section 1 - Victor Technologies
Contents
1. EB EB T4 sw3 A MAIN PIP XFMR SWITCH ean 12414 ee TT a E4 1 Sw2 a TORCH E5 SWITCH 5 5 F Qo D 1 J3 2 ea 4 Es E27 CD START l a B T EB F ANN D is 8 La L1uF L3 Y y T WORK M CURRENT T5 CONDE SAN Oo a 5 r a LAVA XF MR E2 8 E2 8 047UF 14 S E28 E28 E29 Ll 20 x 1 Tel ny TB 18 AMP LI El TORCH GATE a BLOCK DRIVE E28 XFMR R3 111 0 1 4700 40 22 E18 E18 9 pe 4700PF E14 RED E14 EN 3KV Tr 158 Y 1 1 1 1 400v slog E18 P T 3kv R1 PILOT pon i 15 RES poa T 4 E16 BLU E16 BBW i i D 1 1 8 2 E22 RED E22 1 1 g H E21 ORG E21 1K 1K 2 N 38 2 DAMPING 47 B5W lt RES ae E17 RED E17 at woRK E211 E25 23 240 pE25 R4 7 5K 3U0W WW E231 E24 E25 mE VY E281 7 5K 30W J5 2 1 ORG SEN ORG SEN 2 7 013 OUTPUT RUN ING CTOR HI LO SET SWITCH 014 u 4 REV REVISION DATE T A RELEASE 245 PTE 08 24 B EC7788 98 21 C N AA l ajus HEATSINK2. Cot 18 BRI gt BR2 gt 330 330 11 330 V 450vT 45a T 10K ACZ 7 2 Veg eta 4 gos Ace 4A e 12 WATTS EACH swi POWER 26 1 ON OFF A F2 D 40A 30A a 580v an 250y Ki 228 VAC oo oss Y i 108 CHS 1aw m A 16 4 GND 100 Cho AC gt 1aw EI 21 28 IN 220 RTN oo e 4 162 FAN LAN LAN 2 FAN2 DEA 250v FAN CGND AU FAT AUX POWER PCB PA VA XF MR h amp J7 CONNECTIONS 2 SIGNAL PWM ENABLE PWM ENABLE RTN PWN ENABLE PWM ENABLE RTN NC RELAY INRUSH DRIVE NC NC CURRENT SENSE 5 CURRENT SENSE RTN 3 23 CURRENT SENSE CURRENT SENSE RTN 37 PILOT ENABLE PILOT ENABLE RTN TORCH 31 181126 28 PIN 12V RIBBON GROUND CABLE TORCH SWITCH Ji DRIVE FOR J4 al 3 GAS J2 12V SDLENIOD at 61 4 IN OUT LOW PRESSURE l REF LOGIC PCB LIMIT rst 5 SWITCH 7 3 M am 2 AC READY GAS BSTN GREEN GREEN SOLENIOD 12 1 A AC OK DC OK A 01747 1 APPENDIX 36 Manual 0 2671
3. 50 System Schematic 420861 0861 51 5 7 8 10 A 01747 Manual 0 2671 37 APPENDIX APPENDIX 38 Manual 0 2671
4. 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 instruc tion 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 A 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 The parts replacement procedures described in this manual except for filter replacement require that the Power Supply be disassembled The part to be replaced will determine to what extent the Power Supply must be disassembled NOTES Before removing any connection mark each wire with the connection designation When reassem bling make sure the wires go to the proper termi nals Note the routing of wires and make sure the wires are put back in the same place when reassembling the unit Before disassembling any part of the Power Supply first read the procedure for the part to be replaced then pro ceed with the disassembly 27 REPLACEMENT PROCEDURES 5 04 Power Supply Component Replacement Procedures A WAR
5. Frequently review the Important Safety Precau tions at the front of this Manual Be sure the op erator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes into contact with the work piece while the torch is activated p m CAUTION Sparks from the cutting process can cause damage to coated painted and other surfaces such as glass plastic and metal NOTE Handle torch leads with care and protect them from damage 4 02 General Maintenance A Cleaning Power Supply Theonly routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency depending on the usage and the oper ating environment Manual 0 2671 A WARNING Disconnect primary power to the system before dis assembling the torch leads or power supply m CAUTION Do not blow air into the power supply during clean ing Blowing air into the unit can cause metal par ticles to interfere with sensitive electrical compo nents and cause damage to the unit To clean the unit open the enclosure refer to Section 4 08 A Opening 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 m CAUTION When cleaning care must be taken not to move or damage the electr
6. Check Torch Switch per Section 4 08 Torch Switch Check Correct No gt Replace Torch Yes Replace Power Supply Assembly Manual 0 2671 21 CUSTOMER OPERATOR SERVICE Chart 6 Faulty Torch or Torch Switch Checks AC and READY Indicators are ON When Torch Switch is pressed gas flows and Torch does not pilot Check for correct Torch Consumables Torch Consumables Correct Yes Check for shorted Torch pilot return Refer to Chart 4 Torch Pilot Return Correct Yes Check for OCV per Section 4 08 OCV Check Correct No Replace Power Supply Assembly CUSTOMER OPERATOR SERVICE 22 No gt Replace Torch Consumables No Replace Torch and Leads Assembly y Non Replaceable Parts Failure es Replace Power Supply Manual 0 2671 Chart 27 Possible Shipping Damage CURRENT Control Knob Turns Completely Around And Doesn t Stop At Minimum Or Maximum Positions Check Shaft Of CURRENT Control Is Not Loose Or Broken From PC Board Is Control Shaft Okay No 3 Replace Logic PC Board Yes Replace CURRENT Control Knob per Section 5 04 Manual 0 2671 23 CUSTOMER OPERATOR SERVICE 4 08 Test Procedures The checks in these test procedures are all made with the main power disconnected A es Disconnect primary power to the system at the source before opening the Power Supply A Opening Enclosure 1 Remove the following twenty two screws that se cure th
7. Torch with Leads Cut capacity is 1 2 inch 12 8 mm steel Parts In Place PIP is an integral safety feature of this torch to reduce the risk of elec tric shock Spare Parts Kit 3 03 Specifications Design Features 1 Controls ON OFF Switch RUN SET Switch Output Current Control Pressure Regulator Control 2 Panel Indicators LED Indicators AC Power READY Pressure Gauge 3 Input Power 208 230 VAC 60 Hz 25 30 Amp Single Phase 4 Output Power Continuously variable from 15 to 35 Amps maximum 5 OCV 330 VDC 6 Duty Cycle 40 7 Work Lead 10 ft 3 m with clamp Manual 0 2671 8 Cut Capacity 1 2 in 12 8 mm Steel 9 Pilot Circuitry Capacitor Discharge CD Pulsed DC 10 Gas Connection Rear panel entry 1 4 NPT 11 Gases Compressed Air or Nitrogen N Only 12 Pressure 60 psi 4 2 BAR 13 Flow 135 scfh 64 Ipm 14 Weight 70 Ibs 32 kg with 12 5 Torch Leads 15 Dimensions 203 4 527 mm High 93 4 248 mm Wide 25 635 mm Deep 11 DESCRIPTION DESCRIPTION 12 Manual 0 2671 SECTION 4 CUSTOMER OPERATOR SERVICE 4 01 Introduction This Section describes basic maintenance procedures per formable by operating personnel and advanced proce dures for properly trained personnel No other adjust ments or repairs are to be attempted by other than properly trained personnel GS Disconnect primary power at the source before dis assembling the torch or torch leads
8. and star washers securing the Capacitor PC Board to the Heatsink PC Board Assembly The nuts are located at terminals and N Pull the Capacitor PC Board up from the four plas tic PC Mounting Standoffs Remove the black pad on top of the capacitors from the faulty Capacitor PC Board Install the replacement Capacitor PC Board by re versing the above procedure and noting the fol lowing Manual 0 2671 a Place the black pad removed from the faulty PC Board on top of the capacitors on the re placement PC Board b Refer to the following CAUTION and torque the three nuts on terminals and N to 15 inch Ibs 1 695 Nm m CAUTION DO NOT over torque the nuts on the terminals as the PC Board may be damaged Manual 0 2671 29 REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES 30 Manual 0 2671 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts lists provide a breakdown of all replaceable components The parts lists are arranged as follows Section 6 03 Front And Rear Panel Replacement Parts List Section 6 04 Internal Component Replacement Parts List NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a Thermal Dynamics product must be returned for service contact your Thermal Dynamics distributor Ma terials returned to Thermal Dynamics without proper authorization will not be accepted 6 0
9. 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 work piece 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Wash ington 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 WELD ING AND GAS WELDING AND CUTTING obtain able from the Superintendent of Documents U S Government Printing Office Washington D C 20402 4 ANSI Standard Z87 1 SAFE PRACTICES FOR OC CUPATION AND EDUCATIONAL 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 Broad way New York NY 10018 6 ANSI Standard Z49 2 FIRE PREVENTION IN THE US
10. du astu 31 6 01 IntrodUctiOri itte ring 31 6 02 Ordering 31 6 03 Front and Rear Panel Replacement Parts 5 32 6 04 Internal Component Replacement Parts List 34 APPENDIX I SYSTEM 5 36 SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These high lights are categorized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system wmm CAUTION A procedure which if not properly followed may cause damage to the equipment G _ _Q A procedure which if not properly followed may cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN GEROUS AND HAZARDOUS TO YOUR HEALTH 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 Per sons who work near plasma arc cutting applica tions should consult their medical health profes sional and the manufacturer of
11. e Prenez des soins particuliers lorsque la zone de tra vail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes GENERAL INFORMATION A INCENDIE ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res com bustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou in flammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail Procurez une bonne a ration de toutes les fum es inflammables ou explosives Necoupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es 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 moins que le gas hydrog ne peu
12. se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e A CHOC ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail Ne touchez jamais une piece sous tension ou vive portez des gants et des v tements secs Isolez vous de la piece de travail ou des autres par ties du circuit de soudage R parez ou remplacez toute pi ce us e ou endommag
13. to plus directions 4 Connect the volt ohm meter positive lead to the Work Lead and the negative lead to the Torch Block of the output circuit to test for forward bias testing A properly functioning output will conduct in the forward bias direction and indicate between 0 3 to 0 9 volts 6 Reverse the meter leads across the connections for reverse bias testing A properly functioning out put will block in the reverse bias direction and de pending on the meter function will indicate an open or OL G Checking Torch Switch 1 Open the Power Supply per paragraph A above 25 CUSTOMER OPERATOR SERVICE 2 Disconnect the Torch Switch Wire connector from the Main PC Board at J3 black and white wires 3 Using an ohmmeter set on the Rx1 scale make the following check a Measure across the Torch Switch Wiring con nector black to white The meter should indi cate an open when the Torch Switch is not pressed When pressed the meter should indi cate a short NOTE The Shield Cup must be installed to complete the circuit through the Parts In Place PIP contacts 4 Reinstall the Torch Switch Wiring connector back onto the Main PC Board connector H Checking Gas Solenoid Assembly A WARNING Unit must be turned ON to make this check Use caution when making this check 1 Open the Power Supply per paragraph A above 2 Turn unit ON 3 Place RUN SET switch to SET position 4 Measure for 24 V
14. 2 Ordering Information Order replacement parts by catalog number and com plete 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 unit Address all inquiries to your authorized Thermal Dynamics distributor Manual 0 2671 31 PARTS LISTS 6 03 Front and Rear Panel Replacement Parts List Item 1o FP 0 a N Po 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Description GREY CASE Includes Labels and Overlays HANDLE CASTLENUT HANDLE STIFFNER RUBBER FEET CASE BOTTOM GRAY Includes Labels and Overlays ADAPTER REAR PANEL FITTING PRESSURE SWITCH 35 PSI WIRE ASY GAS SOLENOID ASSYINPUT POWER 220V REGULATOR HIGH FLOW GAUGE AIR REGULATOR FITTINGS KIT For units with rev letter T or later see note Includes replacement parts for items 13 14 16 FITTING 1 4 NPT X3 8 TUBE STR FITTING 1 4 NPT X 3 8 TUBE 90 FITTING 1 4 NPT W RING GROOVE 1 8 MNPT X 3 8 TUBE 90 DEG 1 4MX1 8M NIPPLE 1 00 L WORK CABLE 10 AWG W CLAMP Length 10 ft 3 m Standard Length 15 ft 4 6 m Replacement Only Length 20 ft 6 1 m Replacement Only Length 25 ft 7 6 m Replacement Only STRAIN RELIEF FOR 10 STRANDED WIRE STRAIN RELIEF 370 430 DIA CABLE SWITCH DPST TOGGL
15. 450 Section 4 13 Servicing Torch Head Components 3 Faulty Logic PC Board a Refer to Section 4 06 Advanced Troubleshoot ing Guide E AC indicator ON READY indicator ON Torch does not pilot 1 Faulty torch parts a Inspect torch parts and replace if necessary per Operating Manual 0 2450 Section 4 04 2 Gas pressure too high a Set pressure to 60 psi 4 2 BAR 3 Faulty Main PC Board a Refer to Section 4 06 Advanced Troubleshoot ing Guide F Torch pilots but does not cut 1 Work lead not connected a Make sure work lead is connected securely to bare metal 2 AC input power too low a Use shortest service to breaker panel possible 3 Faulty Main PC Board a Refer to Section 4 06 Advanced Troubleshoot ing Guide 4 06 Advanced Troubleshooting Guide A General The troubleshooting covered in this Section requires Power Supply disassembly and live measurements It is helpful for solving the common problems that may arise with the Power Supply Assembly CUSTOMER OPERATOR SERVICE A WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot ing techniques If major complex subassemblies are faulty the assembly must be returned to an authorized service center for re pair Follow all instructions as listed and complete each in the o
16. AC at J2 1 to J2 2 on the Logic PC Board If the voltage is correct replace the Gas Sole noid Assembly If the voltage is not present proceed to the next Step 5 Measure for 24 VAC at J4 1 to J4 3 on the Logic PC Board If the voltage is correct replace the Logic PC Board f the voltage is not present replace the Power Supply CUSTOMER OPERATOR SERVICE 26 l Checking OCV Level A WARNING Danger High Voltage Use caution when making this check 1 Open the Power Supply per paragraph A above 2 Turn Unit ON 3 Using an voltmeter set on DC volts and 1000V scale make the following check a Connect the meter positive lead to the work cable lead of the Power Supply b Touch the meter negative lead to the E6 ter minal on the Power Supply PC Board Access to E6 is through the opening on left side of the unit 4 Turn ON the Power Supply and press the torch switch The voltage should be approximately 395 VDC If voltage is correct and the unit does not pilot then the Power Supply is faulty If the voltage is not correct then the Power Sup ply is faulty Manual 0 2671 SECTION 5 REPAIRS amp REPLACEMENT PROCEDURES 5 01 Introduction This Section describes parts replacement procedures and all cable repairs which may be performed on the EconoPak 50 Power Supply Under no circumstances are field repairs to be attempted on Printed Circuits or other Subassemblies
17. CE 18 Manual 0 2671 Chart 3 READY Indicator Checks AC Indicator ON and READY Indicator is OFF or Blinks When Torch Switch is pressed READY Indicator Blinks Yes Proceed to Chart 4 Check Input Voltage Input Voltage Too High Yes Check Power Source For Proper Input Voltage No Fans Operating Duty Cycle Exceeded Yes Allow Power Supply To Cool READY Indicator Still OFF READY Indicator ON 3 Use Proper Ne Operating Procedures Ne Yes Replace Power Supply Assembly Manual 0 2671 19 CUSTOMER OPERATOR SERVICE Chart 4 Shorted Torch or Resistor R3 Checks AC Indicator ON and READY Indicators Blink When Torch Switch is pressed Check Pilot Return per Section 4 08 Pilot Return Check Correct Replace Torch and i Leads Assembly Yes Check Resistor R3 Assembly per Section 4 08 Resistor R3 Replace Resistor R3 Check Okay Assembly Yes Check Output Resistance per Section 4 08 Output Resistance Check Okay N Replace Power Supply 9 Assembly Yes Y Replace Logic PC Board Assembly CUSTOMER OPERATOR SERVICE 20 Manual 0 2671 Chart 5 Faulty Torch or Torch Switch Checks AC and READY Indicators are ON When Torch Switch is pressed No gas flow and Torch does not pilot Check RUN SET Switch Is In RUN Position RUN SET Switch In RUN Position Place Switch To N RUN POsition Yes
18. DAGE disponible aupres de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupres de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada MOW 1R3 13 ivret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupres de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 GENERAL INFORMATION 14 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRA TIQUES SURES POUR LA PREPARATION ALA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERME DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTEC TION RESPIRATOIRE disponible aupres de l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION 6 Date 6 22 99 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address Industrial Park 2 West Lebanon New Hampshire 03784 USA The equipment described in this manual confo
19. E 600V 40A GAUGE RING RETAINING RING 750 DIA SHAFT KNOB INNER CONCENTRIC LOGIC PCB ASSEMBLY RIBBON CABLE LOGIC POWER The following parts are not shown 1 1 1 1 FILTER AIR 2 STAGE LA MAN REPLACEMENT FIRSTSTAGE FILTER REPLACEMENT SECOND STAGE FILTER Complete Air Filter Kit Assembly NOTE Revision level of the unit is the letter at the end of the unit serial letter PARTS LISTS 32 Catalog 9 7675 9 8115 9 7676 9 7677 8 0381 9 7678 9 6247 9 1044 9 6295 9 7679 8 4382 9 7641 9 6691 9 6230 9 6219 9 4423 9 7680 9 7681 9 6298 9 6595 9 6596 9 6597 8 4249 8 4263 8 4248 9 7682 9 6233 9 4146 9 6598 9 7684 9 1020 9 1021 9 1022 7 3500 Manual 0 267 1 PARTS LISTS 6 04 Internal Component Replacement Parts List Item Oty Description Catalog 1 1 TORCH LEAD CONN BLOCK 9 7686 2 2 FAN 220V 9 7687 3 1 FILTER PCB ASS Y 9 7688 4 2 WIRE SADDLE 9 7689 5 2 MOUNTING BUTTON 9 7690 6 8 BUSHING 9 7691 7 14 NYLON SNAP SLOTTED GROMMET 9 7692 8 1 FANTRAY 9 7693 9 1 BACKSTRAP 9 7694 A 01981 PARTS LISTS 34 Manual 0 2671 Manual 0 2671 35 APPENDIX APPENDIX I SYSTEM SCHEMATIC PIN UJ 22224242200 GAS DK CONNECTORS J1 CAPACITOR PCB
20. E OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Insti tute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS TIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Date 6 22 99 oo NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Pro tection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Ca nadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRA PHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWSF4 1 REC OMMENDED SAFE PRACTICES FOR THE PREPA RATION FOR WELDING AND CUTTING OF CON TAINERS AND PI
21. IHERMAL DYNAMICS A THERMADYNE Company ECONO PAK 50 Air Plasma Cutting Power Supply Service Manual September 5 1999 Manual No 0 2671 Read and understand this entire Service Manual and your WARNING employer s safety practices before installing operating or servicing the equipment While the information contained in this Service Manual repre WARNING sents our best judgement Thermal Dynamics Corporation assumes no liability for its use Econo Pak 50 Air Plasma Cutting Power Supply Service Manual Number 0 2671 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1997 by Thermal Dynamics Corporation All rights reserved 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 the Econo Pak 50 Air Plasma Cutting Power Supply Service Manual whether such error results from negligence accident or any other cause Printed in the United States of America September 1999 TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION ertet ed Ee et ee ert pone teen 1 1 01 Notes Cautions and Warnings 1 1 02 Important Safety Precautions sse 1 1 03 IPublicatiols tim a tam tum etes 2 1 04 Not
22. NING Disconnect primary power to the system before dis assembling the torch leads or power supply A Current Knob Replacement 1 Using a small blade screwdriver loosen the screw securing the knob to the CURENT Control adjust ment shaft Turn the CURRENT Control adjustment shaft fully counterclockwise This will represent the mini mum position Slide the replacement knob onto the shaft Turn the knob so that the line on the knod points towards the C in CURRENT Tighten the screw in the knob to secure the knob to the shaft Turn the knob fully clockwise Theline should now line up with end of the CUR RENT Control adjustment symbol Adjust the knob as required to align the minimum and maximum reference points B Fuse s Replacement The two Fuses are located on the Power PC Board inside the Power Supply The Fuses are behind and next to the terminal block on the left side of the Power Supply Remove the desired Fuse per the following procedure 1 2 3 4 Open the enclosure per Section 4 08 A Using a pair of needle nose pliers carefully remove the Fuse s Replace the Fuse s only with the properly rated and type fuse Fuse F1 is next to the Terminal Block and isa 1 2 amp fuse The other Fuse F2 is a 30 amp fuse Reinstall the Power Supply Cover C AC POWER Switch Replacement 1 2 Open the enclosure per Section 4 08 A Disconnect the wiring f
23. PING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard Z88 2 PRACTICE FOR RESPIRA TORY 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 utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme suit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me wmm ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question Date 6 22 99 SSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes SSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils au
24. ance 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 80XL Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 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 80XL 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 s
25. ctions for Thermal Dynamics EconoPak 50 Air Plasma Power Supply Refer to Operating Manual 0 2450 for individual oper ating procedures Information in this edition is therefore particularly applicable to the Troubleshooting 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 0 2450 thoroughly A complete understanding of the capabili ties 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 equipment should satisfy the customer s require ments 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 selec tion of standard options and Accessories are to be made to this equipment C Customer Operator Responsibilities It is the customer operators responsibility to maintain the equipment and peripheral Accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual and to protect the equipment from accidental or mali cious damage D Repair Restrictions The electronics consists of Printed Circuit Boa
26. d gases Do not use the plasma torch an area where com bustible 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 A 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 op erator or others in the workplace Never touch any parts that are electrically live or hot Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding cir cuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp GENERAL INFORMATION Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publica tions Disconnect power source before performing any ser vice or repairs Read and follow all the instructions in the Operat ing Manual Ay AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable mate rial 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 whe
27. ditif ou autre mat riel de sant electronique Ceux qui travail pres d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il faut communiquer aux op rateurs et au person nel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions U Au etGAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respi ration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz GENERAL INFORMATION Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan
28. e Attention et Avertissement 3 1 05 Precautions De Securite Importantes sse 3 1 06 Documents De Reference ss 5 1 07 Declaration of Conformity cooooocinnncccnnncnnnnccccnnonnnnnnnc conan nn naar nn 7 1 08 Statement of Warranty iii 8 SECTION 2 INTRODUCTION riada 9 2 01 Scope Of Manual iii 9 2 02 General Service Philosophy ss 9 2 03 Service Responsibilities enne 9 SECTION 3 DESCRIPTION a ee a ea ee 11 3 01 Scope of Manual sue 11 3 02 General Description 11 3 03 Specifications Design 11 SECTION 4 CUSTOMER OPERATOR SERVICE iii 13 4 01 Introduction icit eite e Patet te 13 4 02 General Maintenance is 13 4 03 Common Operating Faults ss 14 4 04 Troubleshooting Guides 2 44 44 14 4 05 Basic Troubleshooting Guide 14 4 06 Advanced Troubleshooting Guide sess 15 4 07 Troubleshooting Flow Charts 16 4 08 Test Procedures imet ei petet a Cung 24 SECTION 5 REPAIRS amp REPLACEMENT PROCEDURES sisi 27 5 0 T Introd estote Itt oct ee NOS 27 5 02 Anti Static Handling 27 5 03 Parts Replacement General Information 27 5 04 Power Supply Component Replacement Procedures 28 SECTION 6 PARTS BISTS ot tutta ted ete etu ute
29. e Cover of the Power Supply Three on each top end of the Cover six screws Three on each side along the bottom six screws Two halfway up each side four screws Sixon the right side panel near center NOTE Do not remove the two screws holding the handle to the case or the screws on the rear panel 2 Slide the cover straight up and off the Power Sup ply NOTE Make certain not to strain the ground wire con nection to the Cover of the Power Supply B Checking Input Diode Bridge Testing of diode modules requires a digital volt ohm meter 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 Power Supply 1 Open the Power Supply per paragraph A above 2 Make a visual check of the Input Diode Bride for damage 3 Set digital volt ohm meter to diode test scale 4 Using the Figures for each test check each diode in the module Each diode must be checked in for ward bias plus to negative and reverse bias nega tive to plus direction 5 Connect the volt ohm meter positive lead to the anode ofthe diode and the negative lead to the cathode of the diode for forward bias testing A properly functioning diode will conduct in the forward bias direction and indicate between 0 3 to 0 9 volts CUSTOMER OPERATOR SERVICE 24 AC AC y N e ac pa A AC Figure 4 4 Input Diode Diag
30. g Power Supply Power Line Fuses From Main Power Source Main Power Line Fuses Okay Proceed to Chart 2 No Check Main Disconnect Power Line Fuses For Yes Proceed to Chart 2 Proper Amperage Faulty Main Power Source Manual 0 2671 17 CUSTOMER OPERATOR SERVICE Chart 2 Input Power Checks Check Fuse F2 on the Power PC Board Assembly Fuse F2 5 gt Check Input Diode Bridge on Checks Okay re This Condition could also result if the input Per Section 4 08 line voltage was low and the user was using a high standoff while cutting Yes Check FET Assemblies on Yes Heatsink PC Board Assembly See Note Per Section 4 08 Diode Bridge Checks Okay Check 1 2A Fuse F1 on the Power PC Board Assembly No 1 2A Fuse Checks Okay Replace Power Supply No Assembly FET Assemblies Check Okay Yes Check Capacitor PC Board Assembly on Heatsink PC Board Assembly Per Section 4 08 Unplug J2 Connector on the Heatsink PC Board Assembly Replace Fuse F1 and Apply AC Power to the Power Supply apacitor P Board Assembly hecks Okay No AC Indicator Comes ON Yes Unit Operates Properly Check unit for proper operation Yes Replace Pressure Gauge Solenoid Assembly Replace Cover and follow operating procedures CUSTOMER OPERATOR SERVI
31. ilis s quand l arc est cach par moiceau de travail BRUIT Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d 4ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie l our prot ger votre ouie contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail e Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of Docu ments U S Government Printing Office Washing ton D C 20402 2 Norme ANSI Z49 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE L ARC ET AU GAZ disponible aup
32. limited to non power checks and external Power Supply faults Advanced troubleshoot ing requires fault isolation to the Power Supply or Torch Power Supply disassembly voltage measurements and major component replacement The guides are as follows Section 4 05 Basic Troubleshooting Guide Section 4 06 Advanced Troubleshooting Guide Depending on the level of repair to be done refer to the desired troubleshooting guide 4 05 Basic Troubleshooting Guide A General Basic troubleshooting of the EconoPak 50 plasma cutting system can be performed without special equipment or knowledge and without opening the enclosure This basic troubleshooting guide covers input power gas supply and torch problems For problems not covered here refer to the Advanced Troubleshooting Guide or contact your authorized Ther mal Dynamics distributor Ifa Thermal Dynamics product must be returned for ser vice contact your Thermal Dynamics distributor Mate rials returned to Thermal Dynamics without proper au thorization will not be accepted 14 Manual 0 2671 B How to use this Guide The following information is a guide to help determine the most likely causes for various symptoms This guide is set up in the following manner X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Check Remedy Text Type Locate your symptom check the causes easiest listed first then remedies Repair as needed bei
33. ng sure to verify that the unit is fully operational after any repairs A AC indicator OFE Fan does not operate 1 Circuit Breaker open a Reset Breaker Use 30 amp or greater service 2 Faulty 1 2A Fuse F1 a Replace fuse B AC indicator ON READY indicator OFF 1 Unit is overheated a Make sure the unit has not been operated be yond 40 duty cycle limit 2 Airflow obstructed a Provide atleast 12 inch clearance front and rear 3 Pilot circuit overheated READY indicator lights mo mentarily and unit shuts down a Proper Torch Parts or Assembly Check per Op erating Manual 0 2450 Section 4 04 b Shorted torch head Check per Operating Manual 0 2450 Section 4 10 C AC indicator ON READY indicator ON no gas flow in SET 1 Gas not connected or pressure too low a Check source for at least 60 psi 4 2 BAR In SET position adjust gas pressure to 60 psi 2 Air filter or air line blocked Torch leads blocked a Replace filter cartridge Check that air lines and torch leads are free of twists and kinks 3 Faulty Gas Solenoid a Refer to Section 4 06 Advanced Troubleshoot ing Guide Manual 0 2671 AC indicator ON READY indicator ON no gas flow in RUN when torch switch pressed 1 Shield cup not properly installed on torch a Check that shield cup is fully seated against torch head 2 Faulty Torch Switch or PIP Assembly in torch holder a Replace Torch Head Assembly per Operating Manual 0 2
34. of this unit Evidence of unauthorized repairs may void the factory warranty 5 02 Anti Static Handling Procedures A General Em CAUTION PC boards can be irreparably damaged by improper handling due to electrostatic discharge ESD Replacement PC boards are shipped in a protective en closure to prevent damage from electrostatic discharge ESD during shipping Included with each replacement board is a ground strap to prevent static damage during installation GS Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or remov ing the replacement PC board from its protective enclosure Disconnect primary power to the system before dis assembling 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 Manual 0 2671 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 Open the equipment enclosure see instruction manual for the appropriate equipment and re move the failed PC board
35. onic components Optional In Line Air Filter NOTE Refer to Section 6 Parts Lists for replacement parts and ordering information The Optional In Line Air Filter cartridge should be replaced every 30 days depending on the condition of the compressed air If a noticeable drop in air pres sure occurs the filter may have become filled with contaminants and must be replaced Cleaning Torch GS Disconnect primary power to the system before dis assembling the torch leads or power supply DO NOT touch any internal torch parts while the AC indicator light on the front panel of the power supply is ON Even if precautions are taken to use only clean air with a torch eventually the inside of the torch becomes coated with residue This buildup can affect the pilot arc initiation and the overall cut quality of the torch CUSTOMER OPERATOR SERVICE The inside of the torch should be cleaned with electri cal contact cleaner using a cotton swab or soft wet rag In severe cases the torch can be removed from the leads refer to Operating Manual 0 2450 Section 4 13 Servicing Torch Head Components and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling 4 03 Common Operating Faults The following lists the more common cutting faults and what is the possible cause 1 Insufficient Pene
36. r s du Superin tendent of Documents U S Government Printing Office Washington D C 20402 Date 6 22 99 4 Norme ANSI 787 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales Ameri can National Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupres de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI Z49 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupres de l American National Standards Institute 1430 Broadway New York NY 10018 7 Norme A6 0 de l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Pro tection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NA TIONAL disponible aupres de la National Fire Pro tection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOU
37. ram A 00307 0 75 Forward Bias Diode Conducting Jr Tb Diode Test Symbol VR COM A Anode x Cathode Figure 4 5 Testing Diode Forward Bias Reverse the meter leads across the diode for re verse bias testing A properly functioning diode will block in the reverse bias direction and depend ing on the meter function will indicate an open or OL Manual 0 2671 A 00306 OL Reverse Bias Diode Not Conducting I VR COM A Cathode O Anode Figure 4 6 Testing Diode Reverse Bias 7 If the diode has visible damage or is shorted the diode is faulty replace the Power Supply B Checking FET Assemblies 1 Open the Power Supply per paragraph A above 2 Using an ohmmeter set on the Rx1 scale make the following checks a Measure from Capacitor PC Board to Main Transformer Wire E3 If the meter indicates a short the FET Assemblies are faulty b Measure from Capacitor PC Board to Main Transformer Wire E3 If the meter indicates a short the FET Assemblies are faulty C Checking Capacitor PC Board 1 Open the Power Supply per paragraph A above 2 Visually inspect all the capacitors for any physical damage like burned areas or cracks Ifany capacitor has physical damage then check the Main PC Board inrush resistors for physi cal damage If the inru
38. rd Assem blies which must be carefully handled and must be re placed as units No replacement of printed circuit sol der mounted components is allowed except as noted in this manual If to be returned the replaced Printed Circuit Board As semblies must be properly packaged in protective mate rial and returned intact per normal procedures Manual 0 2671 2 03 Service Responsibilities TheService Technician should be familiar with the equip ment and its capabilities He should be prepared to rec ommend arrangements of components which will pro vide 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 Technical Services Department at West Lebanon for assistance 9 INTRODUCTION INTRODUCTION 10 Manual 0 2671 SECTION 3 DESCRIPTION 3 01 Scope of Manual The information in this Section has two purposes To familiarize the service technician with the capa bilities and limitations of the equipment To provide an overall understanding which will al low the technician in turn to properly train customer s operating personnel 3 02 General Description The power supply provides 35 amps maximum out put cutting current from a standard 208 230 volt 60Hz AC input service All electrical pilot and gas control circuitry is included Hand
39. rder presented The guide has two sections as follows Section 4 07 Troubleshooting Flow Charts Section 4 08 Test Procedures Specific test procedures have been grouped together and are referenced by the flowcharts B How to use this Guide The following information is a guide to help the Service Technician determine the most likely causes for various failures This guide is set up in the following manner 1 Use flowchart s to isolate problem to possible circuit s 2 Perform the test procedures as required and noted on the flowcharts 3 Repair as needed being sure to verify that unit is fully operational after any repairs 4 07 Troubleshooting Flow Charts The following pages are flow charts to be used to isolate problems in the Plasma Cutting System CUSTOMER OPERATOR SERVICE Manual 0 2671 Chart 1 Main Power AC Indicator OFF on Front Panel System AC POWER Power Cable Connect AC Power Operates No Switch ON Yes Plugged In No Input Cable to Properly AC Source No Yes Y Faulty AC Indicator Replace Main Power Place AC POWER Check Main Assembly Switch to ON Power Disconnect Place Main Power No Disconnect to ON Main Power Disconnect ON22 Yes Check Main Disconnect Power Line Fuses Main Power Line Fuses Replaced Once Main Power Line Fuses Okay Unplug Power Supply From Main Power Source Yes No No Yes Y Replace Man Unplu
40. re fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut under water 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 dis sipated Trapped hydrogen gas that is ignited will cause an explosion Apo Noise can cause permanent hearing loss Plasma arc pro cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent per manent loss of hearing To protect your hearing from loud noise wear pro tective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the deci bels 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 m PLASMA ARC RAYS 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 protected GENERAL INFORMATION To protect your eyes always wear a welding hel metor shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when
41. rms to all applicable aspects and regulations of the Low Voltage Direc tive 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 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 requirements among them are CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing 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 represen
42. rom the rear of the AC Power Switch REPLACEMENT PROCEDURES On each side of the switch remove the two nuts securing the switch to the Front Panel Pull the switch out the back of the Front Panel Replace the replacement AC Power Switch by re versing the above procedure D Air Regulator Assembly Replacement The Air Regulator Assembly includes the Air Regulator Pressure Switch Pressure Gauge and Solenoid Assem blies and is removed from the Power Supply as a com plete assembly Remove the assembly per the following procedure 1 2 7 Open the enclosure per Section 4 08 A Disconnect the ground wire from the cover and set the cover aside Remove the Hose Assembly connecting the Torch Block to the Air Regulator Assembly and the long hose from the rear Remove the two nuts securing the Pressure Gauge to the alignment plate Cut the tywraps Remove the plastic retaining nut from front of the regulator assembly and remove complete assem bly with wiring Remove the faulty Air Regulator Pressure Switch Pressure Gauge or Solenoid Assembly and install the replacement assembly Install complete Air Regulator Assembly by revers ing the above procedure NOTE Properly route the pressure switch and gas sole noid wires and secure with cable ties Capacitor PC Board Replacement Procedure 1 2 28 Open the enclosure per Section 4 08 A Remove the two nuts
43. sh resistors are burned then replace the Power Supply If the inrush resistors are okay then proceed to Step 3 3 Using an ohmmeter set on the Rx1 scale make the following check Manual 0 2671 a Measure from Capacitor PC Board to ter minals The meter should increase in resistance as the capacitors charge If the meter indica tion does not increase the Capacitor PC Board is faulty D Checking Pilot Return 1 Open the Power Supply per paragraph A above 2 Using a pair of needle nose pliers remove the red Pilot Return Lead wire from terminal E14 on the Main PC Board 3 Using an ohmmeter set on the Rx1 scale make the following checks a Measure from the Torch Block and the end of the Pilot Return wire The meter should indi cate an open 4 Reinstall the wire back onto the E14 terminal E Checking Resistor R3 11k ohms 1 Open the Power Supply per paragraph A above 2 Using a pair of needle nose pliers remove the red wire from terminal on Resistor R3 3 Using an ohmmeter set on the Rx100 scale make the following check a Measure the Resistance of the Resistor R3 The meter should indicate 11K ohms 2596 4 Reinstall the wire back onto the Resistor terminal F Checking Output 1 Open the Power Supply per paragraph A above 2 Set digital volt ohm meter to diode test scale 3 The output circuit is to be checked in the forward bias plus to negative and reverse bias negative
44. t s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm m RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons ultra vio lets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lu nettes de protection ou une autre sorte de protec tion oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protec tion en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Date 6 22 99 Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent ANSI ASC Z49 1 Nuance Minimum Nuance Sugger e Courant Arc Protective Num ro Num ro Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent tre ut
45. tative Steve Ward Director of Operations Thermadyne UK Chorley England Date 6 22 99 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 stored 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 correct such defects by suitable repair 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 PARTICULAR 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 perform
46. the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and in structions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions Date 6 22 99 As 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 processes You must be very careful when cutting or welding any met als which may contain one or more of the follow ing 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 an
47. tration a Cutting speed too fast b Torch tilted too much c Metal too thick d Worn torch parts e Cutting current too low f Non Genuine Thermal Dynamics Parts 2 Main Arc Extinguishes a Cutting speed too slow b Torch standoff too high from workpiece c Cutting current too high d AC line too low reduce output current e Work cable disconnected f Worn torch parts g Non Genuine Thermal Dynamics Parts 3 Excessive Dross Formation a Cutting speed too slow bottom dross b Cutting speed too fast top dross c Torch standoff too high from workpiece d Worn torch parts e Improper cutting current f Non Genuine Thermal Dynamics Parts 4 Short Torch Parts Life a Oil or moisture in air source b Exceeding system capability material too thick CUSTOMER OPERATOR SERVICE c Excessive pilot arc time d Air flow too low incorrect pressure e Improperly assembled torch f Output current too high g Torch tip contacting workpiece h Damaged or loose torch head components i Non Genuine Thermal Dynamics Parts 5 Poor Pilot Starting a Non Genuine Thermal Dynamics Parts 4 04 Troubleshooting Guides There are two Troubleshooting Guides Basic and Ad vanced provided in this Instruction Manual The Basic Troubleshooting Guide uses symptom cause and rem edy for fault isolation The Advanced Troubleshooting Guide uses Flow Charts and test procedures for fault iso lation Basic troubleshooting is
48. uch distributor to the Purchaser and with the further limitations on such two 2 year period see chart below Parts XL Plus Series amp Parts Parts PAK Units Power Supplies CutMaster 80XL Cougar Drag Gun All Others Labor Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year All Other Circuits And Components Including 1 Year 1 Year 1 Year 1 Year But Not Limited To Starting Circuit Contactors Relays Solenoids Pumps Power Switching Semi Conductors Consoles Control Equipment Heat 1 Year 1 Year 1 Year Exchanges And Accessory Equipment Torch And Leads Maximizer 300 Torch 1 Year 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 May 6 1999 GENERAL INFORMATION 8 Date 6 22 99 SECTION 2 INTRODUCTION 2 01 Scope Of Manual This Manual provides Service Instru
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