• Current Knob per paragraph 'A' above.

• ON/OFF Switch per paragraph 'B' above.

• RUN/SET/LATCH Switch per paragraph 'C'

above.

• Pot/LED PC Board per paragraph 'D' above.

4. Remove the two nuts and washers securing the Access Panel to the Right Side Panel.

5. Install the replacement Access Panel by reversing the above procedure.

5.06 Front Panel Parts Replacement

Refer to Section 6.05 for parts list and overall drawing.

A. Work Cable Replacement

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the Work Cable connection fr om the lower FET/Heatsink Assembly at E18 (OUTPUT) terminal.

4. Remove the Work Cable strain r elief from the Front Panel.

5. Pull the W ork Cable from the unit.

6. Install the replacement Work Cable by reversing the above procedure.

B. Main Contactor Replacement

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Note the orientation of all the wires and then disconnect the input and output wiring from the Main Contactor Assembly .

4. Remove the two nuts and washers securing the Main Contactor to the bottom of the unit.

5. Install the replacement Main Contactor Assembly by reversing the above procedure.

Manual 0-2785 5- 3 REPLACEMENT PROCEDURES

Page 38

C. Unit Base/Front Replacement

NOTE

5.07 Left Side Internal Parts Replacement

Replacing the Unit Base/Front requires removing the center chassis assembly from the unit.

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the Right Side Panel per Section 5.04-C.

4. Remove the Work Cable per Section 5.06-A.

5. Remove the Tor ch from the unit.

6. Remove the following hardware: a. Two mounting nuts from Main Contactor As-

sembly. b. Nut and wire from ground stud. c. Bottom two 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 As-

sembly. e. On the left side remove the three nuts and wash-

ers securing the internal chassis to the bottom

of the unit.

7. Carefully slide the internal components up, back, and out of the Base/Front Assembly.

8. Install the replacement Base/Front Assembly by reversing the above procedure.

D. Current Sensor Replacement

1. Disconnect input power from the power supply .

2. Remove the Work Cable per Section 5.06-A above.

3. Disconnect the cable from the Current Sensor at J17 of the Logic/ PC Board.

Refer to Section 6.06 for parts list and detail drawing.

A. Fuse Replacement

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the Fuse from the fuse holder.

4. Replace the Fuse. See Section 6, Parts Lists, for replacement fuse catalog number.

5. Reinstall the Left Side Panel.

B. Fuse Holder (Block) Replacement

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the Fuse from the Holder.

4. Disconnect the two wires connected to the Fuse Holder.

5. Remove the two small screws securing the Fuse Holder to the chassis.

6. Install the replacement Fuse Holder by reversing the above procedure.

C. Input PC Board Assembly Replacement

Follow the anti-static handling procedures in Section 5.02.

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the Input EMC Filter Assembly .

4. Remove the five screws securing the wiring to the Input PC Board. The wiring connections are as follows:

4. Remove the Sensor from the standoffs at the rear of the Front Panel, behind the W ork Cable Strain Relief.

5. Install the replacement Current Sensor by reversing the above procedure.

5. Remove the clear Input PC Board Insulator sheet.

6. Carefully pull the Input PC Board from the unit far

REPLACEMENT PROCEDURES 5-4 Manual 0-2785

Connection Qty Description

of Cable

(-) 2 Cable 7

(+) 2 Cable 10 AC1 3 Cable 1 AC2 2 Cable 2 AC3 2 Cable 3

enough to disconnect the wiring connections to the component side of the PC Board.

Page 39

7. Install the replacement Input PC Board by reversing the above procedure noting the following:

3. Remove the four screws securing the Logic/Gate PC Board to the standoffs.

NOTE

Failure to properly tighten the five screws securing the Input PC Board to the Diode Bridge will cause damage to the unit.

• The five screws securing the wiring and Input PC Board to the Diode Bridge must be tight enough to prevent the wires from moving.

D. Input Diode Bridge Assembly Replacement

Follow the anti-static handling procedures in Section 5.02.

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the Input PC Board per paragraph 'C' above.

4. Remove the two screws securing the Input Diode Bridge to the Center Chassis.

5. Remove the Input Diode Bridge Assembly from the unit.

6. Remove the Thermal Pad from the Center Chassis.

7. Install the replacement Input Diode Bridge Assembly and new Thermal Pad by reversing the above procedure (see Note).

4. Install the replacement Logic/Gate PC Board by reversing the above procedure.

F . FET/Heatsink Assembly Replacement

CAUTION

The FET/Heatsink Assemblies are matched and balanced during production and must be replaced in pairs.

Follow the anti-static handling procedures in Section 5.02.

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Place the unit on its right side.

4. Remove the Ribbon Cable plug at J6 on the FET/ Heatsink Assembly. To remove the cable, push down on the locking tab and pull the cable plug out of the connector .

5. Disconnect the wiring from wire lug connections on the Capacitor PC Board at '+' and '-' terminals (E25 and E26).

6. Disconnect all the wire lug connections to the FET/ Heatsink Assembly .

NOTE

The two screws removed in Step 3 must be torqued to 35 in-lbs when reinstalled.

E. Logic/Gate PC Board Replacement

Follow the anti-static handling procedures in Section 5.02.

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Carefully remove all cable connections from the Logic/Gate PC Board noting the location of each per the following chart:

Connection Description

J1 Cable from Auxillary

Transformer J2 16-pin Cable J5 16-pin Cable

J17 Cable from Current Sensor J10 Cable from Input PC Board

J8 Ribbon Cable from Top

FET/Heatsink Assembly J7 Ribbon Cable from Bottom

FET/Heatsink Assembly

Connection Description

E14 Main Transf ormer (Primary) E15 Main Transf ormer (Primary)

E16 Main Transf ormer (Secondary) E17 (-) Out put E18 (+) Output E19 Main Transf ormer (Secondary)

7. Remove the two screws securing the Heatsink Mounting Bracket to the chassis.

8. Lift up on the middle where the two FET/Heatsink Assemblies come together and remove the Mounting Bracket.

9. Slide the FET/Heatsink Assembly out and up to remove the FET/Heatsink Assembly from the unit.

Manual 0-2785 5- 5 REPLACEMENT PROCEDURES

Page 40

10. Install the replacement FET/Heatsink Assembly by reversing the above procedure, keeping in mind the following:

4. Note the correct assembly of the filter/spool then remove the filter from the spool and either clean it or replace it.

• Cables marked with 'A' connect to the upper FET/Heatsink Assembly, cables marked 'B' connect to the lower FET/Heatsink Assembly.

• Connect cables with similarly named terminals (i.e.. connect cable 16A to terminal 16).

NOTE

Be sure that the top groove in the FET/Heatsink Assembly is properly seated over the cutout in the chassis.

5.08 Rear Panel Parts Replacement

Refer to Section 6.07 for parts list and detail drawing.

A. Standard Filter/Regulator Element

Replacement

The standard Filter/Regulator Assembly is on the rear panel. For better system performance, the Filter/Regulator Assembly filter element should be checked per the Maintenance Schedule, and either cleaned or replaced. See Section 6, Parts List, for replacement part catalog number .

1. Remove power from the power supply; turn off the gas supply.

2. Unscrew the plastic bowl on the bottom of the Filter/Regulator Assembly. The filter element will be visible and still attached to the main body of the Filter Regulator .

3. Grasp the filter element and unscrew it from the Filter/Regulator body . The filter element will come off with a spool and some additional pieces.

5. The filter element and spool, with the baffle ring in place (teeth facing downward) can be screwed back into the Regulator body by compressing the spring on the spool. Tighten firmly by hand.

B. Optional Single Stage Air Line Filter

Element Replacement

This part is an option and is not installed on all units. See Section 6, Parts List, for replacement part numbers.

NOTE

The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried out, and reused. Allow 24 hours for Element to dry.

1. Remove power from power supply .

2. Shut off air supply and bleed down system before disassembly to change Filter Element.

3. Disconnect gas supply hose.

4. T urn the Cover counterclockwise and remove it from the Filter Housing. The Filter Element is located inside the housing.

5. Remove the Filter Element from the Housing and set Element aside to dry .

6. Wipe inside of housing clean, then insert the replacement Filter Element cup side first, as shown below.

Housing

Regulator/Filter

Assembly

Filter

Element

(Cat. No. 9-7741)

Baffle Ring

Filter Element

Spring

Spool

Bowl

A-02988

Spring

O-ring

Cover

Barbed

Fitting

Assembled Filter

A-02476

Optional Single-Stage Air Filter

Standard Filter Element

REPLACEMENT PROCEDURES 5-6 Manual 0-2785

Page 41

7. Replace Housing on Cover.

8. Reattach gas supply hose.

NOTE

If unit leaks between housing and cover , inspect the "O" Ring for cuts or other damage.

C. Optional Two Stage Air Line Filter

Replacement

This part is an option and may not be installed on all units. See Section 6, Parts List, for replacement parts catalog numbers.

1. Remove power from power supply .

2. Shut off air supply and bleed down system before changing Filter Elements.

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.

7. Hand tighten the two bolts evenly , then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).

8. Slowly apply air pressure to the assembly, checking for leaks.

D. Pressure Switch Replacement

1. Remove power from power supply .

2. Shut off air supply and bleed down system before disassembly.

3. Remove the Right Side Panel per Section 5.04-C.

4. Disconnect the two wires connected to the Pressure Switch Assembly.

W ARNING

Always turn off the air supply and bleed the system before disassembling the Filter Assembly as injury could result.

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

4. Note the location and orientation of the old Filter Elements.

5. Slide out the old Filter Elements.

5. Remove the assembly from the T-fitting.

6. Install the replacement Pressure Switch Assembly by reversing the above procedure and noting the following:

• Apply pipe thread sealant to the fitting before

reassembling.

NOTE

For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch.

E. Solenoid Valve Replacement

1. Remove power from power supply .

2. Shut off air supply and bleed down system before disassembly.

3. Remove the Right Side Panel per Section 5.04-C.

4. Disconnect the two wires connected to the Pressure Switch Assembly.

5. Disconnect the two wires connected to the Sole-

First & Second Stage Cartridges (as marked)

A-02942

noid V alve Assembly.

6. Disconnect the gas tube connected to the bottom of the T-fitting.

7. Remove the T-fitting and gas fitting from the Solenoid V alve Assembly.

Optional Two-Stage Air Filter

8. Remove the Solenoid Valve Assembly from the straight brass fitting.

Manual 0-2785 5- 7 REPLACEMENT PROCEDURES

Page 42

9. Install the replacement Solenoid Valve Assembly by reversing the above procedure.

NOTE

F. Air Line Regulator Bracket Replacement

1. Remove power from power supply .

2. Shut off air supply and bleed down system before disassembly.

3. Disconnect the gas input hose from the input of the Air Line Regulator Assembly.

4. Remove the nut securing the Air Line Regulator to the mounting bracket.

5. Remove the four screws securing the Air Line Regulator Bracket to the Rear Panel.

6. Pull the bracket from the unit.

7. Install the replacement Air Line Regulator Bracket by reversing the above procedure.

G. Air Line Regulator Replacement

1. Remove power from power supply .

9. Install the replacement Air Line Regulator Assembly by reversing the above procedure and noting the following:

• Apply pipe thread sealant to the fitting before

reassembling.

NOTE

5.09 Right Side Internal Parts Replacement

A. Pilot/Output PC Board Assembly

Replacement

Follow the anti-static handling procedures in Section 5.02.

1. Disconnect input power from the power supply .

2. Remove the Right Side Panel per Section 5.04-C.

NOTES

Before removing any connection, mark each wire with the connection designation. When reassembling this makes sure the wires go to the proper terminals.

2. Shut off air supply and bleed down system before disassembly.

3. Disconnect the gas input hose from the input of the Air Line Regulator Assembly.

4. Remove the Right Side Panel per Section 5.04-C.

5. Disconnect the gas tube connected to the bottom of the T-fitting at the Solenoid Valve Assembly .

6. Remove the Air Line Regulator Bracket per paragraph 'C' above.

7. Pull the Air Line Regulator away from the Rear Panel far enough to disconnect the plumbing joint between the reducer and elbow fitting.

8. Remove the elbow fitting from the old assembly .

Note the routing of wires and make sure the wires are put back in the same place when reassembling the unit.

3. Disconnect all the wiring connections to the Pilot/ Output PC Board Assembly.

4. Remove the four screws and washers securing the PC Board to the standoffs.

5. Install the replacement Pilot/Output PC Board Assembly by reversing the above procedure.

REPLACEMENT PROCEDURES 5-8 Manual 0-2785

Page 43

B. CD PC Board Assembly Replacement

D. Main Transf ormer Assembly Replacement

Follow the anti-static handling procedures in Section 5.02.

1. Disconnect input power from the power supply .

2. Remove the Right Side Panel per Section 5.04-C.

NOTES

Before removing any connection, mark each wire with the connection designation. When reassembling this 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 the unit.

3. Disconnect all the wiring connections to the CD PC Board Assembly .

4. Remove the four screws and washers securing the PC Board to the standoffs.

5. Install the replacement CD PC Board Assembly by reversing the above procedure.

C. Relay Replacement

1. Remove the Right Side Panel per Section 5.04-C.

1. Remove the Left Side Panel per Section 5.04-B.

2. Remove the Right Side Panel per Section 5.04-C.

3. Remove the following terminal connections from the two FET/Heatsink Assemblies noting the location of each wire:

Connection Description

E14 MAIN XF MR PR I E15 XF MR PR I E16 M AIN XF MR SEC E19 XF MR SE C

4. Remove the four screws which hold the mounting plate to the bottom chassis.

5. Carefully remove the mounting plate with the Main T ransformer Assembly fr om the unit.

6. Install the replacement Main T ransformer Assembly by reversing the above procedure.

NOTE

NOTES

Before removing any connection, mark each wire with the connection designation. When reassembling this 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 the unit.

2. Disconnect all the wiring connections to the Relay Assembly.

3. Remove the two nuts securing the Relay Assembly and Dust Cover to the Pilot Panel.

4. Install the Dust Cover and replacement Relay Assembly by reversing the above procedure.

The four screws securing the mounting plate to the chassis should have a maximum of 2 to 5 threads protruding through the left side of the chassis.

E. Output Inductor Assembly Replacement

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the Right Side Panel per Section 5.04-C.

4. Disconnect the lead wire on terminal E7 of the Pilot Output PC Board.

5. Disconnect the lead wire on terminal E17 of the top FET/Heatsink Assembly .

6. Remove the four mounting screws securing the Output Inductor Assembly to the chassis.

7. Remove the Output Inductor Assembly from the unit.

8. Install the replacement Output Inductor Assembly by reversing the above procedure

NOTE

The four screws securing the mounting plate to the chassis should have a maximum of 2 to 5 threads protruding through the left side of the chassis.

Manual 0-2785 5- 9 REPLACEMENT PROCEDURES

Page 44

F . Auxiliary Transformer Assembly

Replacement

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the Right Side Panel per Section 5.04-C.

4. Disconnect the white wire with the single pin connector coming from the Auxiliary Transformer Assembly.

G. Bulkhead Adapter Replacement

1. Disconnect input power from the power supply .

2. Remove the Right Side Panel per Section 5.04-C.

3. Remove Tor ch connection at the Bulkhead Adapter .

A-02562

5. Unplug J1 from the Logic/Gate Board and slide through plastic bushing in center chassis.

6. Unplug the voltage selector (blue wire) located on left side of center chassis.

7. Using a socket removal tool, remove the orange wire from the connector housing located on the center chassis.

8. Remove the four mounting screws securing the Auxiliary T ransformer Assembly to the chassis.

9. Remove the Auxiliary T ransformer Assembly from the unit.

10. Install the replacement Auxiliary T ransformer Assembly by reversing the above procedure, noting the following.

• Orange wire to 380V selector connector (J20) on

the voltage selection panel.

Gas Tube

Fitting

Bracket

Nut

Bulkhead Adapter

Nut

4. Disconnect the gas tube from the fitting at the end of the Bulkhead Adapter . Remove the fitting.

5. Remove the first nut from the Bulkhead Adapter .

6. Carefully remove the wire from the Bulkhead Adapter that comes from the CD T ransformer Coil.

7. Remove the second nut securing the Bulkhead Adapter to the bulkhead.

8. Install the replacement Bulkhead Adapter by reversing the above procedure.

H. Fan Replacement

Refer to Section 6.08 for parts list and overall drawing.

1. Disconnect input power from the power supply .

2. Remove the Left Side Panel per Section 5.04-B.

3. Remove the center chassis by following the procedure in Section 5.06-C.

4. Locate the wiring to the Fans and note the orientation of the Fan Assembly wiring push on connectors.

5. Carefully pull the wiring connectors from the lugs on the Fan Assembly.

6. Locate and remove the four screws securing the Fan Assembly to the internal chassis.

7. Carefully pull the Fan Assembly from the internal chassis.

8. Install the replacement Fan Assembly by reversing the above procedure.

This completes the replacement procedures.

REPLACEMENT PROCEDURES 5-10 Manual 0-2785

Page 45

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts lists provide a breakdown of all replaceable components. The parts lists are arranged as follows:

Section 6.03 Major External Replacement Parts Section 6.04 Access Panel Replacement Parts Section 6.05 Front Panel Replacement Parts Section 6.06 Left Side Internal Component Replace-

ment Parts Section 6.07 Rear Panel Replacement Parts Section 6.08 Right Side Internal Component Re-

placement Parts 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

If a product must be returned for service, contact your authorized distributor . Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor .

Manual 0-2785 6- 1 P ARTS LISTS

Page 46

6.03 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 T ube, Lifting Handle, 1.125 OD, 1 1.85 Lg 9-7505 2 2 Mount, Lifting Handle 9-7506 3 1 Cover, Left Side Includes: 9-8001

Cover Left Side

4 1 Cover, Right Side Includes: 9-8024

Cover Right Side Overlay , RH Side Panel Labels Label, W arning, French

5 1 Leads W rap Includes: 9-8025

Panel, Leads W rap Overlay LH Side Panel

NOTE: Illustration may vary slightly from actual unit.

HARDWARE

A #10-32 Regul ar Nylon Lock Nut B #10-32 x 2" PPH HDMS C #10-32 x 0.5" PPH Swageform 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 Swag Screw G #6-32x3/8 PPH STL ZN Screw H Rubber Feet

I #6-32x3 3/4 LG PH S crew

J #10-32 Keput w/Star Washer

A-02641

PARTS LISTS 6-2 Manual 0-2785

Page 47

6.04 Access Panel Replacement Parts

Item # Qty Description Catalog #

11 Assembly, Pot/LED PCB 9-8004

21 Knob, Inner Concentric (Current) 9-8007

31 On/Off Rocker Switch, DPST 8-3258

41 Switch, Rocker, SPST (Run/Set/Latch) 8-3259

51 Panel, Access Includes:

For Units With PCH/M-80 To rch: 9-8026

Overlay, Access Panel Label, Access Panel

For Units With PCH/M-102 To rch: 9-6694

Overlay, Access Panel Label, Access Panel

NOTE: Illustration may vary slightly from actual unit.

A-02532

HARDWARE

A#10-32 Regular Ny lon Lock Nut B#10-32 x 2" PPH HDMS C#10-32 x 0.5" PPH Swageform Stl Zn Screw D1/4-20 x 3" Screw , Soc HD

E#6-32 x 3 1/2" THD Screw F#10-32 x 3/4" PPH Swag Screw G#6-32x3/8 PPH STL ZN Screw HRubber Feet

I#6-32x3 3/4 LG PH Screw J#10-32 Keput w /Star Washer

Manual 0-2785 6-3 PA RTS LISTS

Page 48

6.05 Front Panel Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Panel, Base/Front Includes: 9-8027

Base/Front, Unit USA Label Ground T ag

Overlay , Fr ont Panel 2 1 Contactor , Main, 4P, 40 FLA, 120 V AC MC1 9-7507 3 1 Strain Relief, .325-.360 Dia. 8-5537 4 1 W ork Cable, #6 A WG w/Clamp – 20 ft 9-8008 5 1 Clamp 9-8120

PARTS LISTS 6-4 Manual 0-2785

Page 49

HARDWARE

A #10-32 Regul ar Nylon Lock Nut B #10-32 x 2" PPH HDMS C #10-32 x 0.5" PPH Swageform 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 Swag Screw G #6-32x3/8 PPH STL ZN Screw H Rubber Feet

I #6-32x3 3/4 LG PH S crew

J #10-32 Keput w/Star Washer

A-02642

NOTE: Illustration may vary slightly from actual unit.

Manual 0-2785 6- 5 P ARTS LISTS

Page 50

6.06 Left Side Internal Component Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Insulator , Input PCB See Note 1 2 2 Cable Ass’y, 10 Cir Ribbon, 15" Lg 9-5922 3 1 Logic/Gate Drive Control PCB Assembly 9-8028 4 1 FET/Heatsink Kit 9-8029

2 Assembly , FET/Heatsink

2 Dust Cover, FET/Ass’y 5 1 Fuse Block 9-5562 6 1 Fuse, 0.8A 600V 1FU 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 Input Diode Bridge Ass’y Includes: 9-8030

Diode Bridge, 3 Phase, 40A, 1600V

10 Thermal Pad, Q3, Input Module 11 1 Assembly , Input PCB 9-8012 12 1 Brkt, Heatsink Mounting See Note 1 13 1 Assembly , Current Sensor PCB 9-7602 14 1 EMC Filter 9-7667 15 1 Filter Bracket See Note 1 16 1 T emperature Switch See Note 1

NOTE 1: Item shown for assembly purposes only .

PARTS LISTS 6-6 Manual 0-2785

Page 51

A-02643

HARDWARE

A #10-32 Regul ar Nylon Lock Nut B #10-32 x 2" PPH HDMS C #10-32 x 0.5" PPH Swageform 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 Swag Screw G #6-32x3/8 PPH STL ZN Screw H Rubber Feet

I #6-32x3 3/4 LG PH S crew

NOTE: Illustration may vary slightly from actual unit.

J #10-32 Keput w/Star Washer

Manual 0-2785 6- 7 P ARTS LISTS

Page 52

6.07 Rear Panel Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Pressure Switch-35 psi PS1 9-1044 2 1 V alve, Solenoid 1/8 NPT Sol 8-3370 3 1 Regulator , Air Line 9-7514 4 1 Strain Relief 8-6307 5 2 1/4 NPT Street Elbow 9-2184 6 1 1/8 NPT Str . T ee 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 T ube 90° 9-7525 10 1 Pressure Gauge 9-1045 11 1 Panel, Rear, Includes: See Note 1

Panel, Rear Label, Gas Supply

Label, Input Power Connections 12 1 Bracket, Regulator Mounting 9-7589 13 1 Filter/Regulator Assembly Replacement Element 9-4414 14 1 Panel Mounting Nut 9-5804

The Following Item Is Not Shown:

1 CE Input Power Cable, Three-Phase 9-7668

Note 1: Item Shown For Assembly Purposes Only.

PARTS LISTS 6-8 Manual 0-2785

Page 53

Part of #4

HARDWARE

A #10-32 Regul ar Nylon Lock Nut B #10-32 x 2" PPH HDMS C #10-32 x 0.5" PPH Swageform 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 Swag 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 K #6-32 Regular Nylon Lock Nut

L #6-32X3-3/4"LG, PH Screw M #6- 20X3/8" PPH THD Screw

A-02655

NOTE: Illustration may vary slightly from actual unit.

Manual 0-2785 6- 9 P ARTS LISTS

Page 54

6.08 Right Side Internal Component Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Bulkhead Adapter , O

B - 1/8 NPT 9-4045

2 2 9/16-18 Jam Nut, Brass 8-2149 3 1 Heatsink, Input Bridge See Note 1 4 1 Chassis, Center See Note 1 5 1 Panel, Pilot Ass’y Mounting See Note 1 6 1 Brkt, Bulkhead Mounting See Note 1 7 1 Insulator , Bulkhead See Note 1 8 1 PCR Relay Replacement Kit PCR 8-3163A

9 1 T ransformer , Aux., IEC Bobbin T2 9-7541 10 1 Ass’y, Main Transformer T1 9-7599 11 1 Ass’y , Output Inductor L1 9-7598 12 2 Fitting, 1/8 NPT X 1/4 Tube Str 8-3360 13 1 Coil, Pilot Inductor L2 9-7596 14 1 Coil, CD Xfmr, Secondary T3 9-7597 15 1 Ass’y, CD PCB 9-7517 16 1 Ass’y, Pilot/Output PCB 9-7518 17 2 Fan, 115V, 50/60Hz, 95/115CFM w/.187 Tabs M1, M2 8-3209 18 1 Dust Cover , PCR Relay 8-3164

Note 1: Item Shown For Assembly Purposes Only.

PARTS LISTS 6-10 Manual 0-2785

Page 55

A-02536

NOTE: Illustration may vary slightly from actual unit.

HARDWARE

A #10-32 Regul ar Nylon Lock Nut B #10-32 x 2" PPH HDMS C #10-32 x 0.5" PPH Swageform 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 Swag 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 K #6-32 Regular Nylon Lock Nut

L #6-32X3-3/4"LG, PH Screw M #6- 20X3/8" PPH THD Screw

Manual 0-2785 6-11 PARTS LISTS

Page 56

6.09 Options and Accessories

Qty Description Catalog #

1 Multi-Purpose Cart 7-8888 1 Cutting Guide Kit 7-8910 1 Standoff Cutting Guide 8-7575 1 Single-Stage Air Filter Kit– Includes Filter And Hose 7-7507

1 Replacement Filter Body 9-7740 1 Replacement Filter Element 9-7741 1 Replacement Filter Hose (not shown) 9-7742

1 T wo-Stage Air Line Filter Kit 7-7500 1 T wo-Stage Air Filter Assembly 9-7527 1 Replacement First Stage Filter 9-1021 1 Replacement Second Stage Filter 9-1022 1 Bracket, Filter Mounting (not shown) 9-7535

Remote Options:

Computer Control Cable (CNC) 1 25 ft (7.6 m) 8-5557 1 50 ft (15.2 m) 8-5558

1 Hand Pendant Control W ith 20 ft (6.1 m) Cable 7-3460 1 Hand Pendant Extension Cable -25 ft (7.6 m) 7-7744 1 Metal Mounting T ube W ith Pinion Assembly 7-7745

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Cover

Barbed

Fitting

Single-Stage Air Filter Kit

Assembled Filter

A-02476

First & Second Stage Cartridges (as marked)

A-02942

Two- Stage Air Filter Kit

PARTS LISTS 6-12 Manual 0-2785

Page 57

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Power Input Current Input

Volta g e Freq . 3-Ph 3-Ph Fuse (Amps) Wire (m m

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

380 50/60 19.1 29 35 10 415 50/60 19.4 27 35 10

Line Voltages with Sugg ested Circuit Protection an d Wire Sizes

Sugg e ste d Sizes (se e no te s)

)

NOTES

The table above is based on the following output current & voltage: 140VDC @ 80A

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements. Cable size is de-rated based on the Duty Cycle of the equipment. The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations refer

to local or national codes. Cable conductor 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 distribution equipment. NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

Manual 0-2785 A-1 APPENDIX

Page 58

APPENDIX 2: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

LATCH

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot relay closes.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8

seconds then steady on.

Fans on.

Power circuit ready.

RUN/SET/LATCH switch

gas flows to set pressure.

PILOT ARC

ACTION

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET/LATCH

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed.)

post-flow, pilot arc will immediately restart. If torch is within transfer distance (3/8 in) of

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (15 seconds)

NOTE - If torch is activated during

workpiece, main arc will transfer.

After post-flow:

GAS indicator off.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system.

ACTION

Torch Switch

can be released.

RESULT

Transfer will continue

until torch is removed

from workpiece.

A-02461

APPENDIX A-2 Manual 0-2785

Page 59

APPENDIX 3: POT/LED PC BOARD LAYOUT

J14

A-01206

ACPot/LED PC Board Signals

J14-1 +10 VDC from Logic/Gate PC Board (J3-7) J14-2 Current Control to Logic/Gate PC Board (J3-8) J14-3 Return for Current Control from Logic/Gate PC Board (J3-9) J14-4 +12 VDC from Logic/Gate PC Board (J3-10) J14-5 Logic Low -Signal for AC OK Indicator to Logic/Gate PC Board (J3-11) J14-6 Logic Low -Signal for GAS Indicator to Logic/Gate PC Board (J3-12) J14-7 Logic Low -Signal for TEMP Indicator to Logic/Gate PC Board (J3-13) J14-8 Logic Low - Signal for DC Indicator to Logic/Gate PC Board (J3-14)

D4 Front Panel AC Indicator D5 Front Panel TEMP Indicator D6 Front Panel DC Indicator D7 Front Panel GAS Indicator

Manual 0-2785 A-3 APPENDIX

Page 60

APPENDIX 4: LOGIC/GATE PC BOARD LAYOUT

TP18

TP25

TP24

TP21

Logic/Gate PC Board

TP2

TP20

TP1

D45

D36

D20

TP22

D39

TP5

TP8

TP7

TP26

TP23

A-02528

Logic/Gate PC Board Signals

J1-1 36 VAC from Auxiliary Transformer J1-2 115 VAC from Auxiliary T ransformer J1-3 Center Tap fr om Auxiliary Transformer (36VAC) J1-4 Not Used J1-5 36 VAC from Auxiliary Transformer J1-6 115 VAC Return from Auxiliary Transformer

J2-1 115 VAC Return to Inrush Relay J2-2 115 VAC Return to Fan #1 J2-3 115 VAC Return to Fan #2 J2-4 115 VAC Return to Solenoid J2-5 Not Used J2-6 Not Used J2-7 115 VAC to Inrush Relay (K10) J2-8 115 VAC to Fan #1 J2-9 115 VAC to Fan #2 J2-10 115 VAC to Solenoid J2-11 Not Used J2-12 Not Used J2-13 Logic Low -Pressure Switch Signal J2-14 Return from Pressur e Switch J2-15 Logic Low -Over Temperature Switch on Input Bridge J2-16 Over T emperature Switch Return

APPENDIX A-4 Manual 0-2785

Page 61

J3-1 36 VAC to ON/OFF Switch J3-2 36 VAC fr om ON/OFF Switch to Logic/Gate PC Boar d J3-3 36 VAC to ON/OFF Switch J3-4 36 VAC fr om ON/OFF Switch to Logic/Gate PC Boar d J3-5 Logic Low - From RUN/SET/LATCH Switch on Front Panel (RUN) J3-6 PCB Common J3-7 +10 vdc to Front Panel Current Control Pot J14-1 J3-8 From Front Panel Current Control Pot Wiper J14-2 J3-9 To Current Contr ol Pot J14-3 (Return) J3-10 Unregulated +18 VDC to Front Panel J14-4 J3-11 Logic Low for AC Indicator on Front Panel (J14-5) J3-12 Logic Low for GAS Indicator on Front Panel (J14-6) J3-13 Logic Low for TEMP Indicator on Front Panel (J14-7) J3-14 Logic Low for DC Indicator on Front Panel (J14-8) J3-15 Not Used J3-16 Logic Low - From RUN/SET/LATCH Switch on Front Panel (LATCH) J5-1 36 VAC to CD PC Board (J11-1) J5-2 Return to CD PC Board (J11-2) (36VAC Centertap) J5-3 36 VAC to CD PC Board (J11-3) J5-4 Logic Low - CD Enable Signal to CD PC Board (J11-4) J5-5 CD Enable Return to CD PC Board (J11-5) J5-6 Unregulated +18 vdc to PCR Relay J5-7 Logic Low - PCR Signal to PCR Relay J5-8 Logic Low - Torch Switch Input fr om Pilot/Output PCB (J13-1) J5-9 Torch Switch Return to Pilot/Output PC Boar d (J13-2) J5-10 Logic Low - OK-To-Move Signal to Pilot/Output PC Board (J13-4) J5-11 Unregulated +18 VDC for OK-To-Move (CSR) Relay on Pilot/Output PC Board (J13-3) J5-12 Return (J13-5) P.S. PLUS J5-13 Not Used J5-14 From Pilot/Output PC Board to Sense Drag Cutting (Tip) J5-15 Not Used J5-16 From Pilot/Output PC Board to Sense DC (negative) J10-1 Logic Low - MC1 Contactor to Input PC Board (J16-1) J10-2 Unregulated +18 VDC to Input PC Board for Relays (J16-2) J17-1 Logic Low - CSR Signal from Current Sensor J17-2 Return for CSR Signal J17-3 +12 VDC to Current Sensor

J7-1 +12VDC J7-2 COM J7-3 PWM J7-4 COM J7-5 PRI Current Signal J7-6 COM J7-7 Sec Current Signal J7-8 COM J7-9 Overtemp J7-10 COM

J8-1 +12VDC J8-2 COM J8-3 PWM J8-4 COM J8-5 PRI Current Signal J8-6 COM J8-7 Sec Curent Signal J8-9 Overtemp

J8-10 COM

TP1 Logic Ground TP2 Unregulated +18VDC TP3 Unregulated +18VDC TP4 Not Used TP5 +12VDC TP6 +12VDC TP7 Drag Circuit Disable (jumper to TP1) TP8 Negative Voltage Sensing TP20 Logic Low Primary Overcurrent Shutdown (momentary) TP26 Logic Low CSR input TP22 Current Demand Signal TP25 Gate Drive Signal A TP24 Gate Drive Signal B

Manual 0-2785 A-5 APPENDIX

LED Description D1 Start D2 CD Enable D20 CSR D36 Drag On D39 Pilot D45 PWM Enabled

Page 62

APPENDIX 5: PILOT OUTPUT PC BOARD LAYOUT

J12

Top

A-01389

J13

E10

E29

E30

E20

CGND

E27

E24

E23

E22

Pilot Output PC Board Signals

J12-1 Torch Switch Filter in from J22-3 Torch Control J12-2 Not Used J12-3 Torch Switch Filter Return from J22-4 Torch Control J12-4 Not Used J12-5 Pilot Return Shield to J22-1 T o r ch Control J12-6 Torch Switch Shield to J22-2 Torch Control J12-7 Not Used J12-8 OK to Move TO J22-12 Torch Control J12-9 Not Used J12-10 OK to Move RTN TO J22-14 Torch Control OK to move RTN

J13-1 Torch Switch Filter out to J5-8 Logic Board Torch Sw J13-2 Torch Switch Filter Return to J5-9 Logic Board Torch Sw Return J13-3 Logic Low OK to Move Relay Coil to Logic PCB J5-10 OK to Move J13-4 OK to Move Relay Coil to Logic PCB J5-11 Unregulated +18VDC J13-5 PS(+) to Logic Board J5-12 Output Sense Gnd J13-6 Not Used J13-7 Tip Voltage Sense to Logic Board J5-14 Drag Sense J13-8 Not Used J13-9 PS(-) Sense to Logic Board J5-16 PS(-) Sense DC J13-10 Not Used

APPENDIX A-6 Manual 0-2785

Page 63

CGND Chassis Gnd E7 PS(-) C4 Rtn for Pilot Voltage Twisted with Pilot RTN to E23 E8 PS(-) (Stud) from Output Inductor L1 to CD Xfmr 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 Standof f on bulk head and Torch Cable E27 Pilot RTN to Pilot Choke E29 PS(+) (Stud) from Work lead Through Current Sense To E18 Fet Modules E30 PS(+) to PCR 8 Pin 8

Manual 0-2785 A-7 APPENDIX

Page 64

APPENDIX 6: CD PC BOARD LAYOUT

TP1TP2

J11-1

J11-3

J11-4 J11-5

J11

TP3

A-01208

E2 E1

CD PC Board Signals

J11-1 36 VAC from Logic PC Board (J5-1) J11-2 Return from Logic PC Board (J5-2) 36VAC Center Tap J11-3 36 VAC from Logic PC Board (J5-3) J11-4 Logic Low - CD Enable Signal from Logic PC Board (J5-4) Active Low J11-5 Return for CD Enable Signal from Logic PC Board (J5-5) J11-6 Not Used J11-7 Not Used J11-8 Not Used

TP1 Logic Ground or Return TP2 +12 VDC TP3 Not Used

E1 CD output E2 CD Output

APPENDIX A-8 Manual 0-2785

Page 65

APPENDIX 7: INPUT PC BOARD LAYOUT

J16

2-position connector

Solder Side of PC Board Component Side of PC Board

Input PC Board

AC1

AC2

AC3

CGND

Input PC Board Signals

J16-1 Low Logic Inrush signal from Logic PCB J10-1 J16-2 Unregulated +18VDC to Inrush Relay K11 J16-3 K11 J16-4 Not used J16-5 Not used

CGND Chassis Ground to Chassis Ground (+) Output to Cap Board (-) Rectifier (-) Module (-) Output to the Cap Board (-) E26 AC1 AC Input Phase 1 from the contactor T1 and T4 AC2 AC Input Phase 2 from the contactor T2 AC3 AC Input Phase 3 from the contactor T3 E31 Not Used

A-02551

Manual 0-2785 A-9 APPENDIX

Page 66

APPENDIX 8: FET PC BOARD LAYOUT

Component Side of PC Board

E19

E17

E18

E16

E15

E14

Solder Side of PC Board

E12B

A-02529

E13C

APPENDIX A-10 Manual 0-2785

Page 67

FET PC Board Signals (Upper and Lower Assemblies)

J6-1 +12V from Logic/Gate Drive Board, upper J7-1, Lower J8-1 J6-2 PCB Common, GND, from Logic/Gate Drive Board, Upper J7-2, Lower J8-2 J6-3 PWM Output from the Logic/Gate Drive Board upper J7-3 Lower J8-3 J6-4 PWM Output RTN J6-2 from the Logic/Gate Drive Board upper J7-4 Lower J8-4 J6-5 PRI Current Sense to the Logic/Gate Drive Board upper J7-5 Lower J8-5 J6-6 PRI Current Sense RTN to the Logic/Gate Drive Board upper J7-6 Lower J8-6 J6-7 SEC CCurrent Sense to the Logic/Gate Drive Board upper J7-7 Lower J8-7 J6-8 SEC Current Sense RTN to the Logic/Gate Drive Board upper J7-8 Lower J8-8 J6-9 Logic Low - Over T emp R TN to the Logic/Gate Drive Board upper J7-9 Lower J8-9 J6-10 Over T emp to the Logic/Gate Drive Board upper J7-10 Lower J8-10

E1 Heatsink GND To Heat sink E14 Main XFMR PRI to Main XFMR PRI E15 Main XFMR PRI to Main XFMR PRI E16 Main XFMR SEC from Main XFMR SEC E17 Output (-) to Output Inductor L1 E18 Output (+) to Current Sense T ransformer , E9 on Output Board, and pin 8 PCR E19 Main XFMR SEC from Main XFMR SEC E12B Main Capacitor Plus E13C Main Capacitor Minus

Manual 0-2785 A-11 APPENDIX

Page 68

APPENDIX 9: CAPACITOR PC BOARD LAYOUT

E26

E25

E12C

E13C

E12A

E13A

E12

E13

A-01418

E13B

E12B

Capacitor PC Board Signals

E12 Positive Rail to FET Board E12A Positive Rail 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 Board E25 Positive Input from Input Board (+) E26 Negative Input from Input Board (-) Rectifier (-)

APPENDIX A-12 Manual 0-2785

Page 69

APPENDIX 10: CURRENT SENSOR PC BOARD LAYOUT

J15

A-01419

Current Sensor PC Board Signals

J15-1 Logic Low - Work Cable Sense J15-2 Ground J15-3 +12 VDC

Manual 0-2785 A-13 APPENDIX

Page 70

APPENDIX 11: 36VAC CIRCUIT DIAGRAM

CD PC Board

J11

132

Auxiliary

Transformer

Outputs

36 V AC

115 V AC

3 1 5 2

Logic/Gate

Drive PC

Board

ON/OFF

Switch

132

12 VDC

Circuit

A-02527

APPENDIX A-14 Manual 0-2785

Page 71

APPENDIX 12: MAINTENANCE SCHEDULE

This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Check plasma and secondary supply and 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 proper operation and adequate air flow .

2. Blow or vacuum dust and dirt out of the 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 to the unit.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.

Manual 0-2785 A-15 APPENDIX

Page 72

APPENDIX 13: SYSTEM SCHEMATIC

A-02639

APPENDIX A-16 Manual 0-2785

Page 73

A-02639

Manual 0-2785 A-17 APPENDIX

Page 74

Thermal Dynamics CE Pak Master 100XL Plus Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.05 Precautions De Securite Importantes

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

2.03 Service Responsibilities

2.01 Scope Of Manual

2.02 General Service Philosophy

3.03 Specifications/Design Features

3.01 Scope of Manual

3.02 General Description of System

3.04 Power Supply Options and Accessories

4.01 Introduction

4.02 Periodic Inspection & Procedures

4.03 Common Operating Problems

4.05 Circuit Fault Isolation

4.06 Main Input and Internal Power Problems

4.07 Pilot Arc Problems

4.08 Main Arc Problems

4.09 Test Procedures

5.01 Introduction

5.02 Anti-Static Handling Procedures

5.03 Parts Replacement - General Information

5.04 Major External Parts Replacement

5.05 Access Panel Parts Replacement

5.06 Front Panel Parts Replacement

5.07 Left Side Internal Parts Replacement

5.08 Rear Panel Parts Replacement

5.09 Right Side Internal Parts Replacement

6.01 Introduction

6.02 Ordering Information

6.03 Major External Replacement Parts

6.04 Access Panel Replacement Parts

6.05 Front Panel Replacement Parts

6.06 Left Side Internal Component Replacement Parts

6.07 Rear Panel Replacement Parts

6.08 Right Side Internal Component Replacement Parts

6.09 Options and Accessories

APPENDIX 1: INPUT WIRING REQUIREMENTS

APPENDIX 3: POT/LED PC BOARD LAYOUT

APPENDIX 4: LOGIC/GATE PC BOARD LAYOUT

APPENDIX 5: PILOT OUTPUT PC BOARD LAYOUT

APPENDIX 6: CD PC BOARD LAYOUT

APPENDIX 7: INPUT PC BOARD LAYOUT

APPENDIX 8: FET PC BOARD LAYOUT

APPENDIX 9: CAPACITOR PC BOARD LAYOUT

APPENDIX 10: CURRENT SENSOR PC BOARD LAYOUT

APPENDIX 11: 36VAC CIRCUIT DIAGRAM

APPENDIX 12: MAINTENANCE SCHEDULE

APPENDIX 13: SYSTEM SCHEMATIC