Thermal Dynamics CE PAK Master 150XL Service Manual

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PLASMA CUTTING

POWER SUPPLY

CE PAK Master® 150XL™

T M

September 15, 2003 Manual No. 0-2728

A-03044

Service Manual

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 Pak Master® 150XL Service Manual Number 0-2728

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 Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ............................................................................................... 1-1

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

1.02 Important Safety Precautions ....................................................................... 1-1

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

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 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 Power Supply General Description............................................................... 3-1

3.03 Specifications/Design Features .................................................................... 3-2

3.04 Power Supply Options and Accessories....................................................... 3-3

3.05 Theory Of Operation .................................................................................... 3-3

SECTION 4:

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

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

4.02 Periodic Inspection & Procedures ................................................................ 4-1

4.03 System Theory............................................................................................. 4-3

4.04 Common Operating Problems ...................................................................... 4-4

4.05 T roub leshooting Guide - General Information ............................................... 4-5

4.06 Circuit Fault Isolation .................................................................................... 4-6

4.07 Main Input and Internal Power Problems...................................................... 4-7

4.08 Pilot Arc Problems........................................................................................ 4-9

4.09 Main Cutting Arc Problems......................................................................... 4-11

4.10 Test Procedures ......................................................................................... 4-12

SECTION 5:

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

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

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

5.03 Parts Replacement - General Information .................................................... 5-1

5.04 Major External Parts Replacement............................................................... 5-2

5.05 Access Panel Parts Replacement ................................................................ 5-3

5.06 Left Side Center Chassis Parts Replacement .............................................. 5-4

5.07 Right Side Center Chassis Parts Replacement ............................................ 5-7

5.08 Base Parts Replacement............................................................................ 5-13

5.09 Rear Panel Parts Replacement .................................................................. 5-16

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 Left Side Center Chassis Replacement Parts.............................................. 6-4

6.06 Right Side Center Chassis Replacement Parts ........................................... 6-6

6.07 Base Replacement Parts............................................................................. 6-8

6.08 Rear Panel Replacement P arts ................................................................. 6-10

6.09 Options and Accessories........................................................................... 6-12

APPENDIX 1: INPUT WIRING REQ UIREMENTS ....................................................................A-1

APPENDIX 2: SEQ UENCE OF OPERATION (BLOCK DIAGRAM) .......................................... A-2

APPENDIX 3: POT/LED PC BOARD LAYOUT..........................................................................A-3

APPENDIX 4: LOGIC PC BO ARD LAY OUT ............................................................................. A-4

APPENDIX 5: GATE DRIVE PC BOARD LAYOUT....................................................................A-6

APPENDIX 6: PILOT/OUTPUT PC BOARD LAYOUT

AND WIRING CONNECTION DIA GRAM.................................................................. A-8

APPENDIX 7: CD PC BOARD LAYOUT .................................................................................A-10

APPENDIX 8: INPUT PC BO ARD LAY OUT............................................................................A-11

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

APPENDIX 10: CAPACITOR PC BO ARD LAYOUT.................................................................A-14

APPENDIX 11: CURRENT SENSOR PC BOARD LAY OUT ...................................................A-15

APPENDIX 12: 36VAC CIRCUIT DIAGRAM........................................................................... A-16

APPENDIX 13: RECOMMENDED R OUTINE MAINTENANCE SCHEDULE

FOR LIQUID COOLED PLASMA CUTTING SYSTEMS .......................................A-17

APPENDIX 14: SYSTEM SCHEMATIC (Unit Rev AQ or Earlier) ............................................A-18

APPENDIX 14: SYSTEM SCHEMATIC (Unit Rev AR or Later)............................................... A-20

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

• 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 FACE 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

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. NFP A Standar d 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 Welding Society Standard 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 procédure 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.

• 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

RAYONS D’ARC DE PLASMA

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

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

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

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

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: November 15, 2001

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

SECTION 2:

2.03 Service Responsibilities

INTRODUCTION

2.01 Scope Of Manual

This Manual provides Service Instructions for Thermal Dynamics PAK Master® 150XL CE Plasma Power Supply.

Refer to Operating Manual 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 properly trained Service Technicians 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 are encountered, or the equipment does not function as specified, contact T echnical Services Department at West Lebanon 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/operator's 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 0-2728 2-1 INTRODUCTION

INTRODUCTION 2-2 Manual 0-2728

SECTION 3:

DESCRIPTION

3.01 Scope of Manual

The information in this section has two purposes:

• T o familiarize the service technician with the capabilities and limitations of the equipment,

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

3.02 Power Supply General Description

Power Supply is designed to cut most metals up to 1-1/2 inches (38 mm) using air, nitrogen, or argon/hydrogen as the plasma gas. This system is also capable of satisfying many gouging applications. The Power Supply is ideal for hand applications and can also be used in mechanized applications.

The Power Supply provides 120 amp maximum output current and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle and a 20 ft (6.1 m) work cable with clamp.

The torch used with the Power Supply is available in the following configurations:

• 70° or 90° Hand Torch Head (PCH)

• 180° Machine Torch Head (PCM) with 1-3/8 inch (34 mm) diameter Mounting Tube with Rack and Pinion Assembly

Machine torch systems with unshielded leads include a Remote Hand ON/OFF Pendant; machine torches with shielded leads include a CNC Interface Cable.

NOTES

The power supply can be ordered in various configurations with various options factory installed.

Refer to the supplied T orch Instruction Manual for more information on the Torch.

Refer to Section 3.04 for list of Power Supply Options and Accessories.

T M

A-03044

Figure 3-1 Pak Master 150XL (CE) System

The Standard Coolant supplied with the Power Supply can be used in ambient temperatures down to 10° F (-12° C). If the ambient temperature will be below 10° F (-12° C) then Super Coolant should be used. This coolant can be used in areas where the ambient temperature dr ops to -34° F (-36° C).

A. Typical System

A typical system configuration will contain the following:

• CE Power Supply

• 20 ft (6.1 m) Work Cable with Clamp

• Torch with Leads (torch type and leads length as ordered)

• Torch Spare Parts Kit

• CNC Interface Cable or Remote Pendant Control (depending on type of torch leads ordered)

• Standard Thermal Arc Coolant - 3 gallons (11.4 liters)

NOTE

Refer to Section 3.04 for complete list of Power Supply Options and Accessories.

B. Requirements to Complete System

To complete the system, the user needs to provide the following:

Manual 0-2728 3-1 DESCRIPTION

• Primary Input Power Cable Plug

• Gas Supplies

3.03 Specifications/Design Features

A. Power Supply Specifications

The following specifications apply to the Power Supply only:

Ambient

erature

Tem

Duty Cy cle

Power Supply Duty Cycle

104° F

(40° C)

60% 100%

104° F

(40° C)

1. Front Panel Controls

• ON/OFF, RUN/SET and STANDARD/LATCH Switches

• Output Current Control

• W ork Cable Connection

• T orch Leads Connection

2. Front Panel LED Indicators

•AC

• TEMP

• GAS Pressure/Coolant Flow

• DC Output

3. Rear Panel

• Primary Input Power Cable with Filtering Beads and Strain Relief

• Plasma Gas Regulator/Filter Assembly with Gas Pressure Gauge and Pressur e Adjustment

• Secondary Gas Regulator/Filter Assembly with Gas Pressure Gauge and Pressur e Adjustment

• T wo Stage Air Line Filter Assembly

• EMI Filter Assembly

4. Input Power (see NOTES)

Current

DC Voltage

120 Amps n/a Amps

128 vdc n/a vdc

7. Cut Capacity on Carbon Steel

• Genuine Cut Capacity: 1-1/2 inch (38 mm)

• Severance Cut: 1- 3/4 inch (44 mm)

• Pierce Rating: 5/8 inch (15.9 mm)

8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

9. CNC Interface Signals

Start/Stop and OK-To-Move

10. Coolant Pressure

Internal Service Adjustable (Factory Only)

130 psi (8.8 bar) at zero flow 120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.3 lpm)

11. Coolant Flow Rate

0.5 gpm (1.9 lpm) with 150 feet (45.7 m) of total torch and torch leads at 70°F (21°C)

NOTE

380-415 VAC (±10%), 50/60 Hz, Three-Phase

NOTE

Refer to Appendix 1 for suggested input wiring size, current ratings and circuit protection r equirements.

5. Output Power

Continuously variable from 30 to 120 amps (±5%)

6. Duty Cycle (see NOTE)

NOTE

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.

The flow rate varies with lead length, torch configuration, ambient temperature, amperage level, etc.

12. Cooling Capacity

4,000 to 10,000 BTU

NOTE

Maximum value based on “free flow” condition.

13. Coolant Reservoir Capacity

2 gallons (Use Thermal Arc® coolant only) Capable of handling a total of 150 feet (45.7 m) of

torch lead length

14. Overall Dimensions

Height: 45-3/8 inches (1.2 m) Width: 24-1/2 in (0.6 m) Depth: 35 inches (0.9 m)

DESCRIPTION 3-2 Man ual 0-2728

15. Weight

Power Supply with Torch: 275 lbs (125 kg)

3.04 Power Supply Options and Accessories

Shipping Weight: 350 lbs (158.8 kg)

16. Used W ith Torch

• PCH-120 Hand Torch

• PCM-120 Machine Torch

B. Gas Regulator/Filter Assembly

Specifications

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

1. Gas Regulator Maximum Gauge Pressure

Plasma: 160 psi (11.3 bar) Secondary: 160 psi (11.3 bar)

2. Maximum Input Gas Pressure

125 psi (8.6 bar)

3. Filter

Coalescent type filter

C. Gas Requirements

1. Plasma

Gases: Compressed Air , Nitr ogen, Argon/Hydr ogen Operating Pressure: 65 psi (4.5 bar) Cold Flow:

Cutting: 50 - 78 scfh (23.6 - 36.8 lpm) Gouging: 85 - 95 scfh (40.1 - 44.8 lpm)

CAUTION

Maximum input gas pressure must not exceed 125 psi (8.6 bar).

2. Secondary

Gases: Compressed Air, Carbon Dioxide (C02), Nitrogen

Operating Pressure: 60 psi (4.1 bar) Cold Flow:

Cutting: 340 scfh (160.4 lpm) Gouging: 235 scfh (110.9 lpm)

The following accessories are available for the Power Supply. Refer to Section 6, Parts Lists, for part numbers and ordering information.

A. High Pressure Regulators

High pressure regulators are available for air, nitrogen, and argon-hydrogen. The regulators are used to set the proper pressure for the type of gas being used.

B. CNC Interface Cable

NOTE

Accessory is for use with Shielded PCM Torch & Leads.

The CNC 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-T o-Move and ON/OFF signals.

C. Work Cable Kit

Power Supply is supplied with attached 20 ft (6.1 m) work cable and clamp. Longer cables are available as a user installed kit.

D. Remote Pendant Control

NOTE

Accessory is for use with Unshielded PCM Torch & Leads.

Control used to manually start and stop cutting operations from a location up to 20 ft. (6.1 m) from the Plasma Power Supply.

3.05 Theory Of Operation

A. Plasma Arc Cutting and Gouging

Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma gas to transfer an electric arc to a workpiece. The metal to be cut is melted by the intense heat of the arc and then blown away by the flow of gas.

With a simple change of torch parts, the system can also be used for plasma arc gouging. Plasma arc gouging uses the same process to remove material to a controlled depth and width.

CAUTION

Maximum input gas pressure must not exceed 125 psi (8.6 bar).

Manual 0-2728 3-3 DESCRIPTION

B. Input and Output Power

2. Gas Pressure Interlock

The unit converts AC input power to DC power for the main cutting arc. The negative output is connected to the torch electrode through the negative torch lead, and the positive output connects to the workpiece through the work cable.

C. Pilot Arc

When the torch is activated there is a 2 second (service adjustable) gas pre-flow, followed by an uninterrupted pulsed DC pilot arc established between the electrode and tip. The pilot arc is initiated by a momentary high frequency pulse from the Power Supply. The pilot creates a path for the main arc to transfer to the work. When the main arc is established, the pilot arc shuts off. The pilot automatically restarts when the main arc stops, as long as the torch remains activated.

D. Main Cutting Arc

The power supply converts the AC input power to DC power for the main cutting arc. The negative output is connected to the torch electrode through the negative torch lead. The positive output is connected to the workpiece via the work cable and clamp connection.

A pressure switch acts as an interlock for the plasma gas supply . If the plasma gas supply pressure falls below minimum requirements the pr essure switch will open, shutting off the power to the contactors, and the GAS indicator will go out. When adequate plasma supply pressure is available the pressure switch will close, allowing power to be resumed for cutting.

NOTE

There is no gas pressure interlock for secondary gas.

E. RF Shielding

Machine torch systems using CNC Interface Cables are shielded to minimize radio frequency (RF) interference which results from the high frequency ar c initiation. These shielded systems are designed with features such as a wire for establishing an earth ground and shielded torch and control leads. The CNC control signals are filtered on an internal PC Board.

F. Interlocks

The system has several built-in interlocks to provide safe and efficient operation. When an interlock shuts down the system, the fault condition must be remedied and the system recycled using the applicable control device.

1. Parts-In-Place (PIP) Interlock

The Power Supply has a built-in parts-in-place interlock that prevents accidental torch starting when torch parts are not properly installed. A flow switch on the coolant return lead detects reduced coolant flow caused by improper torch assembly. If not satisfied, the switch interrupts power to the tip and electrode.

DESCRIPTION 3-4 Man ual 0-2728

SECTION 4:

SERVICE

TROUBLESHOOTING

4.01 Introduction

C. Power Supply Cleaning

To clean the unit, open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.

This Section provides service diagnostics for the Pak Master 150XL CE Power Supply, allowing the Technician 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 manual is for the Power Supply only. Troubleshooting other parts of the system (ie. accessories) is covered in separate manuals for those products.

4.02 Periodic Inspection & Procedures

NOTE

Refer to Appendix 13 for a recommended maintenance schedule for water cooled plasma cutting systems.

WARNING

Do NOT blow air into the power supply during cleaning; make sure to always blow air out of the unit. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

While the side panels are off, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected.

D. Coolant Filter Assembly

The Coolant Filter Screen should be cleaned periodically. T o gain access to the Coolant Filter Assembly, remove the right side panel when viewed from front of unit. Remove the Filter Screen by unscrewing the filter holder from the Coolant Filter Assembly. Clean the filter screen by rinsing with hot soapy water . Remove soap r esidue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before r einstalling in the Coolant Filter Assembly.

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. Fan Motor and Pump Lubrication

The fan motor and pump in the power supply should be oiled twice per year or once for each 100 hours of operation. To oil the motor, remove one side panel and add two or three drops of 20 SAE oil to the front and rear oil holes on the motor.

NOTE

Some units may utilize a sealed motor design which does not require lubrication.

Filter

Filter Holder

A-02152

Figure 4-1 Coolant Filter Assembly

Manual 0-2728 4-1 SERVICE TROUBLESHOO TING

E. In-Line Coolant Filter Assembly

G. Draining and Replacing Coolant

The In-line Coolant Filter Screen should be cleaned periodically. To gain access to the In-Line Coolant Filter Assembly remove the right side panel (when viewed from the front of unit). Remove the Filter Screen by unscrewing the Filter Holder from the In-Line Coolant Filter Assembly . Clean the Filter Screen by rinsing with hot soapy water. Remove soap residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before reinstalling in the InLine Coolant Filter Assembly.

Filter

Filter Holder

Remove the old coolant from the Power Supply reservoir as follows:

1. Remove the right side panel from the Power Supply.

2. Disconnect the coolant input hose to the Coolant Filter Assembly .

3. Carefully lower the hose out the right side of the Power Supply and drain the coolant into an acceptable container .

CAUTION

Handle and dispose of the used coolant per recommended procedures.

Coolant Filter

Assembly

A-02153

Figure 4-2 In-Line Filter Assembly

F. Coolant Level and Conductivity

1. Coolant Level

The coolant level should be checked every day at the rear panel coolant gauge. If the coolant in the reservoir is more than 2 inches (50 mm) from the top of the reservoir then add Torch Coolant.

2. Coolant Conductivity

The coolant conductivity level should be checked if the pilot doesn't start.

Check the condition of the deionizer bag in the reservoir basket, if the bag is yellowish brown (straw color) replace the bag and coolant (see NOTE).

NOTE

To accurately measure the coolant conductivity it is recommended to use a Conductivity Sensor similar to Thermal Dynamics Model TDS-73 (Catalog # 7-2844).

Place hose in

bucket to drain

Coolant

Reservoir

Coolant

Input Hose

A-03049

Figure 4-3 Draining Coolant From Reservoir

4. Reconnect the hose to the Coolant Filter Assembly.

5. Remove Coolant Reservoir lid and install new coolant and deionizer bag.

6. Reinstall the right side panel.

SERVICE TR OUBLESHOOTING 4-2 Man ual 0-2728

4.03 System Theory

The Cutting System is designed for hand cutting and simple mechanized operation using the torch control bulkhead as the interface.

A. Logic PC Board Functions

NOTE

Refer to Appendix 4 for Logic PC Board layout.

The Logic PC Board controls the timing and sequencing of the system. It monitors the pressure, temperature, and flow interlocks and controls the gas flow in run and set modes by turning on the plasma and secondary solenoids. The Logic PC Board also controls the power on the voltage selection and prepurge functions.

After the ON/OFF switch is closed on the front panel, the AC Indicator blinks and the GAS Indicator is on steady. The AC Indicator blinks for appr oximately 8 seconds then at that time it becomes steady and the inrush relay closes. The GAS Indicator stays on for approximately 20 seconds (prepurge function) then goes off and the gas stops flowing.

When the torch switch is pressed, D26 "start" Indicator comes on, gas will flow for approximately 2 seconds before DC is established (indicated on the front panel). During this time D25 CD Enable will come on and sends a logic signal to the CD Board which fires the spark gap and initiates the torch to pilot. D25 should go out immediately if the pilot starts immediately.

When the torch is close to the workpiece, the cutting arc "transfers" to the work. Also, if the tip touches the workpiece, the current is automatically folded back to approximately 35 amps to save the tip from being blown out.

The resulting current is sensed by the Current Sense PC Board, resulting in the demand level changing from pilot current to whatever the main current control is set at. During the "transfer" the CSR Indicator (D65) comes on and the transfer enable signal goes low allowing the bottom gate drive and FET modules to come up and start running. Also at this time, D5 (located on the Pilot Output PC Board) shuts off and at this time the main cutting arc is initiated. If the torch is removed from the workpiece, the pilot arc will automatically restart if the torch switch is still pressed.

Logic PC Board

Indicator Meaning

Torch Swit ch Enable - When ON

D26

D25

D65

D47

D31

(start) in di cates t orch swi tch is presse d.

CD Enable - I ni t i at es spark gap on CD PC Board. Indicat or should come ON then go OF F aft er a pilot arc has been establi shed.

CSR - I ndicat es main cutting arc is established.

AC OK - When ON indicates that AC Input volt age is okay.

Drag - When ON indicates that t he torch ti p is making contact with t he workpiece.

B. CD (Capacitive Discharge) PC Board

Functions

NOTE

Refer to Appendix 7 for CD PC Board layout.

The CD Board functions are initiated by the CD Enable signal from the Logic PC Board. The CD arc starting circuit fires the spark gap producing the high voltage spark which starts the DC pilot arc. When a pilot arc is sensed by the Gate Drive Board, the PSR signal shuts off the CD enable.

C. Gate Drive PC Board Functions

NOTE

Refer to Appendix 5 for Gate Drive PC Board layout.

The Gate Drive Board controls the amount of time the FETs are turned on. This is done with a pulse width modulator (PWM) controlled by the demand signal from the Logic PC Board. The longer the FETs are on, the more output current. If a short develops, the primary overcurrent will shut down the gate drive and not allow the power supply to power up and run.

The PSR signal senses any current in the secondary and determines what the PWM should do for a pulse width. If there is current in the secondary, the PSR signal will go back to the Logic PC Board and shut off the CD Enable signal.

Manual 0-2728 4-3 SERVICE TROUBLESHOO TING

Gate D rive P C Bo ards

4.04 Common Operating Problems

Indicator Meaning

Powe r En a bl e - W he n O N PW M

D20

Enable received from the Logic PC Board.

Reset - Normally ON, goes out when torch swit ch is pressed. Indicator will blink if primary overcurrent i s detected when torch switch is pressed.

D. Pilot/Output Board Functions

NOTE

Refer to Appendix 6 for Pilot/Output PC Board layout.

The Pilot/Output PC Board has an IGBT which is turned on by the Logic PC Board for piloting. This allows the DC to flow from the output (-) through the pilot return (tip) to a Pilot Inductor and finally to the work. This path is broken very quickly by the IGBT when the main cutting arc is initiated. This board also filters the torch shield back to the torch () through the Capacitor.

WARNINGS

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

Frequently review the Important Safety Precautions in 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.

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

Handle torch leads with care and protect them fr om damage.

A. Piloting

Piloting reduces parts life more than actual cutting because the pilot arc is directed from the electr ode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

Pilot PC Board

Indicator Meaning

IGBT is t urned on from the logic sign al

comi ng from t he Logic Board PCR J5-6.

NOTE: This LED is on during piloting; it is

off during cu t ting .

E. Current Sense PC Board Functions

NOTE

Refer to Appendix 11 for Curr ent Sense PC Board layout.

The Current Sense PC Board senses current in the work lead (approximately 3 amps). When this happens, it sends a signal back to the Logic Board. This in turn tells the Logic to change demand levels from pilot current to main cutting current.

B. Tor c h 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.

SERVICE TR OUBLESHOOTING 4-4 Man ual 0-2728

E. Dross

4. Short Torch Parts Life

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.

F. Common Cutting Faults

1. Insufficient Penetration

a. Cutting speed too fast b. Torch tilted too much c. Metal too thick

a. Oil or moisture in air source b. Exceeding system capability (material too thick) c. Excessive pilot arc time d. Air flow too low (incorrect pressure) e. Improperly assembled torch f. Incorrect torch parts for the operation g. Non-Genuine Thermal Dynamics parts used

4.05 Troubleshooting Guide General Information

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

d. Worn torch parts e. Cutting current too low f. Torch tip contacts workpiece ("Tip Saver" Circuit ac-

tive)

2. Main Arc Extinguishes

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high d. Work cable disconnected or bad connection e. Worn torch parts

3. Excessive Dross Formation

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current e. Improper gas selection for cutting material

A. Basic Tr oubleshooting

For basic troubleshooting and parts replacement, refer to Operating Manual. This manual should be your first resource for troubleshooting. If the problem cannot be r emedied using the Operating Manual, refer to the advanced troubleshooting in this Service Manual.

B. Advanced T roubleshooting

This manual provides advanced troubleshooting and parts replacement not covered in the basic troubleshooting section of the Operating Manual. In most cases, it requires Power Supply disassembly and live measurements.

T roubleshooting and repair of this unit is a pr ocess which should be undertaken only by those familiar with high voltage high power electronic equipment.

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.

Manual 0-2728 4-5 SERVICE TROUBLESHOO TING

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 six subsections as follows:

Section 4.06 - Circuit Fault Isolation

Section 4.07 - Main Input and Internal Power Prob-

lems Section 4.08 - Pilot Arc Problems Section 4.09 - Main Arc Problems Section 4.10 - Test Procedures

C. How to Use the Troubleshooting Guide

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 4.06, Circuit Fault Isolation. Refer to the Appendix Pages for PC Board layouts, as necessary.

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

X. Symptom (Bold Type)

Any Special Instructions (Text T ype)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

a. Locate your symptom in the appropriate sub-sec-

tion.

b. Check the causes (easiest listed first) for the symp-

tom.

c. Check the remedies listed for each cause.

4.06 Circuit Fault Isolation

This section is used before troubleshooting to help isolate the defective circuit, identify symptoms, and test the unit for proper operation.

NOTE

Follow all instructions as listed and complete each in the order presented.

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

Connect gas supply to rear of Power Supply. T urn on gas supply and adjust the Plasma Gas Regulator

to 65 psi (4.5 bar) and the Secondary Gas Regulator to 60 psi (4.1 bar).

Set the Power Supply controls as follows:

ON/OFF switch to OFF RUN/SET switch to SET CURRENT control potentiometer to maximum STANDARD/LATCH switch to STANDARD (See

NOTE)

NOTE

ST ANDARD/LA TCH Switch was not installed on revision AU or earlier Power Supplies.

B. Main Input and Internal Power Tests

Connect main AC power to the unit. Set the Power Supply ON/OFF switch to ON and note

the following:

3. 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 overheating, fractures and damage.

SERVICE TR OUBLESHOOTING 4-6 Man ual 0-2728

• AC indicator blinks for eight (8) seconds, then steady ON

• Main Contactor energizes (clicks once) while AC Indicator is blinking

• Inrush Relay energizes (clicks once) after AC Indicator stops blinking

• TEMP Indicator OFF

• GAS Indicator ON

• Gas flows

• Fans operate

• DC Indicator OFF

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

• Gas Indicator goes OFF

• Gas flow stops

NOTE

This unit has a 20 second pre-purge feature which begins when the unit is turned ON. As long as the RUN/SET Switch is in the SET position, the gas will flow indefinitely. However, once the RUN/ SET Switch is placed in the RUN position, the gas will stop flowing after approximately 20 seconds (The 20 seconds begins from the time the unit is turned on, not from when the unit was put in the RUN position.)

This completes the Main Input and Internal Power T ests. If the unit functions as described above, and all correct then proceed to the Pilot Ar c Test below.

If the unit does not function as noted then note the symptom and proceed to Section 4.07, Main Input and Internal Power Problems.

C. Pilot Arc Test

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 the Main Arc Test below.

If the above does not function as noted then note the symptom and proceed to Section 4.08, Pilot Ar c Problems.

D. Main Arc Test

Press the Torch Switch to establish a pilot arc. Bring the torch to within 1/8"-3/8" (3.2 - 9.5 mm) of the

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

4.07 Main Input and Internal Power Problems

NOTES

The Input PC Board has a neon light on the upper left hand corner . If AC power is present on L1, L2, L3 of the Main Contactor, the light will be on.

Refer to the Appendix Pages for PC Board Layouts, as required.

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, Section 3.07, Input

Power Cable Connections, and connect input cable

B. Main power line fuses blow when unit is powered

1. Input Bridge Faulty

a. Test Input Bridge Rectifier per Section 4.10-D;

repair as necessary

2. Faulty FET/Heatsink Assembly a. Check per Section 4.10-K; repair as necessary

3. Faulty Input PC Board a. Test Input PC Board per Section 4.10-D; r epair

as necessary

C. 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. Customer's main power line fuses blown

• Main cutting arc initiates

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

If the above does not function as noted then note the symptom and proceed to Section 4.09, Main Arc Problems.

Manual 0-2728 4-7 SERVICE TROUBLESHOO TING

a. Replace main power line Fuses

4. Input power not properly connected to customer's main power panel

a. Check that input power is present and unit is

properly connected (refer to Operating Manual, Section 3.05, Input Power Cable Connections)

5. Actual input voltage is not within the specified range. This unit is designed to be operated from 380-415V, 3Phase input power .

a. Check actual line voltage

6. Defective input power cable

a. Replace input power cable

5. Defective Logic PC Board On Logic PC Board remove J4 and J2 connectors

a. If TEMP Indicator stays ON then r eplace Logic

PC Board

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

flow; GAS and DC indicators OFF

7. Fuse blown inside Power Supply

a. Replace internal Fuse (F1)

8. Faulty Auxiliary Transformer (refer to Appendix 12, 36 VAC Circuit Diagram)

Measure for 36 VAC on Logic PC Board from J1-1 to J1-5.

a. If voltage is not present, replace the Auxiliary

Transformer

9. Faulty ON/OFF switch (refer to Appendix 12, 36 VAC

Circuit Diagram)

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

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

switch

10. Faulty Logic PC Board (refer to Appendix 12, 36 VAC Circuit Diagram)

Measure for 36 VAC on Logic PC Board from J5-1 to J5-3.

a. If voltage is not present, replace the Logic PC

Board

D. AC indicator ON, TEMP indicator ON, RUN/SET

Switch is in RUN position, System will not pilot

1. Air flow through unit is restricted

a. Provide adequate air flow (Refer to Operating

Manual, Section 3.02)

2. Exceeded duty cycle of Power Supply

1. RUN/SET switch in RUN position

a. Switch to SET position

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 switch

a. Check continuity

5. Faulty gas solenoid circuit

a. Test gas solenoid circuit per Section 4.10-I; r e-

pair as necessary

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

DC indicator OFF

1. Gas pressure too low

a. Set pressures above 35 psi (2.4 bar) limit of

Plasma Pressure Switch

2. Faulty pressure switch

Measure for DC voltage from wire #51 to wir e #50 at the gas Pressure Switch at the rear of the Rear Panel Assembly .

a. If 12 vdc is present and pressure is above 35

psi (2.4 bar), replace gas Pressure Switch.

Rear Panel

a. Wait for fans to cool unit and (Refer to Section

2.03 for proper Duty Cycle)

3. Fans not operating

Measure for 1 15 VAC on the Logic PC Board from J96-1 to J96-3 and J96-2 to J96-4.

• If voltage is correct, replace Fan Assembly

• If voltage is incorrect, replace Logic PC Board

4. Faulty temperature circuit

a. Check temperature circuit per Section 4.10-H;

repair as necessary

SERVICE TR OUBLESHOOTING 4-8 Man ual 0-2728

Gas Solenoid

Gas Pressure Switch

Wire #51

Wire #50

A-01184

3. Low or No Coolant Flow

a. Check for proper coolant level. If low, fill to

correct level.

b. Check pump for proper operation (running)

and replace pump if necessary.

4. Clogged coolant filter and/or in-line coolant filter

a. Check internal and external coolant filters.

Clean or replace if necessary . Flush the old coolant from the system.

5. Clogged torch leads

a. Check torch and leads and r eplace if necessary .

Flush the old coolant from the system.

6. Faulty Flow Switch (FS1) or Logic PC Board

a. Check the coolant flow switch and Logic Board

as follows:

The flow switch (FS1) for the coolant is calibrated for 0.25 gpm. When adequate coolant flow satisfies FS1, it closes, connecting J99-1 on the Logic PC Board to J99-3 (common).

H. AC indicator ON; Gas flows; GAS and DC indica-

tors ON; Arc in torch without pressing torch switch; D26 (Torch Switch Enable) on Logic PCB ON

1. Faulty Torch Switch

a. Refer to Torch Instruction Manual and check

continuity.

2. Faulty Torch Leads a. Disconnect the Torch Control Cable from the

J22 connector .

b. If D26 on Logic PCB goes out, replace control

cable in leads package (per Torch Manual).

3. Faulty Pilot Output Board

a. Turn off unit. b. Disconnect J12 and J13 from Pilot Output PC

Board, then check continuity at J12 pin 1 and pin 3 on the Pilot Output Board. If shorted, replace Output PCB.

4. Faulty Logic Board

Measure voltage between J99-pin 1 and J99pin 3. If J99-1 is greater than 2 volts, FS1 or connections to FS1 are faulty. If the voltage is less than 2 vdc, the Logic Board may be faulty. Replace the flow switch or Logic Board as necessary.

G. AC Indicator ON; GAS Indicator ON; gas flows

continually

1. RUN/SET Switch in the SET position.

a. Place Switch in RUN position.

2. Faulty Gas Solenoid(s) or Logic PC Board

a. Turn the ON/OFF Switch to the OFF position.

• If the gas continues to flow, check air filters or replace Solenoid(s).

• If the gas flow stops, replace the Logic PC Board.

a. Disconnect J5 connector from Logic PC Board.

• If D26 stays on, replace Logic PCB.

• If D26 goes out, check wiring to J5 connector from Pilot PC Board.

4.08 Pilot Arc Problems

NOTE

Refer to the Appendix Pages for PC Board Layouts.

Locate your symptom below:

A. AC Indicator ON; gas flows; GAS Indicator ON

when torch switch is closed; DC Indicator OFF or flashes once. No spark or momentary spark at torch.

Measure for 320 vdc at Input PC Board between terminal E8 wire #8 to E3 wire #9. If voltage is present, go to #4, Faulty Logic or Gate PC Board.

1. Faulty Input "W" Contactor.

a. If Input "W" Contactor is not closing then mea-

sure the coil for 120VAC between wires #55 & #59.

Manual 0-2728 4-9 SERVICE TROUBLESHOO TING

• If voltage is not present, go to the next step.

• If voltage is okay, then replace Input "W" Contactor .

2. Faulty Logic PC Board

5. Faulty Torch or Leads (see note above)

a. Measure for 120V AC at the Logic PC Board con-

nector J2-1 and J2-4.

• If voltage is present, then check connections to "W" coil.

• If voltage is not present, measure for 120VAC input to the Logic PC Board between J1-2 and J1-6.

• If voltage is present, replace the Logic PCB.

• If voltage is not present, continue to next

step.

3. Faulty Auxilliary Transformer (T3)

a. Measure for 120V AC between T3 connector J30-

2 to J30-6.

• If voltage is okay, check connections to Logic PC Board.

• If voltage is not present, replace the T3 Auxilliary T ransformer .

NOTE

For #4 through #6 below, J-11 should be disconnected and isolated from the CD PC Board and the torch switch will need to be closed.

4. Faulty Logic PC Board or Gate PC Board (see note above)

a. Close the torch switch. The LED D20 on the

top Gate PC Board should turn off.

• If LED D20 does not turn off, measure for 12 vdc to drop to less than 2 vdc between J9-12 to J9-11.

• If voltage does not drop, replace the Logic

PC Board.

• If voltage drops to less than 2 vdc, replace

the Gate Drive PC Board.

• If LED D20 does turn off, D4 should flash on/ off once two seconds later.

• If D4 does not flash on/off once, measure

for 12 vdc to drop to less than 2 vdc momentarily , between J9-14 to J9-13 on the top Gate Drive PC Board.

• If the voltage does not drop momentarily, then replace the Logic PC Board.

• If the voltage does drop momentarily, r eplace the Gate Drive PC Board.

a. Remove wire 15 from Pilot Output PC Board

terminal E24.

b. Following the procedure detailed in 4.10-K.1,

measure the output voltage at the FET Heatsink Assembly between E17 & E18. If voltage is okay with wires disconnected, repair or replace torch/leads as required.

6. Faulty Output Pilot PC Board (see note above)

a. Test per section 4.10-J. Repair as necessary. b. Disconnect and isolate wires from E8 on Pilot

Output PC Board.

c. Following the procedure detailed in 4.10-K.1,

measure the output voltage at the FET Heatsink assembly between E17 & E18. If voltage is okay with wires disconnected, replace Output Pilot PC Board.

7. Faulty FET PC Board

a. Check per section 4.10-K. Repair or replace as

necessary.

B. AC indicator ON; Gas flows; GAS indicator ON;

DC indicator blinks; Small arc may be visible in torch

1. Shorted torch

a. Remove torch from bulkhead connections.

Measure between Pilot Return Lead and T or ch (-). If the meter doesn't show an open, repair torch.

2. Faulty Pilot Output PC Board

a. Test per Section 4.10-J; repair as necessary

3. Faulty FET/Heatsink Assembly

a. Check per Section 4.10-K; repair as necessary

C. AC indicator ON; Gas flows; GAS and DC indica-

tors ON; No arc in torch; No arc at spark gap on CD PC Board; CD enable indicator D25 on Logic Board ON

1. Faulty CD PC Board

Measure DC voltage between J1 1-4 to J1 1-5 on CD PC Board

a. If voltage is less than 2 vdc replace CD PC

Board

• If D4 on the Gate PC Board does flash for two seconds after D20 turns off, then go to the next step.

SERVICE TR OUBLESHOOTING 4-10 Man ual 0-2728

D. AC indicator ON; Gas flows; GAS and DC indica-

tors ON; Spark at gap on CD PC Board and CD enable indicator (D25) on Logic PC Board ON; No arc or intermittent arc in torch

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

4.09 Main Cutting Arc Problems

NOTE

Refer to the Appendix Pages for PC Board Layouts.

a. Check gas pressures. Plasma Gas Pressure

should be 65 psi (4.5 bar), and Secondary Gas Pressure should be 60 psi (4.1 bar).

2. Oil/moisture in air lines

a. Purge system. If problem corrected add filters

in line with air source

3. Incorrect torch parts

a. Refer to appropriate Tor ch Instruction Manual

4. Faulty leads

a. Check continuity per appropriate Torch In-

struction Manual

5. Faulty torch

a. Check continuity per appropriate Torch In-

struction Manual

6. Faulty connection of wire #15 or #17 to Pilot Output PC Board or pilot inductor wires reversed with wire #17.

a. Check wiring connection

7. Faulty Pilot Output PC Board

a. D5 on the Pilot PC Board should turn on two

seconds after the torch switch is closed.

• If D5 does turn on, install a jumper between E22 and E8 on the Pilot PC Board. If unit will pilot with jumper installed, replace the Output PC Board.

Locate your symptom below:

A. Main cutting arc will not initiate

1. Work cable not connected.

a. Connect work cable.

2. Faulty INR Inrush Contactor

a. While attempting to transfer , measure for 0 vdc

at input PC Board between E1 and E8.

• If the voltage is correct, then replace the INR Inrush Contactor .

• If voltage is not 0 vdc then measure for 120V AC at INR inrush contactor coil wir es #68 and #69.

3. Faulty Logic PC Board

a. If 120V AC is not found at INR Inrush Contactor

wires #68 and #69, measure for 120VAC at the Logic PC Board between J2-4 to J4-8.

• If 120V AC is not present, replace the Logic PC Board.

• If 120VAC is present, check wiring.

4. Faulty Current Sensor PC Board

Check the following:

a. While trying to initiate main cutting arc, mea-

sure the voltage at J99-6 to J99-7 (or TP 10 to Gnd) indicators inside the Power Supply.

• If D5 does not turn on, measure the 12 vdc to drop to less than 2 vdc between J13-18 & J13-17 two seconds after torch switch is closed. If voltage does drop, then measure for 36 VAC between J13-14 & J13-15. If 36V AC is found then replace the Pilot/Output PC Board.

8. Faulty Logic PC Board

a. If the voltage between J13-18 & J13-17 on the

Pilot/Output PC Board does not drop to less than 2 vdc two seconds after the torch switch is pressed, replace the Logic PC Board.

Manual 0-2728 4-11 SERVICE TROUBLESHOO TING

• If voltage is approximately 12 vdc replace the Current Sensor.

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

5. Faulty Transfer Mod Enable Signal

a. Test this Signal by measuring J4-6 to J4-8.

• If voltage approximately 12 vdc, replace Logic Board

• If 0 vdc, replace Gate Drive Board

B. When operating at amperages over 35 amps the

amperage drops off after main cutting arc initiates

Check whether Drag indicator (D31) on the Logic 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" between

cutting tip and workpiece.

2. Faulty Logic PC Board

If torch tip is off the workpiece and the drag indicator , D31, on the Logic PC Board is still ON, then replace the Logic PC Board.

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.

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 board. Use only minimal pressure and gentle movement when disconnecting or connecting printed circuit board plugs.

B. Opening Power Supply Enclosure

C. Main cutting arc will not shut off when torch

signal is deactivated

1. STANDARD/LA TCH Switch in LATCH position

a. Place switch to STANDARD position.

2. Faulty STANDARD/LA TCH Switch

a. Test switch for open condition when in ST AN-

DARD position and replace if necessary.

3. Faulty Logic PC Board or Wiring Harness

Disconnect STANDARD/LATCH Switch from wiring harness at J28 and retest system.

• If main arc will shut off, then Logic PC Board is faulty.

• If main arc will still not shut off, then wiring harness is faulty. Repair as necessary.

4.10 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.

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

WARNING

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

1. Remove input power from the unit.

2. Loosen the two bottom screws in the slotted holes of the desired Side Panel (viewed from the front of the unit).

3. Remove the remaining screws which secure the Side Panel to the Power Supply.

NOTE

Art may differ

from actual unit.

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.

SERVICE TR OUBLESHOOTING 4-12 Man ual 0-2728

A-03058

4. Pull the top of the Side Panel out and then lift up to remove the panel from the Power Supply a short distance (see NOTE).

A-00307

NOTE

There is a ground wire connection to the Side Panel on the inside of the unit.

5. Remove the nut securing the ground wire to the side panel and remove the ground wire.

6. Remove Side Panel from unit and set aside.

7. Reinstall the Side Panel by reversing the above procedure and doing the following:

a. Reconnect the ground wire to the Side Panel, if

disconnected.

b. Place the Side Panel onto the frame and slide the

top edge under the lip on the Top Panel.

c. Reinstall all the screws to secure the Side Panel.

C. Diode Testing Basics

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.

0.75

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”.

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.

Reverse Bias

Diode Not Conducting

Cathode

Anode

Testing Diode Reverse Bias

COM

A-00306

Manual 0-2728 4-13 SERVICE TROUBLESHOO TING

7. If a diode checks bad, replace the diode module.

8. Reconnect all cables to proper terminals.

D. Input PC Board /Input Bridge Rectifier Test

E. Main Contactor (MC1) Test

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

NOTE

Refer to the Appendix Pages for PC Board Layouts.

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

Meter (+) Meter (-) Indi catio n

A (-) Open B (-) Open C (-) Open A (+) Diode Drop B (+) Diode Drop C (+) Diode Drop

(+) (-) Open

Reconnect power and observe proper start-up procedure. Indicator D47 on the Logic PC Board should be ON. If indicator D47 is OFF there is no voltage to the Power Supply or an overvoltage condition exists.

If indicator D47 is OFF check L1, L2, and L3 for proper AC input voltage.

Main Contactor

(MC1)

Coil

Wire #55

A-02453

Coil

Wire #59

Measure voltage on coil of contactor, approximately 115 VAC between wires #55 and #59 (see NOTE).

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

If Input Bridge Rectifier diode(s) is shorted, make the following checks with an ohmmeter at the Main Contactor:

Meter (+) M eter (-) Indicatio n

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

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

• If voltage is correct, replace Main Contactor.

• If voltage is incorrect, replace Logic PC Board.

NOTE

The Main Contactor was located in the Base on earlier units and on the Center Chassis for current units.

F. Inrush Relay Test

If after approximately 8 seconds, the Inrush Relay does not engage, measure for 1 15V AC on wir es #68 and #69. If there is voltage, replace Contactor. If there is no voltage, measure at Logic Board J17- 4 to J17-8. If there is no voltage at the Logic Board, replace Logic Board.

G. Blown Fuse (F1) Test

1. The voltage selector set to the wrong input voltage will cause F1 to fail.

a. Verify input voltage with Voltage Selector.

2. A shorted or frozen pump/motor will cause F1 to fail. T o check the motor:

a. Replace F1 fuse and unplug J32

SERVICE TR OUBLESHOOTING 4-14 Man ual 0-2728

b. T urn power on if fuse is okay.

• Check motor connections

• Check voltage to motor connector

H. Temperature Circuit Test

The Power Supply has seven temperature sensing switches.

• One on each FET Heatsink Assembly (four total)

• One located behind the Input Board near the Input Bridge Diode.

• One on the Pilot/Output Heatsink

• One on the Radiator

If any one of these sense overtemperature, the Overtemp Indicator on the Access Panel will light and not allow DC output.

NOTE

Refer to the Appendix Pages for PC Board Layouts.

Test the temperature circuit per the following:

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

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

8. Check status of the TEMP Indicator. If Indicator is OFF, remove power and replace the upper or lower pair of FET/Heatsink Assemblies.

9. Repeat steps 1-8 for each FET Assembly.

If the TEMP Indicator is still on, go to the next step.

10. Check the Temperature Switch at the Input Bridge Diode, by completing the following:

• Make sure power is off at the wall disconnect.

• Remove one connection from the T emp switch located behind the Input PC Board.

• Turn the unit back on.

If the Temp Indicator is off, remove power and replace T emp Switch.

If the Temp Indicator is still on, go to the next step.

11. Check the Pilot/Output Board.

• Remove power then disconnect J13 on Pilot Output Board

• Turn power back on and check the TEMP Indicator .

A-01410

FET/Heatsink and

Capacitor PC Board

Assembly

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

4. Check the status of the TEMP indicator. a. If indicator has gone OFF , then remove power and

replace the upper or lower pair of FET/Heatsink Assemblies.

b. If the indicator is still on, go to the next step.

5. Place the front panel ON/OFF switch to the OFF po-

sition.

6. Disconnect ribbon cable from the next FET/Heatsink

Assembly at J6.

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

If the Indicator has gone off, replace Pilot Output PC Board.

If the TEMP Indicator is still on, continue with the next step.

12. Unplug J2 on the Logic Board.

13. Place the ON/OFF switch in the ON position. If the TEMP indicator is off replace the Temperature

Switch on the Radiator . If the TEMP indicator is still on replace the Logic

Board.

I. Gas Solenoid Circuit Test

NOTE

Refer to the Appendix Pages for PC Board Layouts.

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

1. Place the RUN/SET Switch in the SET position and

check for 115 VAC from wire #56 to wire #52 at the plasma gas Solenoid.

If approximately 1 15 VAC replace Solenoid. If no voltage is present proceed to Step 2.

Manual 0-2728 4-15 SERVICE TROUBLESHOO TING

2. Measure for 115 VAC from J2-2 to J17-3 at the Logic PC Board.

If voltage is not correct replace Logic PC Board.

3. Check for 115VAC from wire #64 to wire #65 at the secondary gas Solenoid.

If approximately 1 15V AC is present, r eplace Solenoid. If no voltage is present, proceed to step 4.

4. Measure for 115VAC from J17-7 to J2-6 at the Logic Board.

If the voltage is not correct, replace the Logic Board.

1. No DC Output

An open circuit voltage of approximately 280 to 325 vdc (depending on input power selected) is produced when switching transistors in the FET/Heatsink Assemblies are turned ON by a PWM Enable signal from the Logic PC Board. A circuit on the Logic PC Board monitors the output voltage. When the output voltage drops below 60 vdc, indicating a problem exists, the Logic PC Board sends a signal which turns OFF the PWM Enable signal to the Gate Drive 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.

J. Pilot Arc Circuit T est

NOTE

Refer to the Appendix Pages for PC Board Layouts.

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 removed).

K. FET/Heatsink Circuit Tests

NOTE

Refer to the Appendix Pages for PC Board Layouts.

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 PC Board, Pilot/Output PC Board and the Gate Drive PC Board to help in troubleshooting. They are as follows:

NOTES

The upper FET Assemblies provide the power for piloting and the main cutting arc. The lower FET Assemblies are for main cutting arc only.

When the unit is at “idle” the AC OK indicator, D47, should be ON. The Torch Switch Enable indicator, D26, 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 and the DC indicator at the front panel turns ON.

If the front panel DC Indicator turns ON then OFF immediately , the following test should be performed:

a. Disconnect J11 from the CD PC Board to dis-

able the CD signal.

b. Connect a jumper between TP1 and TP8 on

Logic PC Board. This will cause the gas to flow continuously and the DC Indicator on the front panel to turn ON.

WARNING

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

c. Press and hold the hand torch switch (Logic

PC Board Start Indicator, D26, turns ON).

d. Measure open circuit voltage between E8 (+)

to E7 (-) at the Pilot Output PC Board. If voltage is low, each FET/Heatsink Assembly should be tested individually.

The upper Gate Drive Board controls the upper two FET/Heatsink Assemblies and the lower Gate Drive Board controls the bottom two FET/Heatsink Assemblies.

SERVICE TR OUBLESHOOTING 4-16 Man ual 0-2728

2. FET/Heatsink Output Diode Checks

Remove input power from the unit. 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 . W ith 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 shorted or open in both directions then the upper or lower pair of FET/Heatsink Assemblies should be replaced.

3. MOSFET Resistance Checks

The Power Supply contains four 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 Assem-

bly.

FET/Heatsink and

Capacitor PC Board

Assembly

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 protective coating on the MOSFET.

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 Q6 and

meter (-) lead on source lead of Q6. The meter should indicate approximately 2.5K ohms.

f. Place the meter (+) lead on drain lead of Q6 and

meter (-) lead on source lead of Q6. 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 E12 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.

A-01414

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

b. Reverse the meter leads and the indication should

be a capacitor charging.

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

lead on E13 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 tupper or lower pair of FET/Heatsink Assemblies.

Manual 0-2728 4-17 SERVICE TROUBLESHOO TING

5. FET Output Rectifier Check

NOTE

Refer to the Appendix Pages for PC Board Layouts.

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.

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

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.

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 upper or lower pair of FET/Heatsink Assemblies if any of the above tests are open or shorted.

6. FET Output Clamp Diodes Check

NOTE

Refer to the Appendix Pages for PC Board Layouts.

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 upper or lower pair of FET/Heatsink Assemblies if any of the above tests are open or shorted.

SERVICE TR OUBLESHOOTING 4-18 Man ual 0-2728

SECTION 5:

REPLACEMENT

PROCEDURES

5.01 Introduction

This section describes parts replacement procedur es and all cable repairs which may be performed on the Pak Master 150XL CE Power Supply.

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.

5.02 Anti-Static Handling

Procedures

A. General

CAUTION

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

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.

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.

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.

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 require that the Power Supply be disassembled. The part to be replaced will determine to what extent the Power Supply must be disassembled.

WARNINGS

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.

B. Procedure

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

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

NOTES

Before removing any electrical 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 wir es are put back in the same place when reassembling the unit.

Turn OFF all gas inputs to the Power Supply at the source before disconnecting any gas Hose Assemblies.

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

Manual 0-2728 5-1 REPLACEMENT PROCEDURES

WARNING

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 .

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

a. Reconnect the ground wire to the Side Panel,

if disconnected.

b. Place the Side Panel onto the frame and slide

the top edge under the lip on the Top Panel.

c. Reinstall all the screws to secure the Side Panel.

5.04 Major External Parts Replacement

NOTE

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

A. Left or Right Side Panel Replacement

1. Remove input power from the unit.

2. Loosen the two bottom screws in the slotted holes of the desired Side Panel (viewed from the front of the unit).

3. Remove the remaining screws which secure the Side Panel to the Power Supply.

4. Pull the top of the Side Panel out and then lift up to remove the panel from the Power Supply a short distance (see NOTE).

NOTE

There is a ground wire connection to the Side Panel on the inside of the unit.

5. Remove the nut securing the ground wire to the side panel and remove the ground wire.

6. Remove Side Panel from unit and set aside.

B. Top Panel Replacement

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

2. Remove the screws securing the Top Panel to the side and rear panels.

3. Locate and remove the nut securing the T op Panel to the center chassis.

4. Slide the Top Panel stud out of the center chassis hole.

5. Install the replacement T op Panel by r eversing the above procedure.

C. Work Cable Replacement

1. Remove Right Side Panel per Section 5.04-A.

2. Remove the work cable strain relief from the Front Panel.

3. Disconnect work cable connection from E8 on Pilot Output PC Board.

4. Pull the work cable through the Current Sense PC Board and then through the Front Panel, then r emove from unit.

5. Install the replacement work cable by reversing the above procedure.

D. Torch & Leads Assembly Replacement

NOTE

Art may differ

from actual unit.

Figure 5-1 Side Panel Removal

REPLACEMENT PROCEDURES 5-2 Manual 0-2728

A-03058

1. Open the Access Panel per Section 5.05-E.

2. Disconnect all hoses and the cable from the bulkhead.

3. Disconnect Shield Wire from Shield Stud, if present on Torch lead.

4. Install the replacement T or ch Assembly by reversing the above procedure, keeping in mind the following:

a. Connect the bottom hoses first. b. The two fittings on the right side of the bulk-

head (when viewed from the front of unit) ar e for left hand hoses; the two fittings on the left are for right hand hoses.

E. Front Panel Replacement

Run/Set Switch

wire #30

wire #31

A-02284

1. Remove the Left and Right Side Panels per Section 5.04-A.

2. Remove the Work Cable per Section 5.04-D.

3. Remove the Torch & Leads per Section 5.04-E.

4. Remove the two bolts at the bottom of the Front Panel.

5. Remove the nuts on the inside of unit securing the Front Panel to the two studs on the center chassis.

6. Carefully remove Front Panel from the unit.

7. Install the replacement Front Panel by reversing the above procedure.

5.05 Access Panel Parts Replacement

NOTE

Refer to Section 6.04 for parts list and overall detail drawing.

A. CURRENT Knob Replacement

1. Turn the CURRENT adjustment fully counter clockwise and note the location of the pointer at the 30 on the knob.

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

3. Remove 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. T ighten the screw to secure the knob to the potentiometer shaft.

B. ON/OFF Switch (SW1) Replacement

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

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

C. RUN/SET Switch (SW2) Replacement

1. Unlatch the Access Panel to gain access to the r ear of the RUN/SET Switch.

2. Disconnect all the wiring to the RUN/SET Switch. Wiring is as follows:

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

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

D. ST AND ARD/LATCH Switch (SW3)

Replacement (See NOTE)

NOTE

ST ANDARD/LA TCH Switch was not available on earlier units.

1. Unlatch the Access Panel to gain access to the r ear of the ST ANDARD/LATCH Switch.

2. Disconnect all the wiring to the STANDARD/ LA TCH Switch. Wiring is as follows:

STANDARD/LATCH Switch

1. Unlatch the Access Panel to gain access to the r ear of the ON/OFF Switch.

2. Disconnect all the wiring to the ON/OFF Switch. Wiring is as follows:

On/Off Switch

wire #32

wire #33

Manual 0-2728 5-3 REPLACEMENT PROCEDURES

1A 2A

wire #34

wire #35

A-02285

Wire T o J28-3

A-03057

Wire T o J28-1

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

4. Install the replacement STANDARD/LATCH Switch by reversing the above procedure.

E. Pot/LED PC Board Assembly Replacement

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

5.06 Left Side Center Chassis Parts Replacement

NOTE

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

3. Remove the Current Knob.

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

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

6. Disconnect the wire harness on Pot/LED PC Board.

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

F. Access Panel Replacement

1. Turn the two Dzus studs 1/4 turn each to unlatch Access Panel from Front Panel.

2. Lift Access Panel straight up then down until the side hinges lock into place.

3. Disconnect the ground wire on the Access Panel.

4. Remove the following components from the Access Panel by referring to :

Refer to Section 6.05 for parts list and overall detail drawing.

A. Fuse (F1) Replacement

1. Remove power from unit.

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

3. Remove Fuse from the fuse holder.

4. Replace Fuse (5 amp, 600V).

5. Reinstall Left Side Panel.

B. Fuse Holder Replacement

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

2. Remove Fuse from Fuse Holder.

3. Disconnect two wires connected to Fuse Holder.

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

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

• ON/OFF Switch per paragraph 5.05-B.

• RUN/SET Switch per paragraph 5.05-C.

• STANDARD/LATCH Switch per paragraph

5.05-D.

• Current Knob and Pot/LED PC Board per paragraph 5.05-E.

5. To remove the Access Panel, lift up and pull straight out to disengage the Access Panel side hinges and remove the panel from the unit.

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

REPLACEMENT PROCEDURES 5-4 Manual 0-2728

C. Input PC Board Assembly Replacement

D. Input Bridge Rectifier Replacement

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

2. Disconnect all cable lug connections to Input Board, removing star washers and nuts where applicable.

Connection Descripti on of Cable

A Cable #1 from W Contactor B Cable #2 from W Contactor

C Cable #3 from W Contactor

Wires #8E from from INR Contactor Positions L3 & L4

Wires #8E from from INR Contactor Positions L1 & L2

Wire #9 To E26 on Cap PC Board ' A'

Wire #9 To E26 on Cap PC Board ' C'

Wires #8E from INR Contactor Positions T3 & T4; Wire #8 to E25 on C ap PC Board ' B'

Wires #8E from INR Contactor Positions T1 & T2; Wire #8 to E25 on C ap PC Board ' D'

NOTE

Refer to reverse side of replacement board for connection identification.

3. Remove the clear insulator sheet from the Input Board.

4. Remove the three screws in top holes connecting the Input Board to the Bridge Rectifier.

5. Install the replacement Input PC Board by r eversing the above procedure noting the following:

• The three screws securing the wiring and In-

put PC Board to the Bridge Rectifier must be tight enough to prevent the wires from moving.

NOTE

Failure to properly tighten the three scr ews securing the Input PC Board to the Bridge Rectifier will cause damage to the unit.

• Prior to making cable connections, peel pro-

tective coating off insulator sheet and place insulator sheet on replacement input board.

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

2. Remove the Input PC Board per Section 5.06-C.

3. Remove the two nuts securing the Bridge Rectifier to the Heatsink.

4. Remove the Bridge Rectifier Assembly from the unit.

5. Remove the Thermal Pad.

6. Install the replacement Input Diode Bridge Assembly, including Thermal Pad by reversing the above procedure, noting the following:

• Clean Heatsink and back of Bridge Rectifier

surface with a clean rag and alcohol.

• The two nuts removed in Step 3 must be

torqued to 35 in-lbs when reinstalled.

• Install Rectifier with A B C terminals away

from the Thermostat.

E. Thermostat (TS2) Replacement

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

2. Remove the Input PC Board per Section 5.06-C.

3. Remove two screws securing the Thermostat to the Heatsink.

4. Install replacement Thermostat by reversing the above procedure.

F. In-Rush Contactor (INR) Assembly

Replacement

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

2. Note orientation of all the wires connected to the Contactor Assembly and label them.

3. Disconnect the wires from the Contactor Assembly terminals.

4. Remove the two nuts and washers securing the Contactor Assembly to the internal chassis of the unit.

5. Install the replacement Contactor Assembly by reversing the above steps, keeping in mind the following:

• Install Contactor with T1-T4 side towards

heatsinks.

Manual 0-2728 5-5 REPLACEMENT PROCEDURES

G. Logic PC Board Replacement

1. Remove the Left Side Panel per section 5.04-A.

2. Carefully remove all cable connections from the Logic PC Board noting the location of each.

3. Remove the five screws securing the Logic PC Board to the standoffs.

3. Remove the four screws securing the Gate Drive

PC Board to the four standoffs.

4. Reinstall the replacement Gate Drive PCB Assembly by reversing the above procedure.

I. FET/Heatsink Assembly Replacement

NOTE

4. Install the replacement Logic PC Board by r eversing the above procedure.

H. Gate Drive PC Board(s) Replacement

NOTE

The two Gate Drive Boards are identical and are removed in the same manner.

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

2. Carefully remove all cable connections to the Gate Drive PCB Assembly noting the location of each per the following chart:

Connection Description of Cable

J10

J11

Ribbon Cable from FET/Heat sink Assembly

Ribbon Cable from logic Board at J4 to both Gat e Drives a t J9

Twisted 3-wire harness from J11 on top Gate Drive Board

Twisted 3-wire harness from J10 on bottom Gate Drive Board

The four FET/Heatsink Assemblies are identical and are removed in the same manner.

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

2. Remove the Ribbon Cable plugs 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 .

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

Connection Descr iption

E14 Mai n T ransformer (Primary)

E15 Mai n T ransformer (Primary)

E16 Main Transformer (Secondary)

E17 (-) Output

E18 (+) Output

E19 Main Transformer (Secondary)

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

REPLACEMENT PROCEDURES 5-6 Manual 0-2728

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

6. To remove the Mounting Bracket lift up on the top FET/Heatsink Assembly and push down on the bottom FET/Heatsink Assembly in the middle where the two FET/Heatsink Assemblies come together.

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

5.07 Right Side Center Chassis Parts Replacement

NOTE

Refer to Section 6.06 for parts list and overall detail drawing.

A. Pilot/Output PC Board Assembly

Replacement

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

CAUTION

FET/Heatsink Assemblies are matched and balanced during production and must be replaced in pairs per the following illustration.

Replace As

Pair

Replace As

Pair

A-02584

8. Install the replacement FET/Heatsink Assembly by reversing the above procedure.

NOTE

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

NOTES

Before removing any connection mark each wire with the connection designation to ensure that wires go to the proper terminals when reassembling. Also note the routing of wires and make sure the wires are put back in the same place when reassembling the unit.

2. Mark all wirings/connections, then disconnect all the wiring connections to the Pilot/Output PC Board Assembly .

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

4. Install the replacement Pilot/Output PC Board Assembly by reversing the above procedure. Refer to Appendix 6 for wiring connection diagram.

B. Coolant Motor Relay (MC1) Replacement

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

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 wir es are put back in the same place when reassembling the unit.

Manual 0-2728 5-7 REPLACEMENT PROCEDURES

2. Mark all wirings/connections then disconnect all the wiring connections to the Relay Assembly.

3. Remove the two screws securing the Relay Assembly to the Reservoir Panel.

4. Install the replacement Relay Assembly by reversing the above procedure.

C. Pilot Resistor (R1 & R2) Replacement

F. Coolant Filter Replacement

NOTE

This unit has two Pilot Resistors. The replacement instructions are the same for both.

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

2. Remove all wiring connections to the Pilot/Output PC Board Assembly, noting the location of each.

3. Remove two nuts securing Pilot Resistor to Pilot Panel.

4. Remove Pilot Resistor from studs.

5. Install replacement Resistor by reversing the above procedure.

D. Pilot Inductor (L3) Replacement

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

2. Remove all wire connections to the Pilot Inductor , noting the location of each.

3. Remove four nuts securing Pilot Inductor to the Pilot Panel and remove Pilot Inductor from unit.

4. Install replacement Pilot Inductor by reversing the above steps.

E. Capacitive Discharge (CD) PC Board

Assembly Replacement

1. Remove Right Side Panel per Section 5.04-A.

2. Remove the two coolant hose connections to the Filter Assembly .

NOTE

Some residual coolant may drain from the In-Line Filter . It is recommended that a bucket, rag or towels be placed below the hose prior to removing.

3. Remove the two elbow fittings on each side of the Coolant Filter Assembly and remove the damaged Coolant Filter Assembly from the bracket.

4. Clean the old thread sealer from the threads of the elbow fittings.

5. Apply a thin coating of liquid teflon thread sealer to the threads of the elbow fittings.

6. Place the replacement Coolant Filter Assembly in the bracket with the arrow pointing to the left and reinstall the two elbow fittings.

7. Reconnect the two coolant hoses to the Coolant Filter Assembly making sure that the hose to the Pump Assembly is on the output of the Coolant Filter Assembly).

8. Install Right Side Panel.

G. Coolant Reservoir Replacement

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

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 wir es are put back in the same place when reassembling the unit.

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

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

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

CAUTION

Handle and dispose of the used coolant per recommended procedures.

NOTE

The Coolant Reservoir is removed by removing the rear panel.

1. Remove the Left and Right Side Panels per Section 5.04-A.

2. Drain the coolant from the Coolant Reservoir as follows:

a. Disconnect the Coolant Supply Hose input

connection at the Coolant Filter Assembly. The hose goes from the Coolant Filter Assembly to the bottom of the reservoir.

b. Place the end of the hose into a container to

catch the coolant as it flows from the reservoir.

NOTE

REPLACEMENT PROCEDURES 5-8 Manual 0-2728

Do Not run the pump as the coolant will gravity feed from the reservoir.

c. Remove the Coolant Reservoir Cap then re-

move the Deionizer Basket and Deionizer Bag from the Coolant Reservoir filler hole.

3. Disconnect the Coolant Supply Hose output connection from the bottom of the reservoir.

4. Disconnect the In-Line Coolant Filter Assembly where it connects to the reservoir.

NOTE

Some residual coolant may drain from the In-Line Coolant Filter. It is recommended that a bucket, rag or towels be placed below the hose prior to removing.

H. In-Line Coolant Filter Assembly

Replacement

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

CAUTION

Handle and dispose of the used coolant per recommended procedures.

2. Partially drain the coolant from the Coolant Reservoir as follows:

a. Disconnect the Reservoir to Coolant Filter As-

sembly hose at the Coolant Filter Assembly.

5. Disconnect two air lines connected to the two solenoid assemblies.

6. Remove the two bottom screws on Rear Panel.

7. Remove the two nuts and washers on the inside of rear panel connecting the panel to the center chassis.

8. Remove the screw located in the center of the rear panel which secures the rear panel to the reservoir panel.

9. Carefully slide the rear panel out and away from the unit.

10. Remove the four nuts and washers (two top and two bottom) securing the coolant tank to the reservoir panel.

11. Remove the coolant reservoir from the r ear panel.

12. Reinstall the replacement Coolant Reservoir by reversing the above steps, keeping in mind the following:

• Use thread sealant on all fittings when rein-

stalling.

• Refill the Coolant Reservoir with the coolant

removed or fresh Thermal Arc Torch Coolant.

14. Place the Deionizer Basket and Bag into the Coolant Reservoir filler hole and install the Coolant Reservoir Cap.

b. Place the end of the hose into a container to

catch the coolant as it flows from the reservoir. Only enough needs to be removed so that the level is below the In-Line Coolant Filter/Flow Switch Assembly hole located on the end of the reservoir.

NOTE

Do Not run the pump as the coolant will gravity feed from the reservoir.

3. Remove the hose connected to the bottom of the In-Line Coolant Filter Assembly.

NOTE

Some residual coolant will drain from the In-Line Coolant Filter. It is recommended that a bucket, rag or towels be placed below the hose prior to removing.

4. Remove bowl on In-Line Coolant Filter.

5. Remove filter body from Flow Switch.

6. Remove fittings from filter body .

7. Install the replacement In-Line Coolant Filter Assembly by reversing the above steps.

NOTE

Use thread sealant on all the pipe threads when reinstalling.

8. Refill the Coolant Reservoir with the coolant removed or add fresh Thermal Arc T or ch Coolant.

Manual 0-2728 5-9 REPLACEMENT PROCEDURES

I. Flow Switch Assembly (FS1) Replacement

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

CAUTION

Handle and dispose of the used coolant per recommended procedures.

2. Partially drain the coolant from the Coolant Reservoir until the coolant level is below where the Flow Switch connects to the Reservoir . Drain coolant as follows:

a. Disconnect the Reservoir to Coolant Filter As-

sembly hose at the Coolant Filter Assembly.

b. Place the end of the hose into a container to

catch the coolant as it flows from the reservoir . Drain enough coolant so that the coolant level is below the Flow Switch Assembly connection to the reservoir tank.

NOTE

Do Not run the pump as the coolant will gravity feed from the reservoir.

3. Detach red wires at top end of Flow Switch wher e they connect to wire harness.

4. Disconnect In-Line Coolant Filter from the bottom of Flow Switch Assembly.

NOTE

Some residual coolant will drain from the In-Line Filter. It is recommended that a rag or towels be placed below the hose prior to removing.

5. Remove fitting from bottom end of Flow Switch Assembly.

6. Disconnect Flow Switch from Reservoir and remove Switch from unit.

7. Install the replacement Flow Switch Assembly by reversing the above steps, keeping in mind the following:

a. The Flow Switch Assembly should be installed

at a slight angle to allow room for hose attachment with the filter pointing away from the tank.

b. Use thread sealant on all the pipe threads

when reinstalling.

8. Refill the Coolant Reservoir to the full level (refer to label on coolant tank) with either the coolant that was removed or add fresh Thermal Arc T or ch Coolant.

J. Output Inductor Assembly (L1 & L2)

Replacement

NOTES

There are two Output Inductors in this unit. Replacement instructions are the same for both.

The Output Inductor(s) are located behind the Reservoir panel. To gain access to the Output Inductor(s), the rear panel of the unit must be removed, then the internal reservoir panel is disengaged and moved out of the way.

1. Remove the Left and Right Side Panels per Section 5.04-A.

2. Drain the coolant from the Coolant Reservoir as follows:

a. Remove Reservoir Cap from Reservoir. b. Disconnect the Coolant Supply Hose input

connection at the Coolant Filter Assembly. The hose goes from the Coolant Filter Assembly to the bottom of the reservoir.

c. Place the end of the hose into a container to

catch the coolant as it flows from the reservoir.

NOTE

Do Not run the pump as the coolant will gravity feed from the reservoir.

3. Disconnect the Coolant Supply Hose output connection from the bottom of the reservoir.

4. Disconnect the In-Line Filter Assembly where it connects to the reservoir .

NOTE

Some residual coolant may drain from the In-Line Filter. It is recommended that a rag or towels be placed below the hose prior to removing.

5. Disconnect two air lines where they connect to the two solenoid assemblies.

6. Remove the two bottom screws on rear panel.

7. Remove the two nuts and washers on the inside of rear panel connecting the panel to the center chassis.

8. Remove the rear panel from the unit by removing the screw located in the center of the rear panel which secures the rear panel to the reservoir panel.

9. Carefully slide the rear panel out and away from the unit.

REPLACEMENT PROCEDURES 5-10 Manual 0-2728

10. Locate the two nuts on the base which secure the reservoir panel to the base, then remove nuts.

2. Drain the coolant from the Coolant Reservoir as follows:

NOTE

It may be necessary to disconnect some wiring in order to have enough room to work. Note wire connections so that wires can be reconnected again properly.

11. Slide reservoir panel up and out of the 'T' slots on the center chassis and move panel to provide access to main transformers.

12. Complete the following: a. Disconnect single leg orange wire from E17

on the FET/Heatsink Assembly and slide wire back through adjacent bushing hole in center chassis.

b. Disconnect orange wire at E3 on Pilot Output

Board.

13. Note orientation of Inductor, then remove four lock nuts securing Inductor to center chassis.

14. Install the replacement Output Inductor Assembly by reversing the above procedur e, keeping in mind the following:

• Reservoir Panel must seat in corresponding

center chassis slots.

• The four screws securing the Inductor mount-

ing plate to the center chassis should have a maximum of 2 to 5 threads protruding thr ough the left side of the chassis.

a. Remove Reservoir Cap from Reservoir. b. Disconnect the Coolant Supply Hose input

connection at the Coolant Filter Assembly. The hose goes from the Coolant Filter Assembly to the bottom of the Reservoir .

c. Place the end of the hose into a container to

catch the coolant as it flows from the reservoir.

NOTE

Do Not run the pump as the coolant will gravity feed from the reservoir.

3. Disconnect the Coolant Supply Hose output connection from the bottom of the Reservoir .

4. Disconnect the In-Line Filter Assembly where it connects to the Reservoir .

NOTE

Some residual coolant may drain from the In-Line Filter . It is recommended that a bucket, rag or towels be placed below the hose prior to removing.

5. Disconnect two air lines where they connect to the two Solenoid assemblies.

6. Remove the Rear Panel per procedures in Section

5.09-B.

7. Locate the two nuts on the base which secure the Reservoir Panel to the base.

K. Main T ransformer Assembly (T1 & T2)

Replacement

NOTES

There are two Main Transformers in this unit. Replacement instructions are the same for both.

The Main Transformer(s) are located behind the Reservoir Panel. In order to gain access to the Main T ransformer(s), the Rear Panel of the unit must be removed and the internal Reservoir Panel disengaged and moved out of the way.

1. Remove the Left and Right Side Panels per Section 5.04-A.

8. Remove nuts.

NOTE

It may be necessary to disconnect some wiring in order to have enough room to work. Note wire connections so that wires can be reconnected again properly.

9. Slide reservoir panel up and out of the 'T' slots on the center chassis and move panel to provide access to main transformers.

Manual 0-2728 5-11 REPLACEMENT PROCEDURES

10. Carefully r emove all wire connections to the FET

A-02290

Air Flow/Rotation

Label Direction

Air Flow

Arrow

Direction

Air Flow/Rotation

Label Molded Into

Fan Housing

ROTATION

AIR FLOW

PCB Assembly noting the location of each per the following chart:

Ca b le #

14A E14 15A E15 16A E16 19A E19 14B E14 15B E15 16B E16 19B E19

FET PCB

Connection

NOTES

Make sure white #19 wires are looped around and connected from the right side.

Transformer leads are marked 'A' & 'B'. Group 'A' is wired to the top heatsink and group 'B' is wired to the bottom heatsink. Wir es are placed belly up."

4. Carefully note wiring connections, then disconnect wires.

5. Install replacement Fan(s) by reversing the above steps, noting the following:

a. Piggyback tabs face outside. b. Label faces inside unit. c. Orientate Fan so that Air Flow/Rotation La-

bel molded into the Fan Housing is positioned as shown in the following illustration.

L. Pilot Panel Fan (M1 - M4) Replacement

11. Note orientation of Main Transformer Assembly , then remove four lock nuts securing T ransformer to the center chassis.

12. Install the replacement T ransformer Assembly by reversing the above procedure, keeping in mind the following:

• Reservoir Panel must seat in corresponding

center chassis slots.

• The four screws securing the output inductor

mounting plate to the center chassis should have a maximum of 2 to 5 threads protruding through the left side of the chassis.

There are four Fans mounted to the Pilot Fan Panel. Replacement instructions are the same for all Fans.

NOTE

1. Remove Front Panel per Section 5.04-E.

2. Remove the two screws securing the Fan to the two tabs on the Pilot Fan Panel.

3. Turn the fan sideways and pull gently out of unit to where the wires can be disconnected.

M. Current Sense PC Board Assembly

Replacement

1. Remove the Work Cable per Section 5.04-C.

2. Disconnect the ribbon cable from the Current Sensor at J17 on the Logic PC Board.

3. Remove the Sensor by prying off standoffs at the rear of the Bulkhead, behind the Work Cable Strain Relief.

4. Install the replacement Current Sensor PC Board by reversing the above procedure.

REPLACEMENT PROCEDURES 5-12 Manual 0-2728

N. CD Coil Assembly (T4) Replacement

NOTE

Prior to removal, note the location and orientation of the CD Coil Assembly and all its connections.

1. Remove the Left and Right Side Panels per Section 5.04-A.

2. Remove the Top Panel per Section 5.04-C.

3. Disconnect the coolant hose from the fitting at the end of the bulkhead adapter .

4. Drain coolant from hose into bucket.

5. Remove the first nut and washer from the bulkhead adapter .

6. Disconnect CD Coil Leads at E1 & E2 on the CD PC Board.

7. Disconnect stiff CD Coil Wire from PS(-) on Pilot Output Board.

8. Remove two screws in Ferrite U-Core attaching it to the bulkhead chassis and remove CD Coil Assembly from unit.

9. Install the replacement CD Coil Assembly by reversing the above procedure.

5.08 Base Parts Replacement

Screws

Axle

A-02307

Washer

Wheel

Retaining Ring

B. Support Leg(s) Assembly Replacement

NOTE

Both support leg assemblies are removed and replaced in a similar manner .

1. Raise the unit off the floor far enough for the weight of the unit to be removed from the support legs.

A. Wheel/Axle Assembly Replacement

• Wheel Replacement

NOTE

Both Wheels are removed and replaced in the same manner.

1. Raise the unit off the floor far enough for the weight of the unit to be removed from the axle and wheels.

2. For the wheel to be replaced, remove retaining ring, washer, wheel and second washer from end of axle.

3. Install the replacement wheel(s) by reversing above procedure.

• Axle Replacement

1. Raise the unit off the floor far enough for the weight of the unit to be removed from the axle and wheels.

2. Remove both wheels from the axle.

3. Slide the faulty axle out of base.

2. Remove two screws securing support leg to front of base.

3. Install replacement support leg by reversing above step.

C. Auxilliary T ransformer Assembly (T3)

Replacement

NOTE

All Auxilliary T ransformer Assembly replacements incorporate two fuses. Replacement fuses can be found in the Torch Spare Parts Kit.

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

2. Note orientation of all the wires connected to the Auxilliary T ransformer Assembly.

3. Disconnect wires.

4. Remove the four flat washers and nuts securing the Auxilliary T ransformer to the four base studs.

5. Remove Transformer from unit.

6. Install replacement Transformer by r eversing the steps above.

4. Install the replacement axle by reversing above procedure.

Manual 0-2728 5-13 REPLACEMENT PROCEDURES

D. Main Contactor Assembly (W) Replacement

NOTE

The Main Contactor was located in the Base on earlier units and on the Center Chassis for current units.

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

2. Note orientation of the Main Contactor and location of all wires and cables connected to the Contactor Assembly .

3. Disconnect wires and cables at Main Contactor.

4. Remove the two nuts securing the Contactor Assembly to the two mounting studs in the unit.

5. Install the replacement Main Contactor Assembly by reversing the above steps, connecting wires as follows:

c. Attach the main harness wires #4 & #5 to the

inner prong of L1 & L2 respectively of the main contactor .

d. Connect cables 1, 2, and 3 to T1, T2, and T3

respectively.

E. Motor (M5) / Fan / Pump Replacement

The simplest way to replace the Motor is to remove the Motor, Fan and Pump together, then replace the Motor. The procedure below describes how to remove the Motor/Fan Pump Assembly to replace the Motor . To replace the Fan, continue with the procedures outlined in Section 5.08-F , Fan Assembly Only Replacement. To replace the Pump, follow the procedures outlined in Section 5.08G, Pump Assembly Replacement.

1. Remove the Right Panel per Section 5.04-A.

2. Disconnect the following:

a. Connect ground wire as shown.

2-Brass Nuts

3-Star Washers

A-02291

Input Board Ground

Main Harness Ground

Side Panel Ground

b. Attach main harness wires #55 and #59 to the

coil of the Contactor .

Main Contactor

(MC1)

Coil

Wire #55

NOTE

Coolant may drain from the hoses. It is recommended that a bucket, rags or towels be placed below the hose prior to removing.

a. Radiator to In-Line Filter Hose - disconnect

at Filter .

b. Radiator to Torch Hose - disconnect at Bulk-

head.

c. Pump to Coolant Filter Hose - disconnect at

Pump. d. Pump to Torch Hose - disconnect at Bulkhead. e. Remove tie wraps as necessary.

3. Note connection of all wires to Motor then disconnect wires.

4. Remove four nuts and washers securing the Motor Mount to the base, and remove Motor/Pump/ Fan Assembly .

5. Replace Fan and Pump per procedures in Sections

5.09-F and 5.09-G respectively, if required.

6. Install the replacement Motor with pump and fan by reversing the above procedure (see NOTE).

Coil

Wire #59

A-02453

REPLACEMENT PROCEDURES 5-14 Manual 0-2728

NOTE

Before installing the replacement Motor , check that the internal wiring of the Motor is set for the proper input voltage per the information on the Motor nameplate.

F. Fan Assembly Only Replacement

1. Remove Motor/Fan/Pump Assembly from unit per procedure in 5.09-E.

2. Loosen the fan locking screw securing the Fan to the Motor Assembly shaft and remove the Fan.

b. Install check valve with the flow marking to-

wards the bottom (as shown above).

c. Use thread sealant on all pipe threads (Loctite

thread sealant #565, or equivalent).

7. Refill Coolant Reservoir.

3. Install replacement Fan by reversing the above steps, noting the following:

a. The fan locking screw is facing the motor and

aligned with flat of shaft. The motor assembly shaft must be flush with the front part of the Fan Bushing.

b. Apply loctite to the fan screw before tighten-

ing.

G. Pump Assembly Replacement

1. Remove the Motor/Fan/Pump Assembly per procedure in 5.09-E.

2. Loosen the Pump Clamp securing the Pump Assembly to the Motor Assembly.

3. Note the orientation of the Pump Assembly to the Motor Assembly .

4. Pull the Pump Assembly from the Motor Assembly.

5. Disassemble the Pump Assembly in the sequence shown below , beginning with #1:

8. Connect primary power and turn on unit.

H. Radiator Assembly Replacement

NOTE

The Front Panel, Right Side Panel and Motor/ Fan/Pump Assembly must be removed first in order to remove the Radiator.

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

2. Remove the Front Panel per Section 5.04-E.

3. Remove the Motor/Fan/Pump Assembly per Section 5.08-E.

4. Carefully disconnect Thermal Switch (solid state) near the inlet port and slide it out through hole in mounting bracket. Remove ties as required.

5. Remove (6) screws securing Radiator to frame.

6. Install the replacement Radiator by reversing the above procedure.

I. Thermal Switch (TS1) Replacement

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

To Coolant Filter

To Bulkhead

Pump

A-02286

6. Install the replacement Pump Assembly by r eversing the above steps, noting the following:

a. Proper orientation of the Pump Assembly to

the Motor Assembly.

2. Locate the Radiator and carefully disconnect the Thermostat Switch (solid state) near the inlet port and slide out through hole in mounting bracket. Remove ties as required.

3. Install the replacement Thermal Switch by reversing the above procedure.

Manual 0-2728 5-15 REPLACEMENT PROCEDURES

5.09 Rear Panel Parts Replacement

NOTE

Refer to Section 6.08 for parts list and overall detail drawing.

A. Handle Replacement

1. Remove the four hex head screws securing the handle to the Rear Panel of the unit.

2. Remove the Handle from the Rear Panel.

3. To install the replacement Handle, reverse the above procedure.

B. Rear Panel Replacement

1. Remove the Left and Right Side Panels per Section 5.04-A.

2. Remove the Top Panel per Section 5.04-B.

3. Remove the two Regulators on the Rear Panel by completing the following:

a. Disconnect the air line hose connected to the

Solenoid/Pressure Switch Assembly.

b. Disconnect the air line hose connected to the

Solenoid Assembly .

c. Note the location of two blue wires connected

to the Solenoid Assembly (secondary) and four blue wires connected to the Solenoid/ Pressure Switch Assembly (plasma). (Refer to Figure below).

g. Remove the four screws securing each Regu-

lator to the rear panel and remove Regulators.

4. The EMC Filter Assembly must be removed from the Rear Panel as follows:

a. Loosen the two screws holding the strain re-

lief to the input power cable.

b. Remove the six screws securing the EMC Fil-

ter Assembly Cover to the Filter Assembly.

Strain Relief

EMC Filter Cover

A-02388

EMC Filter Panel

c. Slide the Filter Cover and Strain Relief back

along the input power cable to gain access to the inside of the Filter Assembly.

d. Disconnect the following input power wires

from inside the Power Supply:

• L1, L2 & L3 at Main Contactor.

• Ground wire connection at frame.

Secondary Gas

Blue Wires

Gas Tubing

Blue Wires

Pressure Switch

Solenoid

Brass Nipple

A-02298

Brass Nipple

"L" Fitting

Gas T ubing

Plasma Gas

d. Disconnect wires. e. Note Solenoid orientation then remove the So-

lenoid Assembly from the two inch long brass nipple and set assembly aside.

f. Note Solenoid/Pressure Switch orientation,

then remove the Solenoid/Pressur e Switch Assembly from the two inch brass nipple, and set aside.

e. Remove the four nuts and washers securing

the EMC Filter Assembly to the Rear Panel.

f. Carefully remove the EMC Filter Assembly

from the Rear Panel and set aside.

5. Remove reservoir cap from the reservoir.

6. Remove the Rear Panel from unit by completing the following:

a. Remove the two screws on near bottom of rear

panel securing the panel to the base of the unit.

b. Remove the two nuts and washers on the in-

side of rear panel connecting the panel to the center chassis.

c. Remove screw located in the center of the rear

panel securing the rear panel to the frame.

d. Carefully lift the rear panel up, over the reser-

voir, and away from the power supply.

REPLACEMENT PROCEDURES 5-16 Manual 0-2728

7. To install replacement rear panel, reverse the above procedure.

C. Pressure Switch (PS1) Replacement

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

2. Disconnect the two wires connected to the Pressure Switch Assembly (see Figur e below).

3. Remove the Pressure Switch Assembly from the T-fitting.

4. Remove the Pressure Switch, if applicable.

5. Note the orientation of the Solenoid V alve Assembly then remove the Solenoid(s) from the two inch brass regulator fitting(s).

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

E. Air Line Regulator Bracket(s) Replacement

NOTE

4. Install the replacement Pressure Switch Assembly by reversing the above procedur e, keeping in mind the following:

• Apply pipe thread sealant to the fitting before

reassembling.

D. Solenoid Valve (SOL1 & SOL2)

Replacement

NOTE

There are two Solenoid Valve Assemblies in this unit: one for plasma gas and one for secondary gas (as labeled on rear panel). The Solenoid Assembly for secondary gas has a Pressure Switch which must be removed prior to removing the Solenoid. Following the instructions as they pertain to the Solenoid V alve being r eplaced.

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

2. Locate the Solenoid Assembly to be replaced.

There are two Air Line Regulator Brackets in this unit and both are replaced using this same procedure.

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

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

3. Remove bracket from unit.

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

F. Air Line Regulator(s) Replacement

NOTE

This unit has two Air Line Regulators - one for plasma gas and one for secondary gas. This procedure applies to both Regulators.

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

2. Disconnect the gas input hose from the inert B fitting input located on the right side of the Air Line Regulator Assembly.

Secondary Gas

Blue Wires

Gas Tubing

Solenoid

Brass Nipple

Blue Wires

Pressure Switch

A-02298

Brass Nipple

"L" Fitting

Gas T ubing

Gas Pressure Regulator Filter Assemblies

Gas Input

Plasma Gas

3. Note the location of all wires, then complete the following:

a. Disconnect the gas tubing at the solenoid

fitting(s).

A-02327

b. Disconnect blue wires.

Manual 0-2728 5-17 REPLACEMENT PROCEDURES

Input Hoses

3. Remove the four screws securing the Regulator to the Rear Panel.

4. Pull the Air Line Regulator away from the Rear Panel far enough to disconnect the plumbing joint between the Reducer and Elbow Fitting.

5. Remove the Regulator from the 2 inch brass nipple connected to the Solenoid Assembly.

6. Remove the elbow fitting from the old assembly .

7. Install the replacement Air Line Regulator Assembly by reversing the above procedure, keeping in mind the following:

• Apply pipe thread sealant to the fitting before

reassembling.

G. EMC Filter Replacement

1. Remove the Left Side Panel of the Power Supply per Section 5.04-A.

2. Loosen the two screws holding the strain relief to the input power cable.

3. Remove the six screws securing the EMC Filter Assembly Cover to the Filter Assembly.

EMC Filter

Nomex Shield

EMC Filter Base

EMC Filter Panel

A-02389

8. Note the location of the four wires connected to the bottom of the EMC Filter Assembly. Disconnect the four wires from the Filter Assembly.

9. From inside the Power Supply remove the four screws securing the Filter Assembly to the EMC Filter Base. There are four clearance holes in the Rear Panel that allow access to these screws.

Strain Relief

EMC Filter Cover

A-02388

EMC Filter Panel

4. Slide the Filter Cover and Strain Relief back along the input power cable to gain access to the inside of the Filter Assembly.

5. Remove the five screws securing the Filter Side Panel to the EMC Filter Assembly and remove the panel. This will make it easier to remove wiring.

6. Note how the nomex shield is installed around the Filter Assembly, then unwrap the shield from around the Filter Assembly.

7. Note the location of the four wires connected to the top of the EMC Filter Assembly. Disconnect the four wires from the Filter Assembly.

Filter Base

EMC Filter

A-02390

Nomex Shield

Rear Panel

10. Install the replacement EMC Filter Assembly by reversing the above procedure, noting the following:

• Wrap the nomex shield around the Filter As-

sembly , overlapping the edges away fr om the Rear Panel of the Power Supply.

• The nomex shield must extend above and be-

low the EMC Filter so that the wiring connections are covered.

• All wiring connections must be secure.

NOTE

REPLACEMENT PROCEDURES 5-18 Manual 0-2728

The shield paper must cover the wire connections at both ends of the EMC Filter to prevent possible arcing between the Filter and the sheet metal.

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts lists provide a breakdown of all replaceable components. Parts Lists are organized as follows:

Section 6.03 Major External Replacement Parts Section 6.04 Access Panel Replacement Parts Section 6.05 Left Side Center Chassis Replacement

Parts

Section 6.06 Right Side Center Chassis Replacement

Parts Section 6.07 Base Component Replacement Parts Section 6.08 Rear Panel Replacement 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.

C. Product Improvements

Improvements to the product since r elease is denoted by a revision letter(s) located on the data tag of the unit. There are old style and new style data tags that may be encounted. The old style data tag has the revision letter(s) at the end of the serial number. The new style data tag has the revision letter(s) in an area marked 'Rev'. The parts lists may include references to the revision letter(s) for parts that are different between revisions.

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. Addr ess all inquiries to your authorized distributor .

Manual 0-2728 6-1 P A RTS LISTS

6.03 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Right Side Panel With Labels 9-7819 2 1 Left Side Panel With Labels 9-7818 3 1 Front Panel With Labels 9-7816 4 1 Rear Panel 9-7820 5 1 T op Panel

Top Panel for Units Revision I or earlier 9-7817 Top Panel for Units Revision J or later 9-7797

6 1 Access Panel With Labels & Scr ews

Access Panel for Units Revision AQ or earlier 9-7821

Access Panel for Units Revision AR or later 9-9034 7 1 Cable, Work, 20 ft (6.1 m) #4 AWG With Clamp 9-2783 8 1 Boot, Rubber 9-4210

The following is not shown:

1 Torch Coolant – 1 Gallon (3.87 Liters)

Standard 25/75 Mix for Ambient Temperatures to +10°F (-12°C) 7-2850

Super 50/50 Mix for Ambient Temperatures to -34°F (-36°C) 7-2959

A-03059

P AR TS LISTS 6-2 Man ual 0-2728

6.04 Access Panel Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Assembly, POT/LED PCB

Pot/LED Assembly for Units Revision H or earlier 9-7014

Pot/LED Assembly for Units Revision I or later 9-8004 2 1 RUN/SET Switch, SPST SW2 9-1042 3 1 ON/OFF Switch, DPST SW1 8-3258 4 1 Knob, CURRENT Control W ith Foam Seal 9-8007 5 2 DZUS Stud 9-4346 6 2 DZUS Retaining Ring 9-4347 7 1 Pot Protection Kit includes: 7-7575

2 Handles 2 Screws 2 Star W ashers

8 1 ST ANDARD/LATCH Switch (Units Revision A V or Later) SW3 9-1042

A-02256

Manual 0-2728 6-3 P A RTS LISTS

6.05 Left Side Center Chassis Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Fuse Block, 9-5562 2 1 Fuse, 5 AMP, 600V, Delay F1 10-2274 3 1 Input PC Board Assembly 9-7813 4 1 Bridge Rectifier Assembly, 110A 3PH 9-7824

1 Bridge Rectifier, 110A 3PH 9-7800

1 Thermal Pad, QIII, Input Module 5 1 Thermostat, Closes @ 80° C Rising TS2 9-7895 6 1 Contactor , 4 Pole, 40 FLA, 120 VAC (In-Rush Contactor) INR 9-7507 7 1 Logic PC Board Assembly 9-7812 8 2 Gate Drive PC Board Assembly 9-7811 9 1 FET/Heatsink Assembly Kit, Includes: 9-7015

2 FET/Heatsink Assembly

10 1 Main Contactor (Location on current units) W 9-1244

Refer to Section 6.07 for location on earlier units

The following parts are not shown:

1 Cable Assembly, 10 Circuit Ribbon, 15 inches (381 mm) Long 9-5922

1 Cable Assembly, 3 Circuit 9-7509

1 Cable Assembly, 20 Circuit Ribbon, 20 inches (508 mm) Long 9-7804

P AR TS LISTS 6-4 Man ual 0-2728

Manual 0-2728 6-5 P A RTS LISTS

A-02580

6.06 Right Side Center Chassis Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Pilot/Output PC Board Assembly 9-7809 2 1 Relay, DPST, 25A Max, 120 VAC (Coolant Motor Relay) MC1 8-3390 3 2 Resistor R1,R2 9-5843 4 1 Inductor , Pilot L3 9-7801 5 1 CD PC Board Assembly 9-7814 6 1 Coolant Filter 8-4276 7 1 Coolant Reservoir 9-5948 8 1 Filter , In-Line, Female 8-3460 9 1 Flow Switch Assembly, 0.2 GPM FS1 9-5937

10 2 Main Transformer T1, T2 9-7810 11 1 Output Inductor Assembly L1 9-7815 12 4 Fan, 115VAC, 50/60Hz, 95/115CFM W/0.187 Tabs M1-M4 8-3209 13 1 Assembly , Current Sense PC Board 9-7602 14 1 Hose, Filter To Pump 9-7805 15 1 Hose, Radiator To Small Filter 9-7807 16 1 Hose, Reservoir To Filter 9-7808 17 1 Assembly , CD Coil T4 9-7825 18 1 Deionizer Bag 8-3312 19 1 Deionizer Basket 8-4410 20 1 Cap, Coolant Ta nk 8-5142 21 1 Output Inductor Assembly L2 9-7872

P AR TS LISTS 6-6 Man ual 0-2728

10 11

NOTE: Parts may differ slightly from illustration

Manual 0-2728 6-7 P A RTS LISTS

A-02275

6.07 Base Replacement Parts

Item # Qty Description Ref Catalog #

1 2 Wheel 8-5579 2 1 Axle 9-7891 3 2 Support Leg 9-7892 4 1 T ransformer, Auxiliary (220,395,460) T3 9-7802

2 Fuse, 5A, 250V Delay MDL-5 (in Torch Spare Parts Kit) 9-8109 5 1 Main Contactor (Location on earlier units) W 9-1244

Refer to Section 6.05 for location on current units 6 1 Fan, Medium Pressure, 8 inch (203 mm) Diameter 9-7893 7 1 Motor, 1/3 HP, 1425/1725 RPM, 115/230 V, 50/60 Hz M5 9-5932A 8 1 Pump 9-6164 9 1 Radiator Assembly (Includes 6 Grommets) 9-5941

10 1 Hose, T orch Disconnect To Radiator 9-7806 11 2 Foot, Rubber 9-7894 12 1 #6 JIC-3/8 NPT STR Adapter 8-0348 13 1 #6 JIC-3/8 NPT x 90° Adapter 9-3077 14 1 3/8 NPT Close Nipple 9-2384 15 1 3/8 NPT Hex Head Plug 9-4583 16 1 3/8 NPT Female Tee 9-2385 17 1 3/8 NPT Street Elbow 9-2365 18 1 3/8 NPT Close Nipple 9-2384 19 1 Valve, Check 3/8 NPT Female, Brass 9-1402 20 1 Thermal Switch TS1 9-5967 21 1 Clamp, Pump V-Brand 9-5942

P AR TS LISTS 6-8 Man ual 0-2728

23x4274

13 14

19 18

A-02278

Manual 0-2728 6-9 P A RTS LISTS

6.08 Rear Panel Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Handle With Screws 9-7822 2 1 Pressure Switch, 35 psi (2.4 bar) PS1 9-1044 3 2 Valve, Solenoid 1/8 NPT SOL1, SOL2 8-3370 4 2 Air Regulator/Filter Assembly

Air Line Regulator 9-7514 Pressure Gauge 9-1045 Panel Mounting Nut 9-5804

Bracket, Regulator Mounting 9-7589 5 2 Hose 9-3743 6 1 1/4 NPT Female Tee 9-2034 7 1 One Touch, 90°, 1/8 NPT 9-2391 8 2 Fitting 1/8 NPT x 2' Long Nipple, Brass 9-7524 9 2 1/4 - 1/8 NPT Reducer 9-2023

10 2 1/4 NPT Street Elbow 9-2184 11 2 Nipple, Close, 1/4 NPT - 1/4 NPT 9-2186 12 2 1/4 NPT Female Elbow 9-4595 13 1 Fitting 1/8 NPT x 1/4 Tube Str 8-3360 14 2 Fitting, Adapter, 1/4NPT - Inert B, Right Hand 8-0330 15 1 Rubber Grommet 8-4238 16 1 Cover, CE 9-7923 17 1 Base 9-7920 18 1 Filter, EMC 9-7922 19 1 Panel 9-7919 20 1 Strain Relief 9-3164 21 1 Shield, Nomex 9-7921

The following parts are not shown:

1 Wir es, Interconnect, CE, (3 Wires) 9-7924 1 #6 Ground Wire 9-7925 1 Power Cable, CE 9-7890

P AR TS LISTS 6-10 Manual 0-2728

A-02387

Manual 0-2728 6-11 P A RTS LISTS

6.09 Options and Accessories

Qty Description Catalog #

1 Two Stage Air Line Filter Kit 7-7502

Replacement Elements 1 First Stage 9-1021 1 Second Stage 9-1022 1 Mounting Bracket 9-7535

CNC Interface Control Cable - Used W ith Shielded PCM Machine Torch 1 25 ft (7.6 m) 8-5557 1 50 ft (15.2 m) 8-5558

1 "Y" Hose Assembly Kit 9-7827 1 Locking Caster Kit (2 Casters) 9-7868 1 Remote Pendant Control - 20 ft (6.1 m) - Used With Unshielded 7-3460

PCM Machine Torch

P AR TS LISTS 6-12 Manual 0-2728

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Power Input Current Suggested Sizes (See N ote s )

Volta g e Freq . 3-Ph 3-Ph Fuse (A m p s )

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

380 50/60 29.0 44 60 10 415 50/60 29.5 41 60 10

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadia n Electrical Code

Wire (mm

)

NOTES

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 0-2728 A-1 APPENDIX

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK

DIAGRAM)

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch

RESULT

Gas flows (2 seconds).

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8

seconds then steady on.

Fans on.

Power circuit ready.

gas flows to set pressure.

PILOT ARC

ACTION

RUN/SET switch

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

STANDARD/LATCH

switch to STANDARD

ACTION

STANDARD/LATCH

switch to LATCH

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

RUN/SET switch

to RUN.

RESULT

Gas flow stops.

GAS indicator off.

After gas pre-flow:

DC indicator on.

Pilot arc established

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.

A-03050

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

Torch Switch released.

RESULT

Transfer will continue

until torch is removed

from workpiece.

ACTION

Open external

disconnect.

RESULT

No power to system.

APPENDIX A-2 Manual 0-2728

APPENDIX 3: POT/LED PC BOARD LAYOUT

J14

A-01206

Pot/LED PC Board Signals

J14-1 +10 vdc from Logic PC Board (J3-7) - Potentiometer High J14-2 Current Control to Logic PC Board (J3-8) - Potentiometer Wiper J14-3 Return for Current Control from Logic PC Board (J3-9) - Potentiometer Low J14-4 +12 vdc from Logic PC Board (J3-10) J14-5 Signal for AC OK Indicator to Logic PC Board (J3-11) J14-6 Signal for GAS Indicator to Logic PC Board (J3-12) J14-7 Signal for TEMP Indicator to Logic PC Board (J3-13) J14-8 Signal for DC Indicator to Logic 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 0-2728 A-3 APPENDIX

APPENDIX 4: LOGIC PC BOARD LAYOUT

J99

D36

D65

TP1 (Ground)

D47

J96

J17

Logic PC Board

D31

Logic PC Board Signals

J1-1 36 V AC from Auxiliary T ransformer J1-2 115 VAC from Auxiliary Transformer J1-3 Center Tap from Auxiliary T ransformer J1-4 Not Used J1-5 36 V AC from Auxiliary T ransformer J1-6 115 VAC Return from Auxiliary T ransformer

J2-1 115 VAC Return to Main Contactor J2-2 115 VAC Return to Plasma Solenoid J2-3 Not Used J2-4 115 VAC to Main Contactor J2-5 Not Used J2-6 115 VAC to Secondary Solenoid J2-7 Not Used J2-8 Not Used J2-9 Pressure Switch +12 vdc Signal J2-10 Pressure Switch Return

D26

D25

J2-11 Over Temp Sw . (Input Bridge, Pilot Bd, Radiator) 12V J2-12 Over Temp Sw. (Input Bridge, Pilot Bd, Radiator) Return J2-13 Not Used J2-14 Not Used J2-15 Not Used J2-16 Not Used

J3-1 36 VAC to ON/OFF Switch J3-2 36 VAC from ON/OFF Switch J3-3 36 VAC to ON/OFF Switch J3-4 36 VAC from ON/OFF Switch J3-5 RUN/SET Switch on Front Panel +12V signal J3-6 RUN/SET Switch on Front Panel Return J3-7 Main Current Control Signal (High) +10 vdc J3-8 Main Current Control Pot (Wiper) J3-9 Main Current Control Pot (Low)

A-02310

APPENDIX A-4 Manual 0-2728

J3-10 +12 vdc J3-11 Active Low Signal for AC Indicator on Front Panel (J14-5) J3-12 Active Low Signal for GAS Indicator on Front Panel (J14-6) J3-13 Active Low Signal for TEMP Indicator on Front Panel (J14-7) J3-14 Active Low Signal for DC Indicator on Front Panel (J14-8) J3-15 Not Used J3-16 Not Used

J4-1 36 V AC (b) from Gate Driver PC Board (J9-1) J4-2 36 VAC (a) to Gate Drive PC Board (J9-2) J4-3 36 VAC (a) from Gate Drive PC Board (J9-3) J4-4 36 VAC (b) to Gate Drive PC Board (J9-4) J4-5 36 V AC CT Return/PC Board Common J4-6 Transfer Mod Enable Return J4-7 36 V AC CT Return/PC Board Common J4-8 Active Low Transfer Mod Enable Signal J4-9 Return for Temp Switch J4-10 Active Low Over Temp Signal J4-11 Return for Master Enable Signal J4-12 Active Low Master Enable Signal J4-13 Return for Pilot Enable J4-14 Active Low Pilot Enable Signal J4-15 Return for PSR Signal J4-16 Active Low PSR Signal J4-17 Return for Demand Signal J4-18 Demand Signal J4-19 Return for Demand Signal

J5-1 36 V AC (b) to CD PC Board J5-2 36 VAC CT Return to CD PC Board J5-3 36 VAC (a) to CD PC Board J5-4 Active Low CD Enable Signal J5-5 CD Enable Return J5-6 Active Low Pilot Signal to Pilot/Output Board J5-7 Pilot Signal Return J5-8 Active Low Torch Switch Signal J5-9 Tor ch Switch Return J5-10 Active Low Torch Sw Signal to LATCH Sw J5-11 Not Used J5-12 PS+ J5-13 Not Used J5-14 Drag Sensing Signal Voltage (Tip Volts +) J5-15 Not Used J5-16 PSJ5-17 36 VAC (a) to Pilot Output Board J5-18 36 VAC (b) to Pilot Output Board J5-19 36 VAC CT Return to Pilot/Output Board (Opt Remote) J5-20 Active Low ENABLE Signal J5-21 Return for Optional Remote Enable Jumper

J95-1 Not Used J95-2 Not Used

J96-1 115VAC to Fans M3 & M4 J96-2 115VAC to Fans M1 & M2 J96-3 115VAC Fan Rtn for M3 & M4 J96-4 115VAC Fan Rtn for M1 & M2

J17-1 Not Used J17-2 Not Used J17-3 115 VAC to Plasma Solenoid J17-4 115 VAC to Inrush Cont J17-5 115 VAC to Motor Cont J17-6 Not Used J17-7 115 VAC Return Sec. Solenoid J17-8 115 VAC Return Inrush Cont J17-9 115 VAC Return Motor Cont J17-10 Not Used J17-11 OK-To-Move (Isolated Contact Closure) J17-12 OK-To-Move (Isolated Contact Closure)

J99-1 Active Low Coolant Flow Switch Signal J99-2 Not Used J99-3 Coolant Flow Switch Return J99-4 Not Used J99-5 Active Low Torch Sw Signal from LATCH Sw J99-6 Active Low

CSR Signal From Current Sense Board J99-7 Return J99-8

+12 vdc

TP1 Logic Ground TP2 +18 vdc - Unregulated TP3 +18 vdc - Unregulated TP4 +10 vdc TP5 Demand Signal to Gate PC Board TP6 +12 vdc TP7 Drag CRT TP8 (-) DC Sense TP9 Active Low PSR Signal TP10 Active Low CSR Signal TP11 Current Control Demand (Pot Wiper)

D26 T or ch Switch Enable Indicator D25 CD Enable Indicator D65 CSR Indicator D47 AC OK Indicator D31 Drag On Indicator

Manual 0-2728 A-5 APPENDIX

APPENDIX 5: GATE DRIVE PC BOARD LAYOUT

J10

TP4

TP5

TP6

TP13

TP8

D20

TP9

J11 J9

TP15TP16

TP3

TP1

TP11

TP12

TP2

TP10

TP7

Gate Drive PC Board Signals

J7-1 +12 vdc to FET PC Boards (J6-1) J7-2 Return for +12 vdc to FET PC Boards (J6-2) J7-3 PWM Output (A) to FET PC Boards (J6-3) J7-4 PWM Return to FET PC Boards (J6-4)

Gate Drive PC Board

J7-5 Primary Current Sense from FET PC Boards (J6-5) J7-6 Primary Current Sense Return from FET PC Boards (J6-6) J7-7 Secondary Current Sense from FET PC Boards (J6-7) J7-8 Secondary Current Sense Return from FET PC Boards (J6-8) J7-9 Over Temperatur e Sense fr om FET PC Boards (J6-9) J7-10 Over Temperature Sense from FET PC Boards (J6-10)

J8-1 +12 vdc to FET PC Boards (J6-1) J8-2 Return for +12 vdc to FET PC Boards (J6-2) J8-3 PWM Output (B) to FET PC Boards (J6-3) J8-4 PWM Return to FET PC Boards (J6-4) J8-5 Primary Current Sense from FET PC Boards (J6-5) J8-6 Primary Current Sense Return from FET PC Boards (J6-6) J8-7 Secondary Current Sense from FET PC Boards (J6-7) J8-8 Secondary Current Sense Return from FET PC Boards (J6-8) J8-9 Over Temperatur e Sense fr om FET PC Boards (J6-9) J8-10 Over Temperature Sense from FET PC Boards (J6-10)

TP14

A-02323

APPENDIX A-6 Manual 0-2728

J9-1 36 VAC (b) from Logic PC Board (J4-1) J9-2 36 VAC (a) from Logic PC Board (J4-2) J9-3 36 VAC (a) from Logic PC Board (J4-3) J9-4 36 VAC (b) from Logic PC Board (J4-4) J9-5 36 VAC CT Return from Logic PC Board (J4-5) J9-6 Return for Transfer Mod Enable J9-7 36 VAC CT Return from Logic PC Board (J4-7) J9-8 Active Low Transfer Mod Enable Signal J9-9 Active Low Over Temperature Sense from FET PC Boards to Logic PC Board (J4-9) J9-10 Over Temperature Sense from FET PC Boar ds to Logic PC Board (J4-10) J9-11 Return for Master Enable Signal to Logic PC Board (J4-1 1) J9-12 Active Low Master Enable Signal from Logic PC Board (J4-12) J9-13 Return for Pilot Enable Signal to Logic PC Board (J4-13) J9-14 Active Low Pilot Enable Signal from Logic PC Board (J4-14) J9-15 Return for PSR Signal from Logic PC Board (J4-15) J9-16 Active Low PSR Signal to Logic PC Board (J4-16) J9-17 Return for Demand Signal to Logic PC Board (J4-17) J9-18 Demand Signal from Logic PC Board (J4-18) J9-19 Return for Demand Signal from Logic PC Board (J4-19) J9-20 Not Used

TP1 Logic Ground TP2 +12 vdc TP3 Active Low T ransfer Mod Enable Signal TP4 +5 vdc TP5 PWM Signal (B) TP6 PWM Signal (A) TP7 Secondary Current Sense TP8 Primary Current Sense TP9 Active Low Reset Signal TP10 +6 vdc TP11 Current Demand Signal TP12 Active Low Shutdown Signal TP13 Return for Secondary Current Sense TP14 -12 vdc TP15 Active Low Pilot Enable Signal TP16 Active Low Master Enable Signal

D4 Power Enable Indicator D20 Reset Indicator

Manual 0-2728 A-7 APPENDIX

APPENDIX 6: PILOT/OUTPUT PC BOARD LAYOUT AND

WIRING CONNECTION DIAGRAM

Pilot/Output PC Board

TP4

TP5

TP8

TP2 TP6

TP3

TP1

J13

TP7

Pilot Output PC Board Signals

J12-1 Torch Switch from J22-3 Torch Control J12-2 Shield to J22-1 J12-3 Torch Switch from J22-4 Torch Control J12-4 Shield to J22-2 J12-5 Not Used J12-6 Not Used J12-7 OK-To-Move To J22-12 (Isolated Contacts from Logic PC Board) J12-8 OK-To-Move To J22-14 (Isolated Contacts from Logic PC Board) J12-9 Enable Jumper J12-10 Not Used J12-11 Enable Jumper J12-12 Not Used J12-13 Not Used J12-14 Return to J22-8 J12-15 Not Used J12-16 Not Used

A-02311

J12

APPENDIX A-8 Manual 0-2728

J13-1 Active Low Start signal (Torch Switch) J13-2 T or ch Switch Return J13-3 OK-To-Move (Isolated Contacts from Logic PC Board) J13-4 OK-To-Move (Isolated Contacts from Logic PC Board) J13-5 Ground J13-6 Not Used J13-7 Drag Voltage Sensing (T ip Voltage) J13-8 Not Used J13-9 PS(-) Voltage Sensing J13-10 Not Used J13-11 Enable Jumper J13-12 Enable Jumper J13-13 Not Used J13-14 36 V AC (a) from Logic PC Board J13-15 36 VAC (b) from Logic PC Board J13-16 36 V AC CT Common J13-17 Return for Pilot Signal J13-18 Active Low Pilot Signal J13-19 Not Used J13-20 Active Low Overtemp Signal J13-21 Return for Overtemp Signal J13-22 Active Low CSR Sense Signal J98-1 J13-23 Return for CSR Sense Signal J98-2 J13-24 +12 vdc to Current Sense Board J98-3

TP1 Ground TP2 +15 vdc TP3 Pilot Switch to Gate Drive PC Board TP4 Pilot Drive Signal TP5 Not Used TP6 Active Low Pilot Drive Signal TP7 Not Used TP8 Pilot Switch to Gate Drive PC Board

D5 Pilot ON Indicator

Wire #13 To Resistors

Jumper Wire

Stiff CD Coil Wire

Output Inductor Lead

Wire #17 (Black)

Wrapped Around Wire #15

Wire From Transformer

Wire #14 To Resistors

Ground (Green) Wire

Wire #15 (Red) From Bulkhead

Wire From Transformer

Wire #17 (Black)

Wrapped Around Wire #15

Twisted 3-Wire Harness

From Current Sensor PCB

A-02558

Manual 0-2728 A-9 APPENDIX

J13

Work Cable

J12

4-Wires #12 (Red)

From FET/Heatsink

Assemblies

APPENDIX 7: CD PC BOARD LAYOUT

TP1TP2

J11-1

J11-3

J11-4

J11-5

J11

A-01208

E2 E1

CD PC Board Signals

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

TP3

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

E1 CD output E2 CD Output

APPENDIX A-10 Manual 0-2728

APPENDIX 8: INPUT PC BOARD LAYOUT

Component Side of PC Board

LT1

Solder Side of PC Board

(-)

(+)

CGND

A-02313

Input PC Board

A AC Input (L1) B AC Input (L2) C AC Input (L3) (-) Rectifier (-) Output (-) Rectifier (-) Output (+) Rectifier (+) Output LT1 Power ON Indicator

E1 Rectifier (+) Output to INR E2 Rectifier (+) Output to INR E3 Rectifier (-) Output to Capacitor PC Boards (A & C) E4 Rectifier (-) Output to Capacitor PC Boards (A & C) E5 AC Input (L1) for LT1 E6 AC Input (L2) for LT1 E7 Rectifier (+) from INR E8 Rectifier (+) to Capacitor PC Boards (B & D)

CGND Chassis Ground

ABC

Manual 0-2728 A-11 APPENDIX

APPENDIX 9: FET PC BOARD LAYOUT

E14

Component Side Of PC Board

E15

E16

E17

E19

E18

E19

E17

E18

E19

XFMR SEC

- OUTPUT

+ OUTPUT

FET PCB ASSY

E17

E16

E15

MAIN XFMR PRI

MAIN XFMR SEC

E16

E15

E14

MAIN XFMR PRI

E14

Solder Side Of PC Board

A-00479

APPENDIX A-12 Manual 0-2728

FET PC Board Signals (Upper and Lower Assemblies)

J6-1 +12 vdc from the Gate Drive Board upper J7-1 Lower J8-1 J6-2 +12 vdc RTN from the Gate Drive Board upper J7-2 Lower J8-2 J6-3 PWM Output from the Gate Drive Board upper J7-3 Lower J8-3 J6-4 PWM Output RTN J6-2 from the Gate Drive Board upper J7-4 Lower J8-4 J6-5 PRI CURRENT SENSE to the Gate Drive Board upper J7-5 Lower J8-5 J6-6 PRI CURRENT SENSE RTN to the Gate Drive Board upper J7-6 Lower J8-6 J6-7 SEC CURRENT SENSE to the Gate Drive Board upper J7-7 Lower J8-7 J6-8 SEC CURRENT SENSE RTN to the Gate Drive Board upper J7-8 Lower J8-8 J6-9 OVER TEMP RTN to the Gate Drive Board upper J7-9 Lower J8-9 J6-10 Active Low OVER TEMP Signal to the Gate Drive Board upper J7-10 Lower J8-10

E1 HEA TSINK GND To HEAT SINK E14 MAIN XFMR PRI to MAIN XFMR PRI E14 E15 MAIN XFMR PRI to MAIN XFMR PRI E15 E16 MAIN XFMR SEC from MAIN XFMR SEC E16 E17 OUTPUT (-) to OUTPUT INDUCTOR L1 E18 OUTPUT (+) to Current Sense Transformer and E8 on Output Board E19 MAIN XFMR SEC from MAIN XFMR SEC E19

Manual 0-2728 A-13 APPENDIX

APPENDIX 10: CAPACITOR PC BOARD LAYOUT

E26

E25

E12C

E13C

E12A

E13A

E12

E13

A-01418

E13B

E12B

Capacitor PC Board Signals

E12 Positve Rail to FET Board E12A Positve Rail to FET Board E12B Positve Rail to FET Board E12C Positve Rail to FET Board E13 Negative Rail to FET Board E13A Negative Rail to FET Board E13B Negative Rail to FET Board E13C Negative Rail to FET Board E25 Positive Input from E8 on Input PC Board E26 Negative Input from E3 & E4 on Input PC Board

APPENDIX A-14 Manual 0-2728

APPENDIX 11: CURRENT SENSOR PC BOARD LAYOUT

J15

A-01419

Current Sensor PC Board Signals

J15-1 Active Low CSR Sense Signal J15-2 Ground J15-3 +12 vdc

Manual 0-2728 A-15 APPENDIX

APPENDIX 12: 36VAC CIRCUIT DIAGRAM

Auxiliary

Transformer

Outputs

36 V AC

115 V AC

3 5 1 2

J11

Logic PC

Board

CD PC Board

132

Input Voltage Sense

312

Pilot/Output PC Board

17 18 19

5 7

1 4

J13

5 7 3

2 1

Gate Drive

PC Board

A-02325

ON/OFF

Switch

J4-7

J4-5

4 5

Gate Drive

PC Board

APPENDIX A-16 Manual 0-2728

APPENDIX 13: RECOMMENDED ROUTINE MAINTENANCE

SCHEDULE FOR LIQUID COOLED PLASMA CUTTING

SYSTEMS

This schedule applies to all types of 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 Arc Hours:

1. Check torch parts, replace if damaged.

2. Check plasma and secondary supply and pressure/flow.

3. Purge plasma gas line to remove any moisture build-up.

4. Check deionizer bag/cartridge, replace if color is predominantly yellow .

5. Check coolant pressure (100 - 120 psi).

Weekly or Every 30 Arc 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 Arc Hours:

1. Remove and clean in-line filter screens.

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.

4. Check all pillow blocks and bearings, clean and lubricate if necessary.

5. Check fan, pump and pulley belts for wear or cracking, replace if necessary.

Twelve Months or Every 1500 Arc Hours:

1. Drain coolant, fill with distilled water, turn on main power switch and let machine run for approximately 30 minutes.

WARNING

Drain distilled water and replace with Thermal Ar c Coolant. Use Standard Mix Coolant (Catalog # 7-2850) or Super Mix Coolant (Catalog # 7-2959) for environments below +10° F (-12° C).

2. Check radiator fins, clean and comb out if necessary.

3. Repeat six month maintenance.

Manual 0-2728 A-17 APPENDIX

DO NOT energize the Torch.

APPENDIX 14: SYSTEM SCHEMATIC (Unit Rev AQ or Earlier)

A-02329

APPENDIX A-18 Manual 0-2728

NOTE

Transformer T3 in earlier product does not have fuses as part of the Transformer Assembly.

Manual 0-2728 A-19 APPENDIX

A-02329

APPENDIX 14: SYSTEM SCHEMATIC (Unit Rev AR or Later)

A-03054

APPENDIX A-20 Manual 0-2728

NOTE

Transformer T3 in earlier product does not have fuses as part of the Transformer Assembly.

Manual 0-2728 A-21 APPENDIX

A-03054

Thermal Dynamics CE PAK Master 150XL Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual